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 Troubleshooting

26

5814EN-3

4

Troubleshooting

Jerky running

Drive unit is running, conveyor chain is not

Motor overheating on drive unit

Noise

Abnormal wear on plastic parts

Cause

Corrective action

Damaged or badly 
fitted slide rail

Inspect and replace if 
necessary.

Wrongly adjusted 
slip clutch

Check and adjust slip 
clutch.

Worn transmission 
parts

Check/replace 
transmission chain, 
chain drive sprocket.

Conveyor chain is 
too tight/loose

Tension conveyor chain 
correctly.

Dirty conveyor

Clean conveyor chain/
slide rail. Lubricate with 
silicone based lubricant.

Cause

Corrective action

Wrongly adjusted 
slip clutch

Check adjustment of slip 
clutch.

Friction discs in slip 
clutch are worn or 
contaminated

Check and replace if 
necessary.

Damaged/badly 
fitted slide rail

Check the free running 
of the conveyor chain.

Transmission 
products are not 
fitted

Check and fit.

Cause

Corrective action

Overloaded 
conveyor

Remove products from 
conveyor and test run.
Check actual conveyor 
load against 
recommended loading.

Gearbox leaking oil

Check output shaft seal 
and area around motor/
gearbox interface.

Dirty conveyor

Clean the conveyor chain 
with warm water (50°).

Cause

Corrective action

Worn or damaged 
bearings in drive 
unit

Check/replace drive unit.

Damaged/badly 
fitted slide rail

Check the free running 
of the conveyor chain, 
especially in slide rail 
joints.

Excessive conveyor 
speed

Lower speed.

Check actual load 
against recommended 
load.

Incorrect conveyor 
chain tension

Lengthen/shorten 
conveyor chain.

Cause

Corrective action

Overloaded 
conveyor

Remove products from 
conveyor and test run.
Check the free running of 
the conveyor chain.
Check actual conveyor 
load against 
recommended load.

Ambient 
temperature too 
high

Check against 
recommended 
temperature for 
conveyor.

Chemicals in the 
environment are 
affecting plastic 
parts

Check in FlexLink main 
catalogue (section TR) 
for listing of incompatible 
chemicals.

Damage due to 
ingress of 
contaminate

Clean the system.

Particles, swarf 
etc.

Remove source of 
contamination.

Содержание X85

Страница 1: ...5814EN 3 X85 MAINTENANCE MANUAL ...

Страница 2: ......

Страница 3: ... modify products and its manuals without notice FlexLink AB assumes no responsibility or liability on any errors or inac curacies in this program or documentation Any kind of material damag es or other indirect consequences resulting from any FlexLink AB s product part documentation discrepancies and errors or non anticipat ed program behavior are limited to the value of appropriate products purch...

Страница 4: ...ii 5814EN 3 ...

Страница 5: ...placement of worn parts conveyor chain 21 3 10 Replacement of worn parts slide rails 22 4 Troubleshooting 26 4 1 Checklist maintenance schedule 27 5 System dismantling and disposal 28 5 1 Important safety precautions 28 5 2 Dismantling end drive units with suspended motor 29 5 3 Dismantling end drive units no slip clutch 31 5 4 Dismantling end drive units slip clutch 32 5 5 Remove guide rails and ...

Страница 6: ...vi 5814EN 3 ...

Страница 7: ...consider certain as pects This is done when designing a conveyor system The chain is gen erally the critical factor to consider with guarding 1 1 2 Safeguarding All pinch and shear points as well as other exposed moving parts that pres ent a hazard to people at their workstations or their passageways must be safeguarded Overhead conveyors must be guarded to prevent objects fall ing Cleated conveyo...

Страница 8: ...allation or are not cost effective The degree of safeguarding required should be identified during the imple mentation of the essential safety requirements during the design process 1 1 3 Special considerations When correctly applied the FlexLink components are safe to use and maintain It is however necessary for those responsible for design instal lation operation and maintenance of the FlexLink ...

