magnetic conveyor parts and service manual
Contents
1. 021199 peeH xeuf 4109 YEN99 ON ON 3INVN LYVd OO1V1VO WALI PUBLICATION NO 864510 0002 REV 01 NOVEMBER 2003 85 30 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR ELECTRICAL INFORMATION LNS chip conveyors are supplied with a variety of drive packages and electrical controls depending on conveyor application and customer preference Only a qualified electrician or machine service technician should perform any maintenance repairs or adjustments on this equipment READ THIS SECTION BEFORE APPLING ELECTRICAL POWER TO THIS EQUIPMENT ONLY QUALIFIED ELECTRICIAN OR SERVICEMAN SHOULD PERFORM 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 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 whic2. Oil should be changed more often if reducer is used in a severe CAUTION environment i e dusty humid Do not mix different oils in the reducer Oils should be compatible CAUTION with Viton seal material 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 19 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL GEAR REDUCER LUBRICATION REQUIREMENTS The precision made gears and bearings in the Speed Reducer requires high grade lubricants of the proper viscosity to maintain trouble free performance For best results use lubricants on the following chart for worm gear reducers 30 to 100 F Ambient Temperature AGMA Compounded No 7 AGMA Compounded No 8 Worm Gear Lube 140 21 Standard factory installed lubricant shipped with the gear reducer Some gear lubricants contain E P additives that can be corrosive to gear bronze Avoid lubricants that are compounded with sulfur and or chlorine For temperature ranges not shown contact factory Oil Capacities pints Standard Units 1 PINTS Always check for proper oil level after filling Capacities vary somewhat CAUTION with model and mounting position Oil should rise to bottom edge of level hole Do not overfill SPEED REDUCER VENT PLUG LEVEL AND DRAIN LOCATIONS NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV
3. MAGNETIC 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 conveyor 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 three parts an Installation Section a Service Instruction Section followed by Parts Section which includes drawings and parts lists for the basic elements of the conveyors NOVEMBER 2003 LNS PUBLICATION NO 864510 0002 REV 01 T 1 TURBO MAGNETIC 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 CAU
4. 61199 8 99 1 2 4 99 H cHA99 21199 ScIN99 Z 9 PUBLICATION 864510 0002 REV 01 NOVEMBER 2003 85 27 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR DRIVE COMPONENTS Torque Arm Washer Flat Nut Hex Bolt Hex Head Washer Lock Key Set Screw LLI I tc lt x 5 5 Q Q 2 o 52 lt O Snap Ring External Washer Lock Bearing Flange Drive Shaft Sprocket Drive Bolt Hex Head Plug Bolt Hex Head CATALOG NO ITEM NO NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 28 TURBO MAGNETIC PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR DRIVE COMPONENTS 2 4207 J9useA og 1014 JeuseA 1010 N ON ON 3INVN LH Vd IN3 LI AINVN ON PUBLICATION NO 864510 0002 REV 01 NOVEMBER 2003 85 29 TURBO MAGNETIC PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR ACCESS COVER 19 00 55995 jog 271099 8299 Lv ON ON 3INVN LH Vd
5. DISCONNECT THE POWER SUPPLY AND REVERSE THE POWER SUPPLY LEADS TO THE CONVEYOR RECHECK THE DRIVE SHAFT FOR ROTATION CONVEYOR DAMAGE WILL OCCUR IF THE CONVEYOR IS ROTATING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS DO NOT TURN ON ELECTRICAL SUPPLY PRIOR TO COMPLETING THE PRE START CHECK LIST THAT FOLLOWS NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 6 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL CONVEYOR ELECTRICAL SERVICE CONNECTION Upon completion of the above pre start activities check to be sure the conveyor is in the OFF position The conveyor control may be equipped with an emergency stop power control switch If it is supplied with a mushroom type PULL ON PUSH OFF make sure it is in the PULL OFF position during installation of the conveyor After verification that both control switches are in the OFF position connect the conveyor to your power supply Once the power supply connections are completed pull the EMERGENCY STOP button to the PULL ON position and turn the VARIABLE SPEED CONTROL to the FORWARD position Verify the correct conveyor drive rotation VERY IMPORTANT MAKE SURE THE ROTATION OF THE DRIVE SHAFT CORRESPONDS WITH THE DIRECTIONAL ARROWS LOCATED ON THE DRIVE SHAFT OF THE CONVEYOR IF THE DRIVE SHAFT IS MOVING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS IMMEDIATELY STOP THE CONVEYOR DISCONNECT TH
6. 01 20 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL SYNTHETIC LUBRICANTS Synthetic lubricants provide the potential for numerous benefits including wider temperature range and increased interval between changes Use of synthetics can cause problems if they are not compatible with the seals or the conventional lubricants they replace For continuous duty at normal ambient temperatures 10 F to 105 F we recommend the use of Mobil SHC 634 which is compatible with the standard compounded oil shipped in our product and the Viton seal material used For other temperatures or for intermittent operation below 20 F contact the factory for a recommendation MAINTENANCE GEAR REDUCERS Frequently check the oil level of the reducer If oil level is low refer to reducer vent and level position chart add proper lubrication through the filler plug until it comes out the oil level plug Inspect vent plug often to ensure it is clean and operrating Mounting bolts should be routinely checked to ensure that the unit is CAUTION firmly anchored for proper operation Seals Seals are a wear item and eventually need to be replaced Replacement can be accomplished by following the steps below 1 Remove the worn seal without damaging the shaft surface of the seal bore This can be done by drilling a 062 diameter hole in the seal casing being careful not to drill into the bearing behind the seal Screw a 10 sheet metal screw int
