modular transfer system tlm 1500

I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500

Modular transfer system

TLM 1500

User manual

&

Maintenance guide

Translation of the original manual, version 03


Table of contents

Version tracking:...................................................................................................................................... 2 1 General information ........................................................................................................................ 1

1.1 Important remarks .................................................................................................................. 1

1.2 Applicable standards ............................................................................................................... 1

1.3 Applications ............................................................................................................................. 1

1.4 Conditions of use ..................................................................................................................... 1

1.5 Safety instructions ................................................................................................................... 2

1.6 Safety instructions regarding the motor ................................................................................. 2

1.7 Additional information ............................................................................................................ 2

2 Technical specifications ................................................................................................................... 3 3 Commissioning ................................................................................................................................ 4

3.1 Receipt ..................................................................................................................................... 4

3.2 Transfer elements ................................................................................................................... 4

3.3 Stopper .................................................................................................................................... 4

3.4 Positioning unit ........................................................................................................................ 4

3.5 Workpiece carrier .................................................................................................................... 5

4 Maintenance ................................................................................................................................... 5 4.1 Belts wear ................................................................................................................................ 5

4.2 Passageways of workpiece carriers ......................................................................................... 5

4.3 Pins .......................................................................................................................................... 5

4.4 Wear of the belt guide ............................................................................................................ 5

4.5 Transfer parts .......................................................................................................................... 6

4.6 Damped pneumatic Stoppers .................................................................................................. 6

4.7 Positioning units with simple and double effect damped pneumatic stoppers ..................... 7

4.8 Positioning units with damped pneumatic stoppers ............................................................ 9

4.9 Positioning units for station with damped pneumatic stoppers ........................................ 11

4.10 Lift positioning units with damped pneumatic stoppers .................................................... 11

4.11 Other transfer parts .............................................................................................................. 12

5 Motor Replacement ...................................................................................................................... 13 5.1 Disassembly ........................................................................................................................... 13

5.2 Reassembly of the motor ...................................................................................................... 15

5.3 Changing the timing belt ....................................................................................................... 15

6 Responsability ............................................................................................................................... 16 7 Customer service ........................................................................................................................... 16 8 Appendix ........................................................................................................................................ 17

8.1 Maintenance schedule .......................................................................................................... 17

8.2 Quality and environmental commitment: ISO certifications ................................................ 18

8.3 List of part.............................................................................................................................. 18


VERSION TRACKING:

Version Date Description of modifications Prepared by Approved by

00 01/10/15 Initial (translation) S. GUILLAUD-BATAILLE

01 06/12/16 - S. GUILLAUD-

BATAILLE

-

02 19/09/18 2015 edition of ISO 9001 and 14001

standards: deletion of expired certificates S. MAIRET S. MAIRET

03 09/07/19 Addition of paragraph 8.3: List of parts G. DAURIANNES L. HERBIET

I02-115 User manual & maintenance guide Version 03 (translation of the original manual) of TLM 1500 Page 1 sur 22

1 GENERAL INFORMATION 1.1 Important remarks The following instructions will be used as technical documentation for the manufacturer of the

final machine. elcom is the supplier of this TLM 1500 transfer system sub-assembly .

The manufacturer of the final machine must make sure that:

- All safety equipment is provided and functional, - Regular checks are carried out, - All danger (pinching, squashing) due to moving parts is controlled, - The documentation is complete.

1.2 Applicable standards

According to the 2006/42/CE European directive, elcom transfer systems are considered as partly

completed machines.

They are therefore not subject to an EC declaration of conformity but are the subject of a declaration

of incorporation. The latter is transmitted at the time of delivery, accompanied by the exploded view

of the motorized equipment.

However, the following standards are taken into account during the design and the manufacturing of

the elcom transfer systems:

× The European Machinery Directive 2006/42/CE

× The European Low Voltage Directive73/23/CE

elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.

For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.

1.3 Applications

The elements of the linear TLM 1500 transfer systems are designed to carry and position workpiece

carriers according to the end customers’ configuration.

They are intended to be incorporated the customers' production line.

1.4 Conditions of use

The elements of the TLM 1500 transfer systems are suited for a use in normal industrial areas such as

a final assembly plant or equivalent, in a dry environment.

They are not suited for transporting materials such as sand, balls or grain.

The maximum load applicable on the transfer system is mentioned in the catalog and must never be

ignored.

To ensure a proper functioning of the transfer system on a maximum period of time, you must follow

this advice:

- Use temperature between 0 and 40°C (30 and 140°F)

- Avoid dusty or smoky atmosphere

- Avoid accumulation of sharp objects on the transfer system

- Avoid setting the machine in direct exposition to UV rays


1.5 Safety instructions

Safety rules regarding transfer systems, especially the ones regarding the electrical devices, must be followed during all the use phases: mounting, transport, production. Disregarding these rules would be regarded as a wrong use of the machine.

