ELCOM TLM 1000 Guide

Modular transfer system
TLM 1000
User manual
&
Maintenance guide
Translation of the original manual, version 04

I02-118 User manual & maintenance guide Version 04 (translation of the original manual)
of TLM 1000
Table of contents
1 General information........................................................................................................................ 1
1.1 Important remarks .................................................................................................................. 1
1.2 Applicable standards ............................................................................................................... 1
1.3 Applications............................................................................................................................. 1
1.4 Conditions of use..................................................................................................................... 1
1.5 Safety instructions................................................................................................................... 2
1.6 Safety instructions regarding the motor................................................................................. 2
1.7 Additional information............................................................................................................ 2
2 Technical specifications................................................................................................................... 3
3 Commissioning ................................................................................................................................ 4
3.1 Receipt..................................................................................................................................... 4
3.2 Transfer elements ................................................................................................................... 4
3.3 Stopper.................................................................................................................................... 4
3.4 Positioning unit........................................................................................................................ 4
3.5 Workpiece carrier.................................................................................................................... 5
4 Maintenance ................................................................................................................................... 5
4.1 Belts wear................................................................................................................................ 5
4.2 Passageways of workpiece carriers......................................................................................... 5
4.3 Pins .......................................................................................................................................... 5
4.4 Wear of the belt guide ............................................................................................................ 5
4.5 Transfer parts .......................................................................................................................... 6
4.6 Stopper.................................................................................................................................... 6
4.7 Positioning unit........................................................................................................................ 7
4.8 Heavy positioning unit........................................................................................................... 10
4.9 Other transfer parts .............................................................................................................. 11
5 Motor Replacement ...................................................................................................................... 12
5.1 Disassembly........................................................................................................................... 12
5.2 Reassembly of the motor ...................................................................................................... 14
5.3 Changing the belt –Flat belt ................................................................................................. 14
5.4 Changing the belt –Timing belt ............................................................................................ 16
6 Responsability ............................................................................................................................... 17
7 Customer service........................................................................................................................... 17
8 Appendix........................................................................................................................................ 18
8.1 Maintenance schedule .......................................................................................................... 18
8.2 Quality and environmental commitment: ISO certifications ................................................ 19
8.3 Spare parts list....................................................................................................................... 20

I02-118 User manual & maintenance guide Version 04 (translation of the original manual)
of TLM 1000
Version tracking:
Version
Date
Description of modifications
Prepared by
Approved by
01
01/10/15
Initial (translation)
S. GUILLAUD-BATAILLE
02
06/12/16
-
S. GUILLAUD-
BATAILLE
-
03
19/09/18
Upgrade of the safety instructions + 2015
edition of ISO 9001 and 14001 standards:
deletion of expired certificates
S. MAIRET
S. MAIRET
04
06/02/19
ERRATUM - Modification in the
calculation of the flat belt
C. POULET
S. MAIRET

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1GENERAL INFORMATION
1.1 Important remarks
The following instructions will be used as technical documentation for the manufacturer of the
final machine. elcom is the supplier of this TLM 1000 transfer system sub-assembly .
The manufacturer of the final machine must make sure that:
-All safety equipment is provided and functional,
-Regular checks are carried out,
-All danger (pinching, squashing) due to moving parts is controlled,
-The documentation is complete.
1.2 Applicable standards
According to the 2006/42/CE European directive, elcom transfer systems are considered as partly
completed machines. They are therefore not subject to an EC declaration of conformity but are the
subject of a declaration of incorporation. The latter is transmitted at the time of delivery,
accompanied by the exploded view of the motorized equipment.
However, the following standards are taken into account during the design and the manufacturing of
the elcom transfer systems:
–The European Machinery Directive 2006/42/CE
–The European Low Voltage Directive73/23/CE
elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.
For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.
1.3 Applications
The elements of the linear TLM 1000 transfer systems are designed to carry and position workpiece
carriers according to the end customers’ configuration.
They are intended to be incorporated the customers' production line.
1.4 Conditions of use
The elements of the TLM 1000 transfer systems are suited for a use in normal industrial areas such as
a final assembly plant or equivalent, in a dry environment.
They are not suited for transporting materials such as sand, balls or grain.
The maximum load applicable on the transfer system is mentioned in the catalog and must never be
ignored.
To ensure a proper functioning of the transfer system on a maximum period of time, you must follow
this advice:
-Use temperature between 0 and 40°C (30 and 140°F)
-Avoid dusty or smoky atmosphere
-Avoid accumulation of sharp objects on the transfer system
-Avoid setting the machine in direct exposition to UV rays

