Shipping Extendible with Hinged Infeed Belt Conveyor

Transcription

Shipping Extendible with
Hinged Infeed Belt
Conveyor
Field Manual
Publication No. 29327001
May 15, 2012
© 2012 Intelligrated, All rights reserved
To contact Intelligrated:
By Mail or Phone:
Intelligrated
7901 Innovation Way
Mason, OH 45040
For Service:
Customer Service and Support (CSS)
Hotline 1-877-315-3400
On the World Wide Web: www.intelligrated.com
(513) 701-7300
Direct questions and comments concerning the information contained in this
manual to:
Documentation Department
Intelligrated
10045 International Blvd.
Cincinnati, Ohio 45246
Documentation Department
Intelligrated
9301 Olive Boulevard
St. Louis, MO 63132
Ph 1-800-922-1267 - Fax 1-800-881-5274
[email protected]
Ph 1-314-993-4700 - Fax: 1-314-995-2400
Web site: http://www.intelligrated.com
Read these documents thoroughly before attempting to perform installation,
maintenance or repairs to the applicable Intelligrated equipment components or devices.
Exercise extreme caution when working around moving and rotating 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 and OSHA/ANSI standards.
The information presented in these documents is correct at the time of publication.
Intelligrated 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
Intelligrated with any corrections.
This document is copyrighted © 2012 by Intelligrated, all rights reserved. No part of this
manual 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 Intelligrated: Accuglide™,
EZ-set™, IntelliFlow™, I-Watch™, Palmat™, and Versa™.
Casemat™,
The following terms are registered trademarks® of Intelligrated: Accumat®, Accuzone®,
Alvey®, BOSS®, Buschman®, Crisplant®, EASYpick®, FKI Logistex®, FKI Logistex
logo®, "I" Only Logo®, In-24x7®, InControlWare®, Intelligrated®, Intelligrated logo®,
Intelligrated Material Handling Solutions and Services®, IntelliMerge®, IntelliQ®,
IntelliSort®, Mathews®, Maxiclaim®, Real Time Solutions®, Stearns®, SNE Systems®,
Transitread®, and UniSort®.
Revision
Date
Initials
Description
Use of Manual
This manual contains important information. Please read this manual before attempting
to operate or perform installation or maintenance on this Conveyor.
This manual is designed for operator personnel who have a substantial knowledge of
mechanical operations and who have basic knowledge of typical mechanical operations.
Failure to comply with the instructions and warnings contained in this manual, and the
warnings posted on the Conveyor can result in serious injury to personnel and/or
damage to the equipment.
Disclaimers
All terms mentioned in this manual that are known to be trademarks or service marks
have been appropriately capitalized. Intelligrated can not attest to the accuracy of this
information. Use of a term in this manual should not be regarded as affecting the validity
of any trademark or service mark.
This manual contains a generalized description of the Conveyor and its operation
available at the time this manual was approved for printing. Intelligrated reserves the
right to make changes in design and specifications and to make additions to, or
improvements in, the product without imposing any obligations upon it to install them on
previously manufactured products.
TABLE OF CONTENTS
Table of Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Safety Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions
.....................................
Guards and Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interfacing of Equipment . . . . . . . . . . . . . . . . . . . . . . . . .
Guarding Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarded by Location or Position . . . . . . . . . . . . . . . . . .
Headroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stops and Restarts . . . . . . . . . . . . . . . . . . .
Operation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockout / Tagout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Operator Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . .
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping Extendible Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-4
1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-7
1-8
1-8
1-9
1 - 10
1 - 11
1 - 13
1 - 13
1 - 13
1 - 14
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Running the Decline Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Running the Extendible Conveyor . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Receiving & Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting Product Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Claims and Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Layout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Site Preparation for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping Extendible with Hinged Infeed Belt Conveyor | Field Manual | 29327001
May 15, 2012
3-1
3-2
3-2
3-2
3-3
3-3
3-4
3-4
TOC - i
TABLE OF CONTENTS
Conveyor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading and Moving into Position . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the Conveyor System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Pre-Operation Check . . . . . . . . . . . . . . . . . .
Electrical Pre-Operation Check . . . . . . . . . . . . . . . . . . .
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-5
3-6
3-8
3-9
3-9
3-9
3-9
3 - 10
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions for Conveyor Operator’s . . . . . . . . . . . . . . .
Safety Precautions for Service and Maintenance . . . . . . . . . . .
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weekly (40 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly (160 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Semi-Yearly (1040 hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Reducer - Lubrication and Maintenance . . . . . . . . . . . . . . . . . .
Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Extendible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extendible Steering/Tracking Adjustments . . . . . . . . . . . . . . . . . . . . .
4-3
4-3
4-4
4-5
4-5
4-6
4-6
4-6
4-7
4-7
4-7
4-8
4-8
4-8
4-9
4-9
4 - 10
4 - 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Troubleshooting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
TOC - ii
May 15, 2012
TABLE OF CONTENTS
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Part Order Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Warranty Part Order Procedures . . . . . . . . . . . . . . . . . . . . . . . . .
Order Processing and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Parts Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Time Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing the On-Time Parts Catalog . . . . . . . . . . . . . . . . . .
Using the On-Line Parts Catalog . . . . . . . . . . . . . . . . . . . . . . .
Parts Lists and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Parts Lists
...............................
Shipping Extendible - Front End Top View and Front View . . .
Shipping Extendible Rear Caster Assembly . . . . . . . . . . . . . . .
Hinged Belt - Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hinged Belt Upper Pivot Assembly . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-2
6-4
6-4
6-4
6-5
6-5
6-5
6-6
6-9
6 - 10
6 - 12
6 - 13
6 - 16
6 - 18
Index
May 15, 2012
TOC - iii
TABLE OF CONTENTS
TOC - iv
May 15, 2012
LIST OF FIGURES
List of Figures
Figure 1 - 1 Lockout Main Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 12
Figure 2 - 1 Extendible Gravity Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Figure 2 - 2 Extendible Gravity Conveyor Devices . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Figure 2 - 3 Combination Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Figure 2 - 4 CS1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Figure 4 - 1 Lockout Main Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Figure 4 - 2 Setting Hex Nuts to Allow Clearance for Wheel Travel . . . . . . . . . . . .4 - 11
Figure 4 - 3 Pivoting V-Groove Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 12
Figure 6 - 1 Example of Conveyor Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Figure 6 - 2 On-Time Parts Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5
Figure 6 - 1 OPC Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 7
Figure 6 - 3 Warranty Claim Request Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8
Figure 6 - 4 Example of Links in the Electronic Manual. . . . . . . . . . . . . . . . . . . . . .6 - 9
May 15, 2012
LOF - i
LIST OF FIGURES
LOF - ii
May 15, 2012
SAFETY INSTRUCTIONS
1 Safety Instructions
m WARNING
You must read and understand these precautions
completely before operating, setting up, installing,
running, or performing
maintenance on the equipment. Failure to follow this
instruction may result in
serious personal injury
and/or equipment damage.
NOTE:
This chapter provides instructions for the safe and
productive operation of the equipment.
These safety precautions are to be used as a guide
to supplement the following:
1. All other information pertaining to the
equipment.
2. Local safety codes.
3. Plant and shop safety rules and codes.
4. Federal and state safety laws, regulations,
and codes.
Emphasis is placed on the latest edition of the Occupational Safety and
Health Standards, which is available from the Department of Labor,
Washington, D.C. These standards (found in Part 1910, Title 29 of the Code
of Federal Regulations) contain the current, general industry occupational
safety and health regulations set forth by federal legislation. Also, some of
the information contained in this section has been reprinted from ASME,
B20.1-2000 by permission of The American Society of Mechanical
Engineers. All rights reserved.
May 15, 2012
1-1
SAFETY INSTRUCTIONS
For Your Safety
This manual contains important safety information concerning the use, maintenance,
installation, and operation of this equipment. Read and become familiar with the contents
of this manual before attempting to install, operate, or service this equipment. It is
necessary that all operators and maintenance personnel study the applicable sections of
this manual thoroughly before operating the equipment.
m WARNING
If you are unable to understand the contents of this
manual, please bring it to
the attention of your
supervisor or foreman.
Failure to comply with the
instructions and warnings
contained in this manual,
and the warnings posted
on the machine, can result
in serious injury to personnel and damage to the
equipment. Do not operate
this equipment unless you
have read and understood
the contents of this manual.
1-2
May 15, 2012
SAFETY INSTRUCTIONS
m ADVERTENCIA
No dando caso a los
instruciones y precauciones contenidos en el
manual, puede resultar en
graves heridas personal y
daño a la máquina. No
trate de operar el equipo
sin entender claramente
los instruciones del manual.
m AVERTISSEMENT
Si vous ne comprenez pas
le contenu de ce manuel,
s.v.p. aviser votre superviseur ou le contremaître. A
défaut de suivre les
instructions et les avertissements contenus dans
ce manuel, et les avertissements installé sur l'équipement, pourrait occasionner
des blessures graves au
travailleur et endommager
l'équipement. Ne pas opérer cet équipement à moins
d'avoir lu et compris le
contenu de ce manuel
d'opérations.
May 15, 2012
1-3
SAFETY INSTRUCTIONS
Standard Safety Conventions
This section includes information essential to the safety of personnel and equipment.
Throughout this manual, and on the equipment, you will find DANGER, WARNING, and
CAUTION signs. Pay particular attention to these because they signal information that is
important to your safety and to the correct operation of the equipment.
Warning signs and labels posted on or near the equipment shall not be removed, painted
over, or altered at any time. Reference: ANSI Z535.4. All safety devices, warning lights,
and alarms associated with the conveyor system must be regularly tested (at least
monthly) for proper operation and serviced as needed. If the original safety item(s)
become defective or damaged, refer to the conveyor parts list(s) of bill(s)-of-materials for
replacement part numbers.
m DANGER
DANGER - information
appearing under the DANGER caption concerns the
protection of personnel
from immediate and imminent hazards that, if not
avoided, will result in
immediate, serious personal injury or loss of life
in addition to equipment
damage.
1-4
May 15, 2012
SAFETY INSTRUCTIONS
m WARNING
CAUTION
Information
appearing
under the CAUTION caption concerns the protection of personnel and
equipment, software, and
data from hazards that can
result in minor personal
injury or equipment damage.
NOTE:
The term NOTE is used to call attention to useful information and is not a
safety notice. Information appearing in a NOTE provides additional
information that is helpful in understanding the item being explained.
May 15, 2012
1-5
SAFETY INSTRUCTIONS
Safety Precautions
The success of any safety program depends primarily on the attitudes and training of the
installation, maintenance, and operating personnel. The very nature of their work makes
it necessary that they develop a complete and firsthand knowledge of each piece of
equipment that is within their care. This familiarity enables them to recognize the hazards
resulting from improper usage.
Guards and Guarding
Where necessary for the protection of personnel from hazards, all exposed moving
machinery parts that present a hazard to employees at work stations or operator’s
stations shall be mechanically or electrically guarded, or guarded by location or position.
