DynaCon Instruction Manual

Transcription

1 DynaCon Instruction Manual

2 Table of Contents Technical Specification & Warranty Construction, Benefits & Safe Operating Procedures... 4 Noise Levels... 5 Installation, Operation & Maintenance... 5 Before you start assembling... 5 Configuration & connection of conveyors... 6 Belt Installation... 6 Standard Belt... 7 Belt with hold down tabs... 7 Radius Turn Module... 8 Adjusting belt tension... 9 Part Descriptions DynaCon Straight Connector Page 2

3 Technical Specifications Standard Motor: kw 3 phase motor with 80:1 gearbox external Mount kw 1 phase motor with 80:1 gearbox external Mount Belt Surface: - Intralox Series 900 & 1600 Modules: - Tough Engineering Thermoplastic Support Frame: Standard Control: - Aluminium 40 x 40mm profile - DOL 3 phase 415 volt 50Hz with externally mounted Emergency stop - DOL 1 phase 240 volt 50Hz with externally mounted Emergency stop - VSD control ( m/min) 240 volt 50Hz with externally mounted Emergency stop Special motors & controls are available, please ask your Fleming Dynamics (FD) Representative for more information. The information contained in this manual is provided only as an aid and service to our customers. Fleming Dynamics Pty Ltd (FD) does not warrant the accuracy or applicability of such information and is not specifically responsible for property damage and/or personal injury inflicted directly or indirectly, or for damages and/or failures caused by improper application, installation, operation, abuse and/or misuse of its products whether or not based on information contained herein. WARRANTY Fleming Dynamics Pty Ltd (FD) warrants products of DynaCon s manufacture for a period of five (5) years from date of shipment to the extent that FD will repair or replace any products that have failed under normal use due to faulty material or defective workmanship. Motors, electrical components and belt carry the manufacturer s warranty of one (1) year from date of shipment. No other warranty is expressed or implied unless otherwise set forth in writing and approved by a representative duly authorized to extend such approval by Dynamic Conveyor Corporation. LIMIT OF LIABILITY In no event shall Fleming Dynamics Pty Ltd (FD) be liable for any special, indirect, incidental, or consequential damages of any character, including but not limited to loss of production facilities or equipment, lost profits, property damage, lost production, or any consequential downtime, whether suffered by distributor or third party, irrespective of whether claims or actions for such damages are based upon contract, warranty, tort (including negligence), strict liability, or otherwise. FOR YOUR RECORDS Thank for your investment in DynaCon products. We believe our product will become a vital step in your production process and it will grow with your changing needs. Please take the time to complete the following information as thoroughly as possible. It will prove helpful when you call a customer service representative in the event you have any questions about assembly, installation or operation. DATE OF SHIPMENT (Warranty start date) SERIAL NUMBER (found on opposite side of motor) Page 3

4 Construction The DYNACON conveyor system modules are constructed from tough engineering thermoplastics and are bolted together using dome headed 10mm bolts. The track assemblies are connected to one another by aluminium crossbars and polypropylene belt supports are integral to the crossbars. The belt is made from individual links, which are interconnected and laced together using polyester rods, and closed off at each end with clips. The outside edges of the belt run inside a moulded track along the total length of the conveyor. The modules are available from 100mm wide increasing in approximately 50mm increments Up to 1500mm wide. The conveyor can be assembled to achieve 30, 45, 60, 75 and 90-degree angle or swan neck configurations. Side guard extensions are available 100mm high and are fixed to the track assembly modules by using 10mm dome headed bolts and can be fitted at any time. All track assemblies are moulded with spare threaded holes (10mm) and so support frames, controls, chutes etc. Support frames are custom built from extruded aluminium profile 40x40mm, which is of a unique FD design. The DynaCon conveyor system is relatively lightweight although this manual cannot give details of mass, as this is dependent upon the configuration of the conveyor or conveyor system. BENEFITS Modular construction providing full flexibility for changing needs. All Intralox series 900 & 1600 belts can be used. Belt surfaces are impervious to oil and water. Positive gear drive motors with single phase or three phase motor drive eliminates belt slip often caused by oil or water on traditional belt materials. No tracking required. Belt surface resilient to sharp objects. Under belt or tunnel metal detectors available as standard. Under or over belt cooling fans available. Water bath conveyor construction available. Side guarding. Counting and indexing conveyor systems available. SAFE OPERATING PROCEDURES The DynaCon Conveyor presents no special hazards or dangers to the machine operator and no personal protective equipment is required for normal use of the machine. The standard motor which drives the belt is 1.8kw the drive is through a standard 80:1 gearbox with a torque of 34Nm.. Severe injury could be caused if the operator s hair or clothing were to become caught in the belt track whilst the machine is running. Long hair should be tied back or a hair net should be worn if the operator head is likely to be in close proximity to the conveyor. Never reach under the conveyor whilst it is running as loose fitting garments or jewellery may become snagged in the belt track. Never perform maintenance activities on any part of the machine whilst the power supply is connected. Never remove covers from controls whilst the power supply is connected and only qualified personnel should remove covers in any event. Page 4

