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OPERATING INSTRUCTIONS

LTE COMPONENTS

Single-belt Transfer System

BA-100056 English Edition 12/2007

Operating Instructions Single-belt Transfer System LTE®

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Table of Contents

1. Important Information__________________________________________________________ 9 1.1. Manufacturer's Declaration ______________________________________________________ 9 1.2. Product Description and Use_____________________________________________________ 9 1.3. Factors Reducing Service Life ____________________________________________________ 9 1.4. Safety Instructions______________________________________________________________ 9 1.5. Additional Information __________________________________________________________ 9 1.6. Application Scope of the Operating Instructions __________________________________ 11 1.7. Technical Data ________________________________________________________________ 11 1.8. Safety Instructions_____________________________________________________________ 11

2. Workpiece Holder WTE________________________________________________________ 12 2.1. Exploded Views / Spare Parts Lists ______________________________________________ 12 2.1.1. Workpiece holder WTE, version A and B _________________________________________ 12 2.1.2. Spare parts list, version A and B ________________________________________________ 12

3. Conveyor TB/TBD_____________________________________________________________ 13 3.1. Technical data TB/TBD/BPBE ___________________________________________________ 13 3.1.1. Mechanical setup _____________________________________________________________ 13 3.1.2. Electrical connections__________________________________________________________ 14 3.1.3. Direction of travel of the conveyor belt __________________________________________ 15 3.1.4. Setting the required pretension of the conveyor belt ______________________________ 15 3.1.5. Moving the drive unit on the chassis_____________________________________________ 16 3.1.6. Tracking of the conveyor belt___________________________________________________ 16 3.1.7. Changing the conveyor speed __________________________________________________ 18 3.1.8. Procedure for changing the chain sprocket _______________________________________ 19 3.1.9. Procedure for changing the gear motor__________________________________________ 19 3.1.10. Technical data of the conveyor belt _____________________________________________ 20 3.1.11. Replacing an endless belt ______________________________________________________ 20 3.1.12. Replacing belts by “welding” their ends _________________________________________ 20 3.2. Maintenance __________________________________________________________________ 20 3.2.1. Repairs ______________________________________________________________________ 21 3.2.2. Replacing the self-aligning ball bearings / drive rollers _____________________________ 21


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3.3. Exploded Views / Spare Parts Lists ______________________________________________ 22 3.3.1. TB / TBD conveyor with horizontal drive unit _____________________________________ 22 3.3.2. Spare parts list TB / TBD with horizontal drive unit________________________________ 23 3.3.3. Conveyor TB / TBD with vertical drive unit _______________________________________ 24 3.3.4. Spare parts list TB / TBD with vertical drive unit __________________________________ 25 3.3.5. TB conveyor end with diverter roller, single-belt __________________________________ 26 3.3.6. Spare parts list TB conveyor end with diverter roller, single-belt ____________________ 26 3.3.7. TBD conveyor end with diverter rollers, twin-belt _________________________________ 27 3.3.8. Spare parts list TBD conveyor end with diverter roller, twin-belt____________________ 27 3.3.9. Motor support for vertical drive ________________________________________________ 28 3.3.10. Spare parts list motor support for vertical drive (56531) ___________________________ 28 3.3.11. TB / TBD with horizontal drive unit______________________________________________ 29 3.3.12. Spare parts list TB / TBD with horizontal drive unit________________________________ 29 3.3.13. TB / TBD with vertical drive unit ________________________________________________ 30 3.3.14. Spare parts list TB / TBD with vertical drive unit __________________________________ 30 3.3.15. Side covers TB / TBD horizontal ________________________________________________ 31 3.3.16. Spare parts list side covers TB / TBD horizontal (54888) ___________________________ 31 3.3.17. Side covers TB / TBD vertical___________________________________________________ 32 3.3.18. Spare parts list side covers TB / TBD vertical (54889)______________________________ 32 3.3.19. Side cover long, pre-assembled ________________________________________________ 33 3.3.20. Spare parts list side cover long, horizontal (44873)/ vertical (44875) _________________ 33 3.3.21. Side cover short, pre-assembled________________________________________________ 34 3.3.22. Spare parts list side cover long, horizontal (44874)/ vertical (44876) _________________ 34 3.3.23. TB diverter roller drive ________________________________________________________ 35 3.3.24. Spare parts list TB diverter roller drive __________________________________________ 35 3.3.25. TBD diverter roller drive _______________________________________________________ 36 3.3.26. Spare parts list TBD diverter roller drive _________________________________________ 36

4. Bypass Conveyor BPBE _______________________________________________________ 37 4.1. Technical Data BPBE __________________________________________________________ 37 4.1.1. Setting the required pretension of the conveyor belt______________________________ 37 4.2. Exploded Views / Spare Parts Lists ______________________________________________ 38 4.2.1. Bypass conveyor BPBE with horizontal drive unit _________________________________ 38 4.2.2. Spare parts list BPBE horizontal with drive unit ___________________________________ 39 4.2.3. BPBE drive unit horizontal _____________________________________________________ 40


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4.2.4. Spare parts list BPBE drive unit horizontal________________________________________ 40 4.2.5. BPBE side cover ______________________________________________________________ 41 4.2.6. Spare parts list side BPBE covers (56943) ________________________________________ 42 4.2.7. Side cover long, for bypass, pre-assembled ______________________________________ 43 4.2.8. Spare parts list side cover long (55141) __________________________________________ 43 4.2.9. Side cover short to bypass, pre-assembled _______________________________________ 44 4.2.10. Spare parts list side cover short (55142)__________________________________________ 44 4.2.11. Side cover right, pre-assembled ________________________________________________ 45 4.2.12. Spare parts list side cover right (55143) __________________________________________ 45 4.2.13. Side cover left, pre-assembled__________________________________________________ 46 4.2.14. Spare parts list side cover left (55144) ___________________________________________ 46 4.2.15. BPBE diverter rollers drive _____________________________________________________ 47 4.2.16. Spare parts list BPBE diverter rollers drive _______________________________________ 47

5. Conveyor Coupling BKE _______________________________________________________ 48 5.1. Commissioning________________________________________________________________ 48 5.1.1. Setting the required pretension of the conveyor belt ______________________________ 48 5.1.2. Tracking of the conveyor belt___________________________________________________ 49 5.2. Conveyor Belt_________________________________________________________________ 49 5.2.1. Technical data of the conveyor belt _____________________________________________ 49 5.2.2. Replacing an endless belt on the coupling conveyor _______________________________ 49 5.2.3. Replacing belts by “welding” their ends _________________________________________ 49 5.3. Maintenance / Repairs _________________________________________________________ 50 5.3.1. Replacing the synchronous belt _________________________________________________ 50 5.3.2. Replacing the drive rollers on the traction conveyor _______________________________ 51 5.3.3. Replacing the drive rollers on the single-belt coupling conveyor ____________________ 52 5.3.4. Replacing the drive rollers on the twin-belt coupling conveyor______________________ 53 5.4. Maintenance __________________________________________________________________ 54 5.5. Repairs_______________________________________________________________________ 54 5.6. Exploded Views / Spare Parts Lists ______________________________________________ 55 5.6.1. Conveyor coupling TB/TB and TB/TBD___________________________________________ 55 5.6.2. Spare parts list conveyor coupling TB/TB and TB/TBD _____________________________ 55 5.6.3. BKE conveyor end with diverter roller, single-belt _________________________________ 56 5.6.4. Spare parts list BKE conveyor end TB/TB with diverter roller, single-belt_____________ 56 5.6.5. BKE conveyor end with diverter roller, twin belt __________________________________ 57


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5.6.6. Spare parts list BKE conveyor end TBD/TB with diverter roller, twin-belt ____________ 57 5.6.7. Conveyor coupling for TB/TB___________________________________________________ 58 5.6.8. Spare parts list conveyor coupling for TB/TB with diverter roller, single-belt _________ 59 5.6.9. Conveyor coupling for TBD/TB _________________________________________________ 60 5.6.10. Spare parts list conveyor coupling for TBD/TB with diverter roller, twin-belt _________ 61 5.6.11. End piece left for TB/TBD______________________________________________________ 62 5.6.12. Spare parts list end piece left for TB/TBD (55188) ________________________________ 62 5.6.13. End piece right for TB/TBD ____________________________________________________ 63 5.6.14. Spare parts list end piece right for TB/TBD (55189) _______________________________ 63 5.6.15. End piece right for BKE________________________________________________________ 64 5.6.16. Spare parts list end piece right for BKE (55190) __________________________________ 64 5.6.17. End piece left for BKE _________________________________________________________ 65 5.6.18. Spare parts list end piece left for BKE (55191)____________________________________ 65

6. Fixed Curve 90° KFE__________________________________________________________ 66 6.1. Use__________________________________________________________________________ 66 6.2. Commissioning _______________________________________________________________ 66 6.2.1. Curve fixed 90° KFE 105, 140, 185 and 250, version M ____________________________ 66 6.2.2. Curve fixed 90° KFE 105, 140, 185 and 250, version E _____________________________ 68 6.3. Exploded Views / Spare Parts Lists ______________________________________________ 70 6.3.1. Fixed curve 90° KFE 105, 140, 185, and 250, version M____________________________ 70 6.3.2. Spare parts list fixed curve KFE, version M_______________________________________ 70 6.3.3. Fixed curve 90° KFE 105, 140, 185, and 250, version E ____________________________ 71 6.3.4. Spare parts list fixed curve KFE, version E _______________________________________ 71 6.3.5. Connection 90° for KFE, version M______________________________________________ 72 6.3.6. Spare parts list connection 90° for KFE, version M (49628) _________________________ 72 6.3.7. Connection 90° for KFE, version E ______________________________________________ 73 6.3.8. Spare parts list connection 90° for KFE, version E_________________________________ 73

7. Movable Curve 90° KBEA/KBE ________________________________________________ 74 7.1. Use__________________________________________________________________________ 74 7.2. Technical Data ________________________________________________________________ 74 7.2.1. Changeover times ____________________________________________________________ 74 7.3. Commissioning _______________________________________________________________ 75 7.3.1. Setup of curve with drive (outward transfer) and the necessary accessories __________ 75


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7.3.2. Setup of curve without drive (inward transfer) and the necessary accessories _________ 76 7.3.3. Checking and setting the drive unit _____________________________________________ 77 7.3.4. Checking and setting the bearings ______________________________________________ 78 7.3.5. Flowchart for curve with drive (outward transfer)__________________________________ 79 7.3.6. Flowchart for curve with drive (inward transfer) ___________________________________ 81 7.4. Maintenance and Repairs_______________________________________________________ 83 7.4.1. Replacing the drive cylinder ____________________________________________________ 83 7.4.2. Replacing the drive unit________________________________________________________ 84 7.4.3. Checking and setting the swivel angle ___________________________________________ 85 7.5. Exploded Views / Spare Parts Lists ______________________________________________ 87 7.5.1. Movable curve with drive ______________________________________________________ 87 7.5.2. Spare parts list movable curve with drive_________________________________________ 88 7.5.3. Movable curve without drive ___________________________________________________ 89 7.5.4. Spare parts list movable curve without drive _____________________________________ 90 7.5.5. Drive for curve________________________________________________________________ 91 7.5.6. Spare parts list drive for curve (54502) ___________________________________________ 92 7.5.7. Bearing mount for curve _______________________________________________________ 93 7.5.8. Spare parts list bearing mount for curve (54531) __________________________________ 93 7.5.9. Stop for movable curve and bypass _____________________________________________ 94 7.5.10. Spare parts list stop for movable curve and bypass (54630) ________________________ 94

8. Rotary Diverter UR-180°_______________________________________________________ 95 8.1. Use __________________________________________________________________________ 95 8.2. Safety Instructions_____________________________________________________________ 95 8.3. Commissioning________________________________________________________________ 95 8.3.1. Electrical connections__________________________________________________________ 95 8.3.2. Flowchart for UR (key) _________________________________________________________ 96 8.4. Maintenance and Repairs_______________________________________________________ 98 8.4.1. Replacing the conveyor disc ____________________________________________________ 98 8.4.2. Replacing the diverter rollers ___________________________________________________ 99 8.4.3. Replacing the spur wheel back-geared motor____________________________________ 100 8.4.4. Replacing the sliding hub _____________________________________________________ 101 8.4.5. Adjusting the sliding hub______________________________________________________ 101 8.5. Exploded Views / Spare Parts Lists _____________________________________________ 102 8.5.1. Rotary diverter 180° __________________________________________________________ 102


