Montech TB40 Assembly Instructions Manual
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Montech TB40 Assembly Instructions Manual

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Assembly Instructions
TB40 Conveyor
Montech AG
Gewerbestrasse 12, 4552 Derendingen, Switzerland
+41 32 681 55 00 | info@montech.com | www.montech.com
Translation of original German Assembly Instructions / MA-100154-EN-0922

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  • Page 1 Assembly Instructions TB40 Conveyor Montech AG Gewerbestrasse 12, 4552 Derendingen, Switzerland +41 32 681 55 00 | info@montech.com | www.montech.com Translation of original German Assembly Instructions / MA-100154-EN-0922...

  • Page 2: Table Of Contents

    Technical data ................................14 Weight Conveyor TB40 .............................. 15 Nameplate ................................. 15 Dimension Conveyor TB40 ............................16 TB40 Conveyor design / cross-section ........................19 Conveyors separation ..............................20 Electronic performance ............................21 3.8.1 Inputs IN A, IN B, IN 1, IN 2 ............................21 3.8.2...
  • Page 3 TB40 Conveyor electrical hook-up description ......................28 5.2.1 Electrical connection ..............................28 5.2.2 Turn on and turn off behavior TB40 power unit ......................31 5.2.3 Electrical Grounding of the conveyor......................... 31 Setting the necessary pretension of the belt ......................32 Belt Tracking (centric run of the transport belt) ......................

  • Page 4: Definitions

    Assembly Instructions MA-100154 TB40 Conveyor Definitions Type designation Conveyor Designation Type TB40 Document name MA-100154-EN-0922 List of essential health and safety requirements according to Machinery Directive 2006/42/EC, Annex I, Chapter 1 Not relevant for this device  To be met by the system integrator for the (complete) machine  Met for the scope of the partly completed machinery  1.1. General 1.1.1. Definitions  1.1.2. Principles of safety integration ...
  • Page 5 Assembly Instructions MA-100154 TB40 Conveyor Not relevant for this device  To be met by the system integrator for the (complete) machine  Met for the scope of the partly completed machinery  1.4. Requirements for safety guards 1.4.1. General requirements   1.4.2. Special requirements for separable safety guards   1.4.2.1 Fixed safety guards   1.4.2.2 Interlocking movable separable safety guards ...

  • Page 6: Information About This Manual

    TB40 Conveyor Information about this manual This manual contains the data and information required for the installation and maintenance of the TB40 conveyors. All personnel must read this manual carefully and understand it before starting work. The basic prerequisite for safe working is compliance with all the safety instructions and handling instructions given in this manual.

  • Page 7: Location Of The Instructions

    • maintenance work that has not been carried out or has been carried out inadequately Copyright The assembly instructions are to be treated as confidential. They are intended exclusively for personnel working with the conveyor. The disclosure of this document to third parties is prohibited unless approved in writing by Montech AG. NOTICE Copyright The information, texts, drawings, pictures and other representations that form the content of this publication are protec- ted by copyright.

  • Page 8: Service Life

    Assembly Instructions MA-100154 TB40 Conveyor 1.11 Service life The service life depends heavily on the frequency of use, care, and compliance with the specified maintenance requirements. If the intended use is observed, an average product service life of 10 years can be expected. In this context, care must be taken to ensure that wearing parts such as conveyor belts, toothed belts, round belts, shock absorbers and sensors must be replaced according to the specified maintenance intervals.

  • Page 9: Safety Instructions

    Any use that goes beyond the intended use or is different is considered improper use. Improper use A misuse of the TB40 can lead to dangerous situations. In particular, the following uses must be avoided: • Direct exposure to light from UV lamps.

  • Page 10: Personal Protective Equipment

    Assembly Instructions MA-100154 TB40 Conveyor Personal protective equipment Personal protective equipment must be worn when working in order to minimize dangers to health. The following personal protective equipment (PPE) must be worn as a minimum: Wear safety shoes You must wear safety shoes while working in the vicinity of the conveyor.

  • Page 11: Operator

    Further work not described in these assembly instructions may only be carried out by Montech AG's skilled personnel. Other personnel are not authorized to carry out this work. Please contact Montech AG's customer service to have such work car- ried out (for contact information, see chapter 1.12).

