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

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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

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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

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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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
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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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
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1.3.9
Risk of uncontrolled movement
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


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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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
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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.

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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.

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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.

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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.

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TB40 Conveyor
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3Safety
This chapter provides an overview of all necessary safety aspects with regard to the personnel and a safe and
trouble-free operation.
3.1 Use for intended purpose
Conveyors are intended for transporting solid objects that are not below a certain minimum size. They are, e.g.,
not suitable for transporting people and materials such as sand, granules, chips, etc.
The product-specific ratings listed on the nameplate must not be exceeded under any circumstances. The
Conveyor motor does not have a holding brake; consequently, the Conveyor is not suitable for inclined
conveying.
Intended use also includes compliance with all the information in this manual.
Any use other than or beyond the intended use is considered misuse.
3.2 Safety instructions
WARNING!
The safety instructions, particularly those relating to electrical connections, must be followed
in all phases of commissioning, operation and during maintenance and repairs. Failure to
follow these instructions is considered a misuse of the Conveyor and its components.
3.3 Warranty
Any use other than the intended use according to 3.1 shall void the claim to warranty.
WARNING!
Danger from misuse!
Misuse of the TB40 may result in dangerous situations. Refrain from the following uses in
particular:
– Exposure to direct light from UV lamps.
– Operation in air containing smoke, dust, water vapor, or solvents.
– Use in areas with an explosion hazard (flammable gases, vapors or dust).
– Use in a damp environment (rain or dew).
– Do not exceed the maximum permissible total weight.
– Connecting, commissioning or servicing the machine without qualified personnel.

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TB40 Conveyor
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3.4 Changes and modifications to the equipment
In order to avoid hazards and to ensure optimum performance, the unit must not be subjected to any
modifications, additions or conversions that have not been expressly approved by the manufacturer.
3.5 Personal protective equipment
The wearing of personal protective equipment is required during work to minimize health hazards.
Safety shoes
To protect against heavy dropped parts and slipping on slippery surfaces.
Hair net
Hair nets must be worn when working on machines with rotating parts.
3.6 Personnel requirements
The different tasks described in this manual pose different requirements for the qualification of the persons
assigned to perform the tasks.
For all work, only allow persons to perform the work who can be expected to perform it reliably. Persons whose
ability to respond is impaired, e.g. due to drugs, alcohol or medications, shall not be allowed to work on the
machine.
What follows is a list the personnel qualifications for the different tasks:
Machine operator
The machine operator has been instructed by the system operator regarding the tasks assigned to him/her and
the potential hazards in case of improper behavior. The machine operator may perform tasks going beyond
operation in the normal operation mode only if this task has been explicitly assigned by the system operator.
Skilled electrician
A skilled electrician is, due to his/her technical training, knowledge and experience, as well as knowledge of the
applicable standards and regulations, able to perform work on electrical systems and to independently recognize
potential dangers and avoid hazards.
The skilled electrician has been trained specifically for his/her work environment and is familiar with the relevant
standards and regulations.
Skilled personnel
The skilled personnel is, due to their technical training, knowledge and experience, as well as knowledge of the
applicable standards and regulations, able to perform work assigned to them and to independently recognize
potential dangers and avoid hazards.
Manufacturer
Certain work may only be performed by Montech AG’s skilled personnel. Other personnel shall not be
authorized to perform this work. Please contact our Customer Service to have such work performed.

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TB40 Conveyor
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4TB40 Conveyor Specifications
4.1 Technical Data
Ambient temperature +10 to +40°C
Relative humidity <95% (non-condensing)
Air purity level normal shop air
Sound pressure level < 65 dBA
Components’ protection class IP 64
Drive integrated in drive roller
Motor
Brushless EC motor with speed, current and position
controller; sinusoidal commutation with field-oriented
control up to n = 0
Gear
planetary gear
Gear reduction
Belt speed
Load in conveying mode1)
i=30
1 - 33.5 m/min (±10%)
80 kg (50 kg with nose bar)
i=80
0.25 - 12 m/min (±10%)
200 kg (max. 80 kg/m, 180
kg with nose bar)
Rated voltage 24 VDC
Permissible supply voltage range 20 … 28 VDC
Rated current
Dimensioning power supply
(recommendation) Rated output
12.3 A
rated current 20A, peak current 30A
251 W
Target value analog / PWM
2)
/ frequenz
2)
Digital inputs 4
Digital outputs 3
Analog input 1 (0 … 10 V)
Anti-lock function thermal
Overload protection yes
Belt width 300 / 400 / 500 / 600 / 700 / 800 mm
Belt length3) from 3604) mm to 6,000 mm
(belts over 6,000 mm upon request)
Material Lateral section
aluminum, clear anodized
Diverter roller
stainless steel
Drive roller
aluminum
Sliding plate
galvanized steel or stainless steel (optional)
Connection support
aluminum, clear anodized, plastic
Tabs
aluminum
Cable
polyurethane / copper
Warranty 3 Years
motors and gears 1 year
Conveyor Belts are ware parts and thus excluded from the
warranty.
1) mode of operation S1, ambient temperature 30°, belt type ENI-5EE
2) on request
3) Recommended bandwidth to tape length ratio at least 1:1.2
4) with nose bar min. 400 mm

