Installation, Operation and Maintenance Manual Rev 7 December 2010 1 P a g e
Contents General... 4 Safety... 5 Function of the Conveyor:... 5 Operation, Maintenance, and Service... 5 Safety equipment... 5 Operating conditions... 6 Description... 7 TS4200/150 Junctions... 7 Merging Conveyors... 7 Diverting Conveyors... 7 36 Centerline Junction... 7 Installation... 9 Uncrating... 9 Positioning... 9 Supports... 10 Operations... 11 Standard Operations... 11 High Temperature Operations... 11 Low Temperature Operations... 11 Maintenance... 12 Standard Preventive Maintenance... 12 2 P a g e
Tracking the Belt... 13 Gearmotor Maintenance... 15 Bearing Lubrication... 15 Conveyor Repair... 16 Conveyor Belt Replacement... 16 Endless Belt Removal... 16 Clipper Laced Belt... 17 Inline Pulley Bearing Replacement... 18 Inline Pulley Replacement... 19 Offset Pulley Bearing Replacement... 19 Offset Pulley Replacement... 19 Snub Roller Replacement... 20 Tracking Station Replacement... 20 Gearmotor Replacement... 21 Right-Angle Gearmotor: Direct Shaft Mount... 22 Under-hung, In-line Gearmotor: Cog-belt Final Drive... 22 Illustrated Parts List... 24 Bill of Materials... 26 Revision Control... 28 Standards... 28 3 P a g e
General All descriptions in this manual are aimed at qualified engineers and maintenance technicians. They only refer to the Transnorm System Inc belt conveyors with the model numbers TS 4200-150. You can find the serial number of the conveyors on the type plate attached to side-guarding near the drive housing. The same serial number is to be found on the spare parts list which also includes details for ordering spare parts. The exact technical data of the belt conveyor supplied are provided for in the attached "technical specifications which contain: technical data electrical motor/gearmotor data details on special accessories and designs where supplied. The complete conveyor system is described in the system documentation supplied by the conveyor-system-level integrator. This document should include the following information: specifications engineering documents instructions on servicing and operating the complete system documents on control and energy circuits of the system where required, description of transfer sections In the following text, important Instructions are shown as follows:! "Note:" Technical details which have to be observed by the user.! "Caution:" Working procedures which have to be followed exactly in order to avoid damage to the conveyor system.! "Warning:" Working procedures which have to be followed exactly in order to avoid hazards to the user or any other persons. 4 P a g e
Safety Function of the Conveyor: Transnorm belt conveyor system TS 4200-150 may only be used to convey unit loads within a conveyor system and is not designed for bulk flow applications. No persons may be transported on the conveyor. Operation, Maintenance, and Service All work on the conveyor must be performed in accordance with the instructions, the technical specifications of the conveyor, the system documentation, and the following additional regulations in their latest edition: national regulations on the installation and operation of electrical installations accident prevention regulations other statutory government regulations and safety rules of professional associations In order to prevent any danger to users or other persons or damage to the conveyor, all assembly, servicing, maintenance, and operational work on the conveyor has to be carried out by properly Work on electrical equipment may only be carried out by qualified electricians. Warning: Before starting any assembly, maintenance, and service work, make sure the main switch of the system is turned off and secured against being turned on again per your local lockout/tag-out procedures. Safety equipment For mechanical protection, various cover plates and finger guards are fitted to the belt conveyor. These protective parts may only be removed for assembly, maintenance, and service purposes. Warning: When carrying out adjustment work without safety equipment or guarding in-place, be aware that there is a danger of an accident. Secure the danger area against access by unauthorized personnel. trained personnel. 5 P a g e!!
