Contents Introduction... 3 Aout This Instlltion Mnul... 3 Preprtion for Instlltion... 3 Generl Tools... 4 Cutting Bems... 7 Assemly... 8 MODU System Component Groups... 8 Foot Mounting... 9 1.0 Mounting support foot... 9 2.0 Mounting foot cps............... 10 Connecting Structurl Bems... 11 1.0 Connecting em using ngle rckets... 11 2.0 Connecting em using connecting pltes... 11 Conveyor Bems.................. 12 1.0 Mounting conveyor em support rckets......... 12 2.0 Assemling conveyor ems... 13 Drive Units nd Idler Ends... 14 1.0 Mounting of Front Drive nd Suspended Drive Units... 14 2.0 Mounting of Idle End... 16 Slide Ril... 16 1.0 Instlling slide ril... 16 2.0 Joining slide rils... 18 3.0 Instlling slide ril in wheel ends... 19 4.0 Fixing slide ril y using rivets ( for MS2 nd MM3)... 20 5.0 Fixing slide ril y using screws ( for ML2 nd MX2)... 21 Chin... 23 1.0 Joining chin ends... 23 2.0 Mounting the chin............... 24 3.0 Length djustment of the conveyor chin... 24 Conveyor Guides System... 25 1.0 Mounting of guide rils rcket (Polymide)... 25 2.0 Mounting of guide ril rcket (Aluminium distnce tue)... 26 3.0 Connecting guide rils... 27 4.0 Instlling guide ril cover... 28 1
5.0 Guide ril ending... 28 Finl Preprtion.................. 29 1.0 Plug em ends... 29 2.0 Anchor feet to the floor... 29 3.0 Other preprtion... 30 Strt up nd Testing... 30 Sfety Precution.................. 30 To Achieve Sfegurding... 31 Strt up... 31 Trouleshooting Guidelines... 32 2
Introductionn Aout This Instlltion Mnul The purpose of this instlltion mnul is to help self-uilding system. end user, with sic experience, to ssemle MODU System conveyor Every chpter includes instructionn nd photos showing how to ssemle the different prts. Most photos in this mnul include prts from MM3 conveyor system, ut ll instructionss re pplicle to MS2, ML2 nd MX2 conveyor system unless otherwise specified or noted. Preprtion for Instlltionn 1) Mke preprtion y studying the ssemly drwing prepred y design engineers. 2) Ensure tht the necessry tools re ville. 3) Mke sure you hve ll the mterils nd components needed to ssemle the conveyor system. 4) Check ll mterils nd components with prt list. 5) Mke sure you hve enough spce to mount the conveyor system. 6) Check to see if the floor t the instlltion site is even so tht ll feet cn e properly ttched to the floor. 3
Generl Tools To ssemle conveyor, you will need the tools listed elow. Although not ll re essentil, they will mke your ssemly work esier nd more efficient. 1) Hnd tools ) Box wrench, 10, 13, 17 nd 19 mm ) Allen keys set (metric series) c) Tp nd tp wrench (M6 nd M8) d) Countersink it e) Mesuring tpe f) Files g) Socket wrench h) Screw drivers i) Pliers j) Pen knife k) Soft pced hmmer l) Clmp (for chin instlltion) m) Level 4
2) Power tools ) ) Miter sw with cutter for luminium Hnd drill 3) tools ) Chin pin insertion tool Item code: TR CP1 ) Attchment for chin insertion Item code: MS2 AC, for MS2 chin MM3 AC, for MM3 chin ML2 AC, for ML2 chin c) Slide ril ssemly tool Item code: MS2 SRA, for MS2 em 5
MM3 SRA, for MM3 em ML2 SRA, for ML2 em MX2 SRA, for MX2 em d) Slide ril cutter Item code: MA SC e) Slide ril drill fixture Item code: MA SRF, for MS2 nd MM3 f) Rivet crimping Item code: MA RC, for MS2 nd MM3 6
g) Guide ril ender Item code: TR GB h) Aluminium cutting lde Item code: TR CB i) Drilll it Item code: TR DB 2.5, for ML2 nd MX2 screws TR DB 3.2, for MS2 nd MM3 rivets Cutting Bems Bem lengths if you hve ordered 3m or 6m ems (3m is stndrd length), they will need to e cut into suitle length efore ssemly. Plese study your drwing to determine the em lengths tht re required. Sw requirements the miter sw with lde for luminium is required. The speed to cut luminium must e higher thn cutting the steel. The sw should hs the ility of cutting the lrgest profile in one single cutting ction. 7
