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Installation and Maintenance Manual: Shoe Sorter

_____________________________________________________________________________________________

Installation and Mai ntenance Manual: Shoe Sorter

Published October 2019

Rev.A1

Table 9-BOM for GA-SHOE-MW-88-0001

ITEM NO.

PART NUMBER

QTY

UNITS

DESCRIPTION

VARIES

SEW EURODRIVE GEARMOTOR, AVAILABLE 5-40 HP, KA67-KA97 GEARBOXES

A003BR-10037* or A003BR-10038

MOUNTED SPHERICAL ROLLER BEARING, 3in BORE, PILOTED FLANGE, 215 SERIES, SETSCREW LOCKING

A003BR-10038

MOUNTED BALL BEARING, 3in BORE, PILOTED FLANGE, 216 SERIES, SETSCREW LOCKING

VARIES WITH OAW AND MOTOR SELECTION

DRIVE SHAFT, 3in DIA

A001CP-10093**

SPROCKET, LOW RUNOUT, 3" BORE, 40 TEETH, KEYED IN PAIRS

Z075SA-15036

ASM, SHOE SORTER SIDE COVER, 36in L

A003RC-10011

VIBRATION DAMPENING MOUNT, 5/8"-11 UNC MOUNT, BOLT DOWN, SEISMIC RATED

A002SE-10052

PHOTOEYE, RETRO-REFLECTIVE, 0.2m TO 15m SENSING RANGE, PNP, 4 PIN M12 CONNECTOR

A002MC-10017

REFLECTOR, SMALL CUBE, 48mm HEX

Z077SC-10091

CHAIN LEAD-IN BLOCK, SHOE SORTER DRIVE MODULE, STYLE B

Z077SC-10089

TOP CHAIN GUIDE BLOCK, SHOE SORTER DRIVE MODULE, STYLE B

Z077SC-10087

INFEED GUIDE BLOCK, SHOE SORTER CATENARY MODULE, STYLE B

A013LS-10001

CHAIN OIL BRUSH, 1/8" NPT MALE, 2in W, 1.25in BRISTLE L, STYLE D

Z077SC-10090

CHAIN LEAD-IN BLOCK, SHOE SORTER DRIVE MODULE, STYLE A

Z077SC-10088

TOP CHAIN GUIDE BLOCK, SHOE SORTER DRIVE MODULE, STYLE A

Z077SC-10086

INFEED GUIDE BLOCK, SHOE SORTER CATENARY MODULE, STYLE A

A002SE-10024

PROX, M12 X 1 FLUSH MOUNT TO 3 PIN M12 CONNECTOR, 60mm L, 4mm SENSING RANGE, PNP, NORAMALLY OPEN, 2 LOCK NUTS

A012SP-10028

PIN GUIDE EXTRUSION, SHOE SORTER, 27.875in L

A012SP-10061

PIN GUIDE EXTRUSION, CURVED DISCHARGE, SHOE SORTER, STYLE A

A012SC-10031

CHAIN GUIDE EXTRUSION, SHOE SORTER, 30.875in L

A012SP-10062

PIN GUIDE EXTRUSION, CURVED DISCHARGE, SHOE SORTER, STYLE B

*Spherical roller bearing is only used on drives with KA97 gearboxes (2-3/4

” diameter hollow bore)

**Note the sprockets are keyed in pairs and must be replaced as a matched set. Worn sprockets may be swapped with each other to use the unworn side of the sprocket tooth and thereby extend the useful lifespan.

Содержание Shoe Sorter

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 77: ...ment contains information considered proprietary to Bastian Solutions It may not be duplicated used or disclosed without written permission from Bastian Solutions It may not be used in whole or in par...

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