Sorting

Right Angle Transfer Module

M-RAT
Mighty - Right Angle Transfer

User Manual
Read this manual before use
Thank you for purchasing the Right Angle Transfer Module(hereinafter referred to as “this product”).
＊This product refers to all products including standard accessories.

Make sure to read this manual carefully before using, and start
using only after you have understood all the product’ s functions,safety information and precautions.
After reading the manual, make sure to keep it safe in a specified
place for future use, whenever necessary.

ITOH DENKI

ModuleNo.647

Features

M-RAT User Manual

2

1. Introduction
FeaturesFeatures of this product・ This product is a module to transfer trays by diverting at a right angle.
Since trays can be diverted at a right angle without changing their level, there will
be no impact on the trays.
・ All-electric control. No pneumatics or hydraulic pressure.

Operation description(when diverting at a right angle)

Induction

Switch to thediverting direction

Discharge

Switch to thestraight direction

Disclaimer

3

M-RAT User Manual

1. Introduction
Disclaimer

This product is designed as a general industrial device. Do not use for otherapplications. We do not take any responsibility for any damage that may result fromthe disregarding of these warnings.
● In the event that an accident results from the use of this product, we do notcompensate for any damage, including abnormalities of equipment, connection
devices, and/or software, any damage resulting from malfunctions, and/or any
other secondary damage.
● Using the product in a combination other than our MDR and driver card/controller(combination with similar products or products by third party) could result in fire
and/or accidents. We are not responsible for any damage that results from thedisregarding of the above precaution.
●

Notes on industrial
property rights

There are some examples of parts that need to be prepared by customers, as
explained within this manual. However, this does not provide any guarantee against
the existence of any rights, such as our industrial property rights, or those of othercompanies.

Notes on technicalsupportWe respond to technical inquiries based on the contents described within this manual,and on this product within the range of general items for this product unit.
There are some descriptions in this manual, about parts, equipment, and wiring
arranged by customers, as well as the controls and operation under suchcircumstances. However, these are not included in the guaranteed operating range
and/or support.
When in use, please check and perform the aforementioned based on yourresponsibility and operation needs.

About the performancelevel (PL) for this system

This product is based on the performance level “C”＊2 in ISO13849-1＊1.

About installation
environment

This product is not equipped with special dust proof/waterproof countermeasures, andis intended to be used in environments of “Pollution Degree 2”＊2, as defined in
IEC60664 -1＊1.

＊1：International Organization for Standardization＊2：This indicates that even though events that would result in serious injury occur infrequently underassumed risk environment, there is a high probability to avoid danger if you observe the safetycontents described in this manual.

＊1：Insulation coordination for equipment within low-voltage supply systems - Part 1 of the International
Standard.
＊2：Non-conductive pollution will occur, but it is assumed that condensation will happen to generate
conductive property.

About description of
the product・Depending on the signal type (NPN/PNP) specified by customers, different modelsof control driver cards are supplied as being the standard for this product.
・In this manual, the driver card model is described as follows: NPN and PNP input
and output models are described separately, when needed.
Driver card model
NPN

PNP

Description
in this manual

CBK-109FN

CBK-109FP

CBK-109

CB-016BN6

CB-016BP6

CB-016

Procedures from installation to operation

M-RAT User Manual

4

1. Introduction
Procedures frominstallation to operation
Read this manual

Advance preparation

Product check

Start using only after you have understood all the product’ s functions,safety information, and precautions.

Prepare the 24V DC power supply, such as DC power
supply units.
Prepare control devices, such as PLCs.

P.12 〜

Open the package, and check the model, specifications,and voltage, etc.
Check accessories.

P.18 〜

Install the M-RAT main unit.

P.20 〜

Installation

WiringMount the driver card.
Connect the M-RAT and driver card.
Connect power and signal cables to the driver cards.
Perform settings of driver cards.
Connect to power supply units/PLCs.

Control
Perform control (programming).

P.32 〜

Perform start-up inspection.

P.40 〜Start-up inspection

Maintenance/Inspection

P.28 〜

Some errors have been foundNo

Perform maintenance and inspection
based on corresponding parts.
Yes

Troubleshooting

Yes

Have the problems been solved?
No

Take appropriate measures basedon the corresponding symptoms.

Run operation.

P.42 〜

P.45 〜INDEX

5

M-RAT User Manual

…… 7
…… 8
…… 9
…… 10
…… 10
…… 11

4. Advance preparation…… 12

5. Installation/Wiring5-1. Before installation･･･
5-2. Installation
5-3. Wiring
5-4. Connecting to devices

…… 20
…… 21
…… 26
…… 28
…… 31

6. Control/Operation
6-1. Basic operation
6-2. Program example
6-3. Switching the transfer direction
6-4. Switching the transfer surface
6-5. Changing the speed
6-6. What to do before operation

…… 33
…… 34
…… 35
…… 36
…… 37
…… 38
…… 39

7. Maintenance/Inspection
7-1. Driver card LED display and error countermeasures
7-2. Before replacement work
7-3. Replacement of resin sliders
7-4. Replacement of idlers/drive belts
7-5. Replacement of MDR
7-6. Replacement of the carrier wheel cassette

…… 42
…… 44
…… 44
…… 45
…… 48
…… 49

8.

…… 50

Troubleshooting

Appendix
Appendix 1. Product specifications
Appendix 2. Residual risk list/MAP
Appendix 3. Belt tensioning jig

…… 54
…… 55
…… 57
…… 57

Advance preparation

3. Safety precautions
3-1. General precautions
3-2. Precautions on installation
3-3. Precautions on wiring
3-4. Precautions related to operation
3-5. Precautions on start-up inspection/maintenance and inspection

Installation/Wiring…… 5

Control/Operation

2. INDEX

Maintenance/Inspection…… 2

Troubleshooting

1. Introduction

Appendix

INDEX

Safety precautions

2. INDEX

3. Safety precautions

Maintenance/Inspection

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

M-RAT User Manual

3. Safety precautions
3-1. General precautions
3-2. Precautions on installation
3-3. Precautions on wiring
3-4. Precautions related to operation
3-5. Precautions on start-up inspection/maintenance and inspection

……
……
……
……
……

8
9
10
10
11

Troubleshooting

For parts names in sentences, refer to Structures (P.18).

Appendix6Danger level

7

M-RAT User ManualThis indicates a high possibility that injury or only property
damage may result.

■ We categorize the type of those precautions using the following symbols
throughout the manual.
This symbol indicates forced operations that users should
always perform.

This symbol indicates operations that are prohibited.

This symbol indicates a reminder you should pay attention to.

Advance preparation

CAUTIONInstallation/Wiring

This indicates a high possibility that severe injury or evendeath may result.

Control/Operation

Symbol explanation

WARNING

Maintenance/Inspection■ The degree of hazard and/or damage that may result if a user disregards thedescription and operates the product improperly is categorized as the following
symbols and explained below.

Troubleshooting

To prevent hazards to users and/or others, and/or damage to property in advance, we
explain important precautions to be followed securely as below.

Appendix

Danger level

Safety precautions

3. Safety precautions

General precautions

8

M-RAT User Manual

Failure to follow this could result in the inability to control this product due tocontroller malfunction, which could lead to serious accidents.

Do not apply strong impact and/or excessive force to the
product, such as hitting it with objects, or dropping it.
Do not use the product of which the appearance has become
deformed.
Failure to follow this could result in serious or unexpected accidents.

Do not step on or over this product.
Failure to follow this could result in people falling and/or malfunction.

CAUTION
Do not come into contact with the moving parts, such as thecarrier wheels, transfer rollers, or lifting sections, and/or
allow clothes to get close to them.
Failure to follow this could result in hands getting caught and/or stuck.

Never remodel the product.
Failure to follow this could result in serious accidents. We assume no
responsibility for remodeled products.

Make sure to attach ground wires to this product and the DC
power supply unit.
Failure to follow this could result in electric shock if any malfunction orleakage occurs.

Do not put water and/or oil on the product, and do nottransfer wet and/or oily trays.
Failure to follow this could result in electric shock, and/or malfunction.

Stop operation when abnormal sound is heard during operation.
Failure to follow this could result in unexpected accidents.

Do not use in a way exceeding the range of the productspecifications.
Failure to follow this could result in malfunction, fire, and/or injury.

Turn off the power supply to the product before moving,
installing, and/or wiring the product, and before performing
maintenance and inspection (excluding cases when the
power is to remain turned on).
Working while the power is on could result in unexpected accidents.

Advance preparation
Installation/Wiring

When using the product in places where serious accidents
and/or damage may possibly occur, install backup and/or
fail-safe functions systematically.

Control/Operation

Failure to follow this could result in explosion, fire, electric shock and/or
injury.

Maintenance/Inspection

Do not use the product near places subject to explosive,
flammable gas, and/or corrosive atmosphere, and/or
combustible materials.

Troubleshooting

WARNING

Appendix

3-1.
General precautions

Safety precautions

3. Safety precautions

General precautions

9

M-RAT User Manual

3-1.
General precautions

CAUTION
Do not turn on/off relays and/or contactors near power
cables, signal cables, and/or controllers.

Safety precautions

3. Safety precautions

Do not forcibly rotate carrier wheels or transfer rollers withexternal force.
Failure to follow this could result in damage to controllers, and/or their
lifetime to be significantly shortened.

When disposing of the product, make consigning contracts
with licensed industrial waste disposers, and consign thedisposal to them.

WARNING
Ensure the safety of the surrounding area, transportationroute, and footing when carrying the product.
Failure to follow this could result in serious or unexpected accidents.

Have the appropriate number of persons assist when
installing the product.
When moving the product, be sure to use carrying
equipment, such as a transport dolly, pallet truck, and forklift.
Using only manpower could result in unexpected accidents.

When hoisting this product, never enter the area under thesuspended load.
When hoisting, use appropriate hoisting equipment, and pay special attention
to prevent the balance of the suspended load from being lost and/or falling.
Also, have only qualified workers conduct the operation.
Insufficient hoisting could result in serious accidents.

Do not lift this product with goods loaded.
Failure to follow this could result in injury, accidents, and/or damage due toload collapse.

Appendix3-2.
Precautions on installation

Installation/Wiring

Turning on/off the power in the wrong order could result in malfunction.

Control/Operation

Turn ON the power in the order of external control devices,and then this product.
Turn OFF the power in the order of this product, and thenexternal control devices.

Maintenance/Inspection

Carefully check the output circuit.

Troubleshooting

LED or Pull-up/Pull-down circuits implemented on the output
of control devices could result in unexpected operation.

Advance preparation

Failure to follow this could result in malfunction due to noise generation.

Precautions on wiring

10

M-RAT User Manual

CAUTION
When handling, wear protective equipment, such as gloves.
Failure to follow this could result in hands getting injured by metal parts.

Make sure to use the recommended tightening torque totighten screws for fixing the main unit and/or fastening
screws of controllers.
Failure to follow this could result in bolts and/or screws loosening, and/or
malfunction.

If necessary warning/caution labels become hidden after
installation, affix again on places where they can be seen.
3-3.
Precautions on wiring

CAUTION
When attaching or removing connectors, turn off the power
first, securely hold connectors, and perform operation.
Do not apply excessive force to the controller connection
parts, such as obliquely attaching or removing connectors.
Failure to follow this could result in electric shock, malfunction, and/or
accidents due to unexpected operation.

Perform wiring to connectors so that cables make securecontact with connectors.
Barb lines from the cable core could result in heat generation and/or fire due
to changes of contact resistance, and/or short circuit with the adjacentcontact.

Do not forcibly bend and/or pull cables.
Do not put heavy materials on cables, or do not get themstuck between cables.
Failure to follow this could result in fire and/or electric shock due to cabledamage.

3-4.
Precautions related tooperation

WARNING
Do not get close to the product during operation.
If you get close to the product out of need, check the flow of trays andsurrounding conditions, and ensure safety before approaching.