Working site you should use specil re for cutting ems in order to keep the ssemly re clen. Qulity of cut if urrs found fter cutting, they must e removed prior to ssemly. Mke sure the cut is stright for proper ssemly. Sfety ll sfety precutions issued y the cutting followed t ll times. sw mnufcturer should e Assemly Component Groups The sic conveyor components consist of elow: 1. Conveyor ems, drive units nd idler ends nd ends 2. Conveyor guide 3. Structure system 4. Conveyor ccessories The first step in the ssemly process is to ssemlee the support structure which consists of foot, support ems nd em connectors. Most conveyor support designs re sed on verticl support em comined with horizontl support ems. Importnt! You must work ccording to your lyout nd mke sure tht the conveyor is supported t regulr intervls not exceeding 3m. 8
Foot Mounting Foots re ttched to the support ems nd come in different configurtion. 1.0 Mounting support foot Tool ox wrench. Insert hex hed screws nd wshers into holes on the side of the foot. Use the screw to fsten squre nuts.. Slide the squre nuts into the structurl em T-slots. c. Rise the em from the ottom of the foot pproximtely 30mm, to llow for height djustment lter in the ssemly. d. Tighten the screws using wrench. c d 9
2.0 Mounting foot cps Tools Allen key, wrench. Thred the holes using 6mmm tp.. Attched the support rcket to the em y inserting 4 socket hed cp screws into the holes on the support rcket. c. Tighten the screws using n Allen key. d. Screw the foot cp onto the support rcket. e. Tighten the nut using wrench. to c d e 10
Connecting Structurl Bems Structurl ems cn e connected to ech other in mny wys. Two different methods re shown elow. 1.0 Connecting em using ngle rckets Tool ox wrench. Insert the required numer of squre nuts into the structurl em T- slot. Mount the ngle rcket using screws nd wshers.. Mount the ngle rcket to the trnsverse em in the sme mnner. Tighten ll screws. 2.0 Connecting em using connecting pltes Tool ox wrench. Insert the required numer of squre nuts into the structurl em T- slot.. Mount the connecting pltes using screws nd wshers. 11
Conveyor Bems Conveyor ems re mounted onto the support structure y mens of support rckets. There re few different types of conveyor em support rckets. They ll serve the sme purpose ut re connected to the structurl ems in different wys. Note! Plese referr to MODU System Product Ctlogue 1.0 Mounting conveyor em support rckets Tool ox wrench, soft hmmer. Attched screws, squre nuts nd wshers to the support rcket efore mounting. Slide the squre nuts of one support rcket into the support em T-slots. Tighten the screws. Mke sure tht the support rcket is ligned with the em.. Insert the squre nuts of the second support rcket into the support em T-slots. Slide the rcket down so tht it does not protrude ove the support em. c. Use soft hmmer to mount n end cp onto the support em. d. Mount the first support rcket to the conveyor em. Pull the second rcket up nd mount the second support rcket to the conveyor em. Tighten the screws. 12
c d 2.0 Assemling conveyor ems Tool Allen key. Connect two conveyor em ends y inserting connecting strips into the em T-slots. Use two connecting strips per em joint.. Mke sure tht the set screws do not prevent the connection from sliding into plce. c. Tighten the set screws using Allen key. c 13
Drive Units nd Idler Ends This section shows method to mount drive units nd idler ends to the frme structure. All drive nd idler come with connecting strips. Attch them to the conveyor em using n Allen key nd the set screws tht re included. Rememer! Conveyor chin should lwys e pulled, not pushed, y the drive unit. 1.0 Mounting of Front Drive nd Suspended Drive Units Tool Allen key. Relese the set screws tht come together with drive unit connecting strips. Insert the connecting strips into the T-slots of the em you wnt to ttch to the drive unit. Mke sure tht the set screws do not prevent the connecting strips from sliding into plce.. Tighten the set screws using n Allen key. 14
