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transnorm TS 2800 Operating Instructions Manual

Roller conveyor
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TS 2800
Roller conveyor
Operating instructions

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  • Page 1 TS 2800 Roller conveyor Operating instructions...
  • Page 2 Fax +49 (0) 5127 4400 info@transnorm.de http://www.transnorm.com Documentation Operating instructions, -Translation- Version 3.0 ENG, 14.05.2012 Subject to technical modifications. All rights reserved by TRANSNORM SYSTEM GmbH. Reprint and duplications only with written approval. Revision V 1.0 Initial version V 2.0 Layout revised V 3.0...

  • Page 3: Table Of Contents

    Inhaltsverzeichnis Inhaltsverzeichnis Further applicable documents ....................7 EC Declaration of Incorporation ......................7 ............................ 9 Introduction Purpose of this document ........................9 Validity ............................9 Illustrations ............................. 9 Using these instructions ....................... 10 Copyright ............................11 Service ..............................11 Warranty ............................. 12 ...............................
  • Page 4 Replace the pulley on the tail pulley side..................68 Replace pulleys on the drive side ....................70 Replace tensioning rollers ........................72 Fault clearance ..........................75 What to do if............................75 Motor and Gear ........................... 75 Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 5 Inhaltsverzeichnis Decommissioning and disposal ................... 77 Machine disposal ..........................77 Main components of the machine ....................... 78 ..........................79 Contact details Head office ............................79 Subsidiaries, branch offices and sales partners worldwide ..............80 Service branches Germany ........................ 82 Suggestions and comments ....................... 82...
  • Page 6 Inhaltsverzeichnis Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 7: Further Applicable Documents

    Further applicable documents EC Declaration of Incorporation Further applicable documents EC Declaration of Incorporation...
  • Page 8 Further applicable documents EC Declaration of Incorporation Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 9: Introduction

    Introduction Purpose of this document Introduction Purpose of this document These operating instructions enable you to safely operate the delivered machine, defined as partly completed machinery by the EC Machinery Direc- tive, in accordance with its intended use. Read through these instructions carefully before commissioning the machine.

  • Page 10: Using These Instructions

    This is the first step in a sequence of actions. This is a visible result of a sequence of actions. You have achieved an objective. The action has been completed. You have completed an entire process. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 11: Copyright

    This publication must be treated as strictly confidential. It may only be used by authorised persons and within the company. and must not be disclosed to third parties without the written approval of TRANSNORM SYSTEM GmbH. All documents are protected under copyright law. Dissemination or reproduc- tion of these documents, in their entirety or as excerpts, is prohibited.

  • Page 12: Warranty

    We accept no liability for defects or damage caused by improper handling, operation or maintenance. Note that only original spare parts and accesso- ries approved by TRANSNORM SYSTEM GmbH should be used. Unless otherwise stipulated in the contract, the warranty period begins on the day of delivery or with notification of supply readiness.

  • Page 13: Safety

    Safety Operating conditions Safety Operating conditions The conveyor, subsequently referred to as the machine, is an incomplete machine as defined by the EC Machinery Directive. The machine has been manufactured in keeping with current scientific and technological develop- ments. Nevertheless, there may be dangers arising from the machine under the following circumstances: Use other than for its intended purpose Improper use...

  • Page 14: Impermissible Operating Conditions

    Provide instructions on how to proceed and behave in the case of acci- dents and emergencies. Define issues relating to occupational health and safety as well as envi- ronmental protection. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 15 Safety Operating conditions Trouble-free operation of the machine Implement the following measures to ensure trouble-free operation of the machine: Ensure that these instructions are complete, in legible condition and accessible to all personnel at all times. Only operate the machine when it is fully functional. Check the operability of the machine and the safety equipment regularly.

