FlexLink XS User Manual
Conveyor assembly manual
Table of contents
Introduction .................................................................2
About this manual ..................................................2
Installation site preparations ..................................2
Tools ......................................................................3
Fasteners ...............................................................4
Cutting FlexLink beams .........................................5
Assembly.....................................................................6
Introduction ............................................................6
Feet........................................................................7
Beam connectors .................................................15
Conveyor beams ..................................................19
Drive units ............................................................22
Idler units .............................................................24
Slide rail and support rail .....................................26
Chain ................................................................... 33
Guide rail system ................................................. 38
Angle plates......................................................... 46
Drip trays and drip catchers................................. 47
Front piece........................................................... 52
Final preparations ................................................ 54
Conveyor system XK ........................................... 55
XK pallet system.................................................. 58
Start-up and testing .................................................. 65
Safety considerations .......................................... 65
Slip clutch adjustment.......................................... 66
Start-up................................................................ 67
Troubleshooting ................................................... 68
1
Introduction
About this manual
Introduction
The main purpose of this manual is to help self-building
end users, with little or no prior experience, to assemble
a FlexLink conveyor system.
Each chapter includes detailed instructions and pictures showing how to assemble the different parts. Most
pictures in the manual include parts from the XL conveyor system, but all instructions are applicable to the
XS, XL, XM, XH and XK systems unless otherwise noted.
Operations that apply only to the XK conveyor system are
described in a separate chapter.
Installation site preparations
Assembly planning
Work systematically:
1 Prepare by studying your assembly drawing.
2 Ensure that the necessary tools are available.
3 Make sure you have all the materials and components
needed to assemble the conveyor system. Check with
the parts list.
4 Make sure you have enough floor space to mount the
conveyor system.
5 Check to see if the floor at the installation site is even,
so that all feet can be properly attached to the floor.
Document disposition
The document is divided into the following five main
parts:
• Installation site preparations
• Tools and fasteners
• Cutting FlexLink beams
• Assembly
• Start-up and testing
Assembly order
The following list can be used as a checklist during your
conveyor assembly work:
Activity Starts on
Cut all beams into suitable lengths page 5
Connect feet and structural beams page 7
Mount conveyor beam support brackets page 19
Assemble conveyor beams and mount
them on to the support structure
Mount drive and idler units to the ends of
the conveyor
Mount slide rail on to the conveyor beam page 26
Loosen the drive unit slip clutch page 34
Run a short piece of chain through the
conveyor to check that there are no
obstructions
Assemble and mount the chain on to the
conveyor
Mount guide rail, drip trays and other
accessories on to the conveyor
Tighten the slip clutch to a suitable friction
Read Final preparations at the end of
this manual
Go to page 55 for special information relating to conveyor system XK.
page 21
page 22
page 34
page 33
page 38
page 66
page 54
2 Introduction
Tools
General tools
To assemble a FlexLink conveyor, you will need most of
the tools listed on the following pages. Not all are essential, but they will make your assembly work easier and
more efficicient.
Hand tools
10 and 13 mm box wrench
Cutters (for cutting slide rail)
Set of metric Allen keys
Roller thread fluteless tap and tap wrench (M6 and M8)
Countersink bit
Tape measure
In addition, the tools listed below can be useful:
Files
Socket wrench
Screw-driver
Pliers
Knife (for cutting off plastic screw heads)
Soft faced hammer
Clamp (for chain installation)
Level
Power tools
Cross-cut circular saw for aluminium
Hand drill
Drill bit (for fixing of slide rail):
XS: ∅3,2 mm, XL/XM/XH/XK: ∅4,2 mm
FlexLink tools
Rivet crimping pliers
XS (∅ 3 mm):
3924776
XL/XM/XH (∅ 4 mm):
3925800
Rivet crimping clamp
XS (∅ 3 mm):
3924770
XL/XM/XH (∅ 4 mm):
3923005
The riveting tools have replaceable pads. By replacing the pads
you can use the same riveting
tool for 3 mm and 4 mm rivets.
Drill fixture for installation of
slide rail
XS (∅ 3,2 mm):
3924774
XL/XM/XH/XK (∅ 4,2 mm):
3920500
Mounting tool for slide rail
XS/XL: XLMR 140
XM: XMMR 140
XH: XHMR 200
XK: XKMR 200
Mounting toolkit for guide rail (XK)
3926757
Each kit is delivered with two tools.
Pin insertion tool for chain
XS/XL: XLMJ 4
XM: XMMJ 6
XH: XHMJ 6
XK: XKMJ 8
Guide rail bending machine
3922963 (not shown)
Drill fixture for fastener yokes
XCAD 18
To drill for fastener yokes
(page 17–18), the 10 mm
drill insert has to be
removed. The drill insert is
secured by a locking screw.
