installation, operation and maintenance manualbelt conveyor ts4200-150 5 | p a g e transnorm system...

Belt Conveyor TS4200-150

1 | P a g e Transnorm System Inc – 2810 Ave E East – Arlington - Texas - USA – 76011

1-800-331-1749

Installation, Operation and

Maintenance Manual

Rev –

7 December 2010



1-800-331-1749

Contents

General ........................................................................................................................................................... 4

Safety .............................................................................................................................................................. 5

Function of the Conveyor: ......................................................................................................................................... 5

Operation, Maintenance, and Service ....................................................................................................................... 5

Safety equipment ...................................................................................................................................................... 5

Operating conditions ................................................................................................................................................. 6

Description ..................................................................................................................................................... 7

TS4200/150 Junctions ............................................................................................................................................... 7

Merging Conveyors ................................................................................................................................................... 7

Diverting Conveyors .................................................................................................................................................. 7

36” Centerline Junction ............................................................................................................................................. 7

Installation ...................................................................................................................................................... 9

Uncrating ................................................................................................................................................................... 9

Positioning ................................................................................................................................................................. 9

Supports .................................................................................................................................................................. 10

Operations .................................................................................................................................................... 11

Standard Operations ............................................................................................................................................... 11

High Temperature Operations ................................................................................................................................. 11

Low Temperature Operations.................................................................................................................................. 11

Maintenance ................................................................................................................................................. 12

Standard Preventive Maintenance .......................................................................................................................... 12



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Tracking the Belt ..................................................................................................................................................... 13

Gearmotor Maintenance ......................................................................................................................................... 15

Bearing Lubrication ................................................................................................................................................. 15

Conveyor Repair ........................................................................................................................................... 16

Conveyor Belt Replacement..................................................................................................................................... 16

Endless Belt Removal .......................................................................................................................................... 16

Clipper Laced Belt ............................................................................................................................................... 17

Inline Pulley Bearing Replacement .......................................................................................................................... 18

Inline Pulley Replacement ....................................................................................................................................... 19

Offset Pulley Bearing Replacement ......................................................................................................................... 19

Offset Pulley Replacement ...................................................................................................................................... 19

Snub Roller Replacement ......................................................................................................................................... 20

Tracking Station Replacement................................................................................................................................. 20

Gearmotor Replacement ......................................................................................................................................... 21

Right-Angle Gearmotor: Direct Shaft Mount ...................................................................................................... 22

Under-hung, In-line Gearmotor: Cog-belt Final Drive ......................................................................................... 22

Illustrated Parts List ................................................................................................................................................. 24

Bill of Materials ....................................................................................................................................................... 26

Revision Control ............................................................................................................................................ 28

Standards ...................................................................................................................................................... 28



1-800-331-1749

General

All descriptions in this manual are aimed at

qualified engineers and maintenance

technicians. They only refer to the Transnorm

System Inc belt conveyors with the model

numbers TS 4200-150.

You can find the serial number of the conveyors

on the type plate attached to side-guarding

near the drive housing. The same serial number

is to be found on the spare parts list which also

includes details for ordering spare parts.

The exact technical data of the belt conveyor

supplied are provided for in the attached

"technical specifications” which contain:

technical data

electrical motor/gearmotor data

details on special accessories and

designs where supplied.

The complete conveyor system is described in

the system documentation supplied by the

conveyor-system-level integrator. This

document should include the following

information:

specifications

engineering documents

instructions on servicing and operating

the complete system

documents on control and energy

circuits of the system

where required, description of transfer

sections

In the following text, important Instructions are

shown as follows:

"Note:"

Technical details which have to be observed

by the user.

"Caution:"

Working procedures which have to be

followed exactly in order to avoid damage

to the conveyor system.

"Warning:"

Working procedures which have to be

followed exactly in order to avoid hazards

to the user or any other persons.

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Safety

Function of the Conveyor:

Transnorm belt conveyor system TS 4200-150 may

only be used to convey unit loads within a conveyor

system and is not designed for bulk flow

applications.

No persons may be transported on the conveyor.

Operation, Maintenance, and Service

All work on the conveyor must be performed in

accordance with the instructions, the technical

specifications of the conveyor, the system docu-

mentation, and the following additional

regulations in their latest edition:

national regulations on the installation and

operation of electrical installations accident

prevention regulations

other statutory government regulations and

safety rules of professional associations

In order to prevent any danger to users or other

persons or damage to the conveyor, all assembly,

servicing, maintenance, and operational work on

the conveyor has to be carried out by properly

trained personnel.

