125Z Manual

Transcription

125Z Manual

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Table of Contents
Section I – General
Warnings – General Safety
Foreword
Product Description
125 Z Series Conveyor Configurations
Tools Required
1.01
1.02
1.03
1.04
1.05
Section II – Setup and Installation
When your shipment arrives
Installation
Conveyor Setup
Aluminum Exact Width Stands
Angle Braces
Aluminum Cross Ties
Casters
Side Drive Mounting Packages
Top and Bottom Drive Mounting Packages
Install the Speed Reducer’s Vent Plug
Installing a Heavy Duty Motor
Heavy Duty Remote Drives
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
2.11
2.12
Section III – Maintenance
Maintenance Forward
Belt Tracking
Adding Tension
Adjustable Guide Rail Removal
Belt Change
Belt Care
Bearing Replacement
Speed Reducer Oil
Conveyor Exploded View and Parts List
Recommended Spare Parts
Troubleshooting
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
Section IV – Warranty and Return Policy
Conveyor Serial Number
Conveyor Warranty, Lost or Damaged Goods
Returns, Order Cancellation/Revision Policy
4.01
4.02
4.03
Installation,
Maintenance,
and Parts Manual
125Z Series Conveyors
QC Industries LLC
4057 Clough Woods Dr.
Batavia, OH 45103
(513) 753-6000
Fax: (513) 753-6001
www.qcindustries.com
1.01 Warnings – General Safety
Observe safe practices when setting up and operating your QC Industries conveyor.
Climbing, sitting, walking, or riding on conveyor can cause severe injury. Keep off conveyors.
Do not operate conveyors in an explosive environment.
Exposed moving parts can cause severe injury. Lock out power before removing guards or performing
maintenance.
Gear motors may be hot. Do not touch gear motors.
QC Industries cannot control the installation and/or application of conveyors. Taking protective
measures is the responsibility of the user. When conveyors are used in conjunction with other
equipment, or as part of a multiple conveyor system, check for potential pinch points and/or other
mechanical hazards before system start-up.
During normal operation, please make sure that all guards are in place and securely attached to
conveyor.
Loosening stand height or angle adjustment screws can cause conveyor sections to drop down
unexpectedly, causing severe injury. Support conveyor sections prior to loosening stand height or
angle adjustment screws.
Injury is possible if the stands are not lagged to the floor, cross ties are not used, or angle braces are
not present. Never place a conveyor in operation until all proper mounts are installed and secured. It is
the end user’s responsibility to ensure that the support system is safe and secure.
Never operate equipment unless all operating instructions are understood and all guards, interlocks,
covers, safety devices or circuits and protective components are functioning properly.
Never operate or service this equipment if under the influence of alcohol, drugs or other substances or
conditions which decrease alertness or judgment.
QC Industries 125Z Series Installation, Maintenance, and Parts Manual
1.02 Foreword
Congratulations on purchasing a conveyor from QC Industries, LLC, the leader in low profile conveyors!
QC Industries offers the finest low profile conveyors available, using the highest quality materials and
state of the art manufacturing processes. QC Industries conveyors boast a number of innovative
engineering features to assure you hassle-free setup, smooth operation, and years of continued low
maintenance use. We are proud of our quality products and are committed to providing you
dependable service!
Check your shipment
Before opening the shipment, visually inspect the outside of the crate/box for shipping damage.
Carefully unpack the crate/box, inspecting for component damage which may have occurred inside
the packing materials. Contact the carrier and QC Industries regarding any damage that may have
occurred during shipment. Check the contents of your shipment against the supplied packing slip and
inform QC Industries of any discrepancies.
Please read this manual
Inside this manual you will find instructions on how to set up and maintain your QC Industries conveyor
properly, as well as maximize its performance. Please take the time to read this manual and
familiarize yourself with these setup and maintenance instructions. These instructions will help assure
a long product life that requires a minimum amount of service, and keeps your conveyor working at its
maximum capacity.
If you need assistance
If you need assistance with your QC Industries conveyor, a highly trained support staff is only a phone
call away. QC Industries welcomes the opportunity to assist you. You can contact the Customer Service
department Monday through Friday, 8am-5pm EST at (513) 753-6000. In addition, your local
distributor can provide support in many ways. Our distributors have been trained at the factory and
can be dispatched to your facility to help. You can also visit our website for additional information and
technical documents: www.qcindustries.com
1.03 Product Description
The 125Z Series Conveyor has many typical conveyor components. Below is a general description of
the basic parts and options for the 125Z Series Conveyor (Figure 1).
3
10
7
9
1
11
4
2
5
12
8
13
Figure 1
Typical Components
1.
2.
3.
4.
5.
6.
Conveyor
Gear Mounting Package
Side & Guide Accessories
Standard Mounts
Support Stands
Variable Speed Controller
7.
8.
9.
10.
11.
12.
13.
Motor Starter
Emergency Stop
Remote Emergency Stop
Idler End
Drive Pulley End
Cross Tie / Angle Brace
Caster / Leveling Foot
6
1.04 125Z Series Conveyor Configurations
The 125Z Series conveyor comes in three standard configurations: the R conveyor, the Z conveyor,
and the L conveyor.
R Conveyor
Z Conveyor
L Conveyor
1.05 Tools Required
Set of Allen Wrenches
3/32”, 7/64”, 1/8”, 3/16”, 5/32”, 1/4”
Large Adjustable Wrench
A Bubble Level for frame alignment
Screw Gun with T25 Torx bit
Wide Flat Head Screw Driver
OR Tail Turning Tool** in Socket Wrench
QC Industries
Part Number
TK-TAILTURN
Aluminum and Steel Cutting Hack Saw or
equivalent
Wrenches: 1/4”, 5/16”, 1/2”, 9/16”
Tape Measure
** The Tail Turning Tool is QC Industries part number TK-TAILTURN.
Please contact QC Industries Customer Service at (513) 753-6000 to purchase.
2.01 When Your Shipment Arrives
n Check your shipment for damage
a. If you have not already done so, visually inspect the outside of the crate or boxes for shipping
damage.
b. Carefully unpack the crate or box, inspecting the components for damage which may have occurred
inside the packing materials.
c. Contact the carrier and QC Industries regarding any damage that may have occurred during
shipment.
d. Check the contents of the shipment against the included packing slip and notify QC Industries of
any discrepancies.
o Locate the items from your order
a. In most cases, each individual conveyor and its accessories will ship in its own custom built box.
Note: On larger orders, it may be necessary to combine conveyors and accessories in one or more
custom built boxes.
b. Drive Mounting Packages are assembled at the factory with right angle gearboxes attached, and will
be anchored to the bottom of the conveyor box. The motor will be in a separate box, anchored to the
bottom of the conveyor box.
c. Aluminum Exact Width Stands, casters, cross ties, and mounts – including all associated
hardware – will be anchored inside the conveyor box.
d. Sides and Guiderails are assembled and mounted to the conveyor at the factory.
e. Proceed to Section 2.02 for the Sequence of Installation of Conveyors.
2.02 Installation
To set up the conveyor after receiving your shipment, QC Industries recommends following these
steps. Please refer to their respective sections for more detailed instructions.
n Move the Conveyor and Accessories into
location
Using appropriate equipment and safe moving methods,
move the conveyor and accessories to the desired
assembly, staging, or installation area (Figure 1). Set the
conveyor in the correct operating orientation with regard
to the drive position and belt direction.
See Section 2.03 for detailed instructions
Figure 1
o Mount the Conveyor to its Stands and Cross Ties
or Mounts
Use QC Industries stands and mounts (or any compatible stands
and hardware) to mount the conveyor in the desired location
(Figure 2). Make sure the conveyor mounted on stands is on a
flat, level surface. QC Industries recommends that stands with
leveling feet be anchored to the floor.
See Sections 2.04 - 2.07 for detailed instructions
Figure 2
p Install the Drive and Mounting Package
Wire the motor using the appropriate diagrams of the motor
style, voltage and phase you have purchased (Figure 3). QC
Industries recommends that all wiring be completed by a
certified electrician.
See Sections 2.08 – 2.12 for detailed instructions
Figure 3
2.03 Conveyor Setup
n Orient the Conveyor based on the Drive Location
a. Set the conveyor in its operating position, taking care to note its drive location. 125Z Series
conveyors can be assembled with the drive pushing or pulling, as determined by the four drive
positions available: A,B,C, and D (Figure 1).
A Left Hand, Drive Pulling
B Right Hand, Drive Pulling
C Right Hand, Drive Pushing
D Left Hand, Drive Pushing
Figure 1
For a Z configuration, the 18th digit in the conveyor’s part number will indicate the orientation and
direction, as shown in the following example of a 12” wide Z conveyor x 30” long “A” section, 30” long
“B” section, 30” long “C” section, at a 45 deg angle, drive position A:
1ESBZ12-030C030030-ASQ-ZAG013
For an L or R configuration, the 15th digit in the conveyor’s part number will indicate the orientation
and direction, as shown in the following example of a 12” wide L conveyor x 30” long “A” section, and
30” long “B” section, at a 45 deg angle, drive position B:
1ESBL12-030C030-BSQ-ZAG013
Button Or
Head Optional
Button Head
Socket Screw
Socket Screw
Grease Fitting
b. Position the conveyor for operation,
taking care to note that when other
equipment is nearby, access is needed
for the tail idler’s Button Head Socket
Screw (Figure 2). This is important when
tensioning the belt from the tail idler
end.
