Bastian Solutions Shoe Sorter User manual

Installation and Maintenance Manual
Model: Shoe Sorter
Effective September 2020
Rev. B

Installation and Maintenance Manual: Shoe Sorter
_____________________________________________________________________________________________
Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
2
Contributions
Revisions
ROLE
NAME
TITLE
Author
Ben Baker
Senior Design Engineer
Checker
Bryan Routt
Process Engineer
Approver
Chris Perry
Engineering Manager
DATE
REVISION
REVISION DESCRIPTION
AUTHOR
10/21/2019
A1
Initial document creation
Ben Baker
9/22/2020
B
Added info on sprocket alignment and
replacement; added info about decel settings;
crash gates added to installation section; added
tailshaft encoder info to Controls section; added
several part numbers to GA drawings. Changed all
references to “ZiPline” to “BSC” or “Bastian
Solutions Conveyor”.
Ben Baker

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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Term and Acronym Definitions
TERM/ACRONYM
DEFINITION
AC
Alternating current
Accumulation
The collection or staging of multiple cartons, cases, or totes of product on conveyor.
Back pressure
Pressure against carton(s) in the direction of carton flow resulting from weight of densely
accumulated cartons.
BF
Between frame; this refers to the distance between conveyor bed side frames.
BHCS
Button head cap screw
BOM
Bill of Materials
BRBDC
Belted Roller Bed Direct Current; DC roller conveyor format driven by brushless DC servo
motors.
BSC
Bastian Solutions Conveyor
Carton or Case
Term for conveyable items generally contained in cardboard boxes.
CB
Carriage bolt
CCW
Counter-clockwise
CW
Clockwise
DC
Direct current
DC Card
A control card used to power and control the logic used when operating a MDR in DC
conveyor applications.
Diffuse
A photoeye format that houses both the emitter and receiver and senses an object when
the light beam is reflected back to the sensor. This type of photoeye is a standalone unit
and does not use reflectors.
Discharge
The point where cartons, cases, or totes exit a conveyor or similar unit used in a material
handling system.
Divert
(noun) A conveyor unit used to change the direction of a carton, case, or tote in a
controlled manner. (verb) To change the direction of a carton, case, or tote in a
controlled manner.
Drive Pulley
A motor-driven pulley used to transmit rotational energy to linear motion in AC belts.
E-stop
A highly visible button or pull cable designed to shut down equipment in the case of an
emergency.
ETO
Engineered to Order; Orders requiring custom Engineering
FAT
Factory Acceptance Testing
Flange
A feature in sheet metal consisting of a face and bend connected to an existing face
along a straight edge.

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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TERM/ACRONYM
DEFINITION
Gapping
The separation of cartons, cases, or totes which are initially in contact with one another.
Generally done by progressively increasing the speed of consecutive zones, forcing
cartons, cases, or totes to "pull a gap."
Guide Rail
Mechanism used to maintain the desired position of conveyable cartons, cases, or totes
on their respective conveying surface.
HHCS
Hex head cap screw
HMI
Human-Machine Interface; an operating console or control panel of a conveyor system.
HTL
High Threshold Logic. In the context of an encoder, a differential push-pull output
intended to operate on 24VDC.
ID
Inner diameter of a circular, cylindrical or arced body.
Idler Roller
Cylindrically-shaped material handling component that is unpowered and used to
support a belt.
Infeed
The point where cartons, cases, or totes enter a conveyor or similar unit used in a
material handling system.
LOTO
Lockout Tagout
Mark Number
A numeric or alphanumeric term used to uniquely identify a conveyor bed or collection
of beds (of similar model type) within a material handling system.
Match
A mark made on mating conveyor assemblies to assist in identifying orientation and
placement within a system.
MDR
Motorized drive roller; DC powered conveyor roller with an internally mounted motor
which may be controlled via internal or external commutation.
MSD
Master specification document; a document used to describe a product's intended
capabilities, appearance, and interaction with users.
NO
Normally Open
OAW
Overall width of any given conveyor bed.
OD
Outer diameter of a circular, cylindrical, or arced body.
O-Ring
A plastic ring with a circular cross section used for power transmission in DC conveyor
applications.
OSHA
Occupational Safety and Health Administration
OTD
On-Time Delivery
Photoeye
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Installation and Maintenance Manual: Shoe Sorter

