modular transfer system tlm 1500
TRANSCRIPT
I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500
Modular transfer system
TLM 1500
User manual
&
Maintenance guide
Translation of the original manual, version 03
I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500
Table of contents
Version tracking:...................................................................................................................................... 2 1 General information ........................................................................................................................ 1
1.1 Important remarks .................................................................................................................. 1
1.2 Applicable standards ............................................................................................................... 1
1.3 Applications ............................................................................................................................. 1
1.4 Conditions of use ..................................................................................................................... 1
1.5 Safety instructions ................................................................................................................... 2
1.6 Safety instructions regarding the motor ................................................................................. 2
1.7 Additional information ............................................................................................................ 2
2 Technical specifications ................................................................................................................... 3 3 Commissioning ................................................................................................................................ 4
3.1 Receipt ..................................................................................................................................... 4
3.2 Transfer elements ................................................................................................................... 4
3.3 Stopper .................................................................................................................................... 4
3.4 Positioning unit ........................................................................................................................ 4
3.5 Workpiece carrier .................................................................................................................... 5
4 Maintenance ................................................................................................................................... 5 4.1 Belts wear ................................................................................................................................ 5
4.2 Passageways of workpiece carriers ......................................................................................... 5
4.3 Pins .......................................................................................................................................... 5
4.4 Wear of the belt guide ............................................................................................................ 5
4.5 Transfer parts .......................................................................................................................... 6
4.6 Damped pneumatic Stoppers .................................................................................................. 6
4.7 Positioning units with simple and double effect damped pneumatic stoppers ..................... 7
4.8 Positioning units with damped pneumatic stoppers ............................................................ 9
4.9 Positioning units for station with damped pneumatic stoppers ........................................ 11
4.10 Lift positioning units with damped pneumatic stoppers .................................................... 11
4.11 Other transfer parts .............................................................................................................. 12
5 Motor Replacement ...................................................................................................................... 13 5.1 Disassembly ........................................................................................................................... 13
5.2 Reassembly of the motor ...................................................................................................... 15
5.3 Changing the timing belt ....................................................................................................... 15
6 Responsability ............................................................................................................................... 16 7 Customer service ........................................................................................................................... 16 8 Appendix ........................................................................................................................................ 17
8.1 Maintenance schedule .......................................................................................................... 17
8.2 Quality and environmental commitment: ISO certifications ................................................ 18
8.3 List of part.............................................................................................................................. 18
I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500
VERSION TRACKING:
Version Date Description of modifications Prepared by Approved by
00 01/10/15 Initial (translation) S. GUILLAUD-BATAILLE
01 06/12/16 - S. GUILLAUD-
BATAILLE
-
02 19/09/18 2015 edition of ISO 9001 and 14001
standards: deletion of expired certificates S. MAIRET S. MAIRET
03 09/07/19 Addition of paragraph 8.3: List of parts G. DAURIANNES L. HERBIET
I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500 Page 1 sur 22
1 GENERAL INFORMATION 1.1 Important remarks The following instructions will be used as technical documentation for the manufacturer of the
final machine. elcom is the supplier of this TLM 1500 transfer system sub-assembly .
The manufacturer of the final machine must make sure that:
- All safety equipment is provided and functional, - Regular checks are carried out, - All danger (pinching, squashing) due to moving parts is controlled, - The documentation is complete.
1.2 Applicable standards
According to the 2006/42/CE European directive, elcom transfer systems are considered as partly
completed machines.
They are therefore not subject to an EC declaration of conformity but are the subject of a declaration
of incorporation. The latter is transmitted at the time of delivery, accompanied by the exploded view
of the motorized equipment.
However, the following standards are taken into account during the design and the manufacturing of
the elcom transfer systems:
× The European Machinery Directive 2006/42/CE
× The European Low Voltage Directive73/23/CE
elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.
For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.
1.3 Applications
The elements of the linear TLM 1500 transfer systems are designed to carry and position workpiece
carriers according to the end customers’ configuration.
They are intended to be incorporated the customers' production line.
1.4 Conditions of use
The elements of the TLM 1500 transfer systems are suited for a use in normal industrial areas such as
a final assembly plant or equivalent, in a dry environment.
They are not suited for transporting materials such as sand, balls or grain.
The maximum load applicable on the transfer system is mentioned in the catalog and must never be
ignored.
To ensure a proper functioning of the transfer system on a maximum period of time, you must follow
this advice:
- Use temperature between 0 and 40°C (30 and 140°F)
- Avoid dusty or smoky atmosphere
- Avoid accumulation of sharp objects on the transfer system
- Avoid setting the machine in direct exposition to UV rays
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1.5 Safety instructions
Safety rules regarding transfer systems, especially the ones regarding the electrical devices, must be followed during all the use phases: mounting, transport, production. Disregarding these rules would be regarded as a wrong use of the machine.