Figure 2
2.03 Conveyor Setup (continued)
o Install Stands, Drives and Mounting Packages
a. Proceed to Sections 2.04 - 2.07 for instructions on installing Stands, Angle Braces, Cross Ties, and
Casters.
b. Proceed to Sections 2.08 - 2.12 for instructions on installing Drives and Mounting Packages.
2.04 Aluminum Exact Width Stands
Aluminum Exact Width Stands can be located anywhere along the length of the frame, as they mount
directly to the conveyor’s accessory holes in the frame. Ideally, the stands should be placed as far
apart as possible for maximum stability.
When selecting the locations for the stands, consider the Drive and Mounting Package you have
purchased. Some configurations will require the stand to be located a few positions down the
conveyor from the Drive.
The stand at the Tail End of the conveyor normally has no obstructions and can be placed as close to
the end as needed.
Operating
Position
n Prepare the Stand for Installation
Shipping
Position
a. For shipment, the stands will have their mounting bracket slid
down the extrusion. Use a 1/2” Wrench to loosen the Hex Head
Screws holding the Brackets and move them up to engage the
conveyor frame, approximately 1 1/2” (or more for cleated belts)
(Figure 1).
b. If the stands are to be used
with Aluminum Cross Ties, it is
advised to attach the Gusset
Plates prior to mounting the
conveyor (Figure 2). Refer to
Section 2.06 on Aluminum
Cross
Ties
for
specific
instructions.
Figure 1
Cross Tie
Gusset Plate
Figure 2
o Install the Stand
a. Locate the bag of 10-32 x 7/8” long Torx Head Thread Forming
Screws from one of the boxes with the shipment. There are four per
stand.
b. Line up the stand with the accessory holes in the side of the
conveyor frame and use a Screw Gun with a Torx bit to fasten the
stand to the frame (Figure 3).
Figure 3
2.04 Aluminum Exact Width Stands (continued)
p Adjust the Height using the Leveling Feet
Hex Nut
The Leveling Feet on all QC Industries Stands are designed to allow
fine adjustment and so they can be lagged to the floor. Note: if it is
not feasible to permanently attach the stands to the floor or the
conveyor is to be made mobile with casters, then Cross Ties or
Angle Braces must be used.
To adjust the stand height with the Leveling Feet:
a. Use a large adjustable wrench to loosen the Hex Nut
Lag to
floor here
Welded Hex
Figure 4
b. Rotate the hex welded to the foot to the desired height (Figure 4).
c. Retighten the Hex Nut to secure it in position.
Injury is possible if the stands are not lagged to the floor, cross
ties are not used, or angle braces are not present. Never place
a conveyor in operation until all proper mounts are installed
and secured.
d. Frame alignment is one of the key items that assure the belt properly tracks during startup. Make
sure the conveyor frame has no twist by using a bubble level and checking measurements from the
mounting surface.
e. Proceed to Section 2.05 for instructions on installing Angle Braces.
f. Proceed to Section 2.06 for instructions on installing Aluminum Cross Ties.
2.05 Angle Braces
When it is not feasible to bolt the Aluminum Exact Width Stands to
the floor, they can be stabilized by use of Angle Braces. Angle
Braces will only work with stands that are 18” or taller (e.g., part
number 0182-18-21-WW).
Angle Braces are shipped as a set, with one Right Hand Brace and
one Left Hand Brace, with four Torx Head Screws, and four screw
sets (Hex Head Screw, Flat Washer, and Square Nut).
Square Nut
Before installing Angle Braces, the Aluminum Exact Width Stands
should already be assembled to the conveyor.
n Install the Angle Braces to Exact Width Stands
a. Start by inserting the square nuts in the stand leg’s channel at
the base where the channel has been routered (Figure 1).
Figure 1
b. Place the Angle Brace over the Square Nuts, and insert the Hex
Screws and Washers into Square Nuts (but do not fully tighten them). There are four holes provided,
but only two of them will be used.
c. Using a Screw Gun with a Torx bit, drive in the
Torx Head Screws into the top section of the
Brace (Figure 2). The holes will line up with
accessory holes in the conveyor’s frame.
Torx Head Screw
d. Tighten the Hex Head Screws so the Brace is
secured to the stand, and repeat the installation
for the Brace on the other side.
e. Frame alignment is one of the key items that
assure the belt properly tracks during startup.
Make sure the conveyor frame has no twist by
using a bubble level and checking
measurements from the mounting surface.
f. Proceed to Sections 2.08 – 2.12 for
instructions on installing Drives and Mounting
Packages.
Figure 2
2.06 Aluminum Cross Ties
When it is not feasible to bolt the Aluminum Stands to the floor, the conveyor and stand assembly can
be stabilized by use of Cross Ties.
Cross Ties are sold in standard lengths, and are meant to be cut to length during installation based on
the final placement of the stands.
The Cross Ties can be installed once the conveyor has been secured to the stands.
In one of the boxes of the shipment, there will be a bag containing the Cross Tie Gusset Plates and
fasteners.
n Install the Gusset Plates to Aluminum Stands
a. Insert two Square Nuts into each leg’s channel from the base where the
channel has been routered (Figure
1).
b. The Gusset Plate should be
positioned over the Square Nuts in
the channel and secured with the
Hex Head Screws and Flat Washers
(Figure 2). Although there are eight
holes in the Gusset Plate, only four
of them will be used.
Figure 1
Figure 2
o Install the Cross Tie Extrusions
a. Measure the distance between the stands and
cut the Cross Tie Extrusion to fit with a saw blade
that is appropriate for Aluminum (Figure 3).
b. The Gusset Plates can mount to the inside or
outside of the stand’s leg, or to the stand’s Cross
Member if there is no room on the leg (Note: this
will require disassembly of the stand to do so).
Cut Cross Ties
to Length
c. Proceed to Sections 2.08 - 2.12 for instructions
on installing Drives and Mounting Packages.
Figure 3
2.07 Casters
QC Industries offers swivel locking casters to replace the stands’ leveling feet for applications when
conveyors need to be moveable.
In most cases, casters will arrive already assembled to exact width stands they are to be used on. The
leveling feet that are normally included with exact width stands will also be included in the shipment in
the event they are needed.
n Install Casters to Aluminum or Steel Stands
a. Remove the Leveling Foot from the stand by loosening the Hex
Nut with a large adjustable wrench. Spin the foot to unthread it
from the stand leg until it is free.
b. Install the Casters by threading the 4 1/2” stem into the base of
the stand where the Leveling Foot was previously. The Caster will
have its own 3/4-10 Hex Nut (Figure 1).
c. Once the conveyor is mounted on the stand, the caster’s stem
can be used for final height adjustment, up to 1 1/2” up or down.
Use a large adjustable wrench to loosen the hex nut, engage the
swivel lock, then rotate the caster to the desired height by hand,
and finally retighten the Hex Nut to secure it in position.
o Secure the System
a. When the conveyor is not being moved or is in operation, the
Caster’s swivel lock should be engaged. It is conveniently located
over the caster’s wheel so it can be engaged and disengaged by
foot.
Figure 1
b. QC Industries requires the use of Cross Ties or Angle Braces if
Casters are used. Note: The width of the system should be no less
than 1/3 of the system’s height (e.g., for a 36” high system, a
stand assembly on casters should be at least 12” wide). When
assembling, please make sure the assembly is stable for your
application.
Warning: Moving conveyors with casters can create dynamic
forces that could tip the conveyor. Use caution when moving a
conveyor with casters.
c. Proceed to Section 2.08 – 2.12 for instructions on installing Drives and Mounting packages.
2.08 Side Drive Mounting Packages
Side Drives are direct-coupled to the conveyor’s drive pulley. Heavy Duty Electric side drive mounting
packages are the only side drive package offered for the 125Z Series. For these drives, the motor is
always shipped in its own box. The right angle speed reducer will be attached to the drive mounting
package.
They can only be mounted to conveyors with “S” or “D” drive pulleys (i.e., with a 1/2” shaft with
keyway protruding from the drive pulley). They are not compatible with the “H” pulley with the hex
input. If you have a conveyor with a hex input, please consult QC Industries Customer Service
department for the correct parts.
The drive package will ship separate from the conveyor with the speed reducer attached.
n Prepare the conveyor
a. Loosen the Tracking Screw with a 1/4”
Wrench so it is no longer in contact with the
Anvil Block (Figure 1).
b. Remove the two 5/16-18 Hex Nuts using
a 1/2” Wrench.
Tracking Screw
Anvil Block
Remove and
Discard
c. Remove and discard the Anvil Block.
When installed, the Drive Mounting Plate
will act as the anvil for the Tracking Screw.
Nylon Tape
Figure 1
Drive
Mounting
Plate
o Prepare the Drive Package
a. Remove the Drive Mounting Plate by first removing four
Button Head Screws using a 5/32” Allen Wrench (Figure
2). One screw is held in place by a nut. Use a 7/16”
Wrench to remove it.
