Photo-Eye Accuglide Intermediate Section

Transcription

(Supplemental) Product Manual
Photo-Eye Accuglide
Intermediate Section
Application Guidelines, Specifications,
Installation Procedures, Maintenance, and
Spare Parts
8450 12/03
To contact FKI Logistex, Automation Division:
For service: Customer Service and Support Group (CSSG)
Hotline 1-800-992-1267
On the World Wide Web: www.fkilogistex.com/automation
By mail:
FKI Logistex, Automation Division
10045 International Boulevard
Cincinnati, Ohio 45246
(513) 874-0788
Read this document thoroughly before attempting to perform maintenance or repairs to the applicable
FKI Logistex Automation Division conveyor system components or devices. Exercise extreme caution
when working around moving and rotating conveyor equipment. Wear the proper clothing and safety
equipment. DO NOT attempt to perform any maintenance until the equipment is de-energized, locked
out and tagged out in accordance with established company procedures.
The information presented in this document is correct at the time of publication. FKI Logistex
Automation Division has made every effort to ensure that the information presented is correct and free
from error. However, some errors or misprints may occur. Please contact FKI Logistex, Automation
Division with any corrections.
This document is copyrighted © 2001 by FKI Logistex, Automation Division, all rights reserved. No
Part of this Users Guide may be reproduced and/or distributed to parties other than the customer and
the customer’s employees for whom it was originally produced.
The following terms are trademarks™ of FKI Logistex, Automation Division; Accuglide™, BOSS™
UniSort ™, EZ-set™
Direct questions and comments concerning the information contained in this manual to:
[email protected]
8450 12/03
or
Product Management
FKI Logistex, Automation Division
10045 International Boulevard
Cincinnati, Ohio 45246
(513) 874-0788
Table of Contents
Section A Product Summary
Section B Application Guidelines
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Minimum Product Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Maximum Product Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Product Surface Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Minimum Product Height - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Maximum Product Length - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 1
Sensor Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 2
Sensor Position B - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 2
Sensor Position A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 2
Photo-Eye / Reflector Offset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Frame Type(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Type RSL Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Type RSH Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
B-3
B-4
B-4
B-4
Operational Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Singulation Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Dual-Zone Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Auto-Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Slug Acceptance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
B-5
B-5
B-6
B-7
B-8
B-9
Speed Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 10
Environmental Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B - 10
Section C Specifications
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Intermediate Sections (IS) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Frame(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Widths - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lengths - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Rollers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Roller Centers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Roller Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sensor Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sensor / Reflector Offset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Solenoid Control Modules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Standard Operational Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Optional Operational Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Direction of Travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-1
C-1
C-1
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
C-2
Photo-Eye Sensor w/Reflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Photo-Eye (PE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Led Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Reflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-3
C-3
C-3
C-3
C-3
C-3
C-3
TOC - 1
Table of Contents
Solenoid Control Module (SCM) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Photo-Eye Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power / Communication Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Led Indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Temperature Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-4
C-4
C-4
C-4
C-4
AGP Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Output Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Slug Signal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Led Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Temperature Range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Approval - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C-5
C-5
C-5
C-5
C-5
C-5
C-5
AGP T-Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 6
Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 6
AGP Power Isolation Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 6
Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 6
AGP Slug Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 7
Remote Signal Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 7
Power / Communication Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 7
AGP Slug-Module Connector Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 7
AGP Slug-Termination Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 8
Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 8
AGP Connector Cord(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 8
Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C - 8
Section D Engineering Data
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Step 1 - Determine the Conveyor Width (W) - - - - - - - - - - - - - - - - - - - - - - - - - Step 2 - Calculate the Live Load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Step 3 - Determine the Required Sensor Position - - - - - - - - - - - - - - - - - - - - - Step 4 - Determine the Minimum Conveyor Speed Requirement - - - - - - - - - - Step 5 - Determine the Conveyor Speed - - - - - - - - - - - - - - - - - - - - - - - - - - - Release Rate (RR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Acceptance Rate (AR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Step 6 - Determine the Effective Pull - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
D-1
D-1
D-1
D-1
D-1
D-1
D-1
D-3
D-3
Section E Layout dimensions
Drive, Curve and Idler Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - 1
Intermediate Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - 1
Section F Accessories
TOC - 2
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Table of Contents
Section G Installation Procedures
Accepting Shipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Warning Signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Parts Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Factory Assistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Shipment of Intermediate Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing Intermediate Sections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Drive Section / Intermediate Section Connection - - - - - - - - - - - - - - - - - - - - - Idler Section / Intermediate Section Connection - - - - - - - - - - - - - - - - - - - - - - Intermediate Section / Intermediate Section Connection(s) - - - - - - - - - - - - - - Straight / Curve Intermediate Section Connection(s) - - - - - - - - - - - - - - - - - - - AGP Power Supply Installation / Up to 30 Zones - - - - - - - - - - - - - - - - - - - - - AGP Power Supply Installation / Up to 60 Zones - - - - - - - - - - - - - - - - - - - - - AGP Isolation Cord Installation / Multiple Power Supplies - - - - - - - - - - - - - - - AGP Air-Control Assembly Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
G-1
G-1
G-1
G-2
G-2
G-3
G-3
G-4
G-5
G-6
G-7
G-8
G-9
G-9
G - 10
G - 11
Preliminary Sensor Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SCM Switch Setting for Dual-Zone Operational Mode - - - - - - - - - - - - - - - - - - - - - SCM Switch Setting for Auto-Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Complete Conveyor Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Check Operational Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Singulation Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Dual-Zone Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Auto-Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Slug Operational Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
G - 12
G - 13
G - 14
G - 15
G - 16
G - 17
G - 17
G - 17
G - 18
G - 18
Pre-Startup Conveyor Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 19
Conveyor Start-Up Test Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 20
Personnel Training - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - G - 20
Section H Maintenance Procedures
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Factory Assistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Parts Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Periodic Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
H-1
H-1
H-1
H-1
H-1
H-2
Section I Spare Parts
General Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I - 1
Section J Product Index
Intermediate Section, Accumulation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 1
Intermediate Section, Accumulation, One-Inch Increments - - - - - - - - - - - - - - - - - - J - 1
Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J - 2
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TOC - 3
Table of Contents
TOC - 4
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Product Summary
SECTION A: PRODUCT SUMMARY
Overview:
Accuglide Intermediate Sections with photo-eye sensors are an option to
the mechanical, raised roller sensors. They offer improved sensing of
light weight product and a quieter operation. Unique Solenoid Control
Modules (SCM) control the operational mode of each zone providing
zero-pressure accumulation and maximum product throughput.
CSPS Designation:
B11
Applications:
Transportation with Zero-Pressure Accumulation
Operation Mode:
Singulation - Set at factory
Dual-Zone - Set in field as required
Auto-Slug - Set in field as required
Slug - Set in field as required
Section Widths (W):
16”, 22”, 26”, 34”, 40” W (Between Frame Rail Dimension)
Section Lengths
Standard - 12’-0”, 9’-0”, 6’-0” and 3’-0” (nominal)
Odd lengths available in 1” increments from 3’-1” to 5’-11”.
Zone Length:
3’-0”
Section Frame Type: Type RSH - (Rollers Set High) - 6-3/8” deep rail.
Type RSL - (Rollers Set Low) - 9” deep rail.
Carrier Rollers:
No. G196GH (Greased High-Speed)
No. G196AB (ABEC)
Roller Centers:
2”, 3”, 4” and 6”
Sensor:
24 VDC retro-reflective photo-eye with and without time-Delay (adjustable).
Solenoid Control
Module (SCM)
24VDC, 3-way, normally-closed valve, Micro Connector fo photo-eye
connection; 4-wire Power / Communication Cord; Two (2) switches for
selecting zone’s operational mode.
Power Supply:
110VAC input / 24VDCV output transformer, overload protected. Power
up to 60 zones.
Side Guides:
Type RSH sections require fixed Side Guides (Type A, B, C and D)
Type RSL section rails extend 2-5/16” above rollers. Standard Side
Guides can be bolted to frame’s top flanges.
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A-1
Product Summary
A-2
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Application Guidelines
SECTION B: APPLICATION GUIDELINES
Introduction
The Accuglide Intermediate Sections with photo-eye sensors function and operate in the
same manner as Intermediate Sections with roller sensors. Refer to Product Manual
CS8400, Accuglide™ Live Roller Conveyor, Section B - Application Guidelines for other basic
application information.
The following are guidelines that are unique to the application of the Accuglide “photo-eye”
Intermediate Sections.
Minimum Product Weight
There is no minimum product weight limitation because of the fact that a photo-eye detects
the presence of product when it’s light beam is blocked; not when a moving product of
sufficient weight depresses a raised sensor roller. It is necessary to consider several factors
when conveyor very light items.
1. A light product (less than 2 lbs.) may not convey smoothly as it has a tendency to bounce
around due to conveyor vibration, air currents, etc.
2. A light weight product may stop abruptly when entering a non-powered zone when the
rollers have had time to stop turning. The following product will bump the stopped light
weight product and move it further into the zone.
Maximum Product Weight
The maximum weight is 100 lbs./ft. It will be necessary to consider several weight-related
factors when conveying heavy items.
1. Heavy products may be sluggish in starting-up from a dead-stop when being released
from the accumulation mode. This could effect a conveyor’s release rate.
2. Heavy products will coast further than light loads into a non-powered zone. This may limit
the conveyor’s maximum speed especially when handling a mix of load weights.
Product Surface Characteristics
1. Product surfaces must not reflect the photo-eye light beam and cause sensor error.
2. Product must not be transparent or have openings that would allow the photo-eye light
beam to pass through and cause sensor error.
