installation manual: conveyor supports - bastian solutions€¦ · installation manual: conveyor...

Installation Manual:

Conveyor Supports

Effective October 2019

Rev.A1

Installation Manual: Conveyor Supports

Published October 2019 Rev.A1

2

Contributions:

ROLE NAME TITLE

Author Josh Foiles Design Engineer

Checker Ben Baker Senior Design Engineer

Approver Chris Perry Engineering Manager

Revisions:

DATE REVISION DESCRIPTION AUTHOR

10/23/2019 A1 Initial Document Creation Josh Foiles



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Term and Acronym Definitions

TERM/ACRONYM DEFINITION

CB Carriage bolt

Discharge The point where cartons, cases, or totes exit a conveyor or similar unit used in a material handling system.

Infeed The point where cartons, cases, or totes enter a conveyor or similar unit used in a material handling system.

LOTO Lockout Tagout

OAW Overall width of any given conveyor bed.

OSHA Occupational Safety and Health Administration

Polytier Heavy duty floor support with a wide stance, capable of supporting multiple levels and types of conveyor.

Side Cover A PVC cover used to conceal and protect electrical components and wiring from foreign debris and moving obstacles.

Side Frame Structural member used to support rotating components needed for conveyor beds.

Splice Assembly

A five-component assembly-consisting of a plate (or formed plate), two bolts, and two nuts-that is used to secure a piece of guide rail to an adjacent piece of guide rail, or a side frame to an adjacent side frame. This is used to provide additional structural rigidity and ensure relative position of components is maintained.

TOR Top of roller; this refers to the elevation of the conveying surface with respect to the floor on which the conveyor is sitting.

Wiz Nut A serrated flange nut used to cut into the surface of the component it is tightened against.



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Table of Contents

Introduction ....................................................................................................................... 6

Safety ................................................................................................................................. 6

Floor Supports .................................................................................................................. 7

3.1 Installation .................................................................................................................................... 7

Polytier Supports .............................................................................................................10

4.1 Installation .................................................................................................................................. 10

Ceiling Hangers ................................................................................................................12

5.1 Installation .................................................................................................................................. 12

Support Accessories .......................................................................................................15

6.1 Joint Angle Supports ................................................................................................................... 15

6.2 Strongbacks ................................................................................................................................. 16

6.3 Knee braces ................................................................................................................................. 17

6.4 Polytier Sway Braces ................................................................................................................... 18

6.5 Incline/Decline Floor Support Bracket ........................................................................................ 19



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List of Figures

Figure 1: ZiPline Conveyor Floor Support ..................................................................................................... 7

Figure 2: Adjusting Floor Support Height ...................................................................................................... 7

Figure 3: Support at Bed Break ..................................................................................................................... 8

Figure 4: Support at Infeed or Discharge of Conveyor ................................................................................. 8

Figure 5: Conveyor Splice .............................................................................................................................. 9

Figure 6: Conveyor Squaring ......................................................................................................................... 9

Figure 7: ZiPline Conveyor Polytier Support ............................................................................................... 10

Figure 8: Polytier Assembly ......................................................................................................................... 11

Figure 9: Polytier Clamp Mounting ............................................................................................................. 11

Figure 10: Polytier Adjustment ................................................................................................................... 11

Figure 11: ZiPline Conveyor Ceiling Hanger ................................................................................................ 12

Figure 12: Ceiling Hung Bed Section 1 ........................................................................................................ 13

Figure 13: Ceiling Hung Bed Section 2 ........................................................................................................ 13

Figure 14: Ceiling Hanging Multiple Bed Sections ...................................................................................... 14

Figure 15: Joint Angle Support Installation-1 .............................................................................................. 15

Figure 16: Joint Angle Support Installation-2 .............................................................................................. 15

Figure 17: Strongback Installation-1 ........................................................................................................... 16

Figure 18: Strongback Installation-2 ........................................................................................................... 16

Figure 19: Knee Brace Installation-1 ........................................................................................................... 17

Figure 20: Knee Brace Installation-2 ........................................................................................................... 17

Figure 21: Sway Brace Installation-1 ........................................................................................................... 18

Figure 22: Sway Brace Installation-2 ........................................................................................................... 18

Figure 23: Incline/Decline Floor Support Installation ................................................................................. 19



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Introduction Thank you for choosing ZiPline Conveyor. The following manual will serve as a guide for installation of

your ZiPline Conveyor supports. Supports are always shipped loose and installed in the field, so this

manual is provided for and only to be used by conveyor installation technicians.

The information contained in this manual applies only to the products described. Uses, activities, or

processes related to installing or maintaining the equipment that are not explicitly described in this

manual are considered out of scope. Please contact Bastian Solutions ZiPline Conveyor for any

questions or support that is not clearly addressed in this document. ZiPline Conveyor is not responsible

for misuse of the equipment described or information provided in this manual. If you have any

questions, contact ZiPline Conveyor Customer Service or Support at

[email protected].

