Siemens HSDII Service Manual

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SIBAG HSDII High Speed Diverter

Service Manual

Document No.: 747-00216, Rev. 04

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SIBAG HSDII Service Manual

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Siemens Industry, Inc.

This document contains confidential information, trade secrets and/or know-how which is the property of Siemens Industry, Inc., and may not be disclosed to any third party without the written permission of Siemens Industry, Inc.

Product and company names herein may be the trademarks of their respective owners.

Siemens Industry, Inc. 2700 Esters Blvd. Suite 200B DFW Airport, TX 75261

www.siemens.com

972-947-7100

1-800-938-7378 (Parts and Service)

Important: Prior to operating any of the equipment or performing any of the

maintenance procedures described within this manual, it is strongly recommended that the operator and maintenance technician read the information provided within the applicable sections of this manual. All personnel shall pay particular attention to the notes, cautions, warnings, and dangers presented in this manual and posted on or in the area of the equipment. This equipment has been designed for use by trained and qualified operators. Every possible effort to prevent injury to the operator or maintenance personnel has been taken in the preparation of this manual. Damage to the equipment is possible when the procedures contained within this manual are not followed.

Revision History

Revision Date Description

03 2010-November-12 Revised preventive maintenance and repair procedures per HSDII training

video. Revised parts chapter for drive assy adapter plate and transition. Added servo fault table to Troubleshooting section. Modified Automatic Mode Operation – Profibus section and servo control module procedure.

04 2011-March-10 Revised per latest top level electrical drawing changes.

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Warranty

Goods and Services

Siemens Industry, Inc. warrants that the Goods and/or services as set forth in the Sales Agreement and Proposal and sold by Siemens Industry, Inc. to Purchaser will be free from defects in material and workmanship for a period of: one (1) year from the date of (i) completion of installation, (ii) Purchaser acceptance, or (iii) beneficial use; or two thousand hours of operation; whichever occurs first (“Warranty Period”), subject to the following terms and conditions. Where someone other than Siemens Industry, Inc. installs the Goods, the Warranty Period will commence with shipment of the Goods. Siemens Industry, Inc.’s obligation under the warranty is limited to repairing or replacing, at Siemens Industry, Inc.’s option, F.O.B. manufacturing plant, any part of the Goods found to be defective within the Warranty Period.

The warranty obligation is conditioned upon receipt by Siemens Industry, Inc. of prompt written notice of the claimed defect, including a description of the defect and its discovery, and the opportunity for Siemens Industry, Inc. to inspect the Goods in Purchaser's facility.

The warranty obligation does not include costs of labor or other charges incurred in removing or reinstalling parts; and does not apply to Goods damaged by misuse, abuse, neglect or accident or to Goods which have been improperly applied, installed, adjusted, operated, maintained, repaired or altered by persons other than Siemens Industry, Inc.

If Siemens Industry, Inc. fails to repair or replace any defective Goods under warranty within a reasonable time, then Siemens Industry, Inc. shall be liable to Purchaser for the lesser of (1) the reasonable costs of repair or replacement by a third party or (2) that part of the purchase price of the defective item that shall have been paid by Purchaser, but Purchaser shall not obtain repair or replacement by a third party without giving Siemens Industry, Inc. at least twenty (20) days prior written notice, during which time Siemens Industry, Inc. may repair or replace the defective item.

Siemens Industry, Inc. makes no warranties or representations, nor assumes any obligations with regard to Purchaser’s existing equipment or for any equipment supplied by Purchaser or a third party contracted by Purchaser and used in the Siemens Industry, Inc. system and Purchaser assumes full responsibility for the use and operation of such equipment, including compliance with any federal, state and local law, code or regulations

Computer Software and Hardware

For computer software manufactured by Siemens Industry, Inc. under the Agreement, Siemens Industry, Inc. provides emergency telephone support (1-800-938-7378), which is available 24 hours per day, 7 days per week, at no charge for defective computer software during the Warranty Period. Purchaser’s call will be referred to and promptly handled by a Siemens Industry, Inc. technician who will attempt to quickly resolve the problem through telephone discussion. Should troubleshooting efforts by the Siemens Industry, Inc. technician determine that assistance by Siemens Industry, Inc. Engineering is required, Siemens Industry, Inc. will respond in a timely (best effort) manner. Should on-site service be required to resolve a software defect, Siemens Industry, Inc. Software Emergency On-Site Service is available, on best effort response, and on a time and expense basis.

For computer hardware supplied by Siemens Industry, Inc. under the Agreement, the computer hardware warranty includes next-business day response for defective computer hardware by the computer equipment manufacturer or qualified distributor, from 8 a.m. to 5 p.m. site time, Monday

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through Friday, during the Warranty Period. If defective computer hardware covered under warranty is detected, replacement parts will be ordered promptly by the equipment manufacturer or qualified distributor and installed upon their arrival. Some parts are warranted by Siemens Industry, Inc. and require return to Siemens Industry, Inc. for Repair/Replacement. It is the responsibility of Purchaser to reinstall these parts in the computer system as directed by Siemens Industry, Inc.

The warranty does not include updates/upgrades for new versions of computer software and hardware.

The warranty for computer software and hardware will be void and inapplicable to computer software or hardware damaged by misuse, abuse, neglect or accident or to computer hardware or software which has been improperly applied, installed, adjusted, operated, maintained, repaired, modified, changed or altered by persons other than Siemens Industry, Inc. or its subcontractors; or to computer software or hardware that is installed or modified by someone other than Siemens Industry, Inc. or its subcontractors without the written direction or authority of Siemens Industry, Inc. The computer hardware supplied by Siemens Industry, Inc. is suited for an environmentally controlled office environment (e.g., air conditioned, heated and clean office environment) and unless the computer hardware is used in that environment, the computer hardware warranty is null and void for failures.

If the Goods include computer hardware or software acquired from original manufacturers, Siemens Industry, Inc.’s obligation will be limited to conveying and transferring to Purchaser any license, interest, rights and/or warranties which Siemens Industry, Inc. may obtain from the original manufacturer.

Disclaimer

Siemens Industry, Inc. does not warrant and is not responsible for warranties or licenses for any, computer hardware or computer software supplied by Purchaser or acquired from a third party by Purchaser and used in the Siemens Industry, Inc. system. Purchaser will be responsible for all such licenses and warranties under those circumstances, including any problems detected while the equipment, computer hardware or software is being used for development at Siemens Industry, Inc.

Siemens Industry, Inc., herein after known as the Company, makes no other warranty of any kind whatsoever expressed or implied and the Company hereby disclaims all warranties of merchantability and fitness for particular purpose. The Company shall in no case be subject to any other obligations or liabilities whatsoever with respect to products or services manufactured or furnished by it or any acts or omissions relating thereto. The remedy provided under this warranty should be the sole, exclusive and only remedy available to Purchaser. Under no circumstances shall the Company be liable for any special, indirect, incidental or consequential damages, expenses, losses or delays howsoever caused.

No statement, representation, agreement or understanding, oral or written, made by any agent, distributor representative or employee of the Company which is not contained in this Warranty will be binding upon the Company unless made in writing and executed by an officer of the Company. Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company that any product was not so warranted.

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Contents

1 Maintenance Safety.......................................................................1

1.1 Philosophy of Safety ....................................................................... 1

1.2 Training........................................................................................... 2

1.3 Maintenance Safety Procedures ..................................................... 2

1.3.1 Safety Tips Prior to Servicing.......................................................... 2

1.3.2 Safety Tips During Servicing........................................................... 3

1.3.3 Safety Tips After Servicing.............................................................. 4

1.4 Lockout/Tagout ............................................................................... 4

1.5 Basic Safety Rules.......................................................................... 7

1.5.1 Basic Maintenance Safety Rules..................................................... 8

1.6 Safety Design Features................................................................... 8

1.6.1 Emergency Stop Units .................................................................... 8

1.6.2 Emergency Stop Procedure ............................................................ 8

1.6.3 Spill Guards .................................................................................... 9

1.6.4 Headroom and Aisles...................................................................... 9

1.6.5 General Guarding ........................................................................... 9

1.6.6 Safety and Warning Labels ............................................................. 9

1.6.7 Additional Safety References........................................................ 11

1.7 ASME B20.1-2000 Operational and Maintenance Safety .............. 12

2 Model Description.......................................................................13

2.1 Description of Operation ............................................................... 14

2.1.1 Hardware Overview ...................................................................... 15

2.1.2 Basic Operation ............................................................................ 15

2.1.3 Service Mode Operation ............................................................... 16

2.1.4 Manual Mode Operation................................................................ 17

2.1.5 Automatic Mode Operation............................................................ 17

3 Installation................................................................................... 24

3.1 Installation Sequence and Startup Checklist ................................. 24

3.2 Mechanical Installation.................................................................. 24

3.2.1 Unloading and Handling................................................................ 24

3.2.2 Unit Identification .......................................................................... 25

3.2.3 Installation..................................................................................... 25

3.3 Electrical Instructions .................................................................... 26

3.3.1 Specifications................................................................................ 27

3.3.2 Installation..................................................................................... 27

3.4 Initial Startup and Operation.......................................................... 27

3.5 Installation Inspection and Acceptance Report.............................. 28

4 Preventive Maintenance.............................................................30

4.1 General Safety and Maintenance.................................................. 30

4.2 Inspection ..................................................................................... 30

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4.2.1 Return Rollers ...............................................................................31

4.2.2 Servo Gearmotor...........................................................................31

4.2.3 Drive Pulley...................................................................................31

4.2.4 Paddle Assemblies........................................................................31

4.2.5 Shaft Locking Device.....................................................................31

4.2.6 Servo Gearmotor Cables...............................................................31

4.2.7 Diverter Control Panel ...................................................................32

4.2.8 Paddle Belt....................................................................................32

4.3 Lubrication.....................................................................................32

4.3.1 Roller Bearings..............................................................................32

4.3.2 Pivot Bearings ...............................................................................32

4.3.3 Tie Rod End Bearings ...................................................................32

4.3.4 Servo Gearmotor...........................................................................32

4.3.5 Drive Pulley...................................................................................34

4.4 Cleaning ........................................................................................ 36

4.4.1 Servo Gearmotor...........................................................................36

4.4.2 Drive Pulley...................................................................................36

4.4.3 Drive Side Paddle and Cover Debris .............................................37

4.4.4 Transition Assembly Rollers ..........................................................37

4.4.5 Control Panel.................................................................................37

4.5 Adjustment ....................................................................................38

4.5.1 Shaft Locking Device.....................................................................38

4.5.2 Paddle Belt Tracking and Tension .................................................38

4.5.3 Paddle Position .............................................................................38

4.5.4 Setting Paddle Belt Speed.............................................................39

4.6 High Speed Diverter PM Tasks and Time Intervals........................42

4.6.1 High Speed Diverter Monthly Operational Checklists.....................43

4.6.2 High Speed Diverter Checklist Form..............................................45

5 Troubleshooting..........................................................................46

5.1 Mechanical Troubleshooting..........................................................46

5.1.1 Paddle Positioning.........................................................................46

5.1.2 Servo Gearmotor...........................................................................47

5.1.3 Pillow Block Bearings ....................................................................48

5.1.4 Paddle Nose Rollers and Drive Pulley ...........................................48

5.1.5 Paddle Belting ...............................................................................52

5.2 Electrical/Controls Troubleshooting ...............................................53

5.2.1 Diverter Faults...............................................................................53

5.2.2 System Faults (Optional) ............................................................... 56

5.2.3 Servo Faults ..................................................................................57

6 Repair........................................................................................... 60

6.1 Torque Values for Hardware..........................................................61

6.2 Testing HSDII Operation ...............................................................61

6.3 High Speed Diverter Top Level Assembly .....................................62

6.3.1 Long Tie Rod.................................................................................63

6.4 Tie Rod Assembly .........................................................................64

6.4.1 Tie Rods and Bearings..................................................................64

6.5 Conveyor Assembly.......................................................................65

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6.5.1 Return Roller................................................................................. 66

