E-Tech Small Piece Feed Conveyor.pdf

Conveyors

In this section you will find:

- Manual

- Belt Tracking

- PM / Inspection

- Skewing Rollers

Innovative Conveyor Systems

MAINTENANCE & SERVICE MANUAL 1

Maintenance and

Service Manual

Automotion, Inc.

11000 S. Lavergne Avenue

Oak Lawn, IL 60453

Phone: 708-229-3700 � Fax: 708-229-3702

PHONE: 708-229-3700 � FAX: 708-229-3702 2

Table of Contents

INTRODUCTION

�� General Information.............................................Intro-1

SAFETY FIRST

�� Mechanical Safety Features .................Intro-2 – Intro-5 �� Electrical Safety Features ....................Intro-5 – Intro-6 �� Safety Procedures for Common Occurrences ..........................Intro-6 – Intro-7

Conveyor Operation .........................................Intro-6 Proper Lockout/Tagout Procedure....................Intro-6 Proper Procedure for Starting a Conveyor........Intro-7 Proper Procedure for Restarting a Conveyor ....Intro-7 Proper Procedure for Clearing Product Jams....Intro-7 Guidelines for Safe Maintenance Procedures ...Intro-7

�� General Safety Tips ..............................................Intro-8

SYSTEM OVERVIEW

�� Sequence of Operation..........................................Intro-9 �� Equipment List......................................................Intro-9 �� Special Drawings...................................................Intro-9 �� Summary of Conveyor Types ............Intro-9 – Intro-11

PREVENTIVE MAINTENANCE

�� Preventive Maintenance Checklist .........PM-1 – PM-12

Entire System......................................................PM-1 Emergency Stops and Other Safety Devices ......PM-2 System Photo-Eyes and Photo-Eye Accumulation (PE) Photo-Eyes .................................................PM-2 Motors and Reducers ..........................................PM-3 Bearings..............................................................PM-3 Drive Chains and Sprockets................................PM-4 Power Transmission Belts ..................................PM-5 Carrying Belts, Flat Drive Belts, Pulleys, and Snubbers.........................................PM-6 V-Belts................................................................PM-7 Carrying Rollers and Wheel Gravity ..................PM-7 Structural ............................................................PM-7 Compressor and Air System ...............................PM-7 AutoSort XII .....................................................PM-11 Pop-Up Wheel Sorter........................................PM-10 Flat Face Arm Sorter .........................................PM-9 Divert Equipment ..............................................PM-8

GRAVITY CONVEYOR

�� Typical Applications ................................................GC-2 �� Basic Design Features ................................ GC-2 – GC-4

Roller Gravity .....................................................GC-2

Gravity Wheel.....................................................GC-3 Ball Transfer Tables............................................GC-3 Gravity Wheel Flow Rail ....................................GC-3 Gravity Slides and Chutes...................................GC-4

�� General Recommended Preventive Maintenance for Gravity Conveyor Components ............................. GC-4

Rollers/Wheels....................................................GC-4 Bearings ..............................................................GC-4 Guard Rail...........................................................GC-4 Ball Transfer Tables............................................GC-4 Chutes and Slides................................................GC-4

�� Recommended Preventive Maintenance for Specific Gravity Conveyor Assemblies ................... GC-5 – GC-9

Gravity Air Brakes..............................................GC-5 Procedure for Adjusting GAB-6 .........................GC-6 Procedure for Adjusting GAB-9 .........................GC-7 Procedure for Adjusting GAB-11 .......................GC-8 Procedure for Adjusting GAB-17 .......................GC-9

BELT CONVEYOR

�� Typical Applications ................................................BC-2 �� Basic Design Features ..............................................BC-2

Slider Bed Belt Conveyor ...................................BC-2 Roller Bed Belt Conveyor...................................BC-2

�� Typical Slider Bed Configurations .........................BC-3 �� General Recommended Preventive Maintenance for

Belt Conveyor Components......................BC-4 – BC-19 Belt Cleaning for Carrying Belt and Drive Belt............................................................BC-4 Using the Belt Take-Up to Properly Tension the Belt................................................... BC-4 – BC-6

Automatic Take-Up...................BC-4 – BC-5 Manual Take-Up................................... BC-6

Belt Tracking ......................................................BC-7 Pre-Tracking Inspection......................................BC-8 How to Steer the Belt ........................... BC-9 – BC-10 Racking or Squaring the Bed to Adjust the Belt Tracking and Product Flow...............................BC-11 Squaring and Cutting the Belt............ BC-11 – BC-12 Lacing the Belt................................... BC-12 – BC-16 Belt Shortening .................................................BC-17 Belt Replacement ..............................................BC-17 Lacing Selection Guide.....................................BC-17 Typical Belt Paths ............................... BC-18– BC-19 Guard Rail.........................................................BC-19

�� Maintaining Drive Units for Belt Conveyor .........................................BC-20 – BC-31

Basic Drive Units..............................................BC-20 Center Drive ....................................... BC-20 Side Mount End Drive ........................ BC-20 Under Mount End Drive ..................... BC-20

Nose Over Units................................. BC-20 – BC-21

I

MAINTENANCE & SERVICE MANUAL 3

Side Mount Nose Over End Drive .......BC-20 Under Mount Nose Over End Drive ....BC-21

