Elevator - FlexLink
Contents
1. er Available door positions 20 5112204 e Flex Link Introduction function and components 3 2 Description of the Elevator The elevator primarily consists of two main units e Control system e Mechanical lifting device Control system Figure 6 Electrical cabinet Central intelligence and distributed I O The elevator is to be controlled by a Line controller and do not itself contain any intelligence such as PLC The Line controller PLC PC etcetera con trols the elevator through the integrated communication interface in the control box 5112204 21 Introduction function and components 22 Safety system Profibus and DeviceNet versions includes an autonomous safety system for the door switch disconnecting the power suply to the motors through the safety relay and main contactors For Profisafe versions the door switch and emergency switch are connect ed to safety inputs of the communication interface Main contactors are connected2. Er Available door positions Figure 16 Principle sketch elevator In most cases the Elevator is integrated in a system The input output side of the Elevator is determined by the application 5112204 33 Unload the elevator Flex Link 4 Unload the elevator 4 1 Preparation This section describes the steps that are required for unloading the Eleva tor It is recommended to make use of the devices described When using this or another device this device is expected to be provided with a quality mark A Note The operations concerned are to be carried out calmly in order to be able to carefully monitor any movement of the Elevator Before starting the unloading a good preparation is required The appropri ate devices must be available Apart from that the first transport check is an important part of the unloading as in case of damage this should be mentioned on the delivery note in relation to guarantee and the like The first transport check after arrival of the Elevator a transport check is to be carried out The check
3. Figure 8 Electrical cabinet The through puts in the bottom of box is according to module version see electrical drawings In the bottom is also the fast connectors for fieldbus positioned Inside the electrical cabinet is the module safety system fieldbus commu nication interface circuit breakers etcetera The safety system design depends on version Profibus and DeviceNet versions include a safety relay to which the door is connected Profisafe version do not contain any safety relay Common for all versions is that mo tor supply voltage is disconnected at emergency stop through main contac tors In the bottom of cabinet is an earth rail for cables There is also one earth terminal for each terminal group 5112204 Flex Link FlexLink 5112204 Introduction function and components The fieldbus cable is connected by fast connectors as mentioned above see electrical documentation If the module contains several communica tion interfaces such as the advanced versions with field distributor there is still only one connection point for fieldbus Outside and below the electrical cabinet is the connection point for equipo tential bonding see electrical documentation Warning The voltage is 400 V AC or 480 V AC Warning The voltage in the fi
4. Door ES Horizontal switch motion Figure 3 Profisafe version Safety Flex Link 1 3 2 Emergency stops If personal safety is endangered or if there is a risk for equipment damage the emergency stop button must be immediately pressed An emergency stop button is mounted on the front of the electrical cabinet Figure 4 Location of emergency stop button A The emergency stop device does not disconnect power to the ma chine For more detailed information about the emergency stop function see the application manual 10 5112204 Flex Link 9112204 A gt Safety 1 3 3 Guards The elevator consists of moving parts that can cause injury Feed in and feed out areas around the elevator are unprotected they must be protected by for example the installation of tunnels or similar devices The elevator may not be operated if the door switch is inoperable or if a sta tionary guard is improperly fitted Stationary guards The elevator is protected by stationary guards of clear PC and aluminium Openable guard The elevator is equipped with a service door for accessing the interior This door is equipped with a door switch If the door is opened during operation power to elevator motors is disconnected stop category 0 according to EN 60204 1 Stop the elevator before opening the door Do not open the door for the purpose of stopping the elevator The do
5. 175 30 Pallet width 240 320 Pallet width 240 320 XT A A A A Seg ls 745 Al 1A PU PAS Pallet width 400 640 FEEL UME 0e A A h noe 3394 a ALi T 4A as x ea jo a 1754 M MA At aa r 1356 3 1356 175 30 175 30 Figure 5 Elevator description 5112204 FlexLink de 2 2 Ordering information Example of strings obtained from the configurator A C D E F G H J X85 200 ABCD E 900 2800 50 PB ASO A B C D E F G H J XT 400 150 400 1200 Table 2 XT low elevator pallet width 400 Profisafe A C D E F G H J X85 200 ABCD E 900 2800 50 DN ASO Table 3 X85 High elevator with Device net 5112204 17 Technical specification A Platform B Pallet width C Product height D In feed and discharge positions E Door positions a F Lower height G Upper height H Drive unit version l Fieldbus J ESD version Flex Link Variable Low elevator 300 600 mm High elevator 300 1200 mm Low elevator 900 1400 mm High elevator 2400 3000 mm 50 Hz European 60 Hz American PB Profibus PS Profisafe DN Device net Standard ASO Conductive AS2 For
6. Flex Link 7 Alarm reset According to IEC 60417 Pictogram at pushbutton on control box door 8 Up Down According to IEC 60417 Pictogram at pushbutton on control box door 14 5112204 FlexLink de 2 Technical specification Complete turn key version In feed and discharge protections are not included Cycle time 13 16 sec low elevator 18 24 sec high elevator Max weight i Max product height 400 mm A number of pallets can be elevated at the same time Conveyor length Max length 550 640 mm Conveyor speed 15 m min Electrical environment 50 Hz 400 V AC 60 Hz 480 V AC ESD version elevators are available Cabinet for Profibus Profisafe or Device Net communication for Line con trol Maximum product weights are as follows Dimensions LxBxH See appendix Weight Low elevator 300 kg Depending of configuration Weight High elevator 400 kg Depending of configuration Electrical Supply 3 phase neutral PE 400 V AC 50 Hz 24 V DC specifications Max power 1 kW N A Pneumatic N A system Capacity Products per minute See application Max speed See application 5112204 15 Technical specification Flex Link 2 1 Technical data X85 XK
7. Flex Link 9112204 Preface Preface Purpose of this manual The purpose of this manual is to describe a number of operations that are intended for the user concerned Here it becomes clear how the user can work as well and as safely as possible By making use of clear illustrations and texts FlexLink wants to achieve a simple and safe way of working with the Elevator This document contains remarks that point out a risky or spe cific situation to the user In many cases this situation is provided with one of the symbols given below General warning for danger Warning for electrical voltage 1 Attention this is an important notice Compliance with the operations described in this document is important in order to prevent dangerous situations and unnecessary damage to the El evator Carefully keep this document It is recommended to keep one copy near the machine and one copy with your technical documentation Structure of the manual The user s manual has been composed in such a way that a number of op erations can quickly and easily be found This manual will not describe op erations that are not meant for the user It does however indicate what the user must do when carrying out a certain operation for example calling in technical staff The user s manual has been divided into sections These sections describe among other things the safety and the operation of the Elevator FlexLink would like to point out
8. The product that is put into the Elevator may not get stuck as a result of a too high wide or twisted product In order to ensure that products fit in the Elevator and will not get stuck the input of the Elevator can be checked for height width This detection must take place well before the Elevator prior to putting the product on the Elevator The maximum dimensions of the product are given in the technical specification Transition guard 5112204 At the transition between the Elevator and a connected conveyor a guard must have been placed so that persons are kept at a reaching distance from the transition Do not use the Elevator as a platform for maintenance work or in the production use equipment intended for these purposes A A F Note Only technically qualified employees are allowed to change the settings of the safety provisions Safety Flex Link 1 3 1 Safety system architecture The safety system architecture varies depending on elevator version Elevators require motor supply voltage and permanent 24V DC power sup ply for communication devices Motor supply voltage depends on version 50 Hz version 400 V AC 60 Hz version 480 V AC Safe 24V DC disconnected at emergency is not used although the eleva tor provides means for passing on the power
