operation & maintenance manual model ts1500/140 … & maintenance manual model ts1500/140...

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Operation & Maintenance Manual

Model TS1500/140

Aluminum Frame Power Turn

Transnorm System Inc. 2810 Ave E East. Arlington, TX 76011 USA

Telephone: 1-800-331-1749 / 972-606-0303 Fax: 972-606-0768

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OPERATION & MAINTENANCE MANUAL

TABLE OF CONTENTS PAGE

Section I – GENERAL DESCRIPTION 3 Section II – STORAGE & INSTALLATION INSTRUCTIONS –

FLOOR SUPPORTS AND CEILING HUNG SUPPORTS 5 Section III – INITIAL START-UP 10 Section IV – OPERATIONAL TROUBLESHOOTING 13 Section V – PREVENTIVE MAINTENANCE 14 Section VI – SIDE GUARD REMOVAL 15 Section VII – BELT BEAD HOLDER REPLACEMENT 19 Section VIII – DRIVE PACKAGE INSTALLATION 21 Section IX – BELT TRACKING 26 Section X – LACED BELT REPLACEMENT 32 Section XI – VULCANIZED BELT REPLACEMENT 40 Section XII – DRIVE PULLEY REPLACEMENT 45 Section XIII -OUTER HOUSING, FINGER GUARD & INNER BEARING SUPPORT LOCATIONS 47 Appendix A - WARRANTY STATEMENT 50 Appendix B – PACKAGE SIZE FORMULA & TABLES 51 Appendix C – HORSEPOWER REQUIREMENT CHART 54 Appendix D – INSTALLATION / SPARE PARTS LIST 55 Appendix D1/D2/D3 – DRAWINGS 57

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SECTION I GENERAL DESCRIPTION

The Transnorm TS1500/140 power turn features are: All aluminum frame construction - strong, durable, lightweight. Metal holders with quick release bracket and standard clipper laced belting - improves

ease of belt replacement procedure. Steel shell end rolls with removable shaft and universal motor mount locations –

provides for easier drive location changes in the field. Removable perforated guards - improves ventilation for better heat dissipation and

allows for visual inspection of the belt bead guidance system. Ability to bolt on accessories – no drilling required. This manual only refers to the TS1500/140 power turn. The general design is the same for all angles and widths. All descriptions in this manual are prepared for use by professional service and maintenance personnel. In this manual, important instructions are identified as follows:

Notice! Pay attention to technical information.

Attention! Follow the instructions exactly to prevent damage during installation and operation.

Caution! Follow the instructions exactly to prevent injury of personnel.

Intended Use The power turn is made for transportation of material or packages within a conveying system. Transportation of persons, which include but are not limited to climbing, sitting, walking, or riding, on the power turn at any time is strictly prohibited.

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Operation, Installation, Service and Maintenance To prevent damage to the power turn and to assure the safety of the maintenance personnel; the operation, installation, service and maintenance of the power turn must only be performed by properly trained personnel, in accordance with this manual, the technical specifications of the power turn, the documentation of the system and the following requirements: ASME B20.1-1996 OSHA standards 29CFR part 1910 Any applicable local or national codes

Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards.

Caution! There are covers and finger guards mounted on the power turn, which should only be removed for installation, service and maintenance. Operation of the power turn without the provided covers and guards will increase the risk of an accident. All covers and guards must be replaced before operating the power turn. If operating the power turn without the provided covers and guards, proper barriers and signage around the work area must be in place to protect against access by unauthorized personnel.

Operating Conditions The power turn may only be operated in a fixed, mounted state and is designed for use within a non-corrosive atmosphere. The operating environment is as follows: Environment temperature, air: 0° C (32° F) to 40° C (104° F) Humidity, non condensing: 0% to 90% Normal, Non-Corrosive Atmosphere (no oil or gas atmospheres) Closed building (protection against precipitation)

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SECTION II STORAGE & INSTALLATION

Attention! Read and understand all instructions within this section prior to beginning any operation, installation, service or maintenance of the power turn.

Storage The TS1500/140 power turn will be delivered on site completely assembled (including the drives and side guards) unless otherwise directed by the customer. Shaft mounted gearmotors are not shipped mounted to the power turn and will require installation. See Section VIII – Drive Package Installation. All required floor supports are generally secured on the bottom of the shipping crate, under the power turn. Store all units within the shipping crate until the unit is to be installed. Avoid stacking the crated units during storage. If the power turn is to be removed from the shipping crate before being installed, store the unit on a level floor or level the unit using wood blocks to prevent damage. Protect all units during storage and installation from UV light, humidity, condensation, excessive heat, excessive cold and environments that could contaminate the unit (especially the belt and pulleys) with foreign elements.

Installation with Floor Mounted Supports

Caution! All power turns and related conveyor equipment must be properly supported individually. DO NOT support any conveyor equipment using side guard connections only. 1. Place the crated unit in an area clear of clutter with an ample workspace for setting up

the power turn. If provided and accessible, remove the floor supports from the crate. The support height has been preset and should not require any adjustment. If needed, the supports can be adjusted using the following formula: Required top of belt height minus 266.7mm [10.5“] = adjusted support height. (See illustration 2-1) For units requiring ceiling support hangers, see Installation with Ceiling Hung Supports.

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Illustration 2-1

2. Remove all hold-downs and lift the unit from the crate using a forklift, crane or other

means, being careful not to damage the power turn. Attach the supports at the locations as shown in illustration 2-2, using the provided hardware.

Illustration 2-2

57mm [2.25"]

184mm [7.25"]

Inside RadiusBelt Width

Support Locations FromThe Ends Of The Turn.

NOTE: Equally space remainingsupports between the mountedend supports. Outside radiusdistance between supports Isnot to exceed 1524mm [60"].

Top of Belt

266.7mm [10.5"](Frame Depth + 1" Gap)

Required Topof Belt

AdjustedSupportHeight

Floor Support Assembly

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3. Properly position the power turn within the conveyor system and verify that the top of belt height provides a level transition or a downward cascade transition from the upstream conveyor and to the downstream conveyor. The top of belt height should also be level across the width and length of the power turn. Make any adjustments as needed.

