Montech MonTurn TB40 User manual

Assembly Instrucons
TB40 Conveyor
Montech AG
Gewerbestrasse 12, 4552 Derendingen, Switzerland
+41 32 681 55 00 | inf[email protected]om | www.montech.com
Translaon of original German Assembly Instrucons / MA-100154-EN-0922

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Assembly Instrucons MA-100154
TB40 Conveyor
Table of contents
1 Denions ...................................................................................................................................4
1.1 Type designaon .......................................................................................................................................................... 4
1.2 List of essenal health and safety requirements ......................................................................................................... 4
1.3 Informaon about this manual .................................................................................................................................... 6
1.4 Explanaon of Symbols ................................................................................................................................................ 6
1.5 Labels on the conveyor and in these assembly instrucons ........................................................................................ 6
1.6 Locaon of the instrucons ......................................................................................................................................... 7
1.7 Further documentaon ............................................................................................................................................... 7
1.8 Limitaon of liability .................................................................................................................................................... 7
1.9 Copyright ..................................................................................................................................................................... 7
1.10 Warranty provisions ..................................................................................................................................................... 7
1.11 Service life .................................................................................................................................................................... 8
1.12 Customer Service / Contact Details ............................................................................................................................. 8
2 SafetyInstrucons .......................................................................................................................9
2.1 Intended Use................................................................................................................................................................ 9
2.2 Improper use ............................................................................................................................................................... 9
2.3 General safety instrucons .......................................................................................................................................... 9
2.4 Changes and modicaons to the equipment ............................................................................................................. 9
2.5 Personal protecve equipment ................................................................................................................................. 10
2.6 Responsibility of the company responsible for operang the equipment ................................................................. 10
2.7 Personnel qualicaons ............................................................................................................................................. 10
2.7.1 Operator .................................................................................................................................................................... 11
2.7.2 Qualied electrician ................................................................................................................................................... 11
2.7.3 Skilled personnel ........................................................................................................................................................ 11
2.7.4 Manufacturer ............................................................................................................................................................. 11
3 SpecicaonConveyorTB40 ......................................................................................................12
3.1 TB40 Conveyor components ...................................................................................................................................... 12
3.2 Technical data ............................................................................................................................................................ 14
3.3 Weight Conveyor TB40 .............................................................................................................................................. 15
3.4 Nameplate ................................................................................................................................................................. 15
3.5 Dimension Conveyor TB40 ......................................................................................................................................... 16
3.6 TB40 Conveyor design / cross-secon ....................................................................................................................... 19
3.7 Conveyors separaon ................................................................................................................................................ 20
3.8 Electronic performance ............................................................................................................................................ 21
3.8.1 Inputs IN A, IN B, IN 1, IN 2 ....................................................................................................................................... 21
3.8.2 Outputs OUT 1, OUT 2, OUT3 ................................................................................................................................... 21
3.8.3 Analog inputs AIN 1, AGND ........................................................................................................................................ 21
3.8.4 Safety and monitoring funcons ............................................................................................................................... 22
3.8.5 Error acknowledgement ............................................................................................................................................ 22
4 Transport,PackagingandStorage...............................................................................................23
4.1 Transport .................................................................................................................................................................... 23
4.2 Transport inspecon .................................................................................................................................................. 23
4.3 Packaging ................................................................................................................................................................... 23
4.4 Handling of packaging materials ................................................................................................................................ 23
4.5 Storage of packages ................................................................................................................................................... 24