Minimum Product Height
The minimum product height is officially stated to be 1” to insure that the photo-beam is
adequately blocked.
Maximum Product Length
The maximum product length is limited by the ability of an accumulated product to advance
forward when a zone’s rollers return to the “powered” state. See topic Sensor Positions.
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B-1
Sensor Positions
Sensor Position B
The photo-eyes are mounted 12” (nominal) from the zones they control. Provides the
greatest accumulation density when conveying product that is less than 21” in length (27” if
weight is evenly distributed) and weighing less than 50 lbs.
Figure B - 1 Not Available
Sensor Position A
The photo-eyes are mounted 24” (nominal) from the zones they control. Provides four (4)
additional powered rollers (3” roller centers) for restarting heavy (over 50 lbs.) and/or long
(over 21”-27”) accumulated products.
B-2
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Photo-Eye / Reflector Offset
All sensors have a photo-eye/reflector offset to ensure that the photo-eye’s light-beam is
broken by a product conveying in the associated zone. The standard offset is 2”; a 6” offset is
available which serves the same function as “dual” roller sensors.
6"
6"
2"
2"
Reflector Offsets
Reflector Offsets
12"
Photo Eye Position "B"
12"
Zone
Photo Eye Position "A"
Figure B - 3 Photo-Eye / Reflector Offset
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B-3
Frame Type(s)
The photo-eye Intermediate Sections are available with two types of frames;
•
•
RSL, and
RSH
Select the frame type that is best suited for the application requirement (see Figure B - 4).
Figure B - 4 Frame Types
Type RSL Frame
The frame’s 9” depth provides an integral side-guide with the top of the rollers being 2-5/16”
below the top flange. The channel rail’s solid web has punched openings through which the
photo-eye beam is transmitted to the reflector on the other side of the section. the 1” dia.
openings are flared-out to eliminate any possibility of a product snagging on an opening edge
and causing a jam. Available with fixed or pop-out rollers (frame inserts and shortened
rollers).
If the guide height is sufficient for the application, no additional guards and associated fieldinstallation labor are required. If product height and/or the conveyor’s elevation requires the
use of higher side guides, additional side guides (Type A, B, C or D) and standard, optional
mounting types, can be bolted to the top rail flanges.
Type RSH Frame
The frame’s 6-3/8” depth is standard for all of the company’s powered belt and powered roller
product lines with the top of the rollers 5/16” being above the top flange. Available with fixed
or pop-out rollers (via slots in flanges).
Type RSH frames require that optional side guides be used to protect the photo-eyes and
reflectors as well as contain product on the conveyor.
It is recommended that standard Type A, B, C or D side-guide rails be mounted to the frames
using 1” lg. spacers to provide an opening for the photo-eye and reflector. The space also
allows optional pop-out rollers to lift up and out of their mounting slots.
An alternative is to mount the side guide directly to the frame and create the required
openings in the face of the side guide when installing.
B-4
8450 12/03
Operational Modes
Each zone in an Intermediate Section has a Solenoid Control Module (SCM) with an “X”
switch and an “O” switch that can be set to operate in any of the three primary operational
modes (see Figure B - 5).
•
•
•
Singulation
Dual-Zone
Auto-Slug
The sections are shipped from the factory with the Solenoid Control Module (SCM) in each
3’-0” lg. zone set for Singulation Operational Mode. Any or all of a conveyor’s zones can be
easily changed to operate in any of the other modes when installing or at a later date.
-X-
-O-
OFF
-X-
ON
OFF
ON
Each SCM controls the powered / non-powered state of the rollers in the next rearward
“upstream” zone.
-O-
Switch Settings from Factory
Settings = Singulation
X = "ON"
O = "OFF"
Figure B - 5 Solenoid Control Module with “X” and “O” Mode Selection Switches
Note:
When engineering a conveyor system, it is important that the operational-mode
requirement(s) for each conveyor be shown on the system layout drawing. This will show
the installers what field-changes to the operational mode settings are required.
Singulation Operational Mode
In this mode, products convey along the conveyor with a nominal zone-length gap (3’ +/-)
between the products (or groups of small products). Refer to Section D - Engineering Data topics Acceptance Rate and Release Rate capability.
8450 12/03
B-5
The “powered / non-powered” state of the carrier rollers in Zone A is controlled by its
associated SCMB, located in the adjoining, downstream Zone B. SCMB, with its “X” switch
factory-set to “ON”, responds ONLY to input received from its associated Photo-Eyes (PEB)
(see Figure B - 7).
When an SCM’s “X” switch is set for Singulation Operational Mode, the “O” switch setting
(factory set at “OFF”) has no effect on mode setting.
Dual-Zone Operational Mode
In this mode, groups of products (two zones, nominally 6’ lg.) convey along the conveyor with
a nominal 3’ lg. gap (one zone) between two successive groups. Refer to Section D Engineering Data, topics Acceptance Rate and Release Rate capability.
Like Singulation, the powered / non-powered state of the carrier rollers in Zone A is controlled
by its associated SCMB located in the adjoining, downstream Zone B.
The SCMs for zones requiring the Dual-Zone Operational Mode must have their “X” switch
set to “OFF” and their “O” switch set to “ON”. This causes the SCM to respond to input from
either its associated Photo-Eye (PEB) or from the next downstream zone’s Photo-Eye (PEC)
located in Zone C.
B-6
8450 12/03
Auto-Slug Operational Mode
In this mode, groups of products convey along the conveyor with a nominal 3’ lg. gap
between each group. Each group’s length is dependent on the number of zones contained in
the group (Auto-Slug Zone). Refer to Section D - Engineering Data, topics Acceptance Rate
and Release Rate capability.
Like Singulation, the powered / non-powered state of the rollers in Zone A is controlled by the
associated SCMB located in the adjoining, downstream Zone B (see Figure B - 11).
An Auto-Slug Zone’s first (most downstream) Zone C is operated in Singulation Operational
Mode. The SCMs in Zone B and in all associated upstream zones (the number being
determined by the Auto-Slug Zone’s length) must be switched to the Auto-Slug Operational
Mode and the “X” switch set to “OFF”, and the “O” switch left at its factory-setting “OFF”
position. This causes each SCMA to respond to input from either its associated Photo-Eye
(PBB) or from the next downstream SCMAC.
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B-7
Slug Operational Mode
In this mode, products convey along the conveyor with no gaps being generated to cause
product separation. An entire conveyor, or any defined portion(s) of a conveyor can function
in the Slug Operational Mode. These portion(s) are referred to as Slug-Zones and their length
is defined by the number of 3’ zones included. Refer to Section D - Engineering Data, topics
Acceptance Rate and Release Rate capability.
The powered / non-powered state of the rollers in each 3’-0” lg. zone is controlled by it’s
associated SCM. The zones respond to a “slug-signal” that overrides the operational mode
setting of each SCM (Singulation, Dual-Zone or Auto-Slug) (see Figure B - 13).
When the “slug-signal” is removed, the zones return to the operational mode setting of their
SCM.
The following is additional application information that is intended for individuals responsible
for identifying on system layout drawing(s) slug-zone lengths locations, and required
component.
1. A conveyor may have a Slug-Zone at its discharge end for releasing product onto the
downstream conveyor at the maximum rate for a given speed. It is remotely controlled to
activate when product is required downstream and to deactivate after a specified length
of time or some other criteria.
2. A conveyor may have Slug-Zone(s) at any intermediate point(s) along the length of the
conveyor. They may be manually or remotely controlled to activate / deactivate depending upon the specific application requirement.
B-8
8450 12/03
3. A conveyor may have a Slug-Zone in its infeed end for accepting product from the
upstream conveyor at a maximum rate for a given speed. It is remotely controlled to activate upon arrival of upstream product and to deactivate when a sensor detects that product has accumulated back to a specified point along the conveyor.
4. A conveyor may have multiple Slug-Zones (infeed, intermediate, and/or discharge.
5. Slug-Zones cannot overlap.
6. Each Slug-Zone requires its own controlling slug-signal device.
7. The slug-signal(s) come from standard AGP Power Supply(s), and/or optional AGP Slug
Module(s).
8. The AGP Power Supply(s) and/or AGP Slug Module supplies a slug-signal to a SlugZone when a remote signal is received from the main control panel or a local control
device.
9. An AGP Isolation Cord is required at each end of a Slug-Zone if the Power/Communication Cord supplies power and zone communication signals to other zones.
Slug Acceptance
In applications where it is necessary to receive a surge of product from upstream equipment
(example; an after-sort accumulation line), Accuglide conveyors with mechanical sensors and
pneumatic control logic have been limited to two (2) methods of operation.
1. Method 1 - Operate in “slug” mode for an appropriate length at the conveyor’s infeed end.
2. Method 2 - Operate in a “non-slug” mode at an elevated speed that is sufficient to accommodate the incoming surge.
Both methods provide the capability of accepting high volume product rates from the
upstream conveyor. Both methods also have drawbacks.
Method 1 requires that a number of zones be piped for “slug” operation and controlled by
external control components and logic.
Method 2 requires that the entire conveyor operate at a speed that is higher than what would
normally be required. This results in reduced equipment life and increased noise.
The Photo-Eye Accuglide Intermediate Sections offer an additional “method” for accepting
incoming surges of product.
Setting the conveyor up as a single (full-length) Auto-Slug Zone will cause all incoming
product to convey at a 100% flow rate until they reach the downstream accumulated products
(see Figure B - 14).
When product is required downstream, product will discharge at the Auto-Slug release-rate. If
required, a controlled Slug Zone can be located at the discharge-end of the conveyor. Refer
to Section D - Engineering Data topic Auto-Slug release rates.
