trumpf l3030/l3050 conveyor parts and service manual
Contents
1. TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL Thank you for choosing an LNS Chip Conveyor We are proud to have you among our LNS family of users LNS Chip Conveyors simply and reliably remove waste from machining operations Machine efficiency is increased and operator safety is improved since the conveyors work with little operator attention and without interrupting production time LNS Conveyors are available for many types of machine tools or other applications They can be arranged to deliver wet or dry waste to containers or to conveyor or chute type disposal systems For further information contact Inside Sales Department LNS TURBO 203 Turbo Drive Kings Mountains NC 28086 This Service Manual is intended to assist with the normal maintenance that will assure long service life of your LNS Chip Conveyor It is in two parts a Service Instruction Section followed by a Parts Section which includes drawings and parts lists for the basic elements of the conveyors OJANUARY 2004 LNS PUBLICATION NO 864510 0014 Page 1 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL NOTICE ALL INFORMATION CONTAINED IN THIS MANUAL IS INTENDED TO BE CORRECT HOWEVER INFORMATION AND DATA IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE LNS MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS INFORMATION OR DATA FURTHER LNS IS NOT RESPONSIBLE FOR ANY OMISSIONS OR ERRORS OR CONSEQUENTIAL DAMAGE CAUSED BY2. 1 Belt tends to track to one side 2 Excessive wear on outside of side wings p NEN ee EE lel M LN d E Y 8 se Nee 6 NEN PSA T INCORRECT CORRECT FIG 1 OJANUARY E E E PUBLICATION NO 864510 0014 Page 11 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL Once it is determined that retensioning of the belt is necessary the following procedure should be followed INSTRUCTIONS FOR CHECKING CONVEYOR BELT TENSION ae qus Position belt with a link pin directly below the conveyor drive shaft Hold a straightedge across the bottom of the conveyor discharge at the very rear Using a 6 inch scale measure vertically from the straightedge up to the underside of the belt Push up on the underside of the belt and repeat the measurement as in step 3 Under the force applied by the average worker the measurement in step 4 should be approximately 1 16 inch 1 5mm greater than the measurement in step 3 BELT TENSIONING PROCEDURE 1 2 Install belt as stated in Parts and Service Manual except not tension belt Preload exaggerates and or alters torque reading Tighten pillow block bearing bolts and then loosen five 5 1 4 turns This step ensures that bearing is parallel to bearing mount surface and that lock washer is not adding additional torque to the reading Set torque wrench to 25 inch pounds Tighten each bearing adjusting bolt alternately until 25 inch p
3. 9 2 Rotor dragging Motor over 1 Short circuit in power supply Correct the fault condition current conductors or in the motor 2 Motor has ground fault or winding to Have motor repaired by qualified service shop winding short circuit 3 Motor improperly connected Check connection diagram in conduit box cover and correct the wiring WARNING NEVER ATTEMPT TO CLEAR A JAMMED CONVEYOR WITHOUT FIRST TURNING OFF THE POWER TO THE CONVEYOR NEVER USE HANDS TO CLEAR A JAM USE A TOOL OJANUARY UO ENS PUBLICATION NO 864510 0014 Page 19 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL SUPER HEAVY DUTY BELT COMPONENTS jquiesssy 08 gS 9 0qy JO HEd 19302 JOUSEM 9 OH O eld Mur 12910 M eDuiH e1eld Mur 21 9691 801 992 91 992 1 992 9 897 61 962 G jquiessy gs JO 1195 pueH 197 epis pueH 1uBiti epis quiessy 1 892 1 897 21842 12 982 1 894 08 992 ON ON ON ON AINVN WALI 3INVN LH Vd EIN ANI ITC Mal dqadodxa3 PUBLICATION NO 864510 0014 OJANUARY 2004 BIN Sarre u Page 20 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL BRUSH ASSEMBLY ysnig 7 1 798 QIN W
4. moved in the direction opposite normal belt travel ZE Pe e Tt uri ee d A UE Bie TN oW rm E FON E CN CG Se x a D HINGE BELT REMOVAL Remove BELT IN THIS DIRECTION BELTREP4 JANUARY 2004 E PUBLICATION NO 864510 0014 Page 9 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL 13 Before moving the old belt out of the way pay particular attention to the way the side wings overlap When the belt is running in the normal direction of travel the leading ends of the side wings are outboard and the trailing ends are inboard 14 Place the new belt on the floor beneath the conveyor discharge being careful to orient it in the same direction as the old one that was removed 15 If there is not already a hinge pin in the end of the belt use the pin and rollers that were removed to separate the old belt There must be a pin and rollers in the extreme end of the belt for ease of insertion 16 With a person standing on either side of the belt lift up the lead end and start it in the lower track from which the old belt was pulled out Be sure and wear gloves to prevent injury and be sure to maintain a secure hold on the belt until at least five feet have been fed into the conveyor frame At this point the weight of the belt inside the frame should be enough to prevent it running back out on it s own ROLLERS AND PIN MUST BE IN THE EXTREME END OF THE BELT FOR EASE OF INSERTION INSTALL B
