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Summary of Contents for Bastian Solutions BRBDC
- Page 1 Installation and Maintenance Manual Model: BRBDC Effective October 2019 Rev.A1...
- Page 2 Maintenance and Installation Manual: BRBDC Contributions ROLE NAME TITLE Author Brady Miller Design Engineer Checker Raj Choudhuri Design and Cost Engineer Approver Chris Perry Engineering Manager Revisions DATE REVISION DESCRIPTION AUTHOR 10/24/2019 Initial Document Creation Brady Miller Published October 2019...
- Page 3 Maintenance and Installation Manual: BRBDC Term and Acronym Definition List TERM/ACRONYM DEFINITION Belted Roller Bed Direct Current; DC roller conveyor format driven by brushless DC BRBDC servo motor. Carton or Case Term for conveyable items generally contained in cardboard boxes.
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Page 4: Table Of Contents
Figure 5: Roller Removal ..........................13 Figure 6: Removing Roller from Side Frame, Belt Hidden for Visibility ............13 Figure 7: Top View of BRBDC, Belt Hidden for Visibility ................14 Figure 8: Underside View of BRBDC ......................15 Figure 9: Exploded View of Motor Mounting Assembly ................16 Figure 10: Exploded View of Motor and Pulley Assembly ................ - Page 5 Maintenance and Installation Manual: BRBDC List of Tables Table 1: Troubleshooting BRBDC ........................ 20 Table 2: BRBDC Standard Spare Parts Table ....................21 Reference Documents Manufacturer Manual ZiPline Conveyor: Side Cover and Guiderail Installation Manual Bastian Solutions Bastian Solutions ZiPline Conveyor: Support Installation Manual...
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Page 6: Introduction
Please contact Bastian Solutions ZiPline Conveyor for any questions or support that is not clearly addressed in this document. ZiPline Conveyor is not responsible for misuse of the equipment described in this manual or misuse of information in this manual. -
Page 7: Model: Brbdc
Figure 1: Exploded View of BRBDC The model in Figure 1 is a BRBDC bed section. The BRBDC section has 4” roller centers and has (1) zone. The zone is made up of carrying rollers, (1) Teknic motor and (1) head roller. The head roller is connected to the Teknic motor by a Poly-V band while the carrying rollers are only in contact with the belt. -
Page 8: Receiving
Maintenance and Installation Manual: BRBDC 4 Receiving Upon delivery of any ZiPline Conveyor, please review and check the following: • The quantity of items received against the Bill of Lading. • Complete a visual inspection of equipment to determine any damage that may have occurred during shipping. -
Page 9: Skid Documentation
Maintenance and Installation Manual: BRBDC Skid Documentation All shipments will contain a Bill of Lading for the delivery company, a skid label, and a skid manifest. Skid labels have the contents of each shipped item located on the skid. Figure 3 shows a sample of a skid label. -
Page 10: Installation
Figure 4 (floor support shown as an example support structure). The recommended torque specification is 31ft-lbs. FLOOR SUPPORT IS ALSO BOLTED UNDERNEATH SIDE FRAME OF ADJACENT CONVEYOR Figure 4: Fastening BRBDC to Floor Support Published October 2019 Rev.A1... -
Page 11: Maintenance And Operation
7. Attach any guiderail or miscellaneous accessories. For information on guiderail installation, please reference the “Bastian Solutions – ZiPline Conveyor: Side Cover and Guiderail Installation Manual” 8. Check that the height of the infeed and discharge ends are correct per the system layout. -
Page 12: Mechanical Service
The recommended interval for maintenance is at least once every 6 months. 6.2.2 Electrical Service For issues with the drive motor, please refer to the “Bastian Solutions – ZiPline: Teknic Motor Service Bulletin” or the Teknic MCVC-3441D manual • All ZiPline Conveyor DC products operate at either 24V or 48V, nominally. -
Page 13: Figure 5: Roller Removal
Maintenance and Installation Manual: BRBDC ROLLER HEX SHAFT APPLY LINEAR PRESSURE Figure 5: Roller Removal 4. Provide upward force on the roller body until the hex is sitting above the side frame. Refer to Figure 6 (belt hidden for visibility). A putty knife or other flat surface tool is recommended to be placed between the hex shaft and the inside of the frame. -
Page 14: Figure 7: Top View Of Brbdc, Belt Hidden For Visibility
Ensure that the rollers maintain 4” roller spacing and are perpendicular to the side frame as shown in Figure 7. IDLER ROLLER FLOW HEAD ROLLER Figure 7: Top View of BRBDC, Belt Hidden for Visibility 8. Replace side cover. Published October 2019 Rev.A1... -
Page 15: Replacing Head Roller
ADJUST MOTOR POSISTION Figure 8: Underside View of BRBDC 3. Once drive belt tension has been relaxed, the head roller can be removed by following 6.2.3 steps 2-5. Remove the shaft opposite the Poly-V band first when removing head roller. -
Page 16: Replacing Motor
Maintenance and Installation Manual: BRBDC 6.2.5 Replacing Motor 1. Follow the lockout/tagout procedure in place to ensure safety. 2. Relax band tension by first loosening (4) bolts and then the tensioner bolt as shown in Figure 8. 3. Remove drive band guard and motor from motor bracket by removing (6) bolts as shown in Figure 9. -
Page 17: Figure 10: Exploded View Of Motor And Pulley Assembly
Ensure that Poly-V band rests within grooves of motor pulley. 7. Tension drive band by tightening tensioner bolt (refer to Figure 8) until band is taut. 8. Fasten motor bracket to BRBDC bed spacer by torqueing (4) bolts within slots to 31ft-lbs as shown in Figure 8. -
Page 18: Replacing Drive Band
10. Install band guard onto motor bracket as shown in Figure 11. Torque bolts to 80 in-lbs. 11. Tension drive band by adjusting tensioner bolt (refer to Figure 8) until band is taut. 12. Fasten motor bracket to BRBDC bed spacer by torqueing (4) bolts within slots to 31ft-lbs as shown in Figure 8. -
Page 19: Tracking Belt
Refer to the ““Bastian Solutions – ZiPline Conveyor: Support Installation Manual” for more information on adjusting floor supports. The belt on a BRBDC should be biased towards one side of the conveyor as shown in Figure 12. FLOW BELT BIASED... -
Page 20: Tracking Drive Band
For issues with the drive motor, please refer to the “Bastian Solutions – ZiPline: Teknic Motor Service Bulletin” or the Teknic MCVC-3441D manual... -
Page 21: Standard Spare Parts
Maintenance and Installation Manual: BRBDC 8 Standard Spare Parts Table 2: BRBDC Standard Spare Parts Table REF. NO. DESCRIPTION COMMON CONFIGURATIONS DRIVE BAND POLY-V, 4 RIBS NO-GROOVE IDLER ROLLERS HEAD ROLLER POLY-V TRACKING BAND WVT, MULTIPLE LENGTHS, BELT MULTIPLE WIDTHS... - Page 22 All rights reserved. This document contains information considered proprietary to Bastian Solutions. It may not be duplicated, used, or disclosed without written permission from Bastian Solutions. It may not be used in whole or in part for any purpose other than its intended purpose as an operation, installation, and maintenance manual for the product or products described herein.
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