Related Manuals for TREW 1500 Series
Summary of Contents for TREW 1500 Series
- Page 1 INSTALLATION & MAINTENANCE MANUAL SERIES 1500 24VDC MOTORIZED DRIVER ROLLER MDR SPIRAL SECTION 1.800.571.8739 poweredbyTREW.com info@trewautomation.com...
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Page 2: Table Of Contents
www.poweredbyTrew.com 1.800.571.8739 info@trewautomation.com TABLE OF CONTENTS 1 - OVERVIEW Zero Pressure Accumulation (ZPA) Standard Zones 2 - COMPONENTS Motor Control Card - Auto & Full Control Zone Technology Motor Control Card Modes of Operation Motor Control Card Special Features Changing the Operation of the ZPA Motor Control Card Circuit Protection Motor Control Card Installation Dimesions Motor Control Card Replacement... -
Page 3: Overview
www.poweredbyTrew.com 1.800.571.8739 info@trewautomation.com OVERVIEW REV A MDR Spiral - Installation and Maintenance Manual... -
Page 4: Zero Pressure Accumulation (Zpa)
www.poweredbyTrew.com OVERVIEW Zero Pressure Accumulation (ZPA) An MDR conveyor with accumulation is composed of several ‘zones’, as shown in the image below. Each zone is powered by a motorized drive roller (MDR). The MDRs are controlled by a communications network, allowing the zones to communicate with each other to achieve the desired accumulation method. -
Page 5: Standard Zones
www.poweredbyTrew.com OVERVIEW Standard Zones The image below shows a typical zone layout for a standard intermediate zone. Each zone has one motorized drive roller (MDR), photo eye sensor, reflector, motor control card, and carrier rollers. REV A MDR Spiral - Installation and Maintenance Manual... -
Page 6: Components
www.poweredbyTrew.com 1.800.571.8739 info@trewautomation.com COMPONENTS REV A MDR Spiral - Installation and Maintenance Manual... -
Page 7: Motor Control Card - Auto & Full Control
www.poweredbyTrew.com COMPONENTS Motor Control Card - Auto & Full Control The motor control card provides true zero pressure accumulation and other control options to a conveyor system. Each motor control card manages the functionality of (2) motorized drive rollers which in turn drives idler rollers using O-rings or other belts. The ZPA motor control card, MDR and idler rollers, with associated sensors and switches, are assembled into a short conveyor section - or zone. -
Page 8: Motor Control Card Replacement
www.poweredbyTrew.com COMPONENTS Motor Control Card Replacement Before attempting to repair or replace a drive roller, drive card, controller device, or any other device connected to these components, be sure that power to the controls is locked out to prevent premature or accidental start-up. Failure to follow this instruction may result in serious personal injury, and/or equipment damage. -
Page 9: Motorized Drive Roller (Mdr)
www.poweredbyTrew.com COMPONENTS Motorized Drive Roller (MDR) The motorized drive roller (MDR) is the muscle of the conveyor zone. It provides the torque and speed required to move the product to the next zone. The MDR has the motor and gearing encapsulated inside the roller tube. Replacement of MDR 1 Turn off and Lockout / Tag-out all power to the conveyor section 2 Make sure that the Gear Ratio matches that of the roller that is being replaced. - Page 10 www.poweredbyTrew.com COMPONENTS 8 The motor nut threads on to the motorized drive roller shaft, and should be to the proper torque of: See Page 2.5 for Proper Torque Information. 9 Tools required to achieve proper torque can be seen below 10 Plug the motor cable into the motor control card 11 Turn on power to the conveyor section 12 Check to see if roller operates by passing your hand in front of the photo eye sensor...
- Page 11 www.poweredbyTrew.com COMPONENTS Proper Torque Gear Ratios Vary. EC110 and EC100: EC310: 30 ft-lbs +/- 5 ft-lbs 50 ft-lbs +/- 5 ft-lbs (40.7 N-M +/- 6 N-M) (67.8 N-m +/- 6 N-m) ITOH: 22.5 ft-lbs +/- 5 ft-lbs (30.5 N-M +/= 6 N-M) REV A MDR Spiral - Installation and Maintenance Manual...
