Related Manuals for TOYOTA ADVANCED LOGISTICS Bastian SOLUTIONS BSBAC 1 HP
Summary of Contents for TOYOTA ADVANCED LOGISTICS Bastian SOLUTIONS BSBAC 1 HP
- Page 1 Installation and Maintenance Manual Model: BSBAC 1 HP Effective January 2022 Rev. B...
- Page 2 Installation & Maintenance Manual: BSBAC 1 HP Contributions ROLE NAME TITLE Author Rajarshi Choudhuri Design and Cost Engineer Checker Ben Baker Senior Design Engineer Approver Chris Perry Engineering Manager Revision History DATE REVISION REVISION DESCRIPTION AUTHOR 12/27/2019 Initial document creation Rajarshi Choudhuri 11/3/2021 Branding and style updates...
- Page 3 Installation & Maintenance Manual: BSBAC 1 HP Term and Acronym Definitions TERM/ACRONYM DEFINITION Alternating current Between frame; this refers to the distance between conveyor bed side frames. BHCS Button head cap screw Bill of Materials Belt Over Roller Bed Alternating Current; Format of AC conveyor used for cartons, cases, or totes transport optimized for long runs.
- Page 4 Installation & Maintenance Manual: BSBAC 1 HP A numeric or alphanumeric term used to uniquely identify a conveyor bed or collection of beds (of similar model type) within a material Mark Number handling system. A mark made on mating conveyor assemblies to assist in identifying Match orientation and placement within a system.
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Page 5: Table Of Contents
Installation & Maintenance Manual: BSBAC 1 HP Table of Contents Introduction ......................8 OSHA and Safety ....................8 Model: BSBAC 1 HP ....................9 3.1 Drive Section ........................10 3.2 Tail Section ........................... 12 3.3 Bed Section .......................... 13 3.4 Noseover Section ......................... 14 3.5 Power Feeder Section ...................... - Page 6 Installation & Maintenance Manual: BSBAC 1 HP List of Figures Figure 1: BSBAC 1HP configuration - exploded view ................9 Figure 2: BSBAC Incline 1HP configuration - exploded view ..............10 Figure 3: BSBAC 1HP drive section - exploded view ................11 Figure 4: BSBAC 1HP tail section - exploded view .................
- Page 7 Installation & Maintenance Manual: BSBAC 1 HP Reference Documents MANUFACTURER MANUAL Habasit Heavy Conveyor Belts TM120RT-B Habasit Holding AG (H250000385) Habasit Heavy Conveyor Belts TM120LR-B Habasit Holding AG (H250000441) Habasit Heavy Conveyor Belts UMS130SC-B Habasit Holding AG (H250000560) Habasit Holding AG Habasit Product Data Sheet RGLIDE-T Habasit Fabric Conveyor Belts Installation and Habasit Holding AG...
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Page 8: Introduction
Installation & Maintenance Manual: BSBAC 1 HP 1 Introduction Thank you for choosing Bastian Solutions conveyor. The following manual will serve as a guide for installation, part replacement, and general maintenance for your material handling equipment. It is important to read the manual and follow any instructions as it provides important safety information for personnel and will maximize the longevity of the conveyor. -
Page 9: Model: Bsbac 1 Hp
The Belted Roller Bed AC (BSBAC) conveyor is designed to convey product across long distances without product accumulation. The Bastian Solutions BSBAC 1 HP conveyor is available in two configurations: straight and incline/decline. Baldor-Dodge gearmotors drive the BSBAC conveyor. Figure 1 illustrates an exploded view of the different sections that constitute a 1HP BSBAC configuration and some common terms used to describe these sections. -
Page 10: Drive Section
Installation & Maintenance Manual: BSBAC 1 HP Noseover 1HP – motor side left - Drive Section Tail Figure 2: BSBAC Incline 1HP configuration - exploded view 3.1 Drive Section The BSBAC drive section is a 10’ conveyor section that contains the motor, take-up subassembly for the belt tension and the drive pulley. -
Page 11: Figure 3: Bsbac 1Hp Drive Section - Exploded View
