TGW NBC Flat Belt Installation, Operation & Maintenance Manual Download Page 1

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1118140rev102213

NSTALLATION

PERATION

AINTENANCE

ANUAL

NBC™ Flat Belt

Narrow Belt Conveyor

Accumulation with CRUZcontrol

& Transportation

Summary of Contents for NBC Flat Belt

Page 1: ...1118140rev102213 INSTALLATION OPERATION MAINTENANCE MANUAL NBC Flat Belt Narrow Belt Conveyor Accumulation with CRUZcontrol Transportation ...

Page 2: ...aces 25 Ceiling Hangers 26 Anchoring Ceiling Hangers 28 Connectors 29 Line Straightness 30 Setting Logic Modules 31 Installing the NBC Air Transportation Pilot Valve 32 NBC Belts 33 Red Belt 33 Black Belt 34 NBC QUIKmeld Unit 35 PN 1120200Threading Belt in NBC Accumulation Conveyor 35 Threading Belt in NBC Transportation Conveyor 41 Belt Tensioning 42 250 lb Drive Tensioning Spring Screw Take up 4...

Page 3: ...Rates 66 Application NBC Releasing Accessories 68 CRUZcontrol Components 71 CRUZcontrol Logic Assembly 71 Function Modules 73 Power Supplies 81 Accessories 85 CRUZcontrol On Site Installation 88 Pre installed on the conveyor 88 Field Installation 88 Conveyor Flow 89 Overview TGW CRUZcontrol Logic Module 100 Conveyor Details 100 Photoelectric Sensor 101 Standard Logic Module 102 Pneumatic Valve 108...

Page 4: ...es using a T Cable 82 Figure 9 Two Separate CRUZcontrol Sections 83 Figure 10 One CRUZcontrol Section with Two Power Supplies 84 Figure 11 Discharge Logic Control 86 Figure 12 Logic Assembly 88 Figure 13 Left Hand Flow Conveyor Bed 89 Figure 14 Right Hand Flow Conveyor Bed 89 Figure 15 Isolated Input Single Release 92 Figure 16 Non Isolated Input Single Release 92 Figure 17 CRUZcontrol around a cu...

Page 5: ...tring 100 240 VAC 81 Table 9 Power Supply Part Numbers 84 Table 10 Photoelectric sensor 85 Table 11 Reflector 85 Table 12 Sensor Valve Assembly 85 Table 13 Extension Cables 86 Table 14 Discharge Logic Assembly 87 Table 15 Conveyor Specification 100 Table 16 Sensor Optical Specification 101 Table 17 Sensor Electrical Specification 102 Table 18 Logic Module Mechanical Specification 104 Table 19 Logi...

Page 6: ...NBC Flat Belt 1118140rev102213 6 ...

Page 7: ... maintenance and assists in replacement parts identification This service manual is intended for use by personnel who are knowledgeable of installation and safe working practices on conveyor systems Not all applications and conditions can be covered therefore this manual is to be used ONLY as a guide If additional copies of this manual are needed or if you have any question concerning the conveyor...

Page 8: ...ies specified above is conditioned upon the equipment being installed handled operated and maintained in accordance with the written instructions provided or approved in writing by TGW Systems The warranties specified above do not cover and TGW Systems makes no warranties which extend to damage to the equipment due to deterioration or wear occasioned by chemicals abrasion corrosion or erosion Purc...

Page 9: ...the drive related components including sprockets chains shafts universal joints and pneumatic devices can be dangerous We have installed or provided guards to prevent accidental contact with these parts along with warning labels to identify the hazards Special attention must be paid to the following areas of this manual Indicates a potentially hazardous situation which if not avoided could result ...

Page 10: ... and jewelry must be kept away from moving equipment Maintain enough clearance on each side of all conveyor units for safe adjustment and maintenance of all components Provide crossovers or gates at sufficient intervals where needed to eliminate the temptation for personnel to climb over or under any conveyor Walking or riding on a moving conveyor must be prohibited Before performing maintenance o...

Page 11: ...1118140rev102213 11 Before servicing or performing any work in the motor control panel disconnect and lock out the main incoming service If only the panel disconnect is off the incoming side will still be hot WARNING ...

Page 12: ...NBC Flat Belt 1118140rev102213 12 ...

Page 13: ...NBC Flat Belt 1118140rev102213 13 ...

Page 14: ...e belt This belt is held in contact with the underside of the carrying rollers by spring pressure roller channel assemblies mounted on the conveyor side channels Accumulation begins when a product blocks the first sensor from the discharge end The first product stops over the discharge sensor which arms the next sensor upstream while lowering the belt pressure roller channel in that zone When a zo...

Page 15: ...o lock the pressure pan in the down position for ease of belt installation However once the plastic cam is manually deactivated the pressure pan always drives Air Transportation Air transportation uses air diaphragms to retract the pressure assemblies rather than the plastic lockout cam All the diaphragms are linked together to a central valve which is designed to disengage the entire line at once...

Page 16: ...match the conveyor width Skewed roller beds are available to accomplish this During accumulation product density packing increases with product weight and speed A discharge brake is not recommended for speeds over 129 FPM unless used with pivoting blade stop NBC conveyor requires a QUIKmeld Tool Kit for splicing the black belt for 500 lb drives ONLY These tool kits were developed by TGW and are av...

Page 17: ...d Release Efficiencies Overall release efficiency with a single continuous release may vary from Contact Accumulation 40 with Basic Logic 40 product 60 air 80 with Progressive Logic 80 product 20 air Release efficiencies are dependent on whether there are mixed case sizes weights and conveyor speed and also whether Basic or Progressive logic is used and the release operation is either singulate or...