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B-9
Speed Selection
Selecting the speed is one of the most critical aspects in engineering an accumulation
conveyor that is part of an overall case-handling system.
While it is desirable to select the slowest speed applicable (to keep the system’s noise level
low and also to keep the equipment cost low), it is important that the selected speed be
capable of meeting the conveyor’s flow-rate requirements. The flow-rate being the number of
“case-feet” that a conveyor will convey per minute at a given speed.
The conveyor’s flow-rate must be equal to:
1. it’s “release-rate” requirement (supplying product to the adjoining downstream conveyor/
equipment at its required flow-rate.
2. it’s “acceptance-rate” requirement (receiving product from the adjoining upstream conveyor/equipment at it’s flow-rate).
Refer to Section D - Engineering Data topics Acceptance Rate and Release Rate
information.
Environmental Conditions
Intermediate Sections with photo-eye sensors perform properly in all temperatures between
+40°F to +140°F. Do not use/apply in wash-down areas.
Avoid environments where dirt, oil, etc. could build up on the photo-eye and reflector and
interfere with their function.
B - 10
8450 12/03
Specifications
SECTION C: SPECIFICATIONS
Intermediate Sections (IS)
Accuglide Intermediate Sections are fully-assembled and shipped in skid-loads. At
installation, they are combined with the appropriate drive, idler and curve sections (if
required) to form a complete conveyor.
Zone 2
Zone 1
Figure C - 1 Intermediate Section (Type RSH 6-3/8” Rail Shown)
Frame(s)
The Intermediate Section(s) are available with two types of frames;
•
Type RSH - 6-3/8” deep x 1-1/4” flange x 10 ga. formed steel channel rails with bolted
crossmembers. Mounting holes/slots for 7/16” hex axles are punched at 1” centers. Rollers extend 5/16” above the top flange.
•
Type RSL (fixed) - 9” deep x 1-1/4” flange x 10 ga. formed steel channel rails with bolted
crossmembers. Mounting holes for 7/16” hex axles are punched at 1” centers. Rollers are
2-5/16” below the top flange. Rails have 1” dia. openings to provide a path for photo-eye’s
light beam to pass. Openings are flared to prevent product from catching.
Widths
16”, 22”, 28”, 34” and 40” W.
Width (W) = dimension Between Frame rails.
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C-1
Specifications
Lengths
The Photo-eye Accuglide Intermediate Section is available in ?????lengths. Actual lengths
are 1/8” less than stated length.
12’-0”, 9’-0”, 6’-0” and 3’-0”; 3’-1” - 5’-11” in 1” increments.
Rollers
•
•
Note:
Standard - No. G196GH (greased, high-speed bearings)
Optional - No. G196AB (ABEC precision bearings)
Rollers are crated and shipped separate from sections.
Roller Centers
2”, 3”, 4” and 6”
Roller Mounting
•
•
Type RSH Frame - Fixed and Pop-Out
Type RSL Frame - Fixed and Pop-Out
Sensors
Refer to topic Photo-Eye Sensor Assembly in this section.
Sensor Positions
Position A - 24” from a zone’s leading edge.
Position B - 12” from a zone’s leading edge.
Sensor / Reflector Offset
•
•
2” offset of photo-eye and reflector (for single-sensor requirements).
6” offset of photo-eye and reflector (for dual-sensor requirements).
Solenoid Control Modules
Refer to topic Solenoid Control Module in this section.
Standard Operational Modes
•
•
•
•
Singulation (factory set)
Dual-Zone (field-set)
Auto-Slug (field-set)
Slug - Refer to topic Power Supply in this section.
Optional Operational Modes
•
Multiple (Separate) Slug Zones - Refer to topic Slug Module in this section.
Direction of Travel
One way.
C-2
8450 12/03
Specifications
Photo-Eye Sensor w/Reflector
Photo Eye Connection
Photo Eye Bracket
24 volt Photo Eye
Solenoid Valve
Figure C - 2 Photo-Eye Sensor w/Reflector
Photo-Eye (PE)
24 VDC, polarized retro-reflective; 16” lg. cord w/male 12mm Micro Connector that attaches
to the female connector on the Solenoid Control Module. Adjustable Time-Delay (0-2
seconds) optional.
Mounting
Protective steel bracket pivots (for photo-eye/reflector alignment), on a formed steel
mounting bracket that bolts to the frame side rail.
Led Indicators
Green: Steady “ON” = Power “ON”; Flashing “ON” = SCM “OVERLOADED”.
Red: Steady “ON” = Reflected Beam Sensed; Flashing “ON” = Marginal Signal
Temperature
-4° to + 158° F (-20° to +70° C)
Range
3m (10 ft.)
Reflector
Clear, precision-molded reflector attached to formed mounting bracket that bolts to frame rail.
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C-3
Specifications
Solenoid Control Module (SCM)
-X-
-O-
OFF
-X-
ON
OFF
ON
24 VDC solenoid-actuated, normally-closed, 3-way valve; w/molded output and exhaust barb
fittings (5/32” ID tubing); molded air supply barb fittings (1/2” dia. tubing); air flow rate @ 20
psi - 0.8 CFM; current - 69.5 mA; NEMA Type 2 enclosure. Two (2) off-on switches for
selecting zones operational mode. Factory-set for “Singulation Operational Mode”.
-O-
Switch Settings from Factory
Settings = Singulation
X = "ON"
O = "OFF"
Figure C - 3 Solenoid Control Module (SCM)
Photo-Eye Connection
12mm Female Micro Connector.
Power / Communication Cord
4 Conductor cord w/yellow PVC jacket; secured on one end to enclosure, other end 12mm
male Micro Connector; cord length allows connection to next zone’s SCM (at 3’ centers).
Led Indicator
Visible from inside the frame. Green: Steady “ON” = Solenoid valve actuated.
Temperature Range
-4° to +158° F (-20° to +70° C)
Figure C - 4 Not Available
C-4
8450 12/03
Specifications
AGP Power Supply
110VAC/24VDC Transformer; 3.7 amp Output Current; 10W Output Power; On/Off Switch;
Short-circuit, Overload and over voltage protection with reset; Die-cast (NEMA 1) aluminum
enclosure with conduit connection. Provides power to series of 30 zones or to two (2) series
of 30 each.
Output Connection
12mm Micro Connector (male).
Slug Signal
Unit generates a slug-signal through output connection. Internal 8 screw terminal block for
connecting to a remote signal (24VDC or 110VAC).
Led Indicators
Visible from front of unit. Red: “ON” = 120VAC input. Green: “ON” = 24VDC output.
Mounting
Unit has provision (1/4” mounting hardware - non included) for mounting at required location
on conveyor frame or other appropriate structure.
Temperature Range
32° to + _ ° F (0° to + 55° C).
Approval
UL Approved/Label
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C-5
Specifications
AGP T-Cord
The AGP T-Cord connects the AGP Power Supply to a Power / Communication Cord at any
intermediate point. 4-wire cord (with Yellow PVC jacket) with “T” connection introduces
24VDC power and slug-signal (if required) while allowing inter-zone communication signals
to pass between to adjoining zones.
Connectors
12mm Micro Connector; female connector (L) connects to AGP Power Supply and male (B)/
female (L) connectors connect to adjoining zones’ SCMs
AGP Power Isolation Cord
3-wire cord (2’-0” lg.) w/Yellow PVC jacket, isolates parallel power signals of two (2) power
sources. 3-wire cord (with Yellow PVC jacket) allows all communication signals to pass
between two adjoining zones.
Connectors
12mm Micro Connector; male and female.
C-6
8450 12/03
Specifications
AGP Slug Module
24VDC switching device that introduces a slug-signal into the Power/Communication Cord.
This can be installed into any zone within a group of zones (200 max.) requiring Slug
Operational Mode. NEMA type 2 enclosure.
Remote Signal Connection
12mm Female Micro Connector.
Power / Communication Cord
4 line Conductor cord (_” lg.) with 12mm male/female Micro Connectors.
AGP Slug-Module Connector Cord
Connects AGP Slug Module and remote 24VDC control device; 4-wire cord (6’-6” lg. with
Yellow PVC jacket); 12mm male Micro Connector (one end), for two (2) wires leads (other
end).
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C-7
Specifications
AGP Slug-Termination Cord
3-wire cord (5” lg.) w/Yellow PVC jacket, terminates the slug-signal while allowing power and
communication signals to pass between two adjoining zones while SCM.
Connectors
AGP Connector Cord(s)
4-wire cord w/Yellow PVC jacket, transmits all power (24VDC), inter-zone communication
signals (including slug). Lengths available: 1’-0”, 2’0”, 3’-0”, 6’-0”, 9’-0” and 12’-0”.
Connectors
C-8
8450 12/03
Engineering Data
SECTION D: ENGINEERING DATA
Introduction
The application engineering process for an Accuglide conveyor with Intermediate Sections
featuring photo-eye sensors, is no different than that of a conveyor with intermediate sections
with roller sensors. The process is documented in Product Manual CS8400, Accuglide™ Live
Roller - Section D Engineering Data.
The following are all of the steps that will ned to be followed for photo-eye sensors. Those
steps that are covered in Product Manual CS8400 Accuglide™ Live Roller will reference the
user to that manual; new steps that are specific to the photo-eye sensors and Solenoid
Control Modules will be fully covered below.
Step 1 - Determine the Conveyor Width (W)
Refer to Product Manual CS8400 Accuglide™ Live Roller - Section D Engineering Data.
