Page 1 Accuglide ZoneFlex Installation Manual Publication No. 29349916 January 11, 2019...
Page 2 Honeywell. © 2013-2019, 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 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 Safety Devices ......................
Page 4 3.2.2 Claims and Returns ..................20 Layout Requirements ..................21 Codes and Standards ..................21 Safety Precautions ....................21 3.5.1 Installing Pop-Out Rollers/Spill Guards Based on Elevation ......22 Warning Signs ....................26 Parts Replacement ..................... 27 Pre-Installation ....................27 3.8.1 Conveyor Components .................
Page 5 4.4.10 Drive Bottom Covers ................. 52 Idler Section Preparation ..................53 4.5.1 Carrier Roller Removal ................. 53 4.5.2 Idler Sprocket Height Verification ..............53 Operational Zone Control – Discharge Zone ..........53 4.5.3 4.5.4 Brake Module ....................55 4.5.5 Blade Stop ....................56 Factory Air Supply....................
Page 6 4.8.2 Intermediate Accumulating Curve Section Preparation........86 Intermediate Sawtooth Merge Section Preparation ..........103 4.10 Chain Installation ................... 104 4.10.1 Preparation ..................... 105 4.10.2 Drive/Straight Sections ................106 4.10.3 Curve Section ..................107 4.10.4 Idler Section ................... 108 4.10.5 Final Connection ..................109 4.10.6 Spring Tensioner Engagement ..............
Page 7 4.15.4 Fitting Bottom Pans to Ceiling Hangers ............ 134 4.16 Installing Drive Covers ................... 136 4.17 Photo-Eye Installation ..................139 4.17.1 Photo-Eye Indicator Lights ..............139 4.17.2 Installing a Ball Mount ................139 4.17.3 Installing a Photo-Eye ................140 4.17.4 Installing a Reflector ................
Page 8 5.2.11 Slug Interrupt Cord.................. 182 5.2.12 Cable Power Isolator ................182 Chain – RC50 with Extended Pin ............. 183 5.2.13 Chain Tensioner – Drive Section – Air Actuated ........184 5.2.14 Chain Track Lubricator – Solenoid-Controlled (Drive Section) ....185 5.2.15 5.2.16 Drip Pan Kit ....................
Page 9 Side Guide – Transition Step ..............225 5.2.40 Side Guide – Transition PE to Standard ........... 226 5.2.41 Side Guide – Width Transition ..............227 5.2.42 5.2.43 Transition Bracket Field Kit ..............229 PRE-STARTUP PROCEDURES ................... 231 Introduction....................... 231 Pre-Startup Preparation ..................231 Initial Startup/Checks ..................
Page 10 Troubleshooting Problems and Solutions ............250 Troubleshooting Help ..................253 Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 11: 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 precautions are to be used as a guide to supplement the following: All other information pertaining to the equipment.
Page 12: For Your Safety
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 13 Safety Instructions safety items become defective or damaged, refer to the conveyor parts list or bill-of- materials for replacement part numbers. 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.
Page 14: Safety Precautions
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 15: Headroom
Safety Instructions When the equipment passes over a walkway, roadway, or work station, it is considered guarded by location if all moving parts are at least 8 ft. (2.4 m) above the floor or walking surface or are otherwise located so that the employee cannot inadvertently come in contact with hazardous moving parts.
Page 16: Safety Devices
Safety Instructions system function would be seriously hindered or adversely affected by the required time delay, or where the intent of the warning may be misinterpreted (e.g., a work area with many different pieces of equipment and allied devices), a clear, concise, and legible warning sign shall be provided.
Page 17: Operation Safety Precautions
Safety Instructions cause or to safely remove the stoppage. Refer to American National Standard Institute’s Control of Hazardous Energy - Lockout/Tagout and Alternative Methods (ANSI Z244.1) and The Control of Hazardous Energy (Lockout/Tagout) (OSHA Standard 29 CFR 1910.147). Operation Safety Precautions Only a trained person shall be permitted to operate a conveyor.
Page 18: Installation And Maintenance Safety
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 19: Safety Signs
Safety Instructions Effective January 8, 1990, O.S.H.A. has designated the need for a ‘positive, lockable’ means to remove all energy sources from equipment prior to new installations or any maintenance. The electrical power to the equipment can be locked out at the main disconnect switch, which is normally located on the electrical cabinet.
Page 20 Safety Instructions Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 21: General Description
General Description Introduction The Accuglide™ ZoneFlex™ accumulation conveyor provides quiet, positive transportation and zero-pressure accumulation of cartons and totes in accumulation lanes. This chain and pad driven conveyor is designed to control product flow and optimize throughput while minimizing product damage. Photo-eyes send signals to the ZoneFlex modules which then cause the chain and pad to drop away from the carrier rollers.
Page 22: Benefits And Options
General Description The simple, efficient roller chain with attached urethane driver pads is pneumatically raised to engage and power the carrier rollers. The chain and pad are lowered to disengage drive power from the rollers, based on the blocked/unblocked status of the product sensors.
Page 23: Product Summary
General Description Product Summary Table 2-1 Technical Specifications Applications Transportation and zero pressure accumulation Widths 16, 22, 28, 34, and 40 in Between Frame (BF) Orientation Left and right hand 100 lb/ft live load (item weight: <0.5 lb to 200 lb). Capacity Limiting factor is the deflection of the side frames and the performance of the accumulation.
Page 24 General Description Accumulation and transportation types standard lengths: Intermediate Section, Straight 3 ft to 12 ft long in 3 ft operational-zone length increments; incremental lengths (for spanning non- standard distances). 1 in increments: • 3’-1" - 5’-11" (one operational zone •...
Page 25 General Description 6 ft long overall with one 6 ft long or two 3 ft long Idler Section accumulation zones, (controlled by solenoid valve remote 110VAC or 24VDC release signal). Carrier Rollers set High at 2 in centers with fixed-type mounting; all carrier rollers powered.
Page 26 General Description Lubrication Grease packed and sealed (no re-lubrication necessary) Axle in hex (steel) in hex conductive nylon sleeve (over in steel through shaft) Environments -20°F to 104°F 20°F to 104°F Application Guidelines Optional @ Default @ REQUIRED @ speeds < 299 speeds <...
Page 27 General Description Mode/Sensor Mode/sensor type Transportation: No sensor Accumulation: May be configured as 1&2 Zone, 1 Zone, Fixed Auto-slug, or Slug Photo-eye sensor may be mounted: • on the photo-eye guide rail • under the rollers (factory mounted on the channel) •...
Page 28 General Description Continuous, sprocket-driven roller chain with attached Drive Components urethane driver pad and wear indicator stripe Finish Powder-coated Angle end stop Accessories Blade stop – idler section Brake module – idler section Brake module – intermediate straight section Brake module curve solenoid field kit Brake module intermediate section solenoid field kit Brake module single curve air control field kit Cable extensions...
Page 29: Pre-Installation Procedures
Pre-Installation Procedures Introduction This chapter contains an overview of the instructions for receiving, inspecting, conveyor layout requirements, codes and standards, safety precautions, warning signs, parts replacement, factory assistance, pre-installation instructions, and conveyor components. The installer must be qualified and must comply with all applicable codes, ordinances, specifications, and/or other governing data related to the installation of the equipment.
Page 30: Reporting Product Damage
Pre-Installation Procedures During the process of unloading the material, it is important to: • Make sure that the quantity of items received matches the count listed on the Bill of Lading. • Inspect each item for damage to the product, especially if there is any damage to the crate or container.
Page 31: Layout Requirements
Pre-Installation Procedures Layout Requirements Conveyor layout drawings are typically used to determine the conveyor location and elevation based on the building grid. Layout drawings should be referenced in the installation preparations to determine the conveyor layout area and to make sure there are no physical obstructions to the conveyor.
Page 32: Installing Pop-Out Rollers/Spill Guards Based On Elevation
Pre-Installation Procedures • DO use extreme caution near moving parts to avoid the hazard of hands, hair, and clothing being caught. • DO NOT sit on, stand on, walk, ride, or cross (over or under) the equipment at any time except where suitable catwalks, gates, or bridges are provided for personnel travel.
Page 33 Pre-Installation Procedures Do not install trapped rollers in areas readily accessible to general plant personnel. Allow only maintenance personnel access to areas with live, trapped rollers. Live, trapped rollers can quickly pull in hands, clothing or other objects. Failure to follow this instruction could result in serious injury or death. Install only “pop-out”...
Page 34 Pre-Installation Procedures ▪ In areas at floor level in an “Authorized Personnel Access Area Only,” fixed rollers (3 in centers) may be used in conjunction with an emergency pull cord. The area must be apart from normal working areas and access must be marked with a sign, “Warning - Do Not Enter - Authorized Personnel Only”.
Page 35 Pre-Installation Procedures ▪ If any conveyed object may fall off the conveyor for any reason (such as loose bottles in trays or poorly packaged products). ▪ Where the conveyor is above aisles or work spaces. ▪ See the figure below for placement of the sign and the warning information.
Page 36: Warning Signs
Pre-Installation Procedures Warning Signs For floor-level conveyors with fixed rollers located in areas limited to authorized personnel only: 1) install an emergency pull cord, 2) place fixed roller conveyors apart from normal working areas, and 3) mark the area with a “Warning - Do Not Enter - Authorized Personnel Only”...
Page 37: Parts Replacement
Pre-Installation Procedures Table 3-1 Parts for Restricted Access Only Sign Part Number Description 957173 X-Over Sign Frame 3/8 in. dia Nylon Loop Clamp (to attach Sign 957174 to Frame) 1-1/4 in. dia Pipe Ring w/Bolt (to attach Sign 957175 to Frame) 957305 Sign Warn by-WS10 Seton M2540 Parts Replacement...
Page 38 Pre-Installation Procedures Figure 3-3 Conveyor Sections Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 39: Installation Procedures
Installation Procedures Introduction This chapter contains instructions for installing the Accuglide ZoneFlex accumulation conveyor equipment and preparing it for operation. It is essential that the equipment is properly installed, and subsequently maintained, in order to obtain maximum productivity. The installer must be qualified and must comply with all applicable codes, ordinances, specifications, and/or other governing data related to the installation of the equipment.