7. 23 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR MAINTENANCE SCHEDULE The following chart shows a suggested maintenance schedule for the conveyor to insure proper operation and longevity Check conveyor to insure the chips are being carried out properly Daily See the trouble shooting See the trouble shooting guide guide in this manual in this manual If the drive shaft is rotating in the wrong direct it will cause damage to the conveyor Daily Inspect rotation of drive shaft Insure the rotation matches the arrows on the drive shaft Check the coolant flow Either the conveyor is not to insure the baffles level or a restriction is are not overflowing damming up the conveyor If the drive shaft is rotating in the wrong direction immediately stop the conveyor and reverse the motor leads Weekly Level if necessary or clear the restriction baffles Weekly Check slider face to Chips are not being Clean the slider face with an insure there is not a carried up the incline industrial cleaner and polish residue build up effectively with Scotch Brite if necessary Weekly Check slider face to Dents in the slider face Repair or replace slider face if insure there are no can cause the magnet damaged dents assembly shrink wrap material to wear through Check magnet Hemove discharge Refurbish magnet assemblies assemblies for shrink access cover and inspect if necessary and inve
8. MAINTENANCE PROCEDURES AFTER FIRST 100 HOURS After the first 100 hours of operation and the regular intervals complete the following 1 Drain and refill the speed reducer while the oil is warm Refill the housing to the proper oil level on the plug Use high grade gear oil See the speed reducer section of the manual for suggested oil types and grades to match your operating conditions 2 After the initial break in period speed reducer oil should be changed every six 6 months or 2500 operating hours whichever comes first 3 Inspect bearings to determine if they have grease fittings If so grease sparingly when necessary Over greasing the bearings will damage the seal and cause premature failure 4 Remove the access plate on the under side of the discharge section of the magnetic conveyor and visually inspect the shrink tube that encapsulate the magnet assemblies to insure that the shrink tube does not show signs of excessive wear If the magnet s are exposed it indicates a clearance problem normally caused by a heavy object dropping on the stainless steel top cover causing a dent s in the cover THIS CONDITION MUST BE CORRECTED IMMEDIATELY NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 8 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL CONVEYOR TERMINOLOGY MOTOR GEAR REDUCER GUIDE RAIL STAINLESS STEEL TOP COVER DIRECTION
9. MANUAL MAGNETIC CONVEYOR TOP COVER amp SEALS Seal Viton Double Bulb Seal Buna lt lt H tc t O O 52 lt O PART NAME Stainless Steel Top Cover Guide Rail Seal Neoprene ITEM NO CATALOG NO NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 22 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR TENSIONING ASSEMBLY 19 09 5 198 5 qnis uoIssaidwoyg dn exe ON 3INVN LH Vd 92 ON IN3 LI 5 dn oxe 4 uong 1 206 Ma145S 4207 I9USEM og xoH wer INN INN AN TAN ss d 52 s ANN Fi PUBLICATION NO 864510 0002 REV 01 NOVEMBER 2003 85 26 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR TRACK amp MAGNET ASSEMBLY uleyd 3JINVN uieut UMOUS JON PUEH 137 UMOUS INN
10. alternating from side to side as the bolts are tightened in the curve and the load section of the conveyor After tightening these bolts install the guide rails and install and finger tighten the remaining mounting bolts and nuts in the incline and discharge sections Finish tightening the rest of the bolts in the incline and discharge section of the conveyor alternating sides as before Reconnect any wiring if it was removed per the wiring schematic Test run the conveyor making sure that the belt direction is correct The chips should be carried up the incline toward the discharge when the belt is rotating correctly Failure to run the belt in the correct direction can cause damage to the conveyor Reinstall the conveyor into the machine tool Reconnect the electrical power to the conveyor Test run conveyor to insure proper operation 2003 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 16 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL INSTRUCTIONS FOR REMOVAL AND INSTALLATION OF CHAIN TENSIONING COMPONENTS 1 Follow the INSTRUCTONS FOR REPLACING THE CHAIN AND MAGNET ASSEMBLIES which is located in this section of the manual to remove the chain magnet assemblies and stainless steel top cover Slide the take up sprocket off of the stub shaft Remove the take up housing assembly by removing the six barrel nuts Inspect the take up housing gaske
11. ARROW DISCHARGE UPPER CURVE SECTION PA gt E gt Fa d e DRIVE SHAFT BAFFLE WELDMENT E d ACCESS BOTTOM PLATE SIDE FRAME HORIZONTAL SECTION TAIL TENSION BLOCK LOWER CURVE NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 9 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL SERVICE SECTION Most smaller assemblies of the conveyor such as the drive seals gearbox motor and top cover can be disassembled by careful reference to the exploded parts drawings shown later in this manual However the chain magnet assemblies drive sprockets drive shaft and tensioning assembly can be removed by following the sequence described in this section Refer to the Parts Section in this manual for part designation and catalog numbers INSTRUCTIONS FOR INSTALLING SEALS SEAL CROSS SECTION 7 a 74 sS PS DOUBLE BULB SEAL BUNA SEAL NEOPRENE SPONGE SEAL USED N INCLINE amp DISCHARGE USED ON INCLINE amp DISCHARGE USED IN HORIZONTAL SECTION ON TOP OF FRAME a TOP OF SECTION ON TOP OF FRAME ONLY SECTION ON TOP OF STAINLEES STAINLESS STEEL COVER STEEL COVER ONLY 1 Remove baffle weldment guide rails and stainless steel cover by loosening and removing fasteners 2 Remove damaged double bulb seal on frame in load section and Buna Seal in incline and discharge section Note Olde
