Mayfran CleanSweep RM125 Guide
Technical Documentation
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Table of contents
1ISSUE STATUS / REVISION....................................................................................................................................5
2QUALITY DECLARATION AND NON-DISCLOSURE AGREEMENT .................................................................... 6
2.1 Quality declaration ISO 9001:2000.................................................................................................................6
2.2 Non-disclosure agreement..............................................................................................................................6
3PRODUCT AND FUNCTION DESCRIPTION...........................................................................................................7
3.1 Product description..........................................................................................................................................7
3.2 Function description........................................................................................................................................7
3.3 Guarantee statement ......................................................................................................................................8
4PACKAGING AND TRANSPORT ............................................................................................................................ 9
4.1 Packaging........................................................................................................................................................9
4.2 Transport.........................................................................................................................................................9
5DANGER AND SAFETY NOTICES........................................................................................................................10
6COMMISSIONING...................................................................................................................................................11
7INSTRUCTIONS FOR REPAIR, SERVICE, AND FAULT REMEDY.....................................................................13
8PREVENTIVE MAINTENANCE..............................................................................................................................14
8.1 General service points ..................................................................................................................................14
8.2 Maintenance..................................................................................................................................................15
8.2.1 Drive unit.............................................................................................................................................15
8.2.2 Steel belt.............................................................................................................................................16
8.2.3 Conveyor frame and internal filter cartridge........................................................................................16
8.2.4 Inspection, cleaning and maintenance table.......................................................................................17
9REPLACEMENT OF COMPONENTS ....................................................................................................................18
9.1 Removal of the steel belt...............................................................................................................................18
9.2 Replacement and adjustment of brushes and wipers...................................................................................19
9.3 Removal of the discharge auger...................................................................................................................19
9.4 Overview of the drive unit..............................................................................................................................20
9.5 Removal of the drive unit ..............................................................................................................................21
9.6 Removal of the drive shaft ............................................................................................................................21
9.7 Removal of the drive bearings ......................................................................................................................21
9.8 Removal of the filter cartridge.......................................................................................................................21
9.9 Assembly.......................................................................................................................................................21
10 CLEANING THE CONVEYOR................................................................................................................................22
11 ELIMINATION OF FAULTS....................................................................................................................................23
12 MAIN COMPONENTS AND SPARE PART ORDERS...........................................................................................25
12.1 CleanSweep®RM125 main components......................................................................................................25
12.2 Ordering spare parts .....................................................................................................................................26
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Table of figures
Figure 1: Conveyor overview ............................................................................................................................................7
Figure 2: CleanSweep®RM125 overview.......................................................................................................................11
Figure 3: Drive unit..........................................................................................................................................................15
Figure 4: Removal of the steel belt .................................................................................................................................18
Figure 5: Overview of the drive unit ................................................................................................................................20
Figure 6: CleanSweep®RM125 main components.........................................................................................................25
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List of tables
Table 1: Issue status / Revision........................................................................................................................................5
Table 2: Drive unit...........................................................................................................................................................15
Table 3: Connection of the socket ..................................................................................................................................16
Table 4 Gear oil data.......................................................................................................................................................16
Table 5: Maintenance overview ......................................................................................................................................17
Table 6: Removal of the steel belt...................................................................................................................................18
Table 7: Overview of the drive unit .................................................................................................................................20
Table 8: CleanSweep®RM125 main components..........................................................................................................25
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1 ISSUE STATUS / REVISION
Change Date Description Name
Rev. 0 09/2015 Newly created H. Werker
Rev. 1 11-2016 Update J. Schuman
Rev. 2 05-2018 Update M. De
Table 1: Issue status / Revision
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2 QUALITY DECLARATION AND NON-DISCLOSURE AGREEMENT
2.1 QUALITY DECLARATION ISO 9001:2000
Mayfran is a company certified in accordance with ISO 9001:2000.
In order to guarantee safe product function, all Mayfran conveyors are subjected to documented test run without load
for a period of one hour prior to delivery to the customers, unless a different process is defined in the final, valid offer
and in the order confirmation.
2.2 NON-DISCLOSURE AGREEMENT
All rights reserved.
No part of this document may be copied, reproduced, recreated, published online, disclosed, transferred, or distributed
in any manner without the prior written consent of the issuing entity, Mayfran International B. V. Landgraaf (hereinafter
referred to as Mayfran).
Mayfran assumes no liability for the exactness of information for any purposes and makes no claims about the
topicality of the information.