Note! Aove mounting instructions re pplicle for ll type of drive units. Below re explntions of ppliction for other drive units. Comined Drive Unit Comined drive unit is comintion of front drive unit nd idler end in one unit. It cn e instlled nywhere long the conveyor length. Ctenry Drive Unit Ctenry drive units re used in endless chin conveyor system with no return chin. Ctenry drive units cn e instlled nywhere long the conveyor length. Intermedite Drive Unit Intermedite drive units cn e instlled nywhere long the conveyor length, ut preferred to e instlled s close to the end of the conveyor s possile. 15
2.0 Mounting of Idle End Tool Allen key. Insert the idler unit connecting strips into the T-slot of the em end.. Secure the idler end to the em using n Allen key to tighten the set screws. Slide Ril The slide ril is ttched to the sides of the conveyor em to reduce chin friction where the chin would otherwise e in direct contct with the em profile. It is very importnt tht the slide ril is instlled properly, so tht the chin cn run without disruption. When the conveyor is to e mounted high ove the floor level, it might e esier to mount the slide ril onto conveyor section while the conveyor em is still on the floor. If doing so, leve n extr end, pproximtely 300mm longer thn the em, so tht it cn e cut off nd djusted when the em is finlly instlled. 1.0 Instlling slide ril Tools slide ril ssemly tools, slide ril cutter. Strtt t idler end unit. Seprte the top nd ottom flnge of the slide ril t the end of the ril nd press it into plce. 16
. Mke sure thtt you mount the slide ril so tht it snps onto the em. The different types of slide ril so not lock like, so check which flnge should e on top. c. Use the slide ril ssemly tool to press the slide ril into plce. One end of the tool is to use when slide ril is mounted onto only one side of the em, nd the other end is used when you mount slide ril onto the second side. d. Do not forget to mount slide ril oth underneth nd on the upper side of the em (unless top running chin only). c d Importnt! Below shows cross section view every sizes of frme. of conveyor em fter slide rils re instlled for 17
2.0 Joining slide rils Tool slide ril cutter. Cut oth slide ril ends in 45 ngle. The eginning of the new slide ril section in the direction of trvel must e cut ck smll ngle.. Allow spce of pproximtely 10mmm etween two slide ril ends. c. Do not plce two slide ril joints opposite ech other. Mke sure theree is distnce of t lest 100mm etween them to mke sure the chin run smoothly (this does not pply to slide ril tht egins y n idler end or fter drive unit where joints re lwys prllel). c 18
Note! Try to let the slide ril run in s mny continuous lengths s possile, except in circumstnces stted elow: It is recommended to use short slide ril pproximtely 2m to 3m where chemicls my hve n effect on the slide ril composition. It is importnt to cut the slide ril nd llow for elongtion in high lod res. Cuttings re required in wheel ends, y idler units nd where the conveyor will e hevily loded, especilly y drive units. This prevents the slide ril from stretching out nd entering into the drive unit, which my lock the chin. Never join slide ril in plin ends or verticl ends, since forces re higher on the slide ril in these sections. Insted, plce the joint efore the ends. Avoid joining slide ril on top of conveyor em joints. 3.0 Instlling slide ril in wheel ends Tool slide ril cutter Before wheel end:. Cut the slide ril end in 45 ngle.. The slide ril must e longer thn the conveyor em itself nd theree should e 10mm distnce etween the slide ril nd the wheel of the end. Mke sure tht the end of the slide ril is not ent up or down. After wheel end: c. Cut the slide ril in 45 ngle with short ck cut. The slide ril must e longer thn the conveyor em itself nd there should e 2mmm distnce etween the slide ril nd the wheel of the end. d. In the outer end, mke sure tht the slide ril is properly connected to the conveyor em profile. 19
