transnorm TS 6565 User manual

TS 6565
Motor-driven belt diverter
driven side guide
Operating instructions

2
Operating instructions: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
Product Motor-driven belt diverter TS 6565
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 1.0 ENG, 01.03.2017
Subject to modifications. All rights reserved by TRANSNORM SYSTEM
GmbH. Reprint and duplications only with written approval.
Revision V 1.0 Initial version

Contents 3
Contents
Applicable documents................................................................................................................ 5
EC Declaration of Incorporation ........................................................................................................... 5
Introduction .................................................................................................................................... 7
Purpose of the document ..................................................................................................................... 7
Validity ............................................................................................................................................ 7
Illustrations ..................................................................................................................................... 7
Using the instructions ........................................................................................................................... 8
Safety instructions ................................................................................................................................ 9
Copyright protection ........................................................................................................................... 10
Service................................................................................................................................................ 10
Warranty ............................................................................................................................................. 11
Safety............................................................................................................................................... 13
Operating conditions........................................................................................................................... 13
Intended use................................................................................................................................. 13
Impermissible operating conditions ..............................................................................................14
Responsibilities of the operating company / integrator................................................................. 14
Personnel qualification ....................................................................................................................... 16
Remaining risks regarding the machine ............................................................................................. 17
Remaining risks for operating personnel...................................................................................... 17
Remaining risks for technical personnel....................................................................................... 18
Protective devices...................................................................................................................... 21
Protective devices on the machine..................................................................................................... 22
Description.................................................................................................................................... 23
Main dimensions................................................................................................................................. 24
Specifications ..................................................................................................................................... 25
Parts of the machine........................................................................................................................... 27
Parts of the machine........................................................................................................................... 28
Transportation and erection................................................................................................... 29
Delivery of the machine ...................................................................................................................... 29
Unpacking the machine................................................................................................................ 29
Storing the machine for a longer period ....................................................................................... 29
Disposing of packaging materials................................................................................................. 30
Installing the machine......................................................................................................................... 31
Ground requirements ................................................................................................................... 31
Permissible operating conditions.................................................................................................. 31

Contents4
Operating instructions: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
In-company transport..........................................................................................................................32
Auxiliary equipment ......................................................................................................................33
Transportation with industrial truck or crane .......................................................................................33
Final installation on site ......................................................................................................................34
Installing motor-driven belt diverter.....................................................................................................34
Electrical connection...........................................................................................................................36
Operation .......................................................................................................................................37
Commissioning ...................................................................................................................................37
Commissioning and start up after service and maintenance works....................................................37
Normal operation ................................................................................................................................40
Shutdown............................................................................................................................................40
Maintenance and care...............................................................................................................41
Maintenance work...............................................................................................................................41
Lubricants ...........................................................................................................................................41
Maintenance plan ...............................................................................................................................42
Cleaning and care...............................................................................................................................44
Corrective maintenance...........................................................................................................45
Spare part purchasing ........................................................................................................................45
Tools, equipment and supplies ...........................................................................................................45
Tightening torques ..............................................................................................................................46
Guards ................................................................................................................................................47
Replacing the gear motor ...................................................................................................................48
Tensioning/loosening/adjusting the belt ..............................................................................................50
Replacing the flange bearings ............................................................................................................52
Replacing the drive pulley...................................................................................................................53
Replacing the tail pulley......................................................................................................................55
Replacing the belt ...............................................................................................................................57
Exchange the tensioning roller ...........................................................................................................59
Fault clearance ............................................................................................................................61
What to do if .......................................................................................................................................61
Motor and gear unit.............................................................................................................................62
Decommissioning and disposal...........................................................................................63
Machine disposal................................................................................................................................63
Main components of the machine.......................................................................................................64
Contact details.............................................................................................................................65
Head office..........................................................................................................................................65
Subsidiaries, branch offices and sales partners worldwide ................................................................66
Service branches Germany ................................................................................................................68
Suggestions and comments ...............................................................................................................68

Applicable documents
EC Declaration of Incorporation 5
Applicable documents
EC Declaration of Incorporation

Applicable documents
EC Declaration of Incorporation
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Operating instructions: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017

Introduction
Purpose of the document 7
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 separately
supplied order confirmation.

In the chapters below you will find information on the following topics:
 The safe handling of the machine
 Technical specifications
 Transporting, installing and putting the machine into operation
 Maintenance instructions
 Refurbishing the machine
 Fault detection and correction
 Putting the machine out of action
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 installation is not described, this will be carried out in
exactly the opposite order to dismantling.

