OPERATING INSTRUCTIONS BASIC CONVEYOR - … Instructions BTB-K and BTB-M basic conveyor 4 1.5. Induction motor safety instructions In the event of a power failure, shut off the device;

OPERATING INSTRUCTIONS

BASIC CONVEYOR

BTB-K (End Drive) BTB-M (Center Drive)

BA-100105 English, Edition 04/2010

Operating Instructions BTB-K and BTB-M basic conveyor

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Table of Contents

1. Important Information ___________________________________________________________ 3 1.1. Manufacturer’s Declaration _________________________________________________________3 1.2. Product description and use ________________________________________________________3 1.3. Factors reducing useful life _________________________________________________________3 1.4. Safety instructions _________________________________________________________________3 1.5. Induction motor safety instructions __________________________________________________4 1.6. Additional information _____________________________________________________________4 1.7. Validity of the operating instructions_________________________________________________4 1.8. Technical data_____________________________________________________________________5

2. Dimensional Drawing ____________________________________________________________ 7 2.1. Dimensional drawing BTB-K basic conveyor, single-belt, end drive_______________________7 2.2. Dimensional drawing BTB-K basic conveyor, dual-belt, end drive ________________________8 2.3. Dimensional drawing BTB-M basic conveyor, single-belt, center drive____________________9 2.4. Dimensional drawing BTB-M basic conveyor, dual-belt, center drive ___________________ 10

3. Commissioning _________________________________________________________________ 11 3.1. Mechanical setup ________________________________________________________________ 11 3.2. Installation note _________________________________________________________________ 12 3.3. Pivoting the end drive unit________________________________________________________ 13 3.4. Moving the drive unit on the chassis center drive____________________________________ 14 3.5. Electrical connection _____________________________________________________________ 14 3.6. Induction motor _________________________________________________________________ 15 3.7. Frequency converter _____________________________________________________________ 16 3.8. Direction of travel of the conveyor belt_____________________________________________ 26 3.9. Setting the required pretension of the conveyor belt ________________________________ 27 3.10. Tracking the conveyor belt _______________________________________________________ 28 3.11. Conveyor belt technical data______________________________________________________ 30 3.12. Replacing endless belts, end drive _________________________________________________ 30 3.13. Replacing endless belts, center drive_______________________________________________ 30 3.14. Replacing belts by “welding” their ends____________________________________________ 30

4. Maintenance ___________________________________________________________________ 31 4.1. Repairs _________________________________________________________________________ 31


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4.2. Replacing the drive roller, end drive _______________________________________________ 32 4.3. Replacing the drive roller, center drive _____________________________________________ 33 4.4. Replacing the gear motor, end drive _______________________________________________ 34 4.5. Replacing the gear motor, center drive_____________________________________________ 35

5. Exploded Drawings/Parts Lists __________________________________________________ 36 5.1. BTB-K/BTBD-K with end drive_____________________________________________________ 36 5.1.1. Parts list BTB-K/BTBD-K with end drive ____________________________________________ 36 5.2. BTB/BTBD with center drive unit __________________________________________________ 38 5.2.1. Spare parts list BTB/BTBD with center drive unit ____________________________________ 38 5.3. BTBD-K conveyor end with diverter roller, single-belt, end drive ______________________ 39 5.3.1. Spare parts list BTBD-K conveyor end with diverter roller, single-belt, end drive ________ 39 5.4. BTBD-K conveyor end with diverter rollers, dual-belt, end drive _______________________ 40 5.4.1. Spare parts list BTBD-K conveyor end with diverter roller, dual-belt, end drive__________ 40 5.5. BTB conveyor end with diverter roller, single-belt, center drive _______________________ 41 5.5.1. Spare parts list BTB conveyor end with diverter roller, single-belt, center drive _________ 41 5.6. BTBD conveyor end with diverter rollers, dual-belt, center drive_______________________ 42 5.6.1. Spare parts list BTBD conveyor end with diverter rollers, dual-belt, center drive ________ 42 5.7. BTB drive unit, end drive, single-belt_______________________________________________ 43 5.7.1. Spare parts list, end drive unit, single-belt__________________________________________ 44 5.8. BTB drive unit, end drive, dual-belt ________________________________________________ 45 5.8.1. Spare parts list, end drive unit, dual-belt ___________________________________________ 46 5.9. BTB drive unit, center drive, single-belt ____________________________________________ 47 5.9.1. Spare parts list, center drive unit, single-belt _______________________________________ 48 5.10. BTBD center drive unit, dual-belt __________________________________________________ 49 5.10.1. Spare parts list, center drive unit, dual-belt _________________________________________ 50 5.11. BTB accessories _________________________________________________________________ 51 5.11.1. Parts list accessories _____________________________________________________________ 51

6. Environmental Compatibility and Disposal ________________________________________ 52


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1. Important Information

As component kits, conveyors are not subject to an EU Declaration of Conformity (pursuant to MRL Appendix II A)

EU Declaration of Conformity (pursuant to MRL Appendix II)

1.1. Manufacturer’s Declaration

Regulations and standards taken into account: Machinery Directive 89/392/EEC, 91/368/EEC, Low Voltage Directive 73/23/EEC EMC Directive: Generic Emission Standard EN 50081-2:1993, Immunity

Requirements EN 61000-6-2 Induction motor UL1004, UL2111, CSA C22.2Nr.100, CSA C22.2Nr.77, EN 60950 Manufacturer: Montech AG, Gewerbestrasse 12 CH–4552 Derendingen Tel. +41 32 681 55 00, Fax +41 32 682 19 77

1.2. Product description and use

Conveyors are designed for transporting solid objects that are not below a certain minimum size. They are not suitable for transporting materials such as sand, granules, chips, etc. The product-specific ratings listed on the nameplate must never be exceeded.

1.3. Factors reducing useful life

Direct light from UV lamps Queuing when carrying sharp-edged objects. Operation in air containing smoke, dust, water vapor, or solvents.

1.4. Safety instructions

The safety instructions, in particular those relating to electrical connections, shall be followed in all phases of commissioning, operation and during maintenance and service work. Failure to follow these instructions is considered a misuse of the conveyor and its components. Operating a conveyor in an explosive atmosphere (flammable gases, vapors, or dust) can result in their combustion and shall be avoided. Never perform service or setting work on your own. In all cases, there must be a second person present who can shut off the main power and administer first aid, if necessary. Moving the electromechanical drive unit on the chassis, as well as removing the mechanical safety guards may ONLY be performed when the conveyor is disconnected from the main power supply.


