Installation. Natrix

Transcription

1 Installation Natrix

2 Table of Contents 1 Prerequisites for Installation Site On-site Delivery and Insertion at Ground Level On-site Delivery and Insertion via Ramp Intermediate Storage of Materials Transport Routes in the Building Conditions as Delivered Single Device Several Devices/ Modules in Stacks Pictures of Packing Units Unloading Checking the Load for Damage Accessories Floor Space Required Unloading Processes Unloading Using a Crane Unloading Using a Ramp Lateral Unloading Transport in General Insertion and Installation Accessories Preparation Installation Completion and Adjustment Completion General Maintenance Unit Sensors Adjust Chain Target Path Oiler Monitoring of Chain Tension Chapter IV - Installation Natrix

3 5.4 Test Run Chapter IV - Installation Natrix

4 Attention The procedure described below is only a recommendation of TGW Mechanics; the exact procedure must be defined and adapted to the respective installation site situation. The installation must only be carried out by trained and qualified personnel. The responsibility for the correct realisation of the installation work resides with the personnel entrusted with installation. Attention Safety briefing of installation personnel according to occupational health and safety protection plan Chapter IV - Installation Natrix page 1

5 1 Prerequisites for Installation Site 1.1 On-site Delivery and Insertion at Ground Level 1) Door size The delivery and insertion of machinery on site requires a minimum height of H = 3 m and minimum width of W = 2.5 m 2) Determine floor space required or location for mobile crane or truck Check special conditions on hall floor (e.g. do forklift trucks require white tyres?) Check for pits, columns and other obstacles 3) Installation surface Installation surface must be even, dry and clean 4) Forklift truck Check if a forklift truck is available If yes, check if size and weight-bearing capacity is sufficient If no forklift truck is available, rent one if necessary Provide required accessories (see chapter 3.2) Forklift truck with lifting carriage or lifting platform required to remove sling gear 1.2 On-site Delivery and Insertion via Ramp 1) Door size The delivery and insertion of machinery on site requires a minimum height of H = 3 m and minimum width of W = 2.5 m 2) Ramp height Is the available ramp height-adjustable or fixed? Check capacity of ramp 3) Determine floor space required or location for mobile crane or truck Check special conditions on hall floor (e.g. do forklift trucks require white tyres?) Check for pits, columns and other obstacles 4) Installation surface Installation surface must be even, dry and clean 5) Forklift truck Check if a forklift truck is available If yes, check if size and weight-bearing capacity is sufficient If no forklift truck is available, rent one if necessary Provide required accessories (see chapter 3.2) Forklift truck with lifting carriage or lifting platform required to remove sling gear Chapter IV - Installation Natrix page 2

6 1.3 Intermediate Storage of Materials 1) Floor space required for material containers 2) Space required for storage per device = (L m) x (W m) (L or W = length or width of respective device) Package dimensions Æ see chapter 2 Conditions as Delivered 1.4 Transport Routes in the Building 1) Check state and conditions of transport routes Chapter IV - Installation Natrix page 3

7 2 Conditions as Delivered 1) The device is available in standard module widths 820/1020/1220/1420/1620 mm. 2) The drive and return modules are provided separately from the rest of the frame for the most part. 3) The dispatch units mostly consist of three frame modules stacked on top of each other. 4) 2 forms of shipping Single device Several devices/ modules in stacks 5) Supports are always delivered separately 6) Load secured 2.1 Single Device [mm] Packing dimensions Length max Width max Height max Weight max. 600 kg 2.2 Several Devices/ Modules in Stacks [mm] Packing dimensions Length max Width max Height (container shipment) Maximum weight/ stack max (max. 2000) max kg Chapter IV - Installation Natrix page 4

8 2.3 Pictures of Packing Units Chapter IV - Installation Natrix page 5

9 3 Unloading 3.1 Checking the Load for Damage Should you detect damages, please note them down on the delivery note with date and signature (in block letters!) 3.2 Accessories Sling gear Fork extenders 4-chain safety suspension (minimum length 5 m, bearing load approx. 5 t) 3.3 Floor Space Required Æ See chapter 2 Conditions as Delivered and Order Package List 3.4 Unloading Processes 1) Transport the modules to the installation area free from distortion using adequate means of transport Unloading Using a Crane [1] [2] [3] Caption: [1]... Mobile crane [2]... Lifting belt [3]... Stack of transfer devices Chapter IV - Installation Natrix page 6