Safety ZiPline Conveyor is not responsible for ensuring that conveyors used in a system abide by OSHA

standards. Safety is of primary importance to our company, but as a product distributor we ask that

system integrators and end users conform with all applicable OSHA standards. We encourage that all

warnings in this manual are followed to avoid unnecessary risk.

• When handling parts with sharp edges or operating cutting power tools, gloves are required.

• Ensure adherence to PPE and hearing protection requirements associated with the building in

which work is to be performed.

• When performing meticulous work (i.e. landing cables, or hand-tightening hardware) or working

with rotating equipment, gloves shall not be used.

• Long hair and loose clothing must be restrained when working with rotating equipment.

• When performing work which may produce flying debris such as drilling or cutting, a face shield

must be worn.

• Guarding on stationary machines and handheld power tools must never be disabled or removed.

• Questions about other safety protocol? Contact your Environmental Health and Safety Officer.

mailto:[email protected]



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Floor Supports The ZiPline Conveyor floor supports are designed to support an array of product lines. Figure 1 serves as

a reference to become familiar with the components and terminology used in this manual.

3.1 Installation

1. To begin support installation, confirm the infeed

and discharge height of the conveyor being

installed using the systems layout drawing.

System layout information is the

responsibility of the customer.

Please contact your Bastian

Solutions system representative for

layout-related questions.

2. Set the support height to the desired elevation.

When setting the support height remember to

subtract the side frame height to get the correct

top of roller (TOR) height.

3. Refer to Figure 2 for a visual representation of how

to adjust the floor support height.

4. Referencing the systems layout drawing, mark a

chalk line on the floor to locate the center of the

conveyor.

5. Place the supports upright and centered over

the chalk line. The supports should land at

each bed break. If the supports land at the

Figure 1: ZiPline Conveyor Floor Support

Figure 2: Adjusting Floor Support Height



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beginning or end of a conveyor line, the support is to go under the bed completely. Otherwise

the support will accept two beds. (Refer to Figure 3 and Figure 4)

6. Place and bolt all conveyor beds onto the supports using the 3/8”-16 carriage bolts and wiz nuts

provided. Recommended torque: 26 ft-lbs.

7. Splice side frames together using the provided splice plate and 5/16”-18 hardware as shown in

Figure 5. Recommended torque: 17.5 ft-lbs.

Figure 3: Support at Bed Break

Figure 4: Support at Infeed or Discharge of Conveyor



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8. Ensure that the infeed and discharge height of each conveyor bed matches the layout drawing.

9. Ensure that each conveyor bed is square by measuring from corner to corner. (Refer to Figure 6)

10. Verify that each bed is level across its width. If the conveyor is not an incline or decline, ensure

the conveyor is also level along its length.

11. Once ensuring all fasteners are tightly secured, lag the supports to the floor.

Ensure securing method is appropriate for the application. Installations in seismic zones will generally require independent seismic review. ZiPline does not provide general-purpose recommendations for concrete anchors or other fastening methods, as fastening requirements depend on the site-specific details of the mounting surface.

Figure 5: Conveyor Splice

Figure 6: Conveyor Squaring



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Polytier Supports The ZiPline Conveyor polytier supports are designed to support multiple lines of conveyor at once.

Figure 7 serves as a reference to become familiar with the components and terminology used in this

manual.

4.1 Installation

1. Referencing the systems layout drawing, mark a chalk line on the floor to locate the center of

the conveyor.

2. Confirm the infeed and discharge height of the conveyor(s) being installed with the systems

layout.

3. Assemble the polytier supports with the necessary cross braces. Refer to the supplied assembly

drawings of the polytier supports. Be sure to use the specified amount of polytier cross braces in

the assembly drawings. (Figure 8 and Figure 10 show how to assemble and adjust the polytier

cross braces.)

System layout information is the responsibility of the customer. Please contact

your Bastian Solutions system representative for layout-related questions.

Figure 7: ZiPline Conveyor Polytier Support



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4. Place the supports upright and centered over the chalk line.

The supports should land at each bed break. If the supports

land at the beginning or end of a conveyor line, the polytier

clamp is to go under the bed completely. Otherwise the

polytier clamp will accept two beds.

5. After verifying the polytier supports are in the correct

location, lag the supports to the floor.

6. Set the conveyor beds on the cross braces. Ensure they are

placed in the desired position.

7. Bolt all conveyor beds onto the cross braces using the

polytier clamp and the 3/8”-16 hardware provided. (Refer to

Figure 9) Recommended torque: 26 ft-lbs.

8. Splice side frames together using the provided splice plate

and 5/16”-18 hardware as shown in Figure 5. Recommended

torque: 17.5 ft-lbs.





12. The conveyor can be leveled by adjusting the cross brace mounting position as shown in Figure

10.


Figure 8: Polytier Assembly

Figure 10: Polytier Adjustment Figure 9: Polytier Clamp Mounting



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Ceiling Hangers The ZiPline Conveyor Ceiling Hangers are designed to support the conveyor from the ceiling, eliminating

the need for floor supports or polytier supports. Figure 11 serves as a reference to become familiar with

the components and terminology used in this manual.