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1.5. Induction motor safety instructions

In the event of a power failure, shut off the device; otherwise, the motor might start up suddenly when power is restored, which may result in personal injuries and damage. When the overheating (thermal) protection is triggered, always turn off the power supply, as the motor will restart immediately as soon as the overheating protection resets automatically.

The motor surface can reach 70 °C during operation. The motor must not be touched until its temperature has fallen below 40 °C. (Measured surface temperature)

1.6. Additional information

These operating instructions are designed to ensure the safe and proper operation of the conveyor. If information for your intended use is missing, please contact the manufacturer. Additional information, e.g. on mounting the lateral guides, etc., can be found in the Assembly Instructions under BTB. These documents are available from our home page, www.montech.com. Nameplate

Montech AG Senior Management Urs D. Wagner / Gianluca Aloisi

1.7. Validity of the operating instructions

We continually adapt our products to the state-of-the-art and new findings from practical applications. Consequently, the operating instructions will be updated to match the product modifications. Each operating instruction has an item number, e.g., BA-100103. The edition number is on the cover.


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1.8. Technical data

Ambient temperature +10 to +40°C

Relative humidity 5% – 85% (without condensation forming)

Air purity level normal shop air

Sound pressure level < 55 dBA

Drive unit protection class IP40

Motor

Type Induction AC motor

Operating voltage 200 to 230 VAC

Frequency 50 to 60 Hz

Rated current 0.21 to 0.23 A

Rated output 25 W

Rated torque 0.16 to 0.25 Nm

RPM range 1200 to 1600 rpm

Permissible temperatures Max. 70°C (on housing)

Gearbox

Type Spur-wheel

Gear ratios i=1:3, i=1:5, i=1:9, i=1:25, i=1:180

Output torque 0.46 Nm to 8.0 Nm

Output rpm 8.3 to 500 rpm

Conveyor speed 0.8 m/min., 6 m/min., 16 m/min., 30 m/min., 50 m/min.

Permissible temperatures Max. 55°C (on housing)

Lubrication Lifetime lubrication

Service life 10,000 operating hours

Connection

Terminal box Terminal box material: plastic

Cable diameters to be used 6~12

Wire to be used AWG24~12 (0.2~4,0 mm2 )


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The following information can be found on the nameplate, which is located on the drive unit:

Conveyor type

Belt type

Belt width [mm]

Belt length [mm]

Operating Instructions

Order no.

Speed [m/min.]

Pretension [%]

Max. load [N]

Lead angle [°]


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2. Dimensional Drawing

2.1. Dimensional drawing BTB-K basic conveyor, single-belt, end drive

Dimensional drawing with drive on right (also available with drive on left) The standard is front drive; rear drive should only be used if really necessary

Type BTB-45 BTB-60 BTB-80 BTB-105 BTB-140 BTB-185 BTB-250

A [mm] chassis 45 60 80 105 140 185 250

B [mm] conveyor width 0-23 0-38 8-58 33-83 68-118 113-163 178-228

C [mm] sliding plate 24 39 59 84 119 164 229

X [mm] belt width 15 30 50 75 90 135 200

L [mm] total length min. 300 / max. 5 m – conveyors over 5 m upon request


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2.2. Dimensional drawing BTB-K basic conveyor, dual-belt, end drive

Dimensional drawing with drive on right (also available with drive on left) The standard is front drive; rear drive should only be used if really necessary

Type BTBD-105 BTBD-140 BTBD-185 BTBD-250

A [mm] chassis 105 140 185 250

B [mm] conveyor width 55-83 90-118 135-163 200-228

C [mm] sliding plate 84 119 164 229

D [mm] conveyor spacing 23 58 103 168


Rear drive Drive type Front drive


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2.3. Dimensional drawing BTB-M basic conveyor, single-belt, center drive

Type BTB-45 BTB-60 BTB-80 BTB-105 BTB-140 BTB-185 BTB-250

A [mm] chassis 45 60 80 105 140 185 250

B [mm] conveyor width 0-23 0-38 8-58 33-83 68-118 113-163 178-228

C [mm] sliding plate 24 39 59 84 119 164 229

X [mm] belt width 15 30 50 75 90 135 200


Left Direction of transport Right


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2.4. Dimensional drawing BTB-M basic conveyor, dual-belt, center drive

Type BTBD-105 BTBD-140 BTBD-185 BTBD-250

A [mm] chassis 105 140 185 250

B [mm] conveyor width 55-83 90-118 135-163 200-228

C [mm] sliding plate 84 119 164 229

D [mm] conveyor spacing 23 58 103 168


Left Direction of transport Right


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3. Commissioning

3.1. Mechanical setup

The conveyors are shipped in units of up to 3 m length. If the total length of a conveyor exceeds the maximum transportation length of 3 m, assemble the components according to the following schematic. Chassis length (total, in mm) L ≤ 3000 Lateral guide

Chassis

3000< L ≤ 6000 Lateral guide Chassis



Svar variable length of lateral guides, min. = 500 mm, max. = 2000 mm Cvar variable chassis length, Cvar max. = 3000 - 60, or 3000 - (2x60) mm D Disassembly point for transport (tab connection) Secure the tab connections marked “D” prior to startup. The conveyor must be supported at these locations.

The drive unit should be mounted as close to the discharge end of the conveyor as possible. Applications where the drive unit has to be positioned on the infeed side, e.g. because of a lack of space and especially where high loads occur during queuing, should be referred to Montech for evaluation.


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3.2. Installation note

If using a sliding plate (10/20), we recommend connecting the chassis (10/10) and the sliding plate (10/20) with double-sided adhesive tape (10/30). Clean and degrease the surfaces of the sliding plate and chassis before using adhesive. Care should be taken to distribute the adhesive tape(s) evenly on the chassis. We recommend: Double-sided adhesive tape, 25 mm x 55 m (item no. 506333) BTB-60 1 x adhesive tape 25 mm wide BTB-80 2 x adhesive tape 25 mm wide BTB-105 2 x adhesive tape 25 mm wide BTB-140 3 x adhesive tape 25 mm wide BTB-185 3 x adhesive tape 25 mm wide BTB-250 4 x adhesive tape 25 mm wide


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3.3. Pivoting the end drive unit

The drive unit can be pivoted 270°, allowing it to be optimized to the available space. If the drive unit is top-mounted with the position of the terminal box according to illustration, the max. permissible height of the product transported is 70 mm.

