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transnorm TS1400 Operating Instructions Manual

Belt conveyor
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TS1400
Belt conveyor
Operating instructions

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  • Page 1 TS1400 Belt conveyor Operating instructions...
  • Page 2 Fax +49 (0) 5127 4400 info@transnorm.de http://www.transnorm.de Documentation Operating instructions Version 2.0, 16.04.2010 Subject to modifications. All rights reserved by TRANSNORM SYSTEM GmbH. Reprint and duplications only with written approval. Revision V 1.0 Initial version V 1.1 EC-Declaration of conformity updated V 1.2...

  • Page 3: Table Of Contents

    Table of contents Table of contents Further applicable documents ....................7 Declaration of Incorporation ......................... 7 Introduction ............................ 9 Purpose of the document ........................9 Validity ............................9 Illustrations ............................. 9 Handling the instruction manual ....................10 Copyright protection ........................... 10 Service ..............................
  • Page 4 Exchange tail pulley ..........................79 Tail pulley Ø32 ..........................79 Flattened edge ..........................80 Replace the return roller ........................81 Fault clearance ..........................83 What to do if............................83 Motor and gear ........................... 84 Betriebsanleitung: Gurtförderer TS1400 Version 2.0, 16.04.2010...
  • Page 5 Table of contents Decommissioning and disposal ................... 85 Main components of the machine ....................... 85 Contact ............................87 Head office ............................87 Subsidiary companies, branches and foreign distributors worldwide ..........87 Service branches Germany ........................ 89 Suggestions and notifications ......................90...
  • Page 6 Table of contents Betriebsanleitung: Gurtförderer TS1400 Version 2.0, 16.04.2010...

  • Page 7: Further Applicable Documents

    Further applicable documents Declaration of Incorporation Further applicable documents Declaration of Incorporation...
  • Page 8 Further applicable documents Declaration of Incorporation Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 9: Introduction

    Introduction Purpose of the document Introduction Purpose of the document These operating instructions enable you to operate the delivered machine, defined as partly completed machinery by the EC Machinery Directive, safely in accordance with its intended use. Carefully study these instructions before commissioning.

  • Page 10: Handling The Instruction Manual

    This publication must be treated as private and confidential. It is intended only for the in-house use of an authorised person subgroup. It may only be passed on to a third party after the written confirmation of TRANSNORM SYSTEM GmbH.

  • Page 11: Service

    We do not take responsibility for defects and damages caused by inappro- priate use or maintenance faults We would like to point out that only original spare parts and accessories authorised by TRANSNORM SYSTEM GmbH may be used. The warranty period starts on the day of delivery or the notice "ready for dispatch"...
  • Page 12 Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 13: Safety

    Safety Operating conditions Safety Operating conditions The conveyor, designated the machine in the following, is defined by the EC Machinery Directive as partly completed machinery. The machine has been designed according to the state of the art. Nevertheless, there may be dangers arising from the machine under the following circumstances: Improper use Improper application...

  • Page 14: Responsibilities Of The Operating Company / Integrator

    Always keep the complete operating instructions legible, handy and close to the machine so that it is available to personnel at all times. Only operate the machine when it is fully functional. Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 15: Safety Equipment

    Safety Safety equipment Check the machine and its safety equipment regularly to ensure that they are fully functional. Carrying out installation layout Observe the following basic safety princi- ples when connecting several separate components to form one overall system: Install guards in the area of pulleys, apex bends, roller arches, conveyor gates and transmissions.

  • Page 16: Staff Qualification

    Safety Staff qualification Overview of the safety equipment of the TS1400 Safety equipment of Belt conveyorTS1400 Pos. Description Cover, drive Staff qualification Installation, maintenance and repair work as well as commissioning demand specialist know-how and qualification of the staff involved, above and beyond that required in normal application.

