Montech TB30 User manual

ASSEMBLY INSTRUCTIONS
CONVEYOR TB30
Redesign
BA-100156
Translation of the original assembly instructions, Copyright by Montech AG
English Edition 12/2019

Assembly instructions BA-100156
Conveyor TB30
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Content
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 in this manual........................................................................................................ 8
1.4 Explanation of symbols ............................................................................................................ 8
1.5 Limited liability ......................................................................................................................... 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
4Specification conveyor TB30 14
4.1 Components conveyor TB30 single belt center drive ........................................................... 14
4.2 Components conveyor TB30 dual belt center drive.............................................................. 15
4.3 Components conveyor TB30 tandem center drive ............................................................... 16
4.4 Components conveyor TB30 single belt end drive ............................................................... 17
4.5 Components conveyor TB30 dual belt end drive.................................................................. 18
4.6 Components conveyor TB30 tandem end drive.................................................................... 19
4.7 Components conveyor TB30 single belt center drive with three-phase motor ................... 20
4.8 Components conveyor TB30 dual belt center drive with three-phase motor ...................... 21
4.9 Components conveyor TB30 tandem center drive with three-phase motor........................ 22
4.10 Components conveyor TB30 single belt end drive with three-phase motor........................ 23
4.11 Components conveyor TB30 dual belt end drive with three-phase motor .......................... 24
4.12 Components conveyor TB30 tandem end drive with three-phase motor ............................ 25
4.13 Technical Data ........................................................................................................................ 26
4.14 Weight conveyor TB30 ........................................................................................................... 27
4.15 Nameplate .............................................................................................................................. 27

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4.16 Dimension drawings conveyor TB30...................................................................................... 28
4.16.1 Dimension drawing conveyor TB30/M with brushless DC-Motor......................................... 28
4.16.2 Dimension drawing conveyor TB30/M tandem with brushless DC-Motor ........................... 29
4.16.3 Dimension drawing conveyor TB30/K with brushless DC-Motor.......................................... 30
4.16.4 Dimension drawing conveyor TB30/K tandem with brushless DC-Motor ............................ 31
4.16.5 Dimension drawing conveyor TB30/M with three-phase motor........................................... 32
4.16.6 Dimension drawing conveyor TB30/M tandem three-phase motor ..................................... 33
4.16.7 Dimension drawing conveyor TB30/K with three-phase motor ............................................ 34
4.16.8 Dimension drawing conveyor TB30/K tandem with three-phase motor .............................. 35
4.17 Calculation .............................................................................................................................. 36
4.17.1 Conveyor TB30/M .................................................................................................................. 36
4.17.2 Conveyor TB30/K ................................................................................................................... 36
4.18 Mechanical construction......................................................................................................... 37
4.18.1 Chassis separation.................................................................................................................. 37
5Commissioning 40
5.1 Improper installation and commissioning.............................................................................. 40
5.2 Initial commissioning .............................................................................................................. 40
5.2.1 Electrical connection brushless DC-Motor ............................................................................ 41
5.2.2 Driver settings for external control by I/O’s.......................................................................... 43
5.2.3 Electrical connection Three-Phase Motor.............................................................................. 44
5.2.4 Setting the necessary pretension of the belt ........................................................................ 45
5.2.5 Tracking of the conveyor belt ................................................................................................ 46
5.2.6 Relocation of the drive unit along the chassis (center drive) ................................................ 48
6Maintenance 49
6.1 Maintenance plan ................................................................................................................... 49
6.2 Spare parts ............................................................................................................................. 49
6.3 Replacing conveyor belts ....................................................................................................... 50
6.3.1 Technical data of the conveyor belt....................................................................................... 50
6.3.2 Replacing endless belts .......................................................................................................... 50
6.3.3 Replacing belts by welding the ends ..................................................................................... 52
6.4 Installation of the gliding plate on the chassis for replacement delivery ............................. 53
6.5 Replacing the motor............................................................................................................... 54
6.5.1 Brushless DC-motor................................................................................................................ 54
6.5.2 Three-phase motor ................................................................................................................. 55
6.6 Display the conveyor speed................................................................................................... 56
6.7 Mounting the controller with the assembly kit...................................................................... 57
6.8 Direction of travel of the conveyor belt ................................................................................ 58
6.9 Repairs .................................................................................................................................... 59
6.9.1 Replacement of self-aligning ball bearings / drive rollers (center drive) .............................. 59
7Disassembly and Disposal 60
7.1 Improper disassembly ............................................................................................................ 60

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7.2 Disposal .................................................................................................................................. 61

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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
  
1.3.9.
Risk of uncontrolled movements
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
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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



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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
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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
  
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 literature
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1.7.5
Assembly instructions
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1.3 Information in this manual
This manual contains data and information necessary to install and maintain the Conveyor TB30.
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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1.5 Limited liability
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 contact person responsible can be obtained by phone, fax, e-mail or on the
Internet; please refer to the manufacturer’s address on the installation declaration page.

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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 by untrained personnel may result in considerable property
damage.
– Only use trained 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 falling
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 upon detection.
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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Conveyor TB30
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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 machines are stored longer than three months, check the general condition of all parts and
the packaging regularly.

