FlexLink Elevator User Manual
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Elevator
User Manual
eated by EBCCW 00:06
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Created by EBCCW 96:05Created by EBCCW 00:06Created by EBCCW 96:05Created by EBCCW 00:06
Created by EBCCW 96:05Created by EBCCW 00:06
© Flexlink Components AB 2010
Elevator
User Manual
All Rights Reserved
No part of this program and manual may be used, reproduced, stored or
transmitted in any form or by any means without the written permission of
FlexLink Components AB. The contents of this manual are for informational
use only. All information and specifications contained in this document
have been carefully checked to the best efforts of FlexLink Components
AB, and are believed to be true and accurate as of time of publishing.
However, due to continued efforts in product development FlexLink
Components AB reserves the right to modify products and its manuals
without notice.
FlexLink Components AB assumes no responsibility or liability on any
errors or inaccuracies in this program or documentation. Any kind of
material damages or other indirect consequences resulting from any
FlexLink Components AB´s product part, documentation discrepancies
and errors or non-anticipated program behavior are limited to the value of
appropriate products purchased from FlexLink Components AB. The
products are delivered to the customer at th e ’as is’ state and revision level
they are on the moment of purchasing, and are declared in detail in the
license agreements between FlexLink Components AB and user. User
accepts and is obliged to follow the guidelines stated in the separate
license agreement needed in using any parts of this product package.
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Preface 1
1 Safety 3
1.1 System information 3
1.2 Important safety conditions 4
1.3 Description of safety provisions 6
1.4 Safety measures to be taken 13
1.5 Explanation of symbols 13
2 Technical specification 15
2.1 Technical data 16
2.2 Ordering information 17
2.3 Operating conditions 19
3 Introduction function and components 20
3.1 Purpose of use 20
3.2 Description of the Elevator 21
3.3 Working principle 33
4 Unload the elevator 34
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4.1 Preparation 34
4.2 Unloading instructions 35
5 Installation and adjustment 38
5.1 Provisions to be provided 38
5.2 Mechanical assembly 39
5.3 Electrical installation and controls 41
5.4 Test run 43
5.5 Adjustment 44
5.6 Check / Shadow run 56
6 Instructions for use 58
6.1 Handling 58
6.2 Manual operation 59
7 Technical maintenance 60
7.1 Check and control procedures 60
7.2 Maintenance procedures 61
7.3 Troubleshooting 63
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7.4 Maintenance schedule elevator 64
8 Put out of commission 65
8.1 Disconnect the power sources 65
8.2 Disassemble 65
8.3 Transport 66
8.4 Reuse 66
9 Recommended spare parts 67
9.1 Mechanical 67
9.2 Electrical 72
10 Supplier’s information 92
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Preface
Preface
Purpose of this manual
The purpose of this manual is to describe a number of o perations th at a re
intended for the user concerned. Here it becomes clear how the user can
work as well and as safely as possible. By making use of clear illustrations
and texts FlexLink wants to achieve a simple and safe way of working with
the Elevator . This docu ment cont ains rema rks that point o ut a risky or sp ecific situation to the user . In man y ca ses this situation is provided with one
of the symbols given below.
General warning for danger!
.
Warning for electrical voltage!
.
Attention, this is an important notice!
.
Compliance with the operations described in this document is important in
order to prevent dangerous situations and unnecessary damage to the Elevator. Care fully keep this document! It is recommended to keep one copy
near the machine and one copy with your technical documentation.
Structure of the manual
The user’s manual has been composed in such a way, that a number of operations can quickly and easily be found. This manual will not describe operations that are not meant for the user . It does, however , indicate what the
user must do when carrying out a certain operation, for example calling in
technical staff. The user’s manual has been divided into sections. These
sections describe, among other things, the safety and the operation of the
Elevator. FlexLink would like to point out to the user that section Safety is
to be read carefully.
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Preface
Requirements of the user
The Elevator may be operated by any adult person who has become acquainted with section Safety. If the user is not technically qualified, he or
she may not carry out any maintenance or repair activities on the elevator.
