Montech UL40 User manual

ASSEMBLY INSTRUCTIONS
90° DEFLECTION UL40 / UR40
Part of the transport system LT40
BA
-
100
14
8
Translation of the original assembly instructions, Copyright by Montech AG
English, Edition 2017/02

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
2
Content
1General____________________________________________________________________________ 4
1.1 Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B _________________ 4
1.2 List of essential health and safety requirements pursuant to Directive 2006/42/EC, Annex I, Section 1 __ 5
1.3 Information about this manual__________________________________________________________________ 7
1.4 Explanations of symbols _______________________________________________________________________ 7
1.5 Limited liability _______________________________________________________________________________ 8
1.6 Copyright____________________________________________________________________________________ 8
1.7 Warranty terms and conditions _________________________________________________________________ 8
1.8 Customer service _____________________________________________________________________________ 8
2Transport, packaging and storage____________________________________________________ 9
2.1 Arbitrary and improper transport _______________________________________________________________ 9
2.2 Transport inspection __________________________________________________________________________ 9
2.3 Packaging ___________________________________________________________________________________ 9
2.4 Handling of packaging material________________________________________________________________ 10
2.5 Storing the packages_________________________________________________________________________ 10
3Safety ____________________________________________________________________________ 11
3.1 Intended use________________________________________________________________________________ 11
3.2 Safety instructions ___________________________________________________________________________ 11
3.3 Warranty ___________________________________________________________________________________ 11
3.4 Changes and modifications to the equipment ___________________________________________________ 12
3.5 Personal protective equipment ________________________________________________________________ 12
3.6 Personnel requirements ______________________________________________________________________ 12
4Specifications _____________________________________________________________________ 13
4.1 Technical Data_______________________________________________________________________________ 13
4.2 Identification plate___________________________________________________________________________ 13
4.3 Dimension drawing __________________________________________________________________________ 14
4.5 Compatibility________________________________________________________________________________ 15
4.6 Principle of operation ________________________________________________________________________ 16
4.7 Control principle_____________________________________________________________________________ 17
5Commissioning ____________________________________________________________________ 18
5.1 Improper installation and commissioning _______________________________________________________ 18
5.2 Installation __________________________________________________________________________________ 19
5.3 Description of connections____________________________________________________________________ 21

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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6Maintenance______________________________________________________________________ 22
6.1 Maintenance plan____________________________________________________________________________ 22
6.2 Spare parts _________________________________________________________________________________ 23
6.3 Replacing the toothed belts___________________________________________________________________ 23
7Disassembly and disposal __________________________________________________________ 25
7.1 Improper disassembly________________________________________________________________________ 25
7.2 Disposal ____________________________________________________________________________________ 26

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
4
1General
1.1 Installation declaration according to EC Machinery-Directive 2006/42/EG, Annex II B
Manufacturer:
Montech AG, Gewerbestrasse 12, CH–4552 Derendingen Tel. [phone], Fax [phone]
E-Mail: [e-mail], Internet: www.montech.com
Herewith declares that the partly completed machine: Deflection 90oUR40/ UL40
Item No. 66158 / 66174 / 66183 / 66156 / 66175 / 66185 / 66781 / 66782
meets the basic safety and health requirements of Annex I of EC machinery-Directive 2006/42/EC. In addition, the
partly completed machine also complies with the requirements of:
relevant EC Directives:
Applied harmonized standards:
EC Machinery-Directive 2006/42/EC
Low Voltage Directive 2006/95/EC
EN ISO 12100:2010
The technical documentation for this partly completed machine was created according to Annex VII Part B.
Montech AG agrees to electronically transmit these technical documents to state authorities upon request.
Authorized person for preparing the
technical documentations: G. Aloisi Montech AG
Director Sales
CH-4552 Derendingen
The commissioning of the partly completed machine is prohibited until the partly completed machine has been
installed in a machine that is in compliance with the requirement of the EC Machinery-Directive, and the EC
Declaration of Conformity according to Annex II A is on hand.
City, Date
Company
Address
Derendingen, 2017/03/01
Montech AG
Gewerbestrasse 12
CH–4552 Derendingen
Authorized persons (signatures)
Names of the undersigned
Positions of the undersigned
Daniel Pauli Gianluca Aloisi
CEO Director Sales

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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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 
 
