Honeywell Intelligrated IntelliSort HDS Maintenance Manual
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Honeywell Intelligrated IntelliSort HDS Maintenance Manual

Honeywell Intelligrated IntelliSort HDS Maintenance Manual

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IntelliSort HDS
Maintenance Manual
Publication No. 29157701
May 3, 2021

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Summary of Contents for Honeywell Intelligrated IntelliSort HDS

  • Page 1 IntelliSort HDS Maintenance Manual Publication No. 29157701 May 3, 2021...
  • Page 2 © 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

    Table of Contents SAFETY INSTRUCTIONS ....................1 Introduction ........................ 1 For Your Safety ......................2 ANSI Safety Statements ................... 2 Standard Safety Conventions ................... 3 Safety Precautions ....................4 1.5.1 Guards and Guarding ..................4 1.5.2 Headroom ......................5 Controls ........................5 1.6.1 Control Stations ....................
  • Page 4 CONTROL DESCRIPTION ....................23 Introduction ......................23 DCM Operation .......................25 Connecting the DCM ....................26 DCM Layout ......................30 Oiler Control ......................31 SERVICE AND REPAIR .....................33 Introduction ......................33 Flight Removal and Installation ................34 Chain Adjustment and the Catenary ................36 Chain Lubrication ....................40 Chain Temperature ....................40 Chain Wear ......................42 Cleaning the Divert and Crossover Switches ............43 Electric Switch Removal and Installation ..............44...
  • Page 5 IntelliSort HDS Conveyor Checklists ................64 5.3.1 Daily Tasks.......................64 5.3.2 Weekly Tasks ....................65 5.3.3 Quarterly Tasks ....................67 REPLACEMENT PARTS ....................71 Ordering Parts ......................71 Illustrated Parts Lists ....................71 6.2.1 Using the Illustrated Parts Lists ................71 6.2.2 Idler and Infeed ....................74 6.2.3 Pre-Sort Section ....................79 6.2.4 Intermediates ....................81 6.2.5...

  • Page 7: Safety Instructions

    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 procedures are to be used as a guide to supplement the following: •...

  • Page 8: For Your Safety

    Safety Instructions For Your Safety This manual contains important safety information concerning the use, maintenance, installation, and operation of this equipment. Read and become familiar with the contents of this manual before attempting to install, operate, or service this equipment. It is necessary that all operators and maintenance personnel study the applicable sections of this manual thoroughly before operating the equipment.

  • Page 9: Standard Safety Conventions

    Safety Instructions Standard Safety Conventions This section includes information essential to the safety of personnel and equipment. Throughout this manual, and on the equipment, you will find DANGER, WARNING, and CAUTION signs. Pay particular attention to these because they signal information that is important to your safety and to the correct operation of the equipment.

  • Page 10: Safety Precautions

    Safety Instructions Note: The term NOTE is used to call attention to useful information and is not a safety notice. Information appearing in a NOTE provides additional information that is helpful in understanding the item being explained. Safety Precautions The success of any safety program depends primarily on the attitudes and training of the installation, maintenance, and operating personnel.

  • Page 11: Headroom

    Safety Instructions Guarded by Location or Position Remoteness from frequent presence of public or employed personnel shall constitute guarding by location. Overhead conveyors, such as trolley equipment and hanger- suspended tray conveyors, for which guarding would render the equipment unusable or would be impractical, shall have prominent and legible warnings posted in the area or on the equipment, and, where feasible, lines shall be painted on the floor delineating the danger area.

  • Page 12: Control Stations

    Safety Instructions 1.6.1 Control Stations Control stations should be arranged and located so that the operation of the affected equipment is visible from them. Control stations shall be clearly marked or labeled to indicate the function controlled. Equipment that would cause injury when started shall not be started until employees in the area are alerted by a signal, or by a designated person, that the equipment is about to start.

  • Page 13: Safety Devices

    Safety Instructions 1.6.2 Safety Devices All safety devices, including wiring of electrical safety devices, shall be arranged to operate so that a power failure or failure of the device itself will not result in a hazardous condition. Emergency Stops and Restarts The controls shall be arranged so that, in case of emergency stop, manual reset or start at the location where the emergency stop was initiated shall be required of the conveyor(s) and associated equipment to resume operation.

  • Page 14: Installation And Maintenance Safety

    Safety Instructions Routine inspections and preventive and corrective installation and maintenance programs shall be conducted to ensure that all guards and safety features and devices are retained and function properly. Personnel should be alerted to the potential hazard of entanglement in conveyors caused by items such as long hair, loose clothing, and jewelry.

  • Page 15: Lockout/Tagout Guidelines

    Safety Instructions It is the responsibility of the owner/user to add any additional protective components that may be needed whenever changes or variations are made to any of the equipment components or operational characteristics. 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 –...
  • Page 16 Safety Instructions Figure 1-1 CEMA Safety Pictograms IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...