Interfacing of Equipment
When two or more pieces of equipment are interfaced, special attention shall be given to
the interfaced area to ensure the presence of adequate guarding and safety devices.
Guarding Exceptions
Wherever conditions prevail that would require guarding under these standards, but such
guarding would render the conveyor unusable, prominent warning means such as signs
or warning lights shall be provided in the area or on the equipment in lieu of guarding.
Guarded by Location or Position
Remoteness from frequent presence of public or employed personnel shall constitute
guarding by location. Overhead conveyors, such as trolley equipment and
hanger-suspended tray conveyors, for which guarding would render the equipment
unusable or would be impractical, shall have prominent and legible warnings posted in
the area or on the equipment, and, where feasible, lines shall be painted on the floor
delineating the danger area.
When the equipment passes over a walkway, roadway, or work station, it is considered
guarded by location if all moving parts are at least 8 ft. (2.4 m) above the floor or walking
surface or are otherwise located so that the employee cannot inadvertently come in
contact with hazardous moving parts. Although overhead conveyors may be guarded by
location, spill guards, pan guards, or equivalent shall be provided if the product may fall
off the conveyor for any reason and endanger personnel.
Headroom
When the equipment is installed above exit passageways, aisles, or corridors, there shall
be a minimum clearance of 6 ft. 8 in. (2.03 m) measured vertically from the floor or
walking surface to the lowest part of the equipment or guards. Where system function will
be impaired by providing the minimum clearance of 6 ft. 8 in. (2.03 m) through an
1-6
May 15, 2012
SAFETY INSTRUCTIONS
emergency exit, alternate passageways shall be provided. It is permissible to allow
passage under the equipment with less than 6 ft. 8 in. (2.03 m) clearance from the floor
for other than emergency exits if a suitable warning indicates low headroom.
Controls
All electrical installations and wiring shall conform to the National Electrical Code (Article
670 or other applicable articles) as published by the National Fire Protection Association
and as approved by the American National Standards Institute, Inc.
Control Stations
Control stations should be arranged and located so that the operation of the affected
equipment is visible from them. Control stations shall be clearly marked or labeled to
indicate the function controlled.
Equipment that would cause injury when started shall not be started until employees in
the area are alerted by a signal, or by a designated person, that the equipment is about
to start. When the equipment would cause injury and is automatically controlled or must
be controlled from a remote location is started, an audible device shall be provided which
can be clearly heard at all points along the conveyor where personnel may be present.
The audible warning shall be actuated by the controller device starting the equipment
and shall continue for a required period of time before the equipment starts. A flashing
light or similar visual warning may be used in conjunction with, or in place of, the audible
device if a visual warning is more effective. Where system function would be seriously
hindered or adversely affected by the required time delay, or where the intent of the
warning may be misinterpreted (e.g., a work area with many different pieces of
equipment and allied devices), a clear, concise, and legible warning sign shall be
provided. The warning shall indicate that the equipment and allied equipment may be
started at any time, that danger exists, and that personnel must keep clear. These
warning signs shall be provided along the equipment at areas not guarded by position or
location.
Remotely and automatically controlled equipment, and equipment where operator
stations are not manned or are beyond voice or visual contact from drive areas, loading
areas, transfer points, and other potentially hazardous locations on the equipment path
not guarded by location, position, or guards, shall be furnished with emergency stop
buttons, pull cords, limit switches, or similar emergency stop devices. All such
emergency stop devices shall be easily identifiable in the immediate vicinity of such
locations unless guarded by location, position, or guards. Where the design, function,
and operation of such equipment clearly is not hazardous to personnel, an emergency
stop device is not required. The emergency stop device shall act directly on the control of
the equipment concerned and shall not depend on the stopping of any other equipment.
The emergency stop devices shall be installed so that they cannot be overridden from
other locations.
May 15, 2012
1-7
SAFETY INSTRUCTIONS
Inactive and unused actuators, controllers, and wiring should be removed from control
stations and panel boards, together with obsolete diagrams, indicators, control labels,
and other material which may confuse the operator.
Safety Devices
All safety devices, including wiring of electrical safety devices, shall be arranged to
operate so that a power failure or failure of the device itself will not result in a hazardous
condition.
Emergency Stops and Restarts
The controls shall be arranged so that, in case of emergency stop, manual reset or start
at the location where the emergency stop was initiated shall be required of the
conveyor(s) and associated equipment to resume operation.
Before restarting the equipment that has been stopped because of an emergency, an
inspection of the conveyor shall be made and the cause of the stoppage determined. The
starting device shall be locked or tagged out before any attempt is made to remove the
cause of the stoppage, unless operation is necessary to determine the cause or to safely
remove the stoppage. Refer to ANSI Z244.1-1982, American National Standard for
Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety
Requirements, and OSHA Standard 29 CFR 1910.147, “The Control of Hazardous
Energy (Lockout/Tagout)."
1-8
May 15, 2012
SAFETY INSTRUCTIONS
Operation Safety Precautions
Only a trained person shall be permitted to operate a conveyor. Training shall include
instruction in operation under normal conditions and emergency situations.
Where safety is dependent upon stopping devices or starting devices or both, they shall
be kept free of obstructions to permit ready access.
The area around loading and unloading points shall be kept clear of obstructions that
could endanger personnel.
No person shall ride on a conveyor under any circumstances.
Personnel working on or near a conveyor shall be instructed as to the location and
operation of pertinent stopping devices.
A conveyor shall be used to transport only material it is designed to handle safely.
Under no circumstances shall the safety characteristics of the conveyor be altered if
such alterations would endanger personnel.
Routine inspections and preventive and corrective installation and maintenance
programs shall be conducted to ensure that all guards and safety features and devices
are retained and function properly.
Personnel should be alerted to the potential hazard of entanglement in conveyors
caused by items such as long hair, loose clothing, and jewelry.
Conveyors shall not be newly installed, maintained, or serviced while in operation unless
proper installation, maintenance, or service requires the conveyor to be in motion. In this
case, personnel shall be made aware of the hazards and how the task may be safely
accomplished.
May 15, 2012
1-9
SAFETY INSTRUCTIONS
Installation and Maintenance Safety
Installation and Maintenance shall be performed only by qualified and trained personnel.
It is important to establish an installation and maintenance program to ensure that all
conveyor components are maintained in a condition which does not constitute a hazard
to personnel.
When a conveyor is stopped during installation or for maintenance, starting devices or
powered accessories shall be locked or tagged out, see Figure 1 - 1, in accordance with
a formalized procedure designed to protect all persons or groups involved with the
conveyor against an unexpected start. Personnel should be alerted to the hazard of
stored energy, which may exist after the power source is locked out. Refer to ANSI
Z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of
Energy Sources - Minimum Safety Requirements, and OSHA Standard 29 CFR
1910.147, “The Control of Hazardous Energy (Lockout/Tagout)."
Before starting equipment for normal operation, replace all safety devices and guards,
and remove all tools and other material from the conveyor
Conveyors shall not be lubricated while in operation unless it is impractical to shut them
down for lubrication. Only trained and qualified personnel who are aware of the hazards
of the conveyor in motion shall be allowed to lubricate a conveyor that is operating.
Guards and safety devices shall be maintained in a serviceable and operational
condition. Warning signs shall be maintained in a legible and operational condition.
Examples of warning signs are shown later in this section.
It is the responsibility of the owner/user to add any additional protective components that
may be needed whenever changes or variations are made to any of the equipment
components or operational characteristics.
1 - 10
May 15, 2012
SAFETY INSTRUCTIONS
Lockout / Tagout Guidelines
Appropriate lockout and tagout policy and procedures shall comply with the Code of
Federal Regulations, 29 CFR 1910.147 and the minimum safety requirements outlined
in the current publication of the American National Standard Institute’s
Lockout/Tagout of Energy Sources (ANSI Z244.1).
Effective January 8, 1990, O.S.H.A. has designated the need for a ‘positive, lockable’
means to remove all energy sources from equipment prior to new installation(s) or any
maintenance. The electrical power to your equipment can be locked out at the main
disconnect switch, which is normally located on the electrical cabinet. When this is done,
residual energy remains for some time in the capacitors associated with the electrical
system. This residual energy is automatically depleted by features built into the
equipment. After locking out the main disconnect switch, wait at least 60 seconds before
beginning any installation or maintenance procedures. This allows the residual energy to
diminish. (If an equipment-mounted plate indicates that you should wait longer than 60
seconds, wait the recommended period of time before beginning any installation or
maintenance work.)
Whenever you need to install new equipment or perform maintenance on the equipment,
or whenever you need to shut it down for any other reason, a lockout procedure must be
followed. Your employer is required by O.S.H.A. to develop a written lockout/tagout
procedure for this equipment. The following items should be considered in developing
this procedure:
•
Notify everyone who normally operates, sets up, installs, or performs maintenance on the equipment that it will be shut down.
•
Turn off all electric motors.
•
Turn off the main electrical disconnect switch.
•
Lock the main disconnect switch in the OFF position, and place a tag on the
switch to indicate that work is being performed on the equipment.
•
If there is any auxiliary equipment associated with the equipment, make sure the
main electrical disconnect switch is also turned off for each piece of auxiliary
equipment. Then lock each disconnect switch in the OFF position, and tag each
switch to indicate that work is being performed on the equipment.
•
Lock the air supply valves to make sure no air can be supplied to the equipment.
•
Verify that no sources of residual energy (capacitors, suspended equipment components, etc.) are present on the equipment or any piece of auxiliary equipment. If
any such energy sources are located, make sure they are neutralized. If necessary, manually discharge air pressure and capacitor voltage from charged components. Also, block all suspended or spring loaded mechanical parts to prevent
movement.
May 15, 2012
1 - 11
SAFETY INSTRUCTIONS
•
Verify that electrical power has been disconnected from the equipment, and from
any auxiliary equipment, by trying to energize the equipment and any auxiliaries
with the appropriate control switches. If any piece of equipment is found to be
operational, locate the electrical circuit(s) supplying the power, and disconnect all
such power sources. Then lock and tag these power sources.
•
Make sure the air system pressure is 0 PSI.
•
Before you begin any work on the equipment or any auxiliary equipment, make
sure that at least 60 seconds has elapsed since you turned off the main disconnect switch. (If an equipment-mounted plate indicates that you should wait longer
than 60 seconds, wait the recommended period of time before beginning any new
installation or performing any maintenance work.)
•
Verify that any equipment which may have been added, and which is not covered
by previous bulleted items, is considered for the lockout/tagout procedure.
•
After you have completed your work on the equipment, make sure all guards,
gates and other safety-related devices are in place and functioning properly.
•
When the equipment is completely ready to resume operation, remove your lock
and tag from the main electrical disconnect switch. If someone else has placed a
lock and/or tag on the main disconnect, do not remove the additional lock or tag. If
there is no other lock or tag on the main disconnect, turn on the main disconnect
switch and the electric motors, then perform the daily safety checks.