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8.5.2. Spare parts list rotary diverter 90° _____________________________________________ 103

9. Bypass BPEA/BPE ___________________________________________________________ 105 9.1. Use_________________________________________________________________________ 105 9.2. Technical Data _______________________________________________________________ 105 9.2.1. Changeover times ___________________________________________________________ 105 9.3. Commissioning ______________________________________________________________ 106 9.3.1. Setup of bypass with drive (inward transfer) and the necessary accessories _________ 106 9.3.2. Setup of bypass without drive (outward transfer) and the necessary accessories_____ 107 9.3.3. Settings Bypass with drive right and left ________________________________________ 108 9.3.4. Flowchart for bypass with drive (outward transfer) _______________________________ 109 9.3.5. Flowchart for bypass without drive (inward transfer) _____________________________ 111 9.3.6. Flowchart for bypass with drive (inward transfer) ________________________________ 113 9.4. Maintenance and Repairs _____________________________________________________ 115 9.4.1. Replacing the drive cylinder___________________________________________________ 115 9.4.2. Checking and setting the swivel angle__________________________________________ 116 9.4.3. Replacing the drive unit ______________________________________________________ 117 9.5. Exploded Views / Spare Parts Lists _____________________________________________ 118 9.5.1. Bypass with drive ____________________________________________________________ 118 9.5.2. Spare parts list bypass right and left with drive _________________________________ 119 9.5.3. Bypass without drive _________________________________________________________ 120 9.5.4. Spare parts list bypass right and left without drive _______________________________ 121 9.5.5. Drive for bypass _____________________________________________________________ 122 9.5.6. Spare parts list drive for bypass (54486) ________________________________________ 123 9.5.7. Bearing for bypass ___________________________________________________________ 124 9.5.8. Spare parts list bearing for bypass (54496)______________________________________ 124 9.5.9. Spare parts list stop for bypass (54630)_________________________________________ 124

10. Transfer Gate WEE __________________________________________________________ 125 10.1. Use_________________________________________________________________________ 125 10.2. Technical Data _______________________________________________________________ 125 10.2.1. Changeover times ___________________________________________________________ 125 10.3. Commissioning ______________________________________________________________ 125 10.3.1. Setup of inward transfer gate WEE and the necessary accessories _________________ 125 10.3.2. Setup of outward transfer gate WEE and the necessary accessories________________ 126


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10.3.3. Checking and setting the drive unit ____________________________________________ 127 10.3.4. Flowchart for transfer gate (inward transfer)_____________________________________ 128 10.3.5. Flowchart for transfer gate (outward transfer) ___________________________________ 130 10.4. Maintenance and Repairs______________________________________________________ 132 10.4.1. Replacing the drive cylinder ___________________________________________________ 132 10.4.2. Replacing the drive unit_______________________________________________________ 132 10.4.3. Checking and setting the swivel angle __________________________________________ 133 10.5. Exploded Views / Spare Parts Lists _____________________________________________ 134 10.5.1. Transfer gate ________________________________________________________________ 134 10.5.2. Spare parts list transfer gate __________________________________________________ 135 10.5.3. Spare parts list drive for transfer gate (54502) ___________________________________ 135

11. Indexing Device IVE and IVEB_________________________________________________136 11.1. Use _________________________________________________________________________ 136 11.2. Commissioning_______________________________________________________________ 136 11.2.1. Assembling and setting the indexing device IVEB ________________________________ 136 11.2.2. Installation and setting of indexing device IVE ___________________________________ 141 11.2.3. Flowchart for indexing device IVEB/IVE _________________________________________ 141 11.3. Exploded Views / Spare Parts Lists _____________________________________________ 143 11.3.1. Indexing device IVE __________________________________________________________ 143 11.3.2. Spare parts list indexing device IVE (49613) _____________________________________ 143 11.3.3. Indexing device IVEB right and left _____________________________________________ 144 11.3.4. Spare parts list indexing device IVEB right (54492) _______________________________ 144 11.3.5. Spare parts list indexing device IVEB left (54633) ________________________________ 145

12. Positioning Device PVE_______________________________________________________146 12.1. Use _________________________________________________________________________ 146 12.2. Technical Data _______________________________________________________________ 146 12.2.1. Maximum torque_____________________________________________________________ 146 12.3. Commissioning_______________________________________________________________ 148 12.3.1. Mounting and setting positioning device PVE ___________________________________ 148 12.3.2. Flowchart for positioning device PVE ___________________________________________ 152 12.4. Exploded Views / Spare Parts Lists _____________________________________________ 154 12.4.1. Positioning device PVE _______________________________________________________ 154 12.4.2. Spare parts list positioning device PVE _________________________________________ 154


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12.4.3. Support with belt stroke cylinder ______________________________________________ 155 12.4.4. Spare parts list support with belt stroke cylinder ________________________________ 155

13. Environmental Friendliness and Disposal ______________________________________ 156


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1. Important Information

Conveyors as component assemblies are not subject to the EU Declaration of Conformity (pursuant to MRL Appendix II)

EU Declaration of Conformity (pursuant to MRL Appendix II)

1.1. Manufacturer's Declaration

Regulations and standards considered: – Machine Directive 89/392/EEC, 91/368/EEC, – Low Voltage Directive 73/23/EEC, EMC Directive 89/336/EEC, EN 50081-2, EN 50082-2, 91/236/EEC and 92/31/EEC Manufacturer: Montech AG, Gewerbestrasse 12 CH–4552 Derendingen Tel. +41 32 681 55 00, Fax +41 32 682 19 77

1.2. Product Description and Use

The single-belt transfer system is used for the transport of workpiece holders (WTE) in the assembly industry. The single-belt transfer system used the Montech conveyor (TB) as a basis. Under no circumstances must the product-specific ratings listed on the name plate be exceeded.

1.3. Factors Reducing Service Life

– Direct light from UV lamps – Queuing when carrying sharp-edged work pieces. – Operation in air containing smoke, dust, vapor, or solvents.

1.4. Safety Instructions

The safety instructions, in particular those relating to electrical connections, must be followed in all phases of commissioning, operation and during maintenance and service work. Failure to follow these instructions is considered a misuse of the transport system and its components. Operating a conveyor in an explosive atmosphere (flammable gases, vapors, or dust) can result in their combustion and shall be avoided. Never perform service or setting work on your own. In all cases, there must be a second person present who can shut of the main power and administer first aid, if necessary. Moving the electromechanical drive unit on the chassis, as well as removing the mechanical safety guards must ONLY be performed when the conveyor is disconnected from the main power supply.

1.5. Additional Information

These operating instructions are designed to ensure the safe and proper installation of the single-belt transfer system. If you need information in an individual case, please contact the manufacturer.


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Additional information, e.g. on mounting the lateral guides, etc., can be found in the TB Assembly Instructions. These documents are available from our home page, www.montech.com. Additional copies can be provided free-of-charge. When ordering operating instructions, always include the series number or the order number. This document is available from our home page, www.montech.com. Description Nameplate Conveyors

Description Nameplate Other Components Item number Product name Serial number Montech AG Senior Management

U. D .Wagner / C. Wullschleger

ENI-5EE


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1.6. Application Scope of the Operating Instructions

We always adapt our products to the state-of-the-art and new findings from practical applications. Therefore, the operating instructions are updated to match the product modifications. Each operating instruction has an item number, e.g., BA-100056. The item number and edition are on the cover sheet.

1.7. Technical Data

Ambient temperature [°C] 10 – 40

Relative air humidity 5% - 85% (without formation of condensation)

Air purity level normal shop air

Sound pressure level [dBA] < 70

Positioning accuracy WTE in IVE and IVEB [mm] ±0.05

Workpiece carrier sizes WTE [mm]

80x80 (weight 170g) 115x115 (weight 360g) 160x160 (weight 690g) 225x225 (weight 1660g)

Max. weight WTE with load:

For WTE 80x80/115x115/160x160 [kg] 2.5

For WTE 225x225 [kg] 5

Max. torque on WTE in IVE and IVEB [Nm] 5 (at 18m/min)

Max. force of pressure on WTE in IVE and IVEB [N] 120

Operating pressure [Nm] See Safety Instructions

Operating medium 5µM m filtered, oiled or unoiled air, due point < 6°C

Material of workpiece holder WTE Polyethylenterephthalate PET, black

Material of lateral guides Polyethylene PE, black, antistatic

Recommended belt type ENI-5EE, black, antistatic, manufacturer Habasit


The operating pressure for the movable curve, transfer gate, and the bypass must not exceed

2 bar! Otherwise, there is a risk of injuries. Operating pressure for stoppers VSE and VSEB, indexing devices IVE and IVEB is 5-6 bar. According to EN 1050


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2. Workpiece Holder WTE

2.1. Exploded Views / Spare Parts Lists

2.1.1. Workpiece holder WTE, version A and B

Version A Version B

2.1.2. Spare parts list, version A and B

Item Sym. Name Item no. Material

TB/TBD-105 TB/TBD-140 TB/TBD-185 TB/TBD-250

Workpiece holder 80x80 115x115 160x160 225x225

◘ Version A 49609 49610 49611 56181

◘ Version B 49639 49638 49636 56305

10 ◊ Workpiece holder version A 49175 49176 49177 56307 PET

10 ◊ Workpiece holder version B 49640 49637 49635 56308 PET

20 ◊ Centering Sleeve WTE 49174 49174 49174 49174 Steel

30 ◊ Buffer WTE 49608 49608 49608 49608 Polycord

40 ◊ Dowel pin Ø5h8x10 506960 506960 506960 506960 Steel

◊ Not available ex stock individually (upon request) ◘ Price list item available ex stock


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3. Conveyor TB/TBD

3.1. Technical data TB/TBD/BPBE

3.1.1. Mechanical setup

The conveyors are shipped in lengths of up to 3 m. If the total length of a conveyor exceeds the maximum transportation length of 3 m, the components must be reassembled as follows. Chassis length (total, in mm) L � 3000 Lateral guide

Chassis

3000 < L � 6000 Lateral guide Chassis



Svar variable length of lateral guides, min. = 500 mm, max. = 2000 mm Cvar variable chassis length, Cvar max. = 3000 - 60, or 3000 - (2x60) mm

D chassis joint - take apart here for transport (tab connection) Secure the tab connections marked “D” prior to commissioning. The conveyor must be supported at these locations. The drive unit should be mounted near the discharge end of the conveyor. Applications where the drive unit has to be positioned on the infeed side, e.g. because of a lack of space and especially where high loads occur during queuing, should be referred to Montech for evaluation.


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3.1.2. Electrical connections

General safety instructions The operator of the conveyor must have the electrical connection, the commissioning, the adjustment and the servicing carried out by qualified persons. Work on the electrical parts is particularly dangerous. Operation of the conveyor without a mechanical switch in the supply line is forbidden. To achieve optimal protection from the contact guard, the motor must be connected to the ground of the supply network. Never disconnect the electrical connections when voltage is applied. In unfavorable cases, arcs may be produced and people injured or contacts damaged. Connection of the mains voltage 3x400 V

Star connection

(Reverse rotation by exchanging two phases) Connection of the mains voltage 3x230 V

Delta connection

(Reverse rotation by exchanging two phases) Connection of the mains voltage 1x230 V

Clockwise Counterclockwise Motor RPM Cap. D63A-4 1,360 8 µ F DB63A-4 1,300 8 µ F


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3.1.3. Direction of travel of the conveyor belt

For belt type SNI-5E , the direction of travel is of no significance. Flexproof weld seam

3.1.4. Setting the required pretension of the conveyor belt

The correct pretension for a conveyor belt is shown on the nameplate attached to the drive unit. For example: 1.2% After the belt has been mounted, two measuring marks (M) must be attached to the top of the belt in the untensioned state in such a way that they have a spacing (L) of e.g. 500 or 1000 mm. When the two tensioning screws (30) are uniformly tightened, the two measuring marks (M) move apart up to the dimension (L) which corresponds to the required pretension. Example for calculating the belt pretension

1.2%verfund1000mmLBei lose ==

(%)100

vLLL necloose

loosetaut ∗+=

mm1012%2.1%100

mm1000mm1000Ltaut =∗+=


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3.1.5. Moving the drive unit on the chassis

Procedure: – Switch off the motor. – Loosen screws “250” on the side cover short “20” and the screws on side cover long “10”. – Move the drive unit in the desired position and tighten the four screws “250” on both side covers. Should the belt no longer run centered on the diverter rollers, it should be aligned as explained in section “Tracking of the conveyor belt.”

