Flat-Right Angle Transfer

Transcription

1 F-RAT-S User Manual Flat-Right Angle Transfer Thank you for purchasing Flat Right Angle Transfer unit. INDEX Important safeguards P1 Product designation P2 Structure P2 Power P2 Dimensions P3 P5 Installation and operation P5 P9 Maintenance P10 P13 Product specification P14 P15

2 1. Important safeguards Handle F-RAT-S properly in accordance with the information in each section as well as the precautions and instruction of this manual to use it correctly. Confirm the operation first to make sure there is no damage to the F-RAT-S and to avoid an accident WARNING and CAUTION WARNING and CAUTION are placed at critical points on this manual to direct the operators attention to significant items. They are defined as DANGER and CAUTION as follows: WARNING CAUTION Failure to comply with DANGER may cause hazardous conditions, resulting in death or severe injury. Failure to comply with CAUTION may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only WARNING WARNING Incorrect handling may cause hazardous conditions, resulting in death or severe injury. Do not use the product in the conditions of flammable gas, explosive environment or corrosive environment CAUTION CAUTION Incorrect installation or handling may cause hazardous conditions, resulting in medium or slight injury, or cause damage to peripheral devices. Do not step on the product, which might cause failure or accident. Do not touch the product while it is operating, this may cause an injury. Do not modify the product, which might cause a severe accident. Do not pull or bend wires / cables and do not place a heavy objects on the wires / cable, which might cause damage, fire and electric shock. Make sure the DC power supply is grounded, otherwise it might cause electric shock if failure or leakage occurs. Do not touch the product after operation stops, product may be hot and cause a burn. Keep the product away from water otherwise it might cause failure or electric shock. Stop the operation if you hear an abnormal noise while in operation. Make sure that the product is used in the range of the product's specifications Risk category of the product WARNING About risk category of the product This product is in compliance with risk category 2 or lower of EN954-1, and does not apply to risk category 3 or higher

3 2. Product designation F-RAT-S- - - L Speed m/min (Belt / Roller transfer : 17 m/min) m/min (Belt / Roller transfer : 60 m/min) m/min (Belt / Roller transfer : 90 m/min) Signal type selection N NPN signal type (NPN sensor / driver card) P PNP signal type (PNP sensor / driver card) Size AW379mm 758mm BW497mm 758mm CW597mm 758mm DW697mm 758mm Type S1 Belt transfer Roller transfer W Example : F - RAT - S - 17N - B - S1 Speed 17 m/min, NPN signal type, W 497 x L 758 mm, S1type 3. Structure F-RAT-S Transfer belt Idler for transfer V-ribbed belt MDR for roller transfer MDR for lifting MDR for belt transfer Accessories F-RAT-S mounting hardware 4 sets of M8-20 bolt / M8 nut Product label Driver card: CB-016N x3 or CB-016P x3 Proximity NPN sensor or Proximity PNP sensor Label detail Speed type Signal type Size Type (S) MDR rated current Max load weight Serial NO: YY/MM/DD Lot No 4. Power Switching power supply (DC24V, 5A) - 2 -

4 5. Dimensions F-RAT-S SIZE A W379mm L758mm Mounting hole pitch Mounting hole pitch 4-Mounting hole Hex. socket head cap bolt M8 Mounting hole pitch Hex. socket head cap bolt M8 Mounting surface Mounting hole pitch Mounting surface SIZE B W497mm L758mm 4-Mounting hole - 3 -

5 SIZE C W597mm L758mm Mounting hole pitch Mounting hole pitch 4-Mounting hole Hex. socket head cap bolt M8 SIZE D W697mm L758mm Mounting hole pitch Mounting hole pitch Mounting surface Mounting surface 4-Mounting hole Hex. socket head cap bolt M8-4 -