5. AL CONVEYOR ELECTRICAL MOTOR AND BULKHEAD CONNECTOR WIRING INFORMATION MOTOR WIRE CONNECTIONS i4 8903 1196 CLOSED TERMINAL CONNECTORS C UANDAHY 2001 LNS u RI EU UI PUBLICATION NO 864510 0014
6. ELT IN THIS DIRECTION HINGE BELT INSTALLATION BELTREPS OJANUARY OO Fa u u vate sw DIU ee PUBLICATION NO 864510 0014 Page 10 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL 17 18 19 20 21 22 23 24 Continue feeding the belt into the conveyor frame One person may have to use a length of 2 x 4 or a pry bar to help it along from time to time Force should not be required Many times the belt can be pushed in all the way around from the discharge end If the belt hangs up look for some obstruction don t force it Once the belt reaches the tail sprockets the belt will need to be engaged in the teeth around the bottom and the top of the tail sprockets Once belt is wrapped around the tail sprockets with one person feeding the belt at the discharge and the other pulling the upper flight of the belt toward the discharge until the lead end of the belt reaches the drive shaft carefully feed it up over the drive sprockets Remove the hinge pin and rollers that were used to help guide the belt through the track With the ends of the belt engaged in the teeth around the top and bottom of the drive sprockets the two ends should join At this point it may be necessary to remove one or more hinge plates from the new belt Most new belts are supplied longer than necessary Reverse steps 1 through 11 When adjusting the belt tension clamp a pair of vise grip pliers on one of the formed cleats on the belt Use
7. N TO LOOSEN LOOSEN DRIVE SHAFT BELTREP2 11 Being careful to catch the flat washer and roller pull the hinge pin out through the adjustment slot on the side opposite the motor The hinge pin cannot be removed from the motor side because it headed on one end of the pin COTTER PIN FLAT WASHER HINGE PIN COTTER PIN ASSEMBLY pied RT Kot et IUE Wi MM NEI NEI NES NAS EE INR Di ra us P 2 E 4 CN DRIVE SHAFT ADJUSTMENT SLOT bees COTTER PIN THE OPPOSITE SIDE HINGE PIN REMOVAL BELTREP3 O JANUARY 2004 E PUBLICATION NO 864510 0014 Page 14 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL 12 Remove the discharge support plates item 38 from both sides of the conveyor 13 Remove the pillow block bearing mounting bolts item 31 and nuts item 34 on both sides of the conveyor 14 Slide the drive shaft sprocket weldment item 6 out of the conveyor frame 15 Remove the pillow block bearings from the drive shaft sprocket weldment and transfer to the replacement 16 Reverse steps 1 through 15 insuring that the sprockets are centered in the frame during assembly 17 Visually confirm the belt is located in the center of the frame Adjust if necessary by loosening the setscrews in the pillow block bearings and shifting the drive shaft to the left or right as appropriate 18 Re connect power and test run the conveyor The belt should run freely
8. RVICE MANUAL INSTRUCTIONS FOR ORDERING PARTS FURNISH THE FOLLOWING INFORMATION ON YOUR ORDER FURNISH EXACT SHIPPING INSTRUCTIONS e MODEL AND SERIAL NO OF MACHINE e COMPLETE SHIPPING ADDRESS e CATALOG NUMBER AND NAME OF PART e MODE OF DELIVERY e QUANTITY REQUIRED e PARCEL POST TRUCK LINE ETC PURCHASE ORDER NUMBER e BILL TO ADDRESS HOW TO FIND THE MODEL AND SERIAL NUMBER OF YOUR MACHINE The machine model number and serial number is stamped on the machine nameplate located on the motor cover LNS Turbo Inc 203 Turbo Drive Kings Mountain NC 28086 MODELZ 505 1 SERALZ 1 5m 5 An ISO 9001 Certified Company Phone 704 739 7111 Fax 704 739 6039 www LNSAmerica com DIRECT YOUR ORDER TO LNS Turbo 203 Turbo Drive Kings Mountains NC 28086 U S A Telephone 704 739 7111 Fax 704 739 6039 WARRANTY LNS conveyors carry a warranty against defective material or workmanship during manufacture of the conveyor for one year in service or eighteen months from shipment which ever occurs first LNS will repair or replace at its option free of charge except freight FOB shipping point any parts it finds nonconforming on these conditions a b on request user promptly allows LNS to inspect and user returns all requested parts to LNS plant and user has operated and maintained products in accordance with LNS maintenance and operational literature and good business practice has be
9. TERMINALS WITH A SCREWDRIVER OR OTHER METAL DEVICE NEVER SHOULD ADJUSTMENTS MAINTENANCE OR CLEANING BE PREFORMED WITHOUT FOLLOWING PROPER SAFETY PROCEDURES IN ACCORDANCE WITH LOCAL STATE AND NATIONAL SAFETY CODES Before making any electrical connections be certain the voltage for which the conveyor drive and control are wired is the same as incoming voltage being delivered by the electric power supply Failure to do so may result in injury or damage to the equipment It may be necessary in the cases where the motor has dual motor voltage ratings for example 230 460V 3 phase for example to change the motor wiring from one voltage to another Normally a wiring diagram is located inside the motor terminal box which indicates proper wiring for the incoming voltage supplied Some machines are equipped with internal electrical controls and a multi pin type accessory plug for connecting the chip conveyor LNS Chip Conveyors can be ordered with a mating plug so that connecting the conveyor is as simple as plugging it in The best and most common source of power for the chip conveyor is the machine electrical cabinet It is the customer s responsibilities at the time of order to determine what if any electrical components are present and or order the appropriate conveyor control Even if the machine has no plug or other provision for connecting a chip conveyor the conveyor can be ordered from LNS with both halves of a quick disconnect style plu