Installation and Maintenance Manual: Shoe Sorter
_____________________________________________________________________________________________
Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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TERM/ACRONYM
DEFINITION
Spur
A format of DC conveyor used to create linear transitions into intersecting lines of
conveyor positioned at a non-perpendicular angle. Typically includes 30deg and 22deg
configurations.
Tail Pulley
A non-driven pulley located at the tail end of the conveyor.
Takeup Pulley
Pulley with an adjustable position used to eliminate unnecessary slack in a belt.
Takeup Screws
Adjustment screw used to adjust the position of a takeup pulley.
TOCS
Top of Conveying Surface; this refers to the elevation of the conveying surface with
respect to the floor on which the conveyor is sitting. Interchangeable with TOR but
applicable to non-roller conveyors as well.
TOR
Top of roller; this refers to the elevation of the conveying surface with respect to the
floor on which the conveyor is sitting.
Track
To adjust the position of conveyor components in such a way that engourages proper
belt alignment on a system.
Tracking Bands
Thin plastic bands installed on head or secondary drive roller to help keep DC format
conveyor belts tracked.
UHMW
Ultra-high molecular weight polyethylene
VFD
Variable Frequency Drive. An electronic variable-speed control for an AC induction
motor.
Waterfall
Method of overlapping guide rail such that cartons, cases, or totes cannot catch on
downstream guide rail.
Wiz Nut
A serrated flange nut used to cut into the surface of the component it is tightened
against.

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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Table of Contents
1Introduction ................................................................................................................. 11
2OSHA And Safety.......................................................................................................... 11
3Model: Shoe Sorter....................................................................................................... 11
4Receiving...................................................................................................................... 12
4.1 Mark Numbers..................................................................................................................12
4.2 Skid Contents....................................................................................................................13
4.3 Skid Documentation..........................................................................................................13
5Installation................................................................................................................... 14
5.1 Mechanical Installation .....................................................................................................14
5.1.1 Bed Section Placement ..........................................................................................................................14
5.1.2 Floor Support Installation ......................................................................................................................14
5.1.3 Section Fastening and Rail Alignment....................................................................................................15
5.1.4 Spur Installation.....................................................................................................................................17
5.1.5 Chain Installation ...................................................................................................................................19
5.1.6 Slat Installation ......................................................................................................................................21
5.1.7 Setting Infeed Conveyor ........................................................................................................................23
5.1.8 Setting Discharge Conveyor...................................................................................................................27
5.1.9 Installing Debris Sensors........................................................................................................................28
5.1.10 Installing Guards and Guiderail..............................................................................................................29
5.1.11 Installing Side Covers .............................................................................................................................29
5.1.12 Setting Oiler Flow...................................................................................................................................30
5.1.13 Tailshaft Encoder Installation ................................................................................................................33
5.1.14 Initial Startup Procedure........................................................................................................................34
5.2 Electrical Installation.........................................................................................................34
5.2.1 Drive Motor Settings..............................................................................................................................34
5.2.2 Components requiring 3 phase AC power connections.........................................................................35
5.2.3 Components requiring 24VDC power connections................................................................................36
5.2.4 Components requiring 48VDC power connections................................................................................37
5.2.5 Knife Edge control wiring for encoder following ...................................................................................37
5.2.6 List of Sensors (discrete)........................................................................................................................38
5.2.7 Communication between system PLC and divert control box...............................................................42
6Operation..................................................................................................................... 43
6.1 Startup Procedure.............................................................................................................43
6.2 Troubleshooting Faults......................................................................................................44
7Maintenance ................................................................................................................ 46
7.1 Slat and shoe repair, replacement, and service ..................................................................46
7.2 Divert switch repair, replacement, and service...................................................................46
7.3 Chain Adjustment..............................................................................................................46
7.4 Sprocket Adjustment and Replacement .............................................................................47
7.4.1 Tail Sprocket Replacement Procedure...................................................................................................47
7.4.2 Drive Sprocket Replacement Procedure................................................................................................49
7.4.3 Tail Shaft Adjustment Procedure...........................................................................................................52
7.5 Recommended Preventative Maintenance Schedule..........................................................53