  • Page 16: Personnel Qualification

    Are technically qualified and authorised by the operating company personnel to carry out specific tasks such as installation, maintenance and fault elimination. Corresponding training in theory and practice is a prerequisite. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 17: Remaining Risks

    Safety Remaining risks The following work is to be carried out by specialised personnel only: Work requiring specialised knowledge Work on Specialised knowledge pneumatic Such work may only be carried out by personnel with specialised components knowledge of and experience in handling pneumatic systems. electrical Such work may be carried out under the guidance and supervision components...
  • Page 18 Damage to Leaking operating During disposal: the environ- fluids Collect operating fluids in suitable ment containers. Dispose of waste oil, lubricating grease, cleaning agents containing solvents and similar products correctly Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 19: Protective Devices

    Protective devices Protective devices Various covers are installed on the machine to prevent limbs being drawn in and crushed. The protective devices and safety equipment are listed in the following. It is expressly prohibited to render unserviceable, bypass or remove protec- tive devices.

  • Page 20: Protective Devices On The Machine

    Protective devices Protective devices on the machine Protective devices on the machine Protective devices TS 2800, example illustration Picture illustration Item Description Cover drive station Cover tensioning arm Protection plate belt guide Infeed / outfeed guard Operating instructions: Roller conveyor TS 2800...

  • Page 21: Description

    Description Technical description Description The TS 2800 roller conveyor is a basic roller conveyor with which unit loads can be transported over long conveying tracks at high conveying speeds. Technical description The TS 2800 is a roller conveyor. The conveyor can be equipped with a central drive station or a terminal drive station.

  • Page 22: Specifications

    Electrical data Name Data motor voltage supply standard: 230 V / 400 V AC 50 Hz, for deviations see motor type identification plate Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 23 Description Specifications Electrical data (cont'd.) Name Data Motor brake voltage Standard: 230 V AC/400 V AC, see motor type identification plate for variations Protection class Standard: IP55, not explosion-protected Location requirements Name Data Surrounding temperature 5 ° C to +40 ° C, for short periods up to +50 ° C (max.

  • Page 24: Areas Of The Machine

    Areas of the machine The conveyor consists of the following parts: Areas TS 2800, example illustration Key to illustration Designation Tubular side guide (optional) Conveyor track Support Drive belt guide Drive station Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 25: Parts Of The Machine

    Description Parts of the machine Parts of the machine Parts TS 2800, example illustration Picture illustration Name Name Conveyor roller Motor bracket Drive belt Protection plate belt guide Roller track Cover drive station Railing tube Flange bearing Gear motor Threaded spindle...

  • Page 26: Motor Designs

    R 47 The use of special motors from other manufacturers is possible in some cases depending on use. For descriptions of the installation positions, refer to the SEW operating instructions. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 27: Transport And Installation

    Transport and installation Machine delivery Transport and installation Machine delivery Conveyors up to a length of approx. 4 m are completely assembled and preset at the factory. Conveyors with a length exceeding 3 m are generally delivered in several parts The individual parts are marked with labels on the section points.

  • Page 28: Disposing Of Packaging Material

    Permissible operating conditions Danger of explosion! The machine is not explosion-protected. Do not operate the conveyor in explosive atmospheres. DANGER The space required for operation and maintenance depends on individual requirements. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 29: In-Company Transport

    Transport and installation In-Company Transport The place of installation must fulfil the following conditions: normal atmosphere (not containing oil or gas, no corrosive components) Ambient temperature 5 ° C to +40 ° C, short-term up to +50 ° C (max. 1 h) relative air humidity max.

  • Page 30: Auxiliary Equipment

    A = 16 mm B = 51 mm C = 27 mm D = 20 mm F = 42 mm Round steel Ø8 mm min. length BN + 300 mm Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 31: Transport With Industrial Truck Or Crane

    Transport and installation Transport with industrial truck or crane Transport with industrial truck or crane Auxiliary equipment required: 4x lift truck hook 2x round sling 4x chain shackle 2x round steel Ø8, length approx. BN + 300mm...