With the stop tongue down, the fixture is inserted into
the T-slot of the beam until stop, and then locked. The
hole will be drilled 22 mm from the beam end and centered by the fixture.
Introduction 3
Fasteners
1. Standard screws, nuts, washers
M6S, MC6S, MF6S, M6M, BRB 8,4×16, XLAL
2. Slot nuts and square nuts
3. Connecting strips
X..CJ
Connecting strips are used for joining beams together,
end to end. Use Allen key and set screws when attaching
the connecting strip to the beam.
4. T-bolts
XCAN, XLAQ
Square nuts can be used in support beams and small
beams instead of XCAN nuts, but they can also be used
in conveyor beams as opposed to XCAN nuts. They do
not stay in place in vertical positions and have to be
inserted from the beam end.
When using XLAQ square nuts, remember to put in a
sufficient number before completing the assembly.
XCAN
On the support beam, the slot nut can be entered into the
T-slot from the beam side. It will stay in position in vertical
T-slots because of a thin leaf spring.
For small beams (e.g. XCBB ..×24×44), the nut must
be entered from the beam end because of the design of
those beams.
XLAT
T-bolts can be entered from the beam side, and when
turned 90° they will stay in place after tightening with nuts
(XLAN 8) and washers (BRB 8,4×16). The indication
groove in the T-bolt should be at 90° to the conveyor Tslot.
T-bolts are used when attaching support brackets,
guide rails and drip trays to the conveyor beam. Do not
use T-bolts with support beams!
IMPORTANT
Slot nuts can not be used with conveyor beams. (This
does not apply to the XK conveyor system.)
4 Introduction
Cutting FlexLink beams
Beam lengths
If you have ordered 3 m or 6 m beams, they will need to
be cut into suitable lengths before assembly. Study your
drawing to determine the beam lengths that are required.
The FlexLink catalogue 5147, chapter CS, contains a formula for calculation of cutting lengths for support beams.
Saw requirements
The circular cross-cut saw for aluminium must have a
higher speed than when cutting steel, and a carbide tip
blade adapted for aluminium products in order to give a
nice and clean cut.
The saw should have the ability of cutting the largest
profile in one single cutting action.
Working site
You should use a special area for cutting beams in order
to keep the assembly area clean.
Quality of cut
If burrs are evident, they must be removed prior to
assembly.
Make sure the cut is straight for proper assembly.
SAFETY
All safety precautions issued by the cutting saw manufacturer should be followed at all times.
Introduction 5
Assembly
Introduction
Component groups
The basic FlexLink conveyor structure consists of five
component groups:
• support structure
• conveyor beams, straight sections and bends
• drive and idler units
•chain
• other accessories (guide rail, drip trays etc.)
The first step in the assembly process is to assemble the
support structure, which consists of feet, support beams
and beam connectors. Most conveyor support designs
are based on vertical support beams combined, if necessary, with horizontal support beams. There are also a
number of different feet and beam connectors, so check
which ones are used in your application. Some examples
are shown below.
IMPORTANT
You must work in accordance with your layout, and make
sure that the conveyor is supported at regular intervals
not exceeding 3 m.
6 Assembly
Feet
Introduction
Feet are attached to the support beams, and come in a
number of configurations. Follow the mounting instructions for the type of foot used in your application.
Mounting feet
XCFF:
Box wrench 13 mm
Connecting strips (included
Hex head screws (included) M6S 8×16
Washers (included) BRB 8,4×16
Mounting
1 Insert hex head screws and washers into the holes on
the side of the foot.
Use the screws to fasten connecting strips to the inner
side of the foot. Tighten loosely.
:
3 Raise the beam from the bottom of the foot approxi-
mately 50 mm, to allow for height adjustment later in
the assembly.
4 Tighten the screws using a wrench.
2 Slide the connecting strips into the structural beam T-
slots.
Assembly 7
Feet (continued)
Deburring and threading beam ends
Before mounting foot plate XCFB 88/44 F, end plate
XCFE and mounting plate XCFB, the holes in the beam
cross-section must be deburred and threaded.
Countersink
Roller thread fluteless tap M6/M8
Mounting:
1 Deburr the holes using a countersink.
Attaching feet using end plates
XCFE
End plates are used as attachment for adjusting feet and
castors, and are screwed onto the support beam ends
before the actual foot is mounted.
Countersink
Roller thread fluteless tap M6/M8
Allen key 5 mm
Mounting:
2 Thread the holes using a 6 mm or 8 mm roller thread
fluteless tap, depending on beam and component
type.
1 Attach the end plate to the beam by inserting four hex
socket head screws into the holes on the end plate.
