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TGW NBC Installation, Operation & Maintenance Manual Download Page 112

NBC™ Flat Belt - IOM 

P/N: 1118140 

Rev: 07/29/2020 

Page 

112

 of 

129

 

Mechanical 

Problem 

Possible Cause 

Remedy 

Items not 

accumulating 

Improper wiring of 

T-cable to power 

supply 

Only the brown and blue wires of the T-cable 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 

issue 

Insure proper connection, check for damage. 

 

 

Summary of Contents for NBC

Page 1: ...Installation Operation Maintenance Manual NBC Belt Narrow Belt Conveyor Accumulation with CRUZcontrol Transportation P N 1118140 Revision Date July 29 2020 ...

Page 2: ...CEIVING AND SITE PREPARATION 23 4 1 PARTS INVENTORY AND IDENTIFICATION 24 CHAPTER 5 NBC INSTALLATION DETAILS 25 5 1 DIMENSIONAL REFERENCE POINTS 25 5 2 SQUARING CONVEYOR 25 5 3 SUPPORTS CONNECTIONS 27 5 4 ENVIRONMENT 27 5 5 COMPONENT ORIENTATION 27 5 6 ELEVATIONS 28 5 7 LINE STRAIGHTNESS 28 CHAPTER 6 GEAR MOTOR ACTIVATION 29 CHAPTER 7 NBC NITTA BELT WELDING INSTRUCTIONS 31 CHAPTER 8 THREADING THE ...

Page 3: ...K DESCRIPTIONS 73 12 9 JUMPER DESCRIPTIONS 74 12 10 USE OF 115 VAC CONTROLS 75 12 11 FUNCTION MODULE PART NUMBERS 76 CHAPTER 13 NBC POWER SUPPLY REQUIREMENTS 79 13 1 POWER SUPPLY REQUIREMENTS 79 13 2 POWER SUPPLY WIRING 80 13 3 ACCESSORIES 83 CHAPTER 14 CRUZCONTROL ON SITE INSTALLATION 86 CHAPTER 15 CONVEYOR FLOW 88 15 1 OVERVIEW TGW CRUZCONTROL LOGIC MODULE 95 15 2 POWER SUPPLY 100 CHAPTER 16 NBC...

Page 4: ... END PULLEY ASSEMBLY 123 17 9 NBC 12 FT CONTACT ACCUMULATION 124 17 10 NBC LOGIC MODULE COMPONENT 125 17 11 NBC 12 FT CONTACT ACCUMULATION SKEWED ROLLERS 126 17 12 NBC 12 FT CONTACT ACCUMULATION SKEWED ROLLERS 127 TGW GENERAL INFORMATION 128 TGW SYSTEMS INFORMATION 129 ...

Page 5: ...al 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 please contact your TGW Distributor or TGW Lifetime Services at 231 798 4547 or visit TGW at www tgw conveyor com for maintenance videos and other application information Manual Structure You s h o u l d receive a separate documentation for each product line of TGW Sy...

Page 6: ...alled 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 Purchaser s misapplication abuse alteration operation or maintenance...

Page 7: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 7 of 129 1 1 TGW RECOMMENDS PROPER LABELS FOR CONVEYOR TYPES Shown below are some samples of labels applicable to conveyor standards ...

Page 8: ...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 an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations Indicates poten...

Page 9: ... 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 on the conveyor make sure the start up controls are locked out and cannot be turned on by any perso...

Page 10: ...ev 07 29 2020 Page 10 of 129 Before servicing or performing any work in the motor control panel disconnect and lock out air and the main incoming service If only the panel disconnect is off the incoming side will still be hot WARNING ...

Page 11: ...gns or labels Start Pushbuttons Start pushbuttons should be the flush type or guarded such that inadvertently leaning against them will not actuate the conveyor They should be provided with a legend plate clearly defining which conveyors will be started Stop Pushbuttons Stop pushbuttons should be the extended type such that any contact with it is sufficient to stop the conveyor They would also be ...

Page 12: ...cause an output to function erratically For this reason start circuits warning horn circuits and emergency stops should usually be configured using conventional relay logic Safety Switches All conveyor control cabinets and motors should be provided with safety or disconnect switches These switches must have provisions for padlocking As required for maintenance equipment should be locked in the off...

Page 13: ...ers are driven by a nominal 1 75 wide 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 r...

