HB-510 series Hybrid Board Handling Instructions
Thank you for purchasing ITOH DENKI Power Moller or
Motorised drum.
Please read this handling instructions first to understandthe product, safety information and cautions before
operating the product.
Keep this handling instructions readily accessible forreference.

Caution
HB 510 series hybrid board can not be used in conjunction
with HB 508 series card.
All the cards connected though communication cable shouldbe the same and identical.
If different HB cards are used, they should form separate line,
and control between different HB card lines should be madewith PLC or other equivalent equipment.

Applicable Power Moller models【HB-510N】【HB-510P】

PM486FE , PM486FP , PM486FS , PM500FE , PM500FP , PM500FS ,PM570FE , PM605FE , PMT42FE【HB-510BN】【HB-510BP】

Above models with built-in brake option(-BR)

【HB-510N/LT】【HB-510P/LT】 Above Power Moller models with LT(Low temperature)option(-LT) ※※ High speed Power Moller with a speed of higher than 70m/min. is NOT applicable.
Note）Build-in brake option is NOT available.

Make sure the following accessories are enclosed upon opening the package[Option][Standard accessories]●HB card ×１（HB-510□/LT）●Power connector×１（EAHB05:CN１）●Communication cable（CAHB05-□□□□）□stands for length(mm)●Sensor connector×１（SAHB05:CN3）●Control connector（PAHB08:CN2）

LT : Low temperature applications
N：NPN signal input]
P：PNP signal input]
BN：NPN signal input for built-in brake Power Moller unit
BP：PNP signal input for built-in brake Power Moller unit

●Mounting screws and nuts
Screw（M4×15）････ ×4
Nut（M4）･･･････････×4

ITOH DENKI CO.,LTD.

563

【Safety Instructions】● Switch off the power, when removing from conveyor, wiring or maintenance is done, otherwise● Do not pull by force during operation. It causes the HB-510 driver card to malfanction.

you have a risk of electrical shock or injury.
● Respect the electrical regulations of the site or the equipment, where the product in installed.
(Labour safety and sanitary regulations, electrical equipment technical standard, etc)
● Operate the motor driver within its intended design and specifications to avoid electrical shock,injury, fire, or damage to the equipment.
● Do not disassemble, repair nor modify the product (for which we do not warrant) It might cause
electrical shock, injury or fire.
● Separately set the circuitry to monitor the important input and/or output signal status, whichmight cause accident, because the signal may stay ON or OFF in case of the HB-510 drivercard failure.
● Be sure to shut off the power before inserting or removing any connector. Do not wire
connector left in the HB-510 driver card.
● Do not drop, give external impact nor pressure to the HB-510 driver card. If that happens,
do not reuse it.
● Make sure all the connectors are properly engaged with wiring cables.
● Make sure the conveyor frame and control box where the HB-510 driver card is mounted are
grounded.
● Dispose this product in industrial waste.
● Do not switch on or off the relay or contactor in close proximity to power or signal lines, or the
HB-510 driver card as the generated noise could cause malfunction.
● Be sure to inject power or input signal for 15 milli-seconds or over to ensure the proper
reaction.
● Use the Power Moller with brake option (BR) if holding effect is needed. (Except LT option )● Do not force the Power Moller to turn. It may cause of damage to the driver card or shorten

its life cycle.
● Make sure the external controller is powered when HB-510 is controlled by it. If the external

controller is not powered, unexpected behavior may occur on the HB-510, Power Moller orthe external controller.

－ Described below are the precautions for using this product at freezing temperature
along with Power Moller having LT option －● Connenctor and communication cable may harden with low temperature.
● Do not insert and pull them by force.
● Mount this product to the place where Power Moller can be properly connected without

cable loose, extreme bend or pull, or move.
● Power Moller speed may not reach immediately to the set speed if it is left long hours in 0 ℃or below. In addition, the starting current may get larger to activate thermister, or undervoltage error may be resulted. Therefore , warm up operation is recommended before formaluse.
● Be careful for condensation or freeze in case the product is used in varying temperature
particularly between below and above 0℃. If condensation is generated, do not use theproduct until it is completely removed. Use of the product having condensation may result in
malfunction or electrical accident.

【Power】●

24VDC battery or switching power (24VDC 5A) or smoothed and rectified power (≦10% ripple)※ Use stable power supply with 24VDC, 5A or over. The Power supply should not be affected by peak current 20A for 1msec.
※ Max 35mA current is drawn to CN3 for sensor.