Page 18: ...r up or down When product accumulates the conveyor turns to gravity and product control is lost Do not overfeed downstream conveyor with either Basic or Progressive release This will create line pressure The minimum package length is 9 The minimum package height is 1 The maximum product weight is 50 lbs ft Small light products that fit between a zone sensor and the end of the zone may rotate and o...

Page 19: ...penses to repair damaged or replace components must be made against the carrier immediately While unloading a check must be made against the Bill of Lading or other packing lists provided to confirm full receipt of listed items TAKE CARE DURING THE REMOVAL OF EQUIPMENT FROM THE CARRIER Remove small items and boxes first Pull and lift only on the skid not on the frame crossmember or any part of the...

Page 20: ...frame Segregate the conveyor subassemblies by types for inventory and ease of locating during installation An identification label is attached to one side channel or on a crossmember close to one end of each conveyor bed and on all drive packages This label contains item number description job number segment number tag number if specified assembler s initials and date of manufacture On supports th...

Page 21: ...ns manholes etc It may be necessary to reroute the conveyor to avoid the obstruction In this case it would be advisable to begin installation at this point using the obstruction as a reference point Datum and install the section in either direction as required Squaring Conveyor All conveyor sections must be checked for squareness prior to installation as racked or being knocked out of square may h...

Page 22: ...ng laser level or builder s level After the first elevation is established at a critical point the elevation of all other points shall be relative to this first point Normal practice is to dimension the layout and measure elevations from the floor at each point of support As the conveyor system proceeds onto another floor or into another building or room a new elevation will be measured from the f...

Page 23: ...numbers on the I D tags of each component position and orient the conveyor section You must know The direction of product flow The elevation height How the drive is positioned Charge and discharge end beds IMPORTANT Do not make alterations to the equipment without consulting with user s representative and TGW Systems Unauthorized modifications to the equipment may impair its functions create a haz...

Page 24: ...metal bolt clamping force To achieve the support s stated load rating it is necessary to tighten the elevation adjustment bolts 3 8 diameter to 23 ft lbs of torque Supports should always be installed in the vertical position and any variations due to conveyor pitch or floor slope will be compensated for in the pivoting standhead of the support Anchoring Anchoring in concrete floors is accomplished...

Page 25: ...ard the discharge end DOWNSTREAM side putting them in tension Starting the conveyor puts opposite stresses on the supports which is resisted by installing a brace near the drive toward the receiving end UPSTREAM For best results the angle between the knee brace and frame should not exceed 45 degrees or be less than 30 degrees On short supports where a small angle results the knee brace may need to...

Page 26: ...ng ceiling loading or structural limitations of the building for sizing header steel Cross pipes V brackets and flat strap connectors are provided with ceiling hangers Threaded 3 4 rod and attaching nuts are available as an option Tie rods for squaring the conveyor frame are recommended with all ceiling hanger applications If hanger uprights are field fabricated they should be a minimum of 1 1 2 x...

Page 27: ...ld be used to support your maximum anticipated load After hanger uprights are installed and the heavy extension nuts welded to angle hangers thread the drop rods into the extension nuts Thread the jam nuts and stop nuts on the drop rod far enough up the rods to allow installation and adjustment of the cross pipe WARNING ...

Page 28: ...anger with four bolts two per upright minimum size 1 2 diameter Consult your distributor or structural engineer to determine your needs Do not use explosive type anchors For heavier concentrated loads like drives or points where movement or vibration can occur use 5 8 diameter through bolts with backup plates If this is not permissible or possible then header steel must be installed using several ...

Page 29: ...g hung conveyor header steel should be installed well ahead of the conveyor frame installation to minimize congestion Connectors Adjoining NBC beds are connected using welded butt plates For either ceiling hanging or floor mounting supports may be placed anywhere under the bed section while maintain 12 maximum centers The beds should be temporarily supported while the support and connectors are in...

Page 30: ...NBC Flat Belt 1118140rev102213 30 Line Straightness Line straightness must be maintained or belt will mis track and result in damage to the conveyor NBC INSTALLATION CAUTION ...

Page 31: ... This logic mode may be adequate for your conveyor system However if higher product throughput is required some of the basic modules can be switched to progressive which is indicated by an amber light Never switch all the logic modules to progressive For maximum product throughput a pattern of 4 progressive modules and 1 basic module should be followed See Index heading Basic and Progressive Logic...

Page 32: ...LOT KIT TGW ERMANCO NO 1118034 LAST SENSOR ON NBC ACCUMULATION ACTIVATES PILOT ON LARGE AIR VALVE PUTTING ENTIRE AIR TRANSPORTATION INTO NON POWERED GRAVITY Input 30 40 PSI pressure line 3 8 poly tube from downstream conveyor air header Tee into downstream pressure pan air line 3 8 poly tube from upstream air transportation Air pilot input ...

Page 33: ...rethane side of the belt 1 16 in depth and long on both ends of the belt Make sure that you do not cut into the belt fabric Reference the diagram below A hand held right angle grinder can easily and safely remove this material 4 Install a U3 RHT lace with 2 points and twelve hooks centered on one belt end 5 Install the other U3 RHT lace with eleven hooks centered on the other belt end Reference TG...

Page 34: ... supplied This belt must be welded together with a TGW Systems supplied welding machine Black PVC hot welded NBC belt NOTE TRIM URETHANE SIDE OF BELT AS SHOWN BEFORE INSTALLING LACE DO NOT CUT FABRIC Never field splice the black PVC belt with mechanical lacing as the belt fabric is not designed to hold lacing CAUTION 8 long hot welded splice ...