Motors and Reducers........................................ BC-21 Bearings............................................................ BC-21 Drive Chains and Sprockets ............................. BC-22 Drive Chain Alignment ......................BC-22 – BC-23 Drive Chain Tensioning .....................BC-24 – BC-25 Power Transmission Belts ................................ BC-25 Power Transmission Belt Alignment................ BC-25 Power Transmission Belt Tensioning............... BC-25 Inspecting the Tension of the Power Transmission Belt...............................BC-26 – BC-28 Adjusting Tension on Power Transmission Belt.................................. BC-28 Tensioning Power Transmission Belt Based on Drive Condition................................................ BC-29 Replacing Power Transmission Belt................. BC-29 Pulleys ................................................BC-30 – BC-31

Live Shaft Terminal Ends ....................BC-30 Dead Shaft Terminal Ends ..................BC-30 Slaved Terminal End Pulley ................BC-30 Lagged Pulley .....................................BC-31

Split Taper Bushings .........................................BC-31 �� Recommended Preventive Maintenance for Specific

Belt Conveyor Assemblies ...................... BC-32 – BC-33 Power Feeder .................................................... BC-32 Nose Over...........................................BC-32 – BC-33 Terminal Ends .................................................. BC-33

LIVE ROLLER CONVEYOR

�� Typical Applications................................................ LR-2 �� Basic Design Features................................. LR-2 – LR-3

Adjustable Pressure Live Roller ..........................LR-2 Transportation Air Live Roller ............................LR-3 Photo-Eye Accumulation Live Roller ................LR-3 Singulation Air Live Roller .................................LR-3 Singulation Air/Slug Release Live Roller ...........LR-3

�� Typical Live Roller Configurations.........................LR-4 �� Typical Belt Path for 8� Wide Drive Belt...............LR-4 �� How Singulation Air Live Roller (SA)/Accumulation

Works ........................................................................LR-5 �� General Recommended Preventive Maintenance for

Live Roller Conveyor Components ......... LR-6 – LR-19 Air Components ..................................... LR-6 – LR-7

Air Brakes .............................................LR-6 Lifter Roller Assemblies ........................LR-7

Sensor Roller Assemblies....................... LR-7 – LR-8 Air Actuated Live Roller Conveyors......LR-8 Adjustable Pressure Live Roller............LR-8

Locating and Replacing Shorted-Out Photo-Eye/Solenoid Modules ..............................LR-8 Carrying Roller Replacement ................. LR-8 – LR-9 Slave Roller Replacement .................................LR-10 Drive Belt Cleaning...........................................LR-10 Using the Belt Take-Up to Properly Tension the Belt................................................LR-10 – LR-12 Automatic Take-Up................LR-10 – LR-11 Manual Take-Up..................................LR-12

Belt Tracking .................................................... LR-12 Pre-Tracking Inspection.................................... LR-13 How to Steer the Belt..........................LR-14 – LR-16 Squaring and Cutting the Belt........................... LR-16 Lacing the Belt....................................LR-16 – LR-18 Belt Shortening ................................................. LR-18 Belt Replacement................................LR-18 – LR-19 Lacing Selection Guide..................................... LR-19 Guard Rail......................................................... LR-19

�� Maintaining Drive Units for Live Roller Conveyor.............................. LR-20 – LR-30

Basic Drive Units.............................................. LR-20 Center Drive ....................................... LR-20 Side Mount End Drive ........................ LR-20

Motors and Reducers ..........................LR-20 – LR-21 Bearings ............................................................ LR-21 Drive Chains and Sprockets.............................. LR-21 Drive Chain Alignment.......................LR-21 – LR-23 Drive Chain Tensioning......................LR-23 – LR-24 Power Transmission Belts ................................ LR-24 Power Transmission Belt Alignment ................ LR-24 Power Transmission Belt Tensioning ............... LR-24 Inspecting the Tension of the Power Transmission Belt ...............................LR-25 – LR-27 Adjusting Tension on Power Transmission Belt ............................................. LR-27 Tensioning Power Transmission Belt Based on Drive Condition ................................................ LR-28 Replacing Power Transmission Belt ................. LR-28 Pulleys ................................................LR-29 – LR-30

Live Shaft Terminal Ends ....................LR-29 Dead Shaft Terminal Ends...................LR-29 Slaved Terminal End Pulley ................LR-29 Lagged Pulley........................LR-29 – LR-30

Split Taper Bushings......................................... LR-30

V-BELT CONVEYOR

�� Typical Applications ................................................VB-2 �� Basic Design Features ..............................................VB-2 �� Typical V-Belt Configurations ................................VB-3 �� General Recommended Preventive Maintenance for

V-Belt Conveyor Components ................. VB-4 – VB-10 Belt and Sheave Cleaning ...................................VB-4 Replacing & Aligning Sheaves...........................VB-4 Inspecting the Tension of the V-Belt...................VB-5 Tensioning the Belt.............................................VB-6

Terminal End Take-Up ......................... VB-6 Quad Take-Up...................................... VB-6

Belt Replacement................................................VB-7 Replacing the Crossover Belt..............................VB-8 Bearings..............................................................VB-8

PHONE: 708-229-3700 � FAX: 708-229-3702 6

TROUBLESHOOTING GUIDE

�� Troubleshooting Motors and Drives ...................................Trouble-2 – Trouble-4 �� Troubleshooting Eagle Pd Power Transmission Belt.............................................Trouble-5 �� Troubleshooting Pulleys ..................................Trouble-6 �� Troubleshooting Snubbers and Rollers .........Trouble-7 �� Troubleshooting System Photo-Eyes ..............Trouble-7 �� Troubleshooting Belt Tracking .....................................Trouble-8 – Trouble-9 �� Troubleshooting Photo-Eye Accumulation (PE) and