6.6 Drive Subassembly ....................................................................... 67

6.6.1 Paddle Assembly (Drive Side)....................................................... 67

6.6.2 Shaft ............................................................................................. 70

6.6.3 Servo Gearmotor .......................................................................... 71

6.6.4 Pivot Bearings............................................................................... 72

6.6.5 Short Tie Rod................................................................................ 73

6.7 Paddle Assembly .......................................................................... 75

6.7.1 Paddle Belt ................................................................................... 76

6.7.2 Paddle Nose Roller ....................................................................... 76

6.7.3 Paddle Drive Pulley....................................................................... 77

6.8 Transition Subassembly................................................................ 78

6.8.1 Paddle Assembly (Non-Drive Side) ............................................... 79

6.8.2 Shaft ............................................................................................. 81

6.8.3 Pivot Bearings............................................................................... 82

6.8.4 Transition Rollers .......................................................................... 83

6.9 Control Panel ................................................................................ 84

6.9.1 Motor Power Cable ....................................................................... 85

6.9.2 Motor Control Cable...................................................................... 85

6.9.3 Servo Control Unit and Memory Module........................................ 86

6.9.4 Reprogram Servo Control Module................................................. 87

7 Parts.............................................................................................91

7.1 Locating Replacement Parts......................................................... 91

7.2 Spare Parts................................................................................... 91

7.3 Ordering Parts............................................................................... 92

7.3.1 Business Hours............................................................................. 92

7.3.2 Phone Numbers ............................................................................ 92

7.3.3 Web Site ....................................................................................... 92

7.3.4 Order Processing and Shipping .................................................... 92

7.3.5 Repairs ......................................................................................... 92

7.3.6 Returns ......................................................................................... 92

7.3.7 Parts Warranty.............................................................................. 93

7.4 Illustrations and Parts Lists ........................................................... 93

7.4.1 HSDII Top Level Assembly 68.0020.100-XX (39 In. Wide)............ 95

7.4.2 HSDII Top Level Assembly 68.0020.101-XX (1050 mm Wide)...... 96

7.4.3 HSDII Top Level Assembly 68.0020.150-XX (1200 mm Wide)...... 97

7.4.4 Tie Rod Assemblies, Long 68.0020.000-38 and 68.0020.001-12 and

Short 68.0020.000-36 ................................................................... 98

7.4.5 Conveyor Assembly 68.0020.000-63 (39 In. Wide) ..................... 100

7.4.6 Conveyor Assembly 68.0020.000-67 (1050 mm Wide) ............... 100

7.4.7 Conveyor Assembly 68.0020.001-13 (1200 mm Wide) ............... 100

7.4.8 Drive Subassembly 68.0020.102-XX (39 In., 1050 mm Wide)..... 102

7.4.9 Drive Subassembly 68.0020.151-XX (1200 mm Wide)................ 103

7.4.10 Transition Subassembly 68.0020.103-XX (39 In. Wide) .............. 104

7.4.11 Transition Subassembly 68.0020.163-XX (1050 mm Wide) ........ 105

7.4.12 Transition Subassembly 68.0020.152-XX (1200 mm Wide) ........ 106

7.4.13 Paddle Assembly 68.0020.000-01(39 In. Wide) .......................... 108

7.4.14 Paddle Assembly 68.0020.001-16 (1200 mm Wide) ................... 109

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7.4.15 HSDII Control Panel 68.0020.212 (US) and 68.0020.215

(International), Front Door ...........................................................111

7.4.16 HSDII Control Panel 68.0020.212 (US) and 68.0020.215

(International), Inside...................................................................113

7.5 Recommended Spare Parts ........................................................114

7.5.1 39 In. Wide BG............................................................................114

7.5.2 1050 or 1200 mm Wide BG .........................................................115

8 Manufacturers’ Literature .........................................................116

9 Electrical Drawings ...................................................................117

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Figures

Figure 1 Lockout/Tagout Equipment Examples .............................................. 6

Figure 2 Safety and Warning Label Locations .............................................. 10

Figure 3 SIBAG HSDII.................................................................................. 13

Figure 4 Hardware Configuration Screen...................................................... 19

Figure 5 Crated HSDII .................................................................................. 25

Figure 6 Area Guard..................................................................................... 26

Figure 7 Drive Pulley Oil Level ..................................................................... 34

Figure 8 Control Unit 310/320 LEDs During Booting..................................... 54

Figure 9 Control Unit 320 LEDs After Booting............................................... 55

Figure 10 HSDII Top Level Assembly............................................................. 62

Figure 11 Tie Rod Assembly .......................................................................... 64

Figure 12 Conveyor Assembly........................................................................ 65

Figure 13 Drive Subassembly......................................................................... 67

Figure 14 Jacking Two Conical Halves of Shaft Locking Device Apart

(S=Shallow; M=Mid-Depth)............................................................. 68

Figure 15 Preparing Shaft Locking Device for Replacement........................... 69

Figure 16 Paddle Assembly............................................................................ 75

Figure 17 Transition Subassembly ................................................................. 78

Figure 18 Jacking Two Conical Halves of Shaft Locking Device Apart

(S=Shallow; M=Mid-Depth)............................................................. 79

Figure 19 Preparing Shaft Locking Device for Replacement........................... 80

Figure 20 Control Panel, Inside ...................................................................... 84

Figure 21 Sinamics Control Unit and Modules ................................................ 87

Figure 22 Memory Module Card Files............................................................. 88

Figure 23 Servo Component LEDs................................................................. 89

Figure 24 HSDII Top Level Assembly 68.0020.100-XX (39 In. Wide),

68.0020.101-XX (1050 mm Wide), and 68.0020.150-XX (1200 mm

Wide).............................................................................................. 94

Figure 25 Tie Rod Assemblies........................................................................ 98

Figure 26 Conveyor Assembly 68.0020.000-63 (39 In. Wide), 68.0020.000-67

(1050 mm Wide), and 68.0020.001-13, (1200 mm Wide) ............... 99

Figure 27 Drive Subassembly 68.0020.102-XX and 68.0020.151-XX........... 101

Figure 28 Transition Subassembly 68.0020.103-XX (39 In. Wide), 68.0020.163-

XX (1050 mm Wide), and 68.0020.152-XX (1200 mm Wide)........ 104

Figure 29 Paddle Assembly 68.0020.000-01 and 68.0020.001-16................ 107

Figure 30 HSDII Control Panel 68.0020.212 (US) and 68.0020.215

(International), Front Door ............................................................ 110

Figure 31 HSDII Control Panel 68.0020.212 (US) and 68.0020.215

(International), Inside.................................................................... 112

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1 Maintenance Safety

This manual contains basic guidelines for baggage handling safety, lockout/tagout procedures, safety design features, product features, and general operational and maintenance safety. Its purpose is to improve safety and safety education in the workplace. The safety section is not intended to cover all situations or circumstances, and is not a regulatory publication. Much of the information in this manual comes from the “ASME B20.1 - Safety Standards for Conveyors and Related Equipment” accredited by American National Standards and sponsored by the American Society of Mechanical Engineers (ASME). To request copies of the publication contact: American National Standards Institute, 3 Park Avenue, New York, NY 10016-5990, Phone: 212-591-8500, Fax: 212591-8501.

1.1 Philosophy of Safety

The most preferred method of negating a hazard is to design it out of the equipment or installation. If this is not possible, guarding against the hazard is the next best method. Guarding may take on several forms. The most common forms of guarding are location guarding (area guarding) and point guarding. If neither of these methods can negate the hazard while maintaining function, then warnings are used. Warnings should also be used to protect against dangerous practices.

The philosophy of safety is best described in the following manner:

● Remove the hazard.

● Guard where the hazard may exist (area guarding or point guarding).

● Warn against the hazard.

Belts and chains moving over pulleys, sprockets, and sheaves create pinch and nip points which must be guarded. These points present a risk of injury if not guarded properly.

● Ensure that all barriers and warning signs are in place to warn personnel

about equipment that can not be guarded.

● Do NOT operate equipment with guards or safety units removed.

● Operate the equipment with TRAINED personnel ONLY.

● Do NOT perform service or maintenance until all power is disconnected and

locked out.

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1.2 Training

In addition to the initial training of personnel (when equipment is first placed into operation), continuous training is required on a scheduled and periodic basis. The purpose of continuous training is to reinforce the importance of safe work practices by ALL employees, including all new hires and transfers working with or around the equipment.

The employer is responsible for providing trained employees knowledgeable in the safe maintenance practices of the baggage handling equipment. Siemens recommends the video presentation “Safety is in Your Hands” as part of each training program. This video addresses the key points relating to safe work practices around baggage handling equipment. To order a copy of this video presentation, contact the Customer Service Department.

1.3 Maintenance Safety Procedures

This section describes safety precautions that should be followed before, during and after maintenance and troubleshooting tasks. Since voltages encountered in this equipment can cause lethal shock if mishandled, these safety instructions should be strictly adhered to.

1.3.1 Safety Tips Prior to Servicing

● ALWAYS stop the equipment before attempting to clear jams.

● Whenever possible, service electrical equipment with the power "OFF."

This can be done in any combination of the following:

■ With the Motor Safety Disconnect Switch.

■ By padlocking the control cabinet disconnect switch in the "OFF"

position.

■ By removing the line fuses.

● Utilize the OSHA compliant lockout/tagout units at all pertinent disconnect

switches.

● Secure proper tools and wiring diagrams. Be sure that an adequate test

instrument is available.

● READ any instructions or test procedures BEFORE attempting them.

● Inform personnel in the area that maintenance tasks are being performed.

● Before beginning work, ensure that power is actually removed by checking

various points to ground with test meter. Even though power to the unit being serviced is removed, some points of the unit may be energized due to interconnections with other equipment. Such areas are appropriately marked.

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Yellow wires in a control cabinet remain hot even when the disconnect switch is turned OFF. Use extreme caution when servicing a control cabinet with an outside power source.

● If maintenance must be performed with power "ON," be sure the following

precautions are taken:

■ Work in pairs, with the location of the main disconnection switch known

to each worker.

■ Use properly insulated tools, gloves, and an insulated mat, especially in

damp areas.

■ Inform personnel in the area that servicing is being done. Accidentally

removing power to equipment can also cause injury.

■ Use proper test instruments; avoid gimmicks such as jumpers and bulb

testers.

● NEVER “ride” or walk on a conveyor.

1.3.2 Safety Tips During Servicing

While working never forget that other pieces of equipment can be involved when a particular START or STOP pushbutton is pressed. For example, a conveyor in a remote area may be energized by a particular operation. Before energizing

ANY element of the system it is essential that you be sure to:

● Inform all personnel in that area.

● Confirm that all other systems are STILL disabled.

● Stay clear of all chain drives, motor couplings, and belts during equipment

operation.

● Wear safety helmets at all times when performing maintenance duties.

Safety goggles must be used when grinding, drilling or cutting.

● NEVER wire or tape down limit switches.

● ALWAYS observe the signals of the warning lights.

● Be alert to any deficiency of the equipment.

● NEVER "ride" on a conveyor.

● Use eye protection (goggles or face mask) if air pressure is required for any

cleaning task.

:NOTE: Compressed air supply should be 30 PSI (2.1 kgf/cm

) or LESS.

● Do not leave tools or parts where they may be a safety hazard or

obstruction.

● Be absolutely certain that all personnel are clear of any moving parts before

starting the conveyor system.

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● Report all accidents resulting in personal injury or damage to the equipment

to the Supervisor.

In the unlikely event of electrocution, do not touch the victim until the high voltage circuit is broken.

1.3.3 Safety Tips After Servicing

● When servicing is complete, replace test equipment and tools. Remove and

properly dispose of any damaged components and close all panels.

● Do not leave tools or parts where they may be a safety hazard or

obstruction.

● Finally, remove all lockout/tagout equipment and inform personnel in the

area that servicing is completed.