10 3.4.2 Unloading Using a Ramp [2] [1] [3] [1] Caption: [1]... Forklift truck with fork extender (height of forklift truck: low height of lorry) [2]... Stack of transfer devices [3] Single device Attention Do not lift the machinery at the drive! Lift the conveyor stack in the upper third! Remove the lateral guides, if necessary! Chapter IV - Installation Natrix page 7

11 3.4.3 Lateral Unloading [2] [1] [3] [1] Caption: [1]... Forklift truck (with fork extender where appropriate) [2]... Stack of transfer devices [3] Single device Attention Do not lift the machinery at the drive! Lift the conveyor stack in the upper third! Remove the lateral guides, if necessary! Chapter IV - Installation Natrix page 8

12 3.4.4 Transport in General [2] [1] S [1] [3] Caption: [1]... Forklift truck (with fork extender where appropriate) [2]... Stack of transfer devices [3] Single device Attention Do not lift the machinery at the drive! Lift the conveyor stack in the upper third or centre of gravity S under the forklift truck fork! Remove the lateral guides, if necessary! Chapter IV - Installation Natrix page 9

13 4 Insertion and Installation 4.1 Accessories Required special tools: see Tool List 4.2 Preparation 1) Define the axes Sketch the centre axis on the floor 2) Determine the level Determine the point from which the height is measured i Please note Align according to the zero point 4.3 Installation i Please note Further installation requirements can be found in the specifications drawing of TGW. 1) Installation of the supports Drive frame on supports As required, insert the filling plate between the supports and the frame to obtain smooth transitions of the running surfaces All running surfaces smooth bolt together Chapter IV - Installation Natrix page 10

14 2) Assembly of modules Place the connecting from on supports Use the connection for pneumatic tubes Attach the guide bracket X Detail X Screw and adjust the joints and struts Smooth transition bolt together Section A - A Chapter IV - Installation Natrix page 11

15 3) Alignment Align the beginning and the end in the axes according to the layout position and attach them to the floor or steel structure Centre and attach to the floor or steel structure Use a levelling instrument to align the levels Align the straightness using a tensioned cord The reference points are the surfaces of the guide correct i Please note The reference points are the surfaces of the guide. Chapter IV - Installation Natrix page 12

16 Frame butt joint and running surface above Smooth transition Frame butt joint and running surface below Smooth transition 4) Floor (platform) attachment Align the supports perpendicularly Attach the supports one time on each side to the floor or steel structure - I-beam attachment Chapter IV - Installation Natrix page 13

17 Drilling depth 90 Drilling depth 95 - Wood - Concrete Tightening torque Ma = 50Nm Borehole Ø12 - Concrete, aggressive Lining rubber Tightening torque Ma = 20Nm Borehole Ø12 5) Install Adjust and check the bracket and guides. Grind the frame butt ends and guide transitions as required. Attention These activities must be performed for both the running side and the return side. Chapter IV - Installation Natrix page 14

18 Smooth transition Frame butt end Screw connection of the main air line of the sorter 6) Installation of the chain Installation of the sorter link chain in the conveying direction Plug connection Attention All cups must be on the target path side. Place the carrying mat (about 1.4 m) Remove the last aluminium profile located over the end of the chain. Pull in the beginning and end of the support rug using two tensioning belts (max. 5 m in length) Connect the chain to the locking link Reattach the aluminium profile (screw tightening torque = 20Nm) Tightening torque Ma = 20Nm Chapter IV - Installation Natrix page 15

19 Attention The tensioning station must be in the end position if you want to take advantage of the maximum tensioning distance. The closed side of the locking springs must point in the conveying direction. i Please note After the connection of the chain, check whether the aluminium profiles are at a right angle to the sorter frame. 7) Tighten the shrink disc to the gear according to the instructions. 8) Remove the aluminium profiles and make sure that no dirt, tools, or loose screws can be found in the sorter frame along its entire length. Chapter IV - Installation Natrix page 16

20 5 Completion and Adjustment 5.1 Completion General 1) Install the proximity switch. Adjust the sensing distance to 3 mm 2) Install the optional dirt pan. Attach the dirt pan [1] using cross-struts [2] [3] [1] NW 820 = L 4350 A NW NW 1220 = L 8370 NW NW 1620 = L Elevation A [2] [2] Chapter IV - Installation Natrix page 17