  • Page 32: Final Installation On Site

    Transport and installation Final Installation on Site Final Installation on Site We recommend having the installation carried out by TRANSNORM SYSTEM GmbH. Alternatively, the assembly could be carried out under the supervision of or after instructions from TRANSNORM SYSTEM GmbH.
  • Page 33 Transport and installation Final Installation on Site Undo joining elements (3) and adjust the height. Supports have been fitted. Fit the frame Carry out the following procedures: Pre-position the individual sections on the conveyor bed as shown by the decals. Push individual sections (1), (2) together and fit with the fixing elements (3) provided.
  • Page 34 Manually check the transfer accuracy at the front and back of the machine. Use loads according to specifications to carry out this check. The machine has been aligned. The machine has been assembled and aligned. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 35: Operation

    Operation Commissioning Operation Commissioning Commissioning and the start-up after service and maintenance works are near enough the same procedures. The daily start-up process via the control unit of the overall conveyor system is described in the system documentation or in the control documentation. The machine is designed for the following subsequent data: 3 phases, neutral conductor and earthing conductor Alternating voltage 400 V...
  • Page 36 The direction of rotation is checked. Machine is running. Carry out test run Carry out the following procedures: Remove all foreign objects from the working area of the machine. Switch on machine. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 37: Normal Operation

    Operation Normal operation Check that the machine is operating smoothly. Noise If excessive noise occurs Locate source and eliminate fault, see "Troubleshooting". Make sure that the drive belt is correctly tensioned and adjusted. The drive belt runs off track. The drive belt must be readjusted. see "Loosen / tighten and adjust the drive belt“...
  • Page 38 Operation Shutdown Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 39: Maintenance And Care

    Upon your request we will provide an optimised maintenance agreement based on your individual requirements. To guarantee safe operation of the machine, we recommend that you to make use of our TRANSNORM SYSTEM Service at least once a year.

  • Page 40: Lubricants

    Visual inspection: Are belts worn or damaged? If so, replace these belts. Weekly Idler rollers Inspection: Can abnormal running noise be heard? If so, check or replace the idler rollers. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 41: Cleaning And Care

    Maintenance and care Cleaning and Care Maintenance schedule (cont'd.) Interval Assembly group Maintenance/ inspection Depending Gear motor Gear: on the indi- Is there oil below the gearbox? If so, seal Observe the oper- vidual case the leak and optimise the oil level. ating instructions Check attachment and alignment.
  • Page 42 Maintenance and care Cleaning and Care Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 43: Repairs

    The order data has been listed in the spare parts list to enable the correct identification of spare parts. Only original TRANSNORM SYSTEM GmbH spare parts may be used. DIN- parts may be ordered from specialised trade.

  • Page 44: Tightening Torque

    Tightening torque Bush No. 1008 1310 1210 1610 2012 2517 1108 1315 1215 1615 2017 2525 Tightening torque [Nm] Check the tightening torques after one hour of operation. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 45: Replacing The Side Guide

    Repairs Replacing the side guide Replacing the side guide The side guide must be demounted for certain maintenance and repair work, but not replaced. When replacing put out the new side guide ready for use according to the spare parts list. Tubular side guide Demount side guide The side guide may tilt and crush body parts!
  • Page 46 Carry out the following procedures: Fitting the side guide Installation is carried out in reverse order. Rail supports aligned with the marking. Side guide has been fitted. Tubular side guide has been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 47: C-Profile Side Guide

    Repairs Replacing the side guide C-profile side guide Demount side guide The side guide may tilt and crush body parts! Secure the side guide to prevent it falling down. Use hoists to raise and lower the side guide. WARNING Carry out the following procedures: on both sides Mark the position of the rail supports on the conveyor bed.

  • Page 48: Roller Guard Rail-Side Guide

    Side guide is demounted. Mount side guide. Carry out the following procedures: Installation is carried out in the reverse order. Side guide is fitted. The roller guard side guide has been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 49: Replacing The Round Belt

    Repairs Replacing the round belt Replacing the round belt Precondition: Machine has been taken out of operation. Machine has been secured against accidental switch-on. Side guide is demounted. Demount Carry out the following procedures: round belt Move off joining elements (2). Loosen off joining elements (3).

