transnorm TS 1200 User manual

TS 1200
Belt conveyor
Operating instructions

2
Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Product Belt conveyor TS 1200
Manufacturer TRANSNORM SYSTEM GmbH
Förster Str. 2
D-31177 Harsum
Tel. [phone]
Fax [phone]
[email protected]
http://www.transnorm.com
Documentation Operating instructions - Translation -
Version 5.7 ENG, 14.05.2018
Subject to modifications. All rights reserved by TRANSNORM SYSTEM
GmbH. Reprint and duplications only with written approval.
Revision V 5.0 Completely revised edition
V 5.1 Remaining risks and safety instructions revised
V 5.2 Introduction revised
V 5.3 Safety instructions added
V 5.4 Belt guidance added
V 5.5 Ø 80 Tail pulley version added
V 5.6 Disassembling/assembling bottom cover and performance level
added
V 5.7 Maintenance schedule revised

Table of contents 3
Table of contents
Applicable documents................................................................................................................ 7
EC Declaration of Incorporation ........................................................................................................... 7
Introduction .................................................................................................................................... 9
Purpose of the document ..................................................................................................................... 9
Validity ............................................................................................................................................ 9
Illustrations ..................................................................................................................................... 9
Using the instructions ......................................................................................................................... 10
Safety instructions .............................................................................................................................. 11
Copyright Protection ........................................................................................................................... 12
Service................................................................................................................................................ 12
Warranty ............................................................................................................................................. 13
Safety............................................................................................................................................... 15
............................................................................................................................................................ 15
Intended use................................................................................................................................. 15
Non-permitted operating conditions ............................................................................................. 16
Responsibilities of the operating company/integrator................................................................... 16
Personnel qualification ....................................................................................................................... 19
Remaining risks regarding the machine ............................................................................................. 20
Remaining risks for operating personnel...................................................................................... 20
Remaining risks for technical personnel....................................................................................... 21
Protective devices...................................................................................................................... 25
Protective devices on the machine..................................................................................................... 26
Description.................................................................................................................................... 27
Technical description .......................................................................................................................... 28
Main dimensions................................................................................................................................. 29
Technical data..................................................................................................................................... 31
Required performance level (PLr) ...................................................................................................... 33
Areas of the machine.......................................................................................................................... 34
Parts of the machine........................................................................................................................... 35
Conveyor configuration....................................................................................................................... 36
Optional machine equipment.............................................................................................................. 38
Transport and installation....................................................................................................... 39
Delivery of the machine ...................................................................................................................... 39
Unpacking the machine................................................................................................................ 39
Long-term machine storage ......................................................................................................... 39
Disposing of packaging material .................................................................................................. 40

Table of contents4
Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Setting up the machine .......................................................................................................................40
Ground requirements....................................................................................................................40
Permitted operating conditions .....................................................................................................40
Internal transportation.........................................................................................................................41
Auxiliary equipment ......................................................................................................................42
Transport with industrial truck or crane...............................................................................................43
Final installation on-site ......................................................................................................................44
Assembly ......................................................................................................................................44
Installation ....................................................................................................................................45
Mounting the side guides..............................................................................................................48
Electrical connection.....................................................................................................................49
Operation .......................................................................................................................................51
Commissioning ...................................................................................................................................51
Commissioning and start-up after service and maintenance work .....................................................51
Normal operation ................................................................................................................................53
Shutdown............................................................................................................................................54
Maintenance and care...............................................................................................................55
Maintenance work...............................................................................................................................55
Motor maintenance.......................................................................................................................55
Gear unit maintenance .................................................................................................................55
Lubricants ...........................................................................................................................................56
Maintenance schedule........................................................................................................................56
Cleaning and care...............................................................................................................................58
Maintenance and repair............................................................................................................59
Spare part purchasing ........................................................................................................................59
Tools, equipment and supplies ...........................................................................................................59
Tightening torques ..............................................................................................................................60
Guards ................................................................................................................................................61
Disassembling/assembling the bottom cover .....................................................................................62
Replacing the side guide ....................................................................................................................63
Sheet-metal side guide.................................................................................................................63
Tubular side guide ........................................................................................................................65
C-profile side guide.......................................................................................................................66
Replacing the conveyor belt ...............................................................................................................67
Tensioning/adjusting the conveyor belt...............................................................................................70
Terminal drive ...............................................................................................................................70
Tensioning station (conveyor bed)................................................................................................72
Tail pulley......................................................................................................................................73
Replacing the gear motor ...................................................................................................................75
Replacing the flange bearings ............................................................................................................77
Replacing the pulley ...........................................................................................................................79
Tail pulley Ø 42 .............................................................................................................................79
Tail pulley Ø 65 .............................................................................................................................80
Tail pulley/transfer drive Ø 80 .......................................................................................................81
Replacing the drive pulley...................................................................................................................82
Replacing a roller - apex bend............................................................................................................82
Replacing rollers - roller arch..............................................................................................................85

