TS 1500-100M Powered Belt Curve Conveyor

TS 1500-100M Powered Belt Curve
Conveyor
Technical Manual
As of: 22.04.2008 Version: 1.0
© 2008 by Transnorm System Sdn Bhd Right of modification reserved. All rights reserved by
Transnorm System Sdn Bhd. Nothing may be reprinted or reproduced without the written consent
of the company.
In this technical manual, we give the operator appropriate instructions for the safe and proper
operation as well as instructions for installation and correct maintenance. Every person who is
authorized for the transportation, assembly, start up, operation, maintenance, upkeep and repair,
as well as shutdown, of our machines and additional components, is required to have read and
understood the instructions in the individual chapters and sections.
In order to avoid operating error and to guarantee trouble-free operation of our products,
this technical manual must always be available to the operating and maintenance
personnel.
Table of Contents
1.0 General
1.0
1.1
1.2
1.3
1.4
General..................................................................................................................................... 4
Copyright Protection ............................................................................................................... 5
After Sales Service ................................................................................................................. 5
Warranty ............................................................................................................................5 ~ 6
Definition of Terms and Abbreviations for TRANSNORM SYSTEM Conveyors .................... .6
2.0 Operating Priciple
2.0 Operating Principle....................................................................................................................7
3.0 Technical
3.1
3.2
3.3
3.4
Technical Description ..............................................................................................................8
Component Overview ..............................................................................................................9
Technical Data ........................................................................................................................10
Dimensions ............................................................................................................................11
4.0 Transportation and Set Up
4.0
4.1
4.2
4.3
4.4
Transportation and Set Up ............................................................................................12 ~ 14
Location and Operating Conditions .......................................................................................15
Subsurface/Base ...................................................................................................................15
Storage ..................................................................................................................................15
In-house Transportation .........................................................................................................15
5.0 Initial Start up
5.0 Initial Start Up .....................................................................................................16
6.0 Elimination of Malfunctions
6.2 Elimination of Malfunctions, Mechanical ................................................................................ 17
6.2 Elimination of Malfunctions, Electrical ................................................................................... 18
6.3 Service Address ................................................................................................................... .19
7.0 Maintenance and Care
7.0 Maintenance and Care............................................................................................................ 19
7.1 Maintenance Tasks .............................................................................................................. .20
7.2 Cleaning and Care ................................................................................................................ .21
8.0 Repair
8.1 Procurement of Replacement Parts ..................................................................................... . 21
8.2 Tools .................................................................................................................................... 21
8.3 Replace Conveyor belt ...................................................................................................22 ~ 32
9.0 Shutdown and Disposal
9.0 Shutdown and Disposal…………………………………………………………………………… 33
Total number of pages: 33
1.0 General
This instruction manual puts you in a position so that you can safely operate the machine. It is
conceived of as a guide and reference work and will assist in answering questions and solving
problems in the fastest possible manner. If you do not understand the instruction manual or
individual chapters, consult with Transnorm System Sdn Bhd before initiating the corresponding
action. Certain terms are employed in the instruction manual. In order to avoid misunderstandings,
please use the same terms all of the time.
All descriptions in this manual relate exclusively to the make of the machine whose model number
appears on the title page. The operators or users of the machine are prohibited from carrying out
any changes, extensions or alterations on the machine.
All of the technical information, data and references for operation contained in this instruction
manual are up-to-date at the time of printing and are made according to the best of our knowledge,
taking into account our previous experience and knowledge. However, Transnorm System Sdn
Bhd assumes no responsibility for errors or damage which can be directly or indirectly attributed to
the use of this documentation.
Every person who is involved in the operation, installation, maintenance, repair and
shutdown of the machine is required to read and observe the safety-related notes in this
instruction manual, the safety labels mounted directly on the system/machine and the
relevant accident prevention regulations (APR). Ensure that this manual is available at all
times to the operating and maintenance personnel.
This machine is constructed in line with the current state of the art and according to recognized
safety-related standards. Nevertheless, during use of this machine, risks to the user and/or
damage to the machine and other tangible assets can occur, if the machine:
.
• is not operated by properly instructed personnel,
.
• is not used in accordance with regulations,
.
• is improperly maintained.
We reserve the right to make technical changes within the context of further development. The
specifications, illustrations and descriptions in this instruction manual serve, therefore, for
information purposes. The illustrations in this instruction manual do not necessarily correspond to
the scope of the delivery or to a potential replacement part delivery: the drawings and graphics are
not to scale. The documentation pertaining to the respective order has overriding validity. We
reserve the right to change the content of this guide without prior notice.
Additional technical information must be taken into consideration along with the operating
instructions. These include, for example, the operating instructions from engine producers,
control systems, etc. These documents are integral parts of the technical documentation.
The separately delivered documents include:
.
.
.
• the supplier’s declaration or the declaration of conformity,
• the system documentation, if necessary,
• the system layout, if necessary.
The technical data for the machine (as well as possible special accessories) are given
in the product specifications of the order confirmation.
In principle, the assembly of the machine is the same for all lengths and widths. Various
attachments and drives can be mounted on both sides of the machine. Therefore, it is possible that
they are represented as mirror images in individual cases.
