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Bastian Solutions Shoe Sorter, Installation And Maintenance Manual

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Installation and Maintenance Manual: Shoe Sorter 

_____________________________________________________________________________________________ 

 

Installation and Mai ntenance Manual: Shoe Sorter 

Published October 2019 

Rev.A1 

2 

 

Contributions 

 

Revisions 

 

 

 

 

 

ROLE 

NAME 

TITLE 

Author 

Ben Baker 

Senior Design Engineer 

Checker 

Sam Osterhout 

Project Engineer 

Approver 

Chris Perry 

Engineering Manager 

DATE 

REVISION 

REVISION DESCRIPTION 

AUTHOR 

10/21/2019 

A1 

Initial document creation 

Ben Baker 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for Shoe Sorter

Page 1: ...Installation and Maintenance Manual Model Shoe Sorter Effective October 2019 Rev A1...

Page 2: ...____ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 2 Contributions Revisions ROLE NAME TITLE Author Ben Baker Senior Design Engineer Checker Sam Osterhout Project Engin...

Page 3: ...ing a MDR in DC conveyor applications Diffuse A photoeye format that houses both the emitter and receiver and senses an object when the light beam is reflected back to the sensor This type of photoeye...

Page 4: ...tion and placement within a system MDR Motorized drive roller DC powered conveyor roller with an internally mounted motor which may be controlled via internal or external commutation MSD Master specif...

Page 5: ...e Structural member used to support rotating components needed for conveyor beds Singulation The active separation of cartons cases or totes Skatewheel Small unpowered wheels used to replicate nearly...

Page 6: ...this refers to the elevation of the conveying surface with respect to the floor on which the conveyor is sitting Interchangeable with TOR but applicable to non roller conveyors as well TOR Top of rol...

Page 7: ...Conveyor 27 5 1 10 Installing Guards and Guiderail 28 5 1 11 Installing Side Covers 29 5 1 12 Setting Oiler Flow 30 5 2 Electrical Installation 32 5 2 1 Drive Motor Settings 32 5 2 2 Components requi...

Page 8: ...9 Figure 21 General Arrangement Shoe Sorter Divert Switch Sheet 1 of 3 51 Figure 22 General Arrangement Shoe Sorter Divert Switch Sheet 2 of 3 52 Figure 23 General Arrangement Shoe Sorter Divert Switc...

Page 9: ...Reference Documents MANUFACTURER DOCUMENT TITLE DOCUMENT NUMBER URL Teknic Inc ClearPath MC SD User Manual Rev 3 05 N A https www teknic com files downloa ds clearpath_user_manual pdf Teknic Inc AC C...

Page 10: ...f 24745332 pdf SEW Eurodrive Assembly and Operating Instructions Gear unit series R 7 F 7 K 7 K 9 S 7 SPIROPLAN W 21932786 EN https download sew eurodrive com download pdf 21932786 pdf Bijur Delimon I...

Page 11: ...contact ZiPline Conveyor Customer Service or Support at ZiPlineSupport BastianSolutions com 2 OSHA And Safety ZiPline Conveyor is not responsible for ensuring that conveyors used in a system abide by...

Page 12: ...Mark Numbers A mark number is a specific number given to a piece of equipment A mark number is usually made up of a single product line RZPDC RLVDC BZPDC etc but can contain many bed section lengths...

Page 13: ...tions support structures accessories and pertinent hardware For protection of product integrity during shipping accessories and supports may be delivered on separate but labeled skids 4 3 Skid Documen...

Page 14: ...y be shipped separate from the drive unit See SEW Eurodrive Gear Unit Assembly and Operating Instructions section 4 for installation instructions Secure the drive unit to the floor before installing t...

Page 15: ...djusting the floor support Do not use vibration dampers for height adjustment Excessive compression can damage the vibration dampers and will increase vibrations transmitted into the floor supports 5...

Page 16: ...e Diamond Chain Maintenance Guide section 1 for chain alignment tolerances Figure 5 Bed Section Fastening Detail 5 Place a straightedge across the gap in the bearing rail between each bed section and...

Page 17: ...securing method is appropriate for the application Installations in seismic zones will generally require an independent seismic review ZiPline does not provide general purpose recommendations for con...

Page 18: ...________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 18 Figure 6 Typical Spur Positioning Figu...

Page 19: ...section is easy to damage when installing the chain This sensor is shipped separately for this reason recommend installing the sensor only after completing the chain installation 1 The chain comes pr...

Page 20: ...result Fasten any pulling devices winches come alongs etc directly to the chain with the use of a suitable spreader bar to ensure the force is exerted directly along the length of the chain There wil...