1.1.2. Principles of safety integration 
 
1.1.3. Materials and products 
 
1.1.4. Lighting 
 
1.1.5. Design of machinery to facilitate its handling 
 
1.1.6. Ergonomics 
 
1.1.7. Operating positions 
 
1.1.8. Seating 
 
1.2.
Control and systems
1.2.1. Safety and reliability of control systems 
 
1.2.2. Control devices 
 
1.2.3. Starting 
 
1.2.4. Stopping 
 
1.2.4.1. Normal stop 
 
1.2.4.2. Operational stop 
 
1.2.4.3. Emergency stop 
 
1.2.4.4. Assembly of machinery 
 
1.2.5. Selection of control or operating modes 
 
1.2.6. Failure of the power supply 
 
1.3.
Protection against mechanical hazards
1.3.1. Risk of loss of stability 
 
1.3.2. Risk of break-up during operation 
 
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 variations in operating conditions 
 
1.3.7. Risks related to moving parts 
 
1.3.8. Guards or protective 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 
 

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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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 
 
1.4.2.1. Fixed guards 
 
1.4.2.2. Interlocking movable guards 
 
1.4.2.3. Adjustable guards restricting access 
 
1.4.3. Special requirements for protective devices 
 
1.5. Risks due to other hazards
1.5.1. Electricity supply 
 
1.5.2. Static electricity 
 
1.5.3. Energy supply other than electricity 
 
1.5.4. Errors of fitting 
 
1.5.5. Extreme temperatures 
 
1.5.6. Fire 
 
1.5.7. Explosion 
 
1.5.8. Noise 
 
1.5.9. Vibrations 
 
1.5.10. Radiation 
 
1.5.11. External radiation 
 
1.5.12. Laser radiation 
 
1.5.13. Emissions of hazardous materials and substances 
 
1.5.14. Risk of being trapped in a machine 
 
1.5.15. Risk of slipping, tripping or falling 
 
1.5.16. Lightning 
 
1.6. Maintenance
1.6.1 Machinery maintenance 
 
1.6.2. Access to operating positions and servicing points 
 
1.6.3. Isolation of energy sources 
 
1.6.4. Operator intervention 
 
1.6.5. Cleaning of internal parts 
 
1.7.
Informati
on
1.7.1. Information and warnings on the machinery 
 
1.7.1.1. Information and information devices 
 
1.7.1.2. Warning devices 
 
1.7.2. Warning of residual risks 
 
1.7.3. Marking of machinery 
 
1.7.4. Instructions 
 
1.7.4.1. General principles for the drafting of instructions 
 
1.7.4.2. Contents of the instructions 
 
1.7.4.3. Sales literature 
 
1.7.5 Instruction manual 
 

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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1.3 Information about this manual
This manual contains the data and information required for commissioning and maintenance of the 90° deflection
UL40 / UR40 and is only valid for the following versions.
90° Deflection UL40 / UR40 Item. No. 66158 / 66174 / 66183 / 66156 / 66175 / 66185 / 66781 / 66782
Prior to commencing any work on the machine, personnel involved 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 Explanations 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-100148 (2017/02)
90° Deflection UL40 / UR40
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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.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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2Transport, packaging and storage
2.1 Arbitrary and improper transport
CAUTION
!
Damage caused by unauthorized and improper transport!
Transport by untrained personnel can cause considerable damage to property.
Unloading on delivery and internal transport may only be carried out by trained
personnel.
Do not step under suspended loads.
Use means of transport properly.
Always place the component on a flat surface to prevent it from tipping.
2.2 Transport inspection
To check the delivery immediately upon receipt for completeness and transport damage.
In case of externally visible transport damage, proceed as follows:
Do not accept delivery or only under reserve
Note the extent of damage on the transport documents or on the carrier's delivery bill
Initiate complaint
NOTE!
Complain about any defect immediately.
Claims for damages can only be made within the complaint periods.
2.3 Packaging
The individual articles are packed according to the expected transport conditions. Only environmentally friendly
materials were used for packaging.
The packaging should protect the individual components from transport damage, corrosion and other damage
until assembly. Therefore, do not destroy the packaging and remove it only shortly before assembly.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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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. 55%
If machines are stored longer than three months, check the general condition of all parts and the
packaging regularly.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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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 Intended use
The 90° deflection is used to deflect the workpiece carriers in the LT40 transfer system. The 90° deflection may
only be used for the LT40 transfer system intended for this purpose. Furthermore, only the associated workpiece
carriers may be used, as described in chapter 4.5.
Proper use also includes compliance with all the information in this manual.
Any use beyond the intended use or any other use is considered misuse.
3.2 Safety instructions
WARNING!
The safety instructions 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
The 90° deflection is intended for the transport of Montech plastic workpiece carriers. They are, for example, not
suitable for the transport of other workpiece carriers or other solids. Any other or additional use is considered
improper and will void the warranty.
WARN
I
NG!
Danger in case of misuse!
Misuse of the 90° deflection can lead to dangerous situations. Refrain from the following
uses:
Operation in air containing smoke, dust, steam or solvents.
Use in hazardous areas. (flammable gases, vapors or dust).
Use in humid environment. (Rain or dew).
Do not exceed maximum permissible total weight.
Connection and commissioning or service work without qualified personnel.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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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.
While working, always wear the personal protective equipment appropriate for the specific work
Safety shoes
To protect against heavy dropped parts and slipping on slippery surfaces.
Hairnet
Wear hairnet while 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 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.
Qualified electrician
Due to their technical training, knowledge and experience as well as knowledge of the relevant standards and
regulations, skilled electricians can carry out work on electrical systems and to independently recognize and avoid
possible dangers.
The qualified electrician is specially trained for the working environment in which he/she works and knows 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.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
13
4Specifications
4.1 Technical Data
Ambient temperature +10 to +40 [°C]
Rel. humidity < 85 % (without condensation)
Air purity normal workshop atmosphere
Sound pressure level < 60 dBA
Load capacity 1 workpiece carrier WT40
(For load capacity see chapter 4.5 Compatibility)
Drive via the conveyor belt ST40
4.2 Identification plate
A type plate is attached to the 90° deflection. The position of the type plate is shown in Figure 1. In case of
customer inquiries, the data on the type plate must be communicated.
Figure 1: Position of identification plate UL40 / UR40
Figure 2: Identification plate
Identification plate
item no. name
year of production
serial number

