Montech TB30 User manual

Assembly Instrucons
TB30 Conveyor
Montech AG
Gewerbestrasse 12, 4552 Derendingen, Switzerland
[phone] | inf[email protected]om | www.montech.com
Translaon of original German Assembly Instrucons / MA-100156-EN-0123

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Assembly Instrucons MA-100156
TB30 Conveyor
Table of contents
1 Denions ...................................................................................................................................5
1.1 Type designaon .......................................................................................................................................................... 5
1.2 List of essenal health and safety requirements ......................................................................................................... 5
1.3 Informaon about this manual .................................................................................................................................... 7
1.4 Explanaon of Symbols ................................................................................................................................................ 7
1.5 Labels on the conveyor and in these assembly instrucons ........................................................................................ 7
1.6 Locaon of the instrucons ......................................................................................................................................... 8
1.7 Further documentaon ............................................................................................................................................... 8
1.8 Limitaon of liability .................................................................................................................................................... 8
1.9 Copyright ..................................................................................................................................................................... 8
1.10 Warranty provisions ..................................................................................................................................................... 8
1.11 Service life .................................................................................................................................................................... 9
1.12 Customer Service / Contact Details ............................................................................................................................. 9
2 SafetyInstrucons .....................................................................................................................10
2.1 Intended Use.............................................................................................................................................................. 10
2.2 Improper use ............................................................................................................................................................. 10
2.3 General safety instrucons ........................................................................................................................................ 10
2.4 Changes and modicaons to the equipment ........................................................................................................... 10
2.5 Personal protecve equipment ................................................................................................................................. 11
2.6 Responsibility of the company responsible for operang the equipment ................................................................. 11
2.7 Personnel qualicaons ............................................................................................................................................. 11
2.7.1 Operator .................................................................................................................................................................... 12
2.7.2 Qualied electrician ................................................................................................................................................... 12
2.7.3 Skilled personnel ........................................................................................................................................................ 12
2.7.4 Manufacturer ............................................................................................................................................................. 12
3 SpecicaonConveyorTB30 ......................................................................................................13
3.1 Drive with brushless DC motor .................................................................................................................................. 13
3.1.1 Components TB30 single belt conveyor center drive ................................................................................................ 13
3.1.2 Components TB30 dual belt conveyor center drive ................................................................................................... 14
3.1.3 Components TB30 tandem conveyor center drive .................................................................................................... 15
3.1.4 Components TB30 single belt conveyor end drive ..................................................................................................... 16
3.1.5 Components TB30 dual belt conveyor end drive ....................................................................................................... 17
3.1.6 Components TB30 tandem conveyor end drive ......................................................................................................... 18
3.1.7 Components TB30 single belt conveyor end drive pivotable ..................................................................................... 19
3.1.8 Components TB30 dual belt conveyor end drive pivotable ....................................................................................... 20
3.2 Drive with three-phase motor ................................................................................................................................... 21
3.2.1 Components TB30 single belt conveyor center drive ................................................................................................ 21
3.2.2 Components TB30 dual belt conveyor center drive ................................................................................................... 22
3.2.3 Components TB30 tandem conveyor center drive .................................................................................................... 23
3.2.4 Components TB30 single belt conveyor end drive ..................................................................................................... 24
3.2.5 Components TB30 dual belt conveyor end drive ....................................................................................................... 25
3.2.6 Components TB30 tandem conveyor end drive ......................................................................................................... 26
3.3 Technical data ............................................................................................................................................................ 27
3.4 Weight Conveyor TB30 .............................................................................................................................................. 28
3.5 Nameplate ................................................................................................................................................................. 29
3.6 Dimensional drawings of the TB30 conveyor ............................................................................................................. 30
3.6.1 Dimensional drawing of the TB30/M conveyor with a brushless DC motor .............................................................. 30
3.6.2 Dimensional drawing of the TB30/M tandem conveyor with a brushless DC motor ................................................. 31
3.6.3 Dimensional drawing of the TB30/K conveyor with a brushless DC motor ............................................................... 32

