TGW NBS Series Manual de instrucciones

Installation, Operation, Maintenance Manual

NBS®, NBS®30, NBS®90

Narrow Belt Sorter

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Contents

Purpose..................................................................................................................................... 3

Equipment Warranty.................................................................................................................. 4

Warnings & Safety Instructions.................................................................................................. 5

Definition of Terms .................................................................................................................... 8

Introduction to Narrow Belt Sortation....................................................................................... 10

NBS Application....................................................................................................................... 11

Receiving & Site Preparation................................................................................................... 13

General Procedures ................................................................................................................ 14

Supporting Arrangements........................................................................................................ 16

Belt Installation........................................................................................................................ 18

Air Supply Requirements......................................................................................................... 20

Air Line Connections ............................................................................................................... 23

Auxiliary Screw Belt Take-up................................................................................................... 25

Electrical.................................................................................................................................. 26

Commissioning of Equipment.................................................................................................. 28

NBS 90 Transfer Roller Adjustment Procedure....................................................................... 29

Preventive Maintenance.......................................................................................................... 30

NBS Maintenance Checklist.................................................................................................... 33

Maintenance Schedule............................................................................................................ 34

Repair Procedures................................................................................................................... 36

Parts Identification................................................................................................................... 39

Parts Identification - NBS 90 Transfer..................................................................................... 40

NBS 90-24 XM Transfer - Replacement Parts......................................................................... 41

NBS 90-30 XM Transfer - Replacement Parts......................................................................... 42

Parts Identification - NBS End Pulley ...................................................................................... 43

NBS End Pulley- Replacement Parts ...................................................................................... 44

Parts Identification - NBS Intermediate Bed ............................................................................ 45

NBS Intermediate Beds - Replacement Parts.......................................................................... 46

Parts Identification - NBS Drive 5′ Bed .................................................................................... 47

NBS Drive 5′ Bed - Replacement Parts................................................................................... 48

Parts Identification - NBS Drive 3′ Bed .................................................................................... 49

NBS Drive 3′ Bed - Replacement Parts................................................................................... 50

Parts Identification - NBS Take-up 5′ Bed ............................................................................... 51

NBS Take-up 5′ Bed - Replacement Parts .............................................................................. 52

Parts Identification - NBS Auxiliary Take-Up ........................................................................... 53

NBS Auxiliary Take-Up - Replacement Parts .......................................................................... 54

Parts Identification - NBS 30 3R Diverter Assembly................................................................ 55

NBS 30 3R Diverter - Replacement Parts................................................................................ 56

Parts Identification - NBS 30 WAVE™ Diverter Assembly....................................................... 57

NBS 30 WAVE™ Diverter Assembly - Replacement Parts...................................................... 58

Parts Identification - NBS 30 WAVE™ Aligner Assembly........................................................ 59

NBS 30 WAVE™ Aligner - Replacement Parts ....................................................................... 60

Parts Identification - NBS 30 12R Aligner Assembly ............................................................... 61

NBS 30 WAVE™ Aligner - Replacement Parts ....................................................................... 62

NBS Encoder Assembly .......................................................................................................... 63

MISSION.................................................................................................................................... 64

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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 NBS sorters including NBS 30, NBS 90 and NBS 90SP.

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 Customer Support at 231-798-4547 or Fax 231-798-4146.

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Equipment Warranty

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

be furnished in accordance with the specifications stated.

TGW 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 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 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 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 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.

The warranties specified above do not cover, and TGW 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.

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

the manufacturer thereof, which warranty TGW will assign or otherwise make available to

Purchaser without recourse to TGW, provided that such warranty is assignable or may be made

available.

IMPORTANT

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 representative. TGW 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 04/08/2009

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Warnings & Safety Instructions

Failure to follow the instructions, warnings, cautions (throughout this booklet) and warning labels (on the

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

Your TGW Systems NBS Narrow Belt Sorter 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 and driven sprockets, chains, and

pneumatically actuated devices present a danger. We have installed or provided guards to prevent inadvertent

contact with these components along with warning labels to identify the hazards. After maintenance, REPLACE

guards immediately. Keep ALL warning labels clean and clear of any obstructions.

Be sure to read and heed all Warnings. Warnings and Cautions are included throughout this manual and are

defined as follows:

Warning ---- A notice which, if not followed, could

result in serious injury to personnel.