c d 4.0 Fixing slide ril y using rivets ( for MS2 nd MM3) Tools hnd drill, slide ril drill fixture, drill it (TR DB 3..2), rivet crimping. Drilll two holes ner the eginning of ech slide ril section. Use the drill fixture to ensure clen-cut holes nd correct loction of the holes. The holes must e t the eginning edge of the joint piece, in the direction of trvel, to hole the slide ril in plce when the conveyor in use. Use well-shrpened drill it.. Use countersink to deurr nd countersink the holes. Also mke sure no metl fillings left underneth the slide ril. c. Insert rivets in the holes, using rivet crimping tools to crimp the rivets. d. Check tht the rivets do not protrude over the surfce of slide ril. Check oth top nd underneth surfce of slide ril for protruding metl. e. Keep distnce of pproximtely 30mm etween rivets nd idler unit. This is in cse the idler end hs to e removed fter conveyor system ssemly. 20
c d e 5.0 Fixing slide ril y using screws ( for ML2 nd MX2) Tools hnd drill, slide ril drill fixture, drill it (TR DB 2..5), screw it. Drilll two holes ner the eginning of ech slide ril section. Use the drill fixture to ensure clen-cut holes nd correct loction of the holes. The holes must e t the eginning edge of the joint piece, in the direction of trvel, to hole the slide ril in plce when the conveyor in use. Use well-shrpened drill it.. Use countersink to deurr nd countersink the holes. Also mke sure no metl fillings left underneth the slide ril. 21
c. Insert screws in the holes, using screw it nd hnd drill to tighten the screws. d. Check tht the screws do not protrude over the surfce of slide ril. Check oth top nd underneth surfce of slide ril for protruding metl. e. Keep distnce of pproximtely 30mm etween screws nd idler unit. This is in cse the idler end hs to e removed fter conveyor system ssemly. c d e 22
Chin When ll ems hve een ssemled nd the slide ril is in plce, it is ssemle nd mount the chin onto the conveyor system. time to 1.0 Joining chin ends Tools pliers, chin pin insertion tool.. Insert the plstic pivot with the slot fcing outwrd. Insert the steel pin hlfwy. Alwys use new steel pin nd plstic pivot when joining chin ends. c. Line the chin insertion tool up with the pin. Slowly press the trigger until the pin sets. d. Check tht the chin is flexile in the joint nd tht the pin does not stick out or go through the other side. e. Tking the chin prt i. Line the chin insertion tool up with the pin. ii. Press the trigger until the pin pops out. iii. Pulll the pin out nd chin prt. c d 23
2.0 Mounting the chin Tool pin puncher, hmmer. Insert the chin into the underside of the drive unit. Mke sure the chin will e moving in the correct direction, s indictedd y the rrow t the side of chin links.. Feed the chin long the conveyor y pulling it through the idler end nd ck to the drive unit. Jon 5m lengths of chin when necessry. c. Join chin ends. d. Stretch the chin nd remove links if necessry so tht the chin will exhiit some slck t the drive unit. Connect the chin ends. c d 3.0 Length djustment of the conveyor chin. Adjustment of the conveyor chin is crried out t the drive end of the conveyor.. Remove the chin ctenry protection plte. 24
c. The conveyor chin should e tensioned within the conveyor system y pulling down the conveyor chin t the chin ctenry in the underside of the drive unit. Clmp cross the conveyor chin to trp the chin on the em profile. The clmp should e plced over the edges of the drive unit to reducee the risk of dmging to the luminium profile. d. Remove ll slck links from the conveyor chin using chin insertion tool. e. Rejoin the conveyor chin using new steel pin nd plstic pivot. f. Remove the chin clmp nd replce the ctenry protection plte. Conveyor Guides System Conveyor guides or guide rils system re used to guide products eing conveyed nd lso to prevent them from flling off the conveyor. Guide rils re supported y guide ril rckets ttched to the sides of the conveyor em. Follow the mounting instruction for the type of rcket used in your ppliction. Brckets should e plced pproximtely 500mm to 1000mm prt depending on type of product nd if ccumultion occurs or not. If rckets re spced t greter distnces thn 1000mm, there is possiility tht guide rils will ecome deformed due to excessive force. 