installation and maintenance manual · 2 osha and safety bastian automation engineering is not...
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Installation and Maintenance Manual
Bastian Automation Engineering
Model: Roller Zero Pressure Alternating Current (RZPAC )
Effective September, 2016
Supersedes July, 2014 Version
2155 Fields Blvd.
Greenfield, IN 46140 Phone: (317) 467-2583
Web: www.bastiansolutions.com
Contents
List of Figures ii
List of Tables ii
1 Introduction 1
2 OSHA And Safety 1
3 Model: RZPAC 2
4 Receiving 4 4.1 Match-Mark Numbers ....................................................................................................................................................................... 4 4.2 Skid Contents ..................................................................................................................................................................................... 4 4.3 Skid Documentation .......................................................................................................................................................................... 4
5 Installation 5 5.1 Support Types ..................................................................................................................................................................................... 6
5.1.1 Floor Supports...................................................................................................................................................................... 6 5.1.2 Ceiling Hangers .............................................................................................................................................................. 7 5.1.3 Poly-tier ................................................................................................................................................................................. 7
5.2 Connecting Hardware ....................................................................................................................................................................... 8 5.2.1 Conveyor Splice Plate ......................................................................................................................................................... 8 5.2.2 Noseover .............................................................................................................................................................................. 9 5.2.3 Guide Rail Splice Plate .................................................................................................................................................. 9 5.2.4 Strongback ............................................................................................................................................................................ 9 5.2.5 Knee Brace ............................................................................................................................................................................ 9
5.3 Accessories ...................................................................................................................................................................................... 10 5.3.1 Standard Guide Rail ..................................................................................................................................................... 10 5.3.2 Solid Fixed Guide Rail ...................................................................................................................................................... 10 5.3.3 Adjustable Guide Rail .................................................................................................................................................. 10 5.3.4 End Stop .............................................................................................................................................................................. 11
6 Maintenance and Operation 11 6.1 Safety During Operation .......................................................................................................................................................... 11 6.2 Operation ......................................................................................................................................................................................... 11
6.2.1 Motor Wiring .................................................................................................................................................................... 12 6.2.2 Belt Splices ......................................................................................................................................................................... 12 6.2.3 Valve Pneumatics and Wiring .................................................................................................................................... 12
6.3 Maintenance Schedule .............................................................................................................................................................. 13 6.3.1 Mechanical Service ............................................................................................................................................................ 13 6.3.2 Electrical Service ............................................................................................................................................................... 13 6.3.3 Belt Routing and Installation ...................................................................................................................................... 13 6.3.4 Drive Assembly Installation ....................................................................................................................................... 16 6.3.5 Belt Tensioning .................................................................................................................................................................. 16 6.3.6 Replacing Rollers ............................................................................................................................................................... 17 6.3.7 Replacing Cylinders ..................................................................................................................................................... 17 6.3.8 Adjusting Cylinder Stroke ............................................................................................................................................... 17 6.3.9 Replacing Bobbins ........................................................................................................................................................ 18
7 Troubleshooting and Repair 19 7.1 Spare Parts ........................................................................................................................................................................................ 20 7.2 Notes ................................................................................................................................................................................................. 21
List of Figures
3-A A Standard RZPAC Conveyor ......................................................................................................................................................... 2 3-B Drive/Brake Module Components ................................................................................................................................................. 3 3-C A Standard Banded Roller Zone ..................................................................................................................................................... 3 3-D Head or Tail Section Components ................................................................................................................................................. 3 3-E Drive Assembly .................................................................................................................................................................................. 3 4-A Match-Mark Stickers ........................................................................................................................................................................ 4 4-B Skid Label Stickers ............................................................................................................................................................................ 5 5-A A Sample Layout of BastianCAD ................................................................................................................................................... 5 5-B An Exploded View of a Floor Support ........................................................................................................................................... 6 5-C Floor Support Configurations ......................................................................................................................................................... 7 5-D A Ceiling Hanger Mounted to a Conveyor Joint .................................................................................................................... 7 5-E A Poly-tier Support with Two Lanes ............................................................................................................................................. 8 5-F A Poly-tier Support Mounted to a Conveyor Joint .................................................................................................................... 8 5-G A Conveyor Splice Plate ................................................................................................................................................................... 8 5-H An AC Noseover in Two Configurations ...................................................................................................................................... 9 5-I A Guide Rail Splice Plate ............................................................................................................................................................ 9 5-J A Strongback Support ....................................................................................................................................................................... 9 5-K Knee Braces in Both Configurations ...................................................................................................................................... 10 5-L An Exploded View of a Knee Brace ............................................................................................................................................. 10 5-M An Exploded View of a Standard Guide Rail ............................................................................................................................. 10 5-N An Exploded View of a Solid Fixed Guide Rail.......................................................................................................................... 10 5-O An Exploded View of Adjustable Guide Rail ......................................................................................................................... 11 5-P An Exploded View of an End Stop ............................................................................................................................................... 11 6-A A Solenoid Valve ..............................................................................................................................................................................................12 6-B A Power and I/O Splitter Cable .................................................................................................................................................... 12 6-C An End Pulley Without a Belt to Show Motion ........................................................................................................................ 14 6-D Belt Threading .................................................................................................................................................................................. 15 6-E Top View of an End Section ........................................................................................................................................................... 15 6-F An Underside View of a Bed Section........................................................................................................................................... 15 6-G The Effects of Skew on the Belt .................................................................................................................................................... 15 6-H The Proper Routing of the Belt in the Drive Assembly ........................................................................................................... 16 6-I A Mounted Drive Assembly .......................................................................................................................................................... 16 6-J The Tensioner of a Mounted Drive Assembly ........................................................................................................................... 16
List of Tables
1 Key Terms for Match-Mark Numbers ........................................................................................................................................... 4 2 Primary Use for Connecting Hardware Types ............................................................................................................................ 8 3 Troubleshooting Based On Functionality .................................................................................................................................. 19
ii
RZPAC 1
1 Introduction
Thank you for purchasing a Bastian Automation Engineering (BAE) ZiPline material handling system! The following manual will serve as a guide for installation, part replacement, and general maintenance to your material handling equipment. It is important that the manual be read and followed as it provides important safety information for personnel and the longevity of the conveyor.