  • Page 17: General Description

    General Description Introduction ® The IntelliSort HDS is designed for applications requiring high rate positive sortation of products. It is typically supplied with a flat extruded aluminum flight which acts as the carrying surface. The sliding shoe is actuated, or switched, under the carrying surface of the machine. Once the sliding shoes are switched by the control system, products are diverted off the machine to a chute.
  • Page 18 General Description Figure 2-1 IntelliSort HDS Do not touch the chains 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. IntelliSort HDS Maintenance Manual | 29157701...

  • Page 19: Idler Section With Infeed Belt

    General Description Figure 2-2 IntelliSort HDS General Layout Idler Section with Infeed Belt The idler section with infeed belt is located at the infeed end of the IntelliSort. The general function of this section is to induct product onto the sorter. The infeed belt is driven by the sorter drive using a Power Take-Off (PTO).

  • Page 20: Pre-Sort Section

    General Description Figure 2-3 Idler with Infeed Belt Pre-Sort Section In the pre-sort section, the setup switch selects shoes to enter on the correct side of the cartons for left or right divert. The carton is then properly aligned to divert in either direction.
  • Page 21 General Description When a carton is detected at the setup photo-eye, a carton marker is entered in the first tracking array zone. The carton marker contains the information that the sorter controller uses to divert the carton to the assigned chute. The assigned chute is either on the left or right side of the sorter.

  • Page 22: Intermediate Section With Divert Switch

    General Description Intermediate Section with Divert Switch 2.4.1 Divert Switch Operation The divert switch assembly is positioned in the middle of the sorter. The shoes move down the pin guide track to each divert switch assembly. A pivoting divert blade activated by a control signal is located in the divert switch assembly.

  • Page 23: Divert Switch Detail

    General Description Figure 2-5 Intermediate Section with Divert Switch 2.4.2 Divert Switch Detail The IntelliSort HDS is supplied with an electrically actuated divert switch. The divert switch is actuated by a signal from a central control system. The central control system maintains the signal to release the appropriate number of divert shoes needed to guide the product onto predetermined chutes.

  • Page 24: Intermediate Section With Catenary

    General Description Figure 2-6 Divert Switch Intermediate Section with Catenary The catenary is where the carrying chains sag to their lowest point on their return path below the sorter's carrying surface. The catenary is equipped with windows through which maintenance personnel can gauge the amount of sag in the chains and monitor the wear rate of the left and right chains to ensure consistent growth rates.

  • Page 25: Carrying Chain And Drive Unit

    General Description Figure 2-7 Intermediate Section with Catenary It is important to maintain chains in the recommended sag range. Failure to do so could result in excessive sorter alarms, shutdown, or even mechanical damage. Refer to the Chain Adjustment and the Catenary section in the Service and Repair chapter for monitoring and maintenance instructions.
  • Page 26 General Description Figure 2-8 Carrying Chain Figure 2-9 Drive Unit IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...

  • Page 27: Divert Shoes And Flights

    General Description Divert Shoes and Flights IntelliSort HDS utilizes streamlined divert shoes and runs at 400 fpm. Appropriate gap is required between cartons for effective sortation of the product; gap requirements vary based on the product mix and the control system. Smooth sliding divert shoes are attached to each flight and are capable of sliding freely on a fixed divert angle.

  • Page 28: General Product Summary

    General Description General Product Summary Table 2-1 IntelliSort HDS General Product Summary High density sliding shoe sortation of a wide variety of items from Application a single induction conveyor to after-sort chutes. 0.1 lb. Minimum Carton Weight Requirement Less than in.

  • Page 29: Control Description

    Control Description Introduction There are several control devices used in conjunction with the IntelliSort HDS. The typical components that are supplied with every sorter are listed below. Specific requirements on each installation mean the actual devices used may be different from the components listed.
  • Page 30 Control Description Table 3-1 Electrical/Control Components Function Switches power to the drive motor(s) and the control unit. The Main Power fourth pole switches power to the control unit. Located in the Disconnect (may control panel. be 4-pole switch) Switches power to drive motor(s) via a motor disconnect switch Motor Starter(s) and Variable Frequency Drive.

  • Page 31: Dcm Operation

    Control Description DCM Operation The electric switch DCM provides two basic functions on the sorter. The DCM controls the voltage to the brushless rotary actuator that moves the divert switch trigger. The DCM also handles the precise timing of switch actuation to ensure no pin trigger impact.

