Powered Flex Conveyor - Cisco-Eagle

phone 989.358.6119email [email protected]

web www.northamcon.com

Powered Flex ConveyorOperation and Maintenance Manual

DO NOT OPERATE BEFORE READING

20180101



2

Powered Flex Conveyor

Table of Contents

General Overview ..................................................................................................... 3

StandardProductSpecifications ............................................................................ 4-5

Safety Information ..................................................................................................... 6

Installation ................................................................................................................. 7

InterfaceKitSpecifications .................................................................................... 8-9

PowerRequirements ......................................................................................... 10-15

MaintenanceProcedures ........................................................................................ 16

Troubleshooting ................................................................................................. 17-21

Warranty Statement ................................................................................................ 22

WarrantyandReturnMerchandiseAuthorizationProcedures ................................ 23



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General Overview

NACPoweredFlexConveyorisaflexible,expandable,portable,poweredrollerconveyorthatwillstretchorbendtofityouravailablespaceandisidealfortruckloadingandunloadingareas,distributioncentersorportableassemblylines.

Accumulation Style: Eachzonecontainsasensorarray,motorandsmartconveyorcontrollogic.Zonesrunondemandonlywhenthedownstreamzoneisunoccupied.Packagesaccumulateattheendofaconveyororinthezonespriortoafullzone.

TransportationStyle:Conveyorisalwayson,transportingpackagescontinuouslyataconstantspeed.

Features: 1-3/8"diameterrollers,1-1/2"collapsedc/c,3"expandedc/c 110 VAC input power Heavy-duty,sealed,quick-connectpowercabling Rollersdrivenbyhigh-tension,urethaneO-ringbelts Precisionbearings Supportsat30"topofroller Locking,swivelcasterswithbrake Pin-adjustableheightplusorminus4"on1/2"increments Powdercoatedframeandsupports Aluminumsideflexbars Start/Stopbuttonateachend Forward/Reverseswitchonbaseend Entrancezoneinterfaceboxincludesdrycontactrelaysfor controlofentrancezonedrivercard Exitzoneinterfaceboxhasspeedcontrolpotentiometeralong withdrycontactrelaysforcontrolofexitzonedrivercard

Accumulation Features: Motordrivercardscontaininternalaccumulationlogic Multiplereleasemodes Run-On-Demandpowersavings Photoeyesensorarrayacrossfullwidth ineachzone Quick-connectRJ-12 communicationcables Reversemodeistransportation onlywithpackagestopphotoeye



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Standard Product Specifications

FX24-14ABF40T-3A5V1 FX24-14ABF60T-3A5V1Conveyor Bed Width (BF)

Inches 24 or 30 30Millimeters 610 or 762 762

Load Capacity Per Linear Foot (305 mm)Pounds 50 50Kilograms 22.5 22.5

RollersInches 1.4 1.4Millimeters 34.9 34.9Axle 5/16" 5/16"Tube 18 GA 18 GABearings Precision Precision

Product Travel SpeedFeet per minute 60-150 60-150Metersperminute 45.72 45.72

CastersInches 5" x 1-1/4" 5" x 1-1/4"Millimeters 127 x 31.75 127 x 31.75

Adjustable Conveyor HeightInches 26-34 26-34Millimeters 660-864 660-864

Expanded to Compressed Ratios3"(76mm)rollercenters 1.8:1 1.8:1

BeltsMaterial Cyclothane-B Cyclothane-BDurometer 85A +/-3A 85A +/-3ADiameter .1875" .1875"Drive Color Red RedDriveLength 12-3/4" 12-3/4"Idler Color BlueTransparent BlueTransparentIdlerLength 11-15/16" 11-15/16"BaseIdlerColor BlueTransparent BlueTransparentBaseIdlerLength 6-1/4" 6-1/4"



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Standard Product Specifications (cont.)Voltage 120VAC 120VACAmps 9.9amps 15.1ampsDrive Motor

Motor(continuoustorque) 15 in-lbf/66.7N 15 in-lbf/66.7NFull Load Demand 4amps 4ampsVoltage 24VDC 24VDC

Noise LevelRatingatconveyorbedlevel(approx.) 70dB 70dBRatingatearlevel(approx.) 60dB 60dB