Installation & Maintenance Manual: BSBAC 1 HP Figure 3: BSBAC 1HP drive section - exploded view The BSBAC drive section is designed to be positioned towards the center or biased towards the downstream of the conveyor section. In extreme cases, the BSBAC 1 HP drive section can be placed adjacent to two tail sections. -
Page 12: Tail Section
Installation & Maintenance Manual: BSBAC 1 HP 3.2 Tail Section The BSBAC tail section is a 12” conveyor section that contains the tail pulley and tail pulley take-up subassembly. The tail sections are always placed as the first and last bed section in a BSBAC section. The BSBAC tail sections are offered in 18”, 24”, 30”... -
Page 13: Bed Section
Installation & Maintenance Manual: BSBAC 1 HP 3.3 Bed Section The BSBAC bed section are idler bed sections in the BSBAC conveyor. The BSBAC bed section is offered in 18”, 24”, 30” and 36” OAW and range between 12” to 120” OAL in 6” increments. The BSBAC bed sections are identical for all offered BSBAC configurations. -
Page 14: Noseover Section
Installation & Maintenance Manual: BSBAC 1 HP 3.4 Noseover Section The BSBAC noseover section is a 42” conveyor section that is vertically sectioned to allow for angular adjustment between 0 to 25 degrees. The angular adjustment can be made by adjusting the hardware in the bottom of the channel in the side frame on both sides. -
Page 15: Power Feeder Section
Installation & Maintenance Manual: BSBAC 1 HP 3.5 Power Feeder Section The BSBAC power feeder section is a BLVDC conveyor section that is on the upstream section of a BSBAC incline conveyor, or on the downstream section of a BSBAC decline conveyor. The BSBAC power feeder section is offered in 18”, 24”, 30”... -
Page 16: Receiving
Installation & Maintenance Manual: BSBAC 1 HP 4 Receiving Upon delivery of any Bastian Solutions conveyor, please review and check the following: • The quantity of items received against the Bill of Lading. A visual inspection of equipment should be completed to determine any damage that may have •... -
Page 17: Skid Contents
Installation & Maintenance Manual: BSBAC 1 HP MK1100 has the following BSBAC sections, organized from upstream to downstream: SECTION 1 - BSBAC tail section, 12” OAL, 24” OAW • SECTION 2 - BSBAC noseover section, 42” OAL, 24” OAW • SECTION 3 - BSBAC bed section, 120”... -
Page 18: Skid Documentation
Installation & Maintenance Manual: BSBAC 1 HP 4.3 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 9 shows a sample of a skid label. -
Page 19: Installation
Installation & Maintenance Manual: BSBAC 1 HP 5 Installation The installation supervisor on site should have the elevation and layout prints with detailed information regarding the placement of conveyor sections and support structures. This information is not the responsibility of Bastian Solutions to provide unless otherwise specified. 1. -
Page 20: Uniform Levelling And Straightness Of Conveyor Section
Installation & Maintenance Manual: BSBAC 1 HP 5.2 Uniform Levelling and Straightness of Conveyor Section The straightness of the BSBAC sections is critical to the performance of the conveyor. Please ensure that the conveyor bed sections are checked for uniform level and straightness. To check for uniform levelling, use a large level guide to confirm that all conveyor sections are appropriately levelled. -
Page 21: Figure 11: Belt Routing - Bsbac 1 Hp Configurations - Section View
Installation & Maintenance Manual: BSBAC 1 HP The belt provided for the BSBAC mark will come with a clipper style lacing. The following steps outline how to install an AC belt. 1. Complete the physical installation of the conveyor on the floor supports. 2. -
Page 22: Figure 12: Belt Routing - Bsbac 1 Hp Drive - Section View
Installation & Maintenance Manual: BSBAC 1 HP Snub Rollers Belt Drive Pulley Take-up Pulley Figure 12: Belt routing - BSBAC 1 HP drive - section view Figure 13: Belt routing - BSBAC 1 HP tail - section view Figure 14: Belt routing - BSBAC 1 HP tail with noseover - section view 6. -
Page 23: Tensioning And Tracking The Ac Belt
