CT4215 Packaging Leak Detection System - HMC C01 Compression Sample Head
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Loading...Rosemount CT4215 Packaging Leak Detection System - HMC C01 Compression Sample Head Manuals & Guides
00809-200-4245, Rev AA
HMC - C01 Compression Sample Head
Reference Manual
April 2022
Preface
Published by Emerson.
All possible care has been taken in the preparation of this publication, but Emerson and its agents and distributors accept no liability for any
inaccuracies that may be found.
Emerson reserves the right to make changes without notice both to this publication and the products which it describes.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical,
photocopying, recording, or otherwise without the express prior written permission of the copyright holder.
If you require additional technical assistance, request help from
general inquiries to
cascade.support@emerson.com.
cascade.support@emerson.com or Emerson distribution partners.
Send
2 Rosemount HMC-C01
Important information
Important
Users must read, understand, and comply with the following information before proceeding.
All users, installers, operators, and maintainers must be familiar with operating the leak detection system. To install, start up,
operate, maintain, and service the detector in a safe manner, it is MANDATORY to read all additional instruction manuals shipped
with the unit.
User information
Important
All users must read this page before proceeding!
Emerson designs, manufactures, and tests its products to meet national and international standards. To ensure the product, continues to operate
as designed and within normal specifications, it
The following instructions
•
Failure to follow the proper instructions may cause:
—
Loss of life
—
Personal
—
Damage to property
—
Damage to this instrument
—
Warranty invalidation
•
Read all instructions prior to installing, operating, and servicing the product.
•
If you do not understand the instructions, contact
•
Follow all warnings, cautions, and instructions marked on and supplied with the product.
•
Inform and educate your personnel in the proper installation, operation, and maintenance of the product.
•
Install your equipment as specified in the installation instructions of the appropriate manual and in accordance with applicable local and
national codes.
•
Connect all products to the correct electrical and pressure sources.
•
To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.
•
When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson.
•
Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and
YOUR WARRANTY
•
To prevent electrical shock and personal injury, all equipment doors must be closed and protective covers in place, except when
maintenance is being performed by qualified personnel.
•
The information contained in this document is subject to change without notice.
MUST
be adhered to and integrated into your safety program when installing, operating, and
injury
. Look-alike substitutions may result in fire, electrical hazards, or improper operation.
MUST
be installed, used, and maintained correctly.
cascade.support@emerson.com
maintaining the detector
for additional clarification.
VOID
3
General safety notice/residual risk
Installation, operation, and maintenance of the leak detection system must be in accordance with these instructions.
Authorized personnel
Personnel installing, operating, servicing, and maintaining the leak detection system must be instructed, trained and qualified
the operating company and the manufacturer.
It is the operating company's responsibility to:
• Train
• Observe safety regulations
• Follow the safety instructions and procedures in the product manual
Operators must:
• Be trained
• Read and understand all relevant sections of the product manual before commencing work
• Know the safety mechanisms and regulations
staff
with
4 Rosemount HMC-C01
IEC 61010-1:2010 +AMD1:2016 CSV
Std.No. 61010-1 (3rd edition)
Regulations and Standards
UL
Regulation/standards
Description
Safety requirements for electrical equipment for measurement, control, and
laboratory use - Part 1: General requirements.
IEC 61326-1: 2020
2012/19/EU
2014/30/EU
2014/35/EU
FDA 21 CFR 1040.10
NFPA 70 (2021)
Compliance approvals
Important
The analyzer is designed for use in Non Hazardous areas ONLY.
Waste
disposal
Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 1: General requirements.
Waste Electrical and Electronic Equipment (WEEE) Directive.
The Electromagnetic Compatibility Directive.
The Low Voltage Directive.
Performance standards for light-emitting products – Sec. 10 :Laser products.
National Electrical Code (issued by ANSI: American National Standards Institute
NFPA 70: National Fire Protection Association).
and
Do not dispose of in household waste.
In accordance with European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment and its implementation into national right, measuring tools
are no longer usable must be collected separately and disposed of in an
environmentally correct manner.
In accordance with the European Directive 2012/19/EU for Waste Electrical and
Electronic Equipment (WEEE) disposal of the leak detection system when no longer
serviceable must be collected separately and disposed of in an environmentally
correct manner
Only for EC countries:
that
5
DANGER
WARNING
CAUTION
NOTICE
NOTICE
DANGER
WARNING
Hazard messages
This document uses the following criteria for hazard messages based on ANSI standards Z535.6-2011 (R2017).
Serious injury or death will occur if a hazardous situation is not avoided.
Serious injury or death could occur if a hazardous situation is not avoided.