1.4 Lockout/Tagout

The primary purpose for a lockout/tagout procedure is to protect workers from

injury caused by the unexpected energization or start-up of equipment.

As of August 28, 1989, OSHA Standards were amended to incorporate lockout/tagout requirements. It is the opinion of Siemens that this standard applies to most workplaces utilizing powered conveyors. The standard from the Occupational Safety and Health Administration (OSHA) centers on the control of potentially hazardous energy. The rule requires that energy sources for equipment be turned off or disconnected, and that the switches be locked or labeled with a warning tag. This ensures that the equipment has been shut down for servicing or maintenance and will not reactivate while employees are working on it. The regulation defines servicing and maintenance as covering “lubrication, cleaning or unjamming of machines or equipment . . . where the employee may be exposed to the unexpected energization or start up of the equipment . . . ” among other things.

We are bringing this to your attention in the event you are not aware of the standard. We urge you to review the applicability and requirements of the standard with respect to your facilities. The lockout/tagout procedure is considered to be just one element of the control procedures for hazardous energy. The employer is responsible for providing procedures that include deenergization of equipment, isolation of energy sources, verification that equipment has been de-energized, and complete diffusion of stored energy.

The standard requires an ongoing program of control procedures and employee training by the employer (regardless of training provided by the equipment vendor at the time of sale) to ensure that the purpose and functions of energy controls are understood and applied.

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For further information regarding lockout/tagout requirements, refer to the Federal Register, Volume 54, No. 169 published September 1, 1989. The referenced standard may be found at 29 CFR Part 1910, Section 1910.147. Also, copies may be requested from the Siemens Customer Service Department.

Siemens can also furnish OSHA compliant lockout/tagout equipment and training materials; call the Customer Service Department 1-800-938-7378.

● Lockout/tagout should take place before any service or maintenance work

begins. Alert operators of power disconnection. Isolate the power source.

● Attach lockout tags to each lock indicating name of service person, date,

and purpose of the lockout.

● Use padlocks with only one key for all lockout purposes. If duplicate keys

exist, keep them under strict management supervision.

● Check for stored energy. Test the equipment to be sure that it will not

operate.

● The service person who locks and tags a machine must be the one who

unlocks it.

● Never remove a lock or tag that is not yours.

● Never lockout or tag equipment for another person.

● If a lock or tag is left on during a shift change, leave it in lockout/tagout

condition. Assume the equipment is locked or tagged for a good reason. Contact your supervisor.

● If work is done in shifts and the work is not completed, the new shift

employees should install their locks or tags while the existing shift is removing theirs. When possible, the new shift should install their locks before the existing shift removes theirs so nothing is ever unlocked.

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Figure 1 Lockout/Tagout Equipment Examples

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1.5 Basic Safety Rules

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1.5.1 Basic Maintenance Safety Rules

The maintenance staff also plays a key role in the overall safety of the baggage handling equipment. Establishing and practicing a preventive approach to safety helps provide an effective safety program.

● Lockout/tagout must take place before any service or maintenance work

begins.

● All maintenance or service is to be performed by qualified, trained personnel

only.

● A routine inspection plan must be maintained before each shift change and

start up of the material handling equipment.

● Always report unsafe conditions or anything out of the ordinary to the

supervisor.

1.6 Safety Design Features

Baggage handling equipment has safety design features for worker protection. Basic baggage handling safety design features are outlined on the pages that follow.

1.6.1 Emergency Stop Units

Illuminated red emergency stop push-pull buttons, limit switches, emergency pull cords, and other similar emergency stop units are located throughout the system for operator protection during emergency situations.

These emergency stop units are normally used at or near each potential work station. E-stop units are also provided at reasonable intervals throughout material handling systems in areas routinely occupied by operations personnel.

E-stop units are not intended to disable equipment to provide protection for personnel in potentially hazardous contact with such equipment. For example, maintenance, jam clearing, and/or other similar activities require adherence to lockout procedures.

E-stops ideally control all movement visible from and related to the equipment or location of the control unit.

1.6.2 Emergency Stop Procedure

Emergency Stop and restart the entire system as follows:

1. Activate any E-STOP pushbutton (this will stop the associated conveyors).

2. Fix the reason for pushing the E-STOP pushbutton.

3. Reset the activated E-STOP pushbutton.

4. Pull the activated E-STOP pushbutton and restart the system as normal.

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1.6.3 Spill Guards

Many portions of material handling equipment run overhead and around areas accessible to personnel. It is important that these areas be protected with spill guards or other guarding design features.

1.6.4 Headroom and Aisles

When conveyors run above aisles, passageways or exits designated as fire exit pathways, warnings will be provided if head clearance is less than 6 feet 8 inches (2 meters). The clearance of 6 feet 8 inches (2 meters) is measured from the floor to the lowest part of the conveyor or guards. Other aisles or passageways with less than 6 feet 8 inches (2 meters) clearance will be protected by safety tape and warning signs.

In designated aisleways, all moving equipment parts to an elevation of 8 feet (2.4 meters) will be guarded.

1.6.5 General Guarding

When necessary for the proper protection of workers, it is required that areas be properly guarded where equipment meets or exposed moving parts present a potential hazard. It is recommended that warning and caution signs be positioned in the employees’ line of sight.

1.6.6 Safety and Warning Labels

Warning and safety labels are factory installed by the manufacturer or applied after installation. Siemens equipment has safety labels attached with messages warning of potential risks. These labels are located to be useful in any application. Individual installations may have a unique need for additional labels in other mounting locations. Therefore, more of the standard labels are readily available.

These labels and signs may need to be supplemented by other warnings of individual design that may be obtained from local sources or nationally distributed catalogs.

DANGER: Indicates an imminently hazardous situation that, if not avoided, will

result in death or severe injury. The use of danger labels is limited to the most extreme situations

WARNING: Indicates a potentially hazardous situation that, if not avoided,

could result in death or severe injury

CAUTION: Indicates a potentially hazardous situation that, if not avoided, will

result in minor or moderate injury. It may also be used to alert against unsafe practices.

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DANGER or WARNING should not be considered for property damage accidents

unless personal injury risk appropriate to these levels is also involved. CAUTION

is permitted for property-damage-only accidents. Sign placement shall be in the immediate vicinity of the hazard, readily visible so the viewer can recognize the hazard and take appropriate action.

Safety Signs and Labels Verification: On a quarterly basis, walk through the

entire material handling system and make sure that all safety signs and labels are clearly legible and in good condition. Particularly if the system has been reconfigured, verify that the signs and labels are still in the proper locations. If there is a problem with any sign or label, reorder and replace it according to the following identification and ordering pages.

Figure 2 Safety and Warning Label Locations

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1.6.7 Additional Safety References

1.6.7.1 ANSI – American National Standards Institute

B 15.1 Mechanical Power Transmission (ASME) B 20.1 Safety Standard for Conveyors (ASME) Z 535.1 Safety Color Code (NEMA) Z 535.2 Environ. and Facility Safety Signs (NEMA) Z 535.3 Criteria for Safety Symbols (NEMA) Z 535.4 Product Safety Signs and Labels (NEMA) Z 535.5 Accident Prevention Tags (NEMA)

1.6.7.2 CEMA – Conveyor Equipment Manufacturer's Associat i on

102

Terms and Definitions 201 Safety Label Brochure 402 Belt Conveyors

1.6.7.3 OSHA – Occupational Safety and Health Administration

Subpar

t D-(1910) Walking/Working Surfaces

1910.21 Definitions

1910.22 General Requirements

1910.23 Guarding, Floor/Wall Openings

1910.24 Fixed Industrial Stairs

1910.27 Fixed Ladders

1910.30 Other Working Surfaces Subpart J-(l910) General Environmental Controls

1910.144 Safety Color Codes for Marking Physical Hazards

1910.145 Specifications for Accident Prevention Signs and Tags

1910.147 The Control of Hazardous Energy (Lockout/Tagout) Subpart O-(1910) Machinery and Machine Guarding

1910.211 Definitions

1910.212 General Requirements (All Machines)

1910.219 Mechanical Power-Transmission App. Subpart S-(1910)Electrical

1910.301 Introduction

1910.302 Electric Utilizations Systems

1910.303 General Requirements

1910.304 Wiring Design and Protection

1910.305 Wiring Methods, Components, and Equipment-General Use

1910.307 Hazardous Locations

1910.308 Design Safety Standards

1.6.7.4 NFPA – National Fire Protection Association

70E -

Standard for Electrical Safety in the Workplace

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1.7 ASME B20.1-2000 Operational and Maintenance Safety

Portions of the ANSI “Safety Standards of Conveyors and Related Equipment” (ASME B20.1-2000) relate to operational and maintenance personnel.

Introduction

Accidents resulting from the manual handling of materials have been reduced by the use of conveying and other forms of mechanical handling equipment. A further reduction in the accident rate can be gained by following safe practices in the design, construction, installation, operation, and maintenance of such equipment.

The design and installation of conveyors and conveyor systems should be supervised by qualified engineers. Likewise, the maintenance of conveyors and systems should be supervised by trained personnel.

The purpose of this standard is to present certain guides for the design, construction, installation, operation, and maintenance of conveyors and related equipment.

Those portions of this standard relating to maintenance and operation procedures are fully as important as those relating to design and installation. The best design features may be negated by faulty maintenance and operating practices. It is important that operating and maintenance personnel be instructed in recognizing hazards and pertinent safety precautions.

5.2 Maintenance (Repair) a. Maintenance and service shall be performed by qualified

and trained personnel.

b. Where lack of maintenance would cause a hazardous

condition, the user shall establish a maintenance program to ensure that conveyor components are maintained in a condition that does not constitute a hazard to personnel.

c. No maintenance shall be performed when a conveyor is in

operation except as outlined in 5.3 and 5.4.

d. When a conveyor is stopped for maintenance or repair

purposes, the starting units, prime movers, or powered accessories shall be locked out or tagged out in accordance with a formalized procedure designed to protect all persons or groups involved with the conveyor against unexpected restart. Personnel should be alerted to the hazard of stored energy, which may exist after the power source is locked out. Refer to ANSI Z244.1-1982, American National Standard for Personnel Protection – Lockout/Tagout of Energy Sources – Minimum Safety Requirements and OSHA 29 CFR 1910.147 The Control of Hazardous Energy (Lockout/Tagout).

e. All safety units and guards shall be replaced before

starting equipment for normal operations.

5.3 Lubrication a. Conveyors shall not be lubricated while in operation

unless it is impractical to shut down for lubrication. Only trained and qualified personnel who are aware of the hazard of a conveyor in motion shall be allowed to lubricate a conveyor that is operating.

b. Where the drip of lubricants or process liquids on the floor

constitutes a hazard, drip pans or other means of eliminating the hazard shall be provided.

5.4 Adjustment or Maintenance When adjustment or maintenance is required while equipment is in operation, only trained and qualified personnel who are aware of the hazard of the conveyor in motion shall be allowed to make the adjustment or perform the maintenance.

5.9.1 General Requirements of Guarding

5.9.1.3 Guarding Exceptions. Wherever conditions

prevail that would require guarding under these standards but such guarding would render the conveyor unusable, prominent warnings shall be provided in the area or on the equipment in lieu of guarding.

5.9.1.4 Maintenance of Guards and Safety Units.

Guards and safety units shall be maintained in a serviceable and operational condition. Warning signs provided in accordance with 5.9.1.3 shall be maintained in a legible, operational condition.

5.12 Operation a. Only a trained person shall be permitted to operate a

conveyor. Training shall include instruction in operation under normal conditions and emergency situations.

b. Where safety is dependent upon stopping units or starting

units or both, they shall be kept free from obstructions to permit ready access.

c. The area around loading and unloading points shall be

kept clear of obstructions that could endanger personnel.

d. No person shall ride on a conveyor, unless it is a conveyor

engineered for that purpose.

e. Personnel working on or near a conveyor shall be

instructed as to the location and operation of pertinent stopping units.

f. A conveyor shall be used to transport only loads it is

designed to handle safely.

g. Under no circumstances shall the safety characteristics of

the conveyor be altered without proper authorization from the manufacturer.

h. Routine inspections and corrective maintenance

measures shall be conducted to ensure that all guards and safety features are retained and function properly.

i. Personnel should be alerted to the potential hazard of

entanglement in conveyors caused by such items such as long hair, loose clothing, and jewelry.

j. Conveyors shall not be maintained or serviced while in

operation unless proper maintenance or service requires the conveyor to be in motion. In which case, personnel shall be made aware of the hazards and how the task may be safely accomplished.