Figure 1 - 1 Lockout Main Disconnect Switch
1 - 12
May 15, 2012
SAFETY INSTRUCTIONS
Machine Operator Safety Precautions
1. Only authorized, properly trained personnel may operate the equipment.
2. Do not attempt to clear jams before shutting off power.
3. Do not reach into or climb on the machine for any reason before shutting off
power.
4. Extreme care should be taken when near the equipment to prevent fingers, hair,
jewelry, or loose clothing from being caught in moving parts.
5. Do not wear gloves when working near the equipment's moving parts.
6. Remove all tools and non-product material from the equipment before starting.
7. Verify that no persons are in a position to be injured as a result of the start-up.
8. Never step on, over, or into the path of a moving conveyor.
Service and Maintenance Safety Precautions
1. Only authorized and properly trained personnel may service the machine.
2. Turn the main disconnect switch OFF and lockout the equipment before beginning
any maintenance or repairs, see Figure 1 - 1.
3. Before restarting and testing the machine, remove all tools and other material
from the machine.
4. Replace all safety guards and/or covers removed from the machine for
maintenance, before operating the machine.
Safety Signs
In an effort to reduce the possibility of injury to personnel working around conveying
equipment, safety signs are placed at various points on the equipment to alert them of
potential dangers. Please check the equipment and note all safety signs. Make certain
your personnel are alerted to and obey these signs.
The following illustration shows pictograms designed by the Conveyor Equipment
Manufacturers Association (CEMA) Safety Committee as a service to the industry. They
also mirror, to the extent practical, the pictograms on the associated CEMA Safety
Labels placed on the equipment. CEMA Safety Posters are also available to place in
work areas and break areas to remind personnel of safe practices.
May 15, 2012
1 - 13
SAFETY INSTRUCTIONS
Shipping Extendible Safety Features
The Gravity Extendible Shipping Conveyor is equipped with several built-in safety
features designed to decrease the risk of injury to operating personnel, as well as
safeguarding the machine from being damaged due to mechanical failures.
m WARNING
Do not attempt to circumvent any design safety feature. Any attempt to do so
could result in injury to
operating
personnel
and/or damage to the
machine.
The
lockout/tagout procedures for
your company must be followed when entering or
servicing the machine.
Failure to follow these
instructions may result in
1 - 14
1. All photo-eyes, proximity switches, and
push button operator control switches
operate on 24 VDC to reduce electrical
shock hazard.
2. Photo-eyes - detect full conditions.
3. Indicator lights.
4. Over-travel Limit Switches - stops Extendible travel prior to mechanical stops.
5. Mechanical Stops - stops Extendible of
Over-travel Limit Switches or other electrical
devices fail.
May 15, 2012
SAFETY INSTRUCTIONS
May 15, 2012
1 - 15
SAFETY INSTRUCTIONS
1 - 16
May 15, 2012
GENERAL DESCRIPTION
2 General Description
This chapter describes the Extendible Gravity Conveyor machine operations, both
mechanical and electrical. A Glossary of Terms has been provided at the end of this
chapter for explanations of commonly used terms when referring to the equipment.
The shipping Extendibles receive merchandise
from each lane of the sortation system and delivers the merchandise into the shipping truck at the
point where the operator is loading the trailer. The
Extendible Gravity Conveyor consists of a Hinge
Belt pivoting support, a Belt Conveyor hinged vertically and pivoting horizontally, a Gravity Roller
transition section hinged vertically at the discharge
end of the Hinged Belt Conveyor, and a Declined
Gravity Roller Conveyor mounted on a motor
driven framework that is guided at the rear by a
floor mounted track.
The controlling devices for each Extendible are housed in a combination starter
enclosure and a junction box. The combination starter enclosure contains the motor
starter for the hinged belt feeding the Extendible and the disconnect switch that controls
motor voltage to the Hinged Belt Conveyor and the Extendible front wheel drive. The
junction box mounted at the rear (infeed end) contains the reversing starter that extends
and retracts the Extendible Gravity Conveyor. All of the motors, solenoids, and indicator
lights for each Extendible are controlled by the combination starter enclosure CCX.
The location of all components and devices are illustrated in Figure 2 - 1 and Figure 2 - 2.
May 15, 2012
2-1
GENERAL DESCRIPTION
Figure 2 - 1 Extendible Gravity Conveyor
Figure 2 - 2 Extendible Gravity Conveyor Devices
2-2
May 15, 2012
GENERAL DESCRIPTION
Figure 2 - 3 Combination Starter
May 15, 2012
2-3
GENERAL DESCRIPTION
Running the Decline Belt
Use the following procedure to operate the decline belt.
1. Turn the BELT ON/OFF selector switch to the ON position at the decline belt combination starter, see Figure 2 - 3.
2. At the discharge end of the Extendible Conveyor, in CS1, pull the BELT
ON/OFF/JOG switch to the ON position to run the decline belt automatically. In
automatic operation, if the merchandise accumulates back onto the decline belt
and photo-eyes on the transition section are blocked for a period of time this stops
the decline belt.
3. In the event that merchandise becomes Stalled in front of either of the photo-eyes,
pulling the BELT ON/OFF/JOG switch in CS1 to the JOG position will cause the
decline belt to run. The JOG position (on the BELT ON/OFF/JOG switch) will
spring return to the ON position when the switch is released.
Running the Extendible Conveyor
CAUTION
If the safety sensors have a
false trip, operate erratically, receive physical damage, or fail to stop the
Extendible during regular
safety checks to verify the
guarded
are;
IMMEDIATELY lockout the power at
the main disconnect and
have the problem fixed
prior to continuation of
operation. Failure to follow
this instruction may result
in serious personal injury
2-4
1. To run the Extendible forward (into the
truck).
a. Depress the EXTEND push button
CS1. Releasing this push button will
stop the Extendible in the forward
direction, see Figure 2 - 4.
b. If the Extendible does not run forward
when the EXTEND button is
depressed, the extend safety sensors
have been tripped. Inspect the area
guarded by the sensor. Remove the
obstruction and verify it is clear for
the full range of travel. Momentarily
press the EXTEND/RETRACT push
button to reset the safety sensors,
then press the EXTEND/RETRACT
push button to continue.
May 15, 2012
GENERAL DESCRIPTION
2. To run the Extendible reverse (out of the truck):
a. Depress the RETRACT push button in CS1. Releasing the push button will
stop the Extendible in the reverse direction.
b. If the Extendible does not reverse when the RETRACT push button is
depressed, the retract safety sensors have been tripped. Inspect the area
guarded by the sensor. Remove the obstruction and verify it is clear for the
full range of travel. Momentarily press the EXTEND/RETRACT push button
to reset the safety sensors, then press the EXTEND/RETRACT push
button to continue.
Figure 2 - 4 CS1
May 15, 2012
2-5
GENERAL DESCRIPTION
Glossary of Terms
Hinged Belt Conveyor
Belt ON/OFF Selector Switch
Photo-eye
Extend Push Button
Extend Safety Sensors
Forward Safety Switches
Retract Push Button
Retract Safety Sensor
Indicator Lights
Flood Light
Interlock
Over-Travel Limit Switch
Sonalert
2-6
Conveyor that is hinged at the infeed end to follow
Extendible vertical and horizontal position changes
during forward and reverse movement. It acts to hold
back accumulating product on the upstream gravity
line and convey it on demand to the Extendible Gravity Conveyor.
Located on the combination starter and mounted on
the Hinged Belt Support, the Belt ON/OFF Selector
Switch controls the Hinged Belt Conveyor.
A black flush push button that when pressed, extends
the conveyor into the trailer provided that neither the
over-travel limit switch nor the front safety sensor has
been actuated.
A black mushroom head push button that when
pressed will retract the Extendible into the building,
provided neither the over-travel sensor nor the rear
safety sensor has been actuated.
(Amber and Clear) - The indicator lights are located
near the hinged belt combination starter. Each
Extendible has two indicator lights (Amber and Clear).
The Clear light will illuminate when the shipping line is
becoming full. The Amber light will illuminate to indicate that the shipping line is full.
The Flood Light is located on the end of the Extendible and illuminates the trailer during operation. To
turn the light ON, actuate the 3-way switch at either
end of the Extendible. The light will be extinguished
when the Extendible is in the HOME position.
One interlock is provided from each shipping line to
the sortation system that indicates the line is available.
The Sonalert is an audible warning device that is turn
ON when the Extendible is moved in either direction.
May 15, 2012
GENERAL DESCRIPTION
3-Way Light Switch
Junction Box
CCS Panel and Combination
Starter
Actuates the flood light on the front of the Extendible
to illuminate dark trailers.
Contains the reversing starter that extends and
retracts the Extendible Gravity Conveyor.
Located on the Extendible Conveyor, the Combination Starter enclosure contains the motor starter for
the Decline Belt feeding the Extendible Gravity Conveyor.
May 15, 2012
2-7
GENERAL DESCRIPTION
2-8
May 15, 2012
INSTALLATION PROCEDURES
3 Installation Procedures
The Installation chapter contains instructions for receiving, inspecting, and installing the
conveyor equipment and preparing it for operation. It is essential that the equipment be
properly installed, and subsequently maintained, in order to obtain maximum productivity.
m WARNING
The installer must be qualified and must comply with
all applicable codes, ordinances,
specifications,
and/or other governing
data related to the installation of the equipment.
Read the installation chapter of this manual and
resolve any questions you
have before attempting to
move or install the equipment. Obey all safety precautions. Failure to follow
these instructions may
result in serious personal
injury and/or equipment
damage.
Receiving & Inspections
During the process of unloading the material, it is
important to:
1. Make sure that the quantity of items
received matches the count listed on the Bill
of Lading. Once the Bill of Lading has been
signed, the liability of any shortage is on the
receiver.
2. Inspect each item for damage to the
product, especially if there is any damage to
the crate or container. Any obvious shortage
or damage should be noted on the Bill of
Lading before it is accepted.
May 15, 2012
3-1
Reporting Product Damage
Any damage to the product that cannot be detected upon the initial receiving inspection
must be reported to the carrier within 24 hours of the receipt of the product in order to
qualify for a damage claim against the delivering carrier. It is the responsibility of the
recipient to file claims for shipping shortages or damage whenever the freight charges
are borne by that recipient.
Please notify Intelligrated whenever there is a shipment shortage or any damage occurs
to the equipment so that we can provide support services as well as track carrier
performance. In the event that the shipment is refused, it is imperative that Intelligrated
be contacted immediately for return authorization approval to avoid demurrage costs.
If you need further assistance, please visit our website at www.intelligrated.com or call
our Customer Service Department at (513) 701-7300, Monday through Friday 8:00 A.M.
to 5:00 P.M. EST.
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.
Layout Requirements
Conveyor layout drawings are typically used to determine the conveyor location and
elevation based on the building grid. Layout drawings should be referenced in the
installation preparations to determine the conveyor layout area and to make sure there
are no physical obstructions to the conveyor. Special consideration should be given to
drives (motor/reducer combinations) that extend from the conveyor.
In addition, measurements should be taken along the conveyor to ensure that the
support adjustment falls within the conveyor elevation requirements.
