R. Beck Maschinenbau EXAKT HD User manual

TRANSLATION OF THE ORIGINAL VERSION
Reinhold Beck Maschinenbau GmbH
Im Grund 23 | DE -72505 Krauchenwies
Tel.: [phone] / 962 978 - 0 | Fax: [phone] / 962 978 - 90
E-Mail: [e-mail] | Web: https://www.beck-maschinenbau.de
Operating Manual
EXAKT HD
Heavy-duty roller conveyors with and without length stop system
and two available roller conveyor widths (S = 600 mm / W = 1150 mm)
Types for EXAKT HD:
A, C and E

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Table of contents
1 Introduction..................................................................................................................................... 5
1.1 Legal notice............................................................................................................................................ 5
1.2 Illustrations............................................................................................................................................ 5
2 Symbols ........................................................................................................................................... 5
2.1 General Symbols.................................................................................................................................... 5
2.2 Symbols in Safety Instructions............................................................................................................... 6
3 General............................................................................................................................................ 7
3.1 Features................................................................................................................................................. 7
3.2 Application............................................................................................................................................. 7
3.3 Target group and previous experience.................................................................................................. 7
3.4 Requirements for the operators............................................................................................................ 7
3.5 Accident prevention .............................................................................................................................. 8
3.6 General safety regulations..................................................................................................................... 8
4 Safety............................................................................................................................................... 9
4.1 Basic safety instructions ........................................................................................................................ 9
4.2 Application area and intended use........................................................................................................ 9
4.3 Improper use ......................................................................................................................................... 9
4.4 Consequences in case of disregard...................................................................................................... 10
4.5 Conversions and modifications of the roller conveyor........................................................................ 10
4.6 Supplementary safety equipment ....................................................................................................... 10
4.7 Personal protective equipment........................................................................................................... 10
4.8 Residual risks ....................................................................................................................................... 11
4.9 Observe the Environmental Protection Regulations ........................................................................... 12
4.10 Organisational measures..................................................................................................................... 12
4.11 Personnel selection and qualification - basic duties............................................................................ 12
5 Types and product description...................................................................................................... 13
5.1 EXAKT HD C.......................................................................................................................................... 13
5.2 EXAKT HD A.......................................................................................................................................... 14
5.2.1 Material stop for EXAKT HD A.......................................................................................................................................... 15
5.3 EXAKT HD E.......................................................................................................................................... 15
5.3.1 Material stop for EXAKT HD E.......................................................................................................................................... 15
6 Technical specifications................................................................................................................. 16
6.1 Manufacturer ...................................................................................................................................... 16
7 Transport to the installation site................................................................................................... 17
7.1 Unloading with a forklift truck............................................................................................................. 17
7.2 Check delivery condition ..................................................................................................................... 17
7.3 Unpacking and placing......................................................................................................................... 18