  • Page 32: Connecting The Dcm

    Control Description Connecting the DCM All wiring to the DCM is pre-connectorized prior to shipment of the DCM panels to the jobsite. Figure 3-2 DCM Board IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 33 Control Description Figure 3-3 DCM Enclosure, Front View IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 34 Control Description Figure 3-4 DCM Enclosure, Left View IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 35 Control Description Figure 3-5 DCM Enclosure, Right View Table 3-2 DCM Switch Connections Port Device Notes Power Cable Requires 1.5 Amps at 120VAC (50/60Hz, this power should come from a constant voltage transfer. Motor Cable Connect to electric switch motor connector Photo-Eye Connect to electric switch photo-eye connector Cable...

  • Page 36: Dcm Layout

    Control Description DCM Layout The DCM board includes seven LEDs to indicate status and operation of the board. Table 3-3 LED Description Description Label Indicates the state of the two photo-eyes installed for missing pin detection. It will be on when either photo-eye is blocked by a pin. (This is an optional feature and only functional when missing pin photo-eyes are connected.) MISS Indicates the state of the missing pin signal to the control system.

  • Page 37: Oiler Control

    Control Description The DCM includes four jumpers that alter the operation of the board. All jumpers should remain in their default position as supplied unless specifically instructed to move by Honeywell engineering. Table 3-4 Jumper Description Jumper Description Label Controls the timing of the switch activation. It affects the polarity of the photo-eye signal sent back to the control system.

  • Page 39: Service And Repair

    Service and Repair Introduction This chapter contains instructions for removing, replacing, and adjusting various components on the IntelliSort HDS. Be sure to follow all safety precautions and Lockout/Tagout Procedures when servicing and repairing the conveyor. Before performing any maintenance, follow the lockout/tagout procedure in Chapter 1 Safety Instructions to ensure that equipment is safe to work on.

  • Page 40: Flight Removal And Installation

    Service and Repair Flight Removal and Installation Remove the chain cover from the section(s) where you plan to remove the flight. Using screwdrivers or pry bars, lift the chain up and away from the flights. This will allow the chain pins to pull out of the flights. Grasp the flight to be removed and pull it toward you, taking care not to let it fall into the sorter frame.
  • Page 41 Service and Repair Insert the replacement flight onto the chain pins on the far side of the conveyor. (Make sure the sliding shoe faces the same direction as the other flights.) Use the slots in the flight end caps to guide the other end of the flight onto the chain pins. IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...

  • Page 42: Chain Adjustment And The Catenary

    Service and Repair Use screwdriver or pry bar to re-seat the chain in its resting position. Chain Adjustment and the Catenary The catenary is equipped with windows through which maintenance personnel can gauge the amount of sag in the carrying chains and monitor the wear rate of the left and right chains to ensure consistent growth rates.
  • Page 43 Service and Repair The approximate acceptable chain sag range, with the sorter running, depends on catenary depth. All IntelliSort HDS sorters use a 21 in. catenary. • For 21 in. catenary: -3.00 in. to +11.00 in. sag The configuration of each sorter is different, so it may not be possible to achieve the exact sag range of -3.00 in.
  • Page 44 Service and Repair Measure each chain separately, using the window on the corresponding side of the catenary. The amount of sag is the distance from the 0 mark at the top of the catenary window to the top of the chain. Figure 4-2 Catenary Window Keep in mind, removing 5 in.
  • Page 45 Service and Repair Slowly advance the sorter until the corresponding master links (chrome-plated chain coupler) are positioned in the middle of the chain cover opening. Turn the conveyor OFF and perform lockout/tagout. Remove six or seven flight assemblies that are near the connecting link, as described in the Flight Removal and Installation section.

  • Page 46: Chain Lubrication

    Service and Repair Repeat Step 8 to 14 on the opposite side of the sorter. Reinstall flights, chain covers, and guarding. Restore power and slowly rotate the sorter to check operation. Make sure that both sorter chains are properly lubricated. Recalibrate the chain in the machine control HMI.
  • Page 47 Service and Repair • Take infrared thermometer readings of the chain at the idler end of the conveyor with the thermometer as close to the chain as is safely possible. Measure the temperature of the side plates of the chain, not the rollers. •...

  • Page 48: Chain Wear

    Service and Repair Chain Wear Chain wear is checked by measuring the elongation percentage over a new chain. Chains should be replaced when they reach a 2.0% elongation over their original length. Elongation can be checked by measuring the center-to-center distance over 25 extended pins (48 chain pitches).

  • Page 49: Cleaning The Divert And Crossover Switches

    Service and Repair Cleaning the Divert and Crossover Switches Make a window by removing approximately 15 flights in the conveyor to access the divert switches. Move the window to the location of a divert switch. Use compressed air to blow out the debris in the switch mechanisms. Wipe the switches with a clean, dry soft cotton towel to remove any oil or debris which may have collected.