9. C Reflector Reflector Figure 29 Vertical motion sensors The low speed and stop sensors for up and down must be adjusted in re lation to motion speed and flag length The distance between low speed sensor and corresponding stop sensor is affected by e Flag length Distance between sensors may not exceed flag length on lift cage If not fulfilled the lift cage will loose the low speed sensor thus accelerating to high speed the moments be fore reaching stop sensor e Motion speed ramp time 1 The combination of high speed ramp time and distance between sensors should be such that the lift cage successfully ramps down to low speed before reaching stop sensor 2 The combination of low speed and ramp time should be such that the lift cage successfully ramps down to stop on the stop sensor when the stop sensor is activated 5112204 53 Installation and adjustment 54 Flex Link Interlocking sensors The light beam of the photo electric sensor should hit the reflector The lift cage should not act as obstacle at any height 5 5 6 2 2 Adjustment The sensor is adjusted so that the XT conveyers stops within the area lim ited by the two photo electric laser cells WL9L 5 5 6 3 Limit switches This does not apply to RTI units These should be protected by the appli cation Figure 30 Limit switches The limit switches are located in the upper and lower parts of the frame and ar
10. are activated with metal Limit switches are excluded Maneuver interface check Important Service door must be open preventing motions Make sure all push button signals reach the communication interface in control box 42 5112204 Flex Link Installation and adjustment 5 4 Test run The purpose is to check functionality Testing is performed by running man ually with an empty elevator without products Adjustment for making the lift cage stop exactly in horizontal line with con necting tracks is performed in a later stage Manual mode check Elevator can be set to manual mode enabling vertical motion up down Vertical motion and end positions Limit switch check Interlocking sensor check 9112204 Run elevator carefully towards end position See Adjustment on Listen for noise and vibrations page 53 a Check that elevator is running high speed outside the low speed areas b Check ramp down to low speed while inside low speed areas c Check that when stopped in end position the stop and low speed sensors are still activated Disconnect stop position sensors by See Limit switches unscrewing the sensor cable in the sensor on page 54 end The elevator will pass the stop sensor It will probably loose the low speed sensor which may cause it to switch to high speed Check that limit switch interlocks the corresponding motion direction Re connect stop position sensors Check that if
11. can be carried out at the moment the Elevator has been unloaded from the container or the truck The technical specifica tion gives the dimensions to be checked Is the elevator delivered undam aged and is it the correct Elevator Machine serial number type plate A Note Any damage is to be mentioned on the delivery note and should immediately be reported to the supplier This with respect to the guarantee of the machine 34 5112204 FlexLink 5112204 Unload the elevator 4 2 Unloading instructions Before starting unloading all fastening means securing belts screws etc that secure the Elevator unto the means of transport must be removed Subsequently check whether the transport supports are still connected well to the Elevator After this the unloading procedure may be started 4 2 1 Erecting the Elevator See Erecting the Elevator on page 37 When puiting upright just like when moving the Elevator make sure that the floor is level and clean and has sufficient carrying capacity At the mo ment the Elevator is on the correct place it can be put upright Dependent on the situation the Elevator can be put upright using a hoist a crane or a forklift truck Device s Hoist Crane Open end spanner Note Make sure when putting upright there is enough space height to put the Elevator upright Hoist e The hoisting device is to be fastened to the top of the Elevator While hoisting the hoist should be well
12. light At fixed light the ele vator is started and in production Production When the elevator is in production it receives products from connecting tracks elevates to correct vertical level sends the product to receiving con veyor and returns to home position 5112204 Flex Link Flex Link 9112204 Instructions for use Stop procedure Quick stop instruction Press several times during one second The eleva tor will stop immediately quickly It will not finish motions in progress Controlled stop instruction Press once per second The elevator will finish ongoing motions before stopping While stopping the Start indication flash quickly 2 Hz When the elevator is stopped the Start indication is Off Emergency stop Emergency stop must not be used for normal stop It should be used in case of emergency Emergency stopping may cause the whole line to emergency stop An emergency stop of the elevator disconnect parts of the electric power A certain amount of manual labour may be required to get the elevator back into normal run Opening door as stop The door must not be used for normal stop It should be used in case of emergency or when the elevator already is normally stopped Opening the door during production will have the same effect on elevator as an emer gency stop See above Alarm During normal state the Reset indication has steady light At the occa sion of alarm the indication
13. may not be operated if the door switch is inoperable or if a stationary guard is improperly fitted Stationary guards The elevator is protected by stationary guards of clear PC and aluminium These guards must be correctly fitted when the elevator is in service The stationary guards must be in place when the power is on Openable guard The elevator is equipped with a service door for accessing the interior This door is equipped with a door switch If the door is opened during operation power to the elevator motors is disconnected stop category 0 according to EN 60204 1 The door switch is a part of the safety system and may under no circumstances be by passed or in any other way made inoperable Once the door is closed the elevator can be reset and started A Warning Stop the elevator before opening the door Do not open the door for the purpose of stopping the elevator Figure 11 Safety switch door L 28 5112204 FlexLink Introduction function and components Possible conveyor motors placed inside elevator not part of Elevator mod ule are not affected by the door switch Elevator module Discharge conveyor Vertical motion Not part of module 8 o oo A l site Sa a TR o lt lt Horizontal motion In feed conveyor Not part of module gt TS w zmt z 2 bo me Figure 12 Elevator module
14. operation some safety provisions are to be taken care of The purpose of these safety provisions Is to protect the user the product and the Elevator against undesired situations dam age Without these safety provisions FlexLink cannot give a guarantee on any damage caused in absence of these safety provisions The table below gives a general description of the safety provisions re quired Here it should be noted that only technically qualified employees are allowed to work on the settings of the safety provisions Control Emergency stop switch Each Elevator is to be provided with one or more emergency stop switches that can be operated within reach of the user The switch must have the standard red colour The emergency stop switch must make sure that the input and output tracks are switched off simultaneously Motor protection The technical specification of the Elevator is among other things geared to the load given in the order confirmation Should the Elevator motor be overloaded for certain reasons this should be detected Without this protection there is a chance that the Motor or other components of the Elevator will be damaged 6 5112204 Flex Link A Height width detector Safety Note f it cannot be made sure that there will be no product on the machine that exceeds the minimum or maximum dimensions see technical specification the detector described below must be installed on the Elevator
15. 0112204 Elevator User Manual Flex Link 9112204 Elevator User Manual Flexlink Components AB 2010 All Rights Reserved No part of this program and manual may be used reproduced stored or transmitted in any form or by any means without the written permission of FlexLink Components AB The contents of this manual are for informational use only All information and specifications contained in this document have been carefully checked to the best efforts of FlexLink Components AB and are believed to be true and accurate as of time of publishing However due to continued efforts in product development FlexLink Components AB reserves the right to modify products and its manuals without notice FlexLink Components AB assumes no responsibility or liability on any errors or inaccuracies in this program or documentation Any kind of material damages or other indirect consequences resulting from any FlexLink Components AB s product part documentation discrepancies and errors or non anticipated program behavior are limited to the value of appropriate products purchased from FlexLink Components AB The products are delivered to the customer at the as is state and revision level they are on the moment of purchasing and are declared in detail in the license agreements between FlexLink Components AB and user User accepts and is obliged to follow the guidelines stated in the separate license agreement needed in using any p
