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Formax 7202 Series Maintenance Manual

High-volume modular inserters, output conveyor
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7500/7202 Series
High-Volume Modular Inserters
7/2017
MAINTENANCE MANUAL:
Output Conveyor

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Summary of Contents for Formax 7202 Series

  • Page 1 7500/7202 Series High-Volume Modular Inserters MAINTENANCE MANUAL: Output Conveyor 7/2017...

  • Page 2: Table Of Contents

    OUTPUT CONVEYOR SERVICE MANUAL Contents Installation ................1-2 Safety Notes ..............1-2 Installation ................ 1-3 1.2.1 Assembling the backstop and rollers ......1-3 1.2.2 Attachment of Conveyor ..........1-4 1.2.4 Connecting to the inserter .......... 1-5 Service and Operating Adjustments ......... 2-2 Health, Safety &...
  • Page 3 OUTPUT CONVEYOR SERVICE MANUAL Page intentionally left blank Page ii Output Conveyor Service Manual...
  • Page 4 OUTPUT CONVEYOR SERVICE MANUAL Section 1 Unpacking Installation Page Issue 1 February 2017 Page 1-1 Output Conveyor Service Manual...

  • Page 5: Installation

    OUTPUT CONVEYOR SERVICE MANUAL Installation 1.1 Safety Notes BEFORE DISASSEMBLING: THE POWER CABLE MUST REMAIN Warning! Most moving parts UNPLUGGED UNTIL END OF are protected by covers. Don’t operate the ASSEMBLY machine unless all of the covers are in place. Opening covers include...

  • Page 6: Assembling The Backstop And Rollers

    OUTPUT CONVEYOR SERVICE MANUAL 1.2 Installation 1.2.1 Assembling the backstop and rollers Important: all screws in the metal casing are fitted with star washers for earthing purposes. These must always be in place. When the conveyor is used in angled orientation, the backstop must be fitted in order to constrain the envelopes.

  • Page 7: Attachment Of Conveyor

    OUTPUT CONVEYOR SERVICE MANUAL Guide rollers Fig. 2 Assemble the guide roller brackets as described in step 3 and fit the rollers. Adjustment of the backstop and rollers are described in the Conveyor Operator Manual. 1.2.2 Attachment of Conveyor Ensure INF Link Kit A2A-A0004601 is fitted tot he inserter. This is the output plate with location spigots for conveyor attachment.

  • Page 8: Connecting To The Inserter

    OUTPUT CONVEYOR SERVICE MANUAL Inline Version Fig. 4 1.2.4 Connecting to the inserter Connect the DIN lead between the socket on the mains input panel on the in- serter, and the socket in the cavity under the conveyor, as shown in Fig. 5 be- low.
  • Page 9 OUTPUT CONVEYOR SERVICE MANUAL Page intentionally left blank Page 1-6 Page Issue 1 February 2017 Output Conveyor Service Manual...

  • Page 10: Service And Operating Adjustments

    OUTPUT CONVEYOR SERVICE MANUAL Section 2 Service Operating Adjustments Page Issue 1 February 2017 Page 2-1 Output Conveyor Service Manual...

  • Page 11: Health, Safety & Environment

    OUTPUT CONVEYOR SERVICE MANUAL Service and Operating Adjustments 2.1 Health, Safety & Environment 2.1.1 Safety instructions 2.1.1.1 General • This machine must be operated by competent personnel. The manufacturer accepts no responsibility for accidents or injuries caused by operation by incompetent personnel. •...
  • Page 12 OUTPUT CONVEYOR SERVICE MANUAL In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical equipment is marked with the following logo: Do not mix with normal domestic waste. Please use the return or collection system dedicated to electrical and electronic waste.

  • Page 13: Conventions Used In This Manual

    OUTPUT CONVEYOR SERVICE MANUAL 2.2 Conventions used in this Manual 2.2.1 Symbols Draws to your attention a particular difficulty associated with this operation, or indicates a potential hazard with it. Indicates a piece of advice, tip or quick technique to assist in ...

  • Page 14: Information For Engineers

    OUTPUT CONVEYOR SERVICE MANUAL 2.3 Information for Engineers 2.3.1 Service Procedures and adjustments Important: As the conveyor is always used in conjunction with a 7202 in- serter, this Information for Engineers relates to the whole machine as well as the conveyor. The procedures described on the following pages are the recommended methods to be employed when removing or replacing various items.

  • Page 15: Potential Hazards

    OUTPUT CONVEYOR SERVICE MANUAL 2.3.4 Potential Hazards Take extreme care if running the machine with the covers open. To run with the covers open, a magnet will be needed to override the safety interlocks. A spare magnet such as fitted to the opening cover (131-824) is most suitable. The inserter is double-pole fused.

  • Page 16: Conveyor Belt Adjustment And Replacement

    OUTPUT CONVEYOR SERVICE MANUAL 2.4 Conveyor belt adjustment and replacement 2.4.1 Belt adjustment Adjustment of the conveyor belt necessitates removal of the conveyor chassis from the casing. The retaining screws are located underneath, as shown in Fig. 1 below. Fig. 1 Remove screws A in 6 positions.