Advance preparation

Failure to follow this could result in hands or fingers getting stuck.

Installation/Wiring

Do not put hands or fingers in between the machine andframe, and between the machine and stay.

Control/Operation

For example, mount guide rails on the conveyor frames.
Failure to follow this could result in workers getting injured by trays poppingout of the equipment.

Maintenance/Inspection

Take appropriate measures to prevent trays from poppingout of the equipment.

Troubleshooting

WARNING

Appendix3-2.
Precautions on installation

Safety precautions

3. Safety precautions

Precautions on start-up inspection/
maintenance and inspection

11

M-RAT User Manual

Do not unplug power and/or signal cables during operation.
Do not run/stop this product using the power supply.
Failure to follow this could result in malfunction.

In the event that any abnormalities occur, for example, if
abnormal noise is heard from the product, the temperature
becomes high, or electric leakage occurs, turn off the power
immediately.
Failure to follow this could result in unexpected injury.

3-5.
Precautions on start-up
inspection/maintenanceand inspection

WARNING
If any abnormalities are found, do not use this product until
the causes have been eliminated completely.
Using this product with unattended abnormalities could result in not only
damage to the devices, but also unexpected accidents.

Have specialists (or people who have sufficiently acquired
skills) perform maintenance and inspection under
instructions by management supervisors.
At the time of maintenance and inspection, post warninglabels so as to prevent unauthorized persons from turning on
the power.
Failure to follow this could result in unexpected accidents.

CAUTION
Secure the working space for maintenance around thisproduct.
Working in the forced position could result in injury and/or unexpected
accidents.

For maintenance and inspection, wear protective equipment,such as gloves.
Failure to follow this could result in hands getting injured by metal parts.

Do not disassemble sections and/or parts other than thosespecified.
Failure to follow this could result in malfunction and/or unexpected accidents.

Make sure to prepare maintenance parts designated by us.
Using parts other than those designated by us could result in malfunction.

Advance preparation

Wear protective equipment, such as gloves.

Installation/Wiring

Make sure to perform the start-up inspection before starting
operation.

Control/Operation

Failure to follow this could result in damage and/or malfunction.

Maintenance/Inspection

Do not forcibly move trays when they are placed on the
product.

Troubleshooting

CAUTION

Appendix

3-4.
Precautions related tooperation

Safety precautions

3. Safety precautions

Maintenance/Inspection

4. Advance preparation
Troubleshooting

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

12

Appendix

4. Advance preparation

M-RAT User ManualWiring image

13

M-RAT User Manual

SensorSN･R

AC power
supply

PLC, etc.
Controller

Breaker

SN･S

M-RAT main unit
Emergency
stop switch

Advance preparation

Wiring image

Safety precautions

4. Advance preparation

Important ・As for the sensor input, and input/output signals of driver cards,
adopt the number of inputs/outputs based on your operation needs.

① 24V DC power supply

Before introducing this product, prepare the following devices separately.
Power supply equipment to supply 24V DC to this product● Switching power supply● 24V DC battery
Specifications of the power supply unit

・24V DC / 8A, 192 W or more・Peak current 30 A (1 msec or less)
About control■ M-RAT uses MDR for carrier wheel transfer, roller transfer, and transfer surface
switch (3 axes in total). We recommend controlling to allow each axis to run
independently.
■ A switching power supply is recommended as the DC power supply (24V
DC±10%) for the driver card.
■ Use a stabilized power supply that has an adequate capacity and does notfluctuate due to load variation.
■ The power supply shall have a capacity larger than the total of the MDR rated
values.
■ A transformer type power supply cannot be used.
■ Secure a voltage of 24V DC±10% at the power supply terminal of a driver card.
■ If the power supply capacity is less than the rated power of this product, it
may result in malfunction and/or damage due to the supply voltage drop. Be
sure to use a power supply with a capacity larger than the rated power of thisproduct.
■ In addition, the power supply should not activate protection when the peakcurrent flows for 1 msec or less.
■ For the power supply unit, use an isolation type switching power supply compliant
with the safety standard (IEC60950-1 or UL60950-1). Do not use a non-isolation
type power supply for safety reasons, since it may not conform to the radiationnoise regulations.

Appendix

Items to be preparedby customers

Control/Operation

DC24V
Power supply unit

Maintenance/Inspection

CBK-109

Troubleshooting

CB-01616

Installation/Wiring

CBK-109

Items to be prepared by customers

M-RAT User Manual

14

・A stay used to install the M-RAT main unit. For details on how to mount, refer to P.26.
■ Stays, mounting bolts, and washers are not included in the product. Order separately.
■ When installing the M-RAT main unit, make sure to use the designated stay.

Piece＊

Model：MRAT-FST

L：BF length (mm)1Remarks

・With eight height adjustment shims

Installation/Wiring

Model・With mounting bolts/washers＊Two stays are necessary for one unit.
Dimension X

Dimension Y

380mm
500mm

590〜709mm
710〜829mm

7580

620mm

830〜949mm
0
L -0.5（BF length）

5
35
t4.5

t3.2

For machine heightadjustment screw

For machine
fixing screw

①

④

t4.5
2.5

Troubleshooting

（107）

（117）

117

107

60
2×4-R5X（Pitch between mounting screws）
2-M8 weld nut
2-Ø10

2.5
25

Note)
Protrusion

17.5

5

Maintenance/Inspection

Type6060 / 7560
7570

2×2-M8 weld nut
For mounting stay fixing screw

2.5

①②③

2.5

12.5

2×2-C1

2×2-C1

10

Appendix

（35）

（107）
（117）

＊
10.2
（hole）(3.2)

3.4（hole）Height adjustment shim＊（10） （12.5）

2.5＊Dimensions to drill a hole so that a
protrusion will come out when making
the stay.

2.5

10（4）

Height adjustment shim
4

For machine height adjustment

50
30

For fixing the machinePart name4（8）Spring washer No.2 M84（8）Plain washer normal type M84（8）For machine height adjustment

Hex. socket head bolt M8x202（4）For fixing the machine

Hex. bolt with spring washer No.2 and plain washer
large type M8x202（4）For fixing the stay

③
①
④

Piece

Hex. socket head bolt M8x20

①
②

30

For fixing the stay1

■ The number in parentheses shows pieces per M-RAT unit (for two stays).

20

3

117

2

10（4）

Note) Holes need to be drilled in the frame where the stay is mounted. (Refer to P.18)

Mounting bolts/washers
1

Control/Operation② Stay (option)

Advance preparation

Items to be preparedby customers

Safety precautions

4. Advance preparation

20∅

Material: SUS/Board thickness: t0.5

Control devices/Sensors

M-RAT User Manual15

4. Advance preparation
Devices to control this product, such as PLCs

④ Sensors

Zone sensors to check the tray, and area sensors to check loading anddischarging, etc.

Area sensor (Discharge)

Transfer direction

Zone sensor
A sensor to detect the existence of trays within the zone

Installation/Wiring
Control/Operation

M-RAT zone sensor

Maintenance/Inspection

Area sensor (Discharge)

Troubleshooting

Area sensor (Load)

Advance preparation

Safety precautions③ Control devices

Area sensor

Term

Appendix

A sensor to detect load and discharge of trays⑤ Wiring materials

Necessary for wiring of power and signal cables, branch connectors, driver cards,
controllers, such as sensors or PLCs, and power supply.
Available wire diameter for driver card connectors
Connector

Driver card

Power connector
Control connector

CBK-1090.8〜1.5m㎡（AWG：18〜14）

CB-016
0.5〜1.5m㎡（AWG：20〜14）

0.08〜0.5m㎡（AWG：28〜20）■ To select the current capacity of wiring materials, secure a high safety margin
based on the current value in the equipment to be used.
■ Longer wiring between the power supply unit and driver cards/controllers could
cause the voltage to decrease, resulting in malfunction and/or damage.

MDR extension cables (Option)

16

M-RAT User Manual■ CBK-109：12P extension cable(Male side)

12P extension cable length

L= 600mm

ACE-CBM-G1200

L=1200mm(Female side)

37.5

Model
ACE-CBM-G0600

60 ±5

37

■ CB-016：10P extension cable(Male side)

10P extension cable length

ACE-CBM-A0600
ACE-CBM-A0850

L= 850mm

ACE-CBM-A1200

L=1200mm(Female side)

32.5

Model

L= 600mm

L

60 ±5

37

L

Advance preparation

Necessary when the installing location of the M-RAT main unit is far from that ofthe driver card.

Installation/Wiring⑥ MDR extension cables(Option)

Safety precautions

4. Advance preparation

Install the emergency stop equipment on the side of the 24V DC power unit towhich the power is supplied.
Emergency stop
equipment safety circuit

AC power supply
BreakerThis product
24V DCpower supply
unit
PE⑧ Checking the breaker Regarding equipment where this product is installed, check that a breaker with appropriate capacity
for AC input specifications of the 24V DC power supply unit has been installed. If abnormal operation
should occur, protection through the breaker could be effective.
When using an earth leakage breaker, select one that is “inverter corresponding”. Some inverter
non-corresponding earth leakage breakers could result in malfunction, since they may recognize
high-frequency components of the switching power supply as leakage.

⑨ Operation check

When the 24V DC power supply unit has been installed, check that the breaker and safety circuit canwork properly. Perform operation following the trial operation after checking them.
① Input to the 24V DC power supply unit (AC power) is securely turned ON/OFF when turning
ON/OFF the breaker.
② This product input (24V DC) is securely turned OFF/ON when turning ON/OFF the safety circuit.

Maintenance/Inspection

This product does not include the emergency stop equipment.
Customers must make sure to install it.

Troubleshooting⑦ About the emergency
stop equipment

Appendix■ Do not extend cables by connecting multiple extension cables.

Control/Operation■ Use an extension cable of 1200 mm or less.

About the wiring method

M-RAT User Manual

17

When overcurrent protection devices need to be installed to the 24V DC power supply unit, somepower supplies that need to conform to the safety standards (UL62368-1, etc.) require installationof the specified overcurrent protection device based on their specifications. In such cases makesure to install the specified overcurrent protection device as described in the figure below. When
overcurrent protection devices are not required in specifications of the 24V DC power supply unit,
they do not need to be installed.
(Overvoltage Category-2)(Overvoltage Category-3)
Overcurrent
protection

Breaker⑩-2 Installing
When using a power supply other than a limited power supply, install an overcurrent protection
overcurrent
device on the 24V DC line.
protection devices⑩-3 Adding the power
shutdown circuit ofthis product in theevent of a failure

In the event that a failure occurs, such as overload or abnormal temperature, the driver card willtransmit the data of failure generation to PLC devices, as well as stopping product operation.
However, the product does not have the power shutdown function. Accordingly, if the product’s
power needs to be shut down in the event of a failure, as described in SW1 of the figure below, add
the power shutdown circuit using a PLC.
I/O signal
PLC

Factory
AC power

Breaker

Breaker

SW1 shutdown
24V DC
contact
power supply unit

Power

Driver card

Installation/Wiring

Safety circuitControl/Operation

24V DCpower supply unit

Driver card

Maintenance/Inspection

Breaker

Safety circuit■ At the time of power shutdown, not only the main unit power, but also the drivercard control power will be shut down.

Troubleshooting

Factory
AC power

Appendix⑩-1 When overcurrent
protection devices
are required

Advance preparation⑩ About the wiring method

Safety precautions

4. Advance preparation

Checking appearance andmodel/Structures

18

M-RAT User Manual

After unpacking, check that there is no abnormalities in the product.
① Check that the main unit is free from any abnormalities, such as traces of scratches,
dents, dirt, and/or corrosion (rust).
② Check that there is no omission and/or looseness of screws.

If any abnormalities are found, contact the supplier immediately.

Checking the model

Check that the product model is what you ordered.
Carrier wheel cassette

Structures

Resin slider

Idler

Advance preparation

Checking appearance

Safety precautions

4. Advance preparation

Roller transfer MDR＊The photo is for size 7570.