16. 1 3 1 1 Profibus DeviceNet versions Emergency switch The purpose of the safeguard is to be part of the line global emergency safety system and affect the motor power supply to the elevator In case of emergency the motor power supply to elevator shall be discon nected stop category 0 EN60204 1 Door switch The elevator is equipped with a service door for access inside Opening the door results in a elevator internal disconnection to motors stop category 0 EN60204 1 Motor supply voltage Vac gt Line main cabinet Emergency a sn Bel L switch loop system Safe motor supply voltage Vac system interface I O switch Horizontal motion M ES Vertical motion Line global emergency switch loop Figure 2 Profibus or DeviceNet version 5112204 FlexLink 5112204 Safety 1 3 1 2 Profisafe versions Emergency switch and door switch Safety fieldbus protocols provide flexibility in safety architecture The emergency switch and door switch are connected to safe inputs of the communication interface inside the control box of elevator Safety outputs of the communication interface disconnects the motor pow er supply internally in the elevator Motor supply voltage Vac E Line main cabinet Permanent Safety comm interface A A
17. 10 Communication interface 6ES7151 1BA02 0ABO D A420 A430 Input module 6ES7131 4BF00 0AA0 jt Lomme Siemens 6Es108 40m 0m A450 Output module 6ES7132 4BF00 0AA0 a Gomme Siemens 6Esri0s40us00a0 A470 Output module 6ES7138 4FB03 0ABO EEE 2 Gomector Siemens 6ES71064000 00 S420 H450 Pushbutton Moeller Electric 216922 Illuminated White Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 E Contact element Moeller Electric 216503 Fixing adapter 1NC S462 H452 Pushbutton Moeller Electric 216931 Illuminated Blue a Contact element Moeller Electric 216504 Fixing adapter 1NO SE HAST a e L 210508 EA D e L 216976 NO are ter Eee AL 5112204 19 Recommended spare parts Flex Link Des Peme ensure Manufactureritemnr Comme waco fome MurEtcrone 700800220000 OOOO waz fome MurEtcrone 7008002000 CL foose OOOO wss fome eoe oono OOO W438 Cable integrated on unit A438 Split box 80 5112204 oS Flex Link Recommended spare parts Spare parts list Control box 5112235 Manufacturer item nr Comment K360 K361 Moeller Electric 2 6600 DILM7 2300 Wainswich MoeterEecre PY25VISVBSW Q320 Miniature circuit breaker Moeller Electric 1489 A3C160 C16 3 Q320 Auxiliary contact Moeller Electric 1489 AAHS3 _ a K330 Phoenix Contact 2297031 A360 Safety relay PNOZ s3 A410 Communication interface Rockwell 1734 ADN A420 A430 A440 Input module Rockwell 173
18. 16376 D Contact element Moeller Electric 216378 S360 H452 Pushbutton Moeller Electric 216931 Illuminated Blue L Contactelement Moeller Electric 216504 Fixing adapter 1NO P Contact element Moeller Electric 216376 S426 H451 Moeller Electric 216870 3 pos Illuminated Blue Contact element Moeller Electric 216504 Fixing adapter 1NO Contact element Moeller Electric 216376 1NO Lamp Moeller Electric 216557 White 5112204 87 Recommended spare parts Flex Link Des Peme enueeurer Manufactureritemnr Comme SD foe uurEemne 70002200 OO wast fome uurEkerone 700200220000 OOOO o wass foe uurEkerone 700200220000 OOOO OOOO o ws OO O SSS o oo war fome Meene 00222000 OOOO O Item 5113382 Specification 3940647 88 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112133 Manufacturer item nr Comment K470 K471 Moeller Electric 276600 DILM7 300 Main swich Moeller Eleci e PASSES Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 Ss A420 A430 Input module 6ES7131 4BF00 0AA0 Connector Siemens 6ES7I88 40m 0m O OO OOOO O A450 Output module 6ES7132 4BF00 0AA0 a A460 Input module 6ES7138 4FA04 0ABO a fe onnector Siemens 6S 7163 40G30 0RR0 A470 Output module 6ES7138 4FB03 0ABO D a E 400000 S420 H450 Pushbutton Moeller Electric 216922 Illuminated White _ a Contact element Moeller Electric
19. 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 Contact element Moeller Electric 216503 Fixing adapter 1NC D Contact element Moeller Electric 216378 S462 H452 Pushbutton Moeller Electric 216931 Illuminated Blue Contact element Moeller Electric 216504 Fixing adapter 1NO SA25 HST D JOomacr element Moser Elecne 216806 ngadpir MO D JOomacrclemen 7 MoelerElecine 268 FINO EL A 5112204 89 Recommended spare parts Flex Link Des Name Jieruseurr Manvecurermemnr Common wad CL LL O wast ae urEkerne 0802200 O O O was fome urEkerne 0802200 OO O O O O was fome urEkerne 0822200 O O O war fome Mnene LL O Item 5113383 Specification 3940648 90 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112133 Manufacturer item nr Comment Des Name Manufacturer Comment o nsn oclerEeene prasvsvesw OOOO oo hoey cone WoeerEecre O Ko 2 p O aio Communication merece Siemens SESTIST TBAUZOABD O D aa T E A420 A430 Input module 6ES7131 4BF00 0AA0 A450 Output module 6ES7132 4BF00 0AA0 a A 2 OS A470 Output module 6ES7138 4FB03 0AB0 _ LS S420 H450 Pushbutton Moeller Electric 216922 Illuminated White Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 EE Contact element Moeller Electric 216503 Fixing adapter 1NC D Contact element Moeller Electric 216378 S462 H
20. 4 IB8 A450 Output module Rockwell 1734 OB8 S420 H450 Pushbutton Moeller Electric 216922 Illuminated White Se Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 Contactelemen Moeller Electric 216503 Fixing adapter 1NC Contact element Moeller Electric 216378 5360 HABA ____ lentactetement Mosler Elesric 2100 ang adap NO ontactelement 7 MoelerEene 216976 NO LS A Bue ass PE ns SE HAST e L G adapter NO a L 210876 NO iam Meter Elecvic A LS 5112204 81 Recommended spare parts Flex Link Des Name Menuseurer Manufactureritemnr Comme wao Cable e 700080020000 we Gable Uuretcrone 7008020000 wa Os ree 0082220000 we pae oe ooo OOOO W438 Cable integrated on unit A438 Split box 82 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112235 Manufacturer item nr Comment K360 K361 Moeller Electric 2 6600 DILM7 2300 ain swich Moere PY25VISVBSW Q320 Miniature circuit breaker Moeller Electric 1489 A3C160 C16 3 Q320 Auxiliary contact Moeller Electric 1489 AAHS3 a K330 Phoenix Contact 2297031 A360 Safety relay PNOZ s3 A410 Communication interface Rockwell 1734 ADN a A420 A430 A440 Input module Rockwell 1734 IB8 A450 Output module Rockwell 1734 OB8 i 420 H450 Pushbutton Moeller Electric 216922 Illuminated White D Contact element Moeller Electric 216
21. 452 Pushbutton Moeller Electric 216931 Illuminated Blue Contact element Moeller Electric 216504 Fixing adapter 1NO SA25 HST D LOT eme Posters 276508 eme NO D jOomacr element 7 Moser Elie 276976 NO EL A L 5112204 91 Supplier s information Flex Link 10 Supplier s information This manual goes together with the elevator of the type mentioned on the order and on the title page of this manual This document was drawn up by FlexLink Components AB Date 2010 03 01 Copyright FlexLink Sweden 2010 The machine was produced by FlexLink Engineering Polska Sp Z 0 0 ul Za Motelem 2c 62 080 Sady Poland E mail info pl flexlink com www flexlink com A Note n case of failures please contact the system integrator 92 5112204 Flex Link FlexLink Components AB Chief Operating Officer Telephone 46 31 337 31 00 9112204 Svante Anderholm Fax 46 31 337 22 33 www flexlink com Supplier s information EC Declaration of Incorporation FlexLink Components AB SE 41550 Goteborg Sweden We hereby declare that the following equipment is intended to be incorpo rated into a FlexLink conveyor system and thereby forming a machine Op eration is prohibited until it has been determined that the machine in which these products are incorporated has been declared in conformity with the Machinery Directive 2006 42 EC together with amendments which have entered into force as of the date
22. 504 Fixing adapter 1NO 421 Pushbutton Moeller Electric 216590 Black D Contact element Moeller Electric 216503 Fixing adapter 1NC Rx Contact element Moeller Electric 216378 D Contact element Moeller Electric 216376 a S360 HEBD D e e Fixing adaptor INO e e NO EL E E E ns SE HAST O omnee MoclerEeeme 2650 Fino adapter NO CL EL IND EL A te 5112204 83 Recommended spare parts Flex Link Des peme ienuseuer ienuscurertemm Comme MED Joe Murekcronc 7000200 wast Joe UurEtcrone 700080020000 wass oae UurEcrone 700800220000 OOOO we ws Gable Murr Electronic 7008220000 OOOO Item 5113380 Specification 3940645 84 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112233 Manufacturer item nr Comment K360 K361 Moeller Electric 276600 DILM7 300 Main swich Moeller Electrice PT 25VISVB SW ss Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 SD R60 Safety rely m pos nr A410 Communication interface 6ES7151 1AA05 0ABO __ Power suppl Siemens GESTTSB ACABO OABO A420 A430 A440 Input module 6ES7131 4BF00 0AA0 SE A450 Output module 6ES7132 4BF00 0AA0 ad 420 H450 Pushbutton Moeller Electric 216922 Illuminated White E _ Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 es Contact element Moeller Electric 216503 Fixing adapter 1NC
23. A Warning Stop the elevator before opening the door Do not open the door for the purpose of stopping the elevator 5112204 29 Introduction function and components Flex Link 3 2 1 5 Sensors 3 2 1 5 1 Lift cage XT Inductive lift cage position sensor X85 XK Photo electric lift cage position sensor X85 XK Reflector of photo electric lift cage position sensor Figure 13 Photo electric cells Photo electric or inductive sensors depending on version are used for de tecting that product is positioned in the lift cage The photo electric sensor type is retro reflective thus the light beam is re flected by a reflector on the opposite side of conveyor back to sensor mak ing the detection of product less sensitive to colour differences of product The stop position of conveyed item due to sensor position is such that the conveyed item does not reach to the end of lift cage conveyor RTI elevator version For RTI elevators photo electric cells are used mounted at fixed positions in the elevator frame 30 5112204 Flex Lmk Introduction function and components 3 2 1 5 2 Vertical motion Vertical motion position sensors Lifting interlock sensor reflector Figure 14 Inductive sensors Vertical motion sensors Inductive sensors are used at stop positions and low speed stretches of the vertical motion Interlocking sensors