Further safety equipment for the complete conveyor system and the transfer sections are typically described in the conveyor system documentation (spring rollers, covers, position of emergency stop switches etc.). Operating conditions The belt conveyor in its standard design should only be operated when fixed to a solid foundation. Special equipment accessories allowing mobile operation are described in the technical specifications. The belt conveyor is not explosion-protected and may only be operated under the following ambient conditions: Air temperature 0 C up to 50 C (32 F up to 120 F Relative humidity 90% Normal atmosphere o no oil or gas atmospheres o no corrosive atmosphere o no caustic atmosphere Securely protected against precipitation and against direct sunlight onto the belt surface Deviations from the conditions are described in the technical specifications. 6 P a g e
Description TS4200/150 Junctions The TS4200-150 junction can be configured to operate as either a Merging or Diverting Conveyor and is available in 45 and 30 configurations. The centerline length is available from 42 up to 120. All conveyors of this type consist of a conveyor frame supporting and containing a composite slider bed, drive and tail pulley, snub roller, tracking station and a belt. The belt is driven by a 150mm diameter drive pulley. A snub roller supplies belt tracking tension. Belt tracking is via the snub roller. All tracking is done at the Offset Belt Return Station The drive and tail pulleys of the junction are supplied with non-replaceable shafts standard. Standard shaft diameter is 1-7/16in. Replaceable shaft pulleys are available as an option. The tail pulley shafts come standard with drilled and tapped ends 3/8-16x1. The tail pulley is relocated from the inline station to the offset station when the junction is configured as a diverting conveyor. An exception is for very short centerlines (CL < BF). The junction is then a reverse running merge conveyor. Conveyors can be supplied with sideguards. The minimum height for the guards is 0in (no guards) and maximum is 36in. The guards are set at the customer requested width for the conveyor. Funneling or positioning guards can be designed at customer request. Merging Conveyors The TS4200-150 Merging conveyor is driven from the offset belt return station and moves product from the straight end to the angled end. Diverting Conveyors The TS4200-150 Diverting conveyor is driven from the inline belt return station and moves product from the angled end to the straight end. 36 Centerline Junction The TS4200-150 Junction is also available in a 36 centerline conveyor. Both merging and diverting junctions are configured as a merge but the belt is pushed when used as a diverting conveyor. The tracking station must be configured for correct flow. 7 P a g e
Merging Conveyor Diverting Conveyor 8 P a g e
Installation Uncrating All Transnorm modules are shipped in palletized open-sided crates to protect the conveyors during shipment unless special crating requirements are requested by the customer. It is good practice to photograph the conveyor and crate immediately upon receipt to document any shipping damages and to account for all product sections. The best practice is to leave the conveyor module in the crate until it is required and relocate the crate as close as practical to the installation position. Uncrate the conveyor or conveyor components by removing the top and sides of the crate using standard pry-bars and hammers. Use good hygiene with the discard wood as nails may be protruding. Protect the belt material or surface from damage during the uncrating process. The conveyor frame is secured to the shipping pallet by means of shipping brackets. First remove the brackets from the shipping pallet and then remove the brackets from the conveyor frame! Note: All Units are shipped with the belt tensioned for proper operations. No adjustments are required. Positioning Using the integrator layouts (shop drawings), identify and mark critical positions and elevations for the conveyor, conveyor sections and any conveyor interfaces. Install junctions so that they are level (typical) to the elevations on the system level drawings. When floor supports are required, the standard Transnorm supports are designed to readily mount to the conveyor frame. 9 P a g e