Product label details

FLAT RIGHT ANGLE TRANSFER
M-RAT- F15 - 7570 - C N - S1
RATED INPUT: DC24V / 4.9A
RATED POWER: 80W
PAYLOAD: max 250 kg
SERIAL No:K210106090-001
MFG. YEAR: 2019

MADE IN JAPAN

MｰRATｰF15ｰ7570ｰCNｰS 1① Motor specifications
・F … FESeries + KT Series⑥ Version
Appendix

Product designation

ITOH DENKI CO.,LTD

Troubleshooting

Model

・V … VSSeries + KVSeries
・S … VSSeries + KSSeries⑤ Input and output signals
・N … NPN② Nominal speed
・15 / 30 (m/min)③ Size (machine length × machine width) mm
・6060 … L598 × W580 mm
・7560 … L748 × W580 mm
・7570 … L748 × W700 mm
・7580 … L748 × W820 mm(These are reference dimensions.)

・P … PNP④ Driver card type
・C … CBK-109 / CB-016（When ① is F）
・E … CBV40 / CBK70（When ① is S）
・E … IB-E03 / IB-E04（When ① is F）
・E … IBV-E32MB（When ① is V）
・E … IBE-MM7740S（When ① is S）
・P … IBP-MM7740S（When ① is S）

Nominal speed
Terminology

Control/Operation(Can be seen when the top
cover is removed)

Maintenance/Inspection

Top cover

Drive belt

Installation/Wiring

Carrier wheel roller

This is a formal indication of the transfer speed. Values differ from theactual speed.

Checking accessories

19

M-RAT User Manual

Check that all the following items are included.

Driver card

Depending on the M-RAT input and output signal type, driver cards with the NPN (N)or PNP (P) signal input and output are included.
(Not included if driver cards are not specified.)

SPEED

0V
24V

78

23

456

456

CBK-109FN

Driver card

For carrier wheel transfer/transfer surface switch

CB-016BN6

For roller transfer

21Power connector

Installation/Wiring

456
78

5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN

90 1

23

Driver card

9 0 1

78

VR1-ACC

VR2-DEC

0V
24V

90 1

CB-016BN6STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. L/H

78

PLS
ERR
V-IN
DIR
RUN

23

VR1-ACC

9 01

2 3

VR2-DEC

SPEED

4 56

CBK-109FN

STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E-OUT/N-OUT
5. L/HFor M−RAT−F□□−□□□□−CN−S1

Advance preparation

Checking accessories

Safety precautions

4. Advance preparation

Control/Operation

Common to each driver card

EAHB05

3
Control connector
Common to each driver card

PACB16

Cross-recessed head SW screw M4×15 / Hex. nut M4

4 sets

456

90 1

78

456

CBK-109FP

5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN

Driver card

CB-016BP6

For carrier wheel transfer/transfer surface switch

For roller transfer

21Power connector
Common to each driver card

EAHB05

3
Control connector
Common to each driver card

PACB16

3

Cross-recessed head SW screw M4×15 / Hex. nut M4
for securing each driver card

0V
24V

456

Driver card

9 0 1

78

VR1-ACC

VR2-DECSTATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. L/H

78

SPEED

23

78

0V
24V

CB-016BP6

23

90 1

PLS
ERR
V-IN
DIR
RUN

23

VR1-ACC

9 01

2 3

VR2-DEC

SPEED

4 56

CBK-109FP

STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E-OUT/N-OUT
5. L/HFor M−RAT−F□□−□□□□−CP−S1

4 setsAppendix

for securing each driver card

Troubleshooting

Maintenance/Inspection

3

5. Installation/Wiring5-1. Before installation･･･
5-2. Installation
5-3. Wiring
5-4. Connecting to devices

…… 21
…… 26
…… 28
…… 31

Troubleshooting

5. Installation/Wiring

Maintenance/Inspection

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

M-RAT User Manual

Appendix20

Size 6060

M-RAT User Manual

21

・When installing the machine, make sure to use the designated stay.
・Prepare stands, and process conveyor frames in advance.
・Determine the mounting location for zone sensors to check the existence of trays,
and area sensors to check loading and discharging. Then, prepare for them to be
mounted.

Machine dimensions
Size 6060
L598mm×W580mm(Reference dimensions)

601.2
83.4

（431.8）
114.3

101.6

Control/Operation
Troubleshooting

Maintenance/Inspection

480＝P120×4 (Roller pitch)

580 (Base outer dimension)

50

114.3

586.4

(Base outer dimension including bead processing)

101.6

Appendix（601.2）（175）（586.4）380（Pitch between mounting screws） 100

Excluding the protrusion

Installation/Wiring

598 (Base outer dimension)

175（Transfer surface）

Wiring hole ＊(Base outer dimension including bead processing)

Advance preparation

5-1.
Before installation

Safety precautions

5. Installation/Wiring

Wiring hole ＊97.2

403.6 (Pitch between mounting screws)＊Guide for cable marginal projecting length（mm）

M1 : For carrier wheel transfer

750

M2 : For roller transfer

750

M3 : For transfer surface switch

1300

SN・S（Proximity sensor）

800

SN・R（Proximity sensor）

750

Size 7560

M-RAT User Manual

22

Size 7560
L748mm×W580mm(Reference dimensions)

Safety precautions

5. Installation/Wiring

751.2 (Base outer dimension including bead processing)748 (Base outer dimension)

114.3

114.3

Installation/Wiring

50

114.3

Maintenance/Inspection

Control/Operation

480=P120×4 (Roller pitch)

580 (Base outer dimension)(Base outer dimension including bead processing)

127

586.4

Troubleshooting（751.2）

Appendix

380（Pitch between mounting screws）

114.3

（175）

100

Excluding the protrusion

Wiring hole ＊（584.2）

Advance preparation

82.2

175（Transfer surface）

Wiring hole ＊97.2

553.6 (Pitch between mounting screws)＊Guide for cable marginal projecting length（mm）

M1 : For carrier wheel transfer

750

M2 : For roller transfer

750

M3 : For transfer surface switch

1300

SN・S（Proximity sensor）

800

SN・R（Proximity sensor）

750

Size 7570

M-RAT User Manual

23

Size 7570
L748mm×W700mm(Reference dimensions)

Safety precautions

5. Installation/Wiring

751.2 (Base outer dimension including bead processing)748 (Base outer dimension)（584.2）
114.3

114.3

127

114.3

114.3

Installation/Wiring
Maintenance/Inspection

Control/Operation

600=P120×5 (Roller pitch)

700 (Base outer dimension)(Base outer dimension including bead processing)Troubleshooting
Appendix（751.2）（175）

Wiring hole ＊706.4

500（Pitch between mounting screws）

100

50

Excluding the protrusion

Advance preparation

82.2

175（Transfer surface）

Wiring hole ＊97.2

553.6 (Pitch between mounting screws)＊Guide for cable marginal projecting length（mm）

M1 : For carrier wheel transfer

750

M2 : For roller transfer

650

M3 : For transfer surface switch

1300

SN・S（Proximity sensor）

800

SN・R（Proximity sensor）

750

Size 7580

M-RAT User Manual

24

Size 7580
L748mm×W820mm(Reference dimensions)

Safety precautions

5. Installation/Wiring

751.2 (Base outer dimension including bead processing)748 (Base outer dimension)
82.2

175（Transfer surface）（584.2）
114.3

114.3

127

114.3

114.3

Installation/Wiring
Maintenance/Inspection

Control/Operation

720=P120×6 (Roller pitch)

820 (Base outer dimension)(Base outer dimension including bead processing)
826.4

620（Pitch between mounting screws）

100

50

Advance preparation

Excluding the protrusion

Troubleshooting

Wiring hole ＊（175）

Appendix（751.2）

Wiring hole ＊97.2

553.6 (Pitch between mounting screws)＊Guide for cable marginal projecting length（mm）

M1 : For carrier wheel transfer

750

M2 : For roller transfer

650

M3 : For transfer surface switch

1300

SN・S（Proximity sensor）

800

SN・R（Proximity sensor）

750

Preparation to mount driver cards

25

M-RAT User Manual・Perform mounting processing on the frames and control panel by reference tothe mounting holes for driver cards.
・ For cable opening and projection from the M-RAT main unit, refer toMounting preparation for the M-RAT main unit (P.21).
■ Mount driver cards on a flat surface where heat can be released easily.
■ Prevent chips generated during processing from entering driver cards.

0V
24V

40

78
78

23

90 1

18

PLS
ERR
V-IN
DIR
RUN

4.5

STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E-OUT/N-OUT
5. L/H

VR1-ACC

3

47
129
120

78

901

78

18

0V
24V

23

90 1

5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN

40

STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. L/H

VR1-ACC

52

SPEED
2 3

VR2-DEC

4.5

CB-016B□6

23

4 56

■CB-016

47

4.5

4 56

38.5

3

Preparation of MDR
extension cables

When the installation location of the M-RAT main unit is far from that of the driver card,
prepare MDR extension cables separately. (Refer to P.16)

Mounting preparation
for sensors

Determine the mounting location for zone sensors and loading/discharging area
sensors. Then, prepare for them to be mounted.
Example)Mounting location for e
ach sensor
Area sensor (Discharge)

Area sensor (Discharge)

M-RAT zone sensor

Area sensor (Load)

Transfer direction

Control/Operation

456

38.5

Maintenance/Inspection

4.5

VR2-DEC

901
2 3

59

SPEED
456

CBK-109F□

Installation/Wiring

25

129
122

■CBK-109

Troubleshooting

1

Advance preparation

Hole processing on frames and control panel

Appendix

Preparation to mountdriver cards

Safety precautions

5. Installation/Wiring

Installing the M-RAT main unit

M-RAT User Manual

26

Items to be prepared● Stay● Hanging hook (with lock)● Cargo handling equipment
6mm

hex. wrenchsuch as hanging belts

Advance preparation

hex. wrenchInstalling the M-RAT main unit
Frame

For machine fixing screw

Mount stays on conveyor frames.

■ Recommended tightening torque：

For machine heightadjustment screw

Installation/Wiring

1

Stay

25〜29Nmmm

A Frame processing figure
○
3.4

20.2

60

20.2

Transfer surface height from the stay
mounting position

S ize
S

X (P
mou itch betw
nting
een
screw
L (BF
s)
Leng
th)

10.2

2-Φ9

10.2

3.4

A
○

Type

Dimension X

Dimension Y

6060 / 7560
7570

380mm
500mm

590〜709mm
710〜829mm

7580

620mm

830〜949mm

Frame

Plain washer
normal type M8
Spring washer
No.2 M8
Hex. socket
head bolt
M8x20

192.5

Stay

(175)

Control/Operation

3.6

m 55
.6m580：340 7： 0/60 /757
06 60
ize 75Maintenance/Inspection

3mm

Troubleshooting

5-2.
Installation

Safety precautions

5. Installation/Wiring

AppendixTool: 6 mm hex. wrench

Stay

2

Follow the steps below when transporting/moving themachine.

1

Remove the top cover of the machine.

2

Hang the hanging hooks with locks into the holes at the four
corners (four positions) of the machine, and pull it up at thefour positions.
■ Pull the machine vertically at all four
positions.
Do not pull at the center of the machine,
like with crane operation.

Top coverTool: 3 mm hex. wrench∅
22Installing the M-RAT main unit

M-RAT User Manual

27

After checking the machine installation direction,hang the machine and secure it to the stays.

Roller transfer direction

M-RAT■ Recommended tightening torque：
Carrier wheel rollertransfer direction

Dimension X

Dimension Y

380mm
500mm

590〜709mm
710〜829mm

7580

620mm

830〜949mm※ If transfer cannot be carried out smoothly, or
the transfer surface inclination is 0.5% or more,
perform the following steps to adjust the level.