Procedure:

Turn off the motor. Loosen the locking screw (170) Pivot the drive unit into the desired position Tighten the locking screw (170)

Adjusting the toothed belt pretension:

After securing the drive unit in its final position, readjust the toothed belt tension.

Procedure:

Remove the cover plate (70) by removing countersunk screw (80). Loosen the four fastening screws (190) of the gear motor. Tighten the toothed belt by pulling the gear motor (50) by hand. Tighten the four fastening screws (190) of the gear motor. Reinstall the cover (70).


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3.4. Moving the drive unit on the chassis center drive

Procedure: Stop the conveyor Loosen the four fastening screws (110). Move the drive unit in the desired position and tighten the four fastening screws (110). Should the belt no longer run centered on the diverter rollers, it should be aligned as explained in section “Tracking the conveyor belt.”

3.5. Electrical connection

General safety instructions

The operator of the conveyor shall have the electrical connection, the commissioning, the set-up and the servicing carried out by qualified persons. Work on the electrical parts is particularly dangerous. Never disconnect the electrical connections when the device is energized (hot). In unfavorable cases, resulting arcs may injure people or damage contacts.


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3.6. Induction motor

Cable diameter to be used: 6 ~ 12 mm Feed wire to be used: AWG24 ~12 (0.2 ~ 4.0 mm²)

Wiring schematics 3-phase 220/230 VAC, cw

The direction of rotation (cw, clockwise) given in the wiring schematic is the direction of rotation as seen from the motor shaft end. When using a motor with a connected gearbox, the direction of rotation of the gear shaft can be the same as or opposite to the direction of rotation of the motor shaft. To change the direction of rotation, reverse any two connections between R, S and T. Note: Stop the motor before changing its direction of rotation. If the direction of rotation is changed while the motor is running, the motor might ignore the reversal command or execute it with a delay.

Wiring schematics single-phase 220/230 VAC with capacitor, cw

Instructions for connecting a capacitor: With the motor running, apply a voltage to the terminals of the capacitor that is almost twice the supply voltage of the motor. For safety reasons, the terminals should be isolated. Use the capacitor cap to isolate the terminals. Note: Using capacitors > 3µF may result in overheating at the motor and gearbox housings. For permissible temperatures see section “Technical data.”

Wiring schematics single-phase 220/230 VAC with capacitor, ccw

Note: Stop the motor before changing its direction of rotation. If the direction of rotation is changed while the motor is running, the motor might ignore the reversal command or execute it with a delay.

L

N

red

white

black

Capacitor 3µF

red

white

Capacitor 3µF

black N

L

white

black

red

L2 (S)

L3 (T)

L1 (R)


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3.7. Frequency converter

FE 200 frequency converter technical data

Maximum output For motors up to 200 W

Rated output voltage 3-phase 200 VAC (depends on the supply voltage)

Rated output current 1.4 A

Rated voltage 1-phase 200-240 VAC ±10%

Rated frequency 50/60 Hz ±10%

Control system Sinusoidal PWM (V/f control)

RPM adjustment range 6.6~80 Hz (200~2400 rpm)

Acceleration/braking time 0.1~30 s (at 80 Hz)

RPM adjusting method Potentiometer of the converter/DC input (0~10 VDC)

Voltage/frequency characteristic 5 selectable levels, depending on the motor output

Input signals Optocoupler input: resistance 3.3kOhm

Powered by an internal +15V power supply

RUN/STOP, FWD/REV, Alarm reset

Output signals Open Collector Output: 26.4 VDC, max. 10 mA

Operating output, alarm output

Setpoint rpm display The motor’s setpoint rpm is shown as different from the actual rpm of the motor shaft.

Switching of carrier frequency Switches the creeping current of the cable connecting converter and motor (default setting: 15 kHz)

Changing of NPN/PNP logic Select the “sink logic” input (0V, shared) or the PNP logic input (24V, shared)

Changing the rpm display The setpoint rpm shown on the display can be changed to display the rpm based on the gear reduction. A total of 96 ratios can be set using the two rotary switches (default: i= 1:1).

Protection class IP 10

Connection cable to motor 4 conductors: UL 3266, AWG14x4, max. diam. 10 mm, max. length 20 m


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Protective functions of the converter If one of the protective functions is active, the motor will be stopped by a safety device.

Overcurrent protection The output current of the converter has exceeded approx. 200% of the rated output current.

Overheating protection The internal temperature of the converter has exceeded the permissible value.

Overvoltage protection The internal voltage of the converter has exceeded the permissible value.

Circuit fault An error has occurred in the integrated CPU of the converter, etc.

Overload protection For about 1 minute, the output current of the converter remained at approx. 150% of its rated output current.

Ground fault protection A ground contact occurred at the converter’s output side, causing ground current to flow.

Setting error The switch for output selection or gear reduction was set to a value outside of the setting range.

Motor overheating The motor’s integrated thermal protection device was triggered, or a phase is protection missing in the wiring between motor and converter.


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Name and function of the converter parts

Converter front panel POWER-LED will be green if the device is powered. RPM display shows the setpoint frequency, setpoint rpm or alarm code, if the alarm is activated. Speed potentiometer for setting the motor rpm

LED indicator for setpoint frequency will be orange if the frequency is displayed. LED indicator for setpoint rpm will be orange if the rpm is displayed. RUN/STAND-BY switch for running/stopping the motor

Front panel removed

Motor output selector switch for setting the output Switch for setting the gear reduction. The setpoint rpm shown on the display can be changed to display the rpm based on the gear reduction.

Switch for reversing the motor’s direction of rotation Acceleration time potentiometer for setting the motor acceleration time Braking time potentiometer for setting the motor braking time

Note: The rpm shown on the rpm display is the setpoint value, not the actual rpm of the motor output shaft.


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Name and function of the converter parts

Backside of the converter

TB 1: Main circuit terminals Protective ground terminal Protective ground terminal

TB 2: Input signal terminals TB 3: Output signal terminals SW1: DIP switch

Note: At the time of delivery, DL1 and DL2 will be connected by a short-circuit bridge.