Work on electrical equipment may only be carried

out by qualified electricians.

Warning:

Before starting any assembly, maintenance,

and service work, make sure the main switch

of the system is turned off and secured against

being turned on again per your local lock-

out/tag-out procedures.

Safety equipment

For mechanical protection, various cover plates

and finger guards are fitted to the belt conveyor.

These protective parts may only be removed for

assembly, maintenance, and service purposes.

Warning:

When carrying out adjustment work without

safety equipment or guarding in-place, be

aware that there is a danger of an accident.

Secure the danger area against access by

unauthorized personnel.

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Further safety equipment for the complete

conveyor system and the transfer sections are

typically described in the conveyor system

documentation (spring rollers, covers, position of

emergency stop switches etc.).

Operating conditions

The belt conveyor in its standard design should

only be operated when fixed to a solid foundation.

Special equipment accessories allowing mobile

operation are described in the technical

specifications.

The belt conveyor is not explosion-protected and

may only be operated under the following ambient

conditions:

Air temperature 0°C up to 50°C (32°F

up to 120°F

Relative humidity 90%

Normal atmosphere

o no oil or gas atmospheres

o no corrosive atmosphere

o no caustic atmosphere

Securely protected against

precipitation and against direct

sunlight onto the belt surface

Deviations from the conditions are described in the

technical specifications.



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Description

TS4200/150 Junctions

The TS4200-150 junction can be configured to

operate as either a Merging or Diverting Conveyor

and is available in 45° and 30° configurations. The

centerline length is available from 42” up to 120”.

All conveyors of this type consist of a conveyor

frame supporting and containing a composite

slider bed, drive and tail pulley, snub roller,

tracking station and a belt.

The belt is driven by a 150mm diameter drive

pulley. A snub roller supplies belt tracking tension.

Belt tracking is via the snub roller. All tracking is

done at the Offset Belt Return Station

The drive and tail pulleys of the junction are

supplied with non-replaceable shafts standard.

Standard shaft diameter is 1-7/16in. Replaceable

shaft pulleys are available as an option. The tail

pulley shafts come standard with drilled and

tapped ends 3/8-16x1.

The tail pulley is relocated from the inline station

to the offset station when the junction is

configured as a diverting conveyor. An exception

is for very short centerlines (CL < BF). The junction

is then a reverse running merge conveyor.

Conveyors can be supplied with sideguards. The

minimum height for the guards is 0in (no guards)

and maximum is 36in. The guards are set at the

customer requested width for the conveyor.

Funneling or positioning guards can be designed at

customer request.

Merging Conveyors

The TS4200-150 Merging conveyor is driven from

the offset belt return station and moves product

from the straight end to the angled end.

Diverting Conveyors

The TS4200-150 Diverting conveyor is driven from

the inline belt return station and moves product

from the angled end to the straight end.

36” Centerline Junction

The TS4200-150 Junction is also available in a 36”

centerline conveyor. Both merging and diverting

junctions are configured as a merge but the belt is

pushed when used as a diverting conveyor. The

tracking station must be configured for correct

flow.



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Diverting Conveyor

Merging Conveyor



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!

Installation

Uncrating

All Transnorm modules are shipped in palletized

open-sided crates to protect the conveyors during

shipment unless special crating requirements are

requested by the customer.

It is good practice to photograph the conveyor and

crate immediately upon receipt to document any

shipping damages and to account for all product

sections. The best practice is to leave the

conveyor module in the crate until it is required

and relocate the crate as close as practical to the

installation position.

Uncrate the conveyor or conveyor components by

removing the top and sides of the crate using

standard pry-bars and hammers. Use good

hygiene with the discard wood as nails may be

protruding. Protect the belt material or surface

from damage during the uncrating process.

The conveyor frame is secured to the shipping

pallet by means of shipping brackets. First remove

the brackets from the shipping pallet and then

remove the brackets from the conveyor frame

Note:

All Units are shipped with the belt tensioned for proper operations. No adjustments are required.

Positioning

Using the integrator layouts (shop drawings), identify and mark critical positions and elevations for the

conveyor, conveyor sections and any conveyor interfaces.