Following final shutdown, the machine has to be disassembled into its constituent components
and processed according to the local environmental regulations that are in force: see Chapter 9,
“Shutdown and Disposal”.
1.1 Copyright Protection
This instruction manual is confidential. It must only be used by the authorized personnel.
Dissemination of information to third parties is allowed only with written permission by
Transnorm System Sdn Bhd
All documents are protected by copyright in accordance with the law. Insofar as it is not explicitly
allowed, disclosure of documents, or excerpts of documents, usage or impartation of the contents
is forbidden. Violations are punishable and may lead to civil and criminal penalties. We reserve all
rights to exercise our industrial property rights.
1.2 After Sales Service
For technical information about the products of Transnorm System Sdn Bhd and their
systematic usage, our after sales service is at your disposal. Should you have questions, we
request that you have the machine model, order number, position number (see the
specification plate on the sideguard ) at hand. Should you desire to order replacement parts,
please have the part identification and number at hand.
You will find the contact information for Transnorm System Sdn Bhd in Chapter 6.3.
1.3 Warranty
Carefully read through this instruction manual prior to assembly and start up of the machine.
For defects, damage and malfunctions that occur due to inappropriate operation, operating
errors, non-compliance with this instruction manual or negligent or inappropriate
maintenance, servicing and repair, we assume no warranty. We explicitly point out that only
genuine replacement parts and genuine accessory parts of Transnorm System Sdn Bhd,
which are approved by us, may be used.
The warranty begins on the day of delivery, or rather with the notification of readiness to
deliver, if no other contractual agreement is made.
In the case of possible defects in the delivered products or errors in the delivered documentation,
our warranty conforms exclusively to the statutory regulations. Claims in excess of this, in
particular compensation for damage of any kind, are debarred, with the exception of statutory
claims according to product liability law.
Warranty claims should be filed immediately after discovery of the defect, stating the order
number and item number.
The warranty is voided in the case of, for example:
•
•
•
•
Misuse
Faulty connections and pre-assembly, which do not pertain to the scope of our supply and
services, such as, for example, faulty or non-professional laying and connecting of cables
and wires,
Failure to use genuine replacement parts and accessory parts,
Retrofitting, if this has not been verified in writing with Transnorm System Sdn Bhd.
Worn-out parts are excluded from the warranty.
1.4 Definition of Terms and Abbreviations for Transnorm System Conveyors
The following terms and abbreviations are commonly used by Transnorm System Sdn Bhd.
Conveyor (machine)
Clockwise / Anti-Clockwise
Conveyor Height
Inside / Outside
Dimensions
TS model and identification, for example TS
1500-100M
Running direction of the curve when standing at
the inner radius
Height of the conveyor top of belt plane
Position designation, e.g. for the location of the
motor; oriented according to the inner radius or
outer radius.
All dimensions in the technical representations
are given in mm.
Table 1 Terms for Transnorm System Conveyors
IR
N
BG
=
=
=
Inner Radius
HF
Belt Width
CL
=
=
Conveyor Height
Centerline Radius
Conveyor width Between Guards
Table 2 Abbreviations for Transnorm System Conveyors
s. chap.
s. illus.
=
=
see chapter
see illustration
s. spec.
=
see specifications
2.0 Operating Principle
The TS1500-100M Quick Release Curve is a development of the highly successful TS1500-100
curve which was developed in 1969. The quick release holder design was developed in the USA in
the mid 90’s and has been successfully implemented through multiple projects within the United
States since inception. Due to the increasing need for a quick ( 15 ~ 20 min ) belt change in
emergency situations, Transnorm System Sdn Bhd has implemented this proven technology since
the beginning of 2008 for the Asia Pacific region.
The Transnorm belt guidance principle, throughout all TS manufacturing facilities, on all curve
designs, is the same PUE beading sown onto the outer edge of the precision cut, endless, radial
belting that is guided through multiple bearings around the outer edge of the curve. This design
ensures that an even load is taken on all bearings around the outer edge.
The design of the beading has been developed over the last 35 years to be very durable and
resistant to all environmental conditions.
The drive is provided by a driven tapered drive pulley, ensuring a positive drive along the whole
width of the belt.
This tried and tested design allows for a very long life cycle with minimum wear, extremely quiet
operation with positive drive at very high speeds.
Although a steel deckplate can be implemented, it is Transnorm standard policy to provide a
special film covered layered plywood deckboard. This deckplate is considerably lighter than steel
deckplate and is 21mm thick as standard. This enables very high loads to be taken, including the
walking over the conveyor by technical personnel. In addition, the plywood deckplate prevents
reverberation ensuring an extremely quiet operation. ( below 65dba )
Standard overhang for the sideguards from the end of frame is 10mm, To ensure this, a 30mm
diameter drive shaft is standard.
Larger drive shaft diameters are not required on a belt curve with loads under 100kg/m, but are
possible, if a larger overhang of the sideguards is previously agreed.
If customers prefer to mount the gearbox’s to our pulleys without assistance,
particular care must be taken on the assembly to the torque arm bracket and final
tightening of the bolts. Incorrect installation could result in pulley deflection, motor
wobble and premature wear of the gearbox and flange bearing.