3.1.6. Tracking of the conveyor belt

The belt must always run centrally over the diverter rollers or nose-bars and drive rollers. Under no circumstances must the edges of the belt project over the ends of the rollers. The position of the belt running over the diverter rollers and nose-bars can be corrected by tightening or slackening the special screws “280” while the belt is running.


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The correction of the belt position on the drive roller can only be checked after removing the guard plate. Procedure: – Switch off the motor. – Dismantle the chain-guard by unscrewing the two screws “290”. – Release the four screws “240” and pull down the guard plate. – Vertical version: Pull out the two guard plates laterally. For safety reasons it is essential to refit the chain guard before switching the motor on

again.

– Switch on the motor. – If the belt runs more than 2 mm out of center on the drive roller, it must be corrected. – Check the distance “E” on both sides of the drive unit and - if necessary - adjust with one of the screws “30” until the distances are equal. – If the belt is still not running straight, the side cover, short “20” must be displaced. – Lightly loosen the two screws “250” and screw “270”. – Shift the “side cover, short “20” by tapping with a nylon hammer at point P until the belt runs with the desired tolerance on the drive roller. – Switch off the motor and tighten screws “250” and “270”, and reassemble the guard plate. Horizontal drive unit (vertical drive unit not shown)


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3.1.7. Changing the conveyor speed

The conveying speed can be altered by exchanging the driving sprocket “120” and/or by replacing the gear motor “190.” Chain sprocket “130” must not be changed. Conversion parts for changing the conveyor speed

Motor Gearbox Sprocket

Number of teeth Conveyor speed (m/min.)

Motor type Reduction gear

Z1 Item 120

Z2 Item 130

7.5 G80F / 4D63A-4 18.87:1 15 29

9.5 G80F / 4D63A-4 18.87:1 19 29

11.5 G80F / 4D63A-4 18.87:1 23 29

14.5 G80F / 4D63A-4 18.87:1 29 29

19.9 G80F / 4DB63A-4 7.1:1 15 29

The motors are equipped with heat monitors (130°C).


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3.1.8. Procedure for changing the chain sprocket

– Switch off motor and disconnect from mains voltage. – Remove the chain guard by unscrewing the two screws “290”. – To slacken the chain, release the 4 screws “230”. – Open the spring-link “220”. – Release screws “300”. – Pull sprocket “120” off the gear-shaft. – Push the new sprocket “120” onto the gear shaft and align the teeth of “120” and “130” with each other. – Tighten screws “300”. – Fit the chain corresponding to the sprocket combination to “120” and “130”. – Tension the chain by shifting the gear motor and lightly tighten the 4 screws “230”. – The chain has the right tension when the upper strand sags by 1-2 mm when pressed down. – Tighten the 4 screws “230” and fit the chain guard “140”.

3.1.9. Procedure for changing the gear motor

The procedure is the same as for changing the sprocket, except that after removing the driving sprocket “120”, the gear motor is changed. Gearbox type SG-80 is fitted to the “side cover, long” with 4 flange sockets “440”.


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3.1.10. Technical data of the conveyor belt

Data pertinent to the conveyor and belt is found on the nameplate attached to the drive unit and must be taken into consideration when ordering replacement belts.

3.1.11. Replacing an endless belt

The installation of endless belts is recommended when the conveyor is easily accessible or when the equipment needed for “welding” prepared end belts is not available. In particular, electrically or pneumatically supplied consumers mounted on the conveyor chassis side opposite to the chain drive, as well as floor stands and table stands, must be removed to replace an endless belt. Procedure: – Switch off motor and disconnect from mains voltage. – Slacken the conveyor belt by alternately loosening the two screws “30”. – Remove the chain guard by removing the two screws “290”. – Loosen 4 screws “240” and pull out guard plate in a downward direction. – Vertical version: Pull out the two guard plates laterally . – Unscrew all remaining screws in the side cover, short “20”; it can be removed and the belt replaced. – Reassemble the drive unit in the reverse order. – For pre-tensioning the belt see the section on “Setting the necessary pretension of the belt”. – To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

3.1.12. Replacing belts by “welding” their ends

Pulling in new belts and “welding” their ends is the preferred method of belt replacement where accessibility to previous operations is severely restricted. A prerequisite for this method of assembly is the availability of belt welding equipment. Exact instructions for the “welding operation” can be obtained when ordering the new belts. Procedure: – Switch off motor and disconnect from mains voltage. – Slacken the conveyor belt by alternately loosening the two screws “30”. – Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with adhesive tape). – Slowly pulling the old belt automatically pulls the new one through the system. – “Weld” the ends of the new belt according to the manufacturer’s instructions. – For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor belt”. – To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

3.2. Maintenance

Belt conveyors are maintenance free when they are employed in accordance with their purpose and are not exposed to any factors likely to shorten the useful life. The purpose and the factors likely to shorten life are listed in the declaration of conformity. When the belts are exposed to the action of dust, oily air, foreign matter such as metal chips from machine tools, etc., we recommend that they should be regularly cleaned, e.g. once a week, with pure gasoline.


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3.2.1. Repairs

The operating instructions contain the necessary spare parts lists and exploded drawings for repairs to the mechanical part of the conveyor. The safety instructions must also be followed. Repairs to the electrical part may be carried out only by the supplier. It is essential to follow the safety instructions for electrical disconnection of components from the mains or from the motor and for subsequent reinstallation.

3.2.2. Replacing the self-aligning ball bearings / drive rollers

When replacing the self-aligning ball bearing “50” or the drive roller “250,” the inner ring and the bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 or Ergo 4401 (shaft-hub joint). It is essential to allow the adhesive to harden for 24 hours.


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3.3.1. TB / TBD conveyor with horizontal drive unit


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3.3.2. Spare parts list TB / TBD with horizontal drive unit

Item Name Item no.


10 Chassis aluminum with sliding plate

55388/…. 55389/…. 55390/…. 55391/….

Sliding plate sendzimir-galvanized

54869/0084/…. 54869/0119/…. 54869/0164/…. 54869/0229/….

Sliding plate stainless 54868/0084/…. 54868/0119/…. 54868/0164/…. 54868/0229/….

20 Conveyor end with diverter roller, single-belt

56990 56991 56992 56993

20 Conveyor end with diverter roller, twin-belt

56994 56995 56996 56997

40 Horizontal drive unit single-belt

54332 57996 57997 57998

40 Horizontal drive unit twin-belt

54334 58004 58005 58006

50 G80F/D63A-4 / 18.87:1 510003 510003 510003 510003

50 G80F/DB63A-4 / 7.1:1 510004 510004 510004 510004

60 Sprocket set for gearbox G80F v=7.5/19.9 m/min, z=15

44980 44980 44980 44980


44981 44981 44981 44981


44982 44982 44982 44982


44983 44983 44983 44983


24

3.3.3. Conveyor TB / TBD with vertical drive unit


25

3.3.4. Spare parts list TB / TBD with vertical drive unit

Item Name Item no.



55388/…. 55389/…. 55390/…. 55391/….

Sliding plate sendzimir-galvanized 54869/0084/…. 54869/0119/…. 54869/0164/…. 54869/0229/….



56990 56991 56992 56993

20 Conveyor end with diverter roller, twin-belt

56994 56995 56996 56997

30 Motor support Vertical drive unit

56531 56531 56531 56531

40 Vertical drive unit single-belt

54333 58001 58002 58003

40 Vertical drive unit twin-belt

54335 58007 58008 58009

50 G80F/D63A-4 / 18.87:1 510003 510003 510003 510003

50 G80F/DB63A-4 / 7.1:1 510004 510004 510004 510004


44980 44980 44980 44980


44981 44981 44981 44981


44982 44982 44982 44982


44983 44983 44983 44983


26

3.3.5. TB conveyor end with diverter roller, single-belt

3.3.6. Spare parts list TB conveyor end with diverter roller, single-belt


TB-105 TB-140 TB-185 TB-250

◘ Conveyor end, complete 56990 56991 56992 56993 Various

10 ◊ Conveyor end 56918 56917 56916 56915 Aluminum

20 ● Diverter roller, complete 56958 56959 56960 56961 Steel

30 ◘ Conveyor-conveyor elem.,

complete 36546

36546 36546 36546 Steel

● These are wearing parts and available ex stock. ◊ Not available ex stock individually (upon request) ◘ Price list item available ex stock


27

3.3.7. TBD conveyor end with diverter rollers, twin-belt

3.3.8. Spare parts list TBD conveyor end with diverter roller, twin-belt


TBD-105 TBD-140 TBD-185 TBD-250





complete 36546

36546 36546 36546 Steel



28

3.3.9. Motor support for vertical drive

3.3.10. Spare parts list motor support for vertical drive (56531)


TB/TBD-105 - 250

10 ◊ Motor support 56342 Steel

20 ◊ Hex screws M6x12 504386 Steel

30 ◊ Ribbed washer M6. 505255 Steel

40 ◊ Washer M6 504388 Steel

50 ◊ Hex screws M5x12 504351 Steel

60 ◊ Ribbed washer M5. 502365 Steel

70 ◊ Washer M5 504343 Steel

80 ◊ Hex nut M5x0.8d 504903 Steel

◊ Not available ex stock individually (upon request)


29

3.3.11. TB / TBD with horizontal drive unit

3.3.12. Spare parts list TB / TBD with horizontal drive unit



◘ Drive unit TB 54332 57996 57997 57998 Various

◘ Drive unit TBD 54334 58004 58005 58006 Various

10 ◊ Side covers 54888 54888 54888 54888 Various

20 ◊ Diverter rollers for drive TB 54886 58071 58072 58073 Steel

20 ◊ Diverter rollers for drive TBD 54887 56572 56574 56575 Steel

30 ● Guard plate 39807 39808 39809 39810 PS



30

3.3.13. TB / TBD with vertical drive unit

3.3.14. Spare parts list TB / TBD with vertical drive unit



◘ Drive unit TB 54333 58001 58002 58003 Various

◘ Drive unit TBD 54335 58007 58008 58009 Various

10 ◊ Side covers 54889 54889 54889 54889 Various

20 ◊ Diverter rollers for drive

TB 54886 58071 58072 58073 Steel

20 ◊ Diverter rollers for drive

TBD 54887 56572 56574 56575 Steel

30 ● Guard plate 55308 58076 58077 58078 PS



31

3.3.15. Side covers TB / TBD horizontal

3.3.16. Spare parts list side covers TB / TBD horizontal (54888)


TB / TBD horizontal

10 ◊ Side cover long, pre-assembled 44873 Steel

20 ◊ Side cover short, pre-assembled 44874 Steel

30 ● Chain guard 45566 Steel

40 ◊ Machine elements 54320 Various

40/10 ◘ T-nut, square 21913 Steel

40/20 ◊ Spacer M4x30 501488 Steel

40/30 ◊ Oval head screw M4x8 504376 Steel

40/40 ◊ Cheese head screws M6x12 504644 Steel

40/50 ◊ Ribbed washer M6 505255 Steel

40/60 ◊ Hex screws M6x12 504386 Steel

40/70 ◊ Washer M6 504388 Steel



32

3.3.17. Side covers TB / TBD vertical

3.3.18. Spare parts list side covers TB / TBD vertical (54889)


TB / TBD - vertical

10 ◊ Side cover long, pre-assembled 44875 Steel

20 ◊ Side cover short, pre-assembled 44876 Steel

30 ● Chain guard 45566 Steel



40/20 ◊ Spacer M4x30 501488 Steel








33

3.3.19. Side cover long, pre-assembled

3.3.20. Spare parts list side cover long, horizontal (44873)/ vertical (44875)


horizontal vertical

10 ◊ Side cover, long 44763 44788 Steel

20 ◊ Pressure pad 44789 44789 Steel

30 ● Centering ring 38374 38374 Aluminum

40 ◊ Guide screw 21629 21629 Steel

100 ● Self-aligning bearing 503611 503611 Steel

110 ◊ Cheese head screws

M5x16 503785 503785 Steel


M3x12 504371 504371 Steel

130 ◊ Lock washer M3 504374 504374 Steel


● These are wearing parts and available ex stock. ◊ Not available ex stock individually (upon request)


