Montech MonTurn TB40 User manual

ASSEMBLY INSTRUCTIONS
TB40 CONVEYOR
BA-100154
Translation of the original assembly instructions, Copyright by Montech AG
English, Edition 01/2020

Assembly instructions BA-100154
TB40 Conveyor
3
CONTENTS
1. General 5
1.1 Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B ....................... 5
1.2 List of essential health and safety requirements pursuant to Directive 2006/42/EC, Annex I, Section
1 ............................................................................................................................................................. 6
1.3 Information about this manual............................................................................................................... 8
1.4 Explanation of symbols.......................................................................................................................... 8
1.5 Liability waiver........................................................................................................................................ 9
1.6 Copyright ............................................................................................................................................... 9
1.7 Warranty terms and conditions.............................................................................................................. 9
1.8 Customer service ................................................................................................................................... 9
2Transport, Packaging and Storage 10
2.1 Unauthorized or improper transport ................................................................................................... 10
2.2 Transport inspection ............................................................................................................................ 10
2.3 Packaging............................................................................................................................................. 10
2.4 Handling of packaging material........................................................................................................... 11
2.5 Storing the packages ........................................................................................................................... 11
3Safety 12
3.1 Use for intended purpose.................................................................................................................... 12
3.2 Safety instructions................................................................................................................................ 12
3.3 Warranty............................................................................................................................................... 12
3.4 Changes and modifications to the equipment .................................................................................... 13
3.5 Personal protective equipment............................................................................................................ 13
3.6 Personnel requirements....................................................................................................................... 13
4TB40 Conveyor Specifications 14
4.1 Technical Data...................................................................................................................................... 14
4.2 Weight of the Conveyor....................................................................................................................... 15
4.3 Nameplate............................................................................................................................................ 15
4.4 TB40 Conveyor components................................................................................................................ 16
4.5 Dimension Conveyor TB40................................................................................................................... 18
4.6 TB40 Conveyor design / cross-section ................................................................................................ 20
4.7 Conveyors separation .......................................................................................................................... 21
4.8 Electronic performance........................................................................................................................ 22
4.8.1 Inputs IN A, IN B, IN 1, IN 2 .................................................................................................................22
4.8.2 Outputs OUT 1, OUT 2, OUT3..............................................................................................................22
4.8.3 Analog inputs AIN 1, AGND.................................................................................................................22
4.8.4 Safety and monitoring functions...........................................................................................................23
4.8.5 Error acknowledgement .......................................................................................................................23
5Commissioning 24
5.1 Installation and commissioning............................................................................................................ 24
5.2 Assembly and Disassembly .................................................................................................................. 25
5.3 TB40 Conveyor electrical hook-up description.................................................................................... 25
5.3.1 Electrical connection .............................................................................................................................26

Assembly instructions BA-100154
TB40 Conveyor
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5.3.1.1 Signal cable .......................................................................................................................................... 26
5.3.1.2 Power cable.......................................................................................................................................... 26
5.3.1.3 Circuit diagram TB40 power unit......................................................................................................... 27
5.3.1.4 Technical data switching power Supply 24VDC, 20A.......................................................................... 28
5.3.2 Turn on and turn off behavior TB40 power unit ...................................................................................29
5.3.3 Electrical Grounding of the Conveyor ..................................................................................................29
5.4 Setting the necessary pretension of the belt ...................................................................................... 30
5.5 Belt Tracking (straight running of the transport belt).......................................................................... 31
5.6 Conveyor Belt specifications................................................................................................................ 31
5.7 Conveyor Belt direction of travel......................................................................................................... 32
6Operation 33
6.1 Operating mode .................................................................................................................................. 33
6.1.1 PLC speed mode (default) ....................................................................................................................33
6.1.1.1 Default values (factory-set) .................................................................................................................. 34
6.1.1.2 Speed setting via analog input AIN 1.................................................................................................. 34
6.1.1.3 Speed setting via stored values v1 (N1), v2 (N2) and v3 (N3) ............................................................. 35
6.1.1.4 Function «overrun» .............................................................................................................................. 36
6.1.1.5 Output function of digital outputs PLC speed-mode (default) ........................................................... 37
6.1.2 PLC position mode................................................................................................................................38
6.1.2.1 Standard values (factory-set) ............................................................................................................... 38
6.1.2.2 Speed setting via analog input AIN 1 (PLC position mode) ................................................................ 39
6.1.2.3 Function – Execute distance once ....................................................................................................... 40
6.1.2.4 Function – Execute distance several times.......................................................................................... 41
6.1.2.5 Function – «overrun»............................................................................................................................ 42
6.1.2.6 Output function of digital outputs PLC Position mode (default)......................................................... 43
6.1.3 General output functions......................................................................................................................44
6.1.4 Overview of operating modes and parameterizable values TB40 .......................................................45
6.1.4.1 Standard values PLC speed-mode....................................................................................................... 45
6.1.4.2 Standard values PLC position-mode.................................................................................................... 45
7Maintenance 46
7.1 Maintenance plan................................................................................................................................. 46
7.2 Spare parts........................................................................................................................................... 46
7.2.1 Replacing endless belts.........................................................................................................................47
7.2.2Replacing belts by welding the ends....................................................................................................48
7.3 Conveyor Belt Maintenance and Cleaning .......................................................................................... 49
7.3.1 Maintenance..........................................................................................................................................49
7.3.2 Cleaning ................................................................................................................................................49
7.4 Repairs.................................................................................................................................................. 52
7.5 Replacing the drive unit ....................................................................................................................... 52
8Disassembly and Disposal 53
8.1 Improper disassembly.......................................................................................................................... 53
8.2 Disposal................................................................................................................................................ 54