3.0 Technical
3.1 Technical Description
The frame is a mild steel, construction consisting of 50mm x 50mm x 5mm rolled angle iron on the
outer and inner radius’, connected at the ends by 50mm x 50mm x 5mm angle iron.
All four corners have a welded 250mm x 125mm x 9mm plate for frame strengthening and bearing
housing mounting.
Cross spacers are 38 x 38 x 2,8mm square hollow section.
The holders support bar is a powder coated 50mm x 5mm rolled flat bar drilled to accommodate the
outer bearing holders and the outer deck supports.
The holder support bar is supported by extruded or cast aluminum outer deck supports. These also
support the 21mm plyboard deckplate around the outer radius to the exact height through the
center of the bearings located in the outer bearing holders.
The frame and holder support bar are powder coated to RAL 7004 grey as standard.
The fixed outer bearing housings are 100mm x 80mm x 10mm galvanised angle iron which contain
SKF ‘Y’ bearing take up units with cast housings which enable easy adjustment of the belt tension if
needed.
The inner bearing housings are 100mm x 10mm flat plate, which contain SKF ‘Y’ bearing take up
units with cast housings ( specifications included ), and are mounted on a welded block, connected
via 2 x 8mm bolts to enable quick removal from the inner radius.
The drive and tail pulleys are 38.1mm solid shaft machined to 35mm though the ‘Y’ bearings and
down to 30mm for hollow shaft mounting of the gearbox. The pulley is comprehensively checked by
our quality control department through all stages of its manufacture, to ensure that the pulley is
perfectly balanced before final assembly onto one of our units.
The core of the pulley is a moulded, hardened PU foam material which is extremely durable and
lightweight. All pulleys are cured for at least 24hrs before final machining and balancing is
undertaken.
The drive pulley is covered with a PVC grip surface to create the drive required across the whole
width of the belt.
The tail pulley is not covered and remains a smooth painted surface. This is to ensure that there is
no grip at the tail pulley and this enables the belt to move easily over the surface without creating
any undue surface tensions across the curved belt.
3.2 Component / Spares Overview
No.
1
2
3
4
5
6
7
8
9
Description
Belt
Drive Pulley
Tail Pulley
Outer Flange Bearing
Inner Flange Bearing
Outer Bearing Housing
Inner Bearing Housing
Upper Bearing Holder
Lower Bearing Holder
No.
10
11
12
13
14
15
16
17
18
Name
Outer Deckboard Support
Ring
Torque Arm Assembly
Leg Set
Underguard ( Optional )
Deckplate
Inner Aluminium Guarding
Holder Locking Clip
Holder Bearing
Please take not and state all details indicated on the aluminium specification detail plate
located on the sidewall near the motor, when ordering spare parts.
3.3 Technical Data
Data and variations from the norm are documented in the purchase order
contract specifications.
Note
see spec. = see specifications
Description
Model variations
Motor electrical supply
Motor brake tension
Protection category
Air temperature
Relative humidity
Normal atmosphere
Installation location
Non-protection
TS 1500 – 100M Powered Belt Curve Conveyor
TS 1500 – 100M Shaft Driven ( Clockwise / Anti-Clockwise, Inside / Outside
Drive )
TS 1500 – 100M Chain Driven ( Clockwise / Anti-Clockwise, Inside / Outside
Drive )
TS 1500 – 100M Timing Belt Driven ( Clockwise / Anti-Clockwise, Inside /
Outside Drive )
Standard 230 V / 400 V AC 50Hz, Variations: see specification plate on motor
230 V AC / 400 V AC – Standard / optional, Variations: see specification plate
on motor
IP 55
-35°C to +50°C
80 % non condensing
atmosphere without oil or gas, no corrosive atmospheric components
internal – securely protected against condensation firmly fixed only, bolted to a
firm foundation
standard: not protected against explosion
Technical Data
Product Code
Construction year
Dimensions W x H x D
Nominal width between
guards ( BG )
Inner Radius ( IR )
TS 1500 – 100M
see specification plate
see specification plate
see specification plate
500mm ~ 1500mm
In relation to the width
between guards ( BG ) As a
general rule, the IR should
not be specified below
100mm of Belt Width ( BG )
500mm ~ 1500mm
Nominal angle (Degree)
10° ~ 180°
min. 300 mm using shaft mounted motor. Min.
600mm using chain or timing belt drive.
Conveyor height (HF)
Conveyor belt type
Dimensions of conveyed
goods
Load of conveyed goods
Conveyor speed
Drive
Drive capacity
Accessories
Preference Series
Ammeraal or Siegling
To be advised when ordering
To be advised when ordering
To be advised when ordering
To be determined by TS
see specification
plate on motor
see spec.
max. 100 kg/m (depending on speed)
up to 4.0 m/sec.
To suit load and speed requirements
Max 3.0 kW, depending on speed and load
3.4 Dimensions
Please refer to the order
specifications.
