ELCOM TLM 2000 Guide

Modular transfer system
TLM 2000
User Manual
&
Maintenance guide
Translation of the original manual, version 02 / I02-121

I02-121 User manual & maintenance guide Version 02 (translation of the original manual)
of TLM 2000
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 ................................................................................................................................ 3
4. Maintenance.................................................................................................................................... 5
5. Changing the motor....................................................................................................................... 14
5.1. Chain drive ......................................................................................................................... 14
5.2 Direct drive......................................................................................................................... 17
6. changing the chain ........................................................................................................................ 21
7. Changing the flat belt.................................................................................................................... 24
8. Responsability ............................................................................................................................... 26
9. Customer service........................................................................................................................... 26
10. Appendix........................................................................................................................................ 28
10.1. Maintenance schedule................................................................................................... 28
10.2 Quality and environmental commitment : ISO certifications ........................................ 29
10.3 Spare parts list................................................................................................................ 30
10.4 Wearing parts list for maintenance................................................................................ 30

I02-121 User manual & maintenance guide Version 02 (translation of the original manual)
of TLM 2000
Version tracking:
Version
Date
Description of modifications
Prepared by
Approved by
00
04/06/13
Initial (translation)
S. GUILLAUD-BATAILLE
01
01/10/15
-
S. GUILLAUD-
BATAILLE
-
02
19/09/18
Upgrade of the safety instructions + 2015
edition of ISO 9001 and 14001 standards:
deletion of expired certificates
S. MAIRET
S. MAIRET

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1. GENERAL 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 2000 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 2000 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 2000 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 concerning 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 recommend
mounting 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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2. TECHNICAL SPECIFICATIONS
- Maximum load on a workpiece carrier: 10 kg
- Maximum accumulated load on the transfer system: 100 kg for a maximum 6 m unit.
- Electrical power supply of the motors: 380V three-phase
- Motor power: V 9 m /min = 0.25 Kw
(V = belt speed) V 15 m /min = 0.37 Kw
V 19 m /min = 0.55 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 Systems & 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.
3. COMMISSIONING
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,

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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 unit 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.
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.

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4. MAINTENANCE
General visual check
Approximately every 500 hours, check the following points to ensure the proper functioning of
the transfer system:
Belt wear
Regularly verify visually the state of the belt and especially the welding area.
Passageways of the 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.
Pins
Pins are sensitive to wear, especially if the load is heavy on the workpiece carrier. Wear can be
noticed as soon as a loss of efficiency in the guiding of the workpiece carrier occurs.
Wear of the belt guide
Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.
Transfer parts
After the first 100 hours of use:
Lubricate the chain. No disassembly is needed for this operation.
Use the grease ref. 800 00 006 (Chain plus V1 spray).
Wear area of the pins
Belt
Belt guide

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For direct conveying units, no lubrication is necessary.
Every 200 hours:
Remove dust from of the whole system.
Use the product ref. 800 00 003 (Polish plastics Air Industry 2101).
Every 500 hours:
Lubricate the chain.
For direct conveying units, no lubrication is necessary.
Check visually the wear of the belts.
Stoppers
Every 1,000 hours:
Lubricate the rod of the stopper ref. 120 23 011
Use the grease ref. 800 00 002 (Crown ref. 7041 spray).

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To lubricate the cylinder without removing the stopper from the system, remove the four screws
mentioned above to take out the rod and cylinder set.
Positioning unit
All types except heavy positioning unit.
Every 1,000 hours:
Lubricate the positioning unit fingers with a film of grease.
Use grease ref. 800 00 002 (Crown ref. 7041 spray).
Check the lubrication of the guiding shafts
To reach the guiding shafts, remove the central fastening screw from the plate to release it from
the positioning unit without removing the positioning unit from the transfer system.

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Plate fastening screw
Guiding shafts to lubricate

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For a quick lubrication of the guiding shafts, it is also possible to access them, without any
disassembly, only by pulling the plate.
Changing the pins (locating/centering pins)
Extract the previous pins from the press.
Install the new pins in the press while using a bush of a workpiece carrier ref. 120 03 006 as a
support (insert the pin in the bush and then place them on the positioning unit plate).
Pins

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Lubricate the positioning unit finger with a film of grease.
Case of a damped stopper
It is possible to replace the damping rubber stoppers. Remove the 4 screws to access the U-shape
part including the stoppers.
Bush (ref. 120 03 006)

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Lift positioning unit
The operating mode remains the same as the standard positioning unit. It is not necessary to
disassemble the lift positioning unit from the transfer system for this maintenance.
Release the plate to access the guiding shafts and cylinder by removing the fastening screws.
In order to centre the guiding shafts on the plate, the centering device ref. 800 15 001 can be
used.
Plate

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Heavy positioning unit
For the maintenance of the heavy positioning unit, it is necessary to remove it from the transfer
system.
Every 1,000 hours:
Then, remove the screws located underneath the heavy positioning unit to access the drawer.
Lubricate the drawer (inside and outside) ref. 120 08 010 (grease Gulf Crown EP2).
Centering device

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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).
Drawer
Support block
Support block
Drawer

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Changing the pins (locating/centering)
Extract the previous pins from the press.
Install the new pins in the press while using a bush of a workpiece carrier ref. 120 03 006 as a
support (insert the pin in the bush and then place them on the positioning unit plate).
Other transfer parts
The others parts of the transfer system do not need any maintenance. A visual check, looking for
wear or broken parts is recommended from time to time.
5. CHANGING THE MOTOR
5.1. Chain drive
Remove the cap.
Loosened screws
Cap
Loosened screws

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Remove the flange, the chain tensioner and the spring.
Flange
Loosened screws
Tensioner
Spring

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Space out the motor shaft on the sprocket side.
Shaft

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Loosen the four screws fastening the motor on the block.
For reassembly, follow the previous steps in reverse order. Do not forget to lubricate the shaft.
Put the cap on the new motor.
Lubricate the chain (see Maintenance).
5.2 Direct drive
Disassembly
Remove the screw CHC M5x30 holding the locking clip.
Block ref. 120 02 025
Screws