10. THE USER OF THE PRODUCT LNS RESERVES THE RIGHT TO MAKE MANUFACTURING CHANGES WHICH MAY NOT BE INCLUDED IN THIS MANUAL LNS supplies data necessary for the proper instruction test operation and maintenance of this product LNS retains all proprietary rights in and to the information so disclosed and such shall not be reproduced copied or used in whole or in part for purposes other than those for which it is furnished 1 TABLE OF CONTENTS CONTENTS PAGE Introduction amp Table of Contents 1 Instructions for Ordering Parts 2 zur Mes 2 General Installation Instructions 3 4 Installation amp Start Up 5 6 SOI VI ICO SECON osea aud aos a ard oe ed acie Revisa EE 6 16 Hinge Belt Removal Installation Instructions 6 10 Conveyor Belt Tensioning 10 11 Replacement of Drive Shaft Sprocket Weldment 12 14 Replacement of Tail Shaft Sprocket Weldment 14 Replacement of Chain Tensioning Components 12 Gearmotor Maintenance 15 16 Trouble Shooting Guide 17 18 SENCE PANS sow Mea E ER AER 19 24 Electrical zs piyur nnt nete mas 25 27 O JANUARY 2004 ENS u osoba RR ERES PUBLICATION NO 864510 0014 Page 2 TRUMPF L3030 L3050 CONVEYOR PARTS AND SE
11. ail Flange L H Shown Washer Flat M6 Bearing Flanged w Locking Collar Washer Lock M6 Bolt Hex Hd Cap M12 X 45 Collar Washer Lock M12 JANUARY 2004 LNS 2 uuu uyu PUBLICATION NO 864510 0014 Page 24 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL FRAME ROLLER ASSEMBLY ITEM CATALOG PART NAME ITEM CATALOG PART NAME NO NO NO NO 16 75B 108 Washer 3 8 81 75B 17 Cotter Pin 80 75B 14 Roller 82 97A 15 Roller Shaft O JANUARY 2004 in edu odes ua isuu asua st Meee PUBLICATION NO 864510 0014 Page 25 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL ELECTRICAL INFORMATION LNS Chip Conveyors are supplied with a variety of drive packages and electrical controls depending on conveyor application and customer preference Always refer to the electrical schematics sent with the machine tool and conveyor before starting any electrical maintenance or troubleshooting WARNING ONLY QUALIFIED ELECTRICIAN OR SERVICEMAN SHOULD PERFORM ANY ELECTRICAL TROUBLESHOOTING OR MAINTENANCE TO THIS EQUIPMENT DO NOT PERFORM ANY MAINTENANCE REPAIRS OR ADJUSTMENTS ON THIS EQUIPMENT WITHOUT FIRST LOCKING OUT ALL ELECTRICAL CONTROLS PERSONNEL SHOULD BE TRAINED IN OSHA COMPLIANT LOCK OUT TAG OUT AND ELECTRICAL SAFETY PROCEDURES MAKE CERTAIN THAT THE POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENTS AT NO TIMES SHOULD CIRCUIT CONTINUITY BE CHECKED BY SHORTING
12. and the only sound should be a subdued clicking as each hinge plate passes over the drive sprocket TAIL SHAFT SPROCKET WELDMENT REMOVAL AND INSTALLATION Disconnect power to the conveyor before performing any work on the conveyor 2 Follow procedure to remove the belt from the conveyor as described earlier in this manual 3 Remove the bolt on tail flange item 42 from each side to the conveyor 4 Remove the bearing mounting bolts item 78 from each bearing on both sides 5 Slide the tail shaft sprocket weldment item 27 from the frame 6 Transfer bearings and collars to replacement tail shaft sprocket weldment 7 Reverse steps 5 insuring that the tail shaft sprocket weldment is properly centered in the conveyor frame 8 Follow the procedure to reinstall the belt back into the conveyor as described earlier in this manual 9 Visually confirm the belt is located in the center of the frame Adjust if necessary by loosening the setscrews and locking devices on pillow block bearings and shifting the tail shaft to the left or right as appropriate 10 Re connect power and test run the conveyor The belt should run freely and the only sound should be a subdued clicking as each hinge plate passes over the drive sprocket JANUARY 2004 E AERE ree PUBLICATION NO 864510 0014 Page 15 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL GEARMOTOR MAINTENANCE These operating inst