Page 14: ...pressure pan in the down position for ease of belt installation However once the plastic Cam is manually deactivated the pressure pan always holds the drive belt in contact with the carrier roller 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 designe...

Page 15: ...1 NBC conveyor requires a TGW Nitta Belt Welding Tool Kit for splicing the belt This tool kit was developed by Nitta Corporation for TGW NBC belt requirements and are available only from TGW 12 Limit the length of NBC conveyors to 300 If you have a requirement beyond 300 contact Applications Engineering 13 Always locate the drive bed at the charge end of the primary conveyor 14 Totes may have up t...

Page 16: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 16 of 129 25 Ambient temperature is 35 to 120 F for Nitta belts 26 For applications outside this temperature range contact Applications Engineering ...

Page 17: ...r speed whether Basic or Progressive logic is used with the release operation When the speed to meet rate using Basic Logic is over 150 FPM consider using Progressive Logic In the progressive release mode for contact accumulation it is extremely important to set every 5th logic module to basic Discharge Zone A function module is provided for the discharge bed prior to shipping If the NBC line is f...

Page 18: ...e 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 or accumulate side by side Consult Applications Engineering for available options Rollers in the center 4 zone in all 12 intermediate beds are designed to skew if required No other rollers ...

Page 19: ...the last downstream accumulation zone and disengages the pressure pan assemblies for the entire unit Once the downstream zone clears the pilot valve engages the pressure pan assemblies and the transportation conveyor will continue to transport the products The pilot valve can be replaced with a solenoid valve and controlled through a PLC Item Description 1120400 VALVE PNEU PILOT A48 Pilot Valve Te...

Page 20: ...nal is present which causes the NBC Air Transportation conveyor to stop or accumulate When the last NBC Contact Accumulation zone clears a control signal triggers the Solenoid Valve to activate close or stop the air flow and the NBC Air Transportation conveyor will activate and convey the product downstream Review the detail above to determine correct Pilot or Solenoid Valve Kit on the NBC Contact...

Page 21: ...logic line is OFF 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...

Page 22: ... N 1118140 Rev 07 29 2020 Page 22 of 129 1 7 PRODUCT DESCRIPTIONS For the most current list of Product Description and Terms and Abbreviations Log into www tgw conveyor com and select Support Engineering Support Documents ...

Page 23: ...and lift only on the skid not on the frame crossmember or any part of the equipment Be sure the skid is free of other materials which may be on top of or against the side of the skid to be removed Conveyor ready for shipment Preparation of Site After the conveyor is received move it to the installation site or designated dry storage area as soon as possible Clean up all packing material immediatel...

Page 24: ...ck number Date of manufacture QR Quick Response bar code o Scan bar code for IOM manual If Applicable Scan the QR code to retrieve the IOM Manual if nothing happens check your scanner settings to make sure the QR Label setting is enabled On the supports the tag is located on the bottom side of the foot On special devices it is located on a convenient flat surface that is not offensive to the appea...

Page 25: ...f the conveyor is established and a chalk line is snapped between these points Conveyors should be installed with the center line of the bed matching the center line of the conveyor path within 1 8 of true center Locate and mark the center of the crossmembers at each end of the conveyor Use a plumb line or other acceptable means to ensure accuracy to the chalk line Always carry out a thorough chec...

Page 26: ... the longest diagonal dimension and adjusting the turnbuckle until the diagonal measurements are equal in length It is important to loosen the support and connection hardware before attempting any adjustment If gaps appear between bed joints as a result of squaring the conveyor take care not to re rack the conveyor by pulling the sections together at the bed joints Insert optional shim plates or w...

Page 27: ... characteristics Corrosive or Abrasive Substances Will adversely affect various components 1 13 COMPONENT ORIENTATION Using your conveyor system layout drawing and the 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 alte...

Page 28: ...building or room a new elevation will be measured from the floor at that point The new elevation will then become the reference from subsequent elevations When installing an overhead system the first elevation is measured from the floor and becomes the reference elevation point until a change in the elevation is shown on the layout Any new elevation is also measured from the floor and becomes the ...

Page 29: ...unit should have a yellow instruction tag as shown below The tag can be removed after the plug is removed NOTE The rubber sealing plug is in place for shipping and storage purpose only In order for the gear motor to release pressure the vent must be activated by removing the rubber sealing plug PRIOR to gear unit start up Please check you gear unit for a vent and if applicable to your product remo...

