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AmbaFlex SV Series Maintenance Manual

Spiralveyor
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MAINTENANCE MANUAL

AmbaFlex Spiralveyor UK
TYPE: SV
Date: 2008/11/14
AmbaFlex machine number: 8307-01
Customer reference number: 8352944

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Summary of Contents for AmbaFlex SV Series

  • Page 1: Maintenance Manual

    MAINTENANCE MANUAL AmbaFlex Spiralveyor UK TYPE: SV Date: 2008/11/14 AmbaFlex machine number: 8307-01 Customer reference number: 8352944...
  • Page 2 Attention It is very important for the proper functioning of the Spiralveyor that maintenance is done correctly and timely. In the enclosures of this manual you will find a maintenance log in which all maintenance must be documented. Improper, insufficient or not documented maintenance will void any warranty.
  • Page 3 Preface Purpose of this manual Structure of the manual Requirements of the user Technical specification Introduction Supplier’s information Manufacturer’s declaration Purpose of use Operating conditions Description of the Spiralveyor Working principle Control units Safety The most important safety conditions Description of safety provisions Safety measures to be taken Explanation of symbols Unload the Spiralveyor...
  • Page 4 Disconnect the power sources Disassemble Transport Reuse Sales offices AmbaFlex Enclosures SEW Manufacturer’s declaration Spare parts list II - A Article list II - B SV-400 Brakemotor Electrical installation IV - A Wiring diagram for chain overlength detection Maintenance Log...

  • Page 5: Preface

    The user’s manual has been divided into three sections. These sections describe, among other things, the safety and the operation of the Spiralveyor. AmbaFlex would like to point out to the user that section 4 safety [4 Safety] is to be read carefully.
  • Page 6 Technically qualified employees means: employees that have followed an adequate training for carrying out the activities involved. 2008/11/14 Page 6 of 75...

  • Page 7: Technical Specification

    Slope angle (a) 9,98 ° Column diameter 760 mm (563) (175) Supports Standard floor mounting support frame Feet Galvanised feet -70/+110 mm adjustable (AmbaFlex (178) model) Base machine moving parts Slat belt options Slat type TPS Black POM (186) (188)
  • Page 8 1 copies English language (439) address All manuals on CD All manuals supplied to purchase address on 1 CD(s) (728) Identification marker (480) Type plate AmbaFlex Sticker AmbaFlex (481) Product dimensions, weight & throughput Rows Product name Length Width Height...

  • Page 9: Introduction

    Modifications on the machine. This also includes the use of other replacement parts than prescribed. • Insufficient or incorrect maintenance. AmbaFlex does not accept any liability for the consequential damage in case of failures of the machine, for example damage of products, interruption of operation, etc. 2008/11/14...

  • Page 10: Manufacturer's Declaration

    The circumstances under which the Spiralveyor can be applied partly depend on the materials selected. Yet AmbaFlex has defined a number of parameters within which the Spiralveyor would be allowed to function. Should the Spiralveyor still be applied beyond these limiting values, AmbaFlex cannot guarantee the good functioning of the Spiralveyor.

  • Page 11: Description Of The Spiralveyor

    As a standard no lighting is installed on the Spiralveyor and this can neither be installed as an option. Normal ambient lighting is sufficient to work safely with the Spiralveyor. The Spiralveyor is not intended for use in the open air and besides the Spiralveyor is not suitable for an environment with a risk of explosion. For use under deviating circumstances you may contact the supplier of the Spiralveyor.
  • Page 12 Component Description Frame The basic frame of the Spiralveyor consists of a central cylinder, a return tray and an upper and lower end. The materials of these components depend on the configuration selected. The return tray can be divided into a vertical and a horizontal return tray.
  • Page 13 Vertical return tray Conveyor plate Motor reductor Horizontal return tray Chain Drive shaft Link Chain wheel Reaction arm Reversing roller + guide belt Return trays Components conveyor belt Drive Explanation of machine terms This manual contains a number of terms that will frequently be used. The most important terms will be discussed below.