24. Contact element Moeller Electric 216376 1NO ee Contact element Moeller Electric 216378 S360 H452 Pushbutton Moeller Electric 216931 Illuminated Blue Contact element Moeller Electric 216504 Fixing adapter 1NO Contact element Moeller Electric 216376 a Er E AC IGS Iaeae S225 HAST D Comme E 210808 A D Gomme MoslerEeeme 21875 NO EL e 5112204 85 Recommended spare parts Flex Link Des Peme enueeurer Manufacturertemnr Comment we fme Meee LS OOO wa fee eoe 700080022000 OOo wass feae Mur Electronic 7000 88007 2000900 OOOO We waar fee Murr Electronic 7008220000 OOOO Item 5113381 Specification 3940646 86 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112233 Manufacturer item nr Comment K360 K361 Moeller Electric 276600 DILM7 300 Main swich Moeller Electic PY 25 V SVB SW ss Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 Le A360 Safety relay m PNOZ ss A410 Communication interface 6ES7151 1AA05 0ABO power supp Siemens SES71GB 4CAGO OABO A420 A430 A440 Input module 6ES7131 4BF00 0AA0 nnn A450 Output module 6ES7132 4BF00 0AA0 a S420 H450 Moeller Electric 216922 Illuminated White E Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 nes Contact element Moeller Electric 216503 Fixing adapter 1NC Sy Contact element Moeller Electric 2
25. Retro reflective photo electric sensors are mounted in the upper part of frame with reflectors mounted on the bottom plate of elevator Their pur pose is to interlock vertical motion if obstacle is detected 5112204 31 Introduction function and components Flex Link 3 2 1 5 3 Limit switches This does not apply to RTI units These should be protected by the appli cation Figure 15 Limit switches The limit switches are located in the upper and lower parts of the frame and are activated in the event of excessive lifting device travel The upper limit switch interlock the vertical motion upwards electrically and vice versa for the lower limit switch Thus activating the lower limit switch still allows upward motion Mechanical dampers serve as protection after the limit switches To assure correct operation of the elevator ensure that the switches are correctly positioned and are activated in the intended direction of travel 32 5112204 e Flex Link Introduction function and components 3 3 Working principle The purpose of the elevator is to transport products goods vertically to bridge a difference of height or to function as buffer zone Top of chain Level C D 300 600 mm Level A B 900 1400 mm Level C D 300 1200 mm Level B 2400 3000 mm
26. W30DT80K4MMO5BMG XK X85 5111569 W30DT80K4MMO5BMG 5111684 K37DT80N4MM07BMG 50 Hz 35 176 rpm RTI Field distributor 5057737 Z6 PROFIBUS pf ew 3 Roller chain 08 B1 LAMDA FlexLink or local supplier 4A Gear box 5111425 BS 50A0U Benzlers 4B 5111424 BS 50 A0O DP 5 Roller chain 5045327 08 B1 FlexLink or local supplier Carrier link 5986156 08 B1 Special FlexLink Contact FlexLink 7 Chain lock 5045326 08 B1 FlexLink or local supplier 8A Bearings 5052978 6202 2 Z C3 Top SKF 8B 5058259 6204 2 RSH C3 Bottom Guide profile 5986013 Oy FlexLink Sprocket wheel 5986022 Top FlexLink or local 5986183 Bottom supplier Coupling element ROTEX GS 19 98 SHA GS FlexLink or local supplier 60 Hz 43 259 rom US 10A 10B Lifting device Applies to XT X85 and XK variants For spare mechanical parts see FlexLink catalogue 5147 or www flexlink com Inductive sensor 5111460 NBN40 L2 E2 V 1 Applies only to XT pallets Photo electric 5059929 MHL 15 p3336 cell Sensors 16 Reflector 5110995 PL 30A 70 5112204 R NO O1 Flex Link Recommended spare parts Photo electric 5111749 WL9L P430 SICK laser cell Door switch 5112509 PSEN 1 1p 22 504222 Pilz Limit switch 5059096 XCKP 2118 P16 TELE MECANIQUE 5112204 171 Recommended spare parts Flex Link 9 2 Electrical Des Name Manufacturer Manufactureritemnr Comment waed Cable
27. any of these sensors are see Adjustment on activated vertical motion in both directions is page 53 interlocked 43 Installation and adjustment Flex Link 5 5 Adjustment 5 5 1 Electrical cabinet The electrical cabinet contains several items which needs correct settings before usage e Contactor for horizontal drive Communication interface AN 5 5 1 1 Adjustment For designations of contactor and communication interface see electrical documentation Contactor for horizontal drive The contactor includes motor protection which must be adjusted to the rat ed current of motor Before adjustment make sure the device is not activated Reset button Figure 20 Contactor for horizontal drive 44 5112204 o Flex Link Installation and adjustment Instruction 1 Activate the reset button for more than 6 s to reach the operating mode Parameterization the green LED PWR flashes once The LEDs are switched off at intervals of 2 s for 0 3 s in the operating mode Parameterization to differentiate from other operating conditions 2 Set the rated current of the drive with the 240 potentiometer for value see below The four LEDs display the set current Current setting 0 41 A PWR 0 ERR 0 L 1 R 0 3 Store the value by pressing the reset button again retentive area of the memory 4 Actuate the Reset key for more than 2 s and less than 6 s to display the set current for 3 s Commun
28. arts of this product package 9112204 Flex Link 5112204 1 1 1 2 1 3 1 4 1 5 2 1 2 2 2 3 3 1 3 2 3 3 Preface Safety system information Important safety conditions Description of safety provisions Safety measures to be taken Explanation of symbols Technical specification Technical data Ordering information Operating conditions Introduction function and components Purpose of use Description of the Elevator Working principle Unload the elevator 20 20 21 33 34 4 1 4 2 5 1 5 2 5 3 5 4 5 5 5 6 6 1 6 2 7 1 7 2 7 3 Flex Link Preparation Unloading instructions Installation and adjustment Provisions to be provided Mechanical assembly Electrical installation and controls Test run Adjustment Check Shadow run Instructions for use Handling Manual operation Technical maintenance Check and control procedures Maintenance procedures Troubleshooting 34 35 38 38 39 41 43 44 56 58 58 59 60 60 61 63 5112204 Flex Link 5112204 7 4 8 1 8 2 8 3 8 4 9 1 9 2 10 Maintenance schedule elevator Put out of commission Disconnect the power sources Disassemble Transport Reuse Recommended spare parts Mechanical Electrical Supplier s information 64 65 65 65 66 66 6 7 67 72 92 Flex Link
29. awing number shall always be spec ified when communicating with FlexLink with respect to the elevator Project number See machine nameplate Supplier FlexLink Engineering Polska Sp Z 0 0 ul Za Motelem 2c 62 080 Sady Poland Machine type Elevator Date of manufacture See machine nameplate Gen drwg no See machine nameplate Figure 1 Machine nameplate The machine nameplate is located on the electrical cabinet as shown in the figure above Safety Flex Link 1 2 Important safety conditions At the moment that the elevator is going to be operated by a user the fol lowing safety conditions must be met Make sure that children or animals have no access to the machine and its surrounding area by for example screening off the eleva tor with a fence e Only persons who have read and understood the operating in structions are allowed to operate maintain and clean the ma chine e Do not reach into the machine while it is running or on Even if the machine is not running it can be on which means start operating automatically e Safety provisions such as side plating bottom plating emergen cy stops and detectors may not be removed or deactivated while the elevator is running e Provide good ambient lighting to enable the operator to work well and orderly with the elevator 1 2 1 General A e Incorrect use of the equipment can cause personal injury e Do not stand or climb on the equ
30. bleshooting list subsequently a maintenance schedule is set up in section 7 2 on page 61 describes differ ent maintenance activities During carrying out any activities on the elevator make sure that the main switch has been switched off so that there is no voltage on the machine 7 1 Check and control procedures 7 1 1 Daily maintenance e Check for abnormal sound heat e Check for dust and particles especially on sensors 7 1 2 Monthly maintenance e Check function of the emergency stop device e Check chain tension and lubrication e Check the roller chain guides e Check drive chain for wear and tension e Check the bearings 7 1 3 Maintenance performed every third month e Check threaded fasteners e Check that the elevator is running smoothly e Check attachment of the carriers e Check that the chain cog belt and carriers lifting device are free from damage 60 5112204 Flex Link M gt Adjustable 0112204 A Technical maintenance 1 2 Maintenance procedures Disconnect the power when performing maintenance on the elevator A clearly visible sign must be displayed indicating that work is underway If you have questions related to maintenance contact FlexLink 7 2 1 Cleaning Periodic cleaning keeps the elevator in service and extends its service life Do not employ high pressure cleaning on drive ends chains and electrical components Cleaning behind guards is conducted with a damp c