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
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Appendix 1 Section Weights........................................................................................... 55
Appendix 2 Oiler System Recommended Flow Rates and Lubrication Intervals ............... 57
Appendix 3 General Arrangement Drawings................................................................... 58
Appendix 4 Electrical Schematics for Divert Control Box................................................. 81
List of Figures
Figure 1-Shoe Sorter Section Types and General Arrangement.................................................................11
Figure 2-Mark Number Stickers..................................................................................................................12
Figure 3-Skid Sticker....................................................................................................................................13
Figure 4-Floor Support Installation Detail ..................................................................................................15
Figure 5-Bed Section Fastening Detail ........................................................................................................16
Figure 6-Typical Spur Positioning................................................................................................................18
Figure 7-Spur Mounting Detail....................................................................................................................19
Figure 8-Chain Connection Detail ...............................................................................................................20
Figure 9-Slat Installation Detail...................................................................................................................22
Figure 10-Spring Clip Seating Detail............................................................................................................23
Figure 11-Knife Edge Installation Positioning .............................................................................................24
Figure 12-Knife Edge Nosebar Positioning Detail .......................................................................................25
Figure 13-Side View of Knife Edge Conveyor..............................................................................................26
Figure 14-Belt Tracking by Adjusting Snub Rollers .....................................................................................26
Figure 15-Discharge Transition Assembly Positioning Detail......................................................................27
Figure 16-Chain Guard, Guiderail, and Side Cover Installation...................................................................30
Figure 17-Oiler Pump and Flow Adjustment Panel.....................................................................................32
Figure 18-Tailshaft Encoder Installation .....................................................................................................33
Figure 19-General Arrangement, Shoe Sorter Slat and Chain Exploded View, Sheet 1 of 1 ......................58
Figure 20-General Arrangement, Shoe Sorter Divert Section, Sheet 1 of 2 ...............................................59
Figure 21-General Arrangement, Shoe Sorter Divert Section, Sheet 2 of 2 ...............................................60
Figure 22-General Arrangement, Shoe Sorter Divert Switch, Sheet 1 of 3.................................................62
Figure 23-General Arrangement, Shoe Sorter Divert Switch, Sheet 2 of 3.................................................63
Figure 24-General Arrangement, Shoe Sorter Divert Switch, Sheet 3 of 3.................................................64
Figure 25-General Arrangement, Shoe Sorter Divert Receiver and Shoe Return, Sheet 1 of 1 .................65
Figure 26-General Arrangement, Shoe Sorter Tail, Sheet 1 of 2 ................................................................66
Figure 27-General Arrangement, Shoe Sorter Tail, Sheet 2 of 2 ................................................................67
Figure 28-General Arrangement, Shoe Sorter Drive, Sheet 1 of 2 .............................................................68
Figure 29-General Arrangement, Shoe Sorter Drive, Sheet 2 of 2 .............................................................69
Figure 30-General Arrangement, Shoe Sorter Discharge Transition, Sheet 1 of 1.....................................71
Figure 31-General Arrangement, Shoe Sorter Oiler, Sheet 1 of 1 ..............................................................73
Figure 32-General Arrangement, Shoe Sorter Chain Guide Fastening Detail, Sheet 1 of 1........................74
Figure 33-General Arrangement, Shoe Sorter Debris Sensor Detail, Sheet 1 of 1 .....................................75
Figure 34-General Arrangement, Shoe Sorter Knife Edge, Sheet 1 of 2.....................................................77

