Glide-Line Heavy Duty Lift Locate Unit (HLLU)

Transcription

1 V1.0 Glide-Line Heavy Duty Lift Locate Unit (HLLU) Installation & Maintenance Manual Easy Flexible Precise Fast i

2 V1.0 Manual Information Throughout this manual are the following information blocks indicated in the appropriate sections by signal words as specified by ANSI Z535.4 Standard (section 4). Warning This information must be followed to prevent harm to individuals or damage to equipment. Automatic Equipment This equipment may start or stop automatically. Electrical Shock This equipment has connection to an electrical circuit with potentially hazardous energy levels. Consult Manual This manual must be completely reviewed prior to performing any service. Lock Out Power All sources of energy must be controlled before servicing equipment ii

3 V1.0 Table of Contents 1. Introduction... 1 Description of Device... 1 Operating Conditions and Environment... 1 Chemical and Corrosion Resistance... 1 Serial Number Info Installation... 3 Unpacking and Mounting... 3 Device Set-Up... 3 Recommended Pneumatic Schematic Safety Instructions... 5 Operation Maintenance... 6 Lift Cylinder Removal... 6 Preventative Maintenance Schedule Troubleshooting How to Order Spare Parts Returns iii

4 1. Introduction Description of Device The Heavy Duty Lift and Locate Unit is designed to lift pallets off of a conveyor surface and engage with the locating features in the Glide-Line Pallets. The HLLU is designed to sustain press loads of over 20,000lbs. Due to the high loads associated with the application, the HLLU cannot be conveyor mounted and must be mounted to a rigid machine base. Please reference the part number below to understand how the unit was ordered and supplied. Part Number: HLLU-(A)-(B) A = Pallet Width Range 160mm to 360mm B = Pallet Length Range 160mm to 360mm Personnel working on or around this equipment must be properly trained in operation, maintenance, and lock-out/tag-out procedures. Operating Conditions and Environment Equipment should be located in an ambient temperature room. Equipment should not be subject to high humidity or wash-down conditions. Clean-up to be by wipe down / air blow off only. This unit must be connected to an external control system to operate properly. This equipment was not designed to run in a standalone configuration. No control voltage, programmable controller, or other functionality have been provided with this equipment. Chemical and Corrosion Resistance Components used by Glide-Line are made from materials that are highly resistant to common household materials including all fruit and vegetable juices, inks, soaps, and most common detergents. It is recommended that customers contact the factory and obtain samples of applicable modules to be exposed to conditions of the proposed application to determine resistance of material and its durability. SPARES TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 1

5 Serial Number Info The Serial number for your HLLU can be found on the base plate of the unit. Serial number information will be displayed as follows: Glide-Line Job Number XXXXX.GLHLLU.YYY Individual ID Number Device Type SPARES TROUBLESHOOT INTRODUCTION INSTALLATION MAINTANENCE SAFETY 2

6 2. Installation Unpacking and Mounting When the unit arrives, care must be taken to unpack the unit. Smaller units will be packaged in individual boxes, bubble wrapped. Take care to cut away bubble wrap. Do not score with a knife as not to risk damage to the unit. Larger units will ship on a skid. Units will be secured with T-Bolts to a series of support boards and can be loosened with a 13mm ratchet. Prior to mounting the unit into position, it is recommended that air fittings are installed. The unit does not include air fittings. Please select fittings for G1/8 connection to the cylinder body. When mounting the device directly to a station, the device base plate includes (2) 8mm locating dowel holes and (4) M8 bolt locations. For precision mounting, it is advised to transfer this hole pattern in the machine base. First mount locating dowels, then proceed to tighten down the 4 screw locations. It is important to install the device level and straight to achieve the listed performance. A nonlevel installation could induce moment loading to the cylinder body and guide rods, decreasing the design life of the device. Device Set-Up After bolting the unit into the desired location, the unit can be plumbed with air lines and flow controls as required for the application. Device is not supplied with fittings, tubing, flow controls, or solenoids. Reference the pneumatic schematics for the recommended solenoid and piloted valve layout. For proper operation of device, the order of operation is recommended: 1. Lift cylinder actuates to Up position, with the top plate pins engaging the Work Piece Pallet s locating bushings 2. Shuttle Plate cylinder is extended to move support pins into position 3. Exhaust air from lift cylinder so support pins make contact with base plate supports 4. Operations completed to workpiece 5. Re-engage Lift Cylinder to Up position 6. Shuttle Plate Cylinder retracts, pulls support pins out of position. 7. Lift cylinder retracts to Down, disengaging locating pins from pallet SPARES TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 3

7 Recommended Pneumatic Schematic Note, that all ports are G1/8. Fittings and Valves not included. SPARES TROUBLESHOOT INTRODUCTION MAINTANENCE SAFETY INSTALLATION 4

8 3. Safety Instructions Operation Due to the hazardous moving parts of the device, all personnel in the area of a device should be warned when the device is about to be activated. Only properly trained personnel should be permitted to operate Glide-Line devices. Training should include emergency procedures. Machine stopping devices should be clearly marked and easily accessible. Personnel working on or near the equipment should be trained in the location of stopping devices. The area around machinery should be kept clear. Devices must only handle loads they were designed to carry. Safety and warning devices must not be tampered with in any way that could endanger personnel. Personnel must be made aware of all potential hazards including but not limited to entanglement of items such as long hair, loose clothing or jewelry. Personnel must also be aware of any pinch points present on the device that could result in injury. Device should not be operated without safety guards in place. Guards should not be removed by anyone other than authorized personnel. All safety devices, including wiring of electrical safety devices, must be designed to work in a failsafe mode to avoid hazardous conditions from occurring during a power failure. Refer to ANSI Z , American National Standard for Personnel Protection Lockout/Tagout of Energy Sources Minimum Safety Requirements and OSHA Standard Number 29 CFR The Control of Hazardous Energy (Lockout/Tagout). TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION SPARES 5