  • Page 50: Electric Switch Removal And Installation

    Service and Repair Electric Switch Removal and Installation Use the following procedure to remove and install the soft touch electrical switch. Figure 4-4 Electric Switch Note: If either the soft touch switch or DCM fail, replace both. Turn the conveyor OFF and perform lockout/tagout. Remove the flights at the switch location.

  • Page 51: Divert Actuator Assembly Replacement

    Service and Repair Attach the DCM cables to the actuator and the photo-eye. Restore power and test the divert switch operation. Divert Actuator Assembly Replacement The divert switch actuator assembly consists of the trigger, spacer block, and rotary actuator. Turn the conveyor OFF and perform lockout/tagout. Make a window to access the divert switch by removing enough sorter flights.

  • Page 52: Divert Switch Trigger Replacement

    Service and Repair Install the new actuator assembly into the divert switch. a. Apply Loctite 609 to the mounting screw threads. b. Install the screws and washers. c. Torque the screws to 48 in-lbs. Reconnect the cable to the DCM. Restore power to the conveyor and test the divert switch operation.

  • Page 53: Debris Detection Device Adjustment

    Service and Repair Create a working window by removing some flights from the sorter apron. Remove the -20 x 1 in. screw and bridge. Remove the -28 x in. long screw. Remove the 1 in. O.D. washer and lock washer. Remove the trigger.

  • Page 54: Chain Lubricator Adjustment

    4.12 Chain Lubricator Adjustment Lubrication directly affects the life and performance of the sorter chains. Proper oil flow and lubrication is the responsibility of the customer. Honeywell is not responsible for chain damage due to lack of lubrication. Failure to follow this instruction may result in equipment damage.

  • Page 55: Electric Pump Style Oiler

    Service and Repair 4.12.1 Electric Pump Style Oiler Never allow the pump to operate on an empty reservoir. If the reservoir should ever run completely dry, be sure to re-prime the system until oil completely refills the delivery tubing. Failure to follow this instruction may result in equipment damage.
  • Page 56 Service and Repair Oiler Brushes The bristle tips of the oiler brush should be in. lower than the top of the chain side plates. Turn the in. nylock nut to adjust the brush height. Fill the oil reservoir with 20 WT NON-DETERGENT OIL. IntelliSort HDS Maintenance Manual | 29157701...

  • Page 57: Carrying Flight Cleaning

    Service and Repair Electric Pump Oiler Priming Instructions This procedure normally only needs to be completed during initial installation. If the oiler has been running with an empty reservoir, perform the following steps: After the oiler has been installed on the machine, fill the reservoir with 20 weight non- detergent oil.

  • Page 58: Chain Track And Shoe Guidance Replacement

    Service and Repair 4.14 Chain Track and Shoe Guidance Replacement Tools needed for replacing the black UHMW chain track and shoe guidance: • in. drill bit • 10-24 tap • Right angle drill • Hand countersink • Rubber mallet • Permanent marker or grease pencil •...
  • Page 59 Service and Repair Insert the chain track tongue into the expansion block groove of the section being replaced until it reaches the alignment notch. The UHMW chain track comes with a tongue on each end (only one tongue is used per section). 6 in. of tongue should lay on the UHMW chain track to allow expansion.
  • Page 60 Service and Repair Use a permanent marker or grease pencil to mark the UHMW chain track at the drive-side edge of the following section’s expansion block and use a knife to cut the track to fit. Note: Intermediate section expansion blocks have a tongue. Make sure to mark and cut at the expansion block edge and not the tongue edge.
  • Page 61 Service and Repair a. If connecting to an intermediate section, place the cut-end of the UHMW chain track under the tongue of the next expansion block. Starting at the drive end, use a rubber mallet to snap the UHMW chain track in place. b.
  • Page 62 Service and Repair Insert one #10-24 x flat head screw into each hole drilled in Step 6. IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...

  • Page 63: Replacing The Bottom Run Black Uhmw Chain Track

    Service and Repair 4.14.2 Replacing the Bottom Run Black UHMW Chain Track Start from the idler and work toward the drive when installing the bottom run. To replace a bottom run UHMW chain track section: Starting from the idler and working toward the drive, locate the expansion block for the section being replaced and the expansion block in the following section.
  • Page 64 Service and Repair Adjust the expansion block so the top of the expansion block is even with the top surface of the aluminum track support by loosening the nuts that connect the expansion block to the side rail of the sorter. Tighten nuts loosened in Step 3.
  • Page 65 Service and Repair Place the cut-end of the UHMW chain track under the tongue of the next expansion block. Starting at the idler end, use a rubber mallet to snap the UHMW chain track in place. In the center of the cut-end of the UHMW chain track (opposite end from where tongue is inserted into expansion block), drill one in.
  • Page 66 Service and Repair Insert one #10-24 x flat head screw into each hole drilled in Step 7. IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...