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
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Figure 35-General Arrangement, Shoe Sorter Knife Edge, Sheet 2 of 2.....................................................78
Figure 36-General Arrangement, Shoe Sorter Induction Gapper, Sheet 1 of 1..........................................80
Figure 37-Electrical Schematic for Divert Control Box, Sheet 1 of 7...........................................................81
Figure 38-Electrical Schematic for Divert Control Box, Sheet 2 of 7...........................................................82
Figure 39-Electrical Schematic for Divert Control Box, Sheet 3 of 7...........................................................83
Figure 40-Electrical Schematic for Divert Control Box, Sheet 4 of 7...........................................................84
Figure 41-Electrical Schematic for Divert Control Box, Sheet 5 of 7...........................................................85
Figure 42-Electrical Schematic for Divert Control Box, Sheet 6 of 7...........................................................86
Figure 43-Electrical Schematic for Divert Control Box, Sheet 7 of 7...........................................................87
List of Tables
Table 1-Wiring of Knife Edge and AC Gapper IO Cable...............................................................................37
Table 2-List of Sensors ................................................................................................................................39
Table 3-Divert Box I/O Mapping .................................................................................................................42
Table 4-Recommended Preventative Maintenance Schedule ...................................................................53
Table 5-List of Section Weights...................................................................................................................55
Table 6-List of Drive Motor Weights...........................................................................................................56
Table 7-Oiler Pump Runtime (in seconds) Per Lubrication Interval............................................................57
Table 8-Recommended Lubricant Flow Rates and Lubrication Intervals ...................................................57
Table 9-BOM for GA-SHOE-36-120-0001....................................................................................................61
Table 10-BOM for GA-SHOE-MW-88-0001.................................................................................................70
Table 11-BOM for GA-SHOE-MW-88-0002.................................................................................................72
Table 12-BOM for GA-SHOE-MW-120-0002...............................................................................................76
Table 13-BOM for GA-SHOE-MW-48-0001.................................................................................................79
Reference Documents
MANUFACTURER
DOCUMENT TITLE
DOCUMENT
NUMBER
URL
Teknic, Inc.
ClearPath MC/SD User
Manual Rev.3.05
N/A
https://www.teknic.com/files/downlo
ads/clearpath_user_manual.pdf
Teknic, Inc.
AC ClearPath-MC/SD User
Manual Rev.3.06
N/A
https://www.teknic.com/files/downlo
ads/ac_clearpath-sc_manual.pdf
The Diamond
Chain Company
Diamond Chain
Maintenance Guide
11255_201903
https://www.diamondchain.com/wp-
content/uploads/2017/03/catalogs/ma
intenance-guide/maintenance-
guide.pdf
The Diamond
Chain Company
Diamond Series Product
Catalog
DC1000-201905
https://www.diamondchain.com/wp-
content/uploads/2018/01/2019_Diam
ond_Chain_Catalog_links.PDF
The Diamond
Chain Company
Roller Chain Wear Gauge
Instructions
DCWG-2013
N/A

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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MANUFACTURER
DOCUMENT TITLE
DOCUMENT
NUMBER
URL
ABB Motors and
Mechanical, Inc.
(formerly Baldor
Electric
Company)
Instruction Manual for
DODGE® Setscrew,
Eccentric Collar, D-Lok, H-E
Series, E-Z Kleen, Ultra
Kleen and Food Safe
Mounted Ball Bearings
MN3016
https://www.baldor.com/mvc/Downlo
adCenter/Files/MN3016
ifm Efector, Inc.
Operating instructions
Retro-reflective sensor
(OGP7xx)
80284283 / 00
https://www.ifm.com/mounting/8028
4283UK.pdf
Insight
Automation
EZ24 Family Reference
Manual
PR-1100
https://www.pulseroller.com/files/NA
/Control%20Literature%20&%20Drawi
ngs/EZ-
24/Users%20Manual%20and%20Specif
ications/Users_Guide.pdf
SEW Eurodrive
Operating Instructions (AC
Motors DR..71-315, DRN63-
315, DR2..63-80)
24745332/EN
https://download.sew-
eurodrive.com/download/pdf/247453
32.pdf
SEW Eurodrive
Assembly and Operating
Instructions (Gear unit
series R..7, F..7, K..7, K..9,
S..7, SPIROPLAN® W)
21932786/EN
https://download.sew-
eurodrive.com/download/pdf/219327
86.pdf
Bijur Delimon
International
SureFire II Lubricator
Automatic, Oil & Fluid
Grease, Single Phase
36410
http://www.bijurdelimon.com/fileadm
in/products/docs/bdius/Datasheets/36
410_LUB_SureFire-II-PDI-SLR_DS-
R2.pdf
Bijur Delimon
International
Operators Manual
Controller,SureFire II (Single
Phase PDI - SLR(24VDC,
115VAC & 230VAC))
36412
http://www.bijurdelimon.com/fileadm
in/bdide/downloads/36412_SureFire-
II_Controller_OM_2017_1_GB.pdf
Bijur Delimon
International
SureFire II Lubricator Quick
Start Manual
71070
http://www.bijurdelimon.com/fileadm
in/products/docs/bdius/Operator-
Manuals/71070_SureFire-II-
Quick_Start_QS-R3.pdf

