NBS®90 PolySort & SP IOM Table of Contents CHAPTER 1: PURPOSE ............................4 CHAPTER 2: EQUIPMENT WARRANTY........................5 CHAPTER 3: WARNINGS & SAFETY INSTRUCTIONS ..................6 3.1: TGW S ................7 YSTEMS ECOMMENDED TANDARDS FOR ONVEYORS 3.2: TGW R ................8 ECOMMENDS ROPER ABELS FOR...
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RANSFER SSEMBLY EPLACEMENT ARTS IAGRAM 11.10: NBS90 SP END PULLEY ASSEMBLY REPLACEMENT PARTS DIAGRAM ........... 81 WORKS CITED ............................... 82 TGW G ..........................82 ENERAL NFORMATION TGW SYSTEMS INFORMATION ..........................83 Page 3 of 83 P/N: 1193974 Revision Date: 4/25/2019...
Chapter 1: P URPOSE IOM Purpose Manual Structure It is the intent of TGW Systems, through this You s h o u l d receive a separate manual, to provide information that acts as a documentation for each product line of TGW Systems implemented in your installation.
TGW Systems Equipment Warranty TGW Environment Standards TGW Systems warrants that the material and workmanship TGW equipment is designed to be installed in a clean, entering into its equipment is merchantable and will be dry warehouse environment. Exposure to extreme furnished in accordance with the specifications stated.
A safety risk evaluation is required for all of our standard equipment. The safety risk evaluation TGW agrees to the following safety instruction or considers every potential hazard on the conveyor, guidelines listed within this manual. This is not to weighs the probability and the severity of the potential conflict with your state or legal requirements.
TGW recognizes American National Standard Institute (ANSI) booklet entitled Safety Standards for Conveyors and Related TGW recommends these videos for training and education Equipment B20.1. For more information go to: purposes as part of a safe working environment around conveyor http://webstore.ansi.org/default.aspx...
NBS®90 PolySort & SP IOM 3.2: TGW R ECOMMENDS ROPER ABELS FOR ONVEYOR YPES Shown below are some samples of labels applicable to conveyor standards. Page 8 of 83 P/N: 1193974 Revision Date: 4/25/2019...
WARNING Your TGW Systems conveyor is powered by a motor and can be stopped only by turning off electrical power to the motor. As with all powered machinery, the drive-related •...
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• Never remove, deface, or paint over WARNING or CAUTION labels. Any damaged label will be replaced by TGW Systems at no cost by contacting Lifetime Services. • It is very important to instruct personnel in proper conveyor use including the location and function of all controls.
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NBS®90 PolySort & SP IOM WARNING • Before servicing or performing any work in the motor control panel, disconnect and lock out air and the main incoming service. If only the panel disconnect is off, the incoming side will still be hot. Page 11 of 83 P/N: 1193974 Revision Date: 4/25/2019...
The following basic conveyor control safety guidelines are recommended by TGW Systems even though Business Partner may or may not purchase conveyor controls from TGW Systems. The items listed deal with applications of controls equipment. The actual installation of the equipment must always follow the National Electric Code and all other local codes.
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NBS®90 PolySort & SP IOM Actuating an emergency stop must drop-out the start circuit, requiring restarting the system using the start pushbuttons provided. An emergency stop should normally stop all conveyors in the system. Very large systems may involve dividing a system into zones of control based on proximity of personnel, safety hazards, walls obstacles, etc.
IDLER Un-driven pulley used as a tensioning device ITEM NUMBER IT # TGW Systems part identification number Square locking device used on rotating shafts Group of several parts with a single item number LACED The condition of a correctly installed lacing...
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NBS®90 PolySort & SP IOM Definition of Terms KEY WORD ABBREVIATION DESCRIPTION LOOSE PARTS Individual parts that must be installed in the field MODULE A self-contained mechanical assembly MOUNT Part used to hold another, similar to a bracket MOUNTING Location and fasteners to attach a mount MOTOR Rotational power source usually using electricity MUFFLER...
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Any part that requires welding in its manufacture Variable Frequency Drive for motor speed control 3.5.1: Product Description Examples For the most current list of “Product Description” and “Terms and Abbreviations” Log into https://www.tgw-conveyor.com/ and select Support/Engineering Support Documents. Page 16 of 83 P/N: 1193974...
Given the above design features, the nature of conveying products with irregular or loose conveying surfaces are not guaranteed. TGW has tested a wide range of products contained in polybags with successful convey with the vast majority of “normal” industry packaged polybags from companies in the Apparel, Postal/Parcel, and Distribution markets.
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(ins) (CPM) High rates are possible given ideal product size and type, edge aligned and induction control upstream of PolySort, and programming optimization. Consult with TGW Applications Engineering for specific details or to arrange product testing. • To increase rate justify all products along the exit lane side of the NBS90 PolySort sortation for single direction transfer.