Using the transfer system in an explosive atmosphere can have a negative impact on the transfer system and is strongly discouraged.
Never perform any maintenance on your own. Another worker must be present at all time in order to shut the power down or perform first aid actions if needed. Changing the motor position or removing security parts must only be done when the
transfer system is unplugged from any power supply.
When carrying maintenance or handling tasks while the transfer system is operating (belt
tension setting), take care not to slide your hand between the belt and the belt support
in order to avoid any accident.
All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected in the end-user machine in
order to avoid any risks of pinching or squashing. We recommand to mount a protective
housing around it.
1.6 Safety instructions regarding the motor
In case of a power failure, turn off the transfer system: it could restart automatically when the power comes back which could cause damages and even injuries to the operator.
1.7 Additional information
These instructions aim at ensuring the safety of the people and the proper functioning of the transfer
system. If you wish to use the transfer system in any other conditions, please do not hesitate to
contact us.
Other information is available on our website, in the documentation section:
http://elcom-automation.com/transfers/documentation
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2 TECHNICAL SPECIFICATIONS
- Maximum load on a workpiece carrier: 4 kg
- Maximum accumulated load on the transfer system: 35 kg for a maximum 3-meters unit.
- Electrical power supply of the motors: 380V three-phase
- Motor power: V12m/mn = 0.09 Kw (V = belt speed) V16m/mn = 0.09 Kw
Air pressure supply = 5 to 6 bars
Every cylinder must be equipped with a flow limiter.
- Sound emission < 70 dB
- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.
http://elcom-automation.com/transfers/documentation
Warning: All load exceedance can lead to a premature wear of the belt or any other
parts.
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3 COMMISSIONING
3.1 Receipt
When receiving the transfer system, check if the packaging has not suffered any damage and
that the machine is in perfect conditions.
The transfer system can be supplied in kit. It then needs to be assembled.
3.2 Transfer elements
When handling the equipment and parts, take special care to avoid shocks.
1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,
2. Level perfectly the conveying units while checking that the belts are properly laid on the belt guide,
3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of the line, it may be necessary to perform ground fastenings,
4. Check the settings of the motor magneto-thermic circuit breakers,
5. Check the running direction of the belt without any load,
6. Adjust the cams and the selectors using a workpiece carrier,
7. Start the transfer system with all the workpiece carriers on.
3.3 Stopper
1. Place the stopper right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers,
3. Adjust the flow control units.
3.4 Positioning unit
1. Put the positioning unit right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers, 3. Check on the high position that the pins of the workpiece carrier are free,
4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),
5. Adjust the flow controllers.
All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected on the end-user machine
in order to avoid any risk of pinching or squashing. We recommend mounting a
protective housing.
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3.5 Workpiece carrier
1. Check that the springs of the pins located under the carrier are working properly.
2. Check that no part goes over the lower surface of the workpiece carrier.
4 MAINTENANCE
General visual check Approximately every 500 hours, check the following points to ensure the proper functioning of the transfer system:
4.1 Belts wear
Regularly verify visually the state of the belt and especially the welding area.
4.2 Passageways of workpiece carriers
The friction of the pins while operating can make some marks appear. Those marks may over the
long term require the part replacement.
4.3 Pins
Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of
efficiency in the guiding of the workpiece carrier occurs.
4.4 Wear of the belt guide
Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.
Wear area of the pins
Belt
Belt guide
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4.5 Transfer parts
Every 200 hours:
Remove the dust from the complete unit, using the product:
Ref 800 00 003 (polish plastics Air Industry 2101).
Every 3200 hours:
Check the lubrication of the conical torque.
Apply grease to obtain the initial lubrication state if necessary.
Use the grease reference 800 00 009.
4.6 Damped pneumatic Stoppers
Every 5000 hours:
Clean the stopper depending on the working environment.
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4.7 Positioning units with simple and double effect damped pneumatic stoppers
Every 1000 hours:
Remove the positioning unit plate after unscrewing the fastening screw.
Check the lubrication of the guiding shafts
Guiding shafts
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Changing the pins (locating and centering):
Extract the previous pins from the press.
Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support
(insert the pin in the bush and then place the whole on the positioning unit plate).
Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.
Pins
Bush (ref. 110 03 005)
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4.8 Positioning units with damped pneumatic stoppers
Every 1000 hours:
Remove the positioning unit plate after unscrewing the fastening screw.
Check the lubrication of the guiding shafts:
Guiding shafts
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Changing the pins (locating and centering):
Extract the previous pins from the press.
Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support
(insert the pin in the bush and then place the whole on the positioning unit plate).
Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.
Pins
Bush (ref. 110 03 005)
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4.9 Positioning units for station with damped pneumatic stoppers
Every 1000 hours:
Lubricate the positioning unit fingers with a film of grease. Use grease ref. 800 00 002 (Crown ref. 7041 spray).