Conveyor Shipping Weights (per linear foot of expanded conveyor)(lbs./kgs)3" Roller Centers

ConveyorWidth30" 50/22.7 50/22.7



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Safety Information Moveconveyoronlybygraspingthehandleslocatedonthesidesorateachendoftheconveyor. Whenexpandingorcompressingyourconveyor,keephands,clothingandotheritemsclear ofthesidebars. Donotexceedtheconveyorloadcapacity,asitmayresultinpossibleoperatorinjuryor conveyordamage. Avoidwearingexcessivelylooseclothingwhenworkingwithmovingequipment. Keeplonghairpulleduptopreventitfrombecomingcaughtinmovingparts. Brokenorwornpartsmustbereplacedimmediately. PoweredFlexConveyorsmustonlybeservicedbyproperlytrainedand qualifiedtechnicians. Conveyor’spowercordmustbeconnectedtoagroundedreceptaclethatisprotectedbyan overcurrentdeviceratedatnomorethan30amps,unlessotherwisespecified. Neverserviceaconveyorwiththepowerapplied.Alwaysdisconnectpowerbefore servicingequipmentandusethecompany’smachinespecificlockout/tagoutprocedures. Neveroperateconveyorwithanelectricalenclosureopen,oranyguardsremoved.



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Installation*Follow all proper safety precautions and plant installation procedures

1)UnpacktheNACPoweredFlexConveyorandinspectforpossibledamagethatmayhaveoccurredduringshipping.Payparticularattentiontothewiringtoensurethatnowiresarepulledlooseordamagedinanyway.Ifyoufindanydamage,contactthefactorybeforeapplyingpowertotheconveyor.

2)Makesureallstoppush-buttonsaredepressed(therewillbeonestart/stopswitchateachendoftheconveyor.)Makesurefwd/revswitchissettofwd.

3)Rolltheunitintoposition.Ifapplicable,usetheconnecthookstoattachthePoweredFlexConveyortoarigidorotherflexibleconveyor.Connecttheyellowinterfacecableasneeded.

4)Conveyormustbeinstalledtomeetalllocal,city,stateandnationalcodes.

5)Plugthepowercordintoa115VAC/30AMPgrounded receptacle.

6)Tostarttheconveyor,locatethebaseendwithpowersupplyenclosureandturnthedisconnectswitchon.Locateoneoftheon/offswitchesfortheconveyorandpressthegreenonbuttonwhenreadytostarttheconveyor.

Note:Rollerswillbegintomoveassoonastheonbuttonispressed.Ifstep2wasnotfollowed,therollerswillturnonassoonasthedisconnectisturnedtoon.

7)Ifneeded,thespeedoftheconveyorcanbeadjustedviathepotentiometerontheDCVariableSpeedDrivelocatedatthebaseendoftheconveyor.

8)Beginplacingpackagesontheconveyor.



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Interface Kit SpecificationsNorthAmCon’sstandardPoweredFlexConveyorcomeswithabasicinterfacekit.ThebasickitincludeseverythingneededforinterfacingwithotherNorthAmConPoweredFlexConveyors.Itmayalsobecompatiblewithsomeothermanufacturerswithsimilarcontrolsschemesattheinterfacepoint.Ifanothermanufacturer’sinterfaceisnotcompatiblewiththebasickit,anoptionalkitcanbepurchased.Thelistofcompatiblemanufacturersandthosethatrequiretheoptionalkitareshownbelow.Contactthefactorywithquestions.

a. *Nointerfacekitsshouldbeneededforthefollowingconveyormanufacturers: i. Best/FMH ii. Dematic iii. Wynrightb. *OneoptionalinterfacekitwilllikelybeneededperflexconnectionpointwithIntelligrated orRoachequipment. i. IfthereisapossibilityofconnectingallofthePoweredFlexConveyoratonesiteto anIntelligratedorRoachconveyor,thenoneinterfacekitperPoweredFlex Conveyorwouldlikelyberequired. ii. IfconnectingatboththeinfeedanddischargeendsoftheNorthAmConPowered FlexConveyor,then(2)interfacekitswouldlikelyberequiredperunit. *BasedonFeb2017data

TheoperatingvoltageoftheNorthAmCon’sPoweredFlexConveyoris24VDC,howevertheincludedbasicinterfaceusesdrycontacts/relaystoworkwithmultiplevoltages(110VACor24VDC).TherelaysareutilizedtocommunicateReady-To-Receive(RTR)andReady-To-Send(RTS)signalsbetweenconveyors.Seetheinterfaceschematicsformorespecificinformation.