Page 35: ...NBC Flat Belt 1118140rev102213 35 See QUIKmeld belt welding instruction manual for complete belt welding instructions NBC QUIKmeld Unit PN 1120200 ...

Page 36: ...depress the pressure pans and open up a belt path Without air all the rollers are engaged as NBC is a spring to drive system and it will be extremely difficult to thread the belt Note Use the slide switch located at the take up cylinder base to turn the air take up OFF 500 lb 250 lb AT only Primary Conveyor Regulator PN E0034790 Air pressure should be between 30 40 PSI Slide sleeve to engage air p...

Page 37: ...veyor mounted power supplies All logic modules lights should be OFF This will depress the springs in the pressure plan creating a belt path Step 3 Remove bottom guard on drive to have access for belt threading 250 lb manual drive guard shown the 500 lb and 250 lb AT bottom guard is a flat plate Remove guard ...

Page 38: ...rollers without the ends curling NOTE Do not put too much tape on as it will make it difficult to push the belt through the guide rollers Step 5 Remove rollers at each end and insert the splint with belt attached The belt must be installed with the urethane side facing up to contact the carrier rollers Push belt into conveyor It will be necessary to remove sections of rollers every 30 or 40 to hel...

Page 39: ...ged snubber pulley Picture 2 Make sure belt passes between ball bearing belt guide Picture 3 Step 7 Pull belt through the bottom side of the conveyor The belt must be on TOP of the return belt idlers Picture 4 Wrap the belt end around the drive take up pulley 250lb manual drive Picture 5 Wrap the belt end around the drive idler pulley before the air take up pulley in AT drives ...

Page 40: ...t to put the pin through Be sure the pin is through ALL the lacing fingers If the black belt is used see the QUIKmeld Instructions on belt splice for welding the belt on the top side of the conveyor at the charge drive end DRIVE BELT PATH P N 1118030 Belts must be properly installed to ensure belt life This is critical for proper conveyor performance PRODUCT FLOW DRIVE BELT PATH PRODUCT FLOW P N 1...

Page 41: ...h no air To open a belt path two cams under each pressure pan must be rotated to the high side of the cam Step 2 Thread the belt as shown in steps 3 through 8 of the NBC accumulation conveyor Step 3 Rotate each cam back to the low side of the cam re engaging the spring 3 4 socket Rotate to high side of cam Rotate back to low side of cam ...

Page 42: ... nuts with two 15 16 open end wrenches Pull take up pulley back until belt resistance is felt Step 2 Compress springs with nut keeping both sides equal until the end washer indicator is into the tight side of the red area After the conveyor is running RECHECK the belt tension During initial operation the red belt typically loosens and must be retightened frequently until the belt stops stretching ...

Page 43: ...NBC Flat Belt 1118140rev102213 43 Step 3 Be sure the compression springs on both sides of the take up are compressed to exactly equal lengths then tighten jam nuts ...

Page 44: ... and belt installed slide air shutoff switch forward to engage the air tension on the belt shown The belt tension will automatically adjust NOTE FOR 250lb AT DRIVE ONLY The 250 lb AT drive has a regulator prior to the air shutoff slide sleeve The accumulation pressure from the conveyor filter regulator 40PSI is reduced to 30 PSI The 250 lb AT drive air take up pressure should never exceed 30 PSI 5...

Page 45: ...p There is a location for wiring a proximity switch in the air take up This can be used to shut off the drive should the belt stretch to the point of bottoming out the take up or if a belt would break Wiring proximity switch location NOTE PROXIMITY SWITCH MUST BE SET AND TESTED BEFORE DRIVE BELT IS INSTALLED ...

Page 46: ...NBC Flat Belt 1118140rev102213 46 NBC Cross Sections NBC accumulation with CRUZchannel rollers low NBC transportation with C6 channel rollers high ...

Page 47: ...ucts across the conveyor about 16 over the 12 length This side movement is dependent on the bottom condition of the product 12 Skew Bed Installation TGW Systems dedicated 12 skew bed typically is installed as the first 12 bed section in a NBC conveyor line starting from the charge end The rollers are factory skewed to the requested side and the installation is the same as any other NBC intermediat...

Page 48: ...or and 1 of movement on 34 BF conveyor Maintenance skew beds are typically used in contact accumulation NBC lines over 80 which have small product on them After initial alignment by a charge skew bed maintenance skew beds keep products aligned If an NBC conveyor requires maintenance skewing after installation field skewing of the middle section of a 12 bed is possible The required skew pressure pa...

Page 49: ...ons to add a maintenance skew zone are included in zippered bag attached to conveyor side channel 2 Roller Centers Step 1 Select the conveyor section in which the rollers are to be skewed Determine the direction of skew desired and remove one roller from discharge end of the center zone NOTE The bed 4 center zone is the only zone that can be skewed ...

Page 50: ... provided Belt guard provides support of small product at the formation of the skewed zone Step 3 Skew rollers 3 4 to direct the product to the alignment side Right Hand Skew Shown Traveling from Right to Left NOTE Rollers may only be skewed a maximum of 3 4 in either direction ...

Page 51: ...mine the direction of skew desired All rollers in the middle zone are used for skewing NOTE The bed center 4 zone is the only zone that can be skewed Step 2 Skew rollers 3 4 to direct the product to the alignment side NOTE Rollers may only be skewed a maximum of 3 4 in either direction on the side channel opposite the drive belt ...