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1.5 Safety instructions
Safety rules regarding transfer systems, especially the ones regarding the electrical
devices, must be followed during all the use phases: mounting, transport, production.
Disregarding these rules would be regarded as a wrong use of the machine.
Using the transfer system in an explosive atmosphere can have a negative impact on the
transfer system and is strongly discouraged.
Never perform any maintenance on your own. Another worker must be present at all
time in order to shut the power down or perform first aid actions if needed.
Changing the motor position or removing security parts must only be done when the
transfer system is unplugged from any power supply.
When carrying maintenance or handling tasks while the transfer system is operating (belt
tension setting), take care not to slide your hand between the belt and the belt support
in order to avoid any accident.
All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected in the end-user machine in
order to avoid any risks of pinching or squashing. We recommand to mount a protective
housing around it. In case of manual shift, the final machine can not be used without the
protections installed at the indexing and stop station
1.6 Safety instructions regarding the motor
In case of a power failure, turn off the transfer system: it could restart automatically
when the power comes back which could cause damages and even injuries to the
operator.
1.7 Additional information
These instructions aim at ensuring the safety of the people and the proper functioning of the transfer
system. If you wish to use the transfer system in any other conditions, please do not hesitate to
contact us.
Other information is available on our website, in the documentation section:
http://elcom-automation.com/transfers/documentation

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2TECHNICAL SPECIFICATIONS
- Maximum load on a workpiece carrier: 2 kg
- Maximum accumulated load on the transfer system: 25 kg for a maximum 3-meters unit.
- Electrical power supply of the motors: 380V three-phase
- Motor power: V 9 m /min = 0.09 Kw
(V = belt speed) V 15m /min = 0.09 Kw
V 19m /min = 0.09 Kw
Air pressure supply = 5 to 6 bars
Every cylinder must be equipped with a flow limiter.
- Sound emission < 70 dB
- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.
http://elcom-automation.com/transfers/documentation
Warning: All load exceedance can lead to a premature wear of the belt or any other
parts.

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3COMMISSIONING
3.1 Receipt
When receiving the transfer system, check if the packaging has not suffered any damage and
that the machine is in perfect conditions.
The transfer system can be supplied in kit. It then needs to be assembled.
3.2 Transfer elements
When handling the equipment and parts, take special care to avoid shocks.
1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,
2. Level perfectly the conveying units while checking that the belts are properly laid on the
belt guide,
3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of
the line, it may be necessary to perform ground fastenings,
4. Check the settings of the motor magneto-thermic circuit breakers,
5. Check the running direction of the belt without any load,
6. Adjust the cams and the selectors using a workpiece carrier,
7. Start the transfer system with all the workpiece carriers on.
3.3 Stopper
1. Place the stopper right in the middle of the two profiles of the system,
2. Adjust the sensor for the detection of the workpiece carriers,
3. Adjust the flow control units.
3.4 Positioning unit
1. Put the positioning unit right in the middle of the two profiles of the system,
2. Adjust the sensor for the detection of the workpiece carriers,
3. Check on the high position that the pins of the workpiece carrier are free,
4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),
5. Adjust the flow controllers.
Note: For the heavy positioning unit, check the lubrication of the drawer (see Maintenance).
All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected on the end-user machine
in order to avoid any risk of pinching or squashing. We recommend mounting a
protective housing.

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3.5 Workpiece carrier
1. Check that the springs of the pins located under the carrier are working properly.
2. Check that no part goes over the lower surface of the workpiece carrier.
4MAINTENANCE
General visual check
Approximately every 500 hours, check the following points to ensure the proper functioning of the
transfer system:
4.1 Belts wear
Regularly verify visually the state of the belt and especially the welding area.
4.2 Passageways of workpiece carriers
The friction of the pins while operating can make some marks appear. Those marks may over the
long term require the part replacement.
4.3 Pins
Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of
efficiency in the guiding of the workpiece carrier occurs.
4.4 Wear of the belt guide
Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.
Wear area of the pins
Belt
Belt guide

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4.5 Transfer parts
Every 200 hours:
Remove the dust from the complete unit, using the product:
Ref 800 00 003 (polish plastics Air Industry 2101).
Every 3200 hours:
Check the lubrication of the conical torque.
Apply grease to obtain the initial lubrication state if necessary.
Use the grease reference 800 00 009.
4.6 Stopper
Every 5000 hours:
Eventual cleaning of the stopper depending on the working environment.