Page 40 Installation Procedures instructions during the installation of every section of the conveyor. These instructions are also explained in detail on the following pages. Mark a line on the floor to locate the centerline of the conveyor frame using a laser or chalk line.
Page 41: Floor Supports
Installation Procedures 16. Install all the rollers and finger guards (if required). 17. Install all side guides. 18. Connect the photo-eyes to the logic modules. Route the photo-eye cable through an existing hole in the conveyor side frame and up to the photo-eye. 19.
Page 42 Installation Procedures Note: If the conveyor system is located in an area that requires seismic counter- measures, consult the local authority for seismic applications. Figure 4-2 Anchor Bolt Placement If a floor support is mounted at the junction between two conveyor frames, use a splice flat to join the conveyor frames together.
Page 43: Hanger Supports
Installation Procedures 4.2.2 Hanger Supports When installing ceiling hanger rods in an existing building, make sure: 1) the structure loading and connection method are approved by the appropriate authority, 2) the structure and the conveyor components meet the load requirements for intended conveyor materials and human live load (where applicable), and 3) all methods of attachment comply with federal, state, and local building codes.
Page 44 Installation Procedures Figure 4-4 Standard Hanger Offset Spacing Figure 4-5 Standard Channel Hanger Support and with Floor Support Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 45: Frame Couplings
Installation Procedures 4.2.3 Frame Couplings When the conveyor has been leveled and aligned to its final position, fasten the sections together using the appropriate frame couplers as shown in the following illustrations. Make sure that a in gap is maintained between the conveyor sections. There are two types of frame couplings: splice flats and splice plates.
Page 46 Installation Procedures Figure 4-7 Frame Coupling with Flat Splice Plate Figure 4-8 Frame Coupling Curves and Drives Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 47 Installation Procedures Figure 4-9 Frame Coupling with Ceiling Hanger and Splice Flat Connecting Intermediate Curve Sections If an Accuglide ZoneFlex conveyor includes an intermediate curve section, connect it to the adjoining upstream and downstream sections using a common floor support or ceiling hanger.
Page 48 Installation Procedures Connecting Sawtooth Merge Sections If an Accuglide ZoneFlex conveyor includes an Intermediate sawtooth merge section, connect it to the adjoining upstream and downstream sections using a common floor support or ceiling hanger. Make sure the terminal-end of the conveyor that feeds into the spur of the merge section shares a common support with the spur.
Page 49: Conveyor Racking
Installation Procedures Connector Channel Use a connector channel when the depth of the adjoining downstream conveyor’s terminal end is greater than the Accuglide ZoneFlex conveyor’s idler section. The use of a connector channel allows the two components to share a common support. Figure 4-12 Install Connector Channels Conveyor Racking Any conveyor system that includes a range of various item sizes requires good...
Page 50: When To Rack
Installation Procedures Figure 4-13 Square Conveyor Installation Figure 4-14 Racked Intermediates It is important to note that racking is intended to maintain carton orientation, not move cartons from one side of the frame to the other. Use upstream V-belt skews to accomplish the initial alignment whenever possible.
Page 51: How To Rack
Installation Procedures When cartons enter a conveyor aligned to one side of the frame, they might have a tendency to drift away from that frame if the conveyor is completely square or racked in the wrong direction. Racking a conveyor eliminates that tendency and results in improved system performance.
Page 52: Measuring The Rack
Installation Procedures Tap the spreaders with a hammer in the opposite direction to maximize the shift in the relative direction. With the wedge or pry bar in place, use the racking gauge to measure and verify the correct amount of racking. Adjust the wedge or pry bar as necessary until the specified amount of racking is achieved.
Page 53 Installation Procedures To rack the conveyor: Place the top plate (marked with TOP, 1 of 2, and FLOW) on top of the carrier rollers, oriented in the direction of product flow. Bottom Plate (2 of 2) 2 inch Center Line 3 inch Center Line Top of Plate (1 of 2) Align the Edit of the Top Plate with the Correct Bottom Plate Center Line...
Page 54 Installation Procedures Look at the four reference lines etched in the top plate. The reference lines are in apart. The difference in the position of the bottom plate and the top plate is the racking amount between the two side frames. The photograph below illustrates a frame that 1/16 is not square;...
Page 55: Drive Section Preparation
Installation Procedures Note: If the installation drawings call for a conveyor to be racked, the amount of rack to be applied is in, + in, - Repeat the racking procedure until the required amount of rack is achieved per the project specifications.
Page 56: Wiring The Motor
Installation Procedures If the main electrical power supply has been brought to the conveyor, turn off any power circuits and/or lockout/tagout operating controls before making any of the following electrical connections. 4.4.3 Wiring the Motor Wire the power unit’s motor to the electrical power source. Refer to the system’s electrical/control drawings for specific wiring requirements.
Page 57 Installation Procedures When not properly adjusted, the tensioner’s position indicator moves out of safe operating range and is not detected by the proximity sensor. The conveyor then shuts down. The position indicator will move out of safe operating range if the tensioner is not properly adjusted, or if the chain length increases (due to wear).
Page 58: Chain Tensioner - Air-Type
Installation Procedures 4.4.6 Chain Tensioner – Air-Type Installing a Single Chain Tensioner The optional air-type chain tensioner requires a separate filter/regulator (0-100 psi) and pressure switch to provide the required air supply. Check the system’s engineering/layout drawings to identify the requirements. Mount the filter/regulator unit on or near the drive section and wire the air-pressure switch to the system’s control panel.
Page 59 Installation Procedures Adjusting the Air Pressure of the Chain Tensioner The recommended pressure is 60-80 psi. To adjust the air pressure: • Adjust the pressure output of the filter regulator so that: ▪ The tensioner is fully collapsed. ▪ The regulator is consistently supplied with at least 60 psi. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 60: Chain Track Lubricator
Installation Procedures 4.4.7 Chain Track Lubricator The chain track lubricator is factory-assembled into the drive section. An oil reservoir is shipped separately and must be assembled at the time of installation. Attach the oil reservoir and its mounting bracket to the bottom flange of the infeed drive section’s frame rail.
Page 61: Solenoid-Controlled Chain Track Lubricator
Installation Procedures Connect the chain track lubricator’s air supply line (yellow, in OD) to the downstream intermediate section’s main air supply line (red) with a brass inch to inch push-to-connect reducer and a inch push-to-connect type fitting. 4.4.8 Solenoid-Controlled Chain Track Lubricator The optional chain track lubricator has a 2-way, solenoid-valve (115VDC or 24VDC) that remotely controls the flow of lubricant to the track.
Page 62: Timing Belts And Pulleys
Installation Procedures Time required for one complete cycle of the chain: Time for three cycles. 3 x 1.11 min. = 3.33 minutes. Program the solenoid-lubricator’s controller to turn-on and dispense oil (10-weight, non-detergent motor oil) for a period of 3 minutes, 20 seconds for every eight hours of conveyor operation.
Page 63: Idler Section Preparation
Installation Procedures Idler Section Preparation 4.5.1 Carrier Roller Removal Remove all but one carrier roller (located directly above the idler sprocket’s centerline) from the section. This allows for installation of the drive chain/pad (later), and provides access to the idler sprocket, ZoneFlex module, and optional brake module and/or blade stop.
Page 64 Installation Procedures Wire the 3-way solenoid valve to the system control panel. Connect the in black air line from the discharge idler’s ZoneFlex module to the upstream intermediate section’s last air diaphragm. Connect the in clear air line from the discharge idler’s ZoneFlex module to the upstream intermediate section’s ZoneFlex module.
Page 65: Brake Module
Installation Procedures Figure 4-19 Wiring / Piping Connections for Discharge Zone with Two Zones 4.5.4 Brake Module The optional spring-set brake module is factory-assembled into a discharge idler section and its air supply line is connected into the section’s operational-zone piping. No additional wiring or piping is required.
Page 66: Blade Stop
Installation Procedures 4.5.5 Blade Stop The optional blade stop is factory-assembled into a discharge idler section and piped to a separate 4-way solenoid-valve (115VAC/24VDC) that is also installed into the section. A separate filter/regulator unit (0-100 psi) is required. Mount the unit’s separate filter/regulator near the discharge idler section and pipe to the solenoid valve.
Page 67: Factory Air Supply
Installation Procedures Factory Air Supply 4.6.1 Filter/Regulator Piping Requirements Air supplied to the air diaphragms presses the chain and pad against the carrier rollers to convey product. Air supply drops must be installed according to the following instructions: Note: Air regulators are supplied with the conveyor and must be mounted during installation.
Page 68: Connecting The Main Air Supply
Installation Procedures After assembly of the air lines and components, a sight and sound inspection should be made in order to find and repair any air leaks. 4.6.2 Connecting the Main Air Supply Figure 4-20 Air Treatment for Compressed Air Systems Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 69: Intermediate Section Preparation
Installation Procedures Intermediate Section Preparation 4.7.1 Electrical and Air Line Connections The electric cables and air lines are attached to the ZoneFlex module, photo-eyes, and air diaphragms. Note that the cables and lines are attached to the side of the conveyor frame for protection during shipping.
Page 70 Installation Procedures Example A: If 30 ZF modules are placed on one side of a power supply, then no more than 5 ZF modules may be placed on the other side of that power supply (30 + 5 = 35). Example B: If 15 ZF modules are placed on one side of a power supply, then no more than 20 ZF modules may be placed on the other side of that power supply (15 + 20 = 35).
Page 71 Installation Procedures Route the 115VAC supply line through the conduit and connect the black, white, and green wires to their designated terminals. The terminals are quick connect. Use a small screwdriver to press the release tab to open the terminal, insert the wire into the terminal, and remove the screwdriver to capture the wire.
Page 72: Zoneflex Module
Installation Procedures Slug Input 15-132 VAC/DC Slug Output Sinking or sourcing, switch selectable, 80 mA maximum; short circuit protection for loads less than 32 VAC or VDC (Auto Reset) slug output switch set to source output mode Indicators Red LED: AC In; Green LED: DC Out DC Power Monitor Output No contact, solid-state relay, 80 mA maximum Temperature Range...