4. The curve should be centered between feeding and takeaway conveyor. If Transnorm

System provides sideguards, we typically will allow 6.35mm(.25”) gap between outside radius bearing housing and adjoining conveyor frame to allow tightening and adjusting of the belt. This is accomplished by extending the sideguard 22.2mm(.88”) (at OR and IR) beyond the top face of the OR bearing housing. This normally results in a 22.2mm(.88”) gap between the belt on the curve and the frame on the adjoining conveyor. The gap between pulleys can be less than this if the pulley on the adjoining conveyor can extend beyond the conveyor frame. (See Illustration 2-3 and 2-4)

ConnectingConveyor

22.2m m [1.88"]

TransnormPower Turn

6.35m m [.25"] ADJUSTM ENT

Illustration 2-3

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Tra n s n o rmP o w e r Tu rn

C o n n e c t in gP o w e r Tu rn

4 4 .5 m m [ 1 .7 5 "] TO ALLO W F O R6 .3 5 m m [ .2 5 "] AD J U S TM E N T

O N E AC H C U R VE .

2 2 .2 m m [ .8 8 "]

1 2 .7 m m [ .5 0 "]

Illustration 2-4

5. Re-position the power turn as required and re-verify the top of belt height. Make any

adjustments as needed. Attach the end flanges on the power turn side guard assemblies to the connecting conveyor side guard end flanges and then secure the floor support mount feet to the floor. All required installation hardware is to be provided by the installer.

6. To complete the installation of the power turn, all required system controls and electrical power would need to be installed. Only properly trained and certified electricians should perform this function in accordance to all applicable local and national standards.

Installation with Ceiling Hung Supports

Caution! All power turns and related conveyor equipment must be properly supported individually. DO NOT support any conveyor equipment using side guard connections only. 1. Install the 3/4" all-thread rods (supplied by the customer) to provide support locations as

shown in illustration 2-2. NOTE: To assure room for maintenance work, the all-thread rods should be hung to allow a 4” clearance at all non-drive locations and a 10” clearance at the drive location.

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2. Thread (1) 3/4" jam nut onto each of the all-thread rods until it is above the approximate location of where the bottom edge of the power turn frame will be. The nuts should be positioned to avoid any interference with installation of the power turn.

3. Place the crated unit in an area clear of clutter with an ample workspace for setting up

the power turn. Remove all hold-downs and lift the power turn to an appropriate working height. Install and secure the provided support mounting brackets in the locations as shown in illustration 2-2. Refer to illustration 2-5 to confirm proper orientation of the support mounting brackets.

4. Install the support tubes at each location using the 5/16” U-bolts around the pipe and up

through the pre-drilled holes in the support mounting bracket with the appropriate hardware. (See illustration 2-5) Measure from the bottom edge of the power turn frame to the end of the tube allowing 6” for non-drive locations and 12” at the drive. Tighten the U-bolt hardware, securing the power turn to the pipe supports.

5. While lifting the power turn, insert the all-thread rods into the pre-drilled holes in the

support pipes and position the power turn within the conveyor system. Verify that the top of belt height provides a level transition or a downward cascade transition from the upstream conveyor and to the downstream conveyor. The top of belt height should also be level across the width and length of the power turn. Make any adjustments as needed.

6. The curve should be centered between feeding and takeaway conveyor. If Transnorm System

provides sideguards, we typically will allow 6.35mm(.25”) gap between outside radius bearing housing and adjoining conveyor frame to allow tightening and adjusting of the belt. This is accomplished by extending the sideguard 22.2mm(.88”) (at OR and IR) beyond the top face of the OR bearing housing. This normally results in a 22.2mm(.88”) gap between the belt on the curve and the frame on the adjoining conveyor. The gap between pulleys can be less than this if the pulley on the adjoining conveyor can extend beyond the conveyor frame. (See Illustration 2-3 and 2-4)

7. Thread (1) 3/4" jam nut onto each of the all-thread rods and tighten the nuts against the

support pipe. Add an additional jam nut to each of the all-thread rods and tighten until the jam nuts lock against each other. Tighten the previously installed jam nuts (above the pipe) down until they lock firmly against the pipe.

8. Re-check the elevation and proper leveling of the power turn. Re-position the power

turn as required and re-verify the top of belt height. Make any adjustments as needed. Attach the end flanges on the power turn side guard assemblies to the connecting conveyor side guard end flanges. All required installation hardware for this step is to be provided by the installer.

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9. To complete the installation of the power turn, all required system controls and electrical power would need to be installed. Only properly trained and certified electricians should perform this function in accordance to all applicable local and national standards.

Illustration 2-5

SECTION III INITIAL START-UP

Attention! Read and understand all instructions within this section prior to beginning the initial start-up of the power turn.

Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. 1. Check the installation position: Check the top of belt heights between the

TS1500/140 power turn and the connecting conveyors. Verify that the power turn is also level in the width and length directions.

2. Factory Belt Tension: Transnorm marks factory adjustment location with scribed lines

on outer bearing housings showing factory location of bearing. (See Figure 3-1)

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Figure 3-1 Inner housings are marked for factory position on shaft of trommelager assembly. (See Figure 3-2)

Figure 3-2

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3. Cleaning: The power turn must be free of dirt and/or debris. All foreign elements must be removed (especially from the belt and pulleys).

4. Check the side guarding: The side guarding must be mounted so that the guards cannot interfere with the running of the belt or the flow of material.

5. Check the drive motor assembly: To inspect the drive assembly, remove the drive

cover and check the condition of the drive components, verifying that everything is in the correct position. Replace the drive cover. Locate the vent plug on the reducer and insure that it is in an upward position.

Caution! The electrical lock out is to be removed to complete steps 5 & 6. Extreme caution must be taken to ensure the safety of the maintenance personnel.