1.0 Mounting of guide rils rcket (Polymide) Tools socket wrench, Allen key. Insert squre nut into T-slot of the em. Fsten guide ril rcket using hex hed screw nd wsher.. Attch guide ril tue nd guide ril support to the rcket. Tighten the nut or hnd kno. c. Attched the guide ril to the guide ril support. Tighten the screw. 25
d. Spcer cn e dded to increse side guide width. Use long olt when mounting the rcket support nd distnce spcer to the conveyor em. The length of the olt is depending on the numer of spcer dded. c 2.0 Mounting of guide ril rcket (Aluminiumm distnce tue) Tools wrench, Allen key. Insert squre nut into T-slot of the em. Insert set screw to the squre nut.. Tighten the distnce tue to the set screw. c. Attched the guide ril rcket to the distnce tue. Tighten the screw. d. Attched the guide ril to the guide ril support. Tighten the screw. e. The length of the distnce tue cn e dded to increse side guide width. 26
c d 3.0 Connecting guide rils Tool Allen key. Connecting sleeves re fstened to the guide ril ends with set screws nd n Allen key. Mke sure you plce the connecting sleeves on the outer side of the guide ril. 27
4.0 Instlling guide ril cover.. To prevent products from eing scrtched, plstic guide ril cover cn e snpped onto the inside of the guide ril. Mke sure tht ll cover joints re smooth, so tht products do not get cught or dmged. Do not join covers on top of guide ril joints. 5.0 Guide ril ending Tool guide ril ender. Mrk the length of the ril to e ent. Leve n pproximtely 200mm stright section t ech end.. Plce the ril horizontlly etween the top wheel nd the lower wheels. When ending guide ril, you should strt ending from the centre of the required rdius. c. Opertee the crnk to run the ril ck nd forth while lowering the upper wheel step y step until the desiredd rdius nd ngle is chieved. d. To clculte the length of guide ril to e ent, use elow formul, L = (2π x r x α)/360 Where, L = length of end, r = rdius, α = end ngle If multiple ends with the sme rdius re to e mde, note the finl position of the upper wheel is indicted to mke sure correct rdius of susequent rils. It is possile to end ngles up to 180, minimum rdius is 100mm. 28
c Finl Preprtion 1.0 Plug em ends. Mke sure tht end cps hve een fitted to lll luminiumm profile ends. The em profile should e deurred eforee fixing end cps. It my e necessry to tp the cp into position using soft-fce hmmer. 2.0 Anchor feet to the floor. After the ssemly of ll components it my e necessry to nchor the conveyor feet to the floor. Use floor nchor olt (MA BF M10) to nchor the feet.. Instility of the conveyor during opertion my result is dngerous operting environment or dmge the conveyor components. 29
3.0 Other preprtion. Adjust the height of the structurl em if necessry.. Mke sure thtt the instlltion is stle nd tht ll screws hve een properly tightened. c. Use wter-level to mke sure tht the construction is not skew. d. Mke sure tht the electricl equipment is properly connected. e. Mke sure thtt the conveyor is running in the correct direction efore strting the conveyor. Strt up nd Testing Sfety Precution To eliminte the risk of ccident, it is importnt to e wre of certin res of the conveyor where specil cution is required, during instlltion, opertion nd mintennce. Some res present higher dnger to personl sfety nd ecuse of this vrious kinds of sfety devices need to e instlled. 1. All pinch nd sher points s well s other exposed moving prts tht present hzrd to employee t their worksttions or their pssgewys must e sfegurded. 2. Cleted conveyor chins re more susceptilee of creting pinch nd sher points thn plin chin. 3. When two or more pieces of equipment re interfced, specil ttention must e given to the interfced re to ensure proper sfegurding g. 4. For overhed equipment, gurds must e provided if products my fll off the equipment for some reson. The sme pplies to ll ncline, decline nd verticl conveyors. 30