Assembly instructions BA-100154
TB40 Conveyor
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1. General
1.1 Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B
Manufacturer:
Montech AG, Gewerbestrasse 12, CH–4552 Derendingen
Phone [phone], Fax [phone]
E-Mail: [e-mail], Internet: www.montech.com
Herewith declares that the partly completed machine: TB40 Conveyor
Designation: TB40
meets the basic safety and health requirements of Annex I of EC Machinery-Directive 2006/42/EC.
In addition, the partly completed machine also complies with the requirements of:
relevant EC Directives:
Applied harmonized standards:
EC Machinery-Directive 2006/42/
Low Voltage Directive 2014/35/EU
EN ISO 12100; 2010
The technical documentation for this partly completed machine was created according to Annex VII
Part B. Montech AG agrees to electronically transmit these technical documents to state authorities
upon request.
Authorized person for preparing the
technical documentations:
Gianluca Aloisi
Montech AG
Director Sales
CH-4552 Derendingen
The commissioning of the partly completed machine is prohibited until the partly completed machine has been
installed in a machine that is in compliance with the requirements of the EC Machinery-Directive, and the EC
Declaration of Conformity according to Annex II A is on hand.
City, Date
Company
Address
Derendingen,15.01.2019
Montech AG
Gewerbestrasse 12
CH–4552 Derendingen
Authorized persons (signatures)
Names of the undersigned
Positions of the undersigned
Daniel Pauli Gianluca Aloisi
CEO Director Sales

Assembly instructions BA-100154
TB40 Conveyor
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1.2 List of essential health and safety requirements pursuant to Directive 2006/42/EC,
Annex I, Section 1
Not relevant for this device

To be met by the system integrator for the (complete) machine

Met for the scope of the partly completed machine

1.1.
General
1.1.1.
Definitions
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1.1.2.
Principles of safety integration
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1.1.3.
Materials and products
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1.1.4.
Lighting
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1.1.5.
Design of machinery to facilitate its handling
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1.1.6.
Ergonomics
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1.1.7.
Operating positions
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1.1.8.
Seating
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1.2.
Control and systems
1.2.1.
Safety and reliability of control systems
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1.2.2.
Control devices
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1.2.3.
Starting
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1.2.4.
Stopping
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1.2.4.1.
Normal stop
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1.2.4.2.
Operational stop
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1.2.4.3.
Emergency stop
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1.2.4.4.
Assembly of machinery
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1.2.5.
Selection of control or operating modes
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1.2.6.
Failure of the power supply
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1.3.
Protection against mechanical hazards
1.3.1.
Risk of loss of stability
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1.3.2.
Risk of break-up during operation
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1.3.3.
Risks due to falling or ejected objects
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1.3.4.
Risks due to surfaces, edges or angles
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1.3.5.
Risks related to combined machinery
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1.3.6.
Risks related to variations in operating conditions
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1.3.7.
Risks related to moving parts
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1.3.8.
Guards or protective devices designed to protect against risks
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1.3.8.1.
Moving transmission parts
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1.3.8.2.
Moving parts involved in the process
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1.3.9
Risk of uncontrolled movement
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Assembly instructions BA-100154
TB40 Conveyor
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Not relevant for this device

To be met by the system integrator for the (complete) machine

Met for the scope of the partly completed machine

1.4.
Required characteristics of guards and protective devices
1.4.1.
General requirements
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1.4.2.
Special requirements for guards
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1.4.2.1.
Fixed guards
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1.4.2.2.
Interlocking movable guards
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1.4.2.3.
Adjustable guards restricting access
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1.4.3.
Special requirements for protective devices
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1.5.
Risks due to other hazards
1.5.1.
Electricity supply