Install junctions so that they are level (typical) to the elevations on the system level drawings. When

floor supports are required, the standard Transnorm supports are designed to readily mount to the

conveyor frame.



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Supports

Typical supports for the TS4200/150 conveyor are tubular steel with an adjustable uni-strut foot (referred to

as TS Inc. Supports). Supports consist of three single legs and one H-Frame Weldment. The H-Frame is

available as a Channel Support if requested. Ceiling Supports are also available if requested.

Typical TS Inc. Supports



1-800-331-1749

Operations

Standard Operations

The TS4200-150 is supplied in a wide variety of

length and width combinations, and operates a

belt speeds between 10fpm and 400fpm.

For very heavy starting loads (greater than 20lbs

per inch of drive pulley width) and/or speeds in

excess of 300fpm and for all operations requiring a

5hp or larger motor, a motor soft-starter or VFD is

mandatory to keep the warranty in-force. A “soft”

start will also prevent damage to the drive

assembly, drive pulley, and belt system.

All Transnorm supplied bearings are considered

“lubed-for-life” and no maintenance or other

consideration is required.

All units are shipped with the belts tensioned for

proper operations.

High Temperature Operations

For intermittent peak very high temperature

(>140deg F) or sustained high temperature

(>120deg F) operations, the drive reducer oil life

will be shortened. Gear reducer oil should be

changed more often and substituted with high-

temperature specific synthetic lubricant.

Low Temperature Operations

For intermittent very low temperatures (< 20F) or

sustained low temperature (>32def F) operations,

the gear reducer oil should be changed to low-

temperature specific synthetic lubricant. The main

bearing grease may require replacement as well.



1-800-331-1749

Maintenance

Standard Preventive Maintenance

The Transnorm TS4200-150 Belt conveyor is designed to require only periodic inspections and cleanings

under normal operating conditions.

Time Period Action Comment

Monthly Observe the TS4200-150.

Remove trash and other debris,

particularly around the sideguards

and pulley end-guards

Regular observations and cleaning of any conveyor

equipment typically greatly reduces unscheduled

maintenance costs and down time.

Regular cleaning of material handling debris

greatly reduces chances of belt jams, belt tears,

and all other premature wear.

Quarterly Inspect rolling and rotating

components for rough bearings.

Inspect conveyor for loose hardware.

Rough bearings can be identified by higher than

normal noise generation, leaking or weeping

grease, or bearing discoloration (bluing).

Verify that junction controls are

available to identify jam conditions.

Block Photoeyes to check for proper jam logic.

Quick discovery prevents conveyor and product

damage.

Annually Inspect belt and belt-beading

interface for signs of wear or foreign

object damage.

Pay particular attention to the ends of the bead

and to the stitching. Belts with worn stitching

should be repaired at Transnorm and are usually

an indicator that the belt tracking was miss-

aligned.



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Tracking the Belt

Warning:

Observe local safety regulations.

As the belt should be tracked with the guards removed, limit the access to the conveyor to as few

maintenance personnel as possible and only to skilled technicians who are trained in all local safety and

emergency procedures.

To track the belt:

Track and tension the belt as loose as possible to carry the load without slipping

Remove the outer offset station cover from the conveyor.

Square the drive pulley to the conveyor frame, 10mm to 20mm from the end of the frame.

Move the snub roller all the way to the end of the side plate slot.

Start the unit and make the necessary adjustments to the snub roller to center the belt between on the

slider table.

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1-800-331-1749



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Note:

Belt tension on the junction can be very low as the large pulley face and drive snub allows for

significant drive torque to be transmitted to the belt and belt tension is not required for belt

tracking.

After tracking is accomplished, run the conveyor for 20-30 minutes to fine tune the tracking.

Replace the side guides/guards and the outer perforated guards and return the conveyor to service.

Gearmotor Maintenance

Typically, gearmotors or electric motors and gear-reducers only require proper lubrication and cleanliness

for proper performance and long service life.

The lubrication oil change interval is described by the gearmotor or reducer manufacture.

Transnorm System recommends that when possible by reducer specification, synthetic lubricants be

used to extend service life between changes and provide an increased operational temperature

range.

Electric motors typically do not have any provisions for lubrication.

Bearing Lubrication

All bearings used in the TS4200-150 should be considered “Lubed-for-Life”.

The main pulley bearings are not normally equipped with a grease-zerk and no grease is required for

normal service operations.

