ASSEMBLY INSTRUCTIONS SINGLE-BELT TRANSFER SYSTEM … · Assembly Instructions Single-belt Transfer...

ASSEMBLY INSTRUCTIONS

SINGLE-BELT TRANSFER SYSTEM

LTE

BA-100118 Assembly Instructions Original , Copyright by Montech AG

English Edition 03/2013

Assenbly Instructions Single-belt Transfer System LTE

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Contents

1. General _________________________________________________________________________ 6

1.1. Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B ______6

1.2. List of essential health and safety requirements pursuant to Directive 2006/42/EC, Annex I, Section 1 _________________________________________________________________7

1.3. Information for this manual _________________________________________________________9

1.4. Explanation of symbols_____________________________________________________________9

1.5. Limited liability __________________________________________________________________ 10

1.6. Copyright ______________________________________________________________________ 10

1.7. Warranty terms and conditions ____________________________________________________ 10

1.8. Customer service ________________________________________________________________ 10

2. Transport, Packaging and Storage _______________________________________________ 11

2.1. Unauthorized or improper transport _______________________________________________ 11

2.2. Transport inspection _____________________________________________________________ 11

2.3. Packaging ______________________________________________________________________ 11

2.4. Handling of packaging material ___________________________________________________ 11

2.5. Storing the packages ____________________________________________________________ 12

3. Safety _________________________________________________________________________ 13

3.1. Use for intended purpose ________________________________________________________ 13

3.2. Safety instructions _______________________________________________________________ 13

3.3. Warranty _______________________________________________________________________ 13

3.4. Changes and modifications to the equipment _______________________________________ 13

3.5. Personal protective equipment____________________________________________________ 14

3.6. Personnel requirements __________________________________________________________ 14

3.7. Delta data LTE __________________________________________________________________ 15

3.8. Nameplate (Exemple) ____________________________________________________________ 16

4. Commissioning _________________________________________________________________ 17

4.1. Mechanical design _______________________________________________________________ 17

4.2. Mounting instructions ____________________________________________________________ 18

4.3. Electrical connection _____________________________________________________________ 19

4.4. Thermo sensor __________________________________________________________________ 20

4.5. Direction of travel of the conveyor belt_____________________________________________ 21

4.6. Setting the required pretension of the conveyor belt ________________________________ 21

Assembly Instructions Single-belt Transfer System LTE

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4.7. Tracking of the belt ______________________________________________________________ 22

4.8. Moving the drive unit on the chassis________________________________________________ 24

4.9. Changing the conveyor speed _____________________________________________________ 25

4.10. Procedure for changing the chain sprocket__________________________________________ 26

4.11. Procedure for changing the gear motor_____________________________________________ 27

4.12. Technical data of the conveyor belt ________________________________________________ 27

4.13. Replacing an endless belt _________________________________________________________ 27

4.14. Replacing belts by „welding“ their ends ____________________________________________ 28

5. Maintenance____________________________________________________________________ 29

5.1. Maintenance plan ________________________________________________________________ 29

5.2. Spare parts______________________________________________________________________ 29

5.3. Repairs _________________________________________________________________________ 30

5.3.1. Replacement of self-aligning ball bearings / drive rollers______________________________ 30

6. Bypass Coneyor BPBE ___________________________________________________________ 31

6.1. Technical Data BPBE _____________________________________________________________ 31

6.1.1. Setting the necessary pretension of the belt ________________________________________ 31

7. Conveyor Coupling BKE _________________________________________________________ 32

7.1. Commissioning __________________________________________________________________ 32

7.1.1. Setting the required pretension of the conveyor belt ________________________________ 32

7.1.2. Tracking of the belt ______________________________________________________________ 33

7.2. Conveyor belt ___________________________________________________________________ 33

7.2.1. Technical data of the conveyor belt ________________________________________________ 33

7.2.2. Replacing an endless belt on the coupling conveyor _________________________________ 33

7.2.3. Replacing belts by „welding“ their ends ____________________________________________ 34

7.3. Maintenance / Repairs ____________________________________________________________ 34

7.3.1. Replacing the synchronous belt ___________________________________________________ 34

7.3.2. Replacing the drive rollers on the traction conveyor__________________________________ 35

7.3.3. Replacing the drive rollers on the single-belt coupling conveyor_______________________ 36

7.3.4. Replacing the drive rollers on the twin-belt coupling conveyor ________________________ 37

8. Fixed Curve 90° KFE ____________________________________________________________ 38

8.1. Use ____________________________________________________________________________ 38

8.2. Commissioning __________________________________________________________________ 38

8.2.1. Curve fixed 90° KFE 105, 140, 185 and 250 version M________________________________ 38

8.2.2. Curve fixed 90° KFE 105, 140, 185 and 250 version E ________________________________ 40


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9. Movable Curve 90° KBEA/KBE __________________________________________________ 42

9.1. Use ____________________________________________________________________________ 42

9.2. Changeover times _______________________________________________________________ 42

9.3. Commissioning__________________________________________________________________ 43

9.3.1. Setup of curve with drive (outward transfer) and the necessary accessories_____________ 43

9.3.2. Setup of curve without drive (inward transfer) and the necessary accessories ___________ 44

9.3.3. Checking and setting the drive unit________________________________________________ 45

9.3.4. Checking und setting the bearings ________________________________________________ 46

9.3.5. Flowchart for curve with drive (outward transfer)____________________________________ 47

9.3.6. Flowchart for curve with drive (inward transfer) _____________________________________ 49

9.4. Maintenance and Repairs _________________________________________________________ 51

9.4.1. Replacing the drive cylinder ______________________________________________________ 51

9.4.2. Replacing the drive unit __________________________________________________________ 52

9.4.3. Checking and setting the swivel angle _____________________________________________ 53

10. Rotary Diverter UR-180° ________________________________________________________ 55

10.1. Use ____________________________________________________________________________ 55

10.2. Safety Instructions _______________________________________________________________ 55

10.3. Commissioning__________________________________________________________________ 55

10.3.1. Electrical connections____________________________________________________________ 55

10.3.2. Flowchart for UR (key) ___________________________________________________________ 56


10.4.1. Replacing the conveyor disc ______________________________________________________ 58

10.4.2. Replacing the diverter rollers _____________________________________________________ 59

10.4.3. Replacing the spur wheel back-geared motor_______________________________________ 60

10.4.4. Replacing the sliding hub_________________________________________________________ 61

10.4.5. Adjusting the sliding hub_________________________________________________________ 61

11. Bypass BPEA/BPE ______________________________________________________________ 62

11.1. Use ____________________________________________________________________________ 62


11.3. Commissioning__________________________________________________________________ 63

11.3.1. Setup of bypass with drive (inward transfer) and the necessary accessories_____________ 63

11.3.2. Setup of bypass without drive (outward transfer) and the necessary accessories ________ 64

11.3.3. Settings Bypass with drive right and left ___________________________________________ 65

11.3.4. Flowchart for bypass with drive (outward transfer) __________________________________ 66

11.3.5. Flowchart for bypass without drive (inward transfer) _________________________________ 68


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11.3.6. Flowchart for bypass with drive (inward transfer) ____________________________________ 70


11.4.1. Replacing the drive cylinder_______________________________________________________ 72

11.4.2. Checking and setting the swivel angle______________________________________________ 73


12. Transfer Gate WEE______________________________________________________________ 75

12.1. Use ____________________________________________________________________________ 75


12.3. Commissioning __________________________________________________________________ 75

12.3.1. Setup of inward transfer gate WEE and the necessary accessories _____________________ 75

12.3.2. Setup of outward transfer gate WEE and the necessary accessories ___________________ 76

12.3.3. Checking and setting the drive unit ________________________________________________ 77

12.3.4. Flowchart for transfer gate (inward transfer) ________________________________________ 78

12.3.5. Flowchart for transfer gate (outward transfer)_______________________________________ 80

12.4. Maintenance and repairs__________________________________________________________ 82

12.4.1. Replacing the drive cylinder_______________________________________________________ 82


12.4.3. Überprüfen und Einstellen des Schwenkwinkels _____________________________________ 83

