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Summary of Contents for Honeywell Intelligrated IntelliSort WD
- Page 1 IntelliSort WD Maintenance Manual Publication No. 29351003 September 8, 2021...
- Page 2 © 2011, 2014, 2016, 2021 Honeywell International Inc. All Rights Reserved This document contains confidential proprietary information and trade secrets of Honeywell. This document is distributed with the understanding that it will not be disclosed to any third party, in whole or part, without the prior written consent of Honeywell.
- Page 3 Table of Contents SAFETY INSTRUCTIONS ....................1 Introduction......................1 For Your Safety..................... 2 Standard Safety Conventions ................2 Safety Precautions ....................4 1.4.1 Guards and Guarding ..................4 1.4.2 Headroom ...................... 5 Controls ........................ 5 1.5.1 Control Stations ..................... 5 1.5.2 Safety Devices ....................
- Page 4 Removal and Replacement of the Divert Unit ............36 PREVENTIVE MAINTENANCE ..................43 Maintenance Precautions ..................44 Cleaning and Inspection ..................44 Preventive Maintenance Check Lists ..............45 Lubrication ......................46 4.4.1 Shaft Bearings ..................... 46 4.4.2 Motors and Carrier Rollers ................46 REPLACEMENT PARTS ....................
- Page 5 Safety Instructions This chapter provides instructions for the safe and productive operation of the equipment. You must read and understand these precautions completely before operating, setting up, installing, running, or performing maintenance on the equipment. Failure to follow this instruction could result in death or serious injury. Introduction These safety precautions are to be used as a guide to supplement the following: All other information pertaining to the equipment.
- Page 6 Safety Instructions Note: Emphasis is placed on the latest edition of the Occupational Safety and Health Standards, which is available from the Department of Labor, Washington, D.C. These standards (found in Part 1910, Title 29 of the Code of Federal Regulations) contain the current, general industry occupational safety and health regulations set forth by federal legislation.
- Page 7 Safety Instructions DANGER indicates a hazardous situation that, if not avoided will result in immediate, serious personal injury or death. A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
- Page 8 Safety Instructions Safety Precautions The success of any safety program depends primarily on the attitudes and training of the installation, maintenance, and operating personnel. The very nature of their work makes it necessary that they develop a complete and firsthand knowledge of each piece of equipment that is within their care.
- Page 9 Safety Instructions be provided if the product may fall off the conveyor for any reason and endanger personnel. 1.4.2 Headroom When the equipment is installed above exit passageways, aisles, or corridors, there shall be a minimum clearance of 6 ft. 8 in. (2.03 m) measured vertically from the floor or walking surface to the lowest part of the equipment or guards.
- Page 10 Safety Instructions exists, and that personnel must keep clear. These warning signs shall be provided along the equipment at areas not guarded by position or location. Remotely and automatically controlled equipment, and equipment where operator stations are not manned or are beyond voice or visual contact from drive areas, loading areas, transfer points, and other potentially hazardous locations on the equipment path not guarded by location, position, or guards, shall be furnished with emergency stop buttons, pull cords, limit switches, or similar emergency stop...
- Page 11 Safety Instructions Operation Safety Precautions Only a trained person shall be permitted to operate a conveyor. Training shall include instruction in operation under normal conditions and emergency situations. Where safety is dependent upon stopping devices or starting devices or both, they shall be kept free of obstructions to permit ready access.
- Page 12 Safety Instructions Installation and Maintenance Safety Installation and Maintenance shall be performed only by qualified and trained personnel. It is important to establish an installation and maintenance program to ensure that all conveyor components are maintained in a condition which does not constitute a hazard to personnel.
- Page 13 Safety Instructions Lockout / Tagout Guidelines Appropriate lockout and tagout policy and procedures shall comply with the Code of Federal Regulations, 29 CFR 1910.147 and the minimum safety requirements outlined in the current publication of the American National Standard Institute’s Control of Hazardous Energy - Lockout/Tagout and Alternative Methods (ANSI Z244.1).
