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Spiral Elevator

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1. Page 30 of 46 o478EN 5 Flex Link o478EN 5 6 2 6 2 1 Technical maintenance pressed on the centre of the slat Fig 35 The slat lugs will now be spread so the slat can be placed on the steel chain reverse removing procedure Apply force on the middle of the slat so that it clicks onto the steel chain according to Fig 33 and Fig 34 reverse removing procedure Repeat this procedure if more than one slat needs to be placed After maintenance on the slats test run the machine and check if the chain and slats runs correctly Chain Checking chain tension The chain of the Spiral Elevator must have the correct tension If the tension is not correct the following may occur Chain runs off the sprocket jumps a cog Slats grab into the return track causing them to break or become loose from the chain Excessive wear of the end sprocket caused by too high tension In order to prevent these problems it is necessary to regularly check the chain tension for over length Procedure Make sure that the main switch has been switched off and safely isolated Move the chain along the sticker with a scale at the lower end of the Spiral Elevator The scale contains a red and a green area see Fig 36 Compress the transport belt according to A in Fig 36 Take a reference point of one of the slats according to B in Fig 36 Stretch the transport belt according to C in Fig 36 Ifthe slat is
2. checks according to Appendix A must be completed before any continuation 5 4 Integration in a transport system The Spiral Elevator is a machine that is integrated in a system of conveyors which means that an input and output are to be connected to it If the Spiral Elevator is to be fitted into an existing application this usually gives more problems with the installation than in a completely new line Additional information regarding this is also found in Section 5 1 2 5 4 1 Frequency control and check The operation conditions are optimal when the speed of the Spiral Elevator is equal to the speed of the in feed and out feed conveyors or machines If a speed difference does exist this can lead to product jamming at the transfers and wear of the high friction slats If there are speed differences which are unavoidable these should be kept within a 10 margin If the speed differences are higher than 10 then a frequency controller should be used for speed control The settings or the ramp up and ramp down time should be set so that the Spiral Elevator does not snatch or jerk on starting or stopping Page 26 of 46 5478EN 5 Flex Link Mounting installation adjustment Chain length in Spiral Elevator gt 30m lt 30m Speed Spiral Elevator 50 Hz gt 24 m min 50 Hz lt 24 m min 60 Hz gt 28 8 m min 60 Hz lt 28 8 m min Total load in Spiral Elevator gt 250 kg lt 250 kg lt 1 start and stop hour gt 1
3. Do not wear clothing or other articles that can fasten in the machine Follow the instructions in the user manual when transporting the machine FlexLink must approve all modifications or changes to this machine Only use recommended spare parts Only authorised personnel may open electrical units FlexLink is not responsible for damage if service on the equipment is not performed in accordance with this user manual Maintenance and Service technicians Service technicians must have Sufficient knowledge for reading technical information Ability to comprehend technical drawings Page 4 of 46 5478EN 5 Flex Link A 5478EN 5 Safety e Basic knowledge of mechanics e Sufficient knowledge in the use of hand tools e Skilled EN SO 12100 2010 1 2 3 Electricians To avoid risks only experienced personnel with technical knowledge and experience may perform repair work on the machine s electronics components 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 automations e Skilled EN SO 12100 2010 1 3 Description of safety provisions As a standard the Spiral Elevator is not provided with control or any safety provisions Before putting the Spiral Elevator into service some safety provisions are to be incorporated The purpose of these safety provisions is to
4. a risk of explosion although static safe materials are available FlexLink should be contacted and consulted if any doubt regarding the operating conditions Page 9 of 46 een FlexLink Page 10 of 46 5478EN 5 Flex Link o478EN 5 Function and components 3 Function and components This section deals with a number of general matters with respect to the Spiral Elevator This involves among other things the purpose of use the conditions of use and the working principle of the Spiral Elevator Should you have any further questions on the safe operation of the Spiral Elevator please contact FlexLink The warranty conditions have been included in the FlexLink quotation or are available separately from FlexLink FlexLink does not accept any liability for unsafe situations accidents and damages resulting from e Neglect of warnings or stipulations as displayed on the machine in this manual or in the Project Documentation if applicable e Use in applications or circumstances other than those specified in this manual the quotation the Project documentation if applicable or FlexLink catalogue e Modifications to the machine This also includes the use of replacement parts other than those specified and supplied by FlexLink For recommended spare parts see Appendix F Insufficient or incorrect maintenance FlexLink does not accept any liability for the consequential damage in case of failures of
5. by the persons responsible for designing the control system If Start Stop via Direct on lt 3 sec The conveyor will start almost immediately and will stop and overrun a Line control little depending upon speed controller Inverter ramp up and down time in the freguency controller should be set to 2sec Height width detector Direct Where over height or over width detection is incorporated the stopping of the conveyor should be activated immediately with the stopping times If Start Stop via Frequency See Section 5 4 1 Frequency control and check In normal conditions the suggested in the above items 5478EN 5 Page 27 of 46 Mounting installation adjustment 5 6 Test run In this paragraph the Spiral Elevator will be checked with all safety provisions activated Any issues with regard to the safety items should be investigated and discussed with the designer of the control and safety system Note The basic Spiral Elevator supplied by FlexLink does not include any additional safety provisions such as isolators stop Start devices emergency stopping systems or guards at the in feed out feed ends Should the safety provisions not function as expected they should be set or adjusted again or repaired by the person responsible installer techni cian 5 6 1 Method test run Initially start the Spiral Elevator with no product loaded and conduct the items in the checklist below Then gradually add produc
6. follow the guidelines stated in the separate license agreement needed in using any parts of this product package FlexLink is not responsible for damage if service on the equipment is not performed in accordance with this user manual o478EN 5 Flex Link Content PTC EOE 1 Purpose of this manual 1 Structure of the manual 1 Requirements of the user 2 1 Deenen d 1 1 System information and symbols 3 1 2 The most important safety COR OTS makna dean 4 1 3 Description of safety provisions 5 2 Technical specifications 7 2 1 General FlexLink Spiral Elevator SSC CANON M 7 22 Technical dati marenae 8 2 3 Ordering information 8 24 Operating conditions 9 3 Function and components 11 3 1 Purpose of USE nnen 11 3 2 Description of the Spiral Elevator 12 So ZOOM sneden 16 3 4 Accumulation protection 16 4 Unload the Spiral Elevator 17 AT Cae VON metten 17 4 2 Unloading instructions 17 D Mounting installation GOS USE zept kdo hennekam 21 5 1 Provisions to be provided 21 5 2 Assembly armere 22 Sa VAIAU werner 25 5 4 Integration in a transport SOES R PR OP P bende 26 5478EN 5 5 5 Setting of the Spiral Elevator 27 DO TESCU znate in kou e can 28 6 Technical maintenance 29 Oel 5 10 O R O V O 29 OA 1310 een eee
7. maintenance of the Spiral Elevator Danger Before any maintenance functions are carried out make sure that the main switch has been switched off and safely isolated in order that there is no possibility that the Spiral Elevator can be started unexpectedly It s necessary to perform maintenance activities according to the methods described During maintenance proper and safe tools must be used Before disassembling any part please refer to Section 5 Mounting installation ad justment in this manual 6 1 Slats 6 1 1 Checking slats The slats may partly break off see Fig 32 or be pushed from the chain It may be the result of the products becoming jammed If missing or broken slats are detected these are to be replaced Dirt or product labels sticking to the slats may also make the slats to break or become loose It is therefore necessary to regularly check and clean the Spiral Elevator Make sure to find all parts of the broken slats to ensure that they don t get stuck or jammed inside the Spiral Elevator Figure 32 Example of a broken slat Page 29 of 46 Technical maintenance Flex Link 6 1 2 Replacing slats A Note Damage on the products transported or on the Spiral Elevator may occur if the slats are incorrectly mounted The flaps on the underside of the slats are suited for one time use only Disassembly of the slats from the steel chain can cause damage to the flaps and therefore it is not reco