  • Page 67: Preventive Maintenance

    Preventive Maintenance 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. The satisfactory performance and reliability of this equipment is dependent upon a proficient preventive maintenance program with scheduled equipment inspections under normal operating conditions.

  • Page 68: Maintenance Precautions

    Preventive Maintenance Preventive maintenance consists of regular service (lubrication, adjustments, cleaning, etc.). Part of preventive maintenance is becoming aware of potential problems by simply using your senses. Use your eyes to see potential component failure. Use your ears to listen for abnormal or louder than normal noises. Use your nose to smell a motor running abnormally warm in time to prevent its burnout.

  • Page 69: Cleaning And Inspection

    Preventive Maintenance 5.2.1 Cleaning and Inspection Generally, there are many reasons for cleaning: • To allow heat to dissipate (motors and gearboxes). • To prevent wear on moving parts. • To prevent binding. • 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.

  • Page 70: Intellisort Hds Conveyor Checklists

    Preventive Maintenance IntelliSort HDS Conveyor Checklists 5.3.1 Daily Tasks Table 5-1 Preventive Maintenance Daily Checklist Daily Checklist Task Date: Checked By: Changes/Repairs Made: Check with Conveyor Running Listen for abnormal noises that could indicate worn bearings in rollers, motors, reducers, etc. Listen for abnormal noises that could indicate misaligned timing belts or drive belts.

  • Page 71: Weekly Tasks

    Preventive Maintenance 5.3.2 Weekly Tasks Table 5-2 Preventive Maintenance Weekly Checklist Weekly Checklist Task Date: Checked By: Changes/Repairs Made: Check with Conveyor Running Visually inspect for wear, improper alignment, or buildup of foreign materials and repair/clean as required. Visually inspect all motors. While inspecting shoes being diverted, listen for any abnormal clicking sounds at each divert switch location and...
  • Page 72 Preventive Maintenance Weekly Checklist Task Date: Checked By: Changes/Repairs Made: Check for uneven stretch of the carrying chains by comparing their locations in the windows on the catenary. They should be at the same position. Uneven chain stretch is a result of insufficient lubrication.

  • Page 73: Quarterly Tasks

    Check the flight assemblies for cleanliness. The flights can be cleaned with water and a cotton cloth. For extremely contaminated flights, contact Honeywell Customer Service. If the shoe pads show unusual wear, check position of the shoe return wedge on the drive section. Replace the pads as necessary.
  • Page 74 Preventive Maintenance Quarterly Checklist Task Date: Checked By: Changes/Repairs Made: Inspect the drive unit V-belts for proper tension, wear, and alignment. Do not over tighten the drive V-belt. The V- belts are tensioned for in. deflection at their mid-point. Check that all frame supports are in good physical condition and have not been damaged.
  • Page 75 Preventive Maintenance Quarterly Checklist Task Date: Checked By: Changes/Repairs Made: Inspect all plastic parts for signs of unusual wear and deterioration. Replace any worn plastic parts. Check tightness of reducer mounting bolts and torque arm (if equipped). For information on changing oil, oil type, and operating oil level, see reducer checks below.
  • Page 76 Preventive Maintenance Quarterly Checklist Task Date: Checked By: Changes/Repairs Made: Check the unit for oil leakage and find the source of that leakage. The most common leak points are pipe plugs, oil seals, and the cover gasket. Rather than waiting for parts during unscheduled down time, you may wish to order replacement parts when the leaks are minor.

  • Page 77: Replacement Parts

    Replacement Parts Ordering Parts See the Ordering Replacement Parts Instruction Manual for help ordering new parts. Illustrated Parts Lists The following pages contain standard assembly and component part illustrations and parts lists for your equipment. Colors used in these illustrations are for clarifications only and may not match the paint colors of your equipment components.
  • Page 78 Replacement Parts The IntelliSort HDS is engineered to the specific requirements of every project. Refer to the Dashboard project files for each specific machine’s unique spare parts lists. See the Ordering Replacement Parts Instruction Manual for ordering help. Figure 6-1 IntelliSort HDS Sorter Layout IntelliSort HDS Maintenance Manual | 29157701...
  • Page 79 Replacement Parts Parts List Abbreviations The following abbreviations are used in the parts lists: Table 6-1 Parts List Abbreviations 20 Degree Divert Angle Idler 30 Degree Divert Angle Knife Edge Adaptor Left Hand Divert ADAPT Assembly Lubricator LUBR Between Frame Width Medium Speed (in inches) Catenary...