Page 73: Travel Direction Dip Switch Setting
Installation Procedures Each ZoneFlex module has three slide switches: one centrally-located, 2-position Direction of Travel slide switch; and two 3-position primary Operational Mode slide switches. Figure 4-24 ZoneFlex Module Controls Two 4.7.4 Travel Direction DIP Switch Setting The travel DIP switch is always positioned towards the discharge end of the conveyor.
Page 74: Zoneflex Modules Logic
Installation Procedures 4.7.5 ZoneFlex Modules Logic The ZoneFlex modules in the Accuglide ZoneFlex conveyor are connected to the air diaphragms in the next zone upstream from the corresponding photo-eye. Any zone’s state (energized or de-energized) can depend on the status of one or two downstream photo-eyes.
Page 75: Primary Operating Mode
Installation Procedures 4.7.6 Primary Operating Mode The operating mode DIP switch has three settings: • 1 Zone – the local zone is de-energized when the photo-eye in the next downstream zone is blocked. When the next downstream photo-eye becomes unblocked, the local zone becomes energized. •...
Page 76: Secondary (Slug) Operating Mode
Installation Procedures Figure 4-27 Operating Mode Switch Positions 4.7.7 Secondary (Slug) Operating Mode Slug mode is activated by applying a slug signal to the power supply located anywhere along the ZoneFlex module string. The signal propagates in both directions until it is terminated by the last ZoneFlex module in the string. A slug can also be interrupted by a slug terminator cable placed between modules where the slug termination is desired.
Page 77: Primary Mode Release
Installation Procedures Make the wiring connection (115VAC/24VDC) between the system’s control panel and the power supply Release In terminals S1 and S2 for the remote slug signal. Figure 4-28 Remote Slug Signal Connection to Power Supply 4.7.8 Primary Mode Release Initiation of product-release for a conveyor functioning in one of the primary operating modes (1 zone, 1&2 zone, or fixed auto-slug) requires the remote release signal be connected to the discharge zone's (solenoid-type) control valve.
Page 78: Secondary Mode Release
Installation Procedures Figure 4-30 Primary Operating Mode Release (Dual Power Supplies) Note: If 30 ZoneFlex modules are installed on one side of a power supply, no more than 5 ZoneFlex modules are allowed on the other side. (35 - 30 = 5). 4.7.9 Secondary Mode Release A conveyor might require the simultaneous release of a certain length of product (i.e., slug) at one time.
Page 79: Secondary Mode Release - Full-Length
Installation Procedures Figure 4-31 Slug Discharge 4.7.10 Secondary Mode Release - Full-Length Initiating slug release of accumulated product requires an external release-signal that overrides the primary operating logic of all ZoneFlex modules within a defined slug release area. For full-length slug release conveyors consisting of 35 ZoneFlex modules or less, the external release-signal is connected to: 1) the conveyor's power supply which sends the signal through the T-cord to the power communication cord;...
Page 80 Installation Procedures Note: If 30 ZoneFlex modules are installed on one side of a power supply, no more than 5 ZoneFlex modules are allowed on the other side. (35 - 30 = 5). For full-length slug release conveyors consisting of 70 ZoneFlex modules or less, two power supplies are required with a power isolation cable separating the two power sources.
Page 81: Secondary Mode Release (Slug Discharge) Partial-Length
Installation Procedures 4.7.11 Secondary Mode Release (Slug Discharge) Partial- Length A conveyor may require that only a portion of its length operates in the secondary slug release operational mode (with the partial length slug-zone beginning at the discharge-end of the conveyor). The external slug-release signal must be connected to a power supply within the slug-release zone.
Page 82 Installation Procedures Note: If 30 ZoneFlex modules are installed on one side of a power supply, no more than 5 ZoneFlex modules are allowed on the other side. (35 - 30 = 5). A single power supply conveyor (35 ZoneFlex modules maximum) can have a partial-length slug-release that requires the slug termination cord to be connected downstream of the power supply.
Page 83: High Volume Discharge
Installation Procedures For dual power supply conveyors (70 ZoneFlex modules maximum) with a partial- length slug-zone that requires that the slug termination cord to be connected between the power supplies, the external release signal must be connected to: 1) the downstream power supply, and 2) to the discharge zone's (solenoid-type) control valve.
Page 84: Slug Acceptance
Installation Procedures Figure 4-37 High Volume Discharge This setting results in the zones staying energized as product travels through the High Volume Discharge Zone as the furthest downstream zone releases. The High Volume Discharge Zone is always in active slug mode as soon as the discharge zone releases.
Page 85 Installation Procedures The slug acceptance zone is defined with a slug termination cord downstream of a power supply (or slug module). An external slug signal is then required to be supplied to the power supply (or slug module) to force the zones active in the slug acceptance zone.
Page 86 Installation Procedures Initiating infeed-slug requires that a release-signal be connected to the slug module/power supplies in the infeed-slug zone and the common zone. Initiating slug release requires that a release-signal be connected to the slug module/power supplies in the common zone and the slug-release zone and the discharge zone’s (solenoid type) control valve.
Page 87: High Volume Acceptance
Installation Procedures 4.7.14 High Volume Acceptance An alternate method to positively convey product away from an upstream conveyor and accept product at a high rate of speed is to use high volume acceptance. The high volume acceptance zone is defined by setting the DIP switch on the modules in the designated zone to fixed auto-slug.
Page 88 Installation Procedures • Electrical cables • Mounting hardware The discharge idler of the upstream conveyor and the infeed idler of the downstream conveyor are piped as if they are an extension of the intermediate sections and there is no interruption in the conveyor. When installing head-to-tail logic kit, the up and downstream ZoneFlex modules must be on the same side of the conveyors.
Page 89 Installation Procedures Install the control module (item 4) and bracket on the downstream conveyor. Install the photo-eye and reflector (item 2) in the infeed idler of the downstream conveyor Connect the existing downstream control module (item 5) to the new control module (item 4).
Page 90: Brake Module Intermediate Section Solenoid Field Kit
Installation Procedures 4.7.16 Brake Module Intermediate Section Solenoid Field Kit Figure 4-42 Intermediate Solenoid Field Kit for Brake Module The kit includes all mechanical, air and electrical components required for installing two brake modules in any two operational zones in an intermediate section. BM is controlled by a remote signal.
Page 91: Intermediate Curve Section Preparation
Installation Procedures Table 4-2 Installation Procedure for Intermediate Sections Procedures in tube between valve #1 and valve #2. Install onto in tube from valve #1. Install adapter onto tee install in tube from adapter to input port of 3-way solenoid valve. Install connector onto in tube to valve #2.
Page 92 Installation Procedures For accumulating curves at speeds up to 160 fpm, install one brake module in the first upstream zone. For accumulating curves at speeds of 160 fpm and higher, install a brake module in each of the two upstream zones. To install brake modules (if required): Bolt two brake modules to the cross members of each zone using the hardware supplied.
Page 93 Installation Procedures Verify connection of valve D1 to valve U1 and diaphragms using appropriate AGP curve airline and cable kit. If missing, then install. Install brake modules in zones U1 and U2 upstream of curve. Install 3-way solenoid valve in zone D1 or D2 downstream of curve with bracket and hardware in kit.
Page 94 Installation Procedures Brake Module Single Curve Air Control Field Kit Figure 4-43 Single Curve Air Control Field Kit for Brake Module The curve air kit is used to prevent product from entering the transportation curve while product is accumulating. The following are field installation instructions for 3 ft and 9 ft sections after the curve.
Page 95 Installation Procedures Table 4-4 Installation Procedure for Intermediate Sections Procedures in clear tubing between valve “DA” and valve “DB.” Install in tube from valve “DB.” Install in tee onto in adapter into tee. in black tube from adapter to input port of control valve “A”. Install in clear tube to valve “DA.”...
Page 96: Intermediate Accumulating Curve Section Preparation
Installation Procedures 4.8.2 Intermediate Accumulating Curve Section Preparation The zone before the curve always requires a brake. If above 160 fpm, the two immediate zones before the curve should have a brake . To prepare the intermediate accumulating curve section: Remove all carrier rollers from the sections to facilitate the installation of the drive chain and pad.
Page 97 Installation Procedures Figure 4-45 90° Accumulating Curve Cable Installation - Left Hand - Inside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 98 Installation Procedures Figure 4-46 90° Accumulating Curve Cable Installation - Left Hand - Outside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 99 Installation Procedures Figure 4-47 90° Accumulating Curve Cable Installation - Left Hand - Outside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 100 Installation Procedures Figure 4-48 90° Accumulating Curve Cable Installation - Right Hand - Inside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 101 Installation Procedures Figure 4-49 90° Accumulating Curve Cable Installation - Right Hand - Inside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 102 Installation Procedures Figure 4-50 90° Accumulating Curve Cable Installation - Right Hand - Outside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 103 Installation Procedures Figure 4-51 90° Accumulating Curve Cable Installation - Right Hand - Outside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 104 Installation Procedures Figure 4-52 180° Accumulating Curve Cable Installation - Left Hand - Inside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 105 Installation Procedures Figure 4-53 180° Accumulating Curve Cable Installation - Left Hand - Outside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 106 Installation Procedures Figure 4-54 180° Accumulating Curve Cable Installation - Left Hand - Inside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 107 Installation Procedures Figure 4-55 180° Accumulating Curve Cable Installation - Left Hand - Outside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 108 Installation Procedures Figure 4-56 180° Accumulating Curve Cable Installation - Right Hand - Inside Rail – Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 109 Installation Procedures Figure 4-57 180° Accumulating Curve Cable Installation - Right Hand - Outside Rail - Outside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 110 Installation Procedures Figure 4-58 180° Accumulating Curve Cable Installation - Right Hand - Inside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 111 Installation Procedures Figure 4-59 180° Accumulating Curve Cable Installation - Right Hand - Outside Rail – Inside Mount Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 112 Installation Procedures Figure 4-60 3 ft Intermediate or 3 ft 1 in to 5 ft 11 in Incremental Note: Installing a 3 ft intermediate or a 3 ft 1 in to 5 ft 11 in incremental section downstream of a curve, install using the information in the graphic above. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 113: Intermediate Sawtooth Merge Section Preparation
Installation Procedures Intermediate Sawtooth Merge Section Preparation To prepare the intermediate sawtooth merge section: Remove all carrier rollers from the merge sections to facilitate the installation of the drive chain and pad. Install the appropriate field kit to make the pneumatic connections. Table 4-5 Field Kit Part Numbers and Installation Drawing Numbers Intermediate Straight Section - Type Operating Mode...