Installation & Maintenance Manual: BSBAC 1 HP Figure 15: Belt splicing schematic 5.4 Tensioning and Tracking the AC belt The following instructions outline the tensioning and tracking of the AC belt. 1. Ensure the conveyor is level across its width. 2. -
Page 24: Figure 17: Belt Tracking By Adjusting Snub Rollers
Installation & Maintenance Manual: BSBAC 1 HP Please make sure that the E-Stop for the AC motor is connected prior to next step. The E-stop may be required to quickly kill power to the AC motor to preserve life of the belt for tracking purposes. -
Page 25: Installing And Adjusting Noseover Section Angle
Installation & Maintenance Manual: BSBAC 1 HP 5.5 Installing and Adjusting Noseover Section Angle The BSBAC noseover section allows for smooth transition of product travelling from a horizonal section to an angled section in an incline/decline BSBAC. The following instructions outline the installation and adjustment procedure for the BSBAC noseover section. -
Page 26: Installing Underside Covers
Installation & Maintenance Manual: BSBAC 1 HP Location of noseover check dimension Figure 19: BSBAC noseover section - location of check dimension 6. Tighten the 3/8” carriage bolts and serrated flange nuts on the adjustment bracket to hold the specific adjusted noseover angle. The torque requirement for 3/8” carriage bolt and serrated flange nut is 31 ft-lbs. -
Page 27: Figure 21: Installing The Underside Cover To The Bsbac Bed Section
Installation & Maintenance Manual: BSBAC 1 HP 3. Raise the underside cover to the mating BSBAC section. Install the 3/8” carriage bolt and serrated flange to the mounting holes at the bottom of the side frame of the BSBAC section. Figure 21 illustrates the orientation of this operation. -
Page 28: Maintenance And Operation
Installation & Maintenance Manual: BSBAC 1 HP 6 Maintenance and Operation The longevity and proper functionality of Bastian Solutions conveyor is based upon standard operating practices and general maintenance of equipment. Setting up a regular maintenance schedule will help ensure that products comply with the equipment’s warranty. Lockout / Tagout (LOTO) procedures should be implemented before performing any maintenance. -
Page 29: Electrical Maintenance Schedule
Installation & Maintenance Manual: BSBAC 1 HP 6.3 Electrical Maintenance Schedule 1. All Bastian Solutions’ conveyor AC products typically operate using 460VAC 3 phase. Check the motor nameplate prior to any electrical install. 2. For Dodge gearmotor electrical maintenance and installation instructions, refer to document Dodge Quantis RHB Installation and Maintenance Instructions (499322). -
Page 30: Figure 23: Bsbac 1 Hp Tail Pulley Take-Up Hardware
Installation & Maintenance Manual: BSBAC 1 HP Tail pulley Tail pulley Figure 23: BSBAC 1 HP tail pulley take-up hardware 7. Lift up the tail pulley through the cut outs on both sides of the side frame and slide it sideways out of the belt. -
Page 31: Drive Pulley Replacement
Installation & Maintenance Manual: BSBAC 1 HP 9. Install the 3/8” hex head cap screw with the jam nut to the tail pulley on both sides of the tail section. Figure 23 illustrates the hex head cap screw that holds the tail pulley on one side of the tail section and the nylock jam nut on one side of the tail section. -
Page 32: Figure 25: Bsbac 1 Hp Drive Motor Connection - Exploded View
Installation & Maintenance Manual: BSBAC 1 HP AC drive motor and 1 HP drive pulley Torque arm 7/16” hex head cap M8 shoulder Figure 25: BSBAC 1 HP drive motor connection - exploded view Bastian Solutions highly recommends using a lift table or equivalent equipment to remove the motor from the drive section. -
Page 33: Figure 26: Bsbac 1 Hp Drive - Underside Cover
Installation & Maintenance Manual: BSBAC 1 HP 1 HP drive pulley Underside cover Figure 26: BSBAC 1 HP drive - underside cover 8. Remove the guard that is attached to the back of the drive pulley. The guard is attached to the drive section side frame via (2) 1/4”... -
Page 34: Figure 28: Bsbac 1 Hp Drive Pulley Bearing