【Dimensions】

169

26.6

SPEED
SET

CN3
Sensor connector

0V
IN
24V
0V
24V

50

ERR
OUT A
V-IN
DIR/ESTOP
INPUT

□

40

CN6

Power Moller
cable connector

HB-510PWRSENSORERR

1ERR BLOCK
2 DIR BLOCK
3 ESTOP BLOCK
4 SPEED BLOCK L
5 SPEED BLOCK R
6 INT/EXT7 DIR/ESTOP
8 AUTO/MANU
1NPN/PNP OUT
2 SEN/SYN
3 GEAR SET 2
4 GEAR SET 1
5 ZP2/ZP1
6 ZE/ZB
7 DIRECTION
8 STOP/RUN

161

CN1

78

23

90 1

456

CN5

Communication
connector (L)SW14-φ4.5

Power connector

LED3

SW2 SW3

LED2

LED1

CN2

Earth terminal

Control connector

CN4
Communication
connector (R)● SW1 (from left to right)
No Function
1
2
3
4
5

ON

OFF

Error signal transmission to the right adjacentzone
Direction signal transmission to the rightadjacent zone
Valid
Emergency stop signal transmission to theright adjacent zone
Speed variation signal transmission to theleft adjacent zone (external voltage change)
Speed variation signal transmission to theright adjacent zone (external voltage change)

Remarks(※1)OFF=- stops signal discharge to the right zone
- blocks signal input from the right zone
- accepts the signal input from the left zone
- discharges signal to the left zone

Invalid(※1)OFF=- stops signal discharge to the specified direction- blocks signal input from the specified direction

Default setting
ON
ON
ON
ON
ON

6 Selection of internal or external speed variation

External (voltage input) Internal （SW３ pot.）

External voltage is injected to the CN2-3
control connector (varied between 0 and 10V)

Selection of direction signal input or
7 emergency stop signal input (CN2-4)

Emergency stop
signal input

Direction signal input

Input to the CN2-4 control connector

OFF

8 Selection of recovery for thermal or low
voltage error

ManualAutomatic

To reset, first switch on SW1-7 then CN2-4 ON, or
power off then CN2-5 on.

ON

OFF

※1 The direction has nothing to do with the line upstream and downstream. Maximum 30 zones can be controlled from one HB card.

● SW2 (from left to right)
No Function

ON

OFF

Remarks

Default setting

NPN output

Output for error, synchronization and sensor signal

N / BN ＝ OFF
P / BP ＝ ON

Output from CN 2-2 control connector (24V, max 25mA)

ON

Timer is effected for the time to move tote for 1 meter.
The time differs by varied speed accordingly; fasterthe shorter and slower the longer.
Individual timer setting is not feasible.

OFF

1 Selection of PNP or NPN output signal

PNP output

Selection of sensor signal output or
2 synchronization signal output

Synchronization signal
Sensor signal output
output3

Nominal speed

FE FS/FP※１
Power Moller nominal speed setting
4

210
60
17

255
55
15

Timer set time (S)Switch setting
JAM#3#4 Sensor / Run hold
OFF
OFF
ON
ON

OFF
ON
OFF
ON

0.3〜1.2
0.6〜2.2
1〜4
2〜8
4〜14
7.5〜27
Forcible RUN ※ON※ Forcible RUN ceases when sensor in present
and downstream zone is blocked.

5 Selection of ZPA release mode
6 Downstream end setting
7 Motor direction
8 Selection of input terminal function

Slug (train)

Singulated

Invalid

Valid

FE
CCW

FS / FPCW

Forcible RUN

FE
CW

ON
Zone stops after tote receipt and does not evacuate tofurther downstream zone even if it is empty. Evacuationis enabled only by inputting forcible RUN signal.
FS / FP
CCW

Forcible STOP

ON
Input to CN2-5 control connector※1 Speed variation in the table is achieved only by the correct combination of the Power Moller nominal speed and dip switch settings.

-2-

ON

ON

【Wiring diagram】● SW3
Rotary switch for 10 index speed variation(when SW1-6 is set to OFF)24V

sensorPNP

NPN

ON PNP output
OFF NPN output

V-IN

ERR

※1

※1 SW2-1 setting

OUT A

PNP

123

0V
24V

CN1

INPUT

NPN

LED 1 Green Power status. Activates Power Moller
LED 2 Orange Error on sensor or jam error
LED 3 Red
Error on thermister, motor block or current limiter,Low voltage

CN3

0V
IN
24V

24V

12

※1

DIR / ESTOP

● LED

0〜
10V

1 2 3 4 5 CN2

0V
24V※Connecting with external device such as Relay Coil requires apply coil surge absorption
type or add protective devices to protect from surge otherwise remote OUTPUT in HB-510
may be damaged by back EMF when output signal is changed.