Using the transfer system in an explosive atmosphere can have a negative impact on the transfer system and is strongly discouraged.

Never perform any maintenance on your own. Another worker must be present at all time in order to shut the power down or perform first aid actions if needed. Changing the motor position or removing security parts must only be done when the

transfer system is unplugged from any power supply.

When carrying maintenance or handling tasks while the transfer system is operating (belt

tension setting), take care not to slide your hand between the belt and the belt support

in order to avoid any accident.

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected in the end-user machine in

order to avoid any risks of pinching or squashing. We recommand to mount a protective

housing around it.

1.6 Safety instructions regarding the motor

In case of a power failure, turn off the transfer system: it could restart automatically when the power comes back which could cause damages and even injuries to the operator.

1.7 Additional information

These instructions aim at ensuring the safety of the people and the proper functioning of the transfer

system. If you wish to use the transfer system in any other conditions, please do not hesitate to

contact us.

Other information is available on our website, in the documentation section:

http://elcom-automation.com/transfers/documentation



2 TECHNICAL SPECIFICATIONS

- Maximum load on a workpiece carrier: 4 kg

- Maximum accumulated load on the transfer system: 35 kg for a maximum 3-meters unit.

- Electrical power supply of the motors: 380V three-phase

- Motor power: V12m/mn = 0.09 Kw (V = belt speed) V16m/mn = 0.09 Kw

Air pressure supply = 5 to 6 bars

Every cylinder must be equipped with a flow limiter.

- Sound emission < 70 dB

- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.


Warning: All load exceedance can lead to a premature wear of the belt or any other

parts.



3 COMMISSIONING

3.1 Receipt

When receiving the transfer system, check if the packaging has not suffered any damage and

that the machine is in perfect conditions.

The transfer system can be supplied in kit. It then needs to be assembled.

3.2 Transfer elements

When handling the equipment and parts, take special care to avoid shocks.

1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,

2. Level perfectly the conveying units while checking that the belts are properly laid on the belt guide,

3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of the line, it may be necessary to perform ground fastenings,

4. Check the settings of the motor magneto-thermic circuit breakers,

5. Check the running direction of the belt without any load,

6. Adjust the cams and the selectors using a workpiece carrier,

7. Start the transfer system with all the workpiece carriers on.

3.3 Stopper

1. Place the stopper right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers,

3. Adjust the flow control units.

3.4 Positioning unit

1. Put the positioning unit right in the middle of the two profiles of the system, 2. Adjust the sensor for the detection of the workpiece carriers, 3. Check on the high position that the pins of the workpiece carrier are free,

4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),

5. Adjust the flow controllers.

All the different types of positioning units include several mobile parts driven by

pneumatic cylinders. Therefore, they must be well protected on the end-user machine

in order to avoid any risk of pinching or squashing. We recommend mounting a

protective housing.


3.5 Workpiece carrier

1. Check that the springs of the pins located under the carrier are working properly.

2. Check that no part goes over the lower surface of the workpiece carrier.

4 MAINTENANCE

General visual check Approximately every 500 hours, check the following points to ensure the proper functioning of the transfer system:

4.1 Belts wear

Regularly verify visually the state of the belt and especially the welding area.

4.2 Passageways of workpiece carriers

The friction of the pins while operating can make some marks appear. Those marks may over the

long term require the part replacement.

4.3 Pins

Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of

efficiency in the guiding of the workpiece carrier occurs.

4.4 Wear of the belt guide

Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.

Wear area of the pins

Belt

Belt guide


4.5 Transfer parts

Every 200 hours:

Remove the dust from the complete unit, using the product:

Ref 800 00 003 (polish plastics Air Industry 2101).

Every 3200 hours:

Check the lubrication of the conical torque.

Apply grease to obtain the initial lubrication state if necessary.

Use the grease reference 800 00 009.

4.6 Damped pneumatic Stoppers

Every 5000 hours:

Clean the stopper depending on the working environment.


4.7 Positioning units with simple and double effect damped pneumatic stoppers

Every 1000 hours:

Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts

Guiding shafts


Changing the pins (locating and centering):

Extract the previous pins from the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support

(insert the pin in the bush and then place the whole on the positioning unit plate).

Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.

Pins

Bush (ref. 110 03 005)


4.8 Positioning units with damped pneumatic stoppers

Every 1000 hours:

Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts:

Guiding shafts


Changing the pins (locating and centering):

Extract the previous pins from the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support

(insert the pin in the bush and then place the whole on the positioning unit plate).