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Assembly Instrucons MA-100156
TB30 Conveyor
3.6.4 Dimensional drawing of the TB30/KS conveyor with a brushless DC motor.............................................................. 33
3.6.5 Dimensional drawing of the TB30/K tandem conveyor with brushless DC motor ..................................................... 34
3.6.6 Dimensional drawing of the TB30/M conveyor with a three-phase motor ............................................................... 35
3.6.7 Dimensional drawing of the TB30/M tandem conveyor with a three-phase motor .................................................. 36
3.6.8 Dimensional drawing of the TB30/K conveyor with a three-phase motor ................................................................ 37
3.6.9 Dimensional drawing of the TB30/K tandem conveyor with a three-phase motor ................................................... 38
3.7 Calculaon formula .................................................................................................................................................... 39
3.7.1 ConveyorTB30/M ....................................................................................................................................................... 39
3.7.2 Conveyor TB30/K ....................................................................................................................................................... 39
3.8 Mechanical Assembly ................................................................................................................................................ 40
3.8.1 Conveyor separaon .................................................................................................................................................. 40
4 Transport,PackagingandStorage...............................................................................................44
4.1 Transport .................................................................................................................................................................... 44
4.2 Transport inspecon .................................................................................................................................................. 44
4.3 Packaging ................................................................................................................................................................... 44
4.4 Handling of packaging materials ................................................................................................................................ 44
4.5 Storage of packages ................................................................................................................................................... 45
5 Commissioning ..........................................................................................................................46
5.1 Inial commissioning ................................................................................................................................................. 46
5.1.1 Electrical connecon brushless DC-Motor ................................................................................................................. 47
5.1.2 Electrical connecon end drive pivotable .................................................................................................................. 49
5.1.3 Controller sengs for external control by I/O’s ......................................................................................................... 49
5.1.4 Electrical connecon Three-Phase Motor .................................................................................................................. 50
5.1.5 Seng the required pretension of the conveyor belt................................................................................................ 51
5.1.6 Conveyor belt tracking ............................................................................................................................................... 52
5.1.7 Relocaon of the drive unit on the chassis (center drive) ......................................................................................... 54
6 Maintenance..............................................................................................................................55
6.1 Maintenance Schedule .............................................................................................................................................. 55
6.1.1 Checking the conveyor belt (skilled personnel) ......................................................................................................... 55
6.1.2 Cleaning (Operator) ................................................................................................................................................... 55
6.2 Use of spare parts ...................................................................................................................................................... 55
6.3 Replacing conveyor belts ........................................................................................................................................... 56
6.3.1 Technical data of the conveyor belt ........................................................................................................................... 56
6.3.2 Replacing endless belts .............................................................................................................................................. 56
6.3.3 Replacing belts by welding the ends .......................................................................................................................... 58
6.4 Installaon of the gliding plate on the chassis for replacement deliveries ................................................................ 59
6.5 Procedure for changing the motor ............................................................................................................................ 60
6.5.1 Brushless DC motor ................................................................................................................................................... 60
6.5.2 Three-phase motor .................................................................................................................................................... 61
6.6 Speed display on the motor ....................................................................................................................................... 62
6.7 Install the controller with the installaon set ............................................................................................................ 63
6.8 Pivong the drive unit at the end drive pivong ...................................................................................................... 64
6.8.1 Adjusng the drive unit ............................................................................................................................................. 64
6.8.2 Adjusng the toothed belt pretension ...................................................................................................................... 64
6.9 Running direcon of the conveyor belt ..................................................................................................................... 65
6.10 Repairs ....................................................................................................................................................................... 66
6.10.1 Replacing self-aligning ball bearings / drive rollers (center drive) ............................................................................. 66
6.10.2 Replacing the drive roller/ball bearing (End drive pivong) ...................................................................................... 67
6.10.3 Replacing the gear motor (End drive pivong) .......................................................................................................... 68

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Assembly Instrucons MA-100156
TB30 Conveyor
7 Disassemblyanddisposal...........................................................................................................69
7.1 Disposal ...................................................................................................................................................................... 70
Annex1 DeclaraonofIncorporaon ................................................................................................71