ー Machine height adjustment ーX (Pitc
h betw①Mount the bolts for machine heightadjustment, and adjust the height of
the M-RAT main unit.

een mounting screws)

Size 6060：403.6mm
Size 7560/7570/7580：553.6mm

M-RAT
Stay
Machine height adjustment screw

For machine heightadjustment screw

For machine fixing screw

Hex. socket head bolt M8×20＊Height
adjustment
shim
高さ調整シム※機体高さ調整をする
場合に必要です。

②Put the height adjustment shims
based on the adjusted height.

Maintenance/Inspection

・Align the height adjustment shims with theholes so that the machine fixing bolts can bemounted.

M-RAT

Troubleshooting

Stay
Hole for machine fixation
Height adjustment shim

③Remove the bolts for machineheight adjustment.

Installation/Wiring

Type6060 / 7560
7570

Advance preparation

25〜29Nm

Control/Operation

3

Safety precautions

5. Installation/Wiring

L（Lフレ
(BF L
ーム内
engt
寸法h）
)

■ After adjustment, makesure to remove themachine height adjustment
screws.
Machine fixing screw
Tool: 6 mm hex. wrench

Hex. socket head bolt with washer M8×20

M-RAT

Heightadjustment shim
Machine fixing screw
Hex. socket head bolt with washer M8×20

4

Remove the hooks and mount the top cover.
■ Top cover tightening torque：

Top cover

2.9〜3.5Nm

5

Align levels of the machine and adjacentconveyors, etc.
(For level adjustment, refer to step 3 .)Tool: 3 mm hex. wrench

Appendix④Secure the M-RAT using the machine
fixing bolts.

StayMounting driver cards

28

M-RAT User Manual

5. Installation/Wiring
Safety precautions

Mounting driver cards
Use the included screws and nuts to mount driver
cards on the conveyor frames or control panel.
■ Recommended tightening torque:

1.5〜1.9N･m

Mounting sensors, control devices, and power supply units
Mount customer-prepared zone sensor and area sensor for loading and discharging,as well as power supply units, and PLCs.

main unit and driver cards

Connecting the M-RAT main unit and driver cards
・Refer to the labels for cables coming from M-RAT main unit, and securely connect
the MDR connectors and driver cards.
・When using extension cables, securely connect the MDR connector andextension cable, as well as the extension cable and driver card.

Troubleshooting

Connecting the M-RAT

Control/Operation

5-3.
WiringMaintenance/Inspection

Mounting sensors,
control devices, andpower supply units

Installation/Wiring

Advance preparation

1.5〜1.9N･ｍ

SN・S
Belt・
CRR.Wheel●Sensor on the side of carrier wheel transfer
SN･S

SN・R
RollerFor carrier wheel MDR

PLC, etc.

●Sensor on the side of roller transfer
SN･R

M1

Brown：24V
Blue：0V
Black：out＊

Brown：24V
Blue：0V
Black：out＊

PLC, etc.

＊ON when the position is detected
Output current: Max 100 mA

M1
Belt・
CRR.Wheel

M3

CBK-109

For transfer surface
switch MDR

M3
Lifting

CBK-109
M2
M2
Roller

For roller MDR

CB-016■ Besure to use with SW1#5 OFF
and SW5 (SPEED) : 6 settings.
(Refer to P.31)

Appendix

Mounting driver cards

M-RAT 本体とドライバの接続
CBK-109
wiring

M-RAT User Manual29

M3: For transfer surface
switch

CBK-109CN2
0V OUT#2
CN1（Power） #1

1

）

CN1
Detailed description

OutputInstallation/Wiring

Output#3 Analog input

Power connector (CN1)｝ （0V
24V DC・Outputs 2 pulse signals for each rotation of the internal motor.
・NPN open collector output. (NPN output only)
Motor pulse output ・Attach protection resistance so that the output is 25mA or less.
・Protection resistance of 100 Ω is included inside driver cards.

Error signal output
MDR external
speed setting

#2

Input

MDR rotation direction
switching

#1

Input

MDR RUN/STOP・Outputs when MDR abnormalities have detected.
・Signal output settings under the normal condition/when an error occurs can be
specified using DIP-SW1#4 ON/OFF.
・Open collector output.（CBK-109FN : 0V / CBK-109FP : 24V）
・Attach protection resistance so that the output is 25mA or less.
・ Protection resistance of 100 Ω is included inside driver cards.

Control/Operation

CN2（Control） #4

0-10V IN
CBK-109FN：0V
IN
CBK-109FP：24V

0V
24V DC
Function#5

OUT

Advance preparation■ Connector description

0V
24V（ CBK-109FN：0V
CBK-109FP：24V ）1 2 12345

PLS
ERR
V-IN
DIR
RUN

The transfer speed can be set using 0-10 V voltage input.
The transfer direction can be switched.
RUN/STOP signal.

Connect the 24V DC and 0V DC cables to CN1 (2 pins).

Power connector（CN1）■ Do not connect multiple power cables to one

pin.Failure to follow this could result in electric shock,short circuit, and/or damage due to the capacity ofconnectors being exceeded.
(Connector capacity: 10 A)

DC 0V
24V DC■ Connect the 24V DC and 0V DC cables correctly.
■ Do not connect cables when connectors are plugged in.

2

0.80〜1.5mm 2（AWG:18〜14）

Connect each cable to CN2 (5 contacts).

Control connector（CN2）＊Refer to the above, and perform wiring based on your operation needs.
＊Switch the transfer surface using MDR RUN/STOP and rotation direction
switching. As such, CBK-109 for M3: transfer surface switch needs
CN2#1 and #2 wiring.

Appendix

Control connector (CN2)7mm■ Use the same voltage to be input to CN2#1 (MDR

RUN/STOP) and CN2#2 (MDR rotation direction) as
the power supply voltage.
(Connector capacity: 4 A)

7mm
0.08〜0.5mm 2（AWG:28〜20）■ When connecting a relay coil, etc., to the signal

output, use surge protector devices, or perform surge
protection measures using diodes.
Using devices without surge protection measures
could result in damage to the remote output terminal,
if counter electromotive voltage is generated whenswitching the output signal.

3

Connect the power connector (CN1), control connector(CN2), and M1/M3 MDR connectors to driver cards.

MDR
connector

〔M1〕
〔M3〕

For more details on CBK-109, please download the driver card user manual from our web page.

CBK-109

ITOH DENKI

Home>Download/Support>User Manualhttps://www.itohdenki.co.jp/support/manual.html

Maintenance/Inspection

Wiring for CBK-109

Troubleshooting

M1: For carrier wheeltransfer

Safety precautions

5. Installation/Wiring

CBKCB-016 wiring

M-RAT User Manual30

5. Installation/Wiring

CN2

0V
24V

0V

｝IN （ CB-016BN6：0V
CB-016BP6：24V ）
0V
DC24V

CN1

Detailed description

Output・Outputs 2 pulse signals for each rotation of the internal motor.
・NPN open collector output. (NPN output only)
Motor pulse output ・Attach protection resistance so that the output is 25mA or less.
・Protection resistance of 100 Ω is included inside driver cards.

Error signal output
MDR external
speed setting

#2

Input

MDR rotation direction
switching

#1

Input

MDR RUN/STOP・Outputs when MDR abnormalities have detected.
・Signal output settings under the normal condition/when an error occurs can be
specified using DIP-SW1#4 ON/OFF.
・Open collector output.（CBK-109FN : 0V / CBK-109FP : 24V）
・Attach protection resistance so that the output is 25mA or less.
・ Protection resistance of 100 Ω is included inside driver cards.
The transfer speed can be set using 0-10 V voltage input.
The transfer direction can be switched.

RUN/STOP signal.

1 Connect the 24V DC and 0V DC cables to CN1 (2 pins).

Power connector（CN1）

Do not connect multiple power cables to one
pin.Failure to follow this could result in electric shock,short circuit, and/or damage due to the capacity ofconnectors being exceeded.
(Connector capacity: 10 A)

DC 0V
24V

Connect the 24V DC and 0V DC cables correctly.
Do not connect cables when connectors are plugged in.

2

DC

7mm
0.80〜1.5mm 2（AWG:18〜14）

Connect each cable to CN2 (5 contacts).

Control connector（CN2）＊Refer to the above, and perform wiring based on your operation needs.

Appendix

Control connector (CN2)Installation/Wiring

Output#3 Analog input

Power connector (CN1)0-10V IN

Control/Operation

CN2（Control） #4（ CB-016BN6：0V
CB-016BP6：24V ）24V DC
Function#5

OUT

Advance preparation■ Connector description

1 2 12345

0V OUT

5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN

Use the same voltage to be input to CN2#1 (MDR
RUN/STOP) and CN2#2 (MDR rotation direction) as
the power supply voltage.
(Connector capacity: 4 A)
When connecting a relay coil, etc., to the signal
output, use surge protector devices, or perform surge
protection measures using diodes.
Using devices without surge protection measures
could result in damage to the remote output terminal,
if counter electromotive voltage is generated whenswitching the output signal.

7mm
0.08〜0.5mm 2（AWG:28〜20）

MDR
connecto

Connecting to driver cards

3

Connect the power connector (CN1), control connector(CN2), and M2 MDR connector to driver cards.

〔M2〕

For more details on CB-016, please download the driver card user manual from our web page.

CB-016
ITOH DENKI

Home>Download/Support>User Manualhttps://www.itohdenki.co.jp/support/manual.html

Maintenance/Inspection

CB-016#2CN1（Power） #1

Safety precautions

CB-016 wiring

Troubleshooting

M2: For roller transfer

CBKSetting driver cards

M-RAT User Manual31

5. Installation/Wiring
Safety precautions

Setting driver cards

78

Minimum

Advance preparation

01

78

23

9

Minimum

0V
24V

4 56

78

STATUS/
1. AUTO
2. INT/EX
3. DIREC
4. E/N-O
5. L/H

4 56

VR1-ACC

3.V-IN
2.DIR
1.RUN

90 1

VR2

Minimum

Minimum

0V
24V

01

78

23

9

2 3

M2 : CB-016

VR2-DEC

VR1

M3 : CBK-109

Installation/Wiring

4 56

VR1

VR2

78

0V
24V

01

23

9

Control/Operation

78

STATUS/
1. AUTO
2. INT/EX
3. DIREC
4. E/N-O
5. L/H

4 56

VR1-ACC

3.V-IN
2.DIR
1.RUN

90 1
2 3

VR2-DEC■ Make sure to use M3: CBK-109 under the following settings.

4 56

SPEED

SW1
#1

#2

#3

#4

#5

901

456

OFF

VR2

23

VR1

Maintenance/Inspection

Minimum

78

Minimum

5-4.
Connecting to devices
Connecting to power
supply units

Connecting signal cablesof driver cards/sensors to
PLCs

Connecting to power supply units
The power is supplied to the driver card from the power connector (CN1).
Connect customer-prepared power cables of zone and area sensors for loading anddischarging.

Connecting signal cables of driver cards/sensors to PLCs
Connect signal cables of driver cards or standby surfaces to controllers, such as PLCs.
Connect customer-prepared signal cables of zone and area sensors for loading anddischarging.
− Connection example − The following figure is an example. For input and output of each signal,
perform wiring based on your operation needs.。

M-RAT main unit
Carrier wheeltransfer MDR

M1：CBK-109

Rollertransfer MDR

M2：CB-016

Transfer surface
switch MDR
SN･S

M3：CBK-109

SN･R

Output PLC Input

Driver card
CN2＃1 RUN signal
CN2＃1 RUN signal
CN2＃4, ＃5 Switch signal
Load conveyor
RUN signal
Discharge conveyor
RUN signal

Carrier wheel surface standby
Roller surface standby

Area sensor for loading
M-RAT zone sensor
Area sensor for discharging（Carrier wheel roller transfer
direction）
Area sensor for discharging（Roller transfer direction）

Troubleshooting

STATUS/
1. AUTO
2. INT/EX
3. DIREC
4. E/N-O
5. L/H

4 56

VR1-ACC

3.V-IN
2.DIR
1.RUN

90 1
2 3

M1 : CBK-109

VR2-DEC

Check that each driver has the following settings (factory settings).

