Pop-up Diverter Operating Instructions
Pop-up Diverter

Thank you for purchasing Pop-up Diverter● Before using, please read the operating instructions carefully to obtain the product knowledge, safety
information and to understand all of the caution items.
● After reading the instructions, store the booklet in a designated location for readily accessing at any time.
When you open the crate, check the model, specifications, voltage, etc. are correct.

・ When the tray or object is less than 350×350mm, move the tray along the branching sideedge.

When opening the crate …
The crate contains the following items. Check that every item is included.
Also, check if the model, specification, etc. are as you ordered.
Item

Quantity

Remarks① Pop-up Diverter main body

1 unitwith roller bottom sensor (SN･S) / roller top sensor (SN･R）② Hex bolt M8×20 ／ Spring washer

4 sets

For installation of the Pop-up Diverter main body

③ Driver card CB-016□

Note）

6

④ Driver card（Lifting）CBR-306F□

2
Note）

1

⑤ Power connector 734-102 (WAGO)

3⑥ Control connector 733-105 (WAGO)

3⑦ Cross-slotted screw/washer M4×15 / Hex nut M4

6 setsFor mounting driver cardNote）Depending on the input/output type of Pop-up Diverter, the included driver card operates with either NPN (N) or PNP (P) signal input.

①

③

④

⑤

⑥

The photo shows Size B (Left)

ITOH DENKI CO.,LTD.
-1-

No.501INDEX
1. General Cautions ・・・・・・・・・・・・・・・・・・・・・

P3

1 - 1. Basic Warnings ・・・・・・・・・・・・・・・・・・・・・・

P3

1 - 2. Basic Cautions ・・・・・・・・・・・・・・・・・・・・・・

P3

1 - 3. About the Risk Category of the System

・・・・・・・・・・・

P3

2. Product designation ・・・・・・・・・・・・・・・・・・・・

P4

3. Structure ・・・・・・・・・・・・・・・・・・・・・・・・・・

P4

4. Power Supply ・・・・・・・・・・・・・・・・・・・・・・・

P4

5. Dimensions ・・・・・・・・・・・・・・・・・・・・・・・・

P5

6. Installation / Operation ・・・・・・・・・・・・・・・・・・

P9

6 - 1. Cautions during Transportation ・・・・・・・・・・・・・・・

P9

6 - 2. Cautions during Uncrating ・・・・・・・・・・・・・・・・・

P9

6 - 3. Cautions during Installation…Electrical・・・・・・・・・・・

P9

6 - 4. Cautions during Installation…Main Unit

・・・・・・・・・・・ P10

6 - 5. Installation ・・・・・・・・・・・・・・・・・・・・・・・・ P11
6 - 6. Precautions for Trial Run ・・・・・・・・・・・・・・・・・・ P15

7. Repair / Replacement ・・・・・・・・・・・・・・・・・・・ P16
7 - 1. Replacement of Idlers, Roller Drive Belt, Straight MDR・・・・ P16

7 - 2. Replacement of a Diverting Roller ・・・・・・・・・・・・・・ P17
7 - 3. Replacement/Installation of a Diverting Roller Round Belt

・・・ P19

8. Specifications ・・・・・・・・・・・・・・・・・・・・・・・ P22
9. When Questioning a Failure ・・・・・・・・・・・・・・・ P24
Appendix1. CBR-306F□ Detail ・・・・・・・・・・・・・・・ P25
Appendix2. Maintenance・・・・・・・・・・・・・・・・・・ P27

Appendix3. Remaining Risks List / MAP ・・・・・・・・・・ P28-2-

1．General Cautions …… For your safety, please comply with them.
● Be sure to comply with all of the caution items and instructions contained in this safety manual.
● To avoid functional deterioration, unexpected accident or product failure, check the operation according to this manual.

Shown below are the caution items for using the product safely and avoiding danger and damage to the user.
Caution items can be classified into danger, warning and caution as described below.

Warning & Caution
Danger

The most serious danger with possibility of death or serious injury.

Warning

Incorrect handling may lead to death or serious injury, indicating potential danger.

CautionPossible danger of light or medium injury, or only a material damage.

1 - 1. Basic Warning
Incorrect handling may lead to death or serious injury, indicating potential danger.

Warning Comply with the following warning and perform the work correctly.
●

Do not use the product in an explosive, flammable or corrosive atmosphere, or near flammable material.
It may cause explosion, fire, electrical shock or injury.

1 - 2. Basic Cautions

CautionIncorrect work or use may lead to light or medium-level injuries and/or property damages.
Comply with the following warning and perform the work correctly.

● Do not step on the product or apply a load. It may lead to a failure or unexpected accident.
● Do not touch the mechanism by hand during operation. The hand may be caught by the mechanism and injured.
● Do not absolutely modify the Pop-up Diverter or the driver card. Serious injury may be caused.
● Do not forcibly bend or pull the wire. Do not put a heavy item on the wire or pinch the wire. The cord may break and cause fire orelectrical shock.
● To avoid a failure or electrical shock, ground the DC power supply or driver card to the conveyor frame.
● Do not touch the equipment immediately after stopping. It may cause kin burn.
● Do not splash water on the equipment. Electrical shock or failure may be caused.
● Do not apply a strong impact or excessive force such as hitting the equipment or dropping an object. Do not use the equipment

after it is impacted or deformed. It may cause a failure.
● When abnormal sound is heard during motion, stop the operation. Continued operation may cause an accident or failure.
● Do not use the equipment by exceeding the specification. It may cause a failure, fire or injury.
● Do not carry out operation of transfer, connection, maintenance inspection (except maintenance inspection to be performed

during operation). Switch off the power before operation.
● Comply with the safety rules required for the location and equipment to be used.
● Some type of driver card failure may make the input/output ON condition or OFF condition. Apply an external monitoring circuit fo

the input/output signal that may lead to an injury or property damage.
● Connect or disconnect a connector when the power is shut off. Do not perform wiring with the connector inserted in the driver card.
● Securely attach the connector of each connecting cable to the connection point.
● Incorrect wiring may cause a failure. Carefully check the wiring.
● Do apply excessive force for operating the DIP switch.
● Do not perform on/off operation of a relay or connector near the power line, signal line, or driver card. That may cause malfunction

by noise.
● When LED circuit or Pull-up/Pull-down circuit is connected to the output circuit, unexpected operation may occur.
● Apply power ON in the order of external controller→Driver card. Perform power OFF in the order of Driver card→External controller.

Incorrect order may cause malfunction.
● Cutting the power disables electrical braking control, and the roller becomes easy to be rotated.
● Do not pull out a cable during operation. It may cause a failure.
● Do not forcibly rotate MDR except during maintenance inspection. That may cause driver card breakage or make the operation life

extremely short.
● Do not shut off the power during MDR rotation. It may cause a failure.
● Do not apply power while riding on the conveyor or while a tray is unstable condition. MDR rotation immediately after power ON

may cause injury, accident or breakage.
● When error occurs frequently, remove the cause.
● When disposing the equipment, make a consignment contract with an authorized industrial waste processing company for disposal.