:NOTE: Contact the American Society of Mechanical Engineers at the address shown above for the complete ASME B20.1-2000.

:NOTE: These excerpts are printed with the permission of ASME.

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2 Model Description

The SIBAG High Speed Diverter II (HSDII) is a device with two paddles mounted on a horizontal belt conveyor used to divert the flow of one of several bags by moving the paddles into the baggage stream. For better baggage flow, the paddles are equipped with actively driven belts. The HSDII is designed to be an integral part of a main line belt conveyor sort system. The activated paddles of the diverter form a 45 degree vertical powered belt wall for the transfer of luggage from a main sort line to a pier chute or take-away conveyor. The baggage contacts the diverter in a smooth, non-destructive manner, which minimizes the impact forces applied during the sort process.

Figure 3 SIBAG HSDII

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A single servo gearmotor efficiently powers the diverting action of the HSDII, rotating the paddles 45 degrees across the conveyor belt between their diverting and non-diverting positions. It delivers motion to the pivot shaft of both the drive side and non-drive side paddles simultaneously via a tie rod assembly. A drive pulley powers the belt on each paddle.

When system control determines a need, the HSDII is energized, and the paddle belts begin running. Diverter position is determined by the diverter control panel by evaluating the output of the servo gearmotor encoder.

The HSDII is available in the configurations listed in Table 1. This manual pr

ovides service and parts information for all versions.

Table 1 Available HSDII Versions

Part Number Between Guards Width Transition Width Hand

68.0020.100-01 39 in 7 in Left

68.0020.100-02 39 in 7 in Right

68.0020.100-03 39 in 10 in Left

68.0020.100-04 39 in 10 in Right

68.0020.101-01 1050 mm 180 mm Left

68.0020.101-02 1050 mm 180 mm Right

68.0020.101-03 1050 mm 250 mm Left

68.0020.101-04 1050 mm 250 mm Right

68.0020.150-01 1200 mm 180 mm Left

68.0020.150-02

68.0020.150-03

68.0020.150-04

1200 mm 180 mm Right

1200 mm 250 mm Left

1200 mm 250 mm Right

2.1 Description of Operation

The new HSDII uses a Sinamics drive configuration with a Siemens programmable control unit CU320 and two separate output channels (axles), one for servo-positioning of the paddles (SERVO) and one for asynchronous movement of the paddle-belts (VECTOR).

The main supply voltage is separate from the control voltage. Disconnect and lock out/tag out both the main supply voltage and control voltage before performing maintenance.

There is a switch on the control panel door to select service, manual, or auto modes. This switch is wired directly to and controlled by the Sinamics CU so both manual and service modes are available without the high level PLC running.

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A high level PLC with user-defined parameters is used which selects between common signal exchanges wired to communicate via Digital I/O or Profibus interface.

2.1.1 Hardware Overview

The HSDII is controlled by a Sinamics Drive System with programmable control unit. The control is comprised of the following Siemens control equipment:

● Control Unit Sinamics S120 CU320 6SL3040-0MA00-0AA1, FW Version:

2.5 SP 1

● Smart Line Module 6SL3130-6AE15-0AB0 5 kW

● Double Motor Module 6SL3120-2TE21-0AA3 9A/9A

● Servo gearmotor with absolute encoder for positioning

● Asynchronous motors without encoder for paddle belts

● Basic Operator Panel BOP20 6SL3055-0AA00-4BA0

2.1.2 Basic Operation

In the PLC operation, a bag arriving at the tracking photocell (provided by BHS integrator), located at least 12 inches (305mm) upstream of the HSDII on the conveyor bed, is checked to see if it requires diverting from the main conveyor line. Once a determination is made, the diverter responds as outlined below.

If the bag is to be diverted, one of the following occurs:

● If the diverter is in the RETRACTED position, the paddle belt drive pulleys

are started via a maintained RUN PADDLE BELTS signal when the tracking photocell is blocked, and when the bag is tracked nearly to the pivot point of the first paddle, the servo gearmotor is energized via a leading edge trigger of the EXTEND PADDLES signal so that the diverter is moved to the EXTENDED position which will allow the bag to divert.

● If the diverter is already in the EXTENDED position, the paddle belt drive

pulleys are started when the tracking photocell is blocked, and the paddles remain stationary, allowing the bag to divert.

After either case, the paddle belt motors should continue to run for at least 20 seconds to allow for following sort operations without restarting the motors. This 20 second period is reset as each new bag passes the 12 inches (305mm) upstream tracking photocell. If no sort action is required during those 20 seconds, the HSDII paddle belt drive pulleys should be deactivated by removing the RUN PADDLE BELTS signal until the next time they are needed.

If the bag does not require diverting, the following occurs:

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● If the diverter is in the EXTENDED position, when the bag is tracked to

nearly the pivot point of the first paddle, the servo gearmotor is energized via a leading edge trigger of the RETRACT PADDLES signal so that the diverter will return to the RETRACTED position which allows the bag to pass through. The paddle belt drive pulleys do not need to be activated for this action.

● If the diverter is already in the RETRACTED position, the motors remain off

and the paddles remain stationary, allowing the bag to pass through.

Ideally, the HSDII motors are energized only when a sort action is required. Additionally, the paddles are actuated to a different position only when required to do so. If bag spacing is not adequate no sort action shall be attempted. The HSDII will complete a position change actuation in approximately 350 ms.

:NOTE: Reliable operation of the diverter at chutes or parallel takeaways

requires a minimum “gap” between bags of at least 24 inches (610 mm). The average length of each piece of luggage plus the 24 inch (610 mm) gap defines the bag window size.

The PLC should also monitor for fault conditions in the HSDII:

● If the HSDII does not complete an intended position change, the Control

Unit will indicate a fault condition.

● As long as control voltage remains, the HSDII will also indicate a fault if the

main power supply is interrupted.

The Basic Operator Panel (BOP) will display the code for any alarms or faults. The list of alarms and faults can be found in the Siemens Sinamics S List Manual (6SL3097-2AP00-0BP6.)

The HSDII can be operated in three different modes, selected by a three-position selector switch located on the HSDII Diverter Control Panel (DCP):

● Service

● Manual

● Automatic.

2.1.3 Service Mode Operation

Service mode operation of the diverter requires that the MODE OF OPERATION selector switch on the door of the DCP be in the SERVICE position. In this mode the TEACH, PADDLE, and PADDLE BELT switches on the door of the DCP are enabled. The Service mode is used to define new end positions for the servo cycle commands. The paddle extend and retract positions are factory configured, but reconfiguring them might be necessary if the mechanism has been adjusted or repaired. See section 4.5.3 Paddle Position.

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2.1.4 Manual Mode Operation

Manual operation of the diverter requires that the MODE OF OPERATION selector switch on the door of the DCP be in the MAN position. In this mode the PADDLE and PADDLE BELT selector switches are enabled. TEACH selector switch on the door of the DCP is disabled.

:NOTE: Divert All Operation: If there is a need to divert all bags off of the

mainline, the Baggage Handling System (BHS) logic controller will need to provide the signal to maintain the paddles in the extended position while the diverter remains in the AUTO mode. Because the MAN mode replaces the automatic function signals from the BHS controller with the manual door controls, the HSDII would no longer have the ability to turn off the motors in the event of a cascade or normal timeout situation. For this reason, it is not acceptable to place the mode switch in the MAN mode for the purpose of sustained Divert All operation.

2.1.5 Automatic Mode Operation

Automatic operation of the diverter requires that the MODE OF OPERATION selector switch on the door of the DCP be in the AUTO position. In this mode the TEACH, PADDLE, and PADDLE BELT selector switches on the door of the DCP are inactive.

:NOTE: Divert All Operation: If there is a need to divert all bags off of the

mainline, the Baggage Handling System (BHS) logic controller will need to provide the signal to maintain the paddles in the extended position while the diverter remains in the AUTO mode.

In Automatic mode, all switches on the HSDII control panel are disabled, with the exception of the MODE OF OPERATION selector switch and the FAULT RESET illuminated pushbutton.

There are two methods of controlling the HSDII in Automatic mode:

● Common input/output exchange through the use of 120 VAC or 24 VDC

control relays. These relays are located in the HSDII control panel and are wired to the CU320.

● Remote communications over Profibus

There is a parameter P21529.0 located in the HSDII drives that will select the method of control in Automatic mode. This can be adjusted by using the Siemens Starter program, or by using the Basic Operator Panel on the HSDII drive. If this parameter is set to 0, the control relays will operate the HSDII. A setting of 1 will enable the Profibus communications.

Note that the HSDII model that is for Profibus only will not contain the input/output relays. All of the HSDII models will contain the Profibus communications option, as well as the two relays needed for the safety stop.

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2.1.5.1 Automatic Mode - Relays

With parameter P21529.0 = 0 and the selector switch set to the “Auto” position, the HSDII is prepared to accept operating commands from the upstream PLC via the exchange relays. These signals can either be 120 VAC or 24 VDC depending on the model of the HSDII. The signals are described in Table 2:

Table 2 Input/Output Signals

Outputs Inputs

Main Disconnect On Motor Enable (E-Stop)

Fault Signal System Stop

Paddle in Extended Position Move Paddle to Extended Position

Paddle in Zero Position Run Paddle Belts

Automatic Mode On Reset Fault

Smart Line Module Ready Move Paddle to Zero Position

Control Unit Ready

2.1.5.2 Automatic Mode – Profibus

The HSDII can also be controlled over the available Profibus communications port. In order to enable Profibus communications, parameter P21529.0 must be set to 1.

The Profibus communication is broken down into three different telegrams. The three telegrams represent the Control Unit (CU), the servo drive, and the vector drive. The telegrams consist of output words which are received from the upstream PLC to control the HSD, and input words which are sent to the PLC to provide status updates. In addition, the three telegrams contain the same number of words, as illustrated in Table 3.

Table 3 Profibus Telegrams

Telegram Output Words Input Words

Servo 4 4

Vector 4 4

Control Unit 4 4

Configuring the Profibus communication can be done in several ways. One way is using the Siemens Starter program with the Drives ES package. When using this program, the Profibus setup can be exported from Starter directly into the Siemens Step 7.

A second method of configuring the Profibus communication is using the GSD file. The GSD file is a readable ASCII text file that contains general and devicespecific specifications for communications. The GSD file is located on the

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compact flash card that comes with the HSDII. The GSD file is also available on the Siemens website.

When configuring the HSDII in the Hardware Configuration screen, each of the telegrams must be set up as a separate object in different slots. The objects should be configured as a Universal Module, with each having the appropriate number of input and output words as shown in Table 3, and in the same order (

i.e., Servo first, Vector second, and Control Unit third.) Standard telegram 2 (PZD – 4/4) may be used in place of the Universal Module. In addition, each of these objects must be separated by an Axis Disconnector as shown in Figure 4.

Figure 4 Hardware Configuration Screen

Each of the telegrams is further broken down to provide specific status updates or directly control the HSDII. The following tables illustrate the items that compose the telegrams.

:NOTE: Items marked with an * may not be available depending on the model

of HSDII (i.e., an HSDII that is configured for Profibus control only will not have these items.)

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Activating the commands in the output words is accomplished by turning the appropriate bit from 0 to 1. For example, to command the HSDII paddles to move to the extended position is accomplished by changing the signal of Bit 1 in the Servo Output Word #1 from 0 to 1.