The document may contain clerical errors.
Mayfran can make modifications to the described products at any time without prior notification.
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3 PRODUCT AND FUNCTION DESCRIPTION
3.1 PRODUCT DESCRIPTION
Mayfran CleansweepRM conveyors are installed in applications chip-producing machine tools, etc.
They convey metal chips, scrap from a machnine tool to a chip container or a collecting conveyor. The conveyor is
designed with self cleaning maintenance screenbox cartridges used to clean the cooling lubricant applied in the
machining process. The finest chips are transported by means of a patented inner chip handling system in the same
chip tank or collecting conveyor as the coarse chips.
The advantages of CleansweepRM:
• Suitable for all types of metallic chips
• Higher machine availability
• Compact design
• Reduced clean tank maintenance
• Increased service life of coolant, pumps, and tools
• Interchangeable with a standard chip conveyor
This operating manual provides instructions for care, maintenance, and spare part replacement.
The manual is not specific to a conveyor design, which can be designed as straight or have a bend and subsequent
ascending section.
3.2 FUNCTION DESCRIPTION
The conveyed material and contaminated cooling lubricant continually fall to the conveying surface of the conveyor.
Figure 1: Conveyor overview
The conveyed material is then continuously transported to the discharge opening. Long chips are discharged from the
steel belt. Small chips and fine dirt are discharged via the internal chip transport system. An interchangeable, low-
maintenance filter cardridge cleans the cooling lubricant before it is discharged in a coolant tank.
Interchangeable
screen
Steel belt conveyor
F
inest dirt
discharge via
auger
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1 Do not use the system for other purposes!
The discharge point must be visible while the machine is in operation.
Q Noise level: < 70 dB (A)
1
Bear in mind that the conveyor is in continuous operation during machine production.
3.3 GUARANTEE STATEMENT
This operating manual must be available to the operator responsible for the conveyor and to the maintenance
personnel.
The guarantee is only valid if these requirements are strictly observed.
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4 PACKAGING AND TRANSPORT
4.1 PACKAGING
CleanSweep®steel belt conveyors are usually delivered fully assembled. Depending on customer wishes or due to its
lengths, the conveyor can also be delivered in multiple parts.
The steel belt is then delivered on one or multiple pallets; small parts such as screws, belt joint, etc. are delivered in
separate crates / cartons.
4.2 TRANSPORT
1 Do not stand under suspended loads! The figures on this page should be considered examples.
The available load suspension devices must always be used for lifting and transporting.
p
Crane transport: Always use the available load suspension devices (M12x20mm).
The lifting eyes are not part of the delivery. Note that they are according to the local safety directive.
For the total weight please check order documents.
o
Forklift transport: Always transport the conveyor packed on the wooden pallet and secured
against slipping or falling over.
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5 DANGER AND SAFETY NOTICES
1
Affix the supplied sticker in an easy visible location on the conveyor!
All information and instructions in the supplied operating manuals must always be followed!
Unqualified personnel are prohibited from performing work on the system!
Ensure appropriate fastening for customer-provided chip deflection panels!
Never bypass safety devices!
The function of safety devices must always be assured!
2 Work on the electrical system may only be performed by appropriately qualified experts in
observance of the locally applicable statutory regulations.
U
Never stand or reach into the area of the chip discharge opening.
V
All covers must be mounted prior to commissioning.
Do not remove covers during operation of the system!
W Do not reach into the ejection opening!
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6 COMMISSIONING
1 Ensure stable and secure machine setup.
Secure the system against sudden, unexpected operation.
Bear in mind the danger of entanglement of hands and loose clothing.
Figure 2: CleanSweep®RM125 overview
1. The conveyor must be aligned precisely. The deviation from the centre line may not exceed 2 mm on either side.
2. The conveyor steel belt and chain must be lightly oiled.
3. Before the conveyor belt is put into operation, the belt tension must be checked.
The belt tension is correct when it is possible to slighlty lift-up the steel belt from the track by 10-20 mm on the
discharge side in the bottom part. Should this not be the case, then please loosen or tighten the belt.
Make sure that the system is not switched on when checking the belt tension.
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To tighten the belt:
Unscrew the screws on both bearings (See chapter 9: figure 5 of the general assembly drawing).
Adjust the belt tension by turning the tensioning screws. The hinge belt must be able to be pressed inwards
manually approximately 15 mm. Pöease make sure that the conveyor is not switched on when checking belt
tension. Then secure the screws with the lock nuts.