2 OSHA And Safety
Bastian Automation Engineering is NOT responsible for ensuring that conveyors used in a system abide by OSHA standards. Safety is important to our company, but as a product distributor we ask that system integrators and end users comply with all applicable OSHA standards at their own risk. Some standards include but are not limited to: 1926.555, 1917.48, and 1918.64. We encourage that all warnings are followed to avoid unnecessary risk.
WARNING stickers have been placed on machinery and MUST be abided by all those who interact with equipment. While the warnings are in place to help reduce the risk of injury of certain known hazards, they do not fully describe all the ways in which harm can be done. It is important that all personnel are alerted to and observe the warnings on any equipment supplied by Bastian Automation Engineering. Some of the stickers commonly used are shown below:
RZPAC 2
3 Model: RZPAC
The Roller Zero Pressure AC Conveyor (RZPAC ) is used for product that needs to be accumulated without contacting other product. The RZPAC is designed with a single inverter duty motor that is capable of driving the entire length of the conveyor. This capability makes the RZPAC optimized for long runs. Pneumatically actuated drive/brake modules create distinct zones from underneath the roller bed and surrounding guarding to protect personnel from pinch points.
The RZPAC model shown in Figure 3-A serves as a reference to become familiar with the components and terminology used in this manual. These terms will be used throughout the manual and are common among many of the other ZiPline product lines.
HEAD SECTION
BELT
HEAD PULLEY ASSEMBLY
REFLECTOR
STANDARD ROLLER END
RAIL STANDOFF
BED SECTION
SIDE FRAME
DRIVE ASSEMBLY
BED SPACER
FINGER GUARD
TAIL PULLEY ASSEMBLY
DRIVE/ BRAKE MODULE
SOLENOID VALVE
PHOTOEYE
Figure 3-A: A Standard RZPAC Conveyor
RZPAC 3
The RZPAC is comprised of a series of zones that are exact copies of one another. The primary "guts" include standard straight rollers with drive/brake modules underneath. These drive/brake modules are shown in greater detail in the next figure, Figure 3-B.
END PULLEY
TEARDROP BRACKET
GUIDE BEARINGS
SNUB ROLLER
END PULLEY FRAME
DRIVE BOBBIN
DRIVE ARM
END SECTION BED PAN
GUIDE BOBBIN
BRAKE STRIP
CYLINDER END PULLEY
SPACER
Figure 3-D: Head or Tail Section Components
The drive for the conveyor is provided by an inverter duty
AC motor attached to the Drive Assembly, shown in greater detail in Figure 3-E.
Figure 3-B: Drive/Brake Module Components
The tail and head sections of RZPAC are also comprised
of modular components. A standard banded roller bed and tail/head section are shown in Figure 3-C and Figure 3-D, respectively.
Figure 3-E: Drive Assembly
Figure 3-C: A Standard Banded Roller Zone
O-RING DRIVE BAND
GROOVED ROLLER
MOTOR
SNUB ROLLER
DRIVE DRIVE PULLEY COVER
TENSIONER SPRING END STOP PLATE
FLANGE NUT
TAKE-UP PULLEY
RZPAC 4
4 Receiving
Upon delivery of material handling equipment, please review and check the following:
• The quantity of items received against the Bill of
Lading.
• A visual inspection of equipment to determine any damage that may have occurred during shipping. If damage is present, document with pictures.
• Review Match-Mark information and layout locations. More information can be found in subsection 4.1.
Do NOT accept any damaged goods.
If there are any missing components, please contact
Bastian Automation Engineering (BAE) promptly with as much detail as possible. See the front page of this manual for means of contacting BAE.
4.1 Match-Mark Numbers
Match-Mark numbers are stickers located on the side frame of each conveyor bed that provide information to correctly sequence the conveyor system. Match-Mark stickers include the following information:
• SN
• Model
• Mark Number
• Match
• Piece Count
• Flow
These terms are explained in detail in Table 1.
Table 1: Key Terms for Match-Mark Numbers
Figure 4-A: Match-Mark Stickers
4.2 Skid Contents
Skids will contain varying combinations of conveyor sections, support structures, accessories, and hardware. Conveyor sections will be stacked up to five conveyors high. Each skid will contain a BAE box containing the pertinent hardware. For protection of product integrity during shipping, accessories and supports may be delivered on separate, but labeled skids.
Support types, accessories, and their uses are described
in more detail within the Subsection 5.1. Support structures will be labeled with a sticker that closely resembles the stickers used on conveyors to identify proper mark number location.
4.3 Skid Documentation
All shipments will contain a Bill of Lading for the delivery company, a skid label, and a skid manifest.