13. e is any damage a claim should be filed with the freight carrier Also compare the contents of the shipment to the packing list to verify that everything shipped was received For most applications installation of a LNS Chip Conveyor is a simple slide in or drop in process requiring no modification to either the conveyor or the machine In some cases bolted sheet metal panels may have to be removed added or replaced Such removal addition or replacement is part of a normal installation which can be accomplished using common hand tools Some LNS Chip conveyor installations include loose bolt on baffles that are shipped attached to the conveyor These may have to be removed prior to installation DISCHARGE BOLT ON BAFFLES INCLINE NAG A SECTION I HORIZONTAL LOAD SECTION OJANUARY OO Fa ENS u ox Ux DIU MI UE EEUU PUBLICATION NO 864510 0014 Page 4 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL CONVEYOR NOMENCLATURE For most machines conveyor must be slid in tail end first through an opening either in the rear or side of the machine tool Before attempting to slide the conveyor into the machine measure the vertical and horizontal clearance inside the machine to be sure both dimensions are larger than the conveyor load section Remove any obstructions It may also be necessary to remove some type of chip pan basket or tray that was furnished with the machine in lieu of a chip conveyor CAUTION A chip conve
14. e removed by following the sequence described below Refer to the Part Section in this manual for belt part designation catalog number HINGE BELT REMOVAL AND INSTALLATION INSTRUCTIONS 1 Disconnect power to the conveyor before performing any work on the belt 2 Remove the inspection plates located directly under the two pillow block bearings OJANUARY 2004 LNS ira vate DIE ee PUBLICATION NO 864510 0014 Page 7 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL 3 Run the conveyor until the master link reaches the inspection slot The master link can be identified since it has a cotter pin in the end of the link pin 4 Remove the dust cover shown below from the end of the gearmotor item 14 DUST CAP KEY 8 X 7 X 50 SUPPLIED WITH MOTOR MEN d i ST GEARMOTOR DRIVE SHAFT M10 X 80 HHCS zs P011 010 060 5 Remove the 10 mm bolt shown above from the end of the drive shaft 6 Remove the 4 mounting bolts item 37 attaching the gearmotor item 14 to the mounting bracket item 30 and remove the gearmotor 7 Loosen the lock nuts item 34 on the belt tension adjusting screws item 32 located just behind each of the pillow block bearings on the drive shaft and back off the adjusting screws until they are flush with the face of the adjusting bracket 8 Loosen the two bolts item 31 holding each pillow block bearing 9 Slide the drive shaft item 6 toward the tail of the conveyor a
15. en used and products have not been misused abused damaged by accident or altered without LNS written consent and user employs trained maintenance and operating personnel and buyer meets all payment obligations Parts which have expected life shorter than one year under normal usage are excluded USED PRODUCTS ARE SOLD AS IS UNLESS OTHERWISE AGREED UPON AT THE TIME OF PURCHASE SELLER MAKES NO WARRANTY FOR USED PRODUCTS EXCEPT AS TO TITLE BUYER MAY INSPECT AND TEST BEFORE SHIPMENT AND ACCEPTS USED PRODUCTS ON THESE TERMS THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OJANUARY 2004 LNS aes ier cas ate pw DIE ee PUBLICATION NO 864510 0014 Page 3 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL LNS CONVEYOR GENERAL INSTALLATION INSTRUCTIONS Each LNS chip conveyor is carefully engineered to fit a specific make and model of machine tool or special application Given the characteristics of a particular machine configuration LNS conveyors are designed to provide the best possible interface with the machine It must be recognized that there is almost no inter changeability a LNS Chip Conveyor will fit only the make and model s of machine for which it was designed Upon receipt of your LNS Chip Conveyor unpack and inspect for damage The conveyor left the factory in good condition If ther
16. eplace overload relay or fuse 3 Motor not connected to proper Check connection diagram on conduit cover and supply voltage correct the wiring 4 4 Supply voltage varies outside the Assure correct supply voltage allowable tolerance causing an undervoltage or overvoltage condition 5 Ambient temperature is too high Ensure cool air gets to the motor Ducting may be required 6 Sludge Chip build up inside frame Remove belt and clean 7 Defective gear reducer and or Replace as needed motor JANUARY 2004 E PUBLICATION NO 864510 0014 Page 18 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL TROUBLE SHOOTING CONTINUED PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Motor does not 1 Blown fuse Determine and correct cause of failure and Lr replace fuse 2 Motor protection device activated Determine and correct cause of failure and reset overload relay 3 Motor protection device faulty or will Check protection device for defect and replace if not reset necessary Motor will not 1 Motor not connected to proper Check connection diagram in conduit box cover start or starts voltage and correct the wiring sluggishly 2 Large voltage and or frequency Ensure stable power supply fluctuation at starting 1 Motor supply leads misconnected Switch two supply leads wrong direction As 1 Faulty or defective winding Have motor repaired by qualified service shop raws hi Current