Minor or moderate injury will or could occur if a hazardous situation is not avoided.
Data loss, property damage, hardware damage, or software damage can occur if a situation is not avoided. There is no credible risk of physical
injury.
Physical access
Unauthorized personnel can potentially cause significant damage and/or misconfiguration of end users' equipment. Protect against all intentional or
unintentional unauthorized use.
Physical security is an important part of any security program and fundamental to protecting your system. Restrict physical access to protect users'
assets. This is true for all systems used within the facility.
Safety precautions
The precautions in this manual MUST NOT be changed amended or removed. All
authorized users, installation, operation and maintenance personnel, must observe the
safety precautions and warnings.
The system is NOT designed for use in Hazardous areas.
ELECTRIC SHOCK.
Serious injury or death will occur.
The leak detection system operates using mains voltage and must be switched off and the
power cable removed before opening the analyzer.
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment .
6 Rosemount HMC-C01
WARNING
WARNING
WARNING
CAUTION
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed
HIGH PRESSURE AIR
Serious injury or death could occur.
The compressed air supply operate at pressures that can cause injury.
HAZARD BY WRONG SUPPLY VOLTAGE
Serious injury or death could occur.
The rated voltage for the leak detector is fixed during the manufacture and defined on the
ratings label fitted to the unit.
The voltage at the installation site must meet the rated voltage required.
MAINTENANCE
Serious injury or death could occur.
Only authorized maintenance personnel can carry out repair work on the leak detection
system.
On completion verify:
•
All tools and equipment are removed.
•
No contamination (water/dust) is in the compartments. Leak detector is wiped
clean.
•
Vents are clear and free from obstruction.
•
Verify that system is in a safe state for operation.
EQUIPMENT DAMAGE
Minor or moderate injury will or could occur
Always follow the procedures detailed in the manual otherwise damage to the leak detector
may result.
7
CAUTION
Only authorized personnel can operate the leak detection system.
Do not operate the leak detection system unless it is physically secured in position and all
electrical and sample gas connections are in place.
AIR SUPPLY
Minor or moderate injury will or could occur
Air provided must be connected from a pressure regulated clean, filtered and moisture free
supply source.
8 Rosemount HMC-C01
Safety and system labels and annotation
Labels are applied to the system in the positions shown below.
Location Label Type Label Fitted
9
10 Rosemount HMC-C01
Reference Manual
Contents
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April 2022
Contents
Chapter 1 System overview ......................................................................................................... 13
Chapter 2 Equipment and Accessories ...................................................................................... 15
2.1 Base Conveyor ............................................................................................................. 15
2.2 Enclosure Internals ....................................................................................................... 16
2.3 Enclosure Purge ........................................................................................................... 16
2.4
Reject
Station ................................................................................................................ 16
2.6 Electrical Panel ............................................................................................................. 17
2.7 System Controls ........................................................................................................... 18
2.8 Compressed Air Preparation ......................................................................................... 18
Chapter 3 Installation ................................................................................................................... 19
3.1 Unloading/Unpacking ................................................................................................... 19
3.1.1 Unloading ..................................................................................................................... 19
3.1.3 Unpacking ..................................................................................................................... 20
3.2 Installation .................................................................................................................... 20
3.2.1 Installation Requirements ............................................................................................. 20
3.2.2 Electrical Installation ..................................................................................................... 21
3.3 Flat Top & Friction Top Installation ............................................................................... 22
3.3.1 Identify chain and sprockets ......................................................................................... 22
3.3.2 Sprockets and wear strip position ................................................................................ 22
3.3.3 Align drive and idler sprockets ..................................................................................... 22
3.3.4 Idler Wheel and Sprocket Locations ............................................................................. 22
3.3.5 Inspect guide clearance in both straight and corner sections ...................................... 22
3.3.6 Insert section of chain ................................................................................................... 23
3.4 Inspect Conveyor .......................................................................................................... 23
3.4.1 Installation-Chain .......................................................................................................... 23
3.4.2 Installation- the Catenary Sag ...................................................................................... 24
3.4.3 Installation/Disassembly-Chain .................................................................................... 24
3.4.4 Connect the chain / One Piece Chains with Style D Pins. ........................................... 24
3.4.5 Connect the chain/ One Piece Chains with Knurled Style Pins. .................................. 24
3.4.6 Connect the chain/ For Two Piece Chains. .................................................................. 25
3.4.7 Connection style may vary by chain series. ................................................................. 25
Chapter 4 Start Up Procedure 27
4.1 Before You Begin .......................................................................................................... 27
4.1.1 Prior To Startup ............................................................................................................ 27
4.1.2 Startup .......................................................................................................................... 28
4.1.3 Operation ...................................................................................................................... 29
4.1.4 Shutdown ...................................................................................................................... 29
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Contents
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Chapter 5 Maintenance ................................................................................................................ 31
Chapter 6 Scheduled Maintenance ............................................................................................. 33
6.1 GENERAL MAINTENANCE ......................................................................................... 34
6.1.1 Flat Top and Friction Top Maintenance ........................................................................ 34
6.1.2 Inspection ..................................................................................................................... 34
6.1.3 Chain and Sprockets .................................................................................................... 35
6.1.4 Flat Top & Friction Top Chain ....................................................................................... 35
6.1.5 Bearing Lubrication ....................................................................................................... 36
6.1.6 Acceptable lubricants include: ...................................................................................... 36
6.1.7 Motor Maintenance ....................................................................................................... 36
6.1.8 Reducer Maintenance................................................................................................... 37
6.1.9 Manufacturers Recommended Lubricants .................................................................... 37
Chapter 7 Troubleshooting .......................................................................................................... 39
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Reference Manual
System Overview
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1 System overview
The HMC-C01 compression sample head is a system which uses 2 conveyors to
compress MAP filled packages in order to squeeze the MAP gas out of any defect in the
package. The MAP gas is then sampled through sampling points placed at the sides, top,
and/or bottom of the package depending on the specific application.