To Achieve Sfegurding 1. Wrnings instructions, wrning lels or sound or light signls, lerting on hzrdous conditions. Wrnings shll e used when other mens of sfegurding will impir the functionn of the instlltion. 2. Gurds mechnicl gurds or rriers preventing entry in the hzrdous re or protecting ginst flling goods. 3. Control devices mchine controls preventing or interrupting hzrdous conditions. 4. Loction locte the hzrdous re out of rech of the personnel involved. Strt-up 1. Luriction. The conveyor chin is luriction free. However, for some specific ppliction where the operting environment is prticulrly hostile, regulr luriction of the slide ril/conveyor chin will result in lower coefficient of friction, longer life nd reduce running cost. Use silicon-sed luricnt. 2. Wer. The numer of wer on conveyor depends on some fctors, such s running time, lod/contct pressure, speed, product ccumultion, shrp/rough product, chemicls, contmintion, temperture nd plin end.. Try to minimize the running time for the conveyor y stopping it when there is no trnsport. c. Multiple horizontl nd verticl plin ends in conveyor will often result in incresing wer. Also, the contct surfce etween chin nd slide ril is smll nd the chin pull is cting towrds the slide ril in the ends. 31
3. Run in period. Two or three dys re usully enough s run in period. During this time, the conveyor should e clened couple of times to remove dust.. Remove the chin nd clen it with wrm wter (round 50 C), use sop if necessry. After clening, re-instll the chin. c. After run in, wer will minimum, unless prticles from product or process rech the conveyor continuously. 4. Chin elongtion. During the run in period, regulr checks should e mde to the elongtion of the conveyor chin. This is especilly importnt if the conveyor is trnsporting high lods or is of long overll length.. Regulr inspections of the chin elongtion re importnt. The chin should e shortened fter run in time of 40 hours. Trouleshooting Guidelines Symptomm Jerky running Noise Cuse Dmged or dly fitted slide ril Worn trnsmissionn prts Wrongly djusted slip clutch Conveyor chin is too tight/loose Dirty conveyor Worn or dmged erings in drive unit Dmged/dly fitted slide ril Inspect nd replce s necessry Check/replce trnsmissionn chin, chin drive sprocket Check nd djust slip clutch Tension conveyor chin correctly Correction Clen conveyor chin nd slide ril. Luricte with silicone sed luricnt Check/replce drive unit Check the free running of the chin, especilly in slide ril joints 32
Motor overheting on drive unit Anorml wer on plstic prts Drive unit is running, conveyor chin is not Excessive conveyor speed Incorrect conveyor chin tension Overloded conveyor Gerox leking oil Dirty conveyor Overloded conveyor Amient temperture too highh Chemicls in the environment re ffecting plstic prts Dmge due to ingress of contminte Prticles, swrf etc Wrongly djusted slip clutch Friction disc in slip clutch re worn or contminted Trnsmission products re not fitted Lower speed. Check ctul lod ginst recommended loding Tension conveyor chin correctly Remove products from conveyor nd test run Check ctul conveyor lod ginst recommended loding Check output shft sel nd re round motor/gerox interfce Clen the chin nd slide ril Remove products from conveyor nd test run Check the free running of the conveyor chin Check ctul conveyor lod ginst recommended loding Check ginst recommended temperture for conveyor Check in ctlogue (section TR) for listing of incomptile chemicls Clen the system Remove source of contmintion Check djustment of slip clutch. Check nd replce if necessry Check nd fit 33