8. moving within 40 100 mm on the sticker the chain is to long and CAN be shortened Page 31 of 46 Technical maintenance Flex Link Ifthe slat is moving beyond 100 mm on the sticker the chain is too slack and MUST be shortened This doesn t mean that the steel chain must be replaced 0 40 06 08 02 09 os Ov 0e oz OL gt 100 x Figure 36 Distance check for over length 6 2 2 Shorten steel chain If the chain stretch exceeds the limit of 100 mm according to Fig 36 the steel chain must be shortened Shortening the steel chain should be done at the lower end FlexLink delivers a chain tensioner with the machine to assist in this procedure Procedure Every 5 m the steel chain is connected with two connecting links The slats located above these links are marked with two red dots The steel chain can easily be shortened by removing one of these two connecting links e Create access to the steel chain by removing the slats with the red dot plus several slats either side The slats are removed at the end of the lower end unit The procedure for slat removal is detailed in Section 6 1 2 The chain will need to be moved around to access the slats and the procedure for this is detailed in Section 6 2 4 e Remove the security locks from both connecting links Once these have been removed the gold colored plates and the connecting link on the steel chain can be removed e If possible place the chain tens
9. protect the user the product and the Spiral Elevator against undesired situations damage The following table gives a general description of the safety provisions required The safety provisions listed in the table are a general guide only The actual safety provisions to be used must be determined by relevant risk assessment of the overall system Note Only technically qualitied persons should work on and are allowed to change the settings of the safety provisions Page 5 of 46 Safety Flex Link m k E Emergency stop Each Spiral Elevator is to be provided with one or more emergency stop switches that can switch be operated within reach of the user The emergency stop switch must make sure that the input and output conveyors or machines are switched off simultaneously Motor protection The technical specification of the Spiral Elevator is among other things geared to the load given in the technical specification guotation or drawing Should the Spiral Elevator gear motor become overloaded this should be detected by the motor protection in the control system Without this protection there is a risk that the gear motor or other components of the Spiral Elevator will be damaged and this damage will not be covered by the warranty Motor isolation Means of isolating the motor from the power supply must be provided and within close proximity to the motor Operation Remark With a clean floor surface the operator
10. the Spiral Elevator outside of the scope detailed within the technical specification quotation or documentation will invalidate the warranty 2 1 General FlexLink Spiral Elevator specification e 500 mm inclination per winding 9 degree e 3 8 windings e 1 000 mm nominal centre line diameter e Speed 5 60 metres per minute e Lower height 600 700 800 900 or 1 000 mm Adjustable 50 70 mm e Max load 10 kg m specific Spiral Elevators may be with a lower limit due to actual gear motor used e Product size width 50 200 mm length 80 250 mm height 1 5 x Length max 300 mm see Project Documentation if applicable e Drive and idler ends are horizontal e Chain width 100 mm e Friction top chain e Steel chain with bearings running on the inner guide rail e Wet coated mild steel frame e Column diameter 160 mm e M6 thread for guide rail Page 7 of 46 Technical specifications Flex Link 2 2 Technical data 5000 mm Max heigth 8 windings Lower height 800 900 1000 mm 50 100 Machine incl 4 adjustable feet Figure 1 Technical information Spiral Elevator Configuration 2 3 Ordering information Example of a Spiral Elevator designation obtained from the FlexLink product configurator Itemno A B C D E F G H 5995512 100 1000 500 S A TU 800 3 25 5995512 Item number St
11. the lower end e After changing sprockets put in new pre mounted chain at the lower end Page 34 of 46 5478EN 5 Flex Link 94 78EN 5 Technical maintenance e When the chain and all slats are in place start up the Spiral Eleva tor and make sure it runs smoothly and that no noise occur 6 3 Products sliding One of the conditions that apply to the Spiral Elevator is that products being transported should not slide 6 3 1 Checking for products sliding The surface on top of the slats have high friction material to avoid sliding and therefore it should be checked according to Appendix D Observed sliding may have different causes for example e Worn high friction surface on slats which then needs to be replaced with new e Contamination on the Spiral Elevator slats or product This foreign matter must be removed by cleaning 6 4 Sprocket wheel 6 4 1 Align sprocket wheel at lower or upper end If the Spiral Elevator does not run smoothly or is noisy one of the sprocket wheels at the ends may not be aligned correctly This may cause extra wear of the steel chain and sprocket wheel Procedure e Make sure that the main switch has been switched off and safely isolated e Remove 7 8 slats at the lower end so that the sprocket wheel is visible see Fig 40 and Fig 41 It s only possible to remove slats at a small area at the lower end and therefore you have to toggle the Spiral forward for removal of mo
12. the machine for example damage of products interruption of operation etc 3 1 Purpose of use The purpose of use of the Spiral Elevator is to transport products goods in a vertical direction This may be for bridging a difference in height or for functioning as a cooling buffer It should not be used for transporting products with parts that are protruding hanging loose or for transporting products that result in a higher load than mentioned in the documentation Neither for transporting products with measurements deviating from the data given in the technical specification associated with the particular Spiral Elevator Contact FlexLink if any doubts Additionally it is not permitted to walk stand or sit on the Spiral Elevator or to stick objects or body parts between the guards slats or other moving parts Page 11 of 46 Function and components Flex Link 3 2 Description of the Spiral Elevator The Spiral Elevator is applied in a transport system where products can be transported vertically in a relatively small area The height of the Spiral Elevator is dependant upon the low level height plus the number of windings of the spiral see Technical specifications on page 7 The Spiral Elevator can be coupled to other transport systems and be built according to the customer s needs 1 Chain 2 Upper end 3 Lower end 4 Return part 5 Position gear motor gear motor not shown O1 In out
13. to Fig 43 e After this the screw that s connecting the torque arm Fig 44 with the Spiral Elevator should be loosened The gear motor can then be removed Fig 45 Figure 43 Dismounting of screws Figure 44 Screws torgue arm Figure 45 Motor removed Page 36 of 46 5478EN 5 Flex Link Technical maintenance Once the gear motor has been removed the grub screw in the locking rings of the bearing blocks Fig 46 can be loosened The bearing blocks can then be removed and slid off of the ends of the shaft The shaft with sprocket wheel can then be removed from the end unit see Fig 47 Figure 46 Bearing block with locking Figure 47 Shaft with sprocket wheel ring A 6 4 3 Note The shaft and sprocket are removed as one piece Make note of the orientation of the sprocket wheel on the shaft before replacing it Re fitting is the reverse procedure of the removal After assembly the Spiral Elevator must be set up according to Section 5 5 then test runned and checked according to Section 5 6 and Appendix C to ensure correct run Replace sprocket wheel lower end Procedure 5478EN 5 Remove the slat with the colored dot Under this slat there is a locking link and the steel chain can be separated here The sprocket wheel is now released from the steel chain Remove the slide rails to allow necessary space for subsequently remove shaft and wheel Fig 48 Loosen the central screw on ea
14. to an adjoining conveyor 5 2 Assembly This paragraph describes a number of operations for Spiral Elevators that are not delivered fully assembled 5 2 1 Gear motor The gear motor may be delivered separately with the Spiral Elevator and then has to be mounted on site A first check if all the required parts are present e Gear motor e Grease e Torque arm e Key for shaft e Fasteners screw and washer The key and torque arm fastening to the frame may be preassembled Page 22 of 46 5478EN 5 Flex Link Mounting installation adjustment Procedure Determine the installation orientation of the gear motor according to Fig 20 Add 0 2 oil in this position Figure 20 Mounting positions if motor is supplied from FlexLink The conveyor and gear motor shown below are not necessarily the same type as supplied e Apply installation grease on the shaft to slide the gear motor onto the shaft easier and prevent any contact corrosion Fig 21 e Attach the torque arm to the gear motor with appropriate fasteners see Fig 22 e Place the locking ring circlip in the gear motor or move to the desired groove in gear motor if not already in the correct posi tion see Fig 23 Figure 21 Applying grease on shaft Figure 22 Attaching torgue arm Figure 23 Placing the locking ring e Inthe correct orientation slide the gear motor Fig 24 on the shaft up til the locking ring aligning the key
