UniSort® X Sortation Conveyor

Transcription

Product Manual
UniSort X® Sortation Conveyor
Application Guidelines, Specifications,
Installation Procedures, Maintenance, Spare
Parts, and Product Index
9500 12/03
To contact FKI Logistex, Automation Division:
For service: Customer Service and Support Group (CSSG)
Hotline 1-800-992-1267
On the World Wide Web: www.fkilogistex.com/automation
By mail:
FKI Logistex, Automation Division
10045 International Boulevard
Cincinnati, Ohio 45246
(513) 874-0788
Read this document thoroughly before attempting to perform maintenance or repairs to the
applicable FKI Logistex Automation Division conveyor system components or devices.
Exercise extreme caution when working around moving and rotating conveyor equipment.
Wear the proper clothing and safety equipment. DO NOT attempt to perform any
maintenance until the equipment is de-energized, locked out and tagged out in accordance
with established company procedures.
The information presented in this document is correct at the time of publication. FKI Logistex
Automation Division has made every effort to ensure that the information presented is correct
and free from error. However, some errors or misprints may occur. Please contact FKI
Logistex, Automation Division with any corrections.
This document is copyrighted © 2003 by FKI Logistex, Automation Division, all rights
reserved. No Part of this Users Guide may be reproduced and/or distributed to parties other
than the customer and the customer’s employees for whom it was originally produced.
The following terms are trademarks™ of FKI Logistex, Automation Division; Accuglide™,
BOSS™ UniSort ™, E-Z Set™
Direct questions and comments concerning the information contained in this manual to:
[email protected]
or
Product Management
FKI Logistex, Automation Division
10045 International Boulevard
Cincinnati, Ohio 45246
(513) 874-0788
9500 12/03
Table of Contents
Section A Product Summary
UniSort X Product Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A - 1
Section B Application Guidelines
Product Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 2
Drive Section and Power Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Idler Section (Single Sided and Dual Sided) - - - - - - - - - - - - - - - - - - - - - - - - - Single Sided Intermediate Section - Divert Switch Operation - - - - - - - - - - - - - Dual Sided Intermediate Section - Divert Switch Operation - - - - - - - - - - - - - - -
B-2
B-4
B-5
B-6
Section C Standard Specifications and Features
Mechanical and Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 1
Air Consumption - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Filter/Regulator/Lubricator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Pressure Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Solenoid Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Capacity/Size of Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Chain - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Tubes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Center Crossover Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Oiler (Program Controlled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Control Systems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pushers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pusher Out Of Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pusher Pin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switch Dividing Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switch Pivot Block - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Medium - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Sprocket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - End Pop-up Safety Roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Idler Sprocket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lengths - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Minimum Elevation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Number of Diverts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operating Air Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Overload Current Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Paint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Photo Eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Proximity Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Side Switch Air Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Slat Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Speeds - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9500 12/03
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-3
C-3
C-3
C-3
C-3
C-3
C-3
C-3
C-3
TOC - 1
Table of Contents
Sort Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tail Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Take-Away Conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tube Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Variable Frequency Drive (VFD) (Required) - - - - - - - - - - - - - - - - - - - - - - - - - Widths - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-3
C-3
C-4
C-4
C-4
C-4
Control Hardware Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 5
Air Pressure Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Solenoid Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Current Sense Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Photo Eye - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pusher Pin Out Of Track Limit Switch - - - - - - - - - - - - - - - - - - - - - - - - - Emergency Stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - End Pop-up Roller Detection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Motor Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Motor Starter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Photo-electric Eyes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Variable Frequency Drive (VFD) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-5
C-5
C-5
C-5
C-5
C-5
C-5
C-5
C-6
C-6
C-6
Section D Engineering Data
Chain Pull and Required Horsepower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D - 1
Establishing Speed and Gap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D - 1
Section E Layout Dimensions
Layout/Installation Drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - 1
Layout for 20 Degree Diverts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - 2
Layout for 30 Degree Diverts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - 4
Section F Accessories
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F - 1
Section G Installation Procedures
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 1
Accepting Shipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Shortages or Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lost or Damaged Shipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Claims and Returns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Codes and Standards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Warning Signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Parts Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Factory Assistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
G-1
G-1
G-1
G-1
G-1
G-2
G-2
G-2
G-2
Installation Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 3
Installation and Assembly Steps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 3
Installing the Conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 5
Installing Floor Supports - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 5
Sequence of Sorter Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 6
Installing the Idler Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 7
TOC - 2
9500 12/03
Table of Contents
Installing Intermediate Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Drive Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Aligning Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Chain Guide Track - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Aligning the Idler Cam Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Air Piping and Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the Crossover Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checking and Aligning the Divert Switch Mechanism - - - - - - - - - - - - - - - - - - Checklist Prior to Chain, Tube and Pusher Installation - - - - - - - - - - - - - - - - - Installing the Carrying Chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Lubrication and Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Facts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Stretch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Carrying Tubes and Divert Pushers - - - - - - - - - - - - - - - - - - - - - - - - Preparing To Check The Levelness And Clearance - - - - - - - - - - - - - - - - - - - Adjusting the Levelness and Clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Carrying Tubes and Divert Pushers - - - - - - - - - - - - - - - - - - - - - Carrying Chain Take-up Adjustment, (Catenary Take-up) - - - - - - - - - - - - - - - Installing Take-Away Conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Discharge End Conveyor (if used) - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Electrical/Control Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Electrical Power and Control Device Wiring - - - - - - - - - - - - - - - - - - Variable Frequency Drive Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - Verifying Correct Drive Motor Rotation - - - - - - - - - - - - - - - - - - - - - - - - - - Final VFD Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Over-current Relay/Sensor Adjustments - - - - - - - - - - - - - - - - - - - - - Air Pressure Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Pressure Switch Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the Photoeye - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Lubricator(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Idler Sprocket Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switch Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Chain Lubricator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the Oil Injectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Determining Correct Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
G-8
G-9
G - 10
G - 11
G - 15
G - 16
G - 17
G - 18
G - 20
G - 21
G - 23
G - 23
G - 23
G - 23
G - 24
G - 24
G - 25
G - 26
G - 27
G - 28
G - 29
G - 30
G - 31
G - 32
G - 32
G - 32
G - 33
G - 33
G - 33
G - 33
G - 33
G - 33
G - 33
G - 33
G - 34
G - 35
G - 35
Checking Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 37
Internal Jam Detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Assembling the Internal Jam Detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pop-Up Safety Roller Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Product Containment Guarding - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Personnel Safety Guarding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Final Installation Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Before Applying Electrical Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - After Applying Electrical Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Final Installation Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
G - 37
G - 38
G - 39
G - 40
G - 41
G - 41
G - 41
G - 42
G - 43
Checking Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 44
Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 44
Adjusting the Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 44
9500 12/03
TOC - 3
Table of Contents
Section H Maintenance
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 1
Making a Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 3
Initial Start-up/Run-in Period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 4
Dorris Power Unit Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 4
Daily Inspections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 7
Weekly Inspections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 7
Air Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Regulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air Lubricator(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Tubes (Slats) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Control Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pushers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - General Structure/Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sorter Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Section Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Oiler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Setting Up the Idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the Injectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Facts and Care - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Stretch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Chain Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety Guards and Devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Internal Jam Detector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
H-7
H-7
H-7
H-7
H-7
H-7
H-8
H-8
H-8
H-8
H-8
H-8
H-9
H-9
H-9
H - 10
H - 10
H - 11
H - 12
H - 13
Semi Monthly Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 15
Cleaning (General) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Cleaning and Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
H - 15
H - 17
H - 19
H - 20
Monthly Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 21
Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Tubes (Cleaning) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Pushers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Divert Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Photoeye - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive V-Belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Floor Supports/Hangers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Section Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sprockets/Hubs/Pulleys - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Section Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Reducer Oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Reducer Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Other Reducer Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TOC - 4
H - 21
H - 21
H - 22
H - 22
H - 22
H - 23
H - 23
H - 23
H - 23
H - 24
H - 24
H - 24
H - 25
H - 25
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Table of Contents
Semi Annual Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 26
Bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Chains - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Carrying Chain Guides - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Plastic Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Section Reducer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety Provisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Reentry Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
H - 26
H - 26
H - 26
H - 26
H - 26
H - 26
H - 26
H - 27
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - H - 28
Section I Spare Parts
General Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 1
Spare Parts Related by Hand - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 3
Spare Parts Related by Width - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 3
Spare Parts Related by Width and by Hand - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 3
Spare Parts Related by Width and by Hand and by Angle (Deg) - - - - - - - - - - - - - - I - 4
Spare Parts Unique to Dual Sided Sorters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 5
Spare Parts Unique to Dual Sided Sorters Related by Angle - - - - - - - - - - - - - - - - - I - 6
Idler and Intermediate Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 7
Divert Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 8
Crossover Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 9
Internal Jam Detector Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 11
Catenary Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 12
Return Section Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 13
Drive Section Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 14
Oiler (Drive Section) Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 16
Fill Roller (Drive Section) Spare Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 18
Drive Section Spare Part Sheaves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 20
Drive Section Reducers, Bushings, Taper Bushings, V-Belts, and Shafts - - - - - - - - I - 24
Section J Product Index
Unisort X Idlers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 1
Unisort X Intermediate Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 2
Unisort X Catenaries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 3
Unisort X Returns - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 4
Unisort X Drives - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 5
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TOC - 5
Table of Contents
TOC - 6
9500 12/03
Product Summary
SECTION A:PRODUCT SUMMARY
UniSort X Product Summary
Table A 1 Product Summary for the UniSort X Sortation Conveyor
Conveyor
Components
Style
High Speed Sorter
Comments
Sorter applications
should always be
reviewed with
manufacturer
Widths “W”
22”
28”
34”
Divert Switches
Left or Right /
Crossover
Product Handled
Cartons, bags, rolls,
bound packages,
etc.
2 to 100 lbs. Weight
6” to 48” Length
1” to 36” Width
Minimum Elevation
Tube Centers
Slat Centers
Drive Medium
2-1/2”
Divert pushers on 5”
Centers
1-3/8” x 12 ga. steel
5”
Divert pushers on 5”
Centers
Aluminum Slat
#100 Roller Chain w/
Extended Pins and
Carrier
Bearings
Divert Centers
Number of Diverts
Sort Rate
Based on width Consult Factory
Drive Components
Shaft mounted
reducer w/variable
speed controller.
Catenary
after drive
Main Bed Base
Frame
14” x 1-1/4” x 10 ga.
Based on HP
for underhung power Channel
units.
Side mount is
available
9500 12/03
Limited only by
distance between
sort lanes and/or
conveyor pull
requirements
Tail Components
Fixed idler with or
without PTO for
upstream belt
Speeds
350, 400, 450, and
500 fpm
Other speeds available w/variable
speed control.
50 to 250 CPM
Actual rate depends
on product
dimensions, gap
between product,
and conveyor speed.
Maintenance
Reliability
Modular construction, high strength
low friction
materials, automatic
lubrication, “works in
a drawer” divert
switch assemblies
Paint
Medium Gray
Powder-coated
epoxy-base finish
A-1
Product Summary
Table A 2 UniSort X Layout Dimensions
20° Divert Angle
Single Side Sortation
Infeed Conveyor Width “W”
Sorter Width “W”
Infeed Section Length
Intermediate Section Length
Drive Section Length
Dual Side Sortation
28
34
22
34
49-1/2
55-1/2
43-1/2
55-1/2
170
185-3/4
154-1/4
185-3/4
129-1/2
145-1/4
113-3/4
145-1/4
60
60
60
60
30° Divert Angle
Single Side Sortation
Infeed Conveyor Width “W”
Dual Side Sortation
28
34
22
34
Sorter Width “W”
49-1/2
55-1/2
43-1/2
55-1/2
Infeed Section Length
158-1/8
171-1/4
145
171-1/4
Intermediate Section Length
103-1/4
113-3/4
92-3/4
113-3/4
60
60
60
60
Drive Section Length
Table A 3 Delivery Rates
Delivery Rate
Uniform Case Length-Inches
6
9
12
16
18
24
30
36
42
48
A-2
Speeds FPM
(Delivery Rate / Cases Per
Minute)
300
257
225
193
180
150
129
113
100
90
367
314
275
236
220
183
157
138
122
110
Note
The rates shown in this chart at left are based
on constant 12” gap between cases and all
cases being the same length. Actual rates will
depend on case length mix, induction system
thru-put and availability of product at
induction station.
9500 12/03
Application Guidelines
SECTION B:APPLICATION GUIDELINES
Product Description
The UniSort X is a sortation conveyor. It is fitted with either a tubular or contoured flat
conveying surface. The term UniSort Xa is used to differentiate a standard tube sorter and a
sorter with the contoured slats (Figure B - 1). These tubes/slats are attached to and
transported by a special matched pair of RC-100 roller chains. These chains are fitted with
roller bearings which ride on a uniquely designed UHMW chain track. Both the carrying tube
and flat slat surfaces utilize a sliding pusher to affect the diverting of product. The UniSort X
requires a 12” gap between cartons and is capable of operating up to speeds of 500 fpm.
The divert pushers are installed between each pair of tubes or slats and are free to slide at a
fixed angle. The recommended divert angle for speeds of 350 fpm and below is 30°. For
speeds above 350 fpm, a divert angle of 20° is mandatory. The tubes or slats themselves are
installed perpendicular to the direction of travel and function to transport product for diverting.
In all UniSort X designs, the divert pushers travel along the opposite side to which product is
to be diverted. The sortation control unit signals air operated divert switch mechanisms which
direct the correct number of pushers to divert the product onto the pre-assigned take-away
conveyor. Take-away conveyors are located at the fixed divert points along the side (or sides)
of the UniSort X.
As the conveying surface returns, all pushers are moved to the center of the tube or slat.
Returning pushers are maintained in this position until they reach the idler where their
position is set for diverting.
PUSHER
UNISORT X
PUSHER
CARRYING CHAIN
EXTENDED PIN
UNISORT Xa
CARRYING SLAT
CARRYING TUBE
GUIDE PIN
Figure B - 1 UniSort X (Carrying Tubes) and UniSort Xa (Flat Slat) Cross Sections
9500 12/03
B-1
Operation
The following describes the mechanics of sorter operation. Personnel performing
maintenance should be familiar with the UniSort X operation.
Note: The terms Carrying Tubes and Slats are used interchangeably.
Drive Section and Power Unit
The UniSort X drive section with power unit (Figure B - 2) provides the required carrying
chain pull and speed. The product for sorting is conveyed on tubes or contoured flat slats
attached to extended pins in the right and left side carrying chains. The divert pushers are
located between every two consecutive cross (carrying) tubes.
The carrying chains are driven by drive sprockets located on each inside end of a drive shaft.
The drive shaft itself is driven by V-belts connected between a drive sheave on the motor and
a driven sheave on a shaft mounted reducer (Figure B - 2). The reducer is powered by a
TEFC, constant speed AC motor. The power unit (reducer and motor) may be side mounted,
underhung, or floor mounted.
The carrying chains are guided and supported by UHMW chain guides located on the side of
each UniSort X section. The chain tension is maintained either by an included catenary takeup section or by adjusting the drive shaft’s location.
On dual sided UniSort X configurations, the divert pushers are returned and staged for dual
sided diverting on the underside of the idler section. The divert pushers on all UniSort X
configurations are guided by pin guide wheels mounted on the drive shaft.
B-2
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DRIVE SHAFT
FILL ROLLERS
DRIVE SPROCKET
CAM RETURN DISCS
REDUCER
CARRYING CHAIN
SHEAVE
PIN GUIDE
V-BELT
SHEAVE
AC MOTOR
Figure B - 2 Drive Section and Power Unit
9500 12/03
B-3
Idler Section (Single Sided and Dual Sided)
The idler section is located at the infeed end of the UniSort X. Besides functioning as a
terminal end, the idler section typically contains the first divert position.
The divert pushers are guided up and around the infeed end by a divert pusher cam retainer
or by two divert pusher cam retainers for the dual sided UniSort X. The pusher cam retainers
and the carrying chain idler sprockets are mounted on the idler shaft.
The pin guide tracks, which are mounted on every UniSort X section, maintain correct divert
pusher position as they travel between divert points.
On the dual sided UniSort X, return pusher guiding and pusher staging switching are done at
the idler section. For dual-sided pushers using down-the-side configuration, an undersidemounted single-sided divert switch performs the staging by allowing the pushers to return to
the right or left as they travel to the top of the idler section.
RE-ENTRY
BLOCK
RE-ENTRY
BLOCK
PUSHER RETURN
GUIDE
PIN GUIDES
CROSSVER SWITCH
PUSHER STAGING
SWITCH LOCATION
LEFT HAND
DIVERT SWITCH
LOCATION
PUSHER RETURN
GUIDE
CROSSOVER
CAM GUIDE
CAM GUIDE
PIN GUIDE
RIGHT HAND
DIVERT SWITCH
IDLER SHAFT
Figure B - 3 Idler Section (Dual Sided Shown)
B-4
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Single Sided Intermediate Section - Divert Switch Operation
The intermediate section contains a continuation of the divert pusher pin guide tracks and
carrying chain support guide rails. The divert switch assembly and divert pusher pin cam
guide rails are located within the intermediate section to meet the desired divert center
spacing.
For the single sided, the divert switch assembly (Figure B - 4) is located on the side opposite
the divert point. The non-diverted pushers travel down this side to each divert switch
assembly. The guide pin of each divert pusher moves within the pin guide track.
The divert switch assembly also contains a continuation of the pin guide track. A pivoting
divert blade controlled by an air cylinder is located following the pin guide track. In the nondivert position, the switch block will allow the divert pusher to pass straight through and
continue down the non-divert side.
When diverting is to take place, a control unit signals an air solenoid valve which allows
compressed air into the air cylinder. This causes the divert blade to pivot into the divert
position allowing the divert pusher’s cam follower to contact the connecting cam guide rail
and travel to the divert point. The diverted pushers then travel down the divert side for
returning to the idler section. One divert pusher is assigned for each 5” of product length with
the leading edge of the divert pusher calibrated to the leading edge of the product to be
diverted. This calibration process takes place during product induction with photo-eyes used
to sense the product’s leading / trailing edge.
The divert switch uses a thru beam photo-eye to sense the exact position of the pusher
before the pusher’s pin-cam follower enters the switch block. The signal from the photo-eye
is used by the control unit to synchronize the switching action.
RE-ENTRY
BLOCK
CAM GUIDE
PIN GUIDES
RIGHT HAND
DIVERT SWITCH
Figure B - 4 Intermediate Section (Single Sided) with Divert Switch
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B-5
Dual Sided Intermediate Section - Divert Switch Operation
The dual sided UniSort X (Figure B - 5) with the divert pushers located down the side uses a
left and a right hand single sided type divert switch combined with a crossover switch to effect
dual sided product sorting.
The single sided type divert switches operate as previously described. The crossover switch
has an air cylinder actuated gate block located at the crossover point of the two diagonal cam
guide rails.
This design allows pushers on the right side to divert product to the left and likewise for
pushers located on the left side to divert product to the right.
The divert pushers are staged for right hand or left hand diverting by a single sided type divert
switch located on the under side of the idler section. The number of divert pushers assigned
and the divert direction is determined by a control unit based on product length and divert
lane assignment inputs.
RE-ENTRY
BLOCK
RE-ENTRY
BLOCK
PIN GUIDES
CROSSVER SWITCH
LEFT HAND
DIVERT SWITCH
LOCATION
CROSSOVER
CAM GUIDE
CAM GUIDE
PIN GUIDE
RIGHT HAND
DIVERT SWITCH
Figure B - 5 Intermediate Section - Dual Sided with Crossover Switch
B-6
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Standard Specifications and Features
SECTION C:STANDARD SPECIFICATIONS AND FEATURES
Mechanical and Electrical
Air Consumption
.0035 CFM x product divert rate (cases per minute)
Air Filter/Regulator/Lubricator
3/8” I.D. minimum size output line. One air filter/regulator/lubricator for every 100 to 150 feet
of sorter length.