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1 Denions
1.1 Typedesignaon
Designaon Conveyor
Type TB30
Document name MA-100156-EN-0123
1.2 Listofessenalhealthandsafetyrequirements
according to Machinery Direcve 2006/42/EC, Annex I, Chapter 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machinery 
1.1. General
1.1.1. Denions 
1.1.2. Principles of safety integraon 
1.1.3. Materials and products 
1.1.4. Lighng 
1.1.5. Design of machinery to facilitate its handling 
1.1.6. Ergonomics 
1.1.7. Operang posions 
1.1.8. Seang 
1.2. Controlsandsystems
1.2.1. Safety and reliability of control systems 
1.2.2. Control devices 
1.2.3. Starng 
1.2.4. Stopping 
1.2.4.1. Normal stop 
1.2.4.2. Operaonal stop 
1.2.4.3. Emergency stop 
1.2.4.4. Assembly of machinery 
1.2.5. Selecon of control or operang modes 
1.2.6. Failure of the power supply 
1.3. Proteconagainstmechanicalhazards
1.3.1. Risk of loss of stability 
1.3.2. Risk of break-up during operaon 
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 variaons in operang condions 
1.3.7. Risks related to moving parts 
1.3.8. Guards or protecve 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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Notrelevantforthisdevice 
Tobemetbythesystemintegratorforthe(complete)machine 
Metforthescopeofthepartlycompletedmachinery 
1.4. Requirementsforsafetyguards
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-restricng adjustable safety guards  
1.4.3. Special requirements for non-separang safety guards  
1.5. Risksrelatedtomovingparts
1.5.1. Electric power supply 
1.5.2. Stac 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. Vibraons 
1.5.10. Radiaon 
1.5.11/ External radiaon 
1.5.12. Laser radiaon 
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 operang posions and maintenance points 
1.6.3. Isolaon of power sources 
1.6.4. Operator intervenon 
1.6.5. Cleaning of internal machine parts 
1.7. Informaon
1.7.1. Informaon and warnings on the machinery 
1.7.1.1 Informaon and informaon devices 
1.7.1.2 Warning devices 
1.7.2. Warning of residual risks 
1.7.3. Labeling of machines 
1.7.4. Assembly instrucons 
1.7.4.1 General principles for the draing of the assembly instrucons 
1.7.4.2 Contents of the assembly instrucons 
1.7.4.3 Sales literature 
1.7.5 Operang manual 

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1.3 Informaonaboutthismanual
This manual contains the data and informaon required for the installaon and maintenance of the TB30 conveyors.
All personnel must read this manual carefully and understand it before starng work. The basic prerequisite for safe working
is compliance with all the safety instrucons and handling instrucons given in this manual.
The assembly instrucons are part of the conveyor and must be supplied with any transfer of the conveyor.
1.4 ExplanaonofSymbols
Safety instrucons are marked with symbols in this manual. These safety instrucons are introduced by signal words that ex-
press the extent of the danger. It is essenal to ensure that the safety instrucons 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 signicant damage to
property.
WARNING
Indicates a possible imminent danger that may result in serious bodily injury, damage to health, death or signicant dama-
ge to property.
CAUTION
Indicates a potenally hazardous situaon that may result in injury or damage to property.
IMPORTANT
Indicates a potenally hazardous situaon that could result in damage to property.
NOTICE
Indicates special applicaon and operang procedures as well as other useful informaon.
1.5 Labelsontheconveyorandintheseassemblyinstrucons
Readtheassemblyinstrucons
You must have read and understood the assembly instrucons 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 pneumac system.

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Wearahairnet
You must wear a hairnet when working on machinery with rotang parts.
Disposal
Observe the special disposal instrucons.
Disposalofelectronic/electricalcomponents
Observe the special disposal instrucons for the electronic/electrical components.
1.6 Locaonoftheinstrucons
These assembly instrucons must be available at the conveyor to users and operators at all mes.
1.7 Furtherdocumentaon
Also observe the informaon in the following external instrucons:
•Operang Manual BMU Series HM-5187 (Oriental Motor) Link: Downloads
•Short instrucons BLM BMU HM-5191 (Oriental Motor) Link: Downloads
•UL cercaon BMU controller (Oriental Motor) Link: Downloads
•Spare parts list TB30 single belt Link: Downloads
•Spare parts list TB30 dual belt Link: Downloads
•Spare parts list TB30 Tandem Link: Downloads
1.8 Limitaonofliability
All informaon and notes in these installaon instrucons have been compiled taking into account the applicable standards
and regulaons, 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 instrucons
•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 instrucons are to be treated as condenal. They are intended exclusively for personnel working with the
conveyor. The disclosure of this document to third pares is prohibited unless approved in wring by Montech AG.
NOTICE Copyright
The informaon, texts, drawings, pictures and other representaons that form the content of this publicaon are protec-
ted by copyright. Any other use is not permied without wrien permission from Montech AG.
1.10 Warrantyprovisions
The warranty provisions are in the General Terms and Condions (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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TB30 Conveyor
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1.11 Servicelife
The service life depends heavily on the frequency of use, care, and compliance with the specied 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 specied maintenance intervals.
This informaon does not constute an addional guarantee!
1.12 CustomerService/ContactDetails
Our customer service is at your disposal for technical informaon.
Montech AG
Gewerbestrasse 12
4552 Derendingen, Switzerland
[phone]
[email protected]
www.montech.com