NorthAmCon’sPoweredFlexConveyorsareequippedwithayellowTurckMiniconnectorateachendoftheconveyor.Thebelowpicturesshowtheorientationandlocationoftheconnectorsontheconveyor.ToconnecttwoPoweredFlexConveyorstogether(fromacontrolsstandpoint)simplyconnectthemaleandfemaleendsofthecablestogether.Theconveyorsshouldnowfunctionasoneunit.

Powered Flex Conveyor Powered Flex Conveyor DischargeConnector–6PinMale InfeedConnector–6PinFemale



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Interface Kit Specifications (cont.)Powered Flex ConveyorInfeed End/Connector

Powered Flex ConveyorDischargeEnd/Connector

ConnectingTwoPoweredFlexConveyors



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Power RequirementsEachNorthAmConFlexConveyorrequires: • Grounded 115VAC/30 AMP plant L5-30R receptacle locatedcloseenoughtotheconveyortonotcause anystrainonthepowercable. • MustmeetallLocal and National Electrical Codes.Voltageandamperagerequirementforthepoweredflexconveyorareasfollows: • 40’Flex=9.9amps115VAC • 60’Flex=15.1amps115VACTheconveyorsareequippedwith: • (1)10/3SJOOW6-footpowercablewith(1)unmarkedtwistlockL5-30Pplugatthe conveyorbase/dischargeend. • (2)10/3SJOOWpowerextensionpassthroughcables,(1)cablemarked█ red and cable marked█yellow,eachwith(1)L5-30R receptacleflushwiththeconveyorInfeedendand (1) L5-30P plugextended6-feetfromtheconveyorbase/dischargeend. • (1)10/3SJOOWreversepowerextensionpassthroughcablemarked█bluewith (1) L5-30R receptacleflushwiththeconveyorbase/dischargeendand(1)L5-30P plug extended6-feetfromtheconveyorinfeedend.

Receptacle Plug L5-30R L5-30P



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Power Requirements (cont.)TheNorthAmConFlexConveyorcanreceivepowerfrom: • Theunmarkedpowercableatthebase/dischargeendoftheconveyor.(seestepA) • Thepowerextensionpassthroughcablemarked█red,onthefirstflexconveyor,allowsasecondflex conveyortoreceivepowerfromthebase/dischargeendofthefirstflexconveyor.(seestepB) • Thepowerextensionpassthroughcablesmarked█yellow,onthefirstandsecondflexconveyor,allows athirdconveyortoreceivepowerfromthebase/dischargeendofthefirstflexconveyor.(seestepC) • Thereversepowerextensionpassthroughcablemarked█blue,allowstheflexconveyortoreceive powerfromtheinfeedendoftheconveyor.(seestepD)A.WhenpoweringaNorthAmConFlexConveyorfromthebase/dischargeend: • Simplyplugthe6-footpowercablewiththeunmarkedplugintoa115VAC/30AMP grounded plant receptacle.

Plant ReceptacleShownforRefOnly

Conveyor #1UnmarkedPlug

Conveyor #1Base/Discharge



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Power Requirements (cont.)B. WhenpoweringasecondNorthAmConFlexConveyorfromthebase/dischargeendofanother FlexConveyor,viathepowerextensionpassthroughcable: • Followstep(A)forpoweringconveyor#1. • Atthebase/dischargeendofconveyor#2,plugtheunmarkedpluginto theredmarkedextensioncablereceptacleattheinfeedendofconveyor#1.

Atthebase/dischargeendofconveyor#1,plugthe█redmarkedextensioncableplugintoa115VAC/30AMPgrounded plant receptacle.


Conveyor #1 █Red Receptacle

Conveyor #1Infeed End


PlantReceptaclesShownforRefOnly


Conveyor #1 █RedPlug



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Power Requirements (cont.)C. WhenpoweringathirdNorthAmConFlexConveyorfromthebase/dischargeendof anotherFlexConveyor,viathepowerextensionpassthroughcables: • Followstep(B)forpoweringconveyors#1and#2. • Atthebase/dischargeendofconveyor#3,plugtheunmarkedplugintothe█ yellow markedextensioncablereceptacleattheinfeedendofconveyor#2.