5 Only suitable qualified personnel should perform any maintenance activity. Do not operate a standard machine in wet conditions check with your supplier or direct with FD if you are unsure of the machine specification and its ability to work in wet environments. QUOTE THE CONVEYOR SERIAL NUMBER WHEN MAKING ANY TECHNICAL ENQUIRY NOISE LEVELS No data is available as the noise from a DynaCon conveyor of any configuration is below background noise levels in most environments. INSTALLATION Most DynaCon conveyors are supplied with wheels for ease of movement, although this is not always the case. Place the conveyor in the correct location. A suitably qualified person should make the electrical connections as per circuit diagram or instructions supplied with the conveyor. DynaCon conveyors are supplied with mains cable and plug for all Australian conveyors installed. The conveyor should be level and stable before attempting to start the machine. OPERATION DynaCon conveyors are designed to operate continuously in a forward direction, i.e., product is conveyed toward and discharged off of the motorized module (Drive Module), with capability for occasional reversing. If your conveyor requires continuous operation in a reverse direction, please contact FD for recommendations. MAINTENANCE DynaCon conveyors are designed to be easy to maintain and repair. To ensure proper operation, we recommend periodically inspecting the frame, motor, and belt paths for wear and damage. Under ordinary operating conditions, the belt and conveyor frame should be checked for any abnormal wear or stress (i.e., continuous grooves, cracks, etc.). No lubrication of the belt or belt paths is necessary. Under high speed or continuous use conditions, more frequent inspection is encouraged. Under dirty or greasy operating conditions, a daily inspection along with periodic cleaning of the belt, belt paths, and belt support is recommended. This will require removal of the belt in most cases. Note: DynaCon Conveyors are not intended for use in abrasive environments. Necessary steps should be taken to correct any problems as soon as they are discovered. Any questions or concerns may be directed to your local sales representative and/or a customer service technician. BEFORE YOU START ASSEMBLING 1. IMPORTANT: Every DynaCon conveyor requires a minimum of two assemblers. 2. Locate an area where you will have ample space to lay out the conveyor. 3. Follow the step-by-step directions on the proceeding pages. 4. REMEMBER: Your DynaCon conveyor configuration may differ from the following examples shown. 5. If you have any questions while assembling your conveyor, call FD. Page 5

6 CONFIGURATION OF THE CONVEYOR 1. Reference the drawing of your conveyor to determine the proper position of each module. Reference picture #1 2. All DynaCon conveyors consist of a Drive Module, Feed End Module, and depending upon the length of the conveyor, Mid-Modules. 3. Begin by placing the Drive Module on the far end of the arrangement. 4. Lay all Mid-Modules in the proper configuration. 5. Continue placing modules in the intended configuration ending with the Feed End Module at the opposite end of the Drive Module. CONNECTING THE CONVEYOR MODULES Slightly loosen the two screws in doubling links on both sides of each module. Reference picture #2. 1. Determine the modules that leg sets are to be attached to according to drawing provided. 2. Connect each leg set module to one adjoining module. 3. If applicable, connect any remaining modules in two (2) piece sections. 4. Assemble conveyor according to drawing. Reference picture # 2 5. Insert M10x25mm button head screws & flat washer (that are located in holes next to attachment point) at the attachment points. Tighten all screws on every doubling link. BELT INSTALLATION If the underside of your belt has factory installed hold-down tabs, proceed to appropriate section. If your conveyor configuration includes a Radius Turn Module, proceed to appropriate section. Page 6