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Stopper can be disassembled by the two screws located underneath.
Once the screws are taken off, slide the stopper outside of the system for disassembly, cleaning and
greasing.
4.7 Positioning unit
Every 1000 hours:
All types except heavy positioning unit.

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Remove the positioning unit plate after unscrewing the fastening screw.
Check the lubrication of the guiding shafts.
Guiding shafts

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Changing the pins (locating and centering)
Extract the previous pins with the press.
Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support
(insert the pin in the bush and then place the whole on the positioning unit plate).
Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.
Pins
Bush (ref. 110 03 005)

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4.8 Heavy positioning unit
Disassembly of the heavy positioning unit:
Unscrew the fixing screws that fasten the
positioning unit on the rails.
Take off the positioning unit from the
transfer system.
Unscrew the fixing screw fastening the
plate.
Remove the plate to allow access to the
drawer.
Every 1000 hours:
Lubrication of the drawer (inside and outside)
Use the recommended grease (grease Gulf Crown EP2).
Plate fixing screw

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Lubricate the positioning unit finger with a film of grease.
Use the grease ref. 800 00 002 (Crown, ref. 7041 spray).
Changing pins (locating/centering)
Extract the previous pins with a press.
Put the new pins in place with the press while using the bush of a workpiece carrier as a support
(Insert the locating pin in the bush, and then place the whole back on the positioning unit plate.).
For re assembly, follow the previous steps in reverse order.
4.9 Other transfer parts
The others parts of the transfer system do not need any maintenance. A visual check, looking for
wear or breaking parts is recommended from time to time.
Drawer (réf 110 11 007)
Areas to be lubricated

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5MOTOR REPLACEMENT
5.1 Disassembly
Unscrew the four screws from the plastic cover.
Take the circlip and the washer off.
Circlip
Washer

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Remove the motor from the shaft.
Unscrew the anti-rotation screw of the reducer, on the transfer side.
Anti-rotation screw

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5.2 Reassembly of the motor
Put the screw back on the new reducer.
Lubricate the shaft with copper grease.
For reassembly, follow the previous steps in
reverse order.
5.3 Changing the belt –Flat belt
Calculate the belt required length for a single unit:
[(L-160) x 2 + 490] x 0.97
L = total length of the transfer system, including the return.
Calculate the belt required length for a U-shape unit:
[(L-160) x 2 + 678] x 0.97
L = total length of the transfer system,
including the return.
Cut the first bevel.
Trace the point zero.
Cut the right length.
Cut the second bevel with the same
bevelling device.
Do not forget to take the length of the bevel into account when calculating the
length of the belt. The superposition of this length must be subtracted from the
total length.

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Place the belt on the transfer system.
a) Pull
b)Push
Tension the belt until the bevels are juxtaposed.
Clean both sides of the bevels with alcohol.
Spray glue on both sides of the bevels (Glue expiration date: 1 month after opening. We advise you
to write the opening date on the glue bottle. Do not keep it later than one month after this date).
Place the thermic press correctly aligned with the belt.
Fasten the belt on the press.
Use 2 belt pieces to align perfectly the 2 bevels.
Belt position
Driving direction
Driving direction
Belt position

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Close the press and let warm up for 35 minutes at 120°C (250°F).
Let the thermic press cool down for 30 minutes. Remove excess glue with some abrasive paper.
5.4 Changing the belt –Timing belt
The new timing belt is delivered already welded.
Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn
one. (Respect the passage way between the pulleys and belt guide).
Covers to be removed

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Stretch the belt using the tensioning screw and put the covers back into place.
6RESPONSABILITY
elcom cannot be held responsible for any damages or harms due to non-authorized modification of
any parts, especially the safety parts.
Only original components can be used for maintenance or fixing.
elcom cannot be held responsible for any malfunction if some spare parts have been used without
the validation of elcom.
elcom reserves the right to make improvements and technical modifications without any further
notice.
7CUSTOMER SERVICE
Do not hesitate to contact us for any question or advice. We will be glad to assist you.
Tel: + 33 (0)4 74 43 99 61
E-mail: [e-mail]
Adress : 1 rue Isaac Asimov
ZAC de la Maladière
38300 Bourgoin-Jallieu
France
Belt passage way
Access to the tensioning screw