2 Tighten the screws using an Allen key.
8 Assembly
Feet (continued)
Mounting adjusting feet
XCFS 12×68
Wrench 19 mm
Nut (included) M12
Washer (included) For M12 screw
Mounting:
1 Screw the foot onto the XCFE end plate.
2 Tighten the nut using a wrench.
XLFS 8
Foot XLFS 8 can be mounted directly onto beams XCBM/
XCBR 44 or directly into any T-slot.
Connection to beam XCBM/XCBR 44:
1 Attach an end plate to the beam end.
2 Screw the foot onto the end plate and tighten with nut.
Connection to structural beam T-slot:
1 Insert a slot nut into the structural beam T-slot.
2 Screw the foot onto the beam and tighten with nut.
Assembly 9
Feet (continued)
Mounting castors onto end plate
XCAG 80
Allen key 5 mm
Screw (included) K6S 12×25
Washer (included) For M12 screw
Mounting:
1 Insert screw (K6S 12×25) into the screw hole located
on the castor yoke. Add washer.
2 Screw the castor onto the XCFE mounting plate using
an Allen key.
10 Assembly
Feet (continued)
Mounting castors to structural beam T-slot:
XCAG 80
Box wrench 13 mm
Screw (included) M6S 8×25
Filling washer (included) 3905065
Washer (included) BRB 8,4×16
Slot nut (included) XLAQ 8
Mounting:
3 Slide the foot into the structural beam T-slot.
1 The picture shows the mounting order for castor fas-
teners.
2 Insert screw and filling washer into the screw hole
located on the castor yoke. Add washer and slot nut.
4 Screw the castor onto the beam using a wrench.
Assembly 11
Feet (continued)
Mounting foot plates
XCFB...F
Countersink
Roller thread fluteless tap M8
Allen key 5 mm
Hex socket head screws MF6S 8×30
Mounting:
b) For the XCBM 88×88 beam, you can also use four
M8 screws at the centre of the plate.
For the XCBM 44×44 beam, you can also use one M8
screw at the centre of the plate.
1 Deburr and thread beam ends before mounting the
foot plate. (See page 8)
2 a) Mount the foot plate onto an XCBL 88×88 mm light
support beam using four M6 screws at the corners of
the plate.
Mount the foot plate onto an XCBL 44×44 mm light
support beam using four M6 screws at the corners of
the beam.
12 Assembly
Feet (continued)
Mounting polyamide feet
XEFG
Polyamide feet are used with 64 mm structural beams
only.
Allen key 5 mm
Hex socket head screws (included) MC6S 8×16
Mounting:
Adjusting mounts and vibration absorbers
XLFS 20 P, XLFJ 69
Mounting:
1 Adjusting mounts are screwed onto the bottom of the
foot and fastened with the locking nuts that are
included.
1 Mount the foot onto the beam end by sliding the foot
compression clamps into the beam T-slot.
2 Tighten the screws. The recommended tightening
torque is 15 Nm.
2 Vibration absorbers are snapped on to the bottom of
the adjusting mounts.
Assembly 13
Feet (continued)
Height adjustment assembly
XEFU 500
Used with XEFG 70 T foot only.
Allen key 5 mm
Lock brackets (included) 3903139
Hex socket head screws (included) MC6S 8×20
Mounting:
3 Tighten screws using an Allen key. The recom-
mended tightening torque is 15 Nm.
1 Attach the height adjustment assembly to the foot by
sliding the lock brackets into the slots on the beam.
2 Insert screws.
4 Insert the beam into the adjustment assembly and set
it at the required height.
Fasten the beam using the adjustment assembly lock-
ing levers.
14 Assembly
Beam connectors
Introduction
Structural beams can be connected to each other in a
number of ways. Three different methods are described
on the following pages.
Connecting beams using mounting plates
XCFB
Deburr and thread beam ends before assembly. (See
page 8):
Countersink
Roller thread fluteless tap M6
Box wrench 10 mm
Allen key 5 mm
Hex socket head screws MF6S 8×30
Hex head screws M6S 8×16
Washers BRB 8,4×16
Slot nuts M8 thread
Mounting:
1
1
3 Insert slot nuts into the T-slots of the transverse beam.
1
1 Attach a mounting plate to the beam end using
MF6S 8×30 hex socket head screws and washers.
1
4 Screw the mounting plate onto the side of the trans-
verse beam using hex head screws M6S 8×16.
2 Tighten the screws using an Allen key.
Assembly 15
Beam connectors (continued)
Connecting beams using angle brackets
XMFA, XLFA
Angle brackets are used to connect beams end-to-side or
side-to-side.
Box wrench 10 mm
Screws M6S 8×16
Slot nuts M8 thread
Washers BRB 8,4×16
Mounting:
3 Mount the angle bracket to the transverse beam in the
same manner. Tighten all screws.
