XR40 and XR48 IO PURPOSE ..................................... 3 EQUIPMENT WARRANTY ..............................4 XENOROL CONCEPT ................................5 WARNINGS & SAFETY INSTRUCTIONS ........................... 5 INTRODUCTION TO XENOROL ............................5 PRECAUTIONS ..................................5 DEFINITION OF TERMS ..............................6 CAPACITY OF ROLLERS/FRAME ............................7 MINIMUM PRESSURE ACCUMULATION ........................... 7 REDUCTION OF LINE PRESSURE .............................
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COMMISSIONING OF EQUIPMENT ..........................38 DRIVE BELT BREAK-IN ..............................38 GENERAL ................................... 39 MOTOR AND GEARCASE ..............................39 PREVENTIVE MAINTENANCE ............................39 CHAINS AND SPROCKETS .............................. 39 TIMING BELT & PULLEYS..............................40 TIMING BELT TAKEUP & TENSION..........................40 ROLLERS ................................... 41 DRIVE BELTS &...
PURPOSE It is the intent of TGW Systems Inc., through this manual, to provide information that acts as a guide in the installation, operation and mainte- nance of TGW Systems XenoROL conveyors. ® This manual describes basic installation practices, assembly arrange- ments, preventive maintenance, repair procedures, troubleshooting, ser- vice intervals and assists in replacement parts identification.
Consequential damages of any sort are wholly excluded. The liability of TGW Systems will be limited to the replacement cost of any defective part. All freight and installation costs relative to any warranted part will be at the expense of the purchaser. Any liability...
WARNINGS & SAFETY INSTRUCTIONS Failure to follow the instructions, warnings, cau- Never remove, deface or paint over WARNING or tions (throughout this booklet) and warning labels CAUTION labels. Any damaged label will be replaced (on the conveyor) may result in injury to personnel by Ermanco Inc.
DEFINITION OF TERMS Jump Chain - A drive chain or belt which transmits power from one line-shaft to an adjacent parallel line- Accessory - A device which receives power from and shaft. A crossover between adjacent line-shafts within contributes to the horsepower requirement of the line- a common conveyor frame is called an internal jump shaft.
RECEIVING & SITE PREPARATION GENERAL XenoROL line-shaft driven live roller conveyors are ® An identification label is attached to the inside of one shipped in subassemblies. These subassemblies are side channel close to one end of each conveyor bed packaged to guard against damage in shipment. and on all drive packages.
TYPICAL XenoROL LOOSE PARTS ® Part Number Item Illustration Line-shaft Guard End Cover Cover End of Lineshaft at Termination of 41700910 with Set Collar Kit See WARNING Page 13 Conveyor COVER with Set Collar, Kit 90140001 Safety Caps Cover End of Line-shaft Keyway See WARNING Page 20 90314510 Line-shaft Guard, 10' straight...
GENERAL PROCEDURES The following procedures are to be used as guidelines After the first elevation is established at a critical point, only for conveyor installation. Specific methods will vary the elevation of all other points shall be relative to somewhat depending on available equipment on site this first point.
LAYOUT DIMENSIONS affects dimensions "G" and "D" or "J" and "H". Normally, In laying out the conveyor path, the dimensions shown on merging takes place at 45° while most diverting devices uti- this page indicate the relative position between parallel or lize 30°.
LINE-SHAFT TERMINATIONS WARNING WARNING Safety caps are required on ends of all ad- Remove any coupler sprocket which is not joining line-shaft conveyor beds not coupled to an adjacent sprocket. These coupled together. sprockets must be removed BEFORE the bed is installed. The white line-shaft safety caps must be installed in place of the sprockets to cover the end of the keyway.
SUPPORTING ARRANGEMENTS FLOOR SUPPORTS Install bolts used to attach the standhead to the frame so the nut is on the bottom. Standhead bolts should be left finger tight while the conveyor is being as- sembled and aligned. There are various frame rail depths depending on options and accessories.
