Modular transfer system TLM 1500 - elcom

Modular transfer system

TLM 1500

User manual

&

Maintenance guide

Translation of the original manual, version 02

I02-115 User manual & maintenance guide Version 02 (translation of the original manual) of TLM 1500

Table of contents

1 General information ........................................................................................................................ 0

1.1 Important remarks .................................................................................................................. 1

1.2 Applicable standards ............................................................................................................... 1

1.3 Applications ............................................................................................................................. 1

1.4 Conditions of use ..................................................................................................................... 1

1.5 Safety instructions ................................................................................................................... 2

1.6 Safety instructions regarding the motor ................................................................................. 2

1.7 Additional information ............................................................................................................ 2

2 Technical specifications ................................................................................................................... 3

3 Commissioning ................................................................................................................................ 4

3.1 Receipt ..................................................................................................................................... 4

3.2 Transfer elements ................................................................................................................... 4

3.3 Stopper .................................................................................................................................... 4

3.4 Positioning unit ........................................................................................................................ 4

3.5 Workpiece carrier .................................................................................................................... 5

4 Maintenance ................................................................................................................................... 5

4.1 Belts wear ................................................................................................................................ 5

4.2 Passageways of workpiece carriers ......................................................................................... 5

4.3 Pins .......................................................................................................................................... 5

4.4 Wear of the belt guide ............................................................................................................ 5

4.5 Transfer parts .......................................................................................................................... 6

4.6 Damped pneumatic Stoppers .................................................................................................. 6

4.7 Positioning units with simple and double effect damped pneumatic stoppers ..................... 7

4.8 Positioning units with damped pneumatic stoppers .............................................................. 9

4.9 Positioning units for station with damped pneumatic stoppers ........................................... 11

4.10 Lift positioning units with damped pneumatic stoppers ...................................................... 11

4.11 Other transfer parts .............................................................................................................. 12

5 Motor Replacement ...................................................................................................................... 13

5.1 Disassembly ........................................................................................................................... 13

5.2 Reassembly of the motor ...................................................................................................... 15

5.3 Changing the timing belt ....................................................................................................... 15

6 Responsability ............................................................................................................................... 16

7 Customer service ........................................................................................................................... 16

8 Appendix ........................................................................................................................................ 17

8.1 Maintenance schedule .......................................................................................................... 17

8.2 Quality and environmental commitment: ISO certifications ................................................ 18

I02-115 User manual & maintenance guide Version 02 (translation of the original manual) of TLM 1500

Version tracking:

Version Date Description of modifications Prepared by Approved by

00 01/10/15 Initial (translation) S. GUILLAUD-BATAILLE

01 06/12/16 - S. GUILLAUD-

BATAILLE

-

02 19/09/18 2015 edition of ISO 9001 and 14001

standards: deletion of expired certificates S. MAIRET S. MAIRET

I02-115 User manual & maintenance guide Version 02 (translation of the original manual) of TLM 1500 Page 1 sur 18

1 GENERAL INFORMATION 1.1 Important remarks The following instructions will be used as technical documentation for the manufacturer of the

final machine. elcom is the supplier of this TLM 1500 transfer system sub-assembly .

The manufacturer of the final machine must make sure that:

- All safety equipment is provided and functional, - Regular checks are carried out, - All danger (pinching, squashing) due to moving parts is controlled, - The documentation is complete.

1.2 Applicable standards

According to the 2006/42/CE European directive, elcom transfer systems are considered as partly

completed machines.

They are therefore not subject to an EC declaration of conformity but are the subject of a declaration

of incorporation. The latter is transmitted at the time of delivery, accompanied by the exploded view

of the motorized equipment.

However, the following standards are taken into account during the design and the manufacturing of

the elcom transfer systems:

× The European Machinery Directive 2006/42/CE

× The European Low Voltage Directive73/23/CE

elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.

For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.

1.3 Applications

The elements of the linear TLM 1500 transfer systems are designed to carry and position workpiece

carriers according to the end customers’ configuration.

They are intended to be incorporated the customers' production line.

1.4 Conditions of use

The elements of the TLM 1500 transfer systems are suited for a use in normal industrial areas such as

a final assembly plant or equivalent, in a dry environment.

They are not suited for transporting materials such as sand, balls or grain.