34

3.3.21. Side cover short, pre-assembled

3.3.22. Spare parts list side cover long, horizontal (44874)/ vertical (44876)


horizontal vertical

10 ◊ Side cover, short 44764 44787 Steel

20 ◊ Pressure pad 44789 44789 Steel

30 ● Centering ring 38374 38374 Aluminum

40 ◊ Guide screw 21629 21629 Steel

100 ● Self-aligning bearing 503611 503611 Steel


M5x16 503785 503785 Steel


M3x12 504371 504371 Steel





35

3.3.23. TB diverter roller drive

3.3.24. Spare parts list TB diverter roller drive


TB-105 TB-140 TB-185 TB-250

● Diverter rollers, drive 54886 58071 58072 58073 Various

10 ● Diverter roller, complete 38348 38349 38350 38351 Various

20 ● Tension roller, complete 38359 38360 38361 38362 Various

30 ● Drive roller 37237 40760 40761 40762 Various

40 ● Sprocket 44772 44772 44772 44772 Steel

50 ◊ Machine elements 508709 508709 508709 508709 Steel

50/10 ◊ Cheese head screws

M5x12 504384

504384 504384 504384 Steel

50/20 ◊ Lock washer M5 504345 504345 504345 504345 Steel

50/30 ◊ Spline 4x4x20 503604 503604 503604 503604 Steel



36

3.3.25. TBD diverter roller drive

3.3.26. Spare parts list TBD diverter roller drive


TBD-105 TBD-140 TBD-185 TBD-250

● Diverter rollers, drive 54887 56572 56574 56575 Various




40 ● Sprocket 44772 44772 44772 44772 Steel


50/10 ◊ Cheese head screws M5x12 504384 504384 504384 504384 Steel


50/30 ◊ Spline 4x4x20 503604 503604 503604 503604 Steel



37

4. Bypass Conveyor BPBE

4.1. Technical Data BPBE

For missing data see chapter on Conveyor.


The correct pretension for a conveyor belt is shown on the nameplate attached to the drive unit. For example: 1.2% After the belt has been mounted, two measuring marks (M) must be attached to the top of the belt in the untensioned state in such a way that they have a spacing (L) of e.g. 500 or 1000 mm. When the two tensioning screws (30) are uniformly tightened, the two measuring marks (M) move apart up to the dimension (L) which corresponds to the required pretension. Example for calculating the belt pretension

%2.1vandmm1000LWhen necloose ==

mm1012%2.1%100


(%)100

vLLL necloose

loosetaut ∗+=


38


4.2.1. Bypass conveyor BPBE with horizontal drive unit


39

4.2.2. Spare parts list BPBE horizontal with drive unit

Item Name Item no.

TB-105 TB-140 TB-185 TB-250


55388/…. 55389/…. 55390/…. 55391/….


54869/0084/…. 54869/0119/…. 54869/0164/…. 54869/0229/….



56990 56991 56992 56993

40 Horizontal drive unit single-belt

56907 56908 56909 56910

50 G80F/D63A-4 / 18.87:1 510003 510003 510003 510003

50 G80F/DB63A-4 / 7.1:1 510004 510004 510004 510004


44980 44980 44980 44980


44981 44981 44981 44981


44982 44982 44982 44982


44983 44983 44983 44983


40

4.2.3. BPBE drive unit horizontal

4.2.4. Spare parts list BPBE drive unit horizontal


TB-105 TB-140 TB-185 TB-250

◘ BPBE drive unit 56907 56908 56909 56910 Various

10 ◊ Side covers 56943 56943 56943 56943 Steel

20 ◊ Diverter rollers for drive 56911 56912 56913 56914 Steel

30 ● Guard plate 55054 55055 55056 56304 PS



41

4.2.5. BPBE side cover


42

4.2.6. Spare parts list side BPBE covers (56943)


TB / TBD - vertical

10 ◊ Side cover long, for bypass, pre-assembled 55141 Steel

20 ◊ Side cover short, for bypass, pre-assembled 55142 Steel

30 ◊ Side cover right, pre-assembled 55143 Steel

40 ◊ Side cover left, pre-assembled 55144 Steel

50 ● Chain guard 45566 ABS



60/20 ◊ Spacer M4x30 501488 Steel






60/80 ◊ Countersunk screw M6x12 504372 Steel

60/90 ◊ Countersunk screw M5x12 504373 Steel



43

4.2.7. Side cover long, for bypass, pre-assembled

4.2.8. Spare parts list side cover long (55141)


10 ◊ Side cover long, for bypass 55059 Steel

20 ● Bearing ring 55048 Aluminum

30 ◊ Pressure pad 44789 Steel

40 ◊ Guide screw 21629 Steel

100 ● Self-aligning bearing 507049 Steel

110 ◊ Pan head screws M6x12 504644 Steel

120 ◊ Cheese head screws M5x16 503785 Steel

130 ◊ Ribbed washer M6 505255 Steel




44

4.2.9. Side cover short to bypass, pre-assembled

4.2.10. Spare parts list side cover short (55142)


10 ◊ Side cover, short for bypass 55060 Steel

20 ● Bearing ring 55048 Aluminum










45

4.2.11. Side cover right, pre-assembled

4.2.12. Spare parts list side cover right (55143)


10 ◊ Side cover, right 55050 Steel



40 ◊ Countersunk screw M5x16 504564 Steel



46

4.2.13. Side cover left, pre-assembled

4.2.14. Spare parts list side cover left (55144)


10 ◊ Side cover, left 55049 Steel






47

4.2.15. BPBE diverter rollers drive

4.2.16. Spare parts list BPBE diverter rollers drive


TB-105 TB-140 TB-185 TB-250

◘ Diverter rollers, drive 56911 56912 56913 56914 Various




40 ● Sprocket 44772 44772 44772 44772 Steel


50/10 ◊ Cheese head screws

M5x12 504384

504384 504384 504384 Steel


50/30 ◊ Spline 4x4x20 503604 503604 503604 503604 Steel



48

5. Conveyor Coupling BKE

5.1. Commissioning


The correct pretension for a conveyor belt is shown on the nameplate attached to the chassis. For example: 0.6% After the belt has been mounted, two measuring marks (M) must be attached to the top of the belt in the untensioned state in such a way that they have a spacing (L) of e.g. 500 or 1000 mm. When the two tensioning screws (70) are uniformly tightened, the two measuring marks (M) move apart up to the dimension (L) which corresponds to the required pretension. Setting the required pretension of the conveyor belt

(%)100

vLLL necloose

loosetaut ∗+=

mm1012%2.1%100


%2.1vandmm1000LWhen necloose ==


49

5.1.2. Tracking of the conveyor belt

The belt must always run centrally over the diverter roller and the drive roller. Under no circumstances must the edges of the belt project over the ends of the rollers. The position of the belt running over the diverter rollers can be corrected by tightening or slackening the hex screws (70) while the belt is running.

5.2. Conveyor Belt

5.2.1. Technical data of the conveyor belt

Data pertinent to the conveyor and belt is found on the nameplate attached to the chassis and must be taken into consideration when ordering replacement belts.

5.2.2. Replacing an endless belt on the coupling conveyor

The installation of endless belts is recommended when the coupling conveyor is easily accessible or when the equipment needed for “welding” prepared end belts is not available. In particular, electrically or pneumatically supplied consumers mounted on the conveyor chassis side opposite to the synchronous belt drive, as well as floor stands and table stands, must be removed to replace an endless belt. Procedure: – Switch off the motor of the traction conveyor and disconnect from mains voltage. – Slacken the conveyor belt by alternately loosening the two screws “70”. – Remove the countersunk screws (160); remove WTE support (80). – Unscrew the two countersunk screws (140) that secure the end piece to the chassis and remove the end piece (20). – The belt can now be changed. – Reassemble the conveyor coupling in the reverse order. – For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor belt”. – To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

5.2.3. Replacing belts by “welding” their ends

Pulling in new belts and “welding” their ends is the preferred method of belt replacement where accessibility to previous operations is severely restricted. A prerequisite for this method of assembly is the availability of belt welding equipment.


50

Exact instructions for the “welding operation” can be obtained when ordering the new belts. Procedure: – Switch off the motor of the traction conveyor and disconnect from mains voltage. – Slacken the conveyor belt by alternately loosening the two screws (70). – Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with adhesive tape). – Slowly pulling the old belt automatically pulls the new one through the system. – “Weld” the ends of the new belt according to the manufacturer’s instructions. – For pre-tensioning the belt see the section on “Setting the required pretension of the conveyor belt”. – To ensure that the belt runs straight, see the section on “Tracking of the conveyor belt”.

5.3. Maintenance / Repairs

5.3.1. Replacing the synchronous belt

– Switch off the motor of the traction conveyor and disconnect from mains voltage. – Remove the casing (110) by unscrewing the two pan head screws (140). – Loosen countersunk screw (160) and remove together with washer (190). – Pull off toothed lock washer (80) from the drive roller (50). – Replace synchronous belt (210). – Assemble in the reverse order. – The countersunk screw (160) must be secured with Loctite # 234.


51

5.3.2. Replacing the drive rollers on the traction conveyor

– Switch off the motor of the traction conveyor and disconnect from mains voltage. – Remove the casing (100) by unscrewing the two pan head screws (130). – Loosen countersunk screw (150) and remove together with washer (180). – Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). – Remove synchronous belt (200). – Remove splines (120). – Remove the two countersunk screws (160); remove WTE support (80). – Slackening the traction conveyor belt. – Unscrew the two countersunk screws (140) that secure the end piece (30) to the chassis and remove the end piece (30). – Remove drive rollers (50). – When replacing the self-aligning ball bearing (210) or the drive roller (50) the inner ring and the bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 (shaft-hub joint). It is essential to allow the adhesive to harden for 24 hours. – Assemble in the reverse order. – The countersunk screw (160) must be secured with Loctite # 234.


52

5.3.3. Replacing the drive rollers on the single-belt coupling conveyor

– Switch off the motor of the traction conveyor and disconnect from mains voltage. – Remove the casing (100) by unscrewing the two pan head screws (130). – Loosen countersunk screw (150) and remove together with washer (180). – Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). – Remove synchronous belt (210). – Loosen setscrew (170). – Pull off toothed lock washer (60) from the drive roller (50). – Remove splines (120). – Remove the two countersunk screws (160); remove WTE support (80). – Slacken the coupling conveyor belt by alternately loosening the two screws (70). – Unscrew the two countersunk screws (140) that secure the end piece (20) to the chassis and remove the end piece (20). – Remove drive rollers (50). – When replacing the self-aligning ball bearing (210) or the drive roller (50) the inner ring and the bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 (shaft-hub joint). It is essential to allow the adhesive to harden for 24 hours. – Assemble in the reverse order. – The countersunk screw (160) must be secured with Loctite #234.