Installation and Maintenance Manual: Shoe Sorter
_____________________________________________________________________________________________
Installation and Mai ntenance Man ual: Shoe S orter
Published September 2020
Rev. B
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1Introduction
Thank you for choosing Bastian Solutions Conveyor. The following manual serves as a guide for
installation, part replacement, and general maintenance for your material handling equipment. It is
important to read the manual and follow any instructions as it provides important safety information for
personnel and will maximize the longevity of the conveyor.
The information contained in this manual applies only to the products described. Uses, activities, or
processes related to installing or maintaining the equipment that are not explicitly described in this
manual are considered out of scope. Please contact Bastian Solutions Conveyor for any questions or
support that is not clearly addressed in this document. Bastian Solutions Conveyor is not responsible for
misuse of the equipment described in this manual or misuse of information in this manual. If you have
any questions, contact Bastian Solutions Conveyor Customer Service or Support at
[e-mail].
2OSHA And Safety
BSC is not responsible for ensuring that conveyors used in a system abide by OSHA standards. Safety is
of primary importance to our company, but as a product distributor we ask that system integrators and
end users conform with all applicable OSHA standards. We encourage that all warnings in this manual
are followed to avoid unnecessary risk.
3Model: Shoe Sorter
The BSC Shoe Sorter is a slat conveyor with movable shoes that slide laterally on the slats when diverted
by rails below the conveying surface. The shoe sorter is used for high-speed, high-volume primary
sortation, and is optimized for conveyance of cartons and totes.
Figure 1-Shoe Sorter Section Types and General Arrangement
Figure 1 shows a side view of an example shoe sorter. Product flows over an induction conveyor,
containing at least a knife edge transition belt, but commonly also containing one or more gapper
conveyors to set correct product spacing. The product then flows across the sorter, which contains one
or more divert sections. Each divert section will mate to a spur and a takeaway conveyor line. Products
that do not get diverted will continue down the length of the sorter onto discharge conveyor.

Installation and Maintenance Manual: Shoe Sorter
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4Receiving
Upon delivery of any BSC conveyor, please review and check the following:
•The quantity of items received against the Bill of Lading.
•Complete a visual inspection of equipment to determine any damage that may have occurred
during shipping. If damage is present, document with pictures.
•Review Mark Number information and layout locations. More information can be found in
subsection 4.1.
If there are any missing or damaged components contact your BSC representative with as much detail as
possible. If you are unsure of your BSC representative, please contact Customer Service at
[e-mail].
4.1 Mark Numbers
A mark number is a specific number given to a piece of equipment. A mark number is usually made up of
a single product line (RZPDC, RLVDC, BZPDC, etc.) but can contain many bed section lengths. They can
range from two inches to hundreds of feet in length. The mark number is used to help identify where
the piece of equipment will go within the system layout.
Every bed section of conveyor will have (2) stickers. One sticker on the infeed end of the bed, and one
sticker on the discharge end of the bed. Each sticker will contain the following information:
•BSC Project Number and Name
•Model Type
•Mark Number
•Match
•Piece
•Flow
Figure 2 shows the stickers that would appear on an RZPDC that has two bed sections.
•The Match field on the stickers is used to indicate if two bed sections are to be spliced to one
another.
•As shown in Figure 2 the stickers where the two beds splice together both contain Match: 1.
•The Piece field defines the bed section number within the mark.
•The flow refers to the direction of product flow along the conveyor system.
Figure 2-Mark Number Stickers

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4.2 Skid Contents
Skids will contain varying combinations of conveyor sections, support structures, accessories, and
pertinent hardware. For protection of product integrity during shipping, accessories and supports may
be delivered on separate, but labeled skids.
4.3 Skid Documentation
All shipments will contain a Bill of Lading for the delivery company, a skid label, and a skid
manifest. Skid labels have the contents of each shipped item located on the skid. Figure 3 shows
a sample of a skid label. These stickers are placed on the surface of each skid.
Figure 3-Skid Sticker