. Note! Maintenance activities on the elevator may only be carried
out by a technically qualified person.
. NB: Technically qualified employees means: employees that
have followed an adequate training for carrying out the activitie s
involved and have a good ability to read and understand the
English language.
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Safety
1 Safety
The Elevator has been designed in such a way, that it can be used and
maintained in a safe way . This holds for the application, the circumst ances
and the instructions described in the manual. Any person working with or
on this machine should study the manual and follow the instructions. It is
the responsibility of the employer to make sure that the employee is familiar
with and follows these instructions.
The company or the country in which the machine is used ma y r eq uire extra safety measures. This particularly applies to the working conditions.
This manual does not describe how these are to be complied with. In case
of doubt, consult your government or safety officer!
1.1 System information
The project number and/or general drawing number shall always be specified when communicating with FlexLink with respect to the elevator.
Project number See machine nameplate
Supplier FlexLink Engineering Polska
Sp. z.o.o
ul. Za Motelem 2c
62-080 Sady, Poland
Machine type: Elevator
Date of manufacture See machine nameplate
Gen. drwg. no. See machine nameplate
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Figure 1 Machine nameplate
The machine nameplate is located on the electrical cabinet a s shown in the
figure above.
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Safety
1.2 Important safety conditions
At the moment that the elevator is going to be operated by a user, the following safety conditions must be met:
• Make sure that children or animals have no access to the machine
and its surrounding area by, for example, screening off the elevator with a fence.
• Only persons who have read and understood the operating instructions are allowed to operate, maintain and clean the machine.
• Do not reach into the machine while it is running or on. Even if the
machine is not running, it can be ‘on’, which means star t operating
automatically.
• Safety provisions, such as side plating, bottom plating, emergency stops and detectors may not be removed or deactivated wh ile
the elevator is running.
• Provide good ambient lighting to enable the opera tor to work well
and orderly with the elevator.
1.2.1 General
. • Incorrect use of the equipment can cau se pe rso n al inju ry.
• Do not stand or climb on the equipment.
• Do not wear clothing or other articles that can fasten in the machine.
• Follow the instructions in this user manual when transporting the
machine. FlexLink Components AB must approve all modifications or changes to this machine.
• Only use recommended spare parts.
• Only authorised personnel may open electrical units.
• FlexLink is not responsible for damage if service on the equipment is not performed in accordance with this user manual.
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1.2.2 Service technicians
. Service technicians must have:
• Sufficient knowledge for reading technical information
• Ability to comprehend technical drawings
• Basic knowledge of mechanics
• Sufficient knowledge in the use of hand tools
1.2.3 Electricians
. Electricians must have:
• Experience from similar installations
Safety
• Sufficient knowledge to work from drawings and wiring diag ra ms
• Knowledge of local safety regulations for electrical power and automation
To avoid risks, only experienced personnel with technical knowledge and
experience may perform repair work on the machine's electronics components.
1.2.4 Operators
. To correctly use the equipment, operators must have appropriate training
and/or experience.
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Safety
1.3 Description of safety provisions
As a standard the Elevator is not provided with control and an y safety pr ovisions. Before putting the Elevator into operation some safety provisions
are to be taken care of. The purpose of these safety p rovisions is to protect
the user, the product and the Elevator against undesired situations (damage). Without these safety provisions FlexLink cannot give a guarantee on
any damage caused in absence of these safety provisions.
The table below gives a general description of the safety provisions required. Here it should be noted that only technically qualified employees
are allowed to work on the settings of the safety provisions!
Control Remark
Emergency stop switch Each Elevator is to be provided with one or more emerge ncy stop switches
that can be operated within reach of the user.
The switch must have the standard red colour.
The emergency stop switch must make sure that the input and output
tracks are switched off simultaneously.
Motor protection The technical specification of the Elevator is, among other things, geared
to the load given in the order confirmation.
Should the Elevator (motor) be overloaded for certain reasons, this should
be detected. Without this protection there is a chance that the Motor or
other components of the Elevator will be damaged.