Figure 2
2.08 Side Drive Mounting Packages (continued)
p Install the Drive Mounting Plate
a. Place the Drive Mounting Plate over the
conveyor’s spacer block studs and secure it in
place with the two 5/16-18 Hex Nuts (Figure 3).
b. Position the shaft key so its near edge is even
with the face of the Drive Mounting Plate.
q Install the Drive Package
a. Rotate the Drive Pulley by moving the belt by
hand so the Key in the conveyor’s shaft is in the
12 o’clock position (Figure 4).
Figure 3
Key at 12
o’clock
b. Rotate the Input Quill on the speed reducer so the
keyway in the Tapered Coupling Half is in the 12
o’clock position.
c. Slide the Speed Reducer/Casting/Coupling assembly
onto the conveyor’s shaft. While holding the assembly
in place, replace and tighten two of the 1/4-20 x 3/4”
long Button Head Screws using a 5/32” Allen Wrench.
d. The Set Screw in the Tapered Coupling Half should
be visible through the top opening in the Casting
(Figure 5). Using a 3/32” Allen Wrench, tighten the Set
Screw to secure its position on the Key.
Input Quill
Figure 4
e. Replace and tighten the other two 1/4-20 Button Head
Screws (one with a 1/4-20 Hex Nut and 1/4” Lock Washer).
f. Retighten the conveyor’s Tracking Screw until it contacts the
drive mounting plate. The conveyor does not require retracking if the 5/16” Socket Head Cap Screws in the tracking
block were not loosened.
Set Screw
is visible
Figure 5
r Install the Speed Reducer’s Vent Plug and Motor
a. For Heavy Duty Electric Gearmotors, proceed to Section 2.10 for instructions on how to install the
speed reducer’s vent plug, and then to Section 2.11 for instructions on installing the motor. It is
recommended to install the vent plug before the motor to have the best access.
2.09 Top and Bottom Drive Mounting Packages
Top and Bottom Drives are designed to mount the gearmotor either above or below the conveyor for
space savings. They are available with Heavy Duty Electric gearmotors which use right angle speed
reducers, or with Standard Duty Electric and Pneumatic gearmotors which are mounted parallel to the
drive pulley.
The Drive Package will ship separate from the conveyor with the speed reducer attached, and the
speed reducer’s sprocket already attached to its shaft. For Standard Duty and Pneumatic Drives, the
speed reducer and motor will ship installed on the drive mounting package. For Heavy Duty Drives, the
motor is always shipped in its own box; the right angle speed reducer will be attached to the drive
mounting package.
They can only be mounted to conveyors with “S” or “D” drive pulleys (i.e., with a 1/2” shaft with
keyway protruding from the drive pulley). They are not compatible with the hollow pulley style with a
hex input. If you have a conveyor with a hex input, please consult QC Industries Customer Service
Department for the correct parts.
Top and Bottom Drives use either a Timing Belt or Chain transmission. The steps for installation are
the same for both.
The conveyor will ship with one of the spacer block studs replaced by a 5/16” Flat Head Screw on the
side that the drive will be mounted (refer to the conveyor’s drive position in Section 2.03 for an
explanation).
n Prepare the conveyor
a. Remove the Flat Head Screw from the
Bearing Plate with a 3/16” Allen Wrench
(Figure 1).
Tracking Screw
b. Loosen the Tracking Screw with a 1/4”
Wrench so it is no longer in contact with the
Anvil Block.
Anvil Block
Remove and
Discard
c. Remove the Hex Nut holding the Anvil
Block using a 1/2” Wrench.
Flat Head Screw
Figure 1
d. Discard the Anvil Block. When installed,
the Drive Mounting Plate will act as the
anvil for the Tracking Screw.
o Prepare the Drive Package
Socket
Head
Screws
a. Remove the Guard by removing the three 6-32 x
1 1/2” long Socket Head Screws using a 7/64” Allen
Wrench (Figure 2). The top Sprocket and Belt (or Chain)
are loose under the Guard.
Figure 2
2.09 Top and Bottom Drive Mounting Packages (continued)
p Install the Drive Package
a. Mount the Drive Mounting Plate over the conveyor
shaft and Spacer Block Stud (Figure 3).
Spacer
Block Stud
b. Replace and tighten the 5/16-18 x 3/4” long Flat Head
Screw in the countersunk hole of the Drive Mounting
Plate.
c. Replace and tighten the 5/16-18 Hex Nut.
Flat Head
Screw
Figure 3
qInstall the belt (or chain)
a. Remove the nylon tape from the conveyor’s shaft that holds
the key for shipment (Figure 4).
b. Loosen (but do not remove) the three 1/4-20 Socket Head Cap
Screws holding the speed reducer subplate in position using a
3/16” Allen Wrench.
Nylon Tape
c. Thread the Tracking Screw in to allow the Subplate to move
toward the conveyor (Figure 5).
Figure 4
d. Slide the top Sprocket onto the conveyor’s Shaft and Key, so it is
centered over the lower Sprocket. Secure it in place by tightening the
two Set Screws with a 3/32” Allen Wrench. If your drive uses Chain,
the Set Screws in the sprockets require a 1/8” Allen Wrench.
Tracking
Screw used
to Tension
Timing Belt
e. Install the Timing Belt (or Chain) over the Sprockets.
Figure 5
2.09 Top and Bottom Drive Mounting Packages (continued)
r Prepare for operation
a. Tension the Timing Belt (or Chain) by running out
the Square Head Set Screw to move the Subplate
away from the conveyor (Figure 6).
Square Head
Set Screw for
Tension
b. The Timing Belt is properly tensioned when it takes
approximately 60 lbs of force to deflect one span of
the belt .09”.
c. Retighten the three 1/4-20 Socket Head Screws
with a 3/16” Allen Wrench to hold the Subplate in
position (Figure 7).
Subplate
Figure 6
d. Replace the Guard and secure it with the three 6-32 x 1 1/2”
long Socket Head Cap Screws using a 7/64” Allen Wrench.
e. Retighten the conveyor’s Tracking Screw until it contacts the
Drive Mounting Plate. The conveyor does not have to be re-tracked
if the 5/16” Socket Head Cap Screws in the Tracking Block were
not loosened.
Timing
Belt
Span
Socket Head
Screws to hold
Subplate
Figure 7
s Install the Speed Reducer’s Vent Plug and Motor
a. Proceed to Section 2.10 for instructions on how to install the speed reducer’s vent plug, and then to
Section 2.11 for instructions on installing the motor. It is recommended to install the vent plug before
the motor to have the best access.
2.10 Install the Speed Reducer’s Vent Plug
a. Using a 1/4” Allen Wrench, remove the Pipe Plug from the topmost port in the speed reducer
(Figure 1). For Bottom and Side Drives, use the location above the reducer’s flange. For Top Drives,
use the location opposite the shaft above the nameplate.
Topmost Port
(Bottom Drive)
Topmost Port
(Top Drive)
Topmost Port
(Side Drive)
Figure 1
b. While the reducer is open, verify that there is oil
in the case. If there is not, fill the speed reducer as
instructed in Section 3.09 of this manual. All speed
reducers will ship with the proper amount of oil in
them, but should be checked regardless, as this is
the best time to fill it if necessary.
c. Locate the two pieces of the Vent Plug in the gear
reducer’s hardware bag (that also includes the
flange mounting screws, packet of anti-seize, and
other information).
d. Gently thread the brass half into the plastic half,
and install it into the vacated port in the reducer
1/4 turn past hand tightening (Figure 2).
Figure 2
2.11 Installing a Heavy Duty Motor
The motor is always shipped in its own box. It must be installed onto the speed reducer by the
installer.
n Strike the Key on the Motor’s Shaft
a. Unpack the motor from its box and packaging.
b. Position the key so it is 1/4” from the front face of the
shaft.
c. Hold a Flathead Screwdriver with the head at the back
end of the key, and lightly tap the area adjacent to the
key to upset material (Figure 1). This material will not
allow the key to move axially when assembled to the
speed reducer (for more, refer to Boston Gear's 700
SERIES WORM GEAR SPEED REDUCERS INSTALLATION,
LUBRICATION, OPERATION INSUTRUCTIONS AND PARTS
document provided with the speed reducer).
Strike the key
o Install the Motor to the Speed Reducer
Figure 1
a. On the Speed Reducer, rotate the input quill by hand
until the keyway is in the 12 o’clock position. Do the same with the motor.
b. Open the packet of anti-seize compound that shipped with the Speed Reducer. Generously apply it
to the speed reducer input quill and motor shaft.
c. Install the motor onto the speed reducer by guiding the keyed shaft into the speed reducer input
quill. Take care to ensure that the key did not shift during installation.
d. Rotate the motor until the workbox is in the desired location (normally pointing horizontally away
from the conveyor) and secure it in place with the four Hex Head Screws provided using a 7/16”
Wrench (for 42 frame motors) or a 9/16” Wrench (for 56 frame motors).
e. QC Industries recommends that all wiring be completed by a certified electrician. Refer to the
documentation contained in the motor’s box for instructions on electrical connections. Once the motor
is wired, the conveyor is ready for operation.
2.12 Heavy Duty Remote Drives
Remote Drives are used when it is not feasible to mount the Drive directly to the conveyor.
The Speed Reducer will ship assembled to the Remote Drive mount. The motor will ship in its own box.