IR
BG
=
=
Inner Radius
HF
Conveyor width Between Guards
CL
=
=
Conveyor Height
Centerline Radius
4.0 Transportation and set up
The TS 1500M - 100 powered belt curve conveyor is completely assembled in the factory,
subjected to a test run for a performance check and packed according to project status. Due to
transportation efficiency, it is possible that at the sideguards, supports/suspensions and other
component parts will be dis-assembled at our facility and will have to be re-assembled once
unpacked at site. If sideguards are removed, the units will be stacked above each other in each
crate. Care must be taken when removing the units in order from the stack.
The machine is to be hoisted during loading, unloading or moving of the machine. The danger
exists that it can fall down or be overturned. A crushing danger exists for hands and feet when the
machine is set down. In addition, you can fall, be seized or get stuck.
Remain alert, work according to regulations and wear safety equipment (safety shoes,
suits, gloves, if necessary). Comply with provisions for the stability of the machine.
To bring the machine to the assembly or installation location, the following steps must be followed:
1.
The machine is to be removed from the transportation rack and freed from encumbering
parts located laterally and over the top.
2.
Ensure that the top unit is unbolted from the rack. Manually lift the upper unit and place
wooden blocks between the lower conveyor and upper conveyor. This is to ensure a sufficient gap
between the units to allow the forks to enter without damaging either unit.
3.
Ensure that the lifting point for forks or lifting cradle is through the center of the curve
Once the machine is maneuvered to the approximate final location, the following steps must be
followed:
1. The unit is to be placed on the leg sets. There will be holes drilled around the lower frame to
indicate the leg mount positions.
2. Identify the correct sideguards for the unit and replace the outer sideguard ( see
instructions in section 4 ) and align the sideguard to the straight conveyor.
Each sideguard will be marked to each curve unit, and are drilled to suit at our
facility. Ensure that the correct sideguards are used, as different sideguards will not
fit correctly.
Ensure that all locking devices on holders are in position before lifting the outer
sideguard into position. Failure to do so could result in locking device damage and
subsequent failure of the belt guidance system
Never force the sideguard to fit. The sideguard is precision rolled to suit the machine. If
the guards are forced, it may affect the geometry of the curve and ultimately the
performance, which could affect warranties in the future.
3. Adjust the height of the unit by inserting a lifting device under the cross brace. Once the
weight is fully taken by the lifting device, loosen the 2 bolts connecting the cross bar to the
upright
4. Lift the cross bar to the required height, The support feet should slip out of the square
hollow section, if the support foot does not move freely, loosen the bolts a little more and
tap the support foot to the floor or supporting structure.
5. Once the outer sideguard is aligned and the height is set, ensure all leg bolts are fully
tightened. Failure to do so, may result in the height becoming out of alignment during
operation and load being taken by connected sideguards only.
6. Bolt outer sideguard to connecting conveyor.
7. Level the conveyor by adjusting the legs sets as item 4.
4.1 Location and Operating Conditions
The machine is not protected against explosions and may not be operated in an explosive
atmosphere. It may only be operated under the following conditions:
.
• air temperature -35°C to +50 °C,
.
• rel. humidity max. 80 %, non condensing.
.
• normal atmosphere (atmosphere without oil or gas, no corrosive atmospheric
components),
.
• assembly should be securely protected against condensation and moisture.
Variations from this are described in the specifications, if necessary.
The preferred spatial requirements for operation and upkeep is ideally 700mm clearance
around both the outer and inner radius to allow technicians to work. If it is not possible to allow
for this working space, 300mm clearance would be preferred on either radius.
4.2 Subsurface/Base
In the standard configuration, the machine may only be operated in a stationary position on load
2
bearing cement (min. cement class B25 with 25 N/mm nominal hardness) or on a correspondingly
constructed, steel construction. Special devices that allow for mobile operation can be supplied
upon request.
4.3 Storage
Storing the machine is possible at
•
•
•
•
normal atmosphere (atmosphere without oil or gas, no corrosive atmospheric
components),
air temperature -35 °C to +50 °C,
rel. humidity max. 80 %,
machine should be securely protected against condensation and moisture when stored.
4.4 In-house Transportation
The pertinent protective regulations must be observed during in-house transportation. Hoisting the
machine or machine components is permitted at the points intended for this on the framework, if
necessary. Pay attention to the balance point. Please refer to the delivery receipt for the gross
weight. Following removal of the framework or the transport rack, the machine may only be set up
using the supports on the frame.
5.0 Initial Start up
The operation of the conveyor via the control of the entire conveyor system is described
in the system documentation or in the control documentation.
The conveyor is delivered with the conveyor belt assembled. Until the start up of the entire
system, the conveyor belt should remain in the condition in which it was sent. If the belt has
been de-tensioned ( due to long lead time between delivery and start up ) signs will be
attached to indicate this and the tension must be replaced to the relevant marks on the
inner and outer bearing housings ( see chapter 8.4.3 section 29 )
The initial start up is completed as follows:
1.
Check post-assembly positions: Check the clearance measurements and the level
differences in the area of the angled transfer and, if necessary, re-adjust them. Check the transfer
gaps to the connecting conveyor in the drive station area.
2.
Cleaning: The entire conveyor is to be freed of possible dirt and checked for debris within
the belt guide. - Remove debris –
3.