Prior to setting the conveyor or other components in place, scribe all reference
measurements from the layout drawings to the facility floor. Typically, datum lines are
marked with red diamonds, conveyor center lines are marked with yellow diamonds,
3-2
May 15, 2012
conveyor end of locations are marked with white diamonds, and 100 ft. lines are marked
throughout the facility with red arrows to make marking layout lines easier.
Codes and Standards
The 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).
Safety Precautions
•
DO turn off 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 equipment is in operation.
•
DO observe all warning signs, lights, and alarms associated with the equipment
operation and maintenance, and be alert at all times to automatic operation(s) of
adjacent equipment.
•
DO use extreme caution near moving 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 equipment at any
time except where suitable catwalks, gates, or bridges are provided for personnel
travel.
•
DO NOT attempt to repair any equipment while it is running, replace any component without the appropriate replacement part, or modify the equipment 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 equipment.
•
DO NOT clear jams or reach into any unit before first turning off the all power
source(s) and affixing appropriate lockout/tagout device(s).
May 15, 2012
3-3
Parts Replacement
To minimize production downtime, selected spare parts should be stocked for
replacement of defective components when required. Refer to the equipment
bill-of-material where quantity requirements or code numbers are not indicated on the
parts list. For added convenience, information on ordering parts is included in the
Replacement Parts chapter of this manual.
Site Preparation for Installation
This section has instructions for preparing the installation site, inspecting and installing
the equipment, connecting the electrical supplies, and the pre-power check-out. It is
recommended that the installation be supervised by an Intelligrated representative.
1. Inspect the equipment site. The site work should be completed in advance of the
machine arrival. The floor should be level and the trailers to be unloaded must be
consistently positioned in-line with the Extendible travel and level to the building
floor.
2. Clear out the area to receive the equipment. Provide sufficient space at the
installation site for field assembly of the equipment. Adequate clearance at both
ends and along the side of the equipment is necessary for installation.
3. Ensure there are adequate electrical services available to support the equipment.
The main power supply is supplied by the user to the equipment’s high voltage
cabinet. The connection is made inside the cabinet at the main power terminals.
This will supply power to the electrical cabinet for distribution to the system
cabinet. Install the main circuit breaker and facility electrical supply according to
the electrical specifications and plans.
4. Plan for the below slab routing of electrical conduit from the high voltage cabinet
to the Extendible cable carrier.
5. Provide for the necessary equipment and personnel required to unload and
assemble the equipment. The equipment may be shipped fully or in
sub-assemblies, to be fully assemble in the field.
6. When installing the Extendible conveyor(s), the following information will be
needed:
a. Equipment Plan and Elevation Drawings.
b. Conveyor Shipping Bill of Materials.
c. Detailed assembly drawings for field assembly.
7. Mark the center line of the equipment on the installation site floor with a chalk line.
Refer to the equipment plan and elevation drawings provided for exact
dimensions.
3-4
May 15, 2012
Conveyor Installation
The exact equipment furnished and the degree of dismantling may vary from these
general instructions. Review the equipment plan and elevation drawings provided for
special instructions for each installation. Also, review any other installation drawings
provided. If any information is unclear or missing, please call our Customer Service
Department at (513) 701-7300, Monday through Friday 8:00 A.M. to 5:00 P.M. EST.
m WARNING
Lifting the equipment with
a device that is not configured or rated for the conveyor’s load capacity is
dangerous to both the
equipment and to personnel, and could damage the
conveyor’s
structure.
Ensure that the crane,
fork-lift, and tow trucks
being used can lift the full
weight of the equipment.
Failure to follow these
instructions may result in
Unloading and Moving into
Position
Walk the route that the equipment will travel to the
installation site to ensure nothing has changed that
will interfere with the moving plan. Check the horizontal and vertical clearances. Move the equipment to the installation site. When moving the
equipment, DO NOT push directly against the
equipment’s frame. Use timber to protect the frame
and push against the timber instead of the steel.
CAUTION
The Gravity Extendible is
structurally
capable
of
being lifted from below the
open web bar joint that
runs the length of the conveyor. Any other lifting
method could result in distortion of the frame, and/or
mechanical damage. When
removing fully assembled
equipment from the trailer,
it is suggested that the
equipment be raised from
above and that the trailer be
pulled out from under it.
Failure to follow this
equipment damage.
May 15, 2012
3-5
Assembling the Conveyor System
The exact arrangement of the conveyor system can vary from one to another. The plan
and elevation drawings for your equipment will show your particular system and the
required components. The attaching parts for the conveyors will be listed on the bill of
materials. The conveyor hangers and supports are not furnished with the conveyor
system.
The Extendible Gravity Conveyor is normally shipped to the job-site in smaller
sub-components to reduce freight costs. Intelligrated normally assembles and installs the
components in the following sequence.
1. Check all components for shipping damage, paint errors, omissions, and overall
appearance. Report any deficiencies prompty and before starting installation.
2. Weld and assembly the Extendible Gravity Conveyor.
a. Align two bar joist on a level working surface.
b. Weld in cross ties and cross bracing per detail drawings.
c. Weld on front steering sub-assembly.
d. Weld on rear caster sub-assembly.
e. Pre-assemble as much electrical devices and wiring as possible at this
point for ease of access (per Electrical instructions).
f. Mount the Gravity Conveyor to top of joist, making sure to check square
ness so rollers are not skewed.
g. It is possible for Gravity Conveyor sections to become out of square during
shipment. Therefore, check each section to determine if it is perfectly
square before the sections are bolted together. Check the alignment of the
conveyor sections by placing a framing square along one of the side
frames and checking the opposing roller shaft slots to see if they are
directly opposite. If the slots are in line with each other, the rollers will be
perpendicular to the side frames and parallel to each other.
3. Mounting the track to the floor.
a. Layout area track to be mounted per system drawing dimensions.
b. Locate Hinge Belt Support location and install floor slab power feed per
system/electrical drawing details.
c. Anchor the track to the floor and weld/grind splice connections as specified
on the Detail Drawings. Good joint/splice alignment is critical for smooth
cable Carrier/V-Groove Wheel operation. Floor anchor’s height must be
kept to a minimum per detail drawings.
3-6
May 15, 2012
d. Mount the cable carrier to the track. Pull electrical connections through
floor entrance conduit and cable carrier per electrical Bills of Material and
drawings.
e. Weld in loose track pans to cover conduit entrance and verify all welds in
cable carrier run area are recessed or smooth enough to prevent catch
points.
4. Mount Hinged Belt Conveyor and Support.
a. Set Extendible Gravity Conveyor in place over the track.
b. Locate and anchor Hinged Belt Conveyor support per system/detail drawings.
NOTE:
Coordinate this location with adjacent infeed conveyor if field cut to length
sections are not provided or desired as per system requirements.
c. Mount Hinged Belt Conveyor to support Pivoting Hinge point. Discharge
end of Hinge Belt sled rests on the Extendible Gravity Roller Conveyor.
May 15, 2012
3-7
Installing Electrical Connections
m WARNING
Use extreme caution when
working on or around electrical components. Turn off
any power circuit(s) and/or
lockout/tagout operating
control(s) before connecting any electrical components. Failure to follow
these instructions may
result in serious personal
injury and/or equipment
damage.
1. Turn the main power disconnect switch
(located on the high voltage cabinet) to the
OFF position and lockout/tagout the conveyor for safety precautions.
2. Make interconnections with other system (if
required). Refer to the electrical plans for
proper wiring.
3. Route conduit runs and wires for the discharge conveyors. Mount and align all
photo-eyes and reflectors. (All conduit and
wire must be supplied by the installer unless
stipulated to the contrary.) Refer to the plan
and elevation drawings for electrical
devices.
4. Connect the high voltage main electrical power supply line to the equipment’s
main power disconnect switch. The main power disconnect switch is located
inside the high voltage cabinet. Wiring must be sized to carry the service required.
Refer to the electrical plan drawing for proper wiring.
5. Measure the supply voltage to assure conformity with the general specifications.
6. Push the OFF button of all motor starters.
7. Close the main disconnect switch and manually jog conveyor motor starter to
check the rotation direction. If rotation is not correct, switch the incoming line
leads.
8. Check all inputs.
9. Use the manual controls to test each equipment function.
10. The equipment is now ready for inspection by a Customer Service Engineer in
preparation for start-up.
3-8
May 15, 2012
Start-Up
Pre-Operation Check
m WARNING
Turn off any power circuit(s)
and/or
lockout/tagout
operating
control(s) to prevent accidental start-up. Make certain electrical power to all
gearmotors is turned off
and locked out. Failure to
follow these instructions
may result in serious personal injury and/or equipment damage.
m WARNING
Before
pre-operation
check, ensure that all
safety guards are in place,
tools are removed from the
conveyor, and all personnel are clear before starting the conveyor. Failure
to follow these instructions may result in serious
personal injury and/or
equipment damage.
Mechanical Pre-Operation Check
1. Check the alignment (per the detail drawings) with a spirit level and square, making
certain that all mounting bolts are securely
tightened.
2. Check elevations.
3. Install all safety guards removed during
installation.
4. Remove tools and all installation material
from the installation site.
5. Review safety precautions located in Chapter 1 of this manual.
Electrical Pre-Operation Check
1. Check all the wiring connections (see the
motor label or vendor’s instructions) and jog
the motor starter to test the gearmotor for
the proper shaft rotation.
2. Check that all the electrical devices installed
(photo-eyes, proximity sensors, limit
switches, warning lights and alarms, etc.)
are operative and properly adjusted.
3. Check other wiring connections. See the
electrical drawing and test all the electrical
controls for proper operation (photo-eyes,
proximity sensors, limit switches, warning
light and alarms, etc.).
May 15, 2012
3-9
Initial Operation
m WARNING
1. Test Hinged Belt Conveyor for proper direction of travel.
Before initial operation,
ensure that all safety
guards are in place, tools
are removed from the conveyor, and all personnel
are clear before starting
the conveyor. Failure to
follow these instructions
may result in serious personal injury and/or equipment damage.
2. Momentarily, jog the Extendible motor
starter to check for proper direction of travel.
Reverse motor wiring if necessary.
3 - 10
3. To start the Extendible Gravity Conveyor,
run the hinge belt with one or two cases and
verify the operation per the (D.O.) Description of Operation.
4. Re-adjust fixed steering for proper tracking
in and out of trailer.
May 15, 2012
PREVENTIVE MAINTENANCE
4 Preventive Maintenance
m WARNING
Before
performing
any
maintenance or lubrication
services, follow the lockout/tagout procedure in the
Chapter 1 Safety Instructions to ensure that the
equipment is safe to work
on. Failure to follow this
m WARNING
Do not perform maintenance while the conveyor is
running unless specifically
instructed to do so in this
manual. Failure to follow
this instruction may result
in serious personal injury
The satisfactory performance and reliability of this
equipment is dependent upon a proficient preventive maintenance (PM) program with scheduled
equipment inspections under normal operating
conditions. Accurate records of maintenance and
repairs will help to identify problem areas and
repetitive problem patterns. It is imperative that
adequate records be kept in connection with the
preventive maintenance program. These records
should contain the date of inspection, inspection
results, equipment services, repair history, part
replacement history, and any other information that
will help to make the maintenance process more
efficient and accurate. It is recommended that each
conveyor have its own record. Properly kept, the
conveyor record sheet will form a mechanical history of the equipment covered.