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1-800-331-1749

Conveyor Repair

Warning

For all repair/replacement activities, follow local and national safety procedures.

Consult the CEMA Unit Handling safety video for general practices and procedures.

Always isolate power to the motor prior to performing any repair activities.

Conveyor Belt Replacement

Warning

Junction pulleys and snub rollers are very heavy.

Use appropriate lifting methods when handling these parts.

Endless Belt Removal

Remove both sideguards and deckboards.

Loosen the drive and tail pulley bearings and remove the drive and tail pulleys.

Remove the nosebar support bracket.

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Remove the upper section of the Tracking Station and the Cross Support.

Remove the belt by pulling it through the gap between the Nosebars and the Offset Belt Return Side

Plate. If space does not permit this, remove the upper Nosebar.

Install the new belt by reversing the steps above.

Track the belt per instructions in the Maintenance section of this manual.

Clipper Laced Belt

Move the snub roller all the way to the end of the side plate slot and loosen the offset belt return

pulley.

Open the clipper lace splice by removing the plastic-coated lacing pin. If the pin will not come-out of

the clipper lace, cut the belt off of the TS4200-150 wherever it is convenient.

Pull the belt out of the junction.



1-800-331-1749

Install the new belt by feeding the belt around the junction.

o Carefully feed the belt and beading under the inline belt return pulley (and over the snub

roller if the junction is a diverting conveyor).

o Pass the belt through the space between the upper and lower rollers of the tracking station

and then in between the upper and lower nosebars.

o Wrap the belt around the lower nosebar and then feed it over the snub roller and under the

offset station pulley.

o Wrap the belt around the pulley and then under the upper nosebar.

o Wrap the belt around the upper nosebar and then pull it back towards the inline belt return

assembly stopping about halfway down the length of the junction.

o Wrap the other end of the belt around the inline belt return pulley and pull it as close as

possible to the other end of the belt.

Pin the belt using the supplied pin. Tuck the pin back into the lacing at least 15mm (5/8”) on both

ends.

Prior to tensioning the belt, recheck that the belt is following its proper belt path and not hung up

on any conveyor, building, or installation components or other foreign objects.

Track the belt per instructions in the Maintenance section of this manual.

Inline Pulley Bearing Replacement

Loosen the bearing clamp bolts.

Loosen the bearing to pulley shaft mount system.

Debur any set screw deformations on the shaft with a flat mill file.

Loosen the bearing jack-bolt jam-nuts.

Remove the bearing clamp bolt hardware.

Remove the bearing.

Install the new bearing in reverse order – follow any supplied instructions for mounting the bearing

to the pulley shaft.

Return the bearing to the factory marks and run and track the conveyor belt.



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Inline Pulley Replacement

Warning

Junction pulleys are very heavy.

Use appropriate lifting methods when handling this pulley.

Remove the bearing cap or bearing covers as appropriate.

Loosen or open (un-pin) the conveyor belt.

As appropriate, remove the gearmotor, other drive components or other accessory components

from the pulley shaft.

Remove the pulley bearings.

Remove the pulley.

Install the new pulley in reverse order – center the pulley faces between the bearing housing plates.

Offset Pulley Bearing Replacement

Remove the offset belt return station cover.

Loosen the bearing clamp bolts.

Loosen the bearing to pulley shaft mount system.

Loosen the bearing jack-bolt jam-nuts.

Remove the bearing clamp bolt hardware.

Remove the bearing.

Install the new bearing in reverse order – follow any supplied instructions for mounting the bearing

to the pulley shaft.

Return the bearing to the factory marks and run and track the conveyor belt.

Offset Pulley Replacement

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1-800-331-1749

Warning

Junction pulleys are very heavy.

Use appropriate lifting methods when handling this pulley

Remove the offset belt return station cover.

Loosen or open (un-pin) the conveyor belt.

As appropriate, remove the gearmotor, other drive components or other accessory components

Remove the pulley assembly.

Install in reverse order – tighten the 6 bolts to 180in-lbs.

Snub Roller Replacement

Warning

Junction Snub Rollers are very heavy.

Use appropriate lifting methods when handling this roller.

Remove the inline or offset pulley as appropriate per instructions as described above.

Remove the snub roller.

Install in reverse order.

Tracking Station Replacement

Remove the rear deckboard.

Remove the 2 bolts securing the upper tracking station section to the lower section.

Remove the upper tracking station section.