Some words are not broken down into individual bits, such as Servo and Vector Output Words #2. These two words must have a value in them in order for the HSDII to operate. The typical value is to make the value of these words to be 100, thus setting the paddle and belt speeds to nominal settings, although the value can range from 50 – 150.

In addition, Bit 10 of Servo and Vector Output Words #1 must always be set to 1. If these values are not 1, the HSDII will not recognize any other Profibus commands.

Control Unit Input Word #2 indicates the status of the inputs and outputs on the control unit itself.

Also, note that the “Go to Zero Position” and “Go to Extended Position” should never both be active at the same time, otherwise a warning will occur and no movement will be executed.

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Table 4 Servo Telegram Output Words

WORD BYTE BIT DESCRIPTION

10 PLC CONTROL (SET TO 1)

SERVO

OUTPUT WORD

SERVO

OUTPUT WORD

SERVO

OUTPUT WORD

SERVO

OUTPUT WORD

0 GO TO ZERO POSITION

1 GO TO EXTENDED POSITION

6 ACKNOWLEDGE FAULT

(SERVO (PADDLE) SPEED SETPO INT

MEASURED IN PERCENTAGE

OF NOMINAL SPEED: 50 - 150%)

e.g., A VALUE OF 120 IN THIS WORD

WILL SET THE PADDLE SPEED TO

120% OF NOMINAL SPEED)

(RESERVED FOR FUTURE USE)

Table 5 Servo Telegram Input Words

WORD BYTE BIT DESCRIPTION

SERVO

INPUT WORD

SERVO

INPUT WORD

SERVO

INPUT WORD

SERVO

INPUT WORD

0 PADDLES IN ZERO POSITION

1 PADDLES IN EXTENDED POSITION

5 SERVO DRIV E IN OPERATION

6 SYSTEM STOP RELAY DE-ENERGIZED

7 SERVO FAULT PRESENT

(SERVO (PADDLE) ACTUAL SPEED

MEASURED IN PERCENTAGE

OF NOMINAL SPEED: 50 - 150%)

(SERVO (PADDLE) ACTUAL POSITION

COMBINED WITH OUTPUT WORD #4

TO FORM A DOUBLE WORD)

(SERVO (PADDLE) ACTUAL POSITION

COMBINED WITH OUTPUT WORD #3

TO FORM A DOUBLE WORD)

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Table 6 Vector Telegram Output Words

WORD BYTE BIT DESCRIPTION

10 PLC CONTROL (SET TO 1)

VECTOR

OUTPUT

WORD #1

VECTOR

OUTPUT

WORD #2

VECTOR

OUTPUT

WORD #3

VECTOR

OUTPUT

WORD #4

0 RUN PADDLE BELTS

(VECTOR (BELT) SPEED SETPOINT

MEASURED IN PERCENTAGE

OF NOMINAL SPEED: 50 - 150%

e.g., A VALUE OF 120 IN THIS WORD

WILL SET THE BELT SPEED TO 120%

OF NOMINAL SPEED)

(RESERVED FOR FUTURE USE)

Table 7 Vector Telegram Input Words

WORD BYTE BIT DESCRIPTION

VECTOR

INPUT WORD

VECTOR

INPUT WORD

VECTOR

INPUT WORD

VECTOR

INPUT WORD

0 PADDLE BELTS RUNNING STATUS

5 VECTOR DRIVE IN OPERATION

6 SYSTEM STOP RELAY DE-ENERGIZED

7 VECTOR FAULT PRESENT

(VECTOR (BELT) ACTUAL SPEED

MEASURED IN PERCENTAGE

OF NOMINAL SPEED (50 - 150%

(RESERVED FOR FUTURE USE)

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Table 8 Control Unit Telegram Output Words

WORD BYTE BIT DESCRIPTION

0 (RESERVED FOR FUTURE USE)

CONTROL UNIT

OUTPUT WORD

CONTROL UNIT

OUTPUT WORD

CONTROL UNIT

OUTPUT WORD

CONTROL UNIT

OUTPUT WORD

0 (RESERVED FOR FUTURE USE)

(RESERVED FOR FUTURE USE)

Table 9 Control Unit Telegram Input Words

WORD BYTE BIT DESCRIPTION

CONTROL

UNIT

INPUT

WORD #1

CONTROL

UNIT

INPUT

WORD #2

CONTROL

UNIT

INPUT

WORD #3

CONTROL

UNIT

INPUT

WORD #4

6 SYSTEM STOP RELAY DE-ENERGIZED

7 CONTROL UNIT FAULT PRESENT

0 DI 0: SYSTEM STOP RELAY ENERGIZED

1 DI 1: HSD FAULT RESET PUSHBUTTON

2 DI 2: HSD IN SERVICE MODE

3 DI 3: HSD IN AUTOMATIC MODE

4 DI 4: HSD PADDLE RETRACT SWITCH

5 DI 5: HSD PADDLE EXTEND SWITCH

6 DI 6: REMOTE RETRACT PADDLE RELAY *

7 DI 7: SMART LINE MODULE READY

8 DI/DO 8: REMOTE EXTEND P ADDLE RELAY *

9 DI/DO 9: RUN PADDLE BELTS INPUT

10 DI/DO 10: HSD TEACH ZERO POSITION SWITCH

11 DI/DO 11: HSD TEACH EXTEND POSITION SWITCH

12 DI/DO 12: FAULT PRESENT

13 DI/DO 13: PADDLES IN EXTENDED POSITION

14 DI/DO 14: PADDLES IN ZERO POSITION

15 DI/DO 15: CONTROL UNIT READY

(RESERVED FOR FUTURE USE)

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3 Installation

3.1 Installation Sequence and Startup Checklist

Lock Out and Tag Out procedures should be followed with respect to both the main line conveyor and the HSDII before performing this checklist.

Table 10 Installation Sequence and Startup Checklist

Procedure Completed

Review service manual installation procedures.

Review installation layout and detail drawings.

Remove the back covers and visually inspect all factory wiring and inside devices for any damage that may have occurred during shipment.

Install upstream, downstream, and takeaway conveyor beds (including belts and sideguards).

Fasten HSDII conveyor bed to adjacent conveyor beds using Grade 5 (or Class 8.8) hardware.

Level the HSDII bed.

Manually move the paddles by hand. Operation should be smooth with no binding or catch points.

Connect incoming power to diverter control panel.

Adjust the encoder and setpoint configurations using the Teach functions.

Test to verify correct belt direction for paddle belts.

Test to verify correct paddle belt speed.

Test the HSDII operation.



3.2 Mechanical Installation

3.2.1 Unloading and Handling

Each HSDII is separately crated for easy fork-lift handling at the job site (see Figure 5). When out of the crate, the HSDII should only be handled from the bot

tom with all of the packing removed. The HSDII should only be handled with

the long length dimension perpendicular to the lifting forks.

Store each HSDII separately, and do NOT stack any other materials on top of the HSDII.

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The weight of the HSDII is 1530 lb (approximately 1800 lb crated). While 74 percent of the weight is on the drive side of the unit, the weight of the HSDII is approximately equal from one end to the other.

Prior to installation, remove the back covers and visually inspect all factory wiring and inside devices for any damage that may have occurred during shipment. Notify Siemens immediately if any damage is visible.

If lifting with a crane, use straps under the unit with spreader bars to properly distribute the load while preventing damage to the electrical control panel and safety guarding.

Figure 5 Crated HSDII

3.2.2 Unit Identification

Each HSDII has an engraved serial number name plate mounted on the diverter control panel. Each HSDII may also have a conveyor identification number on the rear cover. Refer to the separate installation layout drawings to determine where each HSDII will be installed.

3.2.3 Installation

:NOTE: Adjacent conveyor beds must be installed and leveled prior to attaching

the HSDII bed.

1. Lift the HSDII into position using forklift forks perpendicular to the HSDII

bed.

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2. Fasten the four HSDII conveyor assembly bed conveyor interface brackets to the upstream and downstream conveyor bed frames using 3/8 in Grade 5 (or 10 mm Class 8.8) hardware.

3. Level the HSDII bed.

4. Remove the back covers and visually inspect all factory wiring and inside devices for any damage that may have occurred during shipment.

5. Install the conveyor bed belt and tension.

6. Install the adjacent conveyor bed sideguards.

7. Match drill and install HSDII area guard.

Figure 6 Area Guard

3.3 Electrical Instructions

The HSDII is delivered with a preconfigured memory module card in the Sinamics control unit, which already contains a HSDII standard project with application program, as well as all typical motor and machine specific data including the speed of the vertical paddle belts.

The encoder and setpoint configurations have also been factory adjusted, but fine tuning may be required. The application program therefore contains special “Teach Functions”. The testing technician has to jog in service mode to the desired positions. By activating the corresponding “Teach” Key Switch Encoder Reset respectively, transmission of actual position value to the setpoint parameter will be executed. This means the HSDII can be commissioned without any explicit access to the parameters. The speed of the vertical paddle belts may be changed during testing, if needed, by accessing the speed parameter setting within the program loaded into the control unit.

The HSDII comes with all the electrical devices wired to the terminal strip located in the Diverter Control Panel (DCP) located on the frame of the HSDII.

The HSDII does not include a PLC or any other means of automated control, but the motor controller provides the protection circuitry for each of the motors. The automation controls are normally included in the sort line motor control panel that is connected to the HSDII on the terminal strip located in the DCP.

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3.3.1 Specifications

There are two different versions of the HSDII depending on the country where the HSDII will be installed. The following table shows the specifications for each:

Table 11 Controls Specifications

Specification USA International

Primary Power 480 VAC, 60 Hz, 10.1 A 400 VAC, 50 Hz ,10.1A

Secondary Power

Control Voltage 120 VAC, 1 phase, 60 Hz 24 VDC

Controls Interface

120 VAC, 1 phase, 60 Hz, 3 A

Digital input and output controls interface or PROFIBUS

230 VAC, 1phase, 50 Hz, 3 A

Digital input and output controls interface or PROFIBUS

3.3.2 Installation

1. Connect incoming and outgoing control signal wires to diverter control panel.

2. Connect incoming power to diverter control panel.

3. Adjust the encoder and setpoint configurations using the Teach Functions. See section 4.5.3 Paddle Position.

3.4 Initial Startup and Operation

Perform the following testing checks upon completion of installation to verify the HSDII unit is operating properly:

1. With the main power turned off, manually move the paddles by hand. Operation should be smooth with no binding or catch points. Return the paddle arms to the zero position.

2. Replace the back cover and remove the Lockout/Tagout devices.

3. Test the HSDII operation:

a. Turn the mode switch to the MAN position

b. Turn the disconnect switch to the ON position.

c. Turn the PADDLE BELT selector switch to START.

d. The paddle belts should be operating and the HSDII can be cycled by

turning the PADDLE RET/0/EXT selector switch to EXT and RET.

e. Use a current meter to check current draw and record the reading.

Idling current should be less than the full load amps indicated on the motor nameplate.

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3.5 Installation Inspection and Acceptance Report

SIEMENS HIGH SPEED DIVERTER II INSPECTION/ACCEPTANCE REPORT

Project or Customer Name Project Reference #

Location of Project Date of Inspection

HSDII Serial Number(s)

MECHANICAL STATIC INSPECT IO N MECHANICAL DYNAMIC INSPECT IO N # A

HSDII identification

Paint condition

Safety labels

Cleanliness

Proper installation of floor supports

Proper installation of hanger supports

Mounting hardware grade 5 and secure

Mounting hardware on drive side tight

Mounting hardware on non-drive side tight

No sharp edges or burrs

No baggage snag points

Vertical/horizontal alignment of bed joints

Proper alignment of HSDII paddles

Access to HSDII controls not restricted

Maintenance access not restricted

Guards installed

Correct mainline belting

Correct take-away belting

Take-away transition

# A

Motor operation (noisy/hot/sealed)

Bearing operation (noisy/hot)

Belt operation (noisy/smooth)

Smooth operation of paddles

Covers during operation (rattles/rubbing)

Proper timing for paddle positioning signal

Unit maintained in off position until needed

Take-away clear monitoring

Proper paddle belt direction of rotation

Paddle belt speed is 1.4-1.5 times main belt

speed

SIEMENS Representative Signature Date

OWNER Representative Signature Date

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SIEMENS HIGH SPEED DIVERTER II INSPECTION/ACCEPTANCE REPORT

Project or Customer Name Project Reference #

Location of Project Date of Inspection

HSDII Serial Number(s)

COMMENTS Item # Comment

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4 Preventive Maintenance

4.1 General Safety and Maintenance

Do not perform adjustments, maintenance or other work on this equipment without following OSHA Lock-Out/Tag-Out requirements and state and local requirements. Failure to follow these requirements may result in serious injury and/or equipment damage.