  • Page 12: Specification Conveyor Tb40

    Assembly Instructions MA-100154 TB40 Conveyor Specification Conveyor TB40 TB40 Conveyor components Figure 1 Exploded view of the Conveyor TB40 Item Description Profile lateral Drive unit End section with diverter roller Connecting support Gliding plate Belt Lateral guide (accessories) Cable, power and signal (accessories) www.montech.com...
  • Page 13 Assembly Instructions MA-100154 TB40 Conveyor Figure 2 Exploded view of the Conveyor TB40 with knife edge Item Description Profile lateral Drive unit End section with knife edge Connecting support Gliding plate Belt Lateral guide (accessories) Cable, power and signal (accessories) www.montech.com info@montech.com...

  • Page 14: Technical Data

    Assembly Instructions MA-100154 TB40 Conveyor Technical data Operating temperature + 10 ... + 40 °C Storage temperature + 5 ... + 40 °C Relative humidity (in operation) < 95 % (without condensation) Relative humidity (storage) < 95 % (without condensation) Degree of purity of the air (in operation)

  • Page 15: Weight Conveyor Tb40

    Assembly Instructions MA-100154 TB40 Conveyor Weight Conveyor TB40 Weight [kg] Extension Type (Base L = 1000 mm) per meter [kg] TB40-300 15.2 TB40-400 17.7 TB40-500 19.9 TB40-600 22.2 10.9 TB40-700 24.5 12.4 TB40-800 26.7 13.9 Nameplate Figure 3 Example of a nameplate Position of the nameplate (at the bottom of the chassis)

  • Page 16: Dimension Conveyor Tb40

    Assembly Instructions MA-100154 TB40 Conveyor Dimension Conveyor TB40 Knife edge MonTurn (optional) Conveying direction towards drive only Figure 5 Dimension conveyor TB40 with MonTurn The motor connection is available on the left and right. AR: Drive roller UR: Diverter roller Type TB40-300 TB40-400 TB40-500...
  • Page 17 + 40 mm Knife edge MonTouch (optional) Conveying direction towards drive only Figure 6 Dimension conveyor TB40 with MonTouch The motor connection can be chosen either on the right or left side. AR: Drive roller UR: Deflection roller Type TB40-300 TB40-400...
  • Page 18 Assembly Instructions MA-100154 TB40 Conveyor Config Lateral guide Connection type Minimum lenght [mm] None Fixed Adjustable Standard MonTurn MonTouch TB40-300 TB40-400 With knife edge L + 40 mm www.montech.com info@montech.com +41 32 681 55 00 18 / 56...

  • Page 19: Tb40 Conveyor Design / Cross-Section

    TB40 Conveyor TB40 Conveyor design / cross-section View Y If the support width of the ma- terial to be conveyed is narro- wer than dimension C, the max. conveying width widens Figure 7 TB40 Conveyor design / cross-section Type TB40-300 TB40-400 TB40-500 TB40-600 TB40-700 TB40-800 A Chassis width [mm] B Conveyor width ±...

  • Page 20: Conveyors Separation

    Assembly Instructions MA-100154 TB40 Conveyor Conveyors separation The Conveyors are shipped in units of 3 m length max. If the total length of a Conveyor exceeds the maximum transport length of 3 m, the individual parts should be assembled according to the following schematics.

  • Page 21: Electronic Performance

    Assembly Instructions MA-100154 TB40 Conveyor Electronic performance 3.8.1 Inputs IN A, IN B, IN 1, IN 2 Value / Note Performance Input level PLC level Low level < 5 High level > 15 Protection against reverse connection and voltages ≤ 30 In case of cable break Logic level «0»...

  • Page 22: Safety And Monitoring Functions

    Assembly Instructions MA-100154 TB40 Conveyor 3.8.4 Safety and monitoring functions Value / Note Performance Function volume • Temperature monitoring of the output stage • Overvoltage and undervoltage monito- ring of the system voltages overcurrent limitation • Overload protection by I Temperature cut-off point (Hysteresis: 10K) [°C]...