Install in reverse order – tighten the 2 bracket bolts to 15ft-lbs.

!



1-800-331-1749

Gearmotor Replacement

Warning

Observe local and national safety regulations.

Isolate the motor electrical power prior to any service work.

Gearmotors can be heavy and awkward to lift.

Use proper lifting and securing methods during maintenance activities.

The following text describes the two most common gearmotors supplied by Transnorm System. Most other

motors and reducers combinations use similar mounting systems. The details of the coupling to the pulley

drive shaft vary by manufacture, reducer model, and specified mounting systems.

!



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Right-Angle Gearmotor: Direct Shaft Mount

Remove the outer reducer guard to gain access to the drive-shaft mount system.

As required, remove the inner reducer guard to gain access to the drive-shaft mount system.

Loosen or remove the reducer mount system.

Remove the bolt securing the rod-end to the reducer mounting angle.

Remove the reducer by sliding it off the shaft.

Install in reverse order – follow gearmotor instructions to mount the reducer to the drive shaft.

Under-hung, In-line Gearmotor: Cog-belt Final Drive

Remove at least one of the cotter-pins securing the belt guard.

Open or remove the belt guard upper-half.

Loosen the upper jam nut on the motor plate rod-end and move it up the rod-end about 1-1/2”.

Remove the cog drive belt by:

o Squeezing the belt together, lifting the reducer.

o Chase the reducer/motor-plate up the motor-plate rod-end with the lower jam-nut.

If appropriate, remove the cog-belt pulley from the gearmotor output shaft by removing the two (2)

grub-screws (aka set screws) from the taper-lock bushing and using one of the grub-screws to

disengage the taper-lock bushing.

Remove the lower or inner half of the belt guard.

Remove the gearmotor by loosening and then removing the hardware attaching the gearmotor to

the motor-plate.

Install in reverse order – consult the Transnorm Systems Customer Service groups the for proper

cog-belt tension.



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Underhung Drive Motor Arrangement

Taper Lock Bushing

Side Mount Motor Arrangement



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Illustrated Parts List

Exploded View – Divert



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Exploded View – Merge



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Bill of Materials

Item No Typ. Qty. Description Transnorm Part Number

1 1 Drive Pulley Varies By Type

2 2 Drive Pulley Bearing Varies By Manufacturer

3 1 Tail Pulley Varies By Type

4 2 Tail Pulley Bearing Varies By Manufacturer

5 2 - Divert 1 - Merge

Snub Roller 021816

6 1 Nosebar Support Bracket 033036

7 2 Tracking Station Support Rollers -

8 1 Tracking Station Assembly (See Exploded View)

020167

9 1 Rectangular Deckboard 032991

10 1 Triangular Deckboard – 45° LHM/RHD – 45° RHM/LHD

032990 033013

11 1 Belt Varies by size

12 1 Offset Belt Return Cover 032970

13 1 Inline Belt Return Cover, Left (Divert Only) 033011

14 1 Inline Belt Return Cover, Right (Divert Only) 033012

15 2 Bearing Cap (Merge Only) Varies By Manufacturer



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Item No Typ. Qty. Description Transnorm Part Number

1 1 Diameter 1.9” Roller 020926

2 1 Spring Guide 031090

3 1 Spring -

4 1 M8 Countersink Washer 030409

5 1 M8 x 1.25 x 20mm Flat Socket Head Cap Screw -



1-800-331-1749

Revision Control

Rev Date By Description of Changes

- 7 Dec 2010 John Lynn Initial Release

Standards

This product conforms to the following standards:

Organization Standard-Date Characteristics of Conformance

ANSI B-15.1 Guarding of mechanical power transmission equipment by use of covers,

guards, and when specified - location

ASTM D378 Belt fire rating. See ISO 340

ASTM E84 Deck-board fire retardant characteristics: Pending

ASME B-20.1 Conveyor safety standards as applicable to unit-handling conveyors but

not to include electrical, controls, installation, or integration by others.

CEMA 402 Conveyor design and drive horsepower calculations.

ISO 340 Belt fire rating: Pending

OSHA 29CFR 1910.95 All operating speeds result in less than or equal to 90dBa when

measured 5ft away and 5ft above the conveyor.

OSHA 29CFR 1910.219 See ANSI B15.1

installation, operation and maintenance manualbelt conveyor ts4200-150 5 | p a g e transnorm system...

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