15. will not be hindered while operating the Spiral Elevator This can prevent tripping or slipping so that the operator does not unexpectedly come into contact with the Spiral Elevator Hearing protection Different tests have shown that the Spiral Elevator does not produce more than 85dB A Clean floor surface Height width In order to ensure that product cannot become jammed in the Spiral Elevator due to oversize detector some automatic checks for width and height can be done If used this detection must take place before the product enter the Spiral Elevator in order to stop the product or Spiral Elevator Transition guard The basic Spiral Elevator is not supplied with any guarding at the drive idler ends A risk assessment should be conducted with consideration to the adjacent conveyors equipment product etc to establish any requirements for guarding Back flow No accumulation is allowed on the machine install a back flow protector to shut down the protection gear drive s when there is accumulation The basic Spiral Elevator is not supplied with back flow protection Page 6 of 46 5478EN 5 Flex Link 94 78EN 5 Technical specifications 2 Technical specifications This section lists the technical specifications of the Spiral Elevator Further product details to which the Spiral Elevator has been designed are contained within the overall Project Documentation when purchased as part of a Project System Use of
16. 5478EN 5 Spiral Elevator User Maintenance Manual E L p j i a fo af i r s j 4 A F f T 1 T j i i r i fi ji d P f h j j fi d Flex Link o478EN 5 Spiral Elevator User Maintenance Manual Flexlink AB 2015 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 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 AB and are believed to be true and accurate as of time of publishing However due to continued efforts in product development FlexLink AB reserves the right to modify products and its manuals without notice FlexLink 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 AB product part documentation discrepancies and errors or non anticipated program behavior are limited to the value of appropriate products purchased from FlexLink 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 AB and user User accepts and is obliged to
17. 6 is read understood and followed If any questions or problems occurs and can t be solved please contact FlexLink before continuing the integration Visual check Check for jammed parts or items touching the Spiral Elevator chain links and do not start or stop immediately if this is the case Make sure to remove items and continue Check the rotation direction of the chain If this is not correct then make necessary adjustments to the electrical control circuit or system Check whether the slats have been mounted correctly and that chain and slats run evenly over the slide rail Check whether the chain runs smoothly and without any abnormal or significant noises The chain should move evenly and without jerking motions Look at the behavior of the chain and operation of the drive If any problems switch off the Spiral Elevator immediately and investigate and remedy the cause using Appendix C and or the troubleshooting list in Appendix E Repeat the checks in step 3 above Check for peculiar sounds or unusual movements related to the Spiral Elevator Repeat the checks in step 3 above aa m Yes No minutes 10 10 Yes No minutes 0 1 Yes No minutes 5478EN 5 Flex Link B Checklist Integration in a transport system After the integration the checklist given below should be completed to ensure a satisfactory integration Lower end Is the lower end at the correct height and is
18. Elevator it will continue along the system The chain returns in the underside of the Spiral Elevator to the input position 5478EN 5 Page 13 of 46 Function and components Flex Link 3 2 2 Components and parts Spiral Elevator Central column A Lower end unit B Upper end unit Bearing for chain Link Slide rail NE 5 Sprocket or 2 Sprocket wheel 3 sooo Sprocket or 8 J Sprocket wheel Bearing housing with bearing o Figure 4 Components conveyor chain conveyor drive end and gear motor 1 Slat 4 Bearing Narrow plastic slat provided with a bearing Bearing for the slat The slats are mounted in a row on the steel 5 Gear motor chain and so form the transport surface Optional 2 Steel chain o l l l 6 Drive shaft This is a laterally flexible steel chain on which the slats are mounted 7 Sprocket wheel 3 Link 8 Torque arm Links of steel chain Type specific dependent upon gear motor type Chain slats The chain consists of a steel chain connecting links and slats with bearings Page 14 of 46 5478EN 5 Flex Link o478EN 5 Function and components Fig 3 and Fig 4 The top of the slat has a high friction material to ensure no sliding of products on the chain The chain rotates in a spiral form around the central cylinder and is guided on the plastic slide rail The chain is driven by the gear motor Frame The b
19. Subsequently an initial test run should be made with the Spiral Elevator in an unloaded condition 5 3 1 Dimension check Spiral Elevator The technical specification and or relevant drawing can be used for the dimension check Page 25 of 46 Mounting installation adjustment Flex Link 5 3 2 Adjusting and setting the Spiral Elevator initial test run A Warning t is not recommended to make a test run with the machine while safety provisions have been deactivated or guards removed Make sure there are no unauthorized persons near the Spiral Elevator The initial test run is carried out according to Appendix A Before the start of the initial test run make visual checks for jammed parts or items touching the Spiral Elevator and stop immediately if any exist During the initial test run pay attention to the correct rotation direction of the chain look at the behaviour of the chain and the operation of the drive The chain should move evenly and without jerking motions If during the test run abnormal sounds are heard or if there is an impression that other irregularities occur immediately switch off the Spiral Elevator investigate and remedy the cause The checklist in Appendix C and the troubleshooting list in Appendix E may be of assistance If the problem cannot be solved please contact FlexLink for advice before continuing the integration When read and taken notice to the previous text the initial test run and
20. Teflon based oil see Fig 55 Never use a silicone based cleaner Mila Soap Figure 55 Cleaning procedure 6 5 2 Replacing the slide rail Replacing the slide rail should be done as follows The spring pins are placed with two springs in each end of the slide rail and with a CC distance of 20 mm The following pins are placed with one pin every 300 mm according to Fig 56 Figure 56 Positioning of spring pins mm Recommended tools Pin punch 3 mm Screwdriver slotted Plastic rubber mallet Procedure Make sure that the spring pins are well driven inside the slide rail and not sticking out on the top or bottom Page 39 of 46 Technical maintenance Flex Link e Punch out the spring pins with a pin punch 3 mm and a hammer according to Fig 57 e Bend off the slide rail with an flat ended screwdriver for example Fig 58 e Push on the new slide rail according to Fig 59 e Replace the spring pins Make sure that the spring pins are well driven inside the slide rail and not sticking out in top or bottom Fig 60 e _ Its recommended to check the slide rail with an piece of one meter transport belt Figure 57 Punch out pins Figure 58 Bend off slide rail Figure 59 Mount new slide rail Figure 60 Replace spring pins 6 6 Maintenance schedule Spiral Elevator The list in Appendix D lists the general maintenance operations which must be carried out at the normal time intervals for those mai
21. acturer series or type indication serial number and the year of construction of the Spiral Elevator Gear motor plate Mapas DTBON4 MMO7 MLU BU This indicates the gear motor type H6O 01562883 01 0001 09 3 N2A l 570 75 Sl cos tt NKK applicable voltages power oil type 280 1408 15 73 etc Chain over length sticker This is a scale in mm used to determine if the chain is to long see Fig 6 2 1 Page 3 of 46 Safety 1 2 Flex Link The most important safety conditions To correctly use the equipment operators must have appropriate training and or experience At the moment that the elevator is going to be operated by a user the following safety conditions must be met 1 2 1 1 2 2 Make sure that children and animals have no access to the machine and its surrounding area by for example screenings off elevator with a fence Only persons who have read and understood the operating instructions are allowed to operate maintain and clean the machine Do not reach into the machine while it is on or running Even if the machine is not running it can be on which means start operating automatically Safety provisions must not be removed or deactivated while the elevator is running Provide good ambient lighting to enable the operator to work well and orderly with the elevator General Incorrect use of the equipment can cause personal injury Do not stand or climb on the equipment