  • Page 23: Transport, Packaging And Storage

    Assembly Instructions MA-100154 TB40 Conveyor Transport, Packaging and Storage Transport CAUTION Improper transportation Risk of injury and damage in the event of unauthorized or improper transport! ⇒ Unloading upon delivery and internal transport must only be carried out by trained personnel. ⇒ No one is allowed to stand under suspended loads.

  • Page 24: Storage Of Packages

    Assembly Instructions MA-100154 TB40 Conveyor Storage of packages Store the packages under the following conditions: • Do not store outdoors. • Store in a dry and dust-free environment. • Do not expose to aggressive media. • Protect from exposure sunlight.

  • Page 25: Commissioning

    Assembly Instructions MA-100154 TB40 Conveyor Commissioning DANGER Electricity Risk of electric shock and thereby risk of injury or death in contact with live or live parts! ⇒ Work on the electrical system must only be carried out by qualified personnel.

  • Page 26: Assembly And Disassembly

    Assembly Instructions MA-100154 TB40 Conveyor Assembly and Disassembly IMPORTANT Shafts oiling The shafts and hub bores to be connected must be free from dirt and burrs. Oiling the bearing journals will make assemb- ling and disassembling the coupling hubs easier. Oiling the coupling hubs will not reduce their clamping force.

  • Page 27: Adjust The Height Of The Floor Stand Telescopic

    Assembly Instructions MA-100154 TB40 Conveyor X 3 Position the conveyor with the positioning screw (30) and fasten it to the floor stand with the hex socket head cap screws (20) and washer (10) (tightening torque 6 Nm), repeat on the other side.

  • Page 28: Tb40 Conveyor Electrical Hook-Up Description

    ⇒ Make sure there is no load on the Conveyor prior to disconnecting the power source. NOTICE ook-up description This chapter only describes the use of the TB40 conveyor belt with the standard connection type. NOTICE Power supply 24 VDC A 24 VDC power supply must be provided. The Mean Well-SDR-480-24 switched-mode power supply is recommended.
  • Page 29 Assembly Instructions MA-100154 TB40 Conveyor 5.2.1.2 Power cabel Figure 11 Pin assignment power cabel 12-pin power cabel (M12) Pin 2 black no. 2 / grey Ballast Connection ballast resistor* Pin 1 black no. 1 / brown Up (+V) Power supply (+24V) Pin 3 black no. 3 / black...
  • Page 30 "Logic" (+24V DC) Pull-down resistor 100 kΩ Figure 12 Circuit diagram TB40 power unit 5.2.1.4 Technical data switching-mode power supply 24VDC, 20A The switch-mode power supply is optionally available for the Conveyor TB40. Figure 13 Switch-mode power supply www.montech.com info@montech.com +41 32 681 55 00 30 / 56...

  • Page 31: Turn On And Turn Off Behavior Tb40 Power Unit

    Electrical Grounding of the conveyor Before commissioning the TB40, it must be electrically grounded. The grounding connection TB should be used for this pur- pose. This is mounted in a groove of the chassis. The grounding cable can then be connected between the two washers using a cable lug (included for grounding connection TB).

  • Page 32: Setting The Necessary Pretension Of The Belt

    Assembly Instructions MA-100154 TB40 Conveyor Setting the necessary pretension of the belt NOTICE Pretension according nameplate The correct tension for a conveyor belt is shown on the nameplate attached to the belt drive, for example: 0.4%. Procedure X 1 After the belt is mounted, glue two measuring marks (M) on the top of the belt in an untensioned state so that they have a spacing (L ) of 500 or 1,000 mm for example.

  • Page 33: Belt Tracking (Centric Run Of The Transport Belt)

    Assembly Instructions MA-100154 TB40 Conveyor Belt Tracking (centric run of the transport belt) IMPORTANT Centric run of the transport belt The belt must always run centered over the diverter roller and the drive roller. Under no circumstances may the edges of the belt project laterally over the ends of the rollers! The belt tracking over the deflection rollers is corrected by tightening or loosening the hexagon head screw (90).
  • Page 34 Assembly Instructions MA-100154 TB40 Conveyor Welding connections Flexproof and Quickmelt In the case of zigzag joints (Flexproof) or welded butt joints (Quickmelt), the direction of travel of the belt is unimportant. Welding connections Flexproof and Quickmelt Flexproof Quickmelt Figure 18 Flexproof and Quickmelt welding connections www.montech.com...