Page 30: ...ent to activate The following pictures are examples showing where vent plugs may be located depending on the product line and motor position Sealing Plug The Yellow Tag may be hidden or possibly missing Check motor for a vent and remove sealing plug to activate Sealing Plug Sealing Plug Vent Sealing Plug may be hard to see depending on the product line and motor location ...

Page 31: ... CASE PELICAN 1560 000 110 BLACK CASE W SPECIAL MOBRIK FOAM BW1560 HOLDS THE WELDER PRESETTER 1211172 CASE PELICAN 1620 020 110 BLACK CASE W SPECIAL MOBRIK FOAM BW1620 HOLDS THE PUNCHER TGW NITTABELT FULL WELD PUNCH KITS RENTAL KITS ONLY TGW Rental Kit Include Finger Punch Press T wrench Heated Weld Press Pre setter Mold Silicone Sheet Instruction Manuals and Flash Drive with Instruction Video Eac...

Page 32: ...NITTA BELT PRE SETTER W SILICONE SHEET 1 75 W Item Description 1204525 TOOL NBC NITTA BELT PUNCHER FINGER PUNCHER Item Description 1207004 TOOL CPART NITTA BLADE 2 CUTTERS FOR USE WITH FP 200T 1207118 TOOL NBC NITTA T WRENCH USE WITH PUNCH PRESS 1207119 TOOL NBC NITTA CUTTING BOARD USE WITH PUNCH PRESS 1215576 SCREW HEX HEAD NITTA NO2 FP200 A003 19 1215577 TABLE ALGND NITTA NO2 FP200 P011 E RA REP...

Page 33: ...s 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 Step 2 Disconnect the power to ALL the logic modules switch off SICK conveyor mounted power supplies All logic modules lights should be OFF This will depress the springs in the pressure plan creating a belt path Air pressure sho...

Page 34: ...elt With the air pressure ON the logic and the logic module power OFF attach a sheet metal splint or the belt threading tool attached to each drive from factory P N 1118104 with tape to the end of the belt This will enhance the ability to thread the belt under the rollers without the ends curling NOTE Keep tape smooth and do not apply too much tape as it will make it difficult to push the belt thr...

Page 35: ... over all the return pulleys underneath the conveyor Always reference the belt path label on the side of the drive and pull the belt through Remove the Duct tape Before cutting the belt to length make sure there is 18 overlap for NBC 250 AT30 and for NBC 500 AT 36 overlap The overlap is to compensate for belt loss in the finger splice process Both belt ends must be cut straight b Nitta belt weldin...

Page 36: ...belt into conveyor It will be necessary to remove sections of rollers every 30 or 40 to help pull push the belt through Step 6 Remove bottom guard for end pulley Push belt down between the stationary spacer and 6 dia end pulley and up and over the 6 flanged snubber pulley Make sure belt passes between ball bearing belt guides and end pulley ...

Page 37: ...th label on the side of the drive and pull the belt through Form more NBC applications TGW recommends the following IOM s at https www tgw conveyor com technologies belt driven roller conveyor nbc manual TGW Also recommends NBC maintenance videos for tracking the NBC belt and NBC belt alignment at https www tgw conveyor com media center maintenance videos 82 belt driven live roller Never field spl...

Page 38: ...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 Form more NBC applications TGW recommends the following IOM s at https www tgw conveyor com technologies belt driven roller conveyor nbc manual TGW Also recommends NBC maintenance videos for tracking the NBC belt and NBC belt alignment at https www tgw conveyor com media cente...

Page 39: ...utoff switch forward to engage the air tension on the belt shown The belt tension will automatically adjust NOTE FOR 250 AT30 DRIVE ONLY The 250 AT30 drive has a regulator prior to the air shut off slide sleeve The accumulation pressure from the conveyor filter regulator 40PSI is reduced to 30 PSI The 250 AT30 drive air take up pressure should never exceed 30 PSI 500 LB AT Air Sleeve Valve Assembl...

Page 40: ...witch 500 AT Drive Air Take up 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 Optional Proximity Switch 250 AT30 Drive Air Take up ...

Page 41: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 41 of 129 1 19 NBC CROSS SECTIONS NBC accumulation with CRUZchannel rollers low NBC transportation with C6 channel rollers high ...