【Speed Variation】<PM486FE> ※1(m/min)0

12<PM486FP> ※1

Rotary switch
3

4

5

6

7

8

9

60

(No.)

(m/min)

60 ※2

70

55 ※2

50

35
25
17m/min

15

10
0

4.5

5.5

1

2

0

7

8.5

10

4

5

3

6

55m/min7<PM500FP> ※1
0

1

3

4

5

6

8

7

8

9

9

(No.)

5.6

1

2

3

0

1

8.6

4

11

10

5

6

15 ※2 1614

13

65.8 ※259.7 ※2
55.6

50

7

8

3

4

5

6

7

40

44.2

9

8

30

27.8

0

10 (V)

16.5

10
0

4.6

5.8

7.3

8.8

1

2

3

4

13.4
10.3 11.3

5

6

7

※2

14.4 15.4

16.5 ※260m/min99

10 (V)
External voltage

30.9
20.6

17m/min

4.6

5.7

7.2

8.7

1

2

3

4

0

(m/min)12.9 14.4
10.3 11.3

5

6

7

0

1

2

15.9※2 17.5

8

10 (V)

9

4

5

6

7

8

9

(No.)

8.2

2

3

43.6
37.3
31.1
24.9

17m/min

6.5

16.4
12.9 14.7
10.0 11.7

4

5

6

7

49.8

60m/min

30

23.5

1

62.2
56.0

40

17.6

5.3

68.5 ※2

50

46.9

35.2

0

74.7 ※270

818.2※2 19.9※2

2017m/min

18.7

10
9

10 (V)

00

External voltage

5.6

6.8

8.7

1

2

3

13.7 15.6
10.6 12.4

4

5

6

7

※2

21.2 ※2

910 (V)

17.4 19.3

8

External voltage

・ In case you use Power Moller with nominal speed not given above, please see our catalog or contact us.
※1 Nominal speed 210 (255 for FP series) is NOT available with LT option for low temperature applications.
※2 This product is not applicable for ambient temperature of 0 ℃ or less as it may take 10 minutes or so for motor to reach to the rated speed.

【to those who has used HB 508 series card:】
Please note the following differences between HB 508 and HB 510 series card.
HB-508
Direction selection

Selection of direction or emergency stop (DIR/ESTOP)

When powered

Power Moller no action（activated according to ZPA logic）

Power Moller activated when sensor in the present
zone if off (for the period of sensor timer time)

External control

Setting

Selection of global or distributed control (error output,
Global control（error output, direction, speed variation） direction, speed variation, emergency stop)
Adjustable for sensor timer, RUN hold timer, Jamtimer (individual setting is not feasible)

Timer time
setting

RUN hold timer only

Speed variation

By integral pot. or by varying
external analog voltage

By integral rotary switch or by varying external digital
voltage (10 indexes)※1Forcible RUN

OFF = immediate Power Moller stop

OFF = Power Moller stops after the time set by RUN
holding timer

Thermister

Automatic recovery

Low voltage

Signal discharge from CN2-1 whennormalError※1

HB-510CN2-2 terminal
Wiring※2

Rotary switch
3

60

29.3

20

0

41.2

<PM605FE> ※1
(No.)

41.0

10
8

46.3

External voltage

58.6

30
15m/min

※2

36.0

10

52.8

40

22.6

20

(No.)

9

51.4

60m/min

15.4

70.4 ※264.5 ※2

70

50

39.1
32.9

8

80

60

50.4
55m/min

7

61.7

※2

80

60

6

25.7

Rotary switch

25

56.6 ※2

20

External voltage(m/min)4

40<PM570FE> ※1(No.)

Rotary switch

3

50

15m/min

4.5

2

30

16

0

1

60

27

7.1

0

70

43

22

0

10 (V)

9

70

0

8

38

10

Rotary switch

2

7

32

External voltage(m/min)

6

54

20

17 ※2

15.5 ※2
12.5 14

11

5

49

30

20

4

59 ※2

40

30

20

3

50

40

30

2

(m/min)65 ※2

4560m/min

1

60

50

40

0

<PM500FE> ※1

Rotary switch

Selection of manual or automatic recovery
No signal discharge when normal

Regardless of HB 508 or HB 510, motor in the present zone stops when the sensor in the zone becomes ON during forcible
RUN mode, and is automatically follows the operation on ZPA logic.