  • Page 35: Operation

    6.1.1 PLC Speed-Mode (default) In PLC speed mode, the TB40 will be operated via digital and analog inputs on the motor using a PLC. Either the three stored speeds can be controlled or an analog speed setpoint can be specified. The following functions can be executed via the I/O's: •...
  • Page 36 Assembly Instructions MA-100154 TB40 Conveyor 6.1.1.2 Speed setting via analog input AIN 1 Speed setting via analog input AIN 1 Figure 19 Speed setting via analog input AIN 1 DIN A DIN B DIN 1 DIN 2 Rotation direc. Value Function Freewheel (drive not powered) Positive Variable speed via AIN1 Negative Variable speed via AIN1 Stop (braking and holding) The speed change via the analog input is limited by the general acceleration and deceleration value.
  • Page 37 Assembly Instructions MA-100154 TB40 Conveyor 6.1.1.3 Speed setting via stored values v1 (N1), v2 (N2) and v3 (N3) Figure 20 Speed setting via stored values v1, v2, v3 Speed setting via stored values DIN A DIN B DIN 1 DIN 2 Rotation direc. Value Function Freewheel (drive not powered) Positive Stored, constant speed 1 Positive Stored, constant speed 2...
  • Page 38 Assembly Instructions MA-100154 TB40 Conveyor 6.1.1.4 Function «overrun» NOTICE Defined overrun A defined overrun (fixed value) can be activated at the factory on request or subsequently activated and changed using the control and parameterizing unit MonTouch*. * See assembly instruction control and parameterizing unit MonTouch (BA-100157).
  • Page 39 Assembly Instructions MA-100154 TB40 Conveyor 6.1.1.5 Output function of digital outputs PLC speed-mode (default) Logic Status output Digital output DOUT 1 High-active Eeady indication DOUT 2 High-active Over temperature indication DOUT 3 High-active Ready indication On request other output functions can also be parametrized. See chapter 6.1.3. www.montech.com info@montech.com...

  • Page 40: Plc Position Mode

    PLC position mode In PLC position mode, the TB40 can be operated via digital and analog inputs on the motor using a PLC. The speed is given to the conveying mode via the analog setpoint. In positioning mode, a defined distance is travelled. With a pulse, the distance is executed once.
  • Page 41 Assembly Instructions MA-100154 TB40 Conveyor 6.1.2.2 Speed setting via analog input AIN 1 (PLC position mode) The braking behavior in PLC position mode differs from the behavior in PLC speed mode. At the transition to the IN A = IN B = high state, the conveyor brakes and returns to the position at the trigger point.
  • Page 42 Assembly Instructions MA-100154 TB40 Conveyor 6.1.2.3 Function – Execute distance once Execute distance once Figure 23 Function – Execute distance once DIN A DIN B DIN 1 DIN 2 Rotation direc. Value Function Freewheel (drive not powered) Stop (braking and holding) Stop (braking and holding) 0 → 1 Positive Execute distance once 0 →...
  • Page 43 Assembly Instructions MA-100154 TB40 Conveyor 6.1.2.4 Function – Execute distance several times Figure 24 Execute distance several times FFunction – Execute distance several times DIN A DIN B DIN 1 DIN 2 Rotation direc. Value Function Freewheel (drive not powered) Stop (braking and holding) Stop (braking and holding) 0 → 1 Positive...
  • Page 44 Assembly Instructions MA-100154 TB40 Conveyor 6.1.2.5 Function – «overrun» NOTICE Defined overrun A defined overrun (fixed value) can be activated at the factory on request or subsequently activated and changed using the control and parameterizing unit MonTouch*. * See assembly instruction control and parameterizing unit MonTouch (BA-100157).
  • Page 45 Assembly Instructions MA-100154 TB40 Conveyor 6.1.2.6 Output function of digital outputs PLC Position mode (default) Logic Status output Digital output DOUT 1 High-active Reporting window reached DOUT 2 High-active Encoder A- trace* DOUT 3 High-active Encoder B-trace* * The resolution of the output signal is limited by the max. permissible frequency of the digital output and is 1mm at maxi- mum belt speed with gear reduction 30 as well as 0.4 mm with gear reduction 80.