13. Indexing Device IVE and IVEB____________________________________________________ 84

13.1. Use ____________________________________________________________________________ 84

13.2. Commissioning __________________________________________________________________ 84

13.2.1. Assembling and setting the indexing device IVEB____________________________________ 84

13.2.2. Installation and setting of indexing device IVE_______________________________________ 89

13.2.3. Flowchart for indexing device IVEB/IVE ____________________________________________ 89

14. Positioning Device PVE__________________________________________________________ 91

14.1. Use ____________________________________________________________________________ 91

14.2. Maximum torque ________________________________________________________________ 91

14.3. Commissioning __________________________________________________________________ 93

14.3.1. Mounting and setting positioning device PVE _______________________________________ 93

14.3.2. Flowchart for positioning device PVE ______________________________________________ 97

15. Disassembly and Disposal _______________________________________________________ 99

15.1. Improper disassembly ____________________________________________________________ 99

15.2. Disposal ________________________________________________________________________ 99


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1.2. List of essential health and safety requirements pursuant to Directive 2006/42/EC, Annex I, Section 1

Not relevant for this device !To be met by the system integrator for the (complete) machine •! Met for the scope of the partly completed machine •! 1.1. General 1.1.1. Definitions " # # 1.1.2. Principles of safety integration " # # 1.1.3. Materials and products " # # 1.1.4. Lighting # # " 1.1.5. Design of machinery to facilitate its handling " # # 1.1.6. Ergonomics # " # 1.1.7. Operating positions # " # 1.1.8. Seating # " # 1.2. Control and systems 1.2.1. Safety and reliability of control systems # " # 1.2.2. Control devices # " # 1.2.3. Starting # " # 1.2.4. Stopping # " # 1.2.4.1. Normal stop # " # 1.2.4.2. Operational stop # " # 1.2.4.3. Emergency stop # " # 1.2.4.4. Assembly of machinery # " # 1.2.5. Selection of control or operating modes # " # 1.2.6. Failure of the power supply # " # 1.3. Protection against mechanical hazards 1.3.1. Risk of loss of stability # " # 1.3.2. Risk of break-up during operation " # # 1.3.3. Risks due to falling or ejected objects # " # 1.3.4. Risks due to surfaces, edges or angles " # # 1.3.5. Risks related to combined machinery # # " 1.3.6. Risks related to variations in operating conditions # " # 1.3.7. Risks related to moving parts " " # 1.3.8. Guards or protective devices designed to protect against risks # " # 1.3.8.1. Moving transmission parts " # # 1.3.8.2. Moving parts involved in the process # " # 1.3.9. Risks of uncontrolled movements # " #


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Not relevant for this device !To be met by the system integrator for the (complete) machine ! Met for the scope of the partly completed machine ! 1.4. Required characteristics of guards and protective devices 1.4.1. General requirements # " " 1.4.2. Special requirements for guards # " " 1.4.2.1. Fixed guards # " " 1.4.2.2. Interlocking movable guards # " " 1.4.2.3. Adjustable guards restricting access # " " 1.4.3. Special requirements for protective devices # " " 1.5. Risks due to other hazards 1.5.1. Electricity supply # " # 1.5.2. Static electricity # " # 1.5.3. Energy supply other than electricity # # " 1.5.4. Errors of fitting " # # 1.5.5. Extreme temperatures # " # 1.5.6. Fire # " # 1.5.7. Explosion # " # 1.5.8. Noise " # # 1.5.9. Vibrations # # " 1.5.10. Radiation # # " 1.5.11. External radiation # " # 1.5.12. Laser radiation # # " 1.5.13. Emissions of hazardous materials and substances # # " 1.5.14. Risk of being trapped in a machine # # " 1.5.15. Risk of slipping, tripping or falling # # " 1.5.16. Lightning # # " 1.6. Maintenance 1.6.1 Machinery maintenance # " # 1.6.2. Access to operating positions and servicing points # " # 1.6.3. Isolation of energy sources # " # 1.6.4. Operator intervention # " # 1.6.5. Cleaning of internal parts # # " 1.7. Information 1.7.1. Information and warnings on the machinery " # # 1.7.1.1. Information and information devices # " # 1.7.1.2. Warning devices # " # 1.7.2. Warning of residual risks # # " 1.7.3. Marking of machinery " # # 1.7.4. Instructions " # # 1.7.4.1. General principles for the drafting of instructions " # # 1.7.4.2. Contents of the instructions " # # 1.7.4.3. Sales literature " # #


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1.3. Information for this manual This manual contains data and information necessary to install and maintain LTE. Prior to commencing any work on the machine, personnel must have thoroughly read and understood this manual. Following all safety instructions and directions in this manual is the foundation of safe work. Any illustrations in this manual are meant for general understanding and may differ from the actual configuration.

1.4. Explanation of symbols Safety instructions in this manual are marked by symbols. These safety instructions are introduced by signal words that express the extent of the danger. Absolutely follow these instructions and act carefully to avoid accidents, bodily injuries or property damage.

DANGER! This combination of symbol and signal word indicates a directly dangerous situation that could result in death or serious injury if it is not avoided.

WARNING! This combination of symbol and signal word indicates a potentially dangerous situation that could result in serious injury if it is not avoided.

CAUTION! This combination of symbol and signal word indicates a potentially dangerous situation that could result in minor injury if it is not avoided.

CAUTION! This combination of symbol and signal word indicates a potentially dangerous situation that could cause property damage if it is not avoided.

NOTE! This symbol points out useful hints and recommendations as well as information for efficient and uninterrupted operation.


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1.5. Limited liability All information and instructions in this operating manual were compiled taking into consideration the valid standards and regulations, the state-of-the-art and our many years of experience and expertise. Montech AG will not assume liability for damage resulting from: � Not following the instructions in this manual.

� Using the machine for purposes other than its intended use.

� Use of personnel that has not been trained.

1.6. Copyright Treat the assembly instructions confidentially. They are meant exclusively for persons working on the equipment. Making the operating manual available to a third party without the Montech AG’s written permission is prohibited.

1.7. Warranty terms and conditions The warranty terms and conditions can be found in the Montech AG’s General Terms and Conditions (AGB).

1.8. Customer service Our customer service will provide technical information. Information on the contact person responsible can be obtained by phone, fax, e-mail or on the Internet; please refer to the manufacturer’s address on the installation declaration page.

NOTE! The content information, texts, drawings, pictures and other illustrations are protected by copyright. Any use of them beyond this purpose without the Montech AG’s written permission is prohibited.


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2. Transport, Packaging and Storage

2.1. Unauthorized or improper transport

2.2. Transport inspection Upon delivery, check the shipment immediately for completeness and transport damage. In case of visible transport damage, proceed as follows: � Do not accept the shipment or accept it conditionally only.

� Record the extent of the damage on the shipping documentation or the freight forwarder’s shipping note.

� Initiate a complaint.

2.3. Packaging The individual packages have been packed according to anticipated shipping conditions. Only environmentally friendly materials were used for packaging. The packaging will protect the individual components from shipping damage, corrosion and other damage until they are installed. Consequently, do not destroy the packaging and only remove shortly before installation.

2.4. Handling of packaging material Dispose of packaging material in compliance with applicable laws and local regulations.

CAUTION! Damage may result from unauthorized or improper transport! Moving the machine by untrained personnel may result in considerable property damage. � Only use trained personnel to unload the machine upon delivery and for in-house

transport.

� Do not step under suspended loads.

� Means of transport must be used properly.

� Always place the conveyor on a level surface and secure it against falling over.

NOTE! Complain about any defect immediately upon detection. Claims for damages may only be made within the complaint periods.


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2.5. Storing the packages Store packages under the following conditions: � Do not store outdoors.

� Store in a dry, dust-free environment.

� Do not expose to aggressive media.

� Protect from sunlight.

� Avoid mechanical vibration.

� Storage temperature: 5 to 40 °C.

� Relative humidity: max 55%.

� If machines are stored longer than three months, check the general condition of all parts and the packaging regularly.

CAUTION! Incorrect disposal is an environmental hazard! Packaging materials are valuable raw materials; in many cases, they can be reused or recycled. Incorrect disposal of packaging materials can pose a hazard to the environment. � Always dispose of packaging materials in an environmentally compatible manner.

� Follow local disposal regulations. If applicable, hire a company specializing in disposal.