Main circuit terminals TB1 I/O signal terminals TB2, TB3 U motor connection terminal V motor connection terminal W motor connection terminal DL1 Inductance coil terminal DL2 Inductance coil terminal NC ----- L1 Power supply terminal L1 Power supply terminal

X0 RUN/STOP X1 FWD/REV X2 Alarm reset X3 External rpm setting input C0 SG (shared) Y0 Run C1 Shared Y1 Alarm C2 Shared

Main circuit terminals TB1 S1 switches between remote/direct input

(RUN/STOP) ON: operation via ext. E-signal OFF: operation via RUN/STAND-BY

S2 switches between remote/direct input (direction of rotation)

ON: operation via ext. E-signal OFF: operation via rotary switch

S3 switches between PNP/NPN logic ON: PNP input OFF: NPN input

S4 switches the carrier frequency ON: 10 kHz OFF: 15 kHz

S5 switches the display Set rpm/frequency

ON: displays rpm OFF: displays frequency (Hz)

Note: Default settings: S1, S2, S4 and S5 are set to OFF; S3 is set to ON.


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Frequency converter operation

Prior to operation Set the motor output switch according to the motor combination. If the wrong output is set, the device can overheat or generate insufficient torque. Controls on the converter front panel If the RUN/STAND-BY switch is set to RUN, the motor will start running. If it is set to STAND-BY, the motor will stop. To set the direction of rotation, remove the front panel and set the switch for direction of rotation to FWD (clockwise) or reverse (counterclockwise). Operation via external input signals The DIP switch settings are located on the backside of the converter. S1 (ON): Motor runs or stops via external input. S2 (ON): Direction of rotation changes via external input. Once the DIP switch settings have been changed, the motor can be started and stopped using the RUN/STOP signal. The direction of rotation can be controlled via the FWD/REV signal. RPM settings Changing the rpm via speed potentiometer. If the motor is driven by external DC voltage, the speed potentiometer on the converter must remain at the minimum setting. Setting the acceleration/braking time Upon starting, the motor will accelerate according to the acceleration time set. When stopping, the motor will brake according to the brake time set. The acceleration and brake time can be set within a range from 0.1 to 30 seconds. ACCEL: Acceleration time potentiometer DECEL: Braking time potentiometer Switching the display mode While the motor is running, the setpoint rpm will be shown as a frequency (Hz). Using the DIP switch on the backside of the converter, the display can be set to the setpoint rpm. DIP switch settings S5 (OFF): displays frequency (Hz) S5 (ON) : displays setpoint rpm

The drive unit must be correctly connected according to the following illustrations. Connection errors may damage the control unit or the motor!


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Frequency converter installation

Installation When installing FE200 inverters in an enclosed space, maintain a minimum distance of 30 mm horizontally and 100 mm vertically. Dimensional Drawing Section

Wiring diagram This wiring diagram is an example for single-phase 200-240 VAC specifications. *1 If the ground resistance exceeds

0.1 Ω , the motor should be grounded directly.

*2 Remove the short-circuit bridge if connecting a DC inductance coil.

*3 Input signals X0, X1 and X2 will apply if the converter is connected to a source transistor (0 V, shared) via a mechanical contact or via a sequence connection.

*4 The I/O signal terminals correspond to the SELV circuit and are isolated from dangerous voltages by means of reinforced isolation.

ALARM

Circuit breaker

RUN/STOP

FWD/REV

SG (shared)

LIVE

NEUTRAL

Operating output

Alarm output

Short-circuit bridge

Motor


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Frequency converter installation

Cable lugs to be used

Main power supply terminal (M3.5) Ring terminal with isolation

Protective ground terminal (M4) Ring terminal with isolation

I/O terminals

If a cable lug is used for connections, the terminals shown below shall be used. Cable lugs differ according to the wire gauge. If using the terminals shown below, a wire gauge of AWG20~18 is recommended. Manufacturer: Phoenix Contact

AI0.5-6 Recommended wire gauge AWG20 (0.5 mm²) AI0.75-6 Recommended wire gauge AWG18 (0.75 mm²)

Connect the converter and the motor using a suitable connection cable. Connection cable: 4 conductors, UL 3266, AWG14 x 4, max. diam. 10mm, max. length 20 m. The length of the I/O signal cables must not exceed 10 m. The cables must be separated from the power cables. If the rpm is set externally, use a twisted, shielded wire, a shielded cable or similar. Do not use the ground cable together with a welder or another power generator. When using several converters, make sure that the cables do not get tangled.


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Process diagram

clockwise

(FWD) Motor operation

counterclockwise (REV)

Operation at RUN/STAND-BY front panel of converter FWD/REV

RPM setting (frequency setting)

X0_C0 ON (RUN/STOP) OFF

Input signal X1_C0 ON (FWD/REV) OFF

S1: remote/local DIP switch (RUN/STOP) S2: remote/local (FWD/REV)

Output signal Y0_C1 ON (operating output) OFF

______ Speed potentiometer on the converter front panel - – - – - - External rpm setting with external DC-voltage

The DIP switch setting will only be accepted if the motor is stopped. If a DIP switch setting is changed while the motor is running, the new setting will only be accepted after the motor has been stopped. If an external DC power supply is connected to the converter, depending on the priority, the rpm from terminal X3 (external rpm setting signal) or from the speed potentiometer on the converter front panel will be set. To change the direction of rotation, stop the motor and enter the reversal signal. Immediate changes to the direction of rotation during motor operation may cause damage to the gearbox or motor due to impact loads. The motor’s direction of rotation is as seen from the motor’s shaft end. (FWD: clockwise, REV: counterclockwise). Due to the gear reduction of the gearbox, the direction of rotation of the gearbox shaft may differ from that of the motor shaft.


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Input signal circuit

PNP-LOGIC

Note: If using a serial connection with a source transistor, an external +15 to 24 VDC power supply will be needed. NPN-LOGIC

Connecting an external DC power supply

Input circuit

RUN/STOP

FWD/REV

Alarm reset

SG (shared)

SG (shared)

Analog frequency command

FWD/REV

Alarm reset

Input circuit

SG (shared)

RUN/STOP


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Analog signal circuit

Output circuit

External control device with integrated clamping diode

Example of an NPN logic

If an external control device with integrated clamping diode is used and power is supplied to the converter, a current flow might result that will start the motor even if it is disconnected from the power supply through the external control device. Since power supply capacities differ, the motor may also run when these are turned on/off at the same time. Turn on the converter’s power supply before turning on the external control device.