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Page 12: Carrier Roller
www.poweredbyTrew.com COMPONENTS Carrier Roller The carrier roller is used to take the weight of the product and also distributes the torque generated by the motorized drive rollers via o-belts, chain, timing belts, strip belts, or full-width belts. Generally, no more than nine carrier rollers per motorized drive roller are used in each zone. -
Page 13: Photo Eye Sensor
www.poweredbyTrew.com COMPONENTS Photo Eye Sensor A photo eye sensor is used to sense the presence of the product. Two styles of photo eye sensors are used on standard Conveyor: Retro-Reflective Photoelectric Sensor & Background Suppression Diffused Photoelectric Sensor. Replacement of a Photo Eye Sensor 1 Turn off and Lockout / Tag-out all power to the conveyor section 2 Locate end of Photo Eye Sensor cable and unplug from the roller drive card 3 Carefully remove cable from any holes in conveyor frame. -
Page 14: Standard Retro-Reflective Photoelectric Sensor
www.poweredbyTrew.com COMPONENTS Standard Retro- Reflective Photoelectric Sensor The image and diagram below displays the cable connection types for the Tru-Vue ML17 series photoelectric sensors - 3.5m sensing range - Polarized retro-reflective mode - PNP Dark-Operated Sensor. REV A MDR Spiral - Installation and Maintenance Manual... -
Page 15: Standard Background Suppression Diffused Photoelectric Sensor
www.poweredbyTrew.com COMPONENTS Standard Background Suppression Diffused Photoelectric Sensor (SICK) The image and diagram below displays the connection diagram for the WTR series photoelectric sensors – 90mm sensing range – Background Suppression Diffused-4-in-1 output N.O./N.C. - 2m cable. REV A MDR Spiral - Installation and Maintenance Manual... -
Page 16: Drive Belts (O-Bands)
www.poweredbyTrew.com COMPONENTS Drive Belts (O-Bands) MDR conveyor utilizes drive belts to connect individual rollers together to create a Zone. The drive belts can be O-bands or V belts, depending upon load and speed requirements of the conveyor. Over time the drive belts can exhibit wear. O-bands in particular can wear or stretch, eventually allowing excessive slippage in the roller groove. - Page 17 www.poweredbyTrew.com 1.800.571.8739 info@trewautomation.com PREVENTATIVE MAINTENANCE REV A MDR Spiral - Installation and Maintenance Manual...
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Page 18: Preventive Maintenance
www.poweredbyTrew.com PREVENTATIVE MAINTENANCE The satisfactory performance and reliability of this equipment is dependent upon a proficient preventive maintenance (PM) program with scheduled equipment inspections under normal operating conditions. Accurate records of maintenance and repairs will help to identify problem areas and repetitive problem patterns. -
Page 19: Maintenance Precautions
www.poweredbyTrew.com PREVENTATIVE MAINTENANCE Maintenance Precautions You must read and understand these precautions completely before operating, setting up, running, or performing maintenance on the equipment. Failure to follow this instruction may result in serious personal injury and/or equipment damage. 1 When testing operating performance, do not start the equipment until all operations and maintenance personnel are notified and clear of the unit being tested 2 Be certain that required safety guards are never removed without authorization 3 Never run the equipment under production conditions without safety guards in place... -
Page 20: Inspection
www.poweredbyTrew.com PREVENTATIVE MAINTENANCE Any prescribed cleaning schedule should be modified as experience is gained. A thorough inspection should be performed while cleaning problem areas. The total value of inspection procedures is determined largely by the consistency and regularity of the schedule. A definite interval of inspection must be established and obeyed. This is usually easier to accomplish if a ”round robin”... - Page 21 www.poweredbyTrew.com PREVENTATIVE MAINTENANCE Weekly Inspection 1 Visually inspect belts and rollers for wear, improper alignment, or buildup of foreign materials and repair/clean as required 2 Visually inspect all motors 3 Check pneumatic water traps and drain as required Inspection Every 6 Months 1 Clean and lubricate all drive chains with SAE-10 to SAE-40 oil 2 Check all set screws and tighten as necessary.
