Glide-Line Lift and Rotate Unit (LRU)

Transcription

1 V1.0 Glide-Line Lift and Rotate Unit (LRU) Installation & Maintenance Manual Easy Flexible Precise Fast i

2 V1.0 Manual Information Throughout this manual are the following information blocks indicated in the appropriate sections by signal words as specified by ANSI Z535.4 Standard (section 4). Warning This information must be followed to prevent harm to individuals or damage to equipment. Automatic Equipment This equipment may start or stop automatically. Electrical Shock This equipment has connection to an electrical circuit with potentially hazardous energy levels. Consult Manual This manual must be completely reviewed prior to performing any service. Lock Out Power All sources of energy must be controlled before servicing equipment ii

3 V1.0 Table of Contents 1. Introduction... 1 Description of Device... 1 Operating Conditions and Environment... 1 Chemical and Corrosion Resistance... 2 Serial Number Information Installation... 3 Unpacking and Mounting... 3 Device Set-Up... 3 Recommended Pneumatic Schematic... 4 Mounting Sensors... 4 Stepper Setup and Program... 5 Stepper Wiring Diagram Safety Instructions... 7 Operation Maintenance... 8 Cylinder Removal... 8 Timing Belt Replacement... 9 Preventative Maintenance Schedule Troubleshooting How to Order Spare Parts Returns iii

4 1. Introduction Description of Device The Glide-Line Lift and Rotate Unit is designed to lift workpiece pallets above the belt surface, and rotate them 90 or 180 degrees. The unit is highly customizable and can be programed to suit a wide variety of applications and needs. The unit can be station mounted or conveyor mounted and may or may not include guards. IP65 protection is available for electronics and connectors. The unit does not include any sensors or fittings. For a break-down of how your unit was supplied, please reference the part number table below: Part Number: LRU-(A)-(B)-IP(C)-(D)-(E) A = Pallet Width Range 160mm to 480mm B = Pallet Length Range 160mm to 480mm C = IP Rating, 20 and 65 available D = CM for Conveyor Mounted, SM for Station Mount E = G for Guarded, NG for No Guard INTRODUCTION INSTALLATION SAFETY Personnel working on or around this equipment must be properly trained in operation, maintenance, and lock-out/tag-out procedures. Operating Conditions and Environment Equipment should be located in an ambient temperature room. Equipment should not be subject to high humidity or wash-down conditions. Clean-up to be by wipe down / air blow off only. This unit must be connected to an external control system to operate properly. This equipment was not designed to run in a standalone configuration. Control voltage, programmable controller, or other functionality may have been provided with this equipment. This equipment must be connected to a suitable E-stop circuit for protection. Any reference to an E-stop in this manual requires the customer or user to provide an external E-stop circuit. Failure to connect this equipment to a proper E-stop circuit will void any and all warranties. MAINTANENCE TROUBLESHOOT 1

5 Chemical and Corrosion Resistance Components used by Glide-Line are made from materials that are highly resistant to common household materials including all fruit and vegetable juices, inks, soaps, and most common detergents. It is recommended that customers contact the factory and obtain samples of applicable modules to be exposed to conditions of the proposed application to determine resistance of material and its durability. Serial Number Information The Serial number for your LRU can be found on the base plate of the unit. Serial number information will be displayed as follows: INTRODUCTION INSTALLATION XXXXX.GLLRU.YYY SAFETY Glide-Line Job Number Individual ID Number Device Type MAINTANENCE TROUBLESHOOT 2

6 2. Installation Unpacking and Mounting When the unit arrives, care must be taken to unpack the unit. Smaller units will be packaged in individual boxes and bubble wrapped. Take care to cut away bubble wrap. Do not score with a knife as to not risk damage to the unit. Larger units will ship on a skid. Unit will be secured with T-Bolts to a series of support boards and can be loosened with a 13mm ratchet. Prior to mounting the unit into position, it is recommended that air fittings are installed. The unit does not include air fittings. Please select fittings for G1/8 connection to the cylinder body. Lift and Rotate Units can either be Conveyor Mounted or Station Mounted (designated -CM or - SM respectively in the part number). If conveyor mounted, the unit will come with a conveyor mounting kit. This kit is designed to allow mounting to the underside of a conveyor in 4 locations per device. If you are mounting the device directly to a station, the device base plate includes (2) 8mm locating dowel holes and (4) M8 bolt locations. For precision mounting, it is advised to transfer this hole pattern in the machine base. First mount locating dowels, then proceed to tighten down the 4 screw locations. It is important to install the device level and straight to achieve the listed performance. A nonlevel installation could induce moment loading to the cylinder body and guide rods, decreasing the design life of the device. Device Set-Up After bolting the unit into the desired location, the unit can be plumbed with air lines and flow controls as required for the application. Device is not supplied with fittings, tubing, flow controls, or solenoids. Sending air to the port at the bottom of the cylinder will extend the cylinder, allowing the LTU to rise. Sending air to the port at the top of the cylinder will compress the cylinder and lower the LRU. It should be noted that the unit comes with a hydraulic dampener when coming to top of stroke only. Utilize check valves as noted in the recommended pneumatic schematic to create an air cushion as cylinder arrives at the end of stroke in compression or extension. Additionally, the unit will be supplied with a closed-loop stepper motor with a pre-loaded program to control rotation. For additional information, consult the stepper section. This program is customizable, and the NanoJ Easy V2.05 software is available for free at: TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 3