• Atthebase/dischargeendofconveyor#2,plugthe█yellowmarkedextensioncablepluginto the█yellowmarkedextensioncablereceptacleattheinfeedendofconveyor#1.


Conveyor #2 █ Yellow Receptacle

Conveyor #2 Infeed End



Into Conveyor #1█Red Receptacle

(RefstepB)

Conveyor #1Infeed End

Conveyor #2 █ YellowPlug

Conveyor #3 UnmarkedPlug

Conveyor #1 █ Yellow Receptacle



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Power Requirements (cont.) • Atthebase/dischargeendofconveyor#1,plugthe█ yellowmarkedextensioncableplug intoa115VAC/30AMPgroundedplantreceptacle

D. WhenpoweringaNorthAmConFlexConveyorfromtheinfeedend,viathereversepowerextension passthroughcable: • Atthebase/dischargeendoftheconveyor,plugtheunmarkedpluginto the█bluemarkedextensioncablereceptacle.

PlantReceptaclesShownforRefOnly


(Ref Step A)And █RedPlug(RefstepB)

Conveyor #1 █ YellowPlug



Conveyor #1█ Blue Receptacle

Conveyor #1 UnmarkedPlug



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Power Requirements (cont.) • Attheinfeedendoftheconveyor,plugthe█bluemarkedextensioncablepluginto a 115 VAC/30 AMP grounded plant receptacle.

Plant ReceptacleShownforRefOnly

Conveyor #1█ BluePlug

Conveyor #1 Infeed End



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Maintenance ProceduresFollowgeneralmaintenancesafetyproceduresandreviewsafetymaterialpriortoperformingmaintenanceonanyequipment.Followyourcompanymachinespecificlockout/tagoutprocedurespriortoperforminganymaintenance.

NorthAmConrecommendsregularinspectionsofthepoweredflexibleconveyortoensureproperoperationofmechanical,electrical,andsafetysystems.

DAILY MAINTENANCE • Keeptheconveyorcleanandfreeofdebris,dirtandgreaseaccumulation.• Inspectwiresandcablesfordamage.Ifdamagetowiresorcablesisfound,disconnectthepowercord immediatelyanddonotoperateunituntilproperrepairiscompleted.• Inspectbeltsforwear.Replaceexcessivelywornbelts.• Inspectforloosefastenersormissingparts.Tightenorreplaceasneeded.• VerifyallStart/Stoppush-buttonsoperateproperly.

WEEKLY MAINTENANCE Unit Safety Check • Confirmplacementofallwarninglabels.• Checkforunrestrained/pinchedwiring,loosewiringconnectors,nippointsandotherhazards.• CheckMech-DriveControllerdrivecardforanywarninglights.• Checkforlooseboltsandtightenasneeded.

MONTHLY MAINTENANCE Belt Tension • Checkforconsistentbelttensionbetweenrollersandreplacebeltsasneeded.• Verifydrivesheavesetscrewsaretight.

QUARTERLY MAINTENANCEDrives • Ensurethatmotorisoperatingwithinitsproperheatandnoiserange



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TroubleshootingPROBLEM CAUSE SOLUTION

NoneoftheZonesWillRun

Powersupplyifoff TurnonpowersupplyPowersupplyisnotreceivingACpower CheckACpower

ACpowerfuseisblownorbreakeristripped Replacefuse,checkbreaker

Powersupplybreakeristripped Checkpowersupplybreaker

NopowertoflatmotorZPAmodule Checkoutputpowerofpowersupply

Powersupplyvoltagetoohighortoo low

Checkoutputvoltageofpowersupply

EntryZoneWillNotTurnOn

Missingwake-upzonephoto-eye Addwake-upphoto-eyeEntryzonephoto-eyenotalignedproperly

Checkwake-upphoto-eyealign-ment

Missing/incorrecthandshakingwiring Checkhandshakingwiring

IncorrectDIPswitchsetting CheckDIPswitchesNopowertoZPAmodule CheckpowerconnectionsMotorcablenotconnectedtoZPAmodule Checkmotorconnections