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: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
Using the instructions
Different circumstances are marked appropriately. Important information has
also been marked with additional symbols. The following overview shows the
different information representation types.
 This is an individual, self-contained action.
1. This is the first step in a series of activities.
 This is a useful remark on a specific work step.
?This problem may arise.
This is the cause of the problem.
 This is a measure to solve the problem.
You have completed a sequence of action.
 You have completed the entire activity.
This is a notice
Notices provide additional information.

Introduction
Safety instructions 9
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 respec-
tive severity of the risk.
The following overview shows the safety instructions used in this document.
DANGER
This instruction type 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 instruction type warns of moderate or minor injury
This states the cause of the danger.
 You must take this action to avert the danger.
CAUTION
This instruction type warns of damage to machine or material
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: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
Copyright protection
This publication must be treated as strictly confidential. It is intended only for
in-company 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. Any violation of this provision will lead to legal action and
entitle the holder of the copyright to claim compensation.
Service
Our service is available for technical information on our products and their
systematic application.
Please provide the following information when making inquiries or ordering
spare parts:
 Machine type
 Order-/project number
 Item number
You will find this information on the machine type identification plate. It is
located in the vicinity of the drive unit.
TRANSNORM SYSTEM GmbH type identification plate, example
You will find our contact data at the back of these operating instructions.

Introduction
Warranty 11
Warranty
We shall accept no responsibility for any defects or damage caused by inap-
propriate use, operating errors or incorrect servicing and maintenance. Note
that only original spare parts and accessories 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 quote the order (project) and item number when making a
claim.

The warranty shall be in line with statutory regulations. All claims above and
beyond this are excluded.
Please note that the warranty is rendered null and void in the case of, for
example:
 Improper use.
 Improper connecting and preparatory works not included within our
scope of service
 incorrect use of control units
 Non-use of 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: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017

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
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: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
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 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 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: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
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:
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 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.
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 17
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

Safety
Remaining risks regarding the machine
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Operating instructions: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
Remaining risks for technical personnel
The following table is intended to help the technical personnel (responsible
for installation, repairs or fault elimination) to detect and avoid fundamental
dangers and hazards. Professional conduct and implementation of the corre-
sponding measures prevents remaining dangers.
It is important to observe the instructions and safety instructions during
installation works, maintenance works and repairs described in the corre-
sponding sections. This is essential for works that require to remove protec-
tive devices.
Measures for technical personnel to avert risk and prevent damage
Danger Cause Measure
Risk of fatal
injury Accidental re-start of the machine During maintenance / repair work:
 Inform your colleagues that it is prohibited to
re-start the machine until notified otherwise
 Disrupt power supply
 Apply a label to prevent accidental re-
connection of the power supply
 Prevent accidental re-connection of the
power supply as described in the operating
instructions of the system
Electricity For shut-down:
 Disrupt power supply
 Secure system against accidental re-start
 Measure 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
 Read chapter "Transport and installation"
and carefully observe the instructions
For conveying systems ceiling suspension:
 Observe the assembly instructions of the
suspensions

Safety
Remaining risks regarding the machine 19
Risk of
injury Sharp-edged machine parts During maintenance / repair work:  Be alert and proceed with caution
 Avoid hectic movements
 Wear appropriate protective clothing
Rotating parts For maintenance and adjusting works:
 Do not reach into rotating parts
 Wear close fitting protective clothing
 Have one or more other persons assist you
 Observe warning labels on the machine
Falling off machine
parts During maintenance / repair work:
 Support heavy parts (especially motors)
 Do not step under loose parts or touch them
 Secure working area so that personnel is
not endangered
For works at suspended machines:
 Cordon off the working area
 Have a second person supervise the opera-
tion
 Put tools and parts down carefully and
prevent them from falling
Hot electric motors Before touching:
 Allow enough time for them to cool down
 Wear suitable and thick protective clothing
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 accidental re-start, if
necessary
 Be alert and proceed with caution
During maintenance / repair work:
 Disrupt machine from electric supply during
the works
 Secure system against accidental re-start
Measures for technical personnel to avert risk and prevent damage
Danger Cause Measure

Safety
Remaining risks regarding the machine
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Operating instructions: Motor-driven belt diverter TS 6565
Version 1.0 ENG, 01.03.2017
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 for technical personnel to avert risk and prevent damage
Danger Cause Measure