The Remote Drive should be hard-mounted to a surface in line and at the same elevation as the
conveyor’s drive pulley (Figure 1), with a coupling used between the conveyor and Gearmotor that will
allow for slight misalignment, so the bearings are not unnecessarily loaded.
QC Industries offers two types of couplings for
the Heavy Duty Remote Drive: a Single Piece Flex
Coupling, and a Three Piece Flex Coupling. Both
are sold separately from the Remote Drive.
The Gearmotor has a 1/2” diameter round shaft
with 1/8” square key.
n Installation
a. If a Hex Extension Shaft is to be used (such as
to drive several conveyors in parallel with the
same shaft), select a coupling with a 1/2”
diameter – 1/2” hex.
Figure 1
diameter – 1/2” diameter.
b. If the Remote Drive is to be directly coupled to
the conveyor, select a coupling with a 1/2”
c. The Remote Drive must be rigidly mounted as well. The base has clearance holes for 5/16 screws.
Note: for 56 frame motors, the speed reducer’s flange will protrude below the speed reducer mounting
base.
d. Finally, refer to Section 2.10 for instructions on how to install the speed reducer’s vent plug, and
then to Section 2.11 for instructions on installing the motor. It is recommended to install the vent plug
before the motor to have the best access.
3.01 Maintenance Foreword
Managing conveyor life is both a comprehensive and important consideration from the day a system is
conceived until the day it is retired from service. From a business perspective, maintenance is an
essential activity for the achievement of optimal return on investment, as well as a key to remaining
competitive in a hyper-competitive world.
Like maintenance for many other systems, the maintenance of conveyor systems divides into three
broad categories: predictive, preventive, and corrective. The obvious advantage of predictive and
preventive maintenance is that downtime surprises can be avoided, and when action needs to be
taken, all of the parts, materials, and timing can be arranged for operational convenience.
To assure the highest performance for your conveyor system, QC Industries has combined a selection
of high quality durable components and superior design criteria that support all aspects of conveyor
operational effectiveness with the minimal amount of conveyor preventive maintenance.
Preventive maintenance, such as the cleaning of the conveyor, replacement of conveyor belt and
bearings will be regimented by the type of environment the conveyor system is subjected to, the
number of hours in operation, and the amount of performance demanded of the system.
Predictive measures, such as belt replacement schedules, periodic bearing replacement intervals, and
overall equipment inspection shall be determined by the environment the conveyor is subjected to, the
number of hours in operation, and the production effects of measures taken at the corrective phase.
Maintenance, in general, affects all aspects of conveyor operational effectiveness and risks, not just
system availability and cost — specifically safety, operational efficiency, energy efficiency, product
quality, and environmental integrity.
The following sections are QC Industries’ requirements for assuring the conveyor system is always
operating at the factory specifications with minimal production interruption please follow these
guidelines. If any questions arise please call our customer service department at (513) 753-6000.
3.02 Belt Tracking
All 125Z Series conveyors are shipped assembled with the belt pre-tracked from the factory, so there
should not be a need to adjust belt tracking on your conveyor prior to initial start up. However, if over
the course of time there is a need to track the belt, use the instructions in this section.
The belt is considered to be properly tracked when, while running, both edges of the belt clear all
conveyor components along the entire belt path. The illustrations below provide explanations of
correct and incorrect belt tracking conditions along the conveyor. If one or more of the incorrect
conditions occur, the belt tracking needs to be adjusted to prevent premature wear. Note: some lateral
oscillation of the belt from side to side is common, and is acceptable provided the belt edges clear all
conveyor components.
A
B
Typical 125Z Series conveyor
belt tracking locations
C
C
D
Bottom view (underside)
of conveyor
B
A Belt should be centered, not touching or rubbing against bearing plates.
Clearance
(Both Sides)
CORRECT
Belt contacting
or rubbing against
bearing plate
Clearance
(Both Sides)
CORRECT
INCORRECT
C Belt should be centered, not touching or rubbing against connector plates.
Clearance
(Both Sides)
B Belt should be centered, not touching or rubbing against connector plates.
Belt contacting or
rubbing against
connector plates
INCORRECT
INCORRECT
D Belt should be centered, not touching or rubbing against frame.
Clearance
(Both Sides)
CORRECT
Belt contacting
or rubbing
against
connector plate
CORRECT
Belt contacting or
rubbing against
frame
INCORRECT
3.02 Belt Tracking (continued)
If you have determined from the previous page that your 125Z Series conveyor belt tracking needs to
be adjusted, follow the steps below. Although belt tracking can be adjusted from several locations
along the conveyor, there is an order of adjustments that QC Industries recommends.
2
Note: Most belt tracking corrections are made via the ZTrack idlers.
n
o
p
q
Make tracking adjustments at the Z-Track idlers.
Make tracking adjustments at the drive end.
Make tracking adjustments at the tail end.
Make tracking adjustments at the full width idlers.
4
1
1
3
4
n Z–Track Idler Adjustment
Z–Track Idler assemblies provide both belt tracking
adjustment and tension adjustment, and can be adjusted
independently of each other (Figure 1). Tracking
adjustments made in this area should be made in
modest increments, as they have an affect along the
entire conveyor. Let the belt make at least two
revolutions around the conveyor, checking the entire belt
path for alignment, before adjusting more or moving to
the next step.
Z-Track idler assembly
Z-Track
idler
camber
Z-Track
idler
tension
adjustment
adjustment
Figure 1 (Idler Covers removed for clarity)
Rotate Camber
adjust set screw
counterclockwise
Belt moves away
a. Determine the side of the conveyor belt that has the
mistrack condition.
b. Turn camber adjust set screw counter-clockwise
(threading out). Decreasing the Z-Track camber
adjustment on that side will push the belt away from the
idler (Figure 2). Wait for two belt revolutions around the
conveyor to see if the adjustment corrects the issue. If
not, move to the next step.
Figure 2
c. Loosen tension lock screw to enable Z-Track idler
tension adjustment. Turn the tension adjust set screw
clockwise (threading in). Increasing the Z-Track idler
tension adjustment on that side will push the belt away
from the idler (Figures 3). Tighten tension lock screw
and wait for two complete belt revolutions to see if
adjustment corrects the issue. Do not over-adjust
tension to the point that the belt path interferes with
the tops of the conveyor frames. (Figure 4). If this step
does not correct the issue, move to the next step.
Rotate tension
Adjust set screw
clockwise
Add tension to
Push belt away
Belt moves away
Loosen lock
screw first
Figure 3
d. On the side of the conveyor opposite
the previous adjustments, turn camber
adjust set screw clockwise (threading in).
Increasing the Z-Track camber adjustment
on that side will pull the belt toward the
idler (Figure 5). Wait for two belt
revolutions around the conveyor to see if
the adjustment corrects the issue. If not,
move to the next step.
Rotate
Camber
adjust
set screw
clockwise
Belt pulls toward
Over-tensioned Z-Track idler
causing belt path interference
with frame
Interference
Interference
Figure 4
e. Loosen tension lock screw to enable Z-Track Idler tension
adjustment. Turn the tension adjust set screw counterclockwise (threading out). Decreasing the Z-Track idler
tension adjustment on that side will pull the belt toward the
idler (Figures 6). Tighten tension lock screw and wait for
two complete belt revolutions to see if adjustment corrects
the issue.
f. The idler guard (not shown in figures) may have to be
adjusted to clear the idler with excessive adjustment. It
should never clear the belt more than 1/8”, as this could
create pinch points.
Figure 5
g. The previous steps a. – f. may have to be performed
more than once, and in other areas, as adjustments made
at Z-Track idlers affect tracking in other areas. For example,
the adjustments made at a set of Z-Track idlers will cause a
reaction on either side of that adjustment location (Figure
7).
Decrease tension
To pull belt toward
Belt pulls toward
h. If the above steps have been performed several times
without successfully tracking the belt, it may be beneficial
to reset the Z-Track Idlers in their neutral position and
restart steps a. – f. Refer to Section 3.05 Belt Change for
directions on how to reset Z-Track Idlers to their neutral
positions.
Z-Track –
Belt moves toward
Tail End –
Belt moves toward
Rotate
Tension
Adjust
setscrew
Counterclockwise
Loosen lock
Screw first
Figure 6
Drive End –
Belt moves away
Z-Track –
Belt moves away
Figure 7
o Drive End Tracking
The drive end of 125Z Series conveyors provide fine belt tracking adjustment via the drive assembly
jacking screws. These jacking screws either add tension to the belt or take tension off the belt
depending on which way the screws are turned (Figures 8 & 9).
Rotate jacking
screw clockwise to
decrease tension
Rotate jacking
screw counterclockwise to
increase tension
Belt moves toward
Belt moves away
Drive pulley
moves in
Drive pulley
moves out
Figure 9
Figure 8
a. Loosen all four 5/16” Driver Assembly Screws (two on
each side) one-half turn (Figure 10).
Bearing
Plate
Loosen Socket
Head Screws
before adjusting
Rotate Tracking
Screw to adjust
tracking
Figure 10
b. With the conveyor running, rotate the 1/4" Square Head
Tracking Screw clockwise on the side of the conveyor the
belt is mistracking toward – this will set the Driver
Assembly at an angle and move the belt away from that
side.
c. For best results, make adjustments to only one side.