  • Page 17: Belt Replacement

    OUTPUT CONVEYOR SERVICE MANUAL 2.4.2 Belt replacement The conveyor belt should not normally require replacement, but if damaged, or being replaced for any other reason, proceed as follows. With the conveyor chassis inverted, remove the two white rollers shown in Fig. 3. Note the screw position on the adjustable roller prior to removal.

  • Page 18: Belt Realignment

    OUTPUT CONVEYOR SERVICE MANUAL Slip the belt of the chassis, starting at the motor end. Fit the new belt. Reassemble all parts in reverse order. Initially set the adjustment plates so that the tightening screws are approximately halfway along the slot. Tension the belt as described in 2.4.1 step 3.

  • Page 19: Engineer Mode

    OUTPUT CONVEYOR SERVICE MANUAL 2.4.5 Engineer Mode In order to run the conveyor continuously, enter Engineer Mode in the IMOS operating software and select Solenoids tab. Switch Output conv. pulse ON to run the conveyor, and OFF to stop it (see Fig. 8 below). Fig.

  • Page 20: Recommended Spares List (Output Conveyor)

    OUTPUT CONVEYOR SERVICE MANUAL 2.5 Recommended Spares List (Output Conveyor) The Recommended Spares can be obtained by ordering Part Number A0A-A0007437. ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER 179-8780 9107427C MTR 403:1,10 RPM,32+S+L R/L D3857-20125/230 182-8680 9118704Z LOOM CONVEYOR MOTOR LINK 180-8430 9109916V PCB ASSY INF CONVEYOR IF MODIFIED...
  • Page 21 OUTPUT CONVEYOR SERVICE MANUAL Page intentionally left blank Page 2-12 Page Issue 1 February 2017 Output Conveyor Service Manual...
  • Page 22 OUTPUT CONVEYOR SERVICE MANUAL Section 3 Exploded Views Page Issue 1 February 2017 Page 3-1 Output Conveyor Service Manual...

  • Page 23: Conveyor Chassis Part 1

    OUTPUT CONVEYOR SERVICE MANUAL 3.1 Conveyor Chassis Part 1 Page 3-2 Page Issue 2 May 2017 Output Conveyor Service Manual...

  • Page 24: Conveyor Chassis Part 2

    OUTPUT CONVEYOR SERVICE MANUAL 3.1 Conveyor Chassis Part 2 Page Issue 2 May 2017 Page 3-3 Output Conveyor Service Manual...
  • Page 25 OUTPUT CONVEYOR SERVICE MANUAL 3.1 Conveyor Chassis Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER E2826A 9108961A SCREW M4 x 8mm TORX PAN HD B2-2173-A 9112247Y TENSION ROLLER WASHER 169-140 9100466B CLIP RESTRAINT SMALL E5076A 9104136Z CIRCLIP E TYPE 7mm D1500 F4-0300-A 9109984R GEAR 25T 1M 6ID...

  • Page 26: Conveyor Casing

    OUTPUT CONVEYOR SERVICE MANUAL 3.2 Conveyor Casing Page Issue 1 February 2017 Page 3-5 Output Conveyor Service Manual...
  • Page 27 OUTPUT CONVEYOR SERVICE MANUAL 3.2 Conveyor Casing Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER B2G-A0071428 A0071428 DEFLECTOR END COVER E4036A 9104074K WASHER EXT FAN TAIL M4 E2826A 9108961A SCREW M4 x 8mm TORX PAN HD B2G-A0068408 A0068408 ENV CONV OUTER CHASSIS C8078A 9105500V...

  • Page 28: Conveyor Motor Assembly A2A-A0088621

    OUTPUT CONVEYOR SERVICE MANUAL 3.3 Conveyor Motor Assembly A2A-A0088621 Page Issue 1 February 2017 Page 3-7 Output Conveyor Service Manual...
  • Page 29 OUTPUT CONVEYOR SERVICE MANUAL 3.3 Conveyor Motor Assembly Parts List A2A-A0088621 ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER E2565A 9103937S SCREW M5 CSK SKT HDx10 E1078A 9103835L BEARING FL 8x22x7mm F4-0325-A 9112451L GEAR 25T/48T 1M E1061A 9103826B BEARING BALL 8x16x5mm E4033A 9104072H WASHER WAVED W61370 SPEC...

  • Page 30: Deflector A2-1471-A (9112021N) Parts List

    OUTPUT CONVEYOR SERVICE MANUAL 3.4 Deflector A2-1471-A (9112021N) Parts List Page Issue 1 February 2017 Page 3-9 Output Conveyor Service Manual...
  • Page 31 OUTPUT CONVEYOR SERVICE MANUAL 3.4 Deflector A2-1471-A (9112021N) Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER E0-0632-A 9110194K LOBE KNOB BLACK M6x16 B2-2216-G DEFLECTOR SUPPORT G6-0252-A DEFLECTOR SUPPORT SHIM C2-1260-A DEFLECTOR CLAMP SPACER B2-2217-G DEFLECTOR CLAMP E3529A NUT M6 NYLOC ZP E2827A SCREW M4x12 TORX PAN HD E4048A...