The compression head is designed to be installed alongside the CM-01 base leak
detection system. Please refer to reference manual 00809-0100-4245 for details on the
base unit installation. This document is intended for the personnel who install, operate,
and maintain the detector.
The compression head is designed to be installed as a slot in solution on an existing or
new production line. The main components of the system are summarized below.
A. Base Conveyor
B. System Enclosure Containing Compression Conveyor
C. Enclosure Purge Fan
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System Overview
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D. Reject Station
E. Electrical Panel
F. Control Station
G. Compressed Air Preparation
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Equipment and Accessories
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April 2022
2 Equipment and Accessories
2.1 Base Conveyor
A. Flat top conveyor surface
B. Guide rails – adjustable for different package sizes
C. Package purge point – compressed air knife directed at the surface of the
packages.
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Equipment and Accessories
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2.2 Enclosure Internals
A. Compression Conveyor
B. Upstream and downstream height adjustment
C. Sampling points
2.3 Enclosure Purge
The enclosure purge fan is located at the top of the system enclosure. When in use it can
direct up to 120 CFM of air into the enclosure. Inside the enclosure 2 deflection plates
direct the airflow to the upstream and downstream side of the system.
The net effect is a slight positive pressure is created inside the enclosure which prevents
ingress of contaminated air. If uncontaminated air needs to be ducted in from another
source then this can be done with the 100mm duct fitting on top of the purge fan.
2.4 Reject
The reject station is located after the compression conveyor and has 3 modes of operation:
Station
1.
Normal – in this mode any packs identified as a reject will be automatically
rejected at this point with a blast of compressed air.
2.
Clean – in this cleaning mode the system rejects all packs detected. (As
nominally no packs should be present during cleaning procedures)
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Equipment and Accessories
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3.
Disabled – The reject station can be disabled by not providing reject signal
from the CT4215 base system.
2.6 Electrical Panel
The system electrical panel is shown below
The panel contains the following key components: Safety control circuit, network hub,
isolation switch, PLC, 3 phase to single phase transformer, Power supplies, and conveyor
drives.
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Equipment and Accessories
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2.7 System Controls
From left to right:
A. Start
B. Stop
C. Reset
D. Emergency
Stop
These controls will be covered in more detail in the statup/shutdown section
2.8 Compressed Air Preparation
The components inside the compressed air preparation box are
A. Regulator
B. Solenoid – This solenoid connects to the reject signal
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Reference Manual
Installation
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April 2022
WARNING
3 Installation
3.1 Unloading/Unpacking
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment.
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed.
On receipt of goods, inspect the Tip N Tell and
ShockDot labels fitted to the outside of the
shipping container.
Tip N Tell
80° from vertical.
Shock Dot indicator turns red when a potentially
damaging impact has
The labels will alert the customer to any
mishandling of the analyzer when in transit.
3.1.1 Unloading
Make sure that unloading personnel are qualified and properly equipped for your particular
unloading situation. Don’t attempt to use a forklift truck if you really require a crane!
Twisted frames are difficult to repair. Use the correct rigging slings and lifting equipment to
avoid any frame twisting. Use lifting sling and chain spreaders to avoid compressing or
bending portions of the conveyor.
Immediately upon arrival of your shipment, inspect the outside carton or skid for damage.