  • Page 80: Idler And Infeed

    Replacement Parts 6.2.2 Idler and Infeed HDS Hitch Infeed 30518501 HDS HITCH INF ASY 22BF 120L PART NO DESCRIPTION 530125__ 530 PARCEL 2.75" DIAMETER ROLLER __"BF 531829__ 530 PARCEL ROLLER, RETURN 1.9"DIA ___BF 411466__ 200 KE ROLLER 2.25" TAPERED BRG ___BF 25083500 MLG-2T-PLUG, M12 8 PIN FEMALE AND M12 5 PIN FEMALE TO M12 8 PIN MALE...
  • Page 81 Replacement Parts HDS Idler Infeed Belt 30495001 HDS ID BELT XL FLIP-UP KE ASY 22BF PART NO DESCRIPTION 41146622 200 KE ROLLER 2.25" TAPERED BRG 21.50BF 531829215 530 PARCEL ROLLER, RETURN 1.9"DIA 21.50BF 53180705 530 PARCEL CROWNED ROLLER 4.00"DIA 22"BF 23096500 PROX SW M12X1 6MM RNG PNP N.O.
  • Page 82 Replacement Parts Infeed Idler 305095 HDS ID ASY 22EW 59BF__-PTO PART NO DESCRIPTION 30407601 ISS MH-ID PULY BELT 8.50 OD LAT & FLAT 31.250B 22W 30404901 ISS MH-ID BRG PLATE PTO PULLEY 41006801 200 ANG SNUB ADJUSTER 22003000 BRG F4B-DL-115 (DGE# 128789) 22457500 BT SPKT P48-8M-50-2012 DODGE #112893 IntelliSort HDS...
  • Page 83 Replacement Parts PART NO DESCRIPTION 22003800 BU TL 2012 1.938 22469800 BT DGE HT200 1512-8M-50 / GATES 1512-8MGT-50 22005400 BU TL 2517 1.938 22457900 BT SPKT DODGE P80-8M-50-2517 112897 30354600 ISS IDL TENSIONER SHV & SHAFT ASY 30406902 ISS MH-ID BLOCK ASY CHGD ID TOP LH 30407102 ISS MH-ID BLOCK ASY CHGD BOT 58R 36T LH ISS BLOCK UHMW SUS SD SW PNGD HS/MS ID BOT...
  • Page 84 Replacement Parts Infeed Shaft 30225516 HDS SHAFT IDLER ASY 16EW 59BF CONFIG B PART NO DESCRIPTION 30219904 ISS SHAFT IDL 2 15/16 X 59BF 30220800 ISS PIN GUIDE CAM ASY IDL 30220000 ISS SPKT 100R36 ASY W/R1 BU 22499800 BRG DGE P2B-IP-215R 22001746 COLLAR 2 PC CLAMP-ON 2.938"...

  • Page 85: Pre-Sort Section

    Replacement Parts 6.2.3 Pre-Sort Section 305441 – HDS SUS ASY 59BF LH-IND IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 86 Replacement Parts PART NO DESCRIPTION 30500500 HDS SUS TOP FUNNEL UHMW ENTRY BLOCK 15' INNER HDSS SUS TOP FUNNEL UHMW ENTRY BLOCK 15' 30500402 OUTER 30533503 HDS ST SUS RAIL KIT 57.01L (59B-20D) 30533512 HDS ST SNK RAIL KIT 58.5L (59B-20D) 3051300_ ISS FUTURE FILL BLOCK RT _HD HDS SUS TOP UHMW CENTER MERGE FUNNEL BLOCK...

  • Page 87: Intermediates

    Replacement Parts 6.2.4 Intermediates 30 in. Divert Center Sections IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 88 Replacement Parts 30 in. Divert Center Intermediate Assembly 30607__HDS IS ASY 59BF 30CTR _SP__._L IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 89 Replacement Parts PART NO DESCRIPTION 30504402 HDS ELEC SW ASY SCKT ST LH 304525474 ISS PIN GUIDE EXTR KIT 15.88L 30504401 HDS ELEC SW ASY SCKT ST RH 304525474 ISS PIN GUIDE EXTR KIT 15.88L 30608202 HDS ST DIV BLK UHMW 30D LH 30608302 HDS BLOCK UHMW DIV RE-ENTRY 30D LH 30652464...
  • Page 90 Replacement Parts 48 in. Divert Center Sections IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 91 Replacement Parts 48 in. Divert Center Intermediate Assembly 30544__HDS IS ASY 59BF 20D 48CTR_SP__._L PART NO DESCRIPTION 30504502 HDSS ST DIV BLK UHMW 20D LH 303903101 HDS ST DIV RAIL ASY 34.06L (59B-20D) 30533102 HDS BLOCK UHMW DIV RE-ENTRY 20D LH 304525416 ISS PIN GUIDE EXTR KIT 17.31L 304525329...
  • Page 92 Replacement Parts PART NO DESCRIPTION 30504501 HDSS ST DIV BLK UHMW 20D RH 30504401 HDS ELEC SW ASY SCKT ST RH 304525415 ISS PIN GUIDE EXTR KIT 13.875L 30504402 HDS ELEC SW ASY SCKT ST LH 304525415 ISS PIN GUIDE EXTR KIT 13.875L Note: 2 switch pair and 3 switch pair sections use identical listed components.