17. g One half will come pre wired to the conveyor control cable The other half of the plug will be wired to the machine electrical cabinet where it will be connected to the power supply The chip conveyor can then be quickly unplugged for cleaning or service without having to disconnect hard wired connections Before starting the chip conveyor check to be sure no tools packing or other material have been left on the belt or in the discharge opening Start the conveyor and verify proper direction of belt travel Reverse polarity if the belt is moving in the wrong direction C UANDAHY 2001 LNS u RI EU UI PUBLICATION NO 864510 0014 Page 26 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL TIME DELAY DEVICES The use of a time delay device is not suggested for use on any chip conveyor If the chip conveyor is not running when the machine tool is cutting chips it may cause a large chip build up in the conveyor frame When the conveyor is finally turned on it may not be able to handle the chip load This condition may cause belt and or frame damage to the chip conveyor LNS will not be responsible for damage caused to chip conveyors when a time delay device is being used AC SUPPLY CIRCUIT AMP LOAD FOR CONVEYORS The full load amp draw of the AC drive is based on the horsepower of the AC motor as well as the input AC voltage The conveyor motor control circuit is not separately fused The customer m
18. it has a cotter pin in the end of the link pin 4 Remove the dust cover shown below from the end of the gearmotor item 14 DUST CAP KEY 8 X 7 X 50 SUPPLIED WITH MOTOR GEARMOTOR M10 X 80 HHCS uid P011 010 060 OJANUARY 2004 ENS u u ox DIU M E EIE PUBLICATION NO 864510 0014 Page 13 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL 5 Remove the 10 mm bolt shown above from the end of the drive shaft 6 Remove the 4 mounting bolts item 37 attaching the gearmotor item 14 to the mounting bracket item 30 and remove the gearmotor 7 Loosen the lock nuts item 34 on the belt tension adjusting screws item 32 located just behind each of the pillow block bearings on the drive shaft and back off the adjusting screws until they are flush with the face of the adjusting bracket 8 Loosen the two bolts item 31 holding each pillow block bearing 9 Slide the drive shaft item 6 toward the tail of the conveyor as far as the adjusting slots for the pillow block bearings will allow This will provide maximum slack in the belt 10 Working through the drive shaft adjustment slot remove the cotter pin from one of the belt hinge pins on the end of the pin located on the drive motor side of the frame BELT TENSION ADJUSTING SCREWS ___ ei 4 PILLOW BLOCK BEARING MOUNTING BOLTS u ii emm LOCK NUTS SLIDE DRIVE SHAFT AND ARINGS IN THIS DIRECTIO
19. ld QIN 4907 Ga Z6 ZL X QIN deo uoung ON ON 3INVN LHVd 29OT1V1VO WALI 3INVN LHVd cV 46 726 ON ON WALI PUBLICATION NO 864510 0014 JANUARY 2004 LNS 2 Page 21 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL DRIVE COMPONENTS LEFT HAND SIDE ITEM CATALOG PART NAME ITEM CATALOG PART NAME NO NO NO NO Bearing Pillow Block w Lock Screw Button Hd Cap M6 X 12 Bolt Hex Hd M12 X 30 Washer Flat M6 Washer Flat M12 Washer Lock M6 Washer Lock M12 Slot Cover Drive Shaft Weldment Plate Discharge Support JANUARY 2004 LNS 2 uuu uyu PUBLICATION NO 864510 0014 Page 22 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL DRIVE COMPONENTS RIGHT HAND SIDE ITEM CATALOG PART NAME ITEM CATALOG PART NAME NO NO NO NO 6 35 Drive Shaft Weldment Bolt Hex Hd Gearmotor Washer Lock Bearing Pillow Block Washer Flat Mounting Bracket Gearbox Plate Discharge Support Bolt Hex Hd Cap M12 X 60 Screw Button Hd Cap M6 X 12 Bolt Hex Hd M12 X 120 Washer Flat M6 Washer Flat M12 Washer Lock M6 Nut Hex M12 Washer Lock M12 JANUARY 2004 LNS 2 PUBLICATION NO 864510 0014 Page 23 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL TAIL ASSEMBLY ITEM CATALOG PART NAME ITEM CATALOG PART NAME NO NO NO NO Washer Flat M12 Tail Shaft Weldment Screw Button Hd M6 X 10 Bolt On T
20. lt travel Reverse polarity if the belt is moving in the wrong direction JANUARY 2004 E aaa PUBLICATION NO 864510 0014 Page 5 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL INSTALLATION AND STARTUP Your LNS Conveyor has been run prior to shipment to insure proper operation However it is recommended that the following checks be made before startup Conveyor Drive Check the frame and belt for damage during shipment or storage Locate the conveyor in the proper operating position All drive elements sprockets should be located close to their bearing supports Each set of sprockets should be carefully aligned to prevent excessive wear and noise Drive chains and belts should be properly tensioned Check the speed reducer to see that oil is at the proper level If there is a shipping plug in the gearbox vent remove it Leveling Level should be placed across tail section and on bottom cover at discharge perpendicular to travel of the belt Adjust conveyor support leg if so equipped or shim as necessary to level Electrical Controls If the conveyor is supplied with electrical controls check the voltage of the electrical supply voltage to insure it matches the voltage specified on the control Read the Electrical Controls section in this manual for more details before installing the conveyor A qualified electrician in accordance with all local state and national safety codes local codes must c