6. Start running the power turn: First, check the running direction of the belt by jogging

the motor. The direction of flow should always be towards the drive location as the power turn pulls the belt. If the power turn pushes the belt, the flow direction is not correct and 2 poles of the electrical connections at the motor must be reversed. Turn off the power prior to changing any of the motor lead connections.

7. Check the running of the belt: The power turn should run smoothly and quietly without noises and with a minimum of belt waving (bumps or ripples, not to exceed 10mm in height). Excessive waving is an indication of improper belt tracking and should be adjusted according to Section IX – Belt Tracking.

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SECTION IV

OPERATIONAL TROUBLESHOOTING The following troubleshooting chart refers to possible problems that may occur in the operation of the Transnorm System Inc. power turn. If a problem exists outside the scope of this troubleshooting guide, contact Transnorm System Inc. customer service department for additional assistance.

PROBLEM PROBABLE CAUSE POSSIBLE SOLUTION

Power turn does not run Open circuit Close circuit by professional

Motor defective Replace motor

Power turn does not operate with Motor running Drive belt slipping Tighten drive belt

Rough running belt Belt not tensioned Tension belt

Beading defective Replace belt

Belt blocked by foreign object Remove foreign object

Beading comes out of holders Incorrect belt adjustment Correct adjustment

Belt blocked by foreign object Remove foreign object

Noise in beading holders Bearing damaged Replace holder

Holder damaged Replace holder

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SECTION V PREVENTIVE MAINTENANCE The following points of the maintenance plan have to be checked on regular intervals. The listed intervals are for one-shift-operations under normal conditions as described within the Operating Conditions of Section I – General Description.

TASK PERIOD COMMENT Clean belt, check belt and beading for wear or damage.

Quarterly Use 409 cleaner (diluted with water 50/50) and paper towels to clean the belt. Note: Non-textured belts only.

Check belt tension and belt run.

Quarterly Adjust as necessary per Section IX - Belt Tracking.

Check bearings in the holders for noise.

Every 6 months for the first year, monthly after that.

Replace as needed.

Check inside radius and outside radius bearings for noise.

Every 6 months for the first year, monthly after that.

Replace as needed.

Checking drive pulley for damage

Quarterly Replace as needed.

Check gear motor or motor/reducer for noise.

Quarterly Replace or adjust as needed.

Check oil in gear motor or motor/reducer.

Per manufacturer's specifications.

Check manufacturer's specifications or contact Transnorm System Inc.

Chain / V-belt drive. Quarterly Adjust tension and/or

lubricate as necessary.

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SECTION VI SIDE GUARD REMOVAL


Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. In general, most power turn orders will have side guard assemblies along the inside radius and the outside radius of the power turn assembly. The inside radius side guard is bolted directly through the deck board along the inside radius. The outside radius side guard is welded to the top shroud and the side guard assembly is then bolted to the top of the upper belt bead holders. On some power turns, the outside radius side guard assembly may be made in multiple pieces and will have splice angles between each of the sections. Attached to the outside of the in-feed and discharge ends of the side guard assemblies are flanges for connecting the power turn side guards to the connecting conveyor side guards. Prior to any maintenance work such as changing the belt, the drive pulley, the tail pulley or any of the belt bead holders, the side guard assemblies, the perforated guards and the outer end guards will need to be removed first. After completion of the required maintenance work, reinstall the side guard assemblies, the perforated guards and the outer end guards onto the power turn.

Caution! All power turns and related conveyor equipment must be properly supported individually. DO NOT support any conveyor equipment using side guard connections only. To complete the procedure within this section, the following tools will be required: Wrenches - 13mm & 17mm Phillips Head Screwdriver

Caution! The use of (2) maintenance personnel should be considered for this procedure when the angle of the power turn assembly exceeds 30 degrees. 1. Remove the hardware from the butt flanges at the in-feed and discharge ends of the

side guard assemblies.

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2. If the outside radius side guard is made in multiple sections, the hardware at each splice

will need to be removed using the 13mm wrench.

3. Remove the hardware from the outer end guards (LH and RH) and the outer perforated

guard using the 13mm wrench.

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4. Remove the hardware along the top shroud using the 13mm wrench. Next, remove the

hardware from the outside radius housing using the 17mm wrench. Once the attachment hardware has been removed, take the outside radius side guard assembly off the power turn.

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5. Remove the Phillips head screws at the top of the inner end guards (universal). Next

remove the hardware from the inner end guard and the inner perforated guard using the 13mm wrench.

6. Remove the hardware along the deck board of the inside radius side guard. Once all of

the attachment hardware has been removed, take the inside radius side guard assembly off of the power turn.

7. Upon completion of the maintenance work, reinstall the side guard assemblies in the

reverse order in which they were removed. Verify that there is no interference with the belt from the side guard assemblies after they have been installed. Make any adjustments as required.

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SECTION VII BELT BEAD HOLDER REPLACEMENT


Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. For access to any of the upper and/or lower holders that need to be replaced, remove the outside radius side guard assembly only according to the procedure within Section VI – Side Guard Removal. To complete the procedure within this section, the following tools will be required: Allen Wrench - 6mm

Upper Holder Assembly

1. Open the upper holder assembly by first rotating the locking clip on the backside of the

holder to an unlocked position. Pull the top half of the holder sideways releasing the locking pin mounted in the bottom half of the holder and then rotate the top half of the

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holder towards the outside radius of the power turn, until the bearing clears the belt beading.

2. Using the 6mm Allen wrench, loosen and remove the hardware securing the upper

holder assembly to the holder rail. Remove the upper holder assembly and install a new upper holder assembly in the same location.

Lower Holder Assembly 1. To remove any of the lower holder assemblies, follow the same procedure that is used

for removing the upper holder assemblies. Install a new lower holder assembly in the same location.

2. Upon completion of the maintenance work, reinstall the outer perforated guard, the outside end guards and the outside radius side guard assembly in the reverse order in which they were removed. Verify that there is no interference with the belt from the outside radius side guard assembly after it has been installed. Make any adjustments as required.