1 - 3．About Risk Category of this System

Warning●

About Risk Category of this System

This equipment intends to comply with risk category 2 or below in EN 954-1. It does not comply with risk category 3
or higher.
-3-2．Product designation
POP-D- ① ② - ③ ④ - ⑤ ⑥Divert C / V① Divert direction
L … Divert left
R … Divert right② Divert angle
Straight

Divert left

W

30D … 30 degrees
45D … 45 degrees③ Speed

60 … 60m/min

L

Carry in C / V

Carry out C / V④Signal type selection
N … NPN input/output（NPN input/output driver card / up/down sensor included）
P … PNP input/output（PNP input/output driver card / up/down sensor included）⑤Size
A…W394mm×L760mm
B…W494mm×L760mm
C…W594mm×L760mm
D…W694mm×L760mm⑥Type
1Model Example：POP-D-L45D-60N-B1
Divert left 45 deg, Transport speed 60m/min, NPN input/output type, Size B（W500mm×L774mm）, Type 1

3．Structure■ Main Unit

Diverting MDRLabel detail
POP-UP DIVERTER

Lifting MDRDivert roller

P O P - D - ①② - ③④ - ⑤⑥

Roller coverver⑦

RATED INPUT:DC24V,⑧

PAYLOAD: max
SERIAL No.

A
kg

⑨⑩⑪⑫
ITOH DENKI CO.,LTD
MADE IN JAPAN

Straight MDR
Product label
lab
Idler
Roller drive belt
beProduct model① Divert direction, ②Divert angle, ③Transport speed,④ Input/output type, ⑤Size, ⑥Type

Transport capacity⑦ Rated current of transport MDR, ⑧Available load weight

Serial No.（ YY.MM.DD Lot No）⑨ Year (last 2 digits) ⑩ Month ⑪ Day ⑫ Lot No (3 digits )4．Power Supply■ Switching power supply（24VDC・10A 240W）■ Rectified power（With a rectifying capacitor, ripple rate 10% or below）■ 24VDC Battery
・A switching power supply is recommended as the DC power supply (24VDC ±10%) for drivers.
Use a stabilized power supply that has an adequate capacity of 24VDC and 10A or higher and does not fluctuate due to load variation.
・The power supply shall have a capacity larger than the total of 2 MDRs rated values.
・A transformer type power supply cannot be used.
・Secure a voltage of 24VDC ±10% at the power source terminal of a driver.
・If the power supply capacity is the rated power of 2 MDRs or smaller, the supply voltage may drop to cause failure or damageof MDRs and drivers. Be sure to use a power supply with a capacity larger than the rated power of 2 MDRs.
・In addition, the power supply should not activate protection with peak current 20A, 1ms or below.

■ Wiring between power supply and driver card/controller
・The voltage could be dropped when a wiring between power supply and driver card/controller gets longer, which might cause
malfunctions or damages.
Use recommended wire gauge, AWG: 20 – 14 and secure 24VDC±10%.

-4-5．Dimensions■ Main Unit
● Size A … W394mm×L760mm Divert Left
L 760

94x6(=564)
8
-∅3

∅5

7

400
169

0

Mounting surface 101.4

100

3

Mounting hole pitch 2-671

44.5

4-mounting hole for M8（When divert roller up）

・Divert MDR cable length 1300mm ・Lifting MDR cable length 1300mm

44.5

Frame nominal dimension

Mounting hole pitch 2-249

100・Straight MDR cable length 1200mm
・Sensor cable length 50mm

Straight MDR pipe dim. 305

W 394

63

67.5

21

Sensor position

Diverting MDR

Straight MDR

Lifting MDR● Size A … W394mm×L760mm Divert Rright
L 760

∅38

7-

Frame nominal dimension

Mounting hole pitch 2-249
67.5

169

∅5
0

94x6(=564)

100

Sensor position

3

44.5

Mounting hole pitch 2-671（When divert roller up）

21
44.5

Mounting surface 101.4

・Sensor cable length 50mm

400

4-mounting hole for M8

63

100

・Straight MDR cable length 1200mm

Straight MDR pipe dim.

Ｗ394

305

・Lifting MDR cable length 1300mm ・Divert MDR cable length 1300mm

Straight MDR

Lifting MDRDiverting MDR-5-

● Size B … W494mm×L760mm Divert Left

L 760

・Divert MDR cable length 1300mm ・Lifting MDR cable length 1300mm

94x6(=564)
∅38

∅5

7-

75
169

0

Mounting surface 101.4

100

4-mounting hole for M8（When divert roller up）

Mounting hole pitch 2-671

3

44.5

44.5

Frame nominal dimension 500

Mounting hole pitch 2-349

100・Straight MDR cable length 1200mm
・Sensor cable length 50mm

Straight MDR pipe dim. 405

W 494

63

67.5

21

Sensor position

Diverting MDR

Straight MDR

Lifting MDR● Size B … W494mm×L760mm Divert Right
L 760

94x6(=564)

100
8Frame nominal dimension
75

67.5

169

3
7-∅

Mounting surface 101.4∅50

Sensor position

3

44.5

Mounting hole pitch 2-671（When divert roller up）

21
44.5

Mounting hole pitch 2-349

・Sensor cable length 50mm

500

4-mounting hole for M8

63

100

494
Ｗ

Straight MDR pipe dim.

405

・Straight MDR cable length 1200mm

・Lifting MDR cable length 1300mm ・Divert MDR cable length 1300mm

Straight MDR

Lifting MDRDiverting MDR-6-

● Size C… W594mm×L760mm Diver Left
L 760

100

94x6(=564)
8
-∅3

∅5

7

75
600
169

0

Mounting surface 101.4

44.5（When divert roller up）

Mounting hole pitch 2-671

34-mounting hole for M8・Divert MDR cable length 1300mm ・Lifting MDR cable length 1300mm

44.5

Frame nominal dimension

132

Mounting hole pitch 2-449

・Straight MDR cable length 1200mm
・Sensor cable length 50mm

Straight MDR pipe dim. 505

W 594

63

67.5

21

Sensor position

Diverting MDR

Straight MDR

Lifting MDR● Size C … W594mm×L760mm Divert Right
L 760

8

3
7-∅

Frame nominal dimension 600

Mounting hole pitch 2-44975

94x6(=564)

100

169

∅5
0

Sensor position

Mounting surface 101.4

44.5

Mounting hole pitch 2-671

67.5

44.5

（When divert roller up）

21

63

・Sensor cable length 50mm

4-mounting hole for M8

3

W 594

Straight MDR pipe dim.

505

・Straight MDR cable length 1200mm

・Lifting MDR cable length 1300mm ・Divert MDR cable length 1300mm

Straight MDR

Lifting MDRDiverting MDR-7-

● Size D … W694mm×L760mm Divert Left

L 760

75

120

Frame nominal dimension

700

Mounting hole pitch 2-549

・Straight MDR cable length 1200mm
・Sensor cable length 50mm

Straight MDR pipe dim. 605

W 694

63

67.5

21

Sensor position

・Divert MDR cable length 1300mm ・Lifting MDR cable length 1300mm

94x6(=564)
∅38

∅5

7-

169

0

Mounting surface 101.4

100

3

Mounting hole pitch 2-671

44.5

4-mounting hole for M8（When divert roller up）

44.5

Diverting MDR

Straight MDR● Size D … W694mm×L760mm Divert Right

Lifting MDR

L 760

Frame nominal dimension 700

4-mounting hole for M8

75
169

38
7-∅

Mounting hole pitch 2-549

・Sensor cable length 50mm

94x6(=564)

100

Mounting surface 101.4∅50

Sensor position

67.5

63
44.5

Mounting hole pitch 2-671（When divert roller up）

21
44.5

3

・Straight MDR cable length 1200mm

Straight MDR pipe dim.