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5Installation
Ensure that your conveyor equipment has been securely fastened to the floor or other mounting surface
before full operation occurs.
Consideration should be given to floor point loading prior to installation to ensure
proper support of equipment. See Appendix 1 for section weights.
5.1 Mechanical Installation
5.1.1 Bed Section Placement
1. Lay out chalk lines on floor for placement –See the system layout/installation drawings.
2. Lift the drive section off the skid using the provided lifting eyes on the frame
3. Set the drive section in position. Refer to the system layout/installation drawing and Figure 1.
DO NOT pick up or move drive section using the lifting eyes on the motor or
gearbox. Damage to the gearbox or drive shaft may result.
On larger units, the motor may be shipped separate from the drive unit. See SEW
Eurodrive Gear Unit Assembly and Operating Instructions section 4 for installation
instructions.
Secure the drive unit to the floor before installing the motor. Heavy gearmotors
may cause the drive unit to become unbalanced or tip during installation.
4. Adjust the foot bolts on the drive so all four feet are in contact with the floor and the drive section is
level and aligned to the chalk lines.
5. Check that the height of the drive section matches the specified height on the system layout
drawing (the top of the frame is 3/8” below the final slat surface)
6. If the drive section is out of square, use the provided tension rod for squaring adjustment
7. Set each section and bolt them together, working backwards from the drive to the tail. See Figure 5
for details on fastening the sections together. Hand tighten only at this stage.
8. Check square on each section and check the straightness of the sorter before securing to the floor.
5.1.2 Floor Support Installation
1. See Figure 4
2. Place a thin black neoprene washer between the bolt head and the flange of the sideframe.
3. Place a green urethane vibration damper between the sideframe and the floor support.

Installation and Maintenance Manual: Shoe Sorter
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Installation and Mai ntenance Man ual: Shoe S orter
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Figure 4-Floor Support Installation Detail
4. Adjust the urethane vibration damper to 3/8” to 7/16” tall (1/8” to 1/16” compression).
5. Adjust the top of conveying surface height by adjusting the floor support.
Do not use vibration dampers for height adjustment. Excessive compression can
damage the vibration dampers and will increase vibrations transmitted into the
floor supports.
5.1.3 Section Fastening and Rail Alignment
1. See Figure 5 for details on fastening sections together.
2. Use of a laser level is recommended to set the sorter straight and level.
The sorter must be level front-to-back, side-to side, and all sections must be aligned
straight to within the tolerances specified in step 3. Misalignment can cause noisy
operation and/or damage to the chain, bearings, and slats.

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3. Lateral straightness tolerances must be within +/- 1/2 inch per 100 feet. Check each bed section
joint to ensure there are no bumps or discontinuities (use a laser to sight from the drive to the tail).
4. Twist in the sorter bed must be limited to +/- 1/4 inch per 10 feet of sorter length, with no bumps or
discontinuities and no section out-of-level by more than +/- 1/2 inch across its width.
5. Ensure the drive and tail shafts are level by placing a precision level directly on the respective shafts.
See Diamond Chain Maintenance Guide section 1 for chain alignment tolerances.
Figure 5-Bed Section Fastening Detail
6. Place a straightedge across the gap in the bearing rail between each bed section, and install the
bearing rail splice so that it mates with the installed bearing rail on both the upstream and
downstream ends.
a. If there are any bumps created by misalignment where the bearing rail ends meet, it will cause
excessive noise during operation and, if the misalignment is severe, can damage the chain
mount bearings over time.
The bearing rail splice can also be used for pulling sections together (aligning) left-to-
right. Ensure the section splice bolts are loose enough to allow movement before
pulling the sections together.