Page 52: ...ions when mounted to XenoROL KIT CHANNEL CONN P N 92300004 4to7ChannelConn 89003 ALIGN INSIDE SURFACES OF SIDE CHANNELS 4 1 2 4 7 8 1 1 2 6 3 8 7 1 2 3 8 HARDWARE TYP P N 80700119 P N 92300009 KIT CHANNEL CONN 9to7ChannelConn 89003 ALIGN INSIDE SURFACES OF SIDE CHANNELS 3 8 HARDWARE TYP P N 80700120 7 1 2 6 3 8 3 9 9 3 8 ...

Page 53: ...BC NBC can be supplied with rollers low which uses the CRUZ side channel as a low guardrail If C6 channel is supplied 1 1 2 high angle guardrail can be used as a low guard CRUZchannel side frame acts as a guardrail Use 1 1 2 angle for low C6 channel guardrail ...

Page 54: ...the NBC is designed to use adjustable guardrail The configurations and associated part numbers are shown below Adjustable guard single high and double high Flared lead in section for adjustable channel guardrail Use part 117657 at the entrance of all adjustable channel guardrail ...

Page 55: ...t 1118140rev102213 55 CRUZchannel to C6 Nose Piece A CRUZchannel to C6 nosepiece provides a smooth transition for products moving from rollers high conveyor to rollers low conveyor C6 to CRUZ nosepiece Kit 1125371 ...

Page 56: ... points of use Air Drops TGW Systems recommends using 3 4 pipe on air drops for high flow and low pressure loss The drop is terminated with a drain at the bottom A tee located prior to the drain branches off to the conveyor This branch line must contain a lockout shutoff A shutoff must also be located in the drop before the branch tee OSHA Rule 29 CFR1910 147 requires energy sources air drops be t...

Page 57: ...n out to clear all debris The regulator must be set at 30 40 PSI prior to connecting air to NBC If your air compressor uses synthetic oil a coalescing filter plus a regular filter of 5 micron is required Synthetic oils will shrink the seals in pneumatic devices and valving CAUTION ...

Page 58: ... at 30 40 PSI 3 Maximum conveyor length each way from regulator is 100 Locate the regulator in center of conveyor for minimum air pressure drop 4 Low pressure switch to be set to indicate a pressure drop below 20 PSI 5 In high humidity or low temperature use an air dryer 6 Use 5 micron filter 7 Lockout shutoff valve to be provided by air system installer for factory high pressure line before regul...

Page 59: ...peration and maintenance of TGW Systems conveyors featuring CRUZcontrol Logic This section of the manual describes basic installation practices assembly arrangements preventive maintenance and assists in replacement parts identification It is intended for use by personnel who are knowledgeable of installation and safe working practices on conveyor systems Not all applications and conditions can be...

Page 60: ...FF there is no power on the logic line ON On indicates a logical high signal and or powered For example if a slug line is ON then there is power on the slug line Zone status The zone is considered full if the local zone s sensor detects a package The zone is empty if it does not detect a package JP JP stands for jumper terminal and the number indicates which jumper terminal is being referenced The...

Page 61: ...allation and interfacing CRUZcontrol is a 24 VDC system that will automatically start accumulation when product reaches the end of an accumulation line When a release signal is applied to a function module that is installed at the discharge end of an accumulation line the product will begin to release Product will continue to release until the signal is removed The type of accumulation that occurs...

Page 62: ...progressive logic with a manually activated toggle switch A green light indicates basic mode and an amber light progressive mode The manner in which basic and progressive logic modes change accumulation and release are explained in the following pages Green light indicates basic mode Amber light indicates progressive mode Toggle Switch use paper clip to change ...

Page 63: ...eing transported on accumulation conveyor are separated by a gap of one zone length upon release This will reduce the transportation throughput capacity of the conveyor The rate at which product is introduced onto an accumulation conveyor of this type must not exceed the transportation rate of the conveyor Discharge from Basic Logic A release signal given to the Zone 6 Logic Assembly releases prod...

Page 64: ...lts in all upstream zones Zone 1 through Zone 5 running NOTE Progressive Logic Products being transported on accumulation conveyor can remain tightly packed without any gaps being created The transportation throughput capacity of the conveyor is not reduced due to zoned accumulation Discharge from Progressive Logic When the discharge zone Zone 6 is provided a release signal all upstream zones also...

Page 65: ... to function properly could possibly result in product accumulating with zones not stopping as required While this should be unlikely due to the fail safe nature of the Logic Assembly the effects of such a failure should be considered This type of failure could result in excessive line pressure eventually causing product to push through the discharge zone of the conveyor Jam detection sensors shou...

Page 66: ...ill be indicated by a green light when the 24VDC power is activated Basic Release In the basic release mode all logic modules are set to basic The release efficiency will generally be 40 to 50 depending on the conveyor speed and the type of release at the discharge of the unit A timed pulse release is generally more efficient than a one time flush type of release Diagram of conveyor modes are all ...

Page 67: ...se mode for contact accumulation it is extremely important to set every 5th logic module to basic Do not set all logic modules to progressive unless your line is under 20 long This limits a product jam condition line pressure to 16 of conveyor Failure to set every fifth logic module to basic can result in extreme line pressures that can damage your conveyor product and could cause injury Release e...

Page 68: ...complete wiring descriptions for release function modules are explained in the CRUZcontrol in this section Exercise extreme caution in activating the slug release line TB 2 instead of the singulation logic line TB 1 If used at all it should be limited to the discharge 20 or less of conveyor A slug interrupt cable item number 1117382 can be used to break this signal where you want the slug release ...