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3. Safety

This section provides an overview of all important safety aspects for the optimum protection of workers, and safe and uninterrupted operation.

3.1. Use for intended purpose Conveyors are designed for transporting solid objects that are not below a certain minimum size. They are not suitable for transporting people and materials such as sand, granules, chips, etc. The product-specific ratings listed on the nameplate must never be exceeded. Intended use includes following all instructions in this manual. Any use other than or beyond intended use is considered misuse.

3.2. Safety instructions

3.3. Warranty Conveyors are designed for transporting solid objects that are not below a certain minimum size. They are not suitable for transporting materials such as sand, granules, chips, etc. Any other use or use beyond this shall be deemed ‘not for the intended purpose’ and will void the warranty.

3.4. Changes and modifications to the equipment To avoid hazards and ensure optimum performance, any changes, additions or modifications not expressly permitted by the manufacturer are prohibited.

WARNUNG! The safety instructions, in particular those relating to electrical connections, must be followed in all phases of commissioning, operation and during maintenance and repairs. Failure to follow these instructions is considered a misuse of the conveyor and its components. .

WARNING! Danger from misuse! A misuse of the TB; TBD; TTBD may result in dangerous situations. Refrain from the following uses: � Exposure to direct light from UV lamps.

� Operation in air containing smoke, dust, water vapor, or solvents.

� Use in areas with explosion hazard (flammable gases, vapors or dust).

� Use in a damp environment (rain or dew).

� Do not exceed maximum permissible total weight.

� Connecting, commissioning or servicing of the machine without qualified personnel.


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3.5. Personal protective equipment The wearing of personal protective equipment is required during work to minimize health hazards. While working, always wear the personal protective equipment appropriate for the specific work.

Safety shoes To protect against heavy dropped parts and slipping on slippery surfaces.

3.6. Personnel requirements The different tasks described in this manual pose different requirements for the qualification of the persons assigned to perform the tasks. For all work, only have persons perform the work who can be expected for perform it reliably. Persons whose ability to respond is impaired, e.g. due to the influence of drugs, alcohol or prescription drugs, are not allowed to work on the machine. This manual defines the following personnel qualifications for different tasks: Machine operator The machine operator has been instructed by the system operator regarding the tasks assigned to him/her and the potential hazards in case of improper behavior. The machine operator may perform tasks that go beyond normal operation ONLY if this is stated in the manual and the system operator has explicitly assigned the task to the machine operator. Skilled electrician Based on his/her technical training, knowledge and experience, as well as knowledge of the relevant standards and regulations, a skilled electrician is able to perform work on electrical systems and to independently recognize and avoid potential hazards. The skilled electrician has been trained specifically for his/her work environmental and is familiar with the relevant standards and regulations. Skilled personnel Based on their technical training, knowledge and experience, as well as knowledge of the relevant standards and regulations, skilled personnel is able to perform work assigned to them and to independently recognize and avoid potential hazards. Manufacturer Certain work may only be performed by Montech AG’s skilled personnel. Other personnel is not authorized to perform this work. Please contact our Customer Service to have such work performed.


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3.7. Delta data LTE

Ambient temperature [°C] +10 to +40

Rel. humidity < 95% (without condensation)

Air purity normal workshop atmosphere

Sound pressure level [dBA] < 70

Motor

Voltage/frequency Frequency converter Protection Connection configuration Output Winding Rated current

[W] [A] [A]

3 x 230V / 50/60 Hz 3 x 400V / 50/60 Hz 1 x 230 V / 50 Hz IP55 delta/star (as-delivered state) 180 with 3 temperature contacts delta: 1.2 star: 0.7

Repeatability of WTE in IVE/IVEB/PVE [mm] ±0.05

Workpiece carrier sizes WTE [mm]

80x80 (weight 170g) 115x115 (weight 360g) 160x160 (weight 690g) 225x225 (weight 1660g)

Max. weight WTE 80, 115, 160 (loaded) Max. weight WTE 225 (loaded)

[kg] 2.5 5

Max. torque on WTE in IVE and IVEB [Nm] 5 (at 18m/min)

Max. force of pressure on WTE in IVE and IVEB

[N] 120

Max. force of pressure on WTE in PVE* [Nmm2] 15

Operating pressure [bar] 5-6

Operating medium 5µm filtered, oiled or unoiled air, due point <6 °C

Material of workpiece holder WTE Polyethylenterephthalate PET, black

Material of lateral guides Polyethylene PE, black, antistatic

Recommended belt type ENI-5EE, black, antistatic, manufacturer Habasit

* This force depends on the workpiece carrier material (polyethylene terephthalate) and is thus given as N/mm2.


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3.8. Nameplate (Exemple)


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4. Commissioning

4.1. Mechanical design The conveyors are shipped in units of max. 3 m length. If the total length of a conveyor exceeds the maximum transport length of 3 m, the individual parts should be assembled according to the following diagram. Length of chassis (total, in mm) L ≤ 3000 lateral guide

chassis

3000 < L ≤ 6000 lateral guide chassis



Svar Variable length of the lateral guides, min. = 500 mm, max. = 2000 mm Cvar Variable chassis length, Cvar max. = 3000 - 60, or 3000 - (2x60) mm D Chassis joint for dismantling prior to shipping (joints marked)

NOTE! Prior to commissioning, the joints marked with “D” must be assembled. The conveyor must be supported at these points.


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4.2. Mounting instructions When using the sliding sheet (10/20), we recommend binding the chassis (10/10) and the sliding sheet (10/20) with a double-sided adhesive tape (10/30). Before binding, clean the surfaces of the sliding sheet and chassis and degrease. Ensure that the adhesive tape or the adhesive tapes are uniformly distributed on the chassis. Our recommendation: Double-sided adhesive tape 25 mm x 55 m (Item No. 506333) KTB/TB-105 2 x adhesive tape 25 mm width KTB/TB-140 3 x adhesive tape 25 mm width KTB/TB-185 3 x adhesive tape 25 mm width KTB/TB-250 4 x adhesive tape 25 mm width

NOTE! The drive unit should be mounted near the discharge end of the conveyor. Applications where the drive unit has to be positioned on the infeed side, e.g. because of a lack of space (especially where high loads occur during queueing), should be referred to Montech for evaluation.


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4.3. Electrical connection

Connection of the mains voltage 3x400 V

Star connection

(Reverse rotation by exchanging two phases) Connection of the mains voltage 3x230 V

Delta connection

(Reverse rotation by exchanging two phases)

DANGER! The operator of the conveyor must have the electrical connection, the commissioning, the adjustment and the servicing carried out by qualified persons. Work on the electrical parts is particularly dangerous. Operation of the conveyor without a mechanical switch in the supply line is forbidden. To achieve optimal protection from contact, the motor must be connected to the earth of the supply network. Never disconnect the electrical connections when voltage is applied. In unfavorable cases, arcs may be produced and people injured or contacts damaged.


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4.4. Thermo sensor

The motor is fitted with a thermo sensor. For usage, the thermo sensor must be integrated into the control circuit. See the following schematic example. Δ

L1

L2

L3

N

PE

υ150°C

20

21

OFF

ON

EMERGENCY STOP


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4.5. Direction of travel of the conveyor belt

For belt type ENI-5EE, the direction of travel is of no significance. Flexproof weld seam

4.6. Setting the required pretension of the conveyor belt

After the belt has been mounted, two measuring marks (M) are stuck on the top of the belt in the untensioned state in such a way that they have a spacing (L) of e.g. 500 or 1000 mm. When the two tensioning screws (30) are uniformly tightened, the two measuring marks (M) move apart up to the dimension (L) which corresponds to the required pretension. Example of calculation of pretension of conveyor belt

NOTE! The correct pretension for a specific belt is shown on the nameplate attached to the drive unit e.g: 1.2%


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4.7. Tracking of the belt

The position of the belt running over the diverter rollers and nose-bars can be corrected by tightening or slackening the special screws “280” while the belt is running. The correction of the belt position on the drive roller can only be checked after removing the guard plate. Procedure: � Switch off the motor. � Dismantle the chain-guard “20” by unscrewing the two screws “10”. � Loosen 4 screws “30” and pull out the guard plates “170.” � The guard plate arrangement is identical in the horizontal and the vertical drives. � Reassemble the chain-guard „20“.