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SECTION VIII DRIVE PACKAGE INSTALLATION


Attention! Verify that the vent plug on the reducer is placed on the top. Verify proper oil level for the specific reducer placement.

Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. The TS1500/140 power turn utilizes the following standard drive packages:

Shaft Mounted Motor And Reducer 1. If key stock is required, insert the key stock into the drive shaft keyway. If taper lock

bushings are required proceed to step 2. 2. Slide the drive package onto the drive shaft. If taper lock bushings are required, ensure

that they have been properly installed. 3. Bolt the torque arm bracket to the frame of the conveyor. 4. Secure the reducer to the shaft according to the style of the reducer.

Caution! The electrical lock out is to be removed to complete step 5. Extreme caution must be taken to ensure the safety of the maintenance personnel.

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5. Test run the power turn to check for any problems.

Shaft Mounted Reducer w/ Sidemount Or Underslung Motor

1. Place the motor onto the mounting platform and using the appropriate hardware, hand-tighten the motor into place.

2. Attach the drive components to the motor shaft and to the reducer shaft leaving clearance for the drive guard.

3. Place the power transmission components around the drive components. 4. Attach the torque arm using the brackets on the reducer and on the torque arm mount

bracket. 5. Using a straight edge, check the drive components for proper alignment. Make any

adjustment as required. (See illustration 8-1) 6. Tighten the motor mounting bolts. Recheck the drive components alignment. 7. Secure the reducer to the shaft according to the style of the reducer. 8. Adjust the torque arm to properly tension the power transmission components.

Caution! The electrical lock out is to be removed to complete step 9. Extreme caution must be taken to ensure the safety of the maintenance personnel. 9. Test run the power turn to check for any problems.

Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards upon completion of step 9 and before continuing with steps 10 and 11. 10. Recheck the power transmission components tension and the drive components

alignment. 11. Attach the drive guard to the unit using the appropriate mounting brackets and

hardware.

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NOTE: For proper drive component alignment, 4-point contact must be achieved. (See Illustration 8-1)

Illustration 8-1

Contact Point #4

Contact Point #1

Staight Edge

Reducer

Motor

Contact Point #2

Contact Point #3

Gear / Sheave(drive components)

Gear / Sheave(drive components)

Center Line of Chain / Belt(power transmission components)

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Underslung Gearmotor 1. Place the gearmotor onto the mounting platform and using the appropriate hardware,

hand-tighten the unit into place. 2. Mount the back of the drive guard to the power turn using the appropriate mount

brackets and hardware. 3. Attach the drive components to the gearmotor shaft and to the drive pulley shaft leaving

clearance for the drive guard. 4. Place the power transmission components around the drive components. Adjust the

tension bolts on the mounting platform until proper tension is achieved. 5. Using a straight edge, check the drive components for proper alignment. Make any

adjustments as required. (See illustration 8-2) 6. Tighten the gearmotor mounting bolts. Recheck the power transmission components

tension and the drive components alignment.


7. Test run the power turn to check for any problems.

Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards upon completion of step 7 and before continuing with steps 8 and 9.

8. Recheck the drive components alignment. 9. Place the front of the drive guard on the unit. NOTE: For proper drive components alignment, 4-point contact must be achieved. (See Illustration 8-2)

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Illustration 8-2

Contact Point #4

Contact Point #1

Contact Point #2 Contact Point #3Straight Edge

DrivePulley

Center Line of Chain / Belt(power transmission components)

GearmotorGear / Sheave(drive components)

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Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. When tracking the belt, keep the belt tension as loose as possible. This will guarantee the longest life of the belt. The belt is designed to be fully adjusted when the pulley is flush with the end of the frame. It may be necessary to slightly adjust the belt from this location.

1. Use the 19mm wrench to slightly loosen (do not remove) the hardware on the outside

radius tow bolt flange bearing of the drive and tail pulley assemblies. On the inner bearing supports, use the 4mm Allen wrench and loosen the setscrew that secures the trommellager bearing rod end.

SECTION IX BELT TRACKING

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2. Using the 19mm wrench, tension the bearing adjustment bolts at the inside radius and

outside radius locations of the drive and tail pulleys so that the belt face at all four corners is flush with the bottom cross member of the frame. Turning the tensioning bolt to the left hand will move the holders to the outside (away from the frame) and will tension the belt. Turning the tensioning bolt to the right hand will slacken the belt. Refer to illustration 9-1, illustration 9-2 and the detailed adjustment instructions. Over tensioning can be detected by the bulging of the beading. Illustration 9-1A shows how over tensioning can cause the beading to deform and bulge out.

NOTE: Holes in outside radius aluminum castings that attach to two-bolt flange bearings are slightly larger than bolts used. As such, be sure bearings are raised to maximum position in these holes before tightened in place (see arrow in photo above).

Illustration 9-1A

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Illustration 9-1 BEARINGS TO TIGHT AT: BEARINGS TO LOOSE AT:

A Adjust out (tighten) 3. A Adjust out (tighten) 1. If B becomes to tight, return 3

to its original position and B Adjust out (tighten) 3. adjust in (loosen) 1 slightly. Be sure A does not

become to loose.

B Adjust in (loosen) 3.

Be sure A does not become C Adjust out (tighten) 2. to tight.

D Adjust out (tighten) 4. Be ALTERNATIVE: Adjust in sure C does not become (loosen) 1. Be sure A does to loose. not become to loose.

C Adjust out (tighten) 4. If D becomes to tight, return 4 to its original position and adjust in (loosen) 2 slightly.

D Adjust in (loosen) 4. Be sure C does not become to tight.

ALTERNATIVE: Adjust in (loosen) 2. Be sure C does not become to loose.

3A 1

B

4 2 C

D

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Illustration 9-2 BEARINGS TO TIGHT AT: BEARINGS TO LOOSE AT:

A Adjust out (tighten) 3. A Adjust out (tighten) 1. If B becomes to tight, return 3

to its original position and B Adjust out (tighten) 3 adjust in (loosen) 1 slightly. and 4 equal amounts.

