TGW Natrix Instruction manual

INSTALLATION,OPERATION,MAINTENANCE
MANUAL
Natrix
Shoe Sorter
Revision Date: February 5, 2015

Natrix IOM
Contents
Installation, Operation, Maintenance Manual..............................................................................1
Purpose......................................................................................................................................6
TGW Systems Equipment Warranty...........................................................................................7
Warranty and Liability.................................................................................................................8
TGW Safety Recommendation...................................................................................................9
Conveyor Design and Safety Guidelines....................................................................................9
EN ISO Standard Compliance..................................................................................................10
ANSI Standards for Conveyors.................................................................................................11
ANSI Conveyor Safety Rules................................................................................................11
Conveyor Equipment Manufacturers Association (CEMA) .......................................................12
CEMA Safety Label Meanings..............................................................................................12
Warnings and Safety Instructions.............................................................................................13
Warnings and Safety Instructions .........................................................................................13
Manual Structure......................................................................................................................16
Safety Signs and Symbols........................................................................................................17
Symbols and Units....................................................................................................................19
Other Symbols and Units......................................................................................................20
Technical Data..........................................................................................................................21
Assessment of noise in the working area with regard to specific..........................................21
Operating Materials and Lubricants Norm al Temperatures.....................................................22
Operating Materials and Lubricants Low Temperatures .......................................................23
Operating Materials and Lubricants for Food Industry..........................................................24
Screw Torque Requirements................................................................................................25
Part Inventory & Identification...................................................................................................26
Label Identification................................................................................................................26
Receiving & Site Preparation....................................................................................................27
General.................................................................................................................................27
Preparation of Site................................................................................................................27
Shipment / Receiving Packaging..............................................................................................28
Prerequisites for Installation Site..............................................................................................30
On-site Delivery Requirementrs............................................................................................30
Unloading .................................................................................................................................31
Check the shipment for damage...........................................................................................31
Dock Unloading.....................................................................................................................31
Transport in General.............................................................................................................32
Installation ................................................................................................................................33
Preparation...........................................................................................................................33
Installation of Infeed/Discharge belt conveyor supports........................................................33
Positioning of Infeed/Discharge Belt conveyor......................................................................33
Floor (platform) attachment...................................................................................................34
Natrix Installation......................................................................................................................35
Installation of Natrix supports................................................................................................35
Assembly of modules............................................................................................................36
Screw and adjust the joints and struts...................................................................................36
Alignment..............................................................................................................................37
Floor (platform) attachment..................................................................................................38
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Installation of the chain .........................................................................................................40
Establishing the divert lane location.........................................................................................42
Check chain tension .................................................................................................................43
Drive Chain Adjustments..........................................................................................................44
Tension the Drive Chain .......................................................................................................44
Sorter Link Chain......................................................................................................................46
Replace sorter link chain [7]..................................................................................................47
Cover and Guard Rail Completion and Adjustment..................................................................49
Cover and Guard rail Installation...........................................................................................49
Shoe Position Safety Device Installation..................................................................................50
Install the proximity switch.....................................................................................................50
Proximity Switch Adjustments...............................................................................................51
Install the dirt pan (Optional Accessory)................................................................................52
Install the covers.......................................................................................................................53
Top cover (stainless steel bracket)........................................................................................53
Install Frame Paneling..............................................................................................................54
Install Main Air FilterRegulator...................................................................................................55
Installing the air filter regulator unit........................................................................................55
Oiler Adjustments.....................................................................................................................56
Adjustment of the oiler..........................................................................................................56
Monitoring of Chain Tension.....................................................................................................58
Activation of chain monitoring...............................................................................................58
Monitoring of Chain Tension Picture.....................................................................................59
Replace Sliding Shoe...............................................................................................................60
Replace sliding shoe [5]........................................................................................................61
Change slide element [6, 7]...................................................................................................61
Replace Drive Station Gearmotor.............................................................................................63
Replace drive station gear motor [3] .....................................................................................63
Shrink Disc Removal Procedure...............................................................................................64
Disassemble shrink disc [3]...................................................................................................64
Motor Shrink Disc Requirements ..........................................................................................64
Shrink Disc Assembly Procedure .............................................................................................65
Assemble shrink disc [4]........................................................................................................65
Shaft Encoder Flex Coupling....................................................................................................67
Replace shaft encoder [4].....................................................................................................67