Open the box and inspect for missing items. If your shipment is flawed, stop unloading
and request immediate inspection by the carrier. Take exception on the delivery receipt by
including damage description words; for example, “2 cartons gouged” or “corners
crushed”. Take photos and keep any original containers on hand for carrier inspection, or
it becomes very difficult to get your damages reimbursed.
White arrow becomes blue when
occurred.
tilted
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WARNING
Start a document file for each short or damaged shipment, and don’t delay in filing a claim
against the carrier once the amount of damage or loss is known. The time limit is less than
nine months for domestic truck shipments. Claim forms are available from the delivering
carrier.
Plan to have enough room to temporarily store all of the pieces out of the weather. If the
conveyor will not be installed immediately take all necessary precautions to protect your
investment. Lubricate unpainted parts (like shafts), cover the conveyor, and protect it from
being bumped, and store copies of the instructions manual where you can find them later.
Check your shipment to verify that all operating components have arrived safely and that
all parts have been shipped.
3.1.3 Unpacking
Your conveyor will have been shipped on a wooden skid or completely boxed. The drive
components are mounted to the drive section.
Cross-reference your packing slip and/or approval drawings.
In the event, you find a part that you feel you do not need or is not correct for your
conveyor, please contact our Customer Service Department
3.2 Installation
HEAVY ITEM
Serious injury or death could occur.
The leak detection system weighs 1250 kg (2756 lb) and should only be lifted or moved by
a minimum of two people using suitably rated lifting/moving equipment.
To prevent crushing of hands, feet, or other body parts always wear suitable protective
gloves and footwear when handling.
The selected installation site must be suitable to support the weight of the leak detection
system, cabling and gas sample lines when installed.
3.2.1 Installation Requirements
Use experienced and trained riggers, millwrights, installers, and licensed electricians.
Supports should be securely added as soon as each section is put into place. Use as many
installers as required for safety. Check machine leveling and adjust it frequently during the
installation. Belt tracking later depends heavily on the levelness of the conveyor.
20 Rosemount HMC-C01
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WARNING
Support anchors and customer-supplied supports must be adequate for all foreseeable
loads, including any offset drive weight
Hardware tends to loosen during shipment, and should be tightened correctly. Tighten all
bearings and sprocket set screw; they are especially important for dependable operation of
your unit. As sections are assembled into place, check all hardware for tightness. You are
responsible for any damage caused by loose hardware that was not tightened at this time.
Recheck hardware regularly, to protect your investment and your workers.
Check the access to operator positions. There must be room around the various parts of
the conveyor both for its operation and for maintenance procedures. Add any guardrails or
safety devices now, before the unit is ever put into service.
3.2.2 Electrical Installation
National Electrical Codes are laws for safety. They must be followed, under the guidance of
your local electrician, inspector or licensed journeyman electrician. Here is how this helps
you:
It allows good machine control, protecting operators from mechanical accidents
when material jams.
It safeguards personnel from electrical shock injuries.
It safeguards the machine and its connecting wires from major short circuit current
damage.
It also safeguards the machine from slight amounts of over-current that can slowly
overheat motors, wire, and cause fires.
•
ELECTRICAL CODE REQUIREMENTS
Serious injury or death could occur.
Many conveyors can be electrically reversed, but check that they are not able to jam with
loaded material when doing so. Controls must be clearly labeled which direction is which,
for safety.
Do not install this machine without a lockable electrical disconnect switch.
Variable Speed Controls can be included on any installation. Most of these are DC-type,
requiring DC motors.
ALWAYS
disconnect and lock out electrical power before working
on these controls. It is very easy to accidentally short out the solid state components inside
these controls.
All electrical options require additional operator and maintenance personnel training. The
customer must do this as soon as possible. Operator confusion about how to control, stop,
slow down, or otherwise operate the machine can result in a dangerous and costly
accident. Maintenance confusion can result in ruined controls unless the directions are
read and understood. Always keep copies of these directions in a clean location where they
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can be found and referred to.
3.3 Flat Top & Friction Top Installation
3.3.1 Identify chain and sprockets
Chain identification can be found on the underside of the link/top plate. Sprocket
identification can be found on the face of the sprocket. Detailed information on
each sprocket and chain can also be found in the product catalog.
Check sprocket and wear strip position
Ensure that sprockets, carry and return wear strips are properly positioned.
3.3.2 Sprockets and wear strip position
The distance from the end of the wear strip to the sprocket shaft centerline
should equal 1.50, otherwise the wear strip will interfere with the free articulation
of the chain as it enters the sprocket.
The leading edges of the wear strips should be beveled.