12. ARTS 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 wanted e Parcel post truck line etc e Purchase order number e Bill to address 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 2 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL 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 28086 MODELS 35 1 1 SERIAL 1 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 Seller warrants that within 12 months from original shipment if its products are operated by the original specified user Seller will repair or replace at its option free of charge except freight FOB shipping point any parts it finds nonconforming on these conditions a on request user promptly allows seller to inspect and user returns all requested parts to seller s plant and b user has operated and maintained products in accordance with sellers maintenance and oper
13. E POWER SUPPLY AND REVERSE THE POWER SUPPLY LEADS TO THE CONVEYOR RECHECK THE DRIVE SHAFT FOR ROTATION CONVEYOR DAMAGE WILL OCCUR IF THE CONVEYOR IS ROTATING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS COOLANT FILLING Fill the coolant tank with water soluble coolant solution of your choice After initial start up you may find it necessary to add coolant to restore the desired fluid level This is because the conveyor load section acts as an additional reservoir and complete drain down of the conveyor does not occur even during system idle periods you are using an oil coolant you may need to consult with the factory since the maximum conveyor flow rate allowed is reduced when higher viscosity fluids are used Make sure you know the viscosity of the coolant before consulting the factory to determine the maximum flow rate 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 7 TURBO PARTS AND SERVICE MANUAL ROUTINE MAINTENANCE PERIODIC INSPECTION The LNS Magnetic conveyor has been designed to be almost maintenance free however the following periodic checks should be completed at the recommended service intervals to ensure continuous and trouble free operation Also refer to the RECOMMENDED MAINTENANCE SCHEDULE on page 20 to setup a routine maintenance schedule ALWAYS DISCONNECT POWER TO CONVEYOR BEFORE ATTEMPTING ANY
14. ERVICE MANUAL START UP INSTRUCTIONS LEVELING A Level should be placed across tail section and on the top cover in the load section perpendicular to the travel of the belt Adjust the conveyor support leg if so equipped or shim as necessary to level Failure to properly level the magnetic conveyor can cause coolant and chips to overflow the conveyor baffles causing excessive contamination in the coolant tank and or coolant spills on the floor ELECTRICAL CONTROLS If the conveyor is supplied with electrical controls check the voltage of the system supplied to be sure it matches with that to be used Read the Electrical Controls section in this manual for more details before installing the conveyor A qualified electrician in accordance with local codes must connect electrical equipment to the power source the conveyor power source is the basic machine refer to the basic machine manufacturers wiring diagram DO NOT DRILL HOLES IN CONVEYOR FRAME TO MOUNT ELECTRICAL POWER BOXES OR ACCESSORIES WITHOUT FIRST CONSULTING LNS For proper belt direction refer to the arrow on the end of the drive shaft or the diagram shown on Page 5 If the belt is running backwards stop the conveyor immediately VERY IMPORTANT MAKE SURE THE ROTATION OF THE DRIVE SHAFT CORRESPONDS WITH THE DIRECTIONAL ARROWS LOCATED ON THE DRIVE SHAFT OF THE CONVEYOR IF THE DRIVE SHAFT IS MOVING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS IMMEDIATELY STOP THE CONVEYOR
15. O 864510 0002 REV 01
16. SED BY 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 ELM 2 Magnetic Conveyor Features 3 Installation amp Start up 3 5 Conveyor Terminology 6 xs ies x uon REC 7 15 Instructions for Installing Seals 7 8 Removal amp Installation of Baffle amp Top Cover 8 9 Replacement Of Drive Shaft amp Sprockets 9 10 Replacement of Chain amp Magnet Assemblies 11 12 Replacement of Chain Tensioning Components 12 Gear Reducer Installation Maintenance Repair 12 15 Trouble Shooting Guide 16 17 Maintenance Schedule 18 Magnetic Conveyor Service Parts 19 24 Magnetic Conveyor Electrical Information 25 27 2 INSTRUCTIONS FOR ORDERING PARTS INSTRUCTIONS FOR ORDERING P
17. Y n 222222222221 FIGURE 2 APPLYING BUNA SEAL TO FRAME 7 If the seals are also damaged on top of the stainless steel cover repeat steps 1 8 for these seals but use the Neoprene Sponge Seal in the incline and discharge section instead of the Buna Seal The double bulb seal will still be required in the horizontal section area as before If the seals on the stainless steel cover are not damaged there is no need to replace them 8 Heassemble the conveyor using the assembly procedure outline below NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 11 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL INSTRUCTIONS FOR REMOVING AND ASSEMBLING THE BAFFLE WELDMENT AND STAINLESS STEEL TOP COVER 1 10 11 12 13 14 15 16 17 Disconnect Power from the conveyor Use Lock Out Tag Out Procedure Note only authorized trained electricians are to perform this task Remove the bolts and nuts securing the guide rails from both the right and left side of the conveyor Remove the guide rails that run up the incline on both sides and wrap around the discharge radius peripheral Once the incline guide rails are removed remove the bolts and nuts that attach the stainless steel top cover and baffle weldment to the conveyor frame Remove the baffle weldment and stainless steel top cover Inspect the seals to make sure th