  • Page 14: Working Principle

    Spiralveyor is integrated in. It is possible to have a configuration with which the output side is placed in a certain angle. For this special configuration please contact AmbaFlex in order to discuss the possibilities with respect to this. Working principle The purpose of the Spiralveyor is to transport products / goods vertically to bridge a difference of height or to function as buffer zone.

  • Page 15: Control Units

    1. Conveyor belt 2. Upper end 3. Lower end 4. Return tray horizontal 5. Return tray vertical 6. Motor reductor Principle sketch Spiralveyor In most cases the Spiralveyor is integrated in a system. The input / output side of the Spiralveyor is determined dependent on the system.
  • Page 16 All details in de manual apply, unless stated otherwise in the technical specification. 2008/11/14 Page 16 of 75...

  • Page 17: Safety

    Spiralveyor into operation some safety provisions are to be taken care of. The purpose of these safety provisions is to protect the user, the product and the Spiralveyor against undesired situations (damage). Without these safety provisions AmbaFlex cannot give a guarantee on any damage caused in absence of these safety provisions.

  • Page 18: Safety Measures To Be Taken

    Height / width detector The product that is put into the Spiralveyor may not get stuck as a result of a too high / wide or twisted product. In order to ensure that products fit in the Spiralveyor and will not get stuck, the input of the SV can be checked for height / width.
  • Page 19 Description Picture 1.Type plate Spiralveyor This contains the name and the address of AmbaFlex. Apart from that the CE-mark, series or type indication, serial number and the year of construction of the Spiralveyor. 2.Rotation direction On the Spiralveyor an arrow indicates the rotation direction of the conveyor belt.

  • Page 20: Unload The Spiralveyor

    Unload the Spiralveyor This section describes the steps that are required for unloading the Spiralveyor. It is recommended to make use of the devices described in § 3.1. When using this or another device this device is expected to be provided with a quality mark.

  • Page 21: Unloading Instructions

    Machine serial number foot cross Machine serial number type plate Any damage is to be mentioned on the delivery note and should immediately be reported to the supplier. This with respect to the guarantee of the machine. Unloading instructions The Spiralveyor can be unloaded in many ways. This is because the Spiralveyor is transported in certain positions dependent on the dimensions (horizontal or vertical).
  • Page 22 Unloading procedure truck at the rear side / from the container • If the Spiralveyor is not standing directly at the unloading edge, it should first be moved to the edge. This can be done with the help of the pump carriage or transport roller. Place the transport roller Spiralveyor at the edge •...

  • Page 23: Unload The Spiralveyor From The Truck At The Top

    Mount crane to support Spiralveyor placed 5.2.2 Unload the Spiralveyor from the truck at the top Device(s) Crane Unloading procedure truck unloading at the top • Prior to unloading the Spiralveyor a transport check is to take place. For this we refer to paragraph 3.1.

  • Page 24: Unload The Spiralveyor From The Truck At The Side

    Fasten transport supports Hoist Spiralveyor Put Spiralveyor on the ground 5.2.3 Unload the Spiralveyor from the truck at the side Device(s) Fork-lift truck Unloading procedure from the truck at the side (SV vertical) • Prior to unloading the Spiralveyor a transport check is to take place. For this we refer to the technical specification.

  • Page 25: Unload The Spiralveyor From A Crate

    Lower the Spiralveyor Lower the Spiralveyor Calmly place the Spiralveyor 5.2.4 Unload the Spiralveyor from a crate First remove all connecting devices that secure the case. After this the unloading procedure may be started. Device(s) Crane Fork-lift truck Pump carriage Unloading procedure •...
  • Page 26 Device(s) Hoist Crane Fork-lift truck Open-end spanner Make sure when putting upright there is enough space / height to put the Spiralveyor upright! Mount adjusting feet If the adjusting feet have not been mounted yet, there are two moments to do this. The adjusting feet can be mounted while the Spiralveyor is still in a horizontal position.
  • Page 27 • The crane is to be fastened at the top of the upper transport support. • After that the Spiralveyor can be hoisted in the upright position. Fasten the Spiralveyor to the crane Lift the Spiralveyor a bit Hoist the Spiralveyor in the upright position •...