Preventive maintenance consists of regular service
(lubrication, adjustments, cleaning, etc.). Part of
preventive maintenance is becoming aware of
potential problems by simply using your senses.
Watch for potential component failure. Listen for
abnormal or louder than normal noises. Use your
nose to smell a motor running abnormally warm in
time to prevent its burnout. These sights, noises,
and smells can be indicators of lack of lubrication,
misalignment, or other potential trouble. Ignore
them and you will be replacing a shaft, motor, or
whatever does go out when a component is lacking
proper preventive maintenance.
May 15, 2012
4-1
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.
Only qualified maintenance specialists should maintain the mechanical, electrical and
pneumatic portion of the conveyor.
4-2
May 15, 2012
Maintenance Precautions
For Safety Standards, refer to Chapter 1 Safety Instructions.
m WARNING
1. When testing operating performance, do not
start the equipment until all operations and
maintenance personnel are notified and
clear of the unit being tested.
2. Be certain that required safety guards are
never removed without authorization.
3. Never run the equipment under production
conditions without safety guards in place.
4. Do not make any equipment repairs while
the conveyor is running.
5. Keep hands, hair and clothing clear of any
moving parts.
6. Never attempt to clear load jams while the equipment is running.
7. Always use appropriate tools when making repairs or adjustments.
8. Observe all warning labels and follow plant safety rules.
Safety Precautions for Conveyor Operator’s
Use the following list for operator safety.
1. Only authorized, properly trained personnel may operate the conveyor.
2. Do not attempt to clear jams before shutting off the equipment.
3. Do not reach into or climb on the conveyor for any reason before shutting off the
equipment.
4. Extreme care should be taken when near the equipment to prevent fingers, hair,
jewelry, or loose clothing from being caught in moving parts.
5. Do not wear gloves when working near the equipment's moving parts.
6. Remove all tools and non-product material from the equipment before starting.
7. Verify that no persons are in a position to be injured as a result of the start-up.
8. Never step on, over, or into the path of a moving conveyor.
May 15, 2012
4-3
Safety Precautions for Service and Maintenance
Use the following list for service and maintenance safety.
1. Only authorized and properly trained personnel may service/maintain the conveyor equipment.
2. Turn the main disconnect switch OFF and lockout the equipment before beginning
any maintenance or repairs (see Figure 3-2).
3. Before restarting and testing the equipment, remove all tools and other material
from the machine.
4. Replace all safety guards and/or covers removed from the equipment for
maintenance, before operating the equipment.
Figure 4 - 1 Lockout Main Disconnect Switch
4-4
May 15, 2012
Scheduled Maintenance
m WARNING
Observe all warning signs
posted on or near the conveyor, and be alert at all
times to the operation of
adjacent equipment. Attach
a service tag to the equipment being serviced to
identify the date, maintenance required and downtime. Failure to follow this
Periodic maintenance intervals shown may vary
with load, speed, hours of daily operation, ambient
temperature, humidity, etc. Intervals can be established by fairly frequent maintenance at first, then
lengthen the intervals as justified by observation of
the need for maintenance and past history. Maintenance intervals are based on a five (5) day work
week, eight (8) hours per day.
Daily Inspections
1. General walk-through inspections of the
conveyor equipment (listening for unusual
noises and carefully observing the system)
during daily plant operation is recommended. For continuous duty applications,
conduct conveyor inspections once each
shift.
2. Frequently check equipment safety guards, warning signs, lights, and alarms
associated with the operation of the conveyor system and keep them in good
condition to ensure the safety of all plant personnel. The operator should verify at
the start of each shift that the extend and retract collision avoidance sensors are
operating properly to automatically stop the Extendible's travel should its path of
travel become blocked. Any safety sensor malfunction, unusual conveyor noise,
oil leaks, and operational problems should be immediately reported and promptly
corrected.
3. Check operation of all electrical controls, including dust build-up on photo-eyes
and reflectors.
4. Inspect components for debris (tape, dust, glue, etc.) build-up that may hinder
operation.
May 15, 2012
4-5
Weekly (40 Hours)
1. Inspect bearings, gear reducers and motors for excessive noise or heat. A motor
may be hot to touch as normal. One-half horsepower motors may be slightly hotter.
2. Clean breather Cap on Reducer (if used).
Monthly (160 hours)
1. Inspect hinged belt drive pulley for wear and proper belt tensioning and tracking.
2. Inspect drive unit for leaking seals and oil level in gearcase if applicable.
3. Inspect fasteners and set screws for signs of loosening, fatigue or movement.
4. Inspect safety devices by actuation and observation of results.
Semi-Yearly (1040 hours)
1. Lubricate, drain, and flush gearcase after each 2,500 hours of normal operation or
at least every six (6) months (if applicable).
4-6
May 15, 2012
Speed Reducer - Lubrication and Maintenance
Oil Levels
NOTE:
Excessive oil temperatures may be the result of one or more of the following
circumstances: Overloads, Overfilling, Underfilling or Inadequate Filling.
1. Speed reducers are filled to the proper level for the standard mounting position
with the appropriate grade of oil for operation in a 51°F to 110°F temperature environment. The oil level should be checked and adjusted (if necessary) prior to
operation, using the oil level plug provided and while the unit is oriented in its
operating position.
2. If a speed reducer is overfilled with oil, the energy used in churning the excessive
oil can result in overheating. If this occurs, shut down the drive, remove the oil
level plug and allow oil to drain until oil ceases to drain from the level hole.
Reinstall the oil level plug and restart the drive. If the speed reducer is underfilled,
the resultant friction can cause overheating and possible damage. If this occurs,
fill the speed reducer to the oil level plug hole and check the gearing for excessive
wear.
Temperature
NOTE:
To dissipate internally generated heat, the speed reducer must be installed
in such a way that air can circulate freely.
1. If the operating ambient temperature is outside the range specified above, then
refer to the Vendor Lubrication Chart, and refill the unit with the correct grade
based on actual ambient temperatures.
2. Speed reducers in normal operation can generate high temperatures depending
on the type of reducer and the severity of the application (loading, duration of
service, and ambient temperatures).
May 15, 2012
4-7
Changing Oil
1. When changing oil for any reason, remember that oil of various types may not be
compatible. Therefore, when changing to a different oil, it is recommended that
the housing be completely drained and thoroughly flushed with a light flushing oil
before refilling with the appropriate lubricant. The oil level should be checked after
a short period of operation and adjusted, if necessary. When changing double
reduction models, each housing should be drained and filled independently, even
though there may be a common level.
2. Synthetic lubricants can be advantageous over mineral oils in that they generally
are more stable, have a longer life, and operate over a wider temperature range.
These oils are appropriate for any application, but are especially useful when units
are subjected to low start-up temperatures or high operating temperatures.
However, continuous operation at high temperatures may cause damage to the
seals or other components.
3. It is recommended that the initial oil be changed or filtered after the first 1500 hour
of operation to remove metal particles that accumulate during break-in. Under
normal conditions, after the initial oil change, the oil should be changed after every
2,500 hours of operation, or every six months, whichever occurs first. For
synthetic oils, subsequent oil changes should be made after 5000 hours of
operation if units are operating in a clean environment. Under severe conditions
(rapid temperature changes, moist, dirty, or corrosive environment) it may be
necessary to change oil at intervals of one to three months. Periodic examination
of oil samples taken from the unit will help establish the appropriate interval.
Overloads
1. Overloads may be due to, an increase in speed or product/component weight
exceeding the original design values, an increase in drag caused by a bad bearing, excessive belt snubbing, component interface etc.
2. Always check the speed reducer rating when increasing driven loads or
increasing the horsepower rating of the motor or other prime mover.
Seals
Although high quality seals and precision ground shafts are used to provide a superior
seal contact surface, it is possible that circumstances beyond control can cause oil seal
leakage (defective seal, damage during the shipment or installation, etc.).
1. When replacing a shaft oil seal, using the following suggestion will help to insure
leak-free operation and long seal life.
2. When installing a new seal, cover the keyway and any other surface discontinuity
with smooth tape to protect the seal lip from being damaged. A sealant should be
used between O.D. of the seal and the I.D. of the bore into which the seal is
installed. The seal bore should also be free of any burrs, nicks, or scratches.
4-8
May 15, 2012
Electrical Devices
Periodically inspect photo-eyes, proximity sensors, limit switches, etc. and adjust as
required. Lenses and reflectors on photoelectric devices should be wiped clean on a
daily basis. Refer to appropriate Vendors' Instructions for additional maintenance
information.
Setting Extendible
1. The Honeywell Collision avoidance Photo-eye device has three lights on the front.
They are OUT 1, OUT 2, and POWER. Only POWER and OUT 2 will be used in
this application.
2. The Honeywell Photo-eye device has three potentiometers on the front. They are
SEN 1, SEN 2, and SEN 3. Only SEN 2 and SEN 3 will be used in the application.
3. Turn SEN 1 counter clockwise until you hear or feel a click. SEN 1 is now turned
all the way off.
4. The light OUT 1 will now be off and does not come on when the photo-eye is
blocked.
5. Repeat step #3 for the other potentiometers on both photo-eyes. The POWER
indicator should be the only light on.
6. Begin adjustment of the angled beams. These emanate from the inner beveled
faces of the photo-eyes and are controlled by SEN 3.
7. o verify proper wiring, turn SEN 3 clockwise 1/4 turn. This adjusts the angled
beam that should be on the inner beveled face of the photo-eye.
8. Bring your finger from below and cover the bevel. Do not block any other portion
of the photo-eye's face. OUT 2 should turn on. If OUT 2 does not turn on, then try
the outside bevel.
9. Check both photo-eyes. If they are backward then the Orange and Brown wires
were connected incorrectly. See schematics and correct the wiring.
10. To properly set the photo-eyes it must be understood that these eyes work on a
diffuse (faint) reflection of an infrared beam. Dark, dull surfaces will allow the
photo-eyes to trigger MUCH closer. To obtain maximum safety ranges, wear dark
clothing while setting the photo-eyes.
11. Pick a photo-eye and adjust SEN 3 one and a half turns. Step back from the
photo-eye until OUT 2 turns OFF. Locate the beam by using your leg, hand or foot
to break the beam and turn-on OUT 2. Adjust the potentiometer until the edge of
the beam (the farthest point at which it will trip) is just inside the line of the four leg
supports.
12. Repeat the SEN 3 adjustment for the other photo-eye. DO NOT turn up SEN 2. It
is critical that the longer range straight beam is turned OFF while the short range
beams are being adjusted.