Singluation Air (SA) Accumulation Conveyor.........................................................Trouble-10

GLOSSARY

�� Mechanical and Electrical Terms.....Gloss-1 – Gloss-14

SPARE PARTS

�� Shipping Information .......................................... Intro-2 �� Minimum Order ................................................... Intro-2 �� How to Identify Part Numbers for Spare Parts...................................................... Intro-2

Factory ID Tag ...................................Intro-2 Recommended Spare Parts Listed Alphabetically by Product Class Report .......................................Intro-2 Listing of Spare Parts Where Used by Conveyor Report.................................Intro-2 Listing of Spare Parts Where Used by Part Number Report ...........................Intro-2 Electrical Spare Parts Report.............Intro-2

�� How to Order Spare Parts.....................................Intro-3 Tips on How to Accurately Communicate Your Needs..........................................Intro-3 24 Hour Emergency Hotline ...............Intro-3

�� Warranty

�� Spare Parts for Gravity Conveyor.......... GC-2 – GC-18

�� Spare Parts for Belt Conveyor .................BC-2 – BC-38

�� Spare Parts for Live Roller Conveyor.....LR-2 – LR-24

�� Spare Parts for V-Belt Conveyor .............VB-2 – VB-28

�� Spare Parts for Shaft Driven Conveyor ... LS-2 – LS-17

�� Spare Parts for Sortation Conveyor .........SC-2 – SC-26

II

PHONE: 708-229-3700 � FAX: 708-229-3702 Intro-2

Safety First

The importance of adhering to strict safety rules and regulations whenever you are operating, maintaining, or simply walking in the vicinity of your conveyor system cannot be understated. According to American National Standard ASME B20.1b-1995 – Safety Standard for Conveyors and Related Equipment, “accidents resulting from the manual handling of materials have been reduced by the use of conveying and other forms of material handling equipment. A further reduction in the accident rate can be gained by following safe practices in the design, construction, installation, operation, and maintenance of such equipment”.

This “Safety First” section contains a substantial amount of paraphrases and direct excerpts from the American National Standard ASME B20.1b-1995 – Safety Standard for Conveyors and Related Equipment.

Automotion, Inc. goes to great lengths to incorporate safety precautions within the design and construction of our conveyor equipment. Whenever a potential safety problem cannot be eliminated in the design stages of the equipment we are careful to include proper guarding against potential mishaps. Emergency stops, guard rail, netting, chain guards, and warning labels are representative of the types of built-in safety features provided by Automotion, Inc.

All of Automotion, Inc.’s conveyor equipment is designed to meet or exceed industry safety standards as defined by OSHA and in accordance with the above referenced ASME B20.1 Safety Standards for Conveyors and Related Equipment.

Internal Belt Return Automotion, Inc. is the only conveyor manufacturer to enclose all belt returns within the conveyor bed. By doing this we eliminate the potential hazard of loose clothing, hair, or jewelry becoming entangled in the moving belt. We also eliminate any pinch hazards that may occur between the belt and pulleys or between the belt and the return rollers. This feature is standard on all Automotion, Inc. drive belts as well as carrying belts.

Guard Rails Automotion, Inc. manufactures a wide variety of guard rails and guard rail accessories. While most guard rail designs are intended to help “guide” the product along the conveying surface, they also are designed to prevent cartons or other material conveyed overhead from dropping to the floor and causing harm or injury to warehouse personnel.

Guard rail and/or netting should be employed in overhead conveyor applications where there is a reasonable chance of product jamming or where “pop-out” style rollers are used.

Chain Guards

All motors and reducers are equipped with a permanent chain guard. These are only to be removed by qualified technicians during routine maintenance procedures. Refer to the “Proper Lockout/Tagout Procedures” section on page Intro-6 of this manual when the need for routine maintenance arises. Never run the conveyor without the proper guarding in place.

Bottom Covers and Terminal End Covers Bottom covers are designed to cover the bottom of any conveyor that is inclined or elevated to a level that makes the bottom and all of its’ moving parts accessible to warehouse personnel. Likewise, terminal end covers perform the same function by covering the moving parts at the end of a conveyor bed. Properly installed bottom covers and terminal end covers conceal the moving parts of the conveyor and remove potential hazards associated with moving machinery. Do not operate conveyor when bottom covers or terminal end covers are removed.

Guarding by Location or Position When all moving parts of a conveyor are at least 8� (2.44 meters) above the floor or working surface, or otherwise located so personnel cannot inadvertently come in contact with moving parts, it is considered guarded by location or position. Although an overhead conveyor may be guarded by location, spill guards, guard rail, netting or equivalent may be necessary to avoid injury should product fall from the conveyor.

Netting When overhead conveyor is located above a work area occupied by personnel it may be necessary to install netting.

Netting is typically used when guard rail alone may not contain the potential falling hazard.

Mechanical Safety Features

MAINTENANCE & SERVICE MANUAL Intro-3

Spill Guards When overhead conveyor is located above a work area occupied by personnel it may be necessary to install spill guards. Spill guards are typically used when netting may not contain the potential spill. Liquids or products made of glass are prime examples.