Check side guides: The side guides must be mounted so that no obstruction to the belt
path can arise. Check that there is a sufficient gap of approx 2mm ~ 3mm between the sideguard
and belting around the outer radius. Tensions within the side guides, caused by the bolting on the
connecting side guides, can impact the mounting of the conveyor, so that the conveyor framework
warps. Side guides must be free of tension, so that later maintenance work can also be smoothly
completed.
4.
Set conveyor belt tension: The belt was, if necessary, brought in a de-tensioned
condition, in which the take up units containing the Y bearings are backed off. In order to reset the
conveyor belt tension, as was set for the test run in the factory, the Y bearings should be brought
back to the original factory setting, which will be clearly marked on the take up unit. By this means,
the previous condition for the test run is reestablished.
5.
Activate the conveyor: The conveying direction is checked by activating the conveyor for
a short time (Anti-Clockwise – the belt runs from right to left whilst standing at the inner radius;
Clockwise – the belt runs from left to right whilst standing at the inner radius). If the tested
conveying direction runs opposite to the indicated conveying direction, the polarity of the electrical
connection must be reversed. If the belt runs in the indicated direction, the conveyor can be
continuously activated.
6.
Check belt path: If all of the previous steps are correctly completed, the result should be
that the belt path is running smoothly. Check the initial noise level. Following approx. 1 hour of
continuous operation, recheck the noise level. The moving parts must run quietly during both
inspections. If this specification is not met, one should assume this results from either a foreign
object located inside the unit, or damage to a component. Therefore, the damaged component
must be identified Transnorm immediately notified. The component will be supplied and replaced
according to the instruction manual.
If the previous specifications are met, then the conveyor is ready for use. As a final task, any
removed protective covers must be replaced.
6.0 Elimination of Malfunctions
6.1 Elimination of Malfunctions, Mechanical
No.
Malfunction
Identified
1
Belt conveyor stalling
2
Conveyor stops, motor
running ***
Remedy
See
Chapter
Power supply interrupted
Have specialized staff check
cause and rectify
See operator’s
switching
documentation
Drive motor defect, motor
brake seized
Have specialized staff check
cause and alleviate; if
necessary, replace drive
motor
See operator’s
switching
documentation
or instruction
manual from
motor vendor,
Possible Cause
Pulley shaft broken
Foreign object jammed
around outer guidance
system
Replace drive pulley
Find and remove foreign
objject
3
Belt slipping
Belt de-tensioned
Increase tensioning by
moving y-bearings in outer
housings towards the infeed
and outfeed of the curve.
4
Noise develops in drive
motor
Motor lubrication insufficient
(leak)
Check motor oil level, fill if
necessary, or replace motor
5
Noise develops in
flange bearing
Pulley shaft turning in the
inner ring of the bearing
Replace bearing, pulley if
necessary
Bearing defect
Replace bearing
Bearing defect
Replace roller
6
Noise develops in the
guide bearing holders
8.4.6
8.4.2
See instruction
manual from
the motor
vendor
*** It is highly recommended that tail sensors are installed to indicate when the tail roller ceases to
operate and he motor continues to run. If the belt becomes locked and the motor continues to run,
irreparable damage could occur to the belt and/or drive pulley.
If you experience any further problems, please contact our service department or the control
vendor or motor vendor.
8.4.6
8.4.2
6.2 Elimination of Malfunctions, Electrical
If malfunctions arise in the area of electrical cabling or control, refer to the specifications about
causes and elimination of disruptions in the electro-technical documentation or the control
documentation.
No.
Malfunction
Identified
Possible Cause
Interruption in
connecting harness
Fuse blown
1
2
Motor does not
start up
Fuses blow or
motor protection
trips immediately
Motor protection has
tripped
Motor contactor does
not
Switch, fault in control
Short circuit in line
Short circuit in motor
Lines connected
incorrectly
Ground fault on motor
Inadequate cooling
3
Motor heats up
excessively
(measure
temperature)
Separately driven fan
not functioning (if
present)
Motor incorrectly
connected
(delta/star)
Loose contact in
connecting harness
(one phase missing)
Fuse blown
Rated operating mode
exceeded, e.g. due to
excessive starting
frequency
4
5
Motor
excessively loud
Brake does not
release; Motor
does not brake
Foreign bodies in
cooling air passages
Brake control unit
failure
Inadequate cooling
Brake lining worn down
Working air gap
incorrect
Remedy
See
chapter
Check connections, correct if
necessary
Identify fault and replace fuse
Check motor protection is set
correctly, rectify any fault; check
motor for free movement; check
that all three phases of the power
supply are present; check circuit
arrangement (star/delta)
Check motor contactor control,
Rectify any fault
Rectify short circuit
Motor to specialist workshop
Correct circuit
Motor to specialist workshop
Correct cooling air supply or clear
cooling air passages
Check connection, correct if
necessary.