22. andard 5995958 Item number Fast track Page 8 of 46 5478EN 5 Flex Link 94 78EN 5 Technical specifications Chain width Spiral center of chain diameter Incline per winding Mild steel S material configuration Configuration e g A see Fig 1 Transport direction up down TU or TD Lower height 600 700 800 900 1 000 Ion m UO U gt Number of windings 3 8 Standard Number of windings 3 4 Fast track Shaft diameter 20 mm for gear motor type SA37 25 mm for gear motor type SA47 30 mm for gear motor type SA47 For more information please contact your local FlexLink office 2 4 Operating conditions The circumstances under which the Spiral Elevator can be operated partly depend on the materials selected FlexLink has defined a number of parameters within which the Spiral Elevator would be allowed to function Should the Spiral Elevator still be operated beyond these limiting values FlexLink cannot guarantee the good functioning of the Spiral Elevator Ambient temperature in operation O to 35 C During transport storage 5 to 40 C Relative air humidity RH 30 to 95 not condensing Lighting Normal ambient lighting Height Up to max 2 000 m above sea level No lighting is installed or can be added as an option on the Spiral Elevator but normal ambient lighting is sufficient to work safely The Spiral Elevator is not intended for use in an open air environment or in an area with
23. ar Replace steel chain see Section 6 2 5 5478EN 5 VII Flex Link Check products sliding Sliding products may damage the Spiral Elevator or components of it which can lead to downtime See Section 6 3 Check slide rails for pins sticking Monthly Replace any broken or faulty slide rails See Section out rails coming loose from 6 5 profile cracks or pressure damages Check smooth and even motion Troubleshoot and trace the relevant components of chain in the Spiral Elevator VIII 5478EN 5 Flex Link E Troubleshooting list If no solution of the existing problem can be found or fixed contact FlexLink The warranty will not apply if the instructions in this manual is not followed Spiral Elevator No power volts at the gear motor doesn t start Broken or misaligned slats Product stops due to defective slats 2 The motor is running but the Spiral Elevator doesn t work 5 Product jams beneath guide rail 5478EN 5 Gear motor defective Worn teeth on the sprocket wheel The steel chain is not located on the sprocket Product jamming the Spiral Elevator Product weight overload too much product or weight on the Spiral Elevator Broken steel chain Product jamming the Spiral Elevator Irregularities on slide rail Foreign objects material on chain Chain too long which makes the slats grab at the entry to the underside return guide Missing or defective slat
24. asic frame of the Spiral Elevator consists of a central column an upper end B a lower end A and a base frame that is attached to the floor surface see Fig 3 Both the upper and lower end may function as the input or output part Gear motor In Fig 3 the gear motor in Fig 4 is mounted on the drive shaft in the Spiral Elevator s upper end The standard Spiral Elevator is not delivered with a gear motor However a gear motor may be added as a part of the supply contract Suggested gear motor specifications can be obtained from the FlexLink Configurator or from FlexLink The gear motor requires a Torque arm kit and a Absorber kit to prevent rotation and two types are available as follows e For SA37 type gear motors Torque arm kit 5057039 Absorber kit 5113736 e For SA47 type gear motors Torque arm kit 5050459 Absorber kit 5113736 On the driving shaft a sprocket wheel has been mounted that is connected to the steel chain see Fig 4 Guide rail optional The guide rail ensures that the transported products follows the chain and prevent them from falling off the Spiral Elevator Page 15 of 46 Function and components Flex Link 3 3 Control units As a standard the Spiral Elevator is delivered without any control system It is the responsibility of the system integrator installer to design a suitable control system It is preferable to install an isolating switch Fig 5 for the gear mot
25. ation adjustment e To attach the brackets to the conveyor sides use M8 screws The length depends upon the guide rail bracket arrangement used but should not protrude in to the beam profile by more than 10 mm e With the brackets in place the guide rail profile can be mounted to the brackets and clamps Finished result in Fig 31 Figure 30 Lugs to be removed Figure 31 Connection mounting bracket If the guide rail are FlexLink polyethylene XLRS 3x15 P type pre bend a 150 mm long and 10x10 mm metal bar or an 10 mm metal rod to the radius of the quide rail and insert it in the quide rail at each end to ensure rigidity at the ends Make sure that there s a smooth connection between the guide rail joints to ensure product passes along the guide rail unhindered Products that are transported can make contact with the quide rail which may damage the guide rail A damaged quide rail can result in products getting stuck or damaged Check therefore that the guide rail is free from irregularities and adjust or repair if necessary The guide rail width setting can be adjusted at in feed and out feed ends of the Spiral Elevator in order to align with the feeding and receiving conveyors This may depend upon which guide rail and brackets are fitted It may be possible to flare out the guide rails at the in feed end of the Spiral Elevator 5 3 Validation Initially the validation checks should be for visual condition and dimensions
26. ch side of the shaft at the lower end Fig 49 Page 37 of 46 Flex Link Technical maintenance e When the screws are removed the shaft with the sprocket wheel can be lifted slid out Fig 50 Figure 48 Dismounting of slide rails Figure 49 Dismounting of shaft Figure 50 Sprocket wheel released from steel chain A Note The shaft and sprocket are removed as one piece If replaced as individual items make note of the orientation of the sprocket wheel on the shaft e Re fitting is the reverse procedure of the removal e After assembly the Spiral Elevator must be set up according to Section 5 5 then test runned and checked according to Section 5 6 and Appendix C to ensure correct run 6 5 Slide rail 6 5 1 Maintenance of the slide rail Checking of the slide rail must be done at the location where the most pulling force is present This position is just before the drive shaft Check monthly for following in Fig 51 Fig 52 Fig 53 and Fig 54 If one of these are noticeable then the slide rail of the entire Spiral Elevator should be replaced LFR Figure 51 Pin sticking out Figure 52 Slide rail coming Figure 53 Cracks inside Figure 54 Pressure damage loose of the profile from the profile at the contact point by the bearing the frame Page 38 of 46 5478EN 5 Flex Link 94 78EN 5 Technical maintenance Cleaning of the slide rail must be done with a non aggressive cleaner mild soap or a
27. e condition of transfers Any transfers supplied as part of the system are in addition to the standard Spiral Elevator and generally these transfers are not powered therefore some product may remain on the transfer depending upon various factors such as speeds condition size or weight of product Flex Link ke jee ee Is the product oriented correctly The design of the adjoining eguipment should be checked during transportation on and off Vest No the transfer of the Spiral Elevator Is the product properly Generally the product will not twist whilst travelling up or transported throughout the Spiral down the Spiral Elevator If undue twisting does occur Yes No Elevator contact FlexLink Are there any protrusions or The product should not stick or jam against the guide rail Yes No irregularities along the guide rail see Appendix E If all items above have been complete and the Spiral Elevator runs satisfactorily gradually add products up to 50 of the specified feed rate as detailed in the technical specification or Yes No quotations and then perform step 1 12 again If all items above have been complete and the Spiral Elevator runs satisfactorily gradually add products up to 100 of the specified feed rate as detailed in the technical specification or Yes No quotations and then perform step 1 12 again Safety provisions Should the safety provisions not function as expected they should be
28. ee ae ener 31 6 3 Products sliding sesestuccssrevencevasunencer 35 6 4 Sprocket wheel 35 OS MAGE R O O OE 38 6 6 Maintenance schedule Spiral EIO O SP O O O 40 6 7 Cleaning and maintenance procedure Spiral Elevator 41 7 Put out of COMMISSION 43 7 1 Disconnect the power sources 43 7 2 Disassemble o 43 Ja POISON zenmensen 43 Zk B 0 0 57 sonen 44 TAS PeSS mm 44 8 Supplier s information 45 Appendix A Checklist Initial test run B Checklist Integration In a transport system lt i C Checklist Test run V D Maintenance schedule VII E Troubleshooting IST IX F Spare parts list Spiral Elevator xI Flex Link 94 78EN 5 Preface Purpose of this manual Before using the Spiral Elevator it is mandatory to have read and understood the information in this user manual such as Section 1 Safety and Section 6 and Section 6 7 regarding maintenance The warranty will not apply if the instructions in this manual is not followed The purpose of this manual is to describe various operations that are intended for the user to perform This document contains remarks that point out a risky or specific situation to the user In many cases this situation is provided with symbol below General warning for danger Warning for electrical voltage Attention this is an important notice gt gt p Compliance with the o