Drip Pans All Automotion, Inc. drives are available with optional drip pans designed to catch any oil that may be dripping from the drive unit or reducer. The intent of the drip pan is to prevent any possible slip hazard that may occur by stopping oil from accumulating on the floor and conveyor equipment.

Drip pans should be checked periodically to make sure that any leaks are contained. Consult the “Recommended Preventive Maintenance Schedule” section of this manual for details on maintaining your conveyor drives.

Headroom Clearance Attention to detail during the early design and layout stages can prevent low clearance hazards. When conveyors are installed over an exit passageway, aisle, or corridor there should be a minimum clearance of 6� 8� (2.032 meters) measured vertically from the floor or walking surface to the lowest part of the conveyor. It is permissible, at times, for a conveyor to have less than 6� 8� (2.032 meters) clearance from the floor provided that it is not obstructing an emergency exit and suitable warning labels indicate low headroom clearance.

V-Belt Conveyor Finger Guards

All Automotion, Inc. V-Belt powered conveyors with a 3� or greater roller center include finger guards to prevent finger pinching. The finger guards are located between the carrying rollers, and just above the v-belt on the belt side of the conveyor. The v-belt is located just beneath the carrying rollers on the inside radius of powered curves.

Pop-Out Roller Frames For Live Roller Conveyor, Automotion, Inc. uses a pop-out roller frame whenever possible. This frame is designed to allow rollers to pop out of the frame when pressure is applied from the underside. Thus, if a finger or hand was drawn down into the conveyor it would not be pinched since it would cause the roller to simply pop out of position. In elevations over 60�, the pop-out frame is not utilized because it may pose a hazard if rollers were to pop out and drop to the floor where personnel may be present.

Pop-Out Roller Safety Cable On belt conveyor terminal ends and drive ends where pop-out rollers are present, Automotion, Inc. affixes a safety cable to each end of the roller axle. The safety cable allows the roller to pop-out, but does not allow it to fall to the floor.

Personnel Crossovers Where there is a need for personnel to cross over the top of a conveyor for convenience or safety egress Automotion, Inc. provides durable stairsteps, handrails and step treads between rollers which makes crossing from one side of the conveyor to the other quick, easy and safe.

Safety Warning Labels Safety labels can increase operator and maintenance personnel awareness of the inherent hazards involved in working with conveyors. As part of conveyor users’ comprehensive safety program the users of conveyors must inspect and review safety labels to insure their integrity and maximize their effectiveness in injury prevention.

Automotion, Inc. places safety warning labels on our equipment based on signal words defined in ANSI Z535.4- 1991 designating a degree or level of hazard seriousness.

The signal words for product safety signs are DANGER, WARNING and CAUTION. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Examples of the most commonly used labels along with their purpose and correct position on Automotion, Inc.

equipment are on the next two pages.

All signs are available for re-order by using the Automotion, Inc. Part Number (APN) provided.

To order Automotion, Inc. safety warning labels please contact our customer service department.

Phone: 708-229-3700 Fax: 708-229-3702

Hours:

Monday � Friday

8:00 AM � 5:00 PM

PHONE: 708-229-3700 � FAX: 708-229-3702 Intro-4 b e fo re re m ov in g sev e re in ju ry p a rts can cau se E xp o se d m ov in g

L O C K O U T P O W E R g ua rd

C HR93 000 1

APN 015003

Placed on all removable guards to warn that operation of the machinery with guards removed would expose chains, belts, gears, shafts, pulleys, couplings, etc. which when moving could potentially create hazards.

in ju ry o r d e a th w ill c a u s e s e v e re c o n v e y o r a t a n y tim e w a lk in g o r r id in g o n C lim b in g , s itt in g , K E E P O F F C H R 9 3 0 0 0 4

APN 015001

These are to be placed on 20� centers maximum along conveyors which provide surfaces and profiles attractive, but hazardous, for climbing, sitting, walking or riding.

C H R 9 3 1 0 0 5

K E E P A W A Y s e v e re in ju ry c a n c a u s e M o v in g E q u ip m e n t

APN 015002

To be located on conveyors where there are exposed moving parts which must be unguarded to facilitate function. This includes rollers, pulleys, shafts, chains, etc.

C H S 9 5 0 0 1 7

APN 180558

To be placed on any equipment where two opposing moving parts create a potential shear point. Includes air operated case stops and gravity gates.

APN 015004

Placed on both sides of all drive and terminal ends and also on chain guard covers.

APN 015006

Placed on conveyor after installation to indicate direction of product flow.

MAINTENANCE & SERVICE MANUAL Intro-5

FLOW

APN 015009

To be placed on the side of all Slider Bed and Roller Bed drive units. All center drive units for Slider Bed and Roller Bed conveyor are shipped with the snubber temporarily located within the drive unit. It is to be relocated to final position by installer.

All Automotion, Inc. devices, panels and electrical connections are made in accordance with the National Electric Code (NEC) as published by the National Fire Protection Association (NFPA) and as approved by the American Standards Institute, Inc. Extreme care is given in the design and installation of all field devices. All auto disconnects, fused disconnects, wire sizing, grounding, terminations, etc., are per code.