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7.4 Transport to the place of use .............................................................................................................. 18
7.5 Requirements for the installation site................................................................................................. 18
7.6 Temporary storage .............................................................................................................................. 18
7.6.1 Short term storage .......................................................................................................................................................... 18
7.6.2 Long term storage ........................................................................................................................................................... 18
7.7 Lashing on a transport vehicle............................................................................................................. 19
8 Installation..................................................................................................................................... 20
8.1 Lifting the roller conveyor off the transport pallet.............................................................................. 20
8.2 Moving the roller conveyor to the place of use .................................................................................. 20
8.3 Aligning and levelling the roller conveyor ........................................................................................... 21
8.4 Connecting roller conveyor segments together .................................................................................. 21
8.5 Anchoring in the ground...................................................................................................................... 22
8.6 Installing the magnetic tape for position measurement ..................................................................... 23
8.6.1 Magnetic tape installation for EXAKT HD A and EXAKT HD E........................................................................................... 23
8.7 Connecting the roller conveyor (EXAKT A only) .................................................................................. 23
8.8 Referencing the stop system (EXAKT HD A and E only)....................................................................... 24
8.9 Operational readiness of the roller conveyor (EXAKT A only) ............................................................. 24
9 Operating the stop system............................................................................................................ 24
9.1 Material stop for EXAKT A ................................................................................................................... 24
9.2 Material stop for EXAKT E.................................................................................................................... 25
9.3 Setting the material stop height.......................................................................................................... 25
10 Loading the roller conveyor .......................................................................................................... 26
10.1 Loading with a forklift truck................................................................................................................. 26
10.1.1 Loading models EXAKT HD A and EXAKT HD E................................................................................................................. 26
10.1.2 Loading model EXAKT HD C ............................................................................................................................................. 26
10.2 Loading with a crane............................................................................................................................ 26
11 Troubleshooting ............................................................................................................................ 27
12 Maintenance and repair................................................................................................................ 28
13 Supplementary documents........................................................................................................... 28
13.1 EXAKT HD A.......................................................................................................................................... 28
13.2 EXAKT HD E.......................................................................................................................................... 28
14 Disassembly and scrapping ........................................................................................................... 29
15 Machine card................................................................................................................................. 30
16 Options and accessories................................................................................................................ 31
16.1 Accessories for all models ................................................................................................................... 31
16.2 Accessories for EXAKT HD A ................................................................................................................ 31
EU - Declaration of Conformity ............................................................................................................. 32

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List of figures
Figure 1: Roller conveyor EXAKT HD C .................................................................................................................. 13
Figure 2: Roller and measuring conveyor EXAKT HD A ......................................................................................... 14
Figure 3: Material stop for EXAKT HD A ................................................................................................................ 15
Figure 4: Material stop for EXAKT HD E ................................................................................................................ 15
Figure 5: Lifting down from the transport vehicle with a forklift truck ................................................................ 17
Figure 6: Lifting the roller conveyor off the transport pallet ................................................................................ 20
Figure 7: Moving the roller conveyor to the place of use..................................................................................... 20
Figure 8: Height adjustment ................................................................................................................................. 21
Figure 9: Connecting segments (front side).......................................................................................................... 21
Figure 10: Connecting segments (rear side) ......................................................................................................... 21
Figure 11: Fitting the chain guide tube ................................................................................................................. 22
Figure 12: Chain deflection ................................................................................................................................... 22
Figure 13: Fitting and tensioning the link chain.................................................................................................... 22
Figure 14: Base plate with anchoring holes .......................................................................................................... 22
Figure 15: Magnetic tape installation - EXAKT HD A ............................................................................................. 23
Figure 16: Magnetic tape installation - EXAKT HD E ............................................................................................. 23
Figure 17: Operating elements of the EXAKT HD A stop system .......................................................................... 24
Figure 18: Balance weight and lever for clearance stroke .................................................................................... 24
Figure 19: Operating elements of the EXAKT HD E stop system........................................................................... 25
Figure 20: Setting the material stop height .......................................................................................................... 25
Figure 21: Loading the EXAKT HD roller conveyor with a forklift truck ................................................................ 26
Revisions:
Revision
Autor
Modification
Date
001
AG
Original manual translated
12.09.2023