Страница 9: ...number shall always be speci fied when communicating with FlexLink with respect to the machine 2 2 Important safety conditions Before the machine shall be operated by a user the following safety con ditions must be met Make sure that children or animals have no access to the machine and its surrounding areas by for example screening off the machine with a fence Only personnel who have read and und...

Страница 10: ... The area near the in feed guides for the chain return loop should not be accessible during conveyor operation 2 2 1 3 Horizontal bend drive unit The drive wheel should not be accessible during conveyor opera tion The bottom should be covered with wheel cover 2 2 1 4 Idler units The opening between the links when they turn round the idler roll er could be a risk Idler ends should not be accessible...

Страница 11: ...at the manufacturers address 2 2 1 8 Control system Before operating or completing any maintenance on control system read the associated section as supplied with the equipment documentation If there are any questions as to the safe operating procedures of the equip ment supplied please contact FlexLink immediately Follow the instructions in this user manual when transporting the machine FlexLink A...

Страница 12: ...rams Knowledge of local safety regulations for electrical power and au tomation Skilled EN ISO 12100 2010 To avoid risks only experienced personnel with technical knowl edge and experience may perform repair work on the machine s electronics components 2 2 4 Operators To correctly use the equipment operators must have appropriate training and or experience ...

Страница 13: ...ink supplier 3 1 2 Non FlexLink equipment Equipment and components which are not from the FlexLink family of products should be maintained and serviced in accordance with their re spective manufacturer s instructions 3 1 3 Safety considerations Before starting any maintenance on your FlexLink equipment the following safety instructions must be observed All electricity must be switched off Make sur...

Страница 14: ...ecifications or within design criteria as outlined in the gener al catalogue If a fault occurs on the installation which cannot be rectified with the help of the instructions in the manual or if unexpected conditions occur during servicing contact your FlexLink retailer or FlexLink mainte nance personnel 3 2 2 Warranty guarantee FlexLink conveyors are covered by warranty guarantees as identified w...

Страница 15: ...lling end of the conveyor End drive units are either direct drive types see picture or transmission chain types NB The roller chain transmission has chain guards and gearing protection These guards should always be in position when the conveyor is in operation 2 Intermediate drive units Intermediate drive unit located at an intermediate position along the conveyor 3 Horizontal bend drive units Hor...

Страница 16: ...The installation is carried out as follows Preparations for adjustment Stop the conveyor Ensure that the conveyor can not be started accidentally For ex ample unplug the electric power plug Remove any load on the conveyor Caution If you try to adjust the slip clutch when there is still load on the conveyor the accumulated tension in the chain can cause se vere injuries when you release the clutch ...

Страница 17: ...w 1 on the slip clutch so that the adjustment nut 2 can be freely rotated 3 Turn the adjustment nut 2 clockwise with a hook spanner until the arrow on the nut is aligned with the desired Fmax value 3 See the following table for correct values NB On delivery the clutch is always set to 0 4 Tighten the screw 1 5 Re install the drive unit protection cover Traction force Fmax N No X85 300 0 400 1 500 ...

Страница 18: ...ensioner must be checked at the same time as the lubricating is done NB The discs in the slip clutch must be kept free from oil and grease 3 5 2 Worm gear motor and geared motor The worm gear or geared motor is checked in accordance with the instruc tions from the relevant supplier 3 5 3 Guide for the conveyor chain The purpose of the guide for the conveyor chain is to guide the return chain corre...

Страница 19: ... 00 06 13 5814EN 3 3 5 4 General checks on drive unit Carry out a general inspection of the drive unit Check particularly that the protective covers for the roller chains are complete and firmly in place Replace damaged worn parts ...

Страница 20: ...ks replaced or cleaned Warning Only warm water 50 C with soap if necessary may be used for cleaning conveyor chains Check the guards on cleated chain conveyors 3 6 2 Checking the tension of conveyor chain The chain is made of elastic material The chain eventually stretches as the material creeps The extent of the stretch depends on the traction force in 1 Plain conveyor chains 2 Chain with flexibl...