Correct circuit
Rectify loose contact
Look for and rectify cause (see
above); replace fuse
Adapt rated operating mode of
motor to required operating
conditions; if necessary call in a
specialist to determine what is the
correct drive
Clean the cooling air passages
Check switchgear, brake
solenoid, brake control unit
Check ventilation, air supply
Replace entire brake disk
Check working air gap
See vendor
switching
documentation
and the
instruction
manual from
the motor
vendor
6.3 Service Address
Should ambiguities or difficulties arise during assembly, maintenance, repair or operation of the
technical conveying components, please refer first to the corresponding section in the operating
manual. If you do not find sufficient information there, please contact Transnorm System Sdn Bhd.
You can reach Transnorm System Sdn Bhd Service at:
Telephone: +60 (7) 777 1917
Fax: +60 (7) 777 1928
Email: [email protected]
For fast answers to your questions and to order replacement parts, we require the following
information from you:
.
.
.
• Machine model
• Order number
• Position number
This information is found on the specification plate of technical conveying components. The
specification plate is located near the drive.
Information for the correct ordering of belting is supplied on the stamp located on the inside of all
original TS belting.
When ordering replacement parts, please give us the part description ( see the list of replacement
parts in this documentation).
7.0 Maintenance Care
Because poor maintenance can lead to a breakdown of the machine, the maintenance of the
machine should be completed by personnel who are specially designated and trained for it. At your
request, we can offer you a maintenance contract optimized for your requirements. For safe
operation of your machine, we recommend that you call upon our TRANSNORM SYSTEM Service
at least once per year.
The machine is technically low maintenance to a large extent. The product life and the trouble-free
operation of the machine are dependent, however, on regular and sufficient care and maintenance.
In order to guarantee the operation of the machine, you must comply with the maintenance plan
and the maintenance intervals.
If parts must be disassembled during maintenance work, then proceed according to the
corresponding descriptions in chapter 8 “Repair”. The disassembled parts must be reassembled
without fail after the repair is completed.
7.1 Maintenance Tasks
The maintenance tasks must be repeated at certain time intervals. The following code specifies
the intervals with the respective temporal spacing (based on single shift operation):
.
.
.
.
•
•
•
•
D Daily
W Weekly
M Monthly
A Annually
Non-compliance with the prescribed maintenance intervals can lead to damage to the
system/machine and/or a decrease in or a loss of operational readiness.
Code
D
Component
TS 1500-100 M
Angled – Belt
Conveyor
Maintenance
General visual inspection,
functional check
Clean the conveyor belt and
visually examine for abrasions
and damage
M
Conveyor belt
Check tension and run of
conveyor belt (visual
inspection), correct if
necessary.
M
Rollers and flange
bearing
Check rollers and flange
bearing for noise development,
replace if necessary.
M
Drive pulley
Clean drive pulley and check for
damage
M
Flange bearing
Grease flange bearing
Visual examination for leaks
(oil) and damage
M
Drive motor
Check oil level in drive motor,
refill if necessary.
Notes
See
chapter
After the end of the working day
or at shift change, remove any
debris from conveyed cargo that
may have fallen out into the
machine.
No foreign fluids or objects may
be present in the areas of the
conveyor belt and the
pulleys/rollers.
No foreign fluids or objects may
be present on the conveyor belt.
At the appearance of heavy
abrasions and damage (rips,
damage to the fabric), belt is to
be immediately replaced.
8.4.2
Insufficient or excessive belt
tension leads to premature
abrasion of the drive pulley and
conveyor belt.
8.4.2
8.4.6
Replace drive pulley if necessary
Only if a lubricating nipple is
present: use only non-resinous
and non-corroding bearing
grease
In case of leak or dripping oil, a
new motor is required.
During maintenance, such as oil
changes, for example, comply
with the instruction manual from
the motor vendor.
8.4.6
8.4.5
See
specs.
7.2 Cleaning and Care
Clean the machine regularly and appropriately. Dry clean machine only (brush, cloth, compressed
air, etc.). Ensure that machine and electrical components are protected from moisture.
Clean the area around the machine regularly and appropriately. Personnel can slip on dusty, dirty,
or freshly wet-mopped floors. This can directly lead to injuries, or to injuries from slipping or falling
onto the machine (danger of being hit, crushing, seizing and drawing in of clothing or body parts,
electrical shock). In order to avoid such dangers, always clean the area surrounding the machine
and the machine when the system/machine is deactivated.
Regular cleaning allows for earlier recognition of any friction wear that might arise, which
can require maintenance or repair work.
8.0 Repair
The replacement of worn-out parts/components is primarily described in this chapter. Observe the
operating instructions for the individual components in the machine.
We reserve the right to make technical changes within the context of further development. The
specifications, illustrations and descriptions in this instruction manual serve, therefore, for
information purposes.
8.1 Procurement of Replacement Parts
Only genuine replacement parts from Transnorm System Sdn Bhd may be used. A detailed list
of replacement parts is included with this documentation.
8.2 Tools
When carrying out repair and maintenance, the following tools
are required:
Tool
Auxiliary equipment
Operating equipment
Tool kit (wrench, screwdriver, pliers,
etc)
Pneumatic screw driver
If necessary, frequency meter
and belt tension tester for drive
belts
Power and electrical supply
Torque wrench
Spirit Levels
Device for raising and lowering
the machine
Compressed air supply for
cleaning tasks
Circlip pliers
Square
Combination wrench/box wrenches
10, 13, 14, 15, 17, 19, 22 and 24mm
Dolly, mobile platforms with
automatic locator, etc.