The maximum load applicable on the transfer system is mentioned in the catalog and must never be

ignored.

To ensure a proper functioning of the transfer system on a maximum period of time, you must follow

this advice:

- Use temperature between 0 and 40°C (30 and 140°F)

- Avoid dusty or smoky atmosphere

- Avoid accumulation of sharp objects on the transfer system

- Avoid setting the machine in direct exposition to UV rays


1.5 Safety instructions

Safety rules regarding transfer systems, especially the ones regarding the electrical devices, must be followed during all the use phases: mounting, transport, production. Disregarding these rules would be regarded as a wrong use of the machine.

Using the transfer system in an explosive atmosphere can have a negative impact on the transfer system and is strongly discouraged.

Never perform any maintenance on your own. Another worker must be present at all time in order to shut the power down or perform first aid actions if needed. Changing the motor position or removing security parts must only be done when the

transfer system is unplugged from any power supply.

When carrying maintenance or handling tasks while the transfer system is operating (belt

tension setting), take care not to slide your hand between the belt and the belt support

in order to avoid any accident.

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected in the end-user machine in

order to avoid any risks of pinching or squashing. We recommand to mount a protective

housing around it.

1.6 Safety instructions regarding the motor

In case of a power failure, turn off the transfer system: it could restart automatically when the power comes back which could cause damages and even injuries to the operator.

1.7 Additional information

These instructions aim at ensuring the safety of the people and the proper functioning of the transfer

system. If you wish to use the transfer system in any other conditions, please do not hesitate to

contact us.

Other information is available on our website, in the documentation section:

http://elcom-automation.com/transfers/documentation



2 TECHNICAL SPECIFICATIONS

- Maximum load on a workpiece carrier: 4 kg

- Maximum accumulated load on the transfer system: 35 kg for a maximum 3-meters unit.

- Electrical power supply of the motors: 380V three-phase

- Motor power: V12m/mn = 0.09 Kw (V = belt speed) V16m/mn = 0.09 Kw

Air pressure supply = 5 to 6 bars

Every cylinder must be equipped with a flow limiter.

- Sound emission < 70 dB

- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.


Warning: All load exceedance can lead to a premature wear of the belt or any other

parts.



3 COMMISSIONING

3.1 Receipt

When receiving the transfer system, check if the packaging has not suffered any damage and

that the machine is in perfect conditions.

The transfer system can be supplied in kit. It then needs to be assembled.

3.2 Transfer elements

When handling the equipment and parts, take special care to avoid shocks.

1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,

2. Level perfectly the conveying units while checking that the belts are properly laid on the belt guide,

3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of the line, it may be necessary to perform ground fastenings,

4. Check the settings of the motor magneto-thermic circuit breakers,

5. Check the running direction of the belt without any load,

6. Adjust the cams and the selectors using a workpiece carrier,

7. Start the transfer system with all the workpiece carriers on.

3.3 Stopper

1. Place the stopper right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers,

3. Adjust the flow control units.

3.4 Positioning unit

1. Put the positioning unit right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers, 3. Check on the high position that the pins of the workpiece carrier are free,

4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),

5. Adjust the flow controllers.

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected on the end-user machine

in order to avoid any risk of pinching or squashing. We recommend mounting a

protective housing.


3.5 Workpiece carrier

1. Check that the springs of the pins located under the carrier are working properly.

2. Check that no part goes over the lower surface of the workpiece carrier.

4 MAINTENANCE

General visual check Approximately every 500 hours, check the following points to ensure the proper functioning of the transfer system:

4.1 Belts wear

Regularly verify visually the state of the belt and especially the welding area.

4.2 Passageways of workpiece carriers

The friction of the pins while operating can make some marks appear. Those marks may over the

long term require the part replacement.

4.3 Pins

Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of

efficiency in the guiding of the workpiece carrier occurs.

4.4 Wear of the belt guide

Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.

Wear area of the pins

Belt

Belt guide


4.5 Transfer parts

Every 200 hours:

Remove the dust from the complete unit, using the product:

Ref 800 00 003 (polish plastics Air Industry 2101).

Every 3200 hours:

Check the lubrication of the conical torque.

Apply grease to obtain the initial lubrication state if necessary.