Replace Divert Switch Assembly..............................................................................................68
Replace Divert Switch Assembly [6]......................................................................................69
Switch Blade.............................................................................................................................71
Replace switch blade [6].......................................................................................................71
Adjust Switch Blade..................................................................................................................72
Adjust switch blade [4] ..........................................................................................................73
Replace Crossing.....................................................................................................................74
Replace crossing [4]..............................................................................................................74
Replace Main Air Regulator Unit...........................................................................................75
Replace Main Air Regulator [2].............................................................................................75
Replace Electrical Components................................................................................................76
Replace proximity switch cable [1]........................................................................................77
Change proximity switch [3]..................................................................................................77
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Recommended Inspection Intervals .........................................................................................78
Preventive Maintenance...........................................................................................................79
General PM...........................................................................................................................79
Daily......................................................................................................................................79
Weekly..................................................................................................................................79
Air Systems...........................................................................................................................79
Recommended Maintenance Interval.......................................................................................81
Recommended operating hours per week ............................................................................81
Average system load.............................................................................................................81
Factors of influence on service life........................................................................................81
∑ WBK ...................................................................................................................................81
Replacement Parts Identification..............................................................................................82
Drive Station.............................................................................................................................83
Gearmotor List..........................................................................................................................84
Charge End Chain Tensioning Unit..........................................................................................85
Tension Unit Replacement Parts ..........................................................................................86
Actuating Elements Right & Left Transfer.................................................................................87
Chain Lubricator.......................................................................................................................88
Main Air Regulator....................................................................................................................89
Electrical - Proximity Switch......................................................................................................90
Electrical - Proximity Switch / Shaft Encoder........................................................................91
Sorter Link Chain......................................................................................................................92
Sorter Link Chain..................................................................................................................93
Adjust Conveyor Belt Tension...................................................................................................94
Tension the conveyor belt.....................................................................................................94
Conveyor Belt Tracking ............................................................................................................95
When the belt is running: ......................................................................................................95
Drive Station Tension Timing Belt ............................................................................................96
Tension timing belt................................................................................................................96
Reading Value ......................................................................................................................97
Belt Conveyor Natrix Replacement Parts .................................................................................98
Type of Roller Replacement Parts........................................................................................98
Belt and Roller Replacement Parts.......................................................................................99
Replace Support Roller...........................................................................................................100
Replace support roller [1]....................................................................................................101
Replace intermediate roller [2] ............................................................................................101
Replace tension spring [3]...................................................................................................101
Replace Belt Drive Motor........................................................................................................102
Replace Infeed/Discharge belt motor [6].............................................................................103
Replace Infeed/Discharge timing belt pulley [5] ..................................................................103
Replace Drive Drum...............................................................................................................104
Replace drive drum [5]........................................................................................................104
Replace Return Pulley ∅ 62....................................................................................................105
Replace return pulley ∅62 [5].............................................................................................105
Replace Return Pulley ∅ 63.5.................................................................................................106
Replace return pulley ∅ 63.5mm [6, 7].................................................................................106
Disassemble Taper lock Bushing ...........................................................................................107
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Disassemble Taper lock bushing (TL) [6]............................................................................107
Replace Tension Pulley..........................................................................................................108
Replace tension pulley [5]...................................................................................................108
Replace Change Timing Belt..................................................................................................109
Replace timing belt [3].........................................................................................................109
Works Cited............................................................................................................................110
TGW Systems Inc...................................................................................................................111
Tables
Table 1 symbols and units....................................................................................................... 20
Table 2 Lubricants Normal Temperature................................................................................. 22
Table 3 Lubricants Low Temperature...................................................................................... 23
Table 4 Lubricants for Food Industry....................................................................................... 24
Table 5 Torque Requirements................................................................................................. 25
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Purpose
It is the intent of TGW Systems, through this manual, to provide information that acts as a
guide in the installation, operation and maintenance of TGW Systems Natrix Shoe Sorter.
This manual describes basic installation practices, assembly arrangements, preventive
maintenance and assists in replacement parts identification.
This service manual is intended for use by personnel who are knowledgeable of installation
and safe working practices on conveyor systems.
Not all applications and conditions can be covered; therefore, this manual is to be used ONLY
as a guide.
If additional copies of this manual are needed or if you have any question concerning the
conveyor please contact your TGW Distributor or TGW Lifetime Services at 231-798-4547 or
Fax [phone].
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TGW Systems Equipment Warranty
TGW Systems warrants that the material and workmanship entering into its equipment is
merchantable and will be furnished in accordance with the specifications stated.