Clamping diode

External control device Converter

Output circuitOperating output

Alarm output

COM


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3.8. Direction of travel of the conveyor belt

The direction of travel of the belt must be kept if the belt ends have been joined by a welded overlap joint (Thermofix). Welded joint, overlap (Thermofix)

Position of the belt welding spot (Thermofix) Longitudinal view Horizontal view For zigzag connections (Flexproof) or welded butt joints (Quickmelt), the direction of travel is not significant. Welded connections Flexproof and Quickmelt Flexproof Quickmelt


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3.9. Setting the required pretension of the conveyor belt

The correct pretension for a conveyor belt is shown on the nameplate attached to the drive unit. For example: 1.2% After the belt has been mounted, attach two measuring marks (M) to the top of the belt in the untensioned state in such a way that they have a spacing (L) of e.g. 500 or 1000 mm. When the two tensioning screws (590) are uniformly tightened (see section “Tracking the conveyor belt”), the two measuring marks (M) will move apart up to a dimension (L) which corresponds to the required pretension “V.” Example: Example for calculating the belt pretension

)(VL

LL necloose

loosetaut %∗+=100

%.VandmmLWhen necloose 21100 ==

mm%.%mm

mmL taut 101221100

10001000 =∗+=


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3.10. Tracking the conveyor belt

The belt must always run centered over the diverter rollers and the drive roller. Under no circumstances must the edges of the belt project over the ends of the rollers. Correct the position of the belt running over the diverter rollers by tightening or backing out the hex screws (590) while the belt is running. Tracking over the drive roller is usually guaranteed. Should the belt not be tracking properly over the drive roller, slightly move the drive tabs (40).


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The correction of the belt position on the drive roller of the center drive can only be checked after removing the guard plate (210).

Procedure:

Stop the conveyor. Remove the guard plate (210) by unscrewing the two countersunk screws (230). Start the conveyor with direction of travel right. Check the distance “e” on both sides of the drive unit and – if necessary – adjust with one of the screws (590)

until the distances are equal. If the belt is running more than 2 mm out of center on the drive roller, it needs to be corrected. Stop the conveyor. Start the conveyor with direction of travel left. Set the belt run with the adjustment screw (580). Stop the conveyor. Replace the guard plate (210) and tighten the countersunk screws (230).

Direction of travel

Left

Right


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3.11. Conveyor belt technical data

The pertinent data can be found on the nameplate attached to the drive unit and must be used when ordering replacement belts.

3.12. Replacing endless belts, end drive

Installing endless belts is recommended if the conveyor is easily accessible. Procedure: (see section: Replacing the drive roller, end drive) Stop the conveyor and shut off the power. Loosen the conveyor belt by alternately backing out the two screws (590). Remove the belt by extending it on the drive side over the tab (40). Install a new belt by first placing the belt in the tensioning device and then pulling it over the tab (40). Pre-tension the belt as described in section “Setting the required pretension of the belt.” Track the belt as described in section “Tracking the conveyor belt.”

3.13. Replacing endless belts, center drive

Installing endless belts is recommended if the conveyor is easily accessible. Procedure: (see section: Replacing the Drive Roller, Center Drive) Stop the conveyor and shut off the power. Remove the guard plate (210) by unscrewing the two countersunk screws (230). Loosen the conveyor belt by alternately backing out the two screws (590). Remove the four countersunk screws (110) to remove the side cover (20) on the back. Caution: Catch the

washers (80) that are between cover (40) and side cover (20). Remove the tensioning roller (180), diverter roller (170) and the two countershafts (160). Remove the four fastening screws and lock washers (220) from cover (40). Lightly tap on the cover (40) with a rubber mallet to remove it. Replace the belt. Reassemble the drive unit in the reverse order. Pre-tension the belt as described in section “Setting the required pretension of the belt.” Track the belt as described in section “Tracking the conveyor belt.”

3.14. Replacing belts by “welding” their ends

Pulling in new belts and “welding” their ends is the preferred method of belt replacement where access is too limited to perform the steps described in the previous chapter. Belt “welding” equipment is required for this method of belt assembly. Exact instructions for the “welding operation” can be obtained when ordering the new belts.

Procedure:

Switch off motor and disconnect from power supply.


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Loosen the conveyor belt by alternately backing out the two screws (590). Cut the defective belt and join one end of the old belt with one end of the new belt (for example with

adhesive tape). Make sure the beveled belt ends are positioned correctly for the direction of travel (see section “Direction of travel of the conveyor belt"). Absolutely protect the beveled belt ends from contamination.

Pulling out the old belt will automatically pull in the new one. “Weld” the new belt according to the manufacturer’s instructions. Pre-tension the belt as described in section “Setting the required pretension of the belt.” Track the belt as described in section “Tracking the conveyor belt.”

4. Maintenance

Conveyors are maintenance-free when they are used in accordance with their intended purpose and are not exposed to any factors that shorten their service life. The intended purpose and the factors shortening their service life are listed in the Declaration of Conformity. When the belts are exposed to dust, oily air, foreign matter such as metal chips from machine tools, etc., we recommend cleaning them regularly, e.g. once a week, with benzene.

4.1. Repairs

The operating instructions contain the necessary spare parts lists and exploded drawings for repairs to the conveyor’s mechanical parts. The safety instructions must also be followed. Repairs to the electrical part may be performed by the supplier only. It is essential to follow the safety instructions when disconnecting components from the power supply or from the motor and when reinstalling them.


32

4.2. Replacing the drive roller, end drive

Procedure:

Stop the conveyor and shut off the power. Loosen the conveyor belt by alternately backing out the two screws (590). Remove the cover (20) by unscrewing countersunk screw (200). Slacken and remove the toothed belt (140) by loosening the fastening screws (210) of the gear motor. Loosen the setscrew (350) and remove the tooth lock washer (130) from the drive shaft (50). Remove the tab (40) simply by unscrewing the two fastening screws (230). Replace the drive roller (50) with the self-aligning ball bearings installed. Reassemble the drive unit in the reverse order.