  • Page 17: Remaining Risks

    Safety Remaining risks must be familiar with the basic regulations regarding occupational health and safety as well as the accident prevention regulations and branch- specific regulations These operating instructions differentiate between the following personnel groups: Definition of the person groups Personnel groups Definition Operating company Considered as the operating company is the company that...
  • Page 18 Damage caused to Leaking utilities Collect utilities in suitable the environment intercepting tanks. Waste oil, lubricants, solvent-containing cleaning agents and other consuma- bles must be disposed of in compliance with the appli- cable regulations. Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 19: Transportation And Erection

    If the machine is transported by sea, a seaworthy packaging is required. Observe the valid operating conditions described in the following also for storage periods. If you have any queries concerning storage and transport, please contact Transnorm System GmbH.

  • Page 20: Disposing Of Packaging Material

    The required space for operation and maintenance depends on the indi- vidual requirements. The place of installation must fulfil the following conditions: normal atmosphere (not containing oil or gas, no corrosive components) Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 21: Internal Transportation

    Transportation and erection Internal transportation Ambient temperature 5 °C to +40 °C, for brief periods up to +50 °C (max. 1 h) relative air humidity max. 80% internal set-up safe protection against wetness and rain. Internal transportation Increased risk of accident due to: Falling or slipping loads.

  • Page 22: Auxiliary Materials

    U min = 3 m Round sling hook, load capacity 1000 kg L = 84 mm A = 24 mm D = 35 mm F = 17 mm G = 20 mm M = 8 mm Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 23: Transportation With Industrial Truck

    Transportation and erection Transportation with industrial truck Necessary auxiliary materials Anchor shackle, load capacity 3250 kg A = 16 mm B = 60 mm C = 27 mm D = 43 mm E = 20 mm F = 42 mm Chain shackle, load capacity 3250 kg A = 16 mm...

  • Page 24: Final Installation On Site

    Installation Conveyors are usually delivered in one piece. Conveyors delivered in multi- part require assembly works carried out by TRANSNORM SYSTEM GmbH. Do not mount these machines yourself. To carry out the assembly Depending on the design the supports are either equipped with standpipes or support angles.

  • Page 25: Electrical Connection

    Transportation and erection Final Installation on Site Check the levelling. Observe the correct heights for infeed and discharge. Depending on the system concept, different heights may be useful The system design engineer can decide this. Only in case of floor anchorage: anchor supports so they cannot change position anymore.
  • Page 26 Transportation and erection Final Installation on Site Assembly instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 27: Description

    Description Technical Description Description The belt conveyor TS 1400 is equipped with central or terminal drive. Due to its design features, it can be used for nearly all kinds of in-company trans- port. It is suitable for transport of light unit loads of all kinds, with a horizontal or a slightly rising conveyor track.

  • Page 28: Main Measurements

    Description Main measurements Main measurements Terminal drive Central drive Main measurements TS1400 (example illustration) Used variables Variable Description LFGS Nominal length Nominal width Conveying height Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 29: Technical Data

    Technical data For the technical data regarding your specific machine, please refer to the service specifications of your order confirmation. The following refers to the general technical data of preference items. Mechanical Data TS1400 Name Data Design versions Conveyor length (LFGS) / nominal width (BN) /...

  • Page 30: Areas Of The Machine

    DIN 45635/part 27 below 77 dB (A). Areas of the machine The conveyor consists of the following parts: TS1400 (Example illustration) Picture illustration Name Conveying surface Conveyor belt Tail pulley Drive station Drive assembly Gear motor Supports Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 31: Parts Of The Machine

    Description Parts of the machine Parts of the machine Main assemblies TS1400 (examle illustration) Picture illustration Name Name Conveyor belt Support Tail pulley Gear motor Receptacle for tail pulley Chain drive Return roller Cover Angle bracket Drive pulley Conveyor track sheet...