Unless otherwise specified, be certain that all equipment is de-energized and power is turned off

Any damage found should be repaired or replaced before operating equipment.

Standing or climbing on unit is dangerous to personnel and equipment.

In order to reduce down time and increase the life expectancy of various parts, it is necessary that maintenance personnel become familiar with system components and the periodic servicing they require. Routine inspection of all components is essential to reduce down time and to keep the system operating efficiently.

Proper maintenance of this equipment will ensure proper operation and promote operating personnel safety.

1. Replace broken or worn parts as soon as they are detected.

2. Safety guards must be properly attached to the unit before and while operating the equipment.

3. Keep all CAUTION, WARNING, and DANGER safety labels clean and in

plain sight.

4.2 Inspection

All components should be checked on a monthly basis to ensure the following:

● All hardware is firmly locked in place.

● Belts, bearings, and drive components are in proper operating condition.

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Any unusual audible noises may indicate a component or hardware has become loose. If noises are heard, inspect and correct the problem.

4.2.1 Return Rollers

Check for noise or excessive heat. If any is detected, the internal bearing is defective and the entire roller assembly should be replaced. Inspect roller mounting bracket to ensure that the attachment hardware is secure.

4.2.2 Servo Gearmotor

The servo gearmotor should be checked monthly. Inspect mounting hardware for security. Inspect wiring for damaged insulation, loose connections, or evidence of arcing. The gearbox should be inspected for excessive backlash, noise, or oil leakage.

4.2.3 Drive Pulley

Only perform maintenance work after switching off the power. Lock and tag out equipment.

The drive pulleys should be checked monthly for:

● Securing hardware is tight and not damaged.

● Drive pulley is mounted vertically, square to the conveyor frame, and

parallel to the nose roller.

● Unit is running quiet and cool.

● No visible oil leakage

● Ensure cables, leads and connections are in good condition and fastened

securely.

4.2.4 Paddle Assemblies

Check monthly for secure fastening, belt wear, and alignment in zero (home) and extended positions.

4.2.5 Shaft Locking Device

Every 6 months, check the shaft locking device on the paddle assembly shaft for slippage and tightness of the attaching screws. If the screws need to be tightened see section 4.5.1 Shaft Locking Device.

4.2.6 Servo Gearmotor Cables

Visually inspect the servo gearmotor cables monthly to verify the connections are tight and the cable insulation is not damaged and there is no evidence of arcing.

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4.2.7 Diverter Control Panel

The equipment and components located on the panels and in the cabinets should be visually inspected annually as follows:

1. Turn diverter control panel and main control panel and power off and lockout/tagout the panel.

2. Open access door and inspect the main disconnect.

3. Examine components and devices for correct and secure mounting.

4. Check cable and wiring connections for tightness.

5. Check cable/wire harness clamps and restraints for tightness.

6. Examine all devices for evidence of excessive heat or burning.

7. Examine all wire and cable for burned, scorched or frayed insulation.

8. Examine all components or equipment for broken or damaged wires, connectors, or terminals.

9. After inspection is complete, remove lockout/tagout and turn control panel power back on.

4.2.8 Paddle Belt

Check monthly for proper paddle belt operation. When operating, the paddle belt V-guide should ride smoothly within the groove of the motorized drive pulley. Adjust as necessary to prevent the V-guide from wearing on the edge of the pulley groove. See section 4.5.2 Paddle Belt Tracking.

4.3 Lubrication

4.3.1 Roller Bearings

All roller bearings are grease filled by the manufacturer and do not require maintenance.

4.3.2 Pivot Bearings

All mounted pivot bearings are grease filled by the manufacturer and do not require maintenance.

4.3.3 Tie Rod End Bearings

All tie rod end bearings are grease filled by the manufacturer and do not require maintenance.

4.3.4 Servo Gearmotor

All motors are factory filled with lubricant. It is recommended that oil changes be performed every 2 years.

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:NOTE: Do not use oil additives, which can cause damage to the motor

insulation or seals. Electrically conductive-bases oils, such as graphite and molybdenum disulfide, should not be used as this will result in damage.

4.3.4.1 Oil Change

Unscrew the oil plug and allow the oil to drain completely into a suitable catch basin. Dispose of the oil properly according to site regulations.

:NOTE: There may be internal pressure released when removing the oil plug;

this is normal.

2. Refill the unit with the suggested oil type and amount of oil per the servo gearmotor nameplate data to the level of the oil plug.

3. Re-install the oil plug and if available, install a new copper seal.

4.3.4.2 Oil Level Check

o check the oil level, open the oil plug. In this position, the oil level should be up

to the level of the bottom of the oil plug.

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4.3.5 Drive Pulley

Only perform maintenance work after switching off the power. Lock and tag out equipment. Open terminal box and disconnect the cables.

Figure 7 Drive Pulley Oil Level

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4.3.5.1 Oil Change – Van der Graaf Damage to the motor can result when using the wrong oil type. Refer to

the motor data label or Table 12. Do not use oils containing additives which may damage the motor insulation or seals. Do not use oils containing graphite, molybdenum disulphite or other electrically conductive based oils.

All drive pulleys are factory filled with lubricant. It is recommended that oil changes be performed every 2 years.

:NOTE: Refer to the Van der Graaf Drum Motor manual for specific details.

1. Remove pulley from paddle assembly and place it on work bench. See section 6.7.3 Paddle Drive Pulley.

Allow unit to cool to normal temperature.

3. Rotate drive pulley until oil plug is located in 6:00 o’clock position (bottom).

4. Unscrew oil plug and allow oil to drain completely. Collect oil in container and examine it for wear metals. Dispose of it properly according to site regulations.

:NOTE: There may be internal pressure released when removing the oil plug;

this is normal.

5. Refill pulley with approximately 750 ml of suggested oil type. See Figure 7 and Table 12.

Replace oil plug and install new copper seal.

7. Replace pulley in conveyor and run for 5-10 min.

8. Stop and lockout conveyor then open oil plug to vent it.

9. Close oil plug.

Table 12 Van der Graaf Drive Pulley Suggested Oil Types

Manufacturer Oil

Petro Canada Enduratex EP-150 Gear Oil

Castrol Molub-Alloy Gear Oil 84

Chevron NL Gear Compound 150

Esso/Imperial Oil Spartan EP 150

Citgo EP Compound 150

Gulf EP Lubricant 140

Shell Omala 150

Sunoco SUNEP 150

Mobil Mobil Gear 629, SHC 150

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4.3.5.2 Oil Change – Interroll Damage to the motor can result when using the wrong oil type. Refer to

the motor data label or Table 13. Do not use oils containing additives which may damage the motor insulation or seals. Do not use oils containing graphite, molybdenum disulphite or other electrically conductive based oils.

All drive pulleys are factory filled with lubricant. It is recommended that oil changes be performed every 10,000 hours of operation.

:NOTE: Refer to the Interroll Drum Motor manual for specific details.

1. Remove drive pulley from unit and place it on work bench. See section 6.7.3 Paddle Drive Pulley.

Remove oil plugs and clean any metal particles from magnetic oil plug.

3. Drain oil from drive pulley. Collect oil in a container and examine for wear metals. Dispose of it properly according to site regulations.

4. Fill pulley with new 800 ml of suggested oil type. See Figure 7 and Table 13.

Replace both oil plugs and seals and tighten oil plug.

6. Replace the pulley in conveyor and run for 5-10 min.

7. Stop and lockout the conveyor then open the oil plug to vent it.

8. Close the oil plug.

Table 13 Interroll Drive Pulley Suggested Oil Types

Manufacturer Oil

Shell Omala 150

4.4 Cleaning

4.4.1 Servo Gearmotor

Use a clean cloth and de-greaser to clean the outer surface of the motor once a year. If the motor is in a dirty environment, the motor will require cleaning more often.

4.4.2 Drive Pulley

Only perform maintenance work after switching off the power. Lock and tag out equipment. Open terminal box and disconnect the cables.

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Material build up on the drive pulley or on the underside of the belt will cause belt misalignment and possibly belt damage. Material build-up between the belt and slide bed plate or rollers may also cause belt speed reduction and increase the power requirement. Periodic cleaning will ensure a high drive efficiency and good belt alignment.

Remove foreign material from the drive pulley with standard cleaners.

:NOTE: Do not use sharp-edged tools to clean the drive pulley.

4.4.3 Drive Side Paddle and Cover Debris

Clean out any debris that collects between the drive side paddle assembly and the covers.

4.4.4 Transition Assembly Rollers

Clean out any debris around the transition rollers, such as tape, tags, straps, small padlocks, or string. Remove anything that might keep the rollers from spinning freely.

4.4.5 Control Panel

Do not use water in cleaning electrical components. Damage to the equipment may result.

Do not use compressed air to blow out debris.

Clean control panel internal components periodically as required. Some debris could cause electrical shorts.

● Lubricate cabinet door hinges and door latches using light machine oil. Use

a soft cloth to remove any excess oil.

● Dust the panel, cabinet, and component surfaces using a soft, lint-free cloth.

● Diverter Control Panel Air Filters: Clean or replace intake and exhaust filters

monthly in order to maintain proper airflow through the Diverter Control Panel.

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4.5 Adjustment

4.5.1 Shaft Locking Device

The shaft locking device must be checked to prevent paddle slippage on the shaft. Check all eight clamping screws with a torque wrench set to 30 lb ft (41 Nm). There should not be any movement at this setting. If there is, refer to the replacement procedure in section 6.6.1 Paddle Assembly (Drive Side) or 6.8.1 Paddle Assembly (Non-Drive Side) for the correct method of torqing the clam

ping screws. See the B-Loc manufacturer’s literature for proper installation

instructions. Screws must be evenly tightened to 30 lb ft (41 Nm).

4.5.2 Paddle Belt Tracking and Tension

Adjust paddle belt tracking as necessary to prevent the V-guide from wearing on the edge of the pulley groove.

1. Remove guards as necessary for access.

2. Remove top cover.

3. Loosen hardware securing both top and bottom clamp plate assemblies and shaft clamp plates to top drive plate and bottom drive plate.

4. By adjusting upper and lower tensioning nuts, square paddle drive pulley on paddle to correct belt tracking. V-guide should be square to pulley groove.

5. Tighten upper and lower tensioning nuts evenly.

6. Tension is correct when slack is removed and belt does not slip on drive pulley as it rotates. Tension should be equal across width of belt.

7. If belt is riding incorrectly, belt tracking is adjusted by slightly tightening or loosening upper tension nut. It moves upper portion of drive pulley slightly in or out, which causes belt to move up or down.

8. Tighten hardware securing top and bottom clamp plate assemblies.

9. Replace cover.

10. Replace guards.

4.5.3 Paddle Position

4.5.3.1 Setup of Position Setpoints: Quick Setup by Teach Functions

There is an application program for the HSDII in the Sinamics Control Unit that allows it to reset the zero position and to reconfigure extended position setpoint without any explicit access to parameters by Basic Operator Panel (BOP) or Starter-Tool. Parameter setting will be executed automatically by the application program in the control unit.

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4.5.3.1.1 Step 1: Absolute Encoder Reset

1. Turn the mode switch to SERVICE.

2. In the zero (home) position, the paddles are fully retracted. Move the paddle to the zero (home) position by turning the PADDLE RET/0/EXT selector switch.