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Assembly Instrucons MA-100154
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5 Commissioning ..........................................................................................................................25
5.1 Assembly and Disassembly ........................................................................................................................................ 26
5.1.1 Mounng the oor stands ......................................................................................................................................... 26
5.1.2 Adjust the height of the oor stand telescopic .......................................................................................................... 27
5.2 TB40 Conveyor electrical hook-up descripon .......................................................................................................... 28
5.2.1 Electrical connecon ................................................................................................................................................. 28
5.2.2 Turn on and turn o behavior TB40 power unit ........................................................................................................ 31
5.2.3 Electrical Grounding of the conveyor......................................................................................................................... 31
5.3 Seng the necessary pretension of the belt ............................................................................................................. 32
5.4 Belt Tracking (centric run of the transport belt) ........................................................................................................ 33
5.5 Conveyor belt specicaons ...................................................................................................................................... 33
5.6 Conveyor belt direcon of travel ............................................................................................................................... 33
6 Operaon ..................................................................................................................................35
6.1 Operang modes ....................................................................................................................................................... 35
6.1.1 PLC Speed-Mode (default) ......................................................................................................................................... 35
6.1.2 PLC posion mode ..................................................................................................................................................... 40
6.1.3 General output funcons ........................................................................................................................................... 46
6.1.4 Overview of the operang modes and parameterizable values TB40 ....................................................................... 47
7 Maintenance..............................................................................................................................48
7.1 Maintenance plan ...................................................................................................................................................... 48
7.2 Use of spare parts ...................................................................................................................................................... 48
7.3 Conveyor belt maintenance and cleaning .................................................................................................................. 49
7.3.1 Maintenance .............................................................................................................................................................. 49
7.3.2 Cleaning ..................................................................................................................................................................... 49
7.4 Replacing the belts..................................................................................................................................................... 51
7.4.1 Replacing endless belts .............................................................................................................................................. 51
7.4.2 Replacing belts by welding the ends .......................................................................................................................... 51
7.5 Repairs ....................................................................................................................................................................... 52
7.5.1 Replacing the drive unit ............................................................................................................................................. 52
8 Disassemblyanddisposal...........................................................................................................53
8.1 Disposal ...................................................................................................................................................................... 54
Annex1 DeclaraonofIncorporaon ................................................................................................55

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1 Denions
1.1 Typedesignaon
Designaon Conveyor
Type TB40
Document name MA-100154-EN-0922
1.2 Listofessenalhealthandsafetyrequirements
according to Machinery Direcve 2006/42/EC, Annex I, Chapter 1
Notrelevantforthisdevice
Tobemetbythesystemintegratorforthe(complete)machine
Metforthescopeofthepartlycompletedmachinery
1.1. General
1.1.1. Denions
1.1.2. Principles of safety integraon
1.1.3. Materials and products
1.1.4. Lighng
1.1.5. Design of machinery to facilitate its handling
1.1.6. Ergonomics
1.1.7. Operang posions
1.1.8. Seang
1.2. Controlsandsystems
1.2.1. Safety and reliability of control systems
1.2.2. Control devices
1.2.3. Starng
1.2.4. Stopping
1.2.4.1. Normal stop
1.2.4.2. Operaonal stop
1.2.4.3. Emergency stop
1.2.4.4. Assembly of machinery
1.2.5. Selecon of control or operang modes
1.2.6. Failure of the power supply
1.3. Proteconagainstmechanicalhazards
1.3.1. Risk of loss of stability
1.3.2. Risk of break-up during operaon
1.3.3. Risks due to falling or ejected objects
1.3.4. Risks due to surfaces, edges or angles
1.3.5. Risks related to combined machinery
1.3.6. Risks related to variaons in operang condions
1.3.7. Risks related to moving parts
1.3.8. Guards or protecve devices designed to protect against risks
1.3.8.1. Moving transmission parts
1.3.8.2. Moving parts involved in the process
1.3.9. Risk of uncontrolled movements