Air Pressure Switch
0 to 100 psi; low pressure sensing relay set at 40 to 45 psi.
Air Solenoid Valve
4-way, single solenoid; .26 CV, 24VDC.
Capacity/Size of Product
2 to 100 lbs. weight.
6” to 48” length - 1” to 36” width
Cartons, bags, rolls, bound package, etc.
Carrying Chain
RC100 matched pair single pin extension every other pitch.
Carrying Tubes
1-3/8” O.D. steel tubing on 2-1/2” centers.
Center Crossover Switch
20° divert angle - 70 psi.
30° divert angle - 80 psi.
Chain Guide
UHMW - oil impregnated.
Chain Oiler (Program Controlled)
Pneumatic feed, electrically controlled.
Control Systems
Microprocessor based programmable control features allow complete sortation and induction
control. Inferfaces with main frames. PPLC based system optional.
Divert Centers
Based on width - consult factory
Divert Pushers
Located on 5” centers. UHMW low friction slide guide. Pusher top uses high impact ABS with
snap-on high friction, non-marking pads. Hardened steel guide pin with precision ball bearing
cam follower.
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C-1
Divert Pusher Out Of Position
Limit switch activated when pusher jumps across return guide track.
Divert Pusher Pin
3/8” diameter hardened steel.
Divert Switch
Non-jamming design; activated by double acting cylinder. Photo eye or proximity switch
senses exact pusher position for accurate divert action timing. Left or Right/Crossover.
Divert Switch Dividing Block
Hardened steel.
Divert Switch Pivot Block
UHMW
Drive
1 to 50 HP - shaft mounted reducer with torque arm and V-belt drive.
NEMA design “B” drive motor; 1750 rpm; continuous duty; totally enclosed; fan cooled.
Drive Components
Shaft mounted reducer with variable speed controller. Catenary after drive.
Drive Medium
#100 roller chain with extended pins and carrier bearings.
Drive Reducer
Shaft mounted; helical gear with torque arm.
Drive Sprocket
RC100, 32 tooth, taper lock, “B” style hub, hardened.
End Pop-up Safety Roller
Out of position detected by proximity switch (24 VDC).
Frame
14” x 1-1/4” x 10 ga. channel.
Idler Sprocket
RC100, 28 tooth, taper lock, “B” style hub, hardened (1 keyed and 1 floating).
Lengths
Infeed, intermediate, and drive section lengths based on sorter width. Fill sections
accommodate layout requirements. Total sorter length determined by maximum effective pull
limit per drive.
Minimum Elevation
Based on horsepower for underhung power units. Side mounted power units available (50”
elevation minimum for 40 hp).
C-2
9500 12/03
Number of Diverts
Limited only by distance between sort lanes and/or conveyor pull requirements.
Operating Air Pressure
70 psi regulated (side switches only)
Overload Current Sensor
Adjustable instantaneous trip type or time delayed.
Paint
Medium Gray
Photo Eyes
Required for determining product (case) length; determining case gap; indicating product
jams; sort lane full conditions; recirculation/error lane full, etc.
Proximity Sensor
18 mm (.7” not shielded; 8 mm (.3”) sensing range; 3 wire; current sourcing (PNP) mode; 9.6
to 55 VDC supply; 200 MA maximum load current.
Side Switch Air Cylinder
Double acting; 1-1/16” dia. x 1/2” stroke. Operating pressure at 70 psi.
Slat Centers
Divert pushers on 5” centers - aluminum slat.
Speeds
350, 450, and 550 fpm - other speeds available with variable speed control.
Sort Rate
50 to 250 CPM - actual rate depends on product dimensions, gap between product, and
conveyor speed.
Tail Components
Fixed idler with or without PTO for upstream belt.
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C-3
Take-Away Conveyors
The rates shown in Table C.1 are based on constant 12” gap between cases and all cases
being the same length. Actual rates will depend on case length, mix, induction system thruput, and availability of product at induction station.
Table C 1 Delivery Rate - Cases/Minute - FPM
Uniform Case LengthInches
Speeds FPM
(Delivery Rate / Cases Per
Minute)
6
9
12
16
18
24
30
36
42
48
--225
193
180
150
129
113
100
90
---236
220
183
157
138
122
110
Tube Centers
2-1/2” divert pushers on 5” centers. 1-3/8” x 12 ga. steel.
Variable Frequency Drive (VFD) (Required)
Sized per drive motor horsepower; 0-60 second acceleration time adjustment; 0-150% start
torque adjustment with current overload protection.
Widths
“W” = 22”, 28”, and 34”.
C-4
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Control Hardware Devices
Air Pressure Switch
Located on the sorter to drop drive power when air pressure falls below 50 psi. Contact status
is supplied to control system.
The operating air pressure for the UniSort X is 70 psi (side switch) set at the supplied air filter/
regulator/lubricator located on the sorter.
Air Solenoid Valve
Located at each divert point. Actuates the divert switch which diverts product with the
assigned pushers.
The control system outputs a signal to the air solenoid valve. This output must be properly
synchronized (timed) with the photo eye input for reliable diverting action. The amount of time
the air solenoid valve remains “on” is determined by the control system based on the number
of pushers assigned to that divert point.
The first unassigned pusher causes the switch mechanism to return to the non-divert position
providing the air solenoid valve has been de-energized.
Current Sense Relay
Used to detect excessive drive motor current resulting from an electrical/mechanical drive
fault/jam condition. It is wired between the motor disconnect switch and the motor starter.
When tripped, drive power should be dropped. Relay contact status is supplied to the control
system.
Divert Photo Eye
A divert photo eye is located at each divert point of the sorter and is used for sortation
tracking and synchronizing the divert switching mechanism. The photo eye detects the
presence of a divert pusher by sensing the leading edge of the pusher’s metal backplate.
A photo eye may also be used for verifying the UniSort X’s operating speed.
The divert photo eyes are interfaced to the control system.
Divert Pusher Pin Out Of Track Limit Switch
Used to detect a divert pusher out of position; located at the end of the UniSort X. Drive
power is dropped or inhibited if “pin out of track” is actuated. Switch status is supplied to
control system.
Emergency Stop
Emergency stop push buttons and pull cords are used by the operator to effect an
“emergency stop” -- drive power off condition. Contact status is supplied to control system.
End Pop-up Roller Detection
A proximity switch or limit switch located on the drive end of the UniSort X to detect the
dislodging of the safety roller. Drive power should be dropped or inhibited when pop-out roller
becomes dislodged. Input status to control system.
Motor Disconnect
A motor disconnect switch is used to apply power to the soft start and is located near the
drive end of the UniSort X. The contact status of this switch is supplied to the control system.
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C-5
Motor Starter
Used to switch power to the drive motor via the motor disconnect switch and soft start.
Contact status is supplied to the control system.
Photo-electric Eyes
The usage of photo-eyes depends on the particular UniSort X sortation system configuration
and control system architecture.
Application for photo-eyes include:
1. Determining case (product) length; induction and sortation tracking.
2. Detecting product jam conditions at the sorter’s infeed, discharge ends; jams at sort
lane(s); detecting sort lane full conditions; sensing recirculation and error lane full conditions.
Drive power to the sorter is dropped for any product jam conditions.
Variable Frequency Drive (VFD)
Used to effect a smooth start-up acceleration of the UniSort X drive system. VFD is sized
based on the drive motor’s maximum current draw. One VFD is used for each drive motor.
The VFD is located near the drive motor and wired between the drive motor and a motor
disconnect switch.
For first time start-up, the VFD time, torque, and current limit controls are set at mid-range
before applying power. These controls are then fine-tuned per the VFD manufacturer’s
instructions to achieve a smooth acceleration of the UniSort X. Improper adjustment may
result in the sorter drive chain jumping a sprocket tooth when power is applied.
C-6
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Operator Station
PB’s, Keyboard
Status Display,
CRT
Drive Motor
Control
Motor Contactor
and Disconnect
Switch
Shoe Detect
Eyes
Air Solenoid
Valves
Product Code
Scanner
Product InductCase Length
Eyes
UniSort X
Control System
and
Power Panel
Emergency
Stop
Product
Jam Eyes
Sort Lane(s)
Full Eyes
Variable
Frequency
Drive
Tube Detect
Eyes
Pop-Out Roller
Limit Switch
Pin Out of
Track
Air Pressure
Switch
Line printer and host computer interfaces may also be included
Figure C - 1 UniSort X Basic Control Diagram
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C-7
Power On
• Emergency Stop Off
• Motor Starter/disconnect On
• No Drive Over Current Condition
• No Low Air Pressure
• No Pusher Pin Out of Track
• Pop-Out Roller In
• No Product Jam Condition
Check Sort
Start-Up Status
Status
OK
No
Inhibit
Drive Power
No
Inhibit Product
Induction
Remedy The
Cause
Indicate
Status/Fault On
Status Display
Yes
Sorter at
Speed*
Yes
Refer to
Product Induction
*Can be accomplished by reading pulse repetition
rate from first photo eye (at infeed end).
Figure C - 2 Sequence of Operation - Sorter Power-On Status
C-8
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1
Inhibit
Induction
Sorter
Status OK
No
Yes
Product
Induction
Verify Product
Induction
Conveyors On
Establish Minimum
(12”) Gap
Between Product
Identify Product
Type - Assign
To Sort Lane
Induct Product
Onto Sorter
• Product jam or unreliable sorting may
occur if gap too close.
• Product may be identified from scanner or
via manual input.
• If read error occurs, recirculate product or
divert to “error lane”.
• Product induction typically inhibited if any
defined UniSort X fault conditions exist.
• Product sorting inhibited if gap <12”, or
product ID mis-read occurs.
2
Refer to
Product Sorting
Figure C - 3 Sequence of Operation - Product Induction (Typical)
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C-9
2
Product Sorting
Identify Leading Edge
of Product at
Sorter Infeed
Assign Correct
Number of Divert
Pushers
Identify Product Trailing
Edge - Inhibit Assigning
Divert Pushers
Product Tracking
Verify Assigned
Sort Lane Not
Full
Divert Product
• Induct sensor (photo-eye) detects leading edge.
• Assign one pusher for each 5” product/case length
• Induct sensor detects trailing edge.
• There must be at least one un-assigned divert
pusher between product for dual sided sorters.
• Leading edge of product is “calibrated” with first
assigned divert pusher.
• Input photo eye #1 to establish initial count.
(Photo eye senses cam follower)
• Verify sort lane assignments of first assigned
divert pusher.
• Sort lane assigned during induction process.
• Diverting inhibited if assigned lane full.
• Divert lane air solenoid valve actuation is
synchronized with photo eye sensing first
assigned pusher.
• Divert is inhibited if pusher pin not in divert block.
• First un-assigned divert pusher causes divert block
return to non-divert position.
Figure C - 4 Sequence of Operation - Product Sorting
C - 10
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Engineering Data
SECTION D:ENGINEERING DATA
Prepare a layout drawing for all applications. The drawing will identify the required equipment
elements and will show clearance requirements for building structures, aisles, tie-ins with
adjoining conveyors, equipment, etc. The drawing should be drawn to scale and must be
accurate.
Chain Pull and Required Horsepower
Consult manufacturer’s Engineering department
Establishing Speed and Gap
To properly determine the speed of the system, and the gap between cases the following
items must be redefined.
1. New equipment or interfacing with existing.
2. Is an interface required with peripheral equipment
3. Product to be handled
• Type, length, width, height, and weight of the product.
• Description and same if available.
• Maximum number of cases and minimum number of product.
• Condition of top and bottom of product.
• Vertical or tapered product sides.
4. Rate of handling.
• Maximum number of units per minute.
• Minimum number of units per minute.
• Average number of units per minute.
• Peak number of units per minute
• Breakdown of handling by area: Replenishment, picking, sortation, shipping.
• Type of loading required: Palletized, direct load, load on carts, etc.
• Rate of machines required to sort: Palletizers, case sealers, packaging equipment
etc.
5. Description of Operation - if available; if no, understand the operation and formulate your
understanding of the operation in writing.
6. Type of operation - intermittent, constant.
7. Duty cycle - hours per day.
8. Operating environment.
9. Operating temperatures.
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D-1
Engineering Data
D-2
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Layout Dimensions
SECTION E:LAYOUT DIMENSIONS
Layout/Installation Drawings
The UniSort X layout/installation drawings contain information that identify and show the
placement of the
•
•
•
•
•
Drive Section
Return Section
Intermediate Section(s)
Catenary Section
Idler Section
Each UniSort X section is identified by a label affixed to the unit at the factory. The
information printed on these labels is useful for identifying the different UniSort X sections as
shown by the layout/installation drawings.
The following illustrations show the various sections and assemblies that can be included in a
UniSort X layout.
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E-1
Layout Dimensions
Layout for 20 Degree Diverts
"E"
"B"
STD DIVERT
CENTERS
DRIVE
AVAILABLE
RH OR LH
3"
IDLER
"A"
PTO DRIVE
AVAILABLE
RH OR LH
"D"
STANDARD
INTERMEDIATE
CATENARY
"E"
"F"
RETURN
DRIVE
"G"
"C"
"H"
POSSIBLE POWER UNIT INTERFERENCE
CONTACT BUSCHMAN ENGINEERING
Figure E - 1 Layout (20 Degree Diverts)
Description (20 Degree Diverts)
E-2
Dimension
INFEED CONV. WIDTH (BETWEEN FRAMES) - DIM "A"
22"
28"
34"
PTO DRIVEN INFEED BELT MIN. LENGTH REC. - DIM "B"
4'-0"
4'-0"
4'-0"
SORTER WIDTH (BETWEEN FRAMES) - DIM "C"
43 1/2"
49 1/2"
55 1/2"
IDLER SECTION LENGTH - DIM "D"
12'-10 1/4"
14'-2"
15'-5 3/4"
INTERMEDIATE SECTION LENGTH - DIM "E"
9'-5 3/4"
10'-9 1/2"
12'-1 1/4"
CATENARY SECTION MINIMUM LENGTH - DIM "F"
10'-0"
10'-9 1/2"
12'-1 1/4"
RETURN SECTION MINIMUM LENGTH - DIM "G"
10'-0"
10'-9 1/2"
12'-1 1/4"
DRIVE SECTION LENGTH - DIM "H"
5'-0"
5'-0"
5'-0"
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Layout Dimensions
1/2" FROM END OF SECTION
TO INSIDE RAIL OF SPUR
5 3/8" FROM END OF SECTION
TO DIVERT POINT
(EXCEPT W22 RETURN)
SPUR SIDE RAIL
SORTER SIDE RAIL
2" DIVERTED PACKAGE TO
OUTSIDE RAIL OF SPUR
20°
SORTER SIDE RAIL
DIVERT POINT
END OF SORTER SECTION
DIVERT LINE
Figure E - 2
Divert Location (20 Degree Diverts)
Notes:
1. A knife edge pulley is required on the infeed conveyor. A PTO driven infeed belt is recommended, but not required.
2. Underhung power unit standard, minimum elevation dependent on horsepower. Sidemount optional, minimum elevation 30".
3. Catenary section not required on sorters less than 50'-0" in length.
4. Dimensions for single-sided and dual-sided are identical.
5. If power unit is required on divert side, care must be taken to assure aftersort clearance.
6. Single-sided Unisort X conveyors are available with a special overlapped section which
will decrease sort centers. Contact Buschman Engineered Products group for more information.
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E-3
Layout Dimensions
Layout for 30 Degree Diverts
"E"
"B"
STD DIVERT
CENTERS
DRIVE
AVAILABLE
RH OR LH
3"
"A"
PTO DRIVE
AVAILABLE
RH OR LH
IDLER
STANDARD
INTERMEDIATE
CATENARY
"E"
"F"
"D"
RETURN
DRIVE
"G"
"C"
"H"
POSSIBLE POWER UNIT INTERFERENCE
CONTACT BUSCHMAN ENGINEERING
Figure E - 3 Layout (30 Degree Diverts)
Description (30 Degree Diverts)
INFEED CONVEYOR WIDTH (BETWEEN FRAMES) - DIM "A"
22"
28"
34"
PTO DRIVEN INFEED BELT MIN. LENGTH REC. - DIM "B"
4'-0"
4'-0"
4'-0"
SORTER WIDTH (BETWEEN FRAMES) - DIM "C"
43 1/2"
49 1/2"
55 1/2"
INFEED SECTION LENGTH - DIM "D"
12'-1"
13'-2 1/8"
14'-3 1/4"
7'-8 3/4"
8'-7 1/4"
9'-5 3/4"
CATENARY SECTION MINIMUM LENGTH - DIM "F"
10'-0"
10'-0"
10'-0"
RETURN SECTION MINIMUM LENGTH - DIM "G"
10'-0"
11'-0"
12'-0"
DRIVE SECTION LENGTH - DIM "H"
5'-0"
5'-0"
5'-0"
INTERMEDIATE SECTION LENGTH - DIM "E"
E-4
Dimension
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Layout Dimensions
TO INSIDE RAIL OF SPUR
TO DIVERT POINT
(EXCEPT W22 RETURN)
SPUR SIDE RAIL
SORTER SIDE RAIL
2" DIVERTED PACKAGE TO
OUTSIDE RAIL OF SPUR
DIVERT LINE
30°
SORTER SIDE RAIL
DIVERT POINT
END OF SORTER SECTION
Figure E - 4 Divert Location (30 Degree Diverts)
Notes:
1. A knife edge pulley is required on the infeed conveyor. A PTO driven infeed belt is recommended, but not required.
2. Underhung power unit standard, minimum elevation dependent on horsepower. Sidemount optional, minimum elevation 30".
3. Catenary section not required on sorters less than 50'-0" in length.
4. Dimensions for single-sided and dual-sided are identical.
5. If power unit is required on divert side, care must be taken to assure aftersort clearance.
6. Single-sided Unisort X conveyors are available with a special overlapped section which
will decrease sort centers. Contact Buschman Engineered Products group for more information.
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E-5
Layout Dimensions
VARIABLE LENGTHS
14"
CHAIN SAG
6" TO 8"
CHAIN SUPPORT GUIDE
Figure E - 5 Chain Sag 6” to 8”
60"
TOP OF TUBES
* VARIES
WITH
HORSEPOWER
"W" + 21 1/2"
4 3/16"
24 5/16"
MIN. ELEV.
40" TO 54"
FLOOR
* VARIES
WITH
HORSEPOWER
* = VARIES WITH HORSEPOWER
"W" = INFEED WIDTH
Figure E - 6 Power Unit (Underhung)
"W" + 21 1/2"
60"
4 3/16"
5 1/2"
MIN. ELEV.
30"
29 5/16"
SHIM OR SUPPORT
HEIGHT
* VARIES WITH
HORSEPOWER
FLOOR
* = VARIES WITH HORSEPOWER
"W" = INFEED WIDTH
Figure E - 7 Power Unit (Side-Mount)
E-6
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Accessories
SECTION F: ACCESSORIES
Accessories
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F-1
Accessories
F-2
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Installation Procedures
SECTION G:INSTALLATION PROCEDURES
Introduction
Accepting Shipment
Immediately upon delivery, check that all equipment received agrees with the bill of lading or
carrier’s freight bill. Any shipping discrepancy or equipment damage should be clearly noted
on the freight bill before signing.
Shortages or Errors
Report any shortages or errors to the Manufacturer’s Customer Service in writing within ten
(10) days after receipt of shipment.