W

694

605

120

・Lifting MDR cable length 1300mm ・Divert MDR cable length 1300mm

Straight MDR

Lifting MDRDiverting MDR-8-

■ Accessory● CB-016□6● CBR-306F□※□=N（NPN input/output）or P（PNP input/output）※□=N（NPN input/output）or P（PNP input/output）

129

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

18

78

90 1

0V
24V

4.5
3

23

47

23

38.5

3

4.5

456

3

40

N.A

N.A

9 0 1

7 8

4.5
52

78
78

18

40

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

VR1-ACC

4.5

VR2-DEC

456

47

MODULE

23

38.5

M3：Lifting MDR

0V
24V

23

90 1

CBR-306F□

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

2 3

2 3

52

901

456

SPEED

456

CB-016□6

STATUS/ERR/PWR
1. AUTO/MANU
2. INT-TIME
3. DIRECTION
4. E/N-OUT
5. MDL/TEST

129
120

120

6．Installation and Operation
6 - 1. Cautions during Transportation●

Avoiding injuries
Majority of this product is made from metal and careless handling may cause injury of hands.
Be sure to wear protective means such as gloves to avoid injury.

Caution●Handle the heavy item by two persons as a ruleSome product type weighs over 50kg. To protect the operators, transport the unit by two or more
persons as a rule of handling a heavy item.

● Prohibiting Impacts

・This product contains precision components such as bearing and microchip. Use caution for avoiding impacts by dropping or
collision during transportation as impacts may cause damage of such components.

6 - 2. Cautions during Uncrating

Caution●Avoiding injuries
Majority of this product is made from metal and careless handling may cause injury of hands.
Be sure to wear protective means such as gloves to avoid injury.

● Appearance Check

・Check the following when opening the crate.
① Abnormality on the unit such as dent, concave mark, smear, corrosion (rust), etc.
② Loose or missing screw.
Please report to the supplier when you find abnormality.

6 - 3. Caution during Installation…Electrical● Checking the Circuit breaker・ For the facility equipment using this product, check that a power breaker with appropriate capacity has been installed. Incase the product generates abnormal motions, protection by the breaker is sometimes effective.
If the earth leakage breaker is planned for use as a breaker, select a type compatible with inverter. Certain type of incompatible
ground fault interrupter causes malfunction by sensing high frequency component of switching power supply as leak current.
● Checking the DC Power Supply

・ DC power supply must be an insulation type switching power supply certified by the safety standard ( IEC60950-1 or
UL60950-1 )for ensuring safety. Do not use non-insulation type series power supply for safety as well as conforming toradiation noise restriction.
・ Current capacity of the DC power supply should have sufficient capacity to accommodate this product.
Current capacity of the wiring material should also provide sufficient margin to the specified current value.

-9-● Checking the Wiring

・ When the DC power supply is integrated, check if the equipment breaker and emergency stop switch correctly operate.
Test operation and any further procedure should be performed after finishing this checking.
① ON/OFF operation of the breaker reliably turns ON/OFF of the input (single phase 100V, 200V) to the DC power supply unit.
② ON/OFF operation of the emergency switch reliably turns OFF/ON of the input (DC24V) to this product.
Single phase
100V/200V

Emergency stop switch
Breaker
DC power
supplyCheck if 24V DC input is surely turned
OFF/ON by using a circuit tester, etc.
This product（Not yet connected）

PE・Carefully check if these wiring would not contact any moving parts of this product.

6 - 4．Caution during Installation…Main Unit
● Installation environment
・ This product is not equipped with a special dust or water proof measures, and is intended for use in "pollution level 2"

defined by IEC60664-1. For this reason, when the product is installed in the environment requiring dust or water proof
measures, the user needs to provide additional protection and check the performance.
・ Vibration level of the environment in which this product is used must be 0.5G or below.
・ Install this product with the tilt of 5/1000 or below.
・ Secure a work space around this product for maintenance purpose.
・ Comply with the safety rules required for the place of installation or equipment to be used.

● Main unit installation● During installation, use caution for installing direction (orientation). Be sure to use the specified

Cautionmounting holes. (Refer to 5. Dimension P.5, P.6, P.7, P.8).
Incorrect direction (orientation) or using non-specified securing holes may cause unexpected accident.

・ Perform installation operation always by two persons.
・ Use caution for motor cable or sensor cable not to be pinched byother object.
・ Do not attach the driver card on the pop-up diverter unit.

It may cause loose screws or other failure by vibration.
・ Securely attach the unit on the frame by considering the productweight, tray weight, and vibration.
●

Hold the underside of the unit

Safety assurance

Warning
Caution● Operator should not come close to any moving part that may hook or roll-in objects.

Provide a means for not permitting the operator to touch the moving part with a safety fence.
● To prevent any object from popping out of the area by collision, and to avoid injury by such object,install a safety fence around the equipment.
Use caution for roll-in
g rollerbyy each diverting・ If the warning label becomes hidden by installing the

product, reattach the warning label in a visible place.

Use caution for roll-in
byy each belt and roller

・ When performing maintenance operation, make sure themain power is completely shut off.

Use caution for finger
o both sides
being caught on- 10 -

6 - 5．Installation● Attach the Pop-up Diverter by using the mounting holes (Refer to 5. Dimension)● When using mounting stays, refer to the attachment example shown below.

■ C/V Transport Level (Height)●

Align the inbound C/V level with the roller surface of the Pop-up Diverter, and diverting C/V level with the diverting roller
surface (3mm above the roller surface).

● Attachment reference example

W＋6

When mounting stays(optional) are used forSize A Left diversion

4×2 - φ10
（Pop-up Diverter mounting holes)

Straight MDRDiverting roller

51.5

114

Idler

3

Mounting stay
44.5

44.5

40

2×4-M8（Mounting stay securing holes)
671 Diverting MDR

44.5

Lifting MDR

Mounting stay760

■ Connection●

Attach the power connector <CN1>, Control connector <CN2>, MDR connector <M1：For straight, M2：For diversion,
M3：For Lifting > to the driver card as shown below.
※Connector attachment and detachment must be made after shutting off the power and by holding the connector.
※Securely attach each connector to the contact part.
Diverting to
the left

M1

M2 Diverting MDR

Straight MDR

M3 Lifting MDR

M1
Belt

M3

M1 For straight

M3
Lifting

For lifting

CBR-306F□

CB-016□6
SN・S
Belt
Roller bottom sensor

M2 For diversion
M2
RollerCB-016□6

SN・R
RollerRoller top sensor

SN･S

SN･R

BROWN：24V
BLUE：0V
BLACK：out ※PLC etc.

BROWN：24V
BLUE：0V
BLACK：out ※PLC etc.

※ON when detecting the position,※Pop-up diverter zone sensor is not included. User needs to provide it.
- 11 -

Output current max. 100ｍA

■ Wiring
CB-016□6

M1：For straight／M2：For diversion

M3：For lifting

CBR-306F□

CN2（Control）
Motor pulse outpu
Error signal output
MDR ext speed setting
MDR rotation dir change
MDR run/stop

Use 25ｍA ※or below12345｝IN（ NPN：0V
PNP：24V ）0V
24VDC

Max 2ｍA

3ｍA

5.PLS
4.ERR
3.NA
2.DIR
1.RUN
0V
24V

※Attach a protection resistor｝IN（ NPN：0V
PNP：24V ）
0V
24VDC

2
1

5
4
3
2
1

in/out current
Use 25ｍA ※or below−−

MDR rotation dir change
MDR run/stop

3ｍA※Attach a protection resistor

CN1（Power）
CN1

MotionMotor pulse outpu
Error signal output

CN2
12345

in/out current

1 2

0V
24V

1 2

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

5
4
3
2
1

CN2（Control）

Motion

CN2

CN1（Power）
CN1

0V

2
1

24VDC

0V
24VDC

■ Connector Wiring （Common to CB-016/CBR-306）①Connect 24V DC / 0V wires to the power connector < CN1(2 contacts)>.
※Do not connect any branching wire. It may cause electrical shock,short-circuit or failure due to over capacity of the connector.
(Connector capacity：10A）※Do not wire in reverse polarity.
※Wiring should be made before inserting the connector into the driver card.