Installation & Maintenance Manual: BSBAC 1 HP 10. Slide out the bearings from the drive pulley shaft. Figure 28 illustrates the location of the drive pulley bearing and the corresponding hardware on the motor side. The non-motor side is identical except for the shaft length of the drive pulley. -
Page 35: Figure 29: Bsbac 1 Hp Drive Pulley Removal From Drive Section
Installation & Maintenance Manual: BSBAC 1 HP 1 HP drive pulley Side frame cutout Figure 29: BSBAC 1 HP drive pulley removal from drive section 12. Slide the pulley out of the belt routing. 13. Install the replacement (new) drive pulley in the same location as the old pulley to preserve belt routing. -
Page 36: Take-Up Pulley Replacement
Installation & Maintenance Manual: BSBAC 1 HP 6.6 Take-up Pulley Replacement The following instructions outline the BSBAC 1 HP drive take-up pulley replacement procedure. 1. Ensure that the power to the AC motor is switched off. Bastian Solutions recommends using Lockout/Tagout (LOTO) procedures for this operation. -
Page 37: Figure 31: Bsbac 1 Hp Drive Take-Up Pulley Bearing - Motor Side
Installation & Maintenance Manual: BSBAC 1 HP 1 HP take-up pulley bearing – Figure 31: BSBAC 1 HP drive take-up pulley bearing - motor side 10. Pull out the take-up pulley bearing on the non-motor side. Figure 32 illustrates this operation with an exploded view. -
Page 38: Figure 33: Bsbac 1 Hp Drive - Take-Up Pulley Removal
Installation & Maintenance Manual: BSBAC 1 HP AC drive Take-up motor and Figure 33: BSBAC 1 HP drive - take-up pulley removal 12. When the take-up pulley is put at an angle, drop the take-up the pulley through the bottom of the drive section. -
Page 39: Snub Roller Replacement
Installation & Maintenance Manual: BSBAC 1 HP 6.7 Snub Roller Replacement The following instructions outline the BSBAC snub roller replacement procedure. 1. Ensure that the power to the AC motor is switched off. Bastian Solutions recommends using Lockout/Tagout (LOTO) procedures for this operation. 2. -
Page 40: Idler Roller Replacement
Installation & Maintenance Manual: BSBAC 1 HP 6.8 Idler Roller Replacement The following instructions outline the BSBAC idler roller replacement procedure. 1. Ensure that the power to the AC motor is switched off. Bastian Solutions recommends using Lockout/Tagout (LOTO) procedures for this operation. 2. -
Page 41: Ac Motor Replacement
Installation & Maintenance Manual: BSBAC 1 HP 6.10 AC Motor Replacement The following instructions outline the AC motor replacement procedure. 1. Ensure that the power to the AC motor is switched off. Bastian Solutions recommends using Lockout/Tagout (LOTO) procedures for this operation. 2. -
Page 42: Troubleshooting And Repair
Installation & Maintenance Manual: BSBAC 1 HP 7 Troubleshooting and Repair Several issues that may arise with Bastian Solutions conveyor can be corrected with minimal field repairs. Bastian Solutions encourages using the following troubleshooting techniques shown in Table 1 before contacting your Bastian Solutions representative. -
Page 43: Spare Parts
Installation & Maintenance Manual: BSBAC 1 HP 8 Spare Parts Table 2 refers to general spare parts for a BSBAC. Please refer to Appendix 1 for general arrangements that contain specific spare part lists for each section and configuration. Table 2: General spare parts list for BSBAC DESCRIPTION COMMON CONFIGURATIONS IDLER ROLLERS... -
Page 44: Appendix 1: Spare Parts - General Arrangements
Installation & Maintenance Manual: BSBAC 1 HP 9 Appendix 1: Spare Parts - General Arrangements Please find attached general arrangements for BSBAC conveyor sections. Published January 2022 Rev. B... - Page 45 Installation & Maintenance Manual: BSBAC 1 HP Published January 2022 Rev. B...
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- Page 50 Installation & Maintenance Manual: BSBAC 1 HP Bastian Solutions Conveyor Installation and Maintenance Manual Model: Bastian Solutions BSBAC 1 HP Conveyor © 2022 Bastian Solutions, LLC 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.