transnorm TS 2800 User manual

TS 2800
Roller conveyor
Operating instructions

2
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Product Roller conveyor TS 2800
Manufacturer TRANSNORM SYSTEM GmbH
Förster Str. 2
D-31177 Harsum
Tel. [phone]
Fax [phone]
[e-mail]
http://www.transnorm.com
Documentation Operating instructions, -Translation-
Version 3.0 ENG, 14.05.2012
Subject to technical modifications. All rights reserved by TRANSNORM
SYSTEM GmbH. Reprint and duplications only with written approval.
Revision V 1.0 Initial version
V 2.0 Layout revised
V 3.0 Transport and installation updated

Inhaltsverzeichnis 3
Inhaltsverzeichnis
Further applicable documents ................................................................................................ 7
EC Declaration of Incorporation ........................................................................................................... 7
Introduction .................................................................................................................................... 9
Purpose of this document ..................................................................................................................... 9
Validity ............................................................................................................................................ 9
Illustrations ..................................................................................................................................... 9
Using these instructions ............................................................................................................... 10
Copyright ............................................................................................................................................ 11
Service................................................................................................................................................ 11
Warranty ............................................................................................................................................. 12
Safety ............................................................................................................................................... 13
Operating conditions........................................................................................................................... 13
Intended Use ................................................................................................................................ 13
Impermissible operating conditions .............................................................................................. 14
Responsibilities of the operating company / integrator................................................................. 14
Personnel qualification ....................................................................................................................... 16
Remaining risks .................................................................................................................................. 17
Protective devices ...................................................................................................................... 19
Protective devices on the machine ..................................................................................................... 20
Description .................................................................................................................................... 21
Technical description .......................................................................................................................... 21
Main dimensions................................................................................................................................. 21
Specifications...................................................................................................................................... 22
Areas of the machine......................................................................................................................... 24
Parts of the machine........................................................................................................................... 25
Motor designs ..................................................................................................................................... 26
Transport and installation ....................................................................................................... 27
Machine delivery................................................................................................................................. 27
Unpacking the machine ................................................................................................................ 27
A longer Storage Period of the Machine....................................................................................... 27
Disposing of packaging material................................................................................................... 28
Setting up the machine ....................................................................................................................... 28
Surface requirements ................................................................................................................... 28
Permissible operating conditions.................................................................................................. 28
In-Company Transport ........................................................................................................................ 29
Auxiliary Equipment ...................................................................................................................... 30

Inhaltsverzeichnis4
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Transport with industrial truck or crane ............................................................................................... 31
Final Installation on Site...................................................................................................................... 32
Installation .................................................................................................................................... 32
To carry out installation ................................................................................................................. 32
Operation ....................................................................................................................................... 35
Commissioning ................................................................................................................................... 35
Commissioning and start-up after service and maintenance works.................................................... 35
Normal operation ................................................................................................................................ 37
Shutdown ............................................................................................................................................ 37
Maintenance and care ............................................................................................................... 39
Maintenance work............................................................................................................................... 39
Motor maintenance ....................................................................................................................... 39
Gear unit maintenance ................................................................................................................. 39
Lubricants ........................................................................................................................................... 40
Maintenance Schedule ....................................................................................................................... 40
Cleaning and Care .............................................................................................................................. 41
Repairs ............................................................................................................................................ 43
Spare part purchasing
............................................................................................................................................................ 43
Tools, Equipment and Supplies .......................................................................................................... 43
Tightening torque ................................................................................................................................ 44
Replacing the side guide .................................................................................................................... 45
Tubular side guide ........................................................................................................................ 45
C-profile side guide....................................................................................................................... 47
Roller guard rail-side guide ........................................................................................................... 48
Replacing the round belt..................................................................................................................... 49
Replacing the Idler Rollers.................................................................................................................. 50
Loosen/tighten and adjust the drive belt ............................................................................................. 51
Replace pressure rollers ..................................................................................................................... 53
Replacing the Drive Belt ..................................................................................................................... 55
Replacing gear motor ......................................................................................................................... 57
Replace drive chain ............................................................................................................................ 60
Replacing flange bearings .................................................................................................................. 62
Replacing drive pulley......................................................................................................................... 65
Replace tail pulley rollers .................................................................................................................... 68
Replace the pulley on the tail pulley side...................................................................................... 68
Replace pulleys on the drive side ................................................................................................. 70
Replace tensioning rollers .................................................................................................................. 72
Fault clearance ............................................................................................................................ 75
What to do if........................................................................................................................................ 75
Motor and Gear................................................................................................................................... 75