  • Page 50: Replacing The Idler Rollers

    Idler rollers have been fitted. Fitting the side guide Carry out the following procedures: Proceed as described under "Replacing the side guide.“ Side guide is fitted. Idlers and castors have been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 51: Loosen/Tighten And Adjust The Drive Belt

    Repairs Loosen/tighten and adjust the drive belt Loosen/tighten and adjust the drive belt Precondition: Machine has been taken out of operation. Machine has been secured to prevent it being switched on inadvertently. Loosening/tight- Carry out the following procedures: ening the drive belt Use the hand wheel (1) to tighten / loosen the belt.
  • Page 52 Repeat steps 2 to 5 until the belt shows an accurate running cycle. Fasten the counternut (1). The drive belt has been adjusted. Drive belt is loosened / tightened and adjusted. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 53: Replace Pressure Rollers

    Repairs Replace pressure rollers Replace pressure rollers Precondition: Machine has been taken out of operation. Machine has been secured against accidental switch-on. Side guide is demounted. Drive belt is detensioned. Corresponding idlers and castors are demounted. Carry out the following procedures: Demount pressure rollers Remove joining elements (2).
  • Page 54 Drive belt is tensioned and adjusted. Carry out the following procedures: Fitting the side guide Proceed as described under "Replacing the side guide.“ Side guide is fitted. Pressure rollers have been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 55: Replacing The Drive Belt

    Repairs Replacing the Drive Belt Replacing the Drive Belt Precondition: Machine has been put out of operation. Machine has been secured against accidental switch-on. Drive belt is detensioned. Side guide is demounted. Corresponding idlers and castors are demounted. Carry out the following procedures: Replacing the drive belt Remove joining elements (2).
  • Page 56 Carry out the following procedures: drive belt Proceed as described under "Loosen / tighten and adjust the drive belt“ Drive belt is tensioned and adjusted. The drive belt has been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 57: Replacing Gear Motor

    Repairs Replacing gear motor Replacing gear motor Place the new gear motor ready for use according to the spare parts list and get it ready for operation according to the manufacturer's specifications. Precondition: Machine has been taken out of operation. Machine has been secured against accidental switch-on.
  • Page 58 Remove gear motor (7) with chain wheel. Measure dimension "X.“ Loosen off the grub screw of the chain wheel (8) and remove the chain wheel. The gear motor has been removed. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 59 Repairs Replacing gear motor Carry out the following procedures: Mount gear motor Installation is carried out in reverse order. Set dimension "X.“ Gear motor has been installed. Carry out the following procedures: Tighten and adjust drive belt Proceed as described under "Loosen / tighten and adjust the drive belt.“ Drive belt is tensioned and adjusted.

  • Page 60: Replace Drive Chain

    Remove covers (2). Undo joining elements (3) and counternut (4). Use tensioning bolt (5) to loosen the chain. Lift off the chain (4), using a spanner if necessary. Drive chain is demounted. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 61 Repairs Replace drive chain Carry out the following procedures: Mount drive chain Installation is carried out in the reverse order. Drive chain is mounted. Drive chain has been replaced.

  • Page 62: Replacing Flange Bearings

    Loosen off joining elements (1). Remove covers (2). Undo joining elements (3) and counternut (4). Use tensioning bolt (5) to loosen the chain. Lift off the chain (4), using a spanner if necessary. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 63 Repairs Replacing flange bearings Loosen off the grub screw of the chain wheel (6) and remove the chain wheel. Remove feather key (7). Loosen off the grub screws (9) and remove the joining elements (8). Pull off the bearing (10). Flange bearing is demounted.
  • Page 64 Carry out the following procedures: Tighten and adjust drive belt Proceed as described under "Loosen / tighten and adjust the drive belt.“ Drive belt is tensioned and adjusted. The flange bearing has been replaced. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 65: Replacing Drive Pulley

    Repairs Replacing drive pulley Replacing drive pulley Precondition: Machine has been put out of operation. Machine has been secured against accidental switch-on. Motor has cooled down. Drive belt is detensioned. Carry out the following procedures: Demounting the drive pulley Loosen off joining elements (1). Remove covers (2).
  • Page 66 Move off joining elements (10). Remove the flange bearing with the drive pulley (9). Loosen off the grub screw (11) and remove the drive pulley (9). The drive pulley is demounted. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 67 Repairs Replacing drive pulley Carry out the following procedures: Mounting the drive pulley Installation is carried out in the reverse order. Drive pulley has been installed. Tighten and adjust Carry out the following procedures: drive belt Proceed as described under "Loosen / tighten and adjust the drive belt.“ Drive belt is tensioned and adjusted.