3.3.3 Align drive and idler sprockets
Make sure that the drive and idler sprockets are aligned axially with the center of
the chain. Lock the sprockets in place using the keyway and setscrews.
If multiple strands share a tail shaft, key only one sprocket and allow others to
rotate. Collars should be utilized to prevent axial floating.
3.3.4 Idler Wheel and Sprocket Locations
The idler wheels can only be used in place of tail shaft sprockets on Rex®
TableTop® one piece unit link chains.
Idler wheels should not be used with roller base chains
For proper location and smooth operation, the idler wheels should be mounted
below the top of the wear strips.
3.3.5 Inspect guide clearance in both straight and corner sections
Check the carry and return wear strips at several locations to ensure proper
guide clearance. Check the corner tracks and discs for proper thickness. Make
sure there is adequate clearance for chain TABs. Ensure straight and curved
sections are lined up properly with smooth transitions. Adjust all items as
required.
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CAUTION
3.3.6 Insert section of chain
Run a short section of chain by hand through each conveyor and over each
sprocket. Make sure there are not tight spots or obstructions such as sharp
edges, uneven wear strips, protruding bolts or screws or misaligned sprockets.
Adjust all items as required.
Transfers are very critical! Check all transfer locations by laying chain in the
tracks and sliding products through the transfer by hand. Adjust wear strips,
sprockets, corner tracks, deadplates, and guide rails as required.
3.4 Inspect
Conveyor
Clean the entire conveyor and remove any abrasive such as welding splatter, construction
debris, dirt or metal chips that are present on the conveyor frame or embedded in the
wear strips. If wear strips are damaged or embedded with debris, replace them as
necessary.
Minor or moderate injury will or could occur
All machinery must be turned off and locked out, prior to chain installation, inspection,
maintenance or removal.
Care should be used when handling the chain to avoid crushed or pinched fingers. Keep
the chain under control at all time.
The chain can easily be twisted, causing permanent deformation. Make all chain
connections on the conveyor frame.
3.4.1 Installation-Chain
For side-flexing applications requiring lubrication, apply a light coating of mineral
oil or grease to the inside corner wear strips before installing chain.
If reinstalling used chain it is recommended to oil any roller base chain.
Tread the chain onto each conveyor in 10 ft sections as shipped from the factory
Be careful to avoid twisting and damaging the chain. Make all connections on the
frame at either the drive or idler sprockets locations.
Install chains hand tight. The catenary sag of each conveyor needs to be
checked later.
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CAUTION
3.4.2 Installation- the Catenary Sag
The function of the catenary is to allow a place for excess chain to accumulate.
Rex® TableTop® chains should never be run tight.
The catenary sag should be measured when running with product.
If the catenary sag is excessive or increased due to normal wear, it should be
adjusted by removing links to obtain the proper sag.
3.4.3 Installation/Disassembly-Chain
Connect the chain/One piece Chains with Round Pins
To connect each 10 ft. section, start by positioning the connecting pin into either
one of the double eyes in the appropriate end link. Position the single eye of the
other end link between the double eyes. Then drive pin through the single eye
and into the adjacent double eye, using a drift punch and hammer, until
connecting pin is centered in the link.
Minor or moderate injury will or could occur
The chain should be hand tight when installed. Chain should never be over tensioned.
When installing the last section, separate the chain to required length using a drift
punch and hammer to drive appropriate connecting pin out of chain. Make final
connection to complete the chain loop.
3.4.4 Connect the chain / One Piece Chains with Style D Pins.
To connect each 10 ft. section, start by positioning the connection pin into either
one of the double eyes in the appropriate end link. Take care in positioning the
flat of the pin to match up with the flat on the link hole. Position the single eye of
the other end link between the double eyes. Then drive pin through the single eye
and into the adjacent double eye, using a drift punch and hammer, until
connecting pin is centered in the link. When installing the last section, separate
the chain to required length using a drift punch and hammer to drive appropriate
connecting pin out of chain. Make final connection to complete the chain loop.
3.4.5 Connect the chain/ One Piece Chains with Knurled Style Pins.
To connect each 10 ft. section, start by positioning the connecting pin into the
correct side of the chain.
Always smooth end of pin first. Position the links together then drive pin into the
hinge using a drift punch and hammer until connecting pin is recessed into the
link like adjacent pins.
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3.4.6 Connect the chain/ For Two Piece Chains.
•
Connect each 10 ft. section using the included connecting link. Position the male
portion of the connecting link through the corresponding end roller links of the two
sections which are being connected. Position the female portion of the connecting
link over the male portion. Ensure that the connecting link “flats” are in the down
position. Snap the white top plate in place over the extended pin ends to secure the
connecting link.