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1.5.2.
Static electricity
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1.5.3.
Energy supply other than electricity
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1.5.4.
Errors of fitting
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1.5.5.
Extreme temperatures
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1.5.6.
Fire
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1.5.7.
Explosion
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1.5.8.
Noise
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1.5.9.
Vibrations
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1.5.10.
Radiation
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1.5.11.
External radiation
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1.5.12.
Laser radiation
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1.5.13.
Emissions of hazardous materials and substances
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1.5.14.
Risk of being trapped in a machine
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1.5.15.
Risk of slipping, tripping or falling
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1.5.16.
Lightning
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1.6.
Maintenance
1.6.1
Machinery maintenance
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1.6.2.
Access to operating positions and servicing points
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1.6.3.
Isolation of energy sources
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1.6.4.
Operator intervention
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1.6.5.
Cleaning of internal parts
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1.7.
Information
1.7.1.
Information and warnings on the machinery
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1.7.1.1.
Information and information devices
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1.7.1.2.
Warning devices
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1.7.2.
Warning of residual risks
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1.7.3.
Marking of machinery
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1.7.4.
Instructions
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1.7.4.1.
General principles for the drafting of instructions
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1.7.4.2.
Contents of the instructions
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1.7.4.3.
Sales brochure
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1.7.5
Operating manual
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TB40 Conveyor
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1.3 Information about this manual
This manual contains data and information necessary to install and maintain the TB40
Prior to commencing any work on the machine, personnel must have thoroughly read and understood this
manual. Following all safety instructions and directions in this manual is the foundation of safe work.
Any illustrations in this manual are meant for general understanding and may differ from the actual configuration.
1.4 Explanation of symbols
Safety instructions in this manual are marked by symbols. These safety instructions are introduced by signal
words that express the extent of the danger. Absolutely follow these instructions and act carefully to avoid
accidents, bodily injuries or property damage.
DANGER!
This combination of symbol and signal word indicates a directly dangerous situation that
could result in death or serious injury if it is not avoided.
WARNING!
This combination of symbol and signal word indicates a potentially dangerous situation that
could result in serious injury if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation that
could result in minor injury if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation that
could cause property damage if it is not avoided.
NOTE!
This symbol points out useful hints and recommendations as well as information for efficient
and uninterrupted operation.

Assembly instructions BA-100154
TB40 Conveyor
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1.5 Liability waiver
All information and instructions in this operating manual were compiled taking into consideration the valid
standards and regulations, the state of the art and our many years of experience and expertise.
Montech AG will not assume liability for damage resulting from:
– Not following the instructions in this manual.
– Using the machine for purposes other than its intended use.
– Use of personnel that has not been trained.
1.6 Copyright
Treat the assembly instructions confidentially. They are meant exclusively for persons working on the equipment.
Making the operating manual available to a third party without the Montech AG’s written permission is
prohibited.
NOTE!
The content information, texts, drawings, pictures and other illustrations are protected by
copyright. Any use of them beyond this purpose without the Montech AG’s written
permission is prohibited.
1.7 Warranty terms and conditions
The warranty terms and conditions can be found in the Montech AG’s General Terms and Conditions (GTC).
1.8 Customer service
Our customer service will provide technical information.
Information on the responsible contact person can be obtained by phone, fax, email or on the Internet; please
refer to the manufacturer’s address on the installation declaration page.

Assembly instructions BA-100154
TB40 Conveyor
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2Transport, Packaging and Storage
2.1 Unauthorized or improper transport
CAUTION!
Damage may result from unauthorized or improper transport!
Moving the machine using unskilled personnel may result in considerable property damage.
– Only use skilled personnel to unload the machine upon delivery and for in-house
transport.
– Do not step under suspended loads.
– Means of transport must be used properly.
– Always place the Conveyor on a level surface and secure it against tipping over.
2.2 Transport inspection
Upon delivery, check the shipment immediately for completeness and transport damage.
In case of visible transport damage, proceed as follows:
– Do not accept the shipment or accept it conditionally only.
– Record the extent of the damage on the shipping documentation or the freight forwarder’s shipping note.
– Initiate a complaint.
NOTE!
Complain about any defect immediately.
Claims for damages may only be made within the complaint periods.
2.3 Packaging
The individual packages have been packed according to anticipated shipping conditions. Only environmentally
friendly materials were used for packaging.
The packaging will protect the individual components from shipping damage, corrosion and other damage until
they are installed. Consequently, do not destroy the packaging and only remove shortly before installation.

Assembly instructions BA-100154
TB40 Conveyor
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2.4 Handling of packaging material
Dispose of packaging material in compliance with applicable laws and local regulations.
CAUTION!
Incorrect disposal is an environmental hazard!
Packaging materials are valuable raw materials; in many cases, they can be reused or
recycled. Incorrect disposal of packaging materials can pose a hazard to the environment.
– Always dispose of packaging materials in an environmentally compatible manner.
– Follow local disposal regulations. If applicable, hire a company specializing in
disposal.
2.5 Storing the packages
Store packages under the following conditions:
– Do not store outdoors.
– Store in a dry, dust-free environment.
– Do not expose to aggressive media.
– Protect from sunlight.
– Avoid mechanical vibration.
– Storage temperature: +5 to +40 °C.
– Relative humidity: max. 95%.
– If packages are stored longer than three months, check the general condition of all parts and the
packaging regularly.