Страница 21: ...therefore be pre tensioned while the conveyor is stationary but must never be so tight that there is no slack during operation There should be no appreciable slack on the chain when the conveyor is stationary This can however vary depending on the total length of the chain If there is too much slack there will be excessive wear on the chain guides and the chain This could be a risk for injury If t...

Страница 22: ...losed systems at a wheel bend by removing the outer curve at a conveyor beam section for liftable chain if there are any Instructions 1 Make the conveyor chain accessible at some of the overhead positions 2 Remove the steel pin 1 from the pivot 2 Use the pin insertion tool see figure 2 1 ...

Страница 23: ...divisions between the links 4 Join the chain together with a new pivot NB The old pivot should not be re used When the chain is divided a new pivot must always be fitted 5 Insert the steel pin using the pin insertion tool 6 After inserting the steel pin check that it is centred and that the chain easily bends in the fitted link 3 snap 1 2 3 ...

Страница 24: ...e rail must be checked after every 250 hours operation Carry on the checking on a stationary conveyor with the chain in place Replace the slide rail if necessary see Replacing the slide rail beginning on page 22 Check the fastening points on the slide rail Check the joints on the slide rail Check that there is a gap between the slide rails and that the joints are correctly fitted Check that the jo...

Страница 25: ...ratches and notches Replace the slide rail and fasteners if necessary see Replacement of worn parts slide rails on page 22 Wash the conveyor chain 3 7 2 Conveyor beams idler ends and bends The conveyor beams themselves do not normally require any regular in spection Be observant for damage arising from external factors warping or deformation Deformation can cause the conveyor chain to jam result i...

Страница 26: ...hain Drive units type H have a slack protection for the conveyor chain Check that the slack protection plates are in place and that the chain does not slacken enough to hang below the plates Check the protective cover for the conveyor chain on intermediate drive units There may be other types of guarding which are specific to your installation and these must also be checked See the system document...

Страница 27: ...Checking the tension of convey or chain on page 14 1 Run a sample approx 0 3 m of conveyor chain through the installation in the direction of the conveyor Check that the chain moves easily and correctly through the bends and idler ends Check at the same time that there is enough space for the chain Immediately investigate the reasons for any jamming and take immediate action 2 Put the new conveyor...

Страница 28: ...rs are suit able tools for cutting the slide rails Use mounting tool for slide rail XBMR 170 Be careful not to damage slide rail during assembly Use drill fixture 3920500 The distance between an chor points should be 50 mm Use a high quality drill bit to avoid forming a shoulder preferably one which is in tended for drilling alumini um Use XLAH 4x7 rivets After riveting the slide rail clean out th...

Страница 29: ... visually as well as running a section of conveyor chain through the installation An alternative to the aluminium rivets is to use the plastic screws XLAG 5 See page 25 for fitting instructions The holes for the plastic screws are threaded with a tap 3 10 2 Installation of Slide rails instruction Fixing slide rail to the conveyor beam The beginning of each slide rail section must be fixed to the b...

Страница 30: ...is limited the rivet crimping clamp might be easier to use The two crimping tools perform the same task but the pliers are more efficient and easier to use 3 Check that the rivets do not protrude over the surface of the slide rail Check both top and underneath surface of slide rail for protruding metal 4 Keep a distance of approximately 30 mm between rivets and idler drive units This is in case th...

Страница 31: ...driver 2 Cut off the screw heads by using a knife and a hammer The cut should be made away from the joint in the direction of chain travel 3 Check that the screws do not protrude over the surface of the slide rail Check both top and underneath surface of slide rail for protruding plastic 4 Keep a distance of approximately 30 mm between rivets and idler drive units This is in case the units have to...