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Safety
. Note! If it cannot be made sure that there will be no product on
the machine that exceeds the minimum or maximum dimensions
(see technical specification), the detector described below must
be installed on the Elevator.
Height / width
detector
The product that is put into the Elevator may not get stuck as a result of a too
high / wide or twisted product.
In order to ensure that products fit in the Elevator and will not get stuck, the
input of the Elevator can be checked for height / width.
This detection must take place well before the Elevator prior to putting the
product on the Elevator.
The maximum dimensions of the product are given in the technical
specification.
Mechanical Remark
Transition guard At the transition between the Elevator and a connected conveyor a gua rd must
have been placed, so that persons are kept at a reaching distance from the
transition.
Do not use the Elevator as a platform for maintenance work or in the production,
use equipment intended for these purposes.
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. . Note! Only technically qualified employees are allowed to
change the settings of the safety provisions.
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Safety
Safety
system
Line main cabinet
Safety
system
Door
switch
M
Vertical
motion
ES
M
Horizontal
motion
Motor supply voltage (VAC)
24V
DC
Line global
emergency
switch loop
Elevator
ES
Emergency
switch loop
Comm.
interface
ES
Permanent
I/O
24V
DC
Safe
I/O
Safe motor
supply voltage (V
AC
)
1.3.1 Safety system architecture
The safety system architecture varies depending on elevator version.
Elevators require motor supply voltage and permanen t 24V DC power supply for communication devices. Motor supply voltage depends on version
(50 Hz version: 400 V AC, 60 Hz version: 480 V AC).
Safe 24V DC (disconnected at emergency) is not used although the elevator provides means for passing on the power.
1.3.1.1 Profibus/DeviceNet versions
Emergency switch
The purpose of the safeguard is to be part of the line global emergency
safety system and affect the motor power supply to the elevator.
In case of emergency, the motor power supply to elevator shall be disconnected (stop category 0, EN60204-1).
Door switch
The elevator is equipped with a service door for access inside . Opening the
door results in a elevator internal disconnection to motors (stop category 0,
EN60204-1).
Figure 2 Profibus or DeviceNet version
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Safety
Line main cabinet
Door
switch
M
Vertical
motion
ES
M
Horizontal
motion
24V
DC
Elevator
Safety comm. interface
Permanent
I/O
24V
DC
Safe
I/O
Motor supply voltage (VAC)
1.3.1.2 Profisafe versions
Emergency switch and door switch
Safety fieldbus protocols provide flexibility in safety architecture.
The emergency switch and door switch are connected to safe inputs of the
communication interface inside the control box of elevator.
Safety outputs of the communication in terface disconnect s the motor power supply internally in the elevator.
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Figure 3 Profisafe version
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Safety
1.3.2 Emergency stops
If personal safety is endangered or if there is a risk for equ ipment damage,
the emergency stop button must be immediately pressed.
An emergency stop button is mounted on the front of the electrical cabinet.
Figure 4 Location of emergency stop button
. The emergency stop device does not disconnect power to the ma-
chine.
For more detailed information about th e emerge ncy stop function, see the
application manual.
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1.3.3 Guards
. The elevator consists of moving parts that can cause injury.
Feed-in and feed-out areas around the elevator are unprotected; they must
be protected by, for example, the installation of tunnels or similar devices.
The elevator may not be operated if the door switch is inoperable or if a st ationary guard is improperly fitted.
Stationary guards
The elevator is protected by stationary guards of clear PC a nd alu minium.
Openable guard
The elevator is equipped with a service door for accessing the interior . This
door is equipped with a door switch. If the door is opened dur ing operation,
power to elevator motors is disconnected (stop category 0 according to EN
60204-1).
Safety
. Stop the elevator before opening the door. Do not open the door for
the purpose of stopping the elevator.
The door switch does not disconnect power to the machine.
1.3.4 Noise level
. The noise level produced by the elevator is under 70 dB(A).