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TB30 Conveyor
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2 SafetyInstrucons
2.1 IntendedUse
The conveyors are intended for the transport of solid objects. They are not suitable for transporng people, sand, granules,
chips and the like.
The product-specic performance data listed on the nameplate must not be exceeded under any circumstances.
IMPORTANT Holdingbrake
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 informaon in these instrucons.
Any use that goes beyond the intended use or is dierent is considered improper use.
2.2 Improper use
A misuse of the TB30 can lead to dangerous situaons. In parcular, the following uses must be avoided:
•Direct exposure to light from UV lamps.
•Operaon in air containing smoke, dust, water vapor or solvents.
•Use in potenally 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 specied in the technical data.
•Connecon and commissioning or maintenance work by unqualied personnel.
•Replacement of defecve components with unsuitable components.
•Use without training.
•Use with defecve parts or components.
•Use with safety devices and covers disabled or removed.
•Use in disregard of safety regulaons.
•Use without using personal protecve equipment.
•Use disregarding the local accident prevenon regulaons and operaonal safety regulaons.
2.3 Generalsafetyinstrucons
The safety instrucons, in parcular the instrucons relang to the electrical connecon, must be followed in all phases of
commissioning, operaon, and maintenance or repair work. Failure to follow these instrucons is misuse of the conveyor
and its components.
In parcular, you must observe the following informaon:
•Observe the warning signs aached to the conveyor. Make sure that the labels are always legible and do not remove the
labels.
•In the event of malfuncons, you must shut down and secure the conveyor immediately. You must eliminate all faults
before starng 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 unintenonally!
2.4 Changesandmodicaonstotheequipment
In order to avoid hazards and to ensure opmum performance, no changes, addions or conversions may be made to the
components unless they have been expressly approved by the manufacturer.
Unauthorized modicaons could invalidate the manufacturer's warranty and lead to loss of product conformity.

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2.5 Personalprotecveequipment
Personal protecve equipment must be worn when working in order to minimize dangers to health.
The following personal protecve 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 pneumac system.
Wearahairnet
You must wear a hairnet when working on machinery with rotang parts.
2.6 Responsibilityofthecompanyresponsibleforoperangtheequipment
The company responsible for operang 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 regulaons and residual risks.
•all users have the necessary personal protecve equipment (PPE) (see chapter 2.5).
2.7 Personnelqualicaons
Productstages Task Operator
(2.7.1)
Qualied
electrician
(2.7.2)
Skilled
personnel
(2.7.3)
Manufac-
turer
(2.7.4)
Transport Transportaon
Loading/unloading
Posioning
Storage
X
X
X
X
Commissioning Installaon (mechanical/electri-
cal)
Set up
Test run
X X
X
X
X
Normal operaon Normal operaon X
Maintenance Cleaning
Troubleshoong, Repairing
X
X X
Decommissioning Disassembly
Packing, loading/unloading
Transportaon
X
X
X
Disposal Disposal X

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2.7.1 Operator
The machine operators are obliged to read the assembly instrucons and observe the instrucons given or they must have
received all the necessary informaon through training. If parts of the assembly instrucons are not understood, these
points must be claried with the company responsible for operang the equipment or manufacturer. Tasks that go beyond
normal operaon may only be carried out by the machine operator if the company responsible for operang the equipment
has expressly instructed the machine operator to do so.
2.7.2 Qualiedelectrician
Based on their technical training, knowledge and experience, as well as knowledge of the relevant standards and regula-
ons, a qualied electrician is able to carry out work on electrical systems and to independently recognize and avoid potenal
hazards.
The qualied electrician must have read the relevant chapters of these assembly instrucons.
2.7.3 Skilledpersonnel
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 instrucons 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 informaon, see chapter 1.12).