� Switch on the motor. � If the belt runs more than 2 mm out of center on the drive roller “160”, it must be corrected. � Check the distance “E” on both sides of the drive unit and - if necessary - adjust with one of the

screws “60” until the distances are equal. � If the belt is still not running straight, the side cover, short “70” must be displaced.

NOTE! The belt must always run centrally over the diverter rollers or nose-bars and drive rollers. On no account may the edges of the belt project over the ends of the rollers.

WARNING! For safety reasons it is essential to refit the chain guard “20” before switching the motor on again.


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� Lightly loosen the two screws “150” and screw “140”. � Shift the “side cover, short “20” by tapping with a nylon hammer at point P until the belt runs

with the desired tolerance on the drive roller. � Switch off the motor and tighten screws “150” and “140”, and reassemble the guard plate. � Reassemble the chain-guard „20“. Horizontal drive unit (vertical drive unit not shown)


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4.8. Moving the drive unit on the chassis

Procedure: � Switch off the motor. � Loosen screws “150” on the side cover short „70“ and the two corresponding screws on side

cover long „130“. � Move the drive unit in the desired position and tighten the four screws “150” on both side

covers.

NOTE! Should the belt no longer run centered on the diverter rollers, it should be aligned as explained in section “Tracking of the conveyor belt”.


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4.9. Changing the conveyor speed

The conveying speed can be altered by exchanging the driving sprocket “50” and/or by replacing the gear motor “80.” Chain sprocket “40” must not be changed. Conversions parts for changing the conveyor speed Motor Gearbox Sprocket

Con

veyo

r sp

eed

(m

/min

.)

Gea

r- /

Mot

or t

ype

Item

no.

M

otor

Red

ucti

on g

ear

Num

ber

of

teet

h D

rive

r

Num

ber

of

teet

h D

rive

r ro

ller

Item

no.

Sp

rock

et k

it

7.7 US362/B141 521112 14.08:1 12 / ø10 29 58657

9.7 US362/B141 521112 14.08:1 15 / ø10 29 44980

12.3 US362/B141 521112 14.08:1 19 / ø10 29 44981

14.9 US362/B141 521112 14.08:1 23 / ø10 29 44982

18.7 US362/B141 521112 14.08:1 29 / ø10 29 58658


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4.10. Procedure for changing the chain sprocket

� Switch off motor and disconnect from mains voltage. � Remove the chain guard “20” by unscrewing the two screws “10”. � To slacken the chain, release the 4 screws “110”. � Open the spring-link “90”. � Release screws “100”. � Pull sprocket “50” off the gear-shaft. � Push the new sprocket “50” onto the gear shaft and align the teeth of “50” and “40” with each

other. � Tighten screws “100”. � Fit the chain corresponding to the sprocket combination to “50” and “40”. � Tension the chain by shifting the gear motor and lightly tighten the 4 screws “110”. � The chain has the right tension when the upper strand sags by 1-2 mm when pressed down. � Tighten the 4 screws “110” and fit the chain guard “20”.


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4.11. Procedure for changing the gear motor The procedure is the same as for changing the sprocket, except that after removing the driving sprocket “50”, the gear motor is changed. Gearbox type SG-80 is fitted to the “side cover, long” with 4 flange sockets “130”.

4.12. Technical data of the conveyor belt

4.13. Replacing an endless belt The installation of endless belts is recommended when the conveyor is easily accessible or when the equipment needed for “welding” prepared end belts is not available.

Procedure: � Switch off motor and disconnect from mains voltage. � Slacken the conveyor belt by alternately loosening the two screws “60”. � Remove 2 screws “10” and take off cover “20.” � In addition, remove screws “40” and “50.” � Also remove screws “150” and “30” so that the side plate “70” can be removed. � The belt “200” can now be changed. � Reassemble in the reverse order. � For pre-tensioning the belt see the section on “Setting the necessary pretension of the belt”. � To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

NOTE! Data pertinent to the conveyor and belt is found on the nameplate attached to the drive unit and must be taken into consideration when ordering replacement belts.

NOTE! In particular, electrically or pneumatically supplied consumers mounted on the conveyor chassis side opposite to the chain drive, as well as floor stands and table stands, must be removed to replace an endless belt.


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4.14. Replacing belts by „welding“ their ends Pulling in new belts and “welding” their ends is the preferred method of belt replacement where accessibility to previous operations is severely restricted. A prerequisite for this method of assembly is the availability of belt welding equipment. Exact instructions for the “welding operation” can be obtained when ordering the new belts. Procedure: � Switch off motor and disconnect from mains voltage. � Slacken the conveyor belt by alternately loosening the two screws “60”. � Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with

adhesive tape). Make sure the beveled belt ends are positioned correctly for the direction of travel (see section “Direction of travel of the conveyor belt”). Absolutely protect the beveled belt ends from contamination.

� Slowly pulling the old belt automatically pulls the new one through the system. � “Weld” the ends of the new belt according to the manufacturer’s instructions. � For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor

belt”. � To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.


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5. Maintenance

5.1. Maintenance plan The following table describes the maintenance work required for optimum, uninterrupted operation of the LTE. If regular checks show excessive wear, shorten the necessary maintenance intervals in line with actual wear.

Interval Maintenance work Personal

Mounthly Check transport belt for damage Machine operator

Mounthly Taps, screw check Machine operator

Every 3 months

Check chain and lubricate if necessary Machine operator

Semi-annually Clean the LTE Machine operator

Semi-annually Check the ground connection Skilled electrician

5.2. Spare parts

WARNING! Improper maintenance work can result in injury! Improper maintenance can result in serious injuries or damage. - Have maintenance work performed by qualified personnel only.

- Before starting work, disconnect the power supply to the device and secure against accidental restart.

WARNING! The use of wrong or defective spare parts may pose an injury hazard! The use of wrong or defective spare parts can pose a hazard to the personnel and cause damage, malfunction, or total failure. - Use only OEM parts or spare parts approved by the manufacturer.

If in doubt, always contact the manufacturer.


30

5.3. Repairs The operating instructions contain the necessary spare lists and exploded drawings for repairs in the mechanical part of the conveyor. The safety instructions must also be followed.

5.3.1. Replacement of self-aligning ball bearings / drive rollers

LOSS OF WARRANTY! Use of non-approved spare parts will void the manufacturer’s warranty. Order spare parts directly from the manufacturer. For contact information see the installation declaration.

NOTE! Spare parts list. The spare parts list is available separately!

DANGER! Repairs to the electrical part may be carried out only by the supplier. It is essential to follow the safety instructions for electrical disconnection of components from the mains or from the motor and for their reinstallation.

CAUTION! When replacing the self-aligning ball bearing, Item 50, or the drive roller, Item 250, before installation the inner bearing ring and the bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 (shaft-hub joint). It is essential to allow the adhesive to harden for 24 hours.


31

6. Bypass Coneyor BPBE

6.1. Technical Data BPBE For missing data see chapter on conveyor.

6.1.1. Setting the necessary pretension of the belt


NOTE! The correct pretension for a specific belt is shown on the nameplate attached to the drive unit (e.g. 1.2%).


32

7. Conveyor Coupling BKE

7.1. Commissioning

7.1.1. Setting the required pretension of the conveyor belt


NOTE! The correct pretension for a specific belt is shown on the nameplate attached to the chassis (e.g. 0.6%).


33

7.1.2. Tracking of the belt

The position of the belt running over the diverter rollers can be corrected by tightening or slackening the hex screws “70” while the belt is running.

7.2. Conveyor belt

7.2.1. Technical data of the conveyor belt

7.2.2. Replacing an endless belt on the coupling conveyor The installation of endless belts is recommended when the coupling conveyor is easily accessible or when the equipment needed for “welding” prepared end belts is not available.

Procedure: � Switch off the motor of the traction conveyor and disconnect from mains voltage. � Slacken the conveyor belt by alternately loosening the two screws “70”. � Remove the countersunk screws (160); remove WTE support (80). � Unscrew the two countersunk screws (140) that secure the end piece to the chassis and remove

the end piece (20). � The belt can now be changed. � Reassemble the conveyor coupling in the reverse order.

NOTE! The belt must always run centrally over the diverter rollers and drive rollers. On no account may the edges of the belt project over the ends of the rollers.