Skid labels have the contents of each shipped item
located on the skid. Figure 4-B shows a sample of a skid label. These stickers are placed on the surface of each skid.
Term Description SN Internal project job (serial) number Model Identifies type of conveyor Mark Number Specifies location and placement within the system layout Match Specifies conveyor orientation relative to other connecting pieces within the same Mark Number.
’Start’ refers to the beginning side for its respective Mark Number. Sides labeled with the same Match and within the same Mark Number section should be aligned with each other. See Figure 4-A.
Piece Count Defines unit number within its respective Mark Number. (Ex: ’Piece Count: 2 of 2’ refers to conveyor piece 2 out of 2 total pieces for that Mark Number.)
Flow Refers to the direction of product flow along the conveyor system
Job Number: 15‐46001 Bastian
Model: BZPDC
Mark: C‐101
Match: END
Piece: 2 of 2 Flow: ‐> ‐>‐>‐>
21875
Job Number: 15‐46001 Bastian
Model: BZPDC
Mark: C‐101
Match: START Piece: 1 of 2
Flow: ‐> ‐>‐>‐> 21875
RZPAC 5
Figure 4-B: Skid Label Stickers
The skid manifest summarizes all skids in the shipment
and is included with the Bill of Lading. These documents should be used as additional checks on quantities and content.
5 Installation
The installation supervisor should have elevation and site layout prints with detailed information regarding the placement of conveyor sections and support structures. This information is not the responsibility of BAE to provide unless otherwise specified. A sample portion of a top view layout is shown in Figure 5-A.
Figure 5-A: A Sample Layout of BastianCAD
1. Clear the workspace around the portion of the layout
selected for installation.
2. Measure out from a constrained origin to start placement of supports. It is recommended that snap chalk lines are used, or other method of keeping a consistent line.
3. Use the elevation layouts to determine the conveyor’s top of conveying surface.
4. Place the support type that the layout designates. Each support type has a corresponding Match-Mark sticker. See Subsection 5.1 for more detailed information. This is the optimal time to confirm that the floor support type meant for that location is capable of supporting the top of conveying surface.
5. Check the flow direction on the Match-Mark stickers to ensure that conveyors are mounted properly.
1741
CUSTOMER: Bastian BAE Job Number: 15‐46001
Contents: Mark SRT‐020; BZPDC 1 of 4 Mark SRT‐020; BZPDC 2 of 4 Mark SRT‐020; BZPDC 3 of 4 Mark SRT‐020; BZPDC 4 of 4 Mark SRT‐020; FS‐24‐095‐105 Mark SRT‐020; FS‐24‐035‐045 Mark SRT‐020; FS‐24‐055‐065
RZPAC 6
6. Place the conveyor onto the support structure and fasten it securely.
7. Attach any and all applicable accessories and connecting hardware. See Subsections 5.3 and 5.2 for more detailed information.
8. Check that the conveying surface is level.
9. Lag the supports to the floor (or other permanent fixture).
5.1 Support Types
Conveyor sections are commonly shipped without any support structure attached to them for shipping and handling purposes. The layout of the system governs what support type will be used. There are three types of supports described in this subsection. Each support should be labeled with a Match-Mark sticker that closely resembles the conveyor Match-Mark stickers shown in 4-A. This information will help to associate the proper support type in addition to the proper elevation required to achieve the necessary conveying surface.
SIDE FRAME
SUPPORT BRACKET
ANGLE ADJUSTMENT BOLT
UPPER SUPPORT LEG
HEIGHT ADJUSTMENT BOLT
LOWER SUPPORT LEG
Figure 5-B: An Exploded View of a Floor Support
Floor Supports come in incremental heights with 10
total inches of vertical adjustability. System layouts are designed to provide the top of conveying surface such that the floor support is set roughly in the middle of its range. The support bracket at the top of every floor support is designed to allow for up to 20 degrees of adjustability in both directions for incline and decline situations.
5.1.1 Floor Supports
Floor supports are the most common type of conveyor support used. Figure 5-B shows a standard size of floor support broken down into its components.
Floor supports can be attached to conveyors anywhere along the length of the frames. With the exception of specific circumstances, floor supports are placed at the joint between two connecting conveyor sections. There are two configurations, shown in Figure 5-C, that describe the majority of floor support applications.
RZPAC 7
CONFIGURATION 'A' CONFIGURATION 'B'
Figure 5-C: Floor Support Configurations
Configuration A is used at the joint between conveyors. Configuration B is used at the ends of conveyor sections.
Depending on the layout of the system, a floor support
may not be able to be placed at the joint of a conveyor. See Subsection 5.2 for additional equipment and details that might be required.
5.1.2 Ceiling Hangers
In cases where the layout calls for an overhead application, ceiling hangers may have been supplied as the support structure. Figure 5-D shows how a ceiling hanger mounts to a conveyor at the joint between sections.
Figure 5-D: A Ceiling Hanger Mounted to a Conveyor Joint
Depending on the layout of the system, a ceiling hanger
may not be able to be placed at the joint of a conveyor. See Subsection 5.2 for additional equipment and details that might be required.
5.1.3 Poly-tier
Poly-tier supports provide sturdy support for multi-level conveyor lines. It is important to note that this may require additional warnings for low clearances if work needs to be done beneath the conveyors. Figure 5-E shows a poly-tier support that has two lanes of conveyor attached at adjustable heights. A sway support has been put in for additional structural support due to the height of the poly-tier upright.