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1Introduction
The information in this operating manual enables safe, proper and economical operation of your roller conveyor.
Please observe all the explanations, notes and regulations
•to avoid dangers and malfunctions,
•to reduce repair costs and downtimes
•and to increase reliability and service life
of your roller conveyor.
The operator must ensure that this operating manual is read by the persons entrusted with the operation,
maintenance and repair of the roller conveyor. This operating manual as well as any appendices and additional
documents must be kept easily accessible at the roller conveyor's place of use.
Ignorance or non-observance of these operating instructions may result in certain accident
hazards during handling with the roller conveyor. Before commissioning, this operating man-
ual and any appendices and additional documents must be read thoroughly. All instructions,
in particular the safety regulations, must be observed!
Handling the roller conveyor in the sense of these instructions means
•the installation and commissioning,
•the operation and proper usage,
•the influence on operating conditions, as well as
the maintenance, troubleshooting and repair.
Apart from the operating manual and the legally binding accident prevention provisions applicable in the country
and place of use, the recognized technical regulations for safe and proper work must also be observed.
1.1 Legal notice
All contents of these operating instructions are subject to the rights of use and copyright of Reinhold Beck Mas-
chinenbau GmbH. Any reproduction, modification, further use and publication in other electronic or printed me-
dia, as well as their online publication, requires the prior written consent of Reinhold Beck Maschinenbau GmbH.
1.2 Illustrations
All photos, figures and graphics contained in this document are for illustration and better understanding only
and may differ from the current state of the product.
2Symbols
2.1 General Symbols
Symbol
Meaning

Indicates passages within this operating manual that must be particularly observed in order to
prevent malfunctions or damage to the roller conveyor.

Refers to chapters, sections, or figures within this document.

Refers to an external document or a third-party source.

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2.2 Symbols in Safety Instructions
Safety instructions are provided with corresponding danger symbols which have the following meanings:
Symbol
Safety Instruction
Reading and applying the operating manual is mandatory for the operating personnel.
Failure to abide by the following precautions could lead to fatal injury.
General danger symbol, which requires the highest attention!
Failure to observe may result in damage to the equipment, acute injury or even death.
Reference to a prohibited zone under a lifted load!
Do not enter! There is an increased risk of injury or even death.
Reference to a prohibited zone on a platform!
Do not enter! There is an increased risk of injury or even death.
Reference to a possible crushing hazard!
Non-observance increases the risk of injury to hands and fingers!
Reference to a possible crushing hazard!
Non-observance increases the risk of injury to feet and toes!
Possible dangerous crushing hazard in the area of stationary objects!
Risk of personal injury and additional equipment damage.
Reference to a hazard due to forklift traffic!
Non-observance can result in life-threatening injuries.
Reference to a danger under suspended loads!
Non-observance can result in life-threatening injuries.
Reference to tripping and slipping hazards on the floor!
Non-observance may result in minor or severe injuries.
Reference to possible environmental pollution!
Non-observance poses a risk of pollution of the environment and groundwater!
Reading and applying the operating manual is mandatory for the operating personnel.
Non-observance of the above precautions can lead to serious or fatal injuries.
Note on the obligation to wear tight-fitting protective work clothing!
Non-observance may result in increased risk of injury or even death!
Reference to the obligation to wear safety shoes resp. protective gloves!
Non-observance may result in increased risk of injury to feet & toes or hands & fingers!
Note on the obligation to wear protective goggles/face protection resp. hearing protection!
Non-observance increases the risk of injury to eyes/face resp. ear canals.
Note on the obligation to wear a dust protection resp. respiratory mask!
Non-observance increases the risk of injury to the respiratory tract.
Note on the obligation to wear a safety helmet!
Non-observance may result in increased danger of head injuries or even death!
Fire hazard! Do not smoke and do not ignite open fire.
Access for unauthorized persons prohibited!
Risk of personal injury and additional equipment damage.