TGW Systems agrees to furnish the purchaser without charge any part proved defective within
2 years from date of shipment or before the equipment has forty-one hundred (4100) hours of
running use, whichever period is shorter, provided the purchaser gives TGW Systems
immediate notice in writing and examination proves the claim that such materials or parts were
defective when furnished. For drive components specific to XenoROL®(i.e. Xeno belts, slave
Xeno belts, drive spools, standard and speed-up, and spacers), this warranty shall be
extended to five years or ten thousand (10,000) hours of running use, whichever period is
shorter, provided the conveyors are applied, installed and maintained in accordance with TGW
Systems published standards. Other than the above, there are no warranties which extend
beyond the description on the face hereof. Consequential damages of any sort are wholly
excluded.
The liability of TGW Systems will be limited to the replacement cost of any defective part. All
freight and installation costs relative to any warranted part will be at the expense of the
purchaser. Any liability of TGW Systems under the warranties specified above is conditioned
upon the equipment being installed, handled, operated, and maintained in accordance with the
written instructions provided or approved in writing by TGW Systems.
The warranties specified above do not cover, and TGW Systems makes no warranties which
extend to, damage to the equipment due to deterioration or wear occasioned by chemicals,
abrasion, corrosion or erosion; Purchaser's misapplication, abuse, alteration, operation or
maintenance; abnormal conditions of temperature or dirt; or operation of the equipment above
rated capacities or in an otherwise improper manner.
IMPORTANT
All equipment and components not manufactured by TGW Systems carry only such warranty
as given by the manufacturer thereof, which warranty TGW Systems will assign or otherwise
make available to Purchaser without recourse to TGW Systems, provided that such warranty is
assignable or may be made available.
For service on motors, reduction units, electrical components, controls, air or hydraulic
cylinders, contact the local authorized sales and service representative of respective
manufacturer. If none is available in your locality, contact the TGW Systems representative.
TGW Systems will not be responsible for units that have been tampered with or disassembled
by anyone other than the authorized representative of the respective manufacturer.
THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, EXTENDING BEYOND THOSE SET FORTH IN THIS STATEMENT OF
WARRANTY.
Rev 08/22/2011
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Warranty and Liability
The warranty shall terminate automaticallyin the following cases:
- in case of non-observance of the contents of this documentation
- in case of unauthorized intervention in the construction or mode of operation of
the products
- in case of not using TGW spare parts
Any modification to the system shall absolve TGW Systems from its liability, in particular
with regard to safety-relevant modifications to the system.
All maintenance measures must exclusively be carried out by experts authorized by TGW.
In case maintenance measures are demonstrably carried out by personnel not expressly
authorized by TGW or not according to the instructions, TGW Systems shall be
absolved from any kind of liability and warranty obligation.
All parts or components identified as wear parts are excluded from
warranty.
Warranty and liability claims for injuries to persons or material damage are excluded in
particular in the following cases:
- inappropriate use
- inappropriatemaintenance measures (inspection, maintenance, repair)
- operation of the system with improperly installed or defective safety equipment
- non-observanceof safety instructions
- catastrophes caused by outside intervention and force majeure
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TGW Safety Recommendation
For additional safety information: TGW agrees to the following safety instruction or guidelines
listed with the below recommended web site information. This is not to conflict with your state
or legal requirements.
TGW Recommends for maintenance or repair purposes, to incorporate a lock out or tag
procedure. To ensure all starting devices, prime movers, or powered accessories are off before
attempting to maintenance or repair.The procedures below are designed to protect everyone
involved with the conveyor against an unexpected restart. To include understanding of potential
hazard of stored energy, which can exist after the power source is locked out.
For additional information, refer to the latest issue of ANSI Z244.1, American National
Standard for Personnel Protection −Lockout/Tagout of Energy Sources− Minimum
Safety Requirements. http://www.ansi.org/
OSHA 29CRF Part 1910.147 “Control of Hazardous Energy Sources (Lockout/Tagout)”, which
includes requirements for release of stored energy and OSHA Safety and Health Regulations
for Construction 1926.555 Conveyors https://www.osha.gov/
Conveyor Design and Safety Guidelines
A safety risk evaluation is required for all of our standard equipment. The safety risk
evaluation considers every potential hazard on the conveyor, weighs the probability and the
severity of the potential injury, and addresses methods of mitigation to make the risk of injury
either low or negligible. We use the ANSI B11 TR3 standards for all of our risk evaluation.