Step 2 - Calculate the Live Load
Step 3 - Determine the Required Sensor Position
Refer to Section B Application Guidelines.
Step 4 - Determine the Minimum Conveyor Speed Requirement
Step 5 - Determine the Conveyor Speed
A conveyor’s speed (fpm) must meet the infeed and discharge rate requirements of the
system. These requirements can be defined as Flow Rate (FR).
FR = Case Feet Per Minute (cfpm) = No. of Cases / Minute (max.) X Length (Avg)
The conveyor must have a release rate capability that is equal to or greater than the system’s
discharge rate requirement. It must also have an acceptance rate capability that is equal to or
greater than the system’s infeed rate requirement.
Release Rate (RR)
The Release-Rate (RR) is the flow-rate (cfpm) at which accumulated products release (startup) and discharge onto the adjoining downsteam conveyor or piece of equipment. RR is
dependent upon the conveyor’s speed, operational mode, sensor position, reflector offset
and the condition of the products’ roller contact surface.
Required (RR) Speed =
Required Discharge Flow Rate (CFPM)
RR Factor
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D-1
Engineering Data
Table D - 1 RR Factor
Operational Mode
Conveyor Speed (FPM)
60
90
120
150
180
240
Singulation*
Singulation**
.52
.63
.54
.62
.51
.62
.49
.61
.48
.59
.42
.48
Dual Zone***
.66
.66
.66
.66
.66
.66
Auto-Slug (4 zone)*
Auto-Slug (3 zone)*
Auto-Slug (2 zone)*
.65
.67
.58
.70
.66
.65
.74
.70
.64
.75
.70
.66
.75
.69
.63
.71
.64
.57
Slug****
.90
.90
.90
.90
.90
.90
*
RR factors are based on testing using uniform 12” lg. corrugated cartons weighing approx. 25
lbs. that were acculuated at 100% desnsity.
**
24” lg. cartons.
*** RR factors are estimated on the basis of 2 out of 3 zones always being power. (Actual rates may
vary).
**** RR factors historically used.
To account for the effects of product weight upon the conveyor’s RR capability, factor the RR
by the appropriate LLCF (below).
Table D - 2 Live Load Correction Factor (LLCF)
Product Weight From - To
LLCF
D-2
0 - 25 lbs.
25 - 35 lbs.
35 - 50 lbs.
50 - 100 lbs.
1.00
0.95
0.90
0.85
8450 12/03
Engineering Data
Acceptance Rate (AR)
The Acceptance-Rate (AR) is the flow-rate (cfpm) at which products received from adjoining
upstream equipment will continue to convey along a conveyor until they reach the constantly
changing (increasing / decreasing) product accumulation area. A conveyor’s AR is
dependent upon its speed, operational mode, sensor position, reflector offset and the
condition of the products’ roller contacting surface.
For all operational modes, the AR is equal to or slightly greater than the RR (for the same
speed). The slight increase is due to the fact that incoming products are in motion and do not
have to be brought up to speed from a stopped condition.
Required (AR) Speed =
Required Infeed Flow Rate (CFPM)
AR Factor
Table D - 3 AR Factor
Operational Mode
Conveyor Speed (FPM)
60
90
120
150
180
240
Singulation* (12”)
Singulation* (24”)
.52
.63
.54
.62
.51
.62
.49
.61
.48
.59
.42
.48
Dual Zone*
.66
.66
.66
.66
.66
.66
Auto-Slug (4 zone)*
Auto-Slug (3 zone)*
Auto-Slug (2 zone)*
.65
.67
.58
.70
.66
.65
.74
.70
.64
.75
.70
.66
.75
.69
.63
.71
.64
.57
Slug**
Auto-Slug***
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
*
**
***
RR factors shown; actual AR factors will be equal to or better.
AR factors historically used.
AR factors based on conveyor functioning as a single auto-slug zone.
Having determined the speeds based on Release Rate and Acceptance Rate requirements.
Use the higher speed.
Standard Speed Selection - The selected speed is “actual” speed requirement. It will be
necessary to select the next hgher standard speed.
Step 6 - Determine the Effective Pull
8450 12/03
D-3
Engineering Data
D-4
8450 12/03
Layout Dimensions
SECTION E: LAYOUT DIMENSIONS
Drive, Curve and Idler Sections
Refer to Product Manual CS8400, Accuglide™ Live Roller - Section E Layout Dimensions.
Intermediate Sections
"L"
"W"
"W"+ 2 1/2"
36" Zone
Figure E - 1 Intermediate Sections (w/Photo-Eye Sensor Option)
8450 12/03
E-1
Layout Dimensions
E-2
8450 12/03
Accesories
SECTION F: ACCESSORIES
Some or all of the following Accessory components are required in addition to the basic
Intermediate Section(s) (with photo-eye sensor option) for connecting the sections to
standard Accuglide Drive, Idler and Curve Sections. They should be requisitioned when
cover-sheeting a conveyor.
AGP Drive/Idler Piping Kit Kit includes required tubing and air-line connector fittings
required for connecting the ¼” dia. air lines located in the
Accuglide Drive Section and Idler Section to the ½” dia. main
air supply line that is supplied in the intermediate sections.
(One kit required per conveyor)
AGP air Control Assembly Filter/Regulator/Gage assembly with required tubing and airKit
line connector fittings required for piping the assembly into the
1/2” dia. main air-supply line that is supplied in the intermediate sections. (Refer to Product Manual CS8400, Section G
Installation Procedures, topic Connecting the Filter Regulator
for information regarding the number of assemblies required
and their preferred location.)
AGP Power Supply
Power transformer (110VAC input / 24VDC output) provides
power to a maximum of 60 zones. Must be mounted to the
conveyor or other structure at time of installation.
AGP Connector Cord
Power/Communication cord (4-wire with male/female Micro
(Euro) Connectors) that connects the power supply to the
Solenoid Control Module in the first zone at the conveyor’s
infeed end. For conveyors with a maximum of 30 zones that
are connected together in a daisy-chain. Select cord length (1’,
2’, 3’, 6’, 9’ and 12’) to meet the power unit’s mounting location
requirement.
AGP T-Cord
Power/Communication cord (4-wire with male/female Micro
(Euro) Connectors) that connects the power supply to the conveyor’s 4-wire power/communication cord at any intermeidate
point. Do not exceed 30 zones on either side of the cord connection (60 zones max.). Use an AGP Connector Cord to
extend the cord’s 2 meter trunk-length to meet the power supply’s mounting location 6’-0” requirement.
AGP Power Isolation Cord Communication cord (3-wire with male/female Micro (Euro)
Connectors) that is required when a conveyor has more than
one power supply. Cord isolates parallel power supplies while
passing communication signals.
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F-1
Accessories
AGP Slug-Module
Electronic module (with male/female Micro (Euro) Connectors)
that introduces a “slug” signal to the power/communication
cord’s 4th (slug-release) wire. The slug signal causes all SCMs
that are linked through the Power/Communication cord to actuate their air valve and supply air to their associated zones. May
be installed at any point within a portion of conveyor that
requires “slug-release”. One module can support up to 200
zones.
(Note: The Power Supply has the same ability to supply a
“slug-signal” to the Power/Communication Cord.
AGP Slug-Module Connec- Power cord (with male Micro (Euro) Connector one end and 2tor Cord
wire leads other end) that connects AGP Slug-Start Module to
remote 24VDC signal.
AGP Slug-Termination
Cord
Power/Communication cord (5” lg., 3-wire with male/female
Micro-connectors) that terminates the slug-release signal. Isolates a slug-release portion of a conveyor from portion(s) not
requiring slug-release. Cord terminates “slug-release signal”
while passing along power and communication signals. Not
required if a slug-release is supplied to a conveyor’s entire
length. Two (2) cords required if slug-release is required in a
central portion of the conveyor between two non-slug-release
portions.
AGP CRV Air Line and
Cord
Required if conveyor includes an Accuglide Curve Section.
Includes all necessary components for extending air line(s)
and electrical cord through the curve section and connecting to
the adjoining “upstream” and “downstream” AGP Accuglide
Intermediate Sections. Refer to Table F - 1 to determine component length required (based on the curve’s arc, width and
frame type.
Brake Modules (Curve)
Field Kit; Spring-set, air-released braking device; mounted in
first accumulation zone upstream of curve section at time of
installation. Prevents product from entering a curve when
downstream intermediate sections are full with accumulating
product. Requires signal from downstream sensing device.
Refer to Table F - 2 for kit information
Brake Modules (Intermedi- Spring-set, air-released braking device; mounted in any accuate)
mulation zone along the length of conveyor. Requires remote
signal. Refer to Table F.3 for kit information
AGP Guide Spacer Kit
F-2
(Required when using Type RSH intermediate section frames.)
Includes (10) 1” lg. hex spacers and (20) 3/8” X 3/4” lg. hex
head bolts (with flat & lock washers). Provides 1” spacing
between drive/idler/curve section frame rails and their side
guides to match the spacing in the intermediate sections. (1)
Kit required for drive and idler sections; and (1) kit required for
curve sections (if applicable).
