ELCOM TLM 1000 User Manual & Maintenance Manual

Modular transfer system

TLM 1000

User manual

&

Maintenance guide

Translation of the original manual, version 04

I02-118 User manual & maintenance guide Version 04 (translation of the original manual)
of TLM 1000

Table of contents

1 General information ........................................................................................................................ 1

1.1 Important remarks .................................................................................................................. 1

1.2 Applicable standards ............................................................................................................... 1

1.3 Applications ............................................................................................................................. 1

1.4 Conditions of use ..................................................................................................................... 1

1.5 Safety instructions ................................................................................................................... 2

1.6 Safety instructions regarding the motor ................................................................................. 2

1.7 Additional information ............................................................................................................ 2

2 Technical specifications ................................................................................................................... 3

3 Commissioning ................................................................................................................................ 4

3.1 Receipt ..................................................................................................................................... 4

3.2 Transfer elements ................................................................................................................... 4

3.3 Stopper .................................................................................................................................... 4

3.4 Positioning unit ........................................................................................................................ 4

3.5 Workpiece carrier .................................................................................................................... 5

4 Maintenance ................................................................................................................................... 5

4.1 Belts wear ................................................................................................................................ 5

4.2 Passageways of workpiece carriers ......................................................................................... 5

4.3 Pins .......................................................................................................................................... 5

4.4 Wear of the belt guide ............................................................................................................ 5

4.5 Transfer parts .......................................................................................................................... 6

4.6 Stopper .................................................................................................................................... 6

4.7 Positioning unit ........................................................................................................................ 7

4.8 Heavy positioning unit ........................................................................................................... 10

4.9 Other transfer parts .............................................................................................................. 11

5 Motor Replacement ...................................................................................................................... 12

5.1 Disassembly ........................................................................................................................... 12

5.2 Reassembly of the motor ...................................................................................................... 14

5.3 Changing the belt – Flat belt ................................................................................................. 14

5.4 Changing the belt – Timing belt ............................................................................................ 16

6 Responsability ............................................................................................................................... 17

7 Customer service ........................................................................................................................... 17

8 Appendix ........................................................................................................................................ 18

8.1 Maintenance schedule .......................................................................................................... 18

8.2 Quality and environmental commitment: ISO certifications ................................................ 19

8.3 Spare parts list ....................................................................................................................... 20

I02-118 User manual & maintenance guide Version 04 (translation of the original manual)
of TLM 1000

Version tracking:

Version

Date

Description of modifications

Prepared by

Approved by

01

01/10/15

Initial (translation)

S. GUILLAUD-BATAILLE

02

06/12/16

-

S. GUILLAUD-

BATAILLE

-

03

19/09/18

Upgrade of the safety instructions + 2015
edition of ISO 9001 and 14001 standards:
deletion of expired certificates

S. MAIRET

S. MAIRET
04

06/02/19

ERRATUM - Modification in the
calculation of the flat belt

C. POULET

S. MAIRET

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of TLM 1000 Page 1 sur 25

1 GENERAL INFORMATION

1.1 Important remarks

The following instructions will be used as technical documentation for the manufacturer of the
final machine. elcom is the supplier of this TLM 1000 transfer system sub-assembly .

The manufacturer of the final machine must make sure that:

- All safety equipment is provided and functional,

- Regular checks are carried out,

- All danger (pinching, squashing) due to moving parts is controlled,

- The documentation is complete.

1.2 Applicable standards

According to the 2006/42/CE European directive, elcom transfer systems are considered as partly
completed machines. They are therefore not subject to an EC declaration of conformity but are the
subject of a declaration of incorporation. The latter is transmitted at the time of delivery,
accompanied by the exploded view of the motorized equipment.

However, the following standards are taken into account during the design and the manufacturing of
the elcom transfer systems:

– The European Machinery Directive 2006/42/CE
– The European Low Voltage Directive73/23/CE

elcom ensures an adequate follow-up and products quality formalized by the ISO 9001 certification.

For environmental reasons, elcom also meets the requirements of the ISO 14001 standards.