Note: It is very important that you compare the Order Acknowledgment against the actual
material received when you receive the shipment so you have enough lead time to
order any missing parts. If you find that a part is missing during assembly, you may
have to discontinue assembly while you wait for the part to arrive.
Lost or Damaged Shipment
Report lost shipments to the Manufacturer’s Shipping Department.
If shipping damage is evident upon receipt of the conveyor equipment, note the extent of the
damage on the freight bill and immediately contact the transportation carrier to request an
inspection. Do not destroy the equipment crating and packing materials until the carrier’s
agent has examined them. Unless otherwise agreed by the manufacturer, the Purchaser
(User) shall be responsible for filing claims with the transportation carrier. A copy of the
inspection report along with a copy of the freight bill should be sent to the Manufacturer’s
traffic department.
Claims and Returns
All equipment furnished in accordance with the Manufacturer’s Agreement is not returnable
for any reason except where authorized in writing by the Manufacturer. Notification of return
must be made to the Manufacturer’s Customer Service Department, and if approved, a
“Return Authorization Tag” will be sent to the Purchaser (Users). The return tag sealed in the
“Return Authorization Envelope” should be securely affixed to the exterior surface on any
side of the shipping carton (not top or bottom), or affixed to any smooth flat surface on the
equipment, if not boxed.
Send authorized return shipment(s) transportation charges prepaid to the address indicated
on the Return Authorization Tag. If initial shipment is refused, the Purchaser (User) shall be
liable for all freight charges, extra cost of handling, and other incidental expenses.
Codes and Standards
The conveyor equipment is designed and manufactured to comply with the American
National Standard Institute’s “SAFETY STANDARDS FOR CONVEYORS AND RELATED
EQUIPMENT” (ANSI/ASME B20.1) and with the National Electrical Code (ANSI/NFPA70).
The Purchaser/Operator shall be familiar with, and responsible for, compliance with all codes
and regulations having jurisdiction regarding the installation, use, and maintenance of this
equipment. Appropriate lockout/tagout policy and procedures shall comply with the minimum
safety requirements outlined in the American National Standard Institute’s current publication
(ANSI Z244.1).
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G-1
Warning Signs
Warning signs and labels posted on or near the conveyor equipment shall not be removed,
painted over, or altered at any time. All safety devices, warning lights, and alarms associated
with the conveyor system should be regularly tested for proper operation and serviced as
needed. If the original safety item(s) become defective or damaged, refer to the conveyor
parts list(s) or bill(s)-of-materials for replacement part numbers.
Safety Features
•
•
•
•
•
•
•
•
DO turn off conveyor power source(s) and affix appropriate lockout/tagout device(s) to
operating controls before servicing the equipment. ONLY trained and qualified personnel
who are aware of the safety hazards should perform equipment adjustments or required
maintenance while the conveyor is in operation.
DO observe all warning signs, lights, and alarms associated with the conveyor operation
and maintenance, and be alert at all times to automatic operation(s) of adjacent equipment.
DO use extreme caution near moving conveyor parts to avoid the hazard of hands, hair,
and clothing being caught.
DO NOT sit on, stand on, walk, ride, or cross (over or under) the conveyor at any time
except where suitable catwalks, gates, or bridges are provided for personnel travel.
DO NOT attempt to repair any equipment while the conveyor is running, replace any conveyor component without appropriate replacement parts, or modify the conveyor system
without prior approval by the manufacturer.
DO NOT operate the conveyor until all safety guards are securely in place, all tools and
non-product materials are removed from or near the conveying surfaces, and all personnel are in safe positions.
DO NOT remove or modify any safety devices provided on or with the conveyor.
DO NOT clear jams or reach into any unit before first turning off the equipment power
source(s) and affixing appropriate lockout/tagout device(s).
Parts Replacement
To minimize production downtime, selected conveyor spare parts should be stocked for
replacement of defective components when required. Refer to the equipment bill(s)-ofmaterials where quantity requirements or code numbers are not indicated on the conveyor
parts list. For added convenience, a list of selected spare parts for standard products is
included in this manual (see Section I).
Factory Assistance
Contact Field Service for installation, operation, or maintenance assistance, or Customer
One Protection (COP) for replacement parts.
G-2
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Installation Overview
This topic presents a recommended order for installation, final assembly, and alignment
verification of the UniSort X Sortation Conveyor. The remainder of this section provides
detailed information.
The layout/installation drawings that should be referenced include:
•
•
•
UniSort X layout drawings which show type, location, and elevation of the UniSort X sections and associated conveyors.
Air piping/air connection drawing(s).
Electrical layout drawing(s).
Installation and Assembly Steps
1. Verify receipt of the correct types and quantities of UniSort X sections, installation hardware, loose parts, take-away conveyors, etc. as shown on the installation/layout drawings.
Note:
The parts that are typically shipped loose include: carrying chains, carrying tubes (slats),
divert pushers, air filter/regulator/lubricator, air pressure switch, variable speed controller,
any additional air lubricators, supports, guardrail, PTO components (if applicable), chain
track, and track splice joints.
A Field Kit for checking and performing alignments is also shipped loose. The Field Kit contains two (2) short strands of RC-100 carrying chain and a 3/8” x 18” length of keystock.
2. Mark the Layout - Refer to the layout drawing(s) and mark the location and centerlines of
the UniSort X onto the floor or mezzanine. Perform this for each UniSort X section and all
associated infeed, discharge, and take-away conveyors shown on the layout drawing(s).
It is also recommended that the part number, shown on the layout drawing for each section, be marked on the floor (or mezzanine) to indicate the section to be installed. This part
number is the same as the item number printed on the identification label affixed to each
UniSort X section.
3. Pre-install Floor Supports
Note:
If the conveyor is to be located on an elevated structural steel platform, the platform should
be in place and level along it’s entire length and width before installing any Unisort X section (see “Installing Floor Supports”).
4. Install the UniSort X sections starting at the infeed end (idler section with the PTO driven
infeed belt, if supplied) and working in direction of product travel (see “Installing Idler,
Intermediate, and Drive Sections”).
5. Check all sections for proper alignment.
6. Install the RC-100 VHS carrying chains (see “Installing the Carrying Chains”).
7. Install air piping, air filter/regulator/lubricator, air pressure switch, and any additional lubricators (see “Air Piping and Connections”).
8. With the air supply on, check all divert switches for proper alignment and smooth switching operation (see “Divert Switch Mechanism - Operational Checking and Alignment”).
9. Pass the test fixture through the sorter.
10. Install carrying tubes (slats) and divert pushers (see “Installing Carrying Tubes and Divert
Pushers”).
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G-3
11. Perform carrying chain take-up adjustment (see “Carrying Chain Take-up Adjustment”).
12. Install take-away conveyors/chutes (see “Installing Take-Away Conveyors”).
13. Install discharge end conveyor (if used) (see “Installing Discharge End Conveyor”).
14. Install drive motor variable speed control (see “Installing Drive Motor Variable Frequency
Drive”).
15. Install control panel(s) including motor starters, fuses, relays, terminal strips, sortationinduction control unit, etc.
16. Install photoeyes which are mounted on the UniSort X, induction, take-away, and discharge conveyors (see project electrical layout drawings, not included in standard product
manual).
17. Install all electrical power and control device wiring (see Electrical layout drawings).
18. Perform initial (power-off) variable frequency drive (VFD) adjustments (VFD manufacturer’s manual).
19. Check for proper oil type and quantity in the reducer. For additional information, see
“Monthly Maintenance” in Section G.
20. Install the automatic chain oiler and remove the v-belts from the motor to the reducer.
CAUTION:
All Dorris reducers are shipped without oil.
21. Apply momentary power to the UniSort X drive motor and be sure the direction of rotation
is correct.
22. Perform final VFD adjustments (VFD manufacturer’s manual, not included in standard
product manual).
23. Ensure that the drive over-current electrical relay/sensor is properly adjusted (see manufacturer’s instruction sheet).
24. Set the air pressure to the side switches to 65 - 75 psi operating pressure at air filter/regulator/ lubricator.
25. Be sure the air lubricators have the specified oil type and quantity.
26. Ensure that the chain lubricator oil reservoir contains the correct oil type and quantity and
is properly controlled.
27. Check each divert switch for proper operation by applying the specified voltage to the air
solenoid valve. Then, remove the signal (turn it off) and be sure the divert switch returns
to non-divert position.
28. Check the operation and adjustment of the internal jam detectors.
29. Be sure the pop-out rollers (or pivot-up roller assemblies) operate correctly.
30. Install product containment guarding.
31. Install personnel safety guards and safety labels or signs.
32. Perform final power-off and power-on checks.
33. Test run the installed UniSort X with product being diverted. Make any necessary adjustments.
G-4
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Installing the Conveyor
Installing Floor Supports
See the “Floor Supports and Ceiling Hangers” manual for complete floor support installation
instructions. The floor support information presented here provides additional information for
the UniSort X conveyors.
1. Pre-install type FSMU5 floor supports (supplied) with vibration isolation pads (Unisorb
Pads) to each UniSort X section and initially adjust to meet the installed elevation specification.
CAUTION: In order to reduce the possibility of side frame warping, verify that the sections are well supported while performing assembly operations and when
moving sections into place.
2. Install a single leg FSMU5 floor support to the drive motor mounting plate of side mounted
UniSort X drives (see Figure G - 1). This support may be installed after the drive section
has been set in place and aligned.
STANDARD
FSMU5 SUPPORT
SINGLE LEG SUPPORTS OR
SHIMS REQUIRED FOR
7 1/2 HP OR GREATER
*USE BEVEL WASHERS
FOR THESE SUPPORTS
( 6 LOCATIONS )
Figure G - 1 Side Mounted Drive+
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G-5
Sequence of Sorter Sections
Set the sections in place (see Figure G - 2) in the order of product flow starting with the idler
section (with PTO driven infeed belt, if supplied) and followed by the intermediate section(s).
The catenary come next (if supplied), the return section next and the drive section last.
CAUTION: Before beginning the actual installation of the sections, refer to the layout
drawings to verify proper identification of the sections. It is very important
that the sections be installed as specified by the layout drawings. The part
number shown for each section on the layout drawing corresponds to the
Item Number (#) printed on the identification label affixed to the side frame
of each section.
DRIVE
RETURN
CATENARY
INTERMEDIATE
IDLER
Figure G - 2 Sequence of the sorter sections
G-6
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Installing the Idler Section
To install the UniSort X idler section:
1. Verify the accuracy of the layout marked on the floor or on the structural steel platform, or
to the overhead structure.
2. Identify the idler (see Figure G - 3) and set it in place as shown on the layout drawing.
Adjust the floor supports to achieve the exact specified elevation.
3. Check that the idler section is level and square front-to-back and side-to-side, and correctly aligned with the induction conveyor.
CAUTION: As the idler section will be the “alignment reference section” for aligning
the remaining sections, it is most important that the idler section be carefully aligned and leveled. Re-check all alignments if the idler section is
accidentally bumped during installation of the remaining sections.
.
Figure G - 3 Idler Section
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G-7
Installing Intermediate Sections
To install the UniSort X intermediate sections:
2. Identify the first intermediate section (see Figure G - 4) and set it in place to be installed.
The floor supports must be pre-installed on the down stream corners and at any other
points shown on the layout drawing. Place Unisorb Pads between the floor supports and
the sorter.
3. Carefully align this intermediate section against the idler section. Complete fastening the
floor supports to this intermediate section.
4. Bolt the two sections together. Do not tighten the bolts until the intermediate section has
been carefully aligned to the idler section.
5. Repeat this process for all of the following intermediate sections.
Figure G - 4 Intermediate Section
G-8
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Installing the Drive Section
The drive section is typically the last UniSort X section to be set in place. Be sure floor
supports are pre-installed at the discharge end corners (see Figure G - 1).
2. Identify the drive section (see Figure G - 5), set it in place, and carefully align it against
the previous section.
3. Check the alignment of entire UniSort X after installing the drive section.
4. If the power unit is side mounted (PU-SM), be sure a single leg FSMU5 floor support is
installed on the drive motor mounting plate (see Figure G - 1).
Figure G - 5 Drive Section
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G-9
Aligning Sections
To check the alignment of two sections over their entire length:
1. Assemble a divert pusher onto two carrying tube slats with the two short lengths of chain
furnished in the field kit.
2. Place the test assembly onto the UniSort X with the pusher pin in the pin guide (see Figure G - 6). Slowly move test assembly in direction of travel. Be sure the pusher moves
freely with no interference along the entire length of the UniSort X.
Note:
Check the top and bottom sections of the UHMW pin guide to be sure they are flush where
sections join.
3. Adjust the sections as needed.
Note:
Misalignment of any UniSort X sections may result in accelerated wear and increased operating sound level.
4. After aligning the sections, tighten all bolts located in the section joint flanges. Aso, check
the tightness of all floor support bolts.
SLAT TUBES
DIVERT PUSHER
CHAIN
CHAIN
Figure G - 6 Checking Alignment of Two Sections
G - 10
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Installing the Chain Guide Track
To install the chain guide track:
1. Check the chain track support angle for proper height. Adjust if necessary by loosening
the bolts and adjusting the jack screws.
2. To install the first section of chain guide track, drill, countersink, and secure the track to
the support angle using 1/4” flat head screws and nuts (see Figure G - 7).
Figure G - 7 The Beginning of the First Section of Chain Guide Track
3. Place the splice parts as shown in Figure G - 8 and clamp in place.
4. Be sure the end of the chain guide track is aligned with the notch on the UHMW splice
(see Figure G - 8).
5. Drill through the angles with .187” dia. drill using the drill fixture (part #842086).
6. Install and tighten the No. 8 flat head screws before removing the clamps.
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G - 11
Figure G - 8 The End of the First Section of Chain Guide and the Chain Guide Splice
G - 12
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7. Attach the next section of chain track guide (see Figure G - 9).
8. Continue to install the track guide in 100’ lengths until less than 100’ of conveyor remains.
Figure G - 9 The Beginning of the Second and Subsequent Sections of Chain Guide
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G - 13
9. Install the last UHMW splice using the shop installed section of track in the drive section
of the conveyor as the downstream section of track (see Figure G - 10). Align the end of a
new roll of track with the notch on the UHMW splice and roll the track backward to the
previous splice. Cut to length and install.
Figure G - 10 The Last Section of Chain Guide
10. On the chain return track (underside of sorter) install a single length of chain guide track
from the drive to the catenary. Secure the track to the support angle and bevel the lead
end of the track so the bearing makes a smooth transition from dragging to rolling the
chain.
11. Install track on the remainder of the return similar to the top.
12. Each 100 feet long section of track must have a splice section or other allowance for thermal expansion and contraction. When installing a section 10 feet or less, secure track at
end using 1/4 x 20 flat head screws.
G - 14
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Aligning the Idler Cam Guide
Be sure the pin channel on the top side of the idler is parallel to the groove cut in the banjo on
the bottom side.
To check, watch the shoes as they come up from bottom side (banjo) into the cam guide on
the top (see Figure G - 11). The shoe pins should be centered as they enter the channel in
the guide. If they are off to one side or the other, they tend to bounce back and forth between
the opposite walls of the channel.
If the pins are not centered, adjust the position of the cam guide.
SIDE RAIL
CAM GUIDE
CHANNEL
SPROCKET
BANJO
FRAME
CAM RETURN DISC
Figure G - 11 Idler Pin Guide
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G - 15
Installing Air Piping and Connections
To install the air piping:
1. Refer to your air piping layout drawing for air piping information. This drawing specifies
the type, size, and location of air pipe and tubing as well as the location of the air filter/
regulator/lubricator, air pressure switch, and any additional air lubricators. (Figure G - 12
below shows a typical UniSort X air piping detail.)
2. Install the air filter/regulator/lubricator near or at the mid-point of the UniSort X.
3. Adjust the regulator to 70 psi (side switch only) as indicated by the regulator gauge.
4. Depending on the UniSort X layout, individual solenoid valve air lubricators may be
required. Install these as shown on the air piping layout drawing.
5. Install the air pressure switch between the last and second last divert switch as shown in
the figure. It is adjusted to “trip” whenever the air pressure falls below 50 psi.
PLANT AIR SUPPLY
FILTER/REGULATOR/LUBRICATOR/GAUGE
(SET TO 70psi) (SIDE SWITCH)
PRESSURE SWITCH
1" Ø COPPER PIPE
REGULATED AIR SUPPLY
LINE TO SORTER SWITCH
ASSEMBLIES 3/8" TUBING
SHUT OFF
VALVE
24VDC INPUT
PORT #4 & #5 PNEUMATIC
SILENCER (FACTORY PIPED)
DRAINAGE CONTROL
VALVE
3/8" X 1/4" NPT STRAIGHT
CONNECTOR (FACTORY PIPED)
NOTE: ALL MATERIAL EXCEPT FILTER REGULATOR/GAUGE
LUBRICATOR AND PRESSURE SWITCH ARE TO BE SUPPLIED
BY PIPING CONTRACTOR
PORT #1 SUPPLY
PORT #2 & #3 NORMALLY
CLOSED (FACTORY CLOSED)
SOLENOID VALVE
Figure G - 12 UniSort X Air Piping Detail and Air Pressure Switch
G - 16
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Adjusting the Crossover Switch
WARNING: Do not touch the v-block and gap blocks which are visible on the top side
of the center switch. They can cause serious injury if activated.
1. Be sure the transition from each gap block to the v-block (see Figure G - 13) is smooth
(check with a straightedge, not your hand).
2. If the transition is not smooth, adjust the rubber bumpers inside the switch.
3. Adjust the cam guides to match the position of the v-block and gap blocks.
V-BLOCK
GAP BLOCK
GAP BLOCK
RUBBER BUMPER
RUBBER BUMPER
Figure G - 13 Crossover Switch
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G - 17
Checking and Aligning the Divert Switch Mechanism
Precise timing is necessary for the UniSort X to divert product at high speeds. To achieve
accurate timing, the divert switches must be aligned, and adjusted correctly and uniformly.
After the UniSort X sections have been installed and accurately aligned, check each divert
switch mechanism for proper operation and alignment. Perform this check before installing
the carrying chains, carrying tubes and divert pushers.
Note: To check a divert switch you need 70 psi at the switch.
To check and align each divert switch:
1. Remove the metal cover from the divert switch access opening in the side frame. Set the
cover aside for later re-installation.
2. Connect the air supply to the air solenoid valve, but don’t turn the air on until instructed to
do so.
3. With no air pressure supplied to the divert switch, check the switch blade for free and
smooth movement by manually pivoting the white UHMW switch blade (see Figure G 14) back and forth between the non-divert and the divert positions. Correct any switch
blade binding. Return the blade to the non-divert position.
Figure G - 14 Divert Switch Blade
4. Apply air pressure to check the switch blade position. Place the alignment tool into the
divert switch (see Figure G - 15) so the ends of the tool extend into the pin guide channel
on both sides of the switch. The gap between the alignment tool and the curved part of
the switch blade closest to the tool should be a maximum of 1/16” to 1/8” (to adjust, see
next step.)
5. Adjust the blade if necessary. Remove air pressure from the divert switch. Remove the
alignment tool. Loosen the nuts which hold the damper assembly in place. Adjust the nuts
as needed so the switch blade stops in the correct location.
G - 18
9500 12/03
CAUTION: Do not change the adjustment of the uniball piston in the divert switch. It
must remain in its factory preset position for the divert switch to operate
correctly.
6. Recheck the switch blade position. Reapply air pressure and check the position of the
switch blade with the alignment tool. If it is not correct, repeat the above steps as necessary.