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Notrelevantforthisdevice
Tobemetbythesystemintegratorforthe(complete)machine
Metforthescopeofthepartlycompletedmachinery
1.4. Requirementsforsafetyguards
1.4.1. General requirements
1.4.2. Special requirements for separable safety guards
1.4.2.1 Fixed safety guards
1.4.2.2 Interlocking movable separable safety guards
1.4.2.3 Access-restricng adjustable safety guards
1.4.3. Special requirements for non-separang safety guards
1.5. Risksrelatedtomovingparts
1.5.1. Electric power supply
1.5.2. Stac electricity
1.5.3. Non-electrical power supply
1.5.4. Faulty assembly
1.5.5. Extreme temperatures
1.5.6. Fire
1.5.7. Explosion
1.5.8. Noise
1.5.9. Vibraons
1.5.10. Radiaon
1.5.11. External radiaon
1.5.12. Laser radiaon
1.5.13. Emission of hazardous materials and substances
1.5.14. Risk of being trapped in a machine
1.5.15. Risk of slipping, tripping and falling
1.5.16. Lightning strike
1.6. Maintenance
1.6.1 Machine maintenance
1.6.2. Access to the operang posions and maintenance points
1.6.3. Isolaon of power sources
1.6.4. Operator intervenon
1.6.5. Cleaning of internal machine parts
1.7. Informaon
1.7.1. Informaon and warnings on the machinery
1.7.1.1 Informaon and informaon devices
1.7.1.2 Warning devices
1.7.2. Warning of residual risks
1.7.3. Labeling of machines
1.7.4. Assembly instrucons
1.7.4.1 General principles for the draing of the assembly instrucons
1.7.4.2 Contents of the assembly instrucons
1.7.4.3 Sales literature
1.7.5 Operang manual

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1.3 Informaonaboutthismanual
This manual contains the data and informaon required for the installaon and maintenance of the TB40 conveyors.
All personnel must read this manual carefully and understand it before starng work. The basic prerequisite for safe working
is compliance with all the safety instrucons and handling instrucons given in this manual.
The assembly instrucons are part of the conveyor and must be supplied with any transfer of the conveyor.
1.4 ExplanaonofSymbols
Safety instrucons are marked with symbols in this manual. These safety instrucons are introduced by signal words that ex-
press the extent of the danger. It is essenal to ensure that the safety instrucons are adhered to in order to avoid accidents,
as well as personal injury and property damage.
DANGER
Indicates an imminent danger which may result in serious bodily injury, damage to health, death or signicant damage to
property.
WARNING
Indicates a possible imminent danger that may result in serious bodily injury, damage to health, death or signicant dama-
ge to property.
CAUTION
Indicates a potenally hazardous situaon that may result in injury or damage to property.
IMPORTANT
Indicates a potenally hazardous situaon that could result in damage to property.
NOTICE
Indicates special applicaon and operang procedures as well as other useful informaon.
1.5 Labelsontheconveyorandintheseassemblyinstrucons
Readtheassemblyinstrucons
You must have read and understood the assembly instrucons before using the conveyor.
Wear safety shoes
You must wear safety shoes while working in the vicinity of the conveyor.
Wear safety glasses
You must wear safety glasses while working in the vicinity of the pneumac system.

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Wearahairnet
You must wear a hairnet when working on machinery with rotang parts.
Disposal
Observe the special disposal instrucons.
Disposalofelectronic/electricalcomponents
Observe the special disposal instrucons for the electronic/electrical components.
1.6 Locaonoftheinstrucons
These assembly instrucons must be available at the conveyor to users and operators at all mes.
1.7 Furtherdocumentaon
Also observe the informaon in the following external instrucons:
•Conveyor TB 40 product catalog Link: Downloads
•Operang panel MonTurn Assembly Instrucons Link: Downloads
•Operang panel MonTouch Assembly Instrucons Link: Downloads
•Spare parts list TB 40 Link: Downloads
1.8 Limitaonofliability
All informaon and notes in these installaon instrucons have been compiled taking into account the applicable standards
and regulaons, the state of the art, and our many years of knowledge and experience.
Montech AG does not accept any liability for damages due to:
•failure to comply with these instrucons
•use other than for the intended purpose
•the employment of untrained or inadequately trained personnel
•maintenance work that has not been carried out or has been carried out inadequately
1.9 Copyright
The assembly instrucons are to be treated as condenal. They are intended exclusively for personnel working with the
conveyor. The disclosure of this document to third pares is prohibited unless approved in wring by Montech AG.
NOTICE Copyright
The informaon, texts, drawings, pictures and other representaons that form the content of this publicaon are protec-
ted by copyright. Any other use is not permied without wrien permission from Montech AG.
1.10 Warrantyprovisions
The warranty provisions are in the General Terms and Condions (GTC) issued by Montech AG.
Improper use according to point 2.2 can result in a warranty claim becoming void or product conformity no longer being met.