1 Three different kinds of slot nuts can be used when
mounting angle brackets: connecting strip
XLCJ 5×76, square nut XLAQ 8 or slot nut XCAN 8.
2 Insert the required amount of slot nuts into the struc-
tural beam T-slot. Mount the angle bracket using
screws and washers.
16 Assembly
Beam connectors (continued)
Connecting beams using fastener yokes 1
XCAF
Method 1 – beam end against beam side
Drill ∅ 18,25
Drill fixture XCAD 18
Allen key 5 mm
Hex socket head screws (included) MC6S
Slot nut (included)
Mounting:
3 Place a fastener yoke in the hole and insert one 6×30
hex head screw on each side. Insert a slot nut into the
transverse beam.
1 The fastener yokes shown in the pictures are for
64 mm structural beams.
2 Use an XCAD 18 drill fixture to drill a 18,25 mm hole
through the end of the beam. While drilling in aluminium, be sure to lubricate the drill bit with methylated
spirits.
4 Tighten the screws using an Allen key. (The recom-
mended tightening torque for a lubricated joint is
10 Nm.)
Assembly 17
Beam connectors (continued)
Connecting beams using fastener yokes 2
XCAF
Method 2 – beam end against beam end
Allen key 5 mm
Screws MC6S 6×50
Nuts XLAN 6
Mounting:
3 Connect the two fastener yokes with one screw and
nut. Place the yokes in the holes of the beams.
1 Two fastener yokes are required when mounting
beam end against beam end.
2 Use an XCAD 18 drill fixture to drill a 18,25 mm hole
through the end of the beam. While drilling in aluminium, be sure to lubricate the drill bit with methylated
spirits.
4 Connect the yokes on the other side of the beam.
Tighten both screws.
18 Assembly
Conveyor beams
Introduction
Conveyor beams are mounted on to the support structure
by means of support brackets. There are three different
types of conveyor beam support brackets. They all serve
the same purpose but are connected to the structural
beams in different ways.
Beam support brackets
Type B: X..CS.. (polyamide)
When attaching plastic beam support brackets, always
use a flat washer between nut and bracket. The nuts can
be covered by plastic plugs.
Type A: XLCT..
Type A brackets are used with crossing 64 mm or 88 mm
support beams. These brackets can also be used as drip
tray connectors
Type B: X..CS.. (aluminium)
Type B brackets are used with vertical support beams
and are made from either aluminium or polyamide. The
aluminium types can be used instead of drip tray brackets. (See example on page 48)
Type C: XLCU 73
Type C brackets are used for connecting two parallel conveyor beams to an 88 mm vertical support beam.
Assembly 19
Conveyor beams (continued)
Mounting conveyor beam support brackets
X..CT, X..CU, X..CS
Start by erecting structural beams and attach one conveyor beam support bracket to each beam.
It may be easier not to mount the second bracket until
slide rail has been mounted and, if using catenary or end
drive unit, the chain has been installed.
Box wrench 13 mm
Hex head screws M6S 8×16
Slot nuts XCAN 8
Washers BRB 8,4×16
T-bolts XLAT 17
Nuts XLAN 8
Washers BRB 8,4×16
Mounting
2 Insert the slot nuts of the second support bracket into
the support beam T-slots. Slide the bracket down so
that it does not protrude above the cross-section of
the beam.
1 Attach screws, nuts and washers to the support
bracket before mounting. (Screws and slot nuts are
support beam fasteners, T-bolts and nuts are con-
veyor beam fasteners.)
Slide the slot nuts of one support bracket into the sup-
port beam T-slots. Tighten the screws. Make sure that
the support bracket is aligned with the beam cross-
section as shown in the drawing.
3 Use a soft hammer to mount an end cap on to the
support beam.
4 Mount the first support bracket to the conveyor beam.
Pull the second bracket up and insert the T-bolts into
the conveyor beam T-slot. Tighten the nuts.
20 Assembly
Conveyor beams (continued)
Assembling conveyor beams
The next step is to connect conveyor beams – straight
sections and bends – to each other. Connect all conveyor
beams according to the instructions below.
Straight sections X..CB
Wheel bends X..BH
Horizontal plain bends X..BP
Vertical plain bends X..BV
Allen key 4 mm
Connecting strips with set screws XLCJ
Mounting:
1 Connect two conveyor beam ends by inserting con-
necting strips into the beam T-slots. Use two connecting strips per beam joint.
2 Make sure that the set screws do not prevent the con-
nection strips from sliding into place.
3 Tighten the set screws using an Allen key.
Assemble the entire conveyor beam structure in the
same way. If the conveyor beam is too long to mount onto
the support structure in one continuous length, assemble
shorter lengths and connect them to each other once fastened to the support beams.
Assembly 21
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