- Page 15 General Description The IntelliSort® Wheel Divert (WD) is modular in design and features powered wheels to divert product. The wheel diverts are integrated with high-speed belt conveyor that provides drive for each of the diverting mechanisms, with diverts located at points along the main-line sort belt conveyor. The IntelliSort WD is typically used to sort product onto gravity or powered take-away spur conveyors.
- Page 16 General Description The IntelliSort WD is integrated with a high speed belt conveyor that provides drive for each of the diverting mechanisms. The design includes the divert mechanism in an easily replaceable "tray" module. This allows maintenance to stock a complete spare assembly to minimize potential downtime and repair units on a bench.
- Page 17 General Description Maintaining the IntelliSort WD Do not touch the rollers or belt while they are in motion. Keep clothing and jewelry away from the rollers or belt. Failure to follow this instruction may result in serious personal injury and/or equipment damage. The IntelliSort WD was designed for ease of maintenance.
- Page 18 General Description Product Rate 100 carts per minute (based on 16 inch average carton Length) Capacity • Minimum product size:9 in. L x 6 in. W x 2 in. H • Minimum product weight: 2 lbs • Cartons must be edge aligned to divert side of sorter belt and have relatively flat, stable bottoms Minimum Elevation 24 inches...
- Page 19 Service and Repair There may be occasions when various mechanical components must be replaced or repaired due to damage or wear. Like many other pieces of machinery, there are contributing factors that may lead to failure of components. These factors include runtime, products conveyed, preventive maintenance procedures in place, and overall care and cleaning.
- Page 20 Service and Repair Preliminary Inspection Prior to performing any maintenance there are certain things that should be checked in regards to the entire conveyor system. These items are described on the following pages. The nominal tension on the PTO drive belt should be 1/2 inch measured. If the PTO drive belt is not tensioned properly, use the tensioners located on either side of the wheel divert unit to adjust the tension.
- Page 21 Service and Repair The belt must be cut on a bias not to exceed a maximum of 4.8 degrees. The wheel rack is designed with the first wheels on the divert 1/16 of an inch lower than the second set of wheels. This is done so that product moving up onto the divert has a gradual transition from the belt onto the divert.
- Page 22 Service and Repair Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in Chapter 1 Safety Instructions to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. 3.2.1 O-Rings Quick Fix There may be a time where a few of the O-rings that drive the pop-up wheels break.
- Page 23 Service and Repair There is no reason to totally tear down the roller system to install new O-rings. New O-rings can be added by using the following procedures: Apply the appropriate lockout/tagout procedures to remove all power from the conveyor section. Using a knife, side cutters or other appropriate tool, remove all of the worn/damaged O-rings.
- Page 24 Service and Repair Swing the cover open to expose the PTO drive pulleys and belt. Loosen the 3/8 inch bolt on the tensioner. Remove the belt. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 25 Service and Repair Remove both bearing bolts from the bearing flange for the shaft that requires the addition of O-rings. Pull the bearing away from the bearing flange and place the O-ring around and behind the bearing and through the clearance in the side frame. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 26 Service and Repair Note: Notice that the O-ring is between the bearing and the bearing flange. Push the replacement O-ring(s) through the gap between the frame and the shaft and place them on the shaft. Note: On the forward shaft, the one with 4 O-rings that drive the center roller, slide the 4 O-rings that drive the roller off the shaft and move the replacement O-ring(s) to where they are needed on the shaft.
- Page 27 Service and Repair 10. Replace both of the bearing mounting bolts that hold the bearing in place. 11. Place the belt on the PTO, shaft pulleys, and tensioner pulleys. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 28 Service and Repair 12. With the belt in place, tighten the 3/4 inch bolt in the center of the tensioner for a coarse adjustment of tension. 13. To make fine tensioning adjustments, loosen the nut in the tensioner and move the tensioner until the belt is tensioned to a nominal 1/2 inch.
- Page 29 Service and Repair 14. Close the cover over the PTO drive pulleys and belt and tighten the 1/2 inch bolts that keep the cover in place. 15. Unlock and turn on the power for the conveyor and check for proper operation. Removing and Replacing the Rollers To remove or replace rollers, perform wheel maintenance, O-rings maintenance, bumper replacement, etc., it is not necessary to remove the unit from the tub in the...