CONNECTORS The spacer channel connector kit consists of two formed Adjoining beds may be connected using optional stand- channels 4-1/2" deep with mounting hardware. This head connector plates (one on each side). Connectors connector is a standard component of ceiling hangers are normally used with ceiling hangers when the hanger but is also used to allow a support on the frame joint is not centered on the frame joint.
CEILING HANGERS After hanger uprights are installed and the heavy ex- tension nuts welded to angle hangers, thread the drop rods into the extension nuts. Thread the jam nuts and stop nuts on the drop rods far enough up the rods to allow installation and adjustment of the cross pipe.
SWAY BRACING (CEILING HANGER) 1. Sway bracing should be a minimum of 1-1/2" x 1-1/2" x 3/16" angle. 2. Sway bracing is secured to the hanger upright near the conveyor support and extended upward at an angle of approximately 30 degrees from the hanger upright.
MULTI-LEVEL XENOROL SUPPORT Clamping of stringers or headers to building trusses will nor- ® To mount XenoROL to multiple level support s , bolt two mally be done only at panel points. Specific customer per- V-brackets and two spacer channels to each horizontal mission and load calculations by a qualified engineer are crossmember.
BASICS OF XenoROL INSTALLATION ® GENERAL FRAME ALIGNMENT Conveyor frames must always be installed in a straight XenoROL bed sections stacked on pallets for shipping ® (7) intermediate beds per side. line from end to end as described in GENERAL PRO- CEDURES.
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Angular alignment and gap may be checked by com- Carefully note from the system layout drawings any bed bining a feeler gauge and shim material to check for joint locations which are not to be coupled due to the equal gap of 9/32 every 90 degrees. ending of that conveyor drive.
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Since U-joints are common and basic to the operation of PULSATING EFFECT OF POWERED CURVES XenoROL, they are taken for granted. However, if they are During the operation of the powered curves, a slight not applied or inst a lled correctly, they can cause major prob- pulsating or jerking effect may be noticed in the rollers lems.
SUBASSEMBLY INSTALLATION DRIVES CURVES Curves are installed the same as straight sections. In On drive beds under 24" wide, right angle drive motors addition to end supports, 90 degree curves should have will protrude outside the conveyor frame. The narrower a support in the center of the outside frame channel.
JUMP CHAINS/BELTS The external jump chain connects two parallel convey- ors from one drive motor . Depending on the twist of the Jump chains are preassembled at the factory complete drive belt connecting the line-shaft to the roller , the travel with sprockets aligned and chain tensioned.
MERGE ASSEMBLY Merge assemblies are used at the juncture of two con- While the product is merging, it is being pushed by the veyors where one is required to merge into and join the spur and pulled by the abutting bed. The bottom of the other line.
2. Place the end plate of the spur against the side chan- Guard rails (angle or adjustable channel) are recommended nel of the abutting bed and mark the location of the on both sides of each conveyor. Conveyor rollers may be mounting bolts on the frame of the abutting bed.
WHEEL DIVERTER ASSEMBLY Two rows of powered wheels raise pneumatically to divert product off the main line to a 30° spur. Driven by the main conveyor line-shaft the wheel diverter does not require a separate drive. Air pressure required for quick positive response is 60- A 15"...
URETHANE BELT TRANSFER (UBT) Important: The twist of the drive belt determines the direction of the roller rotation. When devices such as urethane belt transfers (UBTs) are driven from the line- shaft, the motor must run in the direction to suit the UBT.
UBT XenoBRAKE Pivoting roller stops are normally received preassembled, separate from the bed they are to be installed into. The powered roller which will be replaced by the pivoting stop roller must be removed from the conveyor bed. At least two rollers will need to be temporarily removed over the A XenoBRAKE designed for use with UBTs provides pivot point of the arms.