Allen wrenches 4; 5; 6 and 8 mm
Ladders, steps, platforms and
raised platforms, if necessary
Allen wrenches with ball head 4,5
and 6 mm
Extractor for drive pulleys up to
Ø150
mm
Pen for marking
8.3 Replace Conveyor belt
The Transnorm System powered belt curve conveyor is a narrow tolerance
precision conveyor, particularly in its geometry. When changing the belt, this
must be kept in mind. Incorrect fitting of the belt may cause premature
deterioration, which could result in damage to the new belt, drive pulley and
guidance system. If in doubt, please call Transnorm System Sdn Bhd
customer support through any of the support channels indicated in this
document.
Before any work, de-activate
system and ensure against re-activation
1a
Video 1a
1b
Video 1b
1c
Video 1c
1d
Video 1d
1. Remove the motor by:a) Remove the bolt connecting the motor
to drive shaft.
b) Remove the 10mm bolt connecting the
slotted angle bracket to the motor
torque arm.
c) Remove the 2 x 8mm bolts connecting
the slotted angle bracket to the frame
connection bracket..
d) Remove the motor and ensure that it is
paced in a safe area.
2. Remove the inner aluminium cover by:-
2a
Video 2a
a) Remove the fixing screws connecting
the aluminium plate to the deckplate.
b) Placing a flat headed screwdriver
between the center of the aluminium
plate and the deckplate, gently prise
the plate away from the deckboard.
2 b/c/d
Video 2
b/c/d
c) Pull the aluminum plate outwards from
the center until the plate becomes
inverted. Take care not to fold the plate.
d) Remove the aluminum plate and ensure
that it is paced in a safe area.
3
Video 3
3. Remove the inner sidewall by removing
the 8mm bolts securing the sidewall to
the deckplate. Ensure that the removed
guard is placed in a safe area.
4
Video 4
5
Video 5
6
Video 6
4. Remove the outer sidewall by
removing all bolts around the outer
radius securing the sidewall to the
frame / holders.
5. Remove the 2 x 8mm bolts securing the
outer pulley guards to the bearing
housing. Do not remove the top bolt
securing the outer pulley guards to the
sidewall ( indicated )
6. Remove the outer sidewall and place in
a safe area.
7
Video 7
7. Release the tension on the outer radius
by backing off the 12mm tensioning
bolts on the bearing housings until the
bearing is at its full released position.
8
Video 8
8. Release the tension on the inner radius
by backing off the 12mm tensioning
bolts on the bearing housings until the
bearing is at its full released position.
9
Video 9
10
Video 10
9. Using a flat head screwdriver, remove
the bearing covers on the inner radius
bearings.
10. Remove the spring clip located
between the 2 grub screws on the inner
shaft bearings ( indicated )
11
Video 11
11. Loosen grub screws on inner bearings.
12
Video 12
12. Remove the inner bearing housing
plates by removing the 2 x 8mm bolts
located at the bottom of the plates and
sliding the hole plate and bearing off
the shaft.
13. Release the quick release beading
holders ( photo ) around the upper and
lower outer radius by:a) Moving the plate securing clip on each
holder, from its current position (
indicated ).
b) To the position ( indicated ) to unlock
the top an bottom half of the bearing
holder.
c) A quick release tool will be supplied with
your project. Insert the supplied quick
release tool into gap between plates at
top of holder ( top holders ) and
between gap at bottom of holder (
bottom holders )
13a/b/c/d/e
Video 13
a/b/c/d/e
d) Twist the tool anti-clockwise on top and
bottom holders, to release the locking
pin between the two plates.
.
.
e) Using the tool, pull the bearing housing
open to release the beading.
.
13f
Video 13f
f) Continue along bottom until all bearing
holders are released.
14.
a) Once all holders are released fold the
belt back on the top surface to reveal the
outer deck support countersunk screws.
14a/b
Video 14 a/b
b) Release the screws, but do not remove.
.
.
15
Video 15
15. Remove inner deck support
countersunk screws.
16
Video 16
16. You will be supplied belt removal
wheels with your project. Place the belt
removal wheels around the inner deck
supports at the inner radius, ensuring
that the “u” is on the tool is fitted around
the support. Clamp the tool to the 50 x
50 angle steel frame.
17
Video 17
18
Video 18
17. Pull the belt beneath the deckboard up
and over the belt removal wheels,
trapping the belt between the wheels
and the deckplate.
18. Pull the belt towards the inner radius
and over both pulleys using the belt
removal wheels until the beading of the
lower part of the belt becomes trapped
at the wheels. Lift the deckplate to
release the beading and remove belt.
19.
a) You will be supplied 2 x pillar extensions
with your project.
.
19a/b/c/d
Video 19
a/b/c/d
b) Place the pillar supports on top of the 2 x
inner deckplate supports nearest the
inner bearing housings.
c) Slot the collar down over the inner deck
supports.
19d
d) This ensures that there is a gap
between the deckplate and the belt
removal wheel.
20.
a) Place the new belt on top of the
deckplate.