8450 12/03
Accesories
AGP Air Components Kit
An assortment of “extra” parts for use when installing an AGP
Accuglide conveyor/system. Kit includes:
• (50’) Red, 1/2” I.D. tubing (main air-supply line)
• (50’) Yellow, 5/32” O.D tubing
• (2) Solenoid Control Module
• (2) Photo-eye Sensors (24VDC – with Time-Delay or w/o
Time-Delay)
• (10) 1/4” O.D. X 5/32” I.D. tube connector fittings
• (10) 1/4” O.D. X 5/32” I.D. tube Tee connector fittings
• (5) 1/2” X 1/2” X 1/2” O.D. tube connector fittings (push-toconnect)
• (5) 1/2” X 1/2” O.D. tube connector fittings (push-to-connect)
• (5) 1/2” X 3/8” O.D. tube adapter fittings (push-to-connect)
• (5) 1/2” X 1/4” O.D. tube adapter fittings (push-to-connect)
• (5) Plug – for 1/2” connector fitting (push-to-connect)
• (6) Air Actuators (with single air inlet port)
• Air Actuators (with dual air inlet ports)
AGP Side Guide Transitions*
For transitioning from Type RSL frames or Type RSH frames
(with Type B, C or D side guide rails) to adjoining conveyors
with Type B, C or D side guide rails and (bolted to frame) Type
A mounting. Supplied in pairs; 6’-0” and 3’-0” lengths. Transitions are bolted directly to top flanges of drive/idler section
frame rails.
For Type RSH Intermediate Section Frames
• 3-5/8” – 2-5/8”
• 3-5/8” – 7”
• 3-5/8” – 10”
• 8” – 7”
• 8” – 10”
• 11” – 10”
For Type RSL Intermediate Section Frames
• 2-5/8” – 7”
• 2-5/8” – 10”
• 7” – 10”
* These transitions are engineered and made standard upon
receipt of first order.
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F-3
Accessories
Table F - 1 AGP-CRV Air Line and Cord Length Requirement
Curve Section - Arc / Width / Frame Type
Arc
90°
60°
45°
30°
180°
16” W
26IR
22” W
TTF
9’
6’
6’
6’
13’
28” W
34” W - 40” W
26IR
TTF
26IR
TTF
26IR
TTF
9’
6’
6’
6’
13’
9’
9’
6’
6’
15’
9’
6’
6’
6’
13’
12’
9’
9’
6’
18’
9’
6’
6’
6’
13’
12’
9’
9’
6’
21’
Table F - 2 Brake Modules - Curve
Field Kit
Name / Description
Release-Mode of Downstream
Control Signal Medium From
Downstream Source
AGP FK-BM Sing CRV-Air Control
AGP FK-BM Auto CRV-Air Control
AGP FK-BM CRV-Solenoid 120V
AGP FK-BM CRV-Solenoid 24V
Singulation
Air
Auto-Slug
Air
Singulation / Auto-Slug
Singulation / Auto-slug
120 VAC
24 VDC
Table F - 3 Brake Modules - Intermediate
Field Kit
Name / Description
AGP FK-BM IS-Solenoid 120V
AGP FK-BM IS-Solenoid 24V
F-4
Release-Mode of Intermediate
Section
Control Signal medium From
Remote Source
Singulation / Auto-Slug
Singulation / Auto-slug
120 VAC
24 VDC
8450 12/03
Intallation Procedures
SECTION G: INSTALLATION PROCEDURES
Accepting Shipment
For instructions on accepting shipment, see “Accepting Shipment” in “Section D – How To
Use The Shipping List Summary,” Product Manual number 1200, Order Acknowledgement
Manual.
Warning Signs
Do not remove, paint over, or alter at any time the warning signs or labels posted on or near
the conveyor equipment. Regularly test all safety devices, warning lights, and alarms
associated with the conveyor system for proper operation and service as needed. If the
original safety items become defective or damaged, refer to the conveyor parts lists or billsof-materials for replacement part numbers.
Safety Instructions
•
•
•
•
•
•
•
•
Turn off conveyor power sources and affix appropriate lock-out and tag-out devices to
operating controls before servicing the equipment. Only trained and qualified personnel
who are aware of the safety hazards should perform equipment adjustments or required
maintenance while the conveyor is in operation.
Observe all warning signs, lights, and alarms associated with the conveyor operation and
maintenance, and be alert at all times to automatic operations of adjacent equipment.
Exercise extreme caution near moving conveyor parts to avoid the hazard of hands, hair,
and clothing being caught.
Do not sit on, stand on, walk, ride, or cross (over or under) the conveyor at any time
except where suitable catwalks, gates, or bridges are provided for personnel travel.
Do not attempt to repair any equipment while the conveyor is running, replace any conveyor component without appropriate replacement parts, or modify the conveyor system
without prior approval by the manufacturer.
Do not operate the conveyor until all safety guards are securely in place, all tools and
non-product materials are removed from or near the conveying surfaces, and all personnel are in safe positions.
Do not remove or modify any safety devices provided on or with the conveyor.
Do not clear jams or reach into any unit before first turning off the equipment power
sources and affixing appropriate lock-out and tag-out devices.
CAUTION: There is a risk of injury with the roller conveyors with trapped rollers. Turn off conveyors
before handling product or servicing. Limit access to maintenance personnel.
Note:
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Some live roller conveyors are designed to allow the carrier rollers to pop out should some
object accidentally become caught between the carrier roller and the drive belt. This
feature is required whenever the conveyor is installed in an area that is readily accessible
to general plant personnel. However, when the conveyor is installed overhead, take
provisions to prevent this feature from becoming a hazard to personnel below (due to
falling rollers). Use the following guidelines to properly install the conveyors.
G-1
Installation Procedures
•
•
•
•
•
•
For conveyors not installed overhead (below 8’-0” elevation):
All carrier rollers must be free to pop out (an exception to this is the carrier rollers installed
at 2” centers).
For conveyors installed overhead (8’-0” or higher) with no access (no catwalk, walkway,
platform, etc.):
Prevent carrier rollers from falling on personnel below. If the side guides are mounted
directly to the side rails (such as arrangements “A” and “C”), then the side guide serves to
trap the rollers in place.
For conveyors mounted overhead (8’-0” or higher), but accessible to operators by a platform:
Carrier rollers must be free to “pop out” as described above (assuming conveyors are
less than 8’-0” above platform). However, if the platform does not provide a surface which
would suffice as a spill guard, then provide a spill guard. The spill guard must protect
personnel below from carrier rollers that may “pop out” of the frame.
For conveyors installed overhead (8’-0” or higher), but accessible by catwalk or walkways:
Prevent carrier rollers from falling on personnel below. Do not consider the walkways or
catwalks to be operator platforms, but post signs limiting access to maintenance
personnel. The signs must also warn against the danger of pinch points caused by
trapped rollers. In addition, provide an emergency stop pull cord for stopping the
conveyor while clearing jams or performing maintenance.
For all conveyors installed overhead:
Provide spill guards if product may fall off the conveyor for any reason and if personnel
would be endangered. In any overhead installation, if the conveyed material is likely to fall
(i.e., loose bottles in trays, poorly packaged products, etc.), install spill guards where the
conveyor is above aisles or work spaces.
For conveyors mounted overhead:
If the conveyor is mounted overhead, additional guarding is recommended to prevent
injury
Parts Replacement
To minimize production downtime, selected conveyor spare parts should be stocked for
replacement of defective components when required. Refer to the equipment bill(s)-ofmaterials where quantity requirements or code numbers are not indicated on the conveyor
parts list. For added convenience, a list of selected spare parts for standard products is
included in this manual (see Section I).
Factory Assistance
Contact Customer Service for installation, operation, or maintenance assistance, or
replacement parts.
G-2
8450 12/03
Installing the Conveyor
Before starting installation, remove any shipping braces and filler blocks, and check the
alignment of the frames. Corner-to-corner diagonal frame measurements of each section
should be equal with 1/16”.
For general information installing conveyors, floor supports, and ceiling hangers, see Product
Manual 5310, Floor Supports & Ceiling Hangers.
Shipment of Intermediate Sections
Photo-eye Accuglide includes eight (8) Intermediate sections stacked on wooden skids and
shipped. A base section will be secured to a wooden skid. Each additional section will be
bolted to the top flanges of the section below. Protective boards are secured to protect the
top and sides of the sections.
The Type RSH sections (6 3/8” deep rails with rollers set high) will use 1” long spaces to
separate one section from the one below (see Figure G - 1).
CAUTION: When unstacking these sections, be careful not to damage the factory-installed and
adjusted photo-eye and reflector assemblies. DO NOT discard the spacers and
mounting bolts, etc.
•
•
•
•
•
8450 12/03
Make sure that the skidded sections are right-side up.
Remove the top and side crating members.
Unfasten the mounting hardware and remove each section from the stack.
For Type RSH sections, remove the bolts that attach the top section’s bottom flanges to
the spacers that are also attached to the lower section’s top flanges. DO NOT discard
these bolts, etc., they will be used later when installing side guides. DO NOT unfasten the
bolts that attach the spacers to the top flanges of the next lower section. The spacers will
provide a 1” spacing between the side guide and the frame rail that provides an opening
for the photo-eye’s light beam to pass.
Repeat the preceding steps as necessary until all the sections are removed from the
stack.
G-3
Photo-Eye Bracket
Reflector Bracket
Spacer
Pallet
Figure G - 1 Stacked Type RSL Intermediate Sections with 1” Spacers
Installing Intermediate Sections
The installation and mechanical assembly of the Photo-Eye Intermediate Sections is the
same as sections with mechanical roller sensors, refer to Product Manual 8400 Accuglide™
Live Roller - Section G - Installation Procedures.
G-4
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Drive Section / Intermediate Section Connection
Note:
A Drive/Idler Piping Kit (P/N - 004770) is required when connecting the Accuglide Drive
and Idler Sections to the Photo-Eye Intermediate Sections.
Use the following steps to connect the drive section and intermediate section:
1. Connect the red, 1/2” dia. main air supply line (1) to the yellow, 1/4” dia. chain-lubricator
air supply line (2) using a 1/2” - 1/4” Reducer Fitting (3) and a 1/2” - 1/2” Connector Fitting
(4).