May 15, 2012
4-9
13. Begin SEN 2 (straight beam) adjustment by marking the floor 5 ft. from the back of
the Extendible.
14. Turn SEN 2 two turns then back away from the sensor until OUT 2 turns OFF.
15. Slowly walk directly towards the photo-eye until OUT 2 turns on. Adjust the
potentiometers clockwise (up) or counterclockwise (down) until the photo-eye
trips when you reach your 5 ft. marker. Be sure that you are not wearing anything
highly reflective on your shirt (Target I.D. badge, etc.) that will cause the
photo-eye to trip from much further away than it would normally.
16. Repeat this for the other photo-eyes.
17. Run the Extendible fully into a truck and back out to verify that passage can be
made between the supports without triggering the collision avoidance eyes. Do
not adjust more than absolutely necessary. Over adjustment will reduce the
effectiveness of these devices.
Bearings
All bearings in the Extendible Conveyor units are sealed for life and do not require
lubrication. If a defective roller bearing is found, replace the roller.
4 - 10
May 15, 2012
Extendible Steering/Tracking Adjustments
The Extendible uses a fixed steering front wheel drive arrangement to move the Decline
Gravity Conveyor in and out of the trailer being loaded. The steering is initially set to
guide the front of the Extendible straight in and straight out of the trailer. Adjustment is
made by adding or removing shims at the rear of the front wheel drive pivot mounting
point.
1. The rear of the Extendible is guided by a pivoting V-Groove wheel, see Figure 4 3 on a floor track. The V-Groove wheel assembly is vertically spring loaded to
allow for variations in the track/floor height and pivoted to allow it to follow the
track even if the front steering moves Extendible out of parallel with the track. No
adjustment is normally required after initially installed, except to verify that the die
spring retaining the bolt's stop nut does not limit the downward travel of the
V-Groove Wheel.
Figure 4 - 2 Setting Hex Nuts to Allow Clearance for Wheel Travel
May 15, 2012
4 - 11
2. The fixed rear caster assemblies are designed to support the bulk weight of the
Extendible unit and the V-Groove Wheel on the floor track mainly provides only
the horizontal guidance. The real casters are mounted in slotted holes for initial
alignment adjustment. Excessive toe-in or toe-out of the rear casters or grooved
floor conditions may hinder the ability of the V-Groove Wheel to effectively track
the rear of the Extendible, see Figure 4 - 3.
Figure 4 - 3 Pivoting V-Groove Wheel
4 - 12
May 15, 2012
TROUBLESHOOTING
5 Troubleshooting
m WARNING
Before
performing
any
maintenance or lubrication
services, follow the lockout/tagout procedure in the
Safety chapter to ensure
that the equipment is safe
to work on. 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, lockout the conveyor
disconnect before attempting to correct any malfunction. Failure to follow this
When troubleshooting equipment problems, it is
essential to completely understand how the system
functions during normal operation. Thoroughly
review the operational description, the circuit drawings, and the electrical diagrams sent with your
equipment. Once the system operation is understood, it is usually best to start at the problem, and
then work back to the source.
NOTE:
The disassembling or repair of
equipment under warranty may void
such warranty (motor and reducer, for
example). Check to ensure warranty
has not expired or will not be void
before performing disassembly or
repair.
Troubleshooting Guidelines
Procedures are discussed at length in the following
pages; however, there are certain guidelines that
should be followed for all troubleshooting problems:
1. Locate the problem.
2. Listen and observe.
3. Identify problem as electrical, mechanical, or pneumatic.
4. Determine symptoms through observations.
5. Think and act with caution and clear thinking.
6. List short and long term solutions.
7. Select a solution or possible solutions.
8. Implement and document one solution at a time.
May 15, 2012
5-1
TROUBLESHOOTING
Symptom
Probable Cause
Front steering does not track Setting loose or in need of
to home position.
adjustment.
Floor/Dock/Trailer out of
level or path obstructed.
Front wheel loose or bent.
V-groove wheel does not
guide rear of Extendible
along track.
Corrective Action
Add or remove shims and
tighten fasteners.
Level surfaces and remove
obstructions.
Check for damage to wheel
and/or axle. Align/tighten set
screws and lug nuts.
Rigid casters not aligned in Loosen (4) fasteners at each
slots run parallel to floor
caster and align using a
track.
straight-edge and measurement or line of site.
Variation in height of floor to Level floor and/or shim track
top of track over-travel.
and rear rigid caster to
obtain variations within tolerance. Check using
straight-edge on top of track
(perpendicular to travel) and
measure to floor at path of
rear casters.
Threaded adjustment at
Adjust threaded rods as
V-groove wheel does not
shown in Chapter 4 Prevenallow down travel to absorb tive Maintenance, Figure 4-3
variations in height.
for maximum vertical travel.
Extendible will not move in Travel proximity switch at
one direction; but will move rear of extendible is out of
in the other.
adjustment.
Proximity switch, control
switch or wiring.
Adjust proximity switch distance to track and/or range
for consistent operation,
drive to be enabled when
switch is made and de-energized when switch moves
over end of travel track
cut-out.
Test circuits, devices and
connections. Repair, replace
or adjust.
Obstruction in path, obstruc- Clear path of Extendible
tion sensor is out of adjust- travel and test operation of
ment or defective.
obstruction sensor. See
Chapter 4 Preventive Maintenance for adjustment procedure.
5-2
May 15, 2012
TROUBLESHOOTING
Symptom
Product stalls or jams on
gravity sections.
Probable Cause
Corrective Action
Conveyor rollers not perpendicular to side frame resulting in skew that moves
product closer to the side
guides. May be caused by
damage to the Extendible
frame.
Check for damage to the
Extendible frame, loosen
fasteners, and square rollers
to side frame and re-torque
fasteners.
Rollers to not turn.
Replace rollers.
Troubleshooting Help
If you need further assistance, please visit our website at www.intelligrated.com or call
our Technical Support Department at 1-877-315-3400.
May 15, 2012
5-3
TROUBLESHOOTING
5-4
May 15, 2012
REPLACEMENT PARTS
6 Replacement Parts
This chapter contains the contact information and procedures for ordering replacement
parts. Read the information below to ensure receipt of the correct parts, on time, and
shipped to the correct location.
Contact Information
Parts Orders
Voice (Toll-Free):
(877) 315-3400, select “1” at the prompt
Voice (Local):
(513) 701-7346
Fax:
(513) 701-7349
E-mail:
[email protected]
On-Time Parts Catalog:
www.OnTimeParts.com
The Parts Department’s normal working hours are Monday through Friday, 8:00 AM to
5:00 PM, Eastern Time, except holidays. For Emergency parts support outside of normal
business hours, call the Toll-Free number and select “2” at the prompt.
May 15, 2012
6-1
REPLACEMENT PARTS
Warranty Part Order Procedures
The Warranty Replacement Parts program is designed to replace parts used from the
customer’s spare parts inventory and not for supplying emergency replacement parts. To
maximize system up-time, have a well stocked inventory of spare parts.
The warranty period for the conveyor equipment is detailed in the sales contract. The
standard conveyor equipment warranty period is (one) year.
Parts may be ordered by phone, fax, e-mail, or by using our On-Line Parts Catalog. The
On-Linie Parts Catalog displays a complete description and illustration of the part and
also shows the current price and availability.
During the warranty period, all parts that have failed due to defects in material and/or
workmanship will be replaced at no cost.
Damage caused by misuse, accidents, mis-adjustment, improper installation, improper
maintenance, modification by anyone except Intelligrated personnel, lack of preventive
maintenance, power failure or surge, air conditioning or humidity control, transportation,
or causes other than a defect in the materials or workmanship are also not covered.
Use the following procedure when requesting a warranty replacement part(s):
1. Make a copy of the Warranty Parts Request Form located at the end of this section and complete the information requested on the form. Provide as much information about the equipment and part as possible, including the description,
manufacturer, any information stamped on the part, and all the informatin from the
label on the conveyor. Part numbers may also be easily found in the appropriate
maintenance manuals.
Figure 6 - 1 Example of Conveyor Label
Contact the Parts Department via e-mail, fax, phone, or through the On-Time
Parts Catalog to request a copy of the form. The Parts Order Processor will fax or
e-mail a Warranty Part Request Form.
2. Sign the form and fax it to the Parts Department at 513-701-7349.
6-2
May 15, 2012
REPLACEMENT PARTS
3. Upon receipt of the completed Warranty Part Request Form, the Parts Order
Processor will enter the warranty order into the ordering system and issue a
Returned Material Authorization (RMA) number.
4. The Parts Order Processor will record the Returned Material Authorization (RMA)
on the completed Warranty Part Request Form and indicate on the form if the
part(s) must be returned to Intelligrated.
5. The Parts Order Processor will return the Warranty Part Request Form to the
customer by fax or e-mail.
6. If indicated on the form, return the defective part to Intelligrated at the following
address. Be sure to package it to prevent damage during shipment. Also, include
a copy of the Warranty Part Request Form inside the package and clearly mark
the Returned Material Authorization (RMA) number on the outside of the package.
Intelligrated Returns
4436 Muhlhauser Road Suite 300
Attn: Returns
Hamilton, OH 45011
RMA#_________________
Parts received without an RMA number will be returned to the customer.
If Intelligrated does not receive the defective part(s) within 30 days, the customer
will be billed for the part(s).
7. The order will be processed and the replacement part(s) will be shipped to the
customer as soon as possible.
Warranty orders are always shipped via ground service. Other shipping arrangements may be made, but the customer will be billed for all shipping charges.
May 15, 2012
6-3
REPLACEMENT PARTS
Non-Warranty Part Order Procedures
Use the following procedure when ordering a non-warranty replacement part(s).
1. Contact the Parts Department via e-mail, fax, or phone, or by using our On-Time
Parts Catalog to request the replacement part. Provide as much information about
the equipment and part as possible, including the description, manufacturer, any
information stamped on the part, and all the information from the label on the conveyor (see label illustration on the previous pages). Part numbers may also be
easily found in the appropriate maintenance manuals.
2. Parts may be purchased using company issued purchase orders or by credit card
(Visa, MasterCard, American Express and Discover).
NOTE:
There is a $100 minimum order for non-warranty orders.
Order Processing and Shipping
Orders for stock items are normally shipped the next business day.
Non-stock orders are subject to the lead time of the part. Orders are shipped via ground
service (Freight Prepaid and added to invoice) unless otherwise requested. Emergency
service to ship via package carrier or scheduled airlines is also available for an additional
charge.
Warranty orders are always shipped via ground service. Other shipping arrangements
may be made, but the customer will be billed for all additional shipping charges.
New Parts Warranty
All parts purchased from Intelligrated carry a one-year warranty. All parts supplied at no
cost as a warranty replacement for a component assume the warranty of the part being
replaced.
Intelligrated will repair or replace, at our option (F.O.B. shipping point), parts which prove
to be defective in material or workmanship within the warranty period. Intelligrated
reserves the right to deny any warranty claims if during inspection it is determined that
failure or damage was caused by accident, abuse or neglect by the user.