Emergency Stop Devices Emergency stop devices such as pull cords and “mushroom style” emergency stop buttons are typically designed to stop that portion of the conveyor within sight of the actuating device. For instance, all conveyors in a pick area or any other area where warehouse personnel are present will be equipped with an emergency pull cord. Yanking on the pull cord will stop all conveyors in the area and may activate a warning light. In addition, pushbutton or “mushroom style” buttons are located on the perimeter of conveyor systems where warehouse personnel are present. This enables an observer within eyesight of a potential hazard to activate the emergency stop function. Emergency stop buttons, pull cords, limit switches, or other similar emergency stop devices are supplied in the following situations:

1. Conveyors are remotely or automatically controlled.

2. Operator control stations are not manned or are beyond voice and visual contact range of drive areas, transfer points, loading areas, and other potentially hazardous locations not guarded by position or location.

Emergency stop controls must be located such that in the event the emergency stop is activated the conveyor cannot be restarted remotely, or otherwise, without first resetting the manual reset at the location where the emergency stop was activated.

While the emergency stop function is an excellent safety feature it should never be used to stop equipment in order to perform routine maintenance. Refer to the “Proper Lockout/Tagout Procedures” section on page Intro-6 of this manual when the need for routine maintenance arises.

Control Stations During system development each control station is located to provide optimal visibility of the conveyor it is controlling. Each station is clearly labeled as to the function being controlled. All control stations utilize audible alarms to alert personnel that the conveyor is about to start up. It is recommended, but not required, that a flashing light warning device be used in conjunction with the audible warning device for added effectiveness.

Jam Protection Photo-Eyes In high traffic areas where back-ups or line pressure may occur, Automotion, Inc. provides jam protection photo-eyes designed to sense a build-up of product. If the photo-eye remains blocked for a specified amount of time it will automatically shut down the conveyor in that area to allow adequate time to remove any jams. Minimizing jams mitigates the occurrence of hazard conditions.

Full Length Sorter Photo-Eye (AutoSort and Pop-Up Wheel Sorter Only) The sorter is one of the highest traffic areas on a conveyor system. There should be at least one person in the vicinity while the sorter is running. The full length sorter photo-eye shoots a beam down the entire length of the sorter between the sortation platform and the side of the sorter opposite the diverts. Whenever a hand, arm or head, etc. breach the beam, the sorter will automatically shut down.

Electrical Safety Features

Safety Procedures for Common Occurrences

PHONE: 708-229-3700 � FAX: 708-229-3702 Intro-6

Conveyor Operation

1) Only trained employees shall be permitted to operate conveyors. Training must include instruction in operation under normal conditions and emergency situations

2) For employee safety, all stopping and/or starting devices must be kept free of obstructions to permit ready access.

3) The area around loading and unloading points must be kept clear of obstructions that could endanger personnel.

4) Never ride on the conveyor. Do Not Ride Conveyor warning devices are affixed to the conveyor before it leaves the factory.

5) Personnel working at or near a conveyor must be instructed as to the location and operation of pertinent stopping devices.

6) The conveyor should be used to transport only that material for which it was designed to safely handle.

7) Under no circumstances should safety characteristics of the conveyor be compromised as such alterations would endanger personnel.

8) Routine inspections and preventive and corrective maintenance programs should be conducted to ensure all safety features and devices are maintained and functioning properly.

9) Personnel should be alerted to the potential hazard of entanglement in conveyors caused by items such as long hair, loose clothing, and jewelry.

10) Conveyors must not be maintained or serviced while in operation unless proper maintenance or service, such as belt tracking, requires the conveyor to be in motion. In which case, maintenance personnel shall be made aware of the hazards and how the task may be safely accomplished.

Proper Lockout/Tagout Procedure Lockout or Tagout is the procedure outlining the proper way to shut down and lockout power to mechanical equipment requiring electric current to operate. When performing preventive maintenance on conveyor equipment always follow approved lockout/tagout procedures.

1) Advise all operators and supervisors that power will be shut down on the portion of conveyor requiring maintenance.

2) Shut down power at the motor disconnect switch and affix a lockout/tagout device through the lockout tabs provided on your Automotion, Inc. conveyor equipment. Lockout/tagout safety equipment can be obtained through industrial catalog houses.

3) Attach a lockout/tagout to the padlock or lockout device indicating the date, reason for shut down, and name of serviceman performing the maintenance procedure. If multiple servicemen will be involved then a multiple user lockout tag should be used. Multiple user lockout tags require all participating service personnel to unlock their own locks before power can be restored.

4) Verify that power has been shut off.

5) If a shift change occurs before the maintenance service is completed then the service technicians from each shift should review any lockout devices still in place.

The service technician leaving for the day should remove his lockout device and the service technician taking over should immediately install his own lockout device and tag it accordingly.

6) Only the service technician installing the lockout device should remove the device.

7) Do not remove another service technician’s lockout device.

8) Do not install a lockout device for another service technician.

9) If a lockout device has been installed and cannot be accounted for, consult a supervisor.

Proper Procedure for Starting a Conveyor

1) Before starting a conveyor, conduct a visual inspection of the conveyor to insure that there are no foreign objects resting on or leaning against the conveyor.

2) Alert all personnel that the conveyor and allied equipment is about to be started, that danger persists, and that personnel must keep clear.

3) Make sure all stopping devices are free of obstruction to permit ready access.

4) Make sure all personnel are familiar with the audible alarm that indicates the conveyor is about to start.

5) Actuate the start-up button.

MAINTENANCE & SERVICE MANUAL Intro-7

6) Loading personnel, operators, and supervisors should remain alert and be cautious at all times.

Proper Procedure for Restarting a Conveyor

1) When restarting a conveyor that has been stopped for an emergency, jam removal, or other reason, inspect the conveyor to determine why it was stopped.