Table of contents 5
Repairing the pre-conveyor/conveyor gate......................................................................................... 87
Troubleshooting.......................................................................................................................... 91
What to do if... .................................................................................................................................... 91
Motor and gear ................................................................................................................................... 92
Decommissioning and waste disposal.............................................................................. 93
Machine disposal................................................................................................................................ 93
Main components of the machine....................................................................................................... 94
Contact details............................................................................................................................. 95
Head office ......................................................................................................................................... 95
Subsidiaries, branch offices and sales partners worldwide ................................................................ 96
Service branches - Germany.............................................................................................................. 98
Suggestions and information .............................................................................................................. 98

Table of contents6
Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018

Applicable documents
EC Declaration of Incorporation 7
Applicable documents
EC Declaration of Incorporation

Applicable documents
EC Declaration of Incorporation
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Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018

Introduction
Purpose of the document 9
Introduction
Purpose of the document
These operating instructions enable you to safely operate the delivered
machine, defined as partly completed machinery by the EC Machinery Direc-
tive, in accordance with its intended use.
Read through these instructions carefully before commissioning the
machine. For further technical information, please refer to the order confir-
mation supplied separately.
You will find information on the following topics in the sections below:
The safe handling of the machine
Technical specifications
Transporting, installing and putting the machine into operation
Maintenance instructions
Repairing the machine
Fault detection and correction
Taking the machine out of operation and disposal
Validity
These operating instructions apply to the operating company/integrator and
all persons working on or with the machine.
Illustrations
The illustrations show simplified views of the machine.
We reserve the right to carry out technical alterations in case of further
developments. If assembly is not described, it will be carried out in exactly
the opposite order to disassembly.
Due to the numerous possible system configurations of our machines,
details shown in the illustrations may differ from the machine supplied.
See the order confirmation for an exact description
of your specific machine.

Introduction
Using the instructions
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Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Using the instructions
Different circumstances are indicated using specific text/formulations. Impor-
tant information has also been marked with additional symbols. The following
is an overview of the different ways information is formulated.
This is a single, complete step.
1. This is the first step in a series of actions.
This is a useful remark on a specific step.
?This is a problem that may arise.
This is the cause of the problem.
This is a measure to solve the problem.
You have completed a series of actions.
You have completed the entire activity.
This is a notice.
Notices provide additional information.

Introduction
Safety instructions 11
Safety instructions
Safety instructions warn of risks and remaining risks and offer information on
how to prevent them.
The signal words CAUTION, WARNING and DANGER indicate the level of
severity of the risk.
The following overview explains the safety instructions used in this docu-
ment.
DANGER
This notice warns of risk of death or fatal injury
This states the cause of the danger.
You must take this action to avert the danger.
WARNING
This notice warns of moderate or minor injury
This states the cause of the danger.
You must take this action to avert the danger.
CAUTION
This notice warns of damage to materials or to the machine
This states the cause of the danger.
You must take this action to avert the danger.