-3-

【Specifications】
Power voltage

DC24V ±10％

Rated voltage

DC24V

Static current

0.06A

Peak current

20A ≦ 1msec

HB cardside

4.0A
NPN/PNP

Alarm

NPN/PNP

Wiringside

Forcible run/stop

NPN/PNP

Direction

NPN/PNP

Emergency stop

NPN/PNP

External speed variation

DC 0 to 10V

Sensor

NPN/PNP open collector (※1)

Error
Synchronization

NPN/PNP open collector (※1)
NPN/PNP open collector (※1)

Error (red)Power status (green)
Sensor status（orange）

LED indication

Integral 7A fuse ( + side)

Protection

Integral diode against miss wiring
Reacts at 85 ℃ on circuit board, or
105℃ on motor

Thermal protection

Power connector

wago734 - 162(Max:10A)

Sensor connector

wago733 - 363(Max:4A)

Control connector

wago733 - 335(Max:4A)

Power connector

wago734 - 102(Max:10A)
Wire diameter 0.5～1.5mm ２ 〔AWG：20～14〕

Sensor connector

wago733 - 103(Max:4A)
Wire diameter 0.08～0.5mm ２ 〔AWG：28～20〕

Control connector

wago733 - 105(Max:4A)
Wire diameter 0.08～0.5mm ２ 〔AWG：28～20〕

JST S9B-XH-A
0〜40℃ (※3)

Motor connector
Ambient temp.
Environment

SensorMechanical Brake (※2)

Output

Input

Starting current

Electric brake

Brake

Atmosphere≦ 90%RH（no condensation）
No corrosive gas

Vibration≦ 0.5G

From electrical stop
to brake engagement

400msec

Brake current

During brake activation: 0.2A

Relative humidity※1 PNP or NPN signal selectable by dip switch※2 Applicable only for HB 510BN or HB 510BP for Power Moller with built-in brake※3 It is not available at ambient teｍperature of 0 ℃ or less for LT.

【LED error indications and solutions】
signal discharged from CN2-1
green LED1

orange※2 Lights

Lights with sensor
signal

LED2

red

※1
LED3 Signal discharge

OffLightsLights with sensor
signalLights※2 Lights

Lights with sensor
signalLightsLights with sensor
signalLightsBlinks1Hz

OffLights with sensor
signalBlinks1HzLights with sensor
signal24V

Cause of error

Symptom

N/A

N/A

open

Thermal error

Blinks1Hz

24V

Power Moller blocked for 4 seconds while powered

Lightsopen

Power Moller connector is not plugged

Off

open

Blinks1Hz
Blinks
6Hz

24V
24V

Solutions
N/A※3 After the thermister recovery, stop

Power Moller
then restart the motor, or switch off
stops
the power first then on the power.

Lowers Power
Moller output

Remove the cause of motor block

Switch off the power first then plug inPower Moller
does not function the connector properly, then switch on
the power

Power Moller
stops

Remove the cause of the jam error,
then block the adjacent downstream
sensor

Low voltage or blown fuse

Power Moller
stops

Supply correct voltage, or replace
the card if fuse is blown

Current limiter reaction

N/A

Jam timer error※1 Error signal is discharged on normal status, and is not discharged in abnormal status※2 LED 1 blinks at 1Hz while Power Moller is running※3 applicable when set to manual recovery mode

-4-

N/A

【Signal passing between HB-510 and PLC】
PLC cotrol zone C
PH-C sensor

Product６

PLC control

Product７

Right angle transfer

Product５

Product４

Product３

sensorPH-4

sensorPH-B
PLC control zone B

Zone4

sensorPH-3

sensor
PH-2

Zone3

Zone2

（Downstream zone）

sensor
PH-1
Zone1

HB-510 control zones

Signal liaison between HB-510 in upstream end zone and PLC in the adjacent zone.
HB-510(For Zone1)

PLC

Output A

PLC Input

Setting conditions for SW2(Sensor signal of PH-1)

2-1：ON if PLC signal is PNP
OFF if PLC signal is NPN
2-2：OFF（Sensor signal output）
2-6：ON（Not to set downstream end）
2-8：ON（Forcible Run）

PLC Output(Zone1 forcible RUN)

CommonCommon(PLC=NPN: 0V)(PLC=PNP:24V)(PLC=NPN: 0V)(PLC=PNP:24V)

Below is a diagram showing that Product1 moves to PH-A and then, Product2 starts moving
and finally Product1 arrives at PH-1.
Product1

Product2 loaded② PH-1
Product3 loaded

Product1 travels③ PH-2
Product2 travels④ Output A(ON signal output of PH-1)⑤ Input(Forcible RUN)

⑥ Zone 1(PLC controlled zone
is synchronized)

PLC control zone A

PLC control zone

Travel direction① PH-A

sensorPH-A（Upstream zone）

PLC control zone

Input

Product１

Product２

PLC controlled motor
is also ON.