Check the lubrication of the guiding shafts:
To reach the guiding shafts, remove the central fastening screw from the plate to release it from the positioning unit without removing the positioning unit from the transfer system.
For a quick lubrication of the guiding shafts, it is also possible to access them, without any disassembly, only by pulling the plate. Changing the pins (locating/centering pins):
Extract the previous pins from the press. Install the new pins in the press while using a bush of a workpiece carrier ref. 120 03 006 as a support (insert the pin in the bush and then place them on the positioning unit plate).
4.10 Lift positioning units with damped pneumatic stoppers
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Every 1000 hours:
The operating mode remains the same as the standard positioning unit. It is not necessary to disassemble the lift positioning unit from the transfer system for this maintenance. Release the plate to access the guiding shafts and cylinder by removing the fastening screws.
Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.
4.11 Other transfer parts
The others parts of the transfer system do not need any maintenance.
A visual check, looking for wear or breaking parts is recommended from time to time.
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5 MOTOR REPLACEMENT
5.1 Disassembly
Unscrew the four screws from the plastic cover.
Take the circlip and the washer off.
Circlip
Washer
Screws to
be removed
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Remove the motor from the shaft.
Unscrew the anti-rotation screw of the reducer, on the transfer side.
Anti-rotation screw
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5.2 Reassembly of the motor
Put the screw back on the new reducer.
Lubricate the shaft with copper grease.
For reassembly, follow the previous steps in
reverse order.
5.3 Changing the timing belt
The new timing belt is delivered already welded.
Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn
one. (Respect the passage way between the pulleys and belt guide).
Covers to be removed
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Stretch the belt using the tensioning screw and put the covers back into place.
6 RESPONSABILITY elcom cannot be held responsible for any damages or harms due to non-authorized modification of
any parts, especially the safety parts.
Only original components can be used for maintenance or fixing.
elcom cannot be held responsible for any malfunction if some spare parts have been used without
the validation of elcom.
elcom reserves the right to make improvements and technical modifications without any further
notice.
7 CUSTOMER SERVICE Do not hesitate to contact us for any question or advice. We will be glad to assist you.
Tel: + 33 (0)4 74 43 99 61
E-mail: [email protected]
Adress : 1 rue Isaac Asimov ZAC de la Maladière 38300 Bourgoin-Jallieu
France
Prior to any contact, please note down the serial number of the transfer system. This number can be
found on the transfer system sticker.
Belt passage way Access to the tensioning screw
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8 APPENDIX
8.1 Maintenance schedule
Maintenance of the modular transfer system TLM 1500
Frequency Action Component Chapter
200 hours To dust Transfer parts 4.5
500 hours To check Belt - Belt guide – Workpiece carrier 4.1
1000 hours To
lubricate Positioning units (shaft and cylinder) 4.7
3200 hours To
lubricate Conical torque 4.5
5000 hours To clean Stoppers 4.6
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8.2 Quality and environmental commitment: ISO certifications
Our company is recognized according to the following ISO standards and their respective evolutions
since our first certification:
- Quality Management through ISO 9001 [since 2002]
- Environmental Management through ISO 14001 [since 2013]
All our current certificates are available for download in French, English and German on our website
http://elcom-automation.com/
8.3 List of part
11002001 Piston
11002008 Corps
11002009 Guide
11002010 Tiroir
11002201 Ressort
11002202 Joint
11003003 Pion
11003005 Canon diam. 6
11003201 Ressort
11003202 Cache dia 6
11004004 Support
11004005 Support
11004007 Support came
11004008 Rail
11004009 Rail
11004010 Sélecteur
11004011 Sélecteur G
11004014 Sélecteur D
11005002 Poulie dia 26
11005003 Rondelle
11005004 Entretoise
11005005 Poulie motrice
11005010 Bague
11005201 Roulement dia 8
11005202 Roulement dia 35
11005205 Arbre moteur
11007001 Plaque
11007003 Embout
11007005 Guide
11007006 Sélecteur D
11007007 Selecteur G
11007008 Rail