Introduction
Copyright Protection
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Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Copyright Protection
This publication must be treated as strictly confidential. It is intended only for
internal use by an authorised group of persons. and must not be disclosed to
third parties without the written approval of TRANSNORM SYSTEM GmbH.
All documents are protected within the meaning of the Copyright Protection
Act. The transfer and duplication of documents, also by way of extract, is
strictly prohibited. Non-compliance shall be prosecuted and subject to the
payment of compensation.
Service
Our service is available for technical information on our products and their
systematic application.
Please have the following information ready when contacting us with queries
or spare parts orders:
Machine type
Order/project number
Item number
You will find this information on the type identification plate of your machine.
It is located in the vicinity of the drive unit.
TRANSNORM SYSTEM GmbH type identification plate, sample
You will find our contact data at the back of these operating instructions.

Introduction
Warranty 13
Warranty
We shall accept no responsibility for any defects or damage caused by inap-
propriate use, operating errors or incorrect servicing and maintenance. We
expressly point out that only original spare parts and
accessories approved by TRANSNORM SYSTEM GmbH may be used.
Unless otherwise stipulated in the contract, the warranty period begins on
the day of delivery or with notification of readiness to deliver.
Please file all claims under warranty immediately upon identifying the
defect/s. Please quote the order (project) and item number when making a
claim.
The warranty shall be in line with statutory regulations. Further claims are
excluded.
Please note that the warranty shall be rendered null and void in the case of:
Use not in accordance with the intended purpose
Improper connecting and preparatory work not included within our scope
of service
Improper use of controls
Failure to use original spare parts and accessories
Conversions or structural modifications which have not been authorised
by us in writing
Wearing parts are generally excluded from the terms of warranty
.

Introduction
Warranty
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Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018

Safety 15
Safety
Operating conditions
The conveyor, hereinafter referred to as the machine, is an incomplete
machine as defined by the EC Machinery Directive. The machine has been
manufactured in keeping with current scientific and technological develop-
ments.
However, the machine may pose risks under the following circumstances:
Any use other than that intended
Improper operation
Non-permitted operating conditions
Failure to follow these instructions
Failure to comply with the general safety regulations during transport and
installation
Intended use
The machine illustrated on the front page is approved solely for the purpose
of transporting unit loads corresponding to requirements defined in the
service specifications and is intended to be integrated in a fully automatic
intralogistic system with a master controller.
Use other than or use that goes beyond that specified is deemed as not for
its intended purpose and is therefore prohibited.
Never use the machine to transport persons.
It may only be used in a protected industrial environment with restricted
access.
The manufacturer accepts no liability for damage arising from improper use
of the machine.

Safety16
Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Non-permitted operating conditions
Operation of the machine is prohibited under the following circumstances:
There are people or objects in the hazardous areas
Safety devices are not working or have been removed
If the machine is malfunctioning or damaged
Maintenance intervals have been exceeded
Operating parameters have been changed without authorisation
Responsibilities of the operating company/integrator
Machine safety can only be guaranteed when all necessary measures have
been implemented.
The operating company/integrator is responsible for planning and imple-
menting appropriate measures.
These instructions are an integral part of the machine. When selling the
machine, the operating company must pass on this document to the buyer.
The operating company/integrator of the machine is responsible for its
safety. This applies especially to:
Installation as a complete machine with functioning and compliant safety
devices.
Integration of the machine in such a way that no additional
danger/hazards are created.
The safety of all persons in the vicinity of the machine.
Fault-free operation of the machine.