1.3.5 Electrical cabinet
. The voltage in the electrical cabinet is 400 V or 480 V, depending on ver-
sion. Ensure that the electrical cabinet is closed and locked after working
in the electrical cabinet.
Never bypass the safety system.
The electrical cabinet can only be opened using a tool.
Before working in the electrical cabinet, the main switch to the motor must
be turned off and locked. The key is retained by the service technician until
work is finished.
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Safety
Examples of service work include:
• Disconnection of wiring
• Replacement of motors, etc.
• Service work in the electrical cabinet, terminal boxes, etc.
• Service work performed on the machine that cannot be seen from
the electrical cabinet.
For adjustment of photo-electric cells, inductive sensors, etc., power is required:
- Stop the machine and wait until the moving p arts have come
to a complete stop.
- Ensure that "Start" is turned off.
- Open the elevator door.
- Make adjustment.
Verify adjustments using manual operation of the elevator with the door
closed (see Handling
on page 58).
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Safety
1.4 Safety measures to be taken
For a safe operation of the Elevator a number of safety measures are to be
taken. These include the following measures:
• Clean floor surface - With a clean floor surface the operator will
not be hindered while operating the Elevator. This can prevent
tripping or slipping, so that the operator does not unexpectedly
come into contact with the Elevator.
1.5 Explanation of symbols
Just like in the manual, symbols are used that have been placed on the Elevator in order to point the attention of the user to cert ain situations or pr ovide certain information on components of the Elevator.
No. Description Picture
1.Type plate Elevator This contains the name and the address of
the Manufacture. Apart from that the
declaration of incorporation, series or type
indication, serial number and the year of
construction of the Elevator.
2.Type plate motor This contains the name and the address of
the motor supplier. Apart from that the CEmark, kind of motor oil, series or type
indication, serial number and the year of
construction of the motor.
3. Risk for electric shock Placed on control box.
4. Protective earth According to IEC 60417. Placed below
control box. Points out where to connect
equipotential bonding conductors.
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Safety
5. Start According to IEC 60417. Pictogram at
pushbutton on control box door.
6. Stop According to IEC 60417. Pictogram at
pushbutton on control box door.
7. Alarm reset According to IEC 60417. Pictogram at
pushbutton on control box door.
8. Up/Down According to IEC 60417. Pictogram at
pushbutton on control box door.
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Technical specification
2 Technical specification
Complete turn-key version.
In feed and discharge protections are not included.
Cycle time 13- 16 sec (low elevator)
18- 24 sec (high elevator)
Max weight* *
Max product height 400 mm
A number of pallets can be elevated at the same time.
Conveyor length Max. length 550/640 mm
Conveyor speed 15 m/min
Electrical environment 50 Hz: 400 V AC
60 Hz: 480 V AC
ESD version elevators are available.
Cabinet for Profibus, Profisafe or Device Net communication for Line control.
*) Maximum product weights are as follows:
Type Max. load/level Max. total load in elevator
X85/XK/XT 30 Kg 30 Kg
RTI 15 Kg 100 Kg
DAS 80 85 Kg 85 Kg
Dimensions LxBxH: See appendix.
Weight Low elevator: ~ 300 kg (Depending of configuration)
Weight High elevator: ~ 400 kg (Depending of configuration)
Electrical
specifications
Pneumatic
system
Supply: 3 phase + neutral + PE, 400 V AC, 50 Hz, 24 V DC
Max. power: 1 kW N/A
N/A
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Capacity Products per minute: See application.
Max. speed: See application.