3.4.7 Connection style may vary by chain series.
•
To install the last section of chain, separate the chain to require length using a chain
breaker to push the appropriate connecting pins out of the roller base chain. Make
final connection to complete the chain loop.
•
For plastic two piece chains, white top plates are provided to aid in the location of
the connecting links in assembled chain loops. The connecting link may contain a
“flat” portion on the MO pin plate to aid in identification of the connecting link. While
866 chain is a two piece design, it contains a cotter pin and therefore, cotter pins
must be removed to disassemble the chain. This also means every link is a
connecting link.
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Start Up Procedure
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April 2022
WARNING
CAUTION
NOTICE
4 Start Up Procedure
HIGH PRESSURE AIR
Serious injury or death could occur.
The compressed air supply operate at pressures that can cause injury.
AIR SUPPLY
Minor or moderate injury will or could occur
Air provided must be connected from a pressure regulated clean, filtered and moisture free
supply source.
HEAVY ITEM
To stop the start-up procedure at any time, set the main circuit breaker to OFF.
4.1 Before You Begin
Remove all outside encumbrances from the area around the conveyor Secure the
conveyor to its location
4.1.1 Prior To Startup
All guard doors must be closed and latched. There are two guard doors, one on either
side of the conveyor. The conveyor will not start if the doors are not latched properly.
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Start Up Procedure
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4.1.2 Startup
Pull the E-STOP button (solid red) UP
Press the BLUE flashing light until solid blue; the green light will flash
Press and Hold the Green Button until no longer flashing (approximately 3-5 seconds). An
alarm will sound, the status indicator light will go green and the conveyor will start.
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Start Up Procedure
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4.1.3 Operation
The conveyor starts after the Green Button is no longer flashing.
When the system is in Auto mode – it is using the leak detector system in reject mode
When the system is in Clean Mode – it will reject all product and slows down the conveyor
4.1.4 Shutdown
Remove all product from conveyor Push the RED stop button
Safety Information
If product sticks in the compression area of the conveyor, press the EMERGENCY STOP
button.
NEVER stick your hand or any part of your body or any other object into any area of the
conveyor while it is in operation. Wait for the conveyor belt/chain to stop moving before
removing stuck product.
Electrical Panel – Open by Authorized Personnel only. Tool Entry required. Red/yellow
button should be in the OFF position.
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Start Up Procedure
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Scheduled Maintenance
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5 Maintenance
In general, provided the following section is followed the leak detector is a reliable system
requiring limited maintenance or intervention by the customer.
Note
There is no need for a customers to access components not covered in this document.
For further assistance contact cascade.support@emerson.com.
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WARNING
6 Scheduled Maintenance
MAINTENANCE
Serious injury or death could occur.
Only authorized maintenance personnel can carry out repair work on the leak detection
system.
•
On completion verify:
•
All tools and equipment are removed.
•
No contamination (water/dust) is in the compartments. Leak detector is wiped
clean.
•
Vents are clear and free from obstruction.
•
Verify that system is in a safe state for operation.
General Inspection and Maintenance Frequency
Inspect Conveyor for damages At Delivery
Inspect Shipment for missing parts At Delivery
Locate, read and protect your instruction manual At Delivery
Check conveyor levelness and true-ness At Installation
Clean around operator areas, infeed, and discharge Daily
Check inside the frame for material build-up Weekly
Clean off motor and reducer Monthly
Check and adjust belting take up tension Monthly
Check frame for corrosion, cleanliness, and damage Monthly
Check drive chain tension BI-Monthly
Check drives tire air pressure Quarterly
Retighten setscrews and drive mounts Semi-Annually
Check electrical amperages and connections Annually
Lubrication Maintenance Frequency
Lubricate the main drive chain Monthly
Carefully lube the bearings Quarterly
Check reducers lube levels Quarterly
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Belt Tracking Maintenance
Frequency
Safety Requirements
Frequency
Track the belting at both ends of the conveyor Monthly
Check the belt splice for any damage Monthly
Check the snub and any return rollers for build-up Monthly
Make extra copies of this manual Immediately
Train new employees in all safety areas At Hiring
Check that all safety guards are in place Weekly
Check that all warning stickers are readable Monthly
Conduct regular Operation and Safety Training BI-Monthly
Update all safety regulations and literature Annual
6.1 GENERAL MAINTENANCE
6.1.1 Flat Top and Friction Top Maintenance
The effective and useful life of the equipment in a conveyor system are influenced by the
care of servicing it receives. Each piece of equipment should be thoroughly inspected and
serviced at regular intervals for maximum performance. Keep a record to show the
equipment serviced, the date of inspections, the results, the parts required or replaced
and the cause of the trouble. If possible, keep a log sheet on each conveyor so the proper
servicing may be easily maintained.