Appendix

Setting driver cards

6. Control/Operation

6-1. Basic operation
6-2. Program example
6-3. Switching the transfer direction
6-4. Switching the transfer surface
6-5. Changing the speed
6-6. What to do before operation

…… 34
…… 35
…… 36
…… 37
…… 38
…… 40

Troubleshooting

6. Control/Operation

Maintenance/Inspection

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

M-RAT User Manual

Appendix32Device conﬁguration image

33

M-RAT User Manual

Driver card
M1：CBK-109
CN2＃1
RUN signal

Carrier wheeltransfer MDR

M2
2：CB：CB-016016

CN2＃1
RUN signal

Roller transfer MDR

M3：CBK-109
Transfer surface switch MDR

CN2＃1
RUN signal
CN2＃2
DIR signal

SN･S Standby surface signal

Advance preparation

M-RAT main unit

Installation/Wiring

Device configuration image

Safety precautions

6. Control/Operation

Control/Operation

SN･R Standby surface signal

Area sensor for loading
M-RAT zone sensor
Area sensor for discharging(Carrier wheel transfer direction)

Maintenance/Inspection

Area sensor for discharging(Roller transfer direction)
Input

PLC
OutputDischarge conveyor
RUN signal

Label description
M1 ＊1

RUN MDR

Driver card

Carrier wheel transfer MDR

CBK-109

M2＊1

Roller transfer MDR

CB-016

M3＊1

Transfer surface switch MDR

CBK-109＊1 Refer to the labels for cables coming from the M-RAT main unit.

Zone sensor
A sensor to detect the existence of trays within the zone

Area sensor
Terminology

A sensor to detect load and discharge of trays

AppendixTroubleshooting

Load conveyor
RUN signal

Basic operation

M-RAT User Manual

34

About control■ M-RAT uses MDR for each of carrier wheel transfer, roller transfer, andtransfer surface switch (3 axes in total). Make sure to control to allow eachaxis to run independently.

Operation image(Roller transfer → Carrier wheel transfer)

Roller surface standby (SN·R ON)

Load

M2: Roller transfer MDR RUN
NOLoad area sensor ON→ OFF

Advance preparation

6-1.
Basic operation

Safety precautions

6. Control/Operation

Start switching to the carrier wheel surface
SN･S ON
SN･R OFFNO

YES

Stop signal input to M3: CBK-109 CN2#1
Switching to the carrier wheel surface complete

Discharge

Run M1: Carrier wheel transfer MDR
Discharge area sensor ON→ OFF

NO

YES

(Carrier wheel transfer → Roller transfer)

Appendix

Stop running M1: Carrier wheel transfer MDR(loading complete)

Prepare reception(Transfer surface switch)

Maintenance/Inspection(Roller transfer → Carrier wheel transfer)

Signal input to M3: CBK-109 CN2#1

Signal input to M3: CBK-109 CN2# 1 and #2
Start switching to the roller surface
SN･S OFF
SN･R ONNO

YES

Stop signal input to M3: CBK-109 CN2# 1 and #2
Switching to the roller surface complete

Troubleshooting

Switch the transfer surface
to the diverting direction

Control/Operation

Installation/Wiring

YES

Stop running M2: Roller transfer MDR(loading complete)Program example

M-RAT User Manual35

Program example（Operation by loading through carrier wheel transfer and discharging through roller transfer）■ Do not load trays from the roller transfer direction while the standby status on
the carrier wheel surface is output (signal output from SN·S).
Failure to follow this could result in damage to trays, and malfunction.

Operation by loading throughcarrier wheel transfer anddischarging through roller transfer

The following time chart is an example.
For actual control, determine the number of sensors and/or how to place/control them based on youroperation needs.

⇒

Load through carrier wheel transfer⇒

Discharge through roller transfer

Standby on the carrier wheel surface after discharge ends

Installation/Wiring

Basic operation (example)

Zone sensor for discharge conveyor ※1

5

Area sensor for discharging ※2
M-RAT zone sensor ※1

3

Wiring hole

Area sensor for loading

Maintenance/Inspection

2

Control/Operation

4

1

※2

Zone sensor for load conveyor ※1

Input

Zone sensor for load conveyor

Input

Area sensor for loading

Input

M-RAT zone sensor

Input

Area sensor for discharging

3

4

5

ON

ON
OFF
ON
OFF
ON

(Carrier wheel transfer direction) OFF

Carrier wheel transfer MDR

RUN

（M1）

STOP

OutputRoller transfer MDR

RUN

（M2）

STOP

Transfer surface
switch MDR
Output
（M3）

Input

2

OFF

OutputInput

1

Troubleshooting

Tray position

PLC

Appendix

Time chart example

RUN
DIR

SN・R
(Roller surface standby output)

ON

Note 1)

OFF
ON
OFF

Note 2)

ON
OFF

ON
SN・S
(Carrier wheel surface standby output) OFF

It is assumed that driver switches are used based on the initial settings.
Note 1) When controlling the transfer surface switch MDR (M3), keep the time from detection of SN･S or SN･R
until the transfer surface switching MDR stops at less than 20 ms.
Note 2) Make sure to input the MDR rotation direction switch (DIR) signal before inputting the MDR RUN signal.

※1 Zone sensor

A sensor to detect the existence of trays within the zone
※2 Area sensor
Terminology

Advance preparation

6-2.
Program example

Safety precautions

6. Control/Operation

A sensor to detect load and discharge of trays

Note 1)

Switching the transfer direction

36

M-RAT User Manual

Switching the transfer direction

CCW

78
4 56

CN2#
#1

#2

#3

#4

#5

ON

OFF OFF OFF

ON

SW1＃3

CN2#

1 2 3 4 5

0V
24V

0 1

23

78

ON

IN

1 2 3 4 5

STATUS/ERR
1. AUTO/MAN
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. L/H

VR1-ACC

90 1

9

SW1＃3

5.PLS
4.ERR
3.V-IN
2.DIR
1.RUN

SPEED
2 3

VR2-DEC〔CBK-109〕

IN

OFF(Factory setting)

CW

CCW

CCW

CW

Transfer and stop in the CW Note) direction by signal input from the control connector.
Note: When SW1#3 of CBK-109/CB-016 is OFF

CN2#1
CN2#2

24V
0V

Appendix

Power

Control/Operation

M1: Carrier wheel transfer

Maintenance/Inspection

CW

Installation/Wiring

Wiring hole

Troubleshooting〔CB-016〕

CCW M2: Roller transfer CW

Carrier wheel transfer/
Roller transfer

Advance preparation

Switching the transfer direction can be set using the DIP-SW on the driver card and signal input
from the control connector.

4 56

6-3.
Switching the transfer
direction

Safety precautions

6. Control/Operation

RUN
STOP
ON
OFF

Transfer

RUN(MDR rotation)

STOP

20 ms or over

Switching the transfer surface

M-RAT User Manual37

Switching the transfer surface
The transfer surface can be switched by inputting the signal to CN2#1 and CN2#2.
Roller transfer

Carrier wheel transfer

Advance preparation〔M3:CBK-109〕
Roller transfer →Carrier wheel transfer
PLC

Output CN2#1

RUN

ON
OFF

Output CN2#2

DIR

ON
OFF

Input

SN･R

Input

SN･S

OUT1

（

ON

Roller surface
standby output

） OFF

OUT2

（

Carrier wheel surface
standby output

）

※

ON
OFF

Installation/Wiring

6-4.
Switching the transfer
surface

Safety precautions

6. Control/Operation

STOP

Carrier wheel transfer direction RUN

Roller transfer

Maintenance/Inspection

Carrier wheel transfer

PLC

Output CN2#1

RUN

ON
OFF

Output CN2#2

DIR

ON
OFF

Input

SN･R

Input

SN･S

OUT1

（

Roller surface
standby output

）

OUT2

（

Carrier wheel surface
standby output

ONOFF

20 ms or over

※

ON

）OFF

Troubleshooting

Carrier wheel transfer →Roller transfer

Control/Operation

Roller transfer direction RUN
M3: Transfer surface switch MDR

Roller transfer direction RUN
STOPCarrier wheel transfer direction RUN※ When controlling M3: Transfer surface switch MDR, keep the time from detection of SN･S or SN･R until thetransfer surface stops to less than 20 ms.

6-5.
Changing the speed

Changing the speed
There are two speed change settings: the internal speed change setting, where the speed
can be changed using the switch on the driver card, and the external speed change setting,where the speed can be changed by inputting the analog voltage to CN2#3.

M2: Roller transfer〔M2:CB-016〕

Wiring hole

M1: Carrier wheel transfer〔M1:CBK-109 〕

Appendix

M3: Transfer surface switch MDR

Changing the speed

M-RAT User Manual38

6. Control/Operation
External speed setting

1 Turn SW1#2 ON.

2 Set SW1#5 and SW5.

2 Input the voltage to CN2#3.

OFF OFF OFF

1
Speed chart

ON

ON

#2

#3

#4

#5

2

ON

OFF OFF

ON

DC
0〜10V
IN

1

Control/Operation

#1

23

ON

CN2#3

SW1

90 1

2

■Nominal speed of 15 m/min typem/min (Speed accuracy: ±3%)

SW1#5：ON

SW1#5：OFF

9

8

7

6

5

4

3

2

1

0

9

8

7

3

2

1

0

M1
Carrier wheel speed

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

14.8 13.3 11.8 10.4 8.9

7.4

5.9

4.5

M2
Roller speed

ー

ー

ー

ー

ー

14.6 13.2 12.4 11.5 10.7

9.9

9.1

8.2

7.4

6.5

5.8

4.9

4.1

3.3

2.5

9.6

〜

9.1

〜

8.6

〜

8.1

〜

7.6

〜

7.1

〜

6.6

〜

6.1

〜

5.6

〜

5.1

〜

4.6

〜

4.1

〜

3.6

〜

3.1

〜

2.6

〜

2.1

〜

1.6

〜

1.1

〜

0.6

〜

0.1

9.9

9.4

8.9

8.4

7.9

7.4

6.9

6.4

5.9

5.4

4.9

4.4

3.9

3.4

2.9

2.4

1.9

1.4

0.9

0.4

External voltage Input
（V）

6

5

4

〜

SW5

・ indicates the maximum speed that can be set.
・Change the speed up to the values described above.

■Nominal speed of 30 m/min typem/min (Speed accuracy: ±3%)

SW1#5：ON
8

7

6

3

2

1

0

M1
Carrier wheel speed

ー

ー

ー

29.7 28.2 26.7 23.7 22.3 20.8 19.3 17.8 16.3 14.8 13.3 11.8 10.4 8.9

7.4

5.9

4.5

M2
Roller speed

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

ー

29.3 26.4 23.5 20.5 17.6 14.7 11.7 8.8

〜

9.6

〜

9.1

〜

8.6

〜

8.1

〜

7.6

〜

7.1

〜

6.6

〜

6.1

〜

5.6

〜

5.1

〜

4.6

〜

4.1

〜

3.6

〜

3.1

〜

2.6

〜

2.1

〜

1.6

〜

1.1

〜

4

3

2

1

0

0.6

0.1

9.9

9.4

8.9

8.4

7.9

7.4

6.9

6.4

5.9

5.4

4.9

4.4

3.9

3.4

2.9

2.4

1.9

1.4

0.9

0.4

9

8

7

6

5

4

〜

9

（V）

5

SW1#5：OFF

SW5

External voltage Input

Maintenance/Inspection#5

Troubleshooting#4・ indicates the maximum speed that can be set.
・Change the speed up to the values described above.