2) Turn the motor disconnect switch off and follow the “Proper Lockout/Tagout Procedures” section on page Intro-6 of this manual.

3) Remove the cause of the stoppage.

4) Follow the “Proper Procedure for Starting a Conveyor” section on page Intro-7 of this manual.

Proper Procedure for Clearing Product Jams Occasionally, the inevitable product jam occurs and it becomes necessary to temporarily shut down the conveyor system in order to clear the product jam. Only maintenance employees properly trained to clear a product jam should attempt to clear a jam.

1) Turn the motor disconnect switch off and lockout the conveyor where the jam occurred. Refer to the “Proper Lockout/Tagout Procedure” section on page Intro-6 of this manual.

2) Remove the jam. When the jam cannot be reached from the floor, mezzanine, or catwalk use a shepherd stick or pole to clear the jam. If the jam cannot be reached with a shepherd stick use a ladder, scissors lift, or other such means to reach the jam. Never climb on the conveyor.

3) Remove any damaged product and re-align any undamaged product as required to simulate normal operating conditions prior to the product jam.

4) Advise supervisor of any jams so that the cause of the jam can be determined and, therefore, possibly avoided in the future.

5) Restart the conveyor . Refer to the “Proper Procedure for Restarting a Conveyor” section on page Intro-7 of this manual.

Guidelines for Safe Maintenance Procedures

1) Only qualified and trained personnel shall perform maintenance procedures.

2) It is important a maintenance program be established to ensure all conveyor components are maintained in a condition that does not constitute a hazard to personnel.

3) No maintenance or service shall be performed when a conveyor is in operation except in the following situations:

Lubrication

Conveyors shall not be lubricated while in operation

Adjustment or Maintenance during Operation

When adjustments or maintenance must be done while equipment is in operation, such as belt tracking, only trained and qualified personnel who are aware of the hazard of the conveyor in motion shall be allowed to make adjustments or perform the maintenance or service.

4) When a conveyor is stopped for maintenance purposes, starting devices or powered accessories must be locked out/tagged out. This is in accordance with a formalized procedure designed to protect all personnel against an unexpected start-up. Refer to the “Proper Lockout/Tagout Procedures” section on Intro-6 of this manual.

5) Replace all safety devices and guards before starting equipment for normal operation.

6) Maintain all guards and safety devices in position and in safe repair.

7) Maintain all warning signs in a legible condition and obey all warnings.

PHONE: 708-229-3700 � FAX: 708-229-3702 Intro-8

While this list is comprehensive, it is impossible to be all-inclusive. Great care and awareness must always be given to reduce the risk of injury. If a situation arises that requires immediate response, always refer to the emergency devices within the system. While Automotion, Inc. has made every attempt to provide equipment that is safe by design, safe operating guidelines must be followed. Please remember and practice the following:

1) Do not remove chain guards or otherwise attempt to service conveyor equipment without first shutting off power at the motor disconnect switch located in the vicinity of the conveyor to be maintained and properly locking out the equipment. Refer to the “Proper Lockout/Tagout Procedure” section on page Intro-6 of this manual. Never operate machinery without guarding in place.

2) Never put hands or fingers on or near moving equipment

3) Never climb, walk on, sit on, or ride any part of the conveyor at any time.

4) Do not run on Automotion, Inc. installed stairs or crossovers. Do not skip stairs.

5) Never try to dislodge jammed product while the conveyor system is active. During jam conditions refer to the “Proper Procedure for Clearing Product Jams” section on page Intro-7 of this manual.

6) Do not wear loose clothing or jewelry around conveyor.

7) Long hair must be kept in a hairnet or hat or be otherwise held back to avoid getting tangled in the conveyor.

8) Only authorized maintenance personnel shall be allowed to access or open the control panel.

9) Never attempt to remove stretch wrap, tape, stickers, or any other material from the conveyor when it is running until the conveyor is locked out/tagged out. Refer to the “Proper Lockout/Tagout Procedure” section on page Intro-6 of this manual.

10) Operating personnel should not attempt to repair or correct any mechanical or electrical problems.

Report any potential hazard or repair to maintenance personnel.

11) Be aware at all times where emergency shut off devices are located and how to use them. These devices are not to be used as on-off switches.

12) Walk through designated aisles only. Do not pass between lanes, under conveyor or through uprights.

13) Be alert and stay out of the way of dangers such as low clearances, moving parts, or forklifts.

14) Do not operate equipment while under the influence of intoxicating beverages or illegal drugs.

15) Do not operate equipment if taking prescription medication that causes drowsiness.

16) Check to make sure the conveyor is clear of obstruction before start-up.

17) Check to make sure all personnel are clear of conveyor before start-up.

18) Never run in the vicinity of conveyor.

19) Always wear eye protection when operating or servicing conveyor equipment.

20) Identify potential dangers or maintenance requirements and advise supervisor so appropriate measures can be taken to eliminate them.

21) Never try to override or otherwise go around safety lockout/tagout devices.

22) Only properly trained personnel shall be allowed to operate the conveyor.

23) Do not modify any of the equipment.

Remember, the potential for accidents is always present. Be aware of your surroundings at all times and be careful and alert as you perform your daily work.

General Safety Tips

PREVENTIVE MAINTENANCE SCHEDULE PM-1

Preventive Maintenance

Preventive Maintenance refers to the precautionary measures taken to keep your equipment in desirable condition and to ultimately prevent equipment failure. This section outlines some generic procedures as well as some equipment specific procedures that should be performed to maintain your conveyor system at peak operating efficiencies.