Adjustments made in this area may affect tracking in
others. The Drive End is tracked when the belt can make
two full revolutions without contacting either bearing
plate.
p Tail End Tracking
The tail end of 125Z Series conveyors have single point belt tracking adjustment via the Eccentric Tail
Pulley assembly. This idler creates small angles with its eccentric journals to steer the belt at the tail
end (Figures 11 & 12). It is initially assembled in the “neutral” position, defined as the index mark in
the 12 o’clock position, but may have been adjusted at the factory for belt tracking purposes.
Rotate bushing
clockwise
Rotate bushing
counter-clockwise
Belt moves away
Tail pulley moves
out on this side
Belt moves toward
Tail pulley moves
in this side
Figure 11
Figure 12
a. To track the Tail End, first loosen the Button Head Socket Screw with a
5/32” Allen Wrench, which secures the Eccentric Bushing (Figure 13).
NEUTRAL
Neutral
b. Using a 9/16” Wrench, rotate the Eccentric Bushing clockwise (toward
the 3 o’clock position) to track belt toward the Eccentric Bushing; rotate the
Eccentric Bushing counter-clockwise (toward the 9 o’clock position) to track
the belt away from the Eccentric Bushing.
Loosen
1/4-28
LOOSEN
1/4-28
BUTTON
Button
HeadHEAD
SOCKET
Socket
CapCAP
Screw
SCREW
Figure 13
c. Allow the belt to make two full revolutions to determine if more
adjustment is necessary. On longer conveyors, wider conveyors, or
conveyors running at slower speeds, tracking adjustments will take more
time than on shorter and narrower conveyors. Let the belt make at least two
revolutions before making additional adjustments.
d. The Tail End is tracked when the belt can make two full revolutions without contacting either side of
the frame. When finished, tighten the Button Head Socket Screw to secure the Eccentric Bushing.
q Z–Track™ Full Width Idler Adjustment
Full Width Idler assemblies span the width of the conveyor between a pair of connector plate
assemblies. They track the belt by applying tension to it, and are designed to accommodate different
adjustment settings on either side of the conveyor. This is accomplished by threading the adjustment
set screws in or out accordingly (Figures 14 & 15).
Full Width idler assembly
adjustment set screw
Full Width
idler
tension
Full Width
idler
tension
adjustment
adjustment
Full Width idler assembly
Return Flange
Return Flange
Belt Path
Figure 14
Figure 15
a. Determine the side of the conveyor belt that has the mistrack condition.
b. Turn the tension adjust set screw clockwise (threading in). Increasing tension on this side will push
the belt toward the opposite side (Figure 16). Wait for two belt revolutions around the conveyor to see
if the adjustment corrects the issue. If not, move to the next step.
c. On the opposite side of the conveyor from the previous adjustments, turn the tension adjust set
screw counter-clockwise (threading out). Decreasing tension on this side will pull the belt toward this
side (Figure 17).
Rotate
tension
adjust
set screw
clockwise
Increase tension to
push belt away
Rotate
tension
adjust
set screw
counterclockwise
Decrease tension
to pull belt toward
Belt moves away
Belt moves toward
Figure 17
Figure 16
d. Do not over-adjust tension to the point that the belt path interferes with the return flanges on
conveyor frames (Figure 18). Leave at least 1/8” clearance (Figure 15).
Over-tensioned full width idler
causing belt path interference
with frame
Interference
Interference
Figure 18
3.03 Adding Tension
All 125Z Series conveyors are shipped assembled with the belt pre-tensioned from the factory. This
process ensures that the belt has the recommended amount of tension to maximize the conveyor load
carrying capacity. You should not have to adjust the tension of the belt; however, if there is a need to
add additional tension (drive pulley slipping beneath the belt or belt elongation), the drive end of the
conveyor may be used to increase tension.
Note: over-tensioning belts adds unnecessary load to bearings, and subsequently will reduce the
bearings’ useful life.
n Add tension to the Belt
Rotate
Tracking
Screws to
add tension
Loosen before
adjusting
Figure 1
a. Loosen all four 5/16” Driver Assembly screws (there are
two on each side of the conveyor) one-half turn (Figure 1).
b. Increase the tension by extending the 1/4" Square Head
Tracking Screws until desired tension is achieved. On the
drive side of the conveyor the tracking screw will push
against the Drive Mounting Plate. On the opposite side
there is an Anvil Tracking Block which the Tracking Screw
pushes against. The screws should be extended the same
amount on each side. If not, belt tracking will be adversely
affected (refer to Belt Tracking in Section 3.02).
c. If after following these steps additional belt tension is needed, it is recommended that a new belt be
purchased.
Note: Although possible, it is not recommended to add tension to the belt via the Z-Track or Full Width
idler assemblies, as this could adversely affect belt tracking along the conveyor.
3.04 Adjustable Guide Rail Removal
Adjustable Guides are the only guides available on 125Z Series conveyors, and come assembled to
the conveyor from the factory. Adjustable Guides are available in 3 heights: 1”, 2”, and 3”, and are
available with either thumbscrew adjustment or set screw adjustment. The guide rails are supported
by a bracket/cross block/adjustment rod assembly that come assembled from the factory on 125Z
Series conveyors.
Adjustable Guides must be removed for belt change. Please refer to the following instructions should
you have to remove guides for belt replacement or other maintenance. Installation steps are opposite
of removal steps.
n Remove Guide Rail from Guide Brackets
a. Loosen all the guide rail/rod/cross block
assemblies, along one side of the conveyor,
from the vertical rods connected to the guide
brackets, and slide them off vertically
(Figure 1).
b. Leave cross block assemblies mounted to
the rails in their existing location. Try to keep
guide rail assemblies intact when removing
them from the conveyor by not twisting or
bending them. This will prevent the rail
sections from coming detached and aid in
reinstallation.
c. Lay guide rail flush on floor or other flat
surface. Repeat for the opposite side of
conveyor.
Figure 1
o Remove the Guide Brackets
a. Mark existing guide bracket locations
on conveyor. This will ensure that
adjustable rails will be reinstalled in the
same location as before.
b. Remove the guide brackets from the
conveyor frame by unscrewing the Torx
head screws (Figure 2).
c. Repeat for opposite side of conveyor.
Figure 2
3.05 Belt Change
When the belt becomes tattered at the edges, stretched beyond the tension adjustment limits of the
conveyor, or has cleats or corrugated sidewall delaminating from the top surface, a belt change is
recommended.
n Belt Removal
a. Remove Adjustable Guide Rails, if necessary. Conveyors with Corrugated Sidewall belts will not have
guide rails. Refer to Section 3.04 Adjustable Guide Rail Removal.
b. Thread in the two square head set screws (Figure 1) at the drive assembly and reset the drive to its
initial position, so that the drive assembly is resting solidly against the end of the conveyor frame
(Figure 2). This will require loosening the four 5/16” socket head cap screws that hold the tracking
blocks located on the sides of the frame adjacent to the drive assembly (Figure 3).
Figure 1
Figure 2
Figure 3
c. Locate the setscrew in the tail pulley at the tail end of the conveyor. Using a 3/32” Allen Wrench,
turn the setscrew into the tail pulley so that the setscrew is flush with the outer surface of the tail
pulley cartridge (Figure 4).
d. Relieve the tension from the belt by rotating the tail pulley using the QC Industries Tail Turning tool
or large screw driver on the slotted end of the tail pulley (Figure 5).
e. Remove the tail pulley from the conveyor assembly by lifting upward on the tail pulley and setting it
aside temporarily, making sure to place it where it cannot be dropped or damaged (Figure 6).
Figure 4
Figure 5
Figure 6
3.05 Belt Change (continued)
f. Remove idler pulley guards from the Z-Track connector plates using a 5/32” Allen Wrench. There
will be two idler guards per frame bend (Figures 7 & 8).
g. Once these guards have been removed, the idlers will be exposed (Figure 9).
Figure 7
Figure 8
h. Relax all Z-Track and full width idlers to
their most relaxed position by threading out
the tension adjustment screws. This will aid
in the removal of the old belt and
installation of the new belt by providing the
clearance needed to thread the belt on the
conveyor frame and between the idlers
(Figure 10).
Thread screws out
i. Bend the area of the belt where each idler
is located and pull the belt out from
underneath each idler; this can be
accomplished by pulling on a cleat near the
idler . Let the relaxed belt rest on
top of the idlers (Figures 11, 12, & 13).
Figure 11
Figure 9
Figure 10
Figure 12
Figure 13
j. Remove the conveyor from all mounts and/or
stands. To ensure maximum safety while performing
this task, QC Industries recommends at least two
people for conveyors up to 8 feet in length; and 3-4
people for conveyors over 8 feet in length.
k. The conveyor may then be placed on its side; but
should be placed on the side opposite that which
the drive package is mounted (Figure 14).
Note: The drive package does not need to be
removed in order to remove and replace belt.
Figure 14
l. Pull the belt out from the inside of the return flanges on the underside
of each frame section (Figure 15).
m. Starting at the drive end first, remove the belt from the conveyor by
sliding the belt off to the drive side of the conveyor (Figure 16 ), and if
necessary, pulling it around the drive mounting package.