Install the Belleville spring washer (160) correctly. The spring washer must not touch the inner race of the self-aligning ball bearing. Pulling on the gear motor by hand should sufficiently tension the toothed belt.


33

4.3. Replacing the drive roller, center drive

Procedure:

Stop the conveyor and shut off the power. Remove the guard plate (210) by unscrewing the two countersunk screws (230). Loosen the conveyor belt by alternately backing out the two screws (590). Remove the four countersunk screws (110) to remove the side cover (20) on the back. Caution: Catch the

washers (80) between cover (40) and side cover (20). Remove the four fastening screws and lock washers (220) from cover (40). Lightly tap on the cover (40) with a rubber mallet to remove it. Replace the drive roller (190) with self-aligning ball bearings installed. Reassemble the drive unit in the reverse order.

When replacing the complete drive roller (190), make sure to use one of the following greases for connection of the gearbox output shaft/bore with keyway of the drive roller: Molykote G-Rapid plus or OKS 2200


34

4.4. Replacing the gear motor, end drive

Procedure:

Stop the conveyor and shut off the power. Remove the cover plate (20) by unscrewing countersunk screw (200). Slacken and remove the toothed belt (140) by loosening the fastening screws (210) of the gear motor. Remove the gear motor by removing the four fastening screws (210). Loosen the setscrew (350) and remove the tooth lock washer (130) from the gear motor shaft (330). Remove the motor flange (150) by removing the four fastening screws (250). Using a rubber mallet, carefully tap the key (160) until it comes off the output shaft. Replace the gear motor (330). Reassemble the drive unit in the reverse order.

When installing the toothed belt, make sure that both tooth lock washers (130) are aligned. Pulling on the gear motor by hand should sufficiently tension the toothed belt.


35

4.5. Replacing the gear motor, center drive

Procedure:

Stop the conveyor and shut off the power. Remove the gear motor by removing the four fastening screws (250). Using a rubber mallet, carefully tap the key (160) until it comes off the output shaft. Replace the gear motor (330). Reassemble the drive unit in the reverse order.

To avoid burn risks, do not touch the gear motor immediately after shutting it off, as the motor surface can reach 70 °C during normal operation.


36

5. Exploded Drawings/Parts Lists

5.1. BTB-K/BTBD-K with end drive

5.1.1. Parts list BTB-K/BTBD-K with end drive

Item

Name Item no.

BTB-45K BTB-60K BTB-80K BTB-/ BTBD-105K

BTB-/ BTBD-140K

BTB-/ BTBD-185K

BTB-/ BTBD-250K

10 Chassis, aluminum 48396/…. 23584/…. 23583/…. 26330/…. 21476/…. 26331/…. 37435/….

10 Chassis for sliding plate, aluminum

- 58652/…. 58653/…. 58787/…. 58788/…. 58789/…. 58790/….

Sliding plate, stainless steel

- 58791/ 0039/….

58791/ 0059/….

58791/ 0084/….

58791/ 0119/….

58791/ 0164/….

58791/ 0229/….

20 Conveyor end with diverter roller , single-belt

57972 57973 57974 54874 57975 58700 58701

20 BKE conveyor end with diverter roller, dual-belt

- - - 54882 57989 58702 58703

30 BTB-KR drive unit, single-belt

60146 60147 60148 60149 60150 60151 60152

30 BTB-KL drive unit, single-belt

60153 60154 60155 60156 60157 60185 60159

30 BTBD-KR drive unit, dual-belt

- - - 60388 60389 60390 60391

30 BTBD-KL drive unit, dual-belt

- - - 60392 60393 60394 60395


37

Item

Name Item no.

BTB-45K BTB-60K BTB-80K BTB-/ BTBD-105K

BTB-/ BTBD-140K

BTB-/ BTBD-185K

BTB-/ BTBD-250K

40 Induction motor 520772 520772 520772 520772 520772 520772 520772

50 Gear ratio i=1:3 520773 520773 520773 520773 520773 520773 520773

50 Gear ratio i=1:5 520774 520774 520774 520774 520774 520774 520774

50 Gear ratio i=1:9 520775 520775 520775 520775 520775 520775 520775

50 Gear ratio i=1:25 520776 520776 520776 520776 520776 520776 520776

50 Gear ratio i=1:180 520777 520777 520777 520777 520777 520777 520777


38

5.2. BTB/BTBD with center drive unit

5.2.1. Spare parts list BTB/BTBD with center drive unit

Item Name Item no.

BTB-45 BTB-60 BTB-80 BTB/ BTBD-105

BTB/ BTBD-140

BTB/ BTBD-185

BTB/ BTBD-250

10 Chassis, aluminum 48396/…. 23584/…. 23583/…. 26330/…. 21476/…. 26331/…. 37435/….

10 Chassis for sliding plate, aluminum

- 58652/…. 58653/…. 58787/…. 58788/…. 58789/…. 58790/….

Sliding plate, stainless steel

- 58791/ 0039/….

58791/ 0059/….

58791/ 0084/….

58791/ 0119/….

58791/ 0164/….

58791/ 0229/….

20 Conveyor end with diverter roller, single-belt

56987 56988 56989 56990 56991 56992 56993

20 Conveyor end with diverter roller, dual-belt

- - - 56994 56995 56996 56997

30 Drive unit, single-belt 60160 60161 60162 60163 60164 60165 60166

30 Drive unit, dual-belt - - - 60396 60397 60398 60399

40 Induction motor 520772 520772 520772 520772 520772 520772 520772

50 Gear ratio i=1:3 520773 520773 520773 520773 520773 520773 520773

50 Gear ratio i=1:5 520774 520774 520774 520774 520774 520774 520774

50 Gear ratio i=1:9 520775 520775 520775 520775 520775 520775 520775

50 Gear ratio i=1:25 520776 520776 520776 520776 520776 520776 520776

50 Gear ratio i=1:180 520777 520777 520777 520777 520777 520777 520777


39

5.3. BTBD-K conveyor end with diverter roller, single-belt, end drive

5.3.1. Spare parts list BTBD-K conveyor end with diverter roller, single-belt, end drive

Item

Sym.

Name Item no. Mat.

BTB-45K

BTB-60K

BTB-80K

BTB-105K

BTB-140K

BTB-185K

BTB-250K

Conveyor end with diverter roller, single-belt, complete

57972 57973 57974 54874 57975 58700 58701 Var.

