MC3 ChipMaster Operation & Maintenance Manual Download

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ChipMaster Conveyor

Operation & Maintenance Manual

Rev. 05-2021

MC3 Manufacturing Inc.

1979 Setterington Drive, RR2

Kingsville, Ontario N9Y 2E5, Canada

Phone: 519-325-1370

Fax: 519-325-1374

Email: [email protected]

Web:

www.mc3mfg.com

The content of this manual is owned

and copyrighted by MC3 Manufacturing Inc.

Summary of Contents for ChipMaster

Page 1: ...ChipMaster Operation Maintenance Manual ...

Page 2: ...2 Rev 05 2021 MC3 Manufacturing Inc 1979 Setterington Drive RR2 Kingsville Ontario N9Y 2E5 Canada Phone 519 325 1370 Fax 519 325 1374 Email info mc3mfg com Web www mc3mfg com The content of this manual is owned and copyrighted by MC3 Manufacturing Inc ...

Page 3: ...Table of Contents Introduction 4 Delivery Inspection 5 Warranty 6 Safety 7 Safety Sign Off Form 10 Installation Instructions 11 Operating Safety 20 Operating Instructions 21 Maintenance 22 Troubleshooting 29 Replacement Parts 32 Recommended Spare Parts 34 Notes 36 ...

Page 4: ...r We urge you to read this publication carefully and refer to it extensively for correct operating procedures This manual is supplemented by a Safety Section Lubrication and Maintenance Schedule We urge you to read through this information carefully This will help to ensure safe and trouble free operation of your conveyor All information illustrations and specifications in this manual are based on...

Page 5: ... contact MC3 Manufacturing Inc immediately with a description of the missing components and the serial number of the machine See Fig 1 for serial tag location If any components have been damaged in transit note it on the bill of lading and contact the Carrier immediately The serial number is located near the gear drive unit Note For fast correct service please have the serial number when ordering ...

Page 6: ...le product of sizes or weights and shapes or at speeds or methods which differ from information originally provided to Seller chemical action wear caused by abrasive materials or by improper maintenance and lubrication or by improper storage and handling shall not constitute defects Failure to install or assemble equipment properly shall not constitute defects Warranty does not cover consumable it...

Page 7: ... cases WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury and or property damage It may also be used to alert against unsafe practice For any questions not answered in this manual please contact your dealer or MC3 Manufacturin...

Page 8: ...ow them DO NOT allow persons to operate this conveyor until they have read this manual and or been instructed by a qualified person DO NOT use this conveyor while under the influence of drugs or alcohol Replace any safety decals that may be missing or are unreadable Location of decals are indicated in this manual Check that all guards are in place and securely fastened before starting the conveyor...

Page 9: ...moothly in the frame Ensure there are no foreign objects nuts bolts tools etc on the frame or belt before starting for the first time Ensure that the conveyor belt and drive chain are correctly adjusted before starting for the first time and that all adjuster locknuts are tight to prevent slipping Check the oil level in the gear reducer Double check that all bearings locking collars and sprocket s...

Page 10: ...perate or allow anyone to operate this conveyor until such information has been reviewed Annually review this information Make these periodic reviews of SAFETY and OPERATION a standard practice for all your conveyors We feel that an untrained operator is unqualified to operate this conveyor A sign off sheet is provided for your record keeping showing that all personnel who will be working with thi...

Page 11: ...uipment according to your local electrical codes Depending upon the type and configuration some conveyors are supplied fully assembled and only require installing while others are supplied partially assembled and need to be completed on site Please follow the relevant instructions below for your specific conveyor Note If special circumstances or questions arise please contact MC3 Manufacturing Inc...

Page 12: ...mature chain wear and overloading of the drive motor Ensure all sprockets are securely fastened Check the oil level in the gear reducer If your conveyor is supplied with its own control box this now needs to be wired into a suitable electrical supply If your conveyor is supplied without a control box then it will need to be wired into the control system of your machine Note All electrical wiring m...

Page 13: ...olts and check the in feed for level Drill through the holes in the feet and use suitable anchors to fasten the conveyor to the floor For castors lock the wheels with the wheel locks if fitted Remove the incline cover and the two chain guards located under the discharge area Assemble the idle shaft as follows See Fig 1 o Place the idle sprockets on the idle shaft with the hubs to the inside o Plac...

Page 14: ...the tabs on the end pans the side wings and draw bars Replace the axle and cotter pins Bend up both legs of the cotter pins to secure the axle o Repeat these steps for each belt section Fig 2 To assist in the installation of the belt it is recommended that you temporarily remove the drive shaft as follows See fig 3 Fig 3 No Description 1 Draw Bar 2 Roller 3 Side Wings 4 Pan 5 Axle 6 Cotter Pins No...