Figure 15
n. Work down the length of the conveyor, continuing down toward the tail end (Figure 17).
o. Finish by sliding the belt off at the tail end (Figure 18).
Figure 16
Figure 17
Figure 18
o Installing a New Belt
a. 125Z Series belts have a rotation direction arrow inscribed on the back side of the belt. Ensure that
the belt flow will be in the same direction as the rotation arrow indicates.
Figure 20
Figure 19
Figure 21
b. Install the new belt by first sliding the belt over the tail end of
the conveyor frame and continuing on toward the drive end
(Figures 19, 20, & 21).
c. Tuck the belt up inside the conveyor frame, so that the belt is
contained inside the return flange (Figure 22).
Belt in Flanges
Flange
d. Bend the area of the belt where each Z-Track idler is located
and slide the belt underneath each idler pulley (Figure 23). Be
careful to not pull excessively on the cleats or corrugated
sidewall on new belts, as this could delaminate them from the belt top cover.
Figure 22
e. Reset the Z-Track idlers and full width idlers in their neutral
position. This process will reset all previous adjustments so that the
new belt can be tracked properly. This is accomplished by threading
the Z-Track tension adjustment screw ten complete turns from the
inside edge of the retainer slot, threading the full width idler tension
adjustment two complete turns from the inside edge of the retainer
slot, and leveling out the Z-Track idler camber (Figure 24).
Figure 23
Reset to Zero Camber
Camber Adjustment Screw
10 Complete Turns from
Inside Edge of Slot
Loosen Screw to Adjust
Tension – Tighten Screw to
Lock in Place
2 Complete Turns from Inside
Edge of Slot
Retainer
Figure 24
f. Replace the tail pulley that was set aside earlier by sliding the tail pulley between the belt and the
conveyor frame, making sure that the end of the tail pulley containing the setscrew is on the same
side as the notch cutout in the conveyor frame for the setscrew.
g. Snap the tail pulley into the notched area at the tail end of the conveyor frame (Figure 25).
Figure 25
Figure 26
Figure 27
h. Rotate the tail pulley on the slotted end until the setscrew is lined up with the notch cutout (Figure
26).
i. Using a 3/32” hex-key wrench, turn the setscrew in the tail pulley counterclockwise so that the setscrew is flush with the outside of the conveyor frame
(Figure 27).
NEUTRAL
Neutral
j. Set the tail pulley to its neutral position, which is defined as the index mark
on the eccentric bushing in the 12 o’clock position. If adjustments are
needed, begin by loosening the Button Head Socket Screw located on the tail
pulley, which secures the eccentric bushing. Retighten the Button Head
Socket Screw when finished to secure the eccentric bushing.
k. The new belt must now be properly tracked and tensioned before use.
Refer to Section 3.02 Belt Tracking.
Loosen
1/4-28
LOOSEN
1/4-28
BUTTON
Button
HeadHEAD
SOCKET
Socket
CapCAP
Screw
SCREW
Figure 28
3.06 Belt Care
n Belt Cleaning
Belts can usually be cleaned with general household cleaners, however some cleaners (that contain
alcohols, acetone, MEK, chlorinated solvents, etc.) may attack belts.
Never hose off the bearings or use solvents in these areas as this may significantly reduce bearing life.
o Physical Damage
Worn edges do not hurt the conveyor's operation, as the pulleys are crowned; however, the cause of
the edge wear should be determined.
Scoring lines in the belt's surface could be due to product collecting between the frame's underside
flange and the belt. If the conveyor has a wiper, product could be trapped at the scraping edge.
Accessories, such as adjustable guides or bottom mounts could be improperly positioned and in
contact with the belt.
p Camber
Belt camber is the lateral oscillation of the belt, most noticeable at the drive end between the Bearing
Plates. All belts have some camber due to the endless splice not being perfectly square. Crowned
pulley and tracking adjustments should overcome the belt's camber, but in some cases will not (such
as if the belt is excessively worn or has been exposed to an inappropriate chemical or solvent).
Excessive camber is when the belt cannot be tracked without the edges staying in contact with the
Bearing Plates. It is possible that the conveyor can continue to perform at a high level even with
excessive camber, but if it is a problem, replacement of the belt is suggested.
q Belt Slippage
Belt slippage occurs when the belt is undertensioned for the load, which could be caused by a number
of factors:
a. Excessive load on the conveyor. Refer to the Product Catalog to determine the conveyor's
application capacity.
b. Reduced friction between the belt and drive pulley.
c. Belt elongation due to overtensioning.
d. Excessive belt wear due to accumulating product.
e. Belt elongation due to exposure to a chemical or ultraviolet light.
If slippage cannot be overcome by either removing the condition causing it or by adding tension at the
Drive End, it is likely the belt needs to be replaced.
3.07 Bearing Replacement
125Z Series conveyors use roller bearings which have been permanently lubricated with Micro-Poly
solid lubricant at the factory. QC Industries recommends that these bearings be removed and replaced
as needed (See Table Below).
n Bearing Replacement
The replacement interval is dependent on the speed at which the conveyor is running and the
environment. The chart below shows the replacement interval in years.
Replacement Interval in Years
1 Shift
2 Shifts
3 Shifts
6
3
2
Example: a conveyor running in a 3 shift operation can go 2 years between replacements.
Note: The replacement interval can be drastically affected by environmental issues such as moisture,
dust, heat, and chemicals. Please consider these when determining the correct interval for your
application.
The conveyor is shipped with a H1 Food-Grade Micro-Poly Lubricant which is a mixture of polymers,
oils, and other additives.
3.09 Speed Reducer (Gearbox) Oil
Heavy Duty Speed Reducers are filled with oil that will have to be changed after the first 1,500 hours,
and then after every 5,000 hours of service.
n Identify the Type of Oil in the Speed Reducer
In 2006, the type of oil used was changed. The type of oil in your speed reducer can be determined by
the part number on the speed reducer’s nameplate.
a. Speed Reducers with a “K” in the part number on the nameplate have the new oil and should be
filled with Klubersynth UH-1 6-460 (# 096060) oil.
Example:
F710-15PK-B4-J6
b. Speed Reducers with an “S” in the part number have the older oil and should be filled with Mobil
SHC 634 Synthetic oil.
Example:
F710-15PS-B4-J6
o Emptying and Refilling
a. The oil can be emptied by removing the lowest pipe
plug in the box so it can be drained without removing it
from the conveyor (Figure 1). When the speed reducer
is empty, the pipe plug must be replaced tightly to
prevent leakage.
b. The quantity of oil in the speed reducer is 3.3 fluid
ounces. Note that this is the final quantity of oil, which
assumes the speed reducer was completely emptied
prior to filling.
Lowest
Pipe Plug
Figure 1
125 Z Series Assembly
L Configuration
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125-0099-WW-ST-S-A-ML
125-0110-WW-E-ML
Z-0086-A-WW-LLL-F
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Z-0101-AN-001-ASY
Z-0101-AN-002-ASY
ZE-WW-LLLNLLL-ZAXNNN
125-0078-024
SHOP-307
SHOP-325
Description
Item
Part No.
Description
ASSY 125 SERIES LH "S" DRIVER
ASSY 125 SERIES TAIL
ASSY FRAME Z SERIES TAIL
ASSY FRAME Z SERIES DRIVE
ASSY Z TRACK CONNECTOR PLATE - 8", 10", 12"
ASSY Z TRACK CONNECTOR PLATE - 18", 24"
BELT QCL CLEATED
PLUG FRAME
LABEL WARNING
LABEL QC LOGO
4057 Clough Woods Dr. | Batavia, OH 45103 | (513) 753-6000 | Fax: (513) 753-6001 | www.qcindustries.com
125 Z Series Conveyor Assembly
R Configuration
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Z-0086-C-WW-LLL-F
Z-0101-AN-001-ASY
Z-0101-AN-002-ASY
ZE-WW-LLLNLLL-ZAXNNN
125-0078-024
SHOP-307
SHOP-325
Description
Item
Part No.
Description
BELT QCR CLEATED
PLUG FRAME
LABEL WARNING
LABEL QC LOGO
125 Z Series Conveyor Assembly
Z Configuration
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5
6
Part No.
125-0099-WW-ST-S-A-ML
125-0110-WW-E
Z-0086-A-WW-LLL-F
Z-0086-B-WW-LLL-F
Z-0086-C-WW-LLL-F
Z-0101-AN-001-ASY
Z-0101-AN-002-ASY
7 ZE-WW-LLLNLLLLLL-ZAXNNN
8 125-0078-024
9 SHOP-307
10 SHOP-325
8
10
Description
2
Item
Part No.
Description
ASSY FRAME Z SERIES Z INCLINE
BELT QCZ CLEATED
PLUG FRAME
LABEL WARNING
LABEL QC LOGO
Z Track Connector Plate Assembly
Widths 8", 10", 12"
6
LEGEND
10
5
9
@
1
PART# Z-0101-___-001-ASY
3
14
12
2
7
8
10
11
9
5
13
16
15
11
4
3
14
2
4
11
13
15
10
11
9
8
5
Item
Part No.