Supports Typical supports for the TS4200/150 conveyor are tubular steel with an adjustable uni-strut foot (referred to as TS Inc. Supports). Supports consist of three single legs and one H-Frame Weldment. The H-Frame is available as a Channel Support if requested. Ceiling Supports are also available if requested. Typical TS Inc. Supports 10 P a g e
Operations Standard Operations The TS4200-150 is supplied in a wide variety of length and width combinations, and operates a belt speeds between 10fpm and 400fpm. For very heavy starting loads (greater than 20lbs per inch of drive pulley width) and/or speeds in excess of 300fpm and for all operations requiring a 5hp or larger motor, a motor soft-starter or VFD is mandatory to keep the warranty in-force. A soft start will also prevent damage to the drive assembly, drive pulley, and belt system. All Transnorm supplied bearings are considered lubed-for-life and no maintenance or other consideration is required. All units are shipped with the belts tensioned for proper operations. High Temperature Operations For intermittent peak very high temperature (>140deg F) or sustained high temperature (>120deg F) operations, the drive reducer oil life will be shortened. Gear reducer oil should be changed more often and substituted with hightemperature specific synthetic lubricant. Low Temperature Operations For intermittent very low temperatures (< 20F) or sustained low temperature (>32def F) operations, the gear reducer oil should be changed to lowtemperature specific synthetic lubricant. The main bearing grease may require replacement as well. 11 P a g e
Maintenance Standard Preventive Maintenance The Transnorm TS4200-150 Belt conveyor is designed to require only periodic inspections and cleanings under normal operating conditions. Time Period Action Comment Monthly Observe the TS4200-150. Remove trash and other debris, particularly around the sideguards and pulley end-guards Regular observations and cleaning of any conveyor equipment typically greatly reduces unscheduled maintenance costs and down time. Regular cleaning of material handling debris greatly reduces chances of belt jams, belt tears, and all other premature wear. Quarterly Annually Inspect rolling and rotating components for rough bearings. Inspect conveyor for loose hardware. Verify that junction controls are available to identify jam conditions. Inspect belt and belt-beading interface for signs of wear or foreign object damage. Rough bearings can be identified by higher than normal noise generation, leaking or weeping grease, or bearing discoloration (bluing). Block Photoeyes to check for proper jam logic. Quick discovery prevents conveyor and product damage. Pay particular attention to the ends of the bead and to the stitching. Belts with worn stitching should be repaired at Transnorm and are usually an indicator that the belt tracking was missaligned. 12 P a g e
Tracking the Belt! Warning: Observe local safety regulations. As the belt should be tracked with the guards removed, limit the access to the conveyor to as few maintenance personnel as possible and only to skilled technicians who are trained in all local safety and emergency procedures. To track the belt: Track and tension the belt as loose as possible to carry the load without slipping Remove the outer offset station cover from the conveyor. Square the drive pulley to the conveyor frame, 10mm to 20mm from the end of the frame. Move the snub roller all the way to the end of the side plate slot. Start the unit and make the necessary adjustments to the snub roller to center the belt between on the slider table. 13 P a g e
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! Note: Belt tension on the junction can be very low as the large pulley face and drive snub allows for significant drive torque to be transmitted to the belt and belt tension is not required for belt tracking. After tracking is accomplished, run the conveyor for 20-30 minutes to fine tune the tracking. Replace the side guides/guards and the outer perforated guards and return the conveyor to service. Gearmotor Maintenance Typically, gearmotors or electric motors and gear-reducers only require proper lubrication and cleanliness for proper performance and long service life. The lubrication oil change interval is described by the gearmotor or reducer manufacture. Transnorm System recommends that when possible by reducer specification, synthetic lubricants be used to extend service life between changes and provide an increased operational temperature range. Electric motors typically do not have any provisions for lubrication. Bearing Lubrication All bearings used in the TS4200-150 should be considered Lubed-for-Life. The main pulley bearings are not normally equipped with a grease-zerk and no grease is required for normal service operations. 15 P a g e