Page 15: ...track at the discharge end of the conveyor starting with the special lead pan with the welded hook Note The belt must be inserted upside down i e with cleats facing down For correct belt orientation see Fig 4 Fig 4 When the lead end of the belt reaches the idle shaft position the idle sprockets so that the teeth on the sprockets line up with the rollers on the belt Wrap the lead end of the belt ar...

Page 16: ...nveyor Operation Maintenance Manual 16 Rev 05 2021 Fig 5 Fig 6 Fig 7 Note It may be necessary to reposition the winch several times depending upon the length of the incline size of winch etc See Figs 8 9 Fig 8 Fig 9 ...

Page 17: ... in the belt drive sprockets and pillow block bearings Note Double check the tightness of the set screws holding the belt drive sprockets These will not be accessible once the ends of the belt are connected Line up the belt draw bars rollers side wings and pans and insert the axle through the adjustment slots in the conveyor frame Insert new cotter pins into the ends of the axle and bend up both l...

Page 18: ...ntil there is approximately 1 8 of movement in the chain at the mid point between the sprockets When the tension is correct tighten the locknuts on the adjuster Check the oil level in the gear reducer If your conveyor is supplied with its own control box this now needs to be wired into a suitable electrical supply If your conveyor is supplied without a control box then it will need to be wired int...

Page 19: ...e to be adjusted Please refer to the safety considerations regarding the torque limiter on Page 9 of this manual and the manufacturers information sheet in the Appendix Note Do not over tighten the torque limiter This will lead to premature failure or over loading of the drive motor The torque limiter needs to be adjusted so that it will carry no more than the weight of the belt and the required l...

Page 20: ... and sort scrap that accumulates from metal forming Be familiar with the conveyor before starting In addition to the design and configuration of the conveyor hazard control and accident prevention are dependent upon the awareness concern and prudence of personnel involved in the operation and maintenance of the conveyor or in the use and maintenance of facilities It is the responsibility of the ow...

Page 21: ...or The Reverse button if fitted will jog the belt in the reverse direction For conveyors which are tied into another machine control system the start and stop commands will have to be issued from that system In either case it is important that the conveyor is started before any parts chips can accumulate in the in feed and that it is stopped after being allowed to run off any material it is curren...

Page 22: ...igh amperage draw on the motor Note Excess tension causes increased wear and reduced belt life o Too loose a belt will buckle as it leaves the in feed sprockets and as it contacts the drive sprockets This condition often causes jamming and can easily damage the belt Motors Cleaning All motors should be kept free of dirt and grease accumulations Open motors should be periodically vacuumed to remove...

Page 23: ... After approximately two to three weeks of operation the reducer must be drained flushed out and refilled to the correct level with fresh oil This is done to remove any brass particles created during the normal wear in period of the worm gear From then on the oil should be changed every 2500 hours of operation or every 6 months whichever comes first Note Where high temperatures and or a dirty atmo...

Page 24: ... sure reducer remains securely bolted Bearings Lubrication See Fig 13 for correct bearing lubricant Greasing frequency should be regulated to as many times as necessary to keep a small film of grease leaking at the seals This will protect against foreign materials entering the bearing Normal Duty Heavy Duty Texaco Multifak 2 Sun Prestige 742 EP Mobil Mobilux 2 Exxon Lidok 2 EP Amoco Lithium MP Arc...

Page 25: ...hown in Fig 14 below Temperature Recommended Oil Viscosity 20 F to 40 F 7 C to 4 C SAE 20 40 F to 100 F 4 C to 38 C SAE 30 100 F to 120 F 38 C to 49 C SAE 40 120 F to 140 F 49 C to 60 C SAE 50 Fig 14 Note When lubricating the drive chain take care not to contaminate the linings of the torque converter either by direct contamination or by splashing from an over lubricated chain Tension Check chain ...

Page 26: ...an and adjust if necessary and return to service Note Please refer to the specific safety instructions on Page 9 when checking the torque limiter Replacement After continued slipping it is possible that there is sufficient wear to warrant part replacement Install new friction discs tension correctly and then run the conveyor Note Please refer to the torque limiter manufacturer s information sheet ...