Page 42: ... your conveyor If your conveyor line is over 100 long and you have small product on it you may want to add a maintenance skew bed midway down the conveyor to preserve the product alignment 1 20 FACTORY SKEW CHARGE SECTION A standard 12 charge end skew bed is available with factory skewed rollers at 7 degrees This bed is available in left or right hand The wheel guard rail is included This skewed b...

Page 43: ...sted side and the installation is the same as any other NBC intermediate bed section A 12 wheeled guardrail is included to prevent the stalling of product as it is forced against the side channel by the skewed rollers The wheeled guardrail is shipped loose and must be field installed To install line up the bolt holes on the guard with the holes in the top flange of the 12 skew bed side channel The...

Page 44: ...frame indicts the 4 skew area 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 pan is alre...

Page 45: ...attached to the conveyor side channel and located on the inside face of the channel on the opposite side of the belt 1 23 ROLLER CENTERS 2 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 on a 12 intermediate bed ...

Page 46: ...pport 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 One hex hole either side of three hole groups on 3 roller centers New Style Finger Guard ...

Page 47: ...Determine 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 on a 12 intermediate bed Step 2 Skew rollers 3 4 to direct the product to the alignment side NOTE Rollers may only be skewed a maximum of in either direction on the side channel opposite the drive belt ...

Page 48: ...act same connections 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 49: ...lied any of several height angle guardrail can be used CRUZchannel side frame acts as a guardrail Use 1 1 2 angle for C6 channel guardrail Use any of several height angle guardrails on C6 channel depending on photoeye placement and conveyor usage For all elevations requiring high guardrail the NBC is designed to use adjustable guardrail The configurations and associated part numbers are shown belo...

Page 50: ... IOM P N 1118140 Rev 07 29 2020 Page 50 of 129 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 51: ...40 Rev 07 29 2020 Page 51 of 129 1 27 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 52: ...ops TGW Systems recommends using at least 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 turned off an...

Page 53: ...quired Synthetic oils will shrink the seals in pneumatic devices and valving Low Pressure Switch Loss of conveyor control will occur if air pressure is not maintained A pressure switch is required to be installed into the pneumatic circuit feeding an NBC conveyor system to detect a drop in air pressure below operating limits Conveyor system must be shut off if low pressure is indicated 1 28 AIR PR...

Page 54: ...ire additional regulator 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 regulator 8 Low pressure switch is recommended Other 1 Compressor HP total CFM 3 55 2 Air tank size approx 1 gallon per CFM ...

Page 55: ...F POSITION NOTE The air regulator valve label details the on and off positions For air pressure regulations please see detailed instruction in this manual Do not remove and install sleeve valve to infeed side of regulator Back feeding through the regulator will cause damage and void the warranty WARNING ...

Page 56: ...s a guide in the installation operation 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 app...

Page 57: ... cables to ease installation 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 accu...

Page 58: ...adequate for your conveyor system However if higher product throughput is required some of the basic modules can be switched to progressive is indicated by 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 for additional explanation Switc...

Page 59: ... from basic to 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 60: ...ducts being 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 releas...

Page 61: ...OTE 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 release There is no gap between released products assumi...

Page 62: ...ogic Assembly 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...

Page 63: ...ressive Release Conveyors should not be operated with 100 of the logic modules switched to the progressive mode in the contact accumulation mode This could cause line pressure issues if there is a jam since in the release mode progressive ignores the photo sensors and dumps all the zones at once in the same way slug discharge operates In the progressive release mode for contact accumulation it is ...

Page 64: ...ng the factory warranty NBC Releasing Accessories Two items are always required at the discharge end of an NBC accumulation conveyor 1 A signal to release or accumulate product 2 A method of stopping coasting product contact accumulation only Release function module at discharge end of NBC conveyor part number 1116732 CAUTION ...

Page 65: ...d complete wiring descriptions for release function modules are explained in the NBC Installation Operation and Maintenance Manual item number 1118140 Exercise extreme caution in activating the slug release line instead of the logic line 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 ...

Page 66: ...x coated rollers is sufficient Standard 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 ac...

Page 67: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 67 of 129 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 ...

Page 68: ...arized and 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...

Page 69: ...housing allowing 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 As...

Page 70: ...terru pt Zone Statu s Full Function Module x x x x x x x x Release Function Module x x x x x Function Module Functions All directions of upstream and downstream are given with respect to the 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...