6 7 2 Accessory CB-016 NNPNor PPNP CB-016 VR1-ACC VR2-DEC STATUS/ERR/PWR 1. AUTO/MANU 2. INT/EXT 3. DIRECTION 4. E/N-OUT 5. L/H SPEED PLS 4.ERR 3.V-IN 2.DIR 1.RUN 0V 24V Installation and operation 6-1. Precautions for handling Use assistance when handling Handle with care 6-2. Precautions for unpacking Preventing injury Checking appearance of F-RAT-S 6-3. Precautions for installation [Electrical concerns] Circuit breaker Use assistance when carrying F-RAT-S, they weigh at least 110lbs or heavier. Do not drop F-RAT-S, or subject it to impact. Otherwise precision parts like microchips and bearings which are employed in the F-RAT-S may be damaged. Please put gloves on to protect your hands to not get hurt by sharp metal edges. Please check the followings. Make sure there are no cracks, damage, rust or corrosion. Make sure that all bolts are tightened properly. If any concerns are found, please contact our customer support at Breaker should be selected with proper capacity and installed.in case the earth leakage breaker is selected, make sure it is designed for inverter circuit. Otherwise, some earth leakage breakers may malfunction by high frequency component of switching power supply DC power supply Use isolated type switching power supply that conforms to safety standard (IEC or UL ). Non-isolated type power supply is not recommended to use because of safety issues and radiate-noise restriction. DC power supply and wiring material should be selected with proper current capacity for the F-RAT-S

7 6-3-3 Wiring Check Test the operation of the breaker and emergency switch to be sure they are operating correctly when the DC power supply is installed. Trial operation should be done after this testing. Make sure that DC power supply turns ON / OFF in accordance with breaker or Emergency Stop ON / OFF. AC power source E-STOP switch Check voltage and ON/OFF condition Breaker DC Power supply F-RAT-S (Unconnected) Make sure the wiring material does not contact any moving parts. PE 6-4. Precautions for installation [Hardware concerns] Environment Avoid places where F-RAT-S is exposed to water or dust. Use this product in the environment of Pollution level 2 that is defined by IEC Vibration level for the place of installation is 0.5G or less Install the F-RAT-S horizontally. Keep enough space surrounding the F-RAT-S for maintenance. Comply with the safety regulations that are required for installation places or devises Product installation Attach and fix F-RAT-S holding the base plate with assistants. (see Fig )F-RAT-S weight is approx. 110 lbs (50kg) Check installation direction of F-RAT-S, otherwise it may cause malfunction or failure. Be sure to not catch the motor / sensor cables in the product during installation Safety assurance Exposed moving parts may cause injury. Please check the moving parts referring to Fig Keep the safety label (warning / caution label) visible. Exposed belts and rollers Be sure to shut off the power before any maintenance. CAUTION Keep hands clear from moving parts (Belts, Rollers, Frames). Exposed moving parts Fig : - 6 -

8 Supplying power Connect DC24V / 0V wires to power connector CN1. Do not connect two or more wires to a terminal of CN1 and not distribute the power to other. It may exceede the capacity of connector CN1, and this would cause electrical shock, short circuit or failure. (Connector capacity is 10A) Do not wire in reverse polarity. Wiring should be made before inserting the connector into driver card. Connect wires to control connector CN2. When inject 0V signal (NPN) to CN2-1 (RUN/STOP) and CN2-2 (DIR), use same 0V line as the one of power supply. (Connector capacity is 4A) 7mm PPower connector DC 0V DC 24V mm 2 (AWG:2014) Control connector Plug power connector (CN1), control connector (CN2), and motor connector (CN3) to driver card. Plug connectors while power is shut off. Make sure that connectors are plugged to driver card properly. 7mm mm 2 AWG:2820 Refer to the user manual of driver card for the detail instruction of driver card. Installation procedure Mounting Use assistance and recheck the installation precaution before starting the installation. Firmly mount the product in consideration of product weight, load weight and vibration. Transfer level adjustment Transfer level of F-RAT-S and conveyors connected to F-RAT-S need to be adjusted. (Refer to the drawing below) Mounting surface Dedicated stay Mounting hole of F-RAT-S 2 4-M8Mounting hole of the stay Mounting stay is not included as standard accessory