■ The speed can be changed even during transfer (while the RUN signal is being
input).
■ Values in “Setting” indicate the speed when trays are not placed on the M-RAT.
■ The speed values described above are referenced to approximately 30 minutes
after startup. During operation, the rising time to the setting speed may varydepending on ambient temperature. Perform running operation thoroughly.
■ Values described above may differ from the actual transfer speed depending on theweight, material, bottom surface, and/or shape of trays, as well as ambient temperature.

Appendix#3

1 2 3 4 5

#2

78

#1

SW5

4 56

SW1

Installation/Wiring

Advance preparation

1 Set SW1#2 to OFF.

Safety precautions

Internal speed settingStart-up inspection

M-RAT User Manual

39

Turn off the power of all connected devices, and perform the following inspection, taking
necessary measures.
■ Turn off the power, wait a sufficient amount of time, and discharge electricity inside the DC
power supply equipment.

■ Post warning labels so as to prevent unauthorized persons from turning on the power.
Parts to be inspected

Items to be checked

Secured positions of the M-RAT
main unit

Screw looseness

Re-tighten screws

Damage, deformation

Contact the supplierRe-tighten screws

Screw looseness on secured positions
Mounting failure for driver cards andconnectors
Damage to cables/Wiring failure

Driver card

Idler for roller transfer
MDR for roller transfer

Description of measures

External abnormalities, such as
scratches or breakage
External abnormalities, such as
scratches, dents, or breakage

Carrier wheel

Cracks, wear on the surface

OthersParts deformation, damage
Cable damage

Correctly mount connectors
Perform wiring correctly
Refer to P.44
7-2. Before replacement work･･･

Contact the supplierItems to check after turning on the power■ Take safety measures, such as getting ready to shut off the power in the event that

Troubleshooting

Description of measures

Appendix

Manually input the signal to driver cards according to inspection contents.
■ After completing measures to prevent fingers from getting stuck and/or caught in rollers
during transfer switching, and/or transfer operation, perform inspection.
something should happen.

Driver card

Advance preparation

Items to check before turning on the power

Installation/Wiring

operation to the below, and check the safety.

Control/Operation

Start-up inspection

To prevent accidents and/or damage to devices during operation, refer in advance and before

Maintenance/Inspection

6-6.
What to do before
operation･･･

Safety precautions

6. Control/Operation

Parts to be inspected

Items to be checked
Abnormal temperature riseContact the supplier

Error check with LED display
Normal LED display after the power is turned on
If LED is displayed in a status different from thoseshown below, it is judged as error.

Driver card

CBK-109

CB-016

PWR（Green）
ON
ERR（Red）
OFF
STATUS（Orange）OFFPWR（Green）
ERR（Red）

ON
OFF

STATUS（Orange）OFF

Check error contents, andeliminate the causes.
※For driver card LED display anderror countermeasures, refer to
6-1. Driver card LED display anderror countermeasures (P.42).

Commissioning

M-RAT User Manual40

Decrease from the specified speed

Refer to P.44
7-2. Before replacement work･･･

Abnormal temperature rise
Abnormal sound
MDR for carrier wheeltransfer

Transfer surface
switch MDR

Commissioning

Abnormal temperature rise
(Check the LED of driver cards)

Contact the supplier

Abnormal soundAbnormal temperature rise
(Check the LED of driver cards)
Leakage from equipment

Check grounding on
equipment, performgrounding

Performing the commissioning
When the start-up inspection has finished, perform the commissioning with careful attention
to the following points, and check that operation is correctly performed.
■ Prevent other devices around the product from operating.

Other devices incorporated in the system, such as conveyor lines, could create dangerous
situations, since trays may start to flow from upstream when the commissioning is driven.
Check carefully that other elements in the system will not operate when the product starts
running.

■ Make sure to check that wiring, driver card settings, and PLC settings have been carried out
correctly before the commissioning.

■ During operation, the transfer speed may not reach the specified value depending on
ambient temperature. Perform running operation thoroughly.。

Troubleshooting

OthersDecrease from the specified speed

Advance preparation

Rotation failure

Installation/Wiring

Abnormal soundAbnormal sound

MDR for roller transfer

Description of measures

Control/Operation

Idler roller for rollertransfer

Items to be checked

Maintenance/Inspection

Parts to be inspected

Appendix

Idler/MDR

Safety precautions

6. Control/Operation

7. Maintenance and inspection

7-1. Driver card LED display and error countermeasures
7-2. Before replacement work
7-3. Replacement of resin sliders
7-4. Replacement of idlers/drive belts
7-5. Replacement of MDR
7-6. Replacement of the carrier wheel cassette

…… 42
…… 44
…… 44
…… 45
…… 48
…… 49

Troubleshooting

7. Maintenance and inspection

Maintenance/Inspection

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

M-RAT User Manual

Appendix

41

〔CBK-109〕Error details

M-RAT User Manual

42

Identify the cause of errors by checking LEDs and error signal output on driver cards,
and restore the product.

〔CBK-109〕
For carrier wheel transfer： OFF：Blinking(6 Hz)

Errors can be checked by PWR (green), ERR (red), and signals from CN2#4.
■ When error signals have been released using CN2#1 (RUN / STOP), the M-RAT instantly
starts up when RUN is input.

■ When the power supply voltage has experienced an extreme decrease, an unexpected■

To restart the M-RAT, switch the ON→OFF→ON / OFF→ON→OFF / RUN → STOP →RUN signals at intervals of 100 ms or over.

[M]: Manual recovery setting (SW1#1 ON) / [A]: Automatic recovery setting (SW1#1 OFF : factory setting)
CN2#4

ERR

SW1#4 SW1#4

OFF

ON

OPEN Output

OPEN OPEN

OPEN

Output(Red)

CausesNo power supply

OutputSupply 24V DC (Refer to 5-3 Wiring)
Turn off the power, and replace the driver card
(Refer to 5-2 Installation)

Damage to driver cards[A]

Thermal protection has
worked due to a temperaturerise of driver cards or MDR

OutputOutputOutputOutput

OPEN
OPEN

2回点滅

OutputOPEN

MDR disconnection

OPEN

OPEN

[M]

Connector disconnected

OutputOPEN

消灯(1.5秒)

Recovery operation−(Normal operation)

Thermal error
OPEN

How to release error signals

Maintenance/Inspection

PWR(Green) (Error signal)⇔

Error details

operation may occur.

When one minute has elapsed after decreasing to the recovery temperature,
the error signal is released, and the unit starts up instantly
After decreasing to the recovery temperature, the error signal is released
and the unit starts up instantly by RUN → STOP → RUN on CN2#1.
After decreasing to the recovery
Start up the unit by RUN → STOP
temperature, the error signal is released →RUN on CN2#1
and the unit starts up instantly by
RUN → STOP → RUN on CN2#1.
Start up within one minute
After decreasing to the recovery temperature, the error signal is released
and the unit starts up by RUN → STOP → RUN on CN2#1
After decreasing to the recovery
temperature, switch ON → OFF → ON
or OFF → ON→ OFF on CN2#2

Start up the unit by RUN → STOP→RUN on CN2#1

Turn off the power, and connect the connector (Refer to 5-3 Wiring)
Turn off the power, and replace the MDR(Refer to 7-2. Before replacement work)

Lock error

When 4 sec or over have elapsed after an error occurs, the error signal is released
and the unit starts up by RUN → STOP → RUN on CN2#1

MDR has been locked, and
0.5 sec have elapsed

When 4 sec or over have elapsed after anerror occurs, switch ON → OFF → ON or OFF→ ON→ OFF on CN2#2

Low voltage error[A]Power supply voltage has
been 15 V or less for 1 sec,
or decreases to 15 V or less
5 times within 500 ms[M]

Back EMF error[A]

Voltage applied to the MDR has
been 40 V or more for 2 sec, or
has been 60 V or more for 0.1 sec※This error may occur when the
MDR has rotated at speeds
faster than the setting speed.

A current of 7A or more
flows in the MDR

Start up the unit by RUN → STOP→RUN on CN2#1

Secure the power supply voltage of 18V
The unit starts up instantly
DC or more
After securing the power supply voltage of 18 V or more, release the error
signal and start up the unit by RUN→STOP→RUN on CN2#1
After securing the power supply voltage Start up the unit by RUN → STOP
of 18 V or more, switch ON → OFF →→RUN on CN2#1
ON or OFF → ON→ OFF on CN2#2
Voltage applied to the MDR has been
30 V or less for 1 sec

The unit starts up instantly

After voltage applied to MDR has been 30 V or less for 1 sec, release theerror signal and start up the unit by RUN→STOP→RUN on CN2#1[M]

After voltage applied to MDR has
been 30 V or less for 1 sec, switch
ON → OFF → ON or OFF → ON→
OFF on CN2#2

No error signal

Start up the unit by RUN → STOP→RUN on CN2#1−

Troubleshooting：Blinking(1 Hz)

Appendix： ON

LED display explanation

Advance preparation

Checking the driver card status

Installation/Wiring

If errors occur with this product, identify the cause of errors, and perform recovery
work.

Control/Operation

7-1.
Driver card LED display
and error countermeasures

Safety precautions

7. Maintenance and inspection

〔CB-016〕Error details

M-RAT User Manual

43：Blinking(1 Hz)： ON：Blinking(6 Hz)： OFF

Errors can be checked by PWR (green), ERR (red), and signals from CN2#4.
■ When error signals have been released using CN2#1 (RUN / STOP), the M-RAT instantly
starts up when RUN is input.

■ When the power supply voltage has experienced an extreme decrease, an unexpected■

To restart the M-RAT, switch the ON→OFF→ON / OFF→ON→OFF / RUN → STOP →RUN signals at intervals of 100 ms or over.

[M]: Manual recovery setting (SW1#1 ON) / [A]: Automatic recovery setting (SW1#1 OFF : factory setting)Damage to driver cards

How to release error signals

Recovery operation−(Normal operation)

Supply 24V DC (Refer to 5-3 Wiring)

Turn off the power, and replace the driver card
(Refer to 5-2 Installation)
When one minute has elapsed after decreasing to the recovery temperature,
the error signal is released, and the unit starts up instantly[A]

OutputOutput

MDR disconnection

OutputOutputOPEN

Connector
disconnected

OPEN

Thermal protection has
worked due to atemperature rise ofdriver cards or MDR

OPEN

OPEN

Thermal error[M]

After decreasing to the recovery
temperature, the error signal is released
and the unit starts up instantly by
RUN → STOP → RUN on CN2#1.

Start up the unit by RUN → STOP→RUN on CN2#1
Start up within one minute

After decreasing to the recovery temperature, the error signal is released
and the unit starts up by RUN → STOP → RUN on CN2#1
After decreasing to the recovery
temperature, switch ON → OFF → ON
or OFF → ON→ OFF on CN2#2

Start up the unit by RUN → STOP→RUN on CN2#1

Turn off the power, and connect the connector (Refer to 5-3 Wiring)

Turn off the power, and replace the MDR(Refer to 7-2. Before replacement work)

Lock error

The error signal is released and the unit starts up by RUN → STOP → RUN on CN2#1.

MDR has been locked,
and 4 sec have elapsed

Switch ON→OFF→ON or OFF→ON→OFF
on CN2#2[A]
OutputAfter decreasing to the recovery temperature, the error signal is released
and the unit starts up instantly by RUN → STOP → RUN on CN2#1.

Low voltage error
Power supply voltage
is 15 V or lessSecure the power supply voltage of 18V
DC or more

Start up the unit by RUN → STOP→RUN on CN2#1
The unit starts up instantly

After securing the power supply voltage of 18 V or more, release the error
signal and start up the unit by RUN→STOP→RUN on CN2#1[M]

Maintenance/Inspection

OPEN
OPEN

No power supply

OutputCauses

Output

ON

OPEN

OFF

Troubleshooting

SW1#4 SW1#4

OPEN

ERR

(Red)

Control/Operation

CN2#4

After securing the power supply voltageof 18 V or more, switch ON → OFF →ON or OFF → ON→ OFF on CN2#2

Start up the unit by RUN → STOP→RUN on CN2#1

Errors will be also released when the power is OFF (for two seconds or over).