  • Page 28: Mounting, Installation, Adjustment And Commissioning

    Mounting, installation, adjustment and commissioning This section deals with the operations to have the Spiralveyor function well within a (transport) system. First § 4.1, in which the provisions to be taken care of are given, should be studied carefully. Paragraph 4.2 is particularly important for the Spiralveyors that are delivered to the end user not fully assembled.
  • Page 29 Procedure: • Determine the installation orientation of the gear motor (see red arrow on figure 1) • Apply installation grease on the shaft to slide the gear motor onto the shaft easier. • Place the locking ring in the gear motor (if this is not done yet) •...

  • Page 30: Installing Chain Over Length Detection

    6.2.2 Installing chain over length detection The chain tension on the belt must be properly tensioned at all times since the chain is the most important working element on the Spiralveyor. When the chain is not properly tensioned the following issues can occur: •...

  • Page 31: Mounting B-Guide

    6.2.3 Mounting B-guide This paragraph describes how the B-guide, if applicable, is mounted against the side of the glide strip. Tools Open-end spanner Ring spanner Components B-guide Mounting bracket Bolts Screws Procedure B-guide • Start by attaching the mounting brackets to the frame. If an offset has been chosen, an offset bush is to be placed between the frame and the mounting bracket! •...

  • Page 32: Validation

    Fig. 4 Connection mounting bracket Fig. 5 Fastening with offset Fig. 6 Smooth connection Make sure that there is a smooth connection between the guides, so that no products can get stuck. Validation First of all, the validation starts by checking again the dimensions and subsequently a test run is made. The test run takes place in an unloaded condition, which means that no products are to be transported on the Spiralveyor during the test run.
  • Page 33 Test Measurement Duration Carried out Let de motor run Check the SV for .Yes / No slowly (max. 10 the rotation direction of the conveyor belt. If this is not correct, the motor is not connected well (see annex 2b) The rotation Check whether 10 minutes...

  • Page 34: Integration In A (Transport) System

    carried out and in case of any problems these have been solved. Now the SV may be switched off and one can start integrating the SV in the (transport) system. It is not recommended to make a test run with the machine while safety provisions have been deactivated or guards removed.

  • Page 35: Frequency Control

    Fig. 1 Configuration Fig. 2 Fastening plates The quality of integration in the system is co-responsible for the good functioning of the Spiralveyor. Therefore make sure this is done properly! 6.4.2 Frequency control The speed of the output and input track is optimal if this is equal to the speed of the Spiralveyor. The fact is that this can prevent product twisting or wear of the HF conveyor plates.

  • Page 36: Reverse / Adjust / Set

    Component Remark Checked Lower end Has the lower end the Yes / No correct height and is the distance to the connecting track not more (and not less) than 25 mm. For the correct height we refer to the technical specification.

  • Page 37: Controls

    Component Setting / Remark Picture Height setting The adjusting feet Spiralveyor can be used to set the Spiralveyor to the correct height. If necessary, the connecting tracks can be adjusted to this as well. Transition roller lower Aligned or level. The end (optional) roller can be adjusted in height with the...