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Technical specification
A
A
A-A
745
435
1018
75 30±
1754
75 30±
A-A
745
435
1018
75 30±
A
A
3394
A-A
75 30±
1754
A
A
833
604
1356
A-A
745
435
1018
Pallet width 240-320
Pallet width 400-640
A-A
833
604
1356
A-A
745
435
1018
Pallet width 240-320
Pallet width 400-640
A
A
3394
75 30±
XT
X85/XK
2.1 Technical data
Figure 5 Elevator description
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Technical specification
2.2 Ordering information
Example of strings obtained from the configurator:
AC D EF GHIJ
X85 - 200 - ABCD - E - 900 - 2800 - 50 - PB - AS0
Table 1: X85 High elevator with Profibus
AB CDE F G H
I J
XT - 400 - 150 - AB - E - 400 - 1200 - 50 - PS - AS2
Table 2: XT low elevator, pallet width 400, Profisafe
AC D EF GHIJ
X85 - 200 - ABCD - E - 900 - 2800 - 50 - DN - AS0
Table 3: X85 High elevator with Device net
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Technical specification
E
A
B
D
C
F
E
F
Input Variable
A- Platform: X85
XK
XT
B- Pallet width: 240
320
400
480
640
C- Product height: 1-400 mm
D- In feed and discharge positions: A
B
C
D
E- Door positions: E= Left
F= Right
F- Lower height: Low elevator 300-600 mm
High elevator 300-1200 mm
G- Upper height: Low elevator 900-1400 mm
High elevator 2400-3000 mm
H- Drive unit version 50 Hz, European
60 Hz, American
I- Fieldbus: PB: Profibus
PS: Profisafe
DN: Device net
J- ESD version: Standard: AS0
Conductive: AS2
For more information please contact your local FlexLink of fice.
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Technical specification
2.3 Operating conditions
The circumstances under which the Elevator can be ap plied partly depend
on the materials selected. FlexLink has defined a number of parameters
within which the Elevator would be allowed to function. Should th e Elevator
still be applied beyond these limiting values, FlexLink cannot guarantee the
good functioning of the Elevator.
Ambient temperature (in operation) -20°C to +60°C
Relative air humidity (RH) 30% to 95%, not condensing
Lighting Normal ambient lighting
As a standard no lighting is installed on the Elevator and this can neither
be installed as an option. Normal ambient lighting is sufficient to work safely
with the Elevator. The Elevator is not intended for use in the open air and
besides the Elevator is not suitable for an envir onment with a risk of explo sion.
For use under deviating circumstances you may contact the supplier of the
Elevator.
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Introduction function and components
E
A
B
C
D
A
B
D
C
Height
(Top of chain)
F
E
F
E, F
Available door positions
To p
View
Right
Left
3 Introduction function and
components
3.1 Purpose of use
The elevator changes the elevation of products in a flow, such as boxes or
pallets, according to the principle of first in/first out.
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Introduction function and components
3.2 Description of the Elevator
The elevator primarily consists of two main units:
• Control system
• Mechanical lifting device
Control system
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Figure 6 Electrical cabinet
Central intelligence and distributed I/O
The elevator is to be controlled by a Line co ntroller and do not itself contai n
any intelligence such as PLC. The Line controller (PLC/PC/etcetera) controls the elevator through the integrated communication interface in the
control box.
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Introduction function and components
Safety system
Profibus and DeviceNet versions includes an autonomous safety system
for the door switch, disconnecting the power suply to the motors through
the safety relay and main contactors.
For Profisafe versions the door switch and emergency switch are connected to safety inputs of the communication interface. Main contactors are
connected to safety outputs of the communication interface.
For Profibus and DeviceNet versions the conductors of emergency switch
is connected to a terminal group. This terminal group is integrated into the
line global emergency stop safety system by integrator.
The red knob of emergency switch is delivered in pla stic bag a s th e el evator emergency switch functionality is not guaranteed before it is appropriately integrated into the line's safety system by the integrator.
Drives
The horizontal drive is with fixed speed controlled by a device including
contactor and motor protection.
The vertical drive is frequency controlled by a frequency converter placed
on the motor itself.
For standard versions the motor contr ol is discrete: On/Off, Up/Down, High
speed/Low speed. Spee ds are preset in hardware of motor.
For advanced versions a second communication interface provides advanced control of the motor. Speed and ramp times can be controlled by
software in Line controller . Motor current value and error codes can be provided by the motor to the Line controller.
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