21. nd 1 680 SEW 680 Eurodrive SA57 Chevron 5 Non Shell to VG220 Mobilgear leaded Omala BP Energol Kluberoil 77 630 Gear Oil 220 GP XP GEM Compound 1 220 220 Shell BP Alvania Multifak Centoplex Grease EP2 e ZER R3 LS3 Ball amp Grease Cheveron Roller Used for normal applications Dura Lith Bearings Temp Range 22 F to 130 F EP2 The approximate lubricant in US gallons and liters for the gearmotor mounted in the M1 position is as follows GEARMOTOR M1 MOUNTING POSITON Oil changes are required at intervals of 10 000 operating hours or every two years whichever comes first In applications where hostile operating conditions exits such as high humidity corrosive environment or large temperature changes the lubricant should be changed at more frequent intervals SEW Eurodrive SA57 Grease packed bearings should be cleaned and regreased every 10 000 hours Input high speed bearings should not be over greased They should be filled with grease not to exceed 1 8 of the bearing s free volume For output bearings and bearings with replacement grease shields fill to 2 3 of their free volume ATTENION When the recommended lubricant is not available it is permissible to use a lubricant having equivalent characteristics but we do not recommend that lubricants of different brands be mixed Under no circumstances should synthetic lubricants be mixed with one another or with one having mineral base Check alignmen
22. onnect the electrical equipment to the power source If the conveyor power source is the basic machine tool refer to the basic machine tool manufacturer s wiring diagram DO NOT DRILL HOLES IN THE CONVEYOR FRAME TO MOUNT POWER BOXES OR ACCESSORIES WITHOUT FIRST CONSULTING LNS Arrows in the diagram below show the proper forward movement of belt on a hinged belt conveyor DISCHARGE CAUTION ALWAYS DISCONNECT POWER TO THE CONVEYOR BEFORE ATTEMPTING ANY MAINTENANCE PROCEDURES OJANUARY UO ENS PUBLICATION NO 864510 0014 Page 6 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL LUBRICATION AND ROUTINE MAINTENANCE After First 100 Hours of Operation and at regularly scheduled intervals to suit operating conditions Inspect conveyor belt parts for excessive wear If excessive wear is noted belt should be removed and repaired Refer to service section for belt removal instructions Change oil in speed reducer if applicable Refer to gearbox maintenance for proper gear oil Grease pillow block bearings using grease gun Do not over grease or the bearing seals could be damaged Check belt tension CAUTION ALWAYS DISCONNECT POWER TO CONVEYOR BEFORE ATTEMPTING ANY MAINTENANCE PROCEDURES SERVICE SECTION Most smaller assemblies of the conveyor such as the drive shafts and gearmotors can be disassembled by careful reference to the parts drawings on the pages that follow However the belt and related parts can b
23. ounds is obtained and torque wrench no longer turns adjusting bolt but clicks at rotation Manually rotate belt back and forth This distributes tension evenly throughout belt Repeat steps 3 and 4 until belt rotation no longer results in decreased torque setting This step ensures that both sides of belt are tensioned equally Lock adjusting bolts Run machine for 2 hour break in period Loosen adjusting bolt locknuts Loosen bearing bolts as noted in step 2 Repeat steps 3 4 and 5 The belt must be retorqued to obtain correct tension after break in period see guide below NOTE Belts with discharge heights in excess of 50 or load length in excess of 8 ft may require higher torque settings Contact LNS if assistance is needed TORQUE GUIDE Overall Length 225 to 375 100 in Ibs NOTE Material use application and incline angle can affect required torque settings CAUTION ALWAYS DISCONNECT POWER TO CONVEYOR BEFORE ATTEMPTING ANY MAINTENANCE PROCEDURES OJANUARY E PUBLICATION NO 864510 0014 Page 12 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL DRIVE SHAFT SPROCKET WELDMENT REMOVAL AND INSTALLATION 1 Disconnect power to the conveyor before performing any work on the conveyor 2 Remove the inspection plates located directly under the two pillow block bearings Run the conveyor until the master link reaches the inspection slot The master link can be identified since
24. rical power supply Before making any electrical connections be certain the voltage for which the conveyor drive and control are wired is the same as that being delivered by the electric power supply It may be necessary in the case of 220 440V 3 phase for example to change the motor field shunts from one voltage to another Some machines are equipped with internal electrical controls and a multi pin type accessory plug for connecting the chip conveyor LNS Chip Conveyors can be ordered with a mating plug so that connecting the conveyor is as simple as plugging it in The best source of power for the chip conveyor is the machine electrical cabinet It is the customer s responsibility at the time of order to determine what if any electrical components are present and orders the appropriate conveyor control Even if the machine has no plug or other provision for connecting a chip conveyor the conveyor can be ordered from LNS with both halves of a quick disconnect style plug One half will come pre wired to the conveyor cable Mount the other half of the plug to the machine electrical cabinet and connect it to the power supply The chip conveyor can then be quickly unplugged for cleaning or service without having to disconnect hard wired connections Before starting the chip conveyor check to be sure no tools packing or other material have been left on the belt or in the discharge opening Start the conveyor and verify proper direction of be