Page 114: Chain Installation
Installation Procedures 4.10 Chain Installation Note: All chain pins must be on 1 in centers to properly mate with the drive pad. When connecting short chain segments, verify the correct end is connected to maintain 1 in centers. Figure 4-61 Installing the Chain Connector Link Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 115: Preparation
Installation Procedures The single-pitch RC50 roller chain (with extended pins) is shipped separately in 100 ft lengths and is installed after all conveyor sections are installed. Note: The drive section is shipped with the standard spring-loaded chain tensioner disengaged. Do not engage the tensioner until the chain and all connecting links are installed.
Page 116: Drive/Straight Sections
Installation Procedures • For air tensioners, turn off the air supply at the filter/regulator and disconnect the air line to the air tensioner. 4.10.2 Drive/Straight Sections Beginning at the drive section, unreel and lay the first chain segment (100 ft) into the extruded, green drive chain track with the leading end of the chain downstream of the drive sprocket.
Page 117: Curve Section
Installation Procedures 4.10.3 Curve Section To install the chain into the curve section: Lay chain segments into the chain tracks ahead of the idler sprockets. Pull the chains through the idler sprocket assemblies and ensure that they are properly aligned/engaged with the sprocket teeth. Install the connecting link between this chain segment and the segment previously installed.
Page 118: Idler Section
Installation Procedures 4.10.4 Idler Section To install the chain into the idler section: Lay the chain segment into the chain track ahead of the idler sprocket. Pull the chain around the idler sprocket and ensure that it is properly aligned/engaged with the sprocket teeth. Install the connecting link between this chain segment and the segment previously installed.
Page 119: Final Connection
Installation Procedures 4.10.5 Final Connection To complete the installation of the chain: When the last chain segment is placed in the chain track, install the connecting link between this chain segment and the segment previously installed. Note: Make sure the closed end of the spring clip is facing the chain’s direction of travel.
Page 120: Spring Tensioner Engagement
Installation Procedures 4.10.6 Spring Tensioner Engagement The spring tensioner is standard. It may be replaced with the optional air tensioner. Its spring-loaded chain tensioner is disengaged (fully collapsed) when shipped from the factory. When installation of the chain is complete, and when the chain/teeth engagement of all sprockets has been verified, the tensioner is ready to be engaged.
Page 121: Air Tensioner Engagement
Installation Procedures Check the position indicator, and follow one of these steps: • Green zone – the engagement procedure is complete. • Yellow or red zone – follow the instructions in the Removing Chain Links section in this chapter. 4.10.7 Air Tensioner Engagement The air tensioner is an alternative to the spring tensioner.
Page 122: Removing Chain Links
Installation Procedures 4.10.8 Removing Chain Links When the chain tensioner cannot be adjusted into the safe operation (green zone), chain links must be removed. Compressing the Chain Tensioner Turn the conveyor off and perform Lockout/Tagout procedures before starting drive chain and driver pad maintenance. Failure to follow this instruction may result in serious personal injury.
Page 123 Installation Procedures Jog the conveyor until the connector link is located in the open area immediately downstream of the drive sprocket. Fully compress the chain tensioner. • For spring chain tensioners, loosen the lock nut, turn the end retainer (fixed) nut to collapse the middle tube, then turn the compression nut to compress the inner tube into the middle tube.
Page 124: Installing The Driver Pad
Installation Procedures Disconnecting the Chain Starting at the splice, lift the driver pad from the chain’s extended pins to expose the connecting link. Remove the chain’s spring clip, connecting plate, and connecting link. Pull the excess slack out of the chain and determine the number of links to remove. Using a chain break tool, remove the necessary links.
Page 125: Carrier Roller Installation
Installation Procedures Start installing the driver pad with the end of the pad located 12 in from a connector link. This makes it easy to find a connector link assembly in the future. Firmly push the pad onto the chain pins. Continue installing the pad along the entire length of the chain and mark the pad where it overlaps the pad’s other end.
Page 126: Skewed Carrier Roller/Driver Guide Installation
Installation Procedures • Install pop-out carrier rollers at 3 in or 4 in centers only. If curve sections and/or merge sections are required, install fixed carrier rollers. For curves with close (2 in roller) centers: When performing step 5, lower the bolted tapered-rollers until they just touch the drive pad.
Page 127 Installation Procedures DO NOT skew rollers in either the drive section or the idler sections. To skew carrier rollers: Refer to the information below for the maximum skew angle per conveyor width. Width (W) (inches) Maximum Carrying Roller Maximum Skew Angle Skew (inches) 3.58 2.60...
Page 128 Installation Procedures If a roller sits directly over a bearing: a. Move the chain and the driver to their lowest positions. b. Make sure there is clearance between the roller and the screw. If a rotating roller hits the screw, switch it with a more concentric roller from the same conveyor.
Page 129 Installation Procedures Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 130: Finger Guard Installation
Installation Procedures 4.11.2 Finger Guard Installation Install the finger guards, following the pattern shown above. Insert the finger guard between the rollers and snap the mounting tabs into the chain track as shown below. Ensure that the finger guard is lock into the chain track. Ensure the finger guard does not contact the adjoining rollers.
Page 131: Field Wiring Connections
Installation Procedures Part numbers are as follows: Part Numbers Description 750010 Guard Finger AG Is 3"Ctrs Plas 750015 Guard Finger AG Is Skew X0.813 750014 Guard Finger AG Is Skew X0.563 750011 Guard Finger AG Is 4"Ctrs Plas 750013 Guard Finger AG Is Skew X0.250 4.12 Field Wiring Connections 4.12.1 Drive Section Connect the power unit to the power source.
Page 132: Field Piping Connections
Installation Procedures 4.13 Field Piping Connections 4.13.1 Conveyor Connect the conveyor’s filter/regulators (0-15 psi) to the air source. 4.13.2 Drive Section Connect the filter/regulator (0-100 psi) for the optional air tensioner to the air source. 4.13.3 Idler Section Connect the filter/regulator (0-100 psi) for the optional blade stop to the air source. 4.13.4 Sawtooth Merge/Curve Connect the filter/regulator (0-100 psi) for the optional sawtooth merge section to the air source.
Page 133 Installation Procedures Use the following procedure for cutting rail lengths: Remove the end cross member and the advance or return tracks from the discharge end of the section to be shortened, and remove any other hardware in the way of the following procedures.
Page 134 Installation Procedures Follow the procedures in the figure below: Follow the procedures in the figure below: Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 135 Installation Procedures Callout Master/Qty. Part No. Description 51045000 510 Bracket Field Spreader Position 0220003 Bolt Car .375-16 X.750 Short Sq Neck 20033900 Nut Hex .375-16 ZP GRS Cut the advance/return tracks and support channels the same amount as the frame rails.
Page 136 Installation Procedures b. Follow the instructions in the Field-Cutting Special Rail Lengths section in this chapter. Options for Situations Resulting in Short Zones Tie the new short zone air to the adjoining standard zone with tees included in the kit. Run the short zone independently.
Page 137: Molded Bottom Pans
Installation Procedures 4.15 Molded Bottom Pans Attach the bottom pan to the frame rail using the clips. Four clips with the screw hole must go on one side. The opposite side can have four of either type of clip. One side with the screw hole and the other side with the J-leg allows for faster installation and removal.
Page 138 Installation Procedures Insert four clips with the screw hole into the holes on the lower flange of the side rail opposite of the clips installed in step 2. Use one clip at each end and two evenly spaced clips at the center where the bottom pan will be installed. Insert one side of the bottom pan into the four clips with J-legs.
Page 139: Curve Installation
Installation Procedures 4.15.2 Curve Installation Use the following procedure to install the curved bottom pans: Turn off and lockout/tagout all power to the conveyor. Ensure there is no debris collected in areas where the bottom pans will be installed. Insert three clips with J-leg (or with screw hole if not using J-leg clips) into the holes on the lower flange of the side rail.
Page 140 Installation Procedures Cut the bottom pans along the trim guide lines if the curve is not 45° or 90°. Insert one side of the bottom pan into the 3 clips with J-leg. If not using J-leg clips, lift one side of the bottom pan up to the clip with the screw hole and install the self- tapping screw through the pre-drilled hole on the bottom pan into the barrel in the clip.
Page 141 Installation Procedures Lift the other end of the bottom pan up to the clip with the screw hole and install the self-tapping screw through the pre-drilled hole on the bottom pan into the barrel in the clip. Make sure the bottom pan is positioned correctly in the clips with screw holes and install self-tapping screws through the pre-drilled holes on the bottom pan into remaining clips.
Page 142: Field Cut Installation
Installation Procedures 4.15.3 Field Cut Installation If two bottom pans need to be field cut in order to fit in an odd length space, they should be cut in a way that leaves a minimum overlap of 3 in. To field cut and install bottom pans: Turn off and lockout/tagout all power to the conveyor.
Page 143 Installation Procedures Cut the second bottom pan piece close to a rib at a length to cover the remaining space with at least an additional 3 in. overlap with the bottom pan section cut in Step Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 144: Fitting Bottom Pans To Ceiling Hangers
Installation Procedures Overlap the two pieces with the ribs of the first pan nesting over the ribs of the second pan to result in an overall length equal to the space to be filled. Install two self-tapping screws through the outer overlap into the inner overlap. Install the bottom pan as described in the Standard Installation section.
Page 145 Installation Procedures Position the overlap end flange against the hanger pipe so there is no more than a in gap between the bottom pan and the hanger pipe. Cut the bottom pans as described in the Field Cut Installation section. Install the bottom pan as described in the Standard Installation section.
Page 146: Installing Drive Covers
Installation Procedures 4.16 Installing Drive Covers Before performing any maintenance follow the Lockout/Tagout Procedure in the Safety section to ensure the equipment is safe to work on. Replace all drive covers after performing maintenance. Failure to follow this instruction may result in serious personal injury and/or equipment damage.