NOTE! Data pertinent to the conveyor and belt is found on the nameplate attached to the chassis and must be taken into consideration when ordering replacement belts

NOTE! In particular, electrically or pneumatically supplied consumers mounted on the conveyor chassis side opposite to the synchronous belt drive, as well as floor stands and table stands, must be removed to replace an endless belt. .


34

� For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor belt”.

� To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

7.2.3. Replacing belts by „welding“ their ends Pulling in new belts and “welding” their ends is the preferred method of belt replacement where accessibility to previous operations is severely restricted. A prerequisite for this method of assembly is the availability of belt welding equipment. Exact instructions for the “welding operation” can be obtained when ordering the new belts. Procedure: � Switch off the motor of the traction conveyor and disconnect from mains voltage. � Slacken the conveyor belt by alternately loosening the two screws (70). � Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with

adhesive tape). Make sure the beveled belt ends are positioned correctly for the direction of travel (see section “Direction of travel of the conveyor belt”). Absolutely protect the beveled belt ends from contamination.

� Slowly pulling the old belt automatically pulls the new one through the system. � “Weld” the ends of the new belt according to the manufacturer’s instructions. � For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor

belt”. � To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

7.3. Maintenance / Repairs

7.3.1. Replacing the synchronous belt

� Switch off the motor of the traction conveyor and disconnect from mains voltage. � Remove the casing (110) by unscrewing the two pan head screws (140). � Loosen countersunk screw (160) and remove together with washer (190). � Pull off toothed lock washer (80) from the drive roller (50). � Replace synchronous belt (210).


35

� Assemble in the reverse order. � The countersunk screw (160) must be secured with Loctite # 234.

7.3.2. Replacing the drive rollers on the traction conveyor

� Switch off the motor of the traction conveyor and disconnect from mains voltage. � Remove the casing (100) by unscrewing the two pan head screws (130). � Loosen countersunk screw (150) and remove together with washer (180). � Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). � Remove synchronous belt (200). � Remove splines (120). � Remove the two countersunk screws (160); remove WTE support (80). � Slackening the traction conveyor belt. � Unscrew the two countersunk screws (140) that secure the end piece (30) to the chassis and

remove the end piece (30). � Remove drive rollers (50). � When replacing the self-aligning ball bearing (210) or the drive roller (50) the inner ring and the

bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 (shaft-hub joint). It is essential to allow the adhesive to harden for 24 hours.



36

7.3.3. Replacing the drive rollers on the single-belt coupling conveyor

� Switch off the motor of the traction conveyor and disconnect from mains voltage. � Remove the casing (100) by unscrewing the two pan head screws (130). � Loosen countersunk screw (150) and remove together with washer (180). � Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). � Remove synchronous belt (210). � Loosen setscrew (170). � Pull off toothed lock washer (60) from the drive roller (50). � Remove splines (120). � Remove the two countersunk screws (160); remove WTE support (80). � Slacken the coupling conveyor belt by alternately loosening the two screws (70). � Unscrew the two countersunk screws (140) that secure the end piece (20) to the chassis and

remove the end piece (20). � Remove drive rollers (50). � When replacing the self-aligning ball bearing (210) or the drive roller (50) the inner ring and the


� Assemble in the reverse order. � The countersunk screw (160) must be secured with Loctite #234.


37

7.3.4. Replacing the drive rollers on the twin-belt coupling conveyor

� Switch off the motor of the traction conveyor and disconnect from mains voltage. � Remove the casing (100) by unscrewing the two pan head screws (130). � Loosen countersunk screw (150) and remove together with washer (180). � Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). � Remove synchronous belt (210). � Release screw (170). � Pull off toothed lock washer (60) from the drive roller (50). � Remove splines (130). � Remove the two countersunk screws (160); remove WTE support (80). � Slacken the coupling conveyor belt by alternately loosening the two screws (70), Fig. 2. � Unscrew the two countersunk screws (150) that secure the end piece (20) to the chassis and

remove the end pieces (20). � Remove drive rollers (60). � When replacing the self-aligning ball bearing (220) or the drive roller (50) the inner ring and the




38

8. Fixed Curve 90° KFE

8.1. Use To divert a workpiece holder WTE by 90° at the belt end (version E) or in any other place of the conveyor (version M).

8.2. Commissioning

8.2.1. Curve fixed 90° KFE 105, 140, 185 and 250 version M

� Specify position of the conveyor, dimension X. � Mount fastening bracket (40). � Center and snap on finger protection device (30).


39

� Evenly align the curve on the inside (20) and fix with a screw clamp. � Align the curve on the outside (10) and fix with a screw clamp. � Through the fastening holes of the curve, inside and outside, drill the chassis with a 4.3 mm Ø

drill. � Remove curves. � With a 3.6 mm Ø drill, drill 12 mm deep from the upper edge of the chassis. � Fasten the curves with thread-cutting oval head screws (50). � Assemble lateral guides


40

8.2.2. Curve fixed 90° KFE 105, 140, 185 and 250 version E

� Insert special T-nut (10) into the T-slot of the chassis so it is flush. � Screw in and tighten setscrew (90).

� Connect the two chassis with the chassis binder (20). � For reinforcement, screw on brackets (40).


41

� Center and snap on finger protection device (30) � Evenly (=) align the inside curve (20) and fix with a screw clamp. � Align the curve on the outside (10) and fix with a screw clamp. � Through the fastening holes of the curve, inside and outside, drill the chassis with a 4.3 mm Ø

drill. � Remove curves. � With a 3.6 mm Ø drill, drill 12 mm deep from the upper edge of the chassis. � Fasten the curves with thread-cutting oval head screws (50). � Assemble lateral guides


42

9. Movable Curve 90° KBEA/KBE

9.1. Use The curve KBE is used for inward and outward transfer of a workpiece holder WTE into a perpendicular work flow. A stopper should be provided on the inward transfer side.

9.2. Changeover times

Curve with drive 7.7 m/min. 9.7 m/min. 12.3 m/min. 14.9 m/min. 18.7 m/min.

KBEA-105 3.7 3.2 2.6 2.2 1.9

KBEA-140 4.7 3.9 3.3 2.8 2.5

KBEA-185 5.7 4.7 3.9 3.5 2.9

KBEA-250 6.8 5.6 4.5 3.8 3.1

The times given include the setting and resetting time of the curve and the transit time of the workpiece holder. Curve without drive 7.7 m/min. 9.7 m/min. 12.3 m/min. 14.9 m/min. 18.7 m/min.

KBE-105 2.9 2.3 1.9 1.6 1.4

KBE-140 3.6 2.9 2.5 2.2 1.8

KBE-185 4.7 3.9 3.0 2.6 2.2

KBE-250 6.2 5.0 4.0 3.4 2.7

The times given include the setting time of the curve and the transit time of the workpiece holder.


43

9.3. Commissioning

9.3.1. Setup of curve with drive (outward transfer) and the necessary accessories

Proximity switch Item no. 508845

Stopper VSE Item no. 49612

Holder for proximity-switch HNEB Item no. 54634




44

9.3.2. Setup of curve without drive (inward transfer) and the necessary accessories







45

9.3.3. Checking and setting the drive unit

� The drive unit/bearing mount (10) must be mounted at an axle distance of 60 mm from the end of the chassis.