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3General
The operating manual must be read carefully and understood before handling the roller
conveyor! If anything is unclear, please contact the manufacturer.
The roller conveyors of the "Heavy Duty" series EXAKT HD have been specially designed for heavy-duty applica-
tions. The extremely robust welded steel construction, made of thick-walled profile tubes (Ø 108 x 3.25 mm) and
laser-machined sheet metal parts, is particularly suitable for metal and steel construction. Their stable and open
front design allows loading and unloading by crane or forklift truck. Two different roller widths are available for
all models (variant S with 600 mm and variant W with 1150 mm usable roller width).
The positioning of the solid material stop is precise and fast and (depending on the model) by manual shifting or
by handwheel adjustment. On the EXAKT HD A and EXAKT HD E models equipped with a measuring system, the
set dimension can be read off via a digital position indicator.
3.1 Features
•800 kg load capacity per meter roller conveyor
•Roller conveyor lengths 2 to 12 meters (special lengths on request)
•Working height selectively 855 mm or 905 mm (each height adjustable by ± 75 mm)
3.2 Application
The roller conveyor can be used for all work that corresponds to its intended use in section 4.2. The roller
conveyor is suitable for fencing and transporting workpieces in order to bring them into a specific position for
machining. The roller conveyor must not be used for pushing or pulling workpieces.
•The roller conveyor must not be used for work that does not correspond to its intended use (see 4.2).
•The roller conveyor is intended exclusively for commercial use.
3.3 Target group and previous experience
This operating manual is intended for the operating and maintenance personnel of the roller conveyor. The op-
erating personnel is to be determined by the operator and must further meet the following requirements:
•Basic technical and mechanical knowledge as well as knowledge of the associated technical terms
•Reading and understanding these operating and maintenance instructions
In order to acquire the knowledge required to operate this roller conveyor, the operator must ensure the follow-
ing measures:
•Product training for every operator (also possible external personnel)
•Regular safety instruction
3.4 Requirements for the operators
The operator is responsible for the safe use of the roller conveyor!
The roller conveyor may only be operated by trained personnel who have also read this manual.
Inspection, maintenance, cleaning and repair may only be performed by technical specialists
with product-specific training and mechanical and/or electrical training.
Specialists with product-specific training are to be commissioned and held responsible for
planning and checking the work.
The national protective regulations for employees must be observed
The legal minimum age must be observed.

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3.5 Accident prevention
To avoid accidents, the following rules must be observed for operation:
Prevent unauthorised persons from having access to the roller conveyor.
Keep unauthorized persons away from the danger areas.
Repeatedly inform other persons present about existing residual risks (see 4.6).
Conduct recurring training and instructions for persons who have to be in the area of the roller conveyor,
which are also recorded.
New employees must be trained internally for working on a roller conveyor and this training must be doc-
umented.
It is forbidden to enter the roller conveyor or to climb or sit on the roller conveyor.
3.6 General safety regulations
In general, the following safety regulations and obligations apply when handling the roller conveyor:
The roller conveyor may only be operated when in perfect working order.
It is prohibited to remove, modify, bypass or bypass any protective, safety or monitoring device.
Defective or missing safety devices must be repaired resp. replaced immediately by authorised qualified
personnel! The roller conveyor must not be operated during this time!
It is forbidden to modify or change the roller conveyor without the written approval of the manufacturer /
supplier.
Malfunctions or damage must be reported to the operator immediately. In case of malfunctions, proceed
as follows: Take the roller conveyor out of operation, eliminate the cause of the malfunction, eliminate
the malfunction, check the roller conveyor for safe condition and only then put it back into operation!
Repair and maintenance work on electrical and pneumatic components may only be carried out by au-
thorised and trained personnel.
Maintenance work must be carried out and documented according to the maintenance instructions.
Only original spare parts from the roller conveyor manufacturer may be used for repairs.
Additional electronic components may only be purchased from the roller conveyor manufacturer.
Only instructed, trained or qualified persons may work on and with the roller conveyor.
It is not permitted to enter the roller conveyor or to transport persons.
For the operation of the roller conveyor, the respective national safety regulations for employees as well
as the national safety and accident prevention regulations apply.