29. feed configurations Figure 2 Principle sketch Transport direction up Configuration operations Before the Spiral Elevator is put in to service a suitable Risk Assessment should be completed After integration installation the Spiral Elevator should not be relocated without further Risk Assessment 3 2 1 Configuration input output In most cases the Spiral Elevator is integrated into a system The input output side of the Spiral Elevator is determined dependent on the system The configuration of the Spiral Elevator is available in different formats with regard to input output positions These configuration types are expressed in the letters A to H see Fig 2 For any special configurations please con tact FlexLink Page 12 of 46 5478EN 5 Flex Link Function and components In following example it is assumed that the input is at the lower end of the Spiral Elevator and that the product will bridge a difference in height in order to continue the required transport on the output Input end The product is transferred onto the input of the Spiral Elevator The gear motor drives the chain with the required speed Transport of Products Subsequently the product on the chain will travel around the Spiral Elevator and bridge the height difference between input and output Output end When the product arrives at the output of the Spiral
30. g sound is present Are any slats moving unexpectedly at any position throughout the Spiral Elevator Are there any slats which are raised at any position Are there any damaged slats or is there friction material missing Are slats touching the frame the guide the guard or anything else Do all products fit on the chain Do any products slide off of the chain Are there any products that do not continue on or off the transfer of the Spiral Elevator 5478EN 5 Can be due to incorrect tension of the steel chain slats are loose or a sprocket wheel is not aligned see Appendix E Can be due to incorrect tension of the steel chain slats are loose or a sprocket wheel is not aligned see Appendix E Can occur if some slats are loose see Appendix E Can be due to loose slats or if a sprocket wheel is not aligned see Appendix E If so the slats must be replaced see Section 6 1 2 Adjust the guide or the guard and carefully check the correct setting dimension of this Check in the Section 2 1 quotation or drawing for specified product dimensions Are the conditions sizes and weights of the products correct according to Section 2 1 quotation or drawing Is there any foreign substance on the product or Spiral Elevator reducing the effect of the friction material see Section 6 7 Sliding of products should never occur check Appendix E and if problem still remains contact FlexLink Check th
31. he now horizontal position and re fit to the other holes in the frame to have the feet in the vertical position Fig 16 e Check and confirm that all screws and bolts in the lower frame feet and stay brackets are in place and secure Fig 17 e Lower the Spiral Elevator down on to the floor Fig 18 Figure 15 Remount the part of frame removed from the top of column to the fixed frame at the base Figure 16 Dismount the Figure 17 Assemble and fix the part of Figure 18 Final result transport feet from the frame in to fixed base frame using the transport position and four bolts and nuts remount in correct holes e Move the Spiral Elevator to final position taking care not to place undue side load on the feet to avoid damage If the Spiral Elevator is moved using a forklift or Pallet Truck great care must be taken due to the height of the Spiral Elevator to ensure that it does not topple over e The Spiral Elevator can be adjusted to give the correct height see Section 5 1 1 Floor attachment construction Page 20 of 46 5478EN 5 Flex Link 94 78EN 5 Mounting installation adjustment 5 Mounting installation adjustment This section deals with the installation and adjustments of the Spiral Elevator Section 1 Safety should be read and understood before installation 5 1 Provisions to be provided 5 1 1 Floor attachment construction When the Spiral Elevator is in the correct position the Spiral Elevator
32. hed to two positions around the central column see Fig 6 Figure 6 Illustration using slings 4 2 1 Erecting the horizontally delivered Spiral Elevator This is relevant for taller Spiral Elevators which are transported in the horizontal position Fig 7 Warning t is forbidden to walk under the Spiral Elevator during the procedure of rising the Spiral Elevator Note Make sure there are no unauthorized persons near the Spiral Elevator while rising the Spiral Elevator Before raising to upright be sure that there s enough space height to rise the Spiral Elevator When rising or moving the Spiral Elevator make sure that the floor is level clean and has sufficient load carrying capacity It is generally safer to move the Spiral Elevator to a position close to the final area with the Spiral Elevator remaining on the delivery packing where applicable Dependent on the situation the Spiral Elevator can be raised to upright using a hoist a crane or a forklift Page 18 of 46 5478EN 5 Flex Link Unload the Spiral Elevator Procedure typical method utilizing a hoist Carry out these operations calmly in order to be able to carefully monitor any movement of the Spiral Elevator The hoisting device is to be fastened to the cylinder at the top of the Spiral Elevator Fig 8 Whilst hoisting the hoist should be well fixed and aren t to be able to ride shift away unexpectedly Use lifting eyes and shackles if no bar in t
33. ical maintenance Flex Link 6 2 4 To move the chain within Spiral Elevator To shorten the steel chain the slats with colored dots must be removed see Fig 33 Fig 34 and Fig 35 This is done by moving these slats to the end of the lower end unit Procedure e Make sure that the main switch has been switched off and safely isolated e Ensure that the Spiral Elevator is free of products e Release the brake if present on the gear motor so the chain can move freely e Depending upon the ratio of the gear motor it may be necessary to remove the gear motor e Check the chain moves in the Spiral Elevator smoothly A Note f the rotation feels very heavy it s possible that the chain Is jamming somewhere Check the chain and remove any possible obstruction Make sure the brake is released 6 2 5 Replace steel chain If the steel chain is too long or doesn t run smoothly it has to be changed and thereby also have to change the sprocket wheel Procedure e Make sure that the main switch has been switched off and safely isolated e Ensure that the Spiral Elevator is free of products e Release the brake if present on the gear motor so the chain can move freely e Depending upon the ratio of the gear motor it may be necessary to remove gear motor e Remove the slats with the red dots on and then open up the steel chain by removing one of the locking links Pull out all chain from the Spiral Elevator at
34. imilar to the unit used for the initial delivery of the Spiral Elevator Page 43 of 46 Put out of commission Flex Link While transporting the Spiral Elevator a number of safety measures are to be taken Use the same tools and equipment as indicated in Section 4 for the Unloading of the Spiral Elevator A suitable Method Statement and Risk Assessment for the dismantling and transportation should be done by the relevant responsible person This Method Statement should be followed throughout the decommissioning process Transport of the Spiral Elevator in the vertical or horizontal mode depends upon the access route vehicle height and general height of the Spiral Elevator As a quide all Spiral Elevators with a total height above 2 4 m should be transported in the horizontal mode 7 4 Disposal If the Spiral Elevator is to be disposed of then all current regulations for the country and local authorities must be adhered to The main materials within the Spiral Elevator can vary depending upon the design of the Spiral Elevator and any accessories attached to the Spiral Elevator such as guide rail parts 1 5 Reuse A Note Putting the Spiral Elevator out of commission or in to a new use must only be carried out by technically qualified personnel If the Spiral Elevator is to be re used for another application then full details must be checked to establish whether the Spiral Elevator is suitable for this new applica
35. ioner at both loose ends of the steel chain and turn it until both ends meet see Fig 38 e Replace one connecting link including the security lock and the steel chain is then shortened Return the chain back to the service location and replace chain with new slats Make sure you place a marked slat over the connecting link on steel chain Page 32 of 46 5A78EN 5 Flex Link nn e Ifthe steel chain is still too long repeat this procedure at another location which still has two connecting links At least one connecting link must remain at each relevant location Figure 37 Working room lower end Figure 38 Tensioning the steel chain 6 2 3 Check chain stretch Procedure e Make sure that the main switch has been switched off and safely isolated e At the idler or drive end of the Spiral Elevator stretch at least 8 slats apart Measure the distance between the start of slat 1 and the start of slat 8 i e the pitch across 7 slats see Fig 39 For a new chain this distance is 267 mm e Therefore the steel chain must be replaced when the measured distance is more than 271 mm e Refer to Appendix F for spare part numbers and contact FlexLink to procure the necessary parts e If the chain will be replaced make sure to also replace a new sprocket Maximum distance 271 mm NOTE Measure from start of slat no 1 start of slat no 8 Figure 39 Tape measure on chain 5478EN 5 Page 33 of 46 Techn