1.3 Applications

The elements of the linear TLM 1000 transfer systems are designed to carry and position workpiece
carriers according to the end customers’ configuration.
They are intended to be incorporated the customers' production line.

1.4 Conditions of use

The elements of the TLM 1000 transfer systems are suited for a use in normal industrial areas such as
a final assembly plant or equivalent, in a dry environment.
They are not suited for transporting materials such as sand, balls or grain.
The maximum load applicable on the transfer system is mentioned in the catalog and must never be
ignored.
To ensure a proper functioning of the transfer system on a maximum period of time, you must follow
this advice:

- Use temperature between 0 and 40°C (30 and 140°F)

- Avoid dusty or smoky atmosphere

- Avoid accumulation of sharp objects on the transfer system

- Avoid setting the machine in direct exposition to UV rays

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1.5 Safety instructions

Safety rules regarding transfer systems, especially the ones regarding the electrical
devices, must be followed during all the use phases: mounting, transport, production.
Disregarding these rules would be regarded as a wrong use of the machine.

Using the transfer system in an explosive atmosphere can have a negative impact on the
transfer system and is strongly discouraged.

Never perform any maintenance on your own. Another worker must be present at all
time in order to shut the power down or perform first aid actions if needed.

Changing the motor position or removing security parts must only be done when the
transfer system is unplugged from any power supply.

When carrying maintenance or handling tasks while the transfer system is operating (belt
tension setting), take care not to slide your hand between the belt and the belt support
in order to avoid any accident.

All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected in the end-user machine in
order to avoid any risks of pinching or squashing. We recommand to mount a protective
housing around it. In case of manual shift, the final machine can not be used without the

protections installed at the indexing and stop station

1.6 Safety instructions regarding the motor

In case of a power failure, turn off the transfer system: it could restart automatically
when the power comes back which could cause damages and even injuries to the
operator.

1.7 Additional information

These instructions aim at ensuring the safety of the people and the proper functioning of the transfer
system. If you wish to use the transfer system in any other conditions, please do not hesitate to
contact us.

Other information is available on our website, in the documentation section:

http://elcom-automation.com/transfers/documentation

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2 TECHNICAL SPECIFICATIONS

- Maximum load on a workpiece carrier: 2 kg

- Maximum accumulated load on the transfer system: 25 kg for a maximum 3-meters unit.

- Electrical power supply of the motors: 380V three-phase

- Motor power: V 9 m /min = 0.09 Kw

(V = belt speed) V 15m /min = 0.09 Kw

V 19m /min = 0.09 Kw

Air pressure supply = 5 to 6 bars

Every cylinder must be equipped with a flow limiter.

- Sound emission < 70 dB

- Weight of each part: See our catalogue Modular Transfer System & Flat belt conveyors.

http://elcom-automation.com/transfers/documentation

Warning: All load exceedance can lead to a premature wear of the belt or any other
parts.

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3 COMMISSIONING

3.1 Receipt

When receiving the transfer system, check if the packaging has not suffered any damage and
that the machine is in perfect conditions.

The transfer system can be supplied in kit. It then needs to be assembled.

3.2 Transfer elements

When handling the equipment and parts, take special care to avoid shocks.

1. Assemble the parts according to the lay-out of the line with the delivered fastening parts,

2. Level perfectly the conveying units while checking that the belts are properly laid on the

belt guide,

3. Ensure the perfect stability of the whole line. To achieve this and according to the lay-out of

the line, it may be necessary to perform ground fastenings,

4. Check the settings of the motor magneto-thermic circuit breakers,

5. Check the running direction of the belt without any load,

6. Adjust the cams and the selectors using a workpiece carrier,

7. Start the transfer system with all the workpiece carriers on.

3.3 Stopper

1. Place the stopper right in the middle of the two profiles of the system,

2. Adjust the sensor for the detection of the workpiece carriers,

3. Adjust the flow control units.

3.4 Positioning unit

1. Put the positioning unit right in the middle of the two profiles of the system,

2. Adjust the sensor for the detection of the workpiece carriers,

3. Check on the high position that the pins of the workpiece carrier are free,

4. Lubricate the positioning units fingers with a fine layer of grease (see Maintenance),

5. Adjust the flow controllers.

Note: For the heavy positioning unit, check the lubrication of the drawer (see Maintenance).

