Montech MonTurn TB40 User manual

ASSEMBLY INSTRUCTIONS
CONTROL UNIT MONTURN
TB40
BA-100155
Translation of the original assembly instructions, Copyright by Montech AG
English, Edition 02/2020

Assembly Instructions BA-100155
Control unit MonTurn
3
CONTENTS
1. General .............................................................................................................................................. 5
1.1 Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B.......................... 5
1.2 List of essential health and safety requirements pursuant to Directive 2006/42/EC, Annex I, Section 1
6
1.3 Information 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
4Mechanical construction Control unit MonTurn .............................................................................. 14
4.1 Technical Data........................................................................................................................................ 14
4.2 General information ............................................................................................................................... 14
4.3 Handling ................................................................................................................................................. 15
4.4 Dimension drawing................................................................................................................................. 16
4.5 Nameplate.............................................................................................................................................. 17
5Commissioning ................................................................................................................................ 18
5.1 Installation and commissioning .............................................................................................................. 18
5.2 Assembly and Disassembly .................................................................................................................... 19
5.3 Fastening instructions ............................................................................................................................ 19
5.4 Electrical connection MonTurn............................................................................................................... 20
5.4.1 Version overview.................................................................................................................................... 20
5.4.2 Cable set MonTurn................................................................................................................................. 21
5.4.2.1 Connecting cable power TB40............................................................................................................. 21
5.4.2.2 Connecting cable power MonTurn ...................................................................................................... 21
5.4.2.3 Connecting cable signal TB40 <–> MonTurn ...................................................................................... 22
5.4.3 Turn on and turn off behavior................................................................................................................ 22
5.5 Operation mode for MonTurn................................................................................................................ 23
5.6 Speed presetting via analog setpoint (rotary switch) ............................................................................ 23

Assembly instructions BA-100155
Control unit MonTurn
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6Maintenance .................................................................................................................................... 24
6.1 Maintenance plan ................................................................................................................................... 24
6.2 Spare parts ............................................................................................................................................. 24
6.3 Repairs.................................................................................................................................................... 25
7Disassembly and Disposal ............................................................................................................... 26
7.1 Improper disassembly ............................................................................................................................ 26
7.2 Disposal .................................................................................................................................................. 27

Assembly instructions BA-100155
Control unit MonTurn
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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
Ê
Met for the scope of the partly completed machine
Ê
1.1.
General
1.1.1.
Definitions

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1.1.2.
Principles of safety integration
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1.1.3.
Materials and products
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1.1.4.
Lighting
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
1.1.5.
Design of machinery to facilitate its handling
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1.1.6.
Ergonomics
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1.1.7.
Operating positions
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1.1.8.
Seating
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1.2.
Control and systems
1.2.1.
Safety and reliability of control systems
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1.2.2.
Control devices
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1.2.3.
Starting
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1.2.4.
Stopping
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1.2.4.1.
Normal stop
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1.2.4.2.
Operational stop
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1.2.4.3.
Emergency stop
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1.2.4.4.
Assembly of machinery
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1.2.5.
Selection of control or operating modes
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
1.2.6.
Failure of the power supply
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1.3.
Protection against mechanical hazards
1.3.1.
Risk of loss of stability
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1.3.2.
Risk of break-up during operation
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1.3.3.
Risks due to falling or ejected objects
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1.3.4.
Risks due to surfaces, edges or angles
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1.3.5.
Risks related to combined machinery
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1.3.6.
Risks related to variations in operating conditions
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1.3.7.
Risks related to moving parts
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
1.3.8.
Guards or protective devices designed to protect against risks
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
1.3.8.1.
Moving transmission parts
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
1.3.8.2.
Moving parts involved in the process


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1.3.9
Risk of uncontrolled movements
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


Assembly instructions BA-100155
Control unit MonTurn
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Not relevant for this device

To be met by the system integrator for the (complete) machine

Met for the scope of the partly completed machine

1.4.
Required characteristics of guards and protective devices
1.4.1.
General requirements
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

1.4.2.
Special requirements for guards
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1.4.2.1.
Fixed guards
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
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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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
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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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
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1.5.3.
Energy supply other than electricity