25. ructions are intended to assist you to install maintain and operate the gearmotor for trouble free service and operation When installing or disassembling the gearmotor do not hammer it on or off the drive shaft Hammering can cause brineeling of the reducer s bearings therefore shortening the bearing life If the gearmotor does not slide onto the shaft freely check for dents or burrs on the drive shaft or gearmotor bore If none are found we recommend heating the gearmotor bore to approximately 175 F when possible and sliding the gearmotor on the shaft This will reduce possible damage to the reducer s bearings GEARMOTOR REMOVAL AND INSTALLATION Disconnect power to the conveyor before performing any work 2 Unplug the electrical disconnection plug at the gearmotor terminal box 3 Remove the dust cover shown below from the end of the gearmotor item 14 DUST CAP KEY 8 X 7 X 50 SUPPLIED WITH MOTOR as L M10 X 80 HHCS P011 010 060 4 Remove the 10 mm bolt shown above from the end of the drive shaft 5 Remove the 4 mounting bolts item 37 attaching the gearmotor item 14 to the mounting bracket item 30 and slide the gearmotor off of the shaft 6 Reverse steps 1 5 Note When installing the gearmotor it is advised to apply a high quality mounting paste to the keyed drive shaft The mounting paste is to aid in the prevention of rusting and fretting corrosion between the gear reducer hollo
26. s far as the adjusting slots for the pillow block bearings will allow This will provide maximum slack in the belt 10 Working through the drive shaft adjustment slot remove the cotter pin from one of the belt hinge pins on the end of the pin located on the drive motor side of the frame BELT TENSION ADJUSTING SCREWS PILLOW BLOCK BEARING MOUNTING BOLTS LOCK NUTS SLIDE DRIVE SHAFT AND ARINGS IN THIS DIRECT TO LOOSEN LOOSEN DRIVE SHAFT BELTREP2 11 Being careful to catch the flat washer and roller pull the hinge pin out through the adjustment slot on the side opposite the motor The hinge pin cannot be removed from the motor side because it headed on one end of the pin OJANUARY E E E PUBLICATION NO 864510 0014 Page 8 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL COTTER PIN FLAT WASHER HINGE PIN COTTER PIN ASSEMBLY es se gt ARN LION FN ONLI LON LD Ze DRIVE SHAFT ADJUSTMENT SLOT REMOVE COTTER PIN THE OPPOSITE SIDE HINGE PIN REMOVAL BELTREP3 12 Grasp the end of belt below the drive shaft and pull the belt out of the conveyor Be sure to wear gloves to avoid being cut by sharp edges on the belt When only a few feet of belt remain in the conveyor the belt on the floor will have enough weight to begin pulling the remainder out on it s own As the last of the belt begins to run out faster don t attempt to stop it just stand clear and let it run out onto the floor Note that the belt was
27. t belt tension and mounting bolt torque periodically Keep the drive relatively free of dust and dirt JANUARY 2004 E PUBLICATION NO 864510 0014 Page 17 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL TROUBLE SHOOTING The following chart will show some problems and their probable causes and possible solutions PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Conveyor 1 Chip jam If jam does not clear run conveyor in reverse no stalled more than 4 to 6 inches Start conveyor in proper direction to see if jam has cleared If jam has not cleared find and remove obstruction Excessive 1 Belt misalignment Look for sideward motion of belt caused by wear on loose drive shaft sprockets or bearing setscrews outside of or locking device If necessary separate belt side wings align sprockets and retighten set screw and locking device 2 Uneven side to side tension Refer to Tensioning section on 3 Leveling Check leveling of frame to insure it is not twisted If necessary adjust leveling screws A located in foot until conveyor has correct leveling 4 Chip jam inside frame Remove belt and clean frame Motor overloads kick out 1 Singe phasing due to break or loose Repair supply lines connection in supply line blown fuse or Replace fuse or reset overload relay tripped overload relay E x PARRER NE 2 Undersized overload relay or fuse Match full load amps on motor plate and r