7 Recommended Pneumatic Schematic Note that the LRU does not include any fittings or flow control devices. Cylinder ports are G1/8. SAFETY INTRODUCTION INSTALLATION Mounting Sensors The main cylinder of the Lift and Rotate Device includes two sensor rails with dimensions as shown in the drawing below. If position sensing is required for the application, sensors comparable to the listed part number can be utilized to detect the magnetic piston of the lift cylinder. Proper cable management is required to the exit of the guard to ensure there are no interferences with device functionality. Sensor Rail Dimensions: MAINTANENCE TROUBLESHOOT Recommended Sensor Package: Comparable to Canfield #9C Optional Recommended Homing Sensor: Comparable to Pepperl-Fuchs

8 Stepper Setup and Program The Lift and Rotate Unit includes a Nanotec Stepper motor that features a built-in drive card/ controller. For a detailed list of available commands and specifications of the motor, please reference the Nanotec Motor Manual. Glide-Line preloads a basic program as detailed below: Basic Commands: The Glide-Line LRU commands are achieved by sending voltage to pins 1, 2, or 3 and combine with pin 5 to enable the move. The combinations available are listed in the table below. Speed of rotation is set by the factory, but can be modified in the on-board program. Connections: X1 OUTPUT 3: An Open-Drain output. Max 24V 100mA. This output turns on once the move is complete. X2 PIN 1: The input for the proximity probe as well as the 90 deg turn signal. X2 PIN 2: The input for the -90 deg turn signal. X2 PIN 3: The input for the 180 or -180 deg turn. X2 PIN 5: The input for the enable signal. X3 PIN 1: The 24VDC power. X3 PIN 2: The Ground / 0VDC. Optional Homing: Programed into the LRU is the option to add a homing proximity sensor, allowing for the unit to be homed upon command. This is not required for basic applications, as by default the unit will home to its original position at startup. TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 5

9 Stepper Wiring Diagram Please reference the below diagram for the recommended wiring setup of the Stepper Motor: TROUBLESHOOT INTRODUCTION MAINTANENCE SAFETY INSTALLATION 6

10 3. Safety Instructions Operation Due to the hazardous moving parts of the device, all personnel in the area of a device should be warned when the device is about to be activated. Only properly trained personnel should be permitted to operate Glide-Line devices. Training should include emergency procedures. Machine stopping devices should be clearly marked and easily accessible. Personnel working on or near the equipment should be trained in the location of stopping devices. The area around machinery should be kept clear. Devices must only handle loads they were designed to carry. Safety and warning devices must not be tampered with in any way that could endanger personnel. Personnel must be made aware of all potential hazards including but not limited to entanglement of items such as long hair, loose clothing or jewelry. Personnel must also be aware of any pinch points present on the device that could result in injury. Device should not be operated without safety guards in place. Guards should not be removed by anyone other than authorized personnel. All safety devices, including wiring of electrical safety devices, must be designed to work in a failsafe mode to avoid hazardous conditions from occurring during a power failure. Refer to ANSI Z , American National Standard for Personnel Protection Lockout/Tagout of Energy Sources Minimum Safety Requirements and OSHA Standard Number 29 CFR The Control of Hazardous Energy (Lockout/Tagout). TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 7

11 4. Maintenance Only trained personnel should perform maintenance procedures. Company approved lock-out/tag-out procedures should be strictly adhered to. Please consult this manual before servicing. Routine inspections along with preventive and corrective maintenance must be performed to insure proper functioning of equipment. Maintenance schedules should be established to insure proper operation and to avoid potential hazards. Maintenance must not be performed on equipment while in operation. Personnel should be trained in proper maintenance procedures as well has the hazards of not following procedures properly. When equipment is stopped for maintenance, lockout/tagout procedures should be followed in order to avoid potential hazards to personnel performing the maintenance. All safety devices and guards must be replaced before starting conveyors for normal operation. Cylinder Removal Tools Required: (1) Spanner Wrench (1) 5mm Allen Key (1) 6mm Allen Key To replace a lift cylinder please follow the following steps: 1. Remove all guards (if applicable). 2. Loosen the (4) screws in the center of the lift plate and the (1) cylinder rod mount screw. 3. Remove Lift Plate 4. Use spanner wrench in the top holes of the cylinder lock nut. 5. Remove cylinder lock nut, and pull out cylinder. Please note orientation of the notch in the cylinder head with the spring pin in the base plate of the LRU. Also note the orientation of the sensor mount rails with the notches in the lift and bottom plates. Unthread all fittings and remove sensors from mount rails (If applicable). When replacing the cylinder, follow all above steps in reverse. Use blue thread locker on all threads to make sure screws will not back out during operation. TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 8