Power connector (CN1）

0V
24VDC

②Connect wires to control connector < CN2(5 contacts)>.
※Input voltage supplied to CN2#1(MDR run/stop ), CN2#2(MDR rotation
direction change) must be common to the power supply voltage.
( Connector capacity :4A）
③Plug the power connector < CN1(2 contacts)>, control connector < CN2(5 contacts)>, MDR connector <CN3> to the driver card.
※Connector attachment/detachment must be made after shutting off thepower and by holding the connector.
※Securely insert the connector to the contact part.

7mm

0.50〜1.5mm 2 (AWG:20〜14)

Control connector (CN2）7mm

0.08～0.5mm 2（AWG:28～20）

For the detailed specification of CB-016□6, please download the driver card operating instruction
manual from our company HP.

Home > Download / Support > User Manual > CB-016□6＊ For detail of CBR-306, refer to Appendix 1．CBR-306F Detail (P.25）- 12 -

■ Driver Card Setting

78

7 8
456

N.A

9 0 1

2 3

N.A

90 1

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

MODULE

0V
24V

90 1

SW5

SW1

23

78

23

M3：Lifting MDR

456

CBR-306F□

STATUS/ERR/PWR
1. AUTO/MANU
2. INT-TIME
3. DIRECTION
4. E/N-OUT
5. MDL/TEST① M3：Set the driver card for lifting.

456

sure to turn OFF SW1#5.
・Make
ON state does not allow external signal input and may lead to a failure.
Cautionmust be set to "1" when using Pop-up Diverter.
・SW5
Using with other than "1" may lead to a failure.

1

M3：For lifting

CBR-306F□

5

OFF

SW1

SW5

※For detail, refer to Appendix 1. CBR-306F□ Detail ( P.25) .

78
SW1

MDR acc/dec

MDR rot. direction

VR1

SW1#3

VR2

MDR speed

2

3

4

ON

5

OFF

4 56

Divert Left

5

VR1

M2
Diversion

VR2

SW1#3

ON

1

2

3

4

5

MDR rot. direction

VR1

SW1#3

VR2

1

3

4

ON

5

5

VR1

M2
Diversion

VR2

SW1#3

1

2

3

SW5

SW1#5

4

901

23

Divert Right

MDR speed

ON
2

901

※Refer to
Speed Setting
when changing the
speed.

MDR acc/dec

M1
Straight

R

SW5

SW1#5
1

23

M1
Straight

L

SW5

78

78

VR2

78

78

VR1-ACC

VR2-DEC

4 56

23

VR1

456

2 3

0V
24V

90 1

456

901

23

90 1

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

SPEED

456

CB-016××××

STATUS/ERR/PWR
1. AUTO/MANU
2. INT/EXT
3. DIRECTION
4. E/N-OUT
5. L/H② Set M1：Driver card for straight, and M2：Driver card for diversion.

※Refer to
Speed Setting
when changing the
speed.

5OFF

Speed Setting（m/min）Speed accuracy：±3％

SW1#5：OFF

SW1#5：ON
SW2

9

8

7

6

5

4

3

2

1

0

9

8

7

6

5

4

3

2

1

0

M1：Straight

53.5

53.5

53.5

51.4

48.9

46.3

41.2

38.6

36.0

33.4

30.9

28.3

25.7

23.1

20.6

18.0

15.4

12.9

10.3

7.7

M2：Diverting

90.2

90.2

90.2

85.8

81.5

77.4

68.6

64.4

60.0

55.9

51.6

47.2

42.9

38.5

34.4

30.2

25.8

21.5

17.1

12.8

- 13 -

■ Control

Roller bottom sensor (SN･S ）

(O
ut
bo

un

d)

Roller top sensor (SN･R ）Diverting C/Vzone sensor

D
iv
e

rti
ng

C
/V

5

Inbound C/V

1

Outbound boundary
sensor（Diverting）

4

3

2

Straight C/V（Outbound）

Straight C/Vzone sensor

Upstream zone tray sensor
Inbound boundary sensor

Straight MDR（M1）Diverting MDR（M2）

Lifting MDR（M3）Outbound boundary sensor (straight)
Pop-up Diverter zone sensor

Example time chart when divertingWork position
PLC
input

Upstream zone
tray sensor

OFF

PLC
input

Inbound boundary
sensor

OFF

PLC
input

Outbound boundary ON
sensor（Diverting） OFF

PLC
outputStraight MDR（M1） Rot.
Div.MDR（M2）
L：Div.Lt…SW1#3 OFF
R：Div.Rt…SW1#3 ON

PLC
outputRUN

Lifting MDR
（M3）

DIR

PLC
input

Roller bottom sensor
SN･S

PLC
input

Roller top sensor
SN･R※ON to permit straight※ON to permit diversion

3

4

5

ON

Pop-up Diverter zone ON
sensorOFF

PLC
output

2

ON

PLC
input

L：Div.Lt…SW1#3 OFF
R：Div.Rt…SW1#3 ON

1

Stop
Rot.
Stop
ON
OFF
ON
OFF
ON
OFF
ON
OFF

Note 1) Less than 20ms

Note 1) Less than 20ms

Note 1） Suppress the time from detecting SN･S or SN･R until stopping Lifting MDR less than 20ms for Lifting MDR control (M3).
・Use control components with response time 20ms or shorter to avoid abnormal motion.

Example of connector wiring using a PLC
Pop-up Diverter
Straight MDR

M1

CB-016□6

Diverting MDR

M2CB-016□6

Output

M3

Input

CN2＃1

Upstream zone sensor

CN2＃1

Inbound boundary sensor

CN2＃1
Lifting MDR

PLC

Pop-up diverter zone sensor
Outbound boundary sensor (Diversion）

CBR-306F□

CN2＃2

ON to permit
straight motion

Roller bottom sensor
SN・S

OUT

ON to permit
diverting motion

Roller top sensor
SN・R

OUT

Inbound C/Vdrive signal
Diverting C/V (outbound）
drive signal
Straight C/V (outbound）
drive signal- 14 -

Diverting C/V zone sensor
Outbound boundary sensor (Straight）
Straight C/V zone sensor

6 - 6．Precautions for Trial Run● Checking the environment for permitting trial run●

CautionMake sure other devices in the system do not run.
In the case of a conveyor line integrated in a system, starting signal would cause a tray to flow
down the conveyor and cause danger. Before trial run, make sure that other elements of thesystem does not operate.

● Before a trial run, make sure the wiring and driver card setting have been correctly made.

Insufficient check may lead to a damage and failure.
1. Before starting a trial run, check the following.
① Is the wiring correct? Did you check that no loose connector or wire breakage exist?（⇒ P11 〜 13）■ Checking the roller bottom sensor (SN･S ）and roller top sensor (SN･R ）

N.A

9 0 1

7 8

1

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

MODULE
2 3

N.A

M3：Lifting MDR

1

456

CBR-306F□

STATUS/ERR/PWR
1. AUTO/MANU
2. INT-TIME
3. DIRECTION
4. E/N-OUT
5. MDL/TEST・Confirm that roller bottom sensor (SN･S ）ON makes the divert roller lifted down, or roller bottom sensor (SN･S ）ON makes the divert roller lifted up.
・When both the roller bottom sensor (SN･S ）and roller top sensor (SN･R ）are OFF, then perform the following
operation and, confirm that roller bottom sensor (SN･S ）ON makes the divert roller lifted down.