9 F-RAT-S control MDR for roller transferm2 Proximity sensorsn R Proximity sensorsn S MDR for belt transferm1 Roller transfer direction MDR for liftingm3 P/E sensor 3 Belt transfer direction P/E sensor 1 P/E sensor 2 Timing chart Tray position P/E sensor 1 P/E sensor 2 P/E sensor 3 M1 MDR for spine M2 MDR for transfer ON OFF ON OFF ON OFF RUN STOP RUN STOP M3 MDR for lifting RUN DIR ON OFF ON OFF SN S Proximity sensor for spine ON OFF SN R ON Proximity sensor for transfer OFF *1 less than 0.03s *1Make sure that stopping time of lifting MDR should be less than 0.03s after SN-S and SN-R detect. *1 less than 0.03s Response time of control device should be within 20ms. If not it may cause damage or malfunction

10 Wiring diagram Input/Output type for F-RAT-S : NPN CB-016N wiring Input/Output type for F-RAT-S : PNP CB-016P wiring MDR for belt transfer MDR for lifting M1 RUN signal CB-016 RUN signal M3 DIR signal CB-016 Y0 Y1 X0 X1 SN S In-coming signal Prox sensor for belt transfer 5.PLS 4.ERR 3.V-IN 2.DIR 1.RUN CN2 from PLC 0V input from PLC 0V input 5.PLS 4.ERR 3.V-IN 2.DIR 1.RUN CN2 from PLC 24V input from PLC 24V input MDR for roller transfer RUN signal M2 CB-016 Y2 Y3 X2 X3 SN R Prox sensor for roller transfer 0V 24V 1 2 0V DC24V CN1 0V 24V 1 2 0V DC24V CN1 RUN signal for downstream zone RUN signal for upstream zone Y4 Y5 X4 X5 Product sensor signal at downstream zone Product sensor signal at upstream zone DC24V 0V DC24V 0V 6-5. Precautions for Trial Run Checking point for trial run Note) Do not drive a relay with prox sensor output because it may cause damage to the sensor. Make sure other devices in the system do not run. During the trial run, no product should flow from the upstream side. It may cause injury if product comes into F-RAT-S during the trial run. Before the trial run, make sure other devices or functions do not operate. Trial run should be performed without product on F-RAT-S to make sure there is no abnormal operation. Check the following points. No LED blinking on the driver cards that would indicate a motor error. No abnormal noise or heat from motors and cards that would indicate improper operation. Transfer throughput Transfer Speed of F-RAT-S: 60m/min Size: B type Condition of transferred product: cardboard W350xL405mm / 30kg 5000 Throughput [product / hour] Slug release Singulated release Transfer rate [%] The throughput in the graph is only for reference, not guaranteed performance. Stopping distance of the product and transfer throughput depend on product size, its materials and transfer speed

11 7. Maintenance 7-1. Precautions for Maintenance and Inspection Safety check before maintenance and inspection Make sure to confirm your safety before maintenance and inspection to prevent any accident, damage or injury. To prevent damage shut-off all electric power connected to F-RAT-S. Discharge all electric power by leaving the F-RAT-S sit 3 minutes after shuting off the power supply. To prevent power-on by mistake, warning signs and lock outs are recommended Parts repair / replacement Repair / replace parts immediately when you find damaged parts. Do not disassemble entire unit, just designated portions / parts. It may cause damage / accident. It may be nessesary to manually raise or lower the lift to replace/repair parts, be careful to prevent injury Check after maintenance and inspection After maintenance / inspection, make sure to check the following before running. Covers are properly closed. All parts are correctly attached. Transfer MDR replacement Replacement procedure Turn off F-RAT-S and then remove the motor cable of MDR for roller transfer from the dedicated driver card (CB-016N7). Loosen the cap screws of the pulley holding plate to remove it. Remove idlers and poly-v belts. Remove the mounting bracket and MDR paying attention as to not damage the motor cable or connector. When installing, make sure poly-v belts are placed in the correct position as shown on fig.2. Motor cable must be fixed with a cable tie so it will not contact any moving-parts. Fig.1 Dedicated driver card (CB-016N7) Idler for transfer Pulley holding plate Mounting bracket of MDR for roller transfer Fig.2 Poly-v belt position Leave two grooves at inside of pulley. Leave one groove between poly-v belts. Make sure that the belt at the end of pulley does not come off