CHAIN GUIDE
PIN GUIDE
DIVERT SWITCH
PHOTO EYE
CAMGUIDE
LEXAN
ALIGNMENT TOOL
3/8" THICK ALUMINUM
Figure G - 15 Using Alignment Tool in Divert Switch
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G - 19
Checklist Prior to Chain, Tube and Pusher Installation
Check the following before installing the sorter chain, tubes and pushers.
•
•
•
•
•
•
•
With the side channels aligned and the section joints tight, check the alignment of the pin
guides. Make any necessary adjustments to assure smooth uninterrupted travel of the
pins through the UHMW guide transitions.
When installing a UniSort with overlapped switches, align the pusher cam guides to the
switch block/blade. These cam guides are shipped bolted to the downstream section and
must be attached to the section containing the switch in the field.
Check the divert cam guide alignment at the exit of all switches. Align the cam guide to
the switch block/blade as required.
Verify the vertical alignment of the chain guide support angle at all section joints. The top
surface of these angles must be at the same height.
Inspect the upper and lower chain track gap at section joints. If this gap is more than 3/16”
consult the manufacturer’s Engineering department.
Verify that all switches are positioned for straight, non divert, pin travel with compressed
air supplied to all solenoids.
Clean the sorter tubes before installation.
Clean tubular slats by wiping with a suitable solvent/degreaser. For extremely contaminated slats, use a very fine grade emery cloth or steel wool alone or with a cleaning solvent.
Be careful not to allow any solvent to enter the inside of the tube or to remain in contact
with the end bushings. Do not spray the tubes. (Aluminum slats do not need to be cleaned
during installation. However they can be cleaned with a mild degreaser during regular
maintenance.)
The following cleaning solvents/degreasers may be used:
•
Mobilarma 245 - Mobile Oil Corporation
•
Rust Veto® 4214 - E.F. Houghton Company
•
Tectyl 235 - Ashland Oil Company
CAUTION: To ensure the safety of personnel when using any solvent, pay strict attention to the solvent manufacturers’ use instructions and health hazard
warnings.
•
G - 20
Do not lubricate tubular slats. This can cause malfunctions by allowing contamination to
build-up on the slats. It is only necessary clean the slats for trouble free operation.
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Installing the Carrying Chains
The chain is boxed and shipped in matched length coils (two coils per box) in 10’ and/or 30’
increments. The length is based on twice the sorter’s length:
CAUTION: Note: The coils of chain in each box must be installed as a matched pair,
one coil on the right side of the sorter, and the other on the left side. Maintaining this relationship is extremely important.
Notice (due to pin placement) that the ends of the chain are not alike. When installing the
chains, uncoil the chain for one side of the sorter in the direction of product travel. Uncoil the
corresponding chain for the opposite side of the sorter opposite the direction of product
travel. This is necessary to correctly position the connecting links (which facilitates removal of
tubes and pushers).
To install the carrying chains:
1. Remove the drive V-belts from the drive motor (see Figure G - 16) so the drive sprockets
can rotate freely.
DRIVE SPROCKET
DRIVE SPROCKET
V-BELTS
Figure G - 16 Remove the V-Belts
2. Check the idler shaft is to be sure it is square. Adjust the pillow block bearings as necessary.
3. Install the carrying chains on both sides of the UniSort X.
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G - 21
CAUTION: Be sure the extended pins and connecting links of the chains are directly
opposite each other. Do not fasten the ends of each chain strand together
until this is verified.
If the sorter has a catenary take-up, be sure the return run of each chain strand is located
on the grey UHMW chain support guide located in the catenary take-up assembly. Allow
for a chain sag of 6” to 8” in the catenary.
4. Fasten the ends of each chain strand together by installing the master link (see Figure G
- 17).
SNAP RING
MASTER LINK
CARRYING TUBE
ROLLER BEARING
BUSHING
MASTER LINK
COTTER PIN
Figure G - 17 Installing the Master Link
G - 22
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Chain Lubrication and Adjustment
Chain Facts
•
•
•
•
•
•
•
•
•
Manual chain lubrication may be necessary at start-up (of newly installed sorters) to facilitate smooth sorter operation. Once the lubrication system is working correctly manual
lubrication is not necessary. Manual lubrication should be a one-time procedure.
When the chain lubrication system is working correctly, the chain will appear to have a
clean and uniform sheen.
If the chain lubrication system is adjusted correctly, the moving chain remains relatively
cool; measure the temperature with a laser guided infrared thermometer approximately
six hours after start-up. (See “Chain Temperature”, on page G - 23,.)
Do not use cleaners on the chain, although you can wipe off excess lubrication with a rag.
During normal operation a small buildup of lubrication my be noticed at the chain track
expansion joints (splices).
The teeth of the drive sprockets on each end of the drive shaft must be aligned with each
other.
The links of the chains must be aligned with each other; if they are not, the carrying tubes
will be at an angle, producing a skewing effect.
While moving a “window” (remove 20-30 tubes and pushers) around the sorter during
maintenance, check the chain roller bearings as you go and remove any that are loose.
(They may fall and be carried into the sprocket area while you have the open window.)
Consider replacing chain carrier bearings that are unusually loose.
Chain Temperature
An effective method of evaluating the lubrication being applied to the sorter chain is by
checking the temperature of the left hand and right hand chains. The temperature of the
running chains should be initially checked after six hours of operation.
To check the temperature of the chains:
•
•
•
•
Take ambient temperature readings (temperature readings of steel objects in the vicinity
of the sorter).
Take infrared thermometer readings of the chain at the idler end of the sorter with the
thermometer as close to the chain as is safely possible. Measure the temperature of the
side plates of the chain, not the rollers.
The temperature of the chain should be 5 to 10 degrees higher than the ambient temperature. If the temperature variance is greater than 10 degrees, the lubrication system may
need to be adjusted to deliver more oil. (Freezer applications give different readings than
room temperature environments.)
Each chain should be checked separately. Take the chain temperature at the same place
on both sides of the sorter.
Chain Stretch
The UniSort X drive chains stretch with time. To compensate for chain stretch (short sorters
only) adjust the drive shaft take-up screws, thereby moving the drive shaft. (Sorters that are
relatively short must be manually adjusted because they do not have a catenary section.)
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G - 23
Installing Carrying Tubes and Divert Pushers
Before Installing the Tubes
1. Be sure the chain oiler brushes are aligned and centered over the chain, with their long
side diagonal across the chain. Set the brushes between 1/32” and 1/6” above the chain
roller with the bristles between the chain side plates.
2. If sorter infeed conveyor is PTO driven from the idler, disconnect the timing belt from the
PTO drive during chain installation and initial start-up. Once the sorter is operating satisfactorily, reconnect this timing belt and track the infeed belt conveyor.
Preparing To Check The Levelness And Clearance
The carrying tubes and pushers must travel a level path as they move down the conveyor. In
addition, the stiffener plates on the underside of the pushers must clear the cam guide
wearstrips by 3/16” to 1/4”. You can adjust both levelness and clearance by adjusting the
chain guide angles.
Note: If the clearance is less than 3/16”, deflection caused by the weight of product might
cause the pushers to strike the cam guides. If the clearance is greater than 1/4”, the pusher
pins might not extend sufficiently into the pin guide channel.
To prepare to check levelness and clearance:
1. Remove the product side guards (side guides).
2. Find a flat plate that can be easily moved along the side channels. A 4” x 4” electrical
plate cover works well.
3. Remove several carrying tubes (and pushers) to create a “window” in which to work.
4. Find two metal strips, one that is 3/16” thick and the other that is 1/4” thick, that can be
used as feeler gauges.
5. Jog the conveyor motor so the “window” moves to a place directly over a divert switch.
You will begin checking levelness and clearance at the point where the cam guide rail
bolts to the divert switch.
G - 24
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Adjusting the Levelness and Clearance
To adjust levelness and clearance:
1. Check the cam guide rail wearstrip. It should be even with the top of the rail. If it is not,
loosen the bolts and use an 8” C clamp to force the wearstrip down, then tighten the bolts.
(Examine the stiffener plate on the underside of one of the pushers. If you see a mark
going across it then the pushers are scraping this or another cam guide wearstrip.)
2. Check the clearance. It should be between 3/16” and 1/4”. If it is not, loosen the bolts
holding the chain guide angle, then adjust the jack screws underneath the angle. The jack
screws can be accessed through square holes located every 3’ to 5’ along the length of
the conveyor.
3. Check the levelness (see Figure G - 18). Place a metal plate on the top of the side channel. Align the top of the plate with a convenient place on the chain links. Remember this
place, it is your reference point. Move the plate along the top of the channel and be sure
the plate aligns with your reference point as you move along the chain. If it does not,
adjust the jack screws as necessary.
4. Tighten the bolts holding the chain guide angle.
Repeat this procedure for the other side of the conveyor.
REFERENCE POINT
METAL PLATE
Figure G - 18 Adjusting Levelness and Clearance
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G - 25
Installing the Carrying Tubes and Divert Pushers
The carrying tubes and divert pushers are shipped loose. The divert pushers are installed on
the carrying tubes when the carrying tubes are installed on the UniSort X.
To install the carrying tubes and divert pushers:
1. Be sure the extended pins of each carrying chain strand are exactly opposite each other.
2. Install two adjacent carrying tubes by inserting the extended chain pins into the end bushings of the two tubes (on one side of the sorter only).
3. Slide a divert pusher onto the two tubes with the ramp of the pusher facing the discharge
end (drive section) of the UniSort X (see Figure G - 19).
4. Use a screwdriver (or other tool) to pry the chain upward and outward so you can insert
the extended pins into the tubes. (The side guides should not be on the conveyor at this
time.)
CAUTION: When installing the carrying tubes, be sure the tubes are perpendicular to
the side frame.
Install an even number of carrying tubes only. Remove/add carrying chain
links as necessary. (This must be done in 5” length increments.)
5. Repeat Steps 2 - 4 until all tubes with divert pushers are installed. Be sure all the pusher
guide pins drop into the pin guide track.
PUSHER
CARRYING CHAIN
EXTENDED PIN
GUIDE PIN
CARRYING TUBE
Figure G - 19 Installing Carrying Tubes and Divert Pushers
G - 26
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Carrying Chain Take-up Adjustment, (Catenary Take-up)
To adjust the carrying chain on sorters with a catenary take-up.
1. Measure the carrying chain sag on each side in the catenary, it should be 6” to 8” (see
Figure G - 20). Adjust drive shaft position or, add/remove chain links in 5” increments as
necessary.
2. Be sure that the drive shaft is square and that the carrying tubes are not skewed (they
must be perpendicular to the side frame).
3. Re-install the power unit drive belts. Adjust the drive belt tension as shown on decal
affixed to the power unit belt guard. Adjust the drive belt tension for 1/4” maximum deflection at the belt’s mid-point.
VARIABLE LENGTHS
14"
CHAIN SAG
6" TO 8"
CHAIN SUPPORT GUIDE
Figure G - 20 Catenary Chain Sag
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G - 27
Installing Take-Away Conveyors
The layout/installation drawings show the locations of the take-away conveyors (or chutes).
Figure G - 21 shows the take-away location dimensions.
Note:
To divert product most reliably, locate the divert points as shown on the layout/installation
drawings, and mount the divert points as shown in Figure G - 21. Be sure to mount the takeaways at the specified elevation and pitch.
4"
5 3/8" FOR 20°
9 3/16" FOR 30°
SPUR SIDE RAIL
1 1/2" FOR 20° DIVERT
2" FOR 30° DIVERT
DIVERT LINE
20° OR 30°
SORTER SIDE RAIL
DIVERT POINT
SECTION SPLICE
Figure G - 21 Take-Away Location Dimensions for 20° and 30° Divert Angle
G - 28
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Installing Discharge End Conveyor (if used)
See the project layout/installation drawing to locate and install the conveyor at the discharge
end (drive section) of the UniSort X.
Note:
The UniSort X drive section has a factory installed pivot-up safety roller assembly if nondiverted product is to be conveyed from the sorter’s discharge end. This assembly includes a
proximity switch (see Figure G - 22) which must be wired to the control system. When
triggered, the proximity switch drops power to the UniSort X drive motor.
PROXIMITY SWITCH
Figure G - 22 Proximity Switch
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G - 29
Installing the Reducer
•
•
•
•
Do not overtighten the bolt holding the reducer torque arm to the frame. It should not
restrict movement of the turnbuckle. (The reducer needs to “float” a little to allow for irregularities.)
Always install a breather on the reducer to prevent seal failure. The reducer input shaft
seal can fail if the internal pressure increases to as little as 5 psi.
Mount the reducer level for proper lubrication.
Fill the reducer with SP220 oil (this oil can operate in temperatures as high as 220
degrees).
Be careful not to confuse the fill plugs with the oil level hole. (The reducer has fill plugs in
several locations because it can be mounted in four different positions.)
REDUCER
Figure G - 23 Reducer
G - 30
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Installing Electrical/Control Devices
Table H.shows the typical electrical/control devices that may be used for controlling a UniSort
X. Refer to the electrical installation drawings and materials list for the exact type, location,
and wiring of each device used.
Table G 1 Electrical/Control Devices
Device
Function
Main Power Disconnect
(may be 4-pole switch)
Switches power to the drive motor(s) and the control unit. The fourth pole switches
power to the control unit. Located in the control panel.
Motor Starter(s)
Switches power to drive motor(s) via a motor disconnect switch and Variable Frequency Drive. Contact status may be supplied to control unit. Located in control
panel.
Motor Disconnect
Switches power to the drive motor via the Variable Frequency Drive. The contact
status is typically supplied to the control unit.
Variable Frequency Drive
(VFD)
Provides smooth drive motor start-up. Typically wired between drive motor and
motor disconnect switch (one per motor). Located on UniSort X.
Emergency Stop Push Button/Pull Cord
Used to drop power to the drive motor(s). The contact status is typically supplied to
the control unit. Located on the UniSort X.
Air Filter/Regulator/
Lubricator
Adjusted (for single-sided sorters) to supply 70 psi air pressure to the divert
switches. The lubricator provides lubrication for air cylinder and air solenoid.
Air Solenoid Valve
24 VDC actuated valve for enabling air pressure to air cylinder in divert switch
assembly. (Air solenoid valve and air cylinder supplied with UniSort X.)
Air Pressure Switch
Detects low operating air pressure. The contact status is typically supplied to the
control unit.
Photo Eye (On Divert
Switch Assembly)
Used to detect the presence of the divert pusher for synchronizing divert switching.
Located on each divert switch. Signal input to the control unit.
Proximity Switch(es)
(Other uses)
Proximity switches may also be used for detecting divert pusher “out of track”, discharge end “product jam”, pop-up roller “up”, and sorter speed.
Induction Photo-Eye(s)
Located on the UniSort X. Detects the leading/trailing edge of product entering the
UniSort X. Initiates product tracking.
Lane Full Photo-Eye
Located on each take-away conveyor (sort lane) at the point where the takeaway
lane is considered full. Oriented at an angle so product is detected even if small
gaps between product exists. Typically used with a 3-7 second delay timer. Lane is
considered full if photo-eye remains blocked for that period of time. Product diverting to the lane is then inhibited.
Product Jam Detect PhotoEye
Located at extreme up-stream end of each take-away conveyor (sort lane). Oriented perpendicular to product flow direction. Used with 3-7 second time delay.
Product jam condition indicated when product blocks entrance to take-away conveyor for that period of time. Diverting to that lane is inhibited and power to UniSort
X may be dropped.
Current Sensing Relay
(Over-Current Detection)
Used to sense drive motor over-current condition as the result of a jam condition or
mechanical/electrical problem. Power to the UniSort X is dropped. Contact status is
supplied to the control limit.
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G - 31
Installing Electrical Power and Control Device Wiring
Install wiring from the control panel to all electrical/control devices on the UniSort X according
to the electrical layout drawing. Figure G - 24 shows a typical UniSort X drive motor wiring
diagram.
Refer to the appropriate manufacturer’s instruction manual(s) for wiring Variable Frequency
Drive(s), over-current relay(s), air pressure switch(es), and photo-eyes.
L1
L2
480V 3 60Hz
L3
MOTOR STARTER
IN CONTROL PANEL
TERMINALS IN
CONTROL PANEL
DISCONNECT AT MOTOR
LINE
VFD
AUXILIARY
LOAD
FOR E-STOP
DRIVE MOTOR
NOTE: VFD TO BE MOUNTED NEAR MOTOR. REFER
TO MANUFACTUERS INSTRUCTIONS FOR ACTUAL
WIRING AND ADJUSTMENT PROCEDURE.
Figure G - 24 UniSort X Drive Motor Wiring Diagram (Example)
Variable Frequency Drive Adjustments
A variable frequency drive (VFD) is supplied for each UniSort X drive motor. Mount the VFD
as close as possible to the drive motor (6” clearance on top and bottom is needed for
adequate ventilation). See the project electrical installation drawings and VFD Manufacture’s
Manual (included in project) for specific mounting details.
Before applying power to the VFD, perform any required adjustments according to the
manufacturer’s instruction manual. Set the acceleration ramp time to 20 seconds.
Verifying Correct Drive Motor Rotation
WARNING: Before applying power, review the safety checks in Before Applying Electrical Power to ensure the safety of personnel.
•
G - 32
Be sure the drive motor wiring is correct.
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•
•
•
Remove the V-belt drive.
Apply momentary power to the drive motor(s) and check the direction of rotation.
Re-install the V-belts.
CAUTION: A drive motor wiring error can result in reversed motor operation and/or
possible drive motor damage.
Final VFD Adjustments
Perform the final VFD adjustments (with power applied) according to the manufacturer’s
manual.
When the Variable Frequency Drive is correctly adjusted, the sorter will accelerate smoothly
to operating speed, with no jerking or surging of the carrying chains.
Drive Over-current Relay/Sensor Adjustments
The drive over-current relay/sensor is adjusted to match the drive motor’s starting current as
listed on the motor’s name plate. Refer to the manufacturer’s instruction sheet for adjusting
the over-current relay/sensor.
Air Pressure Adjustment
To set the air pressure, adjust the air regulator located on the UniSort X. Set the air regulator
to 70 psi (as indicated on the regulator gauge) for a single-sided sorter and the side switches
of a dual-sided sorter.
Air Pressure Switch Adjustment
The air pressure switch is set to actuate if the air pressure is 20 psi less than the required
operating air pressure. Refer to the manufacturer’s instruction sheet for adjustment
instructions.
Adjusting the Photoeye
Remove several tubes to create a “window”. Slowly move the window toward a divert switch.
As the pushers move past the photoeye send unit, notice where the beam strikes the pusher
bearings. It should strike the center of the bearing. If not, adjust the send unit position and
move pushers past the beam again. Repeat until the beam strikes the center of the bearing.
Air Lubricator(s)
Fill each air lubricator with SAE 5W non-detergent oil.
Idler Sprocket Lubrication
One of the idler sprockets (opposite the PTO, if there is one) is free-wheeling. Grease the
bushing in this sprocket every two weeks with high-speed wheel bearing grease while the
conveyor is running. A zerk fitting on the end of the idler shaft connects to a grease channel
leading to the bushing. Neither the shaft nor the bushing has grease grooves; shaft
movement distributes the grease.
Divert Switch Testing
1. Apply the signal voltage to each air solenoid valve and be sure the switch block moves to
the divert position.
2. Remove the signal (turn off), and be sure the switch block returns to the non-divert position.
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G - 33
Carrying Chain Lubricator
Older Unisort X models used gravity operated lubricators (prior to 1997). Current models use
injector pump operated lubricators. An electric solenoid valve controls the air which operates
the injector pump, and two brushes deliver oil to the chain. Each period of lubrication should
occur after about 65,000 shoe “passes” (5”/shoe). Each period should be long enough for one
full revolution of the chains.
