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ITOH DENKI MABS Operating Instructions Manual

Multi-angle ball sorter
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Multi-Angle Ball Sorter
Operating Instructions
Make sure to read this manual carefully before using, and start using only after you have
understood all the product' s functions, safety information and precautions.
After reading the instructions, store the booklet in a designated location for readily accessing at
any time.
Thank you for purchasing the Multi-directional Transfer Module (hereinafter
referred to as "this product").
※This product refers to all products including standard accessories.
This User Manual is intended to be written under control using not network
communications, but digital I/O, such as PLC signals.
Specifications subject to change without notice
2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: 570-820-8838
www.itohdenki.com

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Summary of Contents for ITOH DENKI MABS

  • Page 1 Multi-Angle Ball Sorter Operating Instructions Make sure to read this manual carefully before using, and start using only after you have understood all the product’ s functions, safety information and precautions. After reading the instructions, store the booklet in a designated location for readily accessing at any time.

  • Page 2: Table Of Contents

    table of contents Subject page Introduction Procedures Safety Precautions 6-10 Advance Preparation 11-15 Product Check Structures Installation/Wiring -Before Installation 18-31 -Installation -Wiring IB-E06F-M1 settings 32-42 -Setting Preparation -Property Settings Control/Operation -Before Starting Control 43-49 -About Swing Control -Basic Operation -What to Do Before Operation Maintenance/Inspection -Controller's LED Display 50-58...

  • Page 3: Introduction

    introduction Features: This product is a module to enable the user to divert totes. This compact diverting module can set the diverting angle freely. All-electric control. No pneumatics, which do not require compressor. operation description (when diverting): Load The transfer ball section swings to the diverting direction Discharge The transfer ball section swings to the...
  • Page 4 Caution : Installation, operation and usage of ITOH DENKI MDRs in combination with a control card designed by a third party could result in fatal phenomena such as fire, electric shock, injuries, etc. which are out of the responsibility of ITOH DENKI.

  • Page 5: Procedures

    Check accessories. Installation Install the MABS (this product) main unit. Mount the controller. Connect the MABS (this product) main unit and Wiring controller. Connect power and signal cables to the controller. Perform settings of the controller. Connect to power supply units.

  • Page 6: Safety Precautions

    Safety Precautions Danger Level: To prevent hazards to users and/or others, and/or damage to property in advance, the important precautions to be followed securely are described below. The degree of hazard and/or damage that may result if a user disregards the description and operates the product improperly is categorized as the following symbols and explained below.
  • Page 7 Safety Precautions General Precautions (Continued): CAUTION Never remodel the product. Failure to follow this could result in serious accidents. We assume no responsibility for remodeled products. Make sure to connect ground wires to this product. Failure to follow this could result in electric shock if any malfunction or leakage occurs. Do not put water and/or oil on the product, and do not transfer wet and/or oily totes.
  • Page 8 When handling, wear protective equipment, such as gloves. Failure to follow this could result in hands getting injured by metal parts. Make sure to use the recommended tightening torque to tighten bolts for installing the MABS main unit and/or fastening screws of controllers.
  • Page 9 Safety Precautions OPERATING Precautions: CAUTION Do not forcibly move totes when they are placed on transfer balls. Failure to follow this could result in damage and/or malfunction. Make sure to perform the start-up inspection before starting operation. Wear protective equipment, such as gloves. Do not unplug power and/or signal cables during operation.
  • Page 10 Precautions on start-up inspection/maintenance and inspection (CONTINUED): CAUTION Make sure to prepare maintenance parts designated by ITOH DENKI. Using parts other than those designated by us could result in malfunction. Perform maintenance and inspection in a “Pollution Degree 2” environment, as defined in IEC60664-1.

  • Page 11: Advance Preparation

    Advance Preparation wiring reference: Master Unit: A MABS unit to operate through signal communications with PLCs. Synchronized unit: A MABS unit to operate by receiving signals from the master unit As for the sensor input, and input/output signals of controllers, adopt the number of inputs/outputs based on customers’...
  • Page 12 Advance Preparation items to be prepared by customers (Continued): 2. Control Devices: devices to control this product, such as PLCs 3. Sensors: Zone sensors to check the tote, and area sensors to check loading and discharging, etc. Zone Sensor: A sensor to detect the existence of totes within the zone Area sensor: A sensor to detect load and discharge of totes to/from the zone...
  • Page 13 advance preparation items to be prepared by customers (Continued): 7. Application Installing the Designated Application For IB-E06F-M1 settings, the following two files are necessary. iCEP Lite Comment file Download at https://www.itohdenki.co.jp/e_softdl.html Illustrations explained and/or procedures may partly differ depending on your PC. In such cases, perform settings and operations to ensure the application will be safely installed of your own accord, and under your own responsibility 7-1.
  • Page 14 8. Designated Stay (optional): A stay used to install the MABS main unit. For details on how to mount, refer to p.25. Designated stays and mounting bolts are not included. Order separately. When installing the MABS main unit, make sure to use the designated stay. If stays other than those designated have been used, the warranty will not be valid.
  • Page 15 SW1 of the figure below, add the power shutdown circuit using a PLC. At the time of power shutdown, not only the MABS main unit power, but also the IB-E06F-M1 control power will be shut down.