3. Briefly turning the selector switch back and forth between RET and PADDLE will allow you to make fine adjustments to the alignment.

4. When the paddle is in the zero (home) position, turn the TEACH ZERO/0/EXT keyswitch to ZERO.

5. The Sinamics will do an absolute encoder calibration and a RAM to ROM copy. The saving procedure takes approximately 20 seconds. During that time, no other teaching function can be carried out. The FAULT light on the door on the control panel will flash during the RAM to ROM copy and it will turn off when finished.

:NOTE: Zero position must be set first before setting extend position (otherwise

the mechanism could crash once the unit is set to MAN or AUTO).

4.5.3.1.2 Step 2: Extended Paddle Position

:NOTE: In the extended position, the two paddles should form a straight line.

1. With the mode switch still in SERVICE, move the paddle to the extended position by turning the PADDLE RET/0/EXT selector switch to EXT.

2. Briefly turning the selector switch back and forth between RET and PADDLE will allow you to make fine adjustments to the alignment.

3. Turn the TEACH ZERO/0/EXT keyswitch to EXT.

4. The Sinamics will copy the actual position into the second traversing block. The fault light will flash to indicate that the position is being saved.

5. Next, verify positioning. Place the mode of operation switch to MAN.

6. Turning the PADDLE RET/0/EXT selector switch to EXT and then RET should activate the paddles to the positions you just taught. When complete, return the mode switch to AUTO.

:NOTE: In the automatic and manual mode the diverter paddle will be moving between the zero (home) and the extended position at full speed. In service mode, the paddle will be moving slowly between the software limit

switches/encoders to allow you to easily set the zero (home) and extended positions.

4.5.4 Setting Paddle Belt Speed

The HSDII paddle belt speed can be adjusted to be compatible with the mainline belt speed using the Siemens BOP20 control panel. The paddle belt speed may need to be adjusted if the memory module (card) is replaced (see section 6.9.3 Servo Control Unit and Memory Module).

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:NOTE: The BOP20 display shows active drive: 01 (control unit), 02 (positioning

servo), or 03 (paddle belt motors).

:NOTE: “A13000” may flash on the display screen occasionally as an alert. This

is not a problem, and it does not affect the adjustment procedure below.

4.5.4.1 Select the Paddle Belt Motor Drive (03)

Press FN and arrow up buttons together so that the drive number in the display begins to flash.

2. Press arrow up to select drive number 03 in the upper left corner of the display.

3. Press P to set. The display will now show “31” on the lower row.

4.5.4.2 Adjust Parameter

Press P to enter the programming mode. The display will show “r00000”.

2. Press arrow up to select parameter “P01001”.

3. Press P to select. The display will show “in0000”.

4. Press P again to show the preset speed parameter.

5. Press FN to enter the edit mode and toggle through the digits.

:NOTE: For parameter values of 1,000 or higher, it will be necessary to press

the FN button several times to toggle the edit digit far enough to the left to be able to see the remaining digits.

6. Press arrow up or down to adjust each digit individually.

:NOTE: Changing the far left parameter value from underscore (_) to dash (–)

or vice versa will reverse the belt travel direction.

:NOTE: Excess motor heating may occur if the parameter is set higher than

1900.

:NOTE: Each speed parameter value change of 10 is approximately equal to 3

fpm change of the paddle belt speed.

Table 14 Example Values

Mainline Conveyor Belt Speed

380 fpm 537 fpm 1810

280 fpm 396 fpm 1330

160 fpm 226 fpm 770

Desired Paddle Belt Speed

Speed Parameter Value

7. Press P to set.

8. Press P again to return to the parameter list.

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:NOTE: This setting must now be saved or it will be lost the next time the

diverter power is cycled.

4.5.4.3 Save Adjusted Parameters :NOTE: It does not matter which drive is active in order to save the parameters.

1. Press arrow up to select parameter P971.

2. Press P to select so that the preset will be displayed. This will be “0”.

3. Press FN to enter the edit mode.

4. Press arrow up to change the value to 1.

5. Press P to set. This will make the servo perform a RAM-to-ROM save.

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4.6 High Speed Diverter PM Tasks and Time Intervals

Table 15 High Speed Diverter PM Tasks

Component Maintenance Function Time Interval

Hardware Visually inspect mounting hardware for tightness Monthly

Servo Gearmotor

Tie Rod Assembly Rod Ends Visually inspect mounting hardware for tightness Monthly

Drive pulley

Shaft Locking Device Inspect and tighten if necessary 6 Months

Paddle Pivot Bearings (Drive Assembly)

Paddle Pivot Bearings (Transition Assembly)

Servo Gearmotor Cables Visually inspect wiring for damaged insulation, loose

Diverter Control Panel Air Filters

Components

:NOTE: These frequencies are based on an 18 hour day and 2 percent duty cycle (assuming the paddles are

actuated to a divert/home cycle 1500 times/day). Six months is equivalent to approximately 500 hours and 275,000 cycles. One year is equivalent to approximately 1000 hour and 550,000 cycles.

:NOTE: Adjust the frequency of inspection operation proportionally for longer run times and/or higher duty

cycles.

Visually inspect for proper operating condition Monthly

Visually inspect mounting hardware for tightness Monthly

Visually inspect wiring for damaged insulation, loose

Monthly

connections, or evidence of arcing

Replace oil 2 Years

Clean outside surface Annually

Inspect for noise or excessive heat Monthly Rollers

Visually inspect mounting bracket hardware for tightness Monthly

Visually inspect mounting hardware for tightness Monthly

Visually inspect pulley for correct mounting position Monthly

Inspect for noise or excessive heat Monthly

Replace oil (See Lubrication Section) Varies

Visually inspect mounting hardware for tightness Monthly Paddle Assembly

Visually inspect the paddle alignment in the zero (home)

Monthly

and extended positions.

Visually inspect for tears/fraying/tension Weekly Paddle Assembly Belt

Visually inspect belt tracking and re-track if necessary Monthly

Visually inspect mounting hardware for tightness Monthly

Monthly

connections, or evidence of arcing

Clean or replace intake and exhaust air filters Monthly

Visually inspect Monthly Diverter Control Panel and

Clean Annually or As

Required

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4.6.1 High Speed Diverter Monthly Operational Checklists

Use two operational checklists: Table 16 for the HSDII when it is locked and tagged out and Table 17 when powered up. Initial each step on a new checklist ev

ery time these inspections are performed. Keep the checklists and the

following High Speed Diverter Checklist Form in a maintenance log book.

:NOTE: Also visually inspect all HSDII components for tension, tracking, wear,

missing hardware, tightness, or other signs of improper operation.

Lock out and tag the local disconnect before removing any covers from the high speed diverter. Failure to isolate the HSDII electrically while performing the checklist could lead to inadvertent machine movement and serious injury.

Table 16 Monthly Operational Checklist with HSDII Locked and Tagged Out

Initials No. Operational Test

1 Place the disconnect switch on the local control panel in the "OFF" position. Lock out and tag

the high speed diverter disconnect switch.

2 Locate the local disconnect switch for the conveyor belt on which the high speed diverter is

installed. Lock out and tag the conveyor disconnect switch.

3 In areas where other equipment is in close proximity to the high speed diverter (inhibiting

completion of this checklist), turn off, lock out and tag this equipment.

4 After ensuring a safe working environment, proceed with the inspection by removing the drive

frame cover and front drive cover.

5 Inspect the condition of the non-drive side bearings, pivot clamp, drive pulley, nose roller, tie rod

assembly (non-drive side), and all accessible hardware. Note findings on the High Speed

verter Checklist Form. Correct as necessary.

6 Inspect the front drive cover of the high speed diverter. Note any damage and tightness of fit.

Note findings on the High Speed Diverter Checklist Form.

7 Visually inspect and physically touch the following components: servo gearmotor, motor pivot

arm, short tie rod, long tie rod assembly (drive side), bearings, pivot clamp, and all accessible hardware. Note indications of looseness, wear, excessive temperature, or other signs of an unusual nature on the High Speed Diverter Checklist Form. Correct as necessary.

8 Manually move the paddle belt and paddles in the normal direction of travel to detect any

binding or other abnormal condition. Note findings on the High Speed Diverter Checklist Form.

9 From the underside of the high speed diverter remove bottom cover, visually inspect and

physically touch the following components: all joints in the long tie rod assembly, pivot points, and all accessible hardware. Note indications of looseness, wear, excessive temperature, or other unusual signs on the High Speed Diverter Checklist Form. Correct as necessary. If

side access is limited, inspection must be performed through the side openings.

under

10 Replace all covers on the high speed diverter.

11 Remove the lock and tag from the high speed diverter local disconnect switch.

12 Remove the lock and tag from the local disconnect of the conveyor belt in which the high speed

diverter is installed.

13 Remove all other locks and tags from disconnects that were secured in the steps above.

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Table 17 Monthly Operational Checklist with HSDII Running

Theses operational tests are performed w ith the power on. Use extreme caution when performing the following tasks to prevent serious injury.

Initials No. Operational Test

1 Visually inspect the high speed diverter in a running condition with all covers and guards in

place. Record any unusual noises on the High Speed Diverter Checklist Form.

2 Place the mode switch on the diverter control panel in the MAN position and start the paddle

belts with the diverter control panel switch.

3 Using extreme caution, physically touch the fixed guards and sides of the HSDII to detect level

of vibration. Note areas of higher levels of vibration and record on the High Speed Diverter

klist Form.

Chec

4 Turn the PADDLE RET/0/EXT selector switch on the diverter control panel to the EXT position to

cycle the paddles to the divert position.

5 Record the action of the movement of the paddles. Note whether there were any visual

indications of vibration or other symptoms of improper actuation on the High Speed Diverter

klist Form.

Chec

6 While the paddle belts are running, visually inspect belts for signs of wear or damage. Record

condition of each belt separately, indicating on the High Speed Diverter Checklist Form which

is which.

belt

7 Turn the PADDLE RET/0/EXT selector switch to RET to return the paddles to the home position.

Note any signs of improper or unusual operation on the High Speed Diverter Checklist Form.

8 Repeat steps (4) thru (7) several times, recording each operation on the High Speed Diverter

Checklist Form.

9 Lock and tag out the diverter. Remove the drive frame cover and front drive cover, and using

extreme caution, remove the lock out and tag from the high speed diverter local disconnect and turn the disconnect to the ON position.

10 Place the mode selector switch on the high speed diverter control panel to the MANUAL

position.

11 Turn the PADDLE RET/0/EXT selector switch to the EXT position to cycle the paddles to the

divert position and observe all moving mechanisms. Note any non-uniform movements on the High Speed Diverter Checklist Form.

12 Repeat manually cycling several times. Record results on the High Speed Diverter Checklist

Form.

13 Lock out and tag the high speed diverter. Replace all guards. Turn the mode selector switch to

AUTO. Remove lock and tag from the high speed diverter local disconnect switch.

14 Remove the lock out and tag from the local disconnect of the conveyor belt on which the high

speed diverter is installed.

15 Remove all other locked out and tagged disconnects that were secured in steps above.

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4.6.2 High Speed Diverter Checklist Form

General Running Condition Notes

Drive Side Paddle Belt Condition

Drive Side Paddle Rigidity

General Notes: Drive Side Paddle (Bearings, Pulleys, Hardware, Etc).

Non-Drive Side Paddle Belt Condition

Manual Cycle Operation Notes

1 6

2 7

Non-Drive Side Paddle Rigidity

General Notes: Non-Drive Side Paddle (Bearings, Pulleys, Hardware, Etc).

3 8

4 9

5 10

Drive Component Inspection

1 6

2 7

3 8

4 9

5 10

Tie Rod Assembly Component Inspection

1 6

2 7

3 8

4 9

5 10

General Notes

Inspector Date

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SIBAG HSDII Service Manual Troubleshooting

5 Troubleshooting

Troubleshooting tables are provided to assist you in diagnosing and resolving symptoms that may occur during the normal operation of this equipment.