  • Page 46: General Output Functions

    Assembly Instructions MA-100154 TB40 Conveyor 6.1.3 General output functions Output DOUT 2 Output DOUT 3 Output DOUT 1 • Without function • Encoder A-trace • Encoder B-trace • Speed signal • Speed signal • Speed signal • Current signal • Current signal •...

  • Page 47: Overview Of The Operating Modes And Parameterizable Values Tb40

    Assembly Instructions MA-100154 TB40 Conveyor 6.1.4 Overview of the operating modes and parameterizable values TB40 • PLC Speed-Mode without overrun function • PLC Speed-Mode with overrun function (on request) • PLC Position mode 6.1.4.1 Standard values PLC speed-mode Default values: Gear i = 30 Gear i = 80 Stored conveyor speeds v1, v2, v3 v1 = 10 m/min...

  • Page 48: Maintenance

    You must wear safety glasses while working in the vicinity of the pneumatic system. Maintenance plan The following table describes the maintenance work required for optimum, uninterrupted operation of the TB40 conveyor. If regular checks show increased wear, shorten the necessary maintenance intervals in line with actual wear.

  • Page 49: Conveyor Belt Maintenance And Cleaning

    Assembly Instructions MA-100154 TB40 Conveyor Conveyor belt maintenance and cleaning 7.3.1 Maintenance In general, synthetic conveyor belts do not require any maintenance besides cleaning. If anything, periodically checking the belt tension is recommended, especially in cases with difficult operating conditions (e.g. frequent starts under full load, major temperature or humidity fluctuations, etc.).
  • Page 50 Assembly Instructions MA-100154 TB40 Conveyor Habasit Resistance category Coating material PVC* EPDM PVC** PTFE Habi- (conveyor belt side) PUR+TPU lene Hamid NBR+TPU SI+TPU Tensile member material (fabric) Glass Hamid Cleaning agent: Neutral          ...

  • Page 51: Replacing The Belts

    Assembly Instructions MA-100154 TB40 Conveyor Replacing the belts 7.4.1 Replacing endless belts The installation of endless belts is recommended when the conveyor is easily accessible or when the equipment needed for welding endless connections is not available. NOTICE Dismanteling In particular, electrically or pneumatically powered consumers, which are mounted on the opposite side of the conveyor chassis to the gear drive, as well as floor and table stands, must be dismantled to replace the endless belt.

  • Page 52: Repairs

    X 5 Assembly takes place in reverse order. X 6 Adjust the pretensioning of the belt as described in chapter 5.3. X 7 To align the belt tracking, follow the instructions in chapter 5.4. Figure 26 Replacing the drive unit TB40 www.montech.com info@montech.com +41 32 681 55 00...

  • Page 53: Disassembly And Disposal

    Assembly Instructions MA-100154 TB40 Conveyor Disassembly and disposal Once the device has reached the end of its service life, it must be dismantled and disposed of in an environmentally friendly manner. DANGER Electricity Risk of electric shock and thereby risk of injury or death in contact with live or live parts! ⇒...

  • Page 54: Disposal

    Assembly Instructions MA-100154 TB40 Conveyor Disposal IMPORTANT Correct disposal Incorrect disposal can cause hazards to the environment! • You must dispose of all components in accordance with the following table via the appropriate disposal operation. • Take note of the general and country-specific disposal regulations.

  • Page 55: Annex 1 Declaration Of Incorporation

    Assembly Instructions MA-100154 TB40 Conveyor Annex 1 Declaration of Incorporation www.montech.com info@montech.com +41 32 681 55 00 55 / 56...
  • Page 56 Montech AG Gewerbestrasse 12, 4552 Derendingen, Schweiz +41 32 681 55 00 | info@montech.com | www.montech.com...

This manual is also suitable for:

Tb40-300Tb40-400Tb40-500Tb40-600Tb40-700Tb40-800

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