Page 27: ...ea After the machine has been used for a long period of time the belt will lose tension due to elongation of the links If this is the case then adjust the belt tension Lubricate each area of the conveyor as shown in Fig 16 Conveyor Section Lubricant Required Lubrication Intervals Drive Chain Mobil Oil or Grease Equivalent to SAE 30 6 Months except the hollow shaft motor type Conveyor Chain Mobil O...

Page 28: ...cleanliness c Check that the conveyor is clear before starting Monthly Inspection a Check belt tension b Check belt for excessive wear c Carry out daily checks Annual Inspection a Remove covers and guards and clean inside conveyor b Inspect and replace any consumable parts c Check the tightness of all fasteners on the conveyor d Carry out daily checks e Carry out monthly checks ...

Page 29: ...nge in equipment performance or product quality Verification of a problem through observation will allow the trouble shooter to determine if a problem actually exists or if the reports of trouble are due to a lack of equipment understanding Identify and locate the root cause of the trouble Trouble is often caused by a change in the system An understanding of the system its modes of operation and h...

Page 30: ...leshooting efforts to quickly restore the conveyor to service Problems symptoms corrective actions modifications and preventive maintenance actions should all have entries that can be referenced at a later date Step by Step Approach Troubleshooting a problem and is a logical step by step procedure The approach is much the same for all conveyors only the steps for implementing the approach may diff...

Page 31: ...ive materials on edge of belt Ensure material is deposited on center of belt Insufficient lubrication Increase amount of lubrication and or lubrication frequency Excessive belt loading Check for material buildup and or reduce loading Load is uneven Ensure material is deposited onto center of belt Belt pulls to one side Conveyor not level Check level and correct if necessary Tail end sprockets are ...

Page 32: ...eshaft bearings Lubricate bearings Clicking Loose drive chain Turn off conveyor and re tension drive chain Foreign material in motor fan Turn off conveyor and and remove foreign material Knocking Loose conveyor belt Turn off conveyor and re tension belt Scratching Foreign material stuck in conveyor pan Turn off conveyor and and remove foreign material Grinding Check gear motor Replace gear motor i...

Page 33: ...ng time The general condition of the conveyor should be inspected daily i e at the start or end of a shift and an in depth inspection should be carried out during regularly scheduled maintenance procedures When you need to procure consumable parts contact MC3 Manufacturing Inc at 519 325 1370 quoting the serial number s of the machine s the part names and quantities of each part required Note Plea...

Page 34: ...cket 3 Sprocket torque limiter 636 9 022 diameter 4 Bushing torque limiter 655 long 5 Drive shaft 6 Torque limiter 1 25 bore 500a2 7 Bearing 8 Gear box 9 Motor gearbox adaptor 10 Motor 11 Gearbox output shaft 12 Gearbox shaft cover 13 Drive shaft sprocket 14 Chain belt 15 Wiper 16 Tail shaft 17 Tail shaft sprocket assembly ...

Page 35: ...ChipMaster Conveyor Operation Maintenance Manual 35 Rev 05 2021 Notes ...

Page 36: ...ings rub in order to obtain maximum rated capacity and optimum life from the Torque Limiter 2 ASSEMBLY Refer to the appropriate sketch see below and assemble on the torque limiter hub the following A Friction facing B Bushing C Center member not shown D Friction facing E Pressure plate F Spring s G Pilot plate 500A and 700A models only H Lockwasher 250A and 350A models only J Adjusting nut 4 TORQU...

Page 37: ...late 6 THIS ADDITIONAL STEP IS APPLICABLE TO THE TORQUE LIMITER COUPLING ONLY a Never use a torque limiter alone as a coupling When shaft coupling is required in conjuction with slip protection use a torque limiter coupling b After setting torque limiter per steps 4 and 5 above with flat sprocket installed as the center member in torque limiter mount it on the shaft Then mount the coupling half th...

Page 38: ...ts Typ SD SI UNIVERSAL Réducteurs à roue et vis sans ﬁn Typ SD SI GB FR Getriebebau NORD GmbH Co KG D 22934 Bargteheide P O Box 1262 D 22941 Bargteheide Rudolf Diesel Straße 1 Tel 0 45 32 401 0 Fax 0 45 32 401 253 NORD Internet http www nord com Diese Sicherheitshinweise sind aufzubewahren These safety instructions must be kept available Ces instructions de sécurité doivent être observées ...

Page 39: ... on shaft mounting gearboxes with torque arm the EC machinery directive must be observed in applications where the failure of the gearbox or motor could be hazardous for personnel appropriate safety measures must be taken Connection of motor Connect motor according to diagram make sure that mains voltage frequency are in accordance with nameplate information make secure protective conductor connec...