18. allen off the chain and are laying in the conveyor f The magnet assemblies are not properly aligned with the belt g Overload relay in drive motor control circuit has tripped out h Overload relay is undersized for the amp draw of the motor See electrical schematic or read the full amp draw ratings on the motor to determine the correct overload relay or fuse setting for the conveyor i Conveyor chain is broken j Sheared or missing key at gear reducer k Worn out drive sprockets excessively loose or broken drive chain Motor has failed m Gear reducer has failed a Conveyor track could be worn or there could be broken magnet assemblies b Slider face has a residue built up on it Change motor leads on the conveyor Make sure drive shaft is rotating in same direction as directional arrows Directional arrows are located on the conveyor frame at the drive shaft section of the conveyor Refer to SERVICE SECTION for proper procedure for taking conveyor apart Check conveyor for worn track and broken magnet assemblies Replace take up stub shaft and or take up sprocket Inspect chain for wear and replace if necessary Reinstall to insure proper timing on both sides of the conveyor Replace the master link assembly Reattach or replace the magnet assemblies if they are damaged Realign the magnet assemblies with the chaint Reset overload relay Replace the overload relay with the c
19. ational literature and good business practice and products have not been misused abused damaged by accident or altered without seller s written consent and d user employs trained maintenance and operating personnel and e buyer meets all payment obligations Seller warrants products manufactured by others to the extent warranted by their original manufacturers on these conditions Parts which have expected life shorter than one year under normal usage are excluded USED PRODUCTS ARE SOLD AS IS 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 NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 3 TURBO PARTS AND SERVICE MANUAL MAGNETIC CONVEYORS LNS Magnetic conveyor design enables efficient removal of ferrous materials Its unique design features self lubricating synthetic track that greatly increases chain guide life and substantially reduces chain wear and stretch Ideal for cast iron applications the Magnetic conveyor is sealed to prevent abrasive material from contacting any moving parts The heavy gauge stainless steel conveying surfa
20. ce eliminates surface deflection and protects magnets from damage The magnetic conveyor handles most chip types except long stringy chips It can be custom designed to meet various coolant flow rates It is imperative to know the maximum flow rate before ordering the conveyor so the unit can be properly sized Most magnetic conveyors are equipped with a variable speed drive AC Inverter as standard equipment This feature maximizes chip removal while minimizing coolant loss 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 4 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL INSTALLATION AND STARTUP PRE START CHECKS Your LNS Conveyor has been test run prior to shipment to insure proper operation However it 15 recommended that the following checks be made before startup 1 Check the conveyor thoroughly for any damage that may have occurred during shipment Be sure to note any damage on the freight bill before accepting the conveyor from the freight company Check the packing list thoroughly before accepting the shipment Remove all shipping and packing materials before installing the conveyor Clean the coolant tank thoroughly before installing the new conveyor Put the conveyor in position under the machine Make sure the conveyor lower horizontal section is level with the machine tool If the conveyor is supplied with an adjustable leg be sure a cra
21. d nuts that attach the stainless steel top cover and baffle weldment to the conveyor frame Remove the baffle weldment and stainless steel top cover Inspect the seals to make sure they are not damaged so replace any damaged seals before reassembling the conveyor Remove the two bolts located in the vertical face at the tail end opposite to the discharge Once the two plugs are removed install the two for 6651 models use 20 X 2 1 4 long screws and for 6650 models use 3 8 16 X 3 long screws screws and tighten both of these screws until they bottom out This will compress the belt tensioning springs and take the tension off of the conveyor belt Remove the master links on the chain on both sides of the conveyor Remove the chain from the sprockets As you remove the chain from the conveyor remove each magnet from the chain as soon as possible by removing the chain pins from the magnet carriers Lay the magnets out to keep them in proper orientation Inspect the chain and magnets and replace any damaged parts To reinstall the chain and magnet assemblies lay the chain out on the floor Make sure each side is the same length and the pins on each side are a mirror image of other Mark the chain if necessary to show where the magnet carriers are to be located Guide the chain over the drive sprockets and install the magnet assemblies in their proper positions as the belt is installed back into the conveyor track until a