Page 71: ... and ZS OFF potentiometers from 0 to 20 seconds User Action Apply a high 24VDC 115VAC signal to TB1 1 2 if using isolated inputs Logic Interrupt Definition Upstream logic line is turned off The upstream Logic Assembly is forced to accumulate when it detects a package regardless of the downstream zone status Configuration When using TB1 JP3 2 3 to accumulate the upstream Logic Assembly When using T...

Page 72: ...other jumper terminals should be on pins 1 2 User Action No action required Zone Status Indication Definition Indicates full or empty status of the downstream zone on TB3 Configuration JP4 1 2 and JP5 1 2 for logic status or 2 3 for sensor status all other jumper terminals should be on pins 1 2 User Action Connect to TB3 for zone status The output transition of the Zone Status from OFF to ON or ON...

Page 73: ... 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 TB3 Zone Status TB3 only available on full function module This terminal is an isolated output 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 whe...

Page 74: ...s NC slug interrupt 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 ...

Page 75: ...es 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 connected to some output devices such as some PLC triac outputs the inputs could sense an on state even if the output connected to it is n...

Page 76: ...N 1118140 Rev 07 29 2020 Page 76 of 129 1 40 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 77: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 77 of 129 Figure 4 Full Function Module Board Layout Figure 5 Full Function Module Circuit ...

Page 78: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 78 of 129 Figure 6 Release Function Board Layout Figure 7 Release Function Module Circuit ...

Page 79: ... also a limit on the maximum number of Logic Assemblies that can be 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 t...

Page 80: ...tion 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 A T cable must be installed between two logic module assemblies Preferably located in the middle of the logic modules connected to the power supply ...

Page 81: ...s can be done to make better use of the full capacity of a 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 Cabl...

Page 82: ... 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 TGW Systems Part Number Description Kit Part Number 1117431 1117972 PWS 24VDC 3 9A 120VAC NBC CLASS 2 W 2X2 T CABLE 1117937 BRKT POWER SUPPLY SICK NBC Kit Pa...

Page 83: ...sor 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 Part Number Description 1117727 PE ASY SICK ZL PNP LIGHT OP 700MM LEAD W FLYING LEADS W REFLECTOR T...

Page 84: ... There are no air connections made to the valve 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 ...

Page 85: ...he mounting brackets provide 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 KIT NBC DISCHARGE LOGIC 1 2 TOR inch above rollers scan height 1117860 KIT NBC DISCHARGE...

Page 86: ...ectric sensors are tested 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 up...

Page 87: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 87 of 129 Figure 12 Logic Assembly ...

Page 88: ...OR FLOW The logic assembly wiring is in line for left hand flow conveyors for right hand flow conveyors the wiring direction will be reversed Cables will cross under the logic module assembly Figure 13 Left Hand Flow Conveyor Bed Figure 14 Right Hand Flow Conveyor Bed ...

Page 89: ...ccumulate A signal must be given to 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 I...

Page 90: ...ion Use the release function module and interrupt the downstream logic to start 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 re...

Page 91: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 91 of 129 Figure 17 Work Zone Figure 18 Work Zone Using TB Figure 19 Work Zone Using TB1 4 ...

Page 92: ...r There is no need for a Function Module to be attached to it The DLA does not need to be given a release signal Product blocking that photoelectric sensor will stop release from the NBC discharge zone until the photoelectric sensor clears again This operation is left enabled and ready to function regardless of whether the induction conveyor is running or off There is no need to interface the CRUZ...

Page 93: ...downstream from the charge end The final locations should be determined based on system performance Example 4 Product Gapping The following describes a technique using CRUZcontrol which creates a gap in a train of moving product In the situation described the gap is used to allow for the raising of a product stop This would apply primarily to the progressive mode of accumulation control which accu...

Page 94: ... raised solenoid 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 configur...

Page 95: ...ounted at each conveyor zone and 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 c...

Page 96: ... on the module and two release modes will be available via wiring Their operation is described 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 16 Logic Function Function Basic Logic Progressive Logic Single Accumulate Yes No Slug Accumulate No Yes Single Release Yes No Slug Release Yes Ye...

Page 97: ...zone When using 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 Progressive Accumulation Module In accumulation a zone will not deactivate until the furthest downstream sensor is detecting product and deactivates The next upstream zone will then become the furthest downstream zone and deactivate when ...