Parts damaged in shipment must be handled by submission of a claim to the shipper.
Please save all boxes and packing materials and contact the Parts Department.
6-4
May 15, 2012
REPLACEMENT PARTS
Recommended Spare Parts
Intelligrated can prepare and recommend a spare parts list for a customer’s specific
material handling system. The spare parts list will take into account the expected failure
rate of each component and the criticality of each part for each segment of a specific
material handling system.
On-Time Parts Catalog
The Intelligrated On-Line Parts Catalog (OPC) is the only comprehensive material
handling on-line parts catalog. Our unique “One Stop Shop” makes it easier to find, order
and receive all replacement and spare parts for Material Handling Systems,
sub-components and assemblies.
Accessing the On-Time Parts Catalog
The On-Time Parts Catalog (OPC) can be accessed via the Web by two methods:
1. Go to www.OnTimeParts.com.
2. Go to www.intelligrated.com. Click the On-Time Parts link at the top of the page,
or move the mouse cursor to the “Support Services” link, move the mouse to
“Parts” and then click the “On-Line Parts Catalog” link on the submenu.
Figure 6 - 2 On-Time Parts Link
With the Intelligrated On-Line Parts catalog, it is easy to place orders on-line. In addition,
phone support is available any time toll free at 1-877-315-3400. Intelligrated is also
available by email; just click on the [email protected] link on the OPC home page.
May 15, 2012
6-5
REPLACEMENT PARTS
Online parts orders are risk free. Intelligrated provides a full money back guarantee if the
customer is not totally satisfied with the service of the On-Line Parts Catalog.
Intelligrated has included contact information, policies, and how-to information. Just click
on the “Help Desk” link at any time.
Click “Help Desk” link and then the “How To” link for details on how to place an order.
Using the On-Line Parts Catalog
To use the On-Time Parts Catalog:
1. Click the Login link. Enter your e-mail address and password and press the
“Login” button. To skip the login step the next time, check the "Remember Me"
box.
If needed, click the “Create Account” link and fill in the account information.
2. Enter search information or use the links at the top of the page to select parts by
category, Intelligrated product line, or by OEM parts or conveyor cross-reference
categories.
3. Choose a part by clicking on the part number or photo. Cross reference and other
information will be displayed.
4. Click the “Add to Cart” button and enter the quantity needed. If your company
requires a requisition prior to ordering, click the “Add to Requisition” button. Your
purchase requisition may be accessed under the “Order Info” link on the left side
of the page.
6-6
May 15, 2012
REPLACEMENT PARTS
Figure 6 - 1 OPC Main Menu
5. To checkout, click the “Shopping Cart” link on the left side of the page.
6. Verify the order information and click the “Checkout” button to submit your order.
7. Once the order is submitted, click the “Log Off” link to end the session.
May 15, 2012
6-7
REPLACEMENT PARTS
Figure 6 - 3 Warranty Claim Request Form
6-8
May 15, 2012
REPLACEMENT PARTS
Parts Lists and Illustrations
The following pages contain standard assembly and component parts illustrations and
parts lists for your equipment. Colors used in these illustrations are for clarification only
and may not match the paint colors of your conveyor components. These illustrations
and parts listings were up-to-date at the time of the printing of this manual.
The row(s) highlighted in GREY are Recommended Spare Parts and may already be in
your parts inventory.
Links have been provided in the electronic version of this manual, where possible, to
locate and order parts. Part numbers highlighted in BLUE and underlined are linked
directly to the On-Time Parts Catalog. When the part number and description are
highlighted in BLUE, it means there is an assembly drawing on another page of the
manual that shows the break down of that assembly.
Shipping Extendible
SEQ
1
2
QTY
1
1
PART NO
2001890
21311500
3
1
21316000
4
5
6
7
8
9
10
11
12
13
1
1
2
2
2
1
1
1
1
2
4810850
800128
1005550
1005560
1007010
140046300
2500330
4718453
B822701001
9000035
DESCRIPTION
RDCR ACCS 5:1 140C TO 140C
REDUCER, TIGEAR-2, SIZE 35
COUPLED INPUT, 20:1 RATIO,
HOLLOW 1.939" BORE OUTPUT,
140TC MOTOR FRAME SIZE
MTR REL 1 HP 575 143FR TEFC /W BR
VBM3546T-5D
WHEEL HUB ASSY-EXTENDIBLE
FLWR 2-1/4OD X 1-1/4WD 7/8-14
CSTR WHL 8 OD 3 FACE
WHL V-GR 4DIA 2FACE 800LB CAP
WHL 16 OD 408025801
ROL G196BLS 30.000"BF AX7
SPR CMPR 1-1/4ODX2 LG
KEEPER DISC
CATRAC GUARD WELDMENT
SIGN DNGR HAZ VOLTAGE
Recommended
Spares highlighted
in grey
Link to On-Time
Parts Catalog
Figure 6 - 4 Example of Links in the Electronic Manual
May 15, 2012
6-9
REPLACEMENT PARTS
Using the Parts Lists
The assemblies and components listed in these parts lists may not be described
completely if they contain special modifications and/or enhancements. Use the part
number shown in this parts list to make sure the correct replacement parts are ordered.
In addition, include nameplate information from motors, reducers, gearboxes,
clutch/brakes, etc., whenever possible.
1. Find the exploded illustration of the applicable components.
2. Find the item number in the parts lists that matches the number in the illustration.
Items on the parts list that are highlighted in GREY are Recommended Spare
Parts and may already be in your spare parts inventory.
3. Note the complete description and part number. See the Recommended Spare
Parts List to verify the part number for your specific project. Be sure to supply all
this information when placing the order.
NOTE:
Do not provide the item number (the number in the circle) assigned to the
part in the illustration. These numbers are used for reference.
4. To Order Spare Parts - click on the part number shaded in grey, see Figure 6 - 4.
The Security Warning Window may be displayed. Click the Allow button and the
Intelligrated Customer Service Dashboard window is displayed. Enter User Name
and Password, and click the Log In button.
6 - 10
May 15, 2012
REPLACEMENT PARTS
5. Enter User Name and Password, and click the Log In button.
NOTE:
If already logged on, the link will take you directly to the part that was
selected.
After clicking the Log In button, the Customer Service Dashborard/On-Time Parts
Catalog is displayed and information about the part that was initially requested.
The detailed information, price and availability are displayed in this window. This
window allows for on-line ordering.
May 15, 2012
6 - 11
REPLACEMENT PARTS
Shipping Extendible - Front End Top View and Front View
6 - 12
May 15, 2012
REPLACEMENT PARTS
Shipping Extendible Rear Caster Assembly
May 15, 2012
6 - 13
6 - 14
1
1
1
1
2
2
2
1
1
1
1
2
8
8
4
2
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
SPR CMPR 1-1/4ODX2 LG
ROL G196BLS 30.00 BF AX7
WHL 16 OD 408025801
WHL V-GR 4DIA 2FACE 800LB CAP
CSTR WHL 8 OD 3 FACE
FLWR 2-1/4OD X 1-1/4WD 7/8-14
MTR REL 1 HP 575 143FR TEFC /W BR
VBM3546T-5D
WHEEL HUB ASSY-EXTENDIBLE
SIGN DNGR HAZ VOLTAGE
SIGN DNGR CLIMBING RIDING
SIGN WRNG MOVING EQPMNT
9000095
SIGN WRNG SERVICING MOVING OR
9000145
SIGN CAUTN MTPL DISC ENG
A215100130- MAPICS.IS GR190 3CTR 10'LG W30 W/
STOP
2618138
9000035
9000045
9000055
34
35
31
32
33
29
30
28
27
26
25
24
23
22
21
DESCRIPTION
SEQ
REDUCER, TIGEAR-2, SIZE 35 COUPLED 19
INPUT, 20:1 RATIO, HOLLOW 1.939"
BORE OUTPUT, 140TC MOTOR FRAME
SIZE
RDCR ACCS 5:1 140C TO 140C
20
4718453
KEEPER DISC
B822701001 CATRAC GUARD WELDMENT
2500330
140046300
1007010
1005560
1005550
800128
4810850
21316000
2001890
QTY. PART NO
1
21311500
2
SEQ
1
Shipping Extendible
1
1
1
1
1
4
1
2
2
1
2
1
1
2
1
2
B824145000 MAPICS.EXT REAR CASTER PART.GRAY
171-2622936 (STD)
168-2622934 (STD)
165-2623039 (STD)
B824115016- MAPICS.FNDR WLDT EX FRNT DR
2622993
WHLS.GRAY (STD)
B824721200- MAPICS.ASSY EX LT/SNSR MT FX
2622983
STEERING
B824711060 MAPICS.AI 1-1/4X1-1/4X3/16X60.GRAY
001-2604722 (STD)
B824712000 MAPICS.EXT TRACK WLDT, FLR RET
003-2605358 GUIDE.GRAY (STD)
22605900
BRG FLG 1-11/16 2-BOLT CONC [DG#
056962]
200025
BRG FLG 1-7/16 2-BOLT CONC (DC#
056961)
E911706004 COLLISION AVOIDANCE SENSOR ASSY
S18AW3FF5 PROXIMINTY SENSOR BANNER
0
21133100
RED BASE TIGEAR 350
21280300
RED DGE 35A05L210
21289000
MTR BALDOR 7.5HP 575 213FR TEFC
VEM3710T-5
22423000
BU TL 2517 1.500
22424300
BU TL 3020 1.813
QTY. PART NO
DESCRIPTION
1
B824720001- MAPICS.SHIPPING EX REAR CSTR ASSY
2622970
REPLACEMENT PARTS
May 15, 2012
1
1
1
1
1
1
1
1
1
1
37
38
39
40
41
42
43
44
45
46
140061400
140027400
41053400
41011705
41007010
41007009
41005725
29092300
22602500
22591500
QTY. PART NO
1
22473500
SEQ
36
53
52
51
50
49
48
SEQ
47
55
ROL G196AB 40.00BF AX7 B2006
ROL G251AB DP CUP 40.00BF NO AXLE 56
200 BT 4PLY NYLON TOP (4129) 39W
200 CROWNED EN PULY 3.19OD X 40BF 54
200 PULY RD S 3 in. RLR FLT X 40
DESCRIPTION
BT DGE HT200 1400-14M-55 / GATES
1400-14MGT-55
PIN CONNECTING .065 DIA
DURASTAINLESS #25, CLIPPER #02826
(REPLACED 41025500)
BELT, TRACKING .188 X .375 X 5.84 83A
(REPLACED 9-M004230-9951)
LACING #1 HIGH TENSILE 12 in. LONG
CLIPPER 02242
8 in. CENTER DRIVE PULLEY CR 40 in.