22. e lowest possible speed that will remove chips fast enough to keep them from accumulating in the load section of the conveyor Setting the belt speed too low may allow chips to build up in the horizontal load section of the conveyor Setting the belt speed too fast increases the amount of coolant carried out into the chip container Note The variable speed control should not be used as an ON OFF switch Only the ON OFF switch switch should be used to turn the conveyor motor on or off The control is designed for safe and convenient operation All controls are mounted on the front cover No access to the inside of the control enclosure is required The OFF FORWARD switch controls the incoming line power to the inverter It must in the FORWARD position for the conveyor to operate The SPEED CONTROL potentiometer controls the inverter output frequency The conveyor belt speed can be varied from nearly zero to the maximum using this control CONTROL PANEL OF VARIABLE INSIDE VIEW OF VARIABLE SPEED CONTROL SPEED CONTROL 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 33 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL 230 VAC INPUT Ee LZNO06 2A INVERTER FORWARD 230 VAC 3e 1 2 HP MOTOR VARIABLE SPEED CONTROL ELECTRICAL SCHEMATIC NOVEMBER 2003 85 PUBLICATION N
23. e right and left side of the conveyor Remove the guide rails that run up the incline on both sides and wrap around the discharge radius peripheral Once the incline guide rails are removed fold back the stainless steel slider face just enough that you can access the drive shaft inside of the conveyor Remove the two bolts located in the vertical face at the tail end opposite to the discharge Once the two plugs are removed install the two for 6651 models use 4 20 X 2 1 4 long screws and for 6650 models use 3 8 16 X 3 long screws screws and tighten both of these screws until they bottom out This will compress the belt tensioning springs and take the tension off of the conveyor belt Remove the master links on the chain on both sides of the conveyor Remove the chain from the sprockets Remove the bearing mounting bolts and remove the flanged bearings by loosening the set screws and untwisting the elliptical locking collar on the bearings Remove the four external snap rings from the drive shaft grooves that are located on each side of the drive sprockets and slide them down the drive shaft Note the snap rings cannot be removed from the shaft without sliding them down the shaft diameter without damaging them Loosen the set screws from the drive sprockets This will allow the sprockets to float freely on the drive shaft Remove the drive shaft Make sure the drive sprockets do not drop into the conveyor
24. e that the belt direction is correct The chips should be carried up the incline toward the discharge when the belt is rotating correctly Failure to run the belt in the correct direction can cause damage to the conveyor Reinstall the conveyor into the machine tool Reconnect the electrical power to the conveyor Test run conveyor to insure proper operation 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 12 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL INSTRUCTONS FOR REPLACING DRIVE SHAFT AND OR DRIVE SPROCKETS 1 20 Remove the 1 gt hole plugs and run the conveyor until a master link on the chain can be seen through the opening Stop the conveyor at this point Disconnect Power from the conveyor Use Lock Out Tag Out Procedure Note only authorized trained electricians are to perform this task Remove the motor and gearbox from the drive shaft by loosening the set screws in the gearbox that clamps onto the drive shaft and unbolting the motor from the motor mounting bracket Remove the flat rectangular inspection plate located on the underneath side of the discharge end Remove one of the bolts from each side of the chain ramp allowing it to drop down a little This will make the drive shaft easier to remove and allow the belt chain more clearance to slide over the sprockets Remove the bolts and nuts securing the guide rails from both th
25. ey are not damaged If so replace any damaged seals before reassembling the conveyor Once the desired maintenance is completed on the stainless steel top cover or baffles weldment reinstall using the following steps Install the stainless steel top cover and baffle weldment making sure the seals are properly seated and in good condition Use a high grade calking if necessary to insure a watertight seal between the stainless steel top cover and the frame Install the baffle weldment making sure the seals are properly seated and in good condition Use a high grade calking if necessary at any seams of the seal to insure a watertight seal between the baffle weldment and the stainless steel top cover After positioning the stainless steel top cover seals and baffle weldment on the conveyor frame insert the mounting bolts in each hole first to keep all parts aligned and then tighten the nuts by hand only Tighten the mounting bolts starting in the lower curve and alternating from side to side as the bolts are tightened in the curve and the load section of the conveyor After tightening these bolts install the guide rails and install and finger tighten the remaining mounting bolts and nuts in the incline and discharge sections Finish tightening the rest of the bolts in the incline and discharge section of the conveyor alternating sides as before Reconnect any wiring if it was removed per the wiring schematic Test run the conveyor making sur
26. h 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 case of 220 440V 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 mateing 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 placing the purchase 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 plug 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 start