Страница 32: ...eyor Remove products from conveyor and test run Check actual conveyor load against recommended loading Gearbox leaking oil Check output shaft seal and area around motor gearbox interface Dirty conveyor Clean the conveyor chain with warm water 50 Cause Corrective action Worn or damaged bearings in drive unit Check replace drive unit Damaged badly fitted slide rail Check the free running of the conv...

Страница 33: ...k adjustment of slip clutch Every 1 000 hours page 10 3 Check conveyor chain guides in drive units and idler ends Every 1 000 hours page 12 4 Check tension of conveyor chain 50 250 500 Then every 500 hours page 14 5 Check slide rails Every 250 hours page 18 6 Check slide rails conveyor chain removed Every 2 000 hours or at least once a year page 18 7 Check slide rails in plain bends Every 500 hour...

Страница 34: ...oned special attention should be given for the safe release of any accumulated pressure from within the circuitry All reservoirs accumulators must be depressurised pri or to removal If there are any doubts as to the most suitable procedure for decommis sioning then consult the equipment supplier 5 1 2 Conveyor system X85 To dismantle a FlexLink conveyor the following tools are required 1 Remove an...

Страница 35: ...ing the slip clutch section in maintenance and service refers to slip clutch adjustment Remove the motor gear unit from the conveyor drive assembly The motor gear unit may be fitted with an oil breather Ensure that the oil from the gearbox cannot leak into the surrounding area when decommissioned Oil should be drained from the gearbox and disposed of in accordance with lo cal environmental regulat...

Страница 36: ...System dismantling and disposal 30 5814EN 3 7 8 9 10 x3 x3 4x x4 4x ...

Страница 37: ... the motor gear unit from the conveyor drive assembly The motor gear unit may be fitted with an oil breather Ensure that the oil from the gearbox cannot leak into the surrounding area when decommissioned Oil should be drained from the gearbox and disposed of in accordance with lo cal environmental regulations 1 4 2 5 3 6 ...

Страница 38: ...System dismantling and disposal 32 5814EN 3 5 4 Dismantling end drive units slip clutch 1 4 2 5 3 x4 ...

Страница 39: ...System dismantling and disposal Created by EBCCW 00 06 33 5814EN 3 5 5 Remove guide rails and guide rail brackets etc 1 2 3 4 ...

Страница 40: ...or chain If removing conveyor chain from over head conveyor special attention should be given when removing the last few metres The weight of the removed chain accelerates the removal from the conveyor beams and can cause injury when the last links exit the extrusion The chain should always be removed in the conveyor working direction 1 4 2 5 3 6 x4 ...

Страница 41: ... and disposal Created by EBCCW 00 06 35 5814EN 3 5 7 Dismantling end drive units Unscrew the inner grub screws from the drive unit connector strips and re move drive end from the conveyor Repeat for idler end unit 1 2 x4 ...

Страница 42: ... 8 Remove slide rails Remove the slide rail on all sides of the conveyor extrusion Remove the slide rail retaining fixings by drilling away the rivets or plastic screws and pulling away the slide rail from the aluminium extrusion profile 1 2 3 x4 ...

Страница 43: ...y EBCCW 00 06 37 5814EN 3 5 9 Dismantle the conveyor extrusions from the support brackets Dismantle the conveyor extrusions from the support brackets This should be done in a systematic manner removing conveyor section by section 1 3 2 4 x4 x2 ...

Страница 44: ...System dismantling and disposal 38 5814EN 3 5 10 Dismantle the conveyor support system 1 3 2 4 5 6 x2 x4 x4 ...

Страница 45: ... equipment is to be dismantled simultaneously with the FlexLink conveyor attention should also be given to the interaction of the other equipment to the FlexLink conveyor Pneumatic equipment should be re moved from the conveyor before dismantling Hydraulic equipment should also first be removed to assist dismantling and handling of the conveyor components during dismantling and disposal ...

Страница 46: ...System dismantling and disposal 40 5814EN 3 ...

Страница 47: ......

Страница 48: ...Publication 5814EN 3 2015 02 ...

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