Page 21: ...completely installed with slats spaced approximately every two feet proceed with the installation of the remainder of the slats See Figure 9 3 Slide retention levers onto the bosses on each chain mou...

Page 22: ...farthest from the retention lever then rotate the spring clip down to snap the E ring end of the spring clip into the groove of the other slat pin a If the spring clip grooves are not fully exposed it...

Page 23: ...here is no binding or other mechanical problems a See Section 5 1 5 steps 3 and 6 for details on advancing the chain by hand 4 Apply power to the drive motor at low speed e g 5Hz Ensure correct direct...

Page 24: ...n Figure 12 a See Figure 13 for adjustment locations The knife edge nosebar horizontal adjustment is indicated by note flag and the vertical adjustment is indicated by note flag 5 Adjust the knife edg...

Page 25: ...7 8 between marks during the adjustment process 7 After adjusting the nosebar retension the knife edge belt to the correct running tension until the measurement between the marks reads 25 5 8 a See F...

Page 26: ...re that the E stop for the AC motor is operational prior to running the conveyor The E stop may be required to quickly kill power to the AC motor to preserve the life of the belt for tracking purposes...

Page 27: ...ng additional adjustments then the belt is tracked properly 13 If improper tracking of the belt persists contact your ZiPline Conveyor representative for technical assistance The nosebar must be set s...

Page 28: ...etracted in the flow direction 5 1 10 Installing Guards and Guiderail 1 See Figure 16 2 The chain guards mount inside the top rail of the sorter frame 3 Guiderail optional mounts outside the top rail...

Page 29: ...ng Side Covers 1 See Figure 16 Figure 16 Chain Guard Guiderail and Side Cover Installation 2 The side covers mount to 2 lower cover brackets fastened to the underside of the sorter frame lower rail an...

Page 30: ...the correct oil flow rate per the procedure provided in this section If the oil flow rate is too low the chain will have a shortened lifespan If the oil flow rate is too high excess oil will be deposi...

Page 31: ...y container of the correct size capable of holding oil if the volume of the container is known accurately c Ensure the container is clean to avoid contaminating the oil If the oil is contaminated with...

Page 32: ...some oil and grease typically deposited at the drive and tail This discharge will reduce in volume once the grease has been washed off the chain typically 10 20 oiler cycles with normal operation 5 2...

Page 33: ...ired a A 460V to 230V transformer may be supplied with the equipment depending on the system electrical layout and available voltages Other options may be available contact ZiPline for details Always...

Page 34: ...RING FAULT TYPE OF FAULT DETECTED RECOMMENDED FAULT RESPONSE NOTES Inductive proximity Discharge transition assembly HIGH LOW Jam or debris at the discharge assembly a slat is out of place Shut down t...

Page 35: ...typ 2 per sorter see the system drawing for quantity and location Photo electric retro reflective Induction conveyor Varies detects product HIGH contin uous Product jam at the sorter infeed Hold produ...

Page 36: ...bricator Quick Start Manual and Bijur Delimon Sure Fire II Operators Manual for detailed wiring instructions and wiring diagrams SPST NO dry contact switch Oiler pressure switch CLOSED when running OP...

Page 37: ...g INPUT OR OUTPUT DESCRIPTION DIVERT BOX PLC PIN INPUT Bearing Detect internal jumper IN 8 Reset All Faults IN 9 Divert 1 CMD Fire signal IN 10 Divert 2 CMD Fire signal IN 11 Divert 3 CMD Fire signal...

Page 38: ...faults while it is actuated will stay continuously diverted and will NOT drop when Divert CMD is set LOW 6 Operation 6 1 Startup Procedure 1 Before startup inspect the conveying surface for jammed pac...

Page 39: ...photoeye fault sorter stop a Only the lower catenary eye will cause a sorter stop If the lower eye is blocked by the slats in the catenary when the catenary is at rest or in a steady state running po...

Page 40: ...ing manually turned or is running slowly to determine correct operation i The missing bearing sensor should turn on triggered by the presence of the shoe pin bearing before the pin sensor turns on and...

Page 41: ...hain Adjustment All chains should be kept well lubricated If slack develops in the chain adjustments should be made by qualified maintenance personnel 1 Periodically check the chain for excessive wear...

Page 42: ...indicate a clog or obstruction and refill when necessary 2 Refill with SAE 30 mineral oil or SAE 85W gear oil ISO 100 for operation between 40 F and 100 F a Consult ZiPline for operation at temperatu...