  • Page 16: Product Check

    Product Check checking the model: Unpack the product, and check that the product model is what you ordered. checking appearance: Check that the main unit is free from any abnormalities, such as traces of scratches, dents, dirt, and/or corrosion (rust). Check that there is no omission and/or looseness of screws.

  • Page 17: Structures

    Structures: MABS Main Unit *The image is for size 400 Product Designation: Nominal Speed: The speed on the transfer surface of transfer balls (m/min), and the nominal speed with a nice round value for convenience. Values differ from the actual speed.

  • Page 18: Installation/Wiring

    Prepare the diverting conveyor to be wider than the straight conveyor W + 200 mm (The conveyor width depends on totes and/or tote position. Install the MABS main unit in a location described in the figure. Install the MABS main units to be combined by securing a space of 5 mm.
  • Page 19 Dimensions of MABS main unit: Size 400 L186mm x W398mm The machine height and height of the mounting surface indicate dimensions at the time of the actual transfer (when load is applied to transfer balls). The origin sensor cable needs to be extended.
  • Page 20 Dimensions of MABS main unit: Size 500 L186mm x W498mm The machine height and height of the mounting surface indicate dimensions at the time of the actual transfer (when load is applied to transfer balls). The origin sensor cable needs to be extended.
  • Page 21 Dimensions of MABS main unit: Size 500 L186mm x W598mm The machine height and height of the mounting surface indicate dimensions at the time of the actual transfer (when load is applied to transfer balls). The origin sensor cable needs to be extended.
  • Page 22 Dimensions of MABS main unit: Size 700 L186mm x W698mm The machine height and height of the mounting surface indicate dimensions at the time of the actual transfer (when load is applied to transfer balls). The origin sensor cable needs to be extended.
  • Page 23 Dimensions of MABS main unit: Size 800 L186mm x W798mm The machine height and height of the mounting surface indicate dimensions at the time of the actual transfer (when load is applied to transfer balls). The origin sensor cable needs to be extended.
  • Page 24 Perform mounting processing on the frames and control panel by reference to the mounting holes for controllers. Cable position of MABS and the cable length from MABS main unit, refer to dimensions of MABS main units (P.19) Mount controllers on a flat surface where heat can be released easily.

  • Page 25: Installation

    Necessary Tools Installing the MABS main unit: When installing the MABS main unit, make sure to use the designated stay. If those other than designated stays have been used, warranty will not be applied. The designated stay has two types to be used for M6 and M8.
  • Page 26 (M8) x 20 Recommended tightening torque: 12 to 14N 5. Adjust the conveyor frame legs on which the MABS main unit has been mounted, and align levels of the MABS main unit and the adjacent conveyor. 2 Great Valley Blvd., Wilkes-Barre, PA 18706...
  • Page 27 (M1) and swing (M2) from the wiring hole. 2. Refer to the labels for cables coming from the MABS main unit, and securely connect the motor connectors and extension cables to the controller. 2 Great Valley Blvd., Wilkes-Barre, PA 18706...
  • Page 28 Synchronized unit: A MABS unit to operate by receiving signals from the master unit ※When each unit set as master unit, each MABS unit can also be operated individually using the signal input/output from PLC. wiring diagram: When using multiple power supply units, 0V of PLC and 0V of controller to be common.
  • Page 29 installation/wiring i/o settings: Specified Swing Direction: Start swinging: swing status output: 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 30 installation/wiring ib-e06f-m1 wiring: CN1: Power Connector Connect the 24V DC and 0V DC cables to CN1 (2 pins). Do not connect multiple power cables to one pin. Failure to follow this could result in electric shock, short circuit, and/or damage due to the capacity of connectors being exceeded.
  • Page 31 installation/wiring ib-e06f-m1 wiring: Input/Output Circuit Connect the COMMON terminal for remote input and remote output separately [Remote input (CN301)] 734-264 (WAGO) Maximum allowable current:10[A] Set the NPN/PNP signal switching for remote input using COMMON. Connect the positive pole to COMMON at the time of NPN input, and 0V to COMMON at the time of PNP input.