20a/b/c
Video 20
a/b/c
b) Unroll the belt along the deckplate.
.
c) Take the beading of the upper
portion of the belt and trap the
beading on several holders at the
center of the outer radius by
snapping the holders back into
position.
21
Video 21
21. Pull the lower half of the belting
back towards the inner radius and
feed the beading through the gap
between the belt removal wheel and
deckplate created by the pillar
supports. Remove the pillar
supports
22
Video 22
22. Feed the belting around the ends of
the 2 pulleys and pull the whole belt
to the outer radius on top surface,
and between wheel and deckplate
on the underside of the deckplate.
23
Video 23
23. Pull the belt into position. Once the
belt is in position, remove the belt
removal wheel.
24
Video 24
24. Fold the belt back. Tighten the outer
deck support countersunk bolts
25
Video 25
26
Video 26
25. Fold the belt back. Pulling the belt
into position, snap the upper and
lower bearing holders back over the
beading and into the locking position
on their pins. Ensure that the locking
device is put into place to lock the
two divided plates on the bearing
holder
26. Replace the inner deck support
countersunk bolts and tighten
27
Video 27
27. Replace the inner bearing housings
by sliding bearings over the shaft
and replacing the 2 x 8mm bolts at
the base of the bearing housings.
28.
28a/b
a) Before tightening the grub screws, to
return to factory settings, tap the
bearing housing plate towards the
deckplate, ensuring that the bearing
plate is touching the deckplate.
Replace spring clips
Video 28 a/b
b) Replace spring clips
29
Video 29
29. e-tension the inner radius and outer
bearings to the factory settings.
These settings are indicated with a
stamp on the bearing and plate
30. Replace inner sideguards.
30
Video 30
31. Replace outer sideguards
31
Video 31
32
Video 32
Ensure all holders locking
devices are secured to prevent
damage when lifting sideguard
back into place
32. Replace inner aluminium cover.
To prevent distortion of the drive
shaft, the motor must be re-installed
in the following order.
33. Replace motor by:-
a) Re-bolting the motor to the drive
shaft.
33a/b/c
Video 33
a/b/c
b) Level the motor and tighten the 2 x
8mm bolts connecting the frame
bracket to the slotted angle bracket.
Ensure that the angled plate is tight
against the motor torque arm. If gap
is present, shaft deflection may
occur
c) Re-bolt the slotted angle bracket to
the motor torque arm tighten.
Ensure that the angled plate is tight
against the motor torque arm before
tightening bolt. If gap is present,
shaft deflection may occur.
9.0 Shut Down and Disposal
If the entire conveyor or parts thereof must be scrapped, local waste regulations are considered in
effect for the disposal.
During shutdown, compliance with all itemized safety instructions in the corresponding chapters
is required. Observe the operating instructions for the individual components in the machine.
Carry out the shutdown as described below:
During shutdown, the system/machine must be deactivated from the main switch and
secured against reactivation.
Depressurize the conveyor’s pneumatic and hydraulic systems, if such exist. If a pressure
reservoir is integrated in the system, the pressure on this must be lowered to 0 Bar.
1.
Loosen motor connection cable from terminal box and remove. Separate the conveyor
from the power supply.
2.
Separate the conveyor from the hydraulic and pneumatic systems, if such are present.
3.
Drain the motor and drive oil, collect it in appropriate containers and dispose of it in an
environmentally correct manner.
4.
Disassemble the conveyor as is described in the individual sections of chapter 8 “Repair”.
Observe all safety precautions, including the safety precautions in chapter 4.2 “In-House
Transportation” and chapter 4.3 “Set Up and Assembly”.
5.
Dispose of the components according to your local waste disposal regulations.
Disposal of Packaging:
The packaging for the system should be separated according to type and conveyed to local waste
channels (according to the local waste regulations). The individual packaging components are
labeled and consist primarily of: wood, cardboard, polypropylene and polyethylene films and
styrofoam.
TRANSNORM SYSTEM Sdn. Bhd.
30, Jalan 18,
Taman Sri Kluang
86000 Kluang
Johor Darul Takzim
MALAYSIA
Tel. +60 777 71 917
Fax. +60 777 71 928
e-mail: [email protected]
TRANSNORM SYSTEM GmbH
Förster Straße 2
31177 Harsum
DEUTSCHLAND
Tel. +49 (0) 5127 4020
Fax. +49 (0) 5127 4400
e-mail: [email protected]
TRANSNORM SYSTEM Ltd.
Ashchurch Industrial Estate
Tewkesbury Gloucestershire
GL 20 8TD GREAT BRITAIN
Tel. +44 (0) 1684 29 11 00
Fax. +44 (0) 1684 29 15 50
e-mail: [email protected]
TRANSNORM SYSTEM Inc.
1906 South Great Southwest Parkway
Grand Prairie,
Texas 75051
USA Tel.
Tel +1 972 60 60 303
Fax. +1 972 60 60 768
e-mail: [email protected]
TRANSNORM SYSTEM GmbH
Sportlaan 261
3364 DK Sliedrecht
NIEDERLANDE
Tel. +31 (0) 184 43 31 00
Fax. +31 (0) 184 49 93 71
e-mail: [email protected]