Page 69: ...rd brake kits are available for NBC For speeds from 130 FPM to 230 FPM a stop is recommended at the discharge end of NBC to stop the coasting product and begin accumulation Standard stop assemblies are available for NBC Please note that a stop cannot be allowed to come up under a product An external PLC controlled sensor must be used to detect a gap and then activate a solenoid to raise the stop C...

Page 70: ...NBC Flat Belt 1118140rev102213 70 A belt unit downstream can be used in place of either a brake or a stop If this belt option is selected use the CRUZ belt 4 series CONTACT ACCUMULATION ...

Page 71: ...is not affected by shiny surfaces On NBC applications the reflector is mounted with a 6 inch offset from the photoelectric sensor so that the sensor scans across the conveyor on a slight angle The sensor bracket as provided allows for easy adjustment of the sensor An amber LED output indicator on the back of the sensor aids in the adjustment of the sensor The LED is off if the sensor is not aligne...

Page 72: ...ing for selection of either Basic Logic or Progressive Logic mode A Mode LED indicates either Basic green or Progressive amber has been selected Pressing and then releasing the button toggles between the two modes Table 1 Logic Assemblies Functions Function Basic Logic Progressive Logic Single Accumulate Yes No Slug Accumulate No Yes Single Release Yes No Slug Release Yes Yes Logic Assembly Part N...

Page 73: ...he Function Module All jumper terminals are on pins 1 2 unless noted otherwise Table 4 Function Module Functions Single Release Definition Upstream logic line is turned on The upstream Logic Assembly will release regardless of zone status Configuration When using TB1 JP3 1 2 to release the upstream Logic Assembly When using TB4 JP4 1 2 to release the upstream Logic Assembly User Action Apply a hig...

Page 74: ...c Assembly User Action Apply a high 24VDC 115VAC signal to TB1 1 2 if using isolated inputs Or Apply a high 24VDC signal to TB4 3 if using a non isolated input Zone Delay Definition Delays turning on the upstream logic line After the downstream zone clears the upstream Logic Assembly releases but only after a length of time set by LOGIC potentiometer 0 20s Configuration Adjust LOGIC potentiometer ...

Page 75: ...that is different than the supply powering CRUZcontrol logic assemblies It can be used when signal voltage is from same power supply that is powering CRUZcontrol logic assemblies TB2 Slug release This terminal is an isolated input it must be used when signal voltage is from a supply that is different than the supply powering CRUZcontrol logic assemblies It can be used when signal voltage is from s...

Page 76: ...rupt JP2 Upstream slug control Pins 1 2 slug pass through Pins 2 3 slug interrupt Pins NC slug interrupt JP3 Release control at TB1 Pins 1 2 single release Pins 2 3 logic interrupt Pins NC pulsed released JP4 Release control at TB4 Pins 1 2 single release Pins 2 3 logic interrupt Pins NC zone status input determined by JP5 JP5 Zone Status control JP5 only available on full function module Pins 1 2...

Page 77: ...anasonic ERZV07D241 or Littlefuse V250LA2 Long conduit runs with motor wiring for multiple motors and the use of variable frequency drives all contribute to electrical noise with a good potential for high voltage spikes If there is any doubt the control signals to the Function Modules should be run in conduits separate from motor wiring The Function Module signal inputs have high impedance When co...

Page 78: ...Flat Belt 1118140rev102213 78 Function Module Part Numbers Table 7 Function Module Part Numbers Part Number Description 1116731 Full Function Module 1116732 Release Function Module Figure 3 Function Modules ...

Page 79: ...NBC Flat Belt 1118140rev102213 79 Figure 4 Full Function Module Board Layout Figure 5 Full Function Module Circuit ...

Page 80: ...NBC Flat Belt 1118140rev102213 80 Figure 6 Release Function Board Layout Figure 7 Release Function Module Circuit ...

Page 81: ...e in one continuous string based on the cable length and power requirement of Logic Assemblies More than one string of Logic Assemblies can be connected to a power supply as long as the power supply output rating isn t exceeded The Function Modules require 10mA of current at 24 VDC This needs to be considered as it will reduce the total number of Logic Modules that can be connected to one Class 2 ...

Page 82: ...es using a T Cable This drawing illustrates a power connection made between two intermediate accumulation zones making use of a T Cable Note that all power and control signals including the Slug and Logic Signals pass through the T Cable uninterrupted Figure 8 Two Logic Assemblies using a T Cable ...

Page 83: ...power supply It could be necessary to extend the T Cable leads to reach the power supply location This should be done with a wire gauge large enough to prevent noticeable voltage drop The number of CRUZcontrol zones that can be connected per string must also be reduced based on the voltage drop of the wire used The brown lead on the T Cable connects to 24 VDC on the power supply The blue lead on t...

Page 84: ... The VDC line is not passed through while the Slug Release and Singulation Release Signals as well as 0VDC are connected to pass the signals through uninterrupted Figure 10 One CRUZcontrol Section with Two Power Supplies Power Supply Part Numbers Table 9 Power Supply Part Numbers TGW Systems Part Number Description Kit Part Number 1117431 1117972 100 120 220 240 VAC input Power Supply and T cable ...

Page 85: ... sensor and appropriate bracket Even though not normally needed an extra reflector and adhesive mounting tape is also included with each kit The 10 30 VDC photo sensors are similar to the CRUZcontrol sensors They are light operate with a 50 mA maximum output current and come with a 27 cable no connector Table 10 Photoelectric sensor Part Number Description 1117727 Photoelectric sensor with bracket...

Page 86: ...alve section of the Logic Assembly When used this way the added Logic Assembly is known as the Discharge Logic Assembly DLA The Discharge Logic Assembly is mounted on the charge end of the conveyor immediately downstream of the last discharge zone of a length of CRUZcontrol accumulation conveyor It is connected to the Logic Assembly of the discharge zone as shown There is no need for a Function Mo...