Safety 17
Minimising the danger of injury
Take steps to guarantee the safety of persons in the vicinity of the machine,
for example:
Ensure that all work on the machine is carried out by qualified and
authorised personnel.
Ensure that at least two people carry out any maintenance and repair
work.
Make sure all operators are familiar with the safety devices.
Ensure that the machine and its environment are kept clean and tidy at
all times.
Provide all personnel with protective equipment, such as suitable safety
footwear (S1), close-fitting clothing and gloves to protect against
mechanical dangers.
Make sure the protective clothing is worn.
Provide instructions on how to proceed or act in the event of malfunc-
tions.
Clarify any issues relating to occupational health and safety as well as
environmental protection.
Operating the machine fault-free
Implement the following measures to ensure fault-free operation of the
machine:
Ensure that these instructions are complete, in legible condition and
accessible to all personnel at all times.
Only operate the machine when fully functional and in perfect working
order.
Regularly check the machine and its safety equipment are functioning
correctly.
Implement installation layout
Observe the following basic safety principles when connecting several sepa-
rate components to form an overall system:
Install guards in areas where there are tail pulley assembles, apex
bends, roller arches, conveyor gates, pre-conveyors and transfer drives.
In any area where there is a transfer drive or conveyor gate, the
conveyor belt must have the same speed or run faster in the outfeed
section than in the infeed section.
The national safety regulations valid in the country of the user as well as
additional branch-specific regulations must be observed.

Safety18
Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Commissioning
This conveyor system is a "partly completed" machine, as defined by the
Machinery Directive 2006/42/EC,Article 2g.
This partly completed machine may only carry out an intralogistic function
when combined with an appropriate control system and, where applicable,
other (partly completed) machinery. It must not be commissioned until it has
been ascertained that the partly completed machinery which is the subject of
this documentation or the machinery into which it is incorporated comply with
the requirements of the Machinery Directive.

Safety
Personnel qualification 19
Personnel qualification
Installation, maintenance and repair work as well as commissioning demand
specialist know-how and qualification of the personnel above and beyond
that required for normal operation.
We recommend that you work only with technical personnel trained and
authorised by TRANSNORM SYSTEM GmbH.
All persons working at or on the machine must:
be suitable and sufficiently qualified to carry out the work required.
have received instruction on handling the machine and be familiar with
the protective devices .
have read and understood these operating instructions and especially
the relevant sections relating to their work.
be familiar with basic occupational health and safety and accident
prevention regulations, and with sector-specific regulations.
In these instructions, a distinction is made between the following groups of
personnel:
The following work is to be carried out by specialised personnel only:
Definition of the personnel groups
Personnel
group Definition
Operating
company The operating company is defined as that using the machine for its intended purpose and having the machine operated by suitable
and instructed persons
.
Integrator The integrator installs the partly completed machine for the oper-
ating company and integrates it into an overall system of
machines with a master controller and safety technology.
(Responsible for ensuring conformity of the overall system)
Operating
personnel Personnel who are appropriately instructed by the operating company in the
:Functional and operating procedures for the machine
Possible dangers arising from improper use
Protective devices and measures
Specialised staff Technically qualified and authorised by the operating company to
carry out specific tasks such as installation, maintenance and trou-
bleshooting. Corresponding training in theory and practice is a
prerequisite.

Safety
Remaining risks regarding the machine
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Operating instructions: Belt conveyor TS 1200
Version 5.7ENG, 14.05.2018
Remaining risks regarding the machine
The machine's protective devices offer protection against injury.
For some tasks, however, personnel are required to enter the danger zone.
Therefore, an element of risk always remains.
Remaining risks for operating personnel
The following table will enable operating personnel to identify and avoid
fundamental dangers and hazards. Professional conduct and implementation
of the corresponding measures will help prevent any remaining risks in
advance.
Work requiring specialised knowledge
Work on Specialised knowledge
Pneumatic
components Such work may only be carried out by personnel with specialised knowledge of and experience in handling pneumatic systems.
Electrical
components Such work may be carried out under the guidance and supervision of an electrician in accordance with the codes of electrical engi-
neering practice.