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7. Place a straightedge across the gap in the pin guide between bed sections, and install the pin guide
splice so that it mates with the installed pin guide on both the upstream and downstream ends. The
pin guide and pin guide splices should be approximately centered in their mounting slots.
a. If there are any bumps created by misalignment where the pin guide ends meet, it will cause
excessive noise during operation and, if the misalignment is severe, can damage the pin guide
covers and the slat mounts over time.
The pin guide fixing screw is always on the upstream end with respect to chain flow.
It is important to maintain this orientation, or the plastic cover could come off and
cause damage.
8. Once the sections are straight and level, fully tighten all section splice bolts and secure to the floor
or decking.
a. Tighten 1/4”-20 fasteners to 8.4 ft-lb.
b. Tighten 3/8”-16 fasteners to 31 ft-lb.
c. Fastening hardware to secure the floor supports to the floor or decking is not provided by BSC.
Consult the hardware manufacturer for appropriate torque values.
Ensure the securing method is appropriate for the application. Installations in seismic
zones will generally require an independent seismic review. BSC does not provide
general-purpose recommendations for concrete anchors or other fastening methods,
since fastening requirements depend on the site-specific details of the mounting
surface.
9. Verify straightness and level again once all sections are fully secured and all bolts are tightened.
Adjust the section positioning as needed if any sections have moved out of alignment.
5.1.4 Spur Installation
1. The spur mounting brackets share mounting bolts with the chain guards. Spur locations use a chain
guard piece painted standard silver color instead of safety yellow.
2. Attach the spurs to the sorter by bolting the spur to the slots in the mounting brackets using 3/8”
carriage bolts.
3. Spur locations are adjustable along the length of the sorter using the provided slots.
4. Locate spurs per the system installation drawing. See Figure 6 for typical spur positioning. Spur
alignment is given relative to the divert rail and the positions of installed shoes.
a. In a typical installation, measure off the divert rail, since the slats and shoes are typically
installed only after spurs have been mounted.
b. The critical dimension (1 3/8” in Figure 6) is measured between the face of the divert rail and
the inside of the spur frame, perpendicular to the divert rail. This measurement will locate the
spur correctly on both 30° divert and 22.5° divert sorters.

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Spur positioning may need to be modified for certain product types (e.g. totes with an
overhanging lip may require the spur to be moved downstream so the overhanging lip
can clear the downstream spur guiderail). Check and follow the system installation
drawing for exact site-specific spur positioning.
5. Set spurs approximately 3/8” lower than the sorter TOCS using the spur jack bolts.
6. Tighten spur mounting bolts once spur is in its final position. See Figure 7.
a. Tighten 3/8”-16 fasteners to 31 ft-lb.
The provided adjustment travel is intended for optimizing the spur location relative to
the divert rail. Moving the spur a large distance may cause problems diverting large
packages, depending on the system layout.
Figure 6-Typical Spur Positioning
2”
1 3/8”

Installation and Maintenance Manual: Shoe Sorter
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Figure 7-Spur Mounting Detail
5.1.5 Chain Installation
Run power to the main drive motor and verify the motor rotation direction before
installing the chain. Running the sorter backwards can cause damage to slats, chain, and
sorter internal components.
The “missing bearing”fork sensor on the first divert section is easy to damage when
installing the chain. Recommend removing the sensor during chain install and replacing
it only after chain installation is completed.
1. The chain comes pre-assembled with chain mounts.
2. The chain is shipped and tagged in matched pairs (right and left)
a. Right and left sides of the sorter are determined by facing in the direction of product flow.

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Figure 8-Chain Connection Detail
3. Always keep the matched pairs across from each other. Keep the tags on the chain until it is installed
in the sorter.
4. Lay out a matched pair of chain and hold it together with one slat approximately every two feet,
starting at the tail sprocket and working towards the drive.
a. See Section 5.1.6 for instructions on slat installation.
5. Join the chain sections with a connecting link, then install the chain mounts over the connecting link
section. See Figure 8.
6. Once the chain is installed on top of the sorter, use the drive sprocket to help pull the chain around.
7. Two options to turn the drive sprocket manually are:
a. The flat on the drive shaft (use a 1-1/8” open end wrench with a cheater bar or other long
handle extension)
b. Remove the fan cover and rotate the fan of the drive motor by hand (this method is slower, but
it requires lower torque due to the mechanical advantage of the gearbox)
The drive must be locked out during chain install—do not use the drive motor to
advance the chain during installation. Death or serious injury could result.
8. Attach ropes to the free end of the chain to help pull the chain through the catenary (force should
be transmitted through the drive sprocket; the ropes are to correctly guide the free end).