Setting Up the Oil Lubricator
1. Fill the lubricator reservoir (see Figure G - 25) with 20 weight nondetergent oil (or as
directed in the table below). This oil is almost clear or amber colored and “washes” the
chain as it lubricates it. A properly lubricated chain has a clean appearance and looks as
if it has been dipped in oil.
Table G 2 Lubricator Oil Selection
Operating Temperature
Oil (Non-Detergent)
Over 100° F (for prolonged periods of time)
SAE 30
40° F to 100° F
SAE 20
20° F to 39° F
SAE 10
•
Do not use 30 weight oil (except as noted in the table above); it can leave a sticky residue which attracts dust.
• Do not use multiblend oil.
2. Set the lubricator brushes at a diagonal and center them over the chain. (Keep the
brushes away from the chain carrier bearings.)
G - 34
9500 12/03
Adjusting the Oil Injectors
Brass nuts on top of the injectors (see Figure G - 25) control oil quantity. Screwing them in
(down) reduces oil flow, screwing them out (up) increases flow. To set them initially:
1. Turn the screws all the way down (off) (do not over tighten).
2. Turn the screws back up (on) 3-1/2 turns.
Figure G - 25 Oiler Assembly
Determining Correct Lubrication
The lubricator meters oil to the applicator brushes. Properly lubricated chains will appear
moist.
The amount of chain lubrication required varies with factors such as sorter speed, ambient
temperature, product type and the volume of product diverting. At times, the divert side chain
may require a different lubricator pump adjustment than the non-divert side. (See “Carrying
Chain Lubricator”, on page G - 34,)
Important: Adjust the lubrication pump stroke to achieve maximum chain lubrication without
causing oil to drip from the chain track. Monitor the chain lubrication as directed in the
maintenance chart.
Warning: Keep the tubes and pushers clean. Do not allow oil (from the lubricator or other
sources) to get on the sorter tubes/slats or pushers. The pushers distribute this oil as they
9500 12/03
G - 35
move along the tubes. The oil then mixes with dirt, dust, and cardboard particles, creating a
mixture that is slightly sticky which induces drag on the pushers. If the pushers encounter too
much drag or resistance, they tend to raise the tubes, which lifts the chain, and then the tubes
can become detached from the chain, causing injury or property damage.
Caution: Excessive chain lubrication can result in lubrication "puddling" on work/
maintenance areas, creating a slip hazard.
The UniSort X uses a pump type lubricator. The solenoid valve (see Figure G - 25) must be
cycled by the sorter control program to operate the injector pump. The pump should be
operated for the entire length of the chains (one revolution). (See “Carrying Chain Lubricator”,
on page G - 34,.) The cycle should be “on” for travel equal to 5 pushers and “off” for travel
equal to 5 pushers, etc. (5 shoes = approx 2 feet of chain travel). There is a separate needle
valve for each chain.
This information is strictly meant to get you started. Only by carefully monitoring the results at
regular intervals will you determine the correct adjustments for your application.
G - 36
9500 12/03
Checking Safety Features
Internal Jam Detector
This safety feature detects:
•
•
Divert pusher pin out of track.
Carton flap, piece of banding, etc., extending between and below the carrying tubes.
Whenever any of these conditions are detected, the internal jam detector sends a signal to
interrupt electrical power to the drive motor.
One detector is supplied with the UniSort X’s idler section, another with the drive section, and
one for approximately every seventy feet (70’) of intermediate section. The electrical
installation drawing shows the detector’s wiring to the control panel.
The internal jam detector consists of a spring tensioned pivoting metal blade (see Figure G 26) extending across the width of the sorter. Movement of the metal blade actuates the limit
switch.
FLIPPER BLADE
TRIP ARM
FLANGE BEARING BOLT
ADJUSTMENT SCREW
RUBBER BUMPER
LIMIT SWITCH ARM ROLLER
LIMIT SWITCH ARM
Figure G - 26 Internal Jam Detector for Dual Sided and Single Sided (Left Hand Shown)
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G - 37
Assembling the Internal Jam Detector
The internal jam detector (IJD) is installed at the site. Only the bearing and shaft are
assembled at the factory. To adjust the IJD (see Figure G - 26):
1.
2.
3.
4.
Assemble all of the jam detector parts.
Loosen the flange bearing bolts so the bearing drops to the lowest position.
Place a magnetic mount torpedo level vertically on the flipper blade.
Place a 1/8” thick flat underneath the flipper blade on each end of the blade. (The objective is to position the flipper blade so it is perpendicular (90 degrees) to the carrying tubes
and 1/8” above them.)
5. Grasp the trip arm and rotate the arm against the rubber bumper until the flipper blade is
at 90 degrees. The flange bearing will move up or down as you do this. If you cannot
move the arm far enough, adjust the rubber bumper as needed.
6. Tighten the flange bearing bolts.
7. Remove the 1/8” thick flats.
8. Readjust the rubber bumper so the flipper blades is vertical. A set screw holds the trip
arm in place. A cotter pin is a shear indicator. If the rubber bumper does not seem to have
enough range to allow correct flipper blade adjustment, do not drill new holes for the cotter pin. An apparent lack of range is an indication that the flipper is not adjusted correctly.
9. Loosen the adjustment screw in the center of the limit switch arm.
10. Move the limit switch arm to the normal operating position. Place a straight edge along
the underneath side of the trip arm. At the same time, place the limit switch arm roller on
the top side of the straight edge. The jam detector trip arm and limit switch arm must not
be set to automatically reset after a jam. The limit switch arm must remain in the “tripped”
position until manually reset. When the limit switch is tripped, the trip arm should move
freely and not come in contact with the limit switch arm.
11. Tighten the limit switch arm.
Note:
The flipper blade in the drive section is only one half a normal flipper blade. The half blade
faces upward (bottom half is blank) with the angled portion facing in the direction of product
travel (towards the discharge end). Adjusting this jam detector is the same as that described
above except that slats/tubes must be above the flipper blade and the 1/8” flates are placed
between the flipper blade and the slats/tubes above it.
G - 38
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Pop-Up Safety Roller Assembly
A pop-up safety roller assembly (see Figure G - 27) is installed at the end of the sorter drive
section whenever the layout allows non-diverted product to be conveyed onto a following
conveyor.
The pop-up safety roller assembly is mounted to a pivoting bracket. When the assembly
pivots, a proximity switch sends a signal to interrupt electrical power to the drive motor.
Check the roller assembly to be sure it pivots freely with no binding.
Note: See “Final Installation Checks” to determine if the pop-up safety roller assembly
correctly interrups electrical power to the drive motor control circuit.
PROXIMITY SWITCH
POP-UP SAFETY
ROLLER ASSEMBLY
PIVOTING BRACKET
Figure G - 27 Pop-up Roller Assembly
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G - 39
Installing Product Containment Guarding
The product containment guarding is typically installed after all the UniSort X installation
adjustments have been made. See the “Side Guides” manual for information about
installing guarding.
CAUTION: Be careful when installing the product containment guarding on the divert
side. Be sure the guard rail does not interfere with the movement of
diverted product.
SIDE GUIDES
Figure G - 28 Typical Guarding
G - 40
9500 12/03
Installing Personnel Safety Guarding
The personnel safety guarding prevents people from coming into contact with UniSort X
moving parts.
To install personnel safety guarding refer to the installation/layout drawing because
requirements vary by installation.
CAUTION: Personnel safety guards fully enclose the UniSort X drive section v-belts
(or drive chain). If these guards were removed during installation, reinstall
them before approving the installation for production.
Final Installation Adjustments
CAUTION: Electrical power must be applied to perform the final checks. To ensure the
safety of personnel and minimize the possibility of damage to the sorter,
verify all of the following before applying electrical power.
Before Applying Electrical Power
1. Be sure the carrying chains, carrying tubes, and divert pushers are correctly installed. Be
especially sure the carrying tubes are perpendicular to the sorter side frames. Check for
any bent, nicked or dirty tubes.
2. Check the divert pushers to make sure they slide freely on the carrying tubes. Be certain
the pin of each divert pusher is in the pin guide track on the non-divert side. Be sure all
returning pushers have the proper clearance as they move towards the idler.
3. Be sure all floor supports are correctly installed. Check the tightness of all mounting bolts
including those fastening the UniSort X sections together.
4. Check to see that the left and right side carrying chains have equal (and correct) tension.
The catenary (if used ) should have a 6” to 8” chain sag (equal for each chain).
Note: If no catenary take-up is used, the chain sag at the bottom of each drive sprocket
should not exceed 1-1/2”. See subsection “Carrying Chain Take-up Adjustment” for
adjusting chain tension.
5. Connect a hand crank to the reducer input shaft. Turn the crank. The chain should move
freely (not necessarily easily) and without catching.
6. Inspect the sorter thoroughly for foreign objects in the chain and in between the runs of
tubing. Look for stray bolts, tubes, pushers, etc.
7. Check the electrical connections at the UniSort X and the control panel(s).
8. Be sure the drive motor rotates in the correct direction.
9. Check the tension of the v-belts between the drive motor and the reducer.
10. Be sure the drive unit safety guarding has been installed.
11. Be sure the divert switch access cover plates have been installed.
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G - 41
12. Check the reducer for correct oil type and oil level. (Refer to manufacturer’s instructions).
Be sure any required oil breather plug has been correctly installed.
CAUTION: All Dorris reducers are shipped without oil. Do not assume that this unit
has been properly lubricated. Prior to start-up, be sure that the proper
type, grade, and amount of oil has been installed into the reducer.
13. Be sure the VFD is adjusted per the manufacturer’s instructions.
14. Check the over-current relay/sensor for correct wiring and to see that it is adjusted for first
time power turn-on. (Refer to manufacturer’s instructions.)
15. Examine the air pressure switch, it must be correctly installed and adjusted to trip at 50
psi (single sided UniSort X).
16. Check the air pressure regulator, it must be set to 70 psi (single-sided UniSort X).
17. Be sure all divert switch blocks are in the non-divert position. Fill all air lubricators with
SAE 5W non-detergent oil.
18. Check to be sure that all foreign objects, tools, spare parts etc., have been removed from
the UniSort X.
19. Before electrical power is applied, instruct all personnel to stand clear of the UniSort X (an
alert will sound before the UniSort X starts).
After Applying Electrical Power
After applying electrical power:
1. Be sure the VFD adjustments following the manufacturer’s instructions.
Note: When correctly adjusted, the Variable Frequency Drive will allow the UniSort X to
smoothly accelerate to operating speed with no jerking of the carrying chains.
2. Observe the carrying chains, they should travel smoothly around each of the sprockets
located in the drive section and the idler section.
CAUTION: If any adjustment is required, be sure the main electrical power switch is in
a locked OFF position and tagged to prevent accidental application of electrical power.
3. Be sure the motor rotates so the pushers move in a forward direction.
4. Verify that motor rotation is correct for forward motion of the sorter pushers.
5. Apply a divert signal (electrical) to each air solenoid valve. The pushers should travel
smoothly to the divert side and return downstream to the non-divert side. The pusher
return is located next to the drive section.
6. Listen for any loud clicking type noises. These would indicate a misalignment at the divert
switch (see “Divert Switch Mechanism - Operation Checking and Alignment”).
7. Remove the electrical signal and verify that the pushers travel smoothly through the divert
switch.
CAUTION: Immediately remedy the cause of any pusher binding on the carrying
tubes. Excessive friction may result in current overload or cause carrying
tubes to become detached (See Section G - Maintenance).
G - 42
9500 12/03
8. Never apply any type of lubricant to the carrying tubes without first consulting the manufacturer.
9. Verify that the carrying chain oil lubricator has the correct oil type and quantity and is
adjusted to keep the chains properly lubricated (see 1.).
Note: The UniSort X should be operating while making the final oil lubricator adjustment.
10. Check the operation of all safety devices.
Final Installation Checks
1. Verify the following:
• Air pressure regulator on the UniSort X set at 70 psi for single side; 70 psi dual sided.
(See Section C for information on center switch).
• Air pressure switch adjusted to trip at 50 psi for single sided; 50 psi dual sided.
• Current overload relay/sensor adjusted to trip at current shown on electrical installation drawing.
• Air lubricator(s) are filled with SAE5 weight non-detergent oil.
• Carrying chain oil reservoir is filled with correct oil type and weight based on ambient
air temperature (see 1.).
2. Control unit and all control devices are installed and operational per the electrical layout
installation drawing.
3. Check for smooth start-up of the UniSort X when power is applied.
4. With product being diverted, verify that product is being smoothly and correctly diverted
onto the correct take-away conveyors.
5. Be sure that installed guard rail will not result in product jams.
6. Check all safety devices to be sure they operate as designed.
7. Be sure that all safety labels are in place and guarding installed.
8. Make any necessary adjustments.
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G - 43
Checking Controls
Operation
A low friction, straight in-line mechanism operates a snap action switch at a
B
predetermined pressure setting. An increase in pressure causes normally
A
C
closed contacts A-B to open and normally open contacts B-C to close. This
is known as the “Trip” pressure. When the pressure returns to a lower
predetermined setting, the contacts A-B close and contacts B-C open. This
is known as the “Reset” pressure. The difference between the “Trip” and “Reset” pressure is
the differential.
Adjusting the Pressure
Unless otherwise specified, controls shipped from the factory are set at the maximum
operating range pressure and minimum differential. The following procedure should be used
to set the control to a particular requirement.
•
Operating Range Adjustment
Turn the range adjustment screw counterclockwise to lower both the upper and the lower
pressure settings. To raise both the upper and the lower settings, turn the range adjustment screw clockwise. The approximate upper pressure setting is shown by the indicators
on the outer edges of the nameplate.
• Differential Adjustment
When the differential blade is at the low point of the differential cam the control functions
with minimum differential. To increase the differential, turn the differential screw counterclockwise. This lowers the low pressure setting only. To decrease the differential, turn the
differential adjustment screw clockwise. This raises the low setting only.
Condensed instructions are supplied with open style controls and are on the inside of the
cover on enclosed devices.
Periodically check the gauge pressure and adjust to compensate for application variables.
Note: It is best to use a pressure gauge when setting the control.
CAUTION: Adjusting the range adjustment screw beyond the pressure indicated on
the scale may cause the control to malfunction.
CAUTION: Do not support the control by the electrical and air piping connections
only. Use a support wrench when tightening the electrical hub and pressure connections. The enclosed device or open type control using a
mounting bracket is not intended to support connecting equipment. This
equipment must be secured to support weight and to reduce vibration.
G - 44
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Maintenance
SECTION H:MAINTENANCE
Introduction
Recommended service checks and equipment maintenance are outlined in this section for
typical, intermittent-duty conveyor applications. Additional maintenance and servicing
schedule adjustments may be required for continuous-duty operation or extreme
environmental conditions.
The indicated preventive maintenance time intervals are based on a UniSort X which is
operating eight hours per day in at or above freezing (40° F to 110° F) environmental
temperatures.
All newly installed equipment should be frequently inspected and serviced as needed during
the first 40 hours of operation; thereafter, an appropriate maintenance program should be
established and followed (see Table G.1). The time intervals should be appropriately adjusted
for more than eight hours per day operation and/or operation in a harsh environment. Also,
sorting product that produces an extraordinary amount of dust, dirt or any other type of
contamination may require more frequent preventive maintenance.
Maintaining separate service log sheets on each type of conveyor is recommended for plants
operating more than one shift. Each log sheet should show dates, detailed inspection service
information, and name or initials of person(s) performing the equipment inspection or service
for future reference.
WARNING: Before performing maintenance on a conveyor, make certain that the conveyor’s
power disconnect is locked in the OPEN position and tagged to prevent accidental or unexpected application of power.
Do not perform maintenance while the conveyor is running unless specifically
instructed to do so in this manual. Note: Other than checking of chain tension, it
is NOT necessary to have the conveyor turned ON to perform any of the work
described in this section.
Maintenance must be performed only by qualified personnel who are trained in
normal and emergency operations of the conveyor and who understand all safety
devices, their locations, and functions.
Before restarting a conveyor:
• Remove all foreign objects from the conveyor.
• Be sure that all guards and safety devices are properly installed and working.
• Make sure that all persons are clear of the conveyor and are aware that the conveyor is
about to be restarted.
Intervals indicated for performing maintenance should be considered for 8 hour per day
operation. An application may subject the equipment to conditions that would necessitate
more frequent maintenance. This may best be determined by performing maintenance more
frequently when the conveyor is first put into operation, and then lengthening the intervals
based on experience.
Note: Power does not need to be applied to the UniSort X drive motor except to observe
divert switching and to verify the operation of the safety and control devices.
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H-1
Maintenance
Table H 1 Scheduled Maintenance
Air Filter
X
Air Lubricator(s)
X
X
X
Carrying Chain Lubricator
X
X
Carrying Tubes (Slats)
Weekly Control Devices (Mounted on UniSort X)
X
X
Divert Pushers
X
X
X
X
Divert Switches
X
General Structure
X
Safety Guards and Devices
X
Carrying Chains
X
X
X
X
X
X
X
X
V-Belts
X
All Plastic Parts
H-2
X
X
Supports/Hangers
Reducer
X
X
Sprockets/Hubs/Pulleys
Bearings
Semi
Carrying Chains
Annually
1040 hrs. Carrying Chain Guides
Drive Motor
X
X
Carrying Tubes
Divert Pushers
Monthly Divert Switches
175 Hrs
Reducer
X
X
Air Regulator
Carrying Chains
Operation
Proper
Position
Physical
Condition
Set Screws
Fasteners
Alignment
Wear
Tension
Oil Level
Components
Lubrication
Item Check
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Maintenance
Making a Window
Opening a “window” in the slats or tubes to work on the conveyor involves removing several
slats/ tubes (see Figure H - 1). This is best done at the idler (cannot be done near a spur).
To remove slats/tubes:
1. Remove the side guide on one side of the conveyor.
2. Pry up the chain with a large screwdriver until the pusher pins clear the pin guide. Slide
the pushers to the center.
3. Continue prying up the chain with the screwdriver until the point of the screwdriver
catches the chain and pulls the chain towards your body. While holding the chain in this
position, use your free hand to push each slat/tube away from yourself until it clears the
chain bearing pin.
4. Lift each slat/tube away from the conveyor and place it on a clean surface.
After you remove the slats/tubes needed to create a “window”, return any remaining pushers
to their position over the pin guide, place the chain back into its track, and shake the pushers
to make sure they have reseated.
WINDOW
Figure H - 1 “Window” in the Tubes/Slats
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H-3
Maintenance
Initial Start-up/Run-in Period
Dorris Power Unit Reducer
CAUTION: All Dorris reducers are shipped without oil. Do not assume that this unit has been
properly lubricated. Prior to start-up, be sure the reducer has been filled with the
proper type, grade, and amount of oil.
Lubricate the reducer by filling the unit to the proper level as per the following instructions.
Select the proper type and grade of oil based on the ambient air temperature range around
the reducer. Choose an oil that meets the requirements in Table G.2.
Fill the reducer with oil based on the following instructions:
Table H 2 Selection of Reducer Lubricators
Oil Designation
Viscosity Range
Ambient
Temp
Range (°F)
AGMA R&0 (EP)
Lube No.
ISO VG (EP)
Grade
cSt (mm2/s)
@ 40°C (104° F)
SUS
@ 100°F
15 - 75
32 - 100
50 - 125
3 (3EP)
4 (4EP)
5 (5EP)
100 (100EP)
150 (150EP)
220 (220EP)
90 - 110
135 - 165
198 - 242
417 - 510
626 - 765
918 - 1122
Make sure that the coolest ambient temperature is at least 10°F greater than the pour point of
the oil chosen.