Recommended Preventive Maintenance Schedule The first section is in table format and summarizes some of the very basic types of maintenance that should be performed.

The table references the equipment, required maintenance, and recommended interval between each specified maintenance procedure.

Factors that may affect your schedule are speed, ambient temperature, live load, the age of the equipment, ratio of downtime to active time, and atmospheric contaminants such as oil, dirt, abrasive dust, or humidity.

The second section breaks the conveyor equipment into five basic categories, namely, Gravity Conveyor, Belt Conveyor, Live Roller Conveyor, V-Belt Conveyor, and Sortation Conveyor. Each subsection provides detailed maintenance and repair procedures specific to each conveyor class.

Entire System

Equipment Required Maintenance Recommended Interval Entire System Look & Listen Method:

“Walk the System” while it is running.

� Look for oil, dirt or other contaminants on or around the system.

� Look for rollers that are not turning indicating a worn bearing, or a malfunctioning pressure or lifter roller.

� Look for and remove any cartons, debris, tape or labels from conveying surface and guard rails.

� Look for slipping or improperly tracked belts.

� Look for fraying or other signs of wear on belts such as cracking, tearing, or cuts. When necessary, heat edge of carrying belt with a propane torch to eliminate belt fray.

� Look for and clean any spills.

� Listen for squeaking, squealing, or chirping belts and noisy or grinding motors, reducers, or bearings.

� Listen for rattling noises that may indicate loose nuts and bolts (especially on chain guards and other safety guarding).

� Listen for metal on metal squeals indicating finger guards are rubbing on carrying rollers in V-belt power curve and power junction assemblies.

� Listen for hissing that may indicate an air leak in Transportation Air (TA), Singulation Air (SA), Photo-Eye Accumulation (PE), and Lineshaft (LS).

At the beginning of each day.

PREVENTIVE MAINTENANCE SCHEDULE PM-2

Emergency Stops and Other Safety Devices

Pull Cord and Push Button Emergency Stops and other Safety Devices as outlined in “Safety First” section of this manual.

� Activate each emergency stop pull cord and push button to verify all are working properly.

Replace/repair any that are not functioning as designed.

� Verify all emergency stops are not blocked and are readily accessible.

� Hand flag all personnel sensing photo-eyes (or any other photo-eye) designed to shut down the system in case of a breach in safety to verify they are working properly. Replace any that are not functioning as designed.

� Verify all chain guards, bottom covers, terminal end covers and other covers designed to conceal moving parts are in place and maintained.

� Verify all guardrail, spill guards, netting, and drip pans are in place and maintained.

� Verify all V-Belt finger guards and other pinch point guards are in place and maintained.

� Verify all pop out roller safety cables are in place and maintained.

At the beginning of each day.

System Photo-Eyes and Photo-Eye Accumulation (PE) Photo-Eyes

System photo-eyes � Clean dust and other debris off reflectors.

� Check that photo-eye is aligned with reflector.

1000 hours

Photo-Eye Accumulation (PE) photo-eyes

� Clean dust and other debris off of reflectors.

� Check operational status of photo-eyes – block the sensor with your hand and verify that rollers in zone coast to a stop and restart again when you remove your hand.

PREVENTIVE MAINTENANCE SCHEDULE PM-3

Motors and Reducers

Motors and Reducers

Direct Drive Motors

� Listen for rattling, grinding, or scraping.

� Check mounting bolts. Refer to the “Motors and

Reducers” section of this manual for the type of conveyor in question. Tighten if necessary.

� Check drip pans for excessive oil deposits.

� Check motor temperature. Motors should typically run ambient plus 100� F. Use a handheld infrared thermometer (Part Number APN 180687) to check temp. High operating temperature may indicate low oil, a live load different from system designed live load, or improper ventilation. Improper ventilation of motor can effect cooling capabilities. Keep motors free of contaminant build up such as dirt, oil, product spills, etc. Wipe clean with a damp cloth and mild detergent. Do not get water on the motor or reducer. Do not store materials around motors.

� Depending on the application, your equipment will utilize one or more reducers. As a general guide, inspect the reducer for leakage, accumulation of dirt, and general operating condition. Some models require the oil to be changed, refer to OEM section of this manual.

� Check insulation resistance between motor windings and motor housing. Refer to the “Original Equipment Manufacturer (OEM) Specifications” section of the Appendix to this manual.

� Check torque arm to frame and torque arm to reducer mounting bolts. Tighten if necessary.

In addition, always refer to the manufacturers recommended preventive maintenance included in the “Original Equipment Manufacturer (OEM) Specifications” section of the Appendix to this manual.

Daily

500 hours

50 hours

500 hours

500 hours

PREVENTIVE MAINTENANCE SCHEDULE PM-4

Bearings Equipment Required Maintenance Recommended Interval

Bearings � Listen for grinding or other metal to metal noises that may indicate wear. All bearings are pre-lubricated for the life of the bearing. Replace any bearing assembly that does not turn freely.

� Verify mounting bolts are tight. Refer to the

“Bearings” section of this manual for the type of conveyor in question.

250 hours

Drive Chains and Sprockets

Drive Chains and Sprockets

� Check the tension of the drive chain. Refer to the “Drive Chains and Sprockets” section of this manual for the type of conveyor in question.

