Created by EBCCW 00:06 96:05 Created by EBCCW 00:06 5683EN Conveyor system WL Conveyor assembly manual
Created by EBCCW 00:06 96:05
Created by EBCCW 00:06 96:05 Created by EBCCW 00:06 5683EN Conveyor system WL
Created by EBCCW 00:06 96:05
1 About this manual 1.1 1.2 1.3 1.4 2 Introduction Document disposition Installation site preparations Assembly order Tools 2.1 General tools 5 5 FlexLink tools 7 4 Fasteners 9 5 Standard screws, nuts, washers Slot nuts and square nuts Connecting strips T-bolts Assembly 5.1 6 7 9 9 10 11 13 Introduction 13 Support design 15 6.1 Special tool when mounting feet Beam assembly 7.
11.1 11.2 11.3 12 12.1 12.2 12.3 13 13.1 13.2 13.3 13.4 13.
About this manual 1 About this manual 1.1 Introduction The main purpose of this manual is to help self-building end users, with little or no prior experience, to assemble a FlexLink WL conveyor system. Each chapter includes instructions and pictures showing how to assemble the different parts. 1.
About this manual 1.
Tools 2 Tools 2.1 General tools To assemble a FlexLink conveyor, you will need most of the tools listed on the following pages. Not all are essential, but they will make your assembly work easier and more efficicient.
Tools 6 5683EN-1
FlexLink tools 3 FlexLink tools Rivet crimping pliers XS (∅ 3 mm): 3924776 XL/XM/XH (∅ 4 mm): 3925800 Rivet crimping clamp XS (∅ 3 mm): 3924770 XL/XM/XH (∅ 4 mm): 3923005 The riveting tools have replaceable pads. By replacing the pads you can use the same riveting tool for 3 mm and 4 mm rivets.
FlexLink tools Rivet crimping pliers XS (∅ 3 mm): 3924776 XL/XM/XH (∅ 4 mm): 3925800 Guide rail bending machine 3922963 (not shown) Drill fixture for fastener yokes 8050040 The drill fixture is slided into the stand and fixed by tightening the star knob.
Fasteners 4 Fasteners 4.1 Standard screws, nuts, washers M6S, MC6S, MF6S, M6M, BRB 8,4×16, XLAL 4.2 Slot nuts and square nuts XCAN, XLAQ Square nuts can be used in support beams and small beams instead of XCAN nuts, but they can also be used in conveyor beams as opposed to XCAN nuts. They do not stay in place in vertical positions and have to be inserted from the beam end. Created by EBCCW 00:06 When using XLAQ square nuts, remember to put in a sufficient number before completing the assembly.
Fasteners Figure 1 XCAN On the support beam, the slot nut can be entered into the T-slot from the beam side. It will stay in position in vertical T-slots because of a thin leaf spring. IMPORTANT Slot nuts can not be used with conveyor beams. 4.3 Connecting strips Figure 2 Connecting strips Connecting strips are used for joining beams together, end to end. Use Allen key and set screws when attaching the connecting strip to the beam.
Fasteners 4.4 T-bolts Figure 3 XLAT T-bolts can be entered from the beam side, and when turned 90° they will stay in place after tightening with nuts (XLAN 8) and washers (BRB 8,4×16). The indication groove in the T-bolt should be at 90° to the conveyor T-slot. Created by EBCCW 00:06 T-bolts are used when attaching support brackets, guide rails and drip trays to the conveyor beam.
Fasteners 12 5683EN-1
Assembly 5 Assembly 5.1 Introduction 5.1.1 Component groups Created by EBCCW 00:06 The basic FlexLink conveyor structure consists of five component groups: • support structure • conveyor beams, straight sections and bends • drive and idler units • chain • other accessories (guide rail, drip trays etc.) The first step in the assembly process is to assemble the support structure, which consists of feet, support beams and beam connectors.