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
1.5.4.
Errors of fitting

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1.5.5.
Extreme temperatures
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1.5.6.
Fire
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1.5.7.
Explosion
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1.5.8.
Noise
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1.5.9.
Vibrations
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1.5.10.
Radiation
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1.5.11.
External radiation
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1.5.12.
Laser radiation
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1.5.13.
Emissions of hazardous materials and substances
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1.5.14.
Risk of being trapped in a machine
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1.5.15.
Risk of slipping, tripping or falling
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1.5.16.
Lightning
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
1.6.
Maintenance
1.6.1
Machinery maintenance
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1.6.2.
Access to operating positions and servicing points
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1.6.3.
Isolation of energy sources
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1.6.4.
Operator intervention
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1.6.5.
Cleaning of internal parts
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1.7.
Information
1.7.1.
Information and warnings on the machinery
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1.7.1.1.
Information and information devices
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1.7.1.2.
Warning devices
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1.7.2.
Warning of residual risks
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1.7.3.
Marking of machinery
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1.7.4.
Instructions
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1.7.4.1.
General principles for the drafting of instructions
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1.7.4.2.
Contents of the instructions
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1.7.4.3.
Sales literature
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
1.7.5
Assembly instructions
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Assembly instructions BA-100155
Control unit MonTurn
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1.3 Information in this manual
This manual contains data and information necessary to install and maintain the MonTurn.
Prior to commencing any work on the machine, personnel must have thoroughly read and understood this
manual. Following all safety instructions and directions in this manual is the foundation of safe work.
Any illustrations in this manual are meant for general understanding and may differ from the actual configuration.
1.4 Explanation of symbols
Safety instructions in this manual are marked by symbols. These safety instructions are introduced by signal
words that express the extent of the danger. Absolutely follow these instructions and act carefully to avoid
accidents, bodily injuries or property damage.
DANGER!
This combination of symbol and signal word indicates a directly dangerous situation that
could result in death or serious injury if it is not avoided.
WARNING!
This combination of symbol and signal word indicates a potentially dangerous situation that
could result in serious injury if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation that
could result in minor injury if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation that
could cause property damage if it is not avoided.
NOTE!
This symbol points out useful hints and recommendations as well as information for efficient
and uninterrupted operation.

Assembly instructions BA-100155
Control unit MonTurn
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1.5 Limited liability
All information and instructions in this manual have been compiled with 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.

Assembly instructions BA-100155
Control unit MonTurn
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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 MonTurn on a level surface.
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.

Assembly instructions BA-100155
Control unit MonTurn
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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.

Assembly instructions BA-100155
Control unit MonTurn
12
3Safety
This chapter provides an overview of all necessary safety aspects with regard to the personnel and a safe and
trouble-free operation.
3.1 Use for intended purpose
The Control unit MonTurn is intended for controlling the TB40 conveyor. The direction of rotation (conveying
direction) and the speed (conveying speed) must be specified by the Control unit MonTurn. For example, it is not
suitable for operating other conveyor belts or devices of any kind.
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 MonTurn 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 MonTurn 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.

Assembly instructions BA-100155
Control unit MonTurn
13
3.4 Changes and modifications to the equipment
In order to avoid hazards and to ensure optimum performance, the unit must not be subjected to any
modifications, additions or conversions that have not been expressly approved by the manufacturer.
3.5 Personal protective equipment
The wearing of personal protective equipment is required during work to minimize health hazards.
Safety shoes
To protect against heavy dropped parts and slipping on slippery surfaces.
Hairnet
Hair nets must be worn when working on machines with rotating parts.
3.6 Personnel requirements
The different tasks described in this manual pose different requirements for the qualification of the persons
assigned to perform the tasks.
For all work, only allow persons to perform the work who can be expected to perform it reliably. Persons whose
ability to respond is impaired, e.g. due to drugs, alcohol or medications, shall not be allowed to work on the
machine.
What follows is a list the personnel qualifications for the different tasks:
Machine operator
The machine operator has been instructed by the system operator regarding the tasks assigned to him/her and
the potential hazards in case of improper behavior. The machine operator may perform tasks going beyond
operation in the normal operation mode only if this task has been explicitly assigned by the system operator.
Skilled electrician
A skilled electrician is, due to his/her technical training, knowledge and experience, as well as knowledge of the
applicable standards and regulations, able to perform work on electrical systems and to independently recognize
potential dangers and avoid hazards.
The skilled electrician has been trained specifically for his/her work environment and is familiar with the relevant
standards and regulations.
Skilled personnel
The skilled personnel is, due to their technical training, knowledge and experience, as well as knowledge of the
applicable standards and regulations, able to perform work assigned to them and to independently recognize
potential dangers and avoid hazards.
Manufacturer
Certain work may only be performed by Montech AG’s skilled personnel. Other personnel shall not be
authorized to perform this work. Please contact our Customer Service to have such work performed.

Assembly instructions BA-100155
Control unit MonTurn
14
4Mechanical construction Control unit MonTurn
4.1 Technical Data
Ambient temperature +10 to +40°C
Rel. Humidity <95% (without condensation)
Air purity normal workshop atmosphere
Protection category of components IP 50
Rated voltage 24 V DC
Permitted supply voltage 20 … 28 V DC
Rated current 0.5 A
Inverse-polarity protection no
Output signal analog 0-10V
Overload protection yes
Material Casing aluminum
Cap stainless steel
Control knop aluminum, anodized natural / plastic
Electronic assembly plastics / fiber-reinforced plastics / metal
Cable polyurethane / copper
Warranty
3 Years
4.2 General information
Function Direction of rotation (transport direction) set via rotary switch
Stepless speed adjustment via rotary switch
Terminal connection method
Signal and power are separated
Metric connector for power and signal
MonTurn incl. cable set available
24 VDC switching power supply available as accessory

Assembly instructions BA-100155
Control unit MonTurn
15
4.3 Handling
Figure 1: MontTurn front view
Direction Velocity
The direction of rotation (transport direction) can be
set via the left-hand rotary switch (positive and
negative).
The conveying speed can be continuously adjusted
from 0-100% using the right-hand rotary switch.
The maximum permissible load on the conveyor belt is
independent of the conveying speed.
The effective maximum acceleration via the analog
input is limited by the acceleration and deceleration
value of the drive on the conveyor belt. The
acceleration value can be changed via the operating
and parameterizing unit MonTouch. See assembly
instructions for the operating and parameterizing unit
MonTouch BA-100157.