36. issioning should be undertaken in a safe and controlled manner This section details the items which must be done for this decommissioning While dismounting the machine the regulations for waste processing applicable for the country and local authorities at the time of the dismantling are to be complied with The machine only contains commonly known materials At the time of assembly and delivery of the Spiral Elevator there were processing possibilities for these materials and no particular risks were known for persons involved in the dismantling process 7 1 Disconnect the power sources Danger First switch off the main switch before the power source may be disconnected The main power isolator must be turned off and locked off or power permanently removed from the isolator If the isolator is mounted on the Spiral Elevator the power supply must be permanently removed from the isolator This is to ensure that there can be no electrical supply to the gear motor connections either before or after the gear motor is removed 7 2 Disassemble The disassembly of the Spiral Elevator generally requires few operations Depending upon the height of the Spiral Elevator it may be required to lay the Spiral Elevator horizontal If this is necessary the procedure for this is generally the reverse of the procedure used to stand up the elevator detailed in Section 4 2 1 7 3 Transport Note A transport frame base should be used which is s
37. lowing e Technical specification e Quotation e Drawing Order Any deviation must be notified to FlexLink immediately 4 2 Unloading instructions Initially the Spiral Elevator should be removed from the delivery vehicle by lifting the Spiral Elevator complete with any pallet base and or packing materials Before starting unloading all fastening means securing belts screws etc that secure the Spiral Elevator onto the transport vehicle must be re moved It is preferable to move the Spiral Elevator complete with any pallet base and or packing materials to an area near to the final position and then unload the Spiral Elevator and place it directly on the floor whilst taking care not to cause any damage to the painted surfaces The Spiral Elevator s delivered horizontally or vertically dependent on the dimensions If vertically delivered it can be lifted using a forklift under the Page 17 of 46 Unload the Spiral Elevator gt P Flex Link base frame or by using a sling and suitable eye bolt in the top of the central column If the Spiral Elevator is delivered horizontally it can be lifted using a truck with forks spaced wide apart and inserted under the horizontal central column Soft packing should be used between the forks and the central column to avoid damage and marking Care must be taken to avoid the Spiral Elevator rolling whilst on the forks Alternatively slings can be used and attac
38. mmended to re use slats If a slat breaks make sure to find all the broken parts to ensure that no parts get left behind or stuck inside the Spiral Elevator Each 5 metre of steel chain is connected by two connecting links To locate these links the slats above them are marked with red dots Make sure that the correct slats are replaced back onto the chain possibly marking them If a slat is replaced because of a missing slat the chain tension should be checked Procedure e Make sure that the main switch has been switched off and safely isolated e The slat can be replaced at the lower end of the Spiral Elevator e The slat is clicked onto a connection link with two lugs underneath and can be removed from the steel chain by spreading these lugs Pull back on both tips of the slat while keeping your thumbs pressed on the centre of the slat Fig 33 and Fig 34 The slat lugs will now be spread so that it can be pulled from the steel chain see Fig 35 Repeat this procedure if more than one slat needs to be removed Figure 33 Press thumbs on the centre of Figure 34 Increase pressure on centre Figure 35 Slat removed the slat of slat to make the lugs to spread e New slats can now be placed on the steel chain Make sure that the slat is always placed on the connecting links of the steel chain and that the bearing on the slat is placed on the column side of the track Pull back on both tips of the slat while keeping your thumbs
39. ntenance operations The maintenance intervals are for a Spiral Elevator operating in normal conditions with single shift working 8 hours per day and in a normal environment For more working hours or for an environment which has more dirt or abrasive particles around or on the Spiral Elevator the end user must decide upon the appropriate maintenance intervals taking in to account all of the conditions To achieve good working life from the Spiral Elevator the various maintenance items must be done correctly and at the correct time intervals Only replacement parts detailed within the recommended spare parts listing detailed in Appendix F should be used The use of other parts which are not detailed within the spare parts list will invalidate the warranty Page 40 of 46 5478EN 5 Flex Link 94 78EN 5 A JAN Technical maintenance For any warranty issues for the Spiral Elevator all of the maintenance operations and times must be fully documented and kept in a suitable main tenance log or the warranty will be void 6 7 Cleaning and maintenance procedure Spiral Elevator Danger Make sure that the main switch has been switched off and safely isolated Warning Do never attempt to climb the machine to reach higher levels but use adequate and approved climbing materials The Spiral Elevator consists of a steel coated frame steel chain shafts and other components A regular scheduled cleaning of the Spiral Eleva
40. op of column see Fig 9 Raise the top of the Spiral Elevator around 200 mm and stop Remove the frame with feet which is temporarily mounted to the Spiral Elevator column top Fig 10 Figure 7 Spiral Elevator in Figure 8 Hoist fastened to Figure 9 Using lifting eyes and Figure 10 transport position column top under bar in top of shackles in top of column Lifting Remove upper column eyes and shackles to be supplied part of frame A 5478EN 5 by customer Raise the Spiral Elevator until lifted completely from the floor see Fig 11 Take care not to put excessive side load on the feet to avoid bending or damaging them Note Be aware that the Spiral Elevator may tip at the moment it is near to the upright position Fig 12 Remove feet which now is in a horizontal position Fig 13 and re fit to the other holes in the frame to have the feet in the vertical position Fig 14 Set the adjusting feet to the lowest height for a minimum risk of damage Fig 14 Page 19 of 46 Unload the Spiral Elevator Flex Link Figure 11 Lifting Spiral Figure 12 Risk of tipping Figure 13 Dismount the adjusting Figure 14 Remount and set the Elevator when almost vertical feet from transport position adjusting feet e _Re attach the frame with feet Fig 15 to the final position at the bottom of the Spiral Elevator column Attach the stay brackets between the Spiral Elevator column and the bottom frames e Remove feet from t
41. or and it should be of a type able to be padlock off With this switch the power to the gear motor can be switched locked off in order to ensure safe working on the Spiral Elevator The designer of the Control System should evaluate the requirements of other devices such as Emergency stops etc in order to provide a safe working system Figure 5 Example of an isolator 3 4 Accumulation protection No accumulation is allowed on the Spiral Elevator To prevent accumulation jams a sensor should be installed on the in feed conveyor before the Spiral Elevator and on the out feed section of the Spiral Elevator to measure product spacing When product spacing is no longer detected the sensor should switch off the drive motors of the in feed belt Spiral Elevator and out feed belt Page 16 of 46 5478EN 5 Flex Link 94 78EN 5 Unload the Spiral Elevator 4 Unload the Spiral Elevator 4 1 Preparation Before starting the unloading good preparation is reguired The appropriate devices must be available The Spiral Elevator must be visually checked e Before off loading from the delivery vehicle e Immediately after off loading e Immediately after unpacking Any damage must be detailed on the delivery note before signing for acceptance of delivery and also notified to FlexLink in order to possibly progress any warranty claim Details of the dimensions and technical specifications are available on one or more of the fol
42. perations described in this document is important in order to prevent dangerous situations and unnecessary damage to the Spiral Elevator It is recommended to keep one copy of this manual 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 operations can quickly and easily be found This manual does not describe operations that are not intended for the user to perform The users manual has been divided into sections which describe a variety of functions including the safety and the safe operation of the Spiral Elevator It is recommended that this manual is read by all users of this equipment with particular reference to Section 1 on page 3 Safety and maintenance Section 6 and Section 6 7 Page 1 of 46 Flex Link Requirements of the user The Spiral Elevator should only be operated by a person who has become acquainted with Section 1 Safety and trained in the use of the unit The Spiral Elevator should only be installed by persons who have become acquainted with Section 4 Unload the Spiral Elevator and Section 5 Mounting installation adjustment All users must have read and understood Section 6 and Section 6 7 regarding Maintenance of the Spiral Elevator Note Maintenance activities on the Spiral Elevator should only be carried out by a technically qualified person Technically qualified employee
