TREW 1500 Series Installation & Maintenance Manual Download Page 1 | Manualshive

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SERIES 1500

24VDC MOTORIZED DRIVER ROLLER
HCAT30 POP-UP DIVERT SECTION

INSTALLATION &

MAINTENANCE MANUAL

1.800.571.8739 poweredbyTREW.com [email protected]

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Summary of Contents for 1500 Series

Page 1: ...SERIES 1500 24VDC MOTORIZED DRIVER ROLLER HCAT30 POP UP DIVERT SECTION INSTALLATION MAINTENANCE MANUAL 1 800 571 8739 poweredbyTREW com info trewautomation com ...

Page 2: ...Roller 2 14 Replacement of Carrier Roller 2 14 Replacement of Carrier Roller for Top Surface 2 14 Drive Belts O Bands 2 15 Proximity Sensors 2 15 Proximity Sensor Adjustment 2 15 PREVENTATIVE MAINTENANCE 3 1 SUPPORT 4 1 Troubleshooting A Dead Zone On The Conveyor 4 2 Controller Check 4 2 Power Supply 4 2 Motor Control Card Motorized Drive Roller Checks 4 3 No Voltage to the Motor Control Card 4 4 ...

Page 3: ...www poweredbyTrew com 1 800 571 8739 info trewautomation com REV A HCAT30 Installation and Maintenance Manual 1 OVERVIEW ...

Page 4: ... rates The HCAT30 is designed to divert packages at a 30 degree angle relative to the main conveyor line while not stopping the package during the divert process The HCAT30 consists of fixed direction rollers divert wheels fitting between the fixed rollers and a lifting mechanism that raises and lowers the divert wheel module All actuated motions of the HCAT30 are directed by an external control s...

Page 5: ...www poweredbyTrew com 1 800 571 8739 info trewautomation com REV A HCAT30 Installation and Maintenance Manual 2 COMPONENTS ...

Page 6: ...ers pop up base and lift drive assembly Assembly of all three sub assemblies is shown in Figure 1 First two images 2 1 will show components of top surface and lift drive assembly Third image 2 2 shows the connection point of all three sub assemblies Fourth image 2 3 shows the overview of the HCAT30 and fifth image 2 4 is the table of components Figure 1 1 Figure 1 2 ...

Page 7: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com COMPONENTS 2 2 2 Figure 1 3 ...

Page 8: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com COMPONENTS 2 2 3 Figure 1 4 ...

Page 9: ...assembly of the pop up base The first image shows the components of the carriage and divert wheel Second and third image shows the components that attach to the sides of the pop up base plate Fourth image is the orientation of the rollers Fifth image is the assembly of the pop up base Sixth image is the table of components 2 4 ...

Page 10: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com COMPONENTS 2 2 5 Figure 2 1 Figure 2 2 ...

Page 11: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com COMPONENTS 2 2 6 Figure 2 3 Figure 2 4 ...

Page 12: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com COMPONENTS 2 2 7 Figure 2 5 Figure 2 6 ...

Page 13: ...t wheel drive assembly rollers and top surface drive roller The divert wheel drive assembly rollers drive the pop up divert wheels The lift device assembly roller as oblong shape plates welded to each end to allow the mechanism to lift to the desired height Figure 3 shows the three types of motorized drive rollers 2 9 Top Surface Drive Roller Lift Drive Assembly Roller Divert Wheel Drive Assembly ...

Page 14: ...Ratio b Hardware kit i star washers qty 2 ii motor nut iii motor instructions 4 Install a star washer on the threaded motor shaft Fold the wires perpendicular to the connector and fan the wires down the backside of the connector When folding the wires over the top of the connector use care not to put too much stress on the connector pins and try not to overlap and wires on top of other wires This ...

Page 15: ...nto the hole in the frame See image below for an exploded view of the process 7 The replacement roller should include a Motorized Drive Roller for BF and Gear Ratio b Hardware kit i star washers qty 2 ii motor nut iii motor instructions 8 The motor nut threads on to the motorized drive roller shaft and should be to the proper torque of See Page 2 13 for Proper Torque Information Note Torque is cri...

Page 16: ...roller operates by blocking the photo eye sensor of the zone that is being serviced or the photo eye sensor located upstream with respect to flow 13 If the MDR does not operate review the Troubleshooting Section These checks must be performed with the power to the conveyor section turned ON Only qualified electricians should be allowed to perform these checks Failure to follow this instruction may...

Page 17: ...n and Maintenance Manual www poweredbyTrew com COMPONENTS 2 EC110 and EC100 30 ft lbs 5 ft lbs 40 7 N M 6 N M ITOH 22 5 ft lbs 5 ft lbs 30 5 N M 6 N M EC310 50 ft lbs 5 ft lbs 67 8 N m 6 N m Gear Ratios Vary Proper Torque 2 13 ...

Page 18: ... the roller from the frame Make sure the axle is not pinched on the frame causing damage during removal 4 Remove the disengaged roller entirely from the frame section 5 Insert the axle of the replacement roller through the conveyor frame 6 Use an appropriate tool to push in the spring loaded axle and lower the roller into position aligning the axle with the hex hole in the conveyor frame 7 Unlock ...

Page 19: ...To check the sensor position the Cam lifting rollers should be rotated and the sensor detection lights should be monitored When the cam is nearly in the up position the up position proximity sensor light should blink on and remain on When the cam is nearly in the down position the down position proximity sensor will blink on and remain on Both sensors should be sensing with very little travel rema...