2. Connect the yellow, 1/4” dia. air line (5) that is connected to the outlet port of the Intermediate Section’s solenoid control Module (SCM) (6) in the first zone to barb fitting of first
diaphragm (7) in the Drive Section.
1/4" Yellow Tubing Supply to Oiler
1/4" to 1/2" Push to Conn Reducer
1/2" Push to Conn Fitting
1/2" Red Tubing
to Solenoid Valve
Solenoid Valve
Drive Section
Figure G - 2 Drive Section / Intermediate Section Connection
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G-5
Idler Section / Intermediate Section Connection
Note:
A Drive/Idler Piping Kit (P/N - 004770) is required when connecting the Accuglide Drive
and Idler Sections to the Photo-Eye Intermediate Sections.
Use the following steps to connect the idler section and intermediate section:
1. Connect one end of the red, 1/2” dia. tubing (1) (provided in the Drive/idler Piping Kit) to
the air supply port of the intermediate section’s first Solenoid control Module (SCM) (2).
2. Using a 1/2” - 1/2” Connector Fitting 93) and a 1/2” - 1/4” Reduction Fitting (4), connect
the other end of the red tubing 91) to the free end of the yellow, 1/4” air line (5) that is connected to the Idler Section’s Discharge Zone Control Valve (6).
3. Connect the free end of the yellow, 1/4” dia. air line (7) that is attached to the Idler Section’s air actuator to the first air actuator (8) in the adjoining intermediate section.
1/2" Red Tubing
1/2" Push to Conn Fitting
1/4" to 1/2" Push to
Conn Reducer
1/4" Yellow Tubing
To Control Valve
Discharge Zone
Control Valve
Tail Section
1/4" Yellow Tubing
To Tail Diaphragm
Figure G - 3 Idler Section / Intermediate Section Connection
G-6
8450 12/03
Intermediate Section / Intermediate Section Connection(s)
Use the following steps to connect one intermediate section to another intermediate section:
1. Connect the free end of the red, 1/2” dia. main air supply line (1) that is connected to
Solenoid Control Module (SCM) (2a) to the air port of SCM (2b).
2. Connect the free end of the yellow, 1/4” air line (3) that is connected to SCM (2a) to the
first air actuator (4) in the adjoining intermediate section.
3. Connect the free end of the yellow power/communication cord (5) (connected to SCM
(2b) to the SCM (2a) using the male/female Micro-connector fittings.
1/4" Yellow Tubing
1/2" Red Tubing
Power Cable
Solenoid Valve
Intermediate
Sections
Figure G - 4 Intermediate Section / Intermediate Section Connections
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G-7
Straight / Curve Intermediate Section Connection(s)
Note:
An AGP CRV Air Line and Cord Kit is required when connecting straight and curve
Intermediate Sections. The kit’s part number is dependent on the curve section being
installed.
1.
Route (a) the red, 1/2” dia. tubing (1); and (b) the yellow power/communication cord* (2)
through the curve section’s crossmembers.
(*) Note: Orient the cord so that it’s female Micro-connector fitting is located at the
upstream end of the curve section and the male connector is located at the downstream
end.
2. Connect both ends of the red tubing (1) to the air supply fittings of SCM (3a & 3b).
3. Connect one end of the curve section’s yellow, 1/4” dia. tubing (4) to the barb fitting of the
first air actuator (5) in the upstream straight section; and using a 1/4” – 1/4” connector fitting (not shown in Figure G - 5) connect the tubing’s other end to the yellow, 1/4” dia. tubing that is shipped coiled and connected to the downstream Solenoid Control Module
(3a).
4. Connect the yellow, power/communication cord (2) to the Micro-connector fittings of SCM
(3a & 3b).
1/2" Red Tubing
Yellow Extension Cable
Curve Section
1/4" Yellow Tubing
Figure G - 5 Straight / Curve Intermediate Section Connection
G-8
8450 12/03
AGP Power Supply Installation / Up to 30 Zones
An AGP Power Supply transformer (24VDC) can power up to 30 zones (max.) that are
connected in single series. An AGP Connector Cord connects the transformer to the SCM in
the conveyor’s most rearward, upstream zone.
Note:
Check the Connector cord’s length. The connector cords are available in lengths up to 12’
and supplied as specified for the conveyor being installed.
1. Mount the AGP Power Supply (1) to any appropriate structure within reach of the AGP
Connector Cord supplied.
2. Connect the AGP Connector Cord’s female Micro-Connector (2) to the AGP Power Supply’s male Micro-Connector (3).
3. Connect the cord’s other end (with male Micro-Connector) to the SCM’s female MicroConnector (4).
4. Wire the 110VAC power source to the AGP Power Supply’s internal connector strip.
Figure G - 6 Not Available
AGP Power Supply Installation / Up to 60 Zones
Using an AGP T-Cord, the AGP Power Supply can be connected to the Power/
Communication Cord at any intermediate point along a conveyor’s length and provide power
to 60 zones (max.). DO NOT exceed 30 zones on either side of the “T” connection.
1. Determine the zone in which the AGP Power Supply is to be connected.
2. Mount the AGP Power Supply (1) to an appropriate structure within reach of the AGP TCord (2).
3. Connect the AGP T-Cord’s long leg (with male Micro-Connector) to the AGP Power Supply’s female Micro-Connector (3).
4. Connect the AGP T-Cord’s two (2) short lengths to the appropriate Micro-Connectors of
the upstream SCM (4) and the downstream SCM (5).
5. Wire the 110VAC power source to the AGP Power Supply’s internal connector strip.
8450 12/03
G-9
AGP Isolation Cord Installation / Multiple Power Supplies
When two or more AGP Power Supplies are supplied, the AGP Isolation Cords are required
to separate a series powered by one source (30 zones max.) from the adjoining series (30
zones max.) powered by second source. The AGP Isolation Cord isolates the power of the
two sources while allowing communication signals to pass through between adjoining zones.
1. Locate the zone in which an AGP Isolation Cord (1) is to be installed.
2. Connect the cord’s male Micro-Connectors to the downstream SCM’s female Micro-Connector (2).
3. Connect the cord’s female Micro-Connector to the male Micro-Connector of the upstream
SCM’s power/communication cord.
Solenoid Valve
Slug Terminator
Solenoid Valve
Slug Module
Figure G - 8 AGP Isolation Cord Connection for Multi-Power Supply Installation
G - 10
8450 12/03
AGP Air-Control Assembly Installation
Note:
An AGP Air-Control Assembly Kit contains the air-filter/regulator/gage and mounting
bracket (FRG) and the necessary air lines and connector fittings required to pipe the
assembly into the conveyor’s main air-supply line.
Use the following steps to install the AGP Air-Control Assembly:
1. Mount the FRG (1) to the conveyor or other convenient structure near the location(s)
specified on the System Layout Drawing.
2. Cut the conveyor’s red, 1/2” dia. air supply line tubing in the specified zone(s), connect
the T-Connector Fitting (2) to the cut ends.
3. Connect the FRG to the T-Connector Fitting (2) using a 3/8” dia. tubing (3) and a 3/8” X 1/
2” Reducer Fitting (4).
4. When a conveyor requires two (2) or more FRG assemblies, it is necessary to separate
the parallel supplies.
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G - 11
Preliminary Sensor Testing
Conducting the preliminary testing of the sensors is most easily accomplished at this point if
system power and air are available and hooked up. If they are not available, continue with the
conveyor installation steps identified in Product Manual 8400 Accuglide™ Live Roller Section
G Installation Procedures.
1. Turn-ON:
• the air and adjust the air-pressure regulator to 15 PSI;
• the main power source (110 VAC); and
• the AGP Power Supply (24VDC).
2. Starting at the zone closest to the power supply, check each (non-blocked) photo-eye and
determine that its green LED indicator is “on-steady”; indicating that: a) the eye’s associated SCM is receiving power and functioning properly; and b) the photo-eye is receiving
power.
If a photo-eye’s green LED is NOT “on-steady”, then it is: a) not receiving power; or b)
defective.
• Check that the main power source and the conveyor’s power supply(s) are properly
wired, connected and turned on.
• Check that the Connector Cord / T-Cord is securely connected to the power supply and
the first zone’s SCM.
• Check that the Power/Communication Cords are securely connected to their adjoining
SCMs.
• Check that the photo-eye’s Micro-Connector is securely connected to the SCM.
• Disconnect the photo-eye from the SCM and connect a reference photo-eye that is
known to be “good”.
- If the green LED of the reference photo-eye is “on-steady”, the original photo-eye is
defective. Replace the photo-eye.
- If the green LED of the reference photo-eye is NOT “on-steady”, the associated
SCM is defective. Replace the SCM.
3. If a green LED is “flashing”, the output is overloaded; generally this indicates that the
associated SCM is drawing too much current and needs to be replaced.
4. Check each photo-eye and determine that its red LED indicator is “on-steady”; indicating
that: a) the photo-eye is properly aligned with its associated reflector (located on the other
side of the conveyor); b) the photo-eye lens is clean; and c) the reflector is clean and not
damaged.
• Check and adjust the photo-eye/reflector alignment.
• Check and clean photo-eye lens and associated reflector.
• Check and replaced damaged reflector.
G - 12
8450 12/03
5. Check each SCM and determine that its red LED indicator is “on-steady”, indicating that
that the solenoid-valve has been actuated and air should be inflating the associated
zone’s air-actuators.