Use the grease reference 800 00 009.

4.6 Damped pneumatic Stoppers

Every 5000 hours:

Clean the stopper depending on the working environment.


4.7 Positioning units with simple and double effect damped pneumatic stoppers

Every 1000 hours:

Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts

Guiding shafts


Changing the pins (locating and centering):

Extract the previous pins from the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support

(insert the pin in the bush and then place the whole on the positioning unit plate).

Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.

Pins

Bush (ref. 110 03 005)


4.8 Positioning units with damped pneumatic stoppers

Every 1000 hours:

Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts:

Guiding shafts


Changing the pins (locating and centering):

Extract the previous pins from the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support

(insert the pin in the bush and then place the whole on the positioning unit plate).


Pins

Bush (ref. 110 03 005)


4.9 Positioning units for station with damped pneumatic stoppers

Every 1000 hours:

Lubricate the positioning unit fingers with a film of grease. Use grease ref. 800 00 002 (Crown ref. 7041 spray).

Check the lubrication of the guiding shafts:

To reach the guiding shafts, remove the central fastening screw from the plate to release it from the positioning unit without removing the positioning unit from the transfer system.

For a quick lubrication of the guiding shafts, it is also possible to access them, without any disassembly, only by pulling the plate. Changing the pins (locating/centering pins):

Extract the previous pins from the press. Install the new pins in the press while using a bush of a workpiece carrier ref. 120 03 006 as a support (insert the pin in the bush and then place them on the positioning unit plate).

4.10 Lift positioning units with damped pneumatic stoppers


Every 1000 hours:

The operating mode remains the same as the standard positioning unit. It is not necessary to disassemble the lift positioning unit from the transfer system for this maintenance. Release the plate to access the guiding shafts and cylinder by removing the fastening screws.


4.11 Other transfer parts

The others parts of the transfer system do not need any maintenance.

A visual check, looking for wear or breaking parts is recommended from time to time.


5 MOTOR REPLACEMENT

5.1 Disassembly

Unscrew the four screws from the plastic cover.

Take the circlip and the washer off.

Circlip

Washer

Screws to

be removed


Remove the motor from the shaft.

Unscrew the anti-rotation screw of the reducer, on the transfer side.

Anti-rotation screw


5.2 Reassembly of the motor

Put the screw back on the new reducer.

Lubricate the shaft with copper grease.

For reassembly, follow the previous steps in

reverse order.

5.3 Changing the timing belt

The new timing belt is delivered already welded.

Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn

one. (Respect the passage way between the pulleys and belt guide).

Covers to be removed


Stretch the belt using the tensioning screw and put the covers back into place.

6 RESPONSABILITY elcom cannot be held responsible for any damages or harms due to non-authorized modification of

any parts, especially the safety parts.

Only original components can be used for maintenance or fixing.

elcom cannot be held responsible for any malfunction if some spare parts have been used without

the validation of elcom.

elcom reserves the right to make improvements and technical modifications without any further

notice.

7 CUSTOMER SERVICE Do not hesitate to contact us for any question or advice. We will be glad to assist you.

Tel: + 33 (0)4 74 43 99 61

E-mail: [email protected]

Adress : 1 rue Isaac Asimov ZAC de la Maladière 38300 Bourgoin-Jallieu

France

Prior to any contact, please note down the serial number of the transfer system. This number can be

found on the transfer system sticker.

Belt passage way Access to the tensioning screw


8 APPENDIX

8.1 Maintenance schedule

Maintenance of the modular transfer system TLM 1500

Frequency Action Component Chapter

200 hours To dust Transfer parts 4.5

500 hours To check Belt - Belt guide – Workpiece carrier 4.1

1000 hours To

lubricate Positioning units (shaft and cylinder) 4.7

3200 hours To

lubricate Conical torque 4.5

5000 hours To clean Stoppers 4.6


8.2 Quality and environmental commitment: ISO certifications

Our company is recognized according to the following ISO standards and their respective evolutions

since our first certification:

- Quality Management through ISO 9001 [since 2002]

- Environmental Management through ISO 14001 [since 2013]

All our current certificates are available for download in French, English and German on our website

http://elcom-automation.com/

http://elcom-automation.com/

Documents

Modular transfer system TLM 1500 - elcom