- Page 30 Service and Repair Remove the flange nuts and carriage bolts from the guard rail. 4. Remove the guard rail as required to expose the ends of the unit. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 31 Service and Repair Remove the rollers beginning with the discharge roller. Note: All of the rollers are spring loaded at both ends, so they can be pulled toward you or away from you by pressing in the ends with a blunt tool. Always lift the rollers from the unit, pull them toward you carefully so as not to dislodge the O-rings, and disengage the axles from the opposite side of the unit.
- Page 32 Service and Repair Remove the center roller. Lift the center roller to gain access to the O-rings that drive the center roller. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 33 Service and Repair Remove the O-rings from the center roller. 10. Lift the rollers out as a unit taking care not to disengage the O-rings that are in place and set them aside. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 34 Service and Repair 11. With the rollers removed, the entire wheel rack is accessible. 12. Remove the O-rings connecting the shaft spools and the pop-up wheels. Note: The O-rings located on the wheels that are most rearward on the wheel rack are removed over the entire wheel.
- Page 35 Service and Repair Note: The O-rings located on the front pop-up wheels are removed forward off of the spool on the wheel. Wheel Rack Removal To remove the wheel rack assembly perform the following: Using a 3/16 inch Allen wrench, remove the two Allen screws and metal washers from the wheel rack bumpers.
- Page 36 Service and Repair Lift up and remove the rubber bumpers. Check the bumpers for wear. If worn, replace. Using a 11/16 inch socket, extension, and ratchet, remove the two hex head bolts from the wheel rack. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 37 Service and Repair Lift the wheel rack from the pop-up wheel divert and remove it. While the wheel rack is accessible, vacuum out, or blow out the area with compressed air. Cardboard dust and assorted debris that gathers in and around the wheel rack can cause problems with the systems operation.
- Page 38 Service and Repair To remove the pneumatic cylinders, first remove the air lines. Note: It is very important to note which tubes go to which fittings. They must be replaced in the proper position for proper operation. Remove the diverter unit as described in the next section. Turn the diverter unit to expose the bottom cover.
- Page 39 Service and Repair 12. When replacing the wheel rack onto the cylinder shafts, make sure that the oblong end of the shaft fits into the oblong slot in the wheel rack to ensure proper pop-up height on both ends of the wheel rack. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 40 Service and Repair Removal and Replacement of the Divert Unit In some cases there may be the need to remove the entire unit from the conveyor. The design is such that the entire unit may be removed and replaced with a spare unit.
- Page 41 Service and Repair Loosen the 3/8 inch bolt on the tensioner. Remove the belt. IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 42 Service and Repair Disengage the air lines from the unit by pressing down on the air fitting connector with a 3/8 inch open end wrench, and pull out on the air line. Unplug the wiring from any existing electric photo-eyes located in the guard rail. Remove the flange nuts and carriage bolts from the guard rail.
- Page 43 Service and Repair Remove the guard rail as required to expose the ends of the unit. Remove the two carriage bolts on the drive pulley side of the conveyor, they are located on the flanges above the bearing flange, by removing the 9/16 inch flange nut.
- Page 44 Service and Repair 10. Remove the two carriage bolts located on the divert side of the conveyor; they are located on the flanges above the bearing flange by removing the 9/16 inch flange nut. Note: On some units, washers may be inserted between the flanges to slightly raise the divert unit for better control of product.
- Page 45 Service and Repair 11. Once the two carriage bolts located on the divert side of the conveyor have been removed, grasp the unit by the side plate on the drive pulley side, and slide it out of the conveyor bucket. If there is not sufficient space to slide the unit out of the side of the divert assembly, the unit may also be removed by lifting it straight up.
- Page 47 Preventive Maintenance Before performing any maintenance or lubrication services, follow the lockout/ tagout procedure in Chapter 1 Safety Instructions to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. 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.
- Page 48 Preventive Maintenance Only qualified maintenance specialists should maintain the mechanical, electrical and pneumatic portion of the conveyor. Maintenance Precautions You must read and understand these precautions completely before operating, setting up, installing, running, or performing maintenance on the equipment. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
- Page 49 Preventive Maintenance • For proper operation. • Operating personnel will most likely treat clean equipment with more care. 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.