TransportZoneWillNotTurnOn

Communicationwiringmissingornotpluggedin

Checkupstreamanddownstreamcommunicationwiring

Photo-eyeisblockedormisaligned Checkphoto-eyeandreflectorIncorrectDIPswitchsetting CheckDIPswitchesNopowertoZPAmodule CheckpowerconnectionsMotorcablenotconnectedtoZPAmodule Checkmotorconnections

TransportZoneWillNotTurnOff

Upstreamzoneisattemptingtosendproduct

Checkphoto-eyealignmentinup-streamzone

Upstreamzoneisattemptingtosendproduct

Checkforjammedproductinup-streamzone

EntryZoneorTransportZonewillNotDischargeProduct

Communicationwiringmissingornotpluggedin Checkcommunicationwiring

Downstreamzoneisfull Removeproductfromdownstreamzone

Downstreamzonephoto-eyenotalignedproperly Checkdownstreamphoto-eye

ExitZoneWillNotDischargeProduct

Incorrecthandshakingwiring CheckhandshakingwiringDownstreamdevicenotsendingareleasesignal

Checkdownstreamdeviceoutputsignals

DIPswitchnotconfiguredproperly CheckDIPswitches



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Figure 1: MECH-DRIVE N24-FM3 Controller Components1) Motor Connection Header 2)+24VDCPowerInputHeader(plugincluded)3)PNPSensorConnectionHeader(plugincluded)4)Smart/UserInput-OutputConnectionHeader(plugincluded)5)FeedbackLEDIndicators6)ConfigurationSwitches7)UpstreamPeer-to-PeerPNPRJ-12Connection8)DownstreamPeer-to-PeerPNPRJ-12Connection9)MountingPlate/HeatSink10) Cover NOTE:Thisguidereferstothecomponentsbytheiritemnumberaslistedabove.

Troubleshooting



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Troubleshooting (cont.)TheMech-DriveN24-FM3providesfour(4)LEDindicatorsshownasitem5inFigure1:Mech-DriveN24-FM3ControllerComponents.TheseLEDsareoftenusefulindiagnosingvariouswiringandconnectionproblems.IfpowerisconnectedtherewillalwaysbeatleastoneLEDilluminatedorflashing.

PROBLEM CAUSE SOLUTIONNoLED’sOn Nopowertothesystem Checkpowersupply

FUSELED(RED)isOn FuseisblownCheckwiringReplacefuse

FAULT LED 5.1 (RED) - ConstantlyOn Stalledmotororblockedphotoeye Checkformechanicalobstructions

FAULTLED5.1(RED)-1Flashin4Seconds ZPAmoduleproblem ReplaceZPAmodule

FAULTLED5.1(RED)-2Flashesin4Seconds Inputvoltagetoohigh Checkpowersupply

FAULTLED5.1(RED)-3Flashesin4Seconds Inputvoltagetoolow Checkpowersupply

FAULTLED5.1(RED)-4Flashesin4Seconds

Problemwithmotorcableconnection

CheckmotorcablefordamageandsecureconnectiontoZPAmodule

FAULTLED5.1(RED)-5Flashesin4Seconds Control over temperature

Allowcardtocool.Checkforambienttemperatureandheatsources.Checkforpropermotor

functionandwiring.Cyclepowertoreset.

FAULTLED5.1(RED)-6Flashesin4Seconds Extreme over current

Checkforpropermotorfunctionanddamagedwiring.Allowunitto

cool.Cyclepowertoreset.MOTOR LED 5.2 (AMBER) -

ConstantlyOnZPAmoduleiscurrentlimitingthe

flatmotorIfconditionpersists,checkfor

obstructions

MOTOR LED 5.2 (AMBER) - Flickering

Flatmotorisdrawingsignificantcurrentduringstartup,ZPAmodule

iscurrentlimiting

No action required

Motormaynotreachfullspeed

MOTOR LED 5.2 (AMBER) - 4 Flashesin4Seconds

ZPAmodulehasoverheatedandcurrentlimitingtheflatmotorto

about 1/2 normal operation

CheckformechanicalobstructionAllowZPAmoduletocool,before

restartingPOWER LED 5.3 (GREEN) -

ConstantlyOnPowerisproperlyappliedandfuse

isnotblown Normal operation



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Troubleshooting (cont.)Mech-DriveControllerwiringandlightsduringnormaloperation.