Industrial petroleum based rust and oxidation inhibited (R&O) gear oils or petroleum based
reducer oils with extreme pressure (EP) additives of sulfur-phosphorus type are
recommended for most applications. Automotive motor oils are not recommended.
Extreme pressure (EP) additive oils are preferred, but are never to be used if the reducer has
an optional backstop installed.
Synthetic hydrocarbon type (polyalphaolefin base) gear oils without EP additives are
recommended for ambient temperatures as low as -20°F or as high as 170°F. For low
temperature operation, use an oil with a viscosity of about 65 cST at 40°C, and for high
temperature operation use an oil with a viscosity of about 150 cSt at 40°C.
When the reducer is used in the food processing industry, be sure the lubrication is approved
for the application.
The oil capacity of the unit depends on its mounting position (see Figure H - 2). The oil
capacities in Table H 3 are based upon the mounting position shown in Figure H - 2 and
assume an output speed of the reducer being 40 rpm or more. For output speeds less than
40 rpm, consult The Dorris Company.
H-4
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Maintenance
BREATHER
BREATHER
BREATHER
(315 ONLY)
OIL LEVEL
OIL LEVEL
MAGNETIC
DRAIN PLUG
BREATHER
BREATHER
OIL LEVEL
(315 ONLY)
MAGNETIC
DRAIN PLUG
OIL LEVEL
MAGNETIC
DRAIN PLUG
MAGNETIC
DRAIN PLUG
(315 ONLY)
MAGNETIC
DRAIN PLUG
BREATHER
OIL LEVEL
AND DRAIN
NOT SHOWN
Figure H - 2 Reducer Orientations
Table H 3 Oil Capacities (in Quarts)
Drive Size
Ratios
(5,10,15,20,25)
6 O’clock
Mount
3 O’clock
Mount
12 O’clock
Mount
Vertical
Mount
107TR
115TR
203TR
207TR
215TR
307TR
315TR
1-1/2
2-1/2
2-1/2
3-1/2
4-1/2
8
10
1
1
1-1/2
2
3
6
6
1-1/2
3
3-1/2
5
6-1/2
12
14-1/2
1-1/2
4
5
6-1/2
9
18
21
The 9 o’clock mount, similar to the 3 o’clock mount but with the input shaft down, has the
same oil capacity as the 3 o’clock mount. For other mounting arrangements, consult The
Dorris Company.
Table H 4 R & O Gear Oils
ISO Viscosity Grade
Company
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100 (AGMA 3)
150 (AGMA 4)
220 (AGMA 5)
AMOCO
American Ind’l Oil 100
CHEVRON
Machine Oil R&O ISO
100
Machine Oil R&O ISO
150
RPM Gear Oil SAE 90
(ISO 220)
CITGO
Pacemaker Oil 100
Pacemaker Oil 150
Pacemaker Oil 220
CONOCO
Dectol R&O Oil 100
Dectol R&O Oil 150
Dectol R&O Oil 220
EXXON
Teresstic 100
Teresstic 150
Teresstic 220
H-5
Maintenance
Table H 4 R & O Gear Oils (Continued)
MOBIL
DTE Heavy
DTE Extra Heavy
DTE BB
PHILLIPS
Magnus Oil ISO VG 100
SHELL
Morlina Oil 100
Morlina Oil 150
Morlina Oil 220
SUN
Sunvis 9100
Sunvis 9150
Sunvis 9220
TEXACO
Regal Oil R&O 100
Regal Oil R&O 150
Regal Oil R&O 220
Table H 5 EP Gear Oils
Company
AMOCO
CHEVRON
CITGO
CONOCO
EXXON
MOBIL
PHILLIPS
SHELL
SUN
TEXACO
H-6
ISO Viscosity Grade
100EP (AGMA 3EP
150EP (AGMA 4EP)
220EP (AGMA 5EP)
Permagear EP LubriPermagear EP LubriPermagear EP Lubricant 100
cant 150
cant 220
Gear Compound EP ISO Gear Compound EP ISO Gear Compound EP ISO
100
150
220
EP Compound 100
EP Compound 150
EP Compound 220
Gear Oil 100
Gear Oil 150
Gear Oil 220
Spartan EP Gear Oil 100 Spartan EP Gear Oil 150 Spartan EP Gear Oil 220
Mobilgear 627
Mobilgear 629
Mobilgear 630
(Not Available)
All Purpose Philgear 150 All Purpose Philgear 220
Omala Oil 100
Omala Oil 150
Omala Oil 220
(Not Available)
Sunep 150
Sunep 220
Meropa 100
Meropa 150
Meropa 220
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Maintenance
Daily Inspections
Perform walk-through inspections of the conveyor equipment each day. For continuous duty
applications, conduct inspections each shift. Listen for unusual noises and carefully observe
the system.
To ensure the safety of personnel, frequently check safety guards, warning signs, lights, and
alarms associated with the Unisort X, and keep them in good condition. Immediately report
and correct any unusual noise, oil leak or operational problem.
Weekly Inspections
Air Filter
Inspect the air filter and clean or replace if dirty. Open the condensation drain to allow
accumulated moisture to escape.
Air Regulator
Check the air regulator gauge for correct operating air pressure and adjust if needed.
Single Sided UniSort X = 80 psi
Dual Sided UniSort X Center Switches = 80 psi 20° and 30°.
Remedy the cause of any chronic air pressure losses.
Air Lubricator(s)
Check oil level in the air lubricators. Fill with SAE 5W non-detergent oil.
Note: The air lubricator may be defective if the oil reservoir is always full.
Carrying Tubes (Slats)
Check the carrying tubes to be sure they are clean, straight and smooth. Replace bent or
nicked carrying tubes.
Clean the carrying tubes by wiping with a degreaser type solvent. Clean extremely dirty or
rusty tubes with steel wool or a fine grade emery cloth with a degreaser.
CAUTION: For trouble free divert pusher operation the carrying tubes must be maintained in
good physical condition. Do not apply any lubricant to the carrying tubes without
first consulting the manufacturer.
Control Devices
(Mounted on the UniSort X) - Be sure all photo-eye and reflector fasteners are tight. Verify
proper operation of the air pressure switch. Check tightness and physical condition of all wire/
conduit fittings.
Divert Pushers
Check all divert pushers for physical damage and replace damaged pushers. Be sure all
pushers slide freely and fix any that are binding.
Note: Typical causes of binding include 1) dirty or bent carrying tubes; 2) pusher fasteners
adjusted to tight.
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H-7
Maintenance
Divert Switches
Observe the pushers as they divert and listen for unusual clicking sounds at each divert
switch. If a random clicking sound occurs, the pin of a divert pusher may be damaged. If a
repetitive clicking sound occurs, the divert switch may be out of adjustment or improperly
synchronized (control timing).
General Structure/Operation
Check the physical condition of and fasteners connected to the following structural items:
floor supports, section joint fasteners, product containment guard rail, and take-away
conveyor mountings.
Sorter Calibration
Perform sorter calibration to verify proper divert operation. Calibration frequency depends on
sorter length, loading, and hours of operation per day.
Drive Section Reducer
Check for signs of oil leakage on the floor and/or in the drip pan. If the leakage persists or the
amount of leakage is significant, repair or replace the unit. Until corrections are made, closely
monitor the unit’s oil level.
The oil level should be inspected and replenished, if required, every 250 hours when the unit
is warm but not running.
Oiler
Older Unisort X models used gravity operated lubricators (prior to 1997). Current models use
injector pump operated lubricators. An electric solenoid valve controls the air which operates
the injector pump, and two brushes deliver oil to the chain. Each period of lubrication should
occur after about 65,000 shoe “passes” (5”/shoe). Each period should be long enough for one
full revolution of the chains.
Setting Up the Idler
1. Fill the lubricator reservoir with 20 weight nondetergent oil (or as directed in the table
below). This oil is almost clear or amber colored and “washes” the chain as it lubricates it.
A properly lubricated chain has a clean appearance and looks as if it has been dipped in
oil.
Table H 6 Lubricator Oil Selection
Operating Temperature
Oil (Non-Detergent)
Over 100° F (for prolonged periods of time)
SAE 30
40° F to 100° F
SAE 20
20° F to 39° F
SAE 10
•
Do not use 30 weight oil (except as noted in the table below); it can leave a sticky residue
which attracts dust.
• Do not use multiblend oil.
2. Set the lubricator brushes at a diagonal and center them over the chain (see Figure H 5). (Keep the brushes away from the chain carrier bearings.)
H-8
9500 12/03
Maintenance
Adjusting the Injectors
Brass adjustment screws on top of the injectors (see Figure H - 3) control oil quantity.
Screwing them in (down) reduces oil flow, screwing them out (up) increases flow. To set them
initially:
1. Turn the screws all the way down (off) (do not over tighten).
2. Turn the screws back up (on) 3-1/2 turns.
Figure H - 3 Oiler Injectors
Chain
Chain Facts and Care
•
Manual chain lubrication may be necessary at start-up (of newly installed sorters) to facilitate smooth sorter operation. Once the lubrication system is working correctly manual
lubrication is not necessary. Manual lubrication should be a one-time procedure.
Note: Wipe up any excess oil that may drip onto the sorter or the floor during manual
lubrication.
•
•
•
•
•
•
9500 12/03
When the chain lubrication system is working correctly, the chain will appear to have a
clean and uniform sheen.
If the chain lubrication system is adjusted correctly, the moving chain remains relatively
cool; measure the temperature with a laser guided infrared thermometer approximately
six hours after start-up.
Do not use cleaners on the chain, although you can wipe off excess lubrication with a rag.
During normal operation a small buildup of lubrication my be noticed at the chain track
expansion joints (splices).
The teeth of the drive sprockets on each end of the drive shaft must be aligned with each
other.
The links of the chains must be aligned with each other; if they are not, the carrying tubes
will be at an angle, producing a skewing effect.
H-9
Maintenance
•
•
While moving a “window” (remove 20-30 tubes and pushers) around the sorter during
maintenance, check the chain roller bearings as you go and remove any that are loose.
(They may fall and be carried into the sprocket area while you have the open window.)
Consider replacing chain carrier bearings that are unusually loose.
PUSHER
CARRYING CHAIN
EXTENDED PIN
CARRYING TUBE
GUIDE PIN
Figure H - 4 Chain with Tubes and Pushers
Chain Temperature
An effective method of evaluating the lubrication being applied to the sorter chain is by
checking the temperature of the left hand and right hand chains. The temperature of the
running chains should be initially checked after six hours of operation.
To check the temperature of the chains:
•
•
•
•
Take ambient temperature readings (temperature readings of steel objects in the vicinity
of the sorter).
Take infrared thermometer readings of the chain at the idler end of the sorter with the
thermometer as close to the chain as is safely possible. Measure the temperature of the
side plates of the chain, not the rollers.
The temperature of the chain should be 5 to 10 degrees higher than the ambient temperature. If the temperature variance is greater than 10 degrees, the lubrication system may
need to be adjusted to deliver more oil. (Freezer applications give different readings than
room temperature environments.)
Each chain should be checked separately. Take the chain temperature at the same place
on both sides of the sorter.
Chain Stretch
The UniSort X drive chains stretch with time. To compensate for chain stretch:
•
•
H - 10
Short sorters – Adjust the drive shaft take-up screws, thereby moving the drive shaft.
(Sorters that are relatively short must be manually adjusted because they do not have a
catenary section.)
Long sorters – Do not do anything. Do not adjust the drive shaft; it is preset at the factory.
(Sorters that are relatively long have a catenary section that creates chain tension and
automatically compensates for chain stretch.)
9500 12/03
Maintenance
Chain Lubrication
Check the carrying chains for proper lubrication. When properly lubricated, the carrying
chain rollers will appear moist. On the single sided UniSort X pay special attention to the
divert side chain.
The carrying chain lubricator (see Figure H - 5) is manually adjusted to dispense the required
oil quantity. Do not over lubricate. See Table G.2 for recommended oil types.
CAUTION: Thoroughly clean and lubricate the carrying chain(s) whenever the chains
become contaminated with foreign material. This may result from product spillage or operation in an excessively harsh environment.
Figure H - 5 Chain Lubricator
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H - 11
Maintenance
Safety Guards and Devices
Check the drive section safety guard for loose fasteners or physical damage. Check all
personnel safety guards for looseness or physical damage. These guards may include, for
example, UniSort X underside guards, safety netting and/or solid type guards mounted on top
of the UniSort X Side Frame(s).
Check the physical condition and operation of all safety devices, including the:
•
•
•
•
•
•
•
Emergency stop pull cord.
Internal jam detector(s).
Discharge end safety roller assembly (see Figure H - 6).
Non-diverted product out of position at UniSort X drive section.
Product jam photo-eyes.
Divert switch access cover plates.
Any other specially applied safety devices.
PROXIMITY SWITCH
Figure H - 6 Pivoting Pop-up Safety Roller Assembly
H - 12
9500 12/03
Maintenance
Internal Jam Detector
The internal jam detector (IJD) is installed at the site. Only the bearing and shaft are
assembled at the factory.
To adjust the internal jam detector (see Figure H - 7):
1. Loosen the flange bearing bolts so the bearing drops to the lowest position.
2. Place a magnetic mount torpedo level vertically on the flipper blade.
3. Place a 1/8” thick flat underneath the flipper blade on each end of the blade. (The objective is to position the flipper blade so it is perpendicular (90 degrees) to the carrying tubes
and 1/8” above them.)
4. Grasp the trip arm and rotate the arm against the rubber bumper until the flipper blade is
at 90 degrees. The flange bearing will move up or down as you do this. If you cannot
move the arm far enough, adjust the rubber bumper as needed.
5. Tighten the flange bearing bolts.
6. Remove the 1/8” thick flats.
7. Readjust the rubber bumper so the flipper plate is vertical. A set screw holds the trip arm
in place. A cotter pin is a shear indicator. If the rubber bumper does not seem to have
enough range to allow correct flipper blade adjustment, do not drill new holes for the cotter pin. An apparent lack of range is an indication that the flipper is not adjusted correctly.
8. Loosen the adjustment screw in the center of the limit switch arm.
9. Move the limit switch arm to the normal operating position. Place a straight edge along
the underneath side of the trip arm. At the same time, place the limit switch arm roller on
the top side of the straight edge. The jam detector trip arm and limit switch arm must not
be set to automatically reset after a jam. The limit switch arm must remain in the “tripped”
position until manually reset. When the limit switch is tripped, the trip arm should move
freely and not come in contact with the limit switch arm.
10. Tighten the limit switch arm.
Note: The IDJ flipper plate in the drive section is only one half a normal flipper plate. The
half plate faces upward (bottom half is blank) with the angled portion facing in the
direction of product travel (towards the discharge end). Adjusting this IDJ is the same
as that described above except that slats/tubes must be above the flipper plate and
the 1/8” flates are placed between the flipper plate and the slats/tubes above it.
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H - 13
Maintenance
TORPEDO LEVEL
FLIPPER BLADE
TRIP ARM
FLANGE BEARING BOLT
1/8" THICK FLAT
ADJUSTMENT SCREW
1/8" THICK FLAT
RUBBER BUMPER
LIMIT SWITCH ARM ROLLER
LIMIT SWITCH ARM
Figure H - 7 Internal Jam Detector
H - 14
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Maintenance
Semi Monthly Maintenance
Cleaning (General)
Use a water displacement penetrating oil (WD40 typical) and a soft cloth to clean conveyor
surfaces. Apply to the rag and wipe all surfaces, removing dust and dirt.
CAUTION: WATER DISPLACEMENT PENETRATING OIL IS NOT A LUBRICANT! Do not get
WATER DISPLACEMENT PENETRATING OIL on bearings, valves, or seals!
Every two weeks clean the divert switch piston rods and seal assemblies. Remove several
tubes to create a “window”. Move the window to each divert switch.
To clean each divert switch piston rod and seal assembly (see Figure H - 8):
1. Use compressed air (or vacuum) and a soft rag to clean each switch.
2. Wipe clean the end of the ball piston attached to the end of the switch blade (wipe all the
way around the piston).
3. Place a rag underneath the piston and spray the piston with 5 weight oil. Work the piston
with the manual pilot valve a couple of time. Wipe out the new dirt that’s been brought out.
Spray with oil again. Repeat until the piston is clean.
4. Look for loose or broken parts.
Note: Be sure to keep the in-line air lubricator working with 5 weight oil. This helps keep the
switch pistons oiled and clean. (Adjust the drip rate to one drip every 20 minutes at
start-up, then check after a couple of weeks. The piston shaft should look wet. If it is
covered with a grey powder and has a dry look it, increase the drip rate. If oil drips
from the shaft, decrease the drip rate.)
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H - 15
Maintenance
Figure H - 8 Cleaning Divert Switch
H - 16
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Maintenance
Divert Switch
Examine the divert switch every two weeks and check (see Figure H - 9):
1. The condition of the rubber bumper inside the damper assembly spring. If it is broken or
freely moving around, replace the damper assembly.
2. The switch blade to see that it strikes the damper squarely and in the center. If the
damper is cocked to one side, or is high or low, the repeated blade impacts will cause
metal fatigue and eventual failure. To correct this, bend the damper rod.
3. The condition of the rubber bumper which the switch blade strikes when it returns.
Replace the bumper if it is broken or worn. (If it is broken or worn, the switch blade does
not rest in the correct position which causes the pushers to travel along the blade in an
undesired path.)
4. The tip of the switch blade for evidence of pusher pins striking the blade tip. This could
indicate timing errors, a sluggish switch, or air pressure problems. Replace the UHMW
blade if broken.
Note: When reattaching the UHMW blade to the metal blade on a divert switch, press the
front round hole (in the UHMW) onto the front pin first, then press the rear oblong hole
(not shown) onto the rear locating pin.
Note: When removing the pigtail from the MAC valve, the two-stage screw sometimes does
not separate. If this happens, separate the second half from the pigtail and screw
back into the pilot valve body before reassembling the valve.
9500 12/03
H - 17
Maintenance
Figure H - 9 Divert Switch Care
H - 18
9500 12/03
Maintenance
Cleaning and Lubrication
Note: Use water displacement penetrating oil to clean conveyor surfaces but do not spray it.
Wet a rag with it and wipe surfaces clean.
CAUTION: WATER DISPLACEMENT PENETRATING OIL IS NOT A LUBRICANT! Do not get
water displacement penetrating oil into bearings, valves, or seals!
•
Lubricate the uniball (in the divert switch).
Each month lubricate the uniball and check for excess wear (you should not be able to feel
play in the fit). The switch can be left in the conveyor. Do not overlubricate.
CAUTION: If the grease gun is difficult to remove from the zerk fitting be careful not to apply
too much force attempting to remove it. If the zerk fitting breaks the switch must
be replaced.
•
Clean the divert switches.
Clean the divert switches every two weeks. Remove several tubes to create a “window”.
Move the window to each divert switch. Wipe each switch clean, watching for loose or
broken parts. Wipe clean the end of the ball piston attached to the end of the switch blade
(wipe all the way around the piston). Place a rag underneath the piston and spray the piston with 5 weight oil. Work the piston a couple of time. Wipe out the new dirt that’s been
brought out. Spray with oil again. Repeat until the piston is clean.
•
9500 12/03
Be sure to keep the in-line air lubricator working with 5 weight oil. This helps keep the
switch pistons oiled and clean.