Note:
If a SCM’s red LED is “on-steady”, but the associated zone’s air-actuators are not being
inflated, then: 1) there is insufficient air; or 2) the SCM’s solenoid-valve is not actuating.
• Check that: 1) there are no faulty air line connections; 2) the air-supply is turned-on; and
3) the air-regulator is adjusted properly.
• If the SCM is properly supplied with air, then the it’s solenoid-valve is not actuating. The
SCM is defective and must be replaced.
Note:
If a SCM’s red LED is NOT “on-steady”, but the associated zone’s air-actuators are being
inflated, then the SCM is functioning properly, but it’s red LED is defective. The SCM may
be replaced.
When the Preliminary Sensor Testing is complete, proceed to make any required changes to
the SCM operational-mode settings.
SCM Switch Setting for Dual-Zone Operational Mode
When required, use the following steps to switch a SCM to Dual-Zone Operational Mode.
1. Determine the zones that are to operate in Dual-Zone Operational Mode.
2. Set each SCM’s “X/O” switch(s) as follows:
• X = OFF
• O = ON
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G - 13
SCM Switch Setting for Auto-Slug Operational Mode
When required, use the following steps to switch a SCM to Auto-Slug Operational Mode.
1. Determine the desired AUTO-SLUG ZONE length(s). An Auto-Slug Zone’s length is
defined by number of individual 3’-0” lg. zones that are set to operate in the Auto-Slug
Operational Mode. The number of zones can range from two (2) to a maximum of the
entire conveyor length.
2. An Auto-Slug Zone’s first (downstream) zone is left in the factory-set Singulation Operational Mode. It’s associated SCM switch settings are: “X” = ON; “O” = OFF.
3. The second (and all additional upstream zones) are set to the Auto-Slug Operational
mode. Set each SCM’s “X/O” switch(s) as shown below.
4. Repeat steps 2 and 3 for each Auto-Slug Zone.
3' Zone
3' Zone
3' Zone
OFF
-X-
ON
OFF
-O-
ON
Switch Setting
X=On O=Off
OFF
-X-
ON
OFF
-O-
ON
Switch Setting
X=Off O=Off
OFF
-X-
ON
OFF
-O-
ON
Switch Setting
X=Off O=Off
OFF
-X-
ON
OFF
ON
Switch Setting
X=Off O=Off
-O-
3' Zone
Auto-Slug Intermediate Section
Drive Section
Intermediate Sections
Idler Section
Figure G - 11 SCM (Left-Hand Assembly Shown) and Auto-Slug Operational Mode Switch Settings
G - 14
8450 12/03
When required, use the following steps to install Slug Operational Mode.
Refer to the system layout drawing to: 1) identify each Slug-Zone’s “slug-signal” control
device and its location; and 2) identify the exact zones in which each Slug-Zone begins and
ends.
1. If an AGP Slug Module controls the Slug-Signal:
• mount the AGP Slug-Module (1) to the lower flange of the frame rail;
• connect the module’s (output) cord (2) to downstream SCM; and
• connect the upstream SCM’s Power/Communication Cord (3) to the module (see Figure
G - 12).
2. Connect the AGP Slug-Module to either the main control panel or a local control device
using the AGP Slug-Module Connector Cord (4) (see Figure G - 12).
3. Where a Slug-Zone abuts a non-slug zone, an AGP Slug Termination Cord (5) must be
inserted into the Power/Communication Cord line (between the last SCM of the SlugZone and the first SCM of the adjoining non-slug zone (see Figure G - 12).
Solenoid Valve
Slug Terminator
Solenoid Valve
Slug Module
Figure G - 12 AGP Slug-Module Components/Installation
8450 12/03
G - 15
4. If an AGP Power Supply controls the “slug-signal”, connect the wiring (15-132 VAC/VDC)
from either the main control panel or a local control device to the “L1 / L2 Release In”
screw-terminal connections in the AGP Power Supply (see Figure G - 13).
Complete Conveyor Installation
When the proper operation of the photo-eyes and SCMs has been verified, proceed with the
following steps to complete the installation of the conveyor. Refer to Product Manual 8400,
Accuglide™ Live Roller - Section G – Installation Procedures, for additional information.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Install Drive Chain and Pad*.
Set up Chain Lubricator* and Tensioner*.
Install Rollers*.
Wire Discharge Zone Control Valve (24VDC or 110 VAC – check).
Install Brake Module(s)* (if required).
Install Case Stop(s)* (if required).
Set Skewed Rollers*.
Install Side-Guides and Transitions (as required).
Check Operational Mode(s) (see the following topics).
(*) Refer to Product Manual 8400, Accuglide™ Live Roller - Section G – Installation
Procedures, for installation details.
G - 16
8450 12/03
Check Operational Modes
To verify that a conveyor’s operational mode(s) are functioning properly – turn ON the airsupply and set the pressure regulator at 12 psi. (DO NOT turn on the power unit at this time)
With no product on the conveyor, check that the drive chain and pad is raised and engaging
the rollers in ALL sections (exception – the chain/pad should not engage the rollers in the
Discharge-ZoneA and in the first (downstream) ZoneB of the adjoining intermediate section.
SensorF
SensorE
O
O
I
I
ZoneF
SensorD
O
I
ZoneE
SensorC
SensorB
O
I
ZoneD
O
I
ZoneC
I
ZoneB
I
Discharge
ZoneA
Figure G - 14 Zone and Sensor Identification
Singulation Operational Mode
1. With the solenoid-actuated control-valve in Discharge-ZoneA NOT actuated, check that
the drive chain/pad is out of roller engagement in that zone and ZoneB.
2. Block photo-eye sensor PEb and the drive chain/pad should drop out of roller engagement in ZonC. Unblock the sensor and the chain/pad in Zonec should raise into roller
engagement.
3. Repeat these steps for all Singulation zones.
Dual-Zone Operational Mode
2. Block the first photo-eye sensor PEB and the drive chain/pad will drop out of roller
engagement in the immediate upstream ZoneC. Unblock the sensor and the chain/pad in
ZoneC should raise into roller engagement.
Block photo-eye sensors PEB and PEC and the drive chain/pad will drop out of roller
engagement in the immediate upstream ZoneD. Unblock either sensor and the chain/pad
in ZoneD should raise into roller engagement.
4. Repeat these steps for all Dual-Zone zones.
3.
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G - 17
Auto-Slug Operational Mode
Note:
For this example, the Auto-Slug Zone is 12’-0” long and consists of ZonesB-E
2. Block photo-eye sensors PEb/c/d/e and the drive chain/pad will drop out of roller engagement in ZonesC-F. Unblock any of the four (4) photo-eye sensors and the chain/pad
should raise into roller engagement in all of the upstream (rearward) zones.
Example: Unblock photo-eye sensor PEc and the drive chain/pad will drop out of roller
engagement in ZonesD-F.
3. Repeat these steps for each Auto-Slug Zone.
1. With all of the photo-eye sensors within a Slug-Zone blocked and the drive chain/pad
dropped-out of roller engagement in the associated zones, Turn-ON the slug-signal and
the drive chain/pad will raise into roller engagement in all of the associated zones.
2. Turn OFF the slug-signal and the drive chain/pad will drop out of roller engagement in all
of the associated zones.
Note:
G - 18
When the slug-signal is Turned OFF, the sections operate in the operational mode that their
SCM was set.
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Pre-Startup Conveyor Preparation
To ensure proper operation of an Accuglide conveyor, perform the following tasks BEFORE
the conveyor is first turned on.
1. Wire the motor/starter and other required electrical devices in accordance with the
National Electrical Code. Wiring information is supplied by the manufacturer(s) of the
motor/starter.
2. Apply electrical power to determine that the motor wiring provides the required rotation of
the reducer’s output shaft and drive sprocket for RH drive assembly (clockwise) (see Figure G - 15) and LH drive assembly (counter-clockwise) (see Figure G - 16).
Note:
If the conveyor’s chain and drive-pad are already installed, they will have to be removed
from the sprocket to keep from causing damage to equipment or injury.
Note:
8450 12/03
For additional pre-start up requirements, refer to Product Manual 8400, Accuglide™ Live
Roller - Section G – Installation Procedures
G - 19
Conveyor Start-Up Test Run
For Start-Up Test Run information, Refer to Product Manual 8400, Accuglide™ Live Roller Section G – Installation Procedures.
Personnel Training
ONLY trained personnel should operate conveyors. They must be knowledgeable about each
conveyor and its intended use as well as the operation of the total system. They must also
know what steps are to be taken in an emergency situation.
G - 20
8450 12/03
Maintenance Procedures
SECTION H: MAINTENANCE PROCEDURES
Introduction
Maintenance for Intermediate Sections with Photo-eye Sensors is mechanically the same as
Intermediate Sections with mechanical pivoting roller sensors. Refer to Product Manual
CS8400 Accuglide™ Live Roller Conveyor
Factory Assistance
Contact Customer Service for maintenance assistance or replacement parts.
Parts Replacement
To minimize production downtime, an inventory of selected spare parts should be kept on
hand for replacing worn or defective components. To identify a component, refer to Section I
Spare Parts of this manual and Product Manual CS8400 Accuglide™ Live Roller Converyor,
which identifies the most common components. For replacement components that are not
shown in Section, refer to the equipment Bill(s) of Materials.
Safety Instructions
•
•
•
•
•
•
•
•
•
•
Observe all warning signs, lights, and alarms associated with the conveyor operation.
Be alert at all times to automatic operation of adjacent equipment.
Do not sit on, stand, walk, ride on conveyors while in operation.
Excerise extreme caution near moving conveyor parts to avoid the hazard of hands, hair
or clothing being caught.