Page 147 Installation Procedures Infeed Drive with Take-Up and End Drive Cover Side Mounted Drive with Take-Up and Drive End Cover Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 148 Installation Procedures Idler with End and Bottom Cover Idler with Case Stop and End Cover Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 149: Photo-Eye Installation
Installation Procedures 4.17 Photo-Eye Installation Before performing any maintenance services, follow the lockout/tagout procedure in the safety section to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or machine damage. 4.17.1 Photo-Eye Indicator Lights There are two colored LEDs in the photo-eyes: Description...
Page 150: Installing A Photo-Eye
Installation Procedures Tighten the anti-rotation screw, torque to 4 ± 1 in-lb (.45 ± .1 Nm) - leave the ball mount clamping screw loose. Insert the photo-eye into the ball mount and tighten the ball mount clamping screw. Remove locks and tags and restore power and air supply to the conveyor section. Align the photo-eye to the reflector as described in the Photo-Eye Alignment section in this chapter.
Page 151 Installation Procedures Insert the photo-eye into the ball mount bracket. Ensure that the photo-eye ball mount is centered in the bracket as shown below Verify that the photo-eye bracket is not around the photo-eye ball neck as shown below. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 152 Installation Procedures Tighten the ball mount clamping screw, torque to 7 ± 1 in-lb (.79 ± .1 Nm). Connect the photo-eye cable. Remove locks and tags and restore power and air supply to the conveyor section. Note: Set to 12 psi; do not exceed 15 psi. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 153: Installing A Reflector
Installation Procedures 4.17.4 Installing a Reflector Place the reflector on the reflector mounting bracket. Push the push nut over the reflector mounting shaft until the back of the reflector rests firmly against the reflector mounting bracket. Realign the photo-eye with the reflector. 4.18 Photo-Eye Alignment Once power has been supplied to the 24VDC power supply, the photo-eyes can be aligned with their reflectors.
Page 154 Installation Procedures Make sure the photo-eye can “lock on” to the reflector. The easiest method of doing this is to hold a reflector close to the photo-eye and make sure the indicator light stays on without flashing. If this does not work, use a different reflector, flip the reflector, or, if the reflector works on other photo-eyes, replace the photo-eye.
Page 155 Installation Procedures Loosen the ball mount clamping screw using a in hex key. Pre-orient the ball mount bracket so the photo-eye tends to aim high (the same position it would tend to jiggle into if it were loose). While holding the bracket in this position, begin aiming the photo-eye until the alignment indicator light comes on solid.
Page 156: Side Guide Installation
Installation Procedures Tighten the ball mount clamping bolt until the ball mount is snug. It is not necessary to tighten the ball mount clamp bolt until the ball mount is squeezed as tight as it can get. This will actually cause the photo-eye to go out of alignment. 4.19 Side Guide Installation Turn off any power circuits and/or lockout/tagout operating controls before installing the side guides.
Page 157: Side Guide Mounting Styles
Installation Procedures • Photo-eye and reflector • Skate wheel • Straight • Side guide transition – end • Side guide transition – direct-mount to spacer • Side guide transition – mid-conveyor Note: See the Accessories chapter for information about sizes, finishes, and part numbers for each side guide type.
Page 158: Direct Mounting Side Guides
Installation Procedures Side Guide Type Mounting Style Direct Offset Spacer Side Guide Transition – End Side Guide Transition – Direct- Mount to Spacer Side Guide Transition – Mid- Conveyor Side Guide Transition – PE to Standard Skate Wheel Side Guides Skate wheel side guides can only be direct-mounted to the frame.
Page 159 Installation Procedures Note: The project might require an alternate photo-eye sensor location within each zone. Verify desired sensor location designated on project specific layout and documentation provided . Note: The curve sections, (standard and accumulating style) have special requirements. See the Intermediate Accumulating Curve Section Preparation section in this chapter for more information on accumulating style curves .
Page 160 Installation Procedures Bolt the side guide to the frame at each end, middle, and the PE tab locations. Use the hardware specified. Repeat steps 1-3 as needed. The placement of the photo-eye is always in the same location. Note: Any deviations to this photo-eye location is noted in the installation drawings .
Page 161 Installation Procedures Figure 4-66 6 ft Discharge Zone – 3 ft Intermediate Zones Note: This dimension will be 60 in if the alternate photo-eye location is used (24 in from the discharge end of the zone). For additional information refer to the Application Guidelines chapter in this manual .
Page 162 Installation Procedures Figure 4-67 3 ft Discharge Zone – 3 ft Intermediate Zones Note: This dimension will be 24 in if the alternate photo-eye location is used (24 in from the discharge end of the zone). For additional information refer to the Application Guidelines chapter in this manual .
Page 163 Installation Procedures Figure 4-68 Direct-Mounting the Photo-Eye Side Guides Direct Mounting Reflector Side Guides In installations with photo-eye side guides, a reflector side guide is mounted across from each photo-eye side guide at a certain distance upstream. Note: The installation drawings list the photo-eye-to-reflector distance. Each reflector in the side guide is placed at a specific distance upstream from a corresponding photo- eye.
Page 164 Installation Procedures Figure 4-69 Reflector Placement for Cartons • For tapered totes, use the following illustration to determine reflector offset. Any deviations to this reflector location is noted in the installation drawings. Figure 4-70 Reflector Placement for Tapered Totes To direct-install the reflector side guides: Make sure all of the photo-eye side guides are installed.
Page 165 Installation Procedures Slide the side guide until each reflector is the correct distance upstream from a corresponding photo-eye. If the side guide butts against a previously installed side guide, follow the procedure in the Overlapping Side Guides section in this chapter. Bolt the side guide to the frame at each end and the middle.
Page 166 Installation Procedures Bolt the transition to the frame using the hardware provided. If either end of the transition is taller than 4 in, follow the procedure in the Connecting Side Guides section in this chapter. Direct Mounting Straight Side Guides To install straight side guides: Refer to the installation drawings for straight side guide locations.
Page 167 Installation Procedures Note: For offset-mounted side guide installation instructions; see the Offset- Mounting Side Guides section in this chapter . Figure 4-71 Direct Mounting Straight Side Guides Direct Mounting Sawtooth Merge Side Guides The sawtooth merge sections require two side guide styles: a bull nose side guide and a sawtooth merge side guide.
Page 168 Installation Procedures Direct Mounting Curve Side Guides The curve side guides are available in a variety of heights, lengths, and radius dimensions. Refer to the Accessories chapter in this manual for a full list of available curve side guides. Two curve rails of different length, radius, and orientation are needed for each conveyor curve section: one for the inside radius, and one for the outside radius.
Page 169 Installation Procedures If the side guide height is greater than 4 in, connect side guides as needed, following the procedure in the Connecting Side Guides section in this chapter. Figure 4-72 Direct Mounting Curve Side Guides Direct Mounting Side Guide Transitions at the Ends The side guide transition ends are placed at each end of the conveyor on each side.
Page 170 Installation Procedures Note: For offset-mounted side guide installation instructions, see the Offset- Mounting Side Guides section in this chapter . Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 171 Installation Procedures Direct Mounting Side Guide Transitions Mid-Conveyor The side guide transitions are placed between side guides of differing heights. They protect personnel from contacting exposed side guide edges. Place the side guide transition on the conveyor frame next to an installed side guide, in places where the next side guide to be installed is a different height.
Page 172 Installation Procedures Direct Mounting Skate Wheel Side Guides The skate wheel side guide consists of two channels with a single row of wheels in the middle. The rows of wheels provide a low-friction surface for guiding product. Figure 4-73 Direct Mounting Skate Wheel Side Guides To install skate wheel side guides directly onto the conveyor frame: Refer to the installation drawings for skate wheel side guide locations.
Page 173: Offset Mounting Side Guides
Installation Procedures 4.19.4 Offset Mounting Side Guides Follow these instructions for offset-mounting side guides. Offset Mounting Standard Side Guides The following standard side guides can be offset installed: • Reflector side guide • Straight side guide • Side guide transition •...
Page 174: Spacer Mounting Side Guides
Installation Procedures Place the other end of the offset bracket on the conveyor frame. Orient the side guide correctly. If the side guide butts against a previously installed side guide, follow the procedure in the Overlapping Side Guides section in this chapter. Bolt each offset bracket to the frame, using the hardware specified.
Page 175 Installation Procedures • Side guide transition • Side guide transition – end The following standard side guides cannot be spacer mounted: • Reflector side guide • Photo-eye side guide • Curve side guide • Skate wheel The height of the spacers is 1 in. The spacers are bolted to the conveyor frame, and the side guide is bolted to spacers.
Page 176: Overlapping Side Guides
Installation Procedures Place the side guide on the spacers. Orient the side guide correctly. If the side guide butts against a previously installed side guide, follow the procedure in the Overlapping Side Guides section in this chapter. Bolt the side guide to the spacers, using the hardware specified below. Make sure each end of the side guide is the same horizontal distance from the conveyor frame.
Page 177: Connecting Side Guides
Installation Procedures After installing the first side guide on a conveyor line, overlap all subsequent upstream and downstream side guides as they are installed. When the side guide tabs are overlapped correctly, the upstream tab is the closest tab to the inside (or belt/roller side) of the conveyor. Figure 4-74 Correct Side Guide Overlapping 4.19.7 Connecting Side Guides Connect all adjacent side guides as follows:...
Page 178 Installation Procedures Note: These instructions do not apply to skate wheel side guides. For information on connecting skate wheel side guides, refer to the Direct-Mounting Skate Wheel Side Guides section in this chapter. Figure 4-75 Connecting Direct Mounted Standard Side Guides Figure 4-76 Connecting Offset-Mounted Standard Side Guides Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 179 Installation Procedures Figure 4-77 Connecting Stacked Standard Side Guides Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 181: Accessories
Accessories Introduction This chapter contains standard and optional accessories available for the Accuglide ZoneFlex accumulation conveyor product line. Note: The graphic dimensions in this chapter are in inches unless otherwise specified. Standard and Optional Accessories 5.2.1 Angle End Stop Figure 5-1 Angle End Stop Table 5-1 Angle End Stop Description Overview Bolts across top flange to keep product from running off the end.