1 Z-0101-030
Z-0101-045
Z-0101-060
Z-0101-075
Z-0101-090
2 Z-0015-00
3 Z-0168-001
4 Z-0114-00
5 Z-0011-001-ASY
6 Z-0002-030
Z-0002-045
Z-0002-060
Z-0002-075
Z-0002-090
1
7
16
6
12
9
10
Description
Item
PLATE CONNECTOR 30 DEGREE
RETAINER BUSHING
PLATE TENSION IDLER LOCK
BUSHING IDLER
ASSY IDLER BELT TENSIONING 8" - 12" WIDTHS
GUARD CONNECTOR PLATE NARROW 30 DEG.
7
8
9
10
11
12
13
14
15
16
Part No.
125-0070-016
125-0070-036
125-0072-008
125-0072-021
125-0072-022
125-0072-033
125-0072-065
125-0072-070
125-0073-040
125-0074-009
Description
WASHER LOCK #10 ZP
SCREW BUTTON HEAD CAP #10-32 X 5/8" ZP
SCREW BUTTON HEAD CAP 1/4-20 X 1/2" ZP
WASHER FLAT 1/4" ZP
WASHER LOCK 1/4" ZP
SCREW SOCKET HEAD SET 1/4-20 X 1 1/4"
SCREW FLAT HEAD CAP 1/4-20 X 3/4" ZP
SCREW SOCKET HEAD SET 1/4-20 X 3/4"
Z Track Connector Plate Assembly
Widths 18", 24"
LEGEND
6
10
9
5
@
1
PART# Z-0101-___-002-ASY
3
14
12
2
7
8
10
11
9
5
13
16
15
11
4
3
14
2
4
11
13
15
10
11
9
8
5
Item
Part No.
1 Z-0101-030
Z-0101-045
Z-0101-060
Z-0101-075
Z-0101-090
2 Z-0015-00
3 Z-0168-001
4 Z-0114-00
5 Z-0011-002-ASY
6 Z-0003-030
Z-0003-045
Z-0003-060
Z-0003-075
Z-0003-090
1
7
16
6
12
9
10
Description
Item
RETAINER BUSHING
PLATE TENSION IDLER LOCK
BUSHING IDLER
ASSY IDLER BELT TENSIONING 18" - 24" WIDTHS
GUARD CONNECTOR PLATE WIDE 30 DEG.
7
8
9
10
11
12
13
14
15
16
Part No.
125-0070-016
125-0070-036
125-0072-008
125-0072-021
125-0072-022
125-0072-033
125-0072-065
125-0072-070
125-0073-040
125-0074-009
Description
WASHER LOCK #10 ZP
SCREW BUTTON HEAD CAP #10-32 X 5/8" ZP
WASHER FLAT 1/4" ZP
WASHER LOCK 1/4" ZP
SCREW SOCKET HEAD SET 1/4-20 X 1 1/4"
SCREW SOCKET HEAD SET 1/4-20 X 3/4"
125 Series "S" Driver Assembly
LEGEND
5
@
PART# 125-0099-WW-ST-S-A
15
10
8
16
14
@
11
9
6
13
@
3
12
2
7
17
4
@
9
1
10
@
14
5
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Part No.
125-0140-WW-S
125-0078-018
125-0078-048
125-0090-001
125-0090-002
SCE148PPOH
125-0154-TB-LH
125-0154-TB-RH
125-0072-025
125-0074-004
125-0025-00-U
125-0027-00
125-0023-00
Description
ASSY 125 SERIES "S" DRIVE PULLEY
KEY STD 1/8" SQ X 3/4"
INSERT CAP S PULLEY THRU
ASSY 125 BEARING PLATE RH
ASSY 125 BEARING PLATE LH
BEARING 125 SERIES DRIVE
BLOCK TRACKING LH 125 SERIES
BLOCK TRACKING RH 125 SERIES
SCREW SQUARE HEAD SET 1/4-20 X 1/2" ZP
SCREW SOCKET HEAD CAP 5/16-18 X 1" ZP
BRACKET DRIVER MOUNTING UNIVERSAL
PLATE DRIVE LOCK
BLOCK ANVIL TRACKING
Item
14
15
16
17
Part No.
125-0074-014
125-0019-WW
125-0022-00
NT14L8
Description
NUT HEX 5/16-18 ZP
ASSY SPACER BLOCK WITH STUDS
STUD SPACER BLOCK
WASHER THRUST NYLON
125 Series "D" Driver Assembly
LEGEND
5
@
PART# 125-0099-WW-SS-D
9
7
14
8
@
15
10
12
13
5
@
11
2
6
3
@
8
9
1
@
16
13
4
Item
1
2
3
4
5
6
7
8
9
10
11
12
Part No.
125-0140-WW-D
125-0078-018
125-0090-001
125-0090-002
SCE148PPOH
125-0154-TB-LH
125-0154-TB-RH
125-0072-025
125-0074-004
125-0025-00-U
125-0027-00
125-0023-00
Description
ASSY 125 SERIES "D" DRIVE PULLEY
KEY STD 1/8" SQ X 3/4"
ASSY 125 BEARING PLATE RH
ASSY 125 BEARING PLATE LH
BEARING 125 SERIES DRIVE
BLOCK TRACKING LH 125 SERIES
BLOCK TRACKING RH 125 SERIES
SCREW SQUARE HEAD SET 1/4-20 X 1/2" ZP
SCREW SOCKET HEAD CAP 5/16-18 X 1" ZP
BRACKET DRIVER MOUNTING UNIVERSAL
PLATE DRIVER LOCK
BLOCK ANVIL TRACKING
Item
13
14
15
16
Part No.
125-0074-014
125-0019-WW
125-0022-00
NT-14LB
Description
NUT HEX 5/16-18 ZP
ASSY SPACER BLOCK WITH STUDS
STUD SPACER BLOCK
WASHER THRUST NYLON
3.11 Recommended Spare Parts
QC Industries recommends that the items listed below be stocked as spares to minimize downtime
and ensure optimum performance of your 125Z Series conveyor (Figure 1). Refer to the previous
section Exploded Views for detailed views of specific conveyor areas and components.
Part #
ZE-WW-LLLYLLLLLL-ZAXNNN
ZE-WW-LLLYLLL-ZAXNNN
125-0110-WW-E
125-0090-001
125-0090-002
Z-0011-001-ASY
Z-0011-002-ASY
Where:
Y
WW
LLL
X
NNN
Description
Belt for “Z” (cleated)
Belt for “L or “R” (cleated)
Sealed Tail Assembly
RH Bearing Plate w/ Bearing
LH Bearing Plate w/ Bearing
Assy Idler Belt Tensioning for 8”-12” Widths
Assy Idler Belt Tensioning for 18”-24” Widths
1
Min. Qty.
1
1
1
1
2
2
= angle of conveyor bend, designated by letter (e.g., B=30, C =45, D=60, E=75, F=90)
= the conveyor’s nominal width in inches (e.g., 08)
= the conveyor section nominal length in inches (e.g., 060)
= cleat height (e.g., E=1/2”, F=3/4”, G=1”, etc.)
= number of cleats (odd numbers only - e.g., 013)
Belt for 125 Z Series conveyor
ZE-WW-LLLYLLLLLL-ZAXNNN
Assy Idler Belt Tensioning
Z-0011-001-ASY (8”-12”)
OR
Z-0011-002-ASY (18” & 24”)
STANDARD:
125-0090-002
LH Bearing Plate, with
Bearing
STANDARD:
125-0110-WW-E
125 Series Sealed Tail Assembly
STANDARD:
125-0090-001
RH Bearing Plate, with
Bearing
Conveyor Part Number to Belt Part Number conversion:
1
E
S
B
Z
1
2
-
0
3
6
C
0
4
8
0
3
6
-
A
S
Q
-
Z
A
G 0
Z
E
-
1
2
-
0
3
6
C
0
4
8
0
3
6
-
Z
A
G
0
1
1
7
To order spare or replacement parts, please contact QC Industries Customer Service department at
(513)753-6000.
Figure 1
7
3.12 Troubleshooting
Note: if you are unable to remedy the problem with these corrective actions, please contact QC
Industries Customer Service at (513) 753-6000. Failure to correct the problem may lead to abnormal
use of the conveyor, thereby voiding the warranty.
Symptoms
Possible Cause
Corrective Action
Belt is slipping or
stops under load
Application demand is more than the
conveyor is rated for
Verify the conveyor’s capacity for the
application
Lubrication between drive pulley and belt Clean bottom of belt and drive pulley
Eccentric tail shaft not rotated into
proper position
Belt does not move
without load
Refer to Section 3.05 Figures 26-27
Timing Belt or Chain under drive guard is Verify correct installation as instructed in
not connected
Section 2.09
Belt does not have tension
Verify that tail pulley is in correct position
as instructed in Section 3.02
Belt will not track at
Drive End
Accumulation; belt wear
Track the belt as instructed in Section 3.02
Belt will not track at
Tail End / Z-Track
connector plates
Belt wear; irregular product loading
Track the belt as instructed in Section 3.02
Belt is becoming brittle Belt is being attacked by chemicals or
or delaminating
excessive heat
Contact factory to discuss application
parameters for proper belt selection
Belt’s useful life has expired
Replace the belt
Belt is discoloring
Urethane Belts are subject to
discoloration when exposed to UV light
None
Motor is hot
Normal operation - motor can run with a None
skin temperature of 221°F under normal
conditions
Speed Reducer is hot
Motor is not protected with overload
protection and is drawing too much
current
Install overload protection on the motor
Normal operation – speed reducer can
run with a skin temperature of 225°F
under normal conditions
None
The reducer’s vent plug was not installed Install vent plug as instructed in Section
2.10
Speed Reducer is
leaking oil
Bearing noise
Speed reducer’s useful life has expired
Bearings are damaged or failing
Motor or speed controller not wired
Belt is traveling the
reverse of the desired properly
direction
Belt top surface has
premature wear or
grooves at outer
edges
Replace the speed reducer
Initial installation not performed correctly Purchase a new speed reducer and follow
and speed reducer input seal is damaged manufacturers installation instructions
carefully
Z-Track Idler Guards are adjusted too low
and digging into belt surface; or belt is
over tensioned at connector plates and
rubbing on return flanges.