Be sure A and C don’t

B Adjust in (loosen) 3 and 4 become to loose. equal amounts. Be sure A

and C do not become to tight. C Adjust out (tighten) 2. ALTERNATIVE: Adjust in (loosen) 1 and 2 equal amounts. Be sure A and C don’t become to loose.

C Adjust out (tighten) 4. If B becomes to tight, return 4 to its original position and adjust in (loosen) 2 slightly.

B

C

A

4

1 3

2

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On large curves, adjusting out (tightening) either of the inside radius tensioning bolts (3 or 4) will cause the belt to stretch across the belt to the center of the outside radius (B). On small curves, adjusting out (tightening) either of the inside radius tensioning bolts (3 or 4) will cause the belt to stretch diagonally across the curve to its opposite point on the outside radius (A or C). Exception for small curves, if the above procedures don’t work, try the following: If A is tight, it is possible to adjust in (loosen) 4 to correct. Be sure C does not become too tight. If C is tight, it is possible to adjust in (loosen) 3 to correct. Be sure A does not become too tight. 3. When Belt Tracking/Tensioning is complete and prior to tightening bolts to lock pulley in place, ensure outside radius shroud has maximum clearance for smooth belt travel. (See Figures 9-3 and 9-4)

Figure 9-3

NOTE: If 1/4”gap between face of belt and inside of outer housing cannot be achieved, it might be necessary to rotate far outside corner of the cast aluminum housing itself further past the outside radius of the frame to achieve proper clearance.

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Figure 9-4

Caution! The electrical lock out is to be removed at this point of operation. Extreme caution must be taken to ensure the safety of the maintenance personnel. Test run the power turn to check the belt tension and tracking. It has to run smooth and without noises.

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Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. Prior to the use of the following procedure, any attached side guard assemblies, perforated guards and outer endplates will need to be removed according to the procedure within Section VI – Side Guard Removal. To complete the procedure within this section, the following tools will be required: Wrench 19mm Allen Wrench - 4mm Box Cutter Knife Needle Nose Pliers Sewing Awl

1. Rotate the belt until the belt lacing is on the deck board surface towards the tail pulley of

the power turn. This may required the power turn to be operated electrically. Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards upon completion of step 1 and before continuing with step 2 of this section.

SECTION X LACED BELT REPLACEMENT

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2. To release the belt tension and allow for bearing movement, use the 19mm wrench to

slightly loosen (do not remove) the hardware on the outside radius bearing of the drive and tail pulley assemblies. Next, back off the locking nut and then the bearing adjustment bolt using the 19mm wrench. On the inside radius tromellager assemblies, use the 4mm Allen wrench to loosen the setscrew that locks the rod end shaft in place. Next, back off the locking nut and then the bearing adjustment bolt using the 19mm wrench.

3. At the point where the belt splice is located, open 4 of the top belt bead holders as

described within Section VI – Belt Bead Holder Replacement, Upper Holder Assembly. This will provide adequate clearance for completing the next steps of this procedure.

4. Using the box cutter knife, cut the stitches located at the belt splice, separating the

beading from the belt material. Open any crimped lace hooks and remove the pin from the belt lacing and separate the belt ends from each other. Lay the back half of the belt back over itself, exposing the deck board below. Place the new belt with the backside of the belt roll on the topside of the exposed deck board (this may require that the new belt be rolled to allow for the same placement and orientation in relation to belt being replaced).

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5. Mesh the old belt lace with the new belt lace and secure the two loose ends together

with the pin. While pulling the loose end of the old belt and feeding the new belt towards the tail pulley of the power turn, you will be able to replace the old belt with the new belt. Once the new belt has been pulled through the bottom side of the power turn and back around to the upper side remove the old pin from the belt lace and separate the old belt from the new belt. Discard the old belt and pin according to local, state or national recycling procedures.

6. Mesh together the lacing from each loose end of the new belt and then use the new pin

(provided with each new belt assembly) to secure the lacing. Using the needle nose pliers, crimp down the first lace hooks on each side of the pin.

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outside radius locations of the drive and tail pulleys so that the belt face at all four corners is flush with the bottom cross member of the frame. This should provide the proper tension across the belt splice and lacing.

Caution! When applying super glue, keep contact with exposed skin to a minimal. Do not allow any contaminated skin surface to adhere to any other surfaces. Upon completion of the use of the super glue, all contaminated skin surfaces will need to be properly cleaned.

Attention! The use of super glue is for the purpose of holding the backside of the belt bead in place during the sewing operation of this procedure.

Caution! Great care must be taken when using the awl to sew the belt bead stitching. The point of the awl is very sharp and will cause injury if not being properly used.

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Notice! The direction of belt flow is always towards the motor as the belt is pulled by the drive rather then being pushed. There are occasions where the drive does push the belt, so it is important to make a proper determination of belt flow before proceeding with this step of the procedure. 8. Cut the beading 4” long from the leading edge of the belt (see figure#1). Mark and cut

the trailing belt beading to mate flush with the end of the leading belt beading (see figure#2). DO NOT CUT BELT. Apply a sufficient amount of super glue to the belt and beading along the 4” cut length of the leading belt beading and any loose section of the trailing belt beading (see figure#3 & 4. Note that the glue is only required to hold the beading in place so to ease the process of sewing). Slip the leading belt beading onto the outer belt edge of the trailing belt and mate with the end of the trailing belt beading and clamp down (see figure#5). Allow proper cure time for the adhesive to dry. Using the supplied hand awl, sew (2 rows) the beading to the belt along the length of the spliced section of beading and across the joint. Figures number six thru eleven show the sewing process. Refer to illustration 10-1.

Figure#1 Figure#2

Figure#3 Figure#4

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Figure#5 Figure#6

Figure#7 Figure#8

Figure#9 Figure#10

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Figure#11

Illustration 10-1

9. Upon completion of the belt replacement, close the 4 top belt bead holders and rotate

the clip along the backside of the holders into their original locked position.