  • Page 68: Replace Tail Pulley Rollers

    Pulley on the tail pulley side is demounted. Mount the pulley Carry out the following procedures: on the tail pulley side Installation is carried out in the reverse order. Pulley on the tail pulley side is mounted. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 69 Repairs Replace tail pulley rollers Carry out the following procedures: Tighten and adjust drive belt Proceed as described under "Loosen / tighten and adjust the drive belt.“ Drive belt is tensioned and adjusted. Pulley on the tail pulley side has been replaced.

  • Page 70: Replace Pulleys On The Drive Side

    Corresponding idlers and castors are demounted. Demount pulleys on Carry out the following procedures: the drive side Remove joining elements (1) and cover (2). Remove joining elements (4) and cover (3). Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 71 Repairs Replace tail pulley rollers Remove joining elements (6) and rollers (5). Pulleys on the drive side are demounted. Carry out the following procedures: Mount the pulley on the drive side Installation is carried out in the reverse order. Pulley on the drive side is mounted. Fit idler rollers Carry out the following procedures: Proceed as described under "Replace idlers and castors.“...

  • Page 72: Replace Tensioning Rollers

    Secure the tensioning rollers against tilting. WARNING Carry out the following procedures: Remove joining elements (1) and cover (2). Remove joining elements (5) and plate (4). Remove rollers (3). Tensioning rollers are demounted. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 73 Repairs Replace tensioning rollers Carry out the following procedures: Mount tensioning rollers Installation is carried out in the reverse order. Tensioning rollers are mounted. Tighten and adjust Carry out the following procedures: drive belt Proceed as described under "Loosen / tighten and adjust the drive belt.“ Drive belt is tensioned and adjusted.
  • Page 74 Repairs Replace tensioning rollers Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 75: Fault Clearance

    Fault clearance What to do if... Fault clearance This section informs you what to do if a malfunction occurs. A disturbance can have various different causes. What to do if... Mechanical malfunctions Diagnosed disturbance Possible cause Remedial action Machine shuts down Power supply disrupted, Cause must be detected and eliminated by trained...
  • Page 76 Fault clearance Motor and Gear Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 77: Decommissioning And Disposal

    Decommissioning and disposal Machine disposal Decommissioning and disposal Machine disposal When disposing of the complete machine or parts of it, please observe your local rules and regulations for waste disposal. The regulations will tell you if the machine has to be dismantled for disposal and how the individual components may be recycled.

  • Page 78: Main Components Of The Machine

    Drive belt, conveyor belt Polyurethane (PU) Polyvinyl chloride (PVC) Conveyor roller Plastic Steel Gear motor Cast iron Copper Steel Basic frame, support Aluminium Steel Pulley Steel Polyurethane- (PUR) coated steel Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

  • Page 79: Contact Details

    In the event of uncertainty or problems during installation, maintenance, repair or operation of the machine, please first consult the corresponding section of the operating instructions. If you cannot find the information you require there, please contact TRANSNORM SYSTEM GmbH. Head office Germany TRANSNORM SYSTEM GmbH Förster Str.

  • Page 80: Subsidiaries, Branch Offices And Sales Partners Worldwide

    Tel.: +31 (0) 1 84 43 31 00 Tel.: +33 (0) 1 48 63 70 61 Fax: +31 (0) 1 84 49 93 71 Fax: +33 (0) 1 48 63 05 62 e-mail: sales.nl@transnorm.de e-mail: eric.cornec@transnorm.de Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...
  • Page 81 Contact details Subsidiaries, branch offices and sales partners worldwide Sales partners Denmark Switzerland Nerak A/S. Frei Fördertechnik AG Viborgvej 22-24 Schwarzbachstraße 26 8600 Silkeborg 3113 Rubigen Tel.: +45 (0) 70 26 50 04 Tel.: +41 (0) 3 17 20 56 56 Fax: +45 (0) 70 23 50 04 Fax: +41 (0) 3 17 20 56 55 e-mail: nerak@email.dk...

  • Page 82: Service Branches Germany

    Fax: 0 21 73 / 93 82 76 Fax: 0 71 43 / 96 58 51 Suggestions and comments ...on this documentation or the machine should be sent to the first address listed above. Operating instructions: Roller conveyor TS 2800 Version 3.0 ENG, 14.05.2012...

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