  • Page 32: Ib-E06F-M1 Settings

    IB-E06F-M1 settings Flow of settings: IB-E06F-M1 controls the MABS using the property setting and ladder logic. This section explains the setting preparation and property settings. Setting the IP address / Checking connection Creating the project file Setting Preparation Registering IB-E06F-M1 to be used...
  • Page 33 IB-E06F-M1 settings 8-1: Setting preparation Setting the IP address / Checking connection: 1. Make sure that all DIP switches of SW401 on IB-E06F-M1 are turned OFF. All switches are OFF under the factory settings. Do not change. 2. “192.168.1.1 / 255.255.255.0” has been set under the IB-E06F-M1 factory settings. Change the “xxx”...
  • Page 34 IB-E06F-M1 settings 4. Set the IP address for the PC to “192.168.1.XXX / 255.255.255.0” (same network). 4-2. Open “Properties”, and select “Internet Protocol Version4 (TCP/IPv4)”. Click “Properties” 4-3. Set the IP address to “192.168.1.XXX”, and Subnet mask to “255.255.255.0”. Click “OK” Set the IP address to avoid overlapping with other addresses for IB-E06F-M1, etc.
  • Page 35 IB-E06F-M1 settings Registering IB-E06F-M1 to be used: Before executing operations, such as writing the property settings to IB-E06F-M1, IB-E06F-M1 to be used needs to be registered in the project. 1. Expand the project management from the project tree window, right-click “Device”, and click “Add”. 2.
  • Page 36 Project tree window 8-2: Property settings IB-E06F-M1 property settings: In the property settings, set the MABS transfer speed to be written to IB-E06F-M1. Perform the property settings for both the master unit controller and synchronized unit controller. 1. Expand “Device” on the project tree window, and display the IP address for the corresponding IB-E06F-M1.
  • Page 37 IB-E06F-M1 settings Property setting window: 1. Selected node The IP address for the IB-E06F-M1 of for which the properties are being specified is displayed. Double- click the node on the “3. Node tree window” to switch the selected node. 2. Ladder logic Select the ladder logic.
  • Page 38 Master. If any have been set to Slave, select the appropriate node, and right-click to set to Master. (The default value is Master for all controllers.) When using only one unit, or operating MABS units individually without connecting each unit using the LAN cable, the Network settings are not necessary.
  • Page 39 IB-E06F-M1 settings 3. Synchronized unit Network settings 3-1. Double-click the synchronized unit. 3-2. Select “MABS2_E06_V×××” for the logic. 3-3. Select the Error/Network tab. 3-4. Put a checkmark in Multicast. 3-5. Enter the address for the master unit in Receive node. (If the IP address for the master unit is “192.168. 1.1”, enter “225.0.
  • Page 40 IB-E06F-M1 settings Motor settings: Perform the Motor Settings 1. Select “MABS2_E06_V×××” for the logic. 2. Select the motor tab. 3. Set the motor type to “Other”. 4. Set the roller diameter to “64.0” for Motor A, and “87.0” for Motor B. 5.
  • Page 41 Reference value of CW/CCW swinging angle and value of the pulse. ※These are reference values. Recommend to adjust angle by actual MABS units. Click “File-Save”, and save the contents that have been specified. 2 Great Valley Blvd., Wilkes-Barre, PA 18706...

  • Page 42: About Swing Control

    IB-E06F-M1 settings About Swing control: Perform swing using the pulse control of IB-E06F-M1 and proximity sensor for origin position. 1. Origin position (Straight) Turn the proximity sensor ON (IB-E06F-M1 Sensor A SEN: origin sensor input ON) for straight direction or origin direction. 2.
  • Page 43 Synchronized unit: A MABS unit to operate by receiving signals from the master unit ※When each unit set as master unit, each MABS unit can also be operated individually using the signal input/output from PLC. wiring diagram: When using multiple power supply units, 0V of PLC and 0V of controller to be common. Failure to follow this could result in operation failure.
  • Page 44 control/operation i/o settings: Specified swing direction: start swinging: swing status output: 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 45 control/operation 9-2: about swing control Perform swing using the pulse control of IB-E06F-M1 and proximity sensor for origin position. 1. Origin position (Straight) Turn the proximity sensor ON (IB-E06F-M1 Sensor A SEN: origin sensor input ON) for straight direction or origin direction. 2.
  • Page 46 control/operation 9-3: Basic operation Initial operation (origin searching) 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 47 control/operation Swing from the loading to diverting direction. ※1 After turning Sensor A SEN OFF, automatically stops when swing has been executed based on the pulse counter in the CW swing angle settings (PC16). 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 48 control/operation Swing from the discharge to diverting direction. ※1 Automatically stops when Sensor A SEN is ON 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 49 Post warning labels so as to prevent unauthorized persons from turning on the power. Parts to be inspected Items to be checked Description of measures Secured positions of the MABS Screw looseness Re-tighten screws main unit Damage, deformation...