- Page 50 Preventive Maintenance Three Month Check List Date Checked Changes/ Repairs Made Check with Conveyor Shut Down Check all screws, nuts and bolts and tighten as necessary. Check all bolted connections and tighten as needed. Lubricate shaft bearings. Six Month Check List Date Checked Changes/...
- Page 51 Replacement Parts Parts Lists and Illustrations The following pages contain standard assembly and component parts illustrations and parts lists for your equipment. Colors used in these illustrations are for clarification only and may not match the paint colors of your conveyor components. These illustrations and parts listings were up-to-date at the time of the printing of this manual.
- Page 52 Replacement Parts Figure 5-1 Example of Links in the Electronic Manual 5.1.1 Using the Parts Lists The assemblies and components listed in these parts lists may not be described completely if they contain special modifications and/or enhancements. Use the part number shown in this parts list to make sure the correct replacement parts are ordered.
- Page 53 Replacement Parts Note: Do not provide the item number (the number in the circle) assigned to the part in the illustration. These numbers are used for reference. To Order Spare Parts - click on the part number shaded in grey; see Figure 5 - 1. The Security Warning Window may be displayed.
- Page 54 Replacement Parts 5.1.2 701189 - IWD Divert Module Assy_H_BF IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 55 Replacement Parts IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 56 Replacement Parts 5.1.3 701191 - IWD Tub Frame Assy_H_BF IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 57 Replacement Parts IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 58 Replacement Parts 5.1.4 701251 - IWD End Idler Assy IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 59 Replacement Parts IntelliSort WD | Maintenance Manual | 29351003 September 8, 2021...
- Page 61 Troubleshooting Introduction Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. When troubleshooting equipment problems, it is essential to completely understand how the system functions during normal operation.
- Page 62 Replacement Parts List short and long term solutions. Select a solution or possible solutions. Implement and document one solution at a time. Troubleshooting Chart Table 6-1 Troubleshooting Problems and Solutions Symptom Probable Cause Corrective Action Motor will not start or it No line voltage.
- Page 63 Replacement Parts Symptom Probable Cause Corrective Action Check for loose or defective relays, switches, etc. Correct as necessary. Motor runs excessively Check for sluggish or seized Overload. hot (over 130° F). bearings, or obstructions. Check all rollers for free rotation. Lack of lubrication in Replace reducer with spare and reducer.
- Page 64 Replacement Parts Symptom Probable Cause Corrective Action Excessive belt stretch. Excessive belt tension. Relieve belt tension by adjusting take-up until return belt sag is approximately 2% of return length between rollers. Severe wear on Belt slipping on drive Adjust take-up, while running underside of belt.
- Page 65 Replacement Parts Symptom Probable Cause Corrective Action Foreign obstruction. Locate and clear obstruction. Check conveyor capacity and Conveyor is overloaded. correct as necessary. Belt has pulsing Too much slack in drive Adjust drive chain tension per movement. chain. “Drive chain and sprocket” section. Excessive belt tension.
- Page 66 Replacement Parts Symptom Probable Cause Corrective Action Chain is rubbing guard. Check for obstruction and adjust as necessary. Chain is pulsing. Insufficient tension. Adjust as instructed. Conveyor/Drive Inspect conveyor for obstructions overload. and correct as necessary. Broken chain. Frozen pulley or Inspect source of problem and sprocket shaft.
- Page 67 Index accessories, 14 finish, 14 AMSE, 2 frames, 14 ANSI, 3, 7, 8, 9 applications, 13 guard, 4, 5, 6, 7, 8 by location, 4 by position, 4 bearing mounting belts guarding, 4 replacing, 23 guarding exceptions, 4 capacity, 14 headroom, 5 carrier rollers, 46 check lists...
- Page 68 daily, 45 replacing divert units, 36 precautions, 44 replacing O-rings, 18, 19 preventive, 43 replacing rollers, 25 six month, 46 rollers three month, 46 carrier, 46 weekly, 45 motor, 46 monthly maintenance, 45 removing, 25 motor rollers, 46 replacing, 25 O-rings safety quick fix, 18...
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