RIGHT ANGLE CONNECTION / URETHANE BELT TRANSFER MODULE (RAC/UBT MODULE) A right angle connection (RAC) module in a 12" bed is The gearbox style designation (A or B) refers to the used at 90° intersections to transmit power from one output shaft rotation.
XenoBRAKES XenoBRAKES are used to stop XenoROL rollers by Normally, XenoBRAKES are factory mounted in the con- ® clamping them from below . XenoBRAKES are mounted veyor bed; however , they may be purchased sep arately to the inside of the side channel between crossmembers and mounted during installation.
POWERED GATE ASSEMBLY The gate provides a break in the conveyor line for pe- destrian traffic. The gate is line-shaft driven from the adjoining conveyor. Powered gate assemblies use the standard 4-1/2" deep frame. They consist of two beds, a 4' gate bed and 2' adjoining bed.
ROLLERS STRAIGHT ROLLERS ROLLER INSTALLATION There are two types of rollers used in straight sections: single grooved and double grooved. Single grooved WARNING rollers are used when connecting the line-shaft pulleys (spools) directly to the rollers. Double grooved rollers Use a blunt object to push on the roller axle. are used with a roller-to-roller "transfer belt"...
LINE-SHAFT GUARDS Line-shaft guarding is installed at the factory on curves, WARNING transfers, merges, gates, jump chains and other acces- sories. During installation, only straight section guards Cutting a 10' line-shaft guard to match a spe- need to be mounted to the conveyor frames. cific length conveyor section can create ra- WARNING zor sharp edges which could result in a se-...
GUARD RAILS ADJUSTABLE CHANNEL GUARD RAIL Adjustable channel guard rail is used to better match ANGLE GUARD RAIL the width between guard rails to the conveyed product. Angle guard rails are bolted to the conveyor frames top It may also be adjusted vertically to better contain prod- flange.
AIR SUPPLY REQUIREMENTS GENERAL AIR CONSUMPTION Every conveyor system is unique with its own specific The highest air consumption is when several devices requirements. Therefore, the following is a general are operating simultaneously. guide. Compressed air for conveyor systems is pro- duced by air compressors.
ELECTRICAL GENERAL NEMA 4 - Indoor and outdoor use, designed to keep out rain and dust. WARNING NEMA 12 - Indoor use, provides protection against dust, All electrical controls must be installed, dirt and oil seepage and dripping of noncorrosive liq- wired and connected by a licensed electri- uids.
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OPERATOR CONTROLS - Additional operator controls WARNING should be designed into the system with the same guide- lines that go into start and stop pushbutton, depending Before restarting a conveyor which has been upon their function. Devices which are repeated on stopped because of an emergency, an in- multiple control stations, such as emergency stops, spection of the conveyor must be made and...
COMMISSIONING OF EQUIPMENT GENERAL Commissioning of the equipment can best be defined as • Verify function of all safety shutoff devices the final adjustments and test of the installed equipment • Verify sequence of operation required for its proper operation. The need for commis- •...
XenoROL® PREVENTIVE MAINTENANCE GENERAL The key to ensuring the expected return on With Reliance Relialube reducers, change oil only investment is to protect against premature failure when performing maintenance that requires gearbox with a well-planned and follow-up program of disassembly using Mobil S HC-634. Wh en replacing preventive maintenance.
XenoROL® During the monthly check, look for damaged or worn For jumps follow the above procedure starting out by links in the chain an d we ar spots on sprockets. If placing the pulleys as close to the line-shaft either the chain or sprockets are worn, then both bearings as possible and aligning the pulleys as must be replaced and the cause of wear corrected.
XenoROL® For our standard HPR or HT D, 8 mm pitch, 30 m m • For MOVIMOT drives the belt strand tension wide Belt, use the following informatio n to program should be 20-30 lbs. the meter. Note: You must use either the Gates 505 C or the •...
XenoROL® DRIVE BELTS Drive belts should require no actual maintenance. CAUTION Visually check for broken or worn belts. Normally, a Avoid touching components until they have had few broken belts will not hamper the performance of time to cool. Some may still be hot XenoROL®.