53

5.3.4. Replacing the drive rollers on the twin-belt coupling conveyor

– Switch off the motor of the traction conveyor and disconnect from mains voltage. – Remove the casing (100) by unscrewing the two pan head screws (130). – Loosen countersunk screw (150) and remove together with washer (180). – Pull off toothed lock washer (70) and sleeve (90) from the drive roller (50). – Remove synchronous belt (210). – Release screw (170). – Pull off toothed lock washer (60) from the drive roller (50). – Remove splines (130). – Remove the two countersunk screws (160); remove WTE support (80). – Slacken the coupling conveyor belt by alternately loosening the two screws (70), Fig. 2. – Unscrew the two countersunk screws (150) that secure the end piece (20) to the chassis and remove the end pieces (20). – Remove drive rollers (60). – When replacing the self-aligning ball bearing (220) or the drive roller (50) the inner ring and the bearing seat on the drive roller must first be degreased and then adhesively bonded with Loctite 641 (shaft-hub joint).It is essential to allow the adhesive to harden for 24 hours. – Assemble in the reverse order. – The countersunk screw (160) must be secured with Loctite # 234.


54

5.4. Maintenance

Belt conveyors are maintenance free when they are employed in accordance with their purpose and are not exposed to any factors likely to shorten the useful life. The purpose and the factors likely to shorten life are listed in the declaration of conformity. When the belts are exposed to the action of dust, oily air, foreign matter such as metal chips from machine tools, etc., we recommend that they should be regularly cleaned, e.g. once a week, with pure gasoline.

5.5. Repairs

The operating instructions contain the necessary spare parts lists and exploded drawings for repairs to the mechanical part of the conveyor. The safety instructions must also be followed. Repairs to the electrical part may be carried out only by the supplier. It is essential to follow the safety instructions for electrical disconnection of components from the mains or from the motor and for subsequent reinstallation.


55


5.6.1. Conveyor coupling TB/TB and TB/TBD

5.6.2. Spare parts list conveyor coupling TB/TB and TB/TBD

Item Name Item no.



55388/…. 55389/…. 55390/…. 55391/….


54869/0084/…. 54869/0119/…. 54869/0164/…. 54869/0229/….


20 Conveyor end to BKE TB/TB with diverter roller, single-belt

55208 55209 55210 55298

20 Conveyor end to BKE TB/TBD with diverter roller, twin-belt

55211 55212 55213 55297

30 Conveyor coupling for TB/TB 55396 55397 55398 56299

30 Conveyor coupling for TB/TBD 55399 55400 55401 56296


56

5.6.3. BKE conveyor end with diverter roller, single-belt

5.6.4. Spare parts list BKE conveyor end TB/TB with diverter roller, single-belt


TB-105 TB-140 TB-185 TB-250




complete 36546

36546 36546 36546 Steel




57

5.6.5. BKE conveyor end with diverter roller, twin belt

5.6.6. Spare parts list BKE conveyor end TBD/TB with diverter roller, twin-belt


TBD-105 TBD-140 TBD-185 TBD-250

◘ Conveyor end, complete 55211 55212 55213 56297



complete 36546

36546 36546 36546 Steel




58

5.6.7. Conveyor coupling for TB/TB


59

5.6.8. Spare parts list conveyor coupling for TB/TB with diverter roller, single-belt


TB-105 TB-140 TB-185 TB-250

◘ Conveyor coupling,

complete 55396 55397 55398 56299 Various

10 ◊ End piece right for BKE 55190 55190 55190 55190 Various

20 ◊ End piece left for BKE 55191 55191 55191 55191 Various

30 ◊ End piece left for TB 55188 55188 55188 55188 Various

40 ◊ End piece right for TB 55189 55189 55189 55189 Various

50 ● Drive roller for BKE 55125 55126 55127 56127 Steel

60 ● Toothed lock washer

5MR-21S 55137 55137 55137 55137 Aluminum


5MR-21S 55138 55138 55138 55138 Aluminum

80 ◊ WT support 55118 55119 55120 56128 Steel

90 ◊ Sleeve 55140 55140 55140 55140 Steel

100 ◊ Casing 55139 55139 55139 55139 Steel

110 ● Synchronous belt

5MR-200-15 508454 508454 508454 508454 Plastics


120/130 ◊ Spline 3x3x18 508453 508453 508453 508453 Steel

120/140 ◊ Countersunk screw M5x10 504901 504901 504901 504901 Steel


120/160 ◊ Setscrew M3x6 501886 501886 501886 501886 Steel

120/170 ◊ Setscrew washer M5 504381 504381 504381 504381 Steel



60

5.6.9. Conveyor coupling for TBD/TB


61

5.6.10. Spare parts list conveyor coupling for TBD/TB with diverter roller, twin-belt


TBD-105 TBD-140 TBD-185 TBD-250

◘ Conveyor coupling,

complete 55399 55400 55401 56296 Various

10 ◊ End piece right for BKE 55190 55190 55190 55190 Various

20 ◊ End piece left for BKE 55191 55191 55191 55191 Various

30 ◊ End piece left for TB 55188 55188 55188 55188 Various

40 ◊ End piece right for TB 55189 55189 55189 55189 Various

50 ● Drive roller for BKE TB 55125 55126 55127 56127 Steel

60 ● Drive roller for BKE TBD 55192 55193 55194 56295 Steel


5MR-21S 55137 55137 55137 55137 Aluminum


5MR-21S 55138

55138 55138 55138 Aluminum

90 ◊ WT support 55118 55119 55120 56128 Steel

100 ◊ Sleeve 55140 55140 55140 55140 Steel

110 ◊ Casing 55139 55139 55139 55139 Steel

120 ● Synchronous belt

5MR-200-15 508454 508454 508454 508454 Plastics


130/130 ◊ Spline 3x3x18 508453 508453 508453 508453 Steel



130/160 ◊ Setscrew M3x6 501886 501886 501886 501886 Steel

130/170 ◊ Setscrew washer M5 504381 504381 504381 504381 Steel



62

5.6.11. End piece left for TB/TBD

5.6.12. Spare parts list end piece left for TB/TBD (55188)


10 ◊ End piece left 55117 Aluminum


30 ◘ T-nut 21913 Steel




63

5.6.13. End piece right for TB/TBD

5.6.14. Spare parts list end piece right for TB/TBD (55189)


10 ◊ End piece right 55114 Aluminum





60 ◊ Ribbed washer M6 Steel



64

5.6.15. End piece right for BKE

5.6.16. Spare parts list end piece right for BKE (55190)


10 ◊ End piece right 55115 Aluminum


30 ◊ Cheese head pin ø5x10 502047 Steel







65

5.6.17. End piece left for BKE

5.6.18. Spare parts list end piece left for BKE (55191)


10 ◊ End piece left 55116 Aluminum


30 ◊ Cylindrical pin ø5x10 502047 Steel





66

6. Fixed Curve 90° KFE

6.1. Use

To divert a workpiece holder WTE by 90° at the belt end (version E) or in any other place of the conveyor (version M).

6.2. Commissioning

6.2.1. Curve fixed 90° KFE 105, 140, 185 and 250, version M

– Specify position of the conveyor, dimension X. – Mount fastening bracket (40). – Center and snap on finger protection device (30).


67

– Evenly align the curve on the inside (20) and fix with a screw clamp. – Align the curve on the outside (10) and fix with a screw clamp. – Through the fastening holes of the curve, inside and outside, drill the chassis with a 4.3 mm Ø drill. – Remove curves. – With a 3.6 mm Ø drill, drill 12 mm deep from the upper edge of the chassis. – Fasten the curves with thread-cutting oval head screws (50). – Assemble lateral guides


68

6.2.2. Curve fixed 90° KFE 105, 140, 185 and 250, version E

– Insert special T-nut (10) into the T-slot of the chassis so it is flush. – Screw in and tighten setscrew (90). – Connect the two chassis with the chassis binder (20). – For reinforcement, screw on brackets (40).


69

– Center and snap on finger protection device (30) – Evenly (=) align the inside curve (20) and fix with a screw clamp. – Align the curve on the outside (10) and fix with a screw clamp. – Through the fastening holes of the curve, inside and outside, drill the chassis with a 4.3 mm Ø drill. – Remove curves. – With a 3.6 mm Ø drill, drill 12 mm deep from the upper edge of the chassis. – Fasten the curves with thread-cutting oval head screws (50). – Assemble lateral guides


70


6.3.1. Fixed curve 90° KFE 105, 140, 185, and 250, version M

6.3.2. Spare parts list fixed curve KFE, version M


TB-105 TB-140 TB-185 TB-250

◘ Fixed curve 49634 49633 49632 56313 Various

10 ● Curve, outside 49479 49486 49489 56013 PE

20 ● Curve, inside 49485 49488 49490 56012 PE

30 ● Finger protection device 49641 49642 49643 56314 PE

40 ◊ Connection 90° (pair) 49628 49628 49628 49628 Steel

50 ◊ Thread-forming

oval head screw M4x20 508972 508972 508972 508972 Steel



71

6.3.3. Fixed curve 90° KFE 105, 140, 185, and 250, version E

6.3.4. Spare parts list fixed curve KFE, version E


TB-105 TB-140 TB-185 TB-250

◘ Fixed curve 49617 49618 49619 56312 Various

10 ● Curve, outside 49479 49486 49489 56013 PE

20 ● Curve, inside 49485 49488 49490 56012 PE


40 ◊ Connection 90° 49393 49394 49395 56311 Steel

50 ◊ Thread-forming

oval head screw M4x20 508972 508972 508972 508972 Steel



72

6.3.5. Connection 90° for KFE, version M

6.3.6. Spare parts list connection 90° for KFE, version M (49628)



20 ◊ Fastening bracket 54547 Steel

30 ◊ Cheese head screw M6x12 504644 PE




73

6.3.7. Connection 90° for KFE, version E

6.3.8. Spare parts list connection 90° for KFE, version E

Item Sym. Name TB-105 TB-140 TB-185 TB-250 Material

◘ Item no. 49393 49394 49395 56311

10 ◊ Special T-nut 49322 49322 49322 49322 Steel

20 ◊ Connection plate 90° 49323 49324 49325 56310 Steel

30 ◘ T-nut 21913 21913 21913 21913 Steel

40 ◊ Fastening bracket 54547 54547 54547 54547 Steel

50 ◊ Cheese head screw M5x10 506396 506396 506396 506396 Steel

60 ◊ Ribbed washer M5 505254 505254 505254 505254 Steel



90 ◊ Setscrew M6x8 505116 505116 505116 505116 Steel



74

7. Movable Curve 90° KBEA/KBE

7.1. Use

The curve KBE is used for inward and outward transfer of a workpiece holder WTE into a perpendicular work flow. A stopper should be provided on the inward transfer side.

7.2. Technical Data

7.2.1. Changeover times

Curve with drive 7.5 m/min. 9.5 m/min. 11.5 m/min. 14.5 m/min. 19.9m/min.

KBEA-105 3.7 3.2 2.6 2.2 1.9

KBEA-140 4.7 3.9 3.3 2.8 2.5

KBEA-185 5.7 4.7 3.9 3.5 2.9

KBEA-250 6.8 5.6 4.5 3.8 3.1

The times given include the setting and resetting time of the curve and the transit time of the workpiece holder.

Curve without drive 7.5 m/min. 9.5 m/min. 11.5 m/min. 14.5 m/min. 19.9m/min.

KBE-105 2.9 2.3 1.9 1.6 1.4

KBE-140 3.6 2.9 2.5 2.2 1.8

KBE-185 4.7 3.9 3.0 2.6 2.2

KBE-250 6.2 5.0 4.0 3.4 2.7

The times given include the setting time of the curve and the transit time of the workpiece holder.