Do not clear jams or reach into any unit before turning off the equipment power sources
and affixing appropriate lock-out and tag-out devices.
Do not attempt to repair or replace any component while the conveyor is running.
Turn off conveyor power sources and affix appropriate lock-out and tag-out devices to
operating controls before servicing equipment.
Only tranined and qualified personnel who are aware of the safety hazards should perform equipment adjustments or required maintenance while the conveyor is in operation.
Do not remove or modify any safety device provided on or with the conveyor.
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.
Periodic Maintenance
The only routine maintenance required for the Intermediate Sections with Photo-Eye Sensors
is check and wiping off the photo-eye and the reflector.
8450 12/03
H-1
Troubleshooting
Refer to Product Manual CS8400 - Section I Maintenance when troubleshooting mechanical
and pneumatic problems. This manual deals only with issues related to the Power Supply,
Photo-Eye Sensors and the Solenoid Control Modules (SCM).
Table H - 1 Troubleshooting Power-Supply (PS)
Condition
Possible Cause
Possible Solution
PROBLEM - 24VDC Power Not Reaching Power/Communication Cord
PS Red LED “AC Power-IN” - OFF PS ON/OFF switch turned OFF.
and PS Green LED, “DC Power-Out” PS NOT receiving power from AC
- OFF
source.
Turn switch to ON.
PS Red LED, “AC Power-IN” - ON
and PS Green LED, “DC PowerOUT” - OFF
Remove short; turn-off ON/OFF
switch; wait at least 2 minutes then
turn-on ON/OFF switch. This will
reset PS.
PS in Short-Circuit Protection Mode
Turn ON AC power source.
Reset AC circuit breaker.
Verify all cord connections.
Table H - 2 Troubleshooting Solenoid Control Module (SCM)
Condition
Possible Cause
Possible Solution
PROBLEM - SCM Air Valve(s) Not Actuating (not supplying to air-actuators)
SCM Yellow LED - OFF and PE Red Faulty air valve.
LED - ON
Replace SCM.
SCM Yellow LED - OFF and
PE Red LED - OFF
Verify all cord connections.
Verify photo-beam path not blocked.
Verify photo-eye and reflector clean.
Verify photo-eye and reflector
alignment.
SCM not receiving power from PS
PROBLEM - SCM Drawing too Much Power
PE Green LED - FLASHING
H-2
SCM faulty.
Replace SCM.
8450 12/03
Table H - 3 Troubleshooting Photo-Eye / Reflector Sensor Assembly
Condition
Possible Cause
Possible Solution
PROBLEM - Photo-Eye Not Receiving Power
PE Green and Red LEDs - OFF
PE-SCM Corrd connection.
Verify connection.
Power/Communication Cord
connection.
Verify connection.
PS-Power/Communication Cord
connections.
Verify connection.
No PS 24VDC output.
Refer to Troubleshooting - PowerSupply (PS)
SCM faulty.
Replace SCM.
PROBLEM - Photo-Beam Signal Obstructed / Weak
PE Green LED - ON and
PE Red LED - OFF
PE / RF beam path obstructed
Accumulated product block eye Condition normal; no problem.
Clear obstruction.
PE Green LED - ON and
PE Red LED - Flashing
8450 12/03
PE / RF not properly aligned.
Verify PE / RF alignment.
PE Lens / RF dirty.
Clean PE Lens / Reflector.
RF damaged.
Replace RF.
PE defective
Replace PE.
PE / RF not properly aligned
Verify PE/RF alignment.
PE Lens / RF dirty.
Clean PE Lens / RF
RF damaged.
Replace RF.
H-3
H-4
8450 12/03
Spare Parts
SECTION I: SPARE PARTS
General Information
The purpose of this section is to provide a list of common spare parts for a preventive
maintenance program and also to minimize the chances for extended DOWNTIME.
The Accuglide Intermediate Sections with photo-eye sensors use the same mechanical
components as the Accuglide Plus Intermediate Sections with pivoting roller sensors. Refer
to Product Manual CS8400, Accuglide™ Plus Live Roller - Section I Spare Parts. The spare
parts identified in this section are sensor and zone-control components.
1
2
3
5
4
Figure I - 1 Photo-Eye Sensor and Zone-Control Components
Key
1
2
3
4
5
6
7
8450 12/03
Description
Photo-Eye, 24 VDC, 18” Cord w/Micro (Euro) Connector
Photo-Eye, 24 VDC, 18” cord w/Micro (Euro) Connector & Time Delay
Solenoid Control Module, 24 VDC w/Power/Communication Cord
Tubing, 1/2” O.D., Red (per foot)
Rubing, 5/32” I.D., Yellow (per foot)
Reflector w/Bracket (not shown) for RSL (9” rail)
Reflector w/Bracket (not shown) for RSL (6 3/8” rail)
Axle Clip - Pop-Out Roller insert
Part Number
301474
302622
272044
271114
271436
465850
465853
7410125
I-1
Spare Parts
8
7
7
Figure I - 2 Pop-Out Roller with Axle Insert
Key
8
I-2
Description
No. G196GH/PO
No. G196AB/PO (6002)
No. G196AB/PO (6203)
Conveyor Width W (Inside Frame Dim)
16”
22”
28”
34”
40”
7005488 7005489 7005490 7005491 7005492
7005493 7005494 7005495 7005496 7005497
7005501 7005502 7005503 7005504 7005505
8450 12/03
Product Index
SECTION J: PRODUCT INDEX
ITEM CLASS B 1 1 3
COMPONENT
STYLE
FAMILY
PRODUCT LINE
Intermediate Section, Accumulation
F1) HAND ASSY
F2) SIDE RAILS
F3) VALVE, PE & REFLECTOR
F4) SENSOR POSITION
DWG NO
W16
W22
W28
W34
W40
AGP IS 3-0 PE ACCUM W__
27147
828725
828726
828727
828728
828729
27148
828730
828731
828732
828733
828734
27149
828735
828736
828737
828738
828739
27150
828740
828741
828742
828743
828744
Intermediate Section, Accumulation, One-Inch Increments
F1) HAND ASSY
F2) SIDE RAILS
F3) VALVE, PE & REFLECTOR
F4) SENSOR POSITION
DWG NO
W16
W22
W28
W34
W40
AGP IS 1” INC 3-1 TO 3-11 W__
27151
828745
828746
828747
828748
828749
AGP IS 1” INC 4-0 TO 4-11 W__
27151
828750
828751
828752
828753
828754
AGP IS 1” INC 5-0 TO 5-11 W__
27151
828755
828756
828757
828758
828759
8450 12/03
J-1
Product Index
Accessories
ITEM CLASS B 1 1 3
Refer to Section F - Accessories, for description and usage requirements for the following
comopnents.
CSPS Code
Description
DWG. NO.
Part No.
N/A
004770
DWG. NO.
Part No.
23335 D
004763
DWG. NO.
Part No.
N/A
302618
DWG. NO.
Part No.
AGP CONNECTOR CORD - 1’0”
25454 B
301475
AGP CONNECTOR CORD - 2’-0”
25454 B
301476
25454 B
301477
25454 B
301478
25454 B
301479
25454 B
301480
DWG. NO.
Part No.
N/A
302616
DWG. NO.
Part No.
N/A
302614
DWG. NO.
Part No.
25455 B
004772
DWG. NO.
Part No.
25454 B
301483
AGP DRIVE/IDLER PIPING KIT
CSPS Code
Description
AGP AIR CONTROL ASSEMBLY KIT
CSPS Code
Description
AGP POWER SUPPLY
CSPS Code
Description
CSPS Code
Description
AGP T-CORD
CSPS Code
Description
AGP POWER ISOLATION CORD
CSPS Code
Description
AGP SLUG MODULE W/BRACKET
CSPS Code
Description
AGP SLUG-MODULE CONNECTOR CORD
J-2
8450 12/03
Product Index
CSPS Code
Description
DWG. NO.
Part No.
25456 B
272052
DWG. NO.
Part No.
AGP CRV AIR LINE & CORD - 6’-0”
N/A
004756
N/A
004757
N/A
004758
N/A
004759
N/A
004760
N/A
004761
N/A
004762
DWG. NO.
Part No.
AGF26
004764
DWG. NO.
Part No.
AGF27
004765
DWG. NO.
Part No.
AGF28
004766
DWG. NO.
Part No.
AGF28
004767
DWG. NO.
Part No.
AGF29
004768
DWG. NO.
Part No.
AGF29
004769
DWG. NO.
Part No.
AGP SLUG-TERMINATION CORD
CSPS Code
CSPS Code
Description
Description
AGP FK-BM SING CRV-AIR CONTROL
CSPS Code
Description
AGP FK-BM AUTO CRV-AIR CONTROL
CSPS Code
Description
AGP FKI-BM CRV-SOLENOID 120V
CSPS Code
Description
AGP FK-BM CRV-SOLENOID 24V
CSPS Code
Description
AGP FK-BM IS-SOLENOID 120V
CSPS Code
Description
AGP FK-BM IS-SOLENOID 24V
CSPS Code
Description
AGP GUIDE SPACER KIT
8450 12/03
004771
J-3
Product Index
CSPS Code
CSPS Code
J-4
Description
DWG. NO.
Part No.
AGP AIR-COMPONENTS KITS
004773
AGP AIR-COMPS KIT-TD PE SENSOR
004774
Description
DWG. NO.
Part No.
AGP ZONE PE RETRO-KIT T-DELAY
004775
AGP ZONE PE RETRO-KIT
004776
8450 12/03

Photo-Eye Accuglide Intermediate Section

Transcription

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