TGW NBC Flat Belt Manual de instrucciones

1118140rev102213

INSTALLATION,OPERATION,MAINTENANCE

MANUAL

NBC™ Flat Belt

Narrow Belt Conveyor

Accumulation with CRUZcontrol®

& Transportation

NBC™ Flat Belt

1118140rev102213 2

NBC Flat Belt Index

Purpose..................................................................................................................................... 7

TGW Systems Equipment Warranty.......................................................................................... 8

Warnings and Safety Instructions.............................................................................................. 9

NBC Flat Belt Accumulation and Transportation Conveyor..................................................... 13

Concept and Operation......................................................................................................... 14

NBC Application Selection....................................................................................................... 16

When to choose NBC........................................................................................................... 16

Application Notes.................................................................................................................. 16

NBC Technical Applications ................................................................................................. 17

Receiving and Site Preparation............................................................................................... 19

General................................................................................................................................. 19

Preparation of Site................................................................................................................ 20

Parts Inventory and Identification ......................................................................................... 20

General Procedures ................................................................................................................ 21

Dimensional Reference Points ............................................................................................. 21

Squaring Conveyor............................................................................................................... 21

Elevations............................................................................................................................. 22

Component Orientation......................................................................................................... 23

Installation Arrangements........................................................................................................ 24

Floor Supports...................................................................................................................... 24

Anchoring ............................................................................................................................. 24

Knee Braces......................................................................................................................... 25

Ceiling Hangers.................................................................................................................... 26

Anchoring Ceiling Hangers................................................................................................... 28

Connectors........................................................................................................................... 29

Line Straightness.................................................................................................................. 30

Setting Logic Modules............................................................................................................. 31

Installing the NBC Air Transportation Pilot Valve..................................................................... 32

NBC Belts................................................................................................................................ 33

Red Belt................................................................................................................................ 33

Black Belt.............................................................................................................................. 34

NBC QUIKmeld Unit................................................................................................................ 35

PN 1120200Threading Belt in NBC Accumulation Conveyor .................................................. 35

Threading Belt in NBC Transportation Conveyor..................................................................... 41

Belt Tensioning........................................................................................................................ 42

250 lb Drive Tensioning (Spring/Screw Take-up)................................................................. 42

500 lb and 250 lb-AT Drive Tensioning (Air Take-up)........................................................... 44

Wiring (Optional) Proximity Switch in the 500 lb & 250 lb-AT Drive Air Take-up .................. 45

NBC Cross Sections................................................................................................................ 46

Skewing NBC Rollers .............................................................................................................. 47

Factory Skew Charge Section.............................................................................................. 47

Maintenance Skew Section .................................................................................................. 48

Installation Steps for Field Installed Skewed Maintenance Pressure Assemblies ................... 49

2" Roller Centers .................................................................................................................. 49

3" Roller Centers .................................................................................................................. 51

CRUZ®channel to XenoROL®Channel Connections............................................................... 52

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Guardrail Mounting on NBC..................................................................................................... 53

CRUZchannel to C6 Nose Piece............................................................................................. 55

Air Supply Requirements......................................................................................................... 56

General................................................................................................................................. 56

Low Pressure Switch............................................................................................................... 58

Pneumatic Requirements ..................................................................................................... 58

CRUZcontrol®.......................................................................................................................... 59

Definition of Terms .................................................................................................................. 60

CRUZcontrol Concepts............................................................................................................ 61

Basic and Progressive Logic ................................................................................................... 62

Basic Logic.............................................................................................................................. 63

Basic Logic Operation........................................................................................................... 63

Discharge from Basic Logic.................................................................................................. 63

Progressive Logic.................................................................................................................... 64

Progressive Logic Operation ................................................................................................ 64

Discharge from Progressive Logic........................................................................................ 64

Application – CRUZ®logic........................................................................................................ 66

Logic Modules and Release Rates....................................................................................... 66

Application – NBC Releasing Accessories .............................................................................. 68

CRUZcontrol Components....................................................................................................... 71