SIDE FRAME
CROSS TUBE CLAMP
CROSS TUBE
MOUNTING BOLT
RZPAC 8
CONVEYOR SUPPORT
POLYTIER UPRIGHT
SWAY SUPPORT
FOOT PLATE
Hardware Primary Use Conveyor Splice Plate Connects level side frames Noseover Connects angled side frames
with a roller bed Guide Rail Splice Plate Connects guide rail Strongback Extra strength at unsupported
joints Knee Brace Sway prevention for floor
supports
5.2 Connecting Hardware
Conveyors require additional hardware to ensure that the conveying surface does not flex, sway, or warp at the joint between connecting conveyors. ALL conveyors should have at least one form of the following equipment. Table 2 explains the primary use of each hardware type.
Table 2: Primary Use for Connecting Hardware Types
Figure 5-E: A Poly-tier Support with Two Lanes
Figure 5-F shows how a poly-tier support mounts to a conveyor at the joint between sections.
5.2.1 Conveyor Splice Plate
When two adjoining conveyors are set to the same height and supports are connected at the conveyor joints, a conveyor splice plate must be attached. These plates are independent of support type. Figure 5-G shows the splice plate as it attaches to the top of the conveyor side frame.
Figure 5-F: A Poly-tier Support Mounted to a Conveyor Joint
Depending on the layout of the system, a poly-tier support may not be able to be placed at the joint of a conveyor. See Subsection 5.2 for additional equipment and details that might be required.
Figure 5-G: A Conveyor Splice Plate
There are two sets of holes on each plate. The splice plate
uses the round holes when attaching to the top of the side frame. If adjoining conveyors do NOT use a support at the joint, but the support is placed within 4 inches of the joint, a conveyor splice plate should be used on the top and bottom of the side frame. The plate should be placed inside the frame
ADJUSTMENT BOLT CROSS TUBE
CROSS TUBE CLAMP
MOUNTING BOLT
CONVEYOR SUPPORT
CEILING HANGER
MOUNTING BOLT
SIDE FRAME
CONVEYOR SPLICE PLATE
RZPAC 9
and use the square holes with carriage bolts and wiz nuts. See Subsection 5.2.4 for more details on unsupported conveyor joints.
5.2.2 Noseover
When two adjoining conveyors are set such that a concave AC conveyor has been created, the standard procedure is to use a noseover. The design for the noseover permits two AC conveyor pieces to merge seamlessly. The angular notches cut into the side frame allow for adjustment in the field to manipulate the frame up to 25 degrees. Figure 5-H shows the range of angular adjustment that the noseover can achieve.
Figure 5-H: An AC Noseover in Two Configurations
5.2.3 Guide Rail Splice Plate
When two adjoining conveyors use standard guide rails, guide rail splice plates are needed to keep the rails in place. Figure 5-I shows how a guide rail splice plate attaches to a conveyor.
5.2.4 Strongback
For unsupported conveyor sections spanning more than 10 linear feet, strongback supports are required. If strongbacks are not provided for such applications or if the conveyor system calls for lengths of 14 linear feet or more, please contact BAE.
Figure 5-J shows a strongback support attached to a conveyor. The layout for this system did not allow for floor supports at the joint, so the strongback was placed under the joint to hold the conveyors together. Both top and bottom splice plates should still be used with the strongback support.
SIDE COVER
STRONGBACK
MOUNTING BOLT
Figure 5-J: A Strongback Support
5.2.5 Knee Brace
Knee braces are necessary for ALL conveyors using floor supports where the top of the conveying surface is over 45 inches. The knee braces provide additional support and help mitigate swaying along the length of the conveyor.
When the floor support is placed at the joint of two
conveyors the knee braces are oriented such that one brace extends along the conveyor while the other brace extends in the opposite direction. When floor supports are located at the ends of conveyors, the knee braces are installed facing the same direction. Figure 5-K shows a knee brace attached in each configuration.
Figure 5-I: A Guide Rail Splice Plate
SIDE FRAME
ROLLER BED
BED SPACER
ANGULAR NOTCHES
SIDE COVER
GUIDE RAIL
MOUNTING BOLT
GUIDE RAIL SPLICE PLATE
RZPAC 10
END INTERMEDIATE KNEE
CONFIGURATION CONFIGURATION BRACE
RAIL
STANDARD GUIDE RAIL
MOUNTING BOLT
Figure 5-K: Knee Braces in Both Configurations SIDE
SPACER
The knee brace is designed to have adjustability in where the brace mounts to the underside of the conveyor. While the design allows for system flexibility, it is important to keep in mind that the optimal range for the placement of the knee brace is such that the underside of the conveyor and the length of the brace form an angle between 30 and 45 degrees. Angles outside this range are not as effective at mitigating sway in the conveyor. Figure 5-L shows a knee brace as it attaches to the frame and floor support.
SIDE COVER
MOUNTING BOLT
COVER
Figure 5-M: An Exploded View of a Standard Guide Rail
5.3.2 Solid Fixed Guide Rail
Solid fixed guide rail is used in applications where the guide rail profile needs to be taller. This helps to keep taller product from tipping and falling off the conveyor line. There are two standard sizes, 5.5 inch and 12 inch, measured from the top of conveying surface to the top of the rail. Figure 5-N shows how the solid fixed guide rail attaches to a conveyor.