•
Qualified and trained personnel shall perform maintenance, such as lubrication
and adjustment.
•
Where a lack of maintenance would cause a hazardous condition, the user shall
establish a maintenance program to insure that conveyor components are
maintained in a condition, which does not constitute a hazard to personnel.
6.1.2 Inspection
A general inspection of all equipment should be made at regular intervals of three to six
months. Inspections uncover trouble spots, which permit correction before serious
breakdown results. Prepare inspection checklist to assure that all parts are carefully
checked.
•
No maintenance shall be performed when a conveyor is in operation
•
Routine inspections and preventive and corrective maintenance programs shall be
conducted to insure that all safety features and drives are retained and function
properly.
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6.1.3 Chain and Sprockets
Check sprocket alignment periodically and correct misalignment immediately. Wear on the
inside sidebars or on one side of a sprocket is a definite indication of misalignment. On
indexing Gear Motor drives or Gear Motor drives equipped with brakes, special attention
must be given to drive sprocket mountings to prevent them from becoming loose and
shifting. After the initial startup inspection, make a careful check at 100 hours and another
at 500 hours. Set up a periodic inspection schedule thereafter based on operating
conditions. Indexing and braking drives require more frequent inspection than
conventional drive. Most conveyor drive chains operate in a semi-protected condition: it is
good practice to remove them periodically for cleaning and re-lubrication. Tight chains are
just as harmful as loose chains. For correct chain tension, the deflection on the slack side
should measure 2% to 3% of the sprocket center distance. For sprocket realignment see
“Drive Chain” under installation.
6.1.4 Flat Top & Friction Top Chain
In many application, rapid build-up of grease, dirt, grit, sand, spilled syrup and beverage
can occur.
Some Tabletop applications require continuous lubrication. (i.e., Stainless Steel TopsRoller Based Chain, etc.) This is of the most importance on the thrust faces at the
entrance of conveyor turns. A lubrication system that provides continuous
and uniform lubrication is recommended. If lubrication is not acceptable or
compatible with the application, a short break in lubrication application is beneficial. The
service life of side flexing chains and wear strips can be improved if sliding surfaces are
lubricated with a light material oil prior to installation. In the case of side flexing roller
chain, the base chain should also be oiled prior to installation.
Oil Base Lubricants-these are vegetable oil or mineral oils, which offer levels of protection
and lubrication to exposed chain parts. These should be used whenever practical on all
metal chains.
Water soluble Lubricants and soaps- these are excellent lubricants with many desirable
properties. Since water is a conveying medium, they are primarily suited for chain having
corrosion resistant parts or those with corrosion resistant top plates.
Water can be used as a lubricant, however, it is not considered as effective. If water is
used on plastic chains sliding on stainless steel pans, then drag on the chain may be
increased. A thin film of water must constantly be sheared as the chain slides over the pan
and overcomes the surface tension. Soap helps to overcome friction.
Applying the lubricant directly to the chin thrust face, directly below the flight just as it
enters the turn, may lubricate side-flexing chains. The lubricant can be applied under
pressure directly to the chain surface. Running the chain through a pan of lubrication on
the return strand can also lubricate the chain. The lubricant can drip on the chain from an
overhead storage tank.
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6.1.5 Bearing Lubrication
Many conveyors come equipped with permanently lubricated bearings, which have no
grease zerks. These include 2 and 3-Bolt Flange Bearings with shaft sizes through 77/16”. This prevents injecting improper or contaminated grease, and leaves the seals
tighter due to elimination of grease purging. Lubricate other bearings regularly with
approved lubricants from the list below.
Avoid over lubrication, especially when shafts are not turning, as this can blow out the
seals and lead to contamination and failure of the bearing. Exercise extreme caution
around all moving equipment when working close to them, for lubrication. Proper intervals
of bearing lubrication depend on the speed, temperature and working conditions. In
normal applications of 16 hours a day or less, a three month interval is adequate (in clean
conditions). Lock off equipment before attempting to wipe or touch movable equipment of
any kind. Clean off grease zerk fittings before lubrication and wipe excess lube from the
shaft seals so you can observe the amount of newly expelled grease. Remember to
tighten the bearing set screws BI-annually while doing the greasing.
6.1.6 Acceptable lubricants include:
Socony Mobil Oil Company Armvac No. 781
Keystone Lubricant Company 84 H Light
Standard Oil Company of Indiana Stanolith No. 57
Sinclair Oil Company Litholene
Texas Oil Company Multi Fak No. 2
Mobil SHC-PM
6.1.7 Motor Maintenance
At regular intervals, check that the motor electrical connections are tight and not corroded.