Page 98: ...r Connection 1 4 in 6mm barbed fitting Operating Mode N O Air to Brake Air supply Non lubricated 5 micron or less Sensor Valve Assembly The Sensor Valve Assembly module differs from the standard module in that it does not have a female cable connection does not connect to a neighboring module does not contain logic and has a unique wiring scheme on the male connection This module may be simply des...

Page 99: ...sors i e WTR style sensors This connection will have a 28 in 711mm length and right angle connector The module requires a PNP sensor input signal that is either Light Operate from a retro reflective sensor or Dark Operate from a proximity sensor Pin out may be found in Figure 30 Figure 24 M12 Sensor Connection Pin out Adaptor Cable for M12 Connector To connect the M12 logic module or M12 WTR senso...

Page 100: ...ons will be available 115 230 VAC single phase 480 VAC two 2 phase supply Cables Application specific cables will be necessary in certain cases A list of necessary components may be found below NOTE that male refers to a male housing on 2x2 connections while female refers to a female housing See Part Number Listing Table 19 Accessories w2 2 Connections Figure 25 T Cable Wiring Figure 26 Power Inte...

Page 101: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 101 of 129 Figure 27 Logic Interrupt Wiring Figure 28 Slug Interrupt Wiring ...

Page 102: ...unting 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 Power Supply Features Adjustable output volt...

Page 103: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 103 of 129 Figure 30 TGW P N 1117432 Connection Diagrams Figure 31 TGW P N 1117431 Dimensional Diagram Figure 32 TGW P N 1117431 Connection Diagram ...

Page 104: ...40 F 50 60 C 122 140 F 50 60 C Storage Temperature 13 185 F 25 85 C 13 185 F 25 85 C Humidity Do not energize w hen condensation is presen 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 w ire end 6 mm 6 mm Note secure wires from strain AC External Prote...

Page 105: ...tion 1117370 Male Cordset 1117371 Female Cordset 1117372 1117373 1117374 Extension Cable male female 1m Extension Cable male female 2m Extension Cable male female 4m 1117375 2x2 M12 Adapter female female 1117376 2x2 M12 Adapter male male 1117377 2x2 M12 Adapter female male 1117378 2x2 M12 Adapter male female 1117379 T Cable with flying leads 2m 1117380 Power Interrupt Cable 1117381 Logic Interrupt...

Page 106: ... E0001901A Basic AtoD E0001904A Progressive AtoB E0001905A Progressive AtoD E0005546 Basic No Valve E0006229 Sensor Valve Assembly N O Valve Table 21 Accessories w M12 Connections for CRUZcontrol TGW Part Description ZPI P1 Power Isolation Cable ZLSI P4 Slug Interrupt Cable E0006304 Function Module Full E0006305 Function Module Release E0003613 Singulation Interrupt Cable ...

Page 107: ...eck any oil leakage Check for loose bolts or parts Check air filter bowls for accumulated water Listen for air leaks Weekly Inspect lacing 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 moving ...

Page 108: ...upports Welded Belt Splice Inspection Belt splice should be inspected every 2 000 hours If belt splice is cracked or coming apart it should be scheduled as soon as possible for a new belt splice to replace the old belt splice 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 ...

Page 109: ...ne member of a crew is working on the conveyor EACH CREW MEMBER MUST HAVE A LOCK ON THE POWER LOCK OUT The air pressure must 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 ...

Page 110: ...igning while 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...

Page 111: ...d 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 interference issue Belt out...

Page 112: ...onnect 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 issue Insure proper...

Page 113: ... be replaced in the event of a component failure that could shut down a critical function of a conveyor system Priority level 1 spare parts include motors gear reducers gearmotor motorized rollers air solenoid valves and related components The majorities of these parts are purchased from TGW Systems vendors and carry their own warranties through these vendors For more warranty information see TGW ...

Page 114: ... CHART SEE CHART SEE CHART SEE CHART 06 PULLEY CABLE 1 4 WIDE X 5 OD 1121143 1121143 1121143 1121143 02 BEARING R6ZZ C3 90050111 90050111 90050111 90050111 05 CYLINDER 2 5 BORE X 28 STK W CABLE 1103837 1103837 1103837 1103837 13 PULLEY ASY 6 W FLANGE E0002214 E0002214 E0002214 E0002214 17 ASY AIR VALVE NBC 3 8 IN 1 4 OUT 1117620 1117620 1117620 1117620 40 TOOL NBC BELT THREADING INSTRUCTIONS 11191...