  • Page 38: Check / Shadow Run

    Component Setting Remark Frequency control The speed difference of the connected conveyor tracks may not be below 15% compared to the Spiralveyor speed. Emergency-stop Direct The reaction of the switch Spiralveyor to pressing should be direct and the conveyor belt will stop between 1 and 3 seconds, dependent on the track speed.
  • Page 39 Check Remarks Does excessive Yes / No This may occur noise occur. because the tension of the chain is not correct, conveyor plates are loose or a chain wheel is not aligned well (see § 5.1 ‘troubleshooting list’ items 8 and 11) There is a ticking Yes / No This may occur...
  • Page 40 Check (safety) provisions AmbaFlex does not deliver the safety provisions and the control connected to that. For proper functioning we refer to the installer who has installed the control. Below a check table is set up with respect to how the safety provisions can be tested for proper functioning.

  • Page 41: Technical Maintenance

    Technical maintenance Technical maintenance is an important part of this manual. Good maintenance will lead to cost reduction, because defects can be timely recognised and solved. This section starts with a troubleshooting list, subsequently a maintenance schedule is set up in § 5.2 and § 5.3 describes different maintenance activities. In some chapters you will find a web page link;...
  • Page 42 Trouble Possible cause Solution Spiralveyor does not work No tension Have proper personnel find the fault and remedy this. Motor defect Replace the motor (see § 4.2.1) Spiralveyor does not work, Teeth chain wheel worn Replace the chain wheel. It but the motor is functioning is recommended to replace the entire chain at once.

  • Page 43: Maintenance Schedule Spiralveyor

    Product stoppage at Product orientation Align the product at the end beginning or end Defect transition roller Contact the supplier of the AmbaFlex Spiralveyor Product stoppage below Product height is too low Contact the supplier the side guide Chain too long Combination of speed and Shorten the chain (see §...
  • Page 44 Execution Interval Remark Clean conveyor belt Monthly Regular cleaning depends on product and environment (see user’s manual § 3.5.1) Check the conveyor belt Daily It is the task of the operator for broken or missing to check this daily (see conveyor plates, replace if user’s manual §...

  • Page 45: Checking Conveyor Plates

    If this is more than 38.5 mm (1.52") (width conveyor plate), a link can be removed from the chain. This gives the chain the correct tension again. See for shortening the chain § 5.3.2. http://www.ambaflex.com/video/?video=88888-9.swf Fig. 1 Tape measure on conveyor Fig.

  • Page 46: Checking Side Guide

    • The maximum allowed chain stretch is 1.5%; the chain must be replaced when the measured distance is more than 387 mm [15,23"]. Contact AmbaFlex service for the replacement. Tape measure on conveyor belt If the chain has been shortened by 1,5% of the total length, the chain is to be replaced.

  • Page 47: Maintenance Procedures

    Before disassembling any part please refer to the assembly chapter in this manual. AmbaFlex has facilities on the Spiralveyor to make the maintenance easier. You can read about these features in the first chapters.

  • Page 48: Slatbelt Service Location

    7.3.2 Slatbelt service location The right angle turn in the return channel of the Spiralveyor contains a slat belt service location. This location must be used to remove slats for maintenance or replace slats which are broken. The location is chosen because usually it has some working room around it and is commonly located close to working height.
  • Page 49 When a slat is wrongly place it can result in damage to the Spiralveyor and the products transported on it. It’s very important to correctly (re)place a slat. Disconnect the main power and activate the working switch so there can be no tension on the drive.
  • Page 50 Fig. 2 Chain without slats Fig. 3 Placing a slat • When all maintenance activities are completed the service location must be placed back into original working condition. • Test run the machine at 10% of the speed and check if the track runs correct. Make sure that the slat is always placed on the connecting links of the chain and that the bearing on the slat is placed on the column side of the track.

  • Page 51: Shorten Chain

    Once chain overlength is detected the chain must be shortened. Shortening the chain can best be done at the lower end. AmbaFlex delivers a chain tensioner with the machine to assist in this procedure. Follow the below procedure to shorten the chain: •...