10 ◊ Conveyor end 48535 48126 48536 48537 48130 50989 50985 Al

20 ◊ Pressure piece 48127 48127 48127 48127 48127 48127 48127 Steel

30 Diverter roller, complete 48527 48488 48528 48529 48530 50990 50987 Var.

40 ◊ Conveyor-conveyor elem., complete

36546 36546 36546 36546 36546 36546 36546 Steel

These are wear parts and available ex stock. ◊ Not available ex stock individually (upon request) Price list item available ex stock


40

5.4. BTBD-K conveyor end with diverter rollers, dual-belt, end drive

5.4.1. Spare parts list BTBD-K conveyor end with diverter roller, dual-belt, end drive

Item Sym. Name Item no. Mat

KTBD-105K KTBD-140K KTBD-185K KTBD-250K

Conveyor end with diverter roller, dual-belt, complete

54882 57989 58702 58703 Var.

10 ◊ Conveyor end 48537 48130 50989 50985 Al

20 ◊ Pressure piece 48127 48127 48127 48127 Steel

30 Diverter roller, complete 54316 54317 58716 58717 Var.


36546 36546 36546 36546

Steel



41

5.5. BTB conveyor end with diverter roller, single-belt, center drive

5.5.1. Spare parts list BTB conveyor end with diverter roller, single-belt, center drive

Item Sym. Name Item no. Mat.

BTB-45 BTB-60 BTB-80 BTB-105 BTB-140 BTB-185 BTB-250

Conveyor end with diverter roller, single-belt, complete

56987 56988 56989 56990 56991 56992 56993 Var.

10 ◊ Conveyor end 56921 56920 56919 56918 56917 56916 56915 Al



36546 36546 36546 36546 36546 36546

36546 Steel



42

5.6. BTBD conveyor end with diverter rollers, dual-belt, center drive

3

5.6.1. Spare parts list BTBD conveyor end with diverter rollers, dual-belt, center drive


BTBD-105 BTBD-140 BTBD-185 BTBD-250

Conveyor end with diverter roller, dual-belt

56994 56995 56996 56997 Var.

10 ◊ Conveyor end 56918 56917 56916 56915 Al



36546 36546 36546 36546 Steel



43

5.7. BTB drive unit, end drive, single-belt


44

5.7.1. Spare parts list, end drive unit, single-belt

Item

Sym. Name Item no. Mat.

KTB-45KR/KL

KTB-60KR/KL

KTB-80KR/KL

KTB-105KR/KL

KTB-140 KR/KL

KTB-185 KR/KL

KTB-250KR/KL

Drive unit, end drive right (KR), single-belt, complete

60146 60147 60148 60149 60150 60151 60152 Var.

Drive unit, end drive left (KL), single-belt, complete

60153 60154 60155 60156 60157 60185 60159 Var.

10 ◊ Tab, drive right, complete (KR) 48458 48458 48458 48458 48458 48458 48458 Var.

10 ◊ Tab, drive left, complete (KL) 48459 48459 48459 48459 48459 48459 48459 Var.

20 ◊ Tab, simple left (KR) 48161 48161 48161 48161 48161 48161 48161 Al

20 ◊ Tab, simple right (KL) 48468 48468 48468 48468 48468 48468 48468 Al

30 ◊ T-nut 21913 21913 21913 21913 21913 21913 21913 Steel

40 ◊ Cheese head screws M6x12 504644 504644 504644 504644 504644 504644 504644 Steel

50 ◊ Ribbed washer M6 505255 505255 505255 505255 505255 505255 505255 Steel

60 ◊ Side piece 48153 48153 48153 48153 48153 48153 48153 Al

70 ◊ Cover plate 48157 48157 48157 48157 48157 48157 48157 Al

80 ◊ Countersunk screw M4x25 506370 506370 506370 506370 506370 506370 506370 Steel

90 ◊ Setscrew M3x6 506368 506368 506368 506368 506368 506368 506368 Steel

100 ◊ Dowel pin, diam. 6x20 508116 508116 508116 508116 508116 508116 508116 Steel

110 ◊ Motor flange 60144 60144 60144 60144 60144 60144 60144 Al

120 Tooth lock washer, gearbox 48106 48106 48106 48106 48106 48106 48106 Al

130 Tooth lock washer, drive 48109 48109 48109 48109 48109 48109 48109 Al

140 Toothed belt 506367 506367 506367 506367 506367 506367 506367 PUR

150 ◊ Spline 3x3x16 506714 506714 506714 506714 506714 506714 506714 Steel

160 ◊ Spring washer OD/ID 29.7/17.3x1.55

506369 506369 506369 506369 506369 506369 506369 Steel

170 ◊ Clip, complete 48469 48469 48469 48469 48469 48469 48469 Steel

180 ◊ Spline 60085 60085 60085 60085 60085 60085 60085 Steel

190 ◊ Cheese head screws M4x16 505328 505328 505328 505328 505328 505328 505328 Steel

200 ◊ Lock washer M4 504382 504382 504382 504382 504382 504382 504382 Steel

210 ◊ Washer M4 506097 506097 506097 506097 506097 506097 506097 Steel

220 Drive roller, complete 48531 48479 48532 48533 48534 50988 50984 Var.



45

5.8. BTB drive unit, end drive, dual-belt


46

5.8.1. Spare parts list, end drive unit, dual-belt


KTBD-105KR/KL

KTBD-140KR/KL

KTBD-185 KR/KL

KTBD-250 KR/KL

Drive unit, end drive right (KR) dual-belt, complete

60388 60389 60390 60391 Var.

Drive unit, end drive left (KL) dual-belt, complete

60392 60393 60394 60395 Var.

10 ◊ Tab, drive right, complete (KR) 48458 48458 48458 48458 Var.

10 ◊ Tab, drive left, complete (KL) 48459 48459 48459 48459 Var.