XenoROL® Grease in the bearing prevents excessive wear of AIR SYSTEMS parts, protects ball races, balls, etc. fro m corrosion, The best preventive maintenance for any air and aids in heat dissipation within the bearing. operated device is clean air. Always be alert for air Lubricate monthly.
XenoROL® MAINTENANCE SCHEDULE Periodic maintenance intervals shown may vary with MONTHLY load, speed, hours of daily operation, ambient • Check air filters for cleanliness. temperature, humidity, etc. Intervals can be • Check coupler chains for cracks. established by fairly frequent maintenance at first, •...
TROUBLESHOOTING GUIDE Troubleshooting is the process of looking at trouble symptoms and then relating these to the most likely cause. By carefully analyzing the prob- lem, the experienced troubleshooter can take appropriate corrective steps. WARNING Do not perform maintenance on the conveyor until the startup controls are locked off and cannot be turned on by any person other than the one...
TROUBLESHOOTING GUIDE-MECHANICAL MECHANICAL PROBLEM POSSIBLE CAUSE REMEDY Not enough rollers being driven Drive more rollers if available Poor bottom on product Improve product conveyability or install drive belts with right tension Overloading of product Remove overload Insufficient drive Lubricant on belts, rollers or drive Clean belts, rollers and spools (Ref.
TROUBLESHOOTING GUIDE-MECHANICAL MECHANICAL PROBLEM POSSIBLE CAUSE REMEDY Pad or tubing not contacting all rollers Shim padded channel Adjust per p. 30 Padded channel bent Replace padded channel Product over XenoBRAKE Accumulating distance too great Add additional XenoBRAKES will not hold Light product Use plastisol coated rollers over XenoBRAKE or add additional...
TROUBLESHOOTING GUIDE-MECHANICAL MECHANICAL PROBLEM POSSIBLE CAUSE REMEDY Chain contacting stationary parts Remove interference Worn sprockets or chain Replace both (Ref. p. 55) Inadequate lubrication Maintain proper lubrication intervals (Ref. p. 44) Broken or missing chain rollers Repair or replace chain (Ref. p. 55) 19.
TROUBLESHOOTING GUIDE-MECHANICAL MECHANICAL PROBLEM POSSIBLE CAUSE REMEDY Replace chain (Ref. p. 19 & 20) Improper chain installation 26. Broken coupler chain Misalignment of line-shaft and Realign shafts and sprocket gap. (Ref. sprockets p.19 and 20) Brakes should be no more than 1/4" below Excessive clearance XenoBRAKE hitting with bottom of rollers...
TROUBLESHOOTING GUIDE-MOTOR/REDUCER MOTOR/REDUCER PROBLEM POSSIBLE CAUSE REMEDY Check oil level in gearcase and be sure breather plug is open (non Relialube Low reducer oil level reducers) Reducer running Check and inspect all bearings on excessively hot conveyor Drag on conveyor Check for excessive product load Check all rollers for free rotation Add recommended oil to gearcase...
TROUBLESHOOTING GUIDE-MOTOR/REDUCER MOTOR/REDUCER PROBLEM POSSIBLE CAUSE REMEDY Drain lubricant to proper level Overfilling Place vent in uppermost position Vent in wrong location Reducer oil leakage (non Extend vent with pipe nipple Reliance Relialube) Tighten all bolts and fittings Defective oil seals on output shaft Install new oil seals Check overload size and replace if Incorrect size...
TROUBLESHOOTING GUIDE-ELECTRICAL ELECTRICAL/SOLENOID POSSIBLE CAUSE REMEDY VALVE PROBLEM Check all wire connections Loose connection Consider adding additional transformer 41. Electrical shorts Improper voltage Check fuses Retroreflective photoeye not properly Realign photoeye with retroreflective target Photoeye or proximity so indicator light comes on aligned with target switches do not energize Replace...