� The axle must be at a right angle to the chassis. � There should be a space of 1 mm between the curve lever (20), the lateral guides, and the inside

curve (30). � If that is not the case, the drive unit/bearing mount (10) must be set to the specified values by

loosening the two screws (130). � The stop (50) must be positioned so that the buffer (90) can hit it. � Check whether there is sufficient contact pressure between the curve lever (20) and the stop (50)

and (100) (only for curve with drive). � If not, reset the swivel angle


46

9.3.4. Checking und setting the bearings


47

9.3.5. Flowchart for curve with drive (outward transfer) straight Z1 Cylinder, double-acting Stopper

Z2 Cylinder, double-acting Drive unit

N1 Proximity switch Presence

N2 Proximity switch Presence/ queue monitoring

N3 Proximity switch Drive unit cylinder OFF

N4 Proximity switch Drive unit cylinder ON

N5 Proximity switch Stopper cylinder ON

N6 Proximity switch Stopper cylinder OFF


queuing

outw

ard


48

Start

Z1 OFF

N6 assigned

Z2 OFF

noyes

N3 assigned

N2 unassigned

N7 unassigned

outwardtransfer

N1 assigned

no

noyes

yes

outwardtransfer

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N7 unassigned

Z1 OFF

T delay time

Z1 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N4 assigned

Z2 ON

no

yesstraight

yes

no

no

noyes


49

9.3.6. Flowchart for curve with drive (inward transfer) straight Z1 Cylinder, double-acting Stopper

Z2 Cylinder, double-acting Stopper



N3 Proximity switch Presence/queue monitoring





tran

sfer

queuing


50

Start

Z1 OFF

N5 assigned

Z2 OFF

noyes

N6 assigned

N3 unassigned

inward transfer

N2 assigned

no

no

yes

yes

inwardtransfer

T expired

N7 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N3 unassigned

T expired

N5 assigned

Z1 OFF

T delay time

Z1 ON

N5 assignedno

no

no

no

yes

yes

yes

yes

N1 assignedno

yesstraight

yes no

no


51

9.4. Maintenance and Repairs

9.4.1. Replacing the drive cylinder

� Turn off system. � Bleed compressed air system. � Remove drive by loosening the two screws (130) (see next page). � Remove the two pneumatic hoses from the exhaust air valve (90). � Release clip (70/2) and pull down out of the fork end (70/1). � Remove the two setscrews with shank (110). � Remove cylinder (80/1). � Remove the fork end (70/1) and the hex nuts (80/2) and (80/3), disassemble ring (30) from the

defective cylinder and mount on the new cylinder. Care must be taken to screw the fork end back to its original size.

� Assemble in the reverse order � Check swivel angles and reset, if necessary


52

9.4.2. Replacing the drive unit

� Turn off system. � Bleed compressed air system. � Loosen countersunk screw (140) and washer (170) and remove. � Pull curve lever (20) up and out. � Remove pad (40). � Remove the two screws (130) and remove. � Replace drive unit (10). � Assemble in the reverse order. � Check swivel angles and reset, if necessary.


53

9.4.3. Checking and setting the swivel angle

� Extend cylinder. � The curve lever (20) must be on position 1. � Check if the curve lever applies noticeable pressure to the stop (50). � If yes, continue with point 16; if not, continue with point 5. � Turn off system. � Bleed compressed air system. � Release clip (70/2) and pull down out of the fork end (70/1). � Swivel cylinder (80/1) out. � Loosen hex nut (80/3). � Loosen fork end approx. ½ turn � Tighten hex nut (80/3). � Swivel cylinder (80/1) in. � Mount clip (70/2). � Turn on system. � Perform steps 1 to 3. � Retract cylinder. � The curve lever (20) must be on position 2. � Check if the curve lever applies noticeable pressure to the stop (100). � If not, the procedure is the same as starting with point 6; except in point 10, the fork end must

be screwed in ½ turn.


54


55

10. Rotary Diverter UR-180°

10.1. Use The rotary diverter UR is used to turn the workpiece holder WTE by 180°. In order to prevent queues in the UR, a stopper for inward transfer and queue monitoring for outward transfer must be provided. Under no circumstances must the product-specific ratings listed on the name plate be exceeded.

10.2. Safety Instructions The safety instructions, in particular those relating to electrical connections, must be followed in all phases of commissioning, operation and during maintenance and service work. Failure to follow these instructions is considered a misuse of the rotary diverter.

10.3. Commissioning

10.3.1. Electrical connections

Mains voltage connection 3x400V (Reverse rotation by exchanging two phases)

DANGER! Operating a rotary diverter in an explosive atmosphere (flammable gases, vapors, or dust) can result in their combustion and shall be avoided. Never perform service or setting work on your own. In all cases, there must be a second person present who can shut of the main power and administer first aid, if necessary. The mechanical contact guard may only be disassembled after the rotary diverter has been disconnected from the main power supply.

DANGER! The operator of the rotary diverter must have the electrical connection, the commissioning, the adjustment and the servicing carried out by qualified persons. Work on the electrical parts is particularly dangerous. Using the rotary diverter without a mechanical switch in the supply line is prohibited.To achieve optimal protection from the contact guard, the motor must be connected to the ground of the supply network. Never disconnect the electrical connections when voltage is present. In unfavorable cases, resulting arcs may injure people or damage contacts.

Star connection


56

10.3.2. Flowchart for UR (key)







57

Start

Z1 OFF

N3 occupiedno

yes

N1 occupied

N4 occupiedno

no

yes

no

yes

N3 occupied

yes

N2 free

Delay timeT1 for Z1

=0

yes

Z1 ON

END OFPROGR.

yes

no

Z1 OFF

END

yes

no

no

yes


58


10.4.1. Replacing the conveyor disc

� Switch off motor and disconnect from mains voltage. � Remove protective plug (180). � Remove guide disc (30) and intermediate ring (50) by removing the four screws (260). � Replace the conveyor disc (140). � Assemble in the reverse order (slide conveyor disc (140) under lateral guide)


59

10.4.2. Replacing the diverter rollers

� See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” � Remove the two screws (230) and the ribbed washer (320). � Remove the four countersunk screws (250) from the round table (10) ; disassemble roller bracket

(90) and diverter rollers (150). � Remove countersunk screw (250) from diverter roller (150) and diverter roller (150) from roller

bracket (90). � Replace diverter roller (150). � Assemble in the reverse order (slide conveyor disc (140) under lateral guide).


60

10.4.3. Replacing the spur wheel back-geared motor

� Switch off motor and disconnect from mains voltage. � Remove protective plug (180). � Remove guide disc (30) and intermediate ring (50) by removing the four screws (260). � Remove the conveyor disc (140). � Loosen screw (240) and remove with washer (70). � Remove sliding hub (170). � Unscrew the four screws (190). � Replace the spur wheel back-geared motor. � Assemble in the reverse order (slide conveyor disc (140) under lateral guide).


61

10.4.4. Replacing the sliding hub

� See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” � Replace the sliding hub. � Assemble in the reverse order (slide conveyor disc (140) under lateral guide).

10.4.5. Adjusting the sliding hub

� See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” � Check the idle torque. If lever L=500 mm, the leverage force is

UR-1 UR-2 UR-3

8-10N 9-11N 10-12N

� Set test torque: Loosen guard panel; tighten nut until a lever force of L=500mm is measured at

the lever (see table below). When measuring, lock the ventilator wheel of the motor.

UR-1 UR-2 UR-3

29N 32N 36N

� Once the test torque has been set, secure the nut with the guard panel. � Assemble in the reverse order.


62

11. Bypass BPEA/BPE

11.1. Use The bypass BPE is used for inward and outward transfer of a workpiece holder WT into a parallel work flow. Both a manual station and an automatic station can be installed in a bypass. Stoppers VSEB or indexing device IVEB should be used for stopping and indexing.


Bypass with drive 7.7 m/min. 9.7 m/min. 12.3 m/min. 14.9 m/min. 18.7 m/min.

BPEA-105 5.3 4.4 3.6 3.0 2.5

BPEA -140 6.3 5.1 4.0 3.5 2.8

BPEA -185 6.8 5.8 4.5 3.9 3.2

BPEA -250 8.8 7.2 5.9 5.0 4.2

The times given include the setting and resetting time of the bypass and the transit time of the workpiece holder. Bypass without drive 12.3 m/min. 14.9 m/min. 18.7 m/min.

BPE-105 2.8 2.4 1.9

BPE -140 4.1 3.6 3.0

BPE -185 4.3 3.6 2.9

BPE -250 5.8 4.8 4.0

The times given include the setting time of the bypass and the transit time of the workpiece holder.

NOTE! As the workpiece carrier will get stuck without an additional driver at the speeds of 7.7 m/min. and 9.7 m/min.; these speeds are not available.


63

11.3. Commissioning

11.3.1. Setup of bypass with drive (inward transfer) and the necessary accessories

Bypass belt Endless belt

Bracket for proximity switch HNEB Item no. 54634



Queue monitoring


64

11.3.2. Setup of bypass without drive (outward transfer) and the necessary accessories Bypass belt Endless belt






Stopper VSEB with air connection left Item no. 54581

Queue monitoring


65

11.3.3. Settings Bypass with drive right and left Endless belt Bypass belt Endless belt Bypass belt Bypass with drive right Bypass with drive left Endless belt Bypass belt Endless belt Bypass belt

NOTE! These settings also apply to bypass without drive left and right.