27. ing the chip conveyor check to be sure no tools packing or other material have been left on the conveyor Start the conveyor and verify proper direction of belt travel VERY IMPORTANT MAKE SURE THE ROTATION OF THE DRIVE SHAFT CORRESPONDS WITH THE DIRECTIONAL ARROWS LOCATED ON THE DRIVE SHAFT OF THE CONVEYOR IF THE DRIVE SHAFT IS MOVING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS IMMEDIATELY STOP THE CONVEYOR DISCONNECT THE POWER SUPPLY AND REVERSE THE POWER SUPPLY LEADS TO THE CONVEYOR RECHECK THE DRIVE SHAFT FOR ROTATION CONVEYOR DAMAGE WILL OCCUR IF THE CONVEYOR IS ROTATING IN THE OPPOSITE DIRECTION OF THE DIRECTIONAL ARROWS NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 31 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL TIME DELAY DEVICES The use of a time delay device is not suggested on a Magnetic Conveyor If the conveyor is not running when the machine tool is cutting chips it may cause a large chip build up in the conveyor frame This condition may cause the coolant flow to be restricted which can result in coolant overflowing the conveyor baffles allowing excessive chips to flow into the coolant tank or coolant spills onto the floor This condition may diminish the effectiveness of the conveyor and result in downtime due to excessive maintenance cost due to more frequent coolant tank cleanings maintenance This may also re
28. ll of the chain and magnets have been installed Position the belt chain over the drive sprockets and re install the master links Make sure both chain and magnets are installed over the sprockets so they are symmetrical and the magnet assemblies run perpendicular with the conveyor track Remove the tension bolts installed in step 7 and reinstall the original bolts Note Apply a high grade caulking to the face of the bolts to make sure this area is watertight Install the stainless steel top cover and baffle weldment making sure the seals are properly seated and in good condition Use a high grade calking if necessary to insure a watertight seal between the stainless steel top cover and the frame Install the baffle weldment making sure the seals are properly seated and in good condition Use a high grade calking if necessary at any seams of the seal to insure a watertight seal between the baffle weldment and the stainless steel top cover 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 20 21 22 23 24 25 26 27 28 12 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL After positioning the stainless steel top cover seals and batfle weldment on the conveyor frame insert the mounting bolts in each hole first to keep all parts aligned and then tighten the nuts by hand only Tighten the mounting bolts starting in the lower curve and
29. ne or forklift properly supports the conveyor before loosening the locking bolts on the support leg Loosen the bolts that secure the adjustable support leg With the casters resting on the floor and the conveyor discharge end supported by a crane or forklift adjust the discharge end of the conveyor vertically until the proper height is obtained to level the horizontal load section of the conveyor Once the conveyor is properly leveled tighten the locking bolts on the support leg The coolant tank should be cleaned of any chip residue from prior machining operations before installing the conveyor Have a certified electrician wire the conveyor to the machine with the electrical cable provided VERY IMPORTANT Make sure the rotation of the drive shaft corresponds with the directional arrows located on the drive shaft of the conveyor If the drive shaft is moving in the opposite direction of the directional arrows immediately stop the conveyor disconnect the power supply and reverse the power supply leads to the conveyor Recheck the drive shaft for rotation Conveyor damage will occur if the conveyor is rotating in the opposite direction of the directional arrows 10 Please contact the LNS Conveyor Service Department if you have any problems with the installation 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 2 TURBO PARTS AND S
30. o the hole and pry out the seal 2 Clean the seal bore of sealant 3 Before installing the new seal use electrical tape to cover any keyways on the shaft to prevent seal lip damage 4 Grease the seal lips with bearing grease and apply a sealant to the seal bore 5 Slide the seal into the shaft being careful not to fold the inner lip over on any shaft steps 6 Press the seal itno its bore with a sleeve that presses on the seal casing being careful to keep the seal square in its bore 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 Conveyor is running in reverse Drive shaft is rotating opposite the directional arrows on the conveyor The conveyor is jamming or the belt will not run After running for some time conveyor starts having trouble lifting fine materials incline section NOVEMBER 2003 LNS Page 21 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR TROUBLE SHOOTING GUIDE The following chart will show some problems their probable causes and possible solutions PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Polarity is wrong on conveyor motor leads a Loose magnet assembly broken magnet assembly or broken chain b Broken take up stub shaft or take up sprocket worn excessively c Chain has jumped time d The master link on the belt of the conveyor has separated e The magnet assemblies have f