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Caution! The electrical lock out is to be removed to complete step 10. Extreme caution must be taken to ensure the safety of the maintenance personnel. 10. Operate the power turn without a load and track the belt according to the procedure

within Section IX – Belt Tracking. Do not touch the belt while the power turn is running. The belt should run smoothly with minimal bumps or ripples (not to exceed 10mm in height) at either end or along the inside radius. If bumps or ripples exceed 10mm in height, the pulleys should be slightly adjusted in small equal amounts at all four corners to make the belt run smoothly.

Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards upon completion of step 10 and before continuing with step 11 of this section. 11. Upon completion of the laced belt replacement procedure the side guard assemblies,

perforated guards and outer end guards will need to be reinstalled in the reverse order in which they were removed. Verify that there is no interference with the belt from the side guard assemblies after they have been installed. Make any adjustments as required.

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SECTION XI VULCANIZED BELT REPLACEMENT


Notice! Clipper laced splice is recommended as the clipper laced splice is the standard type of splice method used on Transnorm System Inc. power turns.

Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. Prior to the use of the following procedure, any attached side guard assemblies, perforated guards and outer endplates will need to be removed according to the procedure within Section VI – Side Guard Removal. If the drive is located at the inside radius of the curve, it will have to be removed. Refer to Section VIII – Drive Package Installation for assistance in reinstalling the drive upon completion of changing the belt assembly. If the drive is mounted on the outside radius of the curve, it does not have to be removed, but may need to be loosened so that the pulley can be moved in order to release the belt tension. To complete the procedure within this section, the following tools will be required: Wrench - 13mm & 19mm Allen Wrench - 4mm

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1. Release the belt tension. Using the 19mm wrench, loosen (do not remove) the hardware on the outside radius bearing of the tail pulley. Next, back off the locking nut and then the bearing adjustment bolt using the 19mm wrench.

2. Open the top belt bead holders as described within Section VII – Belt Bead Holder Replacement, Upper Holder Assembly.

3. Using the 13mm wrench, remove the bolts holding the inner end guards (LH & RH) to

the inner vertical deck supports.

4. Using the 4mm Allen wrench, loosen the setscrews on the bearing collar. Next, remove

the bolts holding the trommellager bearing assembly to the inner vertical deck supports with the 13mm wrench. If needed, use a rubber mallet to assist in removing the trommellager with the bearing support assembly from the shaft.

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5. Remove the mounting bolts from the ends of the cross members using the 6mm Allen

wrench.

6. Lift the deck board with the cross members attached, up and over the top belt bead

holders, pulling the deck board towards the outside radius of the turn.

7. Open the lower belt bead holders in the same manner as the top belt bead holders as described within Section VII – Belt Bead Holder Replacement, Upper Holder Assembly.

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8. Pull the belt towards the inside radius of the power turn and off the inside radius ends of

the drive and tail pulley assemblies. Pull the new belt over the inside radius of the drive and tail pulley assemblies towards the outside radius of the power turn unit. Push the pulley assemblies inwards and work the beading between the finger guard and the outer housing.

9. Re-install the deck board with the cross members attached and the trommelager bearing assemblies in the reverse order in which they were removed.

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outside radius locations of the drive and tail pulleys so that the belt face at all four corners is flush with the bottom cross member of the frame.


12. Operate the power turn without a load and track the belt according to the procedure

within Section IX – Belt Tracking. Do not touch the belt while the power turn is running. The belt should run smoothly with minimal bumps or ripples (not to exceed 10mm in height) at either end or along the inside radius. If any bumps or ripples exceed 10mm in height, the pulleys should be slightly adjusted in small equal amounts at all four corners to make the belt run smoothly.

Caution! The main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards upon completion of step 12 and before continuing with step 13 of this section. 13. Upon completion of the vulcanized belt replacement procedure the side guard

assemblies, perforated guards and outer end guards will need to be reinstalled in the reverse order in which they were removed. Verify that there is no interference with the belt from the side guard assemblies after they have been installed. Make any adjustments as required.

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SECTION XII DRIVE PULLEY REPLACEMENT


Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards. Prior to the use of the following procedure, any attached side guard assemblies, perforated guards and outer endplates will need to be removed according to the procedure within Section VI – Side Guard Removal. To complete the procedure within this section, the following tools will be required: Wrench - 19mm & 13mm Allen Wrench - 4mm Rubber Mallet Changing the drive and tail pulley assemblies are nearly the same. When changing the drive pulley assembly, the drive package will need to be removed. 1. To begin the maintenance work within this section, refer to Section XI – Vulcanized Belt

Replacement. Disassemble the power turn according to the belt replacement procedure until the trommellager assemblies have been removed. On power turns using the standard clipper lacing, the belt should be positioned where the pin can be removed and the belt opened for access to the drive pulley assembly. On power turns using a non-standard vulcanized belt, the belt will have to be removed for access to the drive pulley assembly.

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2. Using the 4mm Allen wrench, loosen the setscrews on the outside radius bearing collar.

If needed, use a rubber mallet to assist in removing the drive and/or tail pulley assembly from the outside radius bearings, freeing the pulley assembly from the power turn.

3. Verify that the new drive and/or tail pulley assembly has the outer pulley spacer installed

on the outside radius shaft, provided by Transnorm System Inc.

4. Install the new drive / tail pulley assembly by inserting the pulley shaft through the outer bearing insert and pushing the outside radius spacer firmly against the inside of the outer bearing assembly. With the new drive / tail pulley assembly properly installed, tighten the setscrews on the outside radius bearing collar using the 4mm Allen wrench.

5. Re-assemble the power turn in the reverse order in which it was disassembled within Section XI – Vulcanized Belt Replacement. Refer to Section VIII – Drive Package Installation for assistance in reinstalling the drive. Track the belt according to the procedure within Section IX – Belt Tracking.