12 Transfer belt replacement Replacement procedure Remove idlers adjacent to the transfer belt being replaced. (Refer to Transfer MDR replacement, P10.) Loosen the screws on the idler wheels that are for belt tension adjustment. (Do not remove the screws). With the belt tension removed you can now slide transfer belt off of the idler wheels. *Remember the installed position of the transfer belt over and under the idler wheels. Install a new transfer belt from the bottom, over the MDR first and then the top tensioning by idler wheels. (2 idler wheels per one flat belt as shown below) Idler wheel for tension adjustment MDR for belt transfer CAUTION for transfer belt Adjust belt tension by idler wheel, and then check the amperage of the MDR for belts, see chart bottom right. Belt tension adjustment with push-pull gauge 5.5mm pushed down Push the transfer belt until the belt surface becomes the same level as the roller plate and then check belt tension. See below table. Belt tension reference Transfer speed type 17m/min, 60m/min type 90m/min type Tension 12N 10N Use a push-pull gauge after reading the manual provided by the manufacturer. Belt tension adjustment with belt tension meter Check belt tension at the right position.(see page12) Belt tension reference Transfer speed type 17m/min, 60m/min type 90m/min type Tension 35N 32N Use a belt tension meter after reading the manual provided by the manufacturer. After transfer belt and MDR for belt transfer replacement, make sure there is no interference and do a running test. After running test, check tension according to the belt tension reference mentioned above. Too much tension on the transfer belt may cause a malfunction because overload is applied to MDR for belt transfer. On the other hand too loose tension may cause decrease transfer belt s speed and cause slippage. The checking position of belt tension depends on the plates attaching position. (See P12) Speed Code Amperage of MDR for roller transfer 1.5A or less 2.3A or less 3.2A or less

13 Position for checking tension on transfer belts With push-pull gauge V-ribbed belt side With belt tension meter V-ribbed belt side Size A V-ribbed belt side V-ribbed belt side Size B V-ribbed belt side V-ribbed belt side Size C V-ribbed belt side V-ribbed belt side Size D 108mm 117mm Idler wheel Idler wheel for tension adjustment Idler wheel Idler wheel for tension adjustment 108mm-pitch between idler wheels for tension measurment. 117mm-pitch between idler wheels for tension measurment

14 Belt transfer MDR replacement Replacement procedure Before replacing turn off F-RAT-S and remove the motor cable of each MDR from thier driver card. Remove the top MDR and all the idlers. (Refer to Transfer MDR replacement, P10.) MDR for belt transfer MDR for roller transfer and idlers for transfer MDR for belt transfer Remove all belt transfer units from the center and un-bolt the outside belts. Outside belts frame supports MDR. The number of belt transfer units depends on F-RAT-S type A,B,C or D. Belt transfer unit Attention Attention Attention: Belt drive MDR is supported by the outside belts, remove the center belts first then lift out MDR by picking up the outer belts. Hex. socket head cap bolt M6 10 A Holding plate for belt transfer MDR B Remove bolt A and nut B, then lift side A out to slide B side shaft and power cable through the frame hole. A B Hex. socket head cap bolt M815 Hex. nut M12 Follow steps to mentioned above to install. Make sure the belt transfer units position is right. (See the dimensional drawing, P3-4) Adjust the belt tension. (See the transfer belt replacement, P11)