5.1 Installation


1. Before the install can begin the threaded rods should already be suspended from the ceiling.

2. To hang the first bed, preassemble the bed with both ceiling hanger assemblies.

3. The “first” ceiling hanger should be bolted up completely under the bed. The “second” should

only be utilizing half the clamp as this will be needed to support the next bed. (See Figure 12 for

visual representation) Use the provided 3/8”-16 hardware. Recommended torque: 26 ft-lbs.

The ceiling hanger that is only utilizing half the clamp needs to be secured firmly to the conveyor bed. If this is not fastened securely the ceiling hanger could potentially fall when installing the next bed.

4. Raise the bed with the clamps up to the threaded rods.

5. Secure the ceiling hanger tube to the threaded rods.

6. Preassemble the second bed with one ceiling hanger assembly (Figure 13). If this is the final bed

section to be hung, be sure to have the clamp completely under the bed. Otherwise, only use

half the clamp as mentioned before.

7. Raise the bed up to the existing bed.

8. Fasten the bed to the shared clamp then secure the ceiling hanger tube to the threaded rods on

the other end. (See Figure 14)

9. Splice side frames together using the provided splice plate and 5/16”-18 hardware as shown in

Figure 5. Recommended torque: 17.5 ft-lbs.

Figure 11: ZiPline Conveyor Ceiling Hanger



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10. Repeat steps 6-9 until the final bed section is installed.





14. The conveyor can be leveled by adjusting the threaded rod that the ceiling hanger tube is

mounted to.

Figure 12: Ceiling Hung Bed Section 1

Figure 13: Ceiling Hung Bed Section 2



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Figure 14: Ceiling Hanging Multiple Bed Sections



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Support Accessories ZiPline Conveyor offers accessories to aid in supporting conveyor. These accessories should only be used

when called for in the systems layout drawing.

6.1 Joint Angle Supports

Joint angle supports are used when a support cannot land at a bed break. These should never be used as

a substitute for a support and should only be used per the systems layout drawing. Figure 15 and Figure

16 show the proper way to install a joint angle support. Recommended torque for 3/8-16 hardware:

26ft-lbs

Figure 15: Joint Angle Support Installation-1

Figure 16: Joint Angle Support Installation-2



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6.2 Strongbacks

Strongbacks are used in situations where a support cannot land in a certain area. Often, long

strongbacks will be used with a support on each side. These should only be installed per the systems

layout drawing. Figure 17 shows the installation of a short strongback. Figure 18 shows a long

strongback being used to eliminate the need for a support in the middle of the bed break.

Recommended torque for 3/8-16 hardware: 26ft-lbs

Figure 17: Strongback Installation-1

Figure 18: Strongback Installation-2



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6.3 Knee braces

Knee braces are used to provide extra support and stability. These are often used in situations where

the conveyor may see heavier loads, or the conveyor is in a seismic zone. These should only be installed

per the systems layout drawing. Figure 19 and Figure 20 show the installation of a knee brace.

Recommended torque for 3/8-16 hardware: 26ft-lbs

Figure 19: Knee Brace Installation-1

Figure 20: Knee Brace Installation-2



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6.4 Polytier Sway Braces

Polytier sway braces are used to provide extra support and stability. These are often used in situations

where the conveyor may see heavier loads, or the conveyor is in a seismic zone. These should only be

installed per the systems layout drawing. Figure 21 shows the installation of a single leg of the sway

brace to a polytier upright. Figure 22 shows a sway brace fully installed. The arrows in the figure are to

show that the legs are adjustable in and out to ensure the slots on the sway brace legs always contact

the slots on the polytier uprights. Recommended torque for 3/8-16 hardware: 26ft-lbs

Figure 21: Sway Brace Installation-1

Figure 22: Sway Brace Installation-2



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6.5 Incline/Decline Floor Support Bracket

The incline/decline floor support brackets are used anywhere a horizontal bed meets an inclined or

declined bed at an angle of + 15°. These should only be used per the systems layout drawing. Figure 23

shows a horizontal bed and a bed at an angle. To change the angle of the incline or decline, slide the

mounting bracket along the slots. Recommended torque for 3/8-16 hardware: 26ft-lbs

Figure 23: Incline/Decline Floor Support Installation



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Bastian Solutions ZiPline Conveyor Installation Manual for Conveyor Supports

© 2019 Bastian Solutions, LLC

All rights reserved. This document contains information considered proprietary to Bastian Solutions. It

may not be duplicated, used, or disclosed without written permission from Bastian Solutions. It may not

be used in whole or in part for any purpose other than its intended purpose as an operation, installation,

and maintenance manual for the product or products described herein. Bastian Solutions reserves the

right to revise the contents of this document as necessary.

Bastian Solutions, LLC

1821 Bastian Court

Westfield, IN 46074

Customer Support: [email protected]

First Edition October 2019

mailto:[email protected]

installation manual: conveyor supports - bastian solutions€¦ · installation manual: conveyor...

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