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1.11 Servicelife
The service life depends heavily on the frequency of use, care, and compliance with the specied maintenance requirements.
If the intended use is observed, an average product service life of 10 years can be expected. In this context, care must be
taken to ensure that wearing parts such as conveyor belts, toothed belts, round belts, shock absorbers and sensors must be
replaced according to the specied maintenance intervals.
This informaon does not constute an addional guarantee!
1.12 CustomerService/ContactDetails
Our customer service is at your disposal for technical informaon.
Montech AG
Gewerbestrasse 12
4552 Derendingen, Switzerland
Telefon +41 32 681 55 00
E-Mail [email protected]
Internet www.montech.com

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2 SafetyInstrucons
2.1 IntendedUse
The conveyors are intended for the transport of solid objects. They are not suitable for transporng people, sand, granules,
chips and the like.
The product-specic performance data listed on the nameplate must not be exceeded under any circumstances.
The motor does not have a holding brake, so the conveyor is not suitable for inclined conveying.
Proper use also includes compliance with all the informaon in these instrucons.
Any use that goes beyond the intended use or is dierent is considered improper use.
2.2 Improper use
A misuse of the TB40 can lead to dangerous situaons. In parcular, the following uses must be avoided:
•Direct exposure to light from UV lamps.
•Operaon in air containing smoke, dust, water vapor or solvents.
•Use in potenally explosive atmospheres (ammable gases, vapors or dust).
•Use in a damp environment (rain or dew).
•Exceeding the maximum permissible total weight.
•Use outside the limits specied in the technical data.
•Connecon and commissioning or maintenance work by unqualied personnel.
•Replacement of defecve components with unsuitable components.
•Use without training.
•Use with defecve parts or components.
•Use with safety devices and covers disabled or removed.
•Use in disregard of safety regulaons.
•Use without using personal protecve equipment.
•Use disregarding the local accident prevenon regulaons and operaonal safety regulaons.
2.3 Generalsafetyinstrucons
The safety instrucons, in parcular the instrucons relang to the electrical connecon, must be followed in all phases of
commissioning, operaon, and maintenance or repair work. Failure to follow these instrucons is misuse of the conveyor
and its components.
In parcular, you must observe the following informaon:
•Observe the warning signs aached to the conveyor. Make sure that the labels are always legible and do not remove the
labels.
•In the event of malfuncons, you must shut down and secure the conveyor immediately. You must eliminate all faults
before starng up again.
•You must shut down the system completely before carrying out maintenance or repair work.
•During all work, make sure that the higher-level system and control system cannot start up the conveyor unintenonally!
2.4 Changesandmodicaonstotheequipment
In order to avoid hazards and to ensure opmum performance, no changes, addions or conversions may be made to the
components unless they have been expressly approved by the manufacturer.
Unauthorized modicaons could invalidate the manufacturer's warranty and lead to loss of product conformity.