Page 182: Blade Stop - Idler Section
Accessories The flat washers are installed between the side rail and the angle Installation stops to clear the rollers. 6-09723-016 – 16 in Part Numbers 6-09723-022 – 22 in 6-09723-028 – 28 in 6-09723-034 – 34 in 6-09723-040 – 40 in 5.2.2 Blade Stop –...
Page 183: Brake Module - Idler Section
Accessories Table 5-2 Blade Stop – Idler Section Description Overview The blade stop is an optional flow-control component for the idler section. The air-actuated plate-type stop is raised to block accumulated product from advancing onto the adjoining take- away conveyor and is lowered when product is discharged. Operation A maintained-signal (115VAC/24VDC) actuates the solenoid- actuated, 4-way valve that controls the double acting air...
Page 184: Brake Module - Intermediate Straight Section
Accessories Table 5-3 Brake Module – Idler Section Description The brake module controls the “accumulation and release” Overview process by stopping products in the conveyor’s discharge- zone and keeping them from advancing onto the adjoining downstream conveyor. Note: A brake module is not a “positive” stopping device. For positive control, use either a blade stop, brake belt, or brake/meter belt conveyor.
Page 185 Accessories Table 5-4 Brake Module – Intermediate Straight Section Description Overview Brake modules control product accumulation and release in the intermediate straight sections: 1) at workstations; 2) in batch assembly areas; 3) upstream of an intermediate merge section; and 4) upstream of an intermediate curve section. Kits include two 3 ft long, spring-set brake modules and the necessary control components for each specific application.
Page 186: Brake Module - Curve Solenoid Field Kit
Accessories 5.2.5 Brake Module – Curve Solenoid Field Kit Figure 5-5 Brake Module – Curve Solenoid Field Kit Table 5-5 Brake Module – Curve Solenoid Field Kit Description Overview The curve air kits are only used when there are accumulating straight sections with a transportation curve.
Page 187: Brake Module - Intermediate Section Solenoid Field Kit
Accessories 5.2.6 Brake Module – Intermediate Section Solenoid Field Figure 5-6 Brake Module – Intermediate Section Solenoid Field Kit Table 5-6 Brake Module – Intermediate Section Solenoid Field Kit Description The kit includes all mechanical, air and electrical components Overview required for installing two brake modules in any two operational zones in an intermediate section.
Page 188: Brake Module - Single Curve Air Control Field Kit
Accessories 5.2.7 Brake Module – Single Curve Air Control Field Kit Figure 5-7 Brake Module – Single Curve Air Control Field Kit Table 5-7 Brake Module – Single Curve Air Control Kit Description Overview The curve air kit is used to prevent product from entering the transportation curve while product is accumulating.
Page 189: Cable - Extension
Accessories 5.2.8 Cable - Extension Figure 5-8 Cable - Extension Table 5-8 Cable - Extension Overview Required when distance between ZoneFlex modules exceeds 6 ft Operation Transmits all power (24VDC), inter-zone communication signals (including slug-release). Cable ID Color Black Cable – Four wire. Cable - Connectors Connectors –...
Page 190: Cable Logic Interrupt
Accessories 5.2.9 Cable Logic Interrupt Figure 5-9 Cable Logic Interrupt Table 5-9 Cable Logic Interrupt Description Overview Transmits power but does not transmit any inter-zone communication signals, including slug-release. Rarely used. Cable ID Color Black with blue shrink wrap Cable – Four wire Cable, Connectors Connectors –...
Page 191: Parallel T-Cable
Accessories 5.2.10 Parallel T-Cable Figure 5-10 Parallel T-Cable Table 5-10 Parallel T-Cable Description The T-cable is required for connecting power-supply Overview and/or slug module to the intermediate straight section. One T-cable is provided with each power supply. Operation Transmits slug-release signal and/or power (24VDC) from the power supply/slug module to the power/communication cord.
Page 192: Slug Interrupt Cord
Accessories 5.2.11 Slug Interrupt Cord Figure 5-11 Slug Interrupt Cord Table 5-11 Slug Interrupt Cord Description Required to terminate a slug-release zone. Transmits power Overview (24VDC) and inter-zone communication signals; does NOT transmit slug-release signal. Cord Three wire with black PVC jacket Slug termination cord –...
Page 193: Chain - Rc50 With Extended Pin
Accessories Table 5-12 Cable Power Isolator Description Overview Required for isolating portions of a conveyor that receive power from separate power supplies. Transmits all inter-zone communication signals including slug-release. Does NOT transmit the 24VDC power between two adjoining ZoneFlex modules. Cord Three wire with black PVC jacket Power isolation cord –...
Page 194: Chain Tensioner - Drive Section - Air Actuated
Accessories 5.2.14 Chain Tensioner – Drive Section – Air Actuated Figure 5-14 Chain Tensioner – Drive Section – Air Actuated Table 5-14 Chain Tensioner – Drive Section – Air Actuated Description The air-actuated chain tensioner is an alternate for the standard, Overview spring-type chain tensioner that provides constant tension to the drive chain.
Page 195: Chain Track Lubricator - Solenoid-Controlled (Drive Section)
Accessories Part Number Description 5102300 Cylinder Tensioner 51025700 Switch Assembly 24024200 High Pressure Regulator 5.2.15 Chain Track Lubricator – Solenoid-Controlled (Drive Section) Figure 5-15 Chain Track Lubricator – Solenoid-Controlled (Drive Section) Table 5-15 Chain Track Lubricator – Solenoid-Controlled (Drive Section) Description The solenoid-controlled chain track lubricator is an alternate for Overview the standard, Magnetic-type track lubricator.
Page 196: Drip Pan Kit
Accessories The solenoid valve (110VAC/24VDC) must be wired to the control Field Wiring panel. Part Number Description 51023501 Track Solenoid-Oil AC115V 51023502 Track Solenoid-Oil 24V 51020300 Magnetic Sensor Chain Lubricator Assembly 5.2.16 Drip Pan Kit Figure 5-16 Drip Pan Kit Table 5-16 Drip Pan Kit Description Overview The drip pan catches oil dripping from the gearbox and/or oiler.
Page 197: Driver Pad With Wear Indicator
Accessories 5.2.17 Driver Pad with Wear Indicator Figure 5-17 Driver Pad with Wear Indicator Table 5-17 Driver Pad with Wear Indicator Description Overview A urethane driver pad is attached on the extended pin of a continuous roller chain as a drive medium. The moving urethane driver pad contacts the bottom surface of the roller to provide the drive force to move the product.
Page 198: Field Cut Kit Template
Accessories 5.2.18 Field Cut Kit Template Figure 5-18 Field Cut Kit Template Table 5-18 Field Cut Kit Template Description Overview The template is used when shortening a section of conveyor in the field. It ensures that the spreader is reinstalled at the proper height to maintain proper drive through the zone.
Page 199: Filter/Regulator Mounting Kit For Intermediates
Accessories 5.2.19 Filter/Regulator Mounting Kit for Intermediates Figure 5-19 Filter/Regulator Mounting Kit for Intermediates Table 5-19 Filter/Regulator Mounting Kit for Intermediates Description Overview Conditions (filters) the air provided by the facility's air source and regulates its pressure to the required pressure for each particular component.
Page 200 Accessories The filter regulator gauge (FRG) assembly’s mounting bracket Installation bolts to the bottom flange of the conveyor frame rail at a power near the middle of the conveyor. The FRG assembly is connected to the conveyor’s main air supply line via the tubing and Adapter and Tee and fittings furnished.
Page 201: Head-To-Tail Logic Kit
Accessories 5.2.20 Head-to-Tail Logic Kit Figure 5-20 Head-to-Tail Logic Kit Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 202: Knee Brace Assembly
Accessories Table 5-20 Head-to-Tail Logic Kit Description Overview The head/tail logic kit provides seamless logic across conveyors installed head-to-tail. The kit consists of one logic module and associated tubing, cables, and mounting hardware. Upstream idler and downstream drive section are piped as if: 1.) they are an extension of the intermediate section, and 2.) there is no interruption in the conveyor.
Page 203: Molded Bottom Pans
Accessories Use knee braces: at the ends of straight runs, before case stops, Operation near the drive, and approximately every 50 ft on a long straight run. Installation Locate the knee braces on the downstream side of the supports, putting them in tension. However, starting the conveyor stresses the legs in the opposite direction.
Page 204 Accessories Table 5-22 Molded Bottom Pans Description • Lightweight – one person installation and can be installed with Overview fasteners on one side only for quick maintenance access. • Does not fasten to the bottom flange of the conveyor; no field trimming for floor supports or electrical device mounting.
Page 205 Accessories Installation There are two installation options: Standard methods: Using four of the clips with screw holes on one side of the bottom pan. Using four of the clips with the J-leg (without screw holes) on the opposite side of the bottom pan. Note: This method allows for easier installation and removal of the bottom pan.
Page 206: Module Relocation Kit
Accessories 5.2.23 Module Relocation Kit Figure 5-23 Relocating Module to Frame Cutout Figure 5-24 Relocating Module to New Bracket and Mounted to Rail Flange Table 5-23 Module Relocation Kit Description Applications requiring the ZoneFlex modules to be Overview relocated in the field. This application is used when merging onto an IntelliQ Operation ZoneFlex conveyor where a ZoneFlex module is...
Page 207: Oil Reservoir - One Liter
Accessories 5.2.24 Oil Reservoir – One Liter Figure 5-25 Oil Reservoir – One Liter Table 5-24 Oil Reservoir – One Liter Description The oil reservoir with float switch is an alternate for the standard, Overview without switch type. It uses SMC Reservoir AL-DUM00277. The oil reservoir without float switch uses SMC Reservoir AL- DU002888.
Page 208: Power Supply Kit
Accessories The chain lubricator is factory assembled into the drive section. Installation The oil reservoir is shipped separate and must be assembled at the time of installation. The illustration shows the oil reservoir mounting location on the drive section’s frame, and the air and oil lines that must be connected.
Page 209 Accessories Table 5-25 Power Supply Kit Description Overview Each power supply can provide power for a maximum of 35 modules (27 modules in either direction) and must be located as close to the center of the zones as possible to balance the power supplied to the zones.