  • Page 32: Motor Designs

    WF 20 DT71 brake The use of special motors of other manufacturers is possible in individual cases. A description of the installation positions can be found in the SEW catalogue. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 33: 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 34 Check the correct direction of rotation. Switch the machine off. The direction of rotation is checked. Machine is running. Carry out test run Please carry out the following work steps: Switch on the machine. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 35: Normal Operation

    Operation Normal operation Check that it is running smoothly. Noise development If noises occur Locate the source and eliminate the disturbance, see "fault clear- ance". Check the conveyor belt for correct tension and adjustment. The belt moves off to the sides. Belt must be readjusted.
  • Page 36 Operation Shutdown Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 37: Maintenance And Care

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

  • Page 38: Lubricants

    Check the fixation and alignment. Is there abnormal running noise? Check bearings. Motor: Check cable feeding and temperature. Abnormal running noises? Check bearings. Check cooling fin and air leak. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 39 Maintenance and care Maintenance plan Maintenance Schedule (cont'd.) Interval Assembly group Maintenance work / check- ups Monthly Drive pulley Clean drive pulley. Visual check-up: Is the surface worn or damaged? If so, replace drive pulley. Monthly Flange bearing Check-up: Abnormal running noises of bearings? If so, replace bearings.

  • Page 40: Cleaning And Care

    Clean the machine regularly and adequately depending on the degree of dirtiness. It may only be cleaned dry (brush, cloth, compressed air, etc.). Make sure the machine and especially the electrical components are protected from wetness. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 41: Repair

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

  • Page 42: Locking Torques

    Generally there is no hazard due to the detachment of fasteners when a fixed guard is only removed from the machine by trained personnel for repair. Transnorm uses fixed guards as protective devices in danger zones. These may be covers that are removed rarely/never,...

  • Page 43: Replacing The Belt

    Repair Replacing the belt that are located on machines operated behind a master protective cover/housing For these covers, there are no undetachable fasteners as the risk of injury is considered as very low. Usually, all parts remain assembled for repairs on the installation location or in workshops.
  • Page 44 Slide off the flange bearing (2) of the pulley journal. Flange bearing is demounted. Dismount the side Please carry out the following work steps: plate Move off joining element (1). Remove the side plate (2). The side plate is dismounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 45 Repair Replacing the belt Remove tail pulley Please carry out the following work steps: Lift the tail pulley (1) from the guide and pull it sideways out of the belt loop. Tail pulley has been removed. Remove the return Please carry out the following work steps: roller Remove the return roller (1).
  • Page 46 Installation to be carried out in reverse order. The side plate is mounted. Please carry out the following work steps: Fitting the flange bearings Installation to be carried out in reverse order. Flange bearing is mounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 47: Central Drive

    Repair Replacing the belt Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. Fitting the side guide Please carry out the following work steps: Mount the side guide.
  • Page 48 Flange bearing is demounted. Dismount the side Please carry out the following work steps: plate Remove the stud bolt (1) and the joining elements (2). Remove the side plate (3). The side plate is dismounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 49 Repair Replacing the belt Remove the Please carry out the following work steps: tensioning rollers Remove the tensioning rollers (1). The tensioning rollers are removed Dismount the spacer Please carry out the following work steps: shafts Move off joining element (1). Remove the spacer shafts (2).
  • Page 50 Lift the tail pulleys (1) from the guide and pull them sideways out of the belt loop. The tail pulleys are removed. Remove the return Please carry out the following work steps: roller Remove the return roller (1). The tail pulley is removed. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 51 Repair Replacing the belt Removing the belt Please carry out the following work steps: Move off joining element (1). Lift the conveyor and remove the belt (2) sideways. Belt has been removed. Inserting the belt Please carry out the following work steps: Installation to be carried out in reverse order.
  • Page 52 The side guide is fitted. Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. Belt is exchanged. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 53: Tension Belt / Adjust

    Repair Tension belt / adjust Tension belt / adjust The belt must run in the centre of the pulleys. The belt run is adjusted by means of the 4 tensioning- and adjustment screws. The pressure of the tail pulleys against the belt is either increased or lowered. A certain pressure is required for optimal operation.
  • Page 54 Repeat steps 2 to 5, until the belt shows an accurate running cycle. Only adjust driving side if necessary. Fasten the counternut (1). Belt is tensioned and adjusted. Belt has been tensioned and adjusted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 55: Replace Gear Motor

    Repair Replace gear motor Replace gear motor Terminal drive For some maintenance and repair works the gear motor must be demounted but not exchanged. In case of a replacement, place the new gear motor ready for use and get it ready for operation according to the manufacturer's specifications.
  • Page 56 Use lifting equipment to lift motor on and off. Please carry out the following work steps: Remove all electrical supply connections from the motor. Move off joining element (1). Remove the gear motor (2). Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 57 Repair Replace gear motor Place gear motor on suitable underlay. The gear motor has been removed. Please carry out the following work steps: Fitting the gear motor Put assembly paste onto pulley journal. Position the gear motor. Mount joining elements (1). Connect electrical cables to motor.