In addition, all of our equipment is designed to comply with the following national and industry
standards: https://www.asme.org/
CEMA Safety Standards and Labels - (CEMA is the Conveyor Equipment Manufacturers
Association)
ASME B20.1- Safety standard for Conveyors and Related Equipment
ASME B15.1 – Safety standard for Mechanical Power Transmission Apparatus
OSHA 1910.147 – The Control of Hazardous Energy
OSHA 1910.212 - General Requirements for all Machines
OSHA 1910.95 – Occupational Noise Exposure
ANSI 2535 – Safety Color Code
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EN ISO Standard Compliance
The Natrix was developed, constructed and manufactured in compliance with the
EC Machinery Directive 2006/42/EC for incomplete machines and in sole responsibility
and complies with the following basic requirements of the Machinery Directive
(2006/42/EC): Annex I, Articles
1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4 and 1.5.1
Furthermore, the incomplete machinery complies with all the provisions of the Directives
for
Electrical Equipment (2006/95/EC) and ElectromagneticCompatibility (89/336/EEC)
This machinery/pieceof machinery must not be put into service until the machinery
into which it is to be incorporated has been declared in conformity with
the provisions of the EC Machinery Directive, the harmonized
standards, the European standards, or the relevant national standards.
List of standards applied:
EN ISO 12100-1/2 Safety of machinery
EN 528 Rail dependent storage and retrieval equipment
EN 619 Continuous handling equipment and systems EN
14121-1 Risk analysis - risk assessment
EN 60204-1 Electrical equipment and controls
The manufacturer undertakes the obligation to transmit the special documentation in
electronic form to the relevant national authorities upon request. The special technical
documents as specified in Annex VII Section B have been duly created.
European Standards go to http://www.en-standard.eu
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ANSI Standards for Conveyors
It is essential for safe and efficient system operation that safety information and guidelines
presented here are properly understood and implemented.
TGW recognizes American National Standard Institute (ANSI) booklet entitled Safety
Standards for Conveyors and Related Equipment B20.1. For more information go to:
http://webstore.ansi.org/default.aspx
With any piece of industrial equipment, conditions exist that might cause injury to you or your
co-workers. Because it is not possible to describe each potentially hazardous situation that
might develop, you must be alert at all times for unsafe conditions. To avoid injury, use
maximum possible care and common sense and adhere to all safety standards.
Take special care while maintaining and inspecting electrical equipment and devices. All
personnel working on or around the system should be aware of, and adhere to, all CAUTION,
DANGER, and WARNING signs.
Labels or signs are posted to reduce the risk of injury to all personnel. Never assume that the
signs and notices are applicable only to inexperienced personnel. Maintain signs in a legible
condition. Contact your supervisor to post additional safety signs if you feel they are
necessary. http://www.ansi.org/
ANSI Conveyor Safety Rules
Conveyor safety rules, as well as specific regulations and guidelines listed in this publication:
• DO NOT touch moving Conveyor parts.
• DO NOT walk, ride, or climb on the Conveyor.
• DO NOT operate the Conveyor with chain guards or other protective guards removed.
• Keep jewelry, clothing, hair, etc., away from the Conveyor.
• Know the location and function of all start/stop devices and keep those devices free from
obstruction.
• Clear all personnel from the equipment before starting the Conveyor.
• DO NOT attempt to clear product jams while the Conveyor is running.
• Allow only trained and authorized personnel to maintain or repair Conveyor equipment.
• DO NOT load the Conveyor beyond specified design limits.
• DO NOT attempt to make repairs to the Conveyor while it is running.
• DO NOT modify equipment without checking with the manufacturer.
• DO NOT operate or perform maintenance on equipment when taking any type of drug,
sedative, when under the influence of alcohol, or when over fatigued.
• Report any unsafe condition to your supervisor or maintenance staff.
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Conveyor Equipment Manufacturers Association (CEMA)
The Conveyor Equipment Manufacturers Association (CEMA) provides safety information
related to conveyor systems. There are Conveyor Safety Video and Conveyor Safety Poster
produced by CEMA.
TGW recommends these video for training and education purposes for a safe working
environment around conveyor equipment. The video introduces awareness of operation
personnel maintenance technicians, and management to safety hazards commonly associated
with the automated material handling conveyor equipment.
Safety poster reviews the important safety labels and is intended to be posted in public places
as a day-to-day reinforcement of good safety practices. These posters can be downloaded
from the CEMA Web Site at http://cemanet.org/safety/posters.htm or for more information on
the CEMA Safety Program visit the CEMA Web Site’s Safety Page at
http://cemanet.org/safety/index.html.