31. colour differences of product The stop position of conveyed item due to sensor position is such that the conveyed item does not reach to the end of lift cage conveyor 51 Installation and adjustment 52 Flex Link 5 5 6 1 1 Adjustments Photo electric sensor Adjust the sensor angle towards the reflector Adjust the reflector angle making the light beam from sensor hit the reflec tor 90 degrees against reflective surface The LED of sensor confirms reflection by reflector with not obstacles be tween Any obstacle between should cause the LED to fall If anything blocks the signal between the sensor and reflector the LED in dicator shall turn off Inductive sensor Adjust the vertical distance between sensor and sensor flag on pallet 5 5 6 2 Vertical motion Lifting interlock sensor Vertical motion position sensors Lifting interlock sensor reflector Figure 28 Inductive sensors Inductive sensors are used at stop positions and low speed stretches of the vertical motion Retro reflective photo electric sensors are mounted in the upper part of frame with reflectors mounted on the bottom plate of elevator Their pur pose is to interlock vertical motion if obstacle is detected 5112204 Flex Link Installation and adjustment 5 5 6 2 1 Adjustment Vertical motion sensors Interlocking Interlocking Vertical motion Lift cage sensor flag
32. coupling dismounting transport and reuse of materials coming from the elevator 8 1 Disconnect the power sources Prior to starting the dismounting the voltage is to be cut off from the power source First the main switch is to be switched off before the power source can be disconnected Danger First switch off the main switch before the power source may be disconnected 8 2 Disassemble While dismounting the machine the regulations for waste processing ap plicable on the place and at the time of the dismantling are to be complied with The machine only contains commonly known materials At the time of assembling the elevator there were processing possibilities for this and no particular risks were known for persons involved in dismantling The disas sembly of the elevator generally requires few operations The elevator can be disposed of in the same way as it was delivered Note At the time of assembling the elevator there were processing possibilities for this and no particular risks were known for persons involved in dismantling 65 Put out of commission 66 A 8 3 Transport While transporting the elevator a number of safety measures are to be tak en Use the tools aids indicated in section If not it is assumed that the tool device used instead is safe and provided with a quality mark Carry out the transport operations calmly in order to be able to carefully monitor any movement of the elevator Not
33. d be repeated that the operations are to be carried out in a calm and control led way After having placed the elevator in the correct position the elevator is to be fastened to the mounting surface by using the holes in the adjusting feet The elevator has an input and output and these are to be connected to the connecting tracks Correct adjustment determines the quality of the sys tem Elevator Connecting track Connecting track Input output without connecting track Figure 18 In feed and discharge 5112204 Flex Link Installation and adjustment 5 2 Mechanical assembly 5 2 1 Integration in a transport system The elevator is a machine that is integrated in a system of conveyors This means that an input and output are to be connected to it If the elevator is to be fitted into an existing situation this usually gives more problems than in a completely new situation In both cases one should aim at optimum functioning 5 2 2 Floor construction Below a number of items are given which should be paid attention to during integrating a elevator as floor construction Tools Opend end spanner Ring spanner Plastic hammer e Before placing the elevator first make sure that it is placed on the right place and at the right height For setting the correct height the adjusting feet mounted under the elevator can be used e Now that the correct height has been established the connecting tracks at th
34. e With a clean floor surface the operator will not be hindered while operating the Elevator This can prevent tripping or slipping so that the operator does not unexpectedly come into contact with the Elevator 1 5 Explanation of symbols Just like in the manual symbols are used that have been placed on the El evator in order to point the attention of the user to certain situations or pro vide certain information on components of the Elevator 1 Type plate Elevator This contains the name and the address of the Manufacture Apart from that the declaration of incorporation series or type indication serial number and the year of construction of the Elevator 2 Type plate motor This contains the name and the address of the motor supplier Apart from that the CE l SEW EURODRIVE J ok pinc mark kind of motor oil series or type Rapes otaona mez 1 ueu i 015626073 Bl 0801 09 3 M2 indication serial number and the year of A Sl na Re m a Eiee ak CAR Bee AF VA JAIR 13 9 Lotte nee ig auena ee eure ie at i Sn ARRA a construction of the motor 7 y im 3 Risk for electric shock Placed on control box 4 Protective earth According to IEC 60417 Placed below control box Points out where to connect equipotential bonding conductors 5112204 13 Safety 5 Start According to IEC 60417 Pictogram at pushbutton on control box door 6 Stop According to IEC 60417 Pictogram at pushbutton on control box door
35. e Vertical or horizontal movement depends on the height of the elevator It is recommended to move a elevator higher than 2400 mm in a horizontal position 8 4 Reuse No fixed rules have been made up for reuse of the elevator because the elevator does not contain any hazardous substances At the time of assem bling the elevator there were processing possibilities for this and no partic ular risks were known for persons involved in the reuse Note Putting the elevator out of operation with all operations involved may only be done by technically qualified personnel 5112204 Flex Link Flex Link Recommended spare parts 9 Recommended spare parts 9 1 Mechanical j 4 nes OS PH i G gt h BE i bay gore F ER PTE EEE He DNS EE i y o O L S i w 5112204 67 Recommended spare parts 68 FlexLink Only XT 5112204 Flex Link Recommended spare parts TI ee WO ti TE F l i I HN 2 D 1 Zz TE ae ey il VAN IS z aa AN TTX 5 A l I LEE Lo NA TT Q EI Al Er IZS 4B 16 5112204 69 Recommended spare parts Flex Link oom rm me rim simi amen er SEW All with KPF6 1 5 M 50 Hz 54 541 rom 50 Hz 27 137 rom 50 Hz 43 213 rom EU Drive unit 1 Motors XT 640 5111464 K37DT80K4MMO7BMG 5111919 W30DT80K4MMO5BMG XT 480 240 XK X85 5111545
36. e activated in the event of excessive lifting device travel Mechanical dampers serve as protection after the limit switches To assure correct operation of the elevator ensure that the switches are correctly positioned and are activated in the intended direction of travel 5112204 FlexLink 5112204 Installation and adjustment 5 5 6 3 1 Adjustment The limit switches are positioned so that they are activated after the upper and lower feed in and discharge positions and before the dampers see the figure 30 99 Installation and adjustment 56 Flex Link 5 6 Check Shadow run In this paragraph the elevator will be checked in a semiloaded condition with all safety provisions activated If during the shadow run irregular sounds or other anomalies occur or if the elevator does not meet the spec ification or if with a test of ALL products some of these do not fit on the track or get stuck or slip the machine may not be tested further and advice should be obtained Carry out the check First the elevator is to be put into operation in order to carry out the checks required The elevator will run with semiload while the specified products are transported through the elevator If no unusual situations occur the check of the elevator and the associated safety provisions can be started Check elevator Below a check table is set up with respect to how the elevator can be checked for a number of items C
37. e lower and upper ends of the elevator can be adjust ed A special sliding bridge or roller bridge may be needed for a safe transfer of products e After the elevator has been well integrated in the system the ele vator can be attached to the floor surface This can be done by an choring the adjusting feet firmly to the floor or and connect through the holes shown in the picture e At installation dismount transport protections and replace them with air vents For more information see the separate manual from gear box manufacture NB The quality of integration in the system is coresponsible for the good functioning of the elevator Therefore make sure this is done properly 5112204 39 Installation and adjustment Flex Link 5 2 3 Validation 1 Lower end Has the lower end the correct height For the correct height we Yes No refer to the technical specification 2 Upper end Has the upper end the correct height For the correct height we Yes No refer to the technical specification Is there enough space around the elevator to allow working on Yes No it 4 Fastening Has the elevator been fastened well so that the elevator is Yes No foundation standing steadily and does not move to the left or to the right 40 5112204 Flex Link Installation and adjustment 5 3 Electrical installation and controls 5 3 1 Electrical installation During this phase all necessary cabling is connected t