Replace bearings
Check wiring, correct per wiring instructions
Adjust Idler Guards to clear belt top surface
(maximum of 1/8” clearance to minimize
pinch points); or track belt as instructed in
Section 3.02
4.01 Conveyor Serial Number
The conveyor’s serial number is located on the
frame at the drive end of the conveyor, opposite the
side on which the gearmotor will be mounted
(Figure 1).
Serial
Number
Record the serial number in a place where it can be
accessed for reference; a place has been provided
on the back cover that can be used for multiple
conveyors. This will assist any future inquires
regarding the conveyor, its accessories, the order it
was shipped on, or replacement parts.
Figure 1
4.02 Conveyor Warranty
QC INDUSTRIES warrants that our conveyors are free from defects in materials and workmanship and
fit for the ordinary purposes for which such goods are used, under normal installation, use and service
for five (5) years from date of purchase or 10,500 hours of running use, whichever is sooner. QC
INDUSTRIES will replace any defective part within the warranty period, without charge, provided:
(1)
(2)
(3)
(4)
The Purchaser gives QC INDUSTRIES prompt written notice of the defect, including the date of
purchase and original purchase order number.
The Purchaser will then be given a return goods authorization number (RGA#) which must be
displayed on all labels and packing slips returned with merchandise. (See RGA section)
The Purchaser pays for delivery of the defective part to QC INDUSTRIES for inspection and
verification of the defect.
The Purchaser shall pay all shipping and insurance charges for the replacement part from QC
INDUSTRIES and the cost of installing the replacement part.
This warranty is limited to the replacement of defective parts. QC INDUSTRIES WILL NOT BE LIABLE
FOR ANY DAMAGES CAUSED BY ANY DEFECT IN THIS UNIT. This warranty shall not apply if any failure
of this unit or its parts is caused by unreasonable use, lack of maintenance, improper maintenance
and/or repairs, incorrect adjustments, exposure to corrosive or abrasive material, moisture causing
damage, or any modification or alteration affecting the operation of the unit which is not authorized by
QC INDUSTRIES in writing. This warranty shall not apply to the following items that are covered by their
manufacturer's warranty, subject to any limitation contained in those warranties.
(A)
(B)
(C)
Bearings
Motors
Reducers
(D)
(E)
(F)
Controllers
Casters
Belts (unless otherwise agreed to in writing)
CAUTION: Any attempt to repair such items may actually void the manufacturer's warranty. Any
description of this unit is only to identify it and is not a warranty that the unit fits the description. Only
an official of QC INDUSTRIES may make any warranties for QC INDUSTRIES. Any warranties implied by
law are limited in duration to the five (5) year term of this warranty. EXCEPT AS SET FORTH HEREIN, QC
INDUSTRIES MAKES NO OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED, OR STATUTORY,
INCLUDING MERCHANTABILITY FOR FITNESS OR ANY PARTICULAR PURPOSE.
Lost or Damaged Goods
Shipments should be inspected immediately upon receipt for lost or damaged goods. Any loss or
damage should be noted on the carriers receipt (or bill of lading) at the time of acceptance. If items
are perceived to be lost or damaged after the shipment has been accepted, it becomes more difficult
to file a claim with the carrier if the receipt does not indicate such loss or damage. Do not, at any time,
request the carrier to return any items or shipment to QC Industries without previous authorization
from our company for such a return. Please notify QC Industries as soon as any loss or damage is
discovered and request the department that handles the lost or damaged goods. You will need to
know a complete description of all lost or damaged items. If replacement items are needed, a
purchase order made out to QC Industries will need to be supplied. QC Industries will then contact the
carrier’s local agent and request that an inspection of the items be performed. This is absolutely
necessary. Unless an inspection is performed, the carrier will not entertain any claim for loss or
damage. After the inspection has been completed, the carrier will notify QC Industries. If the carrier
takes responsibility for the claim, a credit will be issued to you for the replacement item(s), including
freight charges from QC Industries, where applicable. If the carrier does not take responsibility for the
claim, a representative of QC Industries will contact you.
4.03 Returns
If, for any reason, an item needs to be returned to QC Industries or an in-house order needs to be
canceled or revised, the Purchaser is required to adhere to the following series of steps to ensure that
the return or cancellation is handled in the proper manner.
RGA Policy/Instructions:
(1)
(2)
(3)
(4)
(5)
Promptly call QC Industries Customer Service at (513) 753-6000 and request a Returned
Goods Authorization. At this time, you will be asked to answer pertinent questions relating to
the returned items. We ask that you have the following information ready:
(A)
Name of distributor (if applicable) through which item(s) were purchased.
(B)
Name of the Customer and/or end user of the item(s).
(C)
Any/all purchase order numbers related to the item(s) in question.
(D)
Phone numbers and names of contacts involved in the return (if it becomes
necessary that they be contacted later).
(E)
Complete part numbers of all items involved in the return.
(F)
Complete description as to the reason for the return and the actions that need to be
taken. (If the item is to be replaced, a new purchase order number must be supplied
by the Purchaser along with complete shipping and billing instructions. These
replacements will be treated as separate orders by QC Industries and evaluated for
possible credit only after returned items are received and evaluated.
After the call is made to QC Industries, we will process your RGA and you will be faxed the RGA
number to use for returning the item(s). RGA numbers will not be given verbally over the
phone.
Upon receipt of your RGA, you are required to return the item(s) within 30 days of receipt of
authorization. After 30 days, the Return Authorization will be void if item(s) are not received by
QC Industries. All shipping charges and freight insurance charges of returned goods will be
the responsibility of the Purchaser.
The RGA number must be clearly marked on the outside of all packages. It must also be on
any paperwork, packing slips, or delivery receipts. If there is no RGA number visible on the
package, the package may be refused and sent back at the Purchaser's expense.
After receipt of returned goods, QC Industries will evaluate the item(s) for credit and take the
appropriate action. Standard items that are returned in new, resalable condition will be
credited for the amount of the purchase less 20%. Full credit will only be issued on items that
are considered to be defective at the time of shipment from QC Industries and are evaluated
to be under warranty. Please allow 30 days for credits to be issued.
Order Cancellation / Revision Policy
If it becomes necessary to cancel or revise an order prior to the order being shipped, QC Industries
reserves the right to evaluate each order that is to be canceled or revised and determine if any
charges are applicable. A 20% restocking charge will apply if an order is assembled and ready to ship
prior to its cancellation or revision and the order is totally comprised of standard stock items. If the
order contains other than stock items, an evaluation will be made based on the status of the order.
Additional charges will be included with the 20% restocking charge if any of the following conditions
are met:
(A)
The order contains any items that are considered to be non-stock items and these items have
already been produced by QC Industries or one of its suppliers.
(B)
The order contains any items that require special handling or assembly and these processes
have been completed.
(C)
The Customer has specified that they will pick-up an order from QC Industries’ facility by a
predetermined time and that time frame has expired. In this case, QC Industries will make an
attempt to notify the Customer. If this cannot be accomplished in a reasonable time, the order
will be disassembled and the Customer will be charged a restocking fee and any additional
charges based on the orders contents as explained herein.
Notes
Notes
Notes
For future reference, record the date, part number and serial number for each conveyor in your order.
Date
Part Number
Serial Number
Additional Conveyor Products from QC Industries
125 Series
Belt Conveyors
• Available in four
styles:
• Automation
• Corrosion
Resistant
• Cleated
• Magnetic
• Less than 5minute belt
change
Widths up to 24”,
lengths up to 25’
Flextrac Plastic
Chain
300 Series
Indexing
InnerDrive
Conveyors
• Low 3.03” profile
• High speeds – up
to 375 fpm – and
heavy loads – up
to 500 lbs.
• More than 100
belt type and
material
combinations
• Partial belt
changes reduce
maintenance costs
• Precision indexing
tolerance of .015"
• Self-tracking
V-Guide
• Custom cleats and
profiles
• High speeds up to
2000 feet per
minute
• Available in
washdown and
metric versions
• Save space by
moving the motor
inside the
conveyor frame
• Safe, efficient
24vdc motor
• Low profile design
• Variable speed
control card easily
integrates with
“run-on-demand”
applications
For more information, visit our website — www.qcindustries.com —
or contact a member of our knowledgeable sales staff at (513) 753-6000
Part No.: MKTG-MAN-125Z-09-07-100-DS

125Z Manual

Transcription

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