The chassis binder must be mounted so that the bypass conveyor is 0.5 mm lower than the endless belt. Caution: Make sure installation position is correct!

The support for bypass must be set to the same height as the belt of the endless belt.

Support

Chassis binder


66

11.3.4. Flowchart for bypass with drive (outward transfer) outward transfer straight Z1 Cylinder, doule-acting Stopper

Z2 Cylinder, doule-acting Drive unit








queuing


67

Start

Z1 OFF

N4 assigned

Z2 ON

noyes

N6 assigned

N1 unassigned

outwardtransfer

N1 assigned

no

no

yes

yes

outwardtransfer

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N7 assigned

Z2 OFF

no

yesstraight

yes

no

no

noyes

N2 unassigned

no

N3 unassigned


68

11.3.5. Flowchart for bypass without drive (inward transfer) transfer inward straight Z1 Cylinder, double-acting Stopper









queuing


69

Start

Z1 OFF

N5 assignedno

yes

N2 unassigned

N3 unassigned

inward transfer

N2 assigned

no

inwardtransfer

T expired

N6 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N7 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N4 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 EIN

N5 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yesstraight

yes

no

no

noyes

Z2 OFF

N7 assigned

N1 unassigned

no

no

yes

yes

yes


70

11.3.6. Flowchart for bypass with drive (inward transfer) Transfer inward straight Z1 Cylinder, double-acting Stopper












queuing


71

Start

Z1 OFF

N5 assigned

Z3 ON

no

yes

N2 unassigned

N9 assigned

N3 unassigned

inward transfer

N2 assigned

no

no

yes

yes

inwardtransfer

T expired

N6 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N7 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N4 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N5 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N8 assigned

Z3 OFF

no

yesstraight

yes

no

no

noyes

Z2 OFF

N7 assigned

N1 unassigned

no

noyes

yes


72


11.4.1. Replacing the drive cylinder

� Turn off system. � Bleed compressed air system. � Remove the two pneumatic hoses (150) from the exhaust air valve (110). � Release clip (90/2) and pull down out of the fork end (90/1). � Swivel cylinder (100/1) out. � Remove retaining ring (170). � Remove cylinder (100/1). � Remove the fork end (90/1) and exhaust air valve (110) from the defective cylinder and mount on

the new cylinder. Care must be taken to screw the fork end back to its original size. � Assemble in the reverse order. � Check swivel angles and reset, if necessary.


73

11.4.2. Checking and setting the swivel angle

1. Extend cylinder. 2. The curve lever for bypass (60) must be on position 2. 3. Check if the curve lever for bypass applies noticeable pressure to the stop (40). 4. If yes, continue with point 16; if not, continue with point 5. 5. Turn off system. 6. Bleed compressed air system. 7. Release clip (90/2) and pull down out of the fork end (90/1). 8. Swivel cylinder (100/1) out. 9. Loosen hex nut (100/2). 10. Loosen fork end approx. ½ turn. 11. Tighten hex nut (100/2). 12. Swivel cylinder (100/1) in. 13. Mount clip (90/2). 14. Turn on system. 15. Perform steps 1 to 3. 16. Retract cylinder. 17. The curve lever for bypass (60) must be on position 1. 18. Check if the curve lever for bypass applies noticeable pressure to the stop (30). 19. If not, the procedure is the same as starting with point 6; except in point 10, the fork end must

be screwed in ½ turn. Schwenkwinkel = swivel angles


74


� Turn off system. � Bleed compressed air system. � Loosen countersunk screw (120) and washer (140) and remove. � Pull curve lever up and out. � Remove pad (70). � Loosen and remove the three screws (130). � Remove curve for bypass (50). � Loosen the two hex screws (40) and slide sideways out of the chassis binder (20). � Remove endless belt so that the hex screws (30) can be unscrewed. � Mark the position of the drive unit on the bearing and its angle. (This is to circumvent aligning

the drive unit.) � Unscrew the four hex screws (30). � Replace drive unit (10) and reinstall in the location marked. � Assemble in the reverse order. � Check swivel angles and reset, if necessary.


75

12. Transfer Gate WEE

12.1. Use Transfer gates WEE are used to divert a workpiece holder WTE from a conveyor to two (inward transfer gate), or from two conveyors to one conveyor (outward transfer gate). A stopper should be provided on the inward transfer side.


Bypass with drive 7.7 m/min. 9.7 m/min. 12.3 m/min. 14.9 m/min. 18.7 m/min.

WEE-105 3.4 2.7 2.3 2.1 1.7

WEE-140 4.1 3.4 2.8 2.5 2.2

WEE-185 5.8 4.7 3.9 3.5 2.8

The times given include the setting and resetting time of the transfer gate and the transit time of the workpiece holder.

12.3. Commissioning

12.3.1. Setup of inward transfer gate WEE and the necessary accessories





76

12.3.2. Setup of outward transfer gate WEE and the necessary accessories





77

12.3.3. Checking and setting the drive unit

� The drive unit (10) must be installed centered (=) to the incoming chassis. � The axle must be at a right angle to the chassis. � Between the transfer gate (20), the lateral guides, and the inside curve (30) should be a space of

1 mm. � If that is not the case, the drive unit (10) must be set to the specified values by loosening the two

screws (100). � Check if the transfer gate (20) applies noticeable pressure to the stop (70), both on the left and

right sides. � If not, reset the swivel angle.


78

12.3.4. Flowchart for transfer gate (inward transfer) WT from left WT from right Z1 Cylinder, double-acting Stopper












queuing


79

Start

Z1 OFF

N4 assigned

Z2 OFF

noyes

N6 assigned

N3 unassigned

WT from left

N2 assigned

no

no

yes

yes

WT from left

T expired

N7 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N9 assigned

Z3 ON

no

yesWT from right

yes

no

no

Z3 OFF

N8 assigned


80

12.3.5. Flowchart for transfer gate (outward transfer) WT to the left WT to the right Z1 Cylinder, double-acting Stopper





4 Proximity switch Stopper cylinder OFF




queuing

queuing


81

Start

Z1 OFF

N4 assigned

Z2 OFF

no

yes

N2 unassigned

N6 assigned

N3 unassigned

WT to left

N1 assigned

no

no

yes

yes

WT to left

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N7 assigned

Z2 ON

no

yesWT to right

yes

no

no

noyes


82

12.4. Maintenance and repairs

12.4.1. Replacing the drive cylinder See chapter Fehler! Verweisquelle konnte nicht gefunden werden.. Movable Curve 90°.


� Turn off system. � Bleed compressed air system. � Loosen countersunk screw (110) and remove together with washer (140). � Pull transfer gate (20) up and out. � Remove pad (40). � Loosen the two screws (130) and remove. � Replace drive unit (10). � Assemble in the reverse order. � Check swivel angles and reset, if necessary.


83

12.4.3. Überprüfen und Einstellen des Schwenkwinkels

1. Extend cylinder. 2. The transfer gate (20) must be on position 2. 3. Check if the transfer gate applies noticeable pressure to the stop (70). 4. If yes, continue with point 16; if not, continue with point 5. 5. Turn off system. 6. Bleed compressed air system. 7. Release clip (70/2) and pull down out of the fork end (70/1). 8. Swivel cylinder (80/1) out. 9. Loosen hex nut (80/3). 10. Loosen fork end approx. ½ turn. 11. Tighten hex nut (80/3). 12. Swivel cylinder (80/1) in. 13. Mount clip (70/2). 14. Turn on system. 15. Perform steps 1 to 3. 16. Retract cylinder. 17. The curve lever (20) must be on position 2. 18. Check if the curve lever applies noticeable pressure to the stop (60). 19. If not, the procedure is the same as starting with point 6; except in point 10, the fork end must

be screwed in ½ turn.


84

13. Indexing Device IVE and IVEB

13.1. Use The IVE is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE. The IVEB is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE in the bypass.

13.2. Commissioning

13.2.1. Assembling and setting the indexing device IVEB

� Specify position of indexing device (10) according to dimension X. � Slightly tighten the two hex screws (110).