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3Safety
This section provides an overview of all important safety aspects for the optimum protection of
workers, and safe and uninterrupted operation.
3.1 Use for intended purpose
Conveyors are designed for transporting solid objects that are not below a certain minimum size.
They are not suitable for transporting people and materials such as sand, granules, chips, etc.
The product-specific ratings listed on the nameplate must never be exceeded.
The motor does not have a holding brake; consequently, the conveyor is not suitable for inclined
conveying.
Intended use includes following all instructions in this manual.
Any use other than or beyond intended use is considered misuse.
3.2 Safety instructions
WARNING!
The safety instructions, in particular 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!
A misuse of the TB30 may result in dangerous situations. Refrain from the following
uses:
– Exposure to direct light from UV lamps.
– Operation in air containing smoke, dust, water vapor, or solvents.
– Use in areas with explosion hazard (flammable gases, vapors or dust).
– Use in a damp environment (rain or dew).
– Do not exceed maximum permissible total weight.
– Connecting, commissioning or servicing of the machine without qualified
personnel.

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3.4 Changes and modifications to the equipment
To avoid hazards and ensure optimum performance, any changes, additions or modifications not
expressly permitted by the manufacturer are prohibited.
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.
Hairnet
Wear a hair net when working with 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 have persons perform the work who can be expected for perform it reliably.
Persons whose ability to respond is impaired, e.g. due to the influence of drugs, alcohol or
prescription drugs, are not allowed to work on the machine.
This manual defines the following personnel qualifications for 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 that go beyond normal operation ONLY if this is stated in the manual and the system operator
has explicitly assigned the task to the machine operator.
Skilled electrician
Based on his/her technical training, knowledge and experience, as well as knowledge of the relevant
standards and regulations, a skilled electrician is able to perform work on electrical systems and to
independently recognize and avoid potential hazards.
The skilled electrician has been trained specifically for his/her work environmental and is familiar with
the relevant standards and regulations.
Skilled personnel
Based on their technical training, knowledge and experience, as well as knowledge of the relevant
standards and regulations, skilled personnel is able to perform work assigned to them and to
independently recognize and avoid potential hazards.
Manufacturer
Certain work may only be performed by Montech AG’s skilled personnel. Other personnel is not
authorized to perform this work. Please contact our Customer Service to have such work performed.

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4Specification conveyor TB30
4.1 Components conveyor TB30 single belt center drive
Figure 1: Exploded view conveyor TB30 single belt center drive
Pos.
Designation
10
Chassis
20
Gliding plate (optional)
30
Lateral guide
40
End section (divers types)
50
End section with nose bar (optional)
60
Drive unit
70
Motor (brushless DC-Motor displayed; optional Three-Phase motor)
80
Driver (only with brushless DC-Motor)
90
Belt
100 Connecting cable motor/driver (only with brushless DC-Motor)

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4.2 Components conveyor TB30 dual belt center drive
Figure 2: Exploded view conveyor TB30 dual belt center drive
Pos. Designation
10
Chassis
20
Gliding plate (optional)
30
Lateral guide
40
End section (divers types)
50
End section with nose bar (optional)
60
Drive unit
70
Motor (brushless DC-Motor displayed; optional Three-Phase motor)
80
Driver (only with brushless DC-Motor)
90
Belts
100
Connecting cable motor/driver (only with brushless DC-Motor)

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4.3 Components conveyor TB30 tandem center drive
Figure 3: Exploded view conveyor TB30 tandem center drive
Pos.
Designation
10
Chassis
20
Gliding plate (optional)
30 Lateral guide
40
End section (divers types)
50
End section with nose bar (optional)
60 Drive unit
70
Motor (brushless DC-Motor displayed; optional Three-Phase motor)
80
Driver (only with brushless DC-Motor)
90
Belt
100
Connecting cable motor/driver (only with brushless DC-Motor)
110
Joining element

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4.4 Components conveyor TB30 single belt end drive
Figure 4: Exploded view conveyor TB30 single belt end drive
Pos.
Designation
10
Chassis
20 Gliding plate (optional)
30
Lateral guide
40
End section (tension roller-Ø30 resp. Ø40 when using cleats)
50 Drive unit
60
Motor (brushless DC-Motor displayed; optional Three-Phase motor)
70
Driver (only with brushless DC-Motor)
80
Belt
90
Connecting cable motor/driver (only with brushless DC-Motor)

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4.5 Components conveyor TB30 dual belt end drive
Figure 5: Exploded view conveyor TB30 dual belt end drive
Pos.
Designation
10
Chassis
20
Gliding plate (optional)
30
Lateral guide
40
End section (tension roller- Ø30)
50
Drive unit
60 Motor (brushless DC-Motor displayed; optional Three-Phase motor)
70
Driver (only with brushless DC-Motor)
80
Belts
90
Connecting cable motor/driver (only with brushless DC-Motor)

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4.6 Components conveyor TB30 tandem end drive
Figure 6: Exploded view conveyor TB30 tandem end drive
Pos.
Designation
10
Chassis
20 Gliding plate (optional)
30
Lateral guide
40
End section (tension roller- Ø30)
50
Drive unit
60
Motor (brushless DC-Motor displayed; optional Three-Phase motor)
70
Driver (only with brushless DC-Motor)
80
Belt
90
Joining element
100
Connecting cable motor/driver (only with brushless DC-Motor)

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4.7 Components conveyor TB30 single belt center drive with three-phase motor
Figure 7: Exploded view conveyor TB30 single belt center drive with three-phase motor
Pos.
Designation
10
Chassis
20
Drive unit
30
End section (tension roller- Ø30)
40
Motor (three-phase motor)
50
Gliding plate (optional)
60
Belt
70 Lateral guide