Appendix

PWR(Green) (Error signal)

OPEN

Error details

operation may occur.

Advance preparation

LED display explanation

Installation/Wiring〔CB-016〕
For roller transfer

Safety precautions

7. Maintenance and inspectionReplacement of resin sliders

M-RAT User Manual

44

If any abnormalities are found, such as damaged parts, immediately take actions,
including replacement with new parts.
Product label

Product
model

FLAT RIGHT ANGLE TRANSFER
M-RAT- F15 - 7570 - C N - S1
RATED INPUT: DC24V / 4.9A
RATED POWER: 80W
PAYLOAD: max 250 kg
SERIAL No:K210106090-001
MFG. YEAR: 2019

ITOH DENKI CO.,LTD
MADE IN JAPAN

Size

Model

Piece

Carrier wheel
cassette

6060
7560 / 7570 / 7580

MRAT-CC60A
MRAT-CC75A

1・Hex. bolt with spring lock and plain washers M6×15, 7 pieces included
・ With the resin slider

Resin slider

6060
7560 / 7570 / 7580

MRAT-SLD60A
MRAT-SLD75A

1

Use one piece for each carrier wheel cassette

Drive belt

6060 / 7560 / 7570 / 7580

4PJ336117560 / 7570 / 7580

PM570(1)-17-656-D-024-JX(2)017-HX-OS M-RATヨウ

1

6060

ARI-57-506-JX-HX-OS

M-RATヨウ17560 / 7570 / 7580

ARI-57-656-JX-HX-OS

M-RATヨウ1

Before replacement1

Motor specifications (Refer to P.18)
・For F (1) ･･･FE ／ (2) ･･･C・For M or S (1) ･･･VS ／ (2) ･･･D―
Control/Operation

Idler

6060

―

Prepare necessary tools before replacement.
・Tools to be used
8

2 mm hex. wrench 3 mm hex. wrench

4 mm hex. wrench

6 mm hex. wrench

8 mm wrench・Jig… Belt tensioning jig (Refer to Appendix 3)2

Replacement of resin sliders■ Before replacement, perform maintenance with the carrier roller transfer
surface facing up.

the fastener on the carrier cassette
1 Loosenwith the resin slider to be replaced.

Appendix

7-3.
Replacement of resin
sliders

Turn off the power of all connecting devices.

■ Do not loosen the screw so muchthat it comes off.

■ Loosen the screw until clearance topull out the resin slider can be
secured.
(Reference: five to six rotations of
the fixing screw)

Fastener

Tool: 2 mm hex. wrench

the resin slider, and replace it with
2 Removea new one.
Put in the resin slider until it comes into
contact with the end.

3 Fasten the screw■ Be careful not to get the resin
slider caught in the fastener.

■ Tightening torque:

1.6〜1.9Nm

Maintenance/Inspection

MDR for rollertransfer

PM570(1)-17-506-D-024-JX(2)017-HX-OS M-RATヨウRemarks

Installation/Wiring

Replacement parts

Advance preparation

・Check the model of this product, andprepare parts to be replaced with inadvance.
・Contact us for repair/replacement ofparts other than those mentioned below.

Troubleshooting

7-2.
Before replacement
work･･･

Safety precautions

7. Maintenance and inspection

The flat surface faces up.
Resin slider

Replacement of idlers/drive belts

45

M-RAT User ManualTop coverTool: 3 mm hex. wrench

the MDR connector on the roller
2 Remove
unit.

※The actual part is a
JST connector.

Advance preparation

1 Remove the top cover.

Installation/Wiring

Replacement of idlers/drive belts

the screws used to secure the
3 Removeroller unit.

（

Number of fixing screws per size：
6060 / 7560…6 pieces
7570…6 pieces
7580…8 pieces）

Tool: 6 mm hex. wrench

4 Remove the roller unit.

Troubleshooting■ Have more than one person

Maintenance/Inspection

Control/Operation

Roller unit

remove the unit.

■ When holding the side of thedrive belt, first, pull up the roller
unit slightly while holding thedrive belt. Then hold the bottomof the roller unit and remove it.

Appendix

7-4.
Replacement of idlers/
drive belts

Safety precautions

7. Maintenance and inspection

5 Remove the idlers and belts.
Remove them in the order from the side closest
to the idler and drive belt to be replaced.

■ While turning the idler, slide andremove the drive belt.

■ When removing the drive belt on
the machine, remove the outerdrive belt first.

2. Remove thedrive belt on
the machine

1. Remove the drive
belt on the outsideof the machine first

Repeat the above steps until the drive belt isremoved from the idler to be replaced.

Example: When removing the idler 3 ,remove in the order of 1 , 2 , and 3 .

1

2

3

Replacement of idlers/drive belts

46

M-RAT User Manual①
Bearing holder

When mounting, ① put the shaft on the
7 opposite
side of the idler pulley into theplate, and ② stagger the drive belt
around the pulley.

■ When mounting, check that theidler shaft protrudes
sufficiently from the plate.

Maintenance/Inspection①

Advance preparation

the idler and drive belt.
Replace with a new idler or drive belt.

Installation/Wiring②

Control/Operation

Pull up the pulley part of the idler
6 ①
along with the bearing holder, ②Remove

Safety precautions

7. Maintenance and inspection②

Troubleshooting

Bearing holder
To stagger easily, tilt theidler slightly and mountusing the belt tensioning jig.

Turn theindented side up

Appendix

the top and bottom directions of the
8 Alignbearing holder, and tighten the drive belt

■ To mount the drive belt, a jig isnecessary.

Belt tensioning jig

Bearing holder
the plate with the groove of the
9 Alignbearing holder, and push it straight downfrom above to mount the idler.

10 Remove the jig.
the above steps, and mount the
11 Repeat
drive belts and idlers.

Replacement of idlers/drive belts

47

M-RAT User Manual

7. Maintenance and inspection■ They can be easily aligned bymoving the belt while turning theroller.
Drive belt

Hang the belt
Hang the belt
over one groove over four grooves

Installation/Wiring

Hang the belt
over four grooves

Advance preparation

Safety precautions

the groove positions of the drive
12 Align
belt.

13 Mount the roller unit.
■ Have more than one person
mount the unit.

■ When holding the side of theControl/Operation

drive belt, hold the bottom of theroller unit and carry. Whenputting the roller unit on, change
to hold the drive belt, and mountthe roller unit.

■ Check the MDR cable direction

14 Secure the roller unit using screws.

（

Number of fixing screws per size：
6060 / 7560…6 pieces
7570…6 pieces
7580…8 pieces）

Tool: 6 mm hex. wrench

Troubleshooting

Maintenance/Inspection

and mount.

Appendix■ Tightening torque:

25〜29Nm

15 Connect the MDR connector.
■ Put the cable inside the machine.
※The actual part is a
JST connector.

Roller unit

16 Mount the top cover.
■ Tightening torque:

Top cover

2.9〜3.5Nm

Tool: 3 mm hex. wrenchReplacement of MDR

48

M-RAT User Manual

Replacement of MDR

MDR

Idler roller

the fixing bracket screws used to
2 Removesecure the MDR.

①

Remove the screws in the order of: ①
rotation stopper part and ② bracket ﬁxing part②
Fixing bracket
Tool: 8 mm wrench

remove the MDR.

Maintenance/Inspection

pulling up the pulley part along with
3 Afterthe bearing holder, pull the feed shaft, andPull the power
cable fromthe ﬁxing hole
Feed shaft

Fixing hole

Advance preparation

3

Installation/Wiring

2

1

Control/Operationand drive belts until the drive belt hanging
on the MDR comes off.

Remove in the order of 1 , 2 , and 3

Bearing holder

the feed cable through the product4 Passplate, and mount

Troubleshooting

steps 1 to 6 for Replacement
1 Performof idlers/drive belts, and remove the idlers

a new MDR.
Appendix

7-5.
Replacement of MDR

Safety precautions

7. Maintenance and inspection

Fixing hole

steps 7 to 11 for Replacement of
5 Perform
idlers/drive belts, and mount a new MDR,
idlers, and drive belts.

6 Secure the MDR.
Secure in the order of: ① bracket ﬁxing
part and ② rotation stopper part①

■ Tightening torque：②

2.9〜3.4Nm
Tool: 8 mm wrench

steps 12 to 16 for Replacement of
7 Perform
idlers/drive belts.

Replacement of the carrier wheel cassette49

M-RAT User Manual

7. Maintenance and inspection

steps 1 to 4 for Replacement
1 Performof idlers/drive belts, and remove the top
cover and roller unit.
the screws used to secure the2 Removecarrier wheel cassette to be replaced.

Carrier wheel cassette■ Remove the silver screws. Do

Advance preparation

Safety precautions

Replacement of the carrier wheel cassetteTool: 8 mm wrench■ Mount the chain along the grooveof the chain idler.

■ Mount so that the sprocket on themachine side and the chain on
the carrier wheel cassette areengaged.

■ It becomes easier to mount the

Mount the chain along the idler

Control/Operation

Chain idler

Maintenance/Inspection

and mount the carrier wheel
3 Replacecassette.

Installation/Wiring

not remove the black screws.

Troubleshooting

chain by tightening.

Pull the chain slightly
Appendix

7-6.
Replacement of thecarrier wheel cassette

4 Secure the carrier wheel cassette.
■ Tightening torque:

10〜12Nmsteps 13 to 16 for Replacement of
5 Perform
idlers/drive belts.

Maintenance/Inspection

8. Troubleshooting
Troubleshooting

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

50

AppendixTroubleshooting

M-RAT User ManualTroubleshooting

51

M-RAT User Manual

Is PWR LED (Green) for each drivercard ON?
Or, has 24V DC been supplied in
the power connector part of driver
cards?

Supply 24V DC.

Is ERR LED (Red) for each drivercard blinking, or is it ON and is there
an error output?

Remove the cause of error, andrelease the error.

Has each connector beenconnected correctly?
Has wiring been performed properly?

Check wiring, and perform wiringproperly if it has not already been
done so.

Has the product type (NPN input/
output / PNP input/output) matched
the input and output signals (NPN
input/output / PNP input/output) on
PLCs?

Match the product type (NPN input/
output / PNP input/output) with the
input and output signals on PLCs
(NPN input/output / PNP i
nput/output).

7. Installation /Wiring

Is 0 V input to the control signals
common to 0 V to the power supply?

Set it to be common to 0 V to thepower supply.

7. Installation /WiringItems to be checkedCountermeasures

7. Installation /Wiring（⇒P.20）9. Maintenanceand inspection（⇒P.41）
7. Installation /Wiring（⇒P.20）（⇒P.20）※Check the product model.

The transfer surface cannot
be switched, or transfer
surface switching operation
is incorrect

Advance preparation

References

Installation/Wiring

Countermeasures（⇒P.20）

References
9. Maintenanceand inspection

Is ERR LED (Red) on the drivercard for M3: Transfer surface
switch blinking, or is it ON and isthere an error output?

Remove the cause of error, andrelease the error.

Has the RUN signal input to thedriver card for M3: Transfer surface
switch corresponded to the transfer
surface?
Also, is the input timing correct?

Check the signal input and input
timing when the transfer surface isswitched.

8. Control /Operation

Has the setting of the driver card for
M3: Transfer surface been changed?

Check the setting of the driver cardfor M3: Transfer surface switch.

8. Control /Operation

Troubleshooting

Items to be checked（⇒P.41）（⇒P.32）（⇒P.32）

Appendix

M-RAT does not operate

Control/Operation

Symptoms

Maintenance/Inspection

If you believe the product may be malfunctioning, check the contents described inthis section before contacting us and/or asking for repair.

Safety precautions

8. TroubleshootingTroubleshooting

52

M-RAT User Manual

Symptoms

Set either carrier wheels or rollers
on the top of the surface
according to the loading
direction.

