transnorm TS 1600-105FH2 User manual

TS 1600-105FH2
Curve belt conveyor
Operating instructions

2
Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017
Product Curve belt conveyor TS 1600-105FH2
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 5.3 ENG, 16.02.2017
Subject to technical alteration. All rights reserved by TRANSNORM
SYSTEM GmbH. Reprint and duplications only with written approval.
Revision V 3.0 Initial version
V 3.1 EC declaration of conformity updated
V 3.2 Applicable documents replaced
V 4.0 Revised according to Machinery Directive 2006/42/EC
V 4.1 Transport and installation revised
V 4.2 Corrective maintenance updated
V 4.3 Corrective belt exchange updated
V 5.0 Product name revised
V 5.1 Remaining risks, safety instructions and Introduction revised
V 5.2 Corrective maintenance updated
V 5.3 Safety instructions added

Contents 3
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
Operating conditions........................................................................................................................... 15
Intended use................................................................................................................................. 15
Impermissible operating conditions ..............................................................................................16
Responsibilities of the operating company / integrator................................................................. 16
Safety equipment................................................................................................................................ 18
Staff qualifications .............................................................................................................................. 19
Remaining risks regarding the machine ............................................................................................. 21
Remaining risks for operating personnel...................................................................................... 21
Remaining risks for technical personnel....................................................................................... 22
Description.................................................................................................................................... 25
Technical description .......................................................................................................................... 25
Main dimensions................................................................................................................................. 26
Technical data..................................................................................................................................... 27
Machine areas .................................................................................................................................... 29
Machine parts ..................................................................................................................................... 30
Optional machine equipment.............................................................................................................. 31
Transportation and erection................................................................................................... 33
Delivery of the machine ...................................................................................................................... 33
Unpacking the machine................................................................................................................ 33
A longer storage period of the machine........................................................................................ 33
Disposing of Packaging Material .................................................................................................. 34
Installing the machine......................................................................................................................... 34
Ground requirements ................................................................................................................... 34
Tolerable operating conditions...................................................................................................... 34
Transport within the company............................................................................................................. 35
Auxiliary equipment ...................................................................................................................... 36

Contents4
Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017
Transportation with industrial truck or crane.......................................................................................38
TS 1600-105FH2 up to 45°...........................................................................................................38
TS 1600-105FH2 45° up to 90° ....................................................................................................39
TS 1600-105FH2 more than 90° ..................................................................................................40
Final assembly on site ........................................................................................................................41
Assembly ......................................................................................................................................41
Carrying out Installation................................................................................................................42
Mount side guides ........................................................................................................................45
Electrical connection.....................................................................................................................46
Operation .......................................................................................................................................47
Commissioning ...................................................................................................................................47
Commissioning and start-up after service and maintenance works ...................................................47
Normal operation ................................................................................................................................50
Shutdown............................................................................................................................................50
Maintenance and care...............................................................................................................51
Maintenance works.............................................................................................................................51
Motor maintenance.......................................................................................................................51
Gear unit maintenance .................................................................................................................51
Lubricants ...........................................................................................................................................52
Maintenance plan ...............................................................................................................................52
Cleaning and care...............................................................................................................................54
Repairs............................................................................................................................................55
Spare part purchasing ........................................................................................................................55
Work tools...........................................................................................................................................55
Tightening torques ..............................................................................................................................56
Guards ................................................................................................................................................57
Replacing a side guide .......................................................................................................................58
Belt exchange, standard .....................................................................................................................61
Belt exchange, alternative ..................................................................................................................69
Tensioning/adjusting belt ....................................................................................................................77
Replacing the gear motor ...................................................................................................................81
Shaft-mounted bevel wheel gear..................................................................................................81
Shaft-mounted worm gear ............................................................................................................83
Shaft-mounted bevel wheel gear..................................................................................................85
In case of chain drive / toothed belt drive .....................................................................................87
Replace chain drive / toothed belt drive..............................................................................................89
Replacement of flange/pedestal bearing ............................................................................................90
Replacing drive pulley.........................................................................................................................93
Replacing tail pulley..........................................................................................................................100
Replace belt edge holders ................................................................................................................106
Fault clearance ..........................................................................................................................109
What to do if......................................................................................................................................109
Motor and gear ................................................................................................................................. 110

Contents 5
Decommissioning and waste disposal.............................................................................111
Machine disposal...............................................................................................................................111
Main components of the machine..................................................................................................... 112
Contact details........................................................................................................................... 113
Head office ....................................................................................................................................... 113
Subsidiaries, branch offices and sales partners worldwide .............................................................. 114
Service branches - Germany............................................................................................................ 116
Suggestions and information ............................................................................................................ 116

Contents6
Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017

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

Applicable documents
EC Declaration of Incorporation
8
Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017

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: Curve belt conveyor TS 1600-105FH2
Version 5.3ENG, 16.02.2017
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: Curve belt conveyor TS 1600-105FH2
Version 5.3ENG, 16.02.2017
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: Curve belt conveyor TS 1600-105FH2
Version 5.3ENG, 16.02.2017

Safety
Operating conditions 15
Safety
Operating conditions
The conveyor, subsequently referred to as the machine, is an incomplete
machine as defined by the EC Machinery Directive. The machine has been
designed according to the state of the art.
Nevertheless, there may be dangers arising from the machine under the
following circumstances:
Improper use
Improper use
Impermissible operating conditions
Failure to comply with these installation and operating instructions
Failure to comply with the general safety regulations during transport and
installation
Intended use
The machine shown on the front page is intended for the transport of unit
loads in compliance with the performance specification only and is intended
for incorporation into a fully automatic intralogistic system with superordinate
control.
Any use other than this is classed as improper use and is forbidden.
We point out explicitly that the machine is not designed for transporting
human beings.
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.