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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4.3 Dimension drawing
Figure 3: Dimension drawing UL40 / UR40
Typ
e
UL40
-
200 / UR40
-
200
UL40
-
240 / UR40
-
240
UL4
0
-
320 / UR40
-
320
Item
N
o
.
66158 / 66156
66174 / 66175
66781 / 66782
66183 / 66185
A [mm] 201 241 321
B [mm] 201 241 321
C [mm] 131 134* 131
* for article 66781 and 66782: C = 131mm

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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4.5 Compatibility
The 90° deflection is designed for workpiece carriers from Montech AG. The following table shows the
compatibility of workpiece carriers with the respective 90° deflection.
Size 90° Deflection Workpiece carrier WT40 max. load
200x200 66158 / 66156 64632 7 kg
200x240 66158 / 66156 64636 8.4 kg
240x240 66174 / 66175 64644 8.4 kg
240x320 66174 / 66175
66781 / 66782 64646 11.2 kg
320x320 66183 / 66185 64638 11.2 kg
320x480 66183 / 66185 64641 16.8 kg
The maximum permissible workpiece height (dimension H; Figure 4) is equal to the width of the
workpiece carrier.
The maximum center of gravity height (dimension SH; Figure 4 ) of the workpiece above the pallet is half
the pallet length:
The center of gravity of the workpiece must be located within the following area (dimension A x B; Figure
4) in the center
dimension of workpiece carrier[mm] H [mm] SH [mm] A B
200x200 200 100 50 50
200x240 200 120 50 90
240x240 240 120 90 90
240x320 240 160 90 170
320x320 320 160 170 170
320x480 320 240 170 330
Figure 4: Dimensions workpiece on workpiece carrier

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
16
4.6 Principle of operation
A separating stopper must be mounted before the 90° deflection, as the deflection is not accumulative. To check
whether the WT has passed the deflection, an inductive sensor (log-off sensor) with the sensor holder must be
mounted at the exit of the deflection.
Figure 5: Mounting situation 180° deflection
Type UL40-200 / UR40-200 UL40-240 / UR40-240 UL40-320 / UR40-320
WT-200x200 WT-200x240 WT-240x240 WT-240x320 WT-320x320 WT-320x480
A [mm] 7 7 7 14 14 14
B [mm] 118 158 163 214 214 374
C [mm] 12 12 12 19 19 19
The installation of the finger guard is recommended. For further information, please refer to the installation
instructions of the ST40 BA-100144 conveyor belt.
Minimum length of the cross belt for a WT: min L Crossband = Length WT + D + 222mm
Minimale Länge des Querbands ab 2 WT’s: min L Crossband = Quantity WT x Length WT + D+222mm
NOTE
!
The deflection is driven by the drive of the ST40 conveyor belt. Please note that the
conveyor belt is equipped with the cross link Q10 at the installation point of the deflection.
The definition of Q10 is described in the installation instructions of the conveyor belt ST40
BA-100144.
separator
with check-in sensor check-out sensor
min. L transversal conveyor
separator with
check-in sensor
drive
finger protection device (optional)
drive
Check-out sensor (optional
necessary if more than 2 WT’s
are on transversal conveyor)