75

7.3. Commissioning

7.3.1. Setup of curve with drive (outward transfer) and the necessary accessories

Proximity switch Item no. 508845

Stopper VSE Item no. 49612

Holder for proximity-switch HNEB Item no. 54634




76

7.3.2. Setup of curve without drive (inward transfer) and the necessary accessories







77

7.3.3. Checking and setting the drive unit

– The drive unit/bearing mount (10) must be mounted at an axle distance of 60 mm from the end of the chassis. – The axle must be at a right angle to the chassis. – There should be a space of 1 mm between the curve lever (20), the lateral guides, and the inside curve (30). – If that is not the case, the drive unit/bearing mount (10) must be set to the specified values by loosening the two screws (130). – The stop (50) must be positioned so that the buffer (90) can hit it. – Check whether there is sufficient contact pressure between the curve lever (20) and the stop (50) and (100) (only for curve with drive). – If not, reset the swivel angle


78

7.3.4. Checking and setting the bearings


79

7.3.5. Flowchart for curve with drive (outward transfer)

straight

Z1 Cylinder, double-acting Stopper

Z2 Cylinder, double-acting Drive unit

N1 Proximity switch Presence

N2 Proximity switch Presence/ queue monitoring

N3 Proximity switch Drive unit cylinder OFF

N4 Proximity switch Drive unit cylinder ON

N5 Proximity switch Stopper cylinder ON

N6 Proximity switch Stopper cylinder OFF


queuing

outw

ard


80

Start

Z1 OFF

N6 assigned

Z2 OFF

noyes

N3 assigned

N2 unassigned

N7 unassigned

outwardtransfer

N1 assigned

no

noyes

yes

outwardtransfer

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N7 unassigned

Z1 OFF

T delay time

Z1 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N4 assigned

Z2 ON

no

yesstraight

yes

no

no

noyes


81

7.3.6. Flowchart for curve with drive (inward transfer)

straight










tran

sfer

queuing


82

Start

Z1 OFF

N5 assigned

Z2 OFF

noyes

N6 assigned

N3 unassigned

inward transfer

N2 assigned

no

no

yes

yes

inwardtransfer

T expired

N7 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N3 unassigned

T expired

N5 assigned

Z1 OFF

T delay time

Z1 ON

N5 assignedno

no

no

no

yes

yes

yes

yes

N1 assignedno

yesstraight

yes no

no


83

7.4. Maintenance and Repairs

7.4.1. Replacing the drive cylinder

– Turn off system. – Bleed compressed air system. – Remove drive by loosening the two screws (130) (see next page). – Remove the two pneumatic hoses from the exhaust air valve (90). – Release clip (70/2) and pull down out of the fork end (70/1). – Remove the two setscrews with shank (110). – Remove cylinder (80/1). – Remove the fork end (70/1) and the hex nuts (80/2) and (80/3), disassemble ring (30) from the defective cylinder and mount on the new cylinder. Care must be taken to screw the fork end back to its original size. – Assemble in the reverse order – Check swivel angles and reset, if necessary


84

7.4.2. Replacing the drive unit

– Turn off system. – Bleed compressed air system. – Loosen countersunk screw (140) and washer (170) and remove. – Pull curve lever (20) up and out. – Remove pad (40). – Remove the two screws (130) and remove. – Replace drive unit (10). – Assemble in the reverse order. – Check swivel angles and reset, if necessary.


85

7.4.3. Checking and setting the swivel angle

– Extend cylinder. – The curve lever (20) must be on position 1. – Check if the curve lever applies noticeable pressure to the stop (50). – If yes, continue with point 16; if not, continue with point 5. – Turn off system. – Bleed compressed air system. – Release clip (70/2) and pull down out of the fork end (70/1). – Swivel cylinder (80/1) out. – Loosen hex nut (80/3). – Loosen fork end approx. ½ turn – Tighten hex nut (80/3). – Swivel cylinder (80/1) in. – Mount clip (70/2). – Turn on system. – Perform steps 1 to 3. – Retract cylinder. – The curve lever (20) must be on position 2. – Check if the curve lever applies noticeable pressure to the stop (100). – If not, the procedure is the same as starting with point 6; except in point 10, the fork end must be screwed in ½ turn.


86


87


7.5.1. Movable curve with drive


88

7.5.2. Spare parts list movable curve with drive


◘ Item no. 54506 54629 54613 56011

10 ◊ Drive 54502 54502 54502 54502 Steel

20 ●

Curve lever 54511 54509 54510

56008 PA/aluminum

30 ● Curve, inside 54504 54519 54514 56007 PE

40 ◊ Pad D=32 54501 54501 54501 54501 Steel

50 ◊ Stop 54630 54630 54630 54630 Steel



90 ◊ Buffer 54497 54497 54497 54497 Polycord

100 ◊ Pneumatic hose ø6/4 502745 502745 502745 502745 PUR

110 ◘ T-nut 21913 21913 21913 21913 Steel


140 ◊ Countersunk screw M6x10 506710 506710 506710 506710 Steel


160 ◊ Thread-forming oval head screw M4x20

508972 508972 508972 508972 Steel


180 ◊ Setscrew washer M6 504380 504380 504380 504380 Steel



89

7.5.3. Movable curve without drive


90

7.5.4. Spare parts list movable curve without drive


◘ Item no. 54610 54612 54614 56375

10 ◊ Bearing 54531 54531 54531 54531 Steel

20 ●

Curve lever 54511 54509 54510

56008 PA/aluminum

30 ● Curve, inside 54504 54519 54514 56007 PE

40 ◊ Pad D=32 54501 54501 54501 54501 Steel

50 ◊ Stop 54630 54630 54630 54630 Steel


70 ◊ Fastening bracket left 54548 54548 54548 54548 Steel


90 ◊ Buffer 54497 54497 54497 54497 Polycord

100 ◊ Pneumatic hose ø6/4 502745 502745 502745 502745 PUR

110 ◘ T-nut 21913 21913 21913 21913 Steel





508972 508972 508972 508972 Steel





91

7.5.5. Drive for curve


92

7.5.6. Spare parts list drive for curve (54502)


10 ◊ Console for drive 56374 Steel

20 ◊ Shaft for drive 56372 Steel

30 ◊ Ring for drive 54500 Steel

40 ◊ Lever 54488 Steel

50 ● Deep groove ball bearing 520036 Steel

60 ◊ Sliding bearing with collar 508361 Steel

70 ● Fork end SG-M6 503616 Steel

80 ● ISO cylinder CD85N16-40B SMC 508373 Steel

90 ◊ Ex air valve fitting M5 505023 Steel

100 ◊ Countersunk screws M5x10 504901 Steel

110 ◊ Setscrew with shank M5x12 508375 Steel

130 ◊ Setscrew washer M5 504381 Steel

140 ◊ Retaining ring ø10 502448 Steel

150 ◊ Warning sign 54792 Steel



93

7.5.7. Bearing mount for curve

7.5.8. Spare parts list bearing mount for curve (54531)


10 ◊ Console for drive 56371 Steel

20 ◊ Shaft for bearing 56373 Steel





94

7.5.9. Stop for movable curve and bypass

7.5.10. Spare parts list stop for movable curve and bypass (54630)


10 ◊ Stop 54631 Steel


30 ◊ Cheese head screw M6x12 504644 Steel

40 ◊ Lock washer M6 504744 Steel



95

8. Rotary Diverter UR-180°

8.1. Use

The rotary diverter UR is used to turn the workpiece holder WTE by 180°. In order to prevent queues in the UR, a stopper for inward transfer and queue monitoring for outward transfer must be provided. Under no circumstances must the product-specific ratings listed on the name plate be exceeded.


The safety instructions, in particular those relating to electrical connections, must be followed in all phases of commissioning, operation and during maintenance and service work. Failure to follow these instructions is considered a misuse of the rotary diverter. Operating a rotary diverter in an explosive atmosphere (flammable gases, vapors, or dust) can result in their combustion and shall be avoided. Never perform service or setting work on your own. In all cases, there must be a second person present who can shut of the main power and administer first aid, if necessary. The mechanical contact guard may only be disassembled after the rotary diverter has been disconnected from the main power supply.

8.3. Commissioning

8.3.1. Electrical connections

General safety instructions The operator of the rotary diverter must have the electrical connection, the commissioning, the adjustment and the servicing carried out by qualified persons. Work on the electrical parts is particularly dangerous. Using the rotary diverter without a mechanical switch in the supply line is prohibited. To achieve optimal protection from the contact guard, the motor must be connected to the ground of the supply network. Mains voltage connection 3x400V (Reverse rotation by exchanging two phases)

Star connection


96

8.3.2. Flowchart for UR (key)







97

Start

Z1 OFF

N3 occupiedno

yes

N1 occupied

N4 occupiedno

no

yes

no

yes

N3 occupied

yes

N2 free

Delay timeT1 for Z1

=0

yes

Z1 ON

END OFPROGR.

yes

no

Z1 OFF

END

yes

no

no

yes


98


8.4.1. Replacing the conveyor disc

– Switch off motor and disconnect from mains voltage. – Remove protective plug (180). – Remove guide disc (30) and intermediate ring (50) by removing the four screws (260). – Replace the conveyor disc (140). – Assemble in the reverse order (slide conveyor disc (140) under lateral guide)


99

8.4.2. Replacing the diverter rollers

– See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” – Remove the two screws (230) and the ribbed washer (320). – Remove the four countersunk screws (250) from the round table (10) ; disassemble roller bracket (90) and diverter rollers (150). – Remove countersunk screw (250) from diverter roller (150) and diverter roller (150) from roller bracket (90). – Replace diverter roller (150). – Assemble in the reverse order (slide conveyor disc (140) under lateral guide).


100

8.4.3. Replacing the spur wheel back-geared motor

– Switch off motor and disconnect from mains voltage. – Remove protective plug (180). – Remove guide disc (30) and intermediate ring (50) by removing the four screws (260). – Remove the conveyor disc (140). – Loosen screw (240) and remove with washer (70). – Remove sliding hub (170). – Unscrew the four screws (190). – Replace the spur wheel back-geared motor. – Assemble in the reverse order (slide conveyor disc (140) under lateral guide).


101

8.4.4. Replacing the sliding hub

– See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” – Replace the sliding hub. – Assemble in the reverse order (slide conveyor disc (140) under lateral guide).

8.4.5. Adjusting the sliding hub

– See chapter “Replacing the spur wheel back-geared motor” up to “Removing sliding hub.” – Check the idle torque. If lever L=500 mm, the leverage force is

UR-1 UR-2 UR-3 UR-4

8-10N 9-11N 10-12N 13-16N

– Set test torque: Loosen guard panel; tighten nut until a lever force of L=500mm is measured at the lever (see table below). When measuring, lock the ventilator wheel of the motor.

UR-1 UR-2 UR-3 UR-4

29N 32N 36N 49N

– Once the test torque has been set, secure the nut with the guard panel. – Assemble in the reverse order.


102


8.5.1. Rotary diverter 180°


103

8.5.2. Spare parts list rotary diverter 90°


◘ Item no. 56214 56280 56281 56282

10 ◊ Round table 56204 56230 56232 56243 Steel

20 ◊ Guide panel 56206 56219 56220 56221 Steel

30 ◊ Guide disc 56197 56236 56237 56238 PE

40 ● Lateral guide 56338 56340 56339 56227 PE

50 ◊ Intermediate ring 56198 56198 56198 56198 Steel

60 ◊ Friction plate 56201 56201 56201 56201 Steel

70 ◊ Washer 56196 56196 56196 56196 Steel

80 ◊ Adapter 56199 56199 56199 56199 Aluminum

90 ◊ Roller bracket 56211 56211 56211 56211 Steel

100 ◊ Connection tab 40496 40496 40496 40496 Steel

110 ◊ Angle 56200 56200 56200 56200 Steel

120 ◘ T-nut 21913 21913 21913 21913 Steel

130 ◊ Spacer 40598 40598 40598 40598 Steel

140 ● Conveyor disc 42885 42886 42832 56228 TT-04/XVT-2286


160 ● Gear motor G80F 510002 510002 510002 510002 Various

170 ● Sliding hub RT40.2 508808 508808 508808 508808 Steel

180 ◊ Protective plug TL-4-500 504705 504705 504705 504705 PE


M8x16 501781 501781 501781 501781 Steel


M6x18 504383 504383 504383 504383 Steel


M6x12 504644 504644 504644 504644 Steel

220 ◊ Cheese head screws M6x8 505183 505183 505183 505183 Steel


M5x10 506181 506181 506181 506181 Steel


M4x16 505328 505328 505328 505328 Steel



270 ◊ PT screw 503531 503531 503531 503531 Steel

280 ◊ Setscrew M6x6 504377 504377 504377 504377 Steel


104






340 ◊ Hex nut M6x0.8d 504757 504757 504757 504757 Steel



105

9. Bypass BPEA/BPE

9.1. Use

The bypass BPE is used for inward and outward transfer of a workpiece holder WT into a parallel work flow. Both a manual station and an automatic station can be installed in a bypass. Stoppers VSEB or indexing device IVEB should be used for stopping and indexing.