Caution ---- A notice which, if not followed, could

result in damage to equipment.

A thorough understanding and compliance with these Warnings and Cautions will greatly reduce the possibility of

personnel injury or equipment damage.

Never remove, deface or paint over any labels. Any damaged label will be replaced by TGW Systems Inc. at no

cost by contacting the Distributor Services Department.

WARNING

Do not perform maintenance on the conveyor until 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 member of a crew is working on the

conveyor, EACH CREW MEMBER MUST HAVE A LOCK ON THE POWER LOCK OUT. The air pressure must

be turned off to the work area. All pneumatic devices must be de-energized to prevent accidental cycling of the

device.

Make sure personnel are clear of all conveyor equipment before restarting the system.

It is very important to instruct personnel in proper conveyor use including the location and function of all controls.

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 and the wearing of loose

clothing or jewelry when working at or near the conveyor be prohibited.

Maintain enough clearance on each side of the unit for safe adjustment and maintenance of components.

Provide crossovers at sufficient intervals to eliminate the temptation to climb over or under any conveyor. Prohibit

riding or walking on conveyor by anyone.

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WARNING

Before servicing or performing any work in the motor control panel, disconnect and lockout the main incoming

service. If only the panel disconnect is off, the incoming side will still be hot.

Warning examples on conveyor frames.

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Definition of Terms

KEY WORD ABBREVATION DESCRIPTION

AIRBAG Inflatable lifting device used in NBS30

BEARING

“BRG”Low friction rotating or sliding device

BELT

“BLT”Flexible load carrying surface or O-ring

BETWEEN-FRAME

“BF”The distance between conveyor side frames

BRACKET

“BRKT”

Attachment between a main and another part

CHANNEL

“CH”Structural side member of conveyor equipment

CONNECTOR

“CONN”Adapts and holds two other parts together

CROSSMEMBER

“XM”Holds channels apart in NBS bed sections

DIVERTER NBS30 module

DRIVE

“DR”Power unit at the discharge end of NBS sorter

ELEVATION

“EL”Top-of belt height above base surface

ENCODER Electrical distaqnce counter used to track package locatio

ENDPULLEY

"E-PULL" 6” diameter roller at charge end of NBS sorter

EXTRUSION Aluminum base that holds UHMW belt strips

FEET PER MINUTE

“FPM”Speed sorter belts are traveling

FILTER / REGULATOR Combination air pressure regulator / air filter

FLOOR STAND

“FS”Name for conveyor bed support

FLOW CONTROL Needle valve used to control airflow

FOOTPAD Part used to distribute load from a jackscrew

GEARMOTOR

"GEARMTR" One piece gear-reducer motor assembly

GUARD RAIL

“GR”Angle or channel used to keep product on NBS

GUARD

“GRD”Any part used to protect area for safety reasons

IDLER Un-driven pulley used as a tensioning device

ITEM NUMBER

“IT #”TGW-ERMANCO part identification number

JOB NUMBER

"C010_ _ _ _ _" Original factory tracking order number

KEY Square locking device used on rotating shafts

KIT Group of several parts with a single item number

LACED

“LCD”The condition of a correctly installed lacing

LACING Type or method of joining belts together (splice)

LIFT FRAME The lifting structure of a NBS90 transfer

LIFT TABLE Assembly that guides the NBS30 wheels upward

LOCKNUT Self-locking fastener that resists vibration

LOCTITE A thread-locking adhesive that resists vibration

LOOSE PARTS

“LP”Individual parts that must be installed in the field

MULTI-BELT

“MBLT”Another name that describes NBS equipment

MODULE

“MOD”A self contained mechanical assembly

MOUNT

“MNT” Part used to hold another, similar to a bracket

MOUNTING

“MTG”Location and fasteners to attach a mount

MOTOR

“MTR”Rotational power source usually using electricity

MUFFLER Device used to reduce the noise of exhausted air

NATIONAL PIPE THREAD

“NPT”Standard identifier for USA tapered pipe sizes

PHOTOEYE

“PE”Optical sensing device used for product control

PLATE

“PL”Flat piece of metal usually bolted on for strength

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KEY WORD ABBREVATION DESCRIPTION