Safety
Operating conditions
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Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017
Impermissible operating conditions
Do not operate the machine under the following conditions:
While there are people or objects in the danger zones
Safety devices are not working or have been removed
The machine is malfunctioning or damaged
Maintenance intervals have been exceeded
Operating parameters have been changed without authorisation
Responsibilities of the operating company / integrator
The machine safety can only be guaranteed if all required measures are
taken. The operating company/integrator is responsible for planning and
implementing appropriate measures.
These operating instructions are part of the machine. You are obligated to
pass on this document to the buyer of the machine should it be sold.
The operating company/integrator of the machine is responsible for its
safety. This applies especially to:
The installation to form a complete machine with functioning and
compliant safety devices.
The incorporation of the machine in such a way that no additional
danger/hazards are created.
the physical inviolability of all people working near the machine
Fault-free operation of the machine.
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.
Make sure all operators are familiar with the safety devices.
Ensure the machine and its surroundings are always tidy and clean.
Provide safety equipment for operating personnel. Make sure the protec-
tive clothing is worn.
Provide instructions for procedures and behaviour in the case of distur-
bances.
Clarify questions regarding occupational health and safety and protection
of the environment.

Safety
Operating conditions 17
Fault-free operation of the machine
Implement the following measures to ensure trouble-free operation of the
machine:
Always keep the complete operating instructions legible, handy and
close to the machine so that it is available to personnel at all times.
Only operate the machine when fully functional.
Check the machine and its safety equipment regularly to ensure that
they are fully functional.
Carrying out installation layout
Observe the following basic safety principles when connecting several sepa-
rate components to form an overall system:
Install isolating safety devices in areas of pulleys, apex bends, roller
arches, conveyor gates and transfer drives.
In the vicinity of a transfer drive or a conveyor gate, the belt must have
the same speed or run faster in the outfeed area than in the infeed area.
The national safety regulations valid in the country of use as well as
additional sector-specific requirements shall apply.
Commissioning
This conveyor system is a "partly completed" machinery, as defined by the
Machinery Directive 2006/42/EC,Article 2g. Only the use of a respective
control system and if necessary other (partly completed) machinery allows
for intralogistic functionality. 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
Safety equipment
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Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017
Safety equipment
The machine is equipped with various covers to protect parts of the body
from crush injuries or being drawn in. This safety equipment is listed below.
It is explicitly prohibited to render protective devices unusable, to by-pass or
remove them. They may only be taken off temporarily during maintenance or
repair work.
If the purchasing contract specifies that certain safety equipment is not
included in the sale, the operating company/integrator must perform an eval-
uation of the danger areas according to the Machinery Directive. In case that
additional guards are required, especially on nip points and transfer sections,
these need to be provided in accordance with the respective current national
regulations and standards.
For ceiling suspension of the machine without side guides installed, safety
equipment must be provided in accordance with the respective current
national regulations and standards, to prevent harm to personnel.
For data regarding inspection intervals please see the maintenance plan.
Overview of safety equipment
Safety equipment on the TS 1600-105FH2 curve belt conveyor
Item Description
1Finger guard
2Finger guard insert
3Finger guard plate, outfeed side
4Bearing cover
5Bottom cover
6Bearing cover
7Finger guard plate, infeed side
8Finger guard insert
1
8 7 6 5 4 3 2

Safety
Staff qualifications 19
Safety equipment on side guides
Staff qualifications
Assembly, maintenance and repair works as well as the commissioning
demand special knowledge and qualifications of the staff involved.
We recommend to work with personnel trained and authorised by TRANS-
NORM SYSTEM GmbH only.
Every member of staff working on the machine must meet the following
requirements:
must be suitable for the required work and sufficiently qualified
must be instructed in the handling of the machine
must be familiar with the safety arrangements
must have read and understood these operating instructions and espe-
cially the relevant chapters regarding his work
must be familiar with the basic regulations regarding occupational health
and safety as well as the rules for accident prevention and branch-
specific regulations
Safety equipment on the TS 1600-105FH2 curve belt conveyor
Item Description
9finger guard, side guide
10 finger guard, side guide
10
9

Safety
Staff qualifications
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Operating instructions: Curve belt conveyor TS 1600-105FH2
Version 5.3 ENG, 16.02.2017
These operating instructions differentiate between the following person
groups:
The following work is to be carried out by specialised personnel only:
Definition of the groups of persons
Person groups Definition
User Considered as the operating company is the company that
uses the machine in compliance with the law and that operates
it with suitable and instructed members of staff
Integrator The integrator installs the partly completed machinery for the
operating company and integrates it into a system of machines
with a master controller and safety technology. (Responsible
for ensuring conformity of the overall system)
Operating
personnel Appropriately instructed by the user in Operation sequences of the machine
Operational courses
Possible dangers in case of misuse
Safety arrangements and measures
Specialised staff Specialised qualification and authorised by the user to carry
out special tasks such as assembly, maintenance and fault
clearance. Preconditioned is a respective training in both theo-
retical and practical experience.
Works requesting specialised knowledge
Activities Definition
Works on pneu-
matic components Specialised knowledge and experience in the handling of pneumatics
Works on electrical
components Electrical technician. Or: Instruction. The work may be carried out under the supervision of an electrical technician in accord-
ance with the rules and regulations for electrical engineering