9.2. Technical Data


Bypass with drive 7.5 m/min. 9.5 m/min. 11.5 m/min. 14.5 m/min. 19.9m/min.

BPEA-105 5.3 4.4 3.6 3.0 2.5

BPEA -140 6.3 5.1 4.0 3.5 2.8

BPEA -185 6.8 5.8 4.5 3.9 3.2

BPEA -250 8.8 7.2 5.9 5.0 4.2

The times given include the setting and resetting time of the bypass and the transit time of the workpiece holder.

Bypass without drive 7.5 m/min. 9.5 m/min. 11.5 m/min. 14.5 m/min. 19.9m/min.

BPE-105 - - 2.8 2.4 1.9

BPE -140 - - 4.1 3.6 3.0

BPE -185 - - 4.3 3.6 2.9

BPE -250 - - 5.8 4.8 4.0

The times given include the setting time of the bypass and the transit time of the workpiece holder.


106

9.3. Commissioning

9.3.1. Setup of bypass with drive (inward transfer) and the necessary accessories

Bypass belt Endless belt

Bracket for proximity switch HNEB Item no. 54634



Queue monitoring


107

9.3.2. Setup of bypass without drive (outward transfer) and the necessary accessories

Bypass belt Endless belt



Bracket for proximity switchHNEB Item no. 54634



Stopper VSEB with air connection left Item no. 54581

Queue monitoring


108

9.3.3. Settings Bypass with drive right and left

Endless belt Bypass belt Endless belt Bypass belt Bypass with right drive and left drive Endless belt Bypass belt Endless belt Bypass belt

These settings also apply to bypass without drive left and right.

The chassis binder must be mounted so that the bypass conveyor is 0.5 mm lower than the endless belt. Caution: Make sure installation position is correct!

The support for bypass must be set to the same height as the belt of the endless belt.

Support

Chassis binder


109

9.3.4. Flowchart for bypass with drive (outward transfer)

outward transfer straight










queuing


110

Start

Z1 OFF

N4 assigned

Z2 ON

noyes

N6 assigned

N1 unassigned

outwardtransfer

N1 assigned

no

no

yes

yes

outwardtransfer

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N7 assigned

Z2 OFF

no

yesstraight

yes

no

no

noyes

N2 unassigned

no

N3 unassigned


111

9.3.5. Flowchart for bypass without drive (inward transfer)

transfer inward straight










queuing


112

Start

Z1 OFF

N5 assignedno

yes

N2 unassigned

N3 unassigned

inward transfer

N2 assigned

no

inwardtransfer

T expired

N6 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N7 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N4 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 EIN

N5 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yesstraight

yes

no

no

noyes

Z2 OFF

N7 assigned

N1 unassigned

no

no

yes

yes

yes


113

9.3.6. Flowchart for bypass with drive (inward transfer)

transfer inward straight













queuing


114

Start

Z1 OFF

N5 assigned

Z3 ON

no

yes

N2 unassigned

N9 assigned

N3 unassigned

inward transfer

N2 assigned

no

no

yes

yes

inwardtransfer

T expired

N6 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N7 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N4 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N5 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N8 assigned

Z3 OFF

no

yesstraight

yes

no

no

noyes

Z2 OFF

N7 assigned

N1 unassigned

no

noyes

yes


115



– Turn off system. – Bleed compressed air system. – Remove the two pneumatic hoses (150) from the exhaust air valve (110). – Release clip (90/2) and pull down out of the fork end (90/1). – Swivel cylinder (100/1) out. – Remove retaining ring (170). – Remove cylinder (100/1). – Remove the fork end (90/1) and exhaust air valve (110) from the defective cylinder and mount on the new cylinder. Care must be taken to screw the fork end back to its original size. – Assemble in the reverse order. – Check swivel angles and reset, if necessary.


116


– Extend cylinder. – The curve lever for bypass (60) must be on position 2. – Check if the curve lever for bypass applies noticeable pressure to the stop (40). – If yes, continue with point 16; if not, continue with point 5. – Turn off system. – Bleed compressed air system. – Release clip (90/2) and pull down out of the fork end (90/1). – Swivel cylinder (100/1) out. – Loosen hex nut (100/2). – Loosen fork end approx. ½ turn. – Tighten hex nut (100/2). – Swivel cylinder (100/1) in. – Mount clip (90/2). – Turn on system. – Perform steps 1 to 3. – Retract cylinder. – The curve lever for bypass (60) must be on position 1. – Check if the curve lever for bypass applies noticeable pressure to the stop (30). – If not, the procedure is the same as starting with point 6; except in point 10, the fork end must be screwed in ½ turn.

Schwenkwinkel = swivel angles


117


– Turn off system. – Bleed compressed air system. – Loosen countersunk screw (120) and washer (140) and remove. – Pull curve lever up and out. – Remove pad (70). – Loosen and remove the three screws (130). – Remove curve for bypass (50). – Loosen the two hex screws (40) and slide sideways out of the chassis binder (20). – Remove endless belt so that the hex screws (30) can be unscrewed. – Mark the position of the drive unit on the bearing and its angle. (This is to circumvent aligning the drive unit.) – Unscrew the four hex screws (30). – Replace drive unit (10) and reinstall in the location marked. – Assemble in the reverse order. – Check swivel angles and reset, if necessary.


118


9.5.1. Bypass with drive


119

9.5.2. Spare parts list bypass right and left with drive


TB-105 TB-140 TB-185 TB-250

◘ Bypass right 54493 54565 54569 56358 Various

◘ Bypass left 54632 54567 54571 56359 Various

10 ◊ Drive 54486 54486 54486 54486 Various

20 ◊ Chassis binder 54607 54607 54607 54607 Various

30 ◊ Stop 54630 54630 54630 54630 Steel

40 ◊ Pneumatic hose ø6/4 502745 502745 502745 502745 PU

50 ● Curve right 54490 54523 54526 56290 PE

50 ● Curve left 54489 54522 54525 56288 PE

60 ● Curve lever right 54491 54521 54524 56438 PA/aluminum

60 ● Curve lever left 54491 54521 54524 56289 PA/aluminum

70 ◊ Pad D=25 54484 54484 54484 54484 Steel

80 ◊ Support 54487 54529 54530 - Steel

90 ◊ Buffer 54497 54497 54497 54497 PUR

100 ◘ T-nut 21913 21913 21913 - Steel

110 ◊ Hex screw with ribs M6x10

508376 508376 508376 - Steel




508972 508972 508972 508972 Steel




120

9.5.3. Bypass without drive


121

9.5.4. Spare parts list bypass right and left without drive


TB-105 TB-140 TB-185 TB-250

◘ Bypass right 54494 54566 54570 56360 Various

◘ Bypass left 54564 54568 54572 56361 Various

10 ◊ Bearing 54496 54496 54496 54496 Various

20 ◊ Chassis binder 54607 54607 54607 54607 Various

30 ◊ Stop 54630 54630 54630 54630 Steel

40 ◊ Pneumatic hose ø6/4 502745 502745 502745 502745 PU

50 ● Curve right 54490 54523 54526 56290 PE

50 ● Curve left 54489 54522 54525 56288 PE

60 ● Curve lever right 54491 54521 54524 56438 PA/aluminum

60 ● Curve lever left 54491 54521 54524 56289 PA/aluminum

70 ◊ Pad D=25 54484 54484 54484 54484 Steel

80 ◊ Support 54487 54529 54530 - Steel

90 ◊ Buffer 54497 54497 54497 54497 PUR

100 ◘ T-nut 21913 21913 21913 - Steel

110 ◊ Hex screw with ribs M6x10

508376 508376 508376 - Steel




508972 508972 508972 508972 Steel




122

9.5.5. Drive for bypass


123

9.5.6. Spare parts list drive for bypass (54486)


10 ◊ Holder 56366 Steel

20 ◊ Shaft 56367 Steel

30 ◊ Angle 54483 Steel

40 ◊ Peg 54485 Steel

50 ◊ Lever 54488 Steel



80 ● Fork end SG-M6 503616 Steel

90 ● ISO cylinder CD85N16-40B SMC 508373 Steel

100 ◊ Ex air valve fitting M5 505023 Steel

110 ◊ Hex screw M6x12 508372 Steel


130 ◊ Setscrew washer M5 504381 Steel



170 ◊ Warning sign 54792 Steel



124

9.5.7. Bearing for bypass

9.5.8. Spare parts list bearing for bypass (54496)


10 ◊ Holder 56366 Steel

20 ◊ Shaft 56368 Steel




60 ◊ Hex screw M6x12 508372 Steel


9.5.9. Spare parts list stop for bypass (54630)

See chapter 7, “Movable Curve 90°” (Stop for movable curve and bypass).


125

10. Transfer Gate WEE

10.1. Use

Transfer gates WEE are used to divert a workpiece holder WTE from a conveyor to two (inward transfer gate), or from two conveyors to one conveyor (outward transfer gate). A stopper should be provided on the inward transfer side.

10.2. Technical Data


Bypass with drive 7.5 m/min. 9.5 m/min. 11.5 m/min. 14.5 m/min. 19.9m/min.

WEE-105 3.4 2.7 2.3 2.1 1.7

WEE-140 4.1 3.4 2.8 2.5 2.2

WEE-185 5.8 4.7 3.9 3.5 2.8

The times given include the setting and resetting time of the transfer gate and the transit time of the workpiece holder.

10.3. Commissioning

10.3.1. Setup of inward transfer gate WEE and the necessary accessories


Bracket for proximity switch HNEB



126

10.3.2. Setup of outward transfer gate WEE and the necessary accessories





127

10.3.3. Checking and setting the drive unit

– The drive unit (10) must be installed centered (=) to the incoming chassis. – The axle must be at a right angle to the chassis. – Between the transfer gate (20), the lateral guides, and the inside curve (30) should be a space of 1 mm. – If that is not the case, the drive unit (10) must be set to the specified values by loosening the two screws (100). – Check if the transfer gate (20) applies noticeable pressure to the stop (70), both on the left and right sides. – If not, reset the swivel angle.


128

10.3.4. Flowchart for transfer gate (inward transfer)

WT from left WT from right













queuing


129

Start

Z1 OFF

N4 assigned

Z2 OFF

noyes

N6 assigned

N3 unassigned

WT from left

N2 assigned

no

no

yes

yes

WT from left

T expired

N7 assigned

N3 unassigned

Z2 OFF

T delay time

Z2 ON

N6 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N9 assigned

Z3 ON

no

yesWT from right

yes

no

no

Z3 OFF

N8 assigned


130

10.3.5. Flowchart for transfer gate (outward transfer)

WT to the left WT to the right










queuing

queuing


131

Start

Z1 OFF

N4 assigned

Z2 OFF

no

yes

N2 unassigned

N6 assigned

N3 unassigned

WT to left

N1 assigned

no

no

yes

yes

WT to left

T expired

N5 assigned

N3 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

yes

no

N1 assigned

T expired

N5 assigned

N2 unassigned

Z1 OFF

T delay time

Z1 ON

N4 assignedno

no

no

no

no

yes

yes

yes

yes

yes

yes

N7 assigned

Z2 ON

no

yesWT to right

yes

no

no

noyes


132



See chapter 7, “Movable Curve 90°


– Turn off system. – Bleed compressed air system. – Loosen countersunk screw (110) and remove together with washer (140). – Pull transfer gate (20) up and out. – Remove pad (40). – Loosen the two screws (130) and remove. – Replace drive unit (10). – Assemble in the reverse order. – Check swivel angles and reset, if necessary.


133


– Extend cylinder. – The transfer gate (20) must be on position 2. – Check if the transfer gate applies noticeable pressure to the stop (70). – If yes, continue with point 16; if not, continue with point 5. – Turn off system. – Bleed compressed air system. – Release clip (70/2) and pull down out of the fork end (70/1). – Swivel cylinder (80/1) out. – Loosen hex nut (80/3). – Loosen fork end approx. ½ turn. – Tighten hex nut (80/3). – Swivel cylinder (80/1) in. – Mount clip (70/2). – Turn on system. – Perform steps 1 to 3. – Retract cylinder. – The curve lever (20) must be on position 2. – Check if the curve lever applies noticeable pressure to the stop (60). – If not, the procedure is the same as starting with point 6; except in point 10, the fork end must be screwed in ½ turn.