15 8. Product specification Product specification F-RAT-S Roller Diameter Size Height Transfer / Spine Speed Stroke Power voltage Ambient temperature Humidity Below Atmosphere Vibration Installation Width (W) Transfer direction Length (L) Spine direction 50mm 379mm, 497mm, 597mm, 697mm 758mm 170mm 17, 60, 90m/min 10mm DC24V 0 40No freezing 90%RH or lessno condensation No corrosive gas 0.5G or less Indoor Standard motor cable length : 1500mm Standard sensor wire length : 1000mm Product weight F-RAT-S size Size A Size B Size C Size D Weight 81.5 lbs lbs. 108 lbs. 121 lbs. CB-016 = N (NPN) or P (PNP) Power voltage Rated voltage Static current Starting current Power connector CN1 Wire size Control connector CN2 Time difference from RUN signal to motor starting Protections Thermister protection Current limitation Ambient temperature Humidity Atmosphere Vibration Installation DC24V±10 DC24V 0.03A 4.0A AWG: AWG: msec or less Integral 6.3A fuse Diode against miss-wiring 95for circuit board 105for motor 4.0A 0 40 No freezing 90%RH or lessno condensation No corrosive gas 0.5G or less Indoor Transferred goods Recommended size of transferred goods Maximum load weight F-RAT-S size Size A Size W300 L300mm W300 L650mm Speed code Max. load weight Size A Size B, C, D Size B W400 L400mm W400 L650mm lbs 110 lbs Size C W500 L500mm W500 L650mm lbs 110 lbs Size D W600 L600mm W600 L650mm lbs 110 lbs Note: Size and load weight are just guidance. (This may differ by conditions of transferred goods)

16 Replacement parts for F-RAT-S Transfer belt Flat belt : TF10 L1630 W19 V-ribbed belt 3PJ336 (For pitch 100mm) 3PJ316 (For pitch 94mm) For size A MDR for belt transfer For size APM500FE-speed code-277-d-024-jg-c150 For size BPM500FE-speed code-392-d-024-jg-c150 For size CPM500FE-speed code-492-d-024-jg-c150 For size DPM500FE-speed code-592-d-024-jg-c150 Select speed from 17 (17m/min), 60 (60m/min)or 90 (90m/min). Note that it s PM500FC-90 for 90m/min type. MDR for roller transfer PM500FE-speed code-674-d-024-jw-c150-vg Select speed from 17 (17m/min), 60 (60m/min)or 90 (90m/min). Note that it s PM500FC-90 for 90m/min type. Idler for transfer IDR JH-VG for all types Driver card (Specify input and output type NPN (N) or PNP (P).) CB-016N for NPN type CB-016P for PNP type Option for F-RAT-S Dedicated stay F-RAT-S size A B C D Q (Mini.length) Dimension S R R S Q P5 2x2-R20 2x2-R x2-M Extension cable Model CE CBM-B Specifications 9P Extension cable 600mm long (Male side) (Female side) ACE-CBM-B 9P Extension cable 850mm long ACE-CBM-B1200 9P Extension cable 1200mm long Holding plate for F-RAT-S driver card 37 L 60 ±5 Disposal of the Products Treat as industrial waste. Specifications are subject to change without prior notice. Headquarters; ITOH DENKI Co.,Ltd Phone: +08 (0) Fax: +08 (0) Europe, Middle East, Africa: ITOH DENKI Europe SAS Phone: +33 (0) Fax: +33 (0) North & South America: ITOH DENKI USA,INC Phone: Fax: Asia/Oceania: ITOH DENKI Asia Limited Phone: Fax: China: ITOH DENKI Shanghai Company Limited Phone: Fax: