coesia Flexlink X65 User manual

CONVEYOR SYSTEM X65
MAINTENANCE MANUAL

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© Flexlink AB 2014
All Rights Reserved
No part of this program and manual may be used, reproduced, stored or
transmitted in any form or by any means without the written permission
of FlexLink AB. The contents of this manual are for informational use on-
ly. All information and specifications contained in this document have
been carefully checked to the best efforts of FlexLink AB, and are be-
lieved to be true and accurate as of time of publishing. However, due to
continued efforts in product development FlexLink AB reserves the right
to modify products and its manuals without notice.
FlexLink AB assumes no responsibility or liability on any errors or inac-
curacies in this program or documentation. Any kind of material damag-
es or other indirect consequences resulting from any FlexLink AB´s
product part, documentation discrepancies and errors or non-anticipat-
ed program behavior are limited to the value of appropriate products
purchased from FlexLink AB. The products are delivered to the custom-
er at the ’as is’ state and revision level they are on the moment of pur-
chasing, and are declared in detail in the license agreements between
FlexLink AB and user. User accepts and is obliged to follow the guide-
lines stated in the separate license agreement needed in using any parts
of this product package.

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1 General safety and design considerations 1
1.1 Introduction 1
2Safety 3
2.1 System information 3
2.2 Important safety conditions 3
3 Maintenance 7
3.1 System maintenance 7
3.2 Maintenance instructions 8
3.3 Introduction to drive units 9
3.4 Slip clutch adjustment 10
3.5 Inspection – drive units 12
3.6 Inspection – conveyor chains 14
3.7 Inspection – slide rails, beams, idlers, bends 18
3.8 Inspection – safety devices 20
3.9 Replacement of worn parts – conveyor chain 21
3.10 Replacement of worn parts – slide rails 22
4 Troubleshooting 27
4.1 Checklist/maintenance schedule 29
5 System dismantling and disposal 31
5.1 Important safety precautions 31
5.2 Dismantling end drive units with suspended
motor 32
5.3 Dismantling end drive units, no slip clutch 34
5.4 Dismantling end drive units, slip clutch 35
5.5 Remove guide rails and guide rail brackets etc.
36
5.6 Remove the conveyor chain. 37
5.7 Dismantling end drive units 38
5.8 Remove slide rails 39
5.9 Dismantle the conveyor extrusions from the
support brackets. 40
5.10 Dismantle the conveyor support system 41
5.11 Recycle 43

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General safety and design considerations
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1 General safety and design
considerations
1. 1 I n t r o d u c t i o n
1. 1. 1 C r i t i c a l f a c t o r
To achieve an operational installation which is reasonably safe for all people
involved in its use and maintenance, it is necessary to consider certain as-
pects. This is done when designing a conveyor system. The chain is gen-
erally the critical factor to consider with guarding.
1. 1. 2 S a fe g u a r d i n g
All pinch and shear points as well as other exposed moving parts that pres-
ent a hazard to people at their workstations or their passageways must be
safeguarded. Overhead conveyors must be guarded to prevent objects fall-
ing. Cleated conveyor chains are more hazardous and create more pinch
and shear points than plain conveyor chains.

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1.1.2.1 Safeguarding can be achieved by:
• Location
Location of all hazardous areas away from areas occupied by personnel,
wherever possible.
•Guards
Mechanical barriers preventing entry into hazardous areas or protecting
against falling objects.
• Control devices
Machine controls which prevent the interruption of hazardous
operations/conditions.
Warning: Instructions, warning labels, or sound/light signals which alert to
hazardous conditions.
Safeguarding should be designed to minimize discomfort or difficulties to
the operator. Bypassing or overriding the safeguarding during operation
should be difficult.
Warning labels etc. should only be used when all other means of safe-
guarding will impair the function of the installation or are not cost effective.
The degree of safeguarding required should be identified during the imple-
mentation of the essential safety requirements during the design process.
1.1.3 Special considerations
When correctly applied, the FlexLink components are safe to use and
maintain. It is however necessary for those responsible for design, instal-
lation, operation and maintenance of the FlexLink installation to be aware
of certain areas where special attention is required.
1.1.3.1 All drive units with slip clutch
• Before adjusting the slip clutch it is necessary to remove all ob-
jects from the chain to remove any remaining chain tension.
• Adjustment should be conducted in accordance with the mainte-
nance procedures.
• All drive units, except the direct drive units, are fitted with trans-
mission chain covers. These covers must be fitted before the unit
is operated.
NB: The slip clutch is not a personnel safety device, but a device to protect
the conveyor equipment.

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2 Safety
The machine has been designed in such a way, that it can be used and
maintained in a safe way. This holds for the application, the circumstances
and the instructions described in this manual. Any person working with
around this machine should study the manual and follow the instructions.
It is the responsibility of the employer to make sure that the employee is
familiar with, and follows, these instructions.
The company or the country in which the machine is used may require ex-
tra safety measures. This particularly applies to the working conditions.
This manual does not describe how these are to be complied with. In case
of doubt, consult your government or safety officer!
2.1 System information
The order number and/or general drawing number shall always be speci-
fied when communicating with FlexLink with respect to the machine.
2.2 Important safety conditions
Before the machine shall be operated by a user, the following safety con-
ditions must be met:
Make sure that children or animals have no access to the machine and its
surrounding areas by, for example, screening off the machine with a fence.
Only personnel who have read and understood the operating instructions
are allowed to operate, maintain and clean the machine.
Do not reach into the machine while it is running or on. Even if the machine
is not running, it can be ‘on’, which means start operating automatically.
Safety provisions, such as side guards, bottom guards, emergency stops
and detectors shall not be removed or deactivated while the machine is
running.
Provide good ambient lighting to enable the operator to work well and or-
derly with the machine.
2.2.1 General
• Incorrect use of the equipment can cause personal injury.
• Do not stand or climb on the equipment.

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• Do not wear clothing or other articles that can fasten in the ma-
chine.
• For coupled drive units, safety protection should be applied to the
connecting shaft.
2.2.1.1 End drive units
• The chain slack length at the end drive units must be maintained
during the system lifetime. Shorten when necessary.
• If side plates are fitted, the chain must be shortened if the chain
becomes visible below the level of the side plates.
• The opening and closing of the links when they turn round the end
drive and idler wheels could be a risk. Drive and idler ends should
not be accessible during conveyor operation wherever possible.
The area near the in-feed guides for the chain return loop should not be ac-
cessible during conveyor operation.
2.2.1.2 Intermediate drive units
• The area near the in-feed guides for the chain return loop should
not be accessible during conveyor operation.
2.2.1.3 Horizontal bend drive unit
• The drive wheel should not be accessible during conveyor opera-
tion. The bottom should be covered with wheel cover.
2.2.1.4 Idler units
• The opening between the links when they turn round the idler roll-
er could be a risk. Idler ends should not be accessible during con-
veyor operation wherever possible.
2.2.1.5 Wheel bends, horizontal and vertical
• Guarding may be required at wheel bends depending on location
of bends and load applied to the conveyor.
• The opening between the links when they turn round the idler roll-
er could be a risk. Idler ends should not be accessible during con-
veyor operation wherever possible.
2.2.1.6 Cleated chains
• Any application incorporating cleated chains requires careful safe-
ty consideration. Pinch and shear points are generated through-
out the assembly of the incorporated components. Therefore

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generous guarding should always be employed to fully protect
within user operating areas.
• There is a higher risk of product damage when using cleated
chains. Special attention must be given to operator access in the
event of products becoming trapped or similar.
2.2.1.7 Maintenance
The maintenance routine of FlexLink conveyors should also include proce-
dures to ensure that the guarding remains securely fastened and effective
(if not interlocked via control system etc.).
FlexLink components are continuously reviewed to improve performance
either by design modification or material upgrade. In all these reviews user
safety is our primary consideration.
All associated technical data are retained at the manufacturers address.
2.2.1.8 Control system
Before operating or completing any maintenance on control system, read
the associated section as supplied with the equipment documentation.
If there are any questions as to the safe operating procedures of the equip-
ment supplied, please contact FlexLink immediately.
• Follow the instructions in this user manual when transporting the
machine. FlexLink AB must approve all modifications or changes
to this machine.
• Only use recommended spare parts.
• Only authorised personnel may open electrical units.
• FlexLink is not responsible for damage if service on the equip-
ment is not performed in accordance with this user manual.
2.2.2 Maintenance and Service technicians
Service technicians must have:
• Sufficient knowledge for reading technical information
• Ability to comprehend technical drawings
• Basic knowledge of mechanics
• Sufficient knowledge in the use of hand tools
• Skilled (EN ISO 12100:2010)

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2.2.3 Electricians
Electricians must have:
• Experience from similar installations
• Sufficient knowledge to work from drawings and wiring diagrams
• Knowledge of local safety regulations for electrical power and au-
tomation
• Skilled (EN ISO 12100:2010)
• To avoid risks, only experienced personnel with technical knowl-
edge and experience may perform repair work on the machine's
electronics components.
2.2.4 Operators
To correctly use the equipment, operators must have appropriate training
and/or experience.

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3 Maintenance
3.1 System maintenance
3.1.1 Introduction
The following section is designed to offer assistance for your planned
maintenance schedule. It may become evident that the suggested mainte-
nance intervals can be shortened or extended to accommodate your local
environmental conditions.
Maintenance of the FlexLink conveyor systems should only be carried out
by competent persons, who are familiar with FlexLink equipment. If there
is any doubt as to the most suitable procedure for maintenance, consult
your FlexLink supplier.
3.1.2 Non FlexLink equipment
Equipment and components which are not from the FlexLink family of
products should be maintained and serviced in accordance with their re-
spective manufacturer’s instructions.
3.1.3 Safety considerations
Before starting any maintenance on your FlexLink equipment, the follow-
ing safety instructions must be observed:
• All electricity must be switched off.
• Make sure that the motor switch is also switched off and locked
in the “off” position.
• Pneumatic and/or hydraulic power must be disconnected and any
pressure accumulation released.
• Products being transported should be, if possible, removed from
the conveyor chain.
• Staff affected must be informed that maintenance work is being
undertaken.
Warning: Do not climb onto the equipment.

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3.2 Maintenance instructions
3.2.1 Introduction
This maintenance manual contains directions for the standard components
sold through the X65 chapter of the FlexLink main catalogue. For non-Flex-
Link components, such as motors, pneumatic equipment, control systems
etc., the manufacturer’s maintenance instructions apply. In general, main-
tenance instructions are not given for equipment which the customer has
chosen and specified for fitting to the installation.
The instructions supplied should be followed to ensure that the installation
runs with a high degree of safety and to minimize the risk of breakdowns
which can adversely affect the production.
The installation must be used for the transport of goods in accordance with
the system specifications or within design criteria as outlined in the gener-
al catalogue. If a fault occurs on the installation which cannot be rectified
with the help of the instructions in the manual, or if unexpected conditions
occur during servicing, contact your FlexLink retailer or FlexLink mainte-
nance personnel.
3.2.2 Warranty/guarantee
FlexLink conveyors are covered by warranty/guarantees as identified with-
in the trading terms issued for each country. Check the warranty conditions
for your system before submitting claims etc. If you are in any doubt as to
what warranty is applicable to your system, consult your supplying agent
or FlexLink direct.
3.2.3 Spare/replacement parts
If there is a demand for spare parts, contact FlexLink or your supplying
agent.
3.2.4 Checklist/maintenance schedule
A suggested maintenance schedule is shown on page 29.
3.2.5 Important
Consult your system documentation for any special maintenance required
for your specific installation.

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3.3 Introduction to drive units
3.3.1 Three types
There are three different types of drive unit: end drive, intermediate drive
and horizontal bend drive units
1End drive units
End drive unit with return chain,
located at the ‘pulling’ end of the
conveyor. End drive units are either
direct drive types (see picture) or
transmission chain types.
NB: The roller chain transmission has
chain guards and gearing
protection. These guards should
always be in position when the
conveyor is in operation.
2Intermediate drive units
Intermediate drive unit located at an
intermediate position along the
conveyor.
3Horizontal bend drive units
Horizontal bend drive unit for driving
endless conveyors without return
chain.

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3.4 Slip clutch adjustment
3.4.1 Introduction
The slip clutch on the drive unit is a safety device which allows the chain
to stop if the load becomes excessive. It has two purposes:
• Prevent damage to conveyor
• Prevent damage to the products on the conveyor
Where a slip clutch is fitted, it must be adjusted so that it does not slip
whenever the drive unit is started under full load. The installation is carried
out as follows:
Preparations for adjustment
• Stop the conveyor.
• Ensure that the conveyor can not be started accidentally. For ex-
ample: unplug the electric power plug.
• Remove any load on the conveyor.
Caution:
If you try to adjust the slip clutch when there is still load on the
conveyor, the accumulated tension in the chain can cause se-
vere injuries when you release the clutch.
Slip clutch should not be adjusted until
• Motor direction is confirmed
• Conveyor is fully assembled
Important:
The slip clutch is not a personal safety device. It is primarily intend-
ed to protect the equipment.

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3.4.2 Clutch adjustment
3.4.2.1 Clutch adjustment table
Fmax is the desired maximum traction force applied to the chain by the
drive unit. The clutch will start slipping at forces above Fmax.
1 Remove the drive unit protection
cover.
2 Use an Allen key, 3 mm, to loosen
the screw (1) on the slip clutch so
that the adjustment nut (2) can be
freely rotated.
3 Turn the adjustment nut (2)
clockwise with a hook spanner until
the arrow on the nut is aligned with
the desired Fmax value (3). See the
following table for correct values.
NB: On delivery, the clutch is always
set to “0”.
4 Tighten the screw (1).
5 Re-install the drive unit protection
cover.
Traction force, Fmax (N)
No.
X65
300 0
400 1
500 2
Article number for the slip clutch are found in Spare
parts catalogue for X65.
1
2
3

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3.5 Inspection – drive units
3.5.1 Roller chain transmission
The roller chain transmission should be checked and lubricated after 50,
250, 500 hours of operation, and then every 500 hours. If the roller chain
transmission is not fitted with a chain tensioner the chain tension should
be checked on this occasion.
At the same time as the roller chain tension is checked, the chain must
also be lubricated with a suitable chain spray or similar.
If the transmission is fitted with a chain tensioner, lubrication should only
be carried out at the stated intervals. The condition of the chain tensioner
must be checked at the same time as the lubricating is done.
NB: The discs in the slip clutch must be kept free from oil and grease.
3.5.2 Worm gear motor and geared motor
The worm gear or geared motor is checked in accordance with the instruc-
tions from the relevant supplier.
3.5.3 Guide for the conveyor chain
The purpose of the guide for the
conveyor chain is to guide the return
chain correctly into the drive unit.
Fully enclosed drive units do not have
guides. On these, no slack is permitted
at the drive unit since the conveyor
chain is being controlled all the time.
Special attention must be given to
chain elongation in conveyors of this
configuration.
If guides are fitted they can be of two
different types:
• Loose disposable guides in
plastic.
• Guides integrated into the
ends of the drive unit

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3.5.4 General checks on drive unit
Carry out a general inspection of the drive unit.
• Check particularly that the protective covers for the roller chains
are complete and firmly in place.
• Replace damaged/worn parts.

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3.6 Inspection – conveyor chains
3.6.1 Conveyor chains
The most common types of conveyor chains are:
NB: When dealing with cleated chains special safety measures against
pinch and shear points must be considered.
3.6.1.1 Cleated, friction and wedge chains
Cleated chains, friction chains and wedge chains, or other special chains
should be inspected regularly, and any defective links replaced or cleaned.
Warning: Only warm water (50°C), with soap if necessary, may be used
for cleaning conveyor chains.
Check the guards on cleated chain conveyors.
1• Plain conveyor chains
2• Chain with flexible cleats
for vertical wedge convey-
ors
3• Chain with friction surface
for conveyors with an in-
cline up to 30°. The friction
surfaces are normally dis-
tributed over the chain at a
predetermined distance.

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3.6.2 Checking the tension of conveyor chain
The chain is made of elastic material. The chain eventually stretches as the
material creeps. The extent of the stretch depends on the traction force in
the chain. The stretch shows itself as slack on the return side of the drive
unit.
The tension of the conveyor chain should be checked after 50, 250, 500
hours of operation and thereafter every 500 hours.
In operation there will be some slack in the conveyor chain. How much ac-
ceptable slack depends on the length of the conveyor chain. The most suit-
able places to check the slack in the chain are at intermediate or end drive
units.
3.6.3 Important
The chain should therefore be pre-
tensioned while the conveyor is
stationary, but must never be so tight
that there is no slack during operation.
There should be no appreciable slack
on the chain when the conveyor is
stationary. This can, however, vary
depending on the total length of the
chain. If there is too much slack, there
will be excessive wear on the chain
guides and the chain. This could be a
risk for injury.
If the slack on the conveyor chain is
unacceptably high, it must be
shortened by splitting the chain and
removing the necessary number of
links. See Shortening conveyor chains
on page 16.
If the conveyor has a guided drive unit
with no chain slack outlet, the
elongation of the chain has to be
monitored even more carefully, to
ensure trouble free operation
The Conveyor chain must show some
slack during operation
The Conveyor chain does not need to
show any slack when the conveyor chain
is stationary