Page 115: ...02214 E0002214 E0002214 CYL AIR CLIPPARD 2 1 2 BX16 S 1166665 1166665 1166665 1166665 6 ROD END SPHERICAL 1 2 ID 1137475 1137475 1137475 1137475 2 BRG R6 ZZ C3 90050111 90050111 90050111 90050111 43 ASY AIR VALVE NBC 250AT DRIVE 1185955 1185955 1185955 1185955 44 TUBING 1 4 POLYU 95DURO 160ID E0005539 E0005539 E0005539 E0005539 40 TOOL NBC BELT THREADING INSTRUCTIONS 1119143 1119143 1119143 111914...

Page 116: ...28BF 500AT LH Balloon Description 16 BF 22 BF 28 BF 34 BF 5 CYL CABLE 2 5 B X 28S MOD 1103837 1103837 1103837 1103837 6 PULLEY CABLE 1 4 W X 5 OD 1121143 1121143 1121143 1121143 2 BRG R6 ZZ C3 90050111 90050111 90050111 90050111 13 PULLEY ASY 6 DIA W FLANGE E0002214 E0002214 E0002214 E0002214 DRIVE ASSEMBLY NBC 500 AT Air Take UP Width Item REF DWG 165S080 ...

Page 117: ...YL ASY NBC DR250 AT30 1167396 1167396 1167396 1167396 14 GUIDE BELT DR250 NBC 1117950 1117950 1117950 1117950 20 LABEL NBC DRIVE 250 BELT PATH LH 1118030 1118030 1118030 1118030 21 LABEL NBC DRIVE 250 BELT PATH RH 1118031 1118031 1118031 1118031 43 ASY SLEEVE VALVE NBC 3 8 IN 1 4 OUT W 90 ELBOW 1168369 1168369 1168369 1168369 44 TUBING 1 4 POLYU 95DURO 160ID FREELIN WADE 1B 151 10 E0005539 E000553...

Page 118: ...71 1 140 1117678 1117644 1 1 2 SK372 1 90SP 1120871 1 145 1117679 1117645 2 SK572 1 90LP 1191846 1 1 4 150 1214996 1214989 2 SK573 1 90LP 1191846 1 1 4 150 1117682 1117648 3 SK573 1 100LP 1191846 1 1 4 155 1117680 1117646 1 1 2 SK372 1 90SP 1120871 1 165 1117681 1117647 2 SK572 1 90LP 1191846 1 1 4 165 1117685 1117651 3 SK573 1 100LP 1191846 1 1 4 175 1117683 1117649 1 1 2 SK372 1 90SP 1120871 1 1...

Page 119: ...P 1120871 1 155 1117775 1117791 3 4 SK372 1 80S 1120871 1 155 1117776 1117792 1 SK372 1 80LP 1120871 1 155 1117777 1117793 1 1 2 SK372 1 90SP 1120871 1 175 1117778 1117794 1 SK372 1 80LP 1120871 1 175 1117779 1117795 1 1 2 SK372 1 90SP 1120871 1 220 1117780 1117796 1 SK372 1 80LP 1120871 1 220 1117781 1117797 1 1 2 SK372 1 90SP 1120871 1 220 1215000 1214993 2 SK372 1 90LP 1120871 1 250 1117782 111...

Page 120: ...8 BF 34 BF 2 ROLLER PRESSURE NBC 1109203 1109203 1109203 1109203 14 CLIP BELT COVER MIDDLE NBC 1113596 1113596 1113596 1113596 15 CLIP BELT COVER END NBC 1113597 1113597 1113597 1113597 16 DIAPHRAGM ASY PNEUMATIC 1 AIR 60710000 60710000 60710000 60710000 17 18 TUBING 1 4 PLYU 90DUR X 13 89000580 89000580 89000580 89000580 Width Item REPLACEMENT PARTS NBC PRESSURE PAN ASSEMBLY REF DWG 165S004E ...

Page 121: ...F 2 ROLLER PRS NBC W AXLE 1118018 1118018 1118018 1118018 14 ASY BELT GUIDE BRKT NBC SKEW PAN 1132973 1132973 1132973 1132973 16 DIAPHRAGM ASY PNEUMATIC 1 AIR 60710000 60710000 60710000 60710000 17 TUBING URETHANE 250OD 159ID 89000580 89000580 89000580 89000580 18 TUBING URETHANE 250OD 159ID 89000580 89000580 89000580 89000580 21 BEARING R6ZZ 90050111 90050111 90050111 90050111 REPLACEMENT PARTS N...