PROGRAMMABLE Self-contained programmable control unit that

LOGIC CONTROLLER

“PLC” Can control several input and output devices

O-RING Polyurethane cord belts of differing lengths

PULLEY

Roller described by diameter and body length

REDUCER

“RED” A C-face motor mount right-angle worm gearbox

REFLECTOR Target used to reflect a light back to a photo eye

REGULATOR

“REG” Air device that reduces pressure to usable level

RETAINER

Part used to mechanically lock a part in place

ROLLER Described by axle size and BF dimension

ROLLER CHAIN

“RC” Roller link chain used for power transmission

SCANNER A device that recognizes products by bar codes

SCHEMATIC Line drawing of a electrical or pneumatic circuit

SCREW A threaded fastener also called a bolt

SEAL Sealing device on a rotating shaft or cylinder rod

SMART DISTRIBUTED The name for a proprietary software / hardware

SYSTEM

“SDS” Network control system marketed by Honeywell Inc.

SHAFT Round steel rod described by diameter and length

SHEAVE A grooved disc that guides a V-belt or O-ring

SHIM Thin piece of metal, used to fill up a space

SKATEWHEEL

“SW” 2” diameter X 5/8” wide X ¼” axle hole roller

SMILEY

“J” (See standhead)

SOCKET

“SOC” Hex shaped hole in an Allen screw

SOLENOID

“SOL” An electrically operated multi-position air valve

SPACER Thick washer or tube that a fastener passes thru

SPLICE Area where similar materials are joined together

SPRING

“SPR” Coiled wire device used for un-powered return

SPROCKET

“SPKT” Wheel with shaped teeth that engage roller chain

SPUR Transition bed between a diverter and exit lane

STANDHEAD Pivoting bracket that attaches support to the bed

STARTER

Electrical relay that energizes the drive motor

TAG Number that identifies unit in system lay-out

TAKEUP Assembly used to remove slack from a belt / belts

TEE A part with three connections locations

TENSIONER A pneumatic, spring, or static take-up device

THREADED FULL LENGTH

“TFL” Adjusting bolt used in take-up/tracking applications

TRANSFER

“TRNS” NBS90 and NBS-SP module

ULTRA HIGH Industry standard term for the hard milky white

MOLECULAR WEIGHT

“UHMW” polyethylene used in wear strip applications

VALVE An air shut-off or switching device

VENT Small hole in gearbox to allow hot air expansion

WEARSTRIP Low-friction material used to reduce rubbing wear

WELDMENT

“WLDMT” Any part that requires welding in its manufacture

VFD Variable Frequency Drive for motor speed control

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Introduction to Narrow Belt Sortation

CONCEPT

The TGW Systems NBS Narrow Belt Sorter technology was developed to provide an economic alternative to

existing sortation devices, as well as providing sorting options that were not easily available. This technology is

similar to sorters that use wide flat load carrying belts and pop-up wheels to divert product but has eliminated

many of the high cost / maintenance features associated with these sorters. Limitations on availability of bi-

directional diverts, long divert lane center-line distances, as well as the high costs associated with the skilled labor

required to install these wide belt units have been addressed with this new technology.

FEATURES AND BENEFITS

Features and benefits common to the NBS 30, NBS 90, and NBS 90SP technology include:

•Product is continuously carried on multiple narrow belts for smooth bump-free conveying and excellent

tracking accuracy

•Narrow belts slide on low friction UHMW guides, resulting in reduced noise and virtually eliminating tracking

problems

•Multiple narrow belts are progressively guided through the sorter to minimize belt tracking issues

•Narrow belts run flat and straight through NBS modules without snubbing or back-wrapping resulting in

reduced horsepower requirements

•Simple user-friendly design allows ease of installation and maintenance

•Compact modular design of modules allows closer divert/transfer lane center distances

•Modularity and universal mounting of modules allows easy repositioning or reconfiguration in the field

•Gravity take-aways or spurs may be used in many applications to lower initial costs

•NBS technology costs less than conventional full width belt sorters in material as well as installation costs

NBS 30 AND NBS 30 WAVE™

•Simple 30 degree diverter design means less

maintenance and higher uptime

•Diverters use proven true vertical lift for reliability,

consistency and low cost

•High friction, diverter wheels with precision bearings

for positive quiet sorting

NBS 90 AND NBS 90SP

•Separate drive within the transfer module allows

a space saving single or bidirectional unit

•Coated rollers allow positive product acceleration

and transfer rate

•Pickup of product "on the fly" allows maximized

sort rate

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