Conveyor Repair! Warning For all repair/replacement activities, follow local and national safety procedures. Consult the CEMA Unit Handling safety video for general practices and procedures. Always isolate power to the motor prior to performing any repair activities. Conveyor Belt Replacement! Warning Junction pulleys and snub rollers are very heavy. Use appropriate lifting methods when handling these parts. Endless Belt Removal Remove both sideguards and deckboards. Loosen the drive and tail pulley bearings and remove the drive and tail pulleys. Remove the nosebar support bracket. 16 P a g e
Remove the upper section of the Tracking Station and the Cross Support. Remove the belt by pulling it through the gap between the Nosebars and the Offset Belt Return Side Plate. If space does not permit this, remove the upper Nosebar. Install the new belt by reversing the steps above. Track the belt per instructions in the Maintenance section of this manual. Clipper Laced Belt Move the snub roller all the way to the end of the side plate slot and loosen the offset belt return pulley. Open the clipper lace splice by removing the plastic-coated lacing pin. If the pin will not come-out of the clipper lace, cut the belt off of the TS4200-150 wherever it is convenient. Pull the belt out of the junction. 17 P a g e
Install the new belt by feeding the belt around the junction. o Carefully feed the belt and beading under the inline belt return pulley (and over the snub roller if the junction is a diverting conveyor). o Pass the belt through the space between the upper and lower rollers of the tracking station and then in between the upper and lower nosebars. o Wrap the belt around the lower nosebar and then feed it over the snub roller and under the offset station pulley. o Wrap the belt around the pulley and then under the upper nosebar. o Wrap the belt around the upper nosebar and then pull it back towards the inline belt return assembly stopping about halfway down the length of the junction. o Wrap the other end of the belt around the inline belt return pulley and pull it as close as possible to the other end of the belt. Pin the belt using the supplied pin. Tuck the pin back into the lacing at least 15mm (5/8 ) on both ends. Prior to tensioning the belt, recheck that the belt is following its proper belt path and not hung up on any conveyor, building, or installation components or other foreign objects. Track the belt per instructions in the Maintenance section of this manual. Inline Pulley Bearing Replacement Loosen the bearing clamp bolts. Loosen the bearing to pulley shaft mount system. Debur any set screw deformations on the shaft with a flat mill file. Loosen the bearing jack-bolt jam-nuts. Remove the bearing clamp bolt hardware. Remove the bearing. Install the new bearing in reverse order follow any supplied instructions for mounting the bearing to the pulley shaft. Return the bearing to the factory marks and run and track the conveyor belt. 18 P a g e
Inline Pulley Replacement! Warning Junction pulleys are very heavy. Use appropriate lifting methods when handling this pulley. Remove the bearing cap or bearing covers as appropriate. Loosen or open (un-pin) the conveyor belt. As appropriate, remove the gearmotor, other drive components or other accessory components from the pulley shaft. Remove the pulley bearings. Remove the pulley. Install the new pulley in reverse order center the pulley faces between the bearing housing plates. Offset Pulley Bearing Replacement Remove the offset belt return station cover. Loosen the bearing clamp bolts. Loosen the bearing to pulley shaft mount system. Loosen the bearing jack-bolt jam-nuts. Remove the bearing clamp bolt hardware. Remove the bearing. Install the new bearing in reverse order follow any supplied instructions for mounting the bearing to the pulley shaft. Return the bearing to the factory marks and run and track the conveyor belt. Offset Pulley Replacement! 19 P a g e