SUPPORT BRACKET
EXTENDING BRACE
12 INCH SOLID RAIL
MOUNTING RAIL BOLT
Figure 5-L: An Exploded View of a Knee Brace SIDE SPACER
5.3 Accessories
Depending on the application and product SKU, a specific conveyor may call for an additional accessory for optimal functionality.
5.3.1 Standard Guide Rail
This guide rail comes standard on any accumulating conveyors as some form of guide rail is necessary for the protection of the photoeyes. Standard guide rail provides a low profile that helps to keep smaller products on the conveying surface. Figure 5-M shows how the standard guide rail attaches to a conveyor.
COVER 5.5 INCH SOLID RAIL
Figure 5-N: An Exploded View of a Solid Fixed Guide Rail
5.3.3 Adjustable Guide Rail
Adjustable guide rail comes in single and double rail, depending on the needs for the system. Taller product profiles often require double guide rails for tipping prevention. Figure 5-O shows how the single and double guide rail attaches to a conveyor.
RZPAC 11
Figure 5-O: An Exploded View of Adjustable Guide Rail
5.3.4 End Stop
When a conveyor section reaches the end of its path, an end stop is often put in place, depending on the system layout. This accessory helps to stop product from falling off the exposed end of the conveyor section to protect product. Figure 5-P shows an end stop attached to a conveyor.
6.1 Safety During Operation
The list below explains a series of precautions that BAE recommends when personnel are near conveyors. This list is not intended to be the only precautions taken, but it serves as a guide of important steps to follow.
• Only fully trained employees should operate or
perform maintenance on the conveyors. Proper training should include the detailed description of fail-safes, stopping devices, or other emergency regulations put in place.
• WARNING stickers should be replaced if worn or damaged.
• All personnel in the area should be alerted prior to starting any conveyor at all times. This process may vary depending on the conditions and layout of the site, but it should use audible and visual cues and all personnel should be made aware of the protocol.
• Operators should inspect the conveyor for damage, personnel, or foreign object prior to engaging drive.
END STOP PLATE
MOUNTING BOLT
MOUNTING BRACKET
SIDE FRAME
SIDE FRAME MOUNTING BOLT
• Ensure that all areas are clear of objects prior to loading and unloading.
• No personnel should ever ride, climb, step, sit on, or otherwise put body weight on the conveyor. Doing so puts both personnel and equipment in great risk.
• Maintenance should be done at regular intervals to Figure 5-P: An Exploded View of an End Stop
6 Maintenance and Operation
The longevity and proper functionality of ZiPline conveyors is based upon standard operating practices and general maintenance of equipment. Setting up a regular maintenance schedule will help to ensure that products comply with Bastian warranties. Lockout/Tagout procedures MUST be implemented before performing any maintenance.
assure the safety of operators and the longest life of components. Should a component break during operation or prior to operation, then lockout/tagout instructions should be performed immediately to prevent exposure to hazards.
6.2 Operation
It is critical to note that the motors used have enough torque and voltage to harm personnel. Take the proper precautions to avoid injury.
WARNING! The content of this section is critical for the
safe operation of BAE equipment. Each step MUST be followed. Conveying equipment
can cause serious injury to personnel.
MOUNTING BOLT
SIDE COVER
STANDARD RAIL
RAIL SUPPORT
ADJUSTMENT FRAME
RZPAC 12
6.2.1 Motor Wiring
The standard motor used is a 480 Volt, 3 phase inverter duty motor, meaning that it may be connected to a variable frequency drive (VFD) depending on the speed control needed for the system. High voltage electrical work such as this should be done by a certified electrician. The electrician should ALWAYS check the motor voltage from the motor nameplate before hooking up any motors to confirm. All
accumulation.
POWER/IO IN (M12)
EXHAUST MANUAL
SENSOR CABLE (M8)
POWER/IO OUT (M12)
wiring should be properly grounded and abide by national and local codes per application.
6.2.2 Belt Splices
OUTPUT PORTS SUPPLY PORTS
OVERRIDE
Before running conveyors, the belt and splice should be inspected for integrity. Belt splicers can be purchased from BAE per special request, but belts typically arrive cut to the proper length such that the ends are spliced and ready for install.
6.2.3 Valve Pneumatics and Wiring
Air should be run from the compressor through a filter to a regulator module before being connected to any solenoid valves. The filter should be checked for accumulation of fluid on a periodic basis, see Subsection 6.3. This will help to protect and ensure the longevity and functionality of the valves.
Set the regulator to 60 psi for the optimal functionality
of zone accumulation. BAE can provide single units which provide both the filtration and regulation functions for plug and play installation.
Note: There is a red manual override switch located on
the valve just above the output ports, opposite the side with the brass exhaust.
Figure 6-A: A Solenoid Valve
A 24 Volt DC power supply is required to power the
valves. The valves are able to be daisy chained to one another via the attached M12 power connector. This cable contains the power and input/output data for the valve. In order to have the accumulation logic work, the valves must be linked to one another this way. An accessory that allows the power and I/O signals to be split for controls purposes is available upon request. See Figure 6-B for a picture of the splitter.