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NBS®90 PolySort & SP IOM NBS90 PolySort Elevation Top of Belt The minimum elevation at the discharge end of an NBS90 PolySort sortation line is 19". The end drive unit is located at the discharge end and requires a space of 60" or 33” long. Extra room alongside the drive should be provided to allow maintenance personnel access to either side of the drive assembly.
NBS®90 PolySort & SP IOM Chapter 5: NBS®90 SP (S MALL ARCELS ELECTION UIDELINES Use NBS®90 SP When: • Higher speed sortation then NBS is required • Product may be same size and weight, or mixed • Product weight: 1-20 lbs, 1000 lbs. total load Product size: 4"...
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NBS®90 PolySort & SP IOM NBS90 SP Transfer Locations The leading edge of the first transfer module must be a minimum of 28" from the charge end of • the sorter. The trailing edge of the last divert module must be at least 42" from the discharge end. •...
ECEIVING REPARATION General TGW Systems NBS Narrow Belt Sorters are shipped in subassemblies. These subassemblies are packaged to guard against damage in shipment, when handled properly. Examination immediately following unloading will show if any damage was caused during shipment. If damage is evident, claims for recovery of expenses to repair damage or replace components must be made against the carrier immediately.
NBS®90 PolySort & SP IOM 6.1: NBS P & I ARTS NVENTORY DENTIFICATION Each subassembly is shipped completely assembled except the bed joint splice plate/nuts which are shipped with other loose parts. Identify and separate the sorter subassemblies by type or tag number, for inventory and ease of locating during installation.
NBS®90 PolySort & SP IOM Chapter 7: NBS P & I ARTS NVENTORY DENTIFICATION The following procedures are to be used as guidelines only. Specific installation methods will vary somewhat depending on available equipment on site and each installer's preferences based on past experience.
NBS®90 PolySort & SP IOM Chapter 8: NBS I NSTALLATION ETAILS General Procedures The following procedures are to be used as guidelines only. Specific installation methods will vary somewhat depending on available equipment on site and each installer's preferences based on experience.
NBS®90 PolySort & SP IOM 8.1: NBS G ENERAL LECTRICAL EQUIREMENTS WARNING • All electrical controls must be installed, wired, and connected by a licensed electrician only. • All motor controls and wiring must conform to the National Electrical Code as published by the National Fire Protection Association and approved by the American National Standards Institute, Inc.
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NBS®90 PolySort & SP IOM WARNING • All safety devices, including wiring of electrical safety devices, shall be arranged to operate in a “fail safe” manner. That is, if power failure or failure of the device itself would occur, a hazardous condition must not result.
® The SEW-Eurodrive MOVIMOT® is used in many high speed reversing (and non-reversing) applications, such as the transfer drive for the PolySort. The MOVIMOT® as provided by TGW would typically consist of the following: - Three phase induction motor with an integrated variable frequency drive - Speed control potentiometer, built into drive housing.
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NBS®90 PolySort & SP IOM Page 29 of 83 P/N: 1193974 Revision Date: 4/25/2019...
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NBS®90 PolySort & SP IOM Speed, Ramp, and DIP Switch Settings - The speed of the drive can be adjusted by turning the setpoint potentiometer, f1, accessible through a screw plug on the connection box cover. - The ramp time is set with switch t1. Set this to detent position ‘0’ for maximum acceleration. - DIP switch S1 should have all switches in the off position.
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NBS®90 PolySort & SP IOM 8.2.1: NBS90 PolySort Sorter with Ethernet/IP comes pre-mounted from the factory. Page 31 of 83 P/N: 1193974 Revision Date: 4/25/2019...
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NBS®90 PolySort & SP IOM Connection of MFZ21 connection module with MFE62 to MOVIMOT ® Page 32 of 83 P/N: 1193974 Revision Date: 4/25/2019...
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NBS®90 PolySort & SP IOM (Tri-Tronics, 2016) MFZ21 connection module with MFE62 EtherNet/IP™ interface MOVIMOT ® Page 33 of 83 P/N: 1193974 Revision Date: 4/25/2019...
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NBS®90 PolySort & SP IOM Divert #1 PE Page 34 of 83 P/N: 1193974 Revision Date: 4/25/2019...
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NBS®90 PolySort & SP IOM Divert #1 Sol Page 35 of 83 P/N: 1193974 Revision Date: 4/25/2019...
NBS®90 PolySort & SP IOM 8.4: NBS G OTOR CTIVATION PRIOR to systems activation - Please inspect the gear unit for a vent and if applicable to the product remove the rubber sealing plug to activate. The vent is designed to allow excessive pressure to escape. Each gear unit should have a yellow instruction tag as shown below.