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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4.7 Control principle
CAUTION
!
The 90° deflection is not accumulation capable. It is essential to ensure that no workpiece
carrier is in the deflection before another workpiece carrier is to be deflected.
Figure 6: Flowchart UL90 / UR90
Figure 7: Flowchart VL40 / VR40
N1: Proximity switch separating stop
N2: Proximity switch (Exit sensor)
Basic position:
Separating stop: above
CAUTION!
Separating stop and sensor holder with sensor not included in the scope of delivery of the
90° Deflection. It is available as accessory. For further information, refer to the catalog or the
assembly instructions of the conveyor ST40 BA-100144.
separator

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
18
5Commissioning
5.1 Improper installation and commissioning
WARN
I
NG!
Improper installation and commissioning can lead to serious injuries and considerable
material damage.
Ensure sufficient freedom of assembly before starting work.
Handle open, sharp-edged components with care.
Pay attention to order and cleanliness at the installation site! Loose components
and tools lying on top of or around each other are sources of accidents.
Pay attention to order and cleanliness at the installation site! Loose components
and tools lying on top of or around each other are sources of accidents.
Secure components so that they do not fall or overturn.
Before commissioning, please note the following:
Ensure that all installation work has been carried out and completed according to
the information and instructions in this manual.
Ensure that there are no persons in the danger zone.
DANGER
!
Work on the electrical supply and control may only be carried out by a qualified electrician.
WARN
I
NG!
Installation work may only be carried out by a qualified technician.
CAUTION
!
Caution is required when working with pneumatic systems. Loose hoses can pose a hazard
to the eyes due to uncontrolled movements.
Safety glasses
Wear safety goggles to protect the eyes when working with compressed air.

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
19
5.2 Installation
The installation of the 90° UL40 / UR40 deflector in the ST40 conveyor belt must be carried out according to the
following steps:
Loosen the screw pos. 10 or the special screw
Pos. 20
Loosen the two screws pos. 30 and remove the clamping
jaw pos. 40
Remove the two tabs pos. 50
The drive roller of ST40 pos. 60 must be removed
Tool: Allen key SW4; SW5
Figure 8: Installation 1
Mount the snap rings pos. 70 on the drive roller in the
grooves provided for this purpose using assembly pliers.
The snap rings serve to guide the toothed belt laterally.
Tool: Recommendation: Assembly pliers
Make of Knipex*
Item No. 4510710
* Can be purchased directly from the manufacturer
Figure 9: Installation 2
Remove screws pos. 80 and clamping jaws pos. 90 of the
90° deflection pos. 100.
Insert deflection 90° between the chassis of the ST40 and
place on dovetail guide.
Tool: Allen key SW4
Figure 10: Installation 3
10
20
30
40
50
70
60
80
100
90
60

Assembly instructions BA-100148 (2017/02)
90° Deflection UL40 / UR40
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Position deflection 90° with a distance of 85
mm to the chassis front side.
Mount screw pos. 80 and clamping jaws pos. 90 and fix
deflection 90°.
Tool: Allen Key SW4
Tightening torque: 6 Nm
Figure 11: Installation 4
1. reassemble tab pos. 50
Insert drive roller, pos. 60, into the toothed belts and
fasten it in the bracket with the screw, pos. 10 or special
screw, pos. 20.
2. reassemble tab pos. 50.
Mount screw pos. 10 or special screw pos. 20 of the
second bracket.
To adjust the position of the drive or deflection roller, use
screw pos. 10 or screw pos. 20
Tool: Allen key SW4; SW5
Tightening torque: 6 Nm
Note:
In principle, the toothed belt is not pretensioned. The position
of the drive and deflection roller must be set so that the
workpiece carriers are transported without the toothed belt
skipping. Furthermore, it must be ensured that both toothed
belts on the upper side of the ST40 are of the same length or
have the same number of teeth between the drive and
deflection roller. The drive and deflection rollers must be
aligned perpendicular to the chassis.
Figure 12: Installation 5
Adjust the position of the deflection roller using adjusting
screws Item 160. The position and alignment of the
deflection roller must be set so that the toothed belt runs
between the snap rings. In principle, the toothed belt is
not pretensioned. The position of the deflection roller
must be set so that the workpiece pallets are transported
without the toothed belt jumping. It must also be ensured
that the toothed belt is of equal length on the top and
bottom side. The deflection roller must be aligned
perpendicular to the chassis of the ST40.
Tip: At the beginning, the deflection roller must be moved to
the front-end position. This assumes a clearly defined position.
By tightening the screw (pos. 160) on both sides (same number
of turns), the guide roller is pulled backwards evenly.
Tool: Allen key SW4
Figure 13: Installation 6
80
90
50
10
160
20