  • Page 52: Replace Reversing Roller

    Procedure chain wheel lower / upper end • Move the conveyor plate with the coloured dot to the lower / upper end. Then the conveyor plate may be removed, see § 5.3.1. Do this with another number of conveyor plates, so that at the moment the link is removed from the chain the chain wheel is released.
  • Page 53 Allen key Open-end spanner Ring spanner Plastic hammer Procedure • Move the conveyor plate with the coloured dot to the chain wheel at the lower end. • Release the chain wheel by uncoupling the chain of the conveyor belt at the conveyor plate with the coloured dot (see fig.

  • Page 54: Replace Sprocket Wheel

    • Mount (drive) shaft including reversing rollers and then mount motor if present. • Couple conveyor chain again and mount the conveyor plates with coloured dot. • Carry out a test run to see whether no unusual things will happen. See § 4.5.2 for information. •...

  • Page 55: Lubricate The Motor

    Fig. 4 Bearing block with locking Fig. 5 Shaft with chain wheel ring Eventually a shaft with a chain wheel is left. These two components can be replaced as a whole. If one decides to only replace the chain wheel, one should pay due attention to the orientation of the chain wheel.

  • Page 56: Put Out Of Comission

    Put out of comission At the moment a Spiralveyor is put out of operation for some reason, a number of steps are to be taken in order to avoid dangerous situations. This section clearly indicates how one should proceed in a number of cases with respect to uncoupling, dismounting, transport and reuse of materials coming from the Spiralveyor Disconnect the power sources Prior to starting the dismounting, the tension is to be cut off from the tension.
  • Page 57 2008/11/14 Page 57 of 75...

  • Page 58: Sales Offices Ambaflex

    Sales offices AmbaFlex EUROPE NORTH AMERICA AmbaFlex bv AmbaFlex. Inc. De Corantijn 81, 1689 AN Zwaag P.O. Box 210578 P.O. Box 94, 1620 AB Hoorn Bedford, TX 76095-7578 Holland phone +31 (0)229 285 130 phone (877) 800 1634 fax +31 (0)229 285 131 fax (877) 800 1635 e-mail mail@ambaflex.nl...
  • Page 59 SEW Manufacturer’s declaration MANUFACTURER'S DECLARATION (Directive 89/392/EEC, art. 4, paragraph 2 and Appendix II under B) VECTOR AANDRIJFTECHNIEK B.V. Industrieweg 175, 3044 AS Rotterdam We herewith declare, that the SEW Gear Units type R( . . )27( . . ) up to R( . . )167( . . ) type PSF211( .

  • Page 60: Ii Spare Parts List

    Spare parts list 2008/11/14 Page 60 of 75...

  • Page 61: Ii - A Article List

    II - A Article list With Machine VO8307-01 Article # Amount # Drawing # Pos on Description Material drawing 81500001 89040003 Bearing in Slat (H=19) Steel 81310477 89040003 Slat TPS 4 HF RC Acetyl black 50310001 89040001 O-ring noise reducing [395 mm x 8 mm] Pyrathane 50101167 89040002...
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  • Page 63 II - B SV-400 2008/11/14 Page 63 of 75...
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  • Page 68: Iii Brakemotor

    Brakemotor 2008/11/14 Page 68 of 75...
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  • Page 72: Iv Electrical Installation

    Electrical installation 2008/11/14 Page 72 of 75...

  • Page 73: Iv - A Wiring Diagram For Chain Overlength Detection

    IV - A Wiring diagram for chain overlength detection 2008/11/14 Page 73 of 75...

  • Page 74: V Maintenance Log

    Maintenance Log Please copy this maintenance log as many times are required to document all maintenance activities. Each maintenance activity must be dated and signed in the next empty box on the row where the activity is described. For maintenance instructions and intervals, please refer to the chapter technical maintenance. 2008/11/14 Page 74 of 75...
  • Page 75 No Activity Clean conveyor belt Check the conveyor belt for broken or missing conveyor plates Check the chain tension Check the gear for worn teeth and alignment. Check the side guide for dents, damages and connection Clean below ends Check the drive for oil leakage and production of...

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