Warning Junction pulleys are very heavy. Use appropriate lifting methods when handling this pulley Remove the offset belt return station cover. Loosen or open (un-pin) the conveyor belt. As appropriate, remove the gearmotor, other drive components or other accessory components Remove the pulley assembly. Install in reverse order tighten the 6 bolts to 180in-lbs. Snub Roller Replacement! Warning Junction Snub Rollers are very heavy. Use appropriate lifting methods when handling this roller. Remove the inline or offset pulley as appropriate per instructions as described above. Remove the snub roller. Install in reverse order. Tracking Station Replacement Remove the rear deckboard. Remove the 2 bolts securing the upper tracking station section to the lower section. Remove the upper tracking station section. Install in reverse order tighten the 2 bracket bolts to 15ft-lbs. 20 P a g e
Gearmotor Replacement! Warning Observe local and national safety regulations. Isolate the motor electrical power prior to any service work. Gearmotors can be heavy and awkward to lift. Use proper lifting and securing methods during maintenance activities. The following text describes the two most common gearmotors supplied by Transnorm System. Most other motors and reducers combinations use similar mounting systems. The details of the coupling to the pulley drive shaft vary by manufacture, reducer model, and specified mounting systems. 21 P a g e
Right-Angle Gearmotor: Direct Shaft Mount Belt Conveyor TS4200-150 Remove the outer reducer guard to gain access to the drive-shaft mount system. As required, remove the inner reducer guard to gain access to the drive-shaft mount system. Loosen or remove the reducer mount system. Remove the bolt securing the rod-end to the reducer mounting angle. Remove the reducer by sliding it off the shaft. Install in reverse order follow gearmotor instructions to mount the reducer to the drive shaft. Under-hung, In-line Gearmotor: Cog-belt Final Drive Remove at least one of the cotter-pins securing the belt guard. Open or remove the belt guard upper-half. Loosen the upper jam nut on the motor plate rod-end and move it up the rod-end about 1-1/2. Remove the cog drive belt by: o Squeezing the belt together, lifting the reducer. o Chase the reducer/motor-plate up the motor-plate rod-end with the lower jam-nut. If appropriate, remove the cog-belt pulley from the gearmotor output shaft by removing the two (2) grub-screws (aka set screws) from the taper-lock bushing and using one of the grub-screws to disengage the taper-lock bushing. Remove the lower or inner half of the belt guard. Remove the gearmotor by loosening and then removing the hardware attaching the gearmotor to the motor-plate. Install in reverse order consult the Transnorm Systems Customer Service groups the for proper cog-belt tension. 22 P a g e
Underhung Drive Motor Arrangement Taper Lock Bushing Side Mount Motor Arrangement 23 P a g e
Illustrated Parts List Exploded View Divert 24 P a g e
Exploded View Merge 25 P a g e
Bill of Materials Item No Typ. Qty. Description Transnorm Part Number 1 1 Drive Pulley Varies By Type 2 2 Drive Pulley Bearing Varies By Manufacturer 3 1 Tail Pulley Varies By Type 4 2 Tail Pulley Bearing Varies By Manufacturer 5 2 - Divert Snub Roller 021816 1 - Merge 6 1 Nosebar Support Bracket 033036 7 2 Tracking Station Support Rollers - 8 1 Tracking Station Assembly 020167 (See Exploded View) 9 1 Rectangular Deckboard 032991 10 1 Triangular Deckboard 45 LHM/RHD 45 RHM/LHD 032990 033013 11 1 Belt Varies by size 12 1 Offset Belt Return Cover 032970 13 1 Inline Belt Return Cover, Left (Divert Only) 033011 14 1 Inline Belt Return Cover, Right (Divert Only) 033012 15 2 Bearing Cap (Merge Only) Varies By Manufacturer 26 P a g e
Item No Typ. Qty. Description Transnorm Part Number 1 1 Diameter 1.9 Roller 020926 2 1 Spring Guide 031090 3 1 Spring - 4 1 M8 Countersink Washer 030409 5 1 M8 x 1.25 x 20mm Flat Socket Head Cap Screw - 27 P a g e
Revision Control Rev Date By Description of Changes - 7 Dec 2010 John Lynn Initial Release Standards This product conforms to the following standards: Organization Standard-Date Characteristics of Conformance ANSI B-15.1 Guarding of mechanical power transmission equipment by use of covers, guards, and when specified - location ASTM D378 Belt fire rating. See ISO 340 ASTM E84 Deck-board fire retardant characteristics: Pending ASME B-20.1 Conveyor safety standards as applicable to unit-handling conveyors but not to include electrical, controls, installation, or integration by others. CEMA 402 Conveyor design and drive horsepower calculations. ISO 340 Belt fire rating: Pending OSHA 29CFR 1910.95 All operating speeds result in less than or equal to 90dBa when measured 5ft away and 5ft above the conveyor. OSHA 29CFR 1910.219 See ANSI B15.1 28 P a g e