All the different types of positioning units include several mobile parts driven by
pneumatic cylinders. Therefore, they must be well protected on the end-user machine
in order to avoid any risk of pinching or squashing. We recommend mounting a
protective housing.

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3.5 Workpiece carrier

1. Check that the springs of the pins located under the carrier are working properly.

2. Check that no part goes over the lower surface of the workpiece carrier.

4 MAINTENANCE

General visual check

Approximately every 500 hours, check the following points to ensure the proper functioning of the
transfer system:

4.1 Belts wear

Regularly verify visually the state of the belt and especially the welding area.

4.2 Passageways of workpiece carriers

The friction of the pins while operating can make some marks appear. Those marks may over the
long term require the part replacement.

4.3 Pins

Pins are sensitive to wear, especially if the load is heavy. Wear can be noticed as soon as a loss of
efficiency in the guiding of the workpiece carrier occurs.

4.4 Wear of the belt guide

Belt guide must be replaced as soon as wear marks or friction on the belt start to appear.

Wear area of the pins

Belt

Belt guide

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4.5 Transfer parts

Every 200 hours:

Remove the dust from the complete unit, using the product:

Ref 800 00 003 (polish plastics Air Industry 2101).

Every 3200 hours:

Check the lubrication of the conical torque.

Apply grease to obtain the initial lubrication state if necessary.

Use the grease reference 800 00 009.

4.6 Stopper

Every 5000 hours:

Eventual cleaning of the stopper depending on the working environment.

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Stopper can be disassembled by the two screws located underneath.

Once the screws are taken off, slide the stopper outside of the system for disassembly, cleaning and
greasing.

4.7 Positioning unit

Every 1000 hours:

All types except heavy positioning unit.

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Remove the positioning unit plate after unscrewing the fastening screw.

Check the lubrication of the guiding shafts.

Guiding shafts

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Changing the pins (locating and centering)

Extract the previous pins with the press.

Install the new pins in the press, using a bush ref. 120 03 006 from a workpiece carrier as a support
(insert the pin in the bush and then place the whole on the positioning unit plate).

Note: On the lift positioning unit, the cylinder can be lubricated without any prior disassembly.

Pins

Bush (ref. 110 03 005)

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4.8 Heavy positioning unit

Disassembly of the heavy positioning unit:

Unscrew the fixing screws that fasten the
positioning unit on the rails.

Take off the positioning unit from the
transfer system.

Unscrew the fixing screw fastening the
plate.

Remove the plate to allow access to the
drawer.

Every 1000 hours:

Lubrication of the drawer (inside and outside)

Use the recommended grease (grease Gulf Crown EP2).

Plate fixing screw

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Lubricate the positioning unit finger with a film of grease.

Use the grease ref. 800 00 002 (Crown, ref. 7041 spray).

Changing pins (locating/centering)

Extract the previous pins with a press.

Put the new pins in place with the press while using the bush of a workpiece carrier as a support
(Insert the locating pin in the bush, and then place the whole back on the positioning unit plate.).

For re assembly, follow the previous steps in reverse order.

4.9 Other transfer parts

The others parts of the transfer system do not need any maintenance. A visual check, looking for
wear or breaking parts is recommended from time to time.

Drawer (réf 110 11 007)

Areas to be lubricated

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5 MOTOR REPLACEMENT

5.1 Disassembly

Unscrew the four screws from the plastic cover.

Take the circlip and the washer off.

Circlip

Washer

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Remove the motor from the shaft.

Unscrew the anti-rotation screw of the reducer, on the transfer side.

Anti-rotation screw

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5.2 Reassembly of the motor

Put the screw back on the new reducer.

Lubricate the shaft with copper grease.

For reassembly, follow the previous steps in
reverse order.

5.3 Changing the belt – Flat belt

Calculate the belt required length for a single unit:

[(L-160) x 2 + 490] x 0.97

L = total length of the transfer system, including the return.

Calculate the belt required length for a U-shape unit:

[(L-160) x 2 + 678] x 0.97
L = total length of the transfer system,
including the return.