Inhaltsverzeichnis 5
Decommissioning and disposal ........................................................................................... 77
Machine disposal ................................................................................................................................ 77
Main components of the machine....................................................................................................... 78
Contact details ............................................................................................................................. 79
Head office ......................................................................................................................................... 79
Subsidiaries, branch offices and sales partners worldwide ................................................................ 80
Service branches Germany ................................................................................................................ 82
Suggestions and comments ............................................................................................................... 82

Inhaltsverzeichnis6
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012

Further applicable documents
EC Declaration of Incorporation
7
Further applicable documents
EC Declaration of Incorporation

Further applicable documents
EC Declaration of Incorporation
8
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012

Introduction
Purpose of this document
9
Introduction
Purpose of this 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.
The following sections contain information on these topics:
 Safe handling of the machine
 Technical specifications
 Transporting, installing and putting the machine into operation
 Machine care and maintenance
 Machine repairs
 Fault detection and correction
 Taking the machine out of operation and disposal
Validity
These operating instructions apply to the operating company and all persons
working on or with the machine.
Illustrations
The illustrations show simplified views of the machine.
We reserve the right to make technical modifications in the course of further
development. Where installation is not described separately, it is performed
by following the steps for dismantling in reverse order.
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
Purpose of this document
10
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Using these instructions
Various types of information are shown in different types. In addition, impor-
tant information is displayed with symbols. The following examples illustrate
the symbols used.
DANGER
This is a warning! The nature and source of the danger are explained
here.
There is danger to the life and limb of personnel or a risk of damage to the
machine, other objects or the environment.
This measure must be taken in order to avert the danger.
This symbol is displayed beside important notes. Such notes provide supple-
mentary or further information and suggestions.
This is an individual, self-contained action.
1. This is the first step in a sequence of actions.
 This is a visible result of a sequence of actions.
 You have achieved an objective. The action has been completed.

You have completed an entire process.

Introduction
Copyright
11
Copyright
This publication must be treated as strictly confidential. It may only be used
by authorised persons and within the company. and must not be disclosed to
third parties without the written approval of TRANSNORM SYSTEM GmbH.
All documents are protected under copyright law. Dissemination or reproduc-
tion of these documents, in their entirety or as excerpts, is prohibited. Any
violation of this provision will lead to legal action and entitle the holder of the
copyright to claim compensation.
Service
Our service team is available to provide technical information on our prod-
ucts and their systematic application.
Please provide the following information when making inquiries or ordering
spare parts:
 Machine type
 Order / project number
 Item number
This information can be found on the type identification plate of the machine.
The plate is attached near the drive.
TRANSNORM SYSTEM GmbH type identification plate, example
You will find our contact details at the end of this instruction manual.

Introduction
Warranty
12
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Warranty
We accept no liability for defects or damage caused by improper handling,
operation or maintenance. Note that only original spare parts and accesso-
ries approved by TRANSNORM SYSTEM GmbH should be used.
Unless otherwise stipulated in the contract, the warranty period begins on
the day of delivery or with notification of supply readiness.
Please file all claims under warranty immediately after ascertaining the
defects. Please state the order, project and item number.
Warranty is offered exclusively in accordance with the legal stipulations.
Claims above and beyond this cannot be accepted.
Please note that the warranty is rendered null and void in the case of, for
example:
 Improper use
 Incorrect connections and prior installations which do not form part of our
scope of supply
 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
All wear parts are excluded from the warranty.