Page 210: Racking Gauge Tool
Accessories 5.2.26 Racking Gauge Tool Figure 5-27 Racking Gauge Tool Table 5-26 Racking Gauge Tool Description Optional, used for squaring the conveyor. Refer to the Overview Installation Procedures chapter. Part Numbers Kit 400407 Includes two stainless steel plates - 40040701 and 40040702 Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 211: Skewed Driver Field Kit
Accessories 5.2.27 Skewed Driver Field Kit Figure 5-28 Skewed Driver Field Kit Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 212 Accessories Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 213 Accessories Table 5-27 Skewed Driver Field Kit Description Overview Moving packages in a more uniform pattern. Installation If a roller sits directly over a bearing, check clearance between roller and screw when chain and driver are in lowest position. If a roller hits the screw when turned, switch it with a more concentric roller from the same conveyor.
Page 214: Splice Angle For Curves And Drive
Accessories 5.2.28 Splice Angle for Curves and Drive Figure 5-29 Splice Angle for Curves and Drive Table 5-28 Splice Angle for Curves and Drive Description The splice angle is used between a curve and intermediate, Overview curve and drive, or a drive and intermediate when a support cannot be used directly under the joint of two sections.
Page 215: Splice Flat For Curves And Drive
Accessories 5.2.29 Splice Flat for Curves and Drive Figure 5-30 Splice Flat for Curves and Drive Table 5-29 Splice Flat for Curves and Drive Description The splice flat is used between a curve and intermediate, curve Overview and drive, or a drive and intermediate when a support is used directly under the joint of two sections.
Page 216: Splice Plate Kit
Accessories 5.2.30 Splice Plate Kit Figure 5-31 Splice Plate Kit Table 5-30 Splice Plate Kit Description Overview Standard plate for splicing sections together. Installation Use the splice plate to connect adjacent conveyor beds together. FK410241 (Kit for use with ceiling hanger) - 18000800 (plate Part Numbers only) FK410240 (Kit for use with floor support) - 18000800 (plate only)
Page 217: Side Guide - Bull Nose
Accessories 5.2.31 Side Guide – Bull Nose Figure 5-32 Side Guide – Bull Nose Table 5-31 Side Guide – Bull Nose Description Used on all merge (sawtooth) sections for the acute angle Overview between the Accuglide ZoneFlex and the connecting conveyor. •...
Page 218: Side Guide - Accumulation Curve
Accessories 5.2.32 Side Guide – Accumulation Curve Figure 5-33 Side Guide – Accumulation Curve Table 5-32 Side Guide – Accumulation Curve Description Overview Used for all accumulating curve sections. Required. Holes punched in guide for retro-reflective photo-eyes and Specifications reflectors Angle –...
Page 219 Accessories Part Number Description Inside Radius Curve 51065704 511 PE SG 90DEG IR CRV 40 RAD 2.5H 51065705 511 PE SG 90DEG IR CRV 40 RAD 6.5H 51065706 511 PE SG 90DEG IR CRV 40 RAD 10.0H 51065707 511 PE SG 90DEG IR CRV 50 RAD 2.5H 51065708 511 PE SG 90DEG IR CRV 50 RAD 6.5H 51065709...
Page 220 Accessories Part Number Description Inside Radius Curve 51066102 511 PE SG 180/45DEG OR CRV 94"RAD RHINF/LHDIS 6.5H 51066103 511 PE SG 180/45DEG OR CRV 94"RAD RHINF/LHDIS 10.0H 51066104 511 PE SG 180/45DEG OR CRV 94"RAD LHINF/RHDIS 2.5H 51066105 511 PE SG 180/45DEG OR CRV 94"RAD LHINF/RHDIS 6.5H 51066106 511 PE SG 180/45DEG OR CRV 94"RAD LHINF/RHDIS 10.0H Table 5-35 180°...
Page 221 Accessories Part Number Description Inside Radius Curves 51065822 511 PE SG 180DEG(2 OF 2) IR CRV 60 RAD 2.5H 51065823 511 PE SG 180DEG(2 OF 2) IR CRV 60 RAD 6.5H 51065824 511 PE SG 180DEG(2 OF 2) IR CRV 60 RAD 10.0H Outside Radius Curves 51066001 511 PE SG 180DEG (1 OF 2) OR CRV 46 RAD 2.5H...
Page 222: Side Guide - Transportation Curve
Accessories 5.2.33 Side Guide – Transportation Curve Figure 5-34 Side Guide – Transportation Curve Table 5-36 Side Guide – Transportation Curve Overview Used for all transportation curve sections. Angle – 30°, 45°, 60°, 90°, and 180° (180° comprised of two 90°s) Specifications Inside radius –...
Page 223 Accessories Table 5-37 30° Curve Side Guide Part Numbers Part Description Part Description Number Number SG 30DEG IR CRV 30" SG 30DEG OR CRV 46" 12002401 12002501 RAD 2-1/2" H RAD 2-1/2" H SG 30DEG IR CRV 30" SG 30DEG OR CRV 46" 12002402 12002502 RAD 6-1/2"...
Page 224 Accessories Part Description Part Description Number Number SG 45DEG IR CRV 30" SG 45DEG OR CRV 46" 12002602 12002702 RAD 6-1/2" H RAD 6-1/2" H SG 45DEG IR CRV 30" SG 45DEG OR CRV 46" 12002603 12002703 RAD 10" H RAD 10"...
Page 225 Accessories Part Description Part Description Number Number SG 60DEG IR CRV 40" SG 60DEG OR CRV 62" 12002804 12002916 RAD 2-1/2" H RAD 2-1/2" H SG 60DEG IR CRV 40" SG 60DEG OR CRV 62" 12002805 12002917 RAD 6-1/2" H RAD 6-1/2"...
Page 226: Side Guide - Sawtooth Merge
Accessories Part Description Part Description Number Number SG 90DEG IR CRV 40" SG 90DEG OR CRV 62" 12003206 12003318 RAD 10" H RAD 10" H SG 90DEG IR CRV 50" SG 90DEG OR CRV 78" 12003207 12003319 RAD 2-1/2" H RAD 2-1/2"...
Page 227 Accessories Table 5-41 Side Guide – Sawtooth Merge Overview Used for all sawtooth merge sections. Length – varies Specifications Height – 2.5, 6.5, or 10 in. See part numbers information below. If stacked on other side guides, total height limit of the stack is 10 in.
Page 228: Side Guide - Photo-Eye And Reflector
Accessories 5.2.35 Side Guide – Photo-Eye and Reflector Figure 5-36 Side Guide – Photo-Eye and Reflector Table 5-42 Side Guide – Photo-Eye and Reflector Overview Used for field-mounted photo-eyes and reflectors. Specifications Length: 71.9 or 143.9 in (6 or 12 ft nominal). See part numbers information below.
Page 229: Side Guide - Skate Wheel
Accessories Part Side Guide Style/ Length Height # of PEs/ Number Type (feet) (feet) Reflectors Reflector Spacing (feet) 12034201 12019801 12019901 12023001 Reflector side/channel 12023002 12034101 12034103 12016901 12017001 5.2.36 Side Guide – Skate Wheel Figure 5-37 Side Guide – Skate Wheel Table 5-43 Side Guide –...
Page 230 Accessories Mounting Options Direct mounted to the frame Mounting Hardware Provided for direct mounting. Refer to the Installation Kits Procedures chapter for detailed mounting information. Photo-Eye Reflector Length Height Zone Part Part (feet) (feet) Length Number Number (feet) 12017901 12018401 2.50 12017902 12018402...
Page 231: Side Guide - Straight
Accessories 5.2.37 Side Guide – Straight Figure 5-38 Side Guide – Straight Table 5-44 Side Guide – Straight Description Used for all straight sections that do not require special guides, Overview and with factory-installed retro-reflective photo-eyes and reflectors. Specifications Length: 12 ft 1 Height varies.
Page 232: Transition End Side Guide
Accessories “H” Height (inches) Part Number 12000101 2.50 12000102 6.50 10.00 (used only in areas 12000103 without PE/reflector rails) 12000104 7.50 12000105 3.25 12000106 4.00 5.2.38 Transition End Side Guide Figure 5-39 Transition End Side Guide Table 5-45 Transition End Side Guide Description Overview A side guide transition with one end at 0 in is used to end a side guide at the end of a conveyor line or to transition from a...
Page 233: Transition Mid-Conveyor Side Guide
Accessories Specifications Left-hand and right-hand designations Length varies Height, short side of transition – 2.50 and 6.5 in Height, long side of transition – 6.50 and 10 in Refer to the Part Numbers information below. Mounting Options Direct mounted to the frame Offset to the outside of the frame –...
Page 234 Accessories Table 5-46 Transition Mid-Conveyor Side Guide Description Overview The side guide transition with both ends larger than 0 in is used when the side guide changes height. Specifications Left-hand and right-hand designations Length – varies Height, short side of transition – 2.50 and 6.5 in Height, long side of transition –...
Page 235: Side Guide - Transition Step
Accessories 5.2.40 Side Guide – Transition Step Figure 5-41 Side Guide – Transition Step Table 5-47 Side Guide – Transition Step Description Used to transition from a direct-mounted side guide to a stand-off Overview mounted side guide. The stand-off mounted side guide is typically used with photo-eyes/reflectors in brackets mounted to the outside of the frame.
Page 236: Side Guide - Transition Pe To Standard
Accessories Mounting Options Direct mounted to the frame. Mounting Hardware Provided for direct mounting. Refer to the Installation Kits Procedures chapter for detailed mounting information. “A” (inches) “B” (inches) Part Number Designation 12023101 Right hand 3.50 2.50 12023102 Left hand 3.50 2.50 12023103...
Page 237: Side Guide - Width Transition
Accessories Table 5-48 Side Guide – Transition PE to Standard Description Overview Used to transition from the 2.50 in flange on photo-eye and reflector side guides to the 1 in flange on a standard side guide. Specifications Height: 2.50 in Mounting Options Direct mounted to frame.
Page 238 Accessories Specifications Left hand and right hand designations Side guide height designation (2.5, 6.5, and 10 in) Width change designation (3 and 6 in width change) Length of transition (12, 36, or 72 in) Conveyor rail height (6.5 or 9.75 in – on upstream or downstream) Mounting Options Direct-mounted to the frame...