Assembly instructions BA-100155
Control unit MonTurn
16
4.4 Dimension drawing
Figure 2: Dimension drawing MonTurn
Figure 3: Dimension drawing MonTurn connected with conveyor TB40
Conveying direction
towards drive only
min.
max.

Assembly instructions BA-100155
Control unit MonTurn
17
4.5 Nameplate
Figure 4: Nameplate MonTurn
Ref.no.
Serial number
Device designation
Producer year
Producer

Assembly instructions BA-100155
Control unit MonTurn
18
5Commissioning
5.1 Installation and commissioning
WARNING!
Improper installation can result in injury!
Improper installation and commissioning can result in severe injuries and considerable
property damage.
– Make sure there is enough space to perform the installation before starting the
work.
– Handle open, sharp-edged components with care.
– Keep installation space clean and orderly! Components and tools that are lying
around or carelessly stacked pose an accident hazard.
– Install components properly. Follow the specified bolt torques.
– Secure components against dropping or falling over.
Before commissioning:
– Make sure that all installation work has been performed and completed according
to the specifications and instructions in this manual.
– Make sure there are no persons in the hazard zone.
DANGER!
Work on the power hook-up and controller must exclusively be performed by a skilled
electrician.
WARNING!
Only use skilled personnel to perform installation work.

Assembly instructions BA-100155
Control unit MonTurn
19
5.2 Assembly and Disassembly
WARNING!
Do not use oils and greases with molybdenum disulfide or other high-pressure additives, or
antifriction pastes. Use PU-compatible lubricants such as Vaseline or silicone spray.
5.3 Fastening instructions
Figure 5: Fastening instructions side view
The control unit MonTurn can be mounted directly to the chassis of the TB40 conveyor via the fastening
component.
Required tool: Allen key SW4
Lateral profile conveyor TB40

Assembly instructions BA-100155
Control unit MonTurn
20
5.4 Electrical connection MonTurn
5.4.1 Version overview
Ref.no. Figure Designation Shipment
65670 Control unit MonTurn •MonTurn
66342
Control unit MonTurn
incl. cable set, 5m
•MonTurn
•Cable set, consisting of:
Connecting cable power TB40, 5m
Connecting cable power MonTurn, 5m
Connecting cable signal TB40 <->
MonTurn, 2m
66571
Control unit MonTurn
incl. cable set, 10m
•MonTurn
•Cable set, consisting of:
Connecting cable power TB40, 10m
Connecting cable power MonTurn, 10m
Connecting cable signal TB40 <->
MonTurn, 2m
Power cable TB40 (5 / 10 m)
Power cable MonTurn (5 / 10 m)
Signal cable (2 m)
Figure 6: Cabling MonTurn <-> TB40

Assembly instructions BA-100155
Control unit MonTurn
21
5.4.2 Cable set MonTurn
NOTE!
The optics of the cables can vary depending upon manufacturer.
5.4.2.1 Connecting cable power TB40
*The motor-integrated brake chopper with external ballast resistor has the task
of converting the unneeded energy on heavily inclined, non-self-locking
conveyor belts. If the factory-set voltage threshold of 27 V is exceeded, the
external resistor is switched on.
Chopper current = max. 10 A
Recommended braking resistor ≥3.75 Ω.
5.4.2.2 Connecting cable power MonTurn
3 pin power cable (M8)
Pin 1 brown Up (V+) Power supply +24V
Pin 3 blue GND (V-) Power-GND
Pin 4 black PE Protective conductor
CAUTION!
The polarity of the connections on the connecting cable powerTB40 must be observed when
connecting to a power supply unit. The control unit MonTurn is NOT equipped with reverse
polarity protection. Incorrect connection will result in a defect in the unit.
NOTE!
The 24 VDC/25A supply must be provided. The Mean Well SDR-480-24 switching power
supply unit is recommended; available from Montech under part no. 522208.
If MonTurn and conveyor belt are not connected to the same supply, an equipotential
bonding between the two ground connections must be ensured.
3+PE-pin power cable (M12)
Pin 1 black Nr.1 or brown Up (V+) Power supply +24V
Pin 2 black Nr.2 or grey Ballast Ballast resistor connection*
Pin 3 black Nr.3 or black GND (V-) Power- / signal-GND
PE green/yellow PE Protective conductor
Figure 8: Contact picture
power cable MonTurn
Figure 7:
Contact picture power cable