Assembly feet and beam connectors, so check which ones are used in your application. Some examples are shown below. IMPORTANT You must work in accordance with your layout, and make sure that the conveyor is supported at regular intervals not exceeding 3 m.
Support design 6 Support design The WL conveyor system uses standard FlexLink feet, refer to appendix for assembly instructions. 6.1 Special tool when mounting feet Created by EBCCW 00:06 Conveyor beams are mounted on to the support structure by means of support brackets. To get the right distance between the holes, use the drilling template. The drilling template are fitted on the support structure using the T-slots. Tighten the star knob before drilling.
Support design 16 5683EN-1
Beam assembly 7 Beam assembly The beams is connected using the Connecting strips for beam. 7.1 Support profiles Created by EBCCW 00:06 Note the different location of the support profiles due to belt width. See table below for placement of the support profiles.
Beam assembly 18 5683EN-1
Drive and idler unit assembly 8 Drive and idler unit assembly This step is to mount drive and idler units to the frame structure. All drive and idler units come with connecting strips included. Attach them to the conveyor beam using an Allen key and the set screws that are included. Drive units can be attached to supports of various kinds; check your drawing to see how your conveyor is designed. It should be remembered that conveyor belt should always be pulled, not pushed, by the drive unit. 1.
Drive and idler unit assembly 20 5683EN-1
Slide rail and support rail 9 Slide rail and support rail Slide rail and support rail is standard FlexLink equipment and are therefore described in another guideline. The slide rails used in the WL conveyor system are mounted alphabetically as shown below. a WLCS 25x5 H - Mount this first (not neccessary for supportlist) b XBCR 25 HB - Mount as number two c XBCR 25 H - Mount as number three c a b c Created by EBCCW 00:06 Use the mounting tool for slide rail.
Slide rail and support rail 22 5683EN-1
Belts 10 Belts Created by EBCCW 00:06 The belts is delivered in one meter section to be manageable. They are mounted in the conveyor using the belt insertion section. The belt should be mounted with the front in the running direction. 5683EN-1 1. Unscrew the two screws and remove the cover on both sides. 2. Inserting the belt from the top: insert the front of the belt pointing towards the engine. Inserting the belt from the bottom: insert the front of the belt pointing from the engine.
Belts 24 3. Insert the belt and push it forward. 4. To assemble the belt section with the previous belt section, bring together the links on the two belts and insert the rod.
Belts 5. Press the rod into the belt until it "snaps" in place. 6. Continue inserting required number of belts. When the total number of belts are installed and stretched, there should be a total slack of 200300 mm compressed belt for the whole belt length. 200 Created by EBCCW 00:06 7. 5683EN-1 -300 mm Fitting the belt in the drive unit. It is important the belt fits into the cogs. If the belt is not properly fitted on the cogs, it will bypass the teeth of the cogs when operating the conveyor.
Belts If the belt is attached incorrectly, it will appear as a bubble in the belt. 10.1 Roller Kit Use the roller kit to relieve the belt from its own weight. The roller kit is mounted with a C-C of 150 mm all under the belt. C-C 150 Things to consider: 26 1 The profile needs to be mounted horizontally.
Belts Created by EBCCW 00:06 it forms a convex profile.
Belts 28 5683EN-1
Final preparations 11 Final preparations 11.1 Plug beam ends Ensure that end caps (XCBE) have been fitted to all aluminium profile ends. The beam profiles should be deburred before fixing end caps. It may be necessary to tap the cap into position using a soft-faced hammer. 11.2 Anchor feet to the floor After the assembly of all components it may be necessary to anchor the conveyor support feet to the floor. Use a type of fastener that is right for the kind of floor where the conveyor is installed.
Final preparations 30 5683EN-1
Start-up and testing 12 Start-up and testing 12.1 Safety considerations To eliminate the risk of accidents, it is important to be aware of certain areas of the conveyor where special caution is required, during installation, operation and maintenance. Some areas present a higher danger to personal safety, and because of this various kinds of safety devices need to be installed.