Blow clean any open frame motors, and clean off any dust or debris so proper amounts of
heat may be radiated. If motors consistently become covered with debris, construct a
guard above the, which does not hinder heat radiation.
Lubricate any motors with grease fittings every two years unless conditions are extremely
dirty or damp. Lubricate any motors with sleeve bearings with 10- 15drops of SAE # 20
non-detergent or motor oil every year (more often if dirty or damp).
New motors are more efficient, but run at higher temperatures that you may be used to.
Do not become alarmed unless the ambient temperatures at your drive section are >104
o
F. At these high temperatures, normal motors may overheat at full loads, and special
high-temperature motors may be required.
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6.1.8 Reducer Maintenance
Most conveyors come equipped with standard Gear Reducer made by Dodge Gear. This
is a trouble free reducer with normal applications and maintenance. To keep it that way,
make sure you know how to check it over, then do it regularly as shown below.
Try to keep the reducer sprocket installed as close to the reducer as possible to reduce
any overhung loads. Keep the reducer clean so it can dissipate excess heat better. All
mounting bolts should be tightened securely. Check the lube level regularly. Change the
lubricant every six months or 2500 hours, whichever comes first. Gearmotors require no
lubrication change under most conditions.
6.1.9 Manufacturers Recommended Lubricants
Manufacturer AGMA Compound#7 AGMA Compound #8
(15-60
Amoco Oil Company Worm Gear Oil Cylinder Oil # 680
Chevron USA, Inc. Cylinder Oil #460 Cylinder Oil #680X
Exxon Co., USA Cylesstic TK-460 Cylesstic TK-680
Gulf Oil Co. Senate 460 Senate 680D
Mobil Oil Corp. 600W Super Extra Helca Super
Shell Oil Co. Valvata Oil J460 Valvata Oil J680
Sun Oil Co.
Texaco Honor Cylinder Oil 650T Cylinder Oil
Union Oil Co., of CA Steaval A Worm Gear Lube 140
Gear Oil 7C Gear Oil 8C
o
F Ambient Temp) (50-125oF Ambient Temp)
Inspect your reducer vent plug often to make sure it is clear and operating. It is the upper
plug on the reducer. The next lower plug is the level plug and the lowest plug is the drain
plug. The oil level should be kept at the bottom of the threaded hole of the level plug.
However, if the conveyor and reducer are inclined above horizontal, extra oil may be
required for optimum reducer life. Synthetic oil, if used, should not be intermixed with
regular oil.
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7 Troubleshooting
Trouble shooting for flat top & friction top
Problem Possible Cause Possible Solution
Sprockets don’t slide on shaft with
expanding chain.
Chain tracks crooked. Shafts are misaligned. Align head & tail shaft to be
Chain jumps sprocket teeth. No provision for catenary
Chain breakage. Impact loading. Don’t drop load.
Debris on shaft restricts
movement.
Limit device improperly located. Determine max expansion &
Return rollers skewed. Adjust return rollers to be
Improper catenary moves from
head to tail.
Improper shaft drop. Set shaft per Rex.
Improper sprocket positioning. Sprockets must be positioned to
Over back-flexing. Return roller to small dia.
Jam up. Clear cause of jam.
Pins coming out. End plugs missing, check or
Clean shaft.
locate limit device accordingly.
parallel & horizontal.
parallel & level.
Provide for catenary per Rex
recommendations.
engage tooth pocket on chain.
replace.
Transfer plate problem.
Finger breakage.
Finger climb top of chain ribs.
Product tippage.
Cracks thru mounting holes.
Transfer plates don’t move
w/chain.
Screws too tight to allow plates to
move.
Fingers don’t properly engage. Positioning transfer plates
Debris in-between chain ribs. Clean off chain & remove.
Plates are too loose. Secure properly w/correct fastener
“Strictly” mounting surface,
restricts plate movement.
Adjust screw tension.
Use proper screw
correctly.
to keep plate from “rocking”. This
rocking can cause failure thru
mounting holes & product
tippage.
Clean mounting surface & check
for level.
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Problem Possible Cause Possible Solution
Rapid or unusual chain wear. Wear tracks. Don’t use plastic wear tracks on
Rapid sprocket tooth wear. Abrasive debris. Most commonly a problem when
glass lines where breakage
occurs.
Don’t use a dead soft stainless
steel.
using plastic sprockets.
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Rev. AA
April 2022
For more information: Emerson.com
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