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ITOH DENKI MABS2 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-Angle Ball Sorter 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.
2 Great Valley Blvd., Wilkes-Barre, PA 18706
Office Ph: 570-820-8811
Fax: 570-820-8838
www.itohdenki.com
Specifications subject to change without notice
Revised 2/19/2025

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Summary of Contents for ITOH DENKI MABS2

  • 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

    MABS2 Operating Instructions Subject page Introduction Procedures Safety Precautions 6-10 Advance Preparation 11-14 Product Check Structures Installation/Wiring -Before Installation 17-29 -Installation -Wiring Control/Operation -Before Starting Control 30-35 -About Swing Control -Basic Operation -What to Do Before Operation...

  • Page 3: Introduction

    MABS2 Operating Instructions 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):...
  • 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

    MABS2 Operating Instructions Start using only after you have understood all the product´s functions, Read this Manual safety information, and precautions. Prepare the 24V DC power supply, such as DC power supply units. Prepare a Advance Preparation PC, and install necessary applications.

  • Page 6: Safety Precautions

    Safety Precautions MABS2 Operating Instructions 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 MABS2 Operating Instructions 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.
  • Page 8 Safety Precautions MABS2 Operating Instructions INSTALLATION Precautions: WARNING Have the appropriate number of persons assist when carrying and/or installing the product. Use the elevating carriage, etc., and move the product to the level of installation. CAUTION When handling, wear protective equipment, such as gloves.
  • Page 9 Safety Precautions MABS2 Operating Instructions 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.
  • 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 MABS2 Operating Instructions 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 IB-E04F IB-E04F IB-E04F As for the sensor input, and input/output signals of controllers, adopt the number of inputs/outputs based on customers’...
  • Page 12 Advance Preparation MABS2 Operating Instructions 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.
  • Page 13 MABS2 Operating Instructions 7. Application Download the IB-E Configurator software from www.itohdenki.com/ib-e-downloads 8. Stays (mounting brackets): A stay used to install the MABS main unit. For details on how to mount, go to 7-2: Installation Stays and mounting bolts are not included and must be fabricated by the customer. They are required for installation.
  • Page 14 MABS2 Operating Instructions 10. Wiring Method 10-1. When overcurrent protection devices are required When overcurrent protection devices need to be installed to the 24V DC power supply unit, some power supplies that need to conform to the safety standards (UL60950-1, etc.) require installation of the specified overcurrent protection device based on their specifications.

  • Page 15: Product Check

    Product Check MABS2 Operating Instructions 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).

  • Page 16: Structures

    MABS2 Operating Instructions Structures: MABS Main Unit *The image is for size 400 Product Designation: IB-E04F* W 398 mm (15.7”) X L 186 mm (7.3”) W 498 mm (19.6”) X L 186 mm (7.3”) 1200mm (47.24") W 598 mm (23.5”) X L 186 mm (7.3”) 2000mm (78.74")

  • Page 17: Installation/Wiring

    MABS2 Operating Instructions 7-1. Before installation About the MABS main unit installation position and diverting conveyor Perform frame processing by reference to the following instructions and mounting holes of stays. Prepare the diverting conveyor to be wider than the straight conveyor W + 200 mm (7.87") (The conveyor width depends on totes and/or tote position.
  • Page 18 MABS2 Operating Instructions Dimensions of MABS main unit: Size 400 L 186mm x W 398mm L 7.3" x W 15.7" The machine height and height of the mounting *Guide for cable marginal projecting length surface indicate dimensions at the time of the actual M1: Motor of Transfer balls 80mm (3.15")
  • Page 19 MABS2 Operating Instructions Dimensions of MABS main unit: Size 500 L 186mm x W 498mm L 7.3" x W 19.6" The machine height and height of the mounting *Guide for cable marginal projecting length surface indicate dimensions at the time of the actual M1: Motor of Transfer balls 80mm (3.15")
  • Page 20 MABS2 Operating Instructions Dimensions of MABS main unit: Size 500 L 186mm x W 598mm L 7.3" x W 23.5" The machine height and height of the mounting surface indicate dimensions at the time of the actual *Guide for cable marginal projecting length transfer (when load is applied to transfer balls).
  • Page 21 MABS2 Operating Instructions Dimensions of MABS main unit: Size 700 L 186mm x W 698mm L 7.3" x W 27.5" The machine height and height of the mounting *Guide for cable marginal projecting length surface indicate dimensions at the time of the actual M1: Motor of Transfer balls 80mm (3.15")
  • Page 22 MABS2 Operating Instructions Dimensions of MABS main unit: Size 800 L 186mm x W 798mm L 7.3" x W 31.4" The machine height and height of the mounting *Guide for cable marginal projecting length surface indicate dimensions at the time of the actual M1: Motor of Transfer balls 80mm (3.15")

  • Page 23: Installation

    MABS2 Operating Instructions 7-2: 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.
  • Page 24 MABS2 Operating Instructions Installing the MABS main unit (Continued): 4. Fasten the MABS main unit and stays When using stays (M6) Remove the top cover, and fasten from the top at four positions using M6 bolts. Mounting bolt: Hex. bolt with spring lock and plain washers (M6) x 25 Recommended tightening torque: 10 to 12N･ｍ...