Tighten both bearings.
4. The sidewings of the steel belt conveyor must run parallel to each other in the conveying direction. Excessive play
or bent side panels will lead to a jamming of the belt and hooking of the chips.
5. What is the current power supply?
6. Is the current power supply according to the specification of the gear motor?
7. Is the conveyor (especially the overload protection device of the gearmotor) connected correctly to the machine
tool interface according specifications?
8. The conveyor should run without load for at least five hours.
During the run-in, ensure that the steel belt moves freely and do no bend anywhere.
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7 INSTRUCTIONS FOR REPAIR, SERVICE, AND FAULT REMEDY
z
Switch off the main switch!
2 Secure the system against inadvertent electrical activation!
D Depressurise the system!
w Close all gate valves and valves!
Remove all harmful substances!
Cooling lubricant may not be released into the environment!
8
In case of contact with chips:
Use protective clothing, safety shoes, and protective gloves!
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8 PREVENTIVE MAINTENANCE
8.1 GENERAL SERVICE POINTS
With the performance of regular maintenance (regular inspection, cleaning and maintnance intervals) according to
below guidelines, the Mayfran conveyor has a long service life with minimal wear. Please ensure that the steel belt
and chains are always lightly oiled.
The service intervals mentioned in this document are based on normal operating conditions and single shift usage
factors according to the table bleow. Service intervals should be adjusted accordingly when operating conditions and
usage factors change.
Oiling on a monthly basis is adequate for dry machining. If the belt is exposed to the elements, the maintenance work
must be especially diligent.
Check the belt regularly for damage in order to ensure that spare parts can be replaced in good time. Malfunctions
can be avoided as a result.
The maintenance of supplier components, such as pumps, cooling units, etc. must take place according to the
manufacturer's specifications.
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8.2 MAINTENANCE
8.2.1 DRIVE UNIT
Figure 3: Drive unit
Part no.: Description Quantity Comments
1 Drive unit
2 Shaft bearing
3 Guard of roller block chain, axle guard
4 Frame bracket
5 Torque arm
6 Springs of the torque arm
7 Screw for torque transmission
Table 2: Drive unit
The gear unit is intended for installation in dry locations. The gear unit is designed as a slip on gear with hollow shaft.
A torque support is provided for the fastening.
The torque support is fixed in a special fastening construction on the conveyor. It is designed with special disc springs
in order to eliminate errors in the alignment and warping. Harmful impact should also be prevented as a result. The
gears are not subject to any limitations with respect to installation position.
The gear unit is factory pre-filled with sufficient lubrication and then closed for an oil-tight seal. It is operable in a
temperature range between 0°C and 40°C, air humidity below 85%, a barometric elevation of up to 1000m.
To prevent frictional corrosion between the motor journal and the hole of the auger shaft, the motor journal must be
treated with an appropriate lubricant during assembly. The recommended lubricant is KIüber Microlube GL 261.
The gear unit is equipped with an overload protection device (slip coupling). The slip coupling is adjusted to the
necessary torque by the manufacturer.
The microswitch is tested and appropriately adjusted.
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The connection takes place by means of a standard M12x1 plug-type connector (DIN 43650 / ISO 4400) or an
appropriate plug socket as follows:
Number 1 2 3 4
Connection COM in brown NC (normally closed) in white M12x1 plug NO (normally open) in black
Table 3: Connection of the socket
The earthing takes place with an earthing screw on the cover of the shift case.
Gear
unit Type Gear oil quantity Manufacturer
1310651 CMFA020-
230H360GVN 460 ml MOBIL 600W SUPER CYLINDER OIL
(EXXON MOBIL)
Table 4 Gear oil data
The gear unit must be inspected regularly (minimum every three months) for leaks, contamination, and unusual noise.
8.2.2 STEEL BELT
1. The belt must be aligned and tightened after the first 20 days of operation.
The correct belt tension is described under section 3 in chapter 6 'Commissioning'.
2. Re-check the belt tension and tighten as necessary on regular basis, see chapter 6 ‘Commissioning’.
3. Remove the chain guard and check whether there is recongnisable wear or signs of rubbing on the rollers, side
panes, and chains. If this is the case please refer to chapter 11 ‘Elemination of faults’.