Page 40: ... m a m s l The use in hazardous areas is prohibited unless explicitly checked by NORD and confirmed in writing Use gearbox or motor only within the permissible performance data Entretien DU REDUCTEUR DU MOTEUR Les réducteurs et les motoréducteurs à roue et vis sans fin UNIVERSAL sont remplis d huile synthétique ce qui garantit un bon fonctionnement pendant toute la durée de vie De ce fait les rédu...

Page 41: ...Mat Nr 605 06 99 46 05 www nord com ...

Page 42: ...Polyphase Installation and Maintenance Instructions Copyright 2005 NORD Gear Corporation All rights reserved No part of this book covered by the copyright hereon may be reproduced or copied in any form or by any means without the written permission of the NORD Gear Corporation USA CDN ...

Page 43: ...BIM 1004 2005 05 Page 2 of 20 www nord com NOTES ...

Page 44: ...ILLUSTRATIONS Figure No Figure Title Page Figure 1 Motor Nameplates 5 Figure 2 Motor Options Connection Diagrams 12 Figure 3 General Motor Exploded View and Generic Parts List 2 pages 15 LIST OF TABLES Table No Table Title Page Table 1 Related Publications 4 Table 2 Nameplate Data 5 Table 3 Motor Inspection Criteria 6 Table 4 Motor Fault Isolation 8 Table 5 Motor Option Codes Nomenclature 17 Table...

Page 45: ...s BIM 4010 Titan Mechanical Adjustable Speed Drives BIM 4020 NORDISC Friction Disc Mechanical Adjustable Speed Drives Table 1 Related Publications DESCRIPTION AND OPERATION 1 General This manual provides general installation and maintenance information for the NORD family of motors described in this section 2 Description The NORD motors covered in this manual are single phase and poly phase motors...

Page 46: ...ce Factor allowable horsepower loading S Duty Cycle i e S1 S3 40 Encl Enclosure Description Frame Motor Frame Size Code NEMA Code Letter V Motor Voltage EEV A Motor Full Load Amperage COS ϕ Power Factor HP Motor Horsepower MB Motor Brake Force Newton Meters rpm Motor Speed AC Alternating Current pf Power Factor V AC Voltage Amb Maximum Ambient Temperature V DC Voltage Hz Motor Power Frequency Tabl...

Page 47: ...ure the mounting hardware is secure If the mounting hardware is not secure check the motor gearbox alignment and tighten the mounting hardware Check that all electrical connections are secure If the electrical connections are not secure tighten them Motor electrical connections Check the electrical connections for evidence of arcing Loose electrical connections can cause arcing which is evident by...

Page 48: ...ft rotates and by noise 3 Check for smooth rotation with no evidence of binding or catching If the shaft does not rotate smoothly or binds or catches the bearings are worn or failing lack lubrication or are contaminated 4 Check the motor shaft for side play by applying pressure at right angles to the shaft in several places around the circumference If the shaft moves perceptibly the front bearing ...

Page 49: ... for an excessive accumulation of oil and dirt that can inhibit cooling If the motor exterior is excessively dirty clean the motor surface using clean lint free cloths If the motor has a finned casing use a vacuum cleaner and a stiff bristled nylon brush to remove dirt and debris from between the fins If the motor has a vented enclosure check the vent openings to make sure they are clear If necess...

Page 50: ...TCH AND POST IT WITH AN OUT OF SERVICE PLACARD WARNING LARGE MOTORS ARE HEAVY EASY TO UNBALANCE AND ARE AWKWARD TO LIFT AND MOVE EVEN SMALLER MOTORS ARE HEAVY HAVE ASSISTANCE WHEN LIFTING AND MOVING HEAVY MOTORS IF NECESSARY USE APPROPRIATE LIFTING DEVICES TO LIFT AND MOVE HEAVY MOTORS CAUTION TO PREVENT DAMAGE TO THE MOTORSHAFT BEARINGS AND THE MATING HUB SHEAVE IN THE GEARBOX MAINTAIN SHAFT ALIG...

Page 51: ...ay staking the key or using Loctite to retain the key in the keyway according to the following instructions 1 If the drive key is not trapped in the keyway the keyway is open at both ends stake and install the drive key as follows a Make sure the keyway is free of contamination so that the drive key will seat properly b Add a few drops of an approved lubricant to the keyway c Place the drive key o...

Page 52: ...as blue Loctite to the bolt threads according to the instructions Install the bolts and tighten them securely NOTE If the motor gearbox installation uses an input flange mount the input flange to the motor using four mounting bolts and new Dubo gasket Tighten the bolts securely CAUTION DO NOT TO MIX TYPES OF OIL I Check the gearbox oil level If necessary fill the gearbox or add oil to bring the ge...