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NBS®90 PolySort & SP IOM Note: Yellow tags may be tucked out of sight. Please inspect all motors for a vent and remove sealing plug, if present, to activate. The following pictures are examples showing where vent plugs may be located depending on the product line and motor position.
NBS®90 PolySort & SP IOM 8.5: NBS E LEVATIONS All top-of-belt (TOB) heights should be installed in accordance with the elevations shown on the drawings. In addition, all sortation devices must be level across both the frame width and length. Leveling of the frames is best done using a rotating laser level along the length of the conveyor and a builder's level across the width.
UPPORTS ONNECTIONS For details on Supports & Connections, see Support & Connections IOM (#1200485) at https://www.tgw-conveyor.com/support/iom-manuals/supports-and-connections Anchoring Anchoring in concrete floors is accomplished by drilling into the floor and inserting the suitable anchor bolt. The hole diameter and depth must be in accordance with the anchor bolt manufacturer’s instructions, and all applicable codes and requirements.
10” Bed Splice Connector 10” Nut plate Stand-head 8.8: NBS90 P ORT BED CONNECTION KIT Bed Splice Connection Kit TGW # 1207722 Note: CAUTION Note: To avoid the belt rubbing/fraying on the guide ends the belt return roller must •...
IMPORTANT! • Do not make alterations to the equipment without consulting with user's representative and TGW Systems. Unauthorized modifications to the equipment may impair its function, create a hazardous condition, affect its useful life, and/or void the warranty. Page 43 of 83...
NBS®90 PolySort & SP IOM 8.11: NBS90 P ENSING WITCHES Retroreflective photoeye Ray 10 Adjust the retroreflective type as follows: Determine what sizes of target the photoeye must sense. • Adjust for the worst case, usually smallest item, by loosening photoeye mounting nut and •...
NBS®90 PolySort & SP IOM 8.13: NBS90 P EILING UPPORTED The NBS90 PolySort conveyor is designed to ALWAYS be supported at the bed joints. For ceiling hanging applications, an NBS90 PolySort ceiling hanger kit MUST be used at the bed joints as shown in the diagrams below.
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NBS®90 PolySort & SP IOM Ceiling hanger diagrams are a guide to establish a final support design. Consult structural engineer for actual application. WARNING Consult structural engineer for actual application. • Page 48 of 83 P/N: 1193974 Revision Date: 4/25/2019...
NBS®90 PolySort & SP IOM 8.14: NBS A LUMINUM XTRUSION ONNECTORS The aluminum extrusions that hold the UHMW belt guides are installed at the factory. The triple T-nut connectors are mounted, at the factory, flush with the ends of the aluminum extrusions on the discharge side of all NBS bed assemblies.
NSTALLATION Pre-installation Belts, as shipped from TGW Systems, are cut to length with lacing installed. Rolls of belting should be stored on edge on a pallet. Never leave a belt where it may absorb moisture. Remove any tight shipping banding immediately upon arrival. Lacing pins are taped inside the lacing on each belt.
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NBS®90 PolySort & SP IOM CAUTION As shown above: To avoid the belt rubbing/fraying on the guide ends the belt return • roller must face the charge end of the bed. Page 51 of 83 P/N: 1193974 Revision Date: 4/25/2019...
NBS®90 PolySort & SP IOM 8.16: NBS B PECIFICATIONS AND ACING PVC 200 belt • Width: 15/16" + /- 1/32" • Thickness: .203" +/- .015 thick, with a recessed • Thickness at recess: .125" to .156" • Lace: Clipper P/N 05265 U2S12 (tote); minimum number of •...
AIR DROPS: TGW Systems recommends using 3/4" pipe on air drops for high flow and low pressure loss. The drop is terminated with a drain at the bottom. A tee located prior to the drain branches off to the conveyor.
Air Drops (NBS90 PolySort) TGW Systems recommends using 3/4" pipe on air drops for high flow and low pressure loss. The drop is terminated with a drain at the bottom. A tee located prior to the drain branches off to the conveyor.
NBS®90 PolySort & SP IOM 9.2: NBS90 P UPPLY EQUIREMENTS Pneumatic pressure requirements: Maximum conveyor length each way from regulator is 80'. • • Locate regulator in center of conveyor, if possible, for maximum efficiency. • Overhead feeder line pressure to be 100 PSI minimum. •...
NBS®90 PolySort & SP IOM 9.3: NBS90 SP A UPPLY EQUIREMENTS NBS90 SP PNEUMATIC REQUIREMENTS Maximum conveyor length each way from regulator is 80'. Locate regulator in center of • conveyor, if possible, for maximum efficiency. Overhead feeder line pressure to be 100 PSI minimum •...