4. The drive bearings are provided with life-long grease lubrication for normal loads.
5. Check the correct fixation and position of the brushes and wipers of the inner handling system. See Chapter 9.2.
6. The specified conveying capacity of chips can only be achieved if the conveyor runs continuously. This means that
the conveyor must always be operated simultaneaously with the machine tool.
8.2.3 CONVEYOR FRAME AND INTERNAL FILTER CARTRIDGE
1. The conveyor frame and main components must be free from damages and cleaned on a regular basis. See
chapter 9.
2. Check the bottom plate at the discharge opening and the returning steel belt for chip accumulations. If chips
have accumulated, the respective positions need to cleaned.
3. The inner chip handling system (especially the auger discharge funnel) must be free of chip accumulations
and cleaned on regular basis. See chapter 9.3
4. The inner filter cartridge(s), especially the coolant exit openings must be inspected for chip accumulation and
cleaned as necessary on regular basis. See chapter 9.8
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8.2.4 INSPECTION, CLEANING AND MAINTENANCE TABLE
The service intervals guidelines indicated in this document may vary depending on the type of machining, usage factor
and operating conditions at the enduser.
Activity
sequence Operating
hours* Component Service activity Remark
First use 0 Belt and chain Check alignment and re-
tension belt Capter 6
Weekly 40 Frame, belt and chain Check for damage and
strange noise, exchange of
parts if necessary Chapter 8.2.3 / 8.2.4
Check and clean filter
cartridge coolant exits Chapter 8.2.4
Monthly Belt and chain Check for damages and
fixation of wiper cleats Chapter 8.2.3
Oiling in case of dry
operation, check for
damages, exchange of
parts if necessary
Chapter 8.1
3-months 480 Frame, discharge
section
Check for chip
accumulation at bottom belt
plate; cleaning Chapter 8.2.4
Drive unit Check for lekage, soiling
and noise, exchange if
necessary chapter 8.2
Belt
Check brushes and wiper
cleats of visible wear,
adjust or replace in case of
visible wear or damages
chapter 9.2
6-months 950 Filter cartridge
Remove, check and clean
of chip accumulation or
soiling, exchange if
necessary
Chapter 8.2.4
General Visual chek of the general
condition --
1-year 1900 General Full cleaning Chapter 8, 9, 10
2-years 3800 General Replace all rubber seals
and gaskets --
Table 5: Maintenance overview
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9 REPLACEMENT OF COMPONENTS
An overview and list of the main components of the CleanSweep®RM125 are provided in chapter 12.1 'CleanSweep®
RM125 main components'.
9.1 REMOVAL OF THE STEEL BELT
Figure 4: Removal of the steel belt
Part no.: Description Quantity Comments
1 Belt axle
2 Rubber wiper
3 Wiper clamping strip
4 Roller block
5 Belt plate
Table 6: Removal of the steel belt
Remove the left and right chain guard (see figure 5: point 6, 7 and 9).
Move the belt until the joint rod with splint in the bottom part of the drive unit is freely accessible.
Unscrew the screws for the drive bearings (see figure 5: point 5) and unscrew the bolts on the tensioning station
approx. 15 mm. The belt tension decreases. Remove the splint and chain lugs on both sides, as well as the joint rod.
The belt is now opened and can be removed from the frame by briefly switching on the gear motor.
1 It must be ensured that a belt jam is avoided!
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9.2 REPLACEMENT AND ADJUSTMENT OF BRUSHES AND WIPERS
The stell belt comprises special cleats which are composed of a combination of brushes and wipers and which can be
adjusted form the upper side of the belt.
Adjustment is carried out by handpressing the brush or wiper down to the inner chip handling plate in the charge
section of the conveyor. Fixate the bruch or wiper by tightening the bolts firmly and mark their location with a water/oil
proof marker.
The brushes and wipers must be inspected for wear, adjusted as necessary, and possibly replaced on regular basis.
9.3 REMOVAL OF THE DISCHARGE AUGER
The auger and the discharge channel of the CleanSweep conveyor must be inspected periodically for material
accumulation and cleaned as necessary (Figure 4: Removal of the steel belt, position 3).
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9.4 OVERVIEW OF THE DRIVE UNIT
Figure 5: Overview of the drive unit
Part no.: Description Quantity Comments
1 Worm bearing
2 Auger and drive wheel
3 Auger channel
4 Drive unit
5 Bearing shaft
6 Chain guard (sideways)
7 Chain guard (upfront, left side)
8 Shaft
9 Chain guard (upfront, right side)
Table 7: Overview of the drive unit
Table of contents