31. onveyor Install the flat rectangular inspection plate which was removed in step 4 Install the motor and gearbox Reconnect any wiring if it was removed per the wiring schematic Test run the conveyor making sure that the belt direction is correct The chips should be carried up the incline toward the discharge when the belt is rotating correctly Failure to run the belt in the correct direction can cause damage to the conveyor Reinstall the conveyor into the machine tool Reconnect the electrical power to the conveyor Test run conveyor to insure proper operation 2003 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 14 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL INSTRUCTONS FOR REPLACING THE CHAIN AND MAGNET ASSEMBLIES 1 10 11 12 13 14 15 16 17 18 19 Remove the 1 gt hole plugs and run the conveyor until a master link on the chain can be seen through the opening Stop the conveyor at this point Disconnect Power from the conveyor Use Lock Out Tag Out Procedure Note only authorized trained electricians are to perform this task Remove the bolts and nuts securing the guide rails from both the right and left side of the conveyor Remove the guide rails that run up the incline on both sides and wrap around the discharge radius peripheral Once the incline guide rails are removed remove the bolts an
32. orrect size for the conveyor drive motor Repair the damaged section or replace the chain Replace failed or missing parts AFTER determining cause of failure Replace worn or broken parts Replace motor Replace Gear Reducer Refer to SERVICE SECTION for proper procedure for taking conveyor apart Check conveyor for worn track and broken magnet assemblies Clean slider face with a strong solvent cleaner and polish with Scotch Brite m PUBLICATION NO 864510 0002 REV 01 22 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL MAGNETIC CONVEYOR TROUBLE SHOOTING GUIDE CONT PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Conveyor amp Chain may require lubrication Remove discharge access plate and spray lubricate draw is higher than on the chain both sides normal Excessive wear a Conveyor is not level or square Properly level conveyor of the conveyor track Material has a Chain has stretched or tensioning springs in Refer to SERVICE SECTION for proper procedure for jerking motion as it tail section block need replacement taking conveyor apart moves up stainless steel top cover Conveyor has Leaking seals in lower horizontal section or Refer to SERVICE SECTION for proper procedures excess coolant incline section to replace conveyor seals dripping from discharge section 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01
33. r model conveyors may have Neoprene Sponge Rubber on frame in the incline and discharge section 3 otrip off any adhesive left on the surface of the frame and clean surface thoroughly 4 Apply the double bulb seal using Zip Grip starting at the top of the lower curve See fig below The double bulb seal must be run continuously in this area to prevent leakage Do not splice seal In order to make a continuous run of seal a notch must be cut in the seal to turn the two corners at the tail section of the conveyor see notch cutout below SEAL IN CORNER RUN SEAL CONTINUOUSL Y IN CROSS HATCHED AREA NOVEMBER 2003 85 PUBLICATION NO 864510 0002 REV 01 10 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL 5 Apply Buna Seal on top of the adhesive strip in the incline and discharge section starting at the top of the lower curve See fig 2 No notching is required in this section 6 Put holes in seals where there are holes the frame drill may be used for this purpose using the holes in the frame as a guide Do not drill any new holes in the frame Nm Sad Dh Bad dad dodo heh be tod bh bbb bd bb VS D N DN START HERE APPLY BUNA SEAL IN CROSS HATCHED AREA IN INCLINE amp DISCHARGE SECTIONS BUNA SEAL IN THIS AREA ONL
34. reduction in cooling ability due to exterior contaminants Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation GENERAL GEAR REDUCER OPERATION Run the motor which drives the reducer and check the direction of the reducer output rotation If the rotation direction is incorrect read the motor nameplate for instruction to reverse the direction of rotation 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 17 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL GEAR REDUCER INSTALLATION 1 If any of the mounting bolts have been lost use grade 5 or higher fasteners The mounting fasteners should be the largest standard size that will fit in the base mounting hole 2 For shipment of replacement gear reducers pipe plugs are installed in the unit and a vent plug is packed separately After mounting the unit in position remove the appropriate pipe plug and install the vent plug in the location shown on page 5 On double reduction units both the primary and the secondary must be vented Failure to vent the unit can cause premature seal wear or loss of seal and oil These conditions are not covered by warranty Check for correct oil level 3 Connect motor to speed reducer DO NOT CHANGE MOUNTING POSITIONS WITHOUT CAUTION CONTACTING FACTORY Altering the mounting position may require special lubrication provi
35. sions which must be factory installed Do not operate the reducer without making sure it contains the CAUTION correct amount of oil Do not overfill or underfill with oil or injury to personnel reducer or other equipment may result For safe operation and to maintain the unit warranty when changing CAUTION a factory installed fastener for any reason it becomes the responsibility of the person making the change to properly account for fastener grade thread engagement load tightening torque and the means of torque retention 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 18 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL LUBRICATION STANDARD GEAR REDUCTER All standard reducers ordered from the factory are filled with lubricant to operate within a 30 to 100 F ambient temperature range Double and triple reduction units have separate oil sumps and must be filled checked independently Prior to startup verify that the oil is at the level shown on the drawings on page 13 If the ambient temperature will be outside the range for the lubricant installed at the factory drain and refill the reducer with the proper viscosity lubricant prior to use Consult the chart on page 12 or the factory for alternate lubricants Change intervals Standard compounded lubricants should be changed every six months or 2500 operating hours whichever comes first