0V
24V

23

90 1

78

M3：Set SW5 of lifting
driver card CBR-306 to
"1"

SW5

456

#5
ON

2

SW1
OFF

ON

23

78

Change SW1#5 to
OFF→ON.

#5

90 1

3

456

SW1

ON

SW1

OFF

OFF

When SN・S is turned
ON, turn OFF SW1#5.

SW5【Condition of the transfer surface 】
Roller bottom sensor(SN･S ）

Roller top sensor(SN･R ）ON

OFF

Divert roller islifted down

ON

Divert roller islifted up

OFFTransfer surface② Is the driver card setting correct?（⇒ P13）
・M3：In the lifting driver card (CBR-306), is SW1#5 OFF and SW5 "1"?
2. Trial run should be performed without trays and make sure no abnormal operation occurs.
At such time, check the following points.
①No error LED blinks on the driver card.
②No abnormal sound or high temperature is detected.

- 15 -

Idler

Divert roller

7．Repair / Replacement
In order to avoid accident or damage during operations, confirm safety.
The illustration used for repair and inspection is size C, left diversion. Use caution for different shape when othersize or right diversion is used.（Refer to 5. Dimensions）● Safety check before repairing or replacing a part.
● In order to avoid interference by power circuit and signals, turn off the power of all connected devices.

Warning（ａ）After turning off the power switch, leave for more than 3 minutes for discharging the DC power supply.
（ｂ）Indicate warning to prevent other people from turning the power.

● Part repair and replacement

Warning● Perform repair or replacement operations by wearing protective means such as gloves.

Working without protective means results in hand injury such as cut by metal part.

・ When a damaged component is discovered, promptly replace with a new component.
・ Do not perform disassembly other than in a designated place. Unexpected accident may occur.
・ Repair/replacement operation sometimes requires turning or lifting a component. Use caution for being caught or
pinched by other parts and injured.
● Component repair and confirmation after replacement

・ When component repair and replacement is completed, check the following before starting trial run.
（ａ）Roller link belt and diversion roller link belt are attached in the right groove.
（ｂ）The removed cover is securely closed.
（ｃ）All removed components and parts are attached.

7 - 1. Replacement of Idlers, Roller Link Belt, Straight MDR
Tools to be used…

8mm・19mm spanners, flat-tip screw-driver, nipper① Remove the shaft securing plate.
・Loosen the bolts on the shaft securing plate,and pull out the plate to remove.
Bolt

Shaft securing plate② Remove idlers or straight MDR from theend of the module.

Straight MDR removal procedure

Idler removal procedure

・A roller without a power cable is a idler.
・For removing straight MDR, loosen the attachment
bracket on the power cable side and remove thecable tie which secures the MDR connector andcable.

3

Spring loaded
shaft

4

2

- 16 -

1

③ Replace and assemble idlers, roller link belt, straight MDR.
Attach the straight MDR, and assemble idlers from the straight MDR side toward the end of the module.
After assembling straight MDR, attach the MDR connector to the driver card and secure the cable with general-purpose cable-ties.
③ - 1.Engage the link belt on all rollers.
Refer to the following chart for groove position on which the link belt is attached.

Straight MDR attachment procedure2

Spring loaded
shaft●Linking the straight MDR and idlers ・・・PJ316（3PJ316）●Linking idlers ・・・・・・・・・・・・・PJ286（3PJ286）
Straight MDR and idlers

1

1

Use 3 grooves from the left edge

2

Leave 1 groove and then use 3 grooves

1
4
30N･m

2

3
③ - 2. Assemble idlers one by one in the order of the "shaft opposite from the VG roller" → "VG pulley side shaft".
VG pulley

While pressing the
D-cut surface of the
shaft against theplate, drop the shaft
into the groove asshown.

Spring loadedshaft④ Attach the shaft securing plate.

7 - 2. Replacement of a Diverting Roller
Tools to be used…

8mm・19mm spanners, cross-tip screw-driver, flat-tip screw-driver, nipper, 10mm socket wrench① Remove the shaft securing plate.
・Loosen the bolts on the shaft securing plate,and pull out the plate to remove.
Bolt

Shaft securing plate② Remove idler or straight MDR from the endof the module.

Straight MDR removal procedure

Idler removal procedure※Remove idlers until those on both sides of the3

Spring loaded
shaft

diverting roller to be replaced can be removed.
・A roller without a power cable is a idler.
・For removing straight MDR, loosen the attachment
bracket on the power cable side and remove thecable tie which secures the MDR connector andcable.

4

2- 17 -

1

③ Remove the roller cover of the divertingroller to be replaced.

Diverting roller

Roller cover④ Remove the link belt of the divertingroller to be replaced (Round belt).

Diverting roller

Link belt (Round belt)⑤ Replace the diverting roller.
・ Check the direction of the diverting roller whenassembling. (Fastening torque 5.4N･m）・ Always use a new nut.
※Old nut may not be fully fastened.

Diverting roller⑥ Attach the link belt (Round belt) around thediverting roller.

Diverting roller

・ Use caution for the link belt not to be twisted.

Link belt (Round belt)⑦ Attach the roller cover on the diverting roller.

Diverting roller

3.5N･m（Fastening torque 3.5N･m）

Roller cover- 18 -

⑧ Replace and assemble idlers, roller link belt, straight MDR.
Attach the straight MDR, and assemble idlers from the straight MDR side toward the end of the module.
After assembling straight MDR, attach the MDR connector to the driver card and secure the cable with general-purpose cable-ties.
⑧ - 1.Engage the link belt on all rollers.
Refer to the following chart for groove position on which the link belt is attached.

Straight MDR attachment procedure2

Spring loaded
shaft●Linking the straight MDR and idlers ・・・PJ316（3PJ316）●Linking idlers ・・・・・・・・・・・・・PJ286（3PJ286）
Straight MDR and idlers

1

1

Use 3 grooves from the left edge

2

Leave 1 groove and then use 3 grooves

1
4
30N･m

2

3
⑧ - 2. Assemble idlers one by one in the order of the "shaft opposite from the VG roller" → "VG pulley side shaft".
VG pulley

While pressing the
D-cut surface of the
shaft against theplate, drop the shaft
into the groove asshown.

Spring loadedshaft⑨ Attach the shaft securing plate.

7 - 3. Replacing/assembling Linking Belts (round belt) of Diverting Rollers
Tools to be used … 13mm spanner (2), 19mm spanner, Phillips head screw-driver, flat-tip screw-driver, nipper, 8mm box wrench① Loosen the M8 bolts at the 4 corners of Pop-up Diverter and remove the straight transporting unit.
MDR cable

・Disconnect the straight MDR connector from the driver
card.

Straight
transportingunit

・Remove the cable tie which secures the cable.
・When lifting the straight transport unit for removal,
hold the unit as shown.
※Because the straight MDR is heavy, use caution for
not dropping or giving strong impacts.
※Use caution not to damage the straight MDR cableby pinching, hooking, or forcibly pulling.

- 19 -

Straight MDR

M8 bolt

② Remove the diverting roller cover.

Roller cover③ Remove all link belts (round belts) attachedon the diverting rollers.

Diverting roller

Link belt (round belt)④ Remove the idler linked with diverting roller,
or diverting MDR.
・Remove only the attachment shaft opposite from VG
pulley.
（It is not necessary to completely remove the idler
linked with diverting roller or diverting MDR.）※If the spanner cannot be inserted in the gap, movethe roller to VG pulley to secure a gap for inserting
the spanner.