38. e of frequency converter top cover e Switch off power supply prior to removing installing the terminal box cover e Ensure before startup that all protective covers have been fitted correctly 5112204 47 Installation and adjustment FlexLink t1 S51 52 Figure 24 Frequency controlled Standard elevator settings Potentiometers e Nominal speed f1 e Low speed f2 e Acceleration t1 e Dip switch S1 S2 e Address and PWM frequency Advanced elevator settings Potentiometers e Nominal speed f1 e Acceleration f2 e Dip switch S1 S2 e Address and PWM frequency For more information see manufacture manual 48 5112204 e Flex Link Installation and adjustment Adjustment procedure See section 7 2 2 on page 61 Figure 25 Drive and drift chain adjustment 5 5 4 Connecting tracks Elevator lift cage conveyor speed see Technical specification on page 15 The optimal speed of the connecting tracks is equal to elevator lift cage conveyor speed as this prevents product twisting and wear of the high fric tion conveyor plates The speed difference may not exceed 15 If speed difference is unavoidable an increasing speed is preferred 5 5 5 Guards The elevator consists or moving parts that can cause injury Feed in and feed out are covered by stationary and openable guards The elevator may not be operated if the door switch is inoperable or if a stationary guard is improper
39. eld distributor is 400 V There is risk for serious injury due to electrocution Immediately seek the care of a physician if an accident occurs After the main switch of field distributor is turned off voltage is still high in the field distributor Warning Check that the electrical cabinet is closed and locked after working in the electrical cabinet Warning Never bypass the safety system 29 Introduction function and components 26 FlexLink 3 2 1 2 Field distributor The field distributor used in advanced versions is the communication in terface of the adjustable speed drive for the vertical motion Figure 9 Field distributor 5112204 e Flex Link Introduction function and components 3 2 1 3 Motor Figure 10 Adjustable speed drive motor with frequency inverter An adjustable speed drive powers the elevator s lifting motion vertical mo tion via roller chain gears The drive package is mounted in the lower part of the elevator 5112204 27 Introduction function and components Flex Link 3 2 1 4 Guards The elevator consists or moving parts that can cause injury Feed in and discharge are covered by stationary and openable guards The elevator
40. ent of the gear may cause permanent and alignment Replace or wear or make the chain derail and can so cause align if necessary serious stoppages Check the guide rails for Monthly Replace guides dents damages and connection Check the drive for oil Monthly Repair or replace if necessary See the leakage and annoying noise troubleshooting list Check whether the Motor is Monthly Drive vibrations can make the bolts loosen by fastened well to the elevator vibration the faulty alignment of the drive can bend Tighten the bolts if necessary Check the oil level in the gear Monthly boxes fill up if necessary Change the oil in the Gear In accordance with the gear boxes specification of the manufacturer A Note During carrying out any activities on the elevator make sure that the main switch has been switched off so that there is no voltage on the machine the shaft and the chain may derail 64 5112204 Flex Link 9112204 A Put out of commission 8 Put out of commission Place the elevator on a pallet or pallets with specially cut supports and with the electrical cabinet upwards Secure the elevator with straps The eleva tor must be well protected and strapped during transport At the moment a elevator is put out of operation for some reason a number of steps are to be taken in order to avoid dangerous situations This section clearly indicates how one should proceed in a number of cases with re spect to un
41. eset Check that peripheral equip ment produces signals Press Start Wait for products to arrive Clean photo electric cells Only personnel with technical knowledge or equivalent sufficient experience may perform the following actions 1 Clean photo electric cells 2 Adjust photo electric cells 3 Check photo electric cells position and operation and that they are connected 63 Technical maintenance Flex Link 7 4 Maintenance schedule elevator The elevator requires relatively little maintenance Still some maintenance activities are to be carried out Below there is a maintenance schedule with an interval that is referred to normal operating conditions in an organisation with one shift without excessive accumulation of dirt caused by the prod ucts or the environment conditions The user has to apply an appropriate maintenance schedule dependent on the individual operating conditions lt is very important for the proper functioning of the elevator that mainte nance is done correctly and timely Improper insufficient or not document ed maintenance will void any warranty Clean elevator Monthly Regular cleaning depends on product and environment Check the elevator for broken Daily lt is the task of the operator to check this daily see or missing parts replace if user s manual necessary Check the chain tension Monthly See section 7 2 2 on page 61 Check the sprocket wheel Monthly Faulty alignm
42. feeding out pallets These are not in cluded with the elevator For XT X85 XK elevators the lifting device consist of a short conveyer with separate drives for feeding in and feeding out pallets see the figure below Vertical movement of the lifting device is powered by a drive chain to a Mo vimot brake motor mounted in the lower part of the elevator Figure 7 Lifting device Elevator function is controlled by a number of photo electric cells and inductive sensors The photo electric cells check that product feed in is correct and that the product is correctly positioned for discharge For XT elevators this check is made by inductive sensors Inductive sensors control the lowering of the lifting speed and stopping of the lifting movement The machine is of the stand alone design and can be combined with con veyers Feed in and discharge can be single or multiple Maximum product size is dependent on product stability and the dimen sions of the elevator RTI elevators do not include feed in or discharge devices at the top 23 Introduction function and components 24 3 2 1 Components 3 2 1 1 Electrical cabinet The electrical cabinet is fitted in the front of elevator The door is equipped with the required means of maneuvering pushbuttons lamps and module electrical main switch The main switch do not disconnect 24 V DC power supply to module
43. fixed and may not ride shift away unexpectedly e After having mounted the adjusting feet the Elevator can be put upright Now the hoisting device can calmly hoist the Elevator in the upright position 35 Unload the elevator Flex Link Note Be careful that the Elevator does not tip at the moment it almost has been hoisted in the upright position Make sure there are no persons near the Elevator Note Carry out these operations calmly in order to be able to carefully monitor any movement of the Elevator Note t is forbidden to walk under the Elevator during putting upright gt p Re gt Note Make sure that while putting upright there are no unauthorised persons or people that are not supposed to be there near the Elevator 36 5112204 FlexLink T Figure 17 Erecting the Elevator 5112204 37 Installation and adjustment 38 Flex Link 5 Installation and adjustment This section deals with the operations to have the elevator function well within a transport system First section 1 2 on page 4 in which the provi sions to be taken care of are given should be studied carefully section 1 3 on page 6 is particularly important for the elevators that are delivered to the end user not fully assembled 5 1 Provisions to be provided Make sure before integrating that the surroundings are clean and free from obstacles and the mounting surface is clean and level Besides it shoul
44. hecklist Does excessive noise occur Yes No This may occur because the tension of the chain is not correct lifting device are loose ora sprocket wheel is not aligned well see Troubleshooting on page 65 troubleshooting list list There is a ticking sound Yes No This may occur because the tension of the chain is not correct lifting device are loose or a sprocket wheel is not aligned well see Troubleshooting on page 65 troubleshooting elevator frame the guide the guard or Are lifting device touching the Yes No Adjust the lifting device anything else Do all products fit on the Yes No Check in the technical specification whether the track product dimensions are correct troubleshooting list Are the lifting device strongly Yes No This may occur as there are some loose lifting moving at any place in the device see Troubleshooting on page 63 5112204 Flex Link Are there any products that Yes No do not run over the transitions uninterruptedly Is the product correctly Yes No supplied discharged at the input output track Is the product properly Yes No transported through the elevator Installation and adjustment Check the setting of the transition distance or the transition roller See section 5 2 2 on page 39 integration elevator The system designer has determined this and will have guidelines with respect to this and know how to adjus
45. ication interface Integrator responsibility due to situation 5 5 2 Field distributor Apply to advanced elevator versions Reference to electrical document Figure 21 Field distributor 5112204 45 Installation and adjustment Flex Link 5 5 2 1 Adjustments Adress dip switches Figure 22 Terminal box cover e Switch off power supply prior to removing installing the terminal box cover e Ensure before startup that all protective covers have been fitted correctly Necessary settings e Address dip switches For more information see manufacturer manual 46 5112204 o Flex Link Installation and adjustment 5 5 3 Vertical motion drive Figure 23 Adjustable speed drive motor with frequency inverter The motor is frequency controlled with the frequency converter integrated on the motor The converter requires settings according to application The drive powers the elevator s lifting motion via roller chain gears The drive package is mounted in the lower part of the elevator 5 5 3 1 Adjustments Reference to electrical documentation Reference to manufacturer manual Settings are made on the insid