Page 53: ...5 T7 W5 T9 Y low voltage L1 L2 L3 U1 T1 W1 T3 V5 T8 U5 T7 W5 T9 V1 T2 NEMA 3 phase motor high voltage low voltage T1 T2 T3 T6 T4 T5 L1 L2 L3 T5 V2 T3 T4 T6 L3 L2 L1 W2 U2 T2 T1 Y W2 V2 U2 W1 V1 U1 U1 V1 W1 NEMA 3 phase motor High Voltage Low Voltage T4 T1 T2 T3 T5 T6 T7 T8 T9 L1 L2 L3 T6 T9 T3 T5 T4 L3 L2 L1 T7 T8 T2 T1 Y YY Figure 2 Motor Connection and Wiring Diagrams ...

Page 54: ...ll identify the part for your motor application A The following parts must be replaced if they are removed Oil seal 904 Oil seal 933 Gasket 909 Gasket 910 Gasket 921 Gasket on plug 961 Self locking screws 907 1 908 1 923 932 1 940 1 B If the following parts are removed inspect them and replace them if they are deformed Retaining ring 919 Retaining ring 947 Retaining ring 948 Fan clip 952 C Disasse...

Page 55: ... T Box Frame 1 907 1 Screw 4 908 T Box Cover 1 908 1 Screw 4 909 T Box Frame Gasket 1 910 T Box Cover Gasket 1 916 Stator Assembly 1 918 Drive Key 1 919 Retaining Ring 1 920 Oil Plug 1 921 Gasket 1 923 Screw 4 929 Bearing 1 932 B Endbell 1 932 1 Screw 4 933 Oil Seal 1 939 Fan 1 940 Fan Cowl 1 940 1 Screw 4 947 Retaining Ring 1 948 Retaining Ring 1 952 Fan Clip 1 960 NPT Thread Adapter 1 961 Plug i...

Page 56: ...BIM 1004 2005 05 Page 15 of 20 www nord com Figure 3 General Motor Exploded View and Generic Parts List Sheet 1 of 2 ...

Page 57: ...BIM 1004 2005 05 Page 16 of 20 www nord com Figure 3 General Motor Exploded View and Generic Parts List Sheet 2 of 2 ...

Page 58: ... Constant Torque Rated Motor VN 10 1 Constant Torque Rated Motor VW 20 1 Constant Torque Rated Motor VZ F 1000 1 Constant Torque Rated Motor Table 5 Motor Option Codes Examples 90SH 4 IG SH Energy Efficient 1 Speed Encoder Space Heater 100L 4 2 WE RDD 2 speed 2nd Motor Shaft Double Canopy Cover 132M 4 BRE100 HL IR TW Brake Hand Release Current Sensor Thermostat Technical information follows for TH...

Page 59: ...rebound less than 1 millisecond 10g shock in all directions 2 000 VAC Insulation rating 10 000 cycles Normally closed Space Heaters Option SH Connection Diagram shown on Page 12 Space Heaters are mounted directly on the motor winding The leads are brought into the terminal box and labeled H1 and H2 They require a separate voltage supply and must not be energized when the motor is energized The hea...

Page 60: ...V available Signal Color Push pull RS 422 Pin optional mating plug Heidenhain Callouts Explanation Pink B B 1 Ua2 Signal line Blue Sensor 2 UP Sense Supply Voltage Red R R R R 3 Ua0 Signal line Marker Black R 4 Ua0 Signal line Brown A A A A 5 Ua1 Signal line Green A A 6 Ua1 Signal line Violet Spare 7 UaS Spare Gray B B B B 8 Ua2 Signal line Yellow 9 Shield Spare White Green 0 V 0 V 10 0 V UN Commo...

Page 61: ...Single Phase Connection 1 F132 230 332 0 27 89 230 277 0 29 82 F63 230 332 0 08 23 230 290 0 10 27 F71 230 332 0 08 24 230 290 0 10 28 F80 230 332 0 08 25 230 290 0 10 29 F90 230 332 0 21 64 230 290 0 28 86 F100 230 332 0 21 66 230 290 0 27 86 F112 230 332 0 23 70 230 290 0 27 85 F132 230 332 0 25 74 230 290 0 32 96 F160 230 332 0 49 165 230 290 0 53 155 F180 230 332 0 49 165 230 290 0 53 155 F200...

Page 62: ... NOTES ...

Page 63: ... NOTES ...

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