  • Page 25: Mounting The Controller

    MABS2 Operating Instructions Mounting the Controller: Use the included screws and nuts to mount controllers on the conveyor frames or control panel. Recommended tightening torque 0.74N･ｍ Mounting sensors, control devices, and power supply units: Mount customer-prepared zone sensor and area sensor for loading and discharging, as well as control devices, such as PLCs, and power supply units.
  • Page 26 MABS2 Operating Instructions 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 IB-E04F IB-E04F ※When each unit set as master unit,...
  • Page 27 MABS2 Operating Instructions i/o settings: Description Details Motor A For transfer M1: Carrying (labeled on motor cable) CN201 Motor B For swing M2: Rotating (labeled on motor cable) Proximity sensor input for Proximity sensor (Origin position: Prox. Sensor ON for straight...
  • Page 28 MABS2 Operating Instructions ib-e04f 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 29 MABS2 Operating Instructions ib-e04f wiring: Set the voltage used for remote input within the range of 18 [V]DC to 30 [V]DC. [Remote output (CN302)] 734-266 (WAGO) Set the NPN/PNP signal switching for remote output using COMMON. Connect 0V to COMMON at the time of NPN output, and the positive pole to COMMON at the time of PNP output.

  • Page 30: Control/Operation

    MABS2 Operating Instructions 9-1: Before starting control 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 IB-E04F IB-E04F ※When each unit set as master unit, each MABS unit can also be operated individually using the signal input/output from PLC.

  • Page 31: About Swing Control

    control/operation 9-2: about swing control Perform swing using the pulse control of IB-E04F and proximity sensor for origin position. 1. Origin position (Straight) Turn the proximity sensor ON (IB-E04F Sensor A SEN: origin sensor input ON) for straight direction or origin direction. 2.
  • Page 32 MABS2 Operating Instructions 9-3: Basic operation Initial operation (origin searching) IB-E04F Itoh Denki USA Inc. 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 www.itohdenki.com...
  • Page 33 MABS2 Operating Instructions Swing from the loading to diverting direction. IB-E04F ※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). Itoh Denki USA Inc.
  • Page 34 MABS2 Operating Instructions Swing from the discharge to diverting direction. IB-E04F ※1 Automatically stops when Sensor A SEN is ON Itoh Denki USA Inc. 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 www.itohdenki.com...
  • Page 35 MABS2 Operating Instructions 9-4: Start-up inspection To prevent accidents and/or damage to devices during operation, refer in advance and before operation to the below, and check the safety. Items to check before turning on the power: Turn off the power of all connected devices, and perform the following inspection, taking necessary measures.

  • Page 36: Maintenance/Inspection

    MABS2 Operating Instructions 10-1: Controller's led display If errors occur, identify the causes of errors by checking controller’s LEDs and error signals, and perform recovery work. IB-E04F Status Indicators: LED Indication Pattern Description Green Flash Active LAN Communication LAN1 & LAN2...
  • Page 37 MABS2 Operating Instructions error details: The table below described the LED indications, occurrence conditions, error release conditions and MDR status when an error occurs. Use Itoh Configurator E/IP to check the type of error, and release errors manually. Errors will be also reset when the power is OFF.

  • Page 38: Checking And Releasing Errors

    MABS2 Operating Instructions 10-2: Checking and releasing errors Use Itoh Configurator E/IP to check error statuses in IB-E04F, 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”.

  • Page 39: Appendix 2: Replacement Parts/Options

    MABS2 Operating Instructions Releasing the error manually Soft error 1 cannot be released. (The error occurs when proximity sensor has not been detected (refer to 10-1: Error Details) 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 40 MABS2 Operating Instructions others: Link belt replacement jig (Model: MT-BR01) ※Necessary for mounting the link belt. Grease: SUMICO Lubricant: Sumitec 305 replacement parts model number and required quantity per 1 unit: IB-E04F About replacement: Please contact us for replacement of Gear A/B, link belt, and motors for transfer and swing.
  • Page 41 MABS2 Operating Instructions 10-4: Replacement of the transfer ball element set/ Grease filling procedure Replace a ball element which has the following symptoms. The actual speed is slower than a setting. There is occurred an abrasion on ball. (Groove depth is 1.5mm as a guide.)
  • Page 42 MABS2 Operating Instructions 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.
  • Page 43 MABS2 Operating Instructions 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.

  • Page 44: Troubleshooting

    MABS2 Operating Instructions When troubleshooting, check the items shown below before contacting us or requesting a repair. Problem Items to be Checked Countermeasures References Is PWR LED (green) for each Installation/Wiring Supply 24V DC. controller turned on? (p.17) Is ERR LED (red) for each controller...
  • Page 45 MABS2 Operating Instructions When troubleshooting, check the items shown below before contacting us or requesting a repair. Problem Check the Following Perform the Following Refer to Have M1: Transfer motor and Shut down the controller´s power, Installation/Wiring M2: Swing motor been and connect motors correctly (p.17)

  • Page 46: Appendix 1: Specifications

    Appendix 1: Specifications MABS2 Operating Instructions 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 47: Controller Specifications

    Appendix 1: Specifications MABS2 Operating Instructions 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: IB-E04F-□ Itoh Denki USA Inc. 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 www.itohdenki.com...

  • Page 48: Appendix 2: Options

    Appendix 2: options MABS2 Operating Instructions mdr extension cables: 12P extension cable：MABS〔 M1, M2 〕― IB-E04F〔MA, MB〕 Itoh Denki USA Inc. 2 Great Valley Blvd., Wilkes-Barre, PA 18706 Office Ph: 570-820-8811 www.itohdenki.com...

  • Page 49: Appendix 3: Residual Risks

    Appendix 3: Residual Risks MABS2 Operating Instructions 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...

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