  • Page 93: Catenary

    Replacement Parts 6.2.5 Catenary Electric Oiler Catenary 305411 HDS CAT ASY 21.5DP 144.00L PART NO DESCRIPTION 30378101 ISS BLOCK ASY CHGD CAT OUT 48R RH 30378102 ISS BLOCK ASY CHGD CAT OUT 48R LH 30376607 ISS W/STRIP CAT 21.5DP CC 20D-21.5DP 45.25L RH 30379302 ISS CH CARE CAT BLOCK FLIGHT CATCHER 64.50L 30376608...
  • Page 94 Replacement Parts Catenary Assembly 30608501 – HDS IS CAT ASY 59BF 30CTR 30D 2SP ELEC OILER IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 95 Replacement Parts PART NO DESCRIPTION 30504402 HDS ELEC SW ASY SCKT ST LH 304525474 ISS PIN GUIDE EXTR KIT 15.88L 30504401 HDS ELEC SW ASY SCKT ST RH 304525474 ISS PIN GUIDE EXTR KIT 15.88L 30608302 HDS BLOCK UHMW DIV RE-ENTRY 30D LH 30652464 HDS PIN GUIDE EXTR KIT 29.94L 30608202...
  • Page 96 Replacement Parts 30544401 – HDS IS CAT ASY 59BF 20D 48CTR 2SP ELEC OILER PART NO DESCRIPTION 30504402 HDS ELEC SW ASY SCKT ST LH 304525415 ISS PIN GUIDE EXTR KIT 13.875L 30504401 HDS ELEC SW ASY SCKT ST RH 304525415 ISS PIN GUIDE EXTR KIT 13.875L 303903101...

  • Page 97: Drive And Discharge Chute

    Replacement Parts 6.2.6 Drive and Discharge Chute Drive Assembly 305100__HDS DR ASY 59BF__-DR IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 98 Replacement Parts PART NO DESCRIPTION SPLIT TAPER SHEAVE – REFERENCE ORIGINAL ORDER VARIES DOCUMENTATION FOR SPECIFIC CONFIGURATION VARIES BELT – REFERENCE ORIGINAL ORDER DOCUMENTATION FOR SPECIFIC CONFIGURATION SPLIT TAPER SHEAVE – REFERENCE ORIGINAL ORDER VARIES DOCUMENTATION FOR SPECIFIC CONFIGURATION VARIES MOTOR –...
  • Page 99 Replacement Parts Shaft Drive Assembly 302254__ ISS SHAFT DRIVE ASSY _.___TP__EW 59BF PART NO DESCRIPTION 30218110 ISS SHAFT DR 3 7/16 X 1.938 59BF 30218111 ISS SHAFT DR 3 7/16 X 2.438 59BF 30218112 ISS SHAFT DR 3 7/16 X 3.438 59BF 30219200 ISS PIN GUIDE CAM ASY DR 30218200...