9 4. Maintenance Only trained personnel should perform maintenance procedures. Company approved lock-out/tag-out procedures should be strictly adhered to. Please consult this manual before servicing. Routine inspections along with preventive and corrective maintenance must be performed to insure proper functioning of equipment. Maintenance schedules should be established to insure proper operation and to avoid potential hazards. Maintenance must not be performed on equipment while in operation. Personnel should be trained in proper maintenance procedures as well has the hazards of not following procedures properly. When equipment is stopped for maintenance, lockout/tagout procedures should be followed in order to avoid potential hazards to personnel performing the maintenance. All safety devices and guards must be replaced before starting conveyors for normal operation. Lift Cylinder Removal Tools Required: (1) 5mm Allen Key (1) 6mm Allen Key To replace a lift cylinder please follow the following steps: 1. On the top of the unit, remove the (2) cylinder mount screws in the center of the anvil plate with a 5mm Allen Key 2. On the bottom of the unit, remove the cylinder rod screw with an 6mm Allen Key. 3. Pull Top assembly up and remove cylinder. Note orientation of fittings prior to removal to match when replacing cylinder. When replacing the cylinder, follow all above steps in reverse. Use blue thread locker on all threads to make sure screws will not back out during operation. SPARES TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION INTRODUCTION 6

10 Preventative Maintenance Schedule Daily Prior to Starting Equipment 1. Perform a visual inspection of the equipment for possible maintenance needs. 2. Remove any foreign objects that may be on or leaning against conveyor or equipment. 3. Inspect airlines for any damage or loose connection. After Starting - Prior to Production 1. Perform a visual and auditory inspection of the equipment and product transportation for possible maintenance needs. Stop device operation if hissing sound is present. Monthly 1. Check all bolts have remained tightened to designed torque ratings. 2. Wipe guide rods of any debris. 3. Clear anvil plate of any debris. SPARES INTRODUCTION INSTALLATION SAFETY TROUBLESHOOT MAINTANENCE 7

11 5. Troubleshooting Problem Cause Solution Pins do not engage Pallets damage/warped Repair/Replace all effected pallets pallet bushings when lift is actuated. High Tolerance pins not dressed prior to use Use a fine stone to break the edge of the precision locating pins. Retry entry to Pallet Stop incorrectly placed Pallet unable to lie flat due to debris on Anvil Plate Problem Cause Solution pallet, repeat if necessary Pallet stop may need to be moved closer/further from the device to prelocate the pallet so the bushings are aligned with the locating pins Clean off anvil plate. Replace any damaged components if necessary. INTRODUCTION INSTALLATION Lift does not rise. Cylinder or airline damaged/leaking Misalignment in guide rod/bushing assembly Replace cylinder or airlines affected Check that device is installed square and level. Exhaust air from the cylinder and confirm it can freely move. If bound, contact factory for instruction. Problem Cause Solution Shuttle plate not moving, or support pins not aligning. Obstruction in the path of shuttle plate Incorrect operating sequence Clear any obstructions, inspect for damage. Check sequence against the order of operation detailed in the Device Setup Section. Shuttle cylinder rod screw loose Confirm screw is in good condition, retighten. Use thread locker if required. SAFETY MAINTANENCE TROUBLESHOOT SPARES 8

12 6. How to Order Spare Parts Spare parts may be purchased directly from Glide-Line. For a full list of spares for your conveyor or device as configured, please reference the serial number located near the base plate of your device, and contact a Glide-Line representative at SPARES TROUBLESHOOT INTRODUCTION INSTALLATION MAINTANENCE SAFETY 9

13 7. Returns Under no circumstances will a component be accepted without a Glide- Line RMA number. INTRODUCTION When requesting a Return Materials Authorization (RMA), please have the following information available: Customer s name and address Customer original purchase order number Glide-Line s project number or serial number Description of part(s) being returned Reason for return To preserve the return, all returned parts must be properly packaged to prevent shipping damage. The Glide-Line issued RMA number must be clearly marked and visible on the exterior packaging. The Glide-Line issued RMA form must also be included inside the package. Includes: Location, type of service and length of time in service Complete description of the faulty operation of the component and the circumstances of failure. State requested service warranty or non-warranty Complete shipping instructions for return of component Name and telephone number of person to be contacted if there are any questions about the returned part. If a part is damaged or lost during transit, the customer is responsible for directing a claim to the carrier. The customer is responsible for return freight. Upon receipt of the defective component(s), Glide-Line will examine it for warranty defects. A credit will be issued for the replacement when and if the component is found to be defective. Following the above procedure correctly will expedite handling of the returned component and will prevent unnecessary additional charges for inspection and testing to determine the problem with the component. For all orders and service, a written Purchase Order for repairs must be enclosed. SPARES TROUBLESHOOT MAINTANENCE SAFETY INSTALLATION 10