Page 87: ... for the mounting of the Discharge Logic Assembly and reflector either or 3 above a standard CRUZ side channel Since every application is different there will usually be a need to drill mounting holes for the brackets Table 14 Discharge Logic Assembly Part Number Description 1117859 Discharge Logic Assembly Kit inch above rollers scan height 1117860 Discharge Logic Assembly Kit 3 inch above roller...

Page 88: ... to insure proper alignment with the reflectors as well as proper functioning of the Logic Assemblies Field Installation Bed to bed connections Connection of air supply tubing between conveyor beds terminating the ends of the air supply tubing Connection of the Logic Assembly upstream or downstream cable from the last zone of a conveyor bed to the first zone in the next upstream conveyor bed Syste...

Page 89: ...13 89 Conveyor Flow The logic assembly wiring is in line for left hand flow conveyors for right hand flow conveyors the wiring direction will be reversed Figure 13 Left Hand Flow Conveyor Bed Figure 14 Right Hand Flow Conveyor Bed ...

Page 90: ...photoelectric sensors This would probably be the most common cause of excessive line pressure resulting from the use of Progressive Logic mode CRUZcontrol A solution to this problem is to provide one Basic Logic mode zone at the discharge end of every 12 foot bed of conveyor This would limit the length of conveyor that could possibly be driving product against a jam point to 12 feet The use of one...

Page 91: ...above 100 FPM 2 The release of product from the accumulation conveyor could be logically controlled so as to limit the release rate If the NBC running at 180 FPM were to be given a Singulation Release signal for 3 3 seconds and then kept off for 2 7 seconds with that sequence repeating the theoretical release rate should be close to 100 product feet per minute 180 FPM x 3 3 sec 3 3 sec 2 7 sec The...

Page 92: ... the function module to get it to release Configuration Plug Function module into discharge zone All jumpers are set to pins 1 2 Give function module a release signal either through the isolated input as shown in Figure 15 or through the non isolated inputs as shown in Figure 16 Operation Product will release for as long as the release signal is given Figure 15 Isolated Input Single Release Figure...

Page 93: ...m zone 2 to 3 until product has reached zone 1 Operation Carton flow from zone 3 to zone 2 to zone 1 occurs as normal When a carton first clears the zone 2 photoelectric sensor the release of the next carton from zone 3 is inhibited by the setting of the logic delay relay in the full function module No external logic signals are require The release will need to be delayed until the carton released...

Page 94: ...TB4 3 ZS INPUT Wire function module for time delay TB4 1 0VDC to TB1 1 TB4 2 VDC to TB3 2 COM TB3 1 NO to TB1 2 Operation The Full Function Module is connected as shown just downstream of the last accumulation zone prior to the curve Release from that zone is stopped if the Auxiliary Photo Sensor senses full accumulation blocked for a time delay period or if the Logic Assembly just downstream of t...

Page 95: ...NBC Flat Belt 1118140rev102213 95 Figure 18 CRUZcontrol around a curve High rate Figure 19 Function Module Wiring ...

Page 96: ...tart accumulation Configuration When using TB1 to interrupt the logic set jumper terminal JP3 2 3 When using TB4 to interrupt the logic set jumper terminal JP4 2 3 User Action Apply a high signal to TB1 24Vdc 120Vac or TB4 24Vdc Operation All product stops at a specific accumulation zone when the contact is closed and is released when the contact is opened Figure 20 Work Zone Figure 21 Work Zone U...

Page 97: ...he CRUZcontrol operation with the induction conveyor operation since the functioning of it is based solely on product movement NBC conveyor when accumulating and subsequently releasing accumulated product will result in some amount of line pressure at the discharge end of the conveyor This is caused by the momentum of moving product coasting to a stop as it accumulates Example The NBC is running a...

Page 98: ...tes and discharges from accumulation with only very minimal gaps between products The following illustrates an NBC accumulation lane used to release product to a merge conveyor A Product Stop is located at the end of the accumulation lane controlled by the solenoid valve as shown The last two accumulation zones are also provided with brakes as shown These brakes are controlled by the CRUZcontrol L...

Page 99: ...oid and Function Module not energized product blocking the Photosensor of the CRUZcontrol Logic Assembly will result in the conveyor zone going into accumulation and the zone brake being activated This in turn enables accumulation beginning with the next upstream accumulation zone once the photosensor in that zone is blocked Function Module 2 also a Release Function Module is configured and wired ...

Page 100: ...d connected in series with the neighboring upstream and downstream zones The CRUZcontrol module will be comprised of a retro reflective sensor logic module with integrated pneumatic valve and daisy chain connections The retro reflective sensor attached to the CRUZcontrol module will be located in the same zone local zone as the CRUZcontrol module and the valve will control the local zone Conveyor ...

Page 101: ...hieved by mounting while still accommodating fine alignment adjustment Maintain an excess gain of one 1 or more for all BF distances with a maximum skew of six inches Figure 24 Sensor Dimensional Data for 25 Cable Exit Table 16 Sensor Optical Specification Sensor Model ZL2 P2400S04 Sensor Part Number 2048176 Sensor Type Reflex Polarized Switching Logic Light Operate Light Source Red LED Output Ind...

Page 102: ...using and satisfy the following requirements A switch for adjusting between basic and progressive logic shall be located on the housing factory set to basic Visible indication of the selected logic function Logic selection switch must be easily accessible when mounted on the conveyor but requires a simple standard tool to make adjustment Barbed tube fittings on the air supply and air outlet that a...