Page 239: Transition Bracket Field Kit
Accessories 5.2.43 Transition Bracket Field Kit Figure 5-44 Transition Bracket Field Kit Table 5-50 Side Guide – Transition Bracket Field Kit Description The brackets can be ordered to reinforce the coupling of a 6.5 in Overview or a 9.75 in frame conveyor. Note: If there are any changes in frame height in a single conveyor line, the brackets will be included at the factory.
Page 240 Accessories Part Numbers 42001201 - Right Hand 42001202 - Left Hand Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 241: Pre-Startup Procedures
Pre-Startup Procedures Introduction This chapter describes checking various operations and adjustments (if necessary), pre-startup preparation, initial startup, checking the accumulation function, and checking the operational modes. After performing these tasks the conveyor is ready to put into service. The installer must be qualified and must comply with all applicable codes, ordinances, specifications, and/or other governing data related to the installation of the equipment.
Page 242: Initial Startup/Checks
Pre-Startup Procedures • The drive chain/pad’s path is correct • The drive chain/pad is properly tensioned. • Make sure the reducer’s lubricant is up to the oil level plug opening. Note: If additional lubricant is required, refer to the manufacturer’s tag (attached to the reducer) before adding.
Page 243: Chains And Sprockets
Pre-Startup Procedures Note: The reducer will run hot when first put into operation, and for approximately 120 hours thereafter (until the maximum break-in efficiency is reached). Flag each zone photo-eye to check zone operation Check proper operation of oiler (magnetic or solenoid). Chains and Sprockets To keep drive chains in good operating condition, the following lubrication procedures are recommended.
Page 244: Checking Zone Control Components
Pre-Startup Procedures In an atmosphere that contains abrasive particles, it is better not to have conventional lubricants on the surface of the chain that collect or retain abrasive particles. Use dry lubricants such as molybdenum disulfide or deflocculated colloidal graphite in a volatile carrier.
Page 245: Photo-Eye With Time Delay, Factory Or Field Installed
Pre-Startup Procedures Check each photo-eye’s LED indicators. • A green LED indicates that the photo-eye is properly connected to the ZoneFlex module and receiving power. • A yellow LED indicates that the photo-eye is properly aimed and receiving a reflective beam back from its reflector. 6.5.3 Photo-Eye with Time Delay, Factory or Field Installed Optional zone control photo-eyes with manually adjustable time delay are used to delay the valve-activation photo-eye signal to the ZoneFlex module.
Page 246 Pre-Startup Procedures • Reduces air consumption • Maintains constant drive to rollers during transportation Zone activation delay is commonly utilized on accumulation conveyors in manufacturing applications for production, packaging, and palletizing areas. Manufacturing applications typically use accumulation conveyor to provide carton transportation for the majority of it run time, with accumulation only occurring when a downstream machinery error or jam occurs.
Page 247: Adjusting Under Roller Photo-Eyes After Installation
Pre-Startup Procedures Time Delay Adjustment Figure 6-3 Time Delay Adjustment To decrease the time delay: Turn the potentiometer adjustment screw counterclockwise. The minimum delay position is marked by a “-” (minus) symbol. To increase the time delay: Turn the potentiometer adjustment screw clockwise. The maximum delay timing is 2 seconds and is marked by a “+”...
Page 248 Pre-Startup Procedures Figure 6-4 Adjusting the Under Roller Photo-Eye Use the following procedure to adjust the under roller photo-eye: Loosen the nuts (#8 nuts use a wrench). Rotate the photo-eye until it detects the top lip of the tote. Tighten the nuts. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 249: Checking Accumulation Function
Pre-Startup Procedures Checking Accumulation Function Make sure the first product coasts to a stop in the first operational zone at the conveyor’s discharge-end and that trailing products accumulate rearward without a buildup of line pressure. Figure 6-5 Product Accumulation Confirm that product stops in the operational-zone or local zone when: 1) sensor L+1 is blocked by accumulated product;...
Page 250: Checking Operating Mode
Pre-Startup Procedures Confirm that operational-zone L-1 becomes non-powered when the local zone stops. Figure 6-6 Intermediate Section Checking Operating Mode 6.8.1 1 Zone A ZoneFlex module set for 1 sone mode responds to its associated photo-eye sensor mounted in the next downstream zone. Example: The solenoid located on the downstream side of the local zone’s ZoneFlex module activates (provides power to) the rollers in zone L-1 when the photo-eye in the local zone is unblocked.
Page 251: 1&2 Zone Mode
Pre-Startup Procedures Figure 6-8 1 Zone Release To make sure the 1 Zone mode is operating properly: Product Acceptance: Make sure the volume of product being fed onto the conveyor advances correctly on the conveyor with gaps (approximately 3 ft long) between each product (or groups of smaller products).
Page 252 Pre-Startup Procedures Figure 6-9 1&2 Zone Release To make sure the 1&2 zone mode is operating properly: Product Acceptance: Make sure the volume of product being fed onto the conveyor properly advances on the conveyor in groups (approximately 6 ft long) with gaps (approximately 3 ft long) between each group.
Page 253: Fixed Auto-Slug
Pre-Startup Procedures Figure 6-10 Releasing Product in 1&2 Zone Mode 6.8.3 Fixed Auto-Slug A conveyor may consist of one or more modules set to fixed auto-slug. Each fixed auto-slug group of zones consists of a first zone set for 1 zone mode, followed by any desired number of zones set to fixed auto-slug.
Page 254: Slug
Pre-Startup Procedures To make sure the fixed auto-slug mode is operating properly: Product Acceptance: Make sure the volume of product being fed onto the conveyor is advancing with no change in the spacing between product, as long as the first zone’s sensor is unblocked.
Page 255: Chain Track Lubricator - Timing Adjustment
Pre-Startup Procedures To make sure the slug mode is operating properly, provide a slug release signal to the power supply or slug module and confirm that all accumulated product within the defined slug zone advances in a single grouping. If the required slug zone length is less than the conveyor’s length, the zones upstream of the slug zone will release per their primary operating mode setting.
Page 256: Checking Chain/Track Lubrication
Pre-Startup Procedures Time for three cycles. 3 x 1.11 min. = 3.33 min. Program the solenoid-lubricator’s controller to turn-on and dispense oil (10-weight, non-detergent motor oil) for a period of 3 minutes and 20 seconds for every eight hours of conveyor operation. 6.9.2 Checking Chain/Track Lubrication After an eight-hour cycle, stop the conveyor and observe the condition of the chain and track.
Page 257: Putting The Conveyor Into Service
Pre-Startup Procedures Measure the amount of deflection on the slack side of the timing belt. If the deflection on the slack side of the timing belt is more than inch per inch of belt span, tighten the timing belt. The standard length between pulley centers is about 20 in; therefore, the timing belt deflection with four pounds of force is about 6.11 Putting the Conveyor into Service At this point, the Accuglide ZoneFlex conveyor’s mechanical components and...
Page 259: Troubleshooting
Troubleshooting Introduction Before troubleshooting equipment problems, it is essential to completely understand how the system functions during normal operation. Thoroughly review the operational description, the circuit drawings, and the electrical diagrams sent with your equipment. Once the system operation is understood, it is usually best to start at the problem, and then work back to the source.
Page 260: Troubleshooting Guidelines
Troubleshooting Troubleshooting Guidelines Procedures are discussed at length in the following pages; however, there are certain guidelines that should be followed for all troubleshooting problems: Listen and observe. Locate the problem. Identify problem as electrical, mechanical, or pneumatic. Determine symptoms through observations. Think and act with caution and clear thinking.
Page 261 Troubleshooting Table 7-1 Troubleshooting Problems and Solutions Symptom Probable Cause Corrective Action Turn on the system’s control Conveyor will not start Electrical power shut off or control circuit not energized. panels. Reset emergency stop devices. System control devices (e.g., Adjust or replace. photo-eyes, limit switches) are out of adjustment or defective.
Page 262 Troubleshooting Symptom Probable Cause Corrective Action Motor runs hot or Overload Check chain track overheats. lubrication. Reduce the load. If provided, check air pressure of air-operated chain tensioner. Refer to motor’s nameplate High or low voltage. for proper voltage. Check/replace fuses. Inadequate ventilation or Check and clean openings insufficient lubrication.
Page 263: Troubleshooting Help
Troubleshooting Symptom Probable Cause Corrective Action Drive pad not dropping away Clear obstruction. from carrier rollers. Clean carrier rollers. Clean drive pad. Troubleshooting Help If you need further assistance, please visit www.intelligrated.com or call our Technical Support Department at 1-877-315-3400. Accuglide ZoneFlex | Installation Manual | 29349916 January 11, 2019...
Page 265 Index 1 zone mode, 65, 240 capacity, 13 1&2 zone mode, 65 carrier rollers, 15 installing, 115 Caution statements, 2 ceiling hangers, 33 accessories, 18, 171 chain, 183 accumulating curves, 86 installing, 104 accumulation removing links, 112 checking, 239 chain tensioner, 46, 49, 184 accumulation curve side guides, 208 installing, 48 adjacent side guides, 167...
Page 266 drive covers idler sprockets installing, 136 height, 53 drive sections, 106 initial startup, 232 field piping, 122 inspection, 19 wiring, 121 installation, 29 drive sprockets installation safety, 8 height, 45 interfacing equipment, 4 driver pads, 187 intermediate curve sections, 37 installing, 114 intermediate sections, 14 installing, 81...
Page 267 parts replacement, 27 returns, 20 photo-eye LEDs, 139 rollers, 15 photo-eye sensors, 234 installing, 115 photo-eye side guides, 149, 218 photo-eye with delay, 235 photo-eyes safety adjusting, 237 installation, 8 aligning, 143 maintenance, 8 ball mounts, 139 safety conventions, 2 installing, 140 safety devices, 6 LEDs, 236...
Page 268 splice angles, 204 transportation curve side guides, 212 splice flats, 35, 205 transportation curves, 81 splice plates, 35, 206 travel direction, 63 spring tensioner, 110 troubleshooting, 249 sprockets, 233 tubing, 15, 16, 17 squareness, 42 standard safety conventions, 2 standards, 21 warning signs, 26 startup, 232 warning signs/labels, 2...

Honeywell Intelligrated Accuglide ZoneFlex Installation Manual

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