Start-up and testing 12.2 Slip clutch adjustment 12.2.1 Introduction The slip clutch on the drive unit is a safety device which allows the chain to stop if the load becomes excessive. It has two purposes: • Prevent damage to conveyor • Prevent damage to the products on the conveyor Where a slip clutch is fitted, it must be adjusted so that it does not slip whenever the drive unit is started under full load. The installation is carried out as follows: 12.2.2 Preparations for adjustment 1.
Start-up and testing 12.2.4 Adjustment 4 5 9 6 7 8 10 1 3 2 1. Remove the transmission cover. 2. Unscrew the three screws (8) so that the outer ring (7) can be rotated freely. 3. Hand-tighten the outer ring (7) to stop (no tools!). 4. Look for the desired maximum traction force in the table to the right and determine the X value for that force. 5. Positive X-value: (If the X value is negative (X≤0) ignore step 5 and go to step 6.
Start-up and testing The values in the table are approximate and apply to new slip clutches. F max (N) XM XH XW 450 450 475 475 525 575 625 675 725 775 825 875 925 1000 1100 XS XL 12.2.6 XK 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 X (div.) 19 18 17 16 15 14 13 12 11 10 9 8 7 XM XH 1200 F max (N) XW XK X (div.
Start-up and testing 12.3.2 Wear The degree of wear on a conveyor depends on a number of factors, such as: • running time • load, contact pressure • speed • product accumulation • sharp or rough products • chemicals • foreign particles, e.g. chips, grinding particles, broken glass, sand, sugar • temperature • plain bends Try to minimize the running time for the conveyor by stopping it when there is no transport.
Start-up and testing 12.3.4 Chain elongation During the run-in period, regular checks should be made to the elongation of the conveyor chain. This is especially important if the conveyor is transporting high loads or is of long overall length. Regular inspections of the chain elongation are important. The chain should be shortened after a run-in time of 40 hours. Further inspections should be made at 200, 500 and then at 1000 hour intervals.
Troubleshooting 13 Troubleshooting 13.1 Jerky running Cause Corrective action Damaged or badly fitted slide rail Inspect and replace as necessary. Wrongly adjusted slip clutch Check and adjust slip clutch. Worn transmission parts Check/replace transmission belt, belt drive sprocket. Conveyor belt is too tight/ loose Tension conveyor belt correctly. Dirty conveyor Clean conveyor belt/slide rail. Lubricate with silicone based lubricant. 13.
Troubleshooting 13.4 Cause Corrective action Worn or damaged bearings in drive unit Check/replace drive unit. Noise Damaged/badly fitted slide Check the free running of the conveyor rail belt, especially in slide rail joints. Excessive conveyor speed Lower speed. Check actual load against recommended loading. Incorrect conveyor belt tension Lengthen/shorten conveyor belt. 13.5 Abnormal wear on plastic parts Cause Corrective action Overloaded conveyor Remove products from conveyor and test run.
Appendix 14 Appendix Created by EBCCW 00:06 The following single sheet assembly instructions can be used as stand alone or together to assemble a conveyor systems.
Appendix 40 5683EN-1
XEFU 500 XCFF A, C, J Recommended tools PRE-REQUISITES 50 mm B, D, E, I, J A PRODUCTS B C, G, I XCFE XCFS 12x68 E XEFG XLFS 20 P, XLFJ 69 M6 / M8 D C B, D, I XCAG 80 F C, H G J M6 9 Nm / 80 lb. in. 4 Nm / 35 lb. in. M10 24,5 Nm / 217 lb.in. 45 Nm / 398 lb.in. M8 M6 / M8 C, D, F Basic value, Torque for dimension XCFB...F I M5 H The illustration may not always correspond exactly to ordered component.
42 5683EN-1
Incline WL 322 / WL 424 WL 626 WL 322 / WL 424 WL 626 Products Decline Recommended tools PRE-REQUISITES NTATION DOCUME 5116271 The illustration may not always correspond exactly to ordered component.
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