CRUZcontrol Logic Assembly............................................................................................... 71

Function Modules................................................................................................................. 73

Power Supplies..................................................................................................................... 81

Accessories.......................................................................................................................... 85

CRUZcontrol On Site Installation............................................................................................. 88

Pre-installed on the conveyor............................................................................................... 88

Field Installation.................................................................................................................... 88

Conveyor Flow...................................................................................................................... 89

Overview – TGW CRUZcontrol Logic Module .................................................................... 100

Conveyor Details ................................................................................................................ 100

Photoelectric Sensor........................................................................................................... 101

Standard Logic Module....................................................................................................... 102

Pneumatic Valve................................................................................................................. 108

Adaptor Cable for M12 Connector...................................................................................... 110

Conveyor Power Supply..................................................................................................... 111

Power Supply Technical Data............................................................................................. 114

Part Number Listing............................................................................................................... 115

Maintenance Schedule.......................................................................................................... 116

Daily.................................................................................................................................... 116

Weekly................................................................................................................................ 116

Monthly............................................................................................................................... 116

Semi-Yearly........................................................................................................................ 117

Yearly ................................................................................................................................. 117

Belt Splice Inspection ......................................................................................................... 117

Gearmotors......................................................................................................................... 117

Solenoid Valves.................................................................................................................. 118

Sensing Switches............................................................................................................... 119

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1118140rev102213 4

Parts Identification................................................................................................................. 120

NBC 500 lb Drive Train.......................................................................................................... 121

NBC 250 lb Drive Train.......................................................................................................... 123

NBC 250 lb Manual Take-up and Drive Train........................................................................ 125

NBC Pressure Assembly....................................................................................................... 126

NBC Skewed Pressure Pan Assembly.................................................................................. 127

NBC Discharge Brake Assembly........................................................................................... 129

NBC End Pulley Assembly .................................................................................................... 131

NBC 12 ft Contact Accumulation........................................................................................... 132

NBC Logic Module Component............................................................................................. 133

NBC 12 ft Contact Accumulation Skewed Rollers ................................................................. 134

Appendix................................................................................................................................ 135

Troubleshooting Guide – Mechanical/Electrical.................................................................. 135

NBC Belt Routing Troubleshooting Guidelines................................................................... 137

Mission .................................................................................................................................. 138

Table of Figures

Figure 1: Basic Concept Layout..........................................................................................................61

Figure 2: Logic Assembly Mode & Alignment......................................................................................71

Figure 3: Function Modules.................................................................................................................78

Figure 4: Full Function Module Board Layout......................................................................................79

Figure 5: Full Function Module Circuit.................................................................................................79

Figure 6: Release Function Board Layout...........................................................................................80

Figure 7: Release Function Module Circuit .........................................................................................80

Figure 8: Two Logic Assemblies using a T Cable................................................................................82

Figure 9: Two Separate CRUZcontrol Sections...................................................................................83

Figure 10: One CRUZcontrol Section with Two Power Supplies .........................................................84

Figure 11: Discharge Logic Control.....................................................................................................86

Figure 12: Logic Assembly..................................................................................................................88

Figure 13: Left Hand Flow Conveyor Bed ...........................................................................................89

Figure 14: Right Hand Flow Conveyor Bed.........................................................................................89

Figure 15: Isolated Input Single Release.............................................................................................92

Figure 16: Non-Isolated Input Single Release.....................................................................................92

Figure 17: CRUZcontrol around a curve (low rate)..............................................................................93

Figure 18: CRUZcontrol around a curve. (High rate)...........................................................................95

Figure 19: Function Module Wiring .....................................................................................................95

Figure 20: Work Zone.........................................................................................................................96

Figure 21: Work Zone Using TB1........................................................................................................96

Figure 22: Work Zone Using TB4........................................................................................................96

Figure 23: TGW Conveyor C-Channel..............................................................................................100

Figure 24: Sensor Dimensional Data for 25° Cable Exit....................................................................101

Figure 25: Final TGW Logic Module Mechanical Design...................................................................103