46. ipment e Do not wear clothing or other articles that can fasten in the ma chine e Follow the instructions in this user manual when transporting the machine FlexLink Components AB must approve all modifica tions or changes to this machine e Only use recommended spare parts e Only authorised personnel may open electrical units e FlexLink is not responsible for damage if service on the equip ment is not performed in accordance with this user manual 4 5112204 Flex Link Sale 1 2 2 Service technicians J Service technicians must have e Sufficient knowledge for reading technical information e Ability to comprehend technical drawings e Basic knowledge of mechanics e Sufficient knowledge in the use of hand tools 1 2 3 Electricians J Electricians must have e Experience from similar installations e Sufficient knowledge to work from drawings and wiring diagrams e Knowledge of local safety regulations for electrical power and au tomation To avoid risks only experienced personnel with technical knowledge and experience may perform repair work on the machine s electronics compo nents 1 2 4 Operators A To correctly use the equipment operators must have appropriate training and or experience 5112204 5 Safety Flex Link 1 3 Description of safety provisions As a standard the Elevator is not provided with control and any safety pro visions Before putting the Elevator into
47. loth or sponge 7 2 2 Roller chain Chains cog belt replaced as necessary After replacement ensure that the cog belt chain is correctly tensioned The drive chain is Chain tensioning is Once the chain is correctly tensioned conducted at the top correctly tensioned when it does not of the elevator the the chain should be flutter during lower sprocket wheel possible to depress operation and drive shaft shall 2 3 mm between the move freely after lower sprocket wheel tensioning and the chain guide See Recommended spare parts on page 67 61 Technical maintenance Flex Link 7 2 3 Motor For standard elevators without field distributor the main switch of the cabi net needs to be switched off and locked prior to motor replacement e Turn off electrical main switch of module located on control box door e Check no voltage in motor e Replace motor electrically and mechanically Set all DIP switches and thumb wheels in the cover of the motor according to replaced motor e Connect the internal cables on the terminal block according to ei ther the electrical documentation or the replaced motor The vertical drive for advanced versions is connected to the field distributor through a fast connector cable to facilitate service e Turn off the switch on the field distributor and lock it prior to dis connecting the fast connector to the motor e Set all DIP switches and thumb wheels in the cover of the moto
48. ly fitted 5112204 49 Installation and adjustment Flex Link 5 5 5 1 Stationary guards The elevator is protected by stationary guards of clear PC and aluminium These guards must be correctly fitted when the elevator is in service The stationary guards must be in place when the power is on 5 5 5 2 Openable guard The elevator is equipped with a service door for accessing the interior This door is equipped with a door switch 5 5 5 3 Adjustment To be positioned in line according to figure below T7 DRE Figure 26 Safety switch door A Warning Stop the elevator before opening the door Do not open the door for the purpose of stopping the elevator 50 5112204 FlexLink 5112204 5 5 6 5 5 6 1 Figure 27 Photo electric cells Sensors Lift cage Installation and adjustment XT Inductive lift cage position sensor X85 XK Photo electric lift cage position sensor X85 XK Reflector of photo electric lift cage position sensor Photo electric or inductive sensors depending on version are used for de tecting that product is positioned in the lift cage The photo electric sensor type is retro reflective thus the light beam is re flected by a reflector on the opposite side of conveyor back to sensor mak ing the detection of product less sensitive to
49. more information please contact your local FlexLink office 5112204 Flex Link 9112204 Technical specification 2 3 Operating conditions The circumstances under which the Elevator can be applied partly depend on the materials selected FlexLink has defined a number of parameters within which the Elevator would be allowed to function Should the Elevator still be applied beyond these limiting values FlexLink cannot guarantee the good functioning of the Elevator Ambient temperature in operation 20 C to 60 C Relative air humidity RH 30 to 95 not condensing Lighting Normal ambient lighting As a standard no lighting is installed on the Elevator and this can neither be installed as an option Normal ambient lighting is sufficient to work safely with the Elevator The Elevator is not intended for use in the open air and besides the Elevator is not suitable for an environment with a risk of explo sion For use under deviating circumstances you may contact the supplier of the Elevator Introduction function and components Flex Link 3 Introduction function and components 3 1 Purpose of use The elevator changes the elevation of products in a flow such as boxes or pallets according to the principle of first in first out _ Top of chain Level C D 300 600 mm Level B 900 1400 mm High elevator ee Level C D 300 1200 mm Level A B 2400 3000 mm
50. n swich Moeller Eleci e Pt25vSVBSW_ Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 ee A420 A430 Input module 6ES7131 4BF00 0AA0 pu 7 Comector Siemens 6ES710840820 00 A450 Output module 6ES7132 4BF00 0AA0 a A460 Input module 6ES7138 4FA04 0ABO a Joonnector CS EE A470 Output module 6ES7138 4FB03 0AB0 D Come Siemens EC S420 H450 Pushbutton Moeller Electric 216922 Illuminated White Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 rs Contact element Moeller Electric 216503 Fixing adapter 1NC a Contact element Moeller Electric 216378 Rs Enr Rs ei See area CES SS STE EE PE a O EEE EC a ea Es Blue Contact sterient MoelerEecne 216876 NO LS A LE 5112204 17 Recommended spare parts Flex Link Des JNme Menuecurer Manufactureritem nr Comme SGD Jose Mureicronc 000200 wast fee eee LL OOO wass feme Monterone oossoo 220000 O OO O O O O wass feme Monterone 700080267 2200900 OO O OOOO O OO o w feme heee oosa OOOO Item 5113377 Specification 3940642 78 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112234 Manufacturer item nr Comment K470 K471 Moeller Electric 276600 DILM7 300 Main swich Moeller Eleciio PT 25 V SVB SW En Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 ee A4
51. o elevator and appli cation code software for controlling the elevator is downloaded to the line controller IPC PLC as well as the fieldbus hardware configuration Reference to the electrical documentation for the version in question A001 400 VAC mo 24 V DC anal ES loop nr Fieldbus a Equipotential bonding Figure 19 Cabling example Cabling e Power supply e Fieldbus e Safety e Equipotential bonding 9112204 41 Installation and adjustment Flex Link 5 3 2 Validation The purpose of the validation phase is to prepare the elevator for test run The validation is performed with empty elevator No products in elevator Reference to electrical documentation Power on Motor supply Version dependent 50 Hz 400 V AC 60 Hz 480 V AC 24V DC Voltage check Check equipotential bonding Check voltages Turn elevator control box circuit breakers on Safety check Check that safety system is working properly Service door can be opened and cause motor power supply disconnection Closing the door enables safety reset Emergency switch activation cause motor power supply disconnection Deactivating the switch enables safety reset Where disconnections are made is version dependent Manual sensor I O check Important Service door must be open preventing motions Make sure all sensor signals reach the communication interface in control box The sensors are activated manually Inductive sensors
52. of issue of this declaration with particular reference to the essential health and safety requirements in connection with the design construction and manufacture of the below specified equipment Elevator Corresponding EC directives Low Voltage Directive 2006 95 EC Flexlink Components AB N n a gt MEN Responsible Technical file FlexLink Components AB SE 415 50 G teborg Sweden 93 Supplier s information Flex Link 94 5112204
53. or switch does not disconnect power to the machine 1 3 4 Noise level The noise level produced by the elevator is under 70 dB A 1 3 5 Electrical cabinet The voltage in the electrical cabinet is 400 V or 480 V depending on ver sion Ensure that the electrical cabinet is closed and locked after working in the electrical cabinet Never bypass the safety system The electrical cabinet can only be opened using a tool Before working in the electrical cabinet the main switch to the motor must be turned off and locked The key is retained by the service technician until work is finished Safety Flex Link Examples of service work include e Disconnection of wiring e Replacement of motors etc e Service work in the electrical cabinet terminal boxes etc e Service work performed on the machine that cannot be seen from the electrical cabinet For adjustment of photo electric cells inductive sensors etc power is re quired Stop the machine and wait until the moving parts have come to a complete stop Ensure that Start is turned off Open the elevator door Make adjustment Verify adjustments using manual operation of the elevator with the door closed see Handling on page 58 12 5112204 FlexLink Sala 1 4 Safety measures to be taken For a safe operation of the Elevator a number of safety measures are to be taken These include the following measures e Clean floor surfac