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4Safety
4.1 Basic safety instructions
Roller conveyors can cause hazards if used improperly. Therefore, observe the safety instructions listed in this
chapter and the accident prevention regulations of your employer's liability insurance association!
The manufacturer accepts no liability for damage and malfunctions resulting from failure to
observe these operating instructions.
4.2 Application area and intended use
With their conformity to the Machinery Directive 2006/42/EC, the roller conveyors of the EXAKT HD series are
suitable as technical aids for operational/commercial applications.
Improper use may endanger persons and lead to a defect or damage. and to a defect or
damage of the roller conveyor.
The roller conveyor is primarily intended for operation in covered indoor areas.
The roller conveyor is suitable for transporting workpieces to a specific holding position before machining.
Work on the roller conveyor may only be carried out in sufficiently illuminated working areas.
The maximum load capacity (refer to section 6) of the roller conveyor must not be exceeded.
The roller conveyor may only be operated on horizontal floors.
The roller conveyor is not intended for moving and transporting persons.
The roller conveyor must not be operated in potentially explosive working areas.
Any other use is considered improper and is prohibited.
4.3 Improper use
Improper use is when the roller conveyor is used for purposes other than those prescribed in this operating
manual and in section 4.2, for example
use and application for private or non-commercial purposes,
use in disregard of the regulations in the operating manual,
use after unauthorized conversions or modifications,
exceeding the maximum permissible load (refer to section 6)
non-compliance with the permissible workpiece dimensions.
transporting persons or stepping on the roller conveyor
or feeding or pulling of workpieces.
In case of improper use of the roller conveyor, any warranty, liability and other claims for damages of the oper-
ator against the manufacturer are excluded!

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4.4 Consequences in case of disregard
If the roller conveyor is not operated, maintained or repaired in accordance with the safety regulations, not as
intended, improperly or in an abusive manner, the following will result:
Dangers to the health of the operating personnel
Dangers to the roller conveyor and objects in its vicinity
Impairment of the roller conveyor function
In case of improper use of the roller conveyor, any warranty, liability and other claims for damages of the oper-
ator against the manufacturer are excluded!
4.5 Conversions and modifications of the roller conveyor
Only use the roller conveyor in its original condition, i.e. as delivered!
The components of the roller conveyor must not be changed in their type and condition.
Only original spare parts and accessories from the manufacturer may be used.
Deviations are not permitted.

Unauthorized modifications or conversions by the operator, without the written consent of the
manufacturer, are prohibited. This excludes any warranty, liability and other claims for dam-
ages by the operator against the manufacturer!
4.6 Supplementary safety equipment
The functionally safe provision and installation of supplementary machine protection fences and
protective grilles for the roller conveyor supplied is the responsibility of the operator! These
measures are not part of the scope of delivery of Reinhold Beck Maschinenbau GmbH.
4.7 Personal protective equipment
To minimise the risk of injury in case of danger, personal protective equipment must be worn when working on
and with the roller conveyor. The operator of the roller conveyor is obliged to wear the protective equipment
required for the respective work!
Close-fitting protective clothing with low tear resistance, tight sleeves and no protruding parts must be
worn for all work on and with the roller conveyor. The main purpose is to protect against being caught by
moving parts of the installation. Do not wear watches, rings, chains or other jewellery. Wearing long open
hair is prohibited during work.
Safety shoes with non-slip soles must be worn for all work on and with the roller conveyor. These serve to
protect against falling parts and at the same time to prevent slipping on slippery surfaces.
Wearing protective gloves serves to protect the hands from abrasions, puncture wounds or deeper inju-
ries, as well as from irritating and corrosive substances and from burns.
Hearing protection protects the hearing from the effects of noise that is harmful to health. As soon as the
workplace-related noise emission values exceed 85 dB(A), personnel must be provided with suitable hear-
ing protection!
Safety goggles protect the eyes from injuries caused by dust, chips and flying off parts on a processing
machine as well as from compressed air and irritating resp. corrosive or toxic liquids.
A respiratory respirator resp. dust mask protects the respiratory tract from respiratory air contamination
(e.g. from wood dust or similar) and from toxic exhaust gases (e.g. from a forklift truck).
The safety helmet serves to protect against falling parts and head injuries. It is mandatory to wear a safety
helmet especially when unloading the roller conveyor by means of a forklift truck.