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SECTION XIII OUTER HOUSING, FINGER GUARD &

INNER BEARING SUPPORT PLACEMENT


Caution! Before installation, service or maintenance, the main disconnect switch of the system must be turned off and locked out according to all applicable local and national standards.

Outer Housing During assembly of the power turn, the outer housing location is pre-set and should not require repositioning during any maintenance work. If such a situation does occur requiring the outer housing to be moved, use the following instructions to re-position the housing to its proper location. Locate the outer housing by placing 10mm carriage bolts in the bottom of the slots of the housing and in the center set of holes on the outer housing plate. Measure from the front edge of the mounting plate, 64mm [2.52”] back to the lower front edge of the outer housing. Hand-tighten the hardware, verify that housing location is correct and then secure the hardware accordingly. As a reference, the front of the outer housing should be approximately 15.9mm [.63”] past the front end of the frame. (See illustration 13-1)

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Illustration 13-1

Finger Guard

4.8mm [.19"] Minimum clearance between belt and finger guard.

64mm [2.52"]From the front edge of the mounting plate

to the lower front edge of the outer housing.

Illustration 13-2

To ensure proper belt function and longevity, the gap between the finger guard and the outer housing should be set and maintained at 4.8mm [.19”] minimum from the face of the belt to the inner edge of the outer housing. (See illustration 13-2)

15.9mm [.63"] From the end of the lower frame memberto the front of the housing along the centerline.

64mm [2.52"]From the front edge of the mounting plate to the lower front edge of the outer housing.

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Inner Bearing Support During assembly of the power turn, the inner bearing support location is pre-set and will not require repositioning during any maintenance work. Upon completion of any maintenance work in which the inner bearing support has been removed, the angle of misalignment should not exceed 5 degrees when measured along the vertical edge of the lower inner frame profile. (See illustration 13-3)

Illustration 13-3

5°Vertical Edge of Lower Inner Frame Profile

(Bearing Cap Removed For Clarity)

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APPENDIX A WARRANTY STATEMENT

Transnorm System Inc provides a two (2) year warranty on its products from date of shipment. Within the period noted above material showing defects will be repaired or replaced provided:

1. Proper notice (written / oral) is provided within 24 hours after failure.

2. Proof of defective part is returned to Transnorm System Inc. Conditions, which may void warranty:

1. Improper installation.

2. Damage during installation, shipment, or storage prior to installation.

3. Unauthorized modification, alteration or variations from the standard Transnorm System Inc. design.

4. Damage due to improper operation or loading.

Products normally warranted by original manufacturer include:

1. Bearings.

2. Motors.

3. Reducers.

4. Drive components. Notes: Call Transnorm System Inc., Warranty Repair Service for assistance with all warranty work, to obtain an RGA number (return goods authorization) for the return of any parts and for shipping instructions. Please have the serial number ready when calling. In an effort to support customer projects with extended installation schedules Transnorm System, Inc. can ship conveyor unit(s) in an un-tensioned state. In these cases, this must be specified at the time of order. Instructions to properly re-tension the conveyor unit(s) prior to operation will be provided with each conveyor. This service is available so you, our customer, do not inadvertently void the warranty.

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APPENDIX B PACKAGE SIZE FORMULA & TABLES

To select the width and the model of the curve: 1. Determine the maximum length and the maximum width of the package to be conveyed. 2. Select the proper model from the following maximum recommended package size

tables for 59” and 87” outside radius power turns. For loads not shown in the tables, the following formula can be used:

Inside Radius of Belt (IR)

WidthLe

ngth

50.4mm [2.00]Clearance

Belt Width(N)

Unit L

oad

Belt Width = (Inside Belt Radius + Package Width)² + (Package Length / 2)² - (Inside Belt Radius + 50.8mm (2"))

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48-11 39-20 37-22 35-24 33-26 31-28 29-30 27-32 25-34 23-36 Pkg

Lngth

14 16 18 20 22 24 26 28 30 32 30

13 15 17 19 21 23 25 27 29 31 36

12 14 16 18 20 22 24 26 28 30 42

11 13 15 17 19 21 23 25 27 29 47

10 12 14 16 18 20 22 24 26 28 51

9 11 13 15 17 19 21 23 25 27 55

8 10 12 14 16 18 20 22 24 26 58

7 9 11 13 15 17 19 21 23 25 61

6 8 10 12 14 16 18 20 22 24 64

5 7 9 11 13 15 17 19 21 23 67

4 6 8 10 12 14 16 18 20 22 70

3 5 7 9 11 13 15 17 19 21 72

2 4 6 8 10 12 14 16 18 20 75

1 3 5 7 9 11 13 15 17 19 77

2 4 6 8 10 12 14 16 18 79

1 3 5 7 9 11 13 15 17 81

2 4 6 8 10 12 14 16 83

1 3 5 7 9 11 13 15 85

2 4 6 8 10 12 14 87

1 3 5 7 9 11 13 88

2 4 6 8 10 12 90

1 3 5 7 9 11 91

2 4 6 8 10 93

1 3 5 7 9 94

2 4 6 8 96

1 3 5 7 97

2 4 6 98

1 3 5 99

2 4 100

NOTE: 1 3 101

Turn Size 39-20 has an I.R. of 39" and an N length of 20".

Minimum clearance between package and sideguard at I.R. is 1".

Minimum clearance between package and sideguard at O.R. is 2"

For sizes not listed, call Transnorm System Inc., Sales Department for assistance.

Package Width

Turn Sizes

MAXIMUM RECOMMEDED PACKAGE SIZESPOWER TURNS WITH 59" O.R.