Idler linked with diverting roller,
or diverting MDR・When replacing a diverting MDR link belt (round belt),
first, loosen the 2 hex bolts on the attachment bracket
on VG pulley side.

Diverting
MDR
Diverting
MDR
cable

⑤ Attach and replace a link belt from theattachment shaft side.

Link belt（round belt）- 20 -

⑥ Attach a link belt (round belt) on the divertingroller.

Diverting roller

・ Use caution for not twisting the link belt.

Link belt (round belt)

Highest positionof the U-groove⑦ Secure the idler linked with diverting roller,
or diverting MDR.
・Fasten the hex bolt of attachment shaft at the highest
position of the U-groove for securing.

13N･m※ When the link belt (round belt) of a diverting MDR,

Diverting
MDR

tighten the 2 hex bolts the VG pulley side attachment
bracket. (Fastening torque 3N･m）

3N･m
3N

Diverting
MDR
cable

⑧ Attach the roller cover of the divering roller.

3.5N･mRoller cover・ Use caution for avoiding interference between roller
cover of the diverting roller and diverting roller.
（Fastening torque 3.5N･m）⑨ Attach the straight transport unit and secure
the 4 corners.

MDR cable

・Use caution for the orientation of the unit to be attached・Avoid MDR cable being pinched by other objects.
・During attachment operation, avoid interference between
the straight transport unit rollers and roller cover of thediverting roller.
・Attach the connector of straight MDR to the driver card.
・Secure the cable with general-purpose cable ties.

Straight MDR

M8 bolt

13N･mStraight
transportingunit- 21 -

8．Specifications
Product Specifications■ Pop-up diverter unit specifications※□＝N（NPN in/out or P (PNP in/out）

φ50mm

Power voltage

Size

φ39.5mm

Rated voltage

24VDC

Material

Urethane 90°

Static current

0.03A

Width(W)394, 494, 594, 694mm

Starting current

4.0A

Length (L) straight direction

760mm

Roller diameter
Diverting roller
Size■ CB-016□6 / CBR-306F□

Wire dia.

169mm（with diverting roller up：172mm）

Mechanism height

24VDC±10％

Pwr connector（CN1)0.50〜1.5m㎡（AWG:20〜14）Note）

Cntrl connector (CN2)0.08〜0.5m㎡（AWG:28〜20）Note）

Straight

Approx 60m/min

Motor rotation from drive input

15msec or below

Diversion

Approx 90m/min

Protection function

Mis-wiring protection / Integral 6.3A fuseLifting stroke

3mm

Temperature protection

95℃ for circuit board, 105℃ for motor

Drive power

24VDC±10％

Current limit

4A

Operating temperature

0 〜 40℃（No freezing）

Ambient temperature

0〜40℃（No freezing）

Operating humidity

90％RH or below（No condensation）

Ambient humidity

90%RH or below（No condensation）

Atmosphere

No corrosive gas

Atmosphere

No corrosive gas

Vibration

0.5G or below

Vibration

0.5G or below

Installed location

Indoor

Installed location

IndoorTilt of the mounting surface

5/1000 or below

Note) Conforming wire to the included connector

Transfer speed

Lifting sensor

Current consumption 15mA or below
Output（Roller btm sensor SN･S ／Roller top sensor SN･R） Output motion

Maximum inrush current: 100mA
Applied voltage: 30V DC or less (between output and 0V DC)
Residual voltage: 2V DC or less (100mA inrush current)

Power connector

734-162 (WAGO)〔MAX：10A〕

Control connector

733-365 (WAGO)〔MAX： 4A〕

Wiringside

Power conn. (CN1)734-102 (WAGO)〔MAX：10A〕

Control conn. (CN2)733-105 (WAGO)〔MAX： 4A〕

ON when detecting the position
Outer dia.φ3mm

Cable

PCB
side

0.15ｍ㎡ 3 wires■ Product Weight
Size

Weight

SizeA

46kg

Size B

49kg

Size C

51kg

Size D

54kg

Transfer Load
■ Load Size and Weight
Size
Size B
Size C

Min. size

Transport Speed

SizeA

〜

Max. size

Max. Load Weight

W300 × L300mm 〜 W300 × L650mm
60m/min type

Size D

W300 × L300mm 〜 W400 × L650mm
W300 × L300mm 〜 W500 × L650mm

30kg

W300 × L300mm 〜 W600 × L650mm※ Size and mass are approximate, as they vary by the load condition.
※ Certain type of load may not be transfered correctly depending on the bottom shape.

Transfer Throughput
Transfer speed 60m/min
Size D type
Load condition：Carton box W360×L360mm 30kg
Diversion is made from the condition with every load staying in each zone of the inbound C/V※The curves shown are based on thecompany's measurement for reference
only, not warranted values.

※Throughput vary by load size, material,bottom condition and transfer speed.

45°Slug release
30°Slug release
Throughput［cases / hour］※Slug release data is based on the total
control by using id LinX for controllingthe conveyors before and after
Pop-up diverter.

5000

45°Singulated release

4000

30°Singulated release

3000

2000

0
0

20

- 22 -

40
60
Diversion rate［％］

80

100

■ Replacement Parts for Pop-up Diverter
Part Number

Part Name

1

Diverting roller
link belt（round belt）

2

Roller link belt

3

Diverting roller

4

Straight MDR

5

Idler
（For straight motion)

6

Driver card7

Cup square neck bolt M6×45mm ※8

U nut M6 ※MXP5-04/87F

L=260mmIdler ⇔ Idler

3PJ286

MDR ⇔ Idler

3PJ316

POP-D-ROL（sizeA ／ sizeB ／ sizeC ／ sizeD）

PM500FE-60-（ 305 ／ 405 ／ 505 ／ 605 ）-D-024-JW-C150-VG（sizeA ／ sizeB ／ sizeC ／ sizeD）

ARI-38-（ 326 ／ 426 ／ 526 ／ 626 ）-VG
CB-016□6 （M1：Straight ／ M2：Diversion）
CBR-306F□ （M3：Lifting）□：Specify N = NPN or P = PNP
according to the input/output type

※ For diverting roller installation. Need to be purchased with diverting roller.

■ Optional Item List（Extention cable, etc.）● Mounting stay
Size
A
B
C
D

（mm）

Internal dim. of frame
400 500 600 700

A dim.
249
349
449
549

499
599
699

Internal dimension of the frame

65
15

2×2-M8Hex bolt for M8×16
Using spring washer

40

12.5

A

4-φ10

67.5

Hex bolt for M8×25
Using flat washer andspring washer● Extension cable＊ M8 bolt / nut / flat washer / spring washer included.

(Male side)

Cable specification

Model

A

17.5

35

3.2

67.5

ACE-CBM-B0600

9P ext. cable length

600mm

ACE-CBM-B0850

9P ext. cable length

850mm

ACE-CBM-B1200

9P ext. cable length 1200mm(Female side)

60 ±5

37
L

● Driver card attaching plate（F-RAT-S1-DB）
2-φ6.5
180
70

55

122

28.7

206

53
30
20

29.3

Driver card attachment position- 23 -

9．When Questioning a Failure
When questioning a failure, check the items shown below before contacting us or requesting a repair.
Symptom

Pop-up diverter does
not operate

Check the Following

Perform the Following

Is PWR LED of each driver turned on?

Supply 24VDC.

Is LED2 (red) of each driver card
blinking or lit, indicating error output?

Eliminate error cause and cancel theerror setting.

Is each connector correctly connected?

Refer toConnector
wiringP.12

Error detail/cancel method

P.26

CB-016□6 User manual

Connection

P.11

WiringP.12

Check the wiring and rewire correctly.
Is the wiring correct?