20 ◊ Tab, simple left. (KR) 48161 48161 48161 48161 Al

20 ◊ Tab, simple right. (KL) 48468 48468 48468 48468 Al

30 ◊ T-nut 21913 21913 21913 21913 Steel

40 ◊ Cheese head screws M6x12 504644 504644 504644 504644 Steel

50 ◊ Ribbed washer M6 505255 505255 505255 505255 Steel

60 ◊ Side piece 48153 48153 48153 48153 Al

70 ◊ Cover plate 48157 48157 48157 48157 Al

80 ◊ Countersunk screw M4x25 506370 506370 506370 506370 Steel

90 ◊ Setscrew M3x6 506368 506368 506368 506368 Steel

100 ◊ Dowel pin, diam. 6x20 508116 508116 508116 508116 Steel

110 ◊ Motor flange 60144 60144 60144 60144 Al

120 Tooth lock washer, gearbox 48106 48106 48106 48106 Al

130 Tooth lock washer, drive 48109 48109 48109 48109 Al

140 Toothed belt 506367 506367 506367 506367 PUR

150 ◊ Spline 3x3x16 506714 506714 506714 506714 Steel

160 ◊ Spring washer OD/ID 29.7/17.3x1.55

506369 506369 506369 506369 Steel

170 ◊ Clip, complete 48469 48469 48469 48469 Steel

180 ◊ Spline 60085 60085 60085 60085 Steel


200 ◊ Lock washer M4 504382 504382 504382 504382 Steel

210 ◊ Washer M4 506097 506097 506097 506097 Steel

220 Drive roller, complete 55305 55306 57012 57013 Var.



47

5.9. BTB drive unit, center drive, single-belt


48

5.9.1. Spare parts list, center drive unit, single-belt


BTB-45 BTB-60 BTB-80 BTB-105 BTB-140 BTB-185 BTB-250

Drive unit, center drive, single-belt, complete

60160 60161 60162 60163 60164 60165 60166 Var.

10 ◊ Drive side panel 54962 54962 54962 54962 54962 54962 54962 Steel

20 ◊ Side cover, backside 47986 47986 47986 47986 47986 47986 47986 Steel

30 ◊ Bearing ring 48665 48665 48665 48665 48665 48665 48665 Al

40 ◊ Cover 48664 48664 48664 48664 48664 48664 48664 Al

50 ◊ Motor flange 60003 60003 60003 60003 60003 60003 60003 Al

80 ◊ Washer M6 504388 504388 504388 504388 504388 504388 504388 Steel

90 ◊ Countersunk screw M6x16

504566 504566 504566 504566 504566 504566 504566

Steel

100 ◊ T-nut 47629 47629 47629 47629 47629 47629 47629 Steel


504372 504372 504372 504372 504372 504372 504372

Steel

120 ◊ Setscrew washer M6 504380 504380 504380 504380 504380 504380 504380 Steel


506395 506395 506395 506395 506395 506395 506395

Steel

150 ◊ Spline 60085 60085 60085 60085 60085 60085 60085 Steel

160 ◊ Countershaft 48387 47938 48386 48385 48138 50977 50994 Steel


180 Tensioning roller, complete

48423 38357 38358 38359 38360 38361 38362

Var.

190 Drive roller, complete 48434 48435 48436 48437 48438 50983 50997 Var.

200 ◊ Stud bolt 49073 48666 48661 49074 48683 50979 50995 Steel

210 ◊ Guard plate 48439 48440 48441 48442 48443 50978 50993 Steel

220 ◊ Cheese head screws M4x10

505318 505318 505318 505318 505318 505318 505318

Steel

230 ◊ Lock washer M4 504382 504382 504382 504382 504382 504382 504382 Steel


501812 501812 501812 501812 501812 501812 501812

Steel



49

5.10. BTBD center drive unit, dual-belt


50

5.10.1. Spare parts list, center drive unit, dual-belt


BTBD-105 BTBD-140 BTBD-185 BTBD-250

Drive unit center drive dual-belt, complete

60396 60397 60398 60399 Var.

10 ◊ Drive side panel 54962 54962 54962 54962 Steel

20 ◊ Side cover, backside 47986 47986 47986 47986 Steel

30 ◊ Bearing ring 48665 48665 48665 48665 Al

40 ◊ Cover 48664 48664 48664 48664 Al

50 ◊ Motor flange 60003 60003 60003 60003 Al

80 ◊ Washer M6 504388 504388 504388 504388 Steel


100 ◊ T-nut 47269 47269 47269 47269 Steel


120 ◊ Setscrew washer M6 504380 504380 504380 504380 Steel


150 ◊ Spline 60085 60085 60085 60085 Steel

160 ◊ Countershaft 48385 48138 50977 50994 Steel


180 Tensioning roller, complete 55223 55224 55225 55226 Var.

190 Drive roller, complete 48437 48438 50983 50997 Var.

200 ◊ Stud bolt 49074 48683 50979 50995 Steel

210 ◊ Guard plate 48442 48443 50978 50993 Steel


230 ◊ Lock washer M4 504382 504382 504382 504382 Steel




51

5.11. BTB accessories

Item 10 Item 20 Item 30 Item 40

5.11.1. Parts list accessories

Item Name Item No.

10 Frequency converter 520778

20 Front guard plate for frequency converter 520779

30 Connection cable, converter to motor, length 1 meter 520781

30 Connection cable, converter to motor, length 3 meters 520782

30 Connection cable, converter to motor, length 20 meters 520783

40 Capacitor with protective cap 520860



52

6. Environmental Compatibility and Disposal

Raw materials used

! Aluminum ! Steel ! Copper ! ABS Acrylonitrile Butadiene Styrene ! PUR Polyurethane ! POM Polyoxymethylene ! PS Polystyrene ! Polyethylene ! Polyester

Surface treatment

! Anodizing of aluminum ! Chemical nickel-plating of steel

Forming processes

! Aluminum extrusion ! Cutting of aluminum, steel, POM ! Deep-drawing of ABS ! Plastic injection molding of ABS ! LASER cutting of steel ! Vulcanizing of PUR

Emissions during operation

None

Disposal

Conveyors that can no longer be used should not be recycled as entire units, but disassembled and then recycled according to the material types used. The material type of each component is listed in the spare parts lists. Material that cannot be recycled must be appropriately disposed off. The motor must be disposed of as regular industrial waste and in compliance with all applicable regulations.

MONTECH AG Gewerbestrasse 12, CH-4552 Derendingen Fon +41 32 681 55 00, Fax +41 32 682 19 77 [email protected], www.montech.com

Documents

OPERATING INSTRUCTIONS BASIC CONVEYOR - … Instructions BTB-K and BTB-M basic conveyor 4 1.5. Induction motor safety instructions In the event of a power failure, shut off the device;