Page 103: ...NBC Flat Belt 1118140rev102213 103 Figure 25 Final TGW Logic Module Mechanical Design 5 18 0 08 ...

Page 104: ...ube fitting for 1 4 in O D 0 160 in I D tubing Enclosure Rating IP20 Housing Material ABS plastic Color Back cover and manifold Black Front cover PMS 420 Mounting Twin Keyhole same as current module Ambient Temperature Operating 14 122 F 10 50C Ambient Temperature Storage 40 158 F 40 70C Table 19 Logic Module Electrical Specification Supply Voltage 24 VDC 20 15 Voltage Drop 19 mV Current Consumpti...

Page 105: ...ribed below Note that both single and slug release is available in basic mode while progressive mode will only slug release due to the logic refer to Table 20 Table 20 Logic Function Function Basic Logic Progressive Logic Single Accumulate Yes No Slug Accumulate No Yes Single Release Yes No Slug Release Yes Yes 2x2 Female Connector Pin 2 Slug Pin 3 Logic Pin 1 24 VDC Pin 4 0V Black White Brown Blu...

Page 106: ... Accumulation Logic For single release a given zone will release once the sensor in the downstream zone is clear of product This may be done by removing product or applying an electrical release signal VDC to PIN 2 and this also applies to the discharge zone When using slug release all zones to which the slug line is connected will be activated simultaneously This is initiated by applying supply v...

Page 107: ...when the sensor is blocked The logic signal is passed upstream on PIN 2 Figure 28 Progressive Accumulation Logic Progressive mode only allows slug release All zones to which the slug line is connected will be activated simultaneously This is initiated by applying supply voltage to PIN 4 The same effect may be achieved by applying an electric release signal VDC to PIN 2 Sensor Input Sensor Input Ou...

Page 108: ...ain logic and has a unique wiring scheme on the male connection This module may be simply described as a junction box with connection to provide VDC to the sensor and valve sensor output to the PLC and valve input from the PLC The male connection interface will be a cable with flying leads and have two meter 2m length The jacket shall be stripped and conductors perforated See the current Sensor Va...

Page 109: ...NBC Flat Belt 1118140rev102213 109 Pin 3 Pin 1 24 Pin 2 NC n c Pin 4 PNP Sig Logic Module Housing ...

Page 110: ... 2x2 connections while female refers to a female housing Table 22 Interconnection Types and Lengths 1117370 Male Cordset 2x2 78 in 2m 1117371 Female Cordset 2x2 78 in 2m 1117372 1117373 1117374 Extension Cable 2x2 male female Extension Cable 2x2 male female Extension Cable 2x2 male female 39 in 1m 78 in 2m 157 in 4m 1117375 2x2 M12 Adapter female female 6 in 150mm 1117376 2x2 M12 Adapter male male...

Page 111: ...e mounting plate that mounts directly to the side of the conveyor The power supplies are also capable of buffering brief power failure conditions at rated voltage e g 20 ms at 120 VAC in accordance with EN 60204 1 Global acceptance is also achieved by conformance with cULus standards North American compliance and CE standard requirements European compliance n c Pin 2 Pin 3 Pin 1 Pin 4 2x2 Male Con...

Page 112: ...ply Features Adjustable output voltage up to 24 28 VDC 115 230 VAC or 480 2 phase VAC input State of the art design Type 1 enclosure IP 20 Bolt on mounting Figure 34 TGW PN 1117432 Dimensional Diagrams Figure 35 TGW PN 1117432 Connection Diagrams ...

Page 113: ...NBC Flat Belt 1118140rev102213 113 Figure 36 TGW PN 1117431 Dimensional Diagram Figure 37 TGW PN 1117431 Connection Diagram ...

Page 114: ... 122 140 F 50 60 C Storage Temperature 13 185 F 25 85 C 13 185 F 25 85 C Humidity Do not energize when condensation is present 93 95 Input Cable Access 3 4 or 1 2 in hole for conduit AC Connection Wires Stranded cable 0 3 2 5 mm2 AWG 28 12 2 5 mm2 AWG 26 12 Solid cable 0 3 4 mm2 AWG 28 12 2 5 mm2 AWG 26 12 Stripping at wire end 6 mm 6 mm Note secure wires from strain AC External Protection Fusing ...

Page 115: ...apter female male 1117378 2x2 M12 Adapter male female 1117379 T Cable with flying leads 2m 1117380 Power Interrupt Cable 1117381 Logic Interrupt Cable 1117382 Slug Interrupt Cable 1116731 Function Module Full 1116732 Function Module Release 1116733 Function Module Zone Status Table 25 Logic Module w MHL1 Sensor and M12 Daisychain for CRUZcontrol TGW Part Description E0001900A Basic AtoB E0001901A ...

Page 116: ...uards are in place Check any oil leakage Check for loose bolts or parts Check air filter bowls for accumulated water Listen for air leaks Weekly Inspect bearings and gearmotors for excessive noise or heat Check operation of all electrical controls Check for proper PSI on air regulators Prohibit riding on conveyor by anyone Think before making any adjustments It may prevent an injury Remember all m...

Page 117: ...ming apart it should be scheduled as soon as possible for a new belt splice to replace the old belt splice NOTE Never re weld over old belt splice This makes the belt splice weak and brittle Check to confirm tools and foreign objects have not been left on or inside the conveyor Check to confirm all loosened parts have been retightened Check to confirm all guards have been installed Gearmotors NBC ...