Page 122: ...8 1113368 1113368 04 DIAPHRAGM ASYPNEUMATIC SINGLE STEM 60710000 60710000 60710000 60710000 20 ORING 83A ST TRNS 3 16 X 9 15 16 90530005 90530005 90530005 90530005 22 ROLLER _ _ITR 1 9PLTD PRBG E0002412 E0002413 E0002414 E0006220 23 ROLLER PLASTIC COAT 2D 1 9CTD 3 RC 1119631 1119632 1119633 1119634 ROLLER PLASTIC COAT 2D 1 9CTD 2 RC 1127420 1127421 1127422 1127423 BRAKE KIT ASY INCLUDES ROLLERS 3 ...

Page 123: ...PULLEY NBC Balloon Description 16 BF 22 BF 28 BF 34 BF 07 PULLEY ASY 6 DIA FLAT FACE E0002215 E0002215 E0002215 E0002215 08 PULLEY ASY 6 DIA W FLANGE E0002214 E0002214 E0002214 E0002214 05 ACTUATOR SHEAVE ASY E0002212 E0002212 E0002212 E0002212 03 GUIDE BELT END NBC 1117517 1117517 1117517 1117517 REPLACEMENT PARTS NBC TERMINAL PULLEY Width Item Dwg 165S019 ...

Page 124: ...02212 E0002212 STANDOFF ACTUATOR SHEAVE ASY E0002213 E0002213 E0002213 E0002213 PAN PRS ASY 09 02 ROLLER PRESSURE NBC 1109203 1109203 1109203 1109203 09 16 DIAPHRAGM ASYPNEUMATIC 1 AIR SINGLE AIR INLET 60710000 60710000 60710000 60710000 TUBING URETHANE 250OD 159ID 89000580 89000580 89000580 89000580 09 21 BRG R6 ZZ C3 90050111 90050111 90050111 90050111 BED NBC _ _BF 20 ORING 83A ST TRNS 3 16X9 1...

Page 125: ...NBC Flat Belt IOM P N 1118140 Rev 07 29 2020 Page 125 of 129 1 57 NBC LOGIC MODULE COMPONENT Air to brake logic module Straight Beds ...

Page 126: ...F 22BF 28BF 34BF 21 NO GRVS 53 1154835 1154836 1154837 1154838 50 S 3 3 4 4 1154831 1154832 1154833 1154834 52 B 1 1121728 53 C 4 3 3 3 1118554 1121729 1118079 1119832 54 D 1 1118555 1121730 1118080 1119833 55 E 2 1118557 1121731 1118086 1119834 BALLOON ITEM QTY 20 90530003 8 Replacement Part Numbers for NBC Contact Accumulation Skewed Rollers LH Bed with RH Skew Shown DESCRIPTION ORING 83A CURVE ...

Page 127: ...28BF 34BF 21 NO GRVS 52 1154835 1154836 1154837 1154838 50 S 3 4 5 5 1154831 1154832 1154833 1154834 52 B 1 1118078 1119831 53 C 4 3 2 2 1118554 1121729 1118079 1119832 54 D 1 1118555 1121730 1118080 1119833 55 E 3 3 2 2 1118557 1121731 1118086 1119834 BALLOON ITEM QTY 20 90530003 9 Replacement Part Numbers for NBC Contact Accumulation Skewed Rollers RH Bed with RH Skew Shown DESCRIPTION ORING 83A...

Page 128: ...conveyor com media center video gallery Application and Control Guidelines https www tgw conveyor com support application control guidelines Support Connections https www tgw conveyor com support iom manuals supports and connections TGW IOM Manuals https www tgw conveyor com support iom manuals Brochures https www tgw conveyor com support brochures After Hours Contact Information https tgw conveyo...

Page 129: ...ems and equipment since 1964 TGW Systems provides sorters conveyors and accessories to satisfy a broad spectrum of accumulation transportation and sortation applications TGW Systems Inc 1300 E Mount Garfield Road Norton Shores MI 49441 6097 USA 231 798 4547 Email usinfo tgw group com Web Site www tgw group com Web Site www tgw conveyor com Regional sales offices and authorized Business Partners lo...

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