  • Page 58: Central Drive

    Please carry out the following work steps: wheel Loosen the joining elements (1) and displace the motor plate (2) to the right to detension the drive chain. Lift the chain drive (3), if necessary open the chain coupling. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 59 Repair Replace gear motor Loosen the grub screw of the chain wheel (4). Remove chain wheel (5). The chain wheel is dismounted. Demount gear motor Increased risk of accident! Motor may tilt and squash parts of the body. Secure motor against tilting. WARNING Use lifting equipment to lift motor on and off.

  • Page 60: Replacing Flange Bearings

    Machine has been secured against accidental switch-on. Belt has been loosened. Demounting the Please carry out the following work steps: flange bearing Dismount the covers, the drive chain and the drive wheel at the centre station. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 61 Repair Replacing flange bearings Move off joinging element (1). Remove the flange bearing (2). Flange bearing is demounted. Fitting the flange Please carry out the following work steps: bearings Installation to be carried out in reverse order. Flange bearing is mounted. Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment".

  • Page 62: Exchange Drive Chain

    Move off cover (1). Cover is demounted. Demount drive chain Please carry out the following work steps: Loosen the joining elements (1) and displace the motor plate (2) upwards to detension the drive chain. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 63 Repair Exchange drive chain Lift the chain drive (3), if necessary open the chain coupling. Drive chain is dismounted. Please carry out the following work steps: Mount drive chain Installation to be carried out in reverse order. Drive chain is mounted. Mounting the cover Please carry out the following work steps: Installation to be carried out in reverse order.

  • Page 64: Central Drive

    Loosen the joining elements (1) and displace the motor plate (2) to the left to detension the drive chain. Lift the chain drive (3), if necessary open the chain coupling. Drive chain is demounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 65 Repair Exchange drive chain Mount drive chain Please carry out the following work steps: Installation to be carried out in reverse order. Drive chain is mounted. Mounting the cover Please carry out the following work steps: Installation to be carried out in reverse order. Cover is mounted.

  • Page 66: Replace The Drive Wheel

    Move off cover (1). Cover is demounted. Demount drive chain Please carry out the following work steps: Loosen the joining elements (1) and displace the motor plate (2) upwards to detension the drive chain. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 67 Repair Replace the drive wheel Lift the chain drive (3), if necessary open the chain coupling. Drive chain is dismounted. Please carry out the following work steps: Dismount the chain wheel Loosen the grub screws of the chain wheel. Slide of the chain wheel (1) from the pulley journal. The chain wheel is dismounted.

  • Page 68: Central Drive

    Machine has been taken out of operation. Machine has been secured against accidental switch-on. Belt has been loosened. Demount cover Please carry out the following work steps: Move off cover (1). Cover is demounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 69 Repair Replace the drive wheel Demount drive chain Please carry out the following work steps: Loosen the joining elements (1) and displace the motor plate (2) to the left to detension the drive chain. Lift the chain drive (3), if necessary open the chain coupling. Drive chain is dismounted.
  • Page 70 Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. The chain wheel is replaced. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 71: Drive Pulley Replacement

    Repair Drive pulley replacement Drive pulley replacement Terminal drive Precondition: Machine has been put out of operation. Machine has been secured against accidental switch-on. Side guide is demounted. Belt has been loosened. Demount cover Please carry out the following work steps: Move off cover (1).
  • Page 72 Please carry out the following work steps: flange bearing loosen grub screw of flange bearing. Move off joining element (1). Slide off the flange bearing (2) of the pulley journal. Flange bearing is demounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 73 Repair Drive pulley replacement Dismount the side Please carry out the following work steps: plate Move off joining element (1). Remove the side plate (2). The side plate is dismounted. Remove drive pulley Please carry out the following work steps: Loosen the grub screws of the flange bearing on the drive side.
  • Page 74 Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. Drive pulley has been replaced Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 75: Central Drive