134


10.5.1. Transfer gate


135

10.5.2. Spare parts list transfer gate


TB-105 TB-140 TB-185

◘ Transfer gate 54789 54790 54791 Various

10 ◊ Drive 54502 54502 54502 Various

20 ● Transfer gate 54515 54516 54517 PA.

30 ● Transfer gate 54518 54512 54520 PE

40 ◊ Pad D=32 54501 54501 54501 Steel

50 ◊ Fastening bracket 54547 54547 54547 Steel

60 ● Finger protection device 49641 49642 49643 PE

70 ◊ Pneumatic hose ø6/4 502745 502745 502745 PU

80 ◘ T-nut 21913 21913 21913 Steel

100 ◊ Cheese head screws M6x12 504644 504644 504644 Steel

110 ◊ Countersunk screw M6x10 506710 506710 506710 Steel

120 ◊ Thread-forming Oval head screws M4x20

508972 508972 508972 Steel

130 ◊ Ribbed washer M6 505255 505255 505255 Steel

140 ◊ Setscrew washer M6 504380 504380 504380 Steel

150 ◊ Countersunk screw M5x20 501814 501814 501814 Steel


10.5.3. Spare parts list drive for transfer gate (54502)

See chapter 7, “Movable Curve 90°” (spare parts list drive for curve)


136

11. Indexing Device IVE and IVEB

11.1. Use

The IVE is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE. The IVEB is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE in the bypass.

11.2. Commissioning

11.2.1. Assembling and setting the indexing device IVEB

– Specify position of indexing device (10) according to dimension X. – Slightly tighten the two hex screws (110).

Dim

ensi

on


137

– Place a 0.2-0.3 mm thick feeler gauge strip on the belt. – Place WTE on the feeler gauge strip and - using the positioning sleeve in the WTE - align with the indexing stopper (10). – Mount pressure pad IVE (40) and slightly tighten Allen screws (50). – Center pressure pad IVE (40) relative to WTE. – Remove feeler gauge strip. – Use a feeler gauge between belt and WTE to check if the WTE is positioned horizontally. – Align WTE with adjustment screws (60/120). – Tighten fastening screws (50/110) with a torque of MA=6Nm.


138

– Mount left stopper (30) and lightly tighten the two hex screws (110). – The stopper (30) must be aligned so that a 0.1-0.3 mm play remains between the WTE recess and the stopper lock in an indexed WTE. – Tighten fastening screws (110).


139

– Mount right stopper (20) and lightly tighten the two hex screws (110). – The stopper (20) must be aligned so that a play of at least 2 mm remains between the indexed WTE and the following WTE. – Tighten fastening screws (110). – Connect compressed air system with maximum 6 bar


140

– Screw on the two brackets for proximity switch HNEB (70), item no. 49629, using hex screw (90). – Mount proximity switch (80), item no. 508377, in bracket for proximity switch. – Align proximity switch with engagement pin in WTE. – The switching distance should be set to 0.5-1 mm to the WTE .


141

11.2.2. Installation and setting of indexing device IVE

The work steps are identical with assembly and adjustment of IVEB.

11.2.3. Flowchart for indexing device IVEB/IVE


Z2 Cylinder, double-acting Indexing device







N6 Proximity switch Indexing device ON

N7 Proximity switch Indexing device OFF


142

Start

Z1 OFF

N5 assigned

Z2 ON

noyes

N6 assigned

N1 unassigned

N2 assigned

no

no

yes

yes

T2 expired

N3 unassigned

N7 assigned

T2 delay time

Z2 OFF

no

no

no

no

no

yes

yes

yes

yes

yes

yes

no

N4 assigned

N9 assigned

Z1 ON

Z3 OFF

N5 assigned

N2 unassigned

no

no

no

no

no

yes

yes

yes

yes

yes

yes

N3 unassigned

Z2 ON

noyes

no

Z3 ON

N8 assigned

N2 unassigned

yes

N6 assigned

Z1 OFF

Z3 ON

N9 assigned

N8 assigned

no

yes

yes

N1 assigned

Z3 OFF

no

N2 assignedno

yes

T1 delay time

T1 expired


143


11.3.1. Indexing device IVE

11.3.2. Spare parts list indexing device IVE (49613)


10 ● Stopper IVE 54639 Various

20 ◘ Stopper VSE 49612 Various

30 ● Pressure pad 54865 Steel

◘ Bracket for proximity switch HNEB 54634 Steel

● These are wearing parts and available ex stock. ◘ Price list item available ex stock


144

11.3.3. Indexing device IVEB right and left

11.3.4. Spare parts list indexing device IVEB right (54492)


10 ● Indexing device IEB right 54582 Various

20 ◘ Stopper VSEB right 54601 Various

30 ◘ Stopper VSEB left 54581 Various





145

11.3.5. Spare parts list indexing device IVEB left (54633)


10 ● Indexing device IEB left 54602 Various

20 ◘ Stopper VSEB left 54581 Various

30 ◘ Stopper VSEB right 54601 Various





146

12. Positioning Device PVE

12.1. Use

The PVE is used for accurate positioning (+/- 0.05mm) of workpiece holders WTE, which are supported from below for press-in operations.

12.2. Technical Data

12.2.1. Maximum torque

WTE 80x80 Center 4Nm Diamete 0 to 30 3.5Nm 30 to 60 3Nm WTE 115x115 Center 6Nm Diameter 0 to 40 4.5Nm 40 to 80 3Nm


147

WTE 160x160 Center 6.5Nm Diameter 0 to 60 5.5Nm 60 to 120 5Nm WTE 225x225 Center 7Nm Diameter 0 to 90 6Nm 90 to 180 5.5Nm


148

12.3. Commissioning

12.3.1. Mounting and setting positioning device PVE

– Insert support with belt stroke cylinder (10) in chassis. – Support position (10) from below. – Align support (10) centered to recess. – Center the stoppers (20) against the recess in the chassis. – Slightly tighten the two screws (60).

Abstützung = Support


149

– Retract the two belt stroke cylinders (150) so that the belt is free. – Place WTE on the support and - using the positioning sleeve in the WTE - align with the stopper (20). – Mount pressure pad PVE (30) and align centrically with WTE; slightly tighten screws (70). – Use the stopper (20) to index the WTE. – Use a feeler gauge between support (10) and WTE to check if the WTE makes contact with the support (10). – Align WTE with adjustment screws (80/90). Tighten fastening screws (60/70) with a torque of MA=6Nm.


150

– Mount left stopper (40) and lightly tighten the two screws (100). – The stopper (40) must be aligned so that a 0.1-0.3 mm play remains between the WTE recess and the stopper lock in an indexed WTE. – Tighten fastening screws (100) with a torque of MA=6Nm. – Mount right stopper (50) and lightly tighten the two screws (110). – The stopper (50) must be aligned so that a play of at least 2 mm remains between the indexed WTE and the following WTE. – Tighten fastening screws (110). – Connect compressed air system with maximum 6 bar.


151

– Screw on the two brackets for proximity switch HNEB (120), item no. 54634, using screw (140). – Mount proximity switch (130), item no. 508845, in bracket for proximity switch. – Align proximity switch to engagement pin in WTE. – The distance should be set to 0.5-1 mm to the WTE.


152

12.3.2. Flowchart for positioning device PVE


Z2 Cylinder, double-acting Indexing device


Z4 Cylinder, double-acting Belt stroke cylinder

Z5 Cylinder, double-acting Belt stroke cylinder

N1 Proximity switch Presence before PVE

N2 Proximity switch Presence in PVE




N6 Proximity switch Indexing device ON

N7 Proximity switch Indexing device OFF




153

Start

Z1 OFF

N4 occupied

Z2 ON

noyes

N7 occupied

N1 occupiedno

no

yes

N7 occupied

N3 free

no

no

no

yes

yes

yesno

N6 occupied

Z4/Z5OFF

Z2 OFF

N4 occupiedno

noyes

yes

yes

Z1 ON

Z3 OFF

N8 occupied

N2 occupied

yes

N5 occupied

Z4/Z5OFF

Z2 ON

PROCESSING

Z1 OFF

END OFPROGR.

yes

no

Delay timeT2 for Z3

=0

no

yes

N8 occupied

N9 occupied

Z3 OFF

Z3 ON

yes

yes

no

no

Z4/Z5ON

END OFPROCES.

Delay timeT1 for Z1

=0

yes

no

END

yes

yes

nono


154


12.4.1. Positioning device PVE

12.4.2. Spare parts list positioning device PVE


TBD-105 TBD-140 TBD-185 TBD-250

◘ Positioning device PVE 55131 55132 55133 56507 Various

10 ◘ Stopper VSE 49612 49612 49612 49612 Various

20 ● Stopper IVE 54639 54639 54639 54639 Various

30 ● Pressure pad 55183 55159 55184 56309 Steel

40 ◊ Support with belt stroke cylinder 55185 55186 55187 56308 Various

◘ Proximity switch HNEB 54634 54634 54634 54634 Steel



155

12.4.3. Support with belt stroke cylinder

12.4.4. Spare parts list support with belt stroke cylinder


TBD-105 TBD-140 TBD-185 TBD-250

◘ Support with belt stroke cylinder 55185 55186 55187 56308 Various

10 ◊ Support 55111 55112 55113 56120 Steel

20 ● Belt stroke cylinder 55110 55110 55110 55110 Various

30 ◊ Cheese head screws M5x20 504799 504799 504799 504799 Steel




156

13. Environmental Friendliness and Disposal

Raw materials used – Aluminum – Steel – Copper – PUR Polyurethane – ABS Acrylonitrile Butadiene Styrene copolymer – PS Polystyrol – HDPE Polyethylene – PVC Polyvinyl chloride – PET Polyethylene terephthalate – Gear lubricant, V < 4.02m/min. = soda soap Calypsol D 6024 – Gear lubricant, V > 5.26m/min. = Syntheso D 460 EP Surface treatment – Anodizing of aluminum – Electroless nickel-plating of steel Forming processes – Aluminum extrusion – Non-cutting machining of aluminum, steel, polyurethane and deep-drawing of Polystyrene – Injection molding of ABS – Steel laser-cutting Emissions during operation None Disposal Conveyors and their accessories that can no longer be used should not be recycled as entire units, but disassembled and then recycled according to the material types used. The material type of each component is listed in the spare parts lists. Material that cannot be recycled must be disposed of in the appropriate manner. Care should be taken to dispose of gear lubricants separately.

Betriebsanleitung Längstransfersystem LTE®

157

13. Umweltverträglichkeit und Entsorgung

Verwendete Rohmaterialien � Aluminium � Stahl � Kupfer � PUR Polyurethan � ABS Acrylnitril-Butadien-Styrol-Copolymer � PS Polystyrol � HDPE Polyethylen � PVC Polyvinylchlorid � PET Polyethylenterephtalat � Getriebeschmiermittel, V < 4.02m/min. = Natriumseifenfett Calypsol D 6024 � Getriebeschmiermittel, V > 5.26m/min. = Syntheso D 460 EP Oberflächenveredelung � Anodisieren von Aluminium � Stromloses vernickeln von Stahl Formgebungsprozesse � Profilpressen von Aluminium � Spanende Bearbeitung von Alu, Stahl, Polystyrol, Polyurethan und Tiefziehen von Polystyrol � Spritzguss aus ABS � LASER-schneiden von Stahl Emissionen während des Betriebes Keine Entsorgung Nicht mehr verwendbare Transportbänder und ihr Zubehör sollen nicht als ganze Einheiten, sondern demontiert in Einzelteile, nach Materialart rezykliert werden. Die Materialart jedes Einzelteils ist in den Ersatzteillisten aufgeführt. Nicht rezyklierbares Material soll artgerecht entsorgt werden. Speziell zu beachten ist die separate Entsorgung des Getriebeschmiermittels.

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