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Troubleshooting (cont.)PowerSupplywithpowerappliedduringnormaloperation.

Ifnotlitupgreen,powerisnotappliedtotheconveyor:1. ChecktobesuredisconnectisintheONposition2. CheckStart/Stopbuttons3. Checkpowersource4. Checkforloosewiresinsideenclosure



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Warranty StatementTheSellerwarrantsthattheEquipmentwillbefreeofdefectsinworkmanshipandmaterial(ifproperlyinstalled,operatedandmaintained)foraperiodofoneyearor2080hoursofuse,whicheverissooner,fromdateofship-menttoCustomer,subjecttothelimitationshereundersetforth.Ifwithintheoneyearwarrantyperiod,theSellerreceivesfromtheCustomerwrittennoticeofanyallegeddefectsintheEquipmentandiftheEquipmentisnotfoundtobeinconformitywiththiswarranty(theCustomerhavingprovidedtheSellerareasonableopportunitytoperformanyappropriateteststhereon)Sellerwill,atitsoption,eitherrepairtheEquipmentorsupplyareplace-menttherefore.

TheSellerundereitheroptionshallhavetherighttorequireCustomertodelivertheEquipmenttoSeller’sdes-ignatedservicecenterandtheCustomershallpayallchargesforin-boundandout-boundtransportationandforservicesofanykind,diagnosticorotherwise,exceptingonlythedirectandactualcostsofrepairingorreplacingtheEquipment.IfafterreasonableefforttheSellercannotcorrectsaiddeficiencies,theSellerwillmakeanequi-tablepriceadjustmentbasedonactualperformance,providedthatsuchadjustmentshallundernocircumstancesexceedthepurchaseprice.TheSellerfurtherwarrantsthattheparts,andcomponentssuppliedbytheSellerandformingapartoftheEquipmentwillbefreefromdefectsinmaterialandworkmanshipforaperiodofoneyearor2080hoursofuse,whicheverissooner,fromdateofshipmenttotheCustomer.TheSeller’sliabilityshallbesolelylimitedtothesupplyingofreplacementpartsandmaterials.

ForacopyourfullwarrantyincludedinourTermsandConditionsofSale,contactNorthAmCon,Inc.

Seepage25fordetailedReturnMerchandiseAuthorizationProcedures.



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Warranty and Return Authorization ProceduresIfthepartinquestionisincludedinthereplacementpartspackage,thefollowingprocedurewillapply:• Identifythepartnumberfromthemanual• Ifpartisindicatedaswearpart • Replacethedamagedordefectivepartfrompartsinventory • Orderadditionalpartsasrequired• Ifthepartisindicatedasawarrantypart • Replacethedamagedordefectivepartfrompartsinventory • ContactNACforaReturnMerchandiseAuthorization(RMA)number • HaveconveyorserialnumberavailablewhencontactingNAC. • Sendtheparttothefollowingaddress NorthAmCon 3544US23North Alpena,MI49707 Attn:FlexProductManager • IncludetheconveyorserialnumberandRMAnumberonthepackagingandthepackingslip • NACwillinspectthepartandmakeawarrantydetermination • Ifthepartisunderwarranty,NACwill… • shipareplacementtoCustomertoreplenishpartsstock • Issueacreditforthefreight

Ifthepartinquestionisnotincludedinthereplacementpartspackage,thefollowingprocedurewillapply:• Identifythepartnumberfromthemanual• ContactNACforaninitialreviewtoestablishifpartiscoveredunderwarrantyandtoprovidea quote if needed. • HaveconveyorserialnumberavailablewhencontactingNAC• Issueapurchaseorderforareplacementpart• NACwillissueaReturnMerchandiseAuthorization(RMA)numberfortheparttobereturned.• Sendtheparttothefollowingaddress NorthAmCon 3544US23North Alpena,MI49707 Attn:FlexProductManager• IncludetheconveyorserialnumberandRMAnumberonthepackagingandthepackingslip• NACwillinspectthepartandmakeawarrantydetermination• Ifthepartisunderwarranty,NACwillIssueacredittoCustomerforthepurchasedpartandassociated freightcharges

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