21 i Please note Observe the distance between the return pulley [3] and the dirt pan [1]. 3) Install the covers Top cover (stainless steel bracket) Detail X Detail Y Cover oblique (only in case of slide) Attention The cover bracket may not touch the sorter link chain/push-off cup. Chapter IV - Installation Natrix page 18

22 Frame panelling - Attach the side panelling [1] using a clamping plate [2]. - Attach the floor cladding [3] using cross-struts [4] [1] [3] X [4] Detail X [2] Attention During the test phase, check the chain tension constantly and adjust it if necessary. Chapter IV - Installation Natrix page 19

23 5.1.2 Maintenance Unit 1) Installing the maintenance unit Attach the maintenance unit to a base, frame, or target path profile and establish a connection to the main air line. Set an operating pressure of 6 bar on the pressure switch! - Attach the maintenance unit to the support o Drill a borehole Ø 7 mm into the top of the base Elevation F Borehole - Attach the maintenance unit to the U-profile Elevation G Chapter IV - Installation Natrix page 20

24 - Air supply of the maintenance unit sorter main air line o Drill a cable opening on the frame for the air supply of the maintenance unit sorter main air line to Ø 20 mm Elevation G Drill to Ø 20 mm - Attach the maintenance unit to the sorter frame o Install the bracket for the maintenance unit together with the plate for the cover (side panelling) Elevation G Bracket for the maintenance unit Sensors 1) Install sensors according to sensor-actuator layout Chapter IV - Installation Natrix page 21

25 5.2 Adjust Chain 1) Tension chain Loosen screws [1] Remove covers [2] Always perform the following activities alternately on the right and left side of the machine Mark the position of return pulley [5] Loosen screws [3] Use clearance [6] to shift the tension carriage If the tension carriage moves, the tension spring [7] must be returned to the SETPOINT position by tightening the clamping screw [4]. Repeat this procedure until the tension carriage remains permanently in its position (the tension spring must be in the position shown) Fix the tensioning station into place again by tightening the screws [3] whilst checking whether the transitions of the running surfaces [8] are smooth! Run the device at maintenance speed Check the pretension of the sorter link chain! If the chain pretension is correct, reinstall the covers [2] i Please note After tensioning the sorter link chain, check the connection dimensions according to the sketch of GF ZSOR [9]. Chapter IV - Installation Natrix page 22

26 [1] [10] [2] [3] [7] [6] [4] [5] Detail X Spring end flush with retaining plate [8] [9] 2) Check chain tension The chain tension is checked 2 m in front of the return pulley If you unscrew a push-off cup by about 3 mm, the following running wheel must lift 1 ± 0.2 mm from the surface of the guide If the following running wheel does not lift from the surface of the guide, it must be retensioned Chapter IV - Installation Natrix page 23

27 5.2.2 Target Path 1) Marking of the target path position Set a point manually whilst making sure that no bolt is in the vicinity of the point tongue Move the rug by hand until the cups are oblique With a straight edge, mark the first target path position Discharge angle Dimension X mm mm Oiler 1) Adjustment of the oiler ZSOR Variant - Oil interval every 10m, sorter 100 hours/100 operating hours (e.g. 40 m sorter every 100 operating hours, oiler active for 100) Elevation D Elevation E Chapter IV - Installation Natrix page 24

28 i Please note Set oil flow rate to one drop/minute Natrix Variant - For the adjustment instructions see the information on the oiler cover - Bleed the main line by loosening the screw connection of the pressure switch - When the main line is free of air, retighten the screw connection Line free of air Oil/air mixture emerges Attention Only activate the oiler when the sorter is in operation. Oil may not be flung from the conveyor chain. Chapter IV - Installation Natrix page 25

29 5.3 Monitoring of Chain Tension 1) Activation of chain monitoring After tensioning the chain, activate the chain monitoring valves [1] on both sides INI free Deactivated Activated INI switched Distance between the running wheel of the tensioned sorter link chain and the monitoring valve = 7mm [1] Valve position down: running surface and edge on one level 5.4 Test Run 1) Test run at crawling speed, test Chapter IV - Installation Natrix page 26