MALE CONNECTOR (M12)
The solenoid valve is designed to accept air from the source in the lowest port on either side using a 3/8 inch OD tube. The opposite end may be used to connect one valve to another, again with a 3/8 inch OD tube. It is important to note that the final valve in a line of valves needs to have the unused port capped so that the air pressure is contained in the system. A 1/4 inch OD tube is used to run air from the valve to each zone in the conveyor. The air can be run from either of the output ports, but the one not used must be capped. See Figure 6-A for a side and front view of the valve. The other end of the tubing will go into an NPT fitting that is inserted into the port on the cylinder located in the drive/brake module. A quick exhaust valve may be added to all zones between the solenoid valve and the cylinder that require transportation rates of 100 feet per minute or higher. This exhaust valve helps to ensure that the cylinder engages
FEMALE CONNECTOR (M12)
and disengages quickly enough for proper braking and Figure 6-B: A Power and I/O Splitter Cable
RZPAC 13
The M8 lead is used to connect to the photoeye sensors for product detection. A WAGO tool is recommended for adjusting the dials on the photoeyes, which should be preset to Dark Mode in most circumstances with the sensitivity turned up fully. Contact BAE if photoeyes were not preset to these specifications. Proper operation requires that the photoeye make direct contact with the reflector opposite the eye on the conveyor frame. If improperly triggered, the sensor’s yellow LED will shine when no product is present. Adjust the angle of the photoeye’s beam until it is only green when there is no product in its zone. If the green LED is blinking, then the eye is faulting and likely needs the wire reinserted fully or needs replacing.
6.3 Maintenance Schedule
In order to prolong the life of your material handling equipment and reduce the risk of potential safety hazards, it is vital that a preventative maintenance program be set in place and followed. The following instructions will help identify key areas requiring maintenance.
6.3.1 Mechanical Service
• A visual and auditory inspection of the equipment should be performed to identify oil leakage or any unusual noise that may indicate that there is a problem with the equipment.
• All pneumatic components should be checked for leaks, and filters should be cleared of debris or fluid on a daily basis.
• Check bushings at pivot locations for excess wear or slop and replace as needed.
• Belts and tracking belts should be inspected for excessive wear or improper tracking if applicable.
• All bolts and nuts should remain tight. Loose fasteners may result in injury, equipment malfunction, or permanent damage to the system.
• Inspect, clean, re-grease, or replace all bearings as necessary. The recommended interval for maintenance is at least once every 6 months.
6.3.2 Electrical Service
• Electrical connections must be made in accordance with local regulations.
• Keep sensors free from dust, grease, and other debris and make sure mounting brackets are secure.
• Inspect panels regularly for loose wires or connections and tighten as required.
• Keep panels free of dust by wiping them down
regularly.
• Refer to separate electrical manuals provided for additional maintenance procedures. All electrical procedures must be carried out in accordance with that manual.
6.3.3 Belt Routing and Installation
The belt used for RZPAC is a self-tracking, ribbed belt that is designed to require very little manipulation to ride correctly on the machined pulleys. The following steps will help to ensure that the belt is installed and routed properly to allow for proper tracking and conveyance.
1. Follow lockout/tagout procedures to ensure safety.
This includes shutting off air pressure to the conveyor.
2. Check that the frame is square along the entire length. Measurements may need to be taken at multiple points along the length of the conveyor depending on the overall length.
3. Check that the conveying surface is level throughout. This is best done by spot checking multiple points throughout the length.
4. Walk the length of the belt to correct any kinks or flips in the belt, leaving it such that the grooved side is the inner track of the loop and the smooth side is on the outside.
5. The motion of the belt along the underside of the roller bed will be in the opposite direction of the product flow. The belt MUST be put on such that the arc of the grooves align with the end pulleys and point in the direction of the belt motion. Make sure that the belt is oriented properly before attempting to install. See Figure 6-C for a pictorial representation of how the belt, end pulley, and product flow are related.
6. The end pulleys are held in place by a shaft with two spacers to keep it centered in the framework. To remove the pulley, loosen the bolt on the teardrop bracket with an open end wrench and Allen wrench. Slide the shaft out from the end pulley and set the parts in the end section bed pan. Figure 6-C shows the pulley assembled.
7. Take the belt end that matches the orientation of the end pulley and thread it through the second to last bed spacer. Pinch the end of the belt into a tight loop to help push it through the space between the bobbins and bed spacer frame. Be careful not to introduce any twists or kinks in the belt during this process. See Figure 6-D for a pictorial representation of the
RZPAC 14
components involved in the process of threading the belt through the conveyor frame. Figure 6-E is a top down view of the belt in place around the end pulley which will aid in this step and the next steps.
8. Thread the belt end through the gap and pull through to the next bed spacer. Repeat the process and pull the belt end through to the end pulley section. Pull a little excess to give some slack to the belt.
9. Loop the belt end around the end pulley and reassemble the pulley by following the steps described in Step 6 in reverse.
10. Go to the other end of the belt and use electrical tape to create a more firm point to the belt end. Make sure that there is a small radius to the belt so as not to damage the belt. This will help keep the orientation of the belt and aid in pushing/pulling the belt through the tight bed section gaps.
11. Feed the taped belt end in through the subsequent bed section following where the first end was inserted in Step 7. Continue the process of pulling the end through the gap between the bed section and the bobbins. Upon clearing a bed section, pull a length of slack down to provide less resistance when pulling through to the next bed. See Figure 6-F for a pictorial representation of the access holes to help to snake the belt through the belt threading space.
12. Repeat this process along the length of the conveyor. Be careful not to introduce any twists or kinks in the belt.
13. Sections that have skewed rollers may already have a belt guide installed. This guide may cause interference for the belt path and will likely need to be removed for belt installation. It is imperative that the guide be in place at all bed spacers that are located beneath a skewed zone. The guide attaches to the slots on the bed spacer and should be adjusted such that the bearings of the guide are barely touching the belt when it is centered on the bobbins. The guide bracket is designed to have a left and right side depending on which way the rollers are skewed. Refer to Figure 6-G to help determine where the bearings should be placed on the guide per the application.