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69-18 67-20 65-22 63-24 61-26 58-29 57-30 55-32 53-34 51-36 49-38 47-40 45-42 43-44 41-46 39-48 Pkg

Lngth

14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 37

13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45

12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 5211 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 5710 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 639 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 688 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 72

7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 766 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 805 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 844 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 873 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 902 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 931 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 96

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 991 3 5 7 9 11 13 15 17 19 21 23 25 27 29 102

2 4 6 8 10 12 14 16 18 20 22 24 26 28 1051 3 5 7 9 11 13 15 17 19 21 23 25 27 107

2 4 6 8 10 12 14 16 18 20 22 24 26 1101 3 5 7 9 11 13 15 17 19 21 23 25 112

2 4 6 8 10 12 14 16 18 20 22 24 141 3 5 7 9 11 13 15 17 19 21 23 116

2 4 6 8 10 12 14 16 18 20 22 1181 3 5 7 9 11 13 15 17 19 21 120

2 4 6 8 10 12 14 16 18 20 1221 3 5 7 9 11 13 15 17 19 124

2 4 6 8 10 12 14 16 18 1261 3 5 7 9 11 13 15 17 128

2 4 6 8 10 12 14 16 1301 3 5 7 9 11 13 15 131

2 4 6 8 10 12 14 1331 3 5 7 9 11 13 134

2 4 6 8 10 12 1361 3 5 7 9 11 137

2 4 6 8 10 1391 3 5 7 9 140

2 4 6 8 1421 3 5 7 143

NOTE: 2 4 6 144Turn Size 67-20 has an I.R. of 67" and an N length of 20". 1 3 5 145Minimum clearance between package and sideguard at I.R. is 1". 2 4 147Minimum clearance between package and sideguard at O.R. is 2". 1 3 148

For sizes not listed, call Transnorm System Inc., Sales Department for assistance.

Turn Sizes

Package Width

MAXIMUM RECOMMEDED PACKAGE SIZESPOWER TURNS WITH 87" O.R.

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APPENDIX C HORSEPOWER REQUIREMENT CHART

600 FPM

500 FPM

400 FPM

300 FPM

200 FPM

100 FPM

Bel

t Spe

ed's

0 1 2 3 4 5 6 Horsepower

OL FL

Approximate Horsepower Requirements

OL - Zero Live LoadFL - Forty Pounds Per Linear Foot Live Load4938 (39" BF) 90° Curve, Other 87" Curves Will Require Similar Horsepower.For Loads Between Zero & Forty Pounds, You Can Interpolate For Approximate Horsepower Requirements.

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APPENDIX D INSTALLATION PARTS LIST

Notice! Highlighted items are dependant upon the power turn specifications. Please specify inside radius (IR), belt width (N) and serial number when requesting spare parts.

ITEM # QUANTITY PART NO. DESCRIPTION

REC.SPAREPARTS

1 1 See BOM Frame Assembly2 As Req'd 020915 Upper Holder Assembly YES3 As Req'd * Washer, Lock M84 As Req'd * Screw, Cap Hex SHC M8 x 1.25 x 165 As Req'd * Nut, D 8mm6 1 030058 Tail Pulley Assembly YES7 2 See BOM Bearing Rod End Trommelager 1-7/16" YES8 2 See BOM 1-7/16" Bearing Insert - UC207-23 YES9 2 030071 Steel Bearing Cap

10 As Req'd * Bolt, HHD M12 x 1.75 x 14011 2 031289 Outer Bearing Housing Bearing Holder12 As Req'd * Washer, Flat M8 Heavy Thick13 As Req'd * Bolt, HHD M12 x 1.75 x 11014 As Req'd * Bolt, RHSN M10 x 1.50 x 4515 As Req'd * Washer, Flat M1216 As Req'd * Nut, Hex M10 x 1.5017 2 See BOM 2-Bolt Flange Bearing YES18 2 031290 Outer Housing Finger Guard19 As Req'd * Bolt, RHSN M12 x 1.75 x 7020 As Req'd * Washer, Lock M1021 As Req'd * Washer, Lock M1222 As Req'd * Nut, Hex M12 x 1.7523 1 See BOM Outside Drive Pulley Assembly YES24 2 031250 TS1500/140 Inner Bearing Support25 As Req'd * Bolt, HHD M8 x 1.25 x 8026 As Req'd * Washer, Flat M827 As Req'd * Nut, Hex M8 x 1.2528 As Req'd * Screw, Set M8 x 1.25 x 8

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INSTALLATION PARTS LIST (Cont.)

Notice! Highlighted items are dependant upon the power turn specifications. Please specify inside radius (IR), belt width (N) and serial number when requesting spare parts.

ITEM # QUANTITY PART NO. DESCRIPTION

REC.SPAREPARTS

29 2 See BOM TS1500/140 N5 x 10 x 15 COMBI30 1 See BOM Belt Assembly YES31 As Req'd 020916 Lower Holder Assy YES32 1 See BOM Side Guard Assembly, Outside33 1 See BOM Side Guard Assembly, Inside34 1 031321 Finger Guard, Left Inside35 1 031322 Finger Guard, Right Inside36 1 See BOM Shroud, Outside Radius37 1 See BOM Inside Guard, Perforated38 1 See BOM Outside Guard, Perforated39 1 See BOM Lower Finger Guard40 As Req'd * Washer, Flat 5/16"41 As Req'd * Bolt, HHD M8 x 1.25 x 3542 As Req'd * Screw, FHSH M8 x 1.25 x 2543 As Req'd * Bolt, RHSN M10 x 1.50 x 3044 As Req'd * Clip, Retaining C M1045 As Req'd * Nut, Lock M8 x 1.25 w/ Nylon Insert46 As Req'd 030125 Insert, M8 x 1847 As Req'd * Washer, Flat M1048 As Req'd * Bolt, HHD M8 x 1.25 x 1649 As Req'd 031338 1500/140 Curve Bracket50 As Req'd * Bolt, HHD M8 x 1.25 x 2551 1 031347 Outer End Guard, Right52 1 031346 Outer End Guard, Left53 1 031344 Inner End Guard, Right54 1 031344 Inner End Guard, Left55 As Req'd * Screw, Phillips PHD #8 x 5/8"56 2 See BOM End Cap, 2-Bolt Flange Bearing

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operation & maintenance manual model ts1500/140 … & maintenance manual model ts1500/140...

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