Does each driver card type ※ (NPN/PNP input/output) and input/output
signal (NPN input/output /PNP input/
output) of PLC, etc. match?

Match each driver card type (NPN input/
output / PNP input/output) and input/
output signal (NPN input/output / PNP
input/output) of PLC, etc.

WiringP.12

Is the input voltage common to the
supplied power voltage?

Make the input voltage common to the
supplied power voltage.

Connector
wiringP.12

M3：Is the lifting driver card set with
SW1#5 to OFF and SW5 to "1"?

M3：Set the lifting driver card with
SW1#5 to OFF and SW5 to "1".

Driver cardsetting

P.15

Is the control made for detecting
lifted-up/down position when theroller bottom sensor (SN・S) or
roller top sensor (SN・R) is ON?

Make the control to detect the liftedup/down position when the roller
bottom sensor (SN・S) or roller top
sensor (SN・R) is ON.

Control

P.14

M3：Isn't the RUN signal to the lifting
driver card kept continuously entered?

Set the RUN signal to the M3：Lifting
driver card to OFF when the lift
up/down position is detected.

Control

P.14

M3：Is the lifting driver card LED2 (red)blinking or lit, indicating error output?

Eliminate the error cause and cancel
the error.

Error detail/cancel method

P.26

Is speed change of straight MDR byoperating M1：straight driver card
switch, and diversion MDR speed byoperating M2：diversion driver card
switch individually ？

Speed change of straight MDR shouldbe operated by M1：straight driver card
switch, and speed change ofdiverting MDR should be operated by
M2：diversion driver card switch.

Driver cardsetting

P.13

Isn't M3：lifting driver card switch
operated?

If M3：lifting driver card switch isoperated, return it to the original position.

During diversion, eachload moves as if
disturbed

During diversion, both straight MDR(M1) and diverting MDR (M2) are
driven at the same time?

During diversion, straight MDR (M1)needs to be driven.

Control

P.14

Rotation direction does
not match (divertingroller / straight MDR)

Does the diversion type (L/R) of Pop-up Switch setting of M1: straight driver carddiverter and switch setting of M1：straight and M2: diversion driver card should
driver card and M2：diversion driver
match the Pop-up diverter type.
card switch (SW1#3) match?

Driver cardsetting

P.13

Lifting unit does notoperate, or the motion
is abnormal.

Cannot change thespeedSome diverting rollers
do not rotate during
diversion

Is the tension on the diverting roller
comparable to the tension on otherlink belt?

Replace the link belt.

Replacement/assemblyof diverting roller link belt(round belt)

P.19

Isn't any link belt broken?
- 24 -

Appendix 1 ．CBR-306F□ Detail
CBR-306F is a driver card for up/down motion.
MDR is driven by RUN signal input, but is
automatically stopped after counting
predetermined motor pulses.

Keep SW1-5 to be OFF.
It cannot operate by external input signal, or may
cause a failure if SW1-5 is set to ON.

CautionTime Chart● Normal up/down motion
ON

RUN signal input to CBR-306F

OFF
RUN

Lifting MDR●

STOPAbnormal up/down motion
ON

RUN signal input to CBR-306F

OFF
RUN

Lifting MDR

STOPCounting the specified
motor pulses

Counting the specified
motor pulses

1s or 0.5s

■ List of Functions【Wiring】

N.A

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

MODULE
7 8

9 0 1

2 3

N.A

M3：Lifting MDR

0V
24V

78

23

90 1

⑤CN1

456

Not used③ERR LED

1① SW1（DIP switch）

PNP signal input〔FP〕type

CN2

CN2
Motor pulse signal output
Error signal output

CW/CCW
RUN/STOP

CW/CCW
RUN/STOP
0V

0V
24V

24VDC

CN1

24VDC

CN1

※CN2#3(N.A) is not used.

③STATUS LED

Motor pulse signal output
Error signal output

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

0V

0V
24V

⑥SW5

①SW1

③PWR LED

NPN signal input〔FN〕type

5.PLS
4.ERR
3.N.A
2.DIR
1.RUN

456

CBR-306F□

STATUS/ERR/PWR
1. AUTO/MANU
2. INT-TIME
3. DIRECTION
4. E/N-OUT
5. MDL/TEST④CN2※CN2#3(N.A) is not used

Remarks

Description

ON

OFF

Default

Auto/manual recovery selection with thermal,
low voltage, induced voltage error

Manual rec.

Auto rec.

ON

Ref. Error detail, cancellation

0.5sec

1sec

OFFRef. Time chart ● Refer to abnormal lifting operation

OFF（Normally set to OFF）
Ref. E rror signal output

2

Stop holding time3

Rotation direction selection

4

Alarm (error) signal output selection

Normal time output

Error time output

OFF

5

Forcible RUN

RUN

Module selection

OFF（Ref. rotation dir. change）

Keep SW1-5 to be OFF.
It cannot operate by external

Caution input signal, or may cause afailure if SW1-5 is set to ON.
Indication

Color

RemarksPWR LED

Green

Indicates powered condition

ERR LEDRed

Indicates error type

STATUS LED

orangeIndicates number of error occurrence form
thermister reaction, motor stall or under voltage

③

④ CN2
（Control）⑤ CN1（Power）⑥ SW5（Module selection）

No.

Description

5Motor pulse output

4

Error signal output

3

―

2

MDR rotation direction change

1

MDR start/stop

2

0V

1

24VDC

0

Not operating

1

F-RAT-S series／Pop-up Diverter

2

F-RAT-T225

3

F-RAT-U225

Ref. Error detail, canceling method
Refer to CB-016 User Manual
Remarks
Motor pulse signal output（2pulses/1 rev. of internal motor）
Ref. Error signal output（Not used）
Ref. Rotation direction change
ON：RUN／ OFF：STOP （Approx 3mA current flows）

CautionMake sure to select a correct number
for installed product.

＊ Product may be in unexpected behavior in case of incorrect setting.

- 25 -

■ Forcible RUN
SW1#5

・Lifting MDR starts by turning
DIP-SW SW1-5 to ON, without
external signal to CN2-1 / CN2-2.

Lifting MDR

ON
OFF
RUN
STOP

Counting a prescribedmotor pulse

SW1#5（DIP-SW）

SW1-5 must be set to OFF when the roller bottom sensor (SN･S ）is ON,
in case of Pop-up Diverter.
That may cause Pop-up Diverter breakage or make the operation life
extremely short.

Caution

#5
ON
OFF
#5
ON

① Lifting MDR starts by turning DIP-SW SW1-5 to ON after injecting main power.
② Lifting MDR stops by turning OFF.

※MDR rotation in the right turn direction is defined as CW whenviewed from the cable side, and left turn as CCW.
※0V must be common to the power supply.
※CN2#2 carries approx. 3mA current.

OFF

1

2

3

4

ERR
N.A
DIR
RUN

1234

SW1#3

・MDR rotation can be changed by external switch.

②
OFF

ERR
N.A
DIR
RUN

1234

■ Rotation Direction Change

5※Normally use
OFF condition①

CW/CCW
Not
connected

CCW

CW/CCW

CW

Connected■ Error Signal Output
・SW1#4 can change setting of normal-time signal output or error-time signal output.
・CN2#4 delivers error signal output.
※Power ON/OFF operation generates error signal. Make the control to ignore error
signal from the driver card for 0.5sec at power ON, and 2sec at power OFF.
※Use a protection resistor to suppress current to 25mA or below.
Use of higher current damages the transistor in the driver card.
※Protection resistor 100Ω is furnished in the driver card.