11007009 RAIL
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11007201 Vérin
11009002 Corps
11009005 Doigt
11009006 Colonne
11009007 Pion locating
11009008 Pion centrage
11009010 Crochet D
11009011 Crochet G
11009012 Anti-retour G
11009013 Anti-retour D
11009205 Canon
11012003 Arbre
11012006 Guide
11012007 Pion centrage
11012008 Pion locating
11012011 Plaque vérin
11012201 Vérin
11012202 Douille à bille
11017001 Support détecteur
11018002 Equerre
11022001 Piston
11022003 Guide
11022201 Joint Torique
11023003 Tiroir
11034004 Bloc de renvoi
11034010 Flasque renvoi
11034011 Couple conique
11034012 Arbre
11034014 Arbre
11034015 Clavette
11034202 Bande retour 180°
11041201 Accouplement Ø32
11042001 Support moteur
11045201 Butée amortie pneumatique 100
11050003 Poulie contre-enroulement
11050007 Plaquette de maintien
11050009 Poulie dentée
11050010 Flasque poulie entrainement
11050011 Flasque arrêt moteur
11050013 Flasque entraînement
11050014 Flasque entraînement sym
11050016 Poulie de renvoi dentée
11050020 Guide bande 1000 cranté
11050201 Bande antistatique
11051002 Flasque renvoi cranté
11051003 Flasque renvoi cranté sym
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11052001 Flasque jonction 100
11052002 Flasque sym jonction 100
11053001 Flasque entr support came
11053002 Flasque entr support came sym
11053003 Flasque renvoi support came
11053004 Flasque renvoi supp came sym
11053005 Came 100 cranté
11053006 Came sym 100 cranté
11054004 Plaque entretoise
11054005 Flasque couple conique
11054006 Carter inférieur
11054007 Obturateur
11054008 Carter supérieur
11054009 Equerre extérieure
11054010 Equerre centrale
11054011 Rondelle fendue
11054012 Kit 2 pignons
11061003 Plaque de détection
11075201 Vérin
11504008 Rail
11504009 Rail
12003205 Tampon
12005203 Vérin
12021002 Entretoise
12021201 Vérin rotatif
12031202 Vis axe
12034201 Bande
12064253 Roulement
12064254 Circlips exterieur
12064255 Moteur 24V
12065201 Vérin
15002063 Plaque boitier
11005203A Moteur 10m/min (Lisse)-16m/min (Crantée)
11007201F VERIN
11009005F Doigt FESTO
11012201F Vérin
11050203A Moteur 12m/min (cranté)
15002006 Plaque
15002011 Support G
15002012 Support D
15002052 Bloc gauche
15002053 Bloc droit
15002054 Verrou
15002055 Butoir
15002056 Axe
15002057 Came
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15002058 Carter
15002059 Boitier
15004006 Plaque
15007009 RAIL
15007052 Guide
15007053 Sélecteur D
15007054 Sélecteur G
15007055 Embout rampe
15007056 Carter
15007057 Plaque de fermeture
15007058 Axe
15007059 Socle
15009003 Plaque indexage 150
15010001 Plaque
15010001F Plaque FESTO
15010051 Plaque de base
15010052 Plaque indexage
15010053 Entretoise
15010054 Rondelle entretoise
15010055 Guide butée
15010056 Butée à ressort
15010057 Couvercle
15010058 Support ressort
15010059 Centreur ressort
15010060 Crochet D
15010061 Crochet G
15010062 Corps
15010063 Axe fileté
15010063U Axe fileté usinage
15010064 Embout moteur
15010065 Support moteur
15010151 Pied
15010252 Ressort
15010253 Roulement
15010254 Circlips extérieur
15012001 Plaque
15012012 Plaque indexage
15012014 Plaque indexage RAP
15015001 Entretoise
15016001 Support pied
15017001 Came courte SG 150
15017002 Rampe SG
15017003 RAIL
15017004 Support came
15021001 Came double 150
15021002 Plaque
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15021003 Sélecteur 150
15021051 Came double 150 24V
15021053 Sélecteur 150 24V
15021056 Support moteur gauche
15021057 Support moteur droit
15024001 Plaque indexage 150 RAP
15027001 Entretoise
15040001 Demi jonction 150G moteur
15040002 Demi jonction 150D moteur
15040003 Demi jonction 150G renvoi
15040004 Demi jonction 150D renvoi
15045001 Support butée 150
15046001 Came courte SD 150
15046002 Rampe SD
15046003 RAIL
15050001 Bloc entraînement 1500 courroie crantée
15050004 Entretoise
15050005 Poulie motrice
15050006 Cale épaisseur 1mm
15050008 Axe poulie de renvoi
15050012 Couvercle supérieur
15050015 Cale épaisseur 2mm
15050051 Poulie motrice
15050052 Poulie de transmission
15050053 Carter droit
15050054 Carter gauche
15050055 Poulie dentée
15050056 Support moteur
15050057 Rondelle entretoise
15050058 Support moteur
15050059 Poulie dentée
15050060 Rondelle
15050251 Motoréducteur 24V
15050252 Courroie dentée
15050255 Motoréducteur 24V
15051001 Bloc renvoi 1500, courroie crantée
15054002 Guide central 150
15054003 Plaque de base
15062001 Embase 150*150 unidirectionnel
15062001T Embase U 150 x 150 avec tampon
15062002 Plateau 150x150
15062002G Plateau 150x150G
15064001 Embase 150x150 multi.
15064002 Plaque 150x150
15064002G Plaque 150x150G