H - 19
Maintenance
Idler
One of the idler sprockets (opposite the PTO, if there is one) is free-wheeling. Grease the
bushing in this sprocket every two weeks with high-speed wheel bearing grease while the
conveyor is running. A zerk fitting (see Figure H - 10) on the end of the idler shaft connects to
a grease channel leading to the bushing. Neither the shaft nor the bushing has grease
grooves; shaft movement distributes the grease.
ZERK FITTING
Figure H - 10 Greasing the Idler Sprocket Busing
H - 20
9500 12/03
Maintenance
Monthly Maintenance
Lubricants
Lubricate the Unisort X with the following:
Table H 7 Lubricants for the UniSort X Conveyor
Component
Carrying Chains
Pillow Block Bearings
Air Lubricator
Reducers
Drive Motor
Ambient Temperature
Lubricant
+20° F to +40° F
+41° F to +120° F
-25° F to +120° F
SAE 10 Non-Detergent Oil
Lithium Base, NLGI-2 Bearing
Grease
-30° to +100° F
Refer to Manufacturer’s Instruction Manual
Caution
The reducer may be supplied with synthetic type lubricant. Do not
mix synthetic lubricants without checking compatibility. It is a good
practice to flush out one type of lubricant prior to using any other
type or brand.
Refer to Manufacturer’s Instruction Tag or Sheet
Carrying Chains
Check the carrying chain tension after the first month of operation. If the UniSort X is
equipped with a catenary take-up, the carrying chain should sag 6” to 8” (see Figure H - 11)
when the conveyor is not operating. To adjust, remove links in 5” (2 links) increments and/or
adjust the drive shaft position.
VARIABLE LENGTHS
14"
CHAIN SAG
6" TO 8"
CHAIN SUPPORT GUIDE
Figure H - 11 Catenary Chain Sag
9500 12/03
H - 21
Maintenance
Carrying Tubes (Cleaning)
Periodically check the carrying tubes for cleanliness. To clean the tubes, wipe them with a
suitable solvent/degreaser. For extremely contaminated tubes, use a very fine grade emery
cloth or steel wool alone or with a cleaning solvent.
Be careful not to allow solvent to enter the tubes or to remain in contact with the end
bushings. Do not spray the tubes.
Do not lubricate the carrying tubes. This may cause malfunctions by allowing contamination
to build-up on the tubes. It is only necessary to keep the tubes clean for trouble-free
operation.
Use the following solvents/degreasers to clean the tubes:
•
•
•
Mobilarma 245 - Mobile Oil Corporation
Rust Vetro ® 4214 - E.F. Houghton Company
Tectyl 235 - Ashland Oil Company
CAUTION: To ensure the safety of personnel, pay strict attention to the solvent manufacturers’ instructions concerning use and health hazard warnings.
Divert Pushers
Check the nuts on the divert pushers. Do not overtighten; this will cause the pushers to bind
on the carrying tubes.
Note: The divert pushers should slide freely when pushed by hand. To check, lift a pusher
from the pin guide track and push the pusher across the carrying tubes.
Return Wedge - If the pusher pads show unusual wear, check the position of the pusher
return wedge in the drive section.
Divert Switches
Inspect each divert switch for dirt or product spillage and clean as required. Be sure the top of
the proximity switch is free of contamination.
H - 22
9500 12/03
Maintenance
Photoeye
1. Remove several tubes to create a “window”.
2. Slowly move the window toward a divert switch. As the pushers move past the photoeye
send unit (see Figure H - 12), notice where the beam strikes the pusher cam rollers. It
should strike the center of the bearing. If not, adjust the send unit position and move
pushers past the beam again. Repeat until the beam strikes the center of the bearing.
Figure H - 12 Photoeyes
Drive V-Belts
Inspect the drive section V-belts for proper tension, wear and alignment. Do not over tighten
the V-belts; they should deflect 1/4” at their mid-point.
CAUTION: Be sure to reinstall the drive section safety guarding.
Floor Supports/Hangers
Be sure all floor supports are in good condition and have not been damaged. Check that all
fasteners are securely tightened and that none are missing.
Drive Section Motor
Remove any build-up of dirt or dust around the motor vent openings.
Periodically check the motor to see that all mounting bolts are securely tightened and the
motor lead wires securely connected.
Unless otherwise specified wick-oil sleeve bearings should be lubricated every 2000 to 4000
hours after the first 4000 hours of operation with 3 or 4 drops of light-grade mineral oil or
SAE-10W motor oil.
9500 12/03
H - 23
Maintenance
Sprockets/Hubs/Pulleys
Check the tightness of set screws used in sprockets, hubs and pulleys. Recheck alignment if
any set screws are found loose.
CAUTION: Always lock out the electrical power prior to working on the reducer or related
power transmission devices.
Reducer Oil
CAUTION: If the unit(s) is not going to be operated for an extended period of time, fill the unit
completely with the proper oil. This will help prevent internal oxidation of the critical parts. Before resuming use, be sure the oil is of the proper type and at the
proper level. Operating a unit full of oil causes overheating and leakage through
the oil seals and the breather plug.
Store the reducer in a dry location where the temperature remains relatively constant, not passing through the dew point. Do not store the unit outdoors. If the
temperature passes through the dew point, moisture will condense on the inside
of the unit. This will reduce the life of the reducer.
•
Check the unit for oil leaks and the source of those leaks.
The most common leak points are pipe plugs, oil seals, and the cover gasket. Rather than
waiting for parts during unscheduled down time, you may wish to order replacement parts
when the leaks are minor. Occasionally the breather plug is not properly located at the
highest point in the unit. Relocate the breather plug, if required, especially if the lubricant
is foaming out of the breather. Many leaks are caused by overfilling the unit with oil.
Check the proper oil level. Do not let any leak go unattended as loss of oil will eventually
cause a failure.
•
•
•
•
H - 24
Change the oil after an initial period of 500 hours of operation or one month (use SP220
oil), whichever occurs first. Thereafter, for petroleum based reducer oil with or without EP
additives, change the oil every 2500 hours of operation or every six months, whichever
occurs first. If a synthetic hydrocarbon reducer oil without EP additives is used, the recommended oil change interval is doubled to 5000 hours or 12 months, whichever occurs
first.
Be careful not to confuse the fill plugs with the oil level hole. (The reducer has fill plugs in
several locations because it can be mounted in four different positions.)
In cases of severe service applications, such as extreme exposure to water, high humidity, dirty or dusty environment, or chemicals in the air which react with lubrication oil, the
oil change interval must be shortened depending on the severity of the conditions.
For better drainage, drain the oil when the unit is warm. Remove and examine the magnetic drain plug for metal chips and particles. An excessive amount of metal particles signals internal problems. Consult The Dorris Company if you think the amount is excessive.
Small amounts of metal particles are normal and should simply be cleaned off prior to
reinstallation. After draining, remove debris by thoroughly flushing the inside of the unit
with clean oil. Remove and clean the breather plug to ensure that the air passage is clear.
Reinstall the drain plug and breather plug after using a thread sealant.
9500 12/03
Maintenance
•
For units that see a significant seasonal swing in ambient temperature, change the grade
of oil as needed (thinner oil in winter, thicker oil in summer). See Scheduled Maintenance
topic in this section.
Reducer Temperature
•
•
Do not allow the reducer to become covered with dirt, dust or other debris. The insulating
properties of these coverings could cause the unit to overheat. This will lead to a breakdown of the lubrication, causing premature failure of the reducer components.
Periodically check the reducer temperature with an infrared thermometer. Measure the
temperature at several locations and use the highest reading. The reducer temperature
must not exceed 175 degrees (90 degree ambient temperature).
Other Reducer Maintenance
•
•
•
•
•
•
•
•
•
9500 12/03
Be sure the reducer shaft set screws are properly torqued.
Check the torque arm fittings for tightness and wear.
When an optional backstop is installed, be sure the set screw on the OD of the cap is tight
against the output shaft.
At oil change intervals during normal maintenance, add grease to the grease fitting on the
shaft seal or the optional puller cap (whichever is installed), as instructed in the reducer
assembly instructions.
Check the V-belts for wear and proper tension.
Check the V-belt sheaves for tightness to the motor and input shafts.
Check the electrical connections to the motor.
Ensure that all required guard and safety devices are in place and function properly.
In environments where a buildup of unwanted surface coverings is expected, clean the
outer surfaces of the reducer often. Ensure that the breather is clear after cleaning.
H - 25
Maintenance
Semi Annual Maintenance
Bearings
Check the tightness of all pillow block bearing mounting bolts. Lubricate each bearing using
no more than two grease gun shots of lithium base NLGI-2 grease.
CAUTION: Over lubrication may result in bearing failure.
Carrying Chains
Check the carrying chain tension using the procedure listed under “Monthly Maintenance,
Carrying Chains”.
Carrying Chain Guides
Check the physical condition of the grey UHMW carrying chain guides mounted along each
side of the UniSort X.
Check the height of the right and left side grey UHMW carrying chain guides at points
opposite each divert switch. The top of the chain guide should be 1-5/16” below the top of the
UniSort X side frame. If adjustment is required, see Section F Aligning the Section.
Drive Motor
Check the tightness of the drive motor mounting bolts.
Plastic Parts
Inspect all plastic parts for signs of unusual wear and deterioration. Replace any worn plastic
parts.
CAUTION: If carrying tubes come loose, perform a thorough inspection to isolate the cause.
Do not operate the UniSort X with bent carrying tubes, incorrect carrying chain
tension, damaged divert pushers, or damaged divert switches.
Check the tightness of reducer mounting bolts and torque arm (if equipped).
For information on changing oil, oil type, and operating oil level, see “Monthly Maintenance,
Power Unit Reducer”.
Safety Provisions
Check that warning signs and labels posted on or near the conveyor equipment are not
removed, painted over or altered at any time. All safety devices, warning lights, and alarms
associated with the conveyor system should be regularly tested for proper operation and
serviced as needed.
H - 26
9500 12/03
Maintenance
Reentry Guide
To align the reentry guide:
1. Loosen the bolts and screws which hold it down.
2. Place the pin guide alignment tool into the pin guide so that one end is in the pin guide
before the reentry block and the other end is in the pin guide after the reentry block.
3. Adjust the reentry guide as needed and tighten the bolts and screws.
4. Inspect the transition from the metal cam guide rail to the reentry guide. If that transition is
not smooth, adjust the cam guide rail as needed. Do not readjust the reentry guide.
9500 12/03
H - 27
Maintenance
Troubleshooting
Basic troubleshooting provisions are outlined below. For troubleshooting for the specific
conveyor system installed, always check the maintenance information. Basic troubleshooting
is outlined in Table G.3.
WARNING: Do not clear jams or reach into any unit before first turning off the equipment
power source(s) and making certain that all moving parts are fully stopped. To
avoid personal injury or equipment damage, lock out and tag out the conveyor
operation control(s) before attempting to correct any malfunction.
Table H 8 Basic Troubleshooting Problems and Solutions
Problem
Drive Motor Does Not Run
Cause
Tripped Safety Device
• Internal jam detector is
tripped.
• Product jam on sorter.
• Infeed / discharge end safety
rollers out of position.
• Emergency stop on.
• Product out of position
detected at drive section
pusher return.
H - 28
Solution
• Verify limit switch (see Figure
G.6) is not actuated. Remove
any debris.
• Clear jam; verify position and
operation of applicable
photo-eyes
• Verify roller(s) are in safe
position; proximity switch (see
Figure G.4) is actuated
indicating rollers in correct
position.
• Verify emergency stop is OFF.
• Check for product on wrong
side of pushers at drive
section. Check photo-eye and
proximity switch.
9500 12/03
Maintenance
Problem
Drive Motor Does Not Run
(continued)
Cause
Electrical Power Circuits /
Drive Motor
• Drive motor defective.
• Motor disconnect switch.
•
•
•
•
• Check drive motor and wiring.
• Check that motor disconnect
switch is ON and not
defective.
VFD, misadjusted / defective.
• Refer to VFD manufacturer’s
manual for troubleshooting.
Drive overcurrent relay /
• Verify overcurrent relay /
sensor.
sensor not tripped or
defective. Check adjustment.
• Verify motor contactor is not
Motor contactor.
defective.
• Check for blown fuses,
Power fuses / circuit
tripped circuit breakers.
breakers.
• Motor start PB / main power
switch.
• Wiring
Low Air Pressure
• Air regulator set low /
defective.
• Air filter clogged.
• Air pressure switch defective
or misadjusted.
9500 12/03
Solution
• Check that main power switch
is on and motor start PB is not
defective.
• Check all wiring for any loose
connections or broken wires.
• Check air pressure setting at
regulator.
(Single sided = 70 psi). (Side
Switch)
Dual Sided = 70 psi). (XOver
Switch
• Check air filter.
• Check air pressure switch
and adjustment.
(Single Sided = 50 psi).
(Dual Sided = 50 psi).
H - 29
Maintenance
Problem
Cause
Solution
Drive Motor Starts, but Stops
Immediately or UniSort X
does not Reach Specified
Operating Speed.
• Over current relay / sensor is
tripping.
• Check adjustment of relay /
sensor.
• Check carrying chains for
proper lubrication and
tension.
• Check carrying tubes for
contamination or divert
pushers binding.
• Check for any binding in drive
and idler sections.
• Check drive motor for free
rotational movement.
VFD Misadjusted or Defective.
instructions and verify
adjustments.
VFD misadjusted or
defective.
instructions and verify
adjustments.
Carrying chains tension incorrect
• Check carrying chain tension
and adjust if required. Readjust VFD.
UniSort X Takes Long time to
Reach Speed or Carrying
Chains Jerk when Starting.
UniSort X Shuts off Automati- Safety device(s) tripped
cally During Normal Operation.
H - 30
• See the “Drive Motor Does
Not Run” checks in this
section.
Low air pressure.
(Single Sided requires 70 psi).
(Dual Sided requires 70 psi).
• Check air filter/regulator for
proper pressure setting and
filter not clogged.
• Check air pressure switch for
correct adjustment and
operation.
Electrical power circuit / device
problem.
• See to “Electrical Power
Circuits / Drive Motor” in this
section.
Recirculation / overflow conveyor full or not operating
• Clear full condition.
• Trouble shoot drive / power
unit.
Sort control unit.
• Verify control unit is not
inhibiting drive motor power
due to possible control unit
failure / wiring problem.
9500 12/03
Maintenance
Problem
Cause
Drive Switching Noisy at One
or More Divert Switches
• Some divert pushers binding / • Clean carrying tubes / adjust
carrying tubes contaminated.
pusher fasteners as
necessary.
Divert Pushers “Jump”
During Diverting
• Divert switch block binding,
misaligned, or damaged
•
•
•
•
•
9500 12/03
Solution
• Align, adjust, or replace
switch block as necessary.
(see “Divert Switch
Operational Mechanisms
Check and Alignment”.)
• Replace.
Divert pusher pin damaged.
Pin guide track(s) misaligned. • Align pin guide track (see
Aligning the Section)
•
Adjust
height.
Carrying chain support (grey
uhmw) set too low.
• Check air pressure and
Air solenoid valve sluggish
condensation drain or
and/or air cylinder sluggish.
replace.
Switching incorrectly
•
Proximity
switch misadjusted
Synchronized.
or top surface dirty - adjust or
clean as necessary
Take-away Lane-Full.
Air solenoid valve defective.
Air cylinder Defective.
Proximity switch defective.
Air line broken or restricted.
Broken wire / loose
connection to Air solenoid
valve or proximity switch.
•
•
•
•
•
•
Clear take-away lane.
Replace.
Replace.
Replace.
Repair / Replace.
Repair.
Inoperative Divert Switch
•
•
•
•
•
•
All Divert Switches Inoperative - UniSort X Drive Motor
Operates - Sorter Runs at
Correct Speed.
• +24 VDC Supply voltage for
proximity switches.
• Loss of 110 VAC for solenoid
valves.
• Control system failure.
• Check +24 VDC power supply
and wiring.
• Check 110 VAC wiring and
control unit.
• Troubleshoot control system
per control supplier’s
instructions.
Induction Conveyor
Inoperative
• UniSort X not at Speed
• First proximity switch
defective and/or auxiliary
contact on motor starter
defective.
• Induction conveyor drivepower unit.
• Verify induction conveyor run
not inhibited by control unit.
• Troubleshoot induction
conveyor drive-power unit.
H - 31
Maintenance
H - 32
9500 12/03
Spare Parts
SECTION I: SPARE PARTS
General Information
The purpose of this section is to provide a list of common spare parts for a preventive
maintenance program and also to minimize the chances for extended DOWNTIME.
The following pages illustrate the location of these recommended spare parts as they apply to
each particular unit. Keep in mind that these illustrations apply to the STANDARD product
line and to project specific parts. These items will show up on the Bill of Material as a “coded”
item. For example: there will also be items on the Bill of Material such as gearmotors,
sprockets, chain, etc., that will also show up on the price sheets.