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3 SpecicaonConveyorTB30
3.1 DrivewithbrushlessDCmotor
3.1.1 ComponentsTB30singlebeltconveyorcenterdrive
Item Descripon
10 Chassis
20 Gliding plate (oponal)
30 Lateral guide
40 End secon (various versions)
50 End secon with knife edge (oponal)
60 Drive unit
70 Motor (Brushless DC motor)
80 Controller
90 Conveyor belt
100 Motor/controller connecon cable (only with the brushless DC motor)
Figure1 Exploded view of the TB30 single belt conveyor with center drive
10
20
70
50
100
40
80
90
60
30

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3.1.2 ComponentsTB30dualbeltconveyorcenterdrive
Item Descripon
10 Chassis
20 Gliding plate
30 Lateral guide
40 End secon (various versions)
50 End secon with knife edge (oponal)
60 Drive unit
70 Motor (Brushless DC motor)
80 Controller
90 Conveyor belts
100 Motor/controller connecon cable
Figure2
10
20
70
50
100
40
80
90
60
30
Exploded view of the TB30 dual belt conveyor with center drive

Assembly Instrucons MA-100156
TB30 Conveyor
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3.1.3 ComponentsTB30tandemconveyorcenterdrive
Item Descripon
10 Chassis
20 Gliding plate (oponal)
30 Lateral guide
40 End secon (various versions)
50 End secon with knife edge (oponal)
60 Drive unit
70 Motor (Brushless DC motor)
80 Controller
90 Conveyor belts
100 Motor/controller connecon cable
110 Conveyor connecon
Figure3 Exploded view of the TB30 tandem conveyor with center drive
10
20
70
50
100
40
80
90
60
30
110

Assembly Instrucons MA-100156
TB30 Conveyor
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3.1.4 ComponentsTB30singlebeltconveyorenddrive
Item Descripon
10 Chassis
20 Gliding plate (oponal)
30 Lateral guide
40 End secon (tension roller-Ø30 or Ø40 for cleated belts)
50 Drive unit
60 Motor (Brushless DC motor)
70 Controller
80 Conveyor belt
90 Motor/controller connecon cable
Exploded view of the TB30 single belt conveyor with end drive
Figure4
10
20
90
40
50
70
80
60
30

Assembly Instrucons MA-100156
TB30 Conveyor
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3.1.5 ComponentsTB30dualbeltconveyorenddrive
Item Descripon
10 Chassis
20 Gliding plate
30 Lateral guide
40 End secon (tension roller-Ø30)
50 Drive unit
60 Motor (Brushless DC motor)
70 Controller
80 Conveyor belts
90 Motor/controller connecon cable
Figure5 Exploded view of the TB30 dual belt conveyor with end drive
10
20
90
40
50
70 80
60
30

Assembly Instrucons MA-100156
TB30 Conveyor
18 / 72
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3.1.6 ComponentsTB30tandemconveyorenddrive
Item Descripon
10 Chassis
20 Gliding plate (oponal)
30 Lateral guide
40 End secon (tension roller-Ø30)
50 Drive unit
60 Motor (Brushless DC motor)
70 Controller
80 Conveyor belts
90 Conveyor connecon
100 Motor/controller connecon cable
10
20
90
40
100
50
80
70
60
30
Figure6 Exploded view of the TB30 tandem conveyor with end drive

Assembly Instrucons MA-100156
TB30 Conveyor
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3.1.7 ComponentsTB30singlebeltconveyorenddrivepivotable
Item Descripon
10 Chassis
20 Gliding plate (oponal)
30 Lateral guide
40 End secon (tension roller-Ø30 or Ø40 for cleated belts)
50 Motor (Brushless DC motor)
60 Drive unit pivotable
70 Controller
80 Conveyor belt
90 Motor/controller connecon cable
Figure7 Exploded view of the TB30 single belt conveyor with end drive pivotable
10
20
90
40
50
70
80
60
30

Assembly Instrucons MA-100156
TB30 Conveyor
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www.montech.com [e-mail] [phone]
3.1.8 ComponentsTB30dualbeltconveyorenddrivepivotable
Item Descripon
10 Chassis
20 Gliding plate
30 Lateral guide
40 End secon (tension roller-Ø30)
50 Motor (Brushless DC motor)
60 Drive unit pivotable
70 Controller
80 Conveyor belt
90 Motor/controller connecon cable
Figure8 Exploded view of the TB30 dual belt conveyor with end drive pivotable
10
20
90
40
50
70
80
60
30