1/2 OD is available for this purpose. Cut into the supply line along the sorter bed and install the source airline tee fitting TGW Systems part number 89000640. Connect the source air line between this fitting and the filter/regulator output.
"EA" & "EB" that are used to adjust actuation speeds. Solenoids are plumbed such that the diverter/transfer is normally in the down position and raises on solenoid activation. The TGW Systems part numbers for replacement solenoids are: E0002998 VALVE, SMC 4-WAY 24VDC DIN CONN •...
NBS®90 PolySort & SP IOM 9.6: NBS A EGULATOR ALVE N AND OSITION Note: The air regulator valve label details the on and off positions. For air pressure regulations please see detailed instruction in this manual. WARNING • Do not remove and install sleeve valve to infeed side of regulator. Back feeding through the regulator will cause damage and void the warranty.
NBS®90 PolySort & SP IOM 9.7: NBS C OMMISSIONING OF QUIPMENT General Commissioning of the equipment can best be defined as the final adjustments and test of the installed equipment required for its proper operation. The need for commissioning is inherent, since the individual components of equipment are brought together at the installation site to operate as a system.
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NBS®90 PolySort & SP IOM Mechanical Dynamic Checkout (Power to the conveyor, but no product on it.) Turn the motor on. With the belt moving make sure each belt has proper tension. • Actuate each diverter solenoid manually. • Check the belt tracking. •...
NBS®90 PolySort & SP IOM Chapter 10: NBS M & T AINTENANCE ROUBLESHOOTING General The key to ensuring the expected return on investment is to protect against premature failure with a well-planned program of preventive maintenance. Preventive maintenance programs examine what may fail and then formulate action plans which will prevent failure or downtime.
NBS®90 PolySort & SP IOM Rollers All rollers used in NBS equipment have precision, sealed lubed for life bearings and do not require maintenance. Periodically removing the rollers has an added benefit of distributing the wear on the bearing inner race by rotating the axle to a new position. If a defective roller bearing is found, replace the roller.
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NBS®90 PolySort & SP IOM Motor Controls Inspection (Semi-Yearly) WARNING • Before servicing or performing any work in the motor control panel, disconnect and lockout the main incoming service. If only the panel disconnect is off, the incoming side will still be hot.
NBS®90 PolySort & SP IOM 10.1: NBS M AINTENANCE HECKLIST End Pulley Assembly Examine end pulley assembly. Remove any residue clinging to end pulley, and end pulley • snubber. Check to see if belt is tracked correctly thru lower belt guide wheels. Examine guide wheels •...
NBS®90 PolySort & SP IOM 10.2: M AINTENANCE CHEDULE Periodic maintenance intervals shown may vary with load, speed, hours of daily operation, ambient temperature, humidity, etc. Intervals can be established by fairly frequent maintenance at first, then lengthen the intervals as justified by observation of need based on history. The following is based on 5 days per week, 8 hours per day under normal conditions.
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NBS®90 PolySort & SP IOM Monthly Check air filters for cleanliness. • Clean chains and sprockets and lubricate with SAE 30 weight oil or equivalent. (Check • chain tension and tightness of all adjusting screws.) Check drive unit for leaking seals and oil level in gearcase (if applicable), unusual noises, •...
Verify the number of diverts per air proper height drop. Consult IOM Manual to verify that number of diverts per air drop does not exceed TGW recommendations. Divert spur isn’t set to the Inspect and adjust height of divert proper height spur as needed.
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NBS®90 PolySort & SP IOM Problem Possible Cause Remedy Product not diverting Discharge conveyor unit not Based upon product being handled correctly in proper location on NBS discharge conveyor location is variable; refer to IOM Manual for further assistance. Height of discharge conveyor Inspect discharge conveyor, and not correct adjust accordingly.
NBS®90 PolySort & SP IOM 10.4: NBS R EPAIR ROCEDURES Gearmotors NBS drive units use Gearmotors which are properly filled at the factory with sufficient lubrication for more details contact the specified gearmotor manufacture details. Disassembly/assembly procedure as follows: Remove necessary guards to access maintenance areas. •...
(2) weeks after the order is received. It includes part numbers, description, pricing and recommended quantities to be kept on hand for maintenance. If you are unable to locate this document, another may be obtained by contacting the TGW Lifetime Services at 231-798-4547.
NFORMATION Mission TGW Systems, located in Spring Lake, Michigan, is a leading deliverer of “smart” material handling systems, technologies, products, and services, creating solutions for material flow applications. As a global supplier of conveyor systems and equipment since 1964, TGW Systems provides sorters, conveyors, and accessories to satisfy a broad spectrum of accumulation, transportation, and sortation applications.
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