14. Upon reaching the other end pulley section, repeat the process detailed in Step 6 in reverse. There should still be some slack, around two to three feet, left in the belt to wrap around the pulleys in the drive section.
15. Start on one end of the conveyor and push the top of the belt loop onto the bobbins such that the grooves are facing the bobbins and the smooth end touches
the rollers. The bottom of the belt loop should ride underneath the drive bobbins but rest on top of the guide bobbin that is located on a lower plane. This process can be tedious, but is easier with the drive raised. Be careful as the drive and brake are capable of moving, and if the air is still hooked up then the moving parts could be very dangerous. Be sure that the conveyor is fully locked out.
16. If there are sections with skewed zones, a belt guide may need to be installed to help keep the belt in place and tracking properly.
17. Pull the slack in the belt through the drive assembly and follow the flow arrows cut into the metal frame of the assembly. Figure 6-H shows a properly routed drive assembly. Loosening the tensioner all the way will help make the routing process easier. Refer to Subsection 6.3.5 for further instructions on loosening and retensioning the belt.
An end pulley can be seen in Figure 6-C in a top down
view. Note that the belt motion is the opposite of the product flow.
PRODUCT FLOW
BELT MOTION
Figure 6-C: An End Pulley Without a Belt to Show Motion
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ARM
The space in the conveyor used for threading the belt can be seen in greater detail in Figure 6-D.
ACCESS HOLE
BED SPACER
BRAKE DRIVE DRIVE BOBBIN
BELT THREADING SPACE
GUIDE BOBBIN
BELT
GUIDE BEARINGS
Figure 6-D: Belt Threading
Figure 6-F: An Underside View of a Bed Section
The use of skewed rollers imparts a force upon the belt
that can lead to the belt walking off the end pulley. This can lead to catastrophic failure of the equipment if allowed to run for extended periods with a belt that has tracked off. The following figure helps to demonstrate how the direction of
A top down view of the end section with the belt properly threaded is shown in Figure 6-E. In this view, the rollers have been removed to see the components more easily.
the belt motion in relation to the angle of the skewed roller leads to a tracking in a specific direction. To prevent the belt from walking off, belt guides can be placed in the path of the lateral forces experienced.
END PULLEY
BELT
BELT TRACKS
BELT TRACKS
ROLLER BRAKE SNUB ROLLER
GUIDE BEARINGS
Figure 6-E: Top View of an End Section
A view of a bed section with the belt properly threaded
is shown in Figure 6-F.
Figure 6-G: The Effects of Skew on the Belt
Figure 6-H demonstrates the proper routing for the belt
through the drive assembly.
PROD
UC
T M
OTIO
N BE
LT
MO
TIO
N
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SNUB ROLLERS
DRIVE PULLEY
CYLINDER
DRIVE
SNUB
TAKE-UP PULLEY
BELT
BOBBIN ROLLER
Figure 6-H: The Proper Routing of the Belt in the Drive Assembly
6.3.4 Drive Assembly Installation
The placement and installation of the drive assembly is critical for the safe and proper operation of RZPAC conveyors. Drive assemblies should come pre-installed, but the installation instructions are included for convenience.
This process is best done with three people, two to hold
the drive assembly up to the frame and one to insert the carriage bolts and spacers that secure it to the frame. A carriage bolt should be inserted through the slots on the arms of the drive assembly, followed by two (2) 1/2 inch SAE washers which serve as spacers, through the appropriate hole on the underside of the conveyor frame, and finally through the flange nut that locks the assembly in place. It is imperative that each of the four nuts are securely tightened to keep the drive in place and operating correctly. The drive can be placed anywhere in between the infeed and the halfway point of the conveyor. Be sure to place the drive assembly such that the center of the assembly is on the discharge end of a drive/brake module so that there is no interference. If it is not placed properly, then the bobbins of the drive/brake modules will touch the snub pulleys on the drive assembly which could cause premature failures and/or decreased performance of the affected zones. Reference Figure 6-I for a visual of the drive assembly mounted to the conveyor properly.
Figure 6-I: A Mounted Drive Assembly
6.3.5 Belt Tensioning
Belt tracking is crucial for the proper conveyance of product and the longevity of the conveyor. Improperly tracked belts can result in the premature failure of multiple components, which ultimately leads to lower throughput and potential safety hazards. The following items describe the steps taken to tension a belt for RZPAC .
Figure 6-J shows a drive assembly from the side opposite
the pulleys. The tensioner is located here and can be manipulated to deliver the proper tension for belt longevity and tracking.
SNUB ROLLER ADJUSTMENT
FLANGE NUT
END STOP PLATE
TENSIONER TENSIONER
ADJUSTMENT HOLES
Figure 6-J: The Tensioner of a Mounted Drive Assembly
1. Follow lockout/tagout procedures to ensure safety.
2. Check that the frame is square along the entire length. Measurements may need to be taken at multiple points along the length of the conveyor depending on the overall length.
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3. Check that the conveying surface is level throughout. This is best done by spot checking multiple points throughout the length.
4. Put a straight edge up against the pulleys in the motor assembly. Adjust bolts on the snub roller adjustment plates on the back of the assembly to get the pulleys to all be flush with one another on their front plane. Figure 6-J shows the backside of the assembly, where the snub roller adjustment can be found. If the pulleys are not aligned as such then the tensioner will bounce upon start up, putting the conveyor and belt at risk of breaking, which places all personnel at great risk.