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Page 22: Replacing Rollers
www.poweredbyTrew.com PREVENTATIVE MAINTENANCE Replacing Rollers 1 Turn off and Lockout/Tagout all power to the conveyor 2 Use a tool to push in the spring loaded axle on the roller to free one end of the axle from the frame of the conveyor 3 Carefully disengage the opposite end of the roller from the frame and remove. -
Page 23: Lubrication
www.poweredbyTrew.com PREVENTATIVE MAINTENANCE Lubrication Check the following maintenance items immediately after start-up, during initial run-in, at 100 hours, and thereafter at 500 hour intervals under average conditions. Under adverse conditions, more frequent maintenance checks should be performed. Speed Reducers Standard speed reducers are sealed and maintenance free. They incorporate a pressure compensating chamber, which eliminates the lengthy preparation normally required to put a reducer into service and prevents atmospheric contamination. - Page 24 www.poweredbyTrew.com 1.800.571.8739 info@trewautomation.com SUPPORT REV A MDR Spiral - Installation and Maintenance Manual...
- Page 25 www.poweredbyTrew.com SUPPORT When troubleshooting equipment problems, it is essential to completely understand how the system functions during normal operation. Thoroughly review the operational description, the circuit drawings, and the electrical diagrams sent with your equipment. Once the system operation is understood, it is usually best to start at the problem, and then work back to the source.
- Page 26 www.poweredbyTrew.com SUPPORT Troubleshooting a Dead Zone on the Conveyor Perform the following visual checks prior to any troubleshooting: 1 Visually check and confirm that all wires are plugged in, intact and all connectors are secure 2 Visually check and confirm that there are no obstructions to the rollers 3 Inspect the photo eye sensor and check for proper operation as described in the Preventative Maintenance section of this manual.
- Page 27 www.poweredbyTrew.com SUPPORT Motor Control Card / Motorized Drive Roller Checks This check determines if the motor control card and the motorized drive roller are functional and must be done with power to the conveyor turned on. These checks must be performed with the power to the conveyor section turned “ON”. Only qualified electricians should be allowed to perform these checks.
- Page 28 www.poweredbyTrew.com SUPPORT No Voltage to the Motor Control Card This check determines if there is power being supplied to the motor control card and must be done with power to the conveyor turned on. These checks must be performed with the power to the conveyor section turned “ON”. Only qualified electricians should be allowed to perform these checks.
- Page 29 www.poweredbyTrew.com SUPPORT Symptom Probable Cause Corrective Action Zone will not run Mechanical Transmission Insure proper mechanical (dead zone) connection (O-bands, drive chain loops, timing belts, etc.) between MDR & carrier rollers No voltage to motor Check voltage across control card motor control card Check power supply Inspect interconnect wiring...
- Page 30 www.poweredbyTrew.com SUPPORT Symptom Probable Cause Corrective Action Zone runs continuously Disconnected photo-eye Reconnect photo-eye sensor (continued) sensor Faulty communication cable Replace motor control card Motorized drive roller makes Faulty motorized drive roller Replace motorized excessive noise drive roller Zone runs at a different Gear ration of Verify proper MDR, speed than rest of conveyor...
- Page 31 www.poweredbyTrew.com SUPPORT Symptom Probable Cause Corrective Action Boxes run into each other Dead zone See: zone will not run (continued) (dead zone) Speed set too high See: zone runs at different speed than rest of conveyor Package larger than zone Verify package size to original conveyor specifications...
- Page 32 www.poweredbyTrew.com SUPPORT Support If you need further assistance: Website: www.poweredbyTrew.com Email: info@trewautomation.com Phone: 1.800.571.8739 Monday - Friday, 8:00am - 5:00pm CT REV A MDR Spiral - Installation and Maintenance Manual...
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