URETHANE
200 PULY RD S 3 in. RLR CR X 40
Shipping Extendible
1
1
1
1
1
2
2
1
1
41053700
41051200
41013100
22460100
22459800
22002900
22002300
140307400
140292400
QTY. PART NO
1
140062400
DODGE 209S, 1.812 SHFT DODGE
#067019
FLANGE BEARING 2 BOLT 1 in DIA
DODGE #124174
BT SPKT DODGE P38-14M-55-2517
112928
BT SPKT DODGE P48-14M-55-3020
112931
200 BT CENTER DRIVE VAC FRM GRD W/
LEXAN WINDOW .156 (7-1-04)
200 BELT RETAINER EXTRUSION 20 ft.-0
in.
200 TAKE UP WELDMENT 11 in. ASSY
(REPLACED 41006900)
11/16 HEX AXLE PINNED 40.00BF
ROL G196AB 40.00BF W/ SILENCE
BANDS AX7 B2006
DESCRIPTION
ROL G196HS 40.00BF AX7 SLEEVE B2006
REPLACEMENT PARTS
May 15, 2012
6 - 15
REPLACEMENT PARTS
Hinged Belt - Side View
6 - 16
May 15, 2012
May 15, 2012
1
1
2
2
2
1
1
1
1
1
1
1
2
5
6
7
8
9
10
11
12
13
14
15
16
17
1
1
1
3
4
18
QTY
1
1
SEQ
1
2
140027280
200025
200032
80377800
80371300
41007005
41007006
80357800
22420400
22421800
2900463
22420200
21290000
2001437
1203050
1203056
PART NO
1201050
1202050
Hinged Belt
ROL G251AB DP CUP 28.000"BF NO
AXLE
BRG FLG 1-7/16 B 2-BOLT D-LOK
BRG PBLK 1-7/16B TPPD BS DL
200 PULY RD S 3" RLR CR X 28"
200 PULY RD S 3" RLR FLT X 28"
SPCL HINGE BELT END IDLER
4"CROWNED PULLEY 28"BF URETHANE
SPCL HINGE BELT UPPER SEC
4"CROWNED PULLEY 28"BF URETHANE
BLT 25.5X11 POLY W/SEALED EDGES
MTR BALDOR 3/4HP 575 56FR TEFC
BRK VEBM3542-5D
BUSHING TAPER LOCK 1610 1.438
BORE KEYWAY
BU TL 1610 1.688
BU TL 2012 1.438
PLLY 6.5 W28 URTHN LGNG
RDCR 50:1 DDGE 26A H 56C TIG2
CPLG CHN SBR 50 STRAT SPR CLIP
CPLG CHN 50SB STRAT SPR CLIP
DESCRIPTION
CHN 50SB FLEX SIDE BOW
CHAIN 50 RIVETED
34
35
33
32
29
30
31
26
27
28
25
24
23
21
22
SEQ
19
20
1
1
1
1
2
11
1
2
1
2
2
1
1
1
2
QTY
19
1
80378100
D3211350
28
80376200
80368700
4818474
7043889
7045497
2901273
41007503
41053700
22605900
22410200
22409600
140307280
22002600
PART NO
140061280
140062280
SPCL HINGE BELT JACK SHAFT
10.5"LG
SHAFT BELT FLAP W=26.5"
SPECIAL SNUB ROLLER W28
SPCL MACHINED CH SPKT 50BTL18H1610
DESCRIPTION
ROL G196AB 28.00BF AX7 B2006
ROL G196HS 28.00"BF AX7 SLEEVE
B2006
11/16 HEX AXLE PINNED 28.00 BF
DODGE 207 SERIES, 1.4375 SHFT
DODGE# 052016
CH SPKT 50BTL18H-1610 SST or
DODGE 100536
CHAIN SPROCKET 50BTL24H-2012 SST
OR DODGE 100542
BRG 2 BLT FLANGE DODGE DLOK
1.688" F2BDL111 #128769
BRG FLG 1-3/16B 2-BOLT UHMW
BRUSH 27.75" W 4" H 2" D
200 TAKE UP WELDMENT 11" ASSY
(REPLACED 41006900)
ASSY BRKT SNUB RLLR TKUP
R/A,1.38X.049,26.00,SST,Z,SL
R/A 1.38X.049 26.50 SST Z SL
REPLACEMENT PARTS
6 - 17
REPLACEMENT PARTS
Hinged Belt Upper Pivot Assembly
6 - 18
May 15, 2012
QTY
1
4
1
1
54
2
2
4
3
6
1
2
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
22420400
80371300
41006200
41006801
140061280
140002280
41053700
41007005
800260
80357000
22605900
PART NO
200025
SPCL HINGE BELT UPPER SEC
4"CROWNED PULLEY 28"BF
BU TL 1610 1.688
200 RETURN RLR FLT
200 ANG SNUB ADJUSTER
ROL G196 28.00BF
ROL G196AB-28.00"BF AX7
200 TAKE UP WELDMENT 11" ASSY
200 PULY RD S 3" RLR CR 28" LG
DESCRIPTION
BRG FLG 1-7/16 2-BOLT CONC (DG#
056961)
BRG FLG 1-11/16 2-BOLT CONC (DG#
056962)
SPCL HINGE BELT PIVOT FRAME
SHAFT 1.438DIA 4.75LG
SET CLLR 1-7/16 B SPLT SHFT
Hinged Belt Upper Pivot Assembly
24
23
22
20
21
17
18
19
16
15
14
SEQ
13
1
2
2
1
2
1
2
1
1
1
2
QTY
3
22409600
22421800
22410200
41007503
22002600
140031280
41007301
41007403
80357800
80376200
200032
PART NO
80368700
CH SPKT 50BTL18H-1610 SST or
DODGE 100536
SPCL HINGE BELT JACK SHAFT
10.5"LG
SPCL HINGE BELT END IDLER
4"CROWNED PULLEY 28"BF
ROL G250AB 28BF
200 ANG, SNUB RLR ADJUSTER
200 BRUSH HOLDER ALUM
EXTRUSION X 28"
BRUSH 28" W 4" H 2" D
DODGE 207 SERIES, 1.438 SHFT
(124448 )
CHAIN SPROCKET 50BTL24H-2012 SST
OR DODGE 100542
BU TL 2012 1.438
DESCRIPTION
SPCL MACHINED CH SPKT 50BTL18H1610
BRG PBLK 1-7/16B TPPD BS DL
REPLACEMENT PARTS
May 15, 2012
6 - 19
REPLACEMENT PARTS
6 - 20
May 15, 2012
INDEX
Index
A
Accessing the On-Time Parts Catalog 6 - 5
Assembling the System 3 - 6
C
Codes & Standards 3 - 3
Controls 1 - 7
control stations 1 - 7
safety devices 1 - 8
emergency stops and restarts 1 - 8
Controls, Safety Devices 1 - 8
E
Electrical Connections, installing 3 - 8
Electrical Devices 4 - 9
setting extendible 4 - 9
F
For Your Safety 1 - 2
G
General Descripiton
components 2 - 1
General Description 2 - 1
decline belt 2 - 4
extendible conveyor 2 - 4
glossary of Terms 2 - 6
location of components 2 - 1
Glossary of Terms 2 - 6
Guards and Guarding 1 - 6
guarded by location or position 1 - 6
guarding exceptions 1 - 6
interfacing of equipment 1 - 6
H
direction of travel 3 - 10
Installation and Maintenance Safety 1 - 10
Installation Procedures 3 - 1
check hinged belt direction of
travel 3 - 10
codes & standards 3 - 3
conveyor system, assembling 3 - 6
installing electrical connections 3 - 8
parts replacement 3 - 4
receiving & inspections 3 - 1
safety precautions 3 - 3
site preparation 3 - 4
start-up 3 - 9
unloading/moving into position 3 - 5
L
Layout Requirements 3 - 2
Lockout / Tagout Guidelines 1 - 11
M
Maintenance Precautions 4 - 3
operator’s safety precautions 4 - 3
service and maintenance safety 4 - 4
Moving into Position 3 - 5
N
New Parts Warranty 6 - 4
Non-Warranty Part Order Procedures 6 - 4
O
On-Time Parts Catalog 6 - 5
accessing the on-line parts catalog 6 - 5
Operation Safety Precautions 1 - 9
Order Processing and Shipping 6 - 4
Ordering Parts Catalog Main Menu 6 - 7
P
Headroom 1 - 6
I
Identifying parts 6 - 9
Initial Operation 3 - 10
Parts Lists and Illustrations 6 - 9
hinged belt - side view 6 - 16
hinged belt pivot assembly 6 - 18
rear caster assembly 6 - 13
May 15, 2012
Index - i
INDEX
shipping extendible, front end 6 - 12
Parts Orders 6 - 1
Parts Replacement 3 - 4
Preventive Maintenance 4 - 1
bearings 4 - 10
electrical devices 4 - 9
lubrication and maintenance 4 - 7
maintenance precautions 4 - 3
scheduled maintenance 4 - 5
steering/tracking adjustments 4 - 11
Procedure for non-warranty replacement
part(s) 6 - 4
Procedure requesting warranty
replacement part(s) 6 - 2
R
Receiving & Inspections 3 - 1
claims & returns 3 - 2
reporting product damage 3 - 2
Recommended Spare Parts 6 - 5
Replacement Parts 6 - 1
contact information 6 - 1
parts lists and illustrations 6 - 9
parts orders 6 - 1
using parts lists 6 - 10
Running Decline Belt 2 - 4
Running Extendible Conveyor 2 - 4
S
Safety Devices 1 - 8
Safety Instructions 1 - 1
controls 1 - 7
for your safety 1 - 2
lockout / tagout guidelines 1 - 11
operating safety precautions 1 - 9
safety precautions 1 - 6
safety signs 1 - 13
standard safety conventions 1 - 4
Safety Instuctions
installation and maintenance safety 1 10
Safety Precautions 1 - 6, 3 - 3
guards and guarding 1 - 6
headroom 1 - 6
Index - ii
Safety Precautions, Guards and
Guarding 1 - 6
Safety Signs 1 - 13
Scheduled Maintenance 4 - 5
iinspections, monthly 4 - 6
inspections semi-yearly 4 - 6
inspections, daily 4 - 5
inspections, weekly 4 - 6
Site Preparation 3 - 4
Spare Parts Recommended 6 - 5
Speed Reducer - Lubrication and
Maintenance 4 - 7
oil levels 4 - 7
oil, changing 4 - 8
overloads 4 - 8
seals 4 - 8
temperature 4 - 7
Standard Safety Conventions 1 - 4
Start-Up 3 - 9
electrical check 3 - 9
initial operation 3 - 10
mechanical check 3 - 9
pre-operating check 3 - 9
Steering/Tracking Adjustments 4 - 11
T
Troubleshooting 5 - 1
guidelines 5 - 1
Troubleshooting Help 5 - 3
U
Using Parts Lists 6 - 10
Using the On-Line Parts Catalog 6 - 6
W
Warranty Claim Request Form 6 - 8
Warranty New Parts 6 - 4
Warranty Part Order Procedures 6 - 2
Warranty Part Request Form 6 - 8
Warranty period for conveyor 6 - 2
May 15, 2012

Shipping Extendible with Hinged Infeed Belt Conveyor

Transcription

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