8. Control /Operation

When loading by carrier wheels,
have you run the carrier wheel
MDR (M1)? When loading byrollers, have you run theroller MDR (M2)?
Also, have you run the MDR until
loading ends?

Run either carrier wheel MDR (M1)or roller MDR (M2) according to theloading direction until loading ends.

8. Control /Operation

When loading by carrier wheels,
are there any carrier wheels
rotating slower than others?

Replace the carrier wheel cassette
including the slow rotating wheels.

9. Maintenanceand inspection

Has the transfer surface switch
MDR (M3) run at the time ofloading?

Do not run the transfer surface
switch MDR (M3) until loading ends.

Items to be checked（⇒P.32）（⇒P.32）（⇒P.41）9. Maintenanceand inspection（⇒P.32）

Countermeasures

References
7. Installation /WiringIs the discharge conveyor level thesame as the level of the M-RAT?

Align levels of the discharge
conveyor and the M-RAT.

When discharging by carrier wheels,
have they been set on the top of thesurface? When discharging byrollers, have they been set on the
top of the surface?

Set either carrier wheels or rollers
on the top of the surface according
to the discharging direction.

8. Control /Operation

When discharging by carrier wheels,
have you run the carrier wheel MDR(M1)? When discharging by rollers,have you run the roller MDR (M2)?
Also, have you run the MDR until
discharging ends?

Run either carrier wheel MDR (M1)or roller MDR (M2) according to thedischarging direction until
discharging ends.

8. Control /Operation

When discharging by carrier wheels,
are there any carrier wheels
rotating slower than others?

Replace the carrier wheel cassette
including the slow rotating wheels.

9. Maintenanceand inspection

Has the transfer surface switch
MDR (M3) run at the timedischarging?

Do not run the transfer surface
switch MDR (M3) until discharging
ends.

（⇒P.20）（⇒P.32）（⇒P.32）（⇒P.41）

8. Control /Operation（⇒P.32）

Advance preparation（⇒P.20）Installation/Wiring

When loading by carrier wheels,
have they been set on the top of
the surface?
When loading by rollers, havethey been set on the top of thesurface?

7. Installation /WiringControl/Operation

Align levels of the load conveyor
and the M-RAT.

Maintenance/Inspection

Is the load conveyor level the sameas the level of the M-RAT?

References

Troubleshooting

When discharging, trays
get stuck, or cannot betransferredCountermeasures

Appendix

Trays get stuck/Trays
cannot be transferred

Items to be checked

Safety precautions

8. TroubleshootingTroubleshooting

53

M-RAT User Manual

To change the carrier wheel speed,
operate the switch on the drivercard for M1: Carrier wheels(CBK-109). To change the roller
speed, operate the switch on thedriver card for M2: Rollers (CB-016).

Have you changed the external
speed by the voltage input toCN2#3 on CBK-109/CB-016?

Check the external speed settings,
and input the voltage according to
the settings.

Changing the
speed

When changing the speed by theexternal voltage, is the power
supply 0 V of the external voltage
common to 0 V on the driver card?

Use the common power supply 0 V.

7. Installation /WiringItems to be checkedCountermeasures

References

Is the transfer/diverting direction
based on the rotating direction
settings for the driver card for M1:
Carrier wheels/M2: Rollers?

Set the correct transfer/diverting
direction, and the correct therotating direction for the drivercard for M1: Carrier wheels/M2:
Rollers.

8. Control /Operation

Changing thespeed（⇒P.38）（⇒P.38）（⇒P.20）（⇒P.32）

Advance preparation

To change the carrier wheel speed,
have you operated the switch on thedriver card for M1: Carrier wheels(CBK-109)? To change the roller
speed, have you operated theswitch on the driver card for M2:
Rollers (CB-016)?

Installation/Wiring

References

Control/Operation

The transfer direction(rotating direction ofcarrier wheels/rollers)
is incorrect

Countermeasures

Maintenance/Inspection

・ The speed setting isincorrect

Items to be checkedTroubleshooting

・ The speed cannot bechangedAppendix

Symptoms

Safety precautions

8. Troubleshooting

Maintenance/Inspection

AppendixTroubleshooting

Control/Operation

Installation/Wiring

Advance preparation

Safety precautions

54

Appendix

Appendix

M-RAT User ManualProduct speciﬁcations

M-RAT User Manual

55

Appendix
Safety precautions

Appendix 1.
Product specifications
M-RAT main unit specifications

WeightMaximumload weight※1

Maximumload size

※2

Speed

※3

580(586.4)（mm） 580(586.4)（mm）

700(706.4)（mm）

175（mm） (excluding the protrusion part)
80（kg）

Nominal speed of 15m/min type

250（kg）

Nominal speed of 30m/min type150（kg）
L:450×W:450（mm）

Maximum

L:500×W:500（mm） L:650×W:500（mm） L:650×W:600（mm） L:650×W:700（mm）

Nominal speed of 15m/min type15m/minNominal speed of 30m/min type30m/min
0.6（s）

Carrier wheel roller

Steel, Electro‐galvanizing
Glass fiber reinforced plastic Black Conductive grade

Resin slider

High density polyethylene

NPN output

GX-H12APNP output

GX-H12A-P

Ambient temperature
Ambient humidity

Operatingenvironment

124（kg）

Minimum

Frame / Top cover / RollerStandby surface
sensor (proximity)

109（kg）

94（kg）

Lifting time ※4

Material

820(826.4)（mm）0 to 40ºC (no freezing)
90%RH or less (no condensation)

Altitude1,000m or less

Atmosphere

No corrosive gas

Vibration

0.5 G or lessInstallation location

IndoorMounting surface tilt (inclination)
Pollution degree

Advance preparation

748(751.2)（mm）

Installation/Wiring

H598(601.2)（mm）7580

Control/Operation

W

7570

Maintenance/Inspection

Values in ( ) show thebase outer dimension
including bead processing

7560

Troubleshooting

L

6060

0.5% or less2 (according to the definition of IEC60664-1)※1 Values of the maximum load weight are reference only, since they may change depending on tray conditions.
Depending on the bottom shape or unbalanced load of trays, they may not be transferred normally, even if they are within theabove size range.
※2 The size that can be transferred depends on the speed, load weight, material, bottom surface, shape of trays, ambient
temperature, and/or transfer conditions.
※3 Values indicate the speed that can be specified when trays are not placed.
The transfer conditions depend on the speed, load weight, material, bottom surface, shape of trays, and/or ambient temperature.
※4 Indicates the time when trays are not placed.
■ During operation, the rising time to the setting speed may vary depending on ambient temperature. Perform running operation thoroughly.

AppendixSizeDriver card speciﬁcations

56

M-RAT User Manual

CB-016B□6（□=N：NPN, P：PNP）

DC24V±10％Power supply voltage
Rated voltage

DC24V

Static current

0.06A

Starting current

7.0A

4.0A

Peak current

30A (1 ms or less)

20A (1ms or less)Wire diameter Power connector（CN1）
Applicable wires

0.80 〜 1.5mm2（AWG：18 〜 14）

0.50 〜 1.5mm2（AWG：20 〜 14）

to connectors
included as
standard

0.03A

0.08 〜 0.5mm2（AWG：28 〜 20）

Control connector（CN2）

Protective functions

Incorrect wiring protection
Built-in 10A fuse

Incorrect wiring protection
Built-in 6.3A fuse

Protective functions

Driver card unit: 95ºC
Motor: 105ºC

Driver card unit: 95ºC
Motor: 105ºC

Ambient temperature

0 〜 40℃ (no freezing)Ambient humidity

90%RH or less (no condensation)

OperatingAtmosphereenvironment
Vibration

No corrosive gas
0.5G or less
IndoorLocation
Time from RUN signal input
to motor starting

15msec or less15msec or lessTroubleshooting※Refer to P.45.

Appendix

Replacement parts/Options

Advance preparation

CBK-109F□（□=N：NPN, P：PNP）

Maintenance/Inspection

Model

For roller transfer

Installation/Wiring

For carrier wheel transfer
For transfer surface switch

Control/Operation

Driver card speciﬁcations

Safety precautions

Appendix

Residual risk list/MAP

M-RAT User Manual57

No particularlocation

Dropping the machine due to ・Use the hook withthe lock function set
a disconnected load lifting
WARNING hook when carrying may
result in damage to the・Do not get under themachinemachine, and/or bodily injury

2 Installation Transport

No particularlocation

Dropping the machine due to ・Before transporting,ensure the safety of
obstacle collision when
the transportation route
WARNING carrying may result indamage to the machine,
・Do not get under the
and/or bodily injury
machine

No particularlocation・Before transporting,Letting the machine fall due
ensure the safety of
to poor footing may result in the surrounding area
damage to the machine,
and/or bodily injury
・Do not get under themachineTransport/
3 Installation
Having carefully
Installation
read the user
manual, andhaving fullknowledge of
4 Operation Operation all the contents

Operation Operation
5

6

Maintenance/ Maintenance/
Inspection Inspection

Remaining risk factors

WARNING

Measures thathave been taken
independently
Described in the
instruction
manual7

Described in the
instruction
manual7

Described in the
instruction
manual7

If workers accidentally leanover the machine at the time
WARNING of transferring the work,
they may get injured bygetting some body partscaught in the machine

Post warning labels,
and pay attention to
the surrounding
situation during
operation

Described in the
instruction
manualTop panelof the productWorkers may step on themain unit and lose theirWARNING footing, or may fall whenthe main unit moves

・Do not step on themachine・If you step on themachine out of need,wear protective
equipment

Described in the
instruction
manualPower supply
part to the
product

Persons turning on the
power without notice may
WARNING result in unexpected
operation of the product,
and/or injury of workers

Post warning labels
so as to prevent
unauthorized persons
from turning on thepower

Top panelof the product

Reference
page

Affix theWARNING labels

Described in the
instruction
manual669Seriousness of harm
WARNING: Indicates that there is a possibility that severe injury or even death may result if protective measures have not been
taken

No.1

WARNINGNo.2

WARNINGNo.3

WARNING
No.6

No.4

WARNINGNo.5

WARNING

Troubleshooting

Residual risk for which
location on the machine
has not been identified

WARNING

Emergency stop
equipment safety circuit

AC power supply
BreakerThis product
24V DCpower supply
unit

Appendix

Residual risk MAP

Advance preparation

1 Installation Transport

Work

Installation/Wiring

Examples ofassumedmeasures

Seriousnessof harm

Operation
stage

Control/Operation

Residual risk list

Qualifications/educationrequired for work

Locationson machine

No.

Maintenance/Inspection

Appendix 2.
Residual risk list/MAP

Safety precautions

AppendixPE

Appendix 3.
Belt tensioning jig

ge
ed
er
n
r
Co

A-A cross section

Resin or wood
Around t12

Technology for tomorrow

ITOH DENKI CO.,LTD.
Global Headquarters:■ ITOH DENKI CO., LTD.
1146-2, Asazuma-Cho, Kasai, Hyogo 679-0105
Phone: +81 (0)790 47 0955 Fax: +81 (0)790 47 1325
www.itohdenki.co.jp■ ITOH DENKI ASIA LIMITED
Phone: +852 2427 2576 Fax: +852 2427 2203
Europe, Middle East, Africa:■ ITOH DENKI EUROPE SAS
Phone: +33 (0)4 50 03 09 99 Fax: +33 (0)4 50 03 07 60
www.itoh-denki.com
North & South America:■ ITOH DENKI USA, INC
Phone: +1 570 820 8811
www.itohdenki.com

Fax: +1 570 820 8838

China:■ ITOH DENKI SHANGHAI CO., LTD.
Phone: +86 21 6341 0181 Fax: +86 21 6341 0180
www.itohdenki.com.cn

https://www.itohdenki.co.jp
Specifications or appearance of product are subject to change without prior notice.

Ver. 1.0