Page 43: ...cation if it is getting enough oil a The presence of red or brown residue or a scored or galled pin surface means the chain is not getting enough oil check for proper operation of the oiler b If the o...

Page 44: ...do not include floor supports accessories guiderail or crating Table 4 List of Section Weights Sorter OAW in Drive and catenary not including motor Tail Divert Section single sided Intermediate Sectio...

Page 45: ...Weights Motor Horsepower Speed FPM Gearbox Hollow Bore Size in Weight lbs 5 200 240 KA77 2 170 240 600 KA67 1 1 2 125 7 5 200 380 KA77 2 230 380 600 KA67 1 1 2 185 10 200 250 KA87 2 3 8 305 250 600 K...

Page 46: ...8 113 128 143 158 173 188 203 218 233 248 263 278 293 308 250 630 19 31 43 55 67 79 91 103 115 127 139 151 163 175 187 199 211 223 235 247 300 540 17 27 37 47 57 67 77 87 97 107 117 127 137 147 157 16...

Page 47: ...____________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 47 Appendix 3 General Arrangement Drawings Figure 18...

Page 48: ...r _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 48 Figure 19 General Arran...

Page 49: ...r _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 49 Figure 20 General Arran...

Page 50: ...Z075SA 150xx where xx is the cover length in inches length varies depending on section configuration 1 EA ASM SHOE SORTER SIDE COVER 8 Z075SA 15102 1 EA ASM SHOE SORTER SIDE COVER 60in L DIVERT BOX 9...

Page 51: ...r _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 51 Figure 21 General Arran...

Page 52: ...r _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 52 Figure 22 General Arran...

Page 53: ...r _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 53 Figure 23 General Arran...

Page 54: ...______________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 54 Figure 24 General Arrangement Sh...

Page 55: ...Sorter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 55 Figure 25 General...

Page 56: ...Sorter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 56 Figure 26 General...

Page 57: ...orter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 57 Figure 27 General A...

Page 58: ...orter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 58 Figure 28 General A...

Page 59: ...EA CHAIN LEAD IN BLOCK SHOE SORTER DRIVE MODULE STYLE B 11 Z077SC 10089 1 EA TOP CHAIN GUIDE BLOCK SHOE SORTER DRIVE MODULE STYLE B 12 Z077SC 10087 1 EA INFEED GUIDE BLOCK SHOE SORTER CATENARY MODULE...

Page 60: ...____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 60 Figure 29 General Arrangem...

Page 61: ...EL 1 938in OD 0 25in BORE 6 A003BR 10002 44 xxx EA BALL BEARING R6 2RS 7 A003SG 10010 2 EA CONSTANT FORCE SPRING 39 L 0 88in ID 1 19in OD 6lb LOAD 3000 CYCLES 8 A002EW 10022 1 EA CABLE CARRIER 0 2in I...

Page 62: ...orter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 62 Figure 30 General A...

Page 63: ...________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 63 Figure 31 General Arrangement...

Page 64: ...____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 64 Figure 32 General Arrangem...

Page 65: ...1 Z075SA 16039 xxx VARIES EA ASM SHOE SORTER INSIDE SLAT SENSOR 2 Z075SA 16038 xxx VARIES 2 TYP EA ASM SHOE SORTER UNDERNEATH SLAT SENSOR 3 Z077SC 10133 xxx 1 EA BRACKET SHOE SORTER INSIDE TRIP GATE...

Page 66: ...ter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 66 Figure 33 General Arr...

Page 67: ...ter _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 67 Figure 34 General Arr...

Page 68: ...A PULLEY 2 75in OD 1 438in WELDED STUB SHAFT BLIND KEYWAY 1 END 6 A002SE 10025 1 EA PHOTOEYE RETRO REFLECTIVE 0 05m TO 5m SENSING RANGE PNP 4 PIN M8 CONNECTOR 7 A002MC 10006 1 EA REFLECTOR 10 24 THREA...

Page 69: ..._____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 69 Figure 35 General Arrang...

Page 70: ...____________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 70 Appendix 4 Electrical Schematics for Divert Contro...

Page 71: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 71 Figure 37 Electrical S...

Page 72: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 72 Figure 38 Electrical S...

Page 73: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 73 Figure 39 Electrical S...

Page 74: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 74 Figure 40 Electrical S...

Page 75: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 75 Figure 41 Electrical S...

Page 76: ...er _____________________________________________________________________________________________ Installation and Maintenance Manual Shoe Sorter Published October 2019 Rev A1 76 Figure 42 Electrical S...

Page 77: ...ment 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 par...

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