Pins

Bush (ref. 110 03 005)


4.9 Positioning units for station with damped pneumatic stoppers

Every 1000 hours:

Lubricate the positioning unit fingers with a film of grease. Use grease ref. 800 00 002 (Crown ref. 7041 spray).

Check the lubrication of the guiding shafts:

To reach the guiding shafts, remove the central fastening screw from the plate to release it from the positioning unit without removing the positioning unit from the transfer system.

For a quick lubrication of the guiding shafts, it is also possible to access them, without any disassembly, only by pulling the plate. Changing the pins (locating/centering pins):

Extract the previous pins from the press. Install the new pins in the press while using a bush of a workpiece carrier ref. 120 03 006 as a support (insert the pin in the bush and then place them on the positioning unit plate).

4.10 Lift positioning units with damped pneumatic stoppers


Every 1000 hours:

The operating mode remains the same as the standard positioning unit. It is not necessary to disassemble the lift positioning unit from the transfer system for this maintenance. Release the plate to access the guiding shafts and cylinder by removing the fastening screws.


4.11 Other transfer parts

The others parts of the transfer system do not need any maintenance.

A visual check, looking for wear or breaking parts is recommended from time to time.


5 MOTOR REPLACEMENT

5.1 Disassembly

Unscrew the four screws from the plastic cover.

Take the circlip and the washer off.

Circlip

Washer

Screws to

be removed


Remove the motor from the shaft.

Unscrew the anti-rotation screw of the reducer, on the transfer side.

Anti-rotation screw


5.2 Reassembly of the motor

Put the screw back on the new reducer.

Lubricate the shaft with copper grease.

For reassembly, follow the previous steps in

reverse order.

5.3 Changing the timing belt

The new timing belt is delivered already welded.

Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn

one. (Respect the passage way between the pulleys and belt guide).

Covers to be removed


Stretch the belt using the tensioning screw and put the covers back into place.

6 RESPONSABILITY elcom cannot be held responsible for any damages or harms due to non-authorized modification of

any parts, especially the safety parts.

Only original components can be used for maintenance or fixing.

elcom cannot be held responsible for any malfunction if some spare parts have been used without

the validation of elcom.

elcom reserves the right to make improvements and technical modifications without any further

notice.

7 CUSTOMER SERVICE Do not hesitate to contact us for any question or advice. We will be glad to assist you.

Tel: + 33 (0)4 74 43 99 61

E-mail: [email protected]

Adress : 1 rue Isaac Asimov ZAC de la Maladière 38300 Bourgoin-Jallieu

France

Prior to any contact, please note down the serial number of the transfer system. This number can be

found on the transfer system sticker.

Belt passage way Access to the tensioning screw


8 APPENDIX

8.1 Maintenance schedule

Maintenance of the modular transfer system TLM 1500

Frequency Action Component Chapter

200 hours To dust Transfer parts 4.5

500 hours To check Belt - Belt guide – Workpiece carrier 4.1

1000 hours To

lubricate Positioning units (shaft and cylinder) 4.7

3200 hours To

lubricate Conical torque 4.5

5000 hours To clean Stoppers 4.6


8.2 Quality and environmental commitment: ISO certifications

Our company is recognized according to the following ISO standards and their respective evolutions

since our first certification:

- Quality Management through ISO 9001 [since 2002]

- Environmental Management through ISO 14001 [since 2013]

All our current certificates are available for download in French, English and German on our website

