transnorm TS 2733 User manual

TS 2733
Lifting roller outfeed unit
Operating instructions

2
Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
Product Lifting roller outfeed unit TS 2733
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 1.2 ENG, 03.06.2019
Subject to modifications. All rights reserved by TRANSNORM SYSTEM
GmbH. Reprint and duplications only with written approval.
Revision V 1.0 Initial version
V 1.1 Alternative method for replacing the motorised roller added
V 1.2 Repairs updated

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
Operating conditions........................................................................................................................... 15
Intended use................................................................................................................................. 15
Impermissible operating conditions ..............................................................................................16
Responsibilities of the operating company / integrator................................................................. 16
Personnel qualification ....................................................................................................................... 18
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.................................................................................................................................... 29
Technical description .......................................................................................................................... 29
Main dimensions................................................................................................................................. 30
Technical data..................................................................................................................................... 31
Required performance level (PLr) ...................................................................................................... 33
Areas of the machine......................................................................................................................... 34
Parts of the machine........................................................................................................................... 36
Conveyor configurations..................................................................................................................... 38
Optional machine equipment.............................................................................................................. 38
Transport and installation....................................................................................................... 39
Delivery of the machine ...................................................................................................................... 39
Unpacking the machine................................................................................................................ 39
Long-term machine storage ......................................................................................................... 39
Disposal of packaging .................................................................................................................. 40

Table of contents4
Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
Setting up the machine .......................................................................................................................40
Ground requirements....................................................................................................................40
Permitted operating conditions .....................................................................................................40
Internal transportation.........................................................................................................................41
Auxiliary equipment ......................................................................................................................42
Transportation with industrial truck or crane.......................................................................................43
Final installation on-site ......................................................................................................................44
Installation ....................................................................................................................................44
Installation ....................................................................................................................................45
Electrical installation and electrical connection of the machine ....................................................47
Pneumatic block diagram ...................................................................................................................48
Operation .......................................................................................................................................49
Commissioning ...................................................................................................................................49
Commissioning and start-up after service and maintenance work .....................................................49
Normal operation ................................................................................................................................53
Shut-down...........................................................................................................................................53
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 ................................................................................................................................................60
Assembling/disassembling the bottom conveyor track cover .............................................................61
Replacing the side guide ....................................................................................................................62
Tube rail........................................................................................................................................62
C-profile rail ..................................................................................................................................63
Replacing the roller bars.....................................................................................................................64
Replacing the idler roller .....................................................................................................................66
Replacing the belts .............................................................................................................................67
Replacing the Poly-V belts ...........................................................................................................67
Replacing the round belt (roller bars) ...........................................................................................69
Replacing the round belt (rollers) .................................................................................................70
Replacing the motorised roller ............................................................................................................71
Replacing the motorised roller (conveyor track) ...........................................................................71
Replacing the motorised roller (roller bars) ..................................................................................73
Alternative method for replacing the motorised roller (roller bars)................................................75

Table of contents 5
Replacing the gear motor (only for TS 2733-04) ................................................................................ 78
Replacing the gear motor (lift drive) ............................................................................................. 78
Replacing the gear motor (roller bar drive)................................................................................... 80
Replacing the flange bearing (only for TS 2733-04)........................................................................... 82
Replacing the push rod (only for TS 2733-04)....................................................................................83
Replacing the toothed belt (only for TS 2733-04)............................................................................... 85
Replacing the toothed belt pulley (only for
TS 2733-04)........................................................................................................................................ 86
Replacing the pneumatic cylinder (only for
TS 2733-03)........................................................................................................................................ 87
Replacing the pneumatic valve (only for TS 2733-03)........................................................................ 89
Pneumatic block diagram ................................................................................................................... 90
Troubleshooting.......................................................................................................................... 91
What to do if ... ................................................................................................................................... 91
Motor and gear unit ............................................................................................................................ 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

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Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019

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: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019

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: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
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: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
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: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019

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 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
performance specification and is intended to be integrated in a fully auto-
matic 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.

Safety
Operating conditions
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Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
Impermissible operating conditions
Operation of the machine is prohibited under the following circumstances:
There are people or objects in the hazardous areas
If 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 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 as 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 safety of all persons in the vicinity of the machine.
Trouble-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 equipment.
Ensure that the machine and its surroundings are always tidy and clean.
Provide safety equipment for operating personnel.
Make sure the protective clothing is worn.
Provide instructions on how to proceed and behave in case of accidents
and emergencies.
Define issues relating to occupational health and safety as well as envi-
ronmental protection.

Safety
Operating conditions 17
Trouble-free operation of the machine
Implement the following measures to ensure trouble-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.
Routinely check the operability of the machine and the safety equipment.
System 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 conveyor 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" machine, 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
Personnel qualification
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Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
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 in 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 the basic occupational health and safety and accident
prevention regulations and with sector-specific regulations.
In these instructions, a distinction is made between the following personnel
groups:
Definition of the personnel groups
Personnel
group Definition
Operating
company The operating company is defined as the person responsible for deployment of the machine for its intended purpose and having
the machine operated by suitable and instructed persons
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 Personnel who are appropriately instructed by the operating company in the
Functional and operating procedures for the machine
Possible hazards arising from improper operating procedures
Protective devices and measures
Technical
personnel Are technically qualified and authorised by the operating company to carry out specific tasks such as installation, maintenance and
fault elimination. Corresponding training in theory and practice is a
prerequisite.

Safety
Personnel qualification 19
The following work is to be carried out by specialised personnel only:
Works requesting 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.

Safety
Remaining risks regarding the machine
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Operating instructions: Lifting roller outfeed unit TS 2733
Version 1.2ENG, 03.06.2019
Remaining risks regarding the machine
The machine's protective devices offer protection against injury.
However, for some special tasks it is unavoidable to enter the danger zone.
Therefore, an element of risk always remains.
Remaining risks for operating personnel
The following table will enable the operating personnel to detect and avoid
fundamental dangers and hazards. Professional conduct and implementation
of the corresponding measures prevents remaining dangers.
Measures for operating personnel to avert risk and prevent damage
Danger Cause Measure
Risk of
injury Sharp-edged machine parts During fault clearance: Be alert and proceed with caution
Avoid hectic movements
Wear appropriate protective clothing
Rotating parts During fault clearance:
Do not reach into rotating parts
Wear appropriate protective clothing
Observe warning labels on the machine
Hot electric motors Do not touch
Incoming loads Before remedying a fault:
Carefully observe conveyor system
Assess whether the system needs to be
stopped due to an unclear situation
During remedying a fault:
Keep limbs away from the conveyed loads
Fix conveyed loads jam
Only switch the system on again when
conveyed loads jam is fixed
Conveyed loads During operation:
Do not reach into conveyed loads
Observe warning labels on the machine
During remedying a fault:
Assess whether the system needs to be
stopped due to an unclear situation
Secure system against unintentional re-
start, if necessary
Be alert and proceed with caution
Damage
caused to
the environ-
ment
Leaking utilities During operation:
Inform technical personnel/shift supervisor