  • Page 32: Rollers A2A-A0081622

    OUTPUT CONVEYOR SERVICE MANUAL 3.5 Rollers A2A-A0081622 Page Issue 1 February 2017 Page 3-11 Output Conveyor Service Manual...
  • Page 33 OUTPUT CONVEYOR SERVICE MANUAL 3.5 Rollers A2A-A0081622 Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER B2-2218-G 9118920Z SEAL ROLLER BRACKET DR E4036A 9104074K WASHER EXT FAN TAIL M4 E2829A 9108962B SCREW M4 x 8mm TORX PAN HD TAPTITE C2-1263-A 9119068D PIVOT...

  • Page 34: Conveyor Interface Bracket Assembly A2A-A0088635

    OUTPUT CONVEYOR SERVICE MANUAL 3.6 Conveyor Interface Bracket Assembly A2A-A0088635 Page Issue 1 February 2017 Page 3-13 Output Conveyor Service Manual...
  • Page 35 OUTPUT CONVEYOR SERVICE MANUAL 3.6 Conveyor Interface Bracket Assembly Parts List A2A-A0088635 ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER B2-2210-G 9118914T INTERFACE BRACKET E0384A 9110858B SPACER M4 x 12mm HEXAGON 180-8430 9109916V PCB ASSY INF CONVEYOR IF MODIFIED E2826A 9108961A SCREW M4 x 8mm TORX PAN HD E3504A...
  • Page 36 OUTPUT CONVEYOR SERVICE MANUAL 3.7 A2A-A0071137 Conveyor Drive Roller Assembly Page Issue 1 February 2017 Page 3-15 Output Conveyor Service Manual...
  • Page 37 OUTPUT CONVEYOR SERVICE MANUAL 3.7 A2A-A0071137 Conveyor Drive Roller Assembly Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER E5073A 9104134X CIRCLIP 'E' TYPE 9.5mm D1500 C2A-A0070959 A0070959 SIMPLE BELT GUIDE D1078A 9105520R PAPER DIRECTION ROLLER MOULDED G1106A 9104678P SPRING BOTTLE D0017A 9106107C...
  • Page 38 OUTPUT CONVEYOR SERVICE MANUAL 3.8 A2A-A0071167 Conveyor Driven Roller Assembly Page Issue 1 February 2017 Page 3-17 Output Conveyor Service Manual...
  • Page 39 OUTPUT CONVEYOR SERVICE MANUAL 3.8 A2A-A0071167 Conveyor Driven Roller Assembly Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER E5073A 9104134X CIRCLIP 'E' TYPE 9.5mm D1500 C2A-A0070959 A0070959 SIMPLE BELT GUIDE D1078A 9105520R PAPER DIRECTION ROLLER MOULDED G1106A 9104678P SPRING BOTTLE C4-0588-A 9112118P...

  • Page 40: Output Conveyor Roller Sub-Assemblies

    OUTPUT CONVEYOR SERVICE MANUAL 3.9 Output Conveyor Roller Sub-Assemblies Page Issue 1 February 2017 Page 3-19 Output Conveyor Service Manual...
  • Page 41 OUTPUT CONVEYOR SERVICE MANUAL 3.9 Output Conveyor Roller Sub-Assemblies Parts List ITEM NTL PART SAP PART DESCRIPTION NUMBER NUMBER C2-1259-A 9119064Z CONV ROLLER SLIDE C5-1291-A 9119119G SHAFT CONV ROLLER E2505A 9103894X SCREW M4 SOCKET SETx6 D0A-A0024132 A0024132 CONVEYOR ROLLER MOULDED E5073A 9104134X CIRCLIP 'E' TYPE 9.5mm D1500...
  • Page 42 OUTPUT CONVEYOR SERVICE MANUAL Page intentionally left blank Page Issue 1 February 2017 Page 3-21 Output Conveyor Service Manual...

  • Page 43: Electrical & Wiring Diagram

    OUTPUT CONVEYOR SERVICE MANUAL Electrical & Wiring Diagram 4.1 Location of Electrical Items Page 3-22 Page Issue 1 February 2017 Output Conveyor Service Manual...
  • Page 44 OUTPUT CONVEYOR SERVICE MANUAL 4.1 Location of Electrical Items Parts List OUTPUT CONVEYOR Part No. Description 179-8780 MTR 403:1,10 RPM,32V+S+L R/L D3857-20125/230 182-8680 LOOM CONVEYOR MOTOR LINK 180-8430 PCB ASSY INF CONVEYOR IF MODIFIED 182-8540 LOOM INF CONVEYOR 160-5151 EARTH BRAID M6 x 400 Page Issue 1 February 2017 Page 3-23 Output Conveyor Service Manual...

  • Page 45: Output Conveyor Wiring Diagram

    OUTPUT CONVEYOR SERVICE MANUAL Output Conveyor Wiring Diagram Page 3-24 Page Issue 1 February 2017 Output Conveyor Service Manual...

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