Page 118: ...st be turned off to the work area All pneumatic devices must be de energized to prevent accidental cycling of the device Solenoid Valves In order to minimize downtime it is normally not feasible to repair malfunctioning electrical or valve components while leaving the conveyor unusable Spare components should be kept in stock for emergency replacement If feasible the part may be repaired later to ...

Page 119: ...making sure photoeye has unobstructed view of reflector 3 Move the target in and out of the field of detection to ensure that the photoeye energizes and de energizes Adjust the proximity type as follows 1 Loosen proximity switch mounting bolt and adjust sensing switch so that the product passes directly in front of the switch face as close to the switch face as possible without making contact 2 Ch...

Page 120: ...or orders of 20 000 or more It includes part numbers description pricing and recommended quantities to be kept for maintenance If you are unable to locate this document or the order is under 20 000 another may be obtained by contacting TGW Systems Lifetime Services at 231 798 4547 or Fax 231 798 4549 To identify a part and its part number refer to the assemblies and devices on the following pages ...

Page 121: ...NBC Flat Belt 1118140rev102213 121 NBC 500 lb Drive Train ...

Page 122: ...NBC Flat Belt 1118140rev102213 122 ...

Page 123: ...NBC Flat Belt 1118140rev102213 123 NBC 250 lb Drive Train 1135077 SYSTEM OPERATES 40 PSI DRIVE IS PRESSURE REDUCED TO 30 PSI USE ONLY WITH RED LACED URETHANE BELT ...

Page 124: ...NBC Flat Belt 1118140rev102213 124 ...

Page 125: ...NBC Flat Belt 1118140rev102213 125 NBC 250 lb Manual Take up and Drive Train ...

Page 126: ...NBC Flat Belt 1118140rev102213 126 NBC Pressure Assembly ...

Page 127: ...NBC Flat Belt 1118140rev102213 127 NBC Skewed Pressure Pan Assembly LH bed RH skew shown ...

Page 128: ...5 BF SKEW NBC 7 06 1118057 SCREW 10 32 X 3 8 BUTTON HEAD NYLON PATCH 8 14 1118064 CLIP BEARING SKEW NBC 8 19 1101174 NUT 10 32 THIN NYLOC 4 20 1118063 SPACER GUIDE BRG NBC SKEW 4 21 90050111 BEARING R6ZZ 12 22 E0001440 WASHER 10 FLAT SAE 12 Replacement Part Numbers for NBC Skewed Pressure Pan Assembly ...

Page 129: ...NBC Flat Belt 1118140rev102213 129 NBC Discharge Brake Assembly LH shown ...

Page 130: ...KE ASSEMBLY 1 03 1113368 BUMPER BRAKE PAD 8 04 1113560 DIAPHRAGM ASY PNEUMATIC SINGLE INLET 1 23 E0001530 ROLLER PLASTIC COAT 2D GRVS 1 9CTD 6 1117982 1117983 1117975 1117984 BRAKE KIT ASY INCLUDES ROLLERS 1118098 1118099 1118100 1118101 Replacement Part Numbers and Quantities for NBC Brake Assembly ...

Page 131: ...NBC Flat Belt 1118140rev102213 131 NBC End Pulley Assembly Charge Discharge ...

Page 132: ...NBC Flat Belt 1118140rev102213 132 NBC 12 ft Contact Accumulation LH bed shown MODE MODE ...

Page 133: ...NBC Flat Belt 1118140rev102213 133 NBC Logic Module Component Straight Beds AIR TO BRAKE LOGIC MODULE 1114947 ...

Page 134: ...NBC Flat Belt 1118140rev102213 134 NBC 12 ft Contact Accumulation Skewed Rollers LH Bed with RH Skew shown ...

Page 135: ...slowly Belt not engaged with roller Check alignment of pressure pan Zone not active Check alignment of downstream photo eye Interference with roller or belt Locate and correct interference Bent roller Replace roller Excessive Belt Wear Poor routing of belt Correct route of belt insure belt is woven through drive and end terminals correctly Interference within route of belt Locate and correct inter...

Page 136: ...le are used to connect with the Power Supply If the white and black wires connect in any way the logic is turn into progressive mode out of singulation and all function module settings are overridden Broken logic module Located module and replace with new component Lack of air Insure Filter Regulator is functioning properly and is set at proper setting 40psi Zones not releasing Cable connector iss...

Page 137: ...NBC Flat Belt 1118140rev102213 137 NBC Belt Routing Troubleshooting Guidelines Belt is routed thorough terminal end section correctly as you can see the spacers inside the protective guarding ...

Page 138: ...NBC Flat Belt 1118140rev102213 138 Belt is NOT routed through terminal end section correctly as you cannot see the spacers inside the protective guarding ...

Page 139: ...NBC Flat Belt 1118140rev102213 139 Belt is routed through Drive and Take Up section correctly as you can see the belt is ABOVE the top of the protective guarding and ABOVE spacer ...

Page 140: ...at Belt 1118140rev102213 140 Belt is NOT routed thorough Drive and Take Up section correctly as you can see the belt is BELOW the top of the protective guarding and UNDER the spacer Under space is NOT correct ...

Page 141: ...NBC Flat Belt 1118140rev102213 141 Pictures of results from poor belt routing ...

Page 142: ...motes safety and personal development TGW Systems Inc 6870 Grand Haven Road Spring Lake MI 49456 9652 USA 231 798 4547 Sales Fax 231 798 4146 or Corp Fax 231 798 8322 Email usinfo tgw group com Web Site www tgw group com Regional sales offices and authorized Business Partners located throughout the United States and Canada Licensees and Business Partners in Europe South America and Southeast Asia ...

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Summary of Contents for NBC Flat Belt

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