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TB40 Conveyor
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4.2 Weight of the Conveyor
Type Weight [in kg]
(basis L=1000 mm) Extension per meter [in kg]
TB40-300 15.2 6.3
TB40-400 17.7 7.8
TB40-500 19.9 9.3
TB40-600 22.2 10.9
TB40-700 24.5 12.4
TB40-800 26.7 13.9
4.3 Nameplate
Figure 1: Nameplate
Position nameplate (at the bottom of the
chassis)
Figure 2: Position Nameplate

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TB40 Conveyor
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4.4 TB40 Conveyor components
Figure 3: Exploded view of Conveyor TB40
Pos. Designation
10 Profile lateral
20 End section with diverter roller
30 Drive roller
40 Connecting support
50 Gliding plate
60 Belt
70 Lateral guide (accessories)
80 Cable, power and signal (accessories)

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TB40 Conveyor
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Figure 4: Exploded view of Conveyor TB40 with nose bar
Pos. Designation
10 Profile lateral
20 End section with diverter roller
30 End section with nose bar
40 Connecting support
50 Gliding plate
60 Belt
70 Lateral guide (accessories)
80 Cable, power and signal (accessories)

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TB40 Conveyor
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4.5 Dimension Conveyor TB40
The motor connection is available on the left and right.
AR: Drive roller
UR: Diverter roller
TypeTB40-300 TB40-400 TB40-500 TB40-600 TB40-700 TB40-800
A Width of chassis [mm] 300 400 500 600 700 800
L Conveyor length [mm] max. Conveyor length 6000mm (longer Conveyors on request)
Lmin Conveyor length5) [mm] 3605) 4805) 600 720 840 960
5) The minimum length of the conveyor depends on lateral guides, connection type and end section. For
conveyors of widths 300 and 400 mm, dependent upon lateral guides and connection type, the minimal length
according to the table below is valid.
config Lateral guide Connection type minimum lenght [mm]
none fixed adjustable Standard MonTurn MonTouch TB40-300 TB40-400
1 X X X 360 480
2 X X X 460 480
3 X X X 480 480
4 X X 500 500
5 X X 520 520
6 X X 540 540
with nose bar Lmin+ 40mm
MonTurn (optional)
Recommended conveying
direction
(nose bar)
Right-hand motor connection
Figure 5: Dimension conveyor TB40 with MonTurn

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TB40 Conveyor
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The motor connection can be chosen either on the right or left side.
AR: Drive roller
UR: Deflection roller
Type TB40-300 TB40-400 TB40-500 TB40-600 TB40-700 TB40-800
A Chassis width [mm] 300 400 500 600 700 800
L Conveyor length [mm] max. length of conveyor is 6000 mm (longer conveyors on request)
Lmin Conveyor length5) [mm] 3605) 4805) 600 720 840 960
5) The minimum length of the conveyor depends on lateral guides, connection type and end section. For
conveyors of widths 300 and 400 mm, dependent upon lateral guides and connection type, the minimal length
according to the table below is valid.
config lateral guide connection type minimum length [mm]
none fixed adjustable Standard MonTurn MonTouch TB40-300 TB40-400
1 X X X 360 480
2 X X X 460 480
3 X X X 480 480
4 X X 500 500
5 X X 520 520
6 X X 540 540
With nose bar Lmin +40 mm
Motor connection right
Figure 6: Dimension conveyor TB40 with MonTouch

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TB40 Conveyor
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4.6 TB40 Conveyor design / cross-section
Figure 7: TB40 Conveyor design / cross-section
Type TB40-300 TB40-400 TB40-500 TB40-600 TB40-700 TB40-800
A Width of chassis [mm] 300 400 500 600 700 800
B Conveyor width ±0.5 mm [mm] 228-266 328-366 428-466 528-566 628-666 728-766
X Belt width [mm] 257 357 457 557 657 757
Belt
Detail view Y

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TB40 Conveyor
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4.7 Conveyors separation
The Conveyors are shipped in units of 3 m length max. If the total length of a Conveyor exceeds the maximum
transport length of 3 m, the individual parts should be assembled according to the following schematics.
Figure 8: Schematics for component assembly
Figure 9: Schematics for component assembly
Svar Variable length of the lateral guides, min. = 500 mm, max. = 2,000 mm
Cvar Variable chassis length, Cvar max. = 3,000 - 84, or 3,000 - (84+96) mm
D Chassis joint for dismantling prior to shipping (profile connector)
NOTE!
Before commissioning, the profile connectors marked (D) must be installed.
The Conveyor must have additional supports installed in these locations.