54. r so that they are the same positions as the one to be replaced e Connect the internal cables on the terminal block according to ei ther the electrical documentation or the replaced motor e Plug in the connector and tighten it before turning on the power switch To assure trouble free operation the motor and gears must be maintained according to manufacturer s user manual For more information see manufacturer manual 7 2 4 Chain guide profile The chain guide profile shall be replaced as necessary See Recommended spare parts on page 67 62 5112204 Flex Link 9112204 7 3 Troubleshooting Technical maintenance If in doubt concerning the troubleshooting procedures below contact FlexLink Troubleshooting guide The elevator does not start Products fasten have fastened Peripheral equipment is not connected Power not on emergency stop button pressed door not closed no signal from peripheral equipment or circuit breaker tripped No products to discharge Foreign matter on photo electric cells Photo electric cell faulty out of position or dirty Only personnel with technical knowledge or equivalent sufficient experience may conduct the following actions Check circuit breakers Check that peripheral equip ment has started Check that the power is on Check that the emergency stop button is not pressed Check that the door switch is activated Press R
55. re parts Spare parts list Control box 5112396 Manufacturer item nr Comment K360 K361 Moeller Electric 276600 DILM7 300 Main swich Mosler Electric PT25VISVBSW Q320 Miniature circuit breaker Moeller Electric 278873 C16 3 Q320 Auxiliary contact Moeller Electric 286054 ee A410 Communication interface 6ES7151 1AA05 0ABO ee Pme Siemens 6ES71384CA500AB0 A420 A430 A440 Input module 6ES7131 4BF00 0AA0 S420 H450 Pushbutton Moeller Electric 216922 Illuminated White _ S Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 Contact element Moeller Electric 216503 Fixing adapter 1NC Contact element Moeller Electric 216376 1NO Contact element Moeller Electric 216378 S360 H452 Pushbutton Moeller Electric 216931 Illuminated Blue a Contact element Moeller Electric 216504 Fixing adapter 1NO rl Contact element Moeller Electric 216376 a a rs Sa HAST C e A a 2678 INO EL e L 5112204 75 Recommended spare parts Flex Link Des JNme Menuecurer Manufacturerilemnr Comme wed Cable Mureicronc 7000002200 was Oo reee 700080022000 OO was foe Muremcronc 700080022000 OOOO ws OOOO OO S wasr e LE e Item 5113376 Specification 3940641 76 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112234 Manufacturer item nr Comment K470 K471 Moeller Electric 276600 DILM7 300 Mai
56. t an incorrect output The product may not move on the track If so contact the supplier The lifting device may not get stuck anywhere or find resistance otherwise this is to be reworked or improved 9112204 Can any irregularities be Yes No found in the chain guide 57 Instructions for use 58 6 Instructions for use 6 1 Handling The control box contains pushbuttons and indications lamps to start stop jog alarm och to reset alarms Pictograms are used for describing purpose of pushbuttons and indications Start Stop Reset Jog up down Pushbutton and lamp overview Start is used for starting the module Stop is used for stopping the module normally The elevator can be stopped normally in two ways quickly or controlled A quick stop is execut ed when the stop button is activated more than one time per second A quick stop will cause the elevator to stop immediately as quick as possi ble A controlled stop is executed if the stop button is activated once per second and cause the elevator to finish the motions in progress before it stops Alarm reset is used for resetting alarms Jog up down is used for manually adjusting the lift cage s vertical position 2 Fle Lank Start procedure Before the elevator can be started all alarms must be reset Press Start to start The Start indication will start flashing slowly 1 Hz a certain time ca 2 seconds before the flash turns into steady
57. to safety outputs of the communication interface For Profibus and DeviceNet versions the conductors of emergency switch is connected to a terminal group This terminal group is integrated into the line global emergency stop safety system by integrator The red knob of emergency switch is delivered in plastic bag as the eleva tor emergency switch functionality is not guaranteed before it is appropri ately integrated into the line s safety system by the integrator Drives The horizontal drive is with fixed speed controlled by a device including contactor and motor protection The vertical drive is frequency controlled by a frequency converter placed on the motor itself For standard versions the motor control is discrete On Off Up Down High speed Low speed Speeds are preset in hardware of motor For advanced versions a second communication interface provides ad vanced control of the motor Soeed and ramp times can be controlled by software in Line controller Motor current value and error codes can be pro vided by the motor to the Line controller 5112204 Flex Link Flex Link 0112204 Introduction function and components Mechanical lifting device For RTI elevators Paternoster the lifting device consists of a number of carriers attached to a roller chain These are powered by a Movimot brake motor mounted in the lower part of the elevator Feed in and discharge de vices are required for feeding in and
58. to the user that section Safety is to be read carefully Preface Flex Link Requirements of the user The Elevator may be operated by any adult person who has become ac quainted with section Safety If the user is not technically qualified he or she may not carry out any maintenance or repair activities on the elevator Note Maintenance activities on the elevator may only be carried out by a technically qualified person gt gt NB Technically qualified employees means employees that have followed an adequate training for carrying out the activities involved and have a good ability to read and understand the English language 2 5112204 FlexLink 5112204 Safety 1 Safety The Elevator has been designed in such a way that it can be used and maintained in a safe way This holds for the application the circumstances and the instructions described in the manual Any person working with or on this machine should study the manual and follow the instructions It is the responsibility of the employer to make sure that the employee is familiar with and follows these instructions The company or the country in which the machine is used may require ex tra safety measures This particularly applies to the working conditions This manual does not describe how these are to be complied with In case of doubt consult your government or safety officer 1 1 system information The project number and or general dr
59. uurEecrme 7000002200 wast Cable Sreo 700080022000 OOOO QUE EE A A Item 5113374 Specification 3940639 12 5112204 Flex Link Recommended spare parts Spare parts list Control box 5112396 Des Name Manufacturer Manufacturer item nr Comment Comment answer MosierEicne pr vsesw uen come Moser eee fo OOo Contactor Phone Contact r CE eNOS po Communication merae Siemens GES TARN EE Er ee os eee a nn EEE SR ER EE A420 A430 A440 Input module Siemens 6ES7131 4BF00 0AA0 D A450 Output module 6ES7132 4BF00 0AA0 ooo S420 H450 Pushbutton Moeller Electric 216922 Illuminated White Contact element Moeller Electric 216504 Fixing adapter 1NO S421 Pushbutton Moeller Electric 216590 Contact element Moeller Electric 216503 Fixing adapter 1NC S350 Moeller Electric 216515 Emergency Le Contact element Moeller Electric 216376 a Contact element Moeller Electric 216378 Rs ns ne S360 ABD Gontactetement MoslerElectic 276508 Fncadaer NO Leman element Moser Eee 218978 NO LL E DS SR a ees eT S425 HAST a e L 210800 A D e L 2878 INO a LL OL 5112204 13 Recommended spare parts Flex Link Des Pee ie Memeaneemm Comme we LL LS OOOO wa Gable uurEcrme 700080220000 was Gable uunEeerone 7000822000 O was Gable uurEeerone 7008222000 wr fee eeo LL OOOO Item 5113375 Specification 3940640 14 5112204 Flex Link Recommended spa
60. will start flashing until alarm is reset Press He set in order to reset alarm The flashing turns into steady light if alarms are reset 6 2 Manual operation The elevator s vertical motion can be manually adjusted in stopped state Alarms must be reset Stop the elevator wait until it is stopped and adjust the lift cage s vertical position up down using the 3 position switch The mo tion is interlocked to avoid running past the up and down sensors If the el evator is run upwards it will stop automatically when the up sensor is acti vated which is an advantage when verifying an adjusted sensor position checking that lift cage and adjacent conveyor are in level thus making the transition smooth The motion downwards is not affected by the up sensor Occasionally it is necessary to run past the up and down sensors for ex ample at a crash situation In order to realize a run past the up and down sensors keep Stop button pressed Manual operation upward direction Turn the switch to the left Manual operation downward direction Turn the switch to the right To return to operation in automatic mode Leave the switch in neutral posi tion and press Start button 59 Technical maintenance Flex Link 7 Technical maintenance Technical maintenance is an important part of this manual Good mainte nance will lead to cost reduction because defects can be timely recognised and solved This section starts with a trou
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