9500 12/03
I-1
Spare Parts
Spare Parts
Key
Part Number
1/8 THICK RUBBER SHEET 7 1/2 W
000456
1
10028 BUSHED IDLER SPKT2 15/16
908571
2
BUMPER ISOLOSS SANDWICH MOUNT
272010
3
HSS CAM GUIDE ANGLE CUSHION4.5
000681
4
HSS ID CAM RET DISC 2.94 SPLIT
908540
KEY 5/8"SQ X 2 1/2"LG
690557
5
NUT STOP,ELASTIC 5/16-18
220648
6
PHOTOEYE OMRON E3S-BT81
302415
7
PILLOW BLOCK P-B22447H 2 15/16
400437
8
SPKT H100BTL28W/3020 X2 15/16+
970983
9
THRUST BRG-OILITE 2.937 DIA
911465MA
UHMW PIN GUIDE EXTRUSION +
000454
10
VHS CAM DIVERT ANG ADJ SWITCH
842008
11
VHS GUARD ANG SWITCH
842009
12
VHS GUARD DAMP PAD SWIT URETH
842010
13
VHS GUARD UHMW STRIP SWITCH
842011
14
VHS HSA SPACER SWITCH PINGUIDE
842056
VHS ID CHAIN GD/SUPT @SPRKT LH
914803
VHS ID CHAIN GD/SUPT @SPRKT RH
914804
VHS ID L-SHPE CHGD SPLICE SUPT
842169MA
VHS ID RET SW UHMW CAM GD 20D
912988
VHS ID UHMW HOLD DOWN BLOCK LH
914729
VHS ID UHMW HOLD DOWN BLOCK RH
914729MB
15
16
17
I-2
Description
18
VHS IDLER UHMW RETURN FUNNEL
914697
18
VHS PIN GUIDE SWITCH LEAD IN
842013
20
VHS SPRING/DAMP ASSY SWITCH
842014
21
VHS SWITCH PHOTO EYE GRD OS
976378
22
VHS WEARSTRP GUIDE SWITCH UHMW
842007
9500 12/03
Spare Parts
Spare Parts Related by Hand
Key
Right Hand
Dual Sided
(Both Req)
Left Hand
VHS CAM GUIDE RH RET BOT SPEC
913281
—
—
VHS WEARSTRP GD SW UHMW NEW
—
Description
842007MA
PIN GUIDE 6.500
908532
—
908532
23
VHS ASSY SWITCH CAST
842030
842030
842031
842031
24
VHS ASSY SWITCH (24VDC)
842032
842032
842033
842033
25
VHS BLADE DIVERT SWIT UHMW
842027
842027
842028
842028
26
VHS SWITCH PHOTO EYE GRD IS
976376
976376
976377
976377
22”
28”
34”
VHS ID RET "MOON" GUIDE LH
914864
914698
914993
VHS ID RET "MOON" GUIDE RH
914863
914699
914994
VHS ID SHAFT 2 15/16
913687
913688
913689
—
—
909095
Right Hand
Dual Sided
(Both Req)
Left Hand
Spare Parts Related by Width
Key
27
28
Description
VHS ID SHAFT 2 15/16 X 67 PTO
Spare Parts Related by Width and by Hand
Key
Description
Width
22”
29
VHS UHMW BANJO
RNTRY
28”
34”
9500 12/03
913676
913676
913676MA
913676MA
913602
913602
913602MA
913602MA
913297
913297
913297MA
913297MA
I-3
Spare Parts
Spare Parts Related by Width and by Hand and by Angle (Deg)
Key
Description
Deg
VHS ID CAM GUIDE BLK
30
Right Hand
22”
914929
914930
914929
914930
914658
914658
914659
914659
842091MA
842091MA
842092MA
842092MA
842091
842091
842092
842092
905680
907418
905680
905681
905681
907419
907418
907419
907418
907419
—
914652
—
28”
30
34”
31
32
I-4
Dual Sided
(Both Req)
Width
20
all
30
all
20
all
VHS IS PIN GUIDE
63.500
30
28”
VHS LEXAN COVER 6 1/
8
30
28”
908896MA
20
28”
908898
all
34”
all
all
HSA/VHS RE-ENTRY
GUIDE
Left Hand
908896
9500 12/03
Spare Parts
Spare Parts Unique to Dual Sided Sorters
Key
9500 12/03
Description
Dual Sided
Part Number
33
HSS CTR SWITCH SPACER BLOCK
000857
34
VALVE ISOLATION PAD 1/8 RUBBER
000995
ROD END BRG AURORA CW-7Z ZERK
210230
35
SILENCER 1/2MPT(54017 OREQUAL)
270028
36
ELBOW 90DEG 1/2MPT X 1/2TUBE
271644
BRG 6203-ZZ-5/8 SHIELDED40MMOD
350920
37
DIVERT TRACK CUSHION 1/8X3
860204
38
VALVE 24VDC C/O SWITCH MAC6300
861887
39
BUMPER #17120-040 WAMPFLER +
911887
40
HOSE 1/4ID X 3/8OD
8978035
VHS BLADE RET SWIT NYLON MD LH
842028MC
VHS ASSY SWITCH LH SET-UP SPEC
842033MA
I-5
Spare Parts
Spare Parts Unique to Dual Sided Sorters Related by Angle
Key
Description
AIR CYL
41
CTR SWTCH GAP BLOCK
42
CROSSOVER SWITCH
43
44
30D X-OVER SWTCH SWVL ARM ASSY
45
CAM GUIDE CUSHION "H"
CYL BIMBA 2BR X 2ST (2)1/4PORT
46
Dual Sided
Part Number
30
000853
20
000856
30
001087
20
000855
30
001086
20
000850
001076
30
HSS CTR SW DIVERT BLOCK 30 DEG
CONNECTOR 1/2MPT X (2) 3/8T
CONNECTOR 1/4MPT X 3/8T
I-6
Deg
860260
279510
001085
20
271643
271496
9500 12/03
Spare Parts
Idler and Intermediate Section
Figure I - 1 Idler Section and Intermediate Section Spare Parts
9500 12/03
I-7
Spare Parts
Divert Switch
Figure I - 2 Divert Switch Spare Parts
I-8
9500 12/03
Spare Parts
Crossover Switch
Figure I - 3 Crossover Switch Spare Parts
9500 12/03
I-9
Spare Parts
Note:
After January 1, 2004, the UniSort X may be equipped with the mechanical crossover switch.
Key
1
2
3
Description
Part Number
20° Divert
30° Divert
Crossover, Assembly
7001200
7004500
Trigger, Crossover
7001206
7001212
Bearing
Gate, Crossover
7740545
7001204
7001211
Bearing
7740545
4
Arm, Rocker
7001206
5
Linkage, Arm, Nylair
7001207
7001213
Figure I - 4 Crossover Switch - Detail
I - 10
9500 12/03
Spare Parts
Internal Jam Detector Spare Parts
Key
Description
Single Sided
(Right or Left)
Dual Sided
47
ROTARY SPRING
302673
—
48
RUBBER BUMPER
000135
—
49
FLANGE BRG 2-BOLT 1"BR
400980
50
SPRING
310504
51
LIMIT SWITCH ARM
309523
51
LIMIT SWITCH BODY W/LIGHT
—
302101
53
LIMIT SWITCH RECEPTACLE
—
302103
54
LIMIT SWITCH OPERATING HEAD
—
309525
Figure I - 5 Internal Jam Detector Spare Parts
9500 12/03
I - 11
Spare Parts
Catenary Spare Parts
Catenary sections contain many of the spare parts already shown in this section. In addition,
catenaries contain the following spare parts which are unique to catenaries.
Key
Description
Part Number
55
VHS CAT CHN GUIDE UHMW LH DIS+
915856
56
VHS CAT CHN GUIDE UHMW RH DIS+
916143
57
VHS CAT CHN GUIDE UHMW LH INF+
915854
58
VHS CAT CHN GUIDE UHMW RH INF+
915855
59
VHS CAT CHAIN GD UHMW CLIP RH
916144
60
VHS CAT CHAIN GD UHMW CLIP LH
916145
Figure I - 6 Catenary Section Spare Parts
I - 12
9500 12/03
Spare Parts
Return Section Spare Parts
Return sections contain many of the spare parts already shown in this section. In addition,
returns contain the following spare part which is unique to returns.
Key
61
Description
VHS CTR RET FUNNEL GUIDE 10D
Part Number
907543
Figure I - 7 Return Section Spare Parts
9500 12/03
I - 13
Spare Parts
Drive Section Spare Parts
Unisort X drive sections have not been standardized at the time of this writing. This table
presents spare parts used in “typical” (based on spare parts usage) existing drive sections.
Key
62
I - 14
Description
Part Number
VHS OILER ASSEMBLY (120/60)
271568
VHS OILER ASSEMBLY (24VDC)
271568MA
62
SPKT 100E32H 3 7/16BR 2MATCHED
742095
63
HSS DR GUIDE WHEEL 3 7/16
865222
64
BRG SHIM 16GA P-B22455H 3-7/16
865251
65
VHS BRG REAR COVER 3 7/16
905816
66
VHS DR BOT UHMW CAM DEF RH
907729
67
VHS DR BOT UHMW CAM DEF LH
907729MA
68
VHS DR BOT UHMW CAM DEF CLIP
907730
69
VHS DR 5-0 PIN GUIDE
907742
70
PILLOW BLOCK P-B22455H 3 7/16
972539
9500 12/03
Spare Parts
Figure I - 8 Drive Section Spare Parts
9500 12/03
I - 15
Spare Parts
Oiler (Drive Section) Spare Parts
Key
Description
Part Number
VALVE 3WAY MAC .38T CONN 120V+
271770
VALVE 3WAY MAC.38T CONN 24VDC+
977006
73
SINGLE GANG REMOTE BRACKET
000502
74
EVEN-FLO APPLICATOR BRUSH,
000503
75
HOSE CLAMP 1/4" UMP 3173-132
220068
76
TUBE 1/4 OD X 1/8 ID BLUE
271438
77
CONNECTOR STR 1/8MPT X 3/8
271561
78
OILRITE RESERV W/FL LEVEL SWCH
271565
79
OILRITE INJECTOR PUMP 2-FEED
271567
80
TUBE 3/8"OD FLEXIBLE HIPRESS
271731
81
HOSE 1/8ID X 1/4 OD 3814-6
8978025
72
Figure I - 9 Oiler Spare Parts
I - 16
9500 12/03
Spare Parts
Drive Section Spare Parts Related by Horsepower
Horsepower
Key
82
Description
MRRS 1750
THR CON+
9500 12/03
5
7.5
10
15
20
25
30
40
50
331200
331201
331202
331203
331204
331205
331206
331207
331208
I - 17
Spare Parts
Fill Roller (Drive Section) Spare Parts
Width
Key
Description
22
I - 18
28
34
83
HSS HINGE ROLLER BUSHING 5/8"
230623
84
PROX SW IW-3008-BPOG
302447
85
ROLR G196AB 08.375 BU-NOAXLE
499003
86
ROLR G196AB 08.250 BU-NOAXLE
499004
87
ROLR G196AB BU-NOAXLE
499007
499001
499005
88
ROLR G196AB BU-NOAXLE
499008
499002
499006
89
ROLR G138PL K1-NO AXLE
500045MD
500257MD
500339MB
9500 12/03
Spare Parts
Figure I - 10 Fill Roller Spare Parts
9500 12/03
I - 19
Spare Parts
Drive Section Spare Part Sheaves
Unisort X drive sections have not been standardized at the time of this writing. This table presents
spare parts used in “typical” (based on spare parts usage) existing drive sections.
Key
Horsepower
Speed
180
5
350
Description
SHEAVE 3V 2GRV 4.12OD SH
541610
SHEAVE 3V 2GRV 5.30OD SH
541614
SHEAVE WOODS 3V 2GROOVE 10.60
976676
????
200
90
7.5
10
I - 20
350
350
Part No
????
SHEAVE 5V 2GRV 8.00OD SK
541641
SHEAVE 5V 2GRV11.80OD SK
541649
SHEAVE 5V 2GRV 5.50OD SDS
541635
541642
541641
541643
9500 12/03
Spare Parts
Key
Horsepower
Speed
200
250
312
350
15
350
450
500
550
250
300
20
350
350
450
9500 12/03
Description
Part No
541643
2318318
541642
541645
541644
541647
541644
SHEAVE 5V 2GRV 15.0 O.D. SF
977037
541644
541645
SHEAVE 5V 2GRV 5.2OD SDS
541634
541648
541639
SHEAVE 5V 2GRV 14.00 OD SF
975959
541648
2318318
541643
SHEAVE 5V 2GRV 10.30 SK
541646
541638
541643
541638
541647
541639
541649
541639
541643
I - 21
Spare Parts
Key
Horsepower
Speed
325
350
25
400
550
450
30
450
300
350
400
40
450
500
500
I - 22
Description
Part No
541640
541644
541641
541644
541641
541648
541648
2318318
541644
541649
541639
541643
541642
977037
541644
SHEAVE 5V 2GRV 14.00 OD SF
975959
541648
977037
541644
541647
SHEAVE 5V 2GRV 13.2OD SF
541650
2318356
SHEAVE 5V 2GRV 10.30 SK
541646
541647
9500 12/03
Spare Parts
Key
Horsepower
Speed
350
400
450
50
500
500
550
9500 12/03
Description
Part No
541645
977037
541648
977037
541648
541650
541650
2318356
541642
SHEAVE 5V 2GRV16.00 OD SF
977992
973636
975072
I - 23
Spare Parts
Drive Section Reducers, Bushings, Taper Bushings, V-Belts, and
Shafts
The part numbers for these parts do not currently conform to a pattern that can be presented
in table form.
To obtain a part number for one of these parts, refer to the Spare Parts Proposal associated
with your conveyor which lists the part numbers for every recommended spare part.
If you do not have the Spare Parts Proposal, look for the conveyor’s identification label and
write down the following:
•
•
•
•
Item #
S-Number
Job #
Conveyor #
Then contact Buschman for the part number, or to receive a replacement copy of your Spare
Parts Proposal.
Key
91
92
93
I - 24
Description
VHS DR SHAFT 3.438
VHS DR CHAIN GD/SUPT @SPRKT LH
VHS DR CHAIN GD/SUPT @SPRKT RH
VHS UHMW DR BOT GUIDE RH+
VHS UHMW DR BOT GUIDE LH+
94
REDUCER, DORRIS
95
BUSHING TAPER DORRIS
96
BUSHING
97
BUSHING
98
V-BELT 5V
99
AF #8 PLASTI-GROMMET INSERT
9500 12/03
Product Index
SECTION J: PRODUCT INDEX
Unisort X Idlers
ITEM CLASS C 5 5 2
Component
Style
Family
Product Line
(F1) PTO (None, Left, Right)
22” Wide
28” Wide
34” Wide
Description
Dwg No
Part No
Dwg No
Part No
Dwg No
Part No
30 Degree Diverts
VHS ID SRH
19660 D03
674500
19670 D07
674510
19680 D03
674520
VHS ID SLH
19662 D03
674502
19672 D04
674512
19682 D02
674522
VHS ID DS
19664 D03
674504
19674 D05
674514
19684 D02
674524
20 Degree Diverts
9500 12/03
VHS ID SRH
19665 D05
674505
19675 D03
674515
19685 D05
674525
VHS ID SLH
19667 D05
674507
19677 D05
674517
19687 D03
674527
VHS ID DS
19669 D05
674509
19679 D04
674519
19689 D02
674529
J-1
Product Index
Unisort X Intermediate Sections
ITEM CLASS C 5 5 3
22” Wide
28” Wide
34” Wide
Description
Part No
Dwg No
Part No
Dwg No‘
Part No
Dwg No
30 Degree Diverts
VHS IS LH
VHS IS LH IJD
674562
674562MA
VHS IS RH
674566
VHS IS RH
IJD
674566MA
VHS IS DS
674570
VHS IS DS IJD
674570MA
19774 D01
674571
674571MA
19783 D01
674575
19778 D02
19782 D00
674575MA
674579
674579MA
674580
674580MA
19792 D00
674584
19787 D00
19791 D00
674584MA
674588
674588MA
19796 D00
19800 D00
20 Degree Diverts
VHS IS LH
VHS IS LH IJD
VHS IS RH
674535
674535MA
19747 D00
674539
VHS IS RH
674539MA
674544
674544MA
19756 D00
674548
19751 D00
674548MA
674553
674553MA
19765 D00
674557
19760 D01
674557MA
19769 D00
IJD
VHS IS DS
VHS IS DS IJD
J-2
674543
674543MA
19755 D00
674552
674552MA
19764 D00
674561
674561MA
19773 D00
9500 12/03
Product Index
Unisort X Catenaries
Unisort X catenaries have not been standardized at the time of this writing. This table
presents “typical” (based on spare parts usage) existing catenary sections.
ITEM CLASS C 5 5 6
22” Wide
28” Wide
34” Wide
Description
Dwg No
Part No
Dwg No
Part No
Dwg No
Part No
919339
919303
920161
918320
72250 D00
46122 D00
919359
909214
No Diverts
VHS IS CAT
72250 D00
919358
72250 D00
72221 D00
72934 D00
71466 D02
30 Degree Diverts
VHS IS SRH CAT
72640 D00
919817
72222 D00
919304
—
—
VHS IS SLH CAT
72676 D00
70673 D00
919861
917228
72838 D00
72104 D02
920054
919151
—
—
VHS IS DS CAT
70325 D03
70566 D01
916586
917063
—
—
—
—
20 Degree Diverts
VHS IS SRH CAT
—
—
49663 D02
72818 D00
48418 D02
48647 D02
73189 D00
72872 D00
915816
920037
913553
913881
920492
920093
72990 D00
72994 D00
70475 D02
920227
920231
916871
VHS IS SLH CAT
—
—
49521 D03
49682 D02
70545 D04
49349 D06
915361
915453
915131MA
915131
46220 D04
72888 D00
48660 D02
909408
920118
913898
VHS IS DS CAT
—
—
—
—
48060 D03
913017
9500 12/03
J-3
Product Index
Unisort X Returns
Unisort X returns have not been standardized at the time of this writing. This table presents
“typical” (based on spare parts usage) existing return sections.
ITEM CLASS C 5 5 ?
22” Wide
28” Wide
34” Wide
Description
Dwg No
Part No
Dwg No
Part No
Dwg No
Part No
917716
73157 D00
920468
No Diverts
VHS IS RET
—
—
70937 D00
30 Degree Diverts
VHS IS SRH RET
72639 D00
919816
71559 D02
72223 D00
918457
919305
—
—
VHS IS SLH RET
72677 D00
70674 D00
919862
917229
49407 D01
72839 D00
72101 D01
915198
920055
919148
46008 D03
908031
VHS IS DS RET
—
—
70326 D00
70567 D00
916587
917064
—
—
20 Degree Diverts
VHS IS SRH RET
47067 D03
911402
49386 D02
48648 D01
72088 D00
72507 D01
915177
913882
919126
919640
72991 D00
72058 D00
72995 D00
70476 D02
39892 D07
920228
919101
920232
916872
907296
VHS IS SLH RET
—
—
49387 D04
49684 D02
48278 D05
72580 D00
915178
915455
913307
919747
46221 D06
72159 D00
70176 D02
48659 D02
909409
919221
916327
913897
VHS IS DS RET
—
—
—
—
48064 D01
913021
J-4
9500 12/03
Product Index
Unisort X Drives
Unisort X drives have not been standardized at the time of this writing. This table presents
“typical” (based on spare parts usage) existing drive sections.
Note: This table uses following abbreviations: RH = Right Hand, LH = Left Hand, SM = Side
Mount, UH = Under Hung, FM = Floor Mount, PTO = Power Take Off, LPTO =
ITEM CLASS C 5 5 1
Unisort X Drives
Width
(inches)
HP
Speed
(FPM)
Motor
Mount
Drawing No
Item No
22"
5
180
RHUH
70675 D00
917230
7.5
350
LHUH
47069 D03
911404
15
250
LHSM
72636 D00
919813
312
RHSM
71113 D00
917928
325
LHSM
71812 D00
918769
450
LHUH
49116 D01
914741
RHUH
49117 D01
914743
25
9500 12/03
J-5
Product Index
Unisort X Drives
Width
(inches)
HP
Speed
(FPM)
Motor
Mount
Drawing No
Item No
28"
7.5
200
LHSM
71906 D01
918921
350
LHUH
47069 D03
915191
10
350
RHUH
72381 D02
919480MA
15
200
RHSM
71884 D01
918895
350
LHUH
71560 D00
918458
450
RHSM
72935 D00
920162
500
LHSM
72825 D00
920044
550
RHSM
72545 D00
919683
250
RHSM
72840 D00
920056
300
LHUH
70327 D00
916588
350
LHSM
72013 D01
919064
RHSM
49995 D01
916131
LHUN
45928 D07
908838
450
RHFM
49768D
/49785
915560
350
LHUH
70568 D00
917065
RHUH
72708 D00
919910
400
LHSM
72089 D01
919127
550
RHSM
73324 D00
920674
300
LHFM
49409 D
/49446
915200MA
350
RHSM
70943 D00
917722
450
LHFM
49409 D
/49446
915200MB
RHFM
49734 D
/49700
915362
500
RHFM
49734 D
/49700
915458
400
LHSM
48471 D00
913623
450
LHSM
48649 D00
913883
500
LHSM
48279 D02
913308
RHSM
49388 D00
915179
LHSM
49984 D04
916118
RHSM
72425 D00
919529
20
25
40
50
550
J-6
9500 12/03
Product Index
Unisort X Drives
Width
(inches)
HP
Speed
(FPM)
Motor
Mount
Drawing No
Item No
34"
5
350
RHFM
46011 D00
908033
7.5
350
LHUH
47069 D03
913288
10
350
LHSM
72905 D00
920137
RHSM
73041 D00
920321
15
350
RHSM
73158 D00
920469
30
450
LHSM
70477 D01
916873
40
350
RHSM
46270 D00
909477
400
RHSM
46222 D00
909410
500
RHSM
48655 D00
913893
350
RHSM
72889 D00
920119
400
RHSM
46417 D00
909410MA
500
LHSM
73060 D01
920349
RHSM
72162 D02
919226
50
9500 12/03
J-7
Product Index
J-8
9500 12/03

UniSort® X Sortation Conveyor

Transcription

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