SW1#4
OFF

ON

Error-time signal output

Normal-time signal output

Normal time open

Error time open

Transistor in thedriver card is ON
during error

Transistor in thedriver card is OFF
during error.

（

）（

）

■ Error Detail, Cancellation Method
LED Indication

・Error can be checked by PWR LED(green), ERR LED(red),and CN2#4 signal.
※Error signal cancellation by CN2#1 ON → OFF → ON
immediately starts MDR.
※At low power voltage (8.5V or below), the motion same as power
shut down or unexpected motion may occur.
PWR LED (green) CN2#4（Error signal）
SW1#4OFF SW1#4ON
ERR LED (red)MDR

Error Cause

Steady ON

Blinking（1Hz）

Error Signal Cancellation

Blinking
（6Hz）

OFF

MDR RestartOpen

Output−（Normal operation）

Open

Open

Stop

No power

Supply 24V DC−

OutputOpen

Stop

Driver card failed

Shut off the power and replace the driver card−

Thermal protection has
been activated bytemperature rise ofdriver card or MDR(Thermal error)

Auto recsetting−

1 min after reaching recovery temp, error signal cancellation and immediate start

OutputOpen

Stop

MDR connector
has been separated
OutputOutput

Open

Open

Stop

Stop

4sec elapsed with locked
MDR(Lock error)
Power voltage is 15V or
below（Low voltage error）

Manualrecoverysetting

After reaching recovery temp, CN2＃1 ON→OFF→ON to cancel error and start
After reaching recovery temp, CN2＃2
ON→ OFF→ON or OFF→ON→OFF

Start by CN2＃1 ON→OFF→ON
Start within 1 min.

After reaching recovery temp, CN2＃1 ON→OFF→ON to cancel error and start
After reaching recovery temp, CN2＃2
ON→ OFF→ON or OFF→ON→OFF

Start by CN2＃1 ON→OFF→ON

Shut off the power and connect the connector−

CN2＃1 ON→OFF→ON to cancel error and startCN2＃2 ON→OFF→ON or OFF→ON→OFF

Start by CN2＃1 ON→OFF→ON

Auto recsetting

Immediate start

Manualrecoverysetting

Error can be canceled by power OFF（2sec or longer）- 26 -

Secure power voltage 18V or higher

Secure power voltage 18V or higher, CN2＃1 ON→OFF→ON to cancel error and start

Secure power voltage 18V or higher,
CN2＃2 ON→OFF→ON or OFF→ON→OFF

Start by CN2＃1 ON→OFF→ON

Appendix2．Maintenance・When starting and ending daily operation, perform maintenance inspection by referring to the following.
・To avoid accident or damage during operation, perform safety check and procedure.
● Safety check procedure before starting maintenance inspection operation● To avoid interference by power circuit or signal, shut off power to all connected devices.

Warning（ａ）After turning off the power switch, leave for 3min or longer to discharge the DC power supply.
（ｂ）To prevent unrelated personnel from supplying power, post a warning indication.
（ｃ）When inspecting during operation for noise or abnormal rotation, use caution for finger beingcaught by rollers and other moving part. In preparation for immediate stopping of theequipment apply sufficient safety measures.
● Always use protective means such as gloves.

Operations without using protective means may lead to cutting by a metal part and other injury.
● Confirmation after maintenance inspection・After completing maintenance inspection operation, check the following before a trial operation.
（ａ）Whether the roller link belts and diversion roller link belts are attached in the correct groove position.
（ｂ）Once-removed covers are securely installed.
（ｃ）No components have been forgotten for assembly.

Inspection Locations

・Mounting points of Pop-up Diverter
・Loose screws
・Mounting stay（Optional）

・Driver card

・Tighten the screw

・Loose screws at mounting points

・Tighten the screw

・Incorrect attachment of driver card

・Attach connector correctly

・Wire damage, defective wiring

・Correct the wiring

・Abnormal temp rise, damage

・Stop and report to the distributor

・Idler・Abnormal sound・Rotation failure
・Appearance defect by damage

・Roller MDR・Abnormal sound・Speed degradation from setting・Appearance abnormality, dent
・Abnormal temperature rise・Roller link belt

・Crack on belt surface
・Wear on belt surface
・Damage on belt side(degradation）

・Diverting roller

・Surface crack, lost material
・Surface wear
・Appearance abnormality, dent
・Abnormal sound, poor rotation

・Diverting roller link belt

・Belt surface crack
・Belt surface wear

・OtherAction Contents

Inspection Items

・Repair, replacement
P.16

P.23

・Current leak from the equipment

・Equipment grounding

・Component deformation, damage

・Stop and report to distributor- 27 -

Appendix 3．Remaining Risks

List, MAP

■ List of Remaining Risks
No.

Stage

Operation1

Preparation

Uncrate/transfer

Qualificationfor operation

Manualpages

Position on unit

Dangerlevel

Remaining risk factor

Presumed measures

Implemented
measures

Product
metal part

CautionInjury by product metal part

Wear protection: gloves, etc.

Explained in
the manualP9

2 or more operators holdproduct by both hands while
supporting the bottom.

Explained in
the manual

P9

Explained in
the manual

P15

2

Preparation

Transfer

No specificposition

CautionHeavy item transfer by asingle operator may cause
injury or damage on product3

Operation

Trial opr.

No specificposition

CautionDuring stand-alone trial
operation, unexpected loadtransfer causes injury

Cut off the control to avoid
motion of other parts
before starting the unit.

Between moving
parts andbetween moving Warningpart andstationary part

Operator's fingers/hand arecaught between the unit andmoving part, or between
moving parts

・Enclose the area with・Attach ainterlocked fence to prevent
warning/caution
operator coming close.
label
・Explained in・Add a cover to the gap in
the unit to eliminate gap.
the manual

P10

5

All
Operation operations

The upper
surfase of
product

CautionOperator rides on the unit
and slips and falls down

・Enclose the area withsafety fence to prevent
operator coming close.
・Train the operator not toride on the equipment

Explained in
the manual

P3

6

All
Operation operations

No specificposition

CautionOperator is injured by a load
popped out of the C/V

Enclose the area with safety
fence to keep people off andstop object to pop out.

Explained in
the manual

P10

7

Maintenance inspections

All

Power supply
to driver card

Warning

Power-on action by someone
makes the product move
unexpectedly and causes injury

Post a warning sign toprevent unrelated personnel
from supplying power.

Explained in
the manual

P16、P27

8

Maintenance inspections

All

No specificposition

Warning

Operator's finger or hand iscaught by the product

Work carefully by wearing
protective items such as
gloves.

Explained in
the manual

P16、P27

4

All
Operation operations Fully reading
the manual andunderstanding
the content■ Remaining Risk MAP
No.1

Caution

No.7
No.4

Caution

No.5

Warning

Warning
Single phase
100V/200V

Emergency stop switch
Breaker
DC power
supplyThis productPE

Remaining risk without specified position on the unit
No.2

Caution

No.6

Caution

No.3

Caution

No.8

Warning

http://www.itohdenki.co.jp
Headquarters: Itoh Denki Co.,Ltd.
Phone: +81 (0)790 47 1225 Fax: +81 (0)790 47 1328
www.itohdenki.co.jp

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 Fax: +1 570 820 8838
www.itohdenki.com

Asia/Oceania: Itoh Denki Asia Limited
Phone: +852 2427 2576 Fax: +852 2427 2203
China: Itoh Denki Shanghai Company Limited
Phone: +86 21 6341 0181 Fax: +86 21 6341 0180
www.itohdenki.com.cn

Specifications are subject to change without prior notice.

7-00K-1807- 28 -