  • Page 100: Component Details

    Replacement Parts 6.2.7 Component Details Switch Assembly 305044__HDSS ELEC SW ASY SCKT ST _H PART NO DESCRIPTION 7085897 PE,CONNECTOR ASSY,AB 30453802 ISS ELEC SW BRIDGE 20/30 ST LH 30504302 HDS ELEC SW BLOCK ASY SCKT ST LH 30453801 ISS ELEC SW BRIDGE 20/30 ST RH 30504301 HDS ELEC SW BLOCK ASY SCKT ST RH 30453401...
  • Page 101 Replacement Parts DCM Enclosure 23433500 – DCM ELECTRIC ENCLOSURE WITH UL508A STICKER BASIC UNIT IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 102 Replacement Parts DCM Board 23434000 – DCM BOARD W/MISSING PIN DETECT UR LISTED Note: Panel assembly 23433500 includes all required cables and DCM board 23434000. If desired, the DCM circuit board can be replaced independently. IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 103 Replacement Parts DDD Kit 305057__HDS DDD KIT 59BF 20D 48CTR___LS-_ PART NO DESCRIPTION 22612702 WHEEL PLASTIC 2.5 O.D. BUSHING REMOVED 30295804 ISS DDD SHAFT 1" DRILLED 59BF 23086800 LIMIT SWITCH AB 802T-AP 22596600 BRG DGE F2B-SC-100 SERIES 205 #124173 0165431 LIMIT SWITCH ROLLER ARM AB 802T-W2B 30295900 ISS DDD SWITCH TRIGGER MACH 5/8DIA...
  • Page 104 Replacement Parts Aluminum Flight Assembly 30424523 – ISS FLIGHT ASY SLAT ZGS-LS 59BF 20D DS PART NO DESCRIPTION 30424301 ISS PUSHER ASY SLAT ZG-LS 20D DS 30227903 ISS ENDCAP ASY SLAT ZG RH 30227904 ISS ENDCAP ASY SLAT ZG LH IntelliSort HDS Maintenance Manual | 29157701...
  • Page 105 Replacement Parts Electric Oiler 30456600 – ISS STANDARD CHAIN OILER PART NO DESCRIPTION 30456000 ISS STANDARD OILER POLE LIGHT 30293001 ISS OILER 2QT RESERVOIR W/39" LEADS IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...
  • Page 106 Replacement Parts Chain Jump Detection Kit 30642200 – HDS CAT SPCL CHAIN JUMP DETECTION KIT PART NO DESCRIPTION 30353802 ISS DIVERT CONFIRM MOUNTING BLOCK LH 306524233 HDS PIN GUIDE EXTR KIT 15.94L 30353801 ISS DIVERT CONFIRM MOUNTING BLOCK RH 30641002 HDS ST DIV BLK UHMW 20D W/ SNSR MNTG LH 303903115 ISS RT ISS DSD-DIV EXIT RAIL ASY 33.31L (59B-30D)
  • Page 107 Replacement Parts Chain Slack Detection Kit 30630301 – ISS SPCL CHAIN SLACK DETECTION KIT 15.625 TALL PART NO DESCRIPTION 30630401 ISS SPCL CAT WINDOW 12.50 TALL 30381701 ISS LABEL CHAIN HEIGHT 21.5DP 25617200 PROXIMITY SWITCH M30X1 20MM SENSE RANGE SICK MODEL IME30-20BPSZC0S (SICK P/N 1071293) IntelliSort HDS | Maintenance Manual | 29157701 May 3, 2021...

  • Page 109: Troubleshooting

    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 110 Troubleshooting Select a solution or possible solutions. Implement and document one solution at a time. Table 7-1 Troubleshooting Chart Symptom Probable Cause Corrective Action No line voltage. Check emergency stops and reset. Motor will not start or it is slow Check fuses and wiring for open circuit.
  • Page 111 Troubleshooting Symptom Probable Cause Corrective Action Lack of lubrication in Replace reducer with spare. Motor emits reducer excessive noise, hum, or vibration Worn or damaged Replace motor or reducer with spare. motor or reducer Defective bearing Replace motor or reducer with spare. Loose mounting Check motor and reducer for loose mounting hardware.
  • Page 112 Troubleshooting Symptom Probable Cause Corrective Action Divert shoe binding Adjust shoe fasteners. Noisy divert switch Flight assemblies Clean flights. contaminated Switch binding Align, adjust, or replace switch block. Divert shoes misaligned or damaged jump when diverting Guide pin damaged Replace guide pin. Pin guide track Align pin track.
  • Page 113 Troubleshooting Symptom Probable Cause Corrective Action Variable Frequency Check VFD manufacturer’s instructions for proper Conveyor takes Drive (VFD) adjustments. Correct VFD adjustments as necessary. too long to reach misadjusted or Replace VFD if defective. speed (sorter defective. under-speed error detected) Carrying chains are not Check for automatic oiler operation.
  • Page 114 Troubleshooting Symptom Probable Cause Corrective Action Tripped safety device Check if the debris detector has been tripped. Remove Drive motor does any internal debris and reset the detector. Verify that the not run limit switch is actuated. If it is not actuated, replace the limit switch.
  • Page 115 Troubleshooting Symptom Probable Cause Corrective Action A safety device has See “Drive motor does not run” Symptom. Conveyor shuts been tripped off automatically during normal Low oil level in the Check the oil level and refill if necessary. Use only the operation automatic oiler recommended oils.

  • Page 116: Troubleshooting Help

    Troubleshooting Troubleshooting Help If you need further assistance, please visit our website at www.intelligrated.com call our Lifecycle Support Services (LSS) at (877) 315-3400. IntelliSort HDS Maintenance Manual | 29157701 May 3, 2021...
  • Page 117 Index DCM enclosure, 95 DDD, 47 DDD kit, 97 abbreviations, 73 debris detection device. See DDD after-sort, 22 divert aluminum flight assembly, 98 actuator assembly, 45 ANSI, 2–3, 7–9 blade, 16 ASME, 1 switch, 11, 16, 17, 43 switch trigger, 46 divert control module.
  • Page 118 infeed shaft, 78 pin guide, 13, 16 inspection, 63 power take-off, 13 intermediate assembly, 82, 85 precautions, 62 intermediate section, 11, 16 pre-sort section, 11, 14, 79 product summary, 22 PTO, 13 Lifecycle Support Services, 110 lockout/tagout, 9 safety devices, 7 lockout/tagout, 9 maintenance precautions, 4, 7...

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