-5-

Product1 loaded

Signal passing between zone4 of HB-510 and PLC control zone B
PLC

HB-510(For Zone4)

PLC Input

Output A

Setting conditions for SW2
2-1：In case PLC is PNP, it turns ON
In case PLC is NPN, it turns OFF
2-2：OFF（Sensor signal output）
2-6：ON （No set downstream）
2-8：ON （Forcible Stop）(PH-4 sensor signal)

PLC Output

Input(Zone4 forcible RUN)

CommonCommmon(PLC = NPN: 0V)(PLC = PNP:24V)(PLC = NPN: 0V)(PLC = PNP:24V)

Below is a diagram showing that Product5 moves to PH-4 and then, Product6 starts to moveand finally Product5 arrives at PH-B.
Loaded Product6

Movementof Product6

Loaded Product5

LoadedProduct5
搬送物5移動搬送物
移動① PH-B② PH-4Loaded Product5③ Output A(ON signal output of PH-1)④ Input(Forcible RUN)

⑤ Zone 4
Motor PLC control
zone B also turns On.

Signal Passing between zone3 and PLC controled zone C .
PLC

HB-510(For Zone3)

PLC Input

Setting condition for SW2

Output A

2-1：When PLC is PNP, it must be ON.
When PLC is NPN it must be OFF.
2-2：OFF（Sensor signal output）
2-6：ON （Set-up at downstream）
2-8：OFF（Forcible stop）(PH-3 Sensor signal)

PLC Output

Input(Zone3 Forcible stop)

CommonCommon(PLC=NPN: 0V)(PLC=PNP:24V)(PLC=NPN: 0V)(PLC=PNP:24V)

HB-510(For Zone2)

PLC Input

Setting condition for SW2

Output A

2-1：When PLC is PNP, it must be ON.
When PLC is NPN, it must be OFF.
2-2：OFF（Sensor signal output）
2-6：ON （No set-up at downstream）
2-8：OFF（Forcible stop）(PH-2 Sensor signal)

PLC Output

Input(Zone2 Forcible stop)

CommonCommon(PLC=NPN: 0V)(PLC=PNP:24V)(PLC=NPN: 0V)(PLC=PNP:24V)

Below is a diagram showing that Product4 moves to PH-3 and then, Product7 starts to moveand finally Product3 goes through PH-3 and arrives at PH-4.
Loaded Product7

Movementof Product7① PH-C

Traverser
Product 4

Loaded Product4② PH-3③ Output A（On signal output of PH-3)(Right Angle Transfer)

Run
Stop

RAT rising

RAT
falling
直角移載機上昇④ Input（Zone 3）（Forcible Stop）⑤ PH-4(

Release to
Right Angle Transfer)

Acceptable
Unacceptable⑥ Input（Zone 2）（Forcible Stop）⑦ PH-2⑧ Zone 2
RUN Hold Timer⑨ Zone 3

Movement of product3

RUN Hold Timer

ITOH DENKI Co.,Ltd
Phone: +81 790 47 0955
Fax: +81 790 47 1325
URL: http://www.itohdenki.co.jp: http://www.powermoller.com
Email: info@itohdenki.co.jp

ITOH DENKI EUROPE SAS

ITOH DENKI USA,INC

Phone: +33 450 03 09 99
Fax: +33 450 03 07 60
URL: http://www.itoh-denki.com
Email: commercial@itoh-denki.com

Phone: +1 570 820 8811
Fax: +1 570 820 8838
URL: http://www.itohdenki.com
Email: info@itohdenki.com※ Specifications are subject to change without prior notice.

6

伊東電機亞洲有限公司
Phone: +852 2427 2576/7
Fax: +852 2427 2203

上海伊東電機設備貿易有限公司
Phone: +86 21 6341 0181
Fax: +86 21 6341 0180
URL: http://www.itohdenki.com.cn
Email: fhao-ids@itohdenki.cn

7-00K-2005