36. stigate wrap wear magnet assemblies the cause of the shrink wrap wear Every 3 months Check to insure the Conveyor may have been Level per procedures in this conveyor is level bumped or moved out of manual position Every 6 months Check flange bearing Do not over apply grease Grease lightly with a grease to see if they need Too much grease will gun if a grease fitting is in the lubrication break the seal and cause bearing premature bearing failure Remove the discharge Check the full amp draw Spray lubrication on the chain access cover and on the motor before and on both sides inspect the chain for after lubrication of the lubrication chain Change gear reducer Inspect the gear reducer After changing the oil test run oil with proper oil to insure there are no the gear reducer to insure recommended in this leaks at the seal and that proper operation manual vent hole is not clogged Remove the slider Inspect take up Replace any damaged or face and inspect for tensioning assembly excessively worn parts main component wear magnet assemblies drive components and seals Also insure that the inside of the frame is dry Every 3 months Every 6 months Every 6 months or 2500 operating hours whichever comes first Annually 2003 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 24 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE
37. sult in shorter pump life and or more frequent pump maintenance AC SUPPLY CIRCUIT AMP LOAD FOR MICROFINE S CONVEYORS Your LNS chip conveyor is equipped with an AC motors to drive the conveyor chain The full load amp draw 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 must provide a circuit breaker or a fused disconnect switch on the power supply to the conveyor It 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 AC CURRENT REQUIREMENTS FOR MAGNETIC CONVEYORS Voltage Belt Drive Type Belt Drive Full Amp Load Rating 3 Phase Horsepower 230 VAC Fixed Speed 1 2 230 VAC Variable Speed 1 2 460 VAC Fixed Speed 1 2 460 VAC Variable Speed 1 2 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 32 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL OPTIONAL VARIABLE SPEED DRIVE If the conveyor is equipped with a variable speed control the belt speed of the conveyor will be controlled by a variable speed inverter drive located on the conveyor electrical control panel The conveyor belt speed is adjustable from near zero to approximately 32 feet per minute The belt speed should be set at th
38. t to insure it is not damaged Replace if torn or damaged Remove the stub staft springs and roll pins from the take up housing assembly Refer to the MAGNETIC CONVEYOR TENSIONING ASSEMBLY section of this manual which shows an exploded view of the parts for reference Inspect all parts and repair or replace any damaged parts Follow reverse order of this procedure to reassemble GEAR REDUCER MAINTENANCE Hot oil and reducers can cause severe burns Use extreme care when removing WARNING lubrication plugs and vents e Make certain that the power supply is disconnected before attempting to service or remove any components Lock out the power supply and tag it to prevent unexpected application of power e Reducers are not to be considered fail safe or self locking devices If these features are required a properly sized independent holding device should be utilized Reducers should not be used as a brake Any brakes that are used in conjunction with a reducer must be sized or positioned WARNING in such a way so as to not subject the reducer to loads beyond the catalog rating e Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors e lf the speed reducer cannot be located in a clear and dry area with access to CAUTION adequate cooling air supply then precautions must be taken to avoid the ingestion of contaminants such as water and the
39. when removing the drive shaft Replace the drive shaft While installing the drive shaft back into the frame make sure to reinstall the drive sprockets keys and snap rings as shown on the exploded view of the parts section of this manual Make sure the drive shaft is positioned so that the sprockets are correctly centered in the frame before locking the shaft down by tightening the locking collars on the flanged bearings onto the drive shaft Position the belt chain over the drive sprockets re install the master links position the drive sprockets with the keys in place and reinstall the external snap rings Install the bolts in each side of the chain ramp which were removed in step 5 Make sure both sprockets are installed so they are in time with each other Insure that the set screws in the drive sprockets are tighten If the sprockets are not in time the conveyor will not operate 20032 LNS ace co ve rae PUBLICATION NO 864510 0002 REV 01 21 22 23 24 25 26 27 28 29 30 31 13 TURBO MAGNETIC CONVEYOR PARTS AND SERVICE MANUAL Remove the tension bolts installed in step 10 and reinstall the original bolts Note Apply a high grade caulking to the face of the bolts to make sure this area is watertight Fold the stainless steel slider face back down onto the conveyor Reinstall the guide rails on both sides of the c
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