Figure 26: Logic Module Wiring for Overmolded 2x2 Daisy Chain Cables......................................... 105

Figure 27: Basic Accumulation Logic................................................................................................106

Figure 28: Progressive Accumulation Logic......................................................................................107

Figure 29: M12 Sensor Connection Pin-out ......................................................................................108

Figure 30: “T”-Cable Wiring...............................................................................................................110

Figure 31: Power Interrupt Wiring .....................................................................................................111

Figure 32: Logic Interrupt Wiring.......................................................................................................111

NBC™ Flat Belt

1118140rev102213 5

Figure 33: Slug Interrupt Wiring........................................................................................................111

Figure 34: TGW PN 1117432 Dimensional Diagrams........................................................................ 112

Figure 35: TGW PN 1117432 Connection Diagrams.........................................................................112

Figure 36: TGW PN 1117431 Dimensional Diagram..........................................................................113

Figure 37: TGW PN 1117431 Connection Diagram ...........................................................................113

Table of Tables

Table 1: Logic Assemblies Functions..................................................................................................72

Table 2: Logic Assemblies Part Numbers ...........................................................................................72

Table 3: Function Module Types.........................................................................................................73

Table 4: Function Module Functions...................................................................................................73

Table 5: Terminal Block Descriptions..................................................................................................75

Table 6: Jumper Descriptions .............................................................................................................76

Table 7: Function Module Part Numbers.............................................................................................78

Table 8: Maximum Number of Logic Modules per String – 100-240 VAC............................................81

Table 9: Power Supply Part Numbers.................................................................................................84

Table 10: Photoelectric sensor............................................................................................................85

Table 11: Reflector .............................................................................................................................85

Table 12: Sensor Valve Assembly ......................................................................................................85

Table 13: Extension Cables................................................................................................................86

Table 14: Discharge Logic Assembly..................................................................................................87

Table 15: Conveyor Specification .....................................................................................................100

Table 16: Sensor Optical Specification .............................................................................................101

Table 17: Sensor Electrical Specification.......................................................................................... 102

Table 18: Logic Module Mechanical Specification.............................................................................104

Table 19: Logic Module Electrical Specification ................................................................................104

Table 20: Logic Function...................................................................................................................105

Table 21: Pneumatic Valve Specification..........................................................................................108

Table 22: Interconnection Types and Lengths ..................................................................................110

Table 23: Logic Module w/Sensor and 2x2 Daisychain.....................................................................115

Table 24: Accessories w/2x2 Connections........................................................................................115

Table 25: Logic Module w/MHL1 Sensor and M12 Daisychain for CRUZcontrol............................... 115

Table 26: Accessories w/M12 Connections for CRUZcontrol............................................................115

NBC™ Flat Belt

1118140rev102213 6

NBC™ Flat Belt

1118140rev102213 7

Purpose

It is the intent of TGW Systems, through this manual, to provide information that acts as a

guide in the installation, operation and maintenance of TGW Systems NBC Flat Belt

conveyors.

This manual describes basic installation practices, assembly arrangements, preventive

maintenance and assists in replacement parts identification.

This service manual is intended for use by personnel who are knowledgeable of installation

and safe working practices on conveyor systems.

Not all applications and conditions can be covered; therefore, this manual is to be used ONLY

as a guide.

If additional copies of this manual are needed or if you have any question concerning the

conveyor, please contact your Business Partner or TGW Systems Lifetime Services at 231-

798-4547 or Fax 231-798-4549.

NBC™ Flat Belt

1118140rev102213 8

TGW Systems Equipment Warranty

TGW Systems warrants that the material and workmanship entering into its equipment is

merchantable and will be furnished in accordance with the specifications stated.