REPAIR PROCEDURES WARNING Do not perform maintenance on the conveyor until the start-up controls are locked out and cannot be turned on by any person other than the one performing the maintenance. If more than one member of a crew is working on the conveyor, EACH CREW MEMBER MUST HAVE A LOCK ON THE POWER LOCK OUT.
CHAIN/SPROCKET REPLACEMENT ON LINE-SHAFT Shut off and lock out power supply to area of re- Disassembly/assembly procedure as follows: quired maintenance. To provide access, remove necessary rollers. To provide access to maintenance area, remove Remove line-shaft guard. necessary rollers. Disassemble any components involved with the operation of the line-shaft, slave drive, chains, cou- Remove line-shaft guarding in area requiring main- plers, etc.
LINE-SHAFT During manufacturing processes line-shafts are left with 4. No excessive heating a light coating of lubricant. Excess is wiped off before the 5. No unusual vibration or noise assembly of components onto the line-shaft. A certain amount of lubricant is needed to prevent formation of rust Enclosed gear drives (except those tagged as before the conveyor is put in use.
DRIVE BELTS In an emergency the belts may be replaced by cutting When it becomes necessary to replace a XenoROL drive ® and splice welding a new length belt from cord stock us- belt, there are choices depending on the situation. New ing the following procedure: original manufactured belts are the best and will last the longest.
XENOBRAKES SOLENOID VALVES XenoBRAKES are used as an indirect stop to hold prod- In order to minimize downtime, it is normally not feasible uct. The brake is a steel channel with a solid rubberlike to repair malfunctioning electrical or valve components pad or urethane tubing on the top.
MOTOR CONTROLS WARNING WARNING Avoid touching component s until they have Before servicing or performing any work in the had time to cool. Some still may be hot. motor control panel, disconnect and lockout the main incoming service. If only the panel disconnect is off, the incoming side will still Check overload settings on motor controls.
If you are unable to locate this document (orders under $5,000) another may be obtained by contacting the TGW Systems' Cus- tomer Service Department at 231-798-4547 or Fax 231-798-4146. To identify a part and its part number, refer to the assemblies and devices on the following pages.
PARTS IDENTIFICATION JUMP CHAIN ASSEMBLY See Parts Identification List on page 68-70 RIGHT ANGLE CONNECTION / URETHANE BELT TRANSFER MODULE 90480006rev101210...
PARTS IDENTIFICATION LIST Balloon No. Description Part Number Drive Belt Refer to Drive Belt Data Chart page 72 Slave Belt Roller Roller, Slave Refer to Roller Data page 68 Roller, True Taper Non-full length rollers 90050103 Bearing, 1" Bore 900050103 Spool, 1"...
ADDITIONAL REPLACEMENT PARTS Line-shaft Assembly Specify m odel, bed length, zone lengths, Including: Line-shaft bearings, spacers, spools, coupler drive or intermediate bed and driven sprocket sprockets (for 3" rollers) size if drive bed. Contact the Lifetime Service Department for cost and delivery. Spools Split Standar d 90801201...
LOW PROFILE DRIVE DATA DRIVE DATA WITH CHAIN & SPROCKETS Motor HP NORD Output RPM Drive Sprocket Driven Sprocket (Reducer) (Line-shaft) SK272VL-71L/4 H5017 1" SK272VL-80S/4 H5017 1" 5018 1" SK272VL-80L/4 H5018 1" SK272VL-71L/4 H5017 1" SK272VL-80S/4 H5017 1" 5018 1" SK272VL-80L/4 H5017 1"...
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To meet or exceed all customer expectations by providing the highest quality products and services, on time, at exceptional value, in an environment which promotes safety and personal development. TGW Systems Inc. 6870 Grand Haven Road Spring Lake, MI 49456-9652 USA 231.798.4547 Sales Fax 231.798.4146 or Corp Fax 231.798.8322...
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