� Lubricate the drive train with special foam lubricant

(Part Number APN 180686). Refer to the “Drive Chains and Sprockets” section of this manual for the type of conveyor in question.

� Clean or replace chain when dust, lint, or other air born contaminants are causing wear to the chain or sprockets as evidenced by the presence of black or rust colored powder containing shiny specks or fragments on the inside cover of the chain guard.

Use a wire brush and kerosene. Re-lubricate the chain.

� Check alignment of drive and sprockets. Refer to the “Drive Chains and Sprockets” section of this

� Check for wear in the form of black or rust colored powder containing shiny specks or fragments in the housing. Repair or replace chains or sprockets as required. Refer to the “Drive Chains and Sprockets” section of this manual for the type of conveyor in question.

� Tighten any loose setscrews on sprocket hub. Refer to the “Drive Chains and Sprockets” section of this

PREVENTIVE MAINTENANCE SCHEDULE PM-5

Setscrews Equipment Required Maintenance Recommended Interval

All Conveyor Types:

Bushings, Bearings, sprockets, direct drives

LS Conveyor:

Spools (pinned to shaft), universal joints, drive shaft, idler wheels

� Listen for grinding or other metal to metal noises that may indicate wear.

� Verify setscrews are tight. Refer to the

“Maintaining Drive Units” sections of this manual for the type of conveyor in question.

� When installing setscrews for the first time, tighten to torque settings outlined in the “Maintaining Drive Units” sections of this manual for the type of conveyor in question. Remember to recheck after 24 hours.

Check 24 hours after first time installation. 1000 hours thereafter.

Power Transmission Belts

Power Transmission Belts

� Inspect the tension of the power transmission belt and adjust as necessary. Refer to the “Inspecting the Tension of the Power Transmission Belt” section of this manual for the type of conveyor in question.

� Double check belt tension with a non-contact infrared thermometer (Part Number APN 180687).

If belt is running hotter than 140 degrees the belt tension should be checked.

� Check alignment of sprockets. Refer to the “Drive

� Tighten any loose setscrews. Refer to the “Drive

� Listen for squeaking, squealing or chirping belts. A squeaking or squealing belt is an indication that the belt is not tensioned properly. Refer to the “Inspecting the Tension of the Power Transmission Belt” section of this manual for the type of conveyor in question. A chirping belt is indicative of a dry bearing. Replace bearing when this occurs.

Never apply dressing or oil to a belt to eliminate squeaks or chirping.

� Inspect power transmission belt and sheaves to make sure they are clean of dust, oil, or other airborne contaminants. Clean sheaves and belt with water and mild detergent when contaminants are present. Wipe dry.

PREVENTIVE MAINTENANCE SCHEDULE PM-6

Carrying Belts, Flat Drive Belts, Pulleys and Snubbers

Carrying Belts, Flat Drive Belts, Pulleys and Snubbers

� Look for fraying or other signs of wear on belts such as cracking, tearing, or cuts. When necessary, heat edge of belt with a propane torch to eliminate belt fray.

� Keep belts clean. Use water and a mild detergent to clean belts when spills or other mishaps occur.

� Check that the belt is tracking properly. Belt should not move side to side on the pulley nor should it be too far to one side or the other consistently. Look on top, carrying surface, as well as bottom, or belt return area. Track belts as needed. Refer to page BC-7 of the Belt Conveyor section of this manual.

� Inspect pulleys and keep clean of build up caused by spills, adhesive tape, labels or other contaminants.

� Inspect pulley location on automatic belt take-up device to make sure it is within acceptable range.

Refer to the “Using the Belt Take-Up to Properly Tension the Belt” section of this manual for the type of conveyor in question.

� For manual take-up, check belt tension by looking for slippage around the drive pulleys. Adjust tension as needed with take-up devices. If tension cannot be corrected with take-up devices it may be necessary to shorten the belt. Refer to page BC-4 of the Belt Conveyor section of this manual.

� Check Pulleys to make sure they are perpendicular to conveyor frame. Reposition pulley and tighten set screw as required. Refer to page BC-31 of the Belt Conveyor section of this manual.

� Check for loose, wobbling or missing setscrews on bearing collar.

� Inspect bearing on pulley. Bearings on pulleys are pre-lubricated for life and do not require periodic re-lubrication. Replace any bearing or pulley that does not turn freely.

� Examine belt lacing for wear. Look for separation of the lacing or damage to the lacing pin. Replace or repair as needed. Refer to page BC-12 of the Belt Conveyor section of this manual.

� Check snubbers to make sure they are free turning.

250 hours

500 hours

500 hours

500 hours

PREVENTIVE MAINTENANCE SCHEDULE PM-7

V-Belts

V-Belts � Check belts for signs of wear such as cracking, tearing, or cuts.

� Check V-Belt tension. Refer to page VB-5 of the

V-Belt section of this manual.

� Check to make sure the drive sheave is aligned.

Refer to page VB-4 of the V-Belt section of this

Carrying Rollers and Wheel Gravity

Carrying Rollers and Wheel Gravity

� Keep rollers and wheels clean of any spills, adhesive tape or labels, oil, dirt, abrasive dust, or other atmospheric contaminants. Clean with a mild detergent and wet cloth. Wipe dry. Do not get water in roller bearings.

� Inspect rollers for dents and overall bending.

Replace any damaged rollers.

Structural

Structural � Check leg supports, guard rails, bed sections, and other structural equipment for loose nuts and bolts.

Tighten as needed.

� Check all stair…