TGW Systems agrees to furnish the purchaser without charge any part proved defective within

2 years from date of shipment or before the equipment has forty-one hundred (4100) hours of

running use, whichever period is shorter, provided the purchaser gives TGW Systems

immediate notice in writing and examination proves the claim that such materials or parts were

defective when furnished. For drive components specific to XenoROL®(i.e. Xeno belts, slave

Xeno belts, drive spools, standard and speed-up, and spacers), this warranty shall be

extended to five years or ten thousand (10,000) hours of running use, whichever period is

shorter, provided the conveyors are applied, installed and maintained in accordance with TGW

Systems published standards. Other than the above, there are no warranties which extend

beyond the description on the face hereof. Consequential damages of any sort are wholly

excluded.

The liability of TGW Systems will be limited to the replacement cost of any defective part. All

freight and installation costs relative to any warranted part will be at the expense of the

purchaser. Any liability of TGW Systems under the warranties specified above is conditioned

upon the equipment being installed, handled, operated, and maintained in accordance with the

written instructions provided or approved in writing by TGW Systems.

The warranties specified above do not cover, and TGW Systems makes no warranties which

extend to, damage to the equipment due to deterioration or wear occasioned by chemicals,

abrasion, corrosion or erosion; Purchaser's misapplication, abuse, alteration, operation or

maintenance; abnormal conditions of temperature or dirt; or operation of the equipment above

rated capacities or in an otherwise improper manner.

IMPORTANT

All equipment and components not manufactured by TGW Systems carry only such warranty

as given by the manufacturer thereof, which warranty TGW Systems will assign or otherwise

make available to Purchaser without recourse to TGW Systems, provided that such warranty is

assignable or may be made available.

For service on motors, reduction units, electrical components, controls, air or hydraulic

cylinders, contact the local authorized sales and service representative of respective

manufacturer. If none is available in your locality, contact the TGW Systems representative.

TGW Systems will not be responsible for units that have been tampered with or disassembled

by anyone other than the authorized representative of the respective manufacturer.

THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT

LIMITED TO, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE, EXTENDING BEYOND THOSE SET FORTH IN THIS STATEMENT OF

WARRANTY. Rev 08/22/2011

NBC™ Flat Belt

1118140rev102213 9

Warnings and Safety Instructions

Failure to follow the instructions and cautions throughout this book, and warning labels on the

conveyor may result in injury to personnel or damage to the equipment.

Your TGW Systems conveyor is powered by a motor and can be stopped only by turning off

electrical power to the motor. As with all powered machinery, the drive-related components –

including sprockets, chains, shafts, universal joints and pneumatic devices – can be

dangerous. We have installed or provided guards to prevent accidental contact with these

parts, along with warning labels to identify the hazards.

Special attention must be paid to the following areas of this manual:

•Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

•Indicates a situation which, if not avoided, could result in property

damage.

NOTE

This is where you will be notified of helpful information.

WARNING

CAUTION

NBC™ Flat Belt

1118140rev102213 10

•After maintenance, REPLACE guards immediately.

•Keep ALL warning labels clean and clear of any obstructions.

•Never remove, deface or paint over WARNING or CAUTION

labels. Any damaged label will be replaced by TGW Systems

at no cost by contacting Lifetime Services.

•It is very important to instruct personnel in proper conveyor

use including the location and function of all controls.

•Special emphasis must be given to emergency stop

procedures.

•It is important to establish work procedures and access areas

which do not require any part of a person to be under the

conveyor.

•It should be required that long hair is covered by caps or hair

nets.

•Loose clothing, long hair and jewelry must be kept away from

moving equipment.

•Maintain enough clearance on each side of all conveyor units

for safe adjustment and maintenance of all components.

•Provide crossovers or gates at sufficient intervals where

needed to eliminate the temptation for personnel to climb over

or under any conveyor.

•Walking or riding on a moving conveyor must be prohibited.

•Before performing maintenance on the conveyor, make sure

the start-up controls are locked out and cannot be turned on

by any person other than the one performing the maintenance.

•If more than one crew member is working on the conveyor,

EACH CREW MEMBER MUST HAVE A LOCK ON THE

POWER LOCKOUT.

•All pneumatic devices must be de-energized and air removed

to prevent accidental cycling of the device while performing

general maintenance.

•Make sure all personnel are clear of all conveyor equipment

before restarting the system.

WARNING

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