  • Page 50: Maintenance/Inspection

    maintenance/inspection 10-1: Controller's led display If errors is occurred, identify the causes of errors by checking controller’s LEDs and error signals, and perform recovery work. IB-E06F-M1: Position of LED on IB-E06F-M1 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 51 maintenance/inspection led indication: Position of LED on IB-E06F-M1 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 52 maintenance/inspection error details: The table below described the LED indications, occurrence conditions, error release conditions and MDR status when an error occurs. Use iCEP Lite to check the type of error, and release errors manually. Errors will be also reset when the power is OFF. Refer to 10-2.

  • Page 53: Checking And Releasing Errors

    maintenance/inspection 10-2: Checking and releasing errors Use iCEP Lite to check error statuses in IB-E06F-M1, and release errors manually Checking error statuses 1. Select “Error information” from “Dialog” in the menu. 2. Select the IP address for the PC, and click “OK”. 3.

  • Page 54: Appendix 2: Replacement Parts/Options

    maintenance/inspection Releasing the error manually Soft error 1 cannot be released. (The error occurs when proximity sensor has not been detected (refer to P.52)) When specifying the IP address for the controller of which the error is to be released, the selected IP address is displayed in Select IP.
  • Page 55 maintenance/inspection others: Link belt replacement jig (Model: MT-BR01) ※Necessary for mounting the link belt. Grease S UMICO Lubricant Sumitec 305 ： ： replacement parts model number and required quantity per 1 unit: About replacement: Please contact us for replacement of Gear A/B, link belt, and motors for transfer and swing. 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838...
  • Page 56 1. Remove all ultra-low head bolts (M5), and remove the top cover. Replacing the transfer ball element set 1. Remove the transfer ball element set to be replaced from the MABS main unit. Slowly pull directly upward. Failure to follow this could result in damage to parts.
  • Page 57 maintenance/inspection Replacing the transfer ball element set (continued) 2. Mount a new transfer ball element set according to the following procedure. 2-1: Divide the transfer ball element set into each part, and mount the gear cup ❶ to the main unit. (Note 1) 2-2: Align part A of SUS cup ❷...
  • Page 58 maintenance/inspection grease filling procedure: Fill grease once a year from the original date of installation. For the date of installation, check the date of installation label. Removing the top cover 1. Remove all ultra-low head bolts (M5), and remove the top cover. Filling grease 1.
  • Page 59 Check the wiring and rewire Installation/Wiring Has the wiring been performed correctly. (p.28) properly? MABS does not Check if NPN/PNP in/output wiring Check the signal type, NPN or PNP, Product Check operate is correct between controller and wire it correctly.
  • Page 60 (p.41) Align the installation direction of The transfer direction Has the MABS main unit been the MABS main unit (turn the row Installation/Wiring is different from the installed in the correct of less transfer balls to the (p.25)
  • Page 61 Appendix 1: Product Specifications MABS main unit specifications: Values of the maximum load weight are reference only, since they may change depending on totes conditions. Offset load and depending on the bottom shape of totes, they may not be transferred normally, even if they are within the above size range When transferring by setting two units with ball rotation speed of 60 m/min.
  • Page 62 Appendix 1: Product Specifications Product Label: Product Model Input voltage/Rated current Rated output Maximum load weight that can be transferred Serial No. Year of manufacture Date of Installation Label: Controller Specifications: 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 Fax: 570-820-8838 www.itohdenki.com...
  • Page 63 Indicates the product for one stay. Two stays are necessary for one unit. Product Designation: For M6: This is used when securing the MABS main unit on the top side. ※Customers must remove the top cover of the MABS main unit, and fasten the main unit and stay.
  • Page 64 Appendix 3: Residual Risk/map residual risk list: WARNING: Indicates that there is a possibility that severe injury or even death may result if protective measures have not been taken CAUTION: Indicates that there is a possibility that minor injury may result if protective measures have not been taken residual risk map: 2 Great Valley Blvd., Wilkes-Barre, PA 18706...

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