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2.5 Personalprotecveequipment
Personal protecve equipment must be worn when working in order to minimize dangers to health.
The following personal protecve equipment (PPE) must be worn as a minimum:
Wear safety shoes
You must wear safety shoes while working in the vicinity of the conveyor.
Wear safety glasses
You must wear safety glasses while working in the vicinity of the pneumac system.
Wearahairnet
You must wear a hairnet when working on machinery with rotang parts.
2.6 Responsibilityofthecompanyresponsibleforoperangtheequipment
The company responsible for operang the equipment must ensure that:
•the conveyor is only used by authorized and trained personnel.
•the conveyor is only accessible to trained persons.
•all users are aware of the safety regulaons and residual risks.
•all users have the necessary personal protecve equipment (PPE) (see chapter Kapitel 2.5).
2.7 Personnelqualicaons
Productstages Task Operator
(2.7.1)
Qualied
electrici-
an(2.7.2)
Skilled
personnel
(2.7.3)
Manufac-
turer
(2.7.4)
Transport Transportaon
Loading/unloading
Posioning
Storage
X
X
X
X
Commissioning Installaon (mechanical/electri-
cal)
Set up
Test run
X X
X
X
X
Normal operaon Normal operaon X
Maintenance Cleaning
Troubleshoong, Repairing
X
X X
Decommissioning Disassembly
Packing, loading/unloading
Transportaon
X
X
X
Disposal Disposal X

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2.7.1 Operator
The machine operators are obliged to read the assembly instrucons and observe the instrucons given or they must have
received all the necessary informaon through training. If parts of the assembly instrucons are not understood, these
points must be claried with the company responsible for operang the equipment or manufacturer. Tasks that go beyond
normal operaon may only be carried out by the machine operator if the company responsible for operang the equipment
has expressly instructed the machine operator to do so.
2.7.2 Qualiedelectrician
Based on their technical training, knowledge and experience, as well as knowledge of the relevant standards and regula-
ons, a qualied electrician is able to carry out work on electrical systems and to independently recognize and avoid potenal
hazards.
The qualied electrician must have read the relevant chapters of these assembly instrucons.
2.7.3 Skilledpersonnel
Due to their technical training, knowledge and experience as well as their knowledge of the relevant standards and regula-
ons, the skilled personnel are able to carry out the work assigned to them and to independently recognize possible hazards
and to avoid hazards.
2.7.4 Manufacturer
Further work not described in these assembly instrucons may only be carried out by Montech AG's skilled personnel. Other
personnel are not authorized to carry out this work. Please contact Montech AG's customer service to have such work car-
ried out (for contact informaon, see chapter 1.12).

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3 SpecicaonConveyorTB40
3.1 TB40 Conveyor components
Item Descripon
10 Prole lateral
20 Drive unit
30 End secon with diverter roller
40 Connecng support
50 Gliding plate
60 Belt
70 Lateral guide (accessories)
80 Cable, power and signal (accessories)
Figure1 Exploded view of the Conveyor TB40
10
40
30
70
10
50
60
80
20

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Item Descripon
10 Prole lateral
20 Drive unit
30 End secon with knife edge
40 Connecng support
50 Gliding plate
60 Belt
70 Lateral guide (accessories)
80 Cable, power and signal (accessories)
Figure2 Exploded view of the Conveyor TB40 with knife edge
10
40
30
70
10
50
60
80
20

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3.2 Technicaldata
Operang temperature + 10 ... + 40 °C
Storage temperature + 5 ... + 40 °C
Relave humidity (in operaon) < 95 % (without condensaon)
Relave humidity (storage) < 95 % (without condensaon)
Degree of purity of the air (in operaon) normal workshop atmosphere
Sound pressure level (in operaon) < 65 dBA
Components’ protecon class IP 64
Drive Integrated in drive roller
Motor Brushless EC motor with speed, current and
posion controller; sinusoidal commutaon with
eld-oriented control up to n = 0
Gear Planetary gear
Gear reducon i = 30 i = 80
Belt speed 1 ... 33.5 m/min (± 10%) 0.25 ... 12 m/min (± 10%)
Load in conveying mode1) 80 kg (50 kg with knife edge) 200 kg (max. 80 kg/m, 180 kg with knife edge)
Rated voltage 24 VDC
Permissible supply voltage range 20 … 28 VDC
Rated current 12.3 A
Dimensioning power supply (recommendaon) 20 A rated current / 30 A peak current
Rated output 251 W
Target value Analog / PWM2) / Frequency2)
Digital inputs 4
Digital outputs 3
Analog input 1 (0 … 10 V)
An-lock funcon thermal
Overload protecon yes
Belt width 300 / 400 / 500 / 600 / 700 / 800 mm
Belt length3) from 3604) mm to zu 6000 mm
(belts over 6000 mm upon request)
Material Lateral secon Aluminium, clear anodized
Diverter roller Stainless steel
Drive roller Aluminium
Sliding plate Galvanized steel or stainless steel (oponal)
Connecon support Aluminium, clear anodized, plasc
Tabs Aluminium
Cable Polyurethane / copper
1) Mode of operaon S1, ambient temperature 30°, belt type ENI-5EE
2) On request
3) Recommended bandwidth to tape length rao at least 1:1.2
4) with nose bar min. 400 mm