Page 20: ...The divert bank is in the raised position The sensor will read the flag frame to indicate when the divert bank is in the down position Shown in this image is the up position proximity sensor and flag The divert bank is in the raised position The sensor will read the flag frame to indicate when the divert bank is in the up raised position 2 16 ...

Page 21: ...www poweredbyTrew com 1 800 571 8739 info trewautomation com REV A HCAT30 Installation and Maintenance Manual PREVENTATIVE MAINTENANCE 3 ...

Page 22: ...ill form a mechanical history of the equipment covered Preventive maintenance consists of regular service lubrication adjustments cleaning etc In addition it consists of keeping your eyes ears and nose open Use your eyes to see potential component failure Use your ears to listen for abnormal or louder than normal noises Use your nose to smell a motor running abnormally warm in time to prevent its ...

Page 23: ...clear load jams while equipment is running 7 Always use appropriate tools when making repairs or adjustments 8 Observe all warning labels and follow plant safety rules 9 Make sure all connectors are secure and all wires are free from interference obstruction and any moving parts Cleaning and Inspection Generally there are many reasons for cleaning 1 To allow heat to dissipate motors and gearboxes ...

Page 24: ...ions should be documented in the conveyor record of the unit inspected The probability of mechanical electrical problems increase during periods of heavy usage so an additional inspection immediately before and after a these periods is recommended Daily Inspection Walk the entire length of conveyor system and observe the following 1 With the conveyor running listen for abnormal noises that could i...

Page 25: ... 6 Months 1 Clean and lubricate all drive chains with SAE 10 to SAE 40 oil 2 Check all set screws and tighten as necessary These may work loose during normal operation 3 Check all bolted connections and tighten as needed Bolted connectors may work loose during normal operation 3 4 Before performing any maintenance or lubrication services follow the lockout tagout procedure in the Safety section to...

Page 26: ...ot pinched on the frame causing damage during removal 4 Insert the axle of the replacement roller through the hole on the conveyor frame 5 Use tool to compress the spring loaded axle on the roller and lower the roller into its proper position 6 Release the spring loaded axle and make sure it fully engages in the hole in the frame 3 5 Before performing any maintenance or lubrication services follow...

Page 27: ...ed hydrocarbon formulated for extremely long life Refer to the manufacturers instructions for more information In an atmosphere that contains abrasive particles it is better not to have conventional lubricants on the surface of the chain that collect or retain abrasive particles Use dry lubricants such as molybdenum disulfide or deflocculated colloidal graphite in a volatile carrier Motors and Car...

Page 28: ...www poweredbyTrew com 1 800 571 8739 info trewautomation com REV A HCAT30 Installation and Maintenance Manual 4 SUPPORT ...

Page 29: ...s understood it is usually best to start at the problem and then work back to the source Procedures are discussed at length in the following pages however there are certain guidelines that should be followed for all troubleshooting problems Locate the problem Listen and observe Identify the problem as an electrical mechanical or pneumatic problem Determine symptoms through observations Think and a...

Page 30: ...unctioning especially in a PLC controlled area there may be an issue with the controller Check the input voltage into the controller If no voltage is detected check the in line fuse If the in line fuse is functional check the power supply Power Supply Check The power supply typically supplies voltage to multiple zones If the power supply is defective all zones supplied will be inoperative If only ...

Page 31: ...nal differences in the card It is not necessary to remove the drive card from the mounting fixture for this check a Turn off and lock out the power to the conveyor section b Remove connectors from existing motor control card one at a time and install in the exact corresponding connector on the spare motor control card c When all connectors have been installed on test motor control card and connect...

Page 32: ...exists voltage is not between 24 26VDC check the Power Supply 4 If the voltage is between 24 26VDC check the power cable wiring and connector Appendix A gives a general troubleshooting guide for some of the common problems that might be seen with Motorized Drive Roller conveyor Note The troubleshooting guide does not cover issues involving zones controlled by a programmable logic controller Troubl...

Page 33: ...rect Zone will not run dead zone Verify dip switch settings according to electrical interconnect drawing Replace motorized drive roller Replace power supply Replace communication cable Replace motor control card reconnect photo eye sensor Motorized drive roller is defective Faulty power supply Faulty communication cable Disconnected photo eye sensor DC common is not connected between power supplie...

Page 34: ...tion Check wiring Verify photo eye sensor wiring Verify proper photo eye sen sor alignment Clean photo eye sensor lens Faulty power supply Breaker blown at main panel Breaker blown at local power supply Disconnect switched at local power supply Interconnect wires loose connection Photo eye sensor not operating Probable Cause Corrective Action Faulty communication cable Faulty motorized drive rolle...

Page 35: ...veyor Readjust conveyor height Verify dip switch settings according to electrical interconnect drawing See motor control card section of this maintenance manual for fault information No voltage to motor control card Conveyor sections do not have smooth transition at conveyor connection Package large than zone Different zone speeds Debris on conveyed product Debris on conveyor Probable Cause Correc...

Page 36: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com SUPPORT 4 4 8 ...

Page 37: ...REV A HCAT30 Installation and Maintenance Manual www poweredbyTrew com SUPPORT 4 4 9 ...

Page 38: ...allation and Maintenance Manual www poweredbyTrew com SUPPORT 4 4 10 Support If you need further assistance Website www poweredbyTrew com Email info trewautomation com Phone 1 800 571 8739 Monday Friday 8 00am 5 00pm CT ...

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