http://elcom-automation.com/

8.3 List of part

11002001 Piston

11002008 Corps

11002009 Guide

11002010 Tiroir

11002201 Ressort

11002202 Joint

11003003 Pion

11003005 Canon diam. 6

11003201 Ressort

11003202 Cache dia 6

11004004 Support

11004005 Support

11004007 Support came

11004008 Rail

11004009 Rail

11004010 Sélecteur

11004011 Sélecteur G

11004014 Sélecteur D

11005002 Poulie dia 26

11005003 Rondelle

11005004 Entretoise

11005005 Poulie motrice

11005010 Bague

11005201 Roulement dia 8

11005202 Roulement dia 35

11005205 Arbre moteur

11007001 Plaque

11007003 Embout

11007005 Guide


11007007 Selecteur G

11007008 Rail

11007009 RAIL

http://elcom-automation.com/


11007201 Vérin

11009002 Corps

11009005 Doigt

11009006 Colonne

11009007 Pion locating

11009008 Pion centrage

11009010 Crochet D

11009011 Crochet G

11009012 Anti-retour G

11009013 Anti-retour D

11009205 Canon

11012003 Arbre

11012006 Guide

11012007 Pion centrage

11012008 Pion locating

11012011 Plaque vérin

11012201 Vérin

11012202 Douille à bille

11017001 Support détecteur

11018002 Equerre

11022001 Piston

11022003 Guide

11022201 Joint Torique

11023003 Tiroir

11034004 Bloc de renvoi

11034010 Flasque renvoi

11034011 Couple conique

11034012 Arbre

11034014 Arbre

11034015 Clavette

11034202 Bande retour 180°

11041201 Accouplement Ø32

11042001 Support moteur

11045201 Butée amortie pneumatique 100

11050003 Poulie contre-enroulement

11050007 Plaquette de maintien

11050009 Poulie dentée

11050010 Flasque poulie entrainement

11050011 Flasque arrêt moteur

11050013 Flasque entraînement

11050014 Flasque entraînement sym

11050016 Poulie de renvoi dentée

11050020 Guide bande 1000 cranté

11050201 Bande antistatique

11051002 Flasque renvoi cranté

11051003 Flasque renvoi cranté sym


11052001 Flasque jonction 100

11052002 Flasque sym jonction 100

11053001 Flasque entr support came

11053002 Flasque entr support came sym

11053003 Flasque renvoi support came

11053004 Flasque renvoi supp came sym

11053005 Came 100 cranté

11053006 Came sym 100 cranté

11054004 Plaque entretoise

11054005 Flasque couple conique

11054006 Carter inférieur

11054007 Obturateur

11054008 Carter supérieur

11054009 Equerre extérieure

11054010 Equerre centrale

11054011 Rondelle fendue

11054012 Kit 2 pignons

11061003 Plaque de détection

11075201 Vérin

11504008 Rail

11504009 Rail

12003205 Tampon

12005203 Vérin

12021002 Entretoise

12021201 Vérin rotatif

12031202 Vis axe

12034201 Bande

12064253 Roulement

12064254 Circlips exterieur

12064255 Moteur 24V

12065201 Vérin

15002063 Plaque boitier

11005203A Moteur 10m/min (Lisse)-16m/min (Crantée)

11007201F VERIN

11009005F Doigt FESTO

11012201F Vérin

11050203A Moteur 12m/min (cranté)

15002006 Plaque

15002011 Support G

15002012 Support D

15002052 Bloc gauche

15002053 Bloc droit

15002054 Verrou

15002055 Butoir

15002056 Axe

15002057 Came


15002058 Carter

15002059 Boitier

15004006 Plaque

15007009 RAIL

15007052 Guide


15007054 Sélecteur G

15007055 Embout rampe

15007056 Carter

15007057 Plaque de fermeture

15007058 Axe

15007059 Socle

15009003 Plaque indexage 150

15010001 Plaque

15010001F Plaque FESTO

15010051 Plaque de base

15010052 Plaque indexage

15010053 Entretoise

15010054 Rondelle entretoise

15010055 Guide butée

15010056 Butée à ressort

15010057 Couvercle

15010058 Support ressort

15010059 Centreur ressort

15010060 Crochet D

15010061 Crochet G

15010062 Corps

15010063 Axe fileté

15010063U Axe fileté usinage

15010064 Embout moteur


15010151 Pied

15010252 Ressort

15010253 Roulement

15010254 Circlips extérieur

15012001 Plaque

15012012 Plaque indexage

15012014 Plaque indexage RAP

15015001 Entretoise

15016001 Support pied

15017001 Came courte SG 150

15017002 Rampe SG

15017003 RAIL

15017004 Support came

15021001 Came double 150

15021002 Plaque


15021003 Sélecteur 150

15021051 Came double 150 24V

15021053 Sélecteur 150 24V

15021056 Support moteur gauche

15021057 Support moteur droit

15024001 Plaque indexage 150 RAP

15027001 Entretoise

15040001 Demi jonction 150G moteur

15040002 Demi jonction 150D moteur

15040003 Demi jonction 150G renvoi

15040004 Demi jonction 150D renvoi

15045001 Support butée 150

15046001 Came courte SD 150

15046002 Rampe SD

15046003 RAIL

15050001 Bloc entraînement 1500 courroie crantée

15050004 Entretoise


15050006 Cale épaisseur 1mm

15050008 Axe poulie de renvoi

15050012 Couvercle supérieur

15050015 Cale épaisseur 2mm


15050052 Poulie de transmission

15050053 Carter droit

15050054 Carter gauche



15050057 Rondelle entretoise



15050060 Rondelle

15050251 Motoréducteur 24V

15050252 Courroie dentée

15050255 Motoréducteur 24V

15051001 Bloc renvoi 1500, courroie crantée

15054002 Guide central 150

15054003 Plaque de base

15062001 Embase 150*150 unidirectionnel

15062001T Embase U 150 x 150 avec tampon

15062002 Plateau 150x150

15062002G Plateau 150x150G

15064001 Embase 150x150 multi.

15064002 Plaque 150x150

15064002G Plaque 150x150G

modular transfer system tlm 1500

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