12 Timing Belt Replacement Tools Required: (1) 4mm Allen Key (1) 5mm Allen Key (1) 6mm Allen Key To replace a lift cylinder please follow the following steps: 1. Remove all guards (if applicable). 2. Unscrew top (4) screws on top plate with 5mm Allen Key 3. Remove top plate clamp and top plate. 4. Unscrew the (3) screws in the LRU base plate constraining the 3 riser posts with a 6mm Allen Key. This will detach the bottom assembly from the LRU Base plate 5. Loosen the (4) bolts that hold the motor/gearbox to the rotator plate with a 4mm Allen key. Holes are slotted and will allow the motor/gearbox to be pushed closer to the center of assembly to loosen belt. 6. Note belt path and then remove Belt Belt replacement is done in the reverse of these steps. When tightening the belt, use a screwdriver to wedge between the rotator plate and the gearbox plate to tighten the belt, then retighten all screws. Preventative Maintenance Schedule Daily Prior to Starting Equipment 1. Perform a visual inspection of the equipment for possible maintenance needs. 2. Remove any foreign objects that may be on or leaning against conveyor or equipment. 3. Inspect airlines for any damage or loose connection. TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION After Starting - Prior to Production 1. Perform a visual and auditory inspection of the equipment and product transportation for possible maintenance needs. Stop device operation if hissing sound is present. Monthly 1. Check timing belt for signs of wear and replace as necessary. 2. Check all bolts have remained tightened to designed torque ratings. 3. Wipe guide rods of any debris. 4. Check that timing belt is tight with no signs of wear, adjust as necessary. 9

13 5. Troubleshooting Problem Cause Solution Top plate does not spin. Motor not receiving power/commands Check all connections and program. If problem persists, contact Glide-Line Timing belt loose/damaged Inspect belt, tighten or replace as necessary Problem Cause Solution Top plate misaligned Plate has been shifted, or unit restarted without being homed at center position loosen the (4) bolts in the top plate clamp and rotate the plate to the correct position. Cross tighten all bolts. INTRODUCTION Problem Cause Solution Lift does not rise. Cylinder or airline damaged/leaking Misalignment in guide rod/bushing assembly Replace cylinder or airlines affected Check that device is installed square and level. Exhaust all air from the cylinder and confirm it can freely move. If bound, contact factory for instruction. Problem Cause Solution Lift extended position drifting upwards Shock absorber loose Reposition Shock absorber position, apply thread locker Bottom strike plate loose on guide rods Reposition bottom strike plate, retighten screws, and apply thread locker. INSTALLATION SAFETY MAINTANENCE TROUBLESHOOT 10

14 Problem Cause Solution Lift Aggressively hits top or bottom position Shock Absorber loose or damaged Air Cushion not set with flow controls Reposition shock absorber confirming it is limiting the end of stroke. If damaged, replace. Reference the recommended pneumatic layout, utilize flow controls to create a cushion of air at extension and retraction of stroke. TROUBLESHOOT INTRODUCTION INSTALLATION MAINTANENCE SAFETY 11

15 6. How to Order Spare Parts Spare parts may be purchased directly from Glide-Line. For a full list of spares for your conveyor or device as configured, please reference the serial number located near the base plate of your device, and contact a Glide-Line representative at TROUBLESHOOT INTRODUCTION INSTALLATION MAINTANENCE SAFETY 12

16 7. Returns Under no circumstances will a component be accepted without a Glide- Line RMA number. INTRODUCTION When requesting a Return Materials Authorization (RMA), please have the following information available: Customer s name and address Customer original purchase order number Glide-Line s project number or serial number Description of part(s) being returned Reason for return To preserve the return, all returned parts must be properly packaged to prevent shipping damage. The Glide-Line issued RMA number must be clearly marked and visible on the exterior packaging. The Glide-Line issued RMA form must also be included inside the package. Includes: Location, type of service and length of time in service Complete description of the faulty operation of the component and the circumstances of failure. State requested service warranty or non-warranty Complete shipping instructions for return of component Name and telephone number of person to be contacted if there are any questions about the returned part. If a part is damaged or lost during transit, the customer is responsible for directing a claim to the carrier. The customer is responsible for return freight. Upon receipt of the defective component(s), Glide-Line will examine it for warranty defects. A credit will be issued for the replacement when and if the component is found to be defective. Following the above procedure correctly will expedite handling of the returned component and will prevent unnecessary additional charges for inspection and testing to determine the problem with the component. For all orders and service, a written Purchase Order for repairs must be enclosed. TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION 13