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3.3 WeightConveyorTB40
Type Weight[kg]
(BaseL=1000mm)
Extension
permeter[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
3.4 Nameplate
Figure3 Example of a nameplate
Figure4 Posion nameplate
Posion of the nameplate (at the
boom of the chassis)

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3.5 DimensionConveyorTB40
The motor connecon is available on the le and right.
AR: Drive roller
UR: Diverter roller
Type TB40-300 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. 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, connecon type and end secon. For conveyors of widths
300 and 400 mm, dependent upon lateral guides and connecon type, the minimal length according to the table below is
valid.
Figure5 Dimension conveyor TB40 with MonTurn
Conveying direcon towards
drive only
MonTurn (oponal)
Knife edge
Right-hand motor connecon

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Cong Lateralguide Connecontype Minimumlenght[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 knife edge Lmin + 40 mm
The motor connecon can be chosen either on the right or le side.
AR: Drive roller
UR: Deecon roller
Type TB40-300 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. 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, connecon type and end secon. For conveyors of widths
300 and 400 mm, dependent upon lateral guides and connecon type, the minimal length according to the table below is
valid.
Figure6 Dimension conveyor TB40 with MonTouch
Conveying direcon towards
drive only
Right-hand motor connecon
Knife edge
MonTouch (oponal)

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Cong Lateralguide Connecontype Minimumlenght[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 knife edge Lmin + 40 mm

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3.6 TB40Conveyordesign/cross-secon
Type TB40-300 TB40-400 TB40-500 TB40-600 TB40-700 TB40-800
A Chassis width [mm] 300 400 500 600 700 800
B Conveyor width ± 0.5
(Lateral guide xed)
[mm] 212 – 266 312 – 366 412 – 466 512 – 566 612 – 666 712 - 766
X Belt width [mm] 257 357 457 557 657 757
C Chassis width inside [mm] 267 367 467 567 667 767
F Lateral guide width [mm] depends on conveying width B
D Conveyor width (Ad-
justable lateral guides
type A)
[mm] 208 – 266 308 – 366 408 – 466 508 – 566 608 – 666 708 - 766
D Conveyor width (Ad-
justable lateral guides
type B)
[mm] 201 – 266 301 – 366 401 – 466 501 – 566 601 – 666 701 - 766
D Conveyor width (Ad-
justable lateral guides
type C)
[mm] 203 – 266 303 – 366 403 – 466 503 – 566 603 – 666 703 - 766
Figure7 TB40 Conveyor design / cross-secon
If the support width of the ma-
terial to be conveyed is narro-
wer than dimension C, the max.
conveying width widens
ViewY
Belt

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3.7 Conveyorsseparaon
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 schemacs.
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 (prole connector)
NOTICE Fixingtheproleconnectors
Before commissioning, the prole connectors marked (D) must be installed.
The conveyor must have addional supports installed in these locaons.
Figure8 Schemacs for component assembly
Figure9 Schemacs for component assembly
Other manuals for MonTurn TB40
2
This manual suits for next models
6
Table of contents
Other Montech Accessories manuals