43. product amp specification the actual transfer may vary Oil leaking on the seal between drive shaft and motor Torque arm locked too tightly which may cause torsion between shaft and motor shaft hole Gear motor becoming too hot due to overload Noise level from the Spiral Elevator is above normal Chain tension Check cause of products incorrect orientation Contact FlexLink The feed rate of the product is too high for the Spiral Elevator speed Check to see if why the feed rate is above the specification or why the Spiral Elevator speed is below the specification Typically the products should have a minimum distance between of 25 of the product length Align the product before the Elevator Shorten the steel chain Check the specification in Section 2 for the maximum product weight or contact FlexLink Transfer unit not aligned correctly Align the transfer unit Transfer unit dirty Clean the transfer unit Replace the seal and look whether the mounting causes the problem Check cause of overload and remove Replace gear motor or seal Sprocket wheel not aligned Align sprocket wheel Check the chain tension and shorten the steel chain if necessary Broken slats Check chain and replace the slat s Oil level on gear motor Contact the gear motor manufacturer Worn high friction surface on slats Replace the affected slats Contamination on Spiral Elevator slats or on product P
44. re slats Two slats can be re moved before toggling is necessary e In lower end measure the distance from the side plate to the mid dle of the steel chain as seen in Fig 40 To adjust the sprocket wheel release the socket head screw Fig 42 and then move it to correct position Don t forget to tighten it after the adjustment To check the upper end run the Spiral until the part of the steel chain with no slats appears in the upper end see Fig 41 and then measure and make the adjustment if necessary Correct measure upper and lower end 49 1 mm Page 35 of 46 Technical maintenance Flex Link e Replace the removed slats after the adjustment In the upper end run the spiral until the steel chain is visible in the lower end and mount the slats When all slats are in place start the Spiral Elevator and make sure it runs smoothly and that no noise occur 49 1mm 49 1mm Figure 40 Lower end Figure 41 Upper end Figure 42 Socket head screw 6 4 2 Replace sprocket wheel upper end Procedure e Make sure that the main switch has been switched off and safely isolated e Remove guides at upper end e Remove the slat with the colored dot Under this slat there is a locking link and the steel chain can be separated here The sprocket wheel is now released from the steel chain e Dismount the gear motor from the shaft This is done by removing the screw mounted in the hollow shaft of the gear motor according
45. roducts sliding Clean the contaminated parts investigate and correct the source of the problem Poor product transfer Product stoppage Repair the transfer unit if faulty on or and off the X o478EN 5 Flex Link Item Description Part No 1 Slat kit 5119707 2 Bearing kit 5112486 3 Connection link kit 5112487 4 Sprocket wheel 5112488 5 Bearing 5112489 6 Steel chain 5112491 7 Slide rail kit 5112492 8 Sprocket wheel 5112493 9 Slide guide kit 5116179 A 10 Guide kit lower 5119549 10 Guide 5115568 B 11 Guide kit upper 5119550 11 Guide 5117173 12 Guide rail kit 5119551 13 Chain pre mounded kit 5120032 5478EN 5 Spare parts list Spiral Elevator Use of other parts which are not detailed within the spare parts list will invalidate the warranty Bon BS FAF Recommended Comments spare parts 20 pcs 20 pcs 3 4 steel 5 pcs 3 4 19T for shaft 30 mm 3 4 Side flexing L 5 m 8no connecting links included 20 meter slide rail 24x18 single ditch SV with 12 pins 3mm drill bit 3 4 19T for shaft 20 mm L R guide 12 pins drill bit and assembly instruction L R Pre mounted chain L 5 m 2 connecting links slats bearing connections link steel chain Xl 5478EN 5
46. s Product height is too low for guide rail The cause for lack of power to be investigated by qualified personnel Replace the motor Replace the sprocket wheel and also the entire steel chain see Section 6 2 5 Realign the sprocket and investigate the cause Remove the product jam and check the width height detectors if fitted Remove product and operate within the specification limits in Section 2 1 Repair or replace the steel chain see Section 6 2 5 and check sprockets Remove the product jam and check the width height detectors if fitted Replace slats see Section 6 1 2 Repair or replace the relevant slide rail Replace slats see Section 6 1 2 Remove the foreign objects Replace slats see Section 6 1 2 Shorten the steel chain Replace broken slats see Section 6 1 2 Replace defective slats Guide rails not set correctly Set guide rails to correct height Check if product is meeting the specifications in Section 2 or contact FlexLink Flex Link Product orientation Product stops at beginning or end of the Spiral Elevator Defective transition roller arrangement if fitted The product is pushed to the outside because there is no space between the products on the Spiral Elevator Poor alignment of the products Chain too long Combination of speed and continuous load of product stoppage Spiral Elevator Product load too high depending on
47. s means persons that have received adequate training for carrying out the activities involved Page 2 of 46 5478EN 5 Flex Link 94 78EN 5 Safety 1 safety The Spiral Elevator has been designed such 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 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 extra 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 FlexLink is not responsible for damage if service on the equipment is not performed in accordance with this user manual 1 1 system information and symbols The project number and or general drawing number identification number shall always be specified when communicating with FlexLink with respect to the Spiral Elevator Pictogram symbols have been placed on the Spiral Elevator in order to identify to the user certain conditions or provide certain information on components of the Spiral Elevator Spiral Elevator machine plate T powered ty AmbaFlex This contains the name and the address of the initial manuf
48. set or adjusted again or repaired by the person responsible installer technician eee jee em Does the stop button stop the Both the Spiral Elevator and the input output chain should Spiral Elevator within the time stop immediately within the time dictated in the control o en Yes No expected design specification or within 3 seconds depending upon speed pressed Does the optional height width The height width detector should react when a product is indicator reacts when processing coming by that is larger than the specified product Yes No Does the Spiral Elevator stop The Spiral Elevator should stop immediately and this should when the emergency stop is be less than 3 seconds depending upon speed Yes No a product which is too large mentioned in Section 2 1 or guotation VI 94 78EN 5 Flex Link D Maintenance schedule AN Note Before any maintenance make sure that Section 6 and Section 6 7 is read understood and followed eee ee O Monthly Regular cleaning depends on product and environment 2 Check the chain for broken or Daily missing slats Check the chain tension It is the task of the operator to do this check Replace if necessary see Section 6 1 for details Monthly Remove a link if the chain too long see Section 6 2 for details If more than two links at the same time are to be removed contact FlexLink Check the sprocket wheel and its alignment Monthly Faulty alignment of
49. should be set to the correct height and the column must be vertical The adjusting feet can be used to set the Spiral Elevator to the correct height If necessary the connecting conveyors should be adjusted to this as well The feet should be fastened to the floor surface by using the holes in the adjusting feet and with fasteners suitable for the type of floor mounting surface Make sure all four feet are adjusted evenly It is not possible to change the difference in height between the lower and upper ends after the Spiral Elevator has been manufactured i e the pitch between turns are fixed 5 1 2 Links to adjacent conveyor systems Any additional bracing of the Spiral Elevator in feed and out feed section must be provided Following requirements are mandatory for a safe and correct installation of the Spiral Elevator in a conveyor system e Upper and lower end must be connected to adjoining conveyors e The connecting conveyor to the lower end of the Spiral Elevator must leave adequate space to remove insert the transport slats of the Spiral Elevator A space of minimum 10 mm and maximum 25 mm is required Page 21 of 46 Mounting installation adjustment Flex Link If conveyors are to be attached to the Spiral Elevator they must be connected to the in feed out feed section of the Spiral Elevator Specially designed transfers are available from FlexLink ety 5 Figure 19 Example of typical connection