28. the vise grips to rock the belt back and forth to feel the slack and drag on the belt There should not be more than enough slack to allow rocking the drive shaft through 15 degrees of rotation without moving the belt On a new belt zero slack is O K but if the belt is difficult to move with the vise grips it s too tight Correctly adjusted it should be possible if difficult to move the belt with one s gloved hands by turning the drive shaft Visually confirm the belt is located in the center of the frame Adjust if necessary by loosening the setscrews in the pillow block bearings and shifting the drive shaft to the left or right as appropriate Re connect power and test run the conveyor The belt should run freely and the only sound should be a subdued clicking as each hinge plate passes over the drive sprocket WARNING Hinge plates can pinch hands and fingers CONVEYOR BELT TENSIONING Correct conveyor belt tension is essential to ensure proper operation and extended life of conveyor components The belt has been properly tensioned during factory assembly As normal wear occurs the belt may become slack and need adjustment The following factors may be used to determine if the belt needs adjustment Belt Too Loose Belt Slack at exit point of the drive sprocket before re entry into frame See fig 1 Belt Too Tight Belt has intermittent jerks and a popping sound while conveyor is in operation Uneven Tension side to side
29. ust provide a circuit breaker or a fused disconnect switch on the power supply to the conveyor lt may be necessary to change a circuit protection device on the incoming power supply line to accommodate the higher full load amp draw Refer to the following tables to determine the full load amp draw on the AC supply circuit DANGER IMPROPER ELECTRICAL INTERFACE BETWEEN THE MACHINE TOOL AND CONVEYOR MAY CAUSE INJURY TO PERSONNEL CONVEYOR DAMAGE OR MOTOR FAILURE THE ELECTRICAL INTERFACE MUST BE INSTALLED IN ACCORDANCE WITH LOCAL STATE AND NATIONAL SAFETY CODES ONLY A QUALIFIED ELECTRICIAN OR SERVICE PERSON SHOULD PERFORM ANY ELECTRICAL TROUBLESHOOTING OR MAINENANCE THE CONVEYOR IS NOT SEPARTELY FUSED THE USER MUST PROVIDE EITHER A CIRCUIT BREAKER OR A FUSED DISCONNECT SWITCH ON THE INPUT AC LINE IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES SEE THE MACHINE TOOL MANUFACTURE S ELECTRICAL SCHEMATICS FOR CIRCUIT DIAGRAM FOR PROPER ELECTRICAL INTERFACE BETWEEN THE CONVEYOR AND MACHINE TOOL AC CURRENT REQUIREMENTS All Trumpf Conveyors are wired for 460 Volts before being shipped from the factory Voltage Belt Drive Type Belt Drive Current per phase Recommended Overload Relay Setting 3PH Line Line Horsepower at Rated Load 460 VAC Fixed Speed 1 25 Amps 1 12A C UANDAHY 2001 LNS u RI EU UI PUBLICATION NO 864510 0014 Page 27 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANU
30. w shaft and the conveyor drive shaft For transportation the gearmotor is supplied with the breather plug already mounted After the unit is installed the black rubber seal located on the breather MUST BE REMOVED Fig 1 In addition the oil level should be checked Remove the plated non painted oil level plug The oil level is correct when the surface of the oil is level with the lowest point of that tapped hole After installation the actual mounting plate position should be confirmed against the mounting position shown on the gear reducer nameplate Adequate lubrication is only guaranteed if the unit is mounted in the specific nameplate mounting position OJANUARY OO Fa ENS u u ox Ux sw DIU MI UE EEUU PUBLICATION NO 864510 0014 Page 16 TRUMPF L3030 L3050 CONVEYOR PARTS AND SERVICE MANUAL WARNING Always ensure equipment is secure and electrical power is off before removing or performing maintenance on the drive assembly Oil levels and oil quality should be checked on regular intervals determined by usage and the environment Grease and oil should be changed per the recommendations below LUBRICATION SCHEDULE FOR GEARMOTORS Gear Lubrication Ambient air Mobil Chevron Shell Texaco BP Kluber Reducer Type temperature Viscosity Oil Co Oil Co Oil Co Oil Co Oil Co Oil Co Type Range F Chevron 32 Non Shell to VG680 Mobilgear leaded Omala BP Energol Kluberoil 104 636 Gear Oil 680 GP XP 680 GEM Compou
31. yor is normally top heavy and easily tipped over Be sure to use proper lifting and rigging procedures to prevent accidental tipping Using a lifting device such as a hoist or forklift raise the conveyor until the tail of the conveyor is high enough to clear the lower edge of the conveyor outlet opening in the end or rear of the machine with the load section level Carefully slide the conveyor into the machine When in the correct installed position the conveyor baffles will extend up under and be overlapped by the machine baffles so that all chips are directed onto the conveyor in a waterfall effect with none falling into the machine enclosure or outside of the conveyor baffles Once the conveyor is in the proper position secure any machine support brackets if provided Insure the conveyor is level and not in a bind If the conveyor is not level from side to side premature wear can occur causing failure of the belt or frame Any bolt on conveyor baffling that was not attached prior to conveyor installation should be installed at this time Also at this time install any additional or replacement sheet metal machine parts supplied with the chip conveyor ELECTRICAL CONNECTION LNS Chip Conveyors are supplied with variety of drive packages and electrical controls depending on conveyor application and customer preference Only a qualified electrician or machine service technician should perform connecting the chip conveyor to an elect
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