    Repair Drive pulley replacement Central drive Precondition: Machine has been taken out of operation. Machine has been secured against accidental switch-on. Side guide is demounted. Belt has been loosened. Demount covers Please carry out the following work steps: Remove covers (1) and (2). Move off cover (3).
  • Page 76 Please carry out the following work steps: flange bearing Loosen grub screw of flange bearing. Move off joining element (1). Slide off the flange bearing (2) of the pulley journal. Flange bearing is demounted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...
  • Page 77 Repair Drive pulley replacement Dismount the side Please carry out the following work steps: plate Remove the stud bolt (1) and the joining elements (2). Remove the side plate (3). The side plate is dismounted. Remove drive pulley Please carry out the following work steps: Loosen the grub screws of the flange bearing on the drive side.
  • Page 78 Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. Drive pulley has been replaced Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 79: Exchange Tail Pulley

    Repair Exchange tail pulley Exchange tail pulley Tail pulley Ø32 Precondition: Machine has been put out of operation. Machine has been secured against accidental switch-on. Side guide is dismounted. Belt is detensioned. Remove tail pulley Please carry out the following work steps: Lift the tail pulley (1) from the guide and pull it sideways out of the belt loop.

  • Page 80: Flattened Edge

    Assembly to be carried out in reverse order. The flattened edge is mounted. Fitting the side guide Please carry out the following work steps: Mount the side guide. The side guide is fitted. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 81: Replace The Return Roller

    Repair Replace the return roller Tension belt / adjust Please carry out the following work steps: Carry out work steps as described under "Belt tensioning / adjustment". Belt has been tensioned and adjusted. The flattened edge is replaced. Replace the return roller Precondition: Machine has been taken out of operation.
  • Page 82 Repair Replace the return roller Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 83: Fault Clearance

    Fault clearance What to do if... Fault clearance This section informs you what to to if a malfunction occurs. A disturbance can have various different causes. What to do if... Mechanical disturbances Detected disturbance Possible cause Remedial action Machine shutdown Power supply disrupted, Cause must be detected and eliminated by trained...

  • Page 84: Motor And Gear

    Should the drive motor have a disturbance, please refer to the operating instructions of the motor for information on fault clearance. The operating instructions for the motor are part of the installation. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 85: Decommissioning And Disposal

    Decommissioning and disposal Main components of the machine 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 86 Supports Steel Covers Steel plate / aluminium plate Pulleys Steel, polyurethane (PUR) coated / steel Conveyor rollers Steel / plastic Belt edge holders Polyamide (PA) Gear motor Cast iron, partly steel, copper Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 87: Contact

    Should you have any queries or difficulties during installation, maintenance or repair work or during operation, please first consult the relevant section of the operating instructions. If you can not find satisfactory advice there, please contact TRANSNORM SYSTEM GmbH. Head office Germany TRANSNORM SYSTEM GmbH Förster Str.
  • Page 88 Fax +45 (0) 70 23 50 04 Fax +41 (0) 3 17 20 56 55 e-mail: nerak@email.dk e-mail: frei.fördertechnik@spectraweb.de Spain Austria J. Hernando BFM Industrieeinrichtungen GmbH & Co. c/ Iplacea n°6 Leobersdorfer Straße 31-33 Poligono Industrial Las Matillas Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

  • Page 89: Service Branches Germany

    Contact Service branches Germany (cont'd.) Spain Austria 28803 Alcalá de Henares (Madrid) 2552 Hirtenberg Tel. +34 (0) 9 18 79 62 86 Tel. +43 (0) 2 25 68 17 13 Fax +34 (0) 9 18 79 78 70 Fax +43 (0) 2 25 68 17 34 e-mail: info@jhernando.com e-mail: bfm@hirtenberger.at United Arab Emirates...

  • Page 90: Suggestions And Notifications

    Contact Suggestions and notifications Suggestions and notifications ...regarding the machine or this documentation should be sent to the first address listed above. Operating instructions: Belt conveyor TS1400 version 2.0, 16.04.2010...

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