Dim

ensi

on


85

� Place a 0.2-0.3 mm thick feeler gauge strip on the belt. � Place WTE on the feeler gauge strip and - using the positioning sleeve in the WTE - align with

the indexing stopper (10). � Mount pressure pad IVE (40) and slightly tighten Allen screws (50). � Center pressure pad IVE (40) relative to WTE. � Remove feeler gauge strip. � Use a feeler gauge between belt and WTE to check if the WTE is positioned horizontally. � Align WTE with adjustment screws (60/120). � Tighten fastening screws (50/110) with a torque of MA=6Nm.


86

� Mount left stopper (30) and lightly tighten the two hex screws (110). � The stopper (30) must be aligned so that a 0.1-0.3 mm play remains between the WTE recess

and the stopper lock in an indexed WTE. � Tighten fastening screws (110).


87

� Mount right stopper (20) and lightly tighten the two hex screws (110). � The stopper (20) must be aligned so that a play of at least 2 mm remains between the indexed

WTE and the following WTE. � Tighten fastening screws (110). � Connect compressed air system with maximum 6 bar


88

� Screw on the two brackets for proximity switch HNEB (70), item no. 49629, using hex screw (90). � Mount proximity switch (80), item no. 508377, in bracket for proximity switch. � Align proximity switch with engagement pin in WTE. � The switching distance should be set to 0.5-1 mm to the WTE .


89

13.2.2. Installation and setting of indexing device IVE The work steps are identical with assembly and adjustment of IVEB.

13.2.3. Flowchart for indexing device IVEB/IVE Z1 Cylinder, double-acting Stopper

Z2 Cylinder, double-acting Indexing device







N6 Proximity switch Indexing device ON

N7 Proximity switch Indexing device OFF


90

Start

Z1 OFF

N5 assigned

Z2 ON

noyes

N6 assigned

N1 unassigned

N2 assigned

no

no

yes

yes

T2 expired

N3 unassigned

N7 assigned

T2 delay time

Z2 OFF

no

no

no

no

no

yes

yes

yes

yes

yes

yes

no

N4 assigned

N9 assigned

Z1 ON

Z3 OFF

N5 assigned

N2 unassigned

no

no

no

no

no

yes

yes

yes

yes

yes

yes

N3 unassigned

Z2 ON

noyes

no

Z3 ON

N8 assigned

N2 unassigned

yes

N6 assigned

Z1 OFF

Z3 ON

N9 assigned

N8 assigned

no

yes

yes

N1 assigned

Z3 OFF

no

N2 assignedno

yes

T1 delay time

T1 expired


91

14. Positioning Device PVE

14.1. Use The PVE is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE, which are supported from below for press-in operations.

14.2. Maximum torque

WTE 80x80 Center 4Nm Diameter 0 bis 30 3.5Nm 30 bis 60 3Nm WTE 115x115 Center 6Nm Diameter 0 bis 40 4.5Nm 40 bis 80 3Nm


92

WTE 160x160 Center 6.5Nm Diameter 0 bis 60 5.5Nm 60 bis 120 5Nm WTE 225x225 Center 7Nm Diameter 0 bis 90 6Nm 90 bis 180 5.5Nm


93

14.3. Commissioning

14.3.1. Mounting and setting positioning device PVE

� Insert support with belt stroke cylinder (10) in chassis. � Support position (10) from below. � Align support (10) centered to recess.

� Center the stoppers (20) against the recess in the chassis. � Slightly tighten the two screws (60). �

= Support


94

� Retract the two belt stroke cylinders (150) so that the belt is free. � Place WTE on the support and - using the positioning sleeve in the WTE - align with the stopper

(20). � Mount pressure pad PVE (30) and align centrically with WTE; slightly tighten screws (70). � Use the stopper (20) to index the WTE. � Use a feeler gauge between support (10) and WTE to check if the WTE makes contact with the

support (10). � Align WTE with adjustment screws (80/90). Tighten fastening screws (60/70) with a torque of

MA=6Nm.


95

Mount left stopper (40) and lightly tighten the two screws (100). � The stopper (40) must be aligned so that a 0.1-0.3 mm play remains between the WTE recess

and the stopper lock in an indexed WTE. � Tighten fastening screws (100) with a torque of MA=6Nm. �

� Mount right stopper (50) and lightly tighten the two screws (110). � The stopper (50) must be aligned so that a play of at least 2 mm remains between the indexed

WTE and the following WTE. � Tighten fastening screws (110). � Connect compressed air system with maximum 6 bar.


96

� Screw on the two brackets for proximity switch HNEB (120), item no. 54634, using screw (140). � Mount proximity switch (130), item no. 508845, in bracket for proximity switch. � Align proximity switch to engagement pin in WTE. � The distance should be set to 0.5-1 mm to the WTE.


97

14.3.2. Flowchart for positioning device PVE Z1 Cylinder, double-acting Stopper

Z2 Cylinder, double-acting Indexing device


Z4 Cylinder, double-acting Belt stroke cylinder

Z5 Cylinder, double-acting Belt stroke cylinder

N1 Proximity switch Presence before PVE

N2 Proximity switch Presence in PVE




N6 Proximity switch Indexing device ON

N7 Proximity switch Indexing device OFF




98

Start

Z1 OFF

N4 occupied

Z2 ON

noyes

N7 occupied

N1 occupiedno

no

yes

N7 occupied

N3 free

no

no

no

yes

yes

yesno

N6 occupied

Z4/Z5OFF

Z2 OFF

N4 occupiedno

noyes

yes

yes

Z1 ON

Z3 OFF

N8 occupied

N2 occupied

yes

N5 occupied

Z4/Z5OFF

Z2 ON

PROCESSING

Z1 OFF

END OFPROGR.

yes

no

Delay timeT2 for Z3

=0

no

yes

N8 occupied

N9 occupied

Z3 OFF

Z3 ON

yes

yes

no

no

Z4/Z5ON

END OFPROCES.

Delay timeT1 for Z1

=0

yes

no

END

yes

yes

nono


99

15. Disassembly and Disposal

After the device has reached the end of its service life, disassemble the device and dispose of it in an environmentally compatible manner.

15.1. Improper disassembly

Removal - Switch off system and secure against accidental restart.

- Disconnect the power supply.

- Clean the components.

- Take components apart and sort according to material type.

15.2. Disposal If a return or disposal agreement has not been entered into, please recycle the disassembled components. Materials which cannot be recycled should be disposed of appropriately. In particular, it should be noted that the gear lubricant must be disposed of separately. - Scrap metals.

- Recycle plastic parts.

- Sort all other components according to their material and dispose of them.

CAUTION! Improper disassembly can result in injury! Stored residual energies, sharp-edged components, corners and points on and in the device or necessary tools may cause injury. - Make sure there is enough room prior to starting any work.

- Handle open, sharp-edged components with care.

- Keep installation space clean and orderly! Components and tools that are lying around or carelessly stacked are an accident hazard.

- Disassemble components properly.

- Secure components against falling down or over.


100

Materials used

$ Aluminium $ Steel $ Copper $ ABS Acrylonitrile Butadiene Styrene copolymer $ PUR Polyurethane $ HDPE Polyethylene $ PS Polystyrol $ PVC Polyvinyl chloride $ PET Polyethylene terephthalate $ Gear lubricant, V < 4.02m/min. = soda soap Calypsol D 6024 $ Gear lubricant, V > 5.26m/min. = Syntheso D 460 EP $ Various electronic components

Surface treatment

$ Anodizing of aluminum $ Electroless nickel-plating of steel

Forming processes

$ Aluminum extrusion $ Non-cutting machining of aluminum, steel, polyurethane and deep-drawing of Polystyrene $ Steel laser-cutting $ Injection molding of ABS

Emissions during operation

NOTE! Incorrect disposal is an environmental hazard! Incorrect disposal can pose a hazard to the environment. - Have authorized specialty firms dispose of electronic scrap and electronic

components.

- If in doubt, contact your municipality or special disposal companies for information on environmentally compatible disposal.

MONTECH AG Gewerbestrasse 12, CH-4552 Derendingen Fon +41 32 681 55 00, Fax +41 32 682 19 77 [email protected], www.montech.com

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