Safety
Operating conditions
13
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
manufactured in keeping with current scientific and technological develop-
ments.
Nevertheless, there may be dangers arising from the machine under the
following circumstances:
 Use other than for its intended purpose
 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
14
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Impermissible operating conditions
Do not operate the machine under the following conditions:
 When 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
 If maintenance intervals have been exceeded
 If 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. 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:
 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 the case of acci-
dents and emergencies.
 Define issues relating to occupational health and safety as well as envi-
ronmental protection.

Safety
Operating conditions
15
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 it is fully functional.
 Check the operability of the machine and the safety equipment regularly.
System layout
Observe the following basic safety principles when connecting several sepa-
rate components to form an overall system:
 Install guards 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 "partly completed" machinery as defined in the
Machinery Directive 2006/42/EC, Article 2g. Intralogistic functionality can
only be achieved through the use of a corresponding control system and if
necessary 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 incorpo-
rated comply with the requirements of the Machinery Directive.

Safety
Personnel qualification
16
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
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
Remaining risks
17
The following work is to be carried out by specialised personnel only:
Remaining risks
The machine's protective devices offer protection against injury.
For some tasks, however, personnel have to enter the danger zone. An
element of risk therefore always remains.
The following table will enable you to detect and avoid fundamental dangers
and hazards. Professional conduct and implmentation of the corresponding
measures minimise risks.
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.
Measures to avert risk and prevent damage
Danger Cause Measure
Risk of fatal
injury
Accidental restarting of
the machine
During maintenance / repair work:
Effectively interrupt the power supply to
all equipment
Secure the pneumatic system against
accidental re-start
Electricity During decommissioning:
Cut off the power supply
Secure against accidental re-start
Measure to ensure that the power is off
Falling or slipping of
loads
Transport and installation:
Observe the centre of gravity of the
machine and the permissible lifting load of
the hoists
Secure the machine and hoists to prevent
slipping

Safety
Remaining risks
18
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Risk of
injury
Sharp-edged machine
parts
During maintenance / repair work:
Be alert and proceed with caution
Wear appropriate protective clothing
Rotating shafts During adjustment work:
Never reach into rotating parts
Wear close-fitting protective clothing
Have one or more other persons assist
you
Falling machine parts During maintenance / repair work:
Support heavy parts (especially motors)
Never step or reach under loose parts
Hot electric motors Before touching:
Allow enough time for them to cool down
Wear appropriate thick protective clothing
Incoming loads Before remedying a fault:
Carefully observe the conveyor system
Keep limbs away from the conveyed
loads
Damage to
the environ-
ment
Leaking operating
fluids
During disposal:
Collect operating fluids in suitable
containers.
Dispose of waste oil, lubricating grease,
cleaning agents containing solvents and
similar products correctly
Measures to avert risk and prevent damage
Danger Cause Measure

Protective devices 19
Protective devices
Various covers are installed on the machine to prevent limbs being drawn in
and crushed. The protective devices and safety equipment are listed in the
following.
It is expressly prohibited to render unserviceable, bypass or remove protec-
tive devices. 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 scope of delivery, the operating company/integrator must
assess the potential dangers in accordance with the Machinery Directive.
Refer to the maintenance schedule for information on inspection intervals.

Protective devices
Protective devices on the machine
20
Operating instructions: Roller conveyor TS 2800
Version 3.0 ENG, 14.05.2012
Protective devices on the machine
Protective devices TS 2800, example illustration
Picture illustration
Item Description
1 Cover drive station
2 Cover tensioning arm
3 Protection plate belt guide
4 Infeed / outfeed guard
1 2 3
4