Cut the first bevel.

Trace the point zero.

Cut the right length.

Cut the second bevel with the same
bevelling device.

Do not forget to take the length of the bevel into account when calculating the
length of the belt. The superposition of this length must be subtracted from the
total length.

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Place the belt on the transfer system.

a) Pull

b)Push

Tension the belt until the bevels are juxtaposed.

Clean both sides of the bevels with alcohol.

Spray glue on both sides of the bevels (Glue expiration date: 1 month after opening. We advise you
to write the opening date on the glue bottle. Do not keep it later than one month after this date).

Place the thermic press correctly aligned with the belt.

Fasten the belt on the press.

Use 2 belt pieces to align perfectly the 2 bevels.

Belt position
Driving direction

Driving direction

Belt position

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Close the press and let warm up for 35 minutes at 120°C (250°F).

Let the thermic press cool down for 30 minutes. Remove excess glue with some abrasive paper.

5.4 Changing the belt – Timing belt

The new timing belt is delivered already welded.

Unscrew the caps on each side of the transfer system and slide the new belt in place of the worn
one. (Respect the passage way between the pulleys and belt guide).

Covers to be removed

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Stretch the belt using the tensioning screw and put the covers back into place.

6 RESPONSABILITY

elcom cannot be held responsible for any damages or harms due to non-authorized modification of

any parts, especially the safety parts.

Only original components can be used for maintenance or fixing.

elcom cannot be held responsible for any malfunction if some spare parts have been used without

the validation of elcom.

elcom reserves the right to make improvements and technical modifications without any further

notice.

7 CUSTOMER SERVICE

Do not hesitate to contact us for any question or advice. We will be glad to assist you.

Tel: + 33 (0)4 74 43 99 61

E-mail: [e-mail]

Adress : 1 rue Isaac Asimov

ZAC de la Maladière
38300 Bourgoin-Jallieu

France

Belt passage way

Access to the tensioning screw

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Prior to any contact, please note down the serial number of the transfer system. This number can be
found on the transfer system sticker.

8 APPENDIX

8.1 Maintenance schedule

Maintenance of the modular transfer system

TLM 1000

Frequency

Action

Component

Chapter

200 hours

To dust

Transfer parts

4.5

500 hours

To check

Belt - Belt guide – Workpiece carrier

4.1

1000 hours

To

lubricate

Positioning units (shaft and cylinder)

4.7

1000 hours

To

lubricate

Heavy positioning units (shaft, drawer and cylinder)

4.8

3200 hours

To

lubricate

Conical torque

4.5

5000 hours

To clean

Stoppers

4.6

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8.2 Quality and environmental commitment: ISO certifications

Our company is recognized according to the following ISO standards and their respective evolutions
since our first certification:

- Quality Management through ISO 9001 [since 2002]

- Environmental Management through ISO 14001 [since 2013]

All our current certificates are available for download in French, English and German on our website