5. Check that the belt has been routed properly through the drive assembly. Refer to Subsection 6.3.3 and Figure 6-H. To assist the routing process, loosen the tensioner on the back side of the drive assembly by loosening the flange nut on the end of the tensioner.
6. Once the belt is routed properly, begin to tighten the drive assembly tensioner until the flange reaches the end stop plate and is flush. Each conveyor will have a different amount of turns to reach the proper tension which is marked by having a belt taught enough to not cause slipping. Once the flange is flush with the end stop, slowly run the conveyor for a full revolution with the air disengaged. The belt should work out the excess slack, and the flange will no longer be flush to the end stop plate. Tighten the flange again to keep the belt tensioned. If tightening the flange to the end stop plate of the tensioner mechanism a second time does not provide enough tension, release the tension by loosening the nut, and shift the tensioner to another set of tensioner adjustment holes on the drive assembly. Repeat the tightening process until the flange reaches the end stop plate. Contact BAE if the belt is still not tight enough to run without slipping.
7. Turn the conveyor on and allow the belt to run for at least 2 complete revolutions. The RZPAC uses an inverter duty motor, allowing a VFD to be used to control speed. It is encouraged that the VFD controls are used upon the first time powering up the RZPAC in order to test if the proper tension has been reached.
6.3.6 Replacing Rollers
1. Follow the lockout/tagout procedure in place to ensure safety.
2. Remove the side cover from the intended work area.
3. Apply pressure on one end of the hex shaft using a small diameter punch or similar tool until the shaft clears the frame. Be careful NOT to apply a side load to the hex shaft.
4. Provide upward force on the roller body. A putty knife
or other flat surface tool is recommended to be placed between the hex shaft and the inside of the frame. This will help protect frame paint integrity.
5. Remove the roller from the opposite conveyor side.
6. Slide one end of the new roller’s hex shaft into the hex hole of the frame on the opposite side.
7. Use a putty knife or other flat surface tool to guide the hex shaft into the proximal hex hole.
6.3.7 Replacing Cylinders
1. Follow the lockout/tagout procedure in place to ensure safety.
2. Remove the rollers from the intended work area. See Subsection 6.3.6.
3. Remove any finger guarding that may be in the way. These are simply attached with bolts in Pem nuts.
4. Pull the cotter keys holding the shaft ends of the cylinder in place.
5. Remove the shafts and spacers and detach the cylinder from the air line.
6. Repeat these steps in reverse order with the new cylinder.
6.3.8 Adjusting Cylinder Stroke
1. Follow the lockout/tagout procedure in place to ensure safety.
2. Remove the rollers from the intended work area. See Subsection 6.3.6.
3. Remove any finger guarding that may be in the way. These are simply attached with bolts in self-clinching nuts.
4. Pull the cotter keys holding the shaft ends of the cylinder in place.
5. Remove the shafts and spacers and detach the cylinder from the air line.
6. Loosen the nut on the cylinder’s piston.
7. Tighten or loosen the eyelet on the end of the piston to increase or decrease the effective length of the stroke.
8. Repeat these steps in reverse order with to put the cylinder back in position.
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6.3.9 Replacing Bobbins
1. Follow the lockout/tagout procedure in place to ensure safety.
2. Remove the rollers from the intended work area. See Subsection 6.3.6.
3. Remove any finger guarding that may be in the way. These are simply attached with bolts in Pem nuts.
4. Bend the wire holding the bobbins’ shafts in line and pull the wire out until the shaft of the intended bobbin is free.
5. Remove the shaft and slide the bobbin out.
6. Repeat these steps in reverse order with the new bobbin.
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7 Troubleshooting and Repair
A majority of issues that arise with ZiPline conveyors can be corrected with minimal field repairs. BAE encourages using the following troubleshooting techniques before contacting BAE support as these are the same techniques used by our field service engineers. To assist in data collection, BAE asks that any issues that arise be recorded in a log with the mark-number, a description of the issue, and the steps taken to remedy the issue.
Table 3: Troubleshooting Based On Functionality
ERROR CAUSE ACTION
Belt edges fraying
Incorrectly tracked
Check Belt Routing and Installation and Belt Tensioning, Subsections 6.3.3 and 6.3.5
Product not hitting rates Incorrect pressure Check Valve Pneumatics and Wiring, Subsection 6.2.3
Product not accumulating Faulty photoeye Check Valve Pneumatics and Wiring, Subsection 6.2.3
Belt slipping on pulleys Incorrectly tensioned Check Belt Tensioning, Subsection 6.3.5
Belt tensioner jumping Incorrectly installed drive assembly Check Drive Assembly Installation, Subsection 6.3.4
Clicking or rattling sound Faulty bobbin Check Replace Bobbins, Subsection 6.3.9
Air leaking Faulty tubing Check Valve Pneumatics and Wiring, Subsection 6.2.3
Rollers spinning when disengaged Incorrect stroke length Check Adjusting Cylinder Stroke, Subsection 6.3.8
Belt not seated on end pulley
Incorrect belt installation
Check Belt Routing and Installation and Belt Tensioning, Subsections 6.3.3 and 6.3.5
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7.1 Spare Parts
Call BAE directly for information regarding spare parts for any ZiPline equipment. (317) 467-2583
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7.2 Notes