Both the safety poster and the video can be purchased from CEMA. Visit their web site –
www.cemanet.org for additional information or contact them at:
Conveyor Equipment Manufacturers Association
6724 Lone Oak Blvd. Naples FL 34109
Phone [phone]
CEMA Safety Label Meanings
The word or words that designate a degree or level of hazard seriousness. The signal words for product
safety signal are: DANGER, WARNING, and CAUTION.
•DANGER -Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme situations.
•WARNING – Indicates potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used to alert against unsafe practices.
•CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
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Warnings and Safety Instructions
Failure to follow the instructions and cautions throughout this book, and warning labels on the
conveyor, may result in injury to personnel or damage to the equipment.
Your TGW Systems conveyor is powered by a motor and can be stopped only by turning off
electrical power to the motor. As with all powered machinery, the drive-related components –
including sprockets, belts, shafts, universal joints and pneumatic devices – can be dangerous.
We have installed or provided guards to prevent accidental contact with these parts, along with
warning labels to identify the hazards.
Special attention must be paid to the following areas of this manual:
Warnings and Safety Instructions
•Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
•Indicates a situation which, if not avoided, could result in property
damage.
NOTE
This is where you will be notified of helpful information.
WARNING
CAUTION
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•After maintenance, REPLACE guards immediately.
•Keep ALL warning labels clean and clear of any
obstructions.
•Never remove, deface or paint over WARNING or
CAUTION labels. Any damaged label will be replaced by
TGW Systems at no cost by contacting Lifetime Services.
•It is very important to instruct personnel in proper
conveyor use including the location and function of all
controls.
•Special emphasis must be given to emergency stop
procedures.
•It is important to establish work procedures and access
areas which do not require any part of a person to be
under the conveyor.
•It should be required that long hair is covered by caps or
hair nets.
•Loose clothing, long hair and jewelry must be kept away
from moving equipment.
•Maintain enough clearance on each side of all conveyor
units for safe adjustment and maintenance of all
components.
•Provide crossovers or gates at sufficient intervals where
needed to eliminate the temptation for personnel to climb
over or under any conveyor.
•Walking or riding on a moving conveyor must be
prohibited.
•Before performing maintenance on the conveyor, make
sure the start-up controls are locked out and cannot be
turned on by any person other than the one performing
the maintenance.
•If more than one crew member is working on the
conveyor, EACH CREW MEMBER MUST HAVE A LOCK
ON THE POWER LOCKOUT.
•All pneumatic devices must be de-energized and air
removed to prevent accidental cycling of the device while
performing general maintenance.
•Make sure all personnel are clear of all conveyor
equipment before restarting the system.
WARNING
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•Before servicing or performing any work in the motor
control panel, disconnect and lock out the main incoming
service. If only the panel disconnect is off, the incoming
side will still be hot.
WARNING
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Manual Structure
You should receive a separate documentation for each product line of TGW
Systems implemented in your installation. You can identify the respective product line on
the back of the folder or on the cover sheet of the IOM (Installation Operation Maintenance
Manual).
•IOM Conveyor System
•PN = Part Number
•Revision Date (MM/DD/YYYY)
•Page Numbers
•
•
Pay attention to the safety instructions!
•Prior to working at or in the immediate vicinity of the
system it is recommended that you make yourself
familiar with the safety instructions included in the
present document!
WARNING
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)
i
Safety Signs and Symbols
For your own safety please pay attention to the safety and indication signs in this
documentation!
Caution!
•For your own safety strictly observe the necessary
working and operating procedures
•.TGW Safety Recommendation
Attention!
•In order to maintain the operations of your
installation, strictly observe the necessary
instructions and procedures.
•Warranty and Liability
TGW Safety Recommendation
•Conveyor Design and Safety Guidelines
Please Note!
•Observe the technical requirements for the correct
use of the installation machinery.
•Conveyor Design and Safety Guidelines
Additional information
•Know all safety requirements and functions of your
machinery.
WARNING
WARNING
WARNING
CAUTION
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Symbols and Units
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Other Symbols and Units
Table 1 Symbols and units
Symbol Unit Description
v m/s (meter/second) speed M
Mkg (kilograms) mass
PKW (kilowatts) power
fHz (Hertz) frequency
nrpm revolutions per minute
Ømm diameter
Lmm L length
Wmm W width
Hmm H height
smm S distance
i : transmission ratio
FN (neutons) force
MA Nm (neuton/meters) tightening torque
Symbol Description
÷to
≤less thanor equal to
≥greater thanor equalto
>greater than
<less than
=equal to
Other Symbols
Symbols and Units
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