50. start and stop hour Setting of the ramp up and LSF If the speed difference is lower ramp down should be set accordingly ZZ than 10 a frequency controller is 60 not necessary T1 ramp down time sec coe T2 ramp up time sec T 1 5x y ox 10 fi an te ae a NSE V speed m min 2 30 on Line control instead After the integration the checklist in Appendix B must be completed to ensure a satisfactory integration 35 Setting of the Spiral Elevator The control setting for the Spiral Elevator needs to be done correctly with particular regard to the ends and transfers to ensure good operation 5 5 1 Controls The table below gives some general guidelines with regard to the control system used to operate the Spiral Elevator C e Freguency control The speed difference of the feeding conveyor to the Spiral Elevator or the Spiral Elevator to the receiving conveyor should generally be below the setting value This is to avoid product twisting at the transfers and excessive slipping of the product on the conveyor or Spiral Elevator chain Emergency stop switch Direct The Spiral Elevator should be protected via an emergency stop circuit such that if the relevant emergency stop button or other is activated all power is removed from the Spiral Elevator gear motor following which the Spiral Elevator may overrun a little depending upon speed The full details of the emergency stop circuit and procedure must be evaluated
51. t to the system up to 50 of the specified feed rate as detailed in the technical specification or quotations and conduct the items in the checklist again Gradually add more product to the system up to 100 of the specified feed rate as detailed in the technical specification or quotations and conduct the items in the checklist again If during any of the tests problems are detected or if any of the following situations occur the Spiral Elevator must be stopped not to be tested further until the problem has been investigated remedied and then the tests restarted e Irregular sounds e Other irregularities abnormalities e Spiral Elevator does not meet specifications e Some of the product do not fit on the Spiral Elevator Product become stuck or slip When read and taken notice to previous text the test run and checks according to Appendix C must be completed It contains details of the main items to check when the test runs is carried out Page 28 of 46 5478EN 5 Flex Link Flex Link 94 78EN 5 Technical maintenance 6 Technical maintenance Good maintenance will prolong the life of the Spiral Elevator and help to reduce any costs resulting from breakages or downtime If maintenance is not performed as recommended the warranty will not apply Before any maintenance functions are carried out on the Spiral Elevator the power supply to the gear motor must be safely isolated This always applies for any
52. the distance to the adjacent conveyor Yes No machine satisfactory should be gt 10 mm and lt 25 mm and suitable for other considerations regarding product transfer and safety For correct height refer to technical specification Section 2 quotation details or drawings Upper end Is the upper end at the correct height and is the distance to the adjacent conveyor Yes No machine satisfactory should be below 25 mm and suitable for other considerations regarding product transfer and safety For correct height refer to technical specification Section 2 quotation details or drawings Spiral Is there sufficient space around the Spiral Elevator to allow adequate access for Yes No Elevator operation and maintenance Fastening Is the Spiral Elevator fixed to the floor satisfactorily and is the central column Yes No foundation vertical o478EN 5 u 5478EN 5 Flex Link C A Checklist Test run Note Before the test run is carried out make sure that Section 5 6 on page 28 is read understood and followed If any questions or problems occur or can t be solved please contact FlexLink before continuing ea e ooo e Start test run with no product loaded and check following If any problems are detected or occurs the Spiral Elevator must be stopped and cannot be tested further until the problem has been investigated remedied and the tests restarted Does excessive noise occur A tickin
53. the sprocket may cause permanent wear or make the steel chain derail which may cause serious stoppages Replace or align if necessary see Section 6 4 Check the guide rails for dents damages and connection 3 4 5 Monthly Replace guide rail components if they have any impact on the products to be transported If the cause is bad guide rail contact the FlexLink For more details see Section 5 2 2 Monthly Accessible dirt will accumulate at the bottom side see Section 6 7 7 Check the drive for oil leakage and undue noise Monthly Repair or replace if necessary See the Appendix E Check whether the Motor is fastened well to the Spiral Elevator Monthly Tighten the screws if necessary Drive vibrations can make screws to come loose then faulty alignment of the drive can bend the shaft and the steel chain may derail Check the oil level in the Motor Monthly Take a look at the gear motor specifications of the manufacturer fill up if necessary 10 l i Clean slats Daily 12 Remove several slats and all covers to clean the slide rails 13 Remove chain to clean the inside the guide rails and chain Change the oil in the Gear motor In accordance with the gear motor specifications of the manufacturer M Clean inside below ends See Section 6 7 Cleaning and maintenance procedure Spiral Elevator Every two weeks Removal of slats see Section 6 1 2 Cleaning of slide rails see Section 6 5 1 Every half ye
54. tion Clarification for the new application should be sought from FlexLink though there may be a charge for this service A full Risk Assessment will need to be completed for the use in the new application before the Spiral Elevator can be put in to service Page 44 of 46 5478EN 5 FlexLink n 8 Supplier s information This document was drawn up by FlexLink AB Date 2015 02 12 Copyright FlexLink Sweden 2015 The machine was supplied by FlexLink AB Tel 46 0 31 337 31 00 SE 415 50 Goteborg Fax 46 0 31 337 31 95 Sweden E mail info flexlink com www flexlink com and Local FlexLink Systems supplier A Note n case of failures please contact the system integrator 5478EN 5 Page 45 of 46 a FlexLink Page 46 of 46 5478EN 5 Flex Link 94 78EN 5 A A Start the Spiral Elevator at 10 Hz if variable speed motor Run the Spiral Elevator run at 10 Hz if variable speed motor Run the Spiral Elevator at 25 Hz if variable speed motor Let the Spiral Elevator run at the nominal speed described in the technical specification or detailed within the quotation If all of the items above have been complete and the Spiral Elevator runs satisfactorily then the remaining parts of the overall system can be checked and the overall subseguently run described Checklist Initial test run Note Before the initial test run is carried out make sure that Section 5 3 2 on page 2
55. tor will extend the lifetime of the machine and contribute to the overall line efficiency in which the unit is integrated In time the machine will collect dust and debris particles inside the machine affecting the chain slide rails bearings and the friction of the slats thus increasing the risk of downtime and maintenance cost The loss of friction on the chain will eventually result in an inconsistent product flow impacting the efficiency of subsequent equipment Furthermore the products transported on the Spiral Elevator may carry debris over from preceding equipment in the line We recommend to eliminate this carry over as much as possible to ensure a consistent throughput 6 7 1 Cleaning procedure Note mproper or insufficient cleaning will void the warranty Clean the machine with a damp cloth and mild soap solution Do not wash or rinse down with water The chain including the friction inserts can be cleaned with white spirit Don not use scrapers or knifes on the coated parts or chain surface Cleaning interval according to Appendix D e All cleaning products must be applied according the manufacturer s instructions e Maximum water temperature is 60 C 140 F e Do not spray directly on electrical components bearings lubrication systems chain and stickers Page 41 of 46 er FlexLink Page 42 of 46 5478EN 5 Flex Link A 5478EN 5 Put out of commission T Put out of commission Decomm
56. way to key 5478EN 5 Page 23 of 46 Mounting installation adjustment Flex Link e Add the torque arm washer Fig 25 before attaching the torque arm to the Spiral Elevator drive end see Fig 26 Figure 24 Sliding on the gear motor Figure 25 Add torque arm washer Figure 26 Attaching torque arm e Fasten the shaft to the motor with screw and washer inside the gear motor hollow shaft Fig 27 Place the cover to protect the opening if cover is applicable Fig 28 e Check all fastenings and remove excess installation grease Fig 29 Figure 27 Fasten shaft to motor Figure 28 Placing cover Figure 29 Check installation 5 2 2 Mounting guide rail components The basic Spiral Elevator does not include guide rail or brackets Along the sides of the conveyor track there are M8 tapped holes typically every 45 to allow brackets to be attached The following describes how a typical FlexLink guide rail bracket system can be used on the Spiral Elevator For final detail of the optimum guide rail and bracket arrangement consult FlexLink Procedure e Grind or cut off the small lugs on the FlexLink guide rail bracket or distance piece acc to Fig 30 before assembly e Attach the guide rail brackets to the frame If an offset has been chosen any distance piece has to be placed between the frame and the guide rail bracket Page 24 of 46 5478EN 5 Flex Link 94 78EN 5 Mounting install

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