http://elcom-automation.com/

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8.3 Spare parts list

11001001

Belt guide

11001201

Belt 12.5 x 1

11002001

Piston

11002006

Plate

11002008

Body

11002009

Guide

11002010

Tray

11002011

Sensor bracket L

11002012

Sensor bracket R

11002201

Spring

11002202

Joint

11003003

Pin

11003005

Bush diam. 6

11003201

Spring

11003202

Cover dia 6

11004001

Cap

11004002

Cam SD 100

11004003

Cam SG 100

11004004

Support

11004005

Support

11004006

Plate

11004007

Cam support

11004008

Rail

11004009

Rail

11004010

Selector

11004011

Selector L

11004012

Cap

11004013

Cap

11004014

Selector G

11005001

Driving unit block 100

11005002

Pulley dia 26

11005003

Washer

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11005004

Spacer

11005005

Driving pulley

11005008

Shaft

11005009

Cap

11005010

Ring

11005201

Bearing dia 8

11005202

Bearing dia 35

11005203A

Motor 10m

11005203B

Motor 15m

11005203C

Motor 20m

11005205

Driving shaft

11006001

Idling unit block 100

11006005

Cap

11007001

Plate

11007003

Nozzle

11007005

Guide

11007006

Selector D

11007007

Selector G

11007008

Rail

11007009

RAIL

11007201

Cylinder

11007201F

Cylinder 16-5

11008001

Plate

11008002

Body

11008003

Selector

11008201

Spring

11009001

Plate

11009001F

Plate FESTO

11009002

Body

11009003

Positioning unit plate

11009005

Finger

11009005F

Finger FESTO

11009006

Shaft

11009007

Locating pin

11009008

Centering pin

11009010

Hook L

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11009011

Hook R

11009012

Anti-bouncing back L

11009013

Anti-bouncing back R

11009205

Bush

11010001

Plate

11010001F

Plate FESTO

11010003

Stand

11011001

Lever

11011002

Nozzle

11011003

Shaft

11011004

Cylinder plate

11011005

Plate

11011006

Plate

11011008

Block

11011009

Shaft

11011010

Tray L

11011011

Tray R

11011201

Ring

11011202

Cylinder

11011202F

Cylinder 25-25

11011203

Shoulder screw

11012001

Plate

11012003

Shaft

11012005

2 shaft 14 for lift positioning unit

11012005A

Machining tapping

11012006

Guide

11012007

Centering pin

11012008

Locating pin

11012011

Cylinder plate

11012012

Position unit plate

11012201

Cylinder 32 - XXX

11012201F

Cylinder 32 - XXX

11012202

Ball bearing 14

11014004

Rail

11014005

Rail

11014101

Festo cylinder fastening plate

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11014101A

Festo cylinder fastening plate

11014102

Spacer

11014201

Cylinder 12

11015001

Spacer

11016001

Stand support

11017001

Sensor bracket

11018002

Squarre

11018003

Cap L

11018004

Cap R

11019001

Positioning unit plate modification

11019001F

FESTO Positioning unit plate modification

11019001U

Positioning unit plate modification

11019001UF

Positioning unit plate modification

11019002

Plate

11019003

Spacer

11020001F

Plate FESTO

11020002F

FESTO Positioning unit plate modification

11020002UF

Positioning unit plate modification

11022001

Piston

11022003

Guide

11022201

Seal 2.5 x 1.5

11023003

Tray

11034001

External guide

11034002

Central guide

11034003

Main plate

11034004

Idling unit block

11034006

Gearing with shaft 11034005

11034007

Lower housing

11034008

Upper housing

11034009

Cap

11034010

Idling cap

11034011

Conical torque

11034012

Shaft

11034013

Spacer

11034014

Shaft

11034015

Clavette

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11034016

Gear+shafts+spacer

11034201

Belt

11050001

Driving block 1000 notched

11050002

Idling pulley

11050003

Anti-winding pulley

11050004

Spacer

11050005

Poulie motrice

11050006

Wedge-1 mm thickness

11050007

Retaining bar

11050008

Idling pulley axis

11050009

Poulie dentée

11050010

Driving pulley flange

11050011

Motor-off flange

11050012

Upper cover

11050013

Left driving flange

11050014

Right driving flange

11050015

Wedge-2 mm thickness

11050016

Idling pulley timing belt

11050020

Belt guide 1000 notched

11050021

Profile 40x20 1000 notched

11050201

Bande antistatique

11050201A

Belt joining part

11050203A

Motor 10m/mi

11051001

Idling unit block 100 timing belt

11051002

Idling cap timing belt

11051003

Sym idling cap timing belt

11052001

Joining part cap 100

11052002

Sym joining part cap 100

11052003

Joining part square

11053001

Driving flange left cam support

11053002

Driving flange right cam support

11053003

Idling flange left cam support

11053004

Idling flange right cam support

11053005

Cam SG 100 notched

11053006

Cam SD 100 notched

11053007

Training support timing belt

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11054003

Main plate timing belt

11054004

Spacer plate

11054005

Conical torque flange

11054006

Low housing

11054007

Obturateur

11054008

Upper housing

11054009

External square

11054010

Central square

11054011

Split washer

11061003

Detection bar

11062001

Plastic base unidirectional 100*100

11062001T

Plastic base U 100x 100 with shock absorber

11062002

Plate

11063001

Plastic base 100*100 multidirectional