7 STANDARD BELT 1. Remove the Feed End sides and belt guides by removing three button-head screws on each side. Reference picture #4. Note that one screw is longer than the other two. 2. Slide belting into the belt path on the top side of the Feed End Module. Feed belt to the end of the Drive Module, making sure that drive sprockets are engaged. 3. Guide the belt along the underside of the conveyor. 4. Bring belting together. The ends should interlock without much effort. If the ends overlap, remove the necessary number of links. Punch out a lacing rod from the end without a head on it. (Radius Turn belt lacing rod is without a head on either end you can pull out rod from either end.) Retain any extra rows for use as replacement parts. Reference picture # 5 Lace belting together using the provided rod. Be sure the head snaps into place. 5. Place feed end sides back into position and attach with removed screws. Tighten completely. BELT WITH HOLD-DOWN TABS Hold-down tabs are installed some belts 600mm wide and above. They are used to support the belt as it travels on the underside of the conveyor. 1. Same as above Standard Belt instructions. 2. Slide belt into paths at the top side of the feed end module making sure hold down tabs locate centrally in the two centre belt supports. 3. Guide the belt along the top of the conveyor. Feed belt to drive sprockets making sure they engage with sprockets correctly. 4. Bring belting together. The ends should interlock without much effort. Note: If the ends overlap, remove the necessary number of links. Punch out a lacing rod from the end without a head on it. Reference picture # 5. Retain any extra rows for use as replacement parts. 5. Place belting together using the provided rod. Be sure the head snaps into place. 6. Place feed end sides back into position and attach with removed screws. Tighten completely. Page 7

8 RADIUS TURN MODULE 1. Remove the Feed End sides and belt guides by removing three button-head screws on each side. Reference picture #9. Notice that one screw is longer than the other two. 2. Align belt supports along the entire length of the conveyor. 3. Slide belting into the belt path on the top side of the Feed End Module. 4. Pull belting from the outer most arc. Reference picture #4 Note: Radius turn drives operate in forward position only. IMPORTANT: The teeth on a Radius Turn sprocket are not evenly spaced. Determine the larger of two adjoining spaces. Reference picture #10.. Fit the rod section on the belt in the larger space on the sprocket. The sprocket must be fitted to the belt in this manner for proper tracking. 6. Guide the belt along the underside of the conveyor. Reference picture #10 7. Bring belting together. The ends should interlock without much effort. Note: If the ends overlap, remove the necessary number of links by pulling out a lacing rod. The Radius Turn belt lacing rod is without a head on either end. You can pull from either end. Retain any extra rows for use as replacement parts. 8. Place feed end sides back into position and attach with removed screws. Tighten completely. Note: Belts will elongate from 0.5% to 1% of their total length during the break-in period. This usually occurs during the first several days of operation. If belt elongation is excessive, it may be necessary to remove one or more rows of belt modules in order to maintain adequate belt tension. Page 8

9 ADJUSTING THE BELT TENSION ON STANDARD FEED A minimal amount of slack is needed for smooth operation of the belt. Too much tension or slack may yield poor performance. Some belts may not require adjustment. 1. With end sides and end belt guides removed, loosen the adjustment spacer screw that holds the idler shaft in position. Adjust one side at a time. Reference picture # Increase tension by moving the spacer and idler shaft assembly to the outer position, away from the motor. 3. Line up adjustment spacer pins with holes in bracket. Reference picture #12. Tighten screw and repeat for other side. Reference picture # If additional belt tension is needed, remove a row of belting and slide adjustment spacer and idler shaft assembly to inner position. Note: It may be necessary to repeat the tension adjustment procedure as the belt may stretch over time. 5. Once proper tension is achieved, place belt end guides in position. 6. Place end sides over belt guides and secure them with the button-head screws. Page 9

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