To use a troubleshooting table:

1. Identify equipment malfunction in left most column of table.

2. Identify most likely possible cause in center column.

3. Follow corrective measures outlined in far right column.

5.1 Mechanical Troubleshooting

5.1.1 Paddle Positioning

Malfunction Probable Cause Corrective Action

Paddles do not hold position Servo gearmotor encoder or

setpoints incorrect

Paddles stop at partial stroke Servo gearmotor encoder or

setpoints incorrect

Paddles are properly positioned but transition side paddle is loose

Paddles are properly positioned but both paddles are loose

Paddles do not move or move erratically

Motor pivot arm is broken or

Pivot clamp is broken or loose Tighten or replace pivot clamp.

Shaft locking device is broken or

Tie rod assembly broken or loose Retighten tie rod ends or replace tie

Long tie rod assembly broken or loose

Drive side short tie rod assembly broken or loose

Servo gearmotor is broken Replace motor and return defective

loose

Adjust encoder and setpoints. See section 4.5.3 Paddle Position.

Retighten tie rod ends or replace tie rod assembly.

motor to an authorized service center for repair.

Tighten or replace motor pivot arm.

Tighten or replace shaft locking device. See the B-Loc manufacturer’s literature for details.

rod assembly.

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5.1.2 Servo Gearmotor

Malfunction Probable Cause Corrective Action

Abnormal vibration Servo gearmotor damage Replace motor and return defective

motor to an authorized service center for repair.

Loose attachment hardware Check and tighten screw connections.

Noisy motor

Motor overheats (surface temperature > 140C [284F])

Temperature monitoring responds

Motor will not start

Foreign objects inside motor Replace motor and return defective

motor to an authorized service center for repair.

Damaged bearing Replace motor and return defective

motor to an authorized service center for repair.

Motor overload a. Check conveyor for jams or

obstructions. Clear and restart.

b. Check drive train for obstructions.

Clear and restart.

Motor cooling impaired by cleanliness

Clean surface of motor to improve heat dissipation and ventilation. Ensure cooling air can flow in and out freely.

Incorrect voltage Refer to the Electrical Troubleshooting

section of this manual.

No voltage Refer to the Electrical Troubleshooting

section of this manual.

Conveyor jammed a. Check conveyor belt for jams,

obstructions, or excessive load. Remove source of jam and restart the system.

b. Check drive train for obstructions,

damage, or foreign matter.

Internal defect in motor Replace motor and return defective

motor to an authorized service center for repair.

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SIBAG HSDII Service Manual Troubleshooting

5.1.3 Pillow Block Bearings

Malfunction Probable Cause Corrective Action

Bearings run noisy Internal or seal damage Replace bearing.

Bearings run hot Conveyor overload a. Check HSDII for jams or

obstructions. Clear and restart.

b. Check drive train for obstructions.

Clear and restart.

c. Check to see if conveyor bed is

clean and free of obstructions.

Damage or defect in bearing or

Replace bearing.

seal

5.1.4 Paddle Nose Rollers and Drive Pulley

Malfunction Probable Cause Corrective Action

Roller runs noisy Loose or failed bearing Replace roller.

Roller rubs paddle frame Check roller for proper alignment and

adjust as needed.

Improper paddle belt tension Check belting for proper tension and

adjust as needed.

Pulley will not run Faulty electrical power or

connections

Check for correct connections.

In a 3-phase unit, check for equal

Motor winding phase or winding

short circuit (insulation) failure

Brake does not release (Interroll) a. Check if brake operates at start

Pulley or belt obstructed Make sure the belt and the pulley are

Check for correct power supply voltage.

voltage in all 3 phases.

Replace pulley. Contact manufacturer for additional support.

up.

b. Check connections and continuity

of brake winding. If connections and brake winding are OK, check the rectifier.

free from obstructions and that all rollers and pulleys rotate freely.

If the pulley cannot rotate freely, it might be a seize-up of transmission or bearing. In this case, contact manufacturer for additional support.

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Service Manual SIBAG HSDII Troubleshooting

Malfunction Probable Cause Corrective Action

Low ambient temperature / high

oil viscosity

a. Check if oil viscosity is suitable for

the ambient temperature. If not, replace with oil having the correct specification.

b. Contact manufacturer for

additional support.

Pulley runs hot High current draw Check the current draw and make

sure it is not higher than the rated current on the nameplate.

The load exceeds the capacity of

the unit

Lessen the load on the unit and space loads properly.

Excessive belt tension Check belt tension and reduce as

necessary.

Excessive/frequent stops/starts Check if the number of stops/starts

meets the pulley’s specifications and reduce frequency as necessary. Install frequency converter to optimize motor performance.

Back stop rotation incorrect (non-

reversible-bearing) (Interroll)

Turn the power off immediately, rotate the pulley by hand to determine if the fault is electrical or mechanical. Check the connection for correct rotation and, if necessary, change the phase connection so that the pulley rotates in the right direction or, if possible, re-install the pulley so that it operates in the opposite direction.

Incorrect power supply or

frequency converter (Interroll)

Check power supply. If in case of single phase: possibly wrong start capacitors or run capacitors installed.

Check if frequency converter settings meet specifications and revise.

Pulley runs intermittently, or slower, or faster than specified

Pulley / belt is intermittently or partially blocked

Make sure the belt and pulley are free from obstructions and that all rollers and pulleys rotate freely.

Faulty electrical power or

Check for correct connections.

connections

Damaged transmission (Interroll) Check rotation by hand. Replace

pulley or contact manufacturer.

Incorrect power supply or

frequency converter (Interroll)

a. Check power supply. If in case of

single phase: possibly wrong start capacitors or run capacitors installed.

b. Check if frequency converter

settings meet specifications and revise.

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SIBAG HSDII Service Manual Troubleshooting

Malfunction Probable Cause Corrective Action

Incorrect pulley a. Check specification tolerances.

b. Incorrect rubber lagging thickness

has increased belt speed over nominal speed of motor. Reduce the lagging thickness or install frequency converter or replace with correct pulley.

Belt slipping a. Check lagging condition and

adhesion of lagging to shell. Replace lagging. Shot blast or roughen the shell surface to ensure good lagging adhesion.

b. Check motor specification and

tolerances against supply voltage / frequency.

The pulley:

● Hums

● Starts very slowly

Electrical malfunction Check for equal voltage on all 3

phases or open phase in the drive pulley winding.

● Will not start at all

The pulley trips overload or fuses High current draw Check the current draw with an

ammeter (it should be no more than the name plate current, and should be balanced in all 3 phases (within 10 percent). If it is not, either:

● The voltage supply is not equal

● There is a short circuit in the

motor winding

Short in wires Check for short to the ground.

The pulley is noisy Incorrect installation Verify installation is correct and that

mounting hardware is tight.

Excess belt tension Loosen paddle belt tension.

Loose mounting brackets Check mounting brackets, shaft

tolerances and fixing bolts.

Faulty / incorrect profile between

pulley and belt

Make sure the belt and pulley profiles match and are engaged properly. Replace if necessary.

One phase of the power lead is

not connected properly

The pulley runs with high vibration

Incorrect frequency converter settings

Check the cable connection and correct it if necessary.

Check if frequency converter settings meet specifications and revise.

Loose mounting brackets Check mounting brackets, shaft

tolerances and fixing bolts.

Pulley out of balance Check if specifications for pulley

include static or dynamic balancing and adjust.

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Service Manual SIBAG HSDII Troubleshooting

Malfunction Probable Cause Corrective Action

The unit leaks oil Loose oil fill screws Tighten all screws.

Faulty seal Replace pulley.

Shaft bearings damaged/worn Check the belt for excessive tension

and loading. Check for water or chemical

infiltration.

Excess grease in labyrinth

sealing (Interroll)

Check for oil or grease leakage. Oil remains fluid and grease will solidify when it is cold. Clean away excess grease.

Oil leakage around

cable/terminal box due to:

● Loose cable connector gland

Make sure the glands and seals are tight and not subject to excessive heat or chemicals.

● Internal cable seal fault

● Loose connector gland

● Terminal box seal fault

Oil leakage around shell / end

house due to:

● End housing loose in shell

● End house / shell seal broken

Check for gaps between shell and end housings.

Check for excessive belt tension or shock loading.

Check for excessive heat or belt tension and shock loading.

Motor winding failure (Interroll) One phase failed: Winding

isolation failure/ overload

Check continuity, current and resistance on each phase winding. Replace pulley or contact manufacturer.

Two phases failed: Power supply

failure on one phase causing overload on the other two phases / isolation failure

Check the supply to all phases. Check continuity, current and resistance on each phase winding. Replace pulley or contact manufacturer.

Three phases failed: Motor

overloaded / wrong supply connected

Check correct supply voltage. Check continuity, current and resistance on each phase winding. Replace pulley or contact manufacturer.

Shaft bearing failure Overload Check if the application loading

meets the pulley specifications.

Shock loading Check if application loading meets

the pulley specifications.

Excessive belt tension Check for excessive belt tension.

Correct as necessary.

Lack of lubrication Check the pulley’s oil level and

installation. If vertically mounted, check pulley specifications.

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SIBAG HSDII Service Manual Troubleshooting

Malfunction Probable Cause Corrective Action

Shaft stress or misalignment Check for excessive screw tension

and frame or mounting bracket misalignment.

Shaft seal damaged / worn Check for external contamination.

Loose or tight bearing journal

Contact the manufacturer.

fitting

5.1.5 Paddle Belting

Malfunction Probable Cause Corrective Action

Belt wear on outside Obstruction or debris

accumulated in belt path

Check belt path for damage or obstruction and remove or correct as needed.

Belt wear on inside

Frozen paddle nose roller Check to see if paddle roller is clean

and free of obstruction. Check rollers and pulleys for surface

damage or frozen bearings. Replace as needed.

Drive pulley slipping Check paddle belt tension and adjust

as needed.

Obstruction or debris accumulated in the belt path

Check belt path for damage or obstruction and remove or correct as needed.

Belting tears Baggage impacts Trim loose belting or replace as

needed.

Old belting, aged and brittle Replace belting.

Belt mistracking Drive pulley misaligned Square pulley and reset belt tension.

(V-guide wear) Nose roller misaligned Square roller and reset belt tension.

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Service Manual SIBAG HSDII Troubleshooting

5.2 Electrical/Controls Troubleshooting

5.2.1 Diverter Faults

Malfunction Probable Cause Corrective Action

Diverter does not cycle Diverter not in AUTO mode Turn mode switch to AUTO.

FAULT indicator light is

illuminated

Diverter disconnect is OFF Turn diverter disconnect to the ON

Memory card corrupt (indicated

by three red lights on the control module)

Servo control unit fault If an error occurs while the control

If an error occurs after the control unit

Diverter does not stop at home position

Servo gearmotor encoder or setpoints incorrect

Motor/paddles run backwards Incorrect power phasing to motor

after initial connection or motor change

Servo crank arm is 180° out of

phase

Diverter continuously jams Sort object is moving or shifting

before the divert

Upstream conveyor photoeye

sensor alignment is wrong

Diverter not in MAN mode Turn mode switch to MAN. Diverter can not be cycled using

selector switch

Faulty input module Check input module and replace as

Correct fault: a. Verify control panel door is closed. b. Servo gearmotor failure. See

section 5.1.2 Servo Gearmotor.

. Inspect PLC output module. d. Check motor contactor. e. Check output module fuse. f. Check incoming power.

position.

Reload program onto memory card. Teach new home and extend positions. See section 4.5.3 Paddle

ition.

Pos

unit is booted, booting is aborted and the cause of the error is indicated via the LEDs. See Figure 8. To correct,

nsert the CF card with the correct

i software and parameters.

is booted, see Figure 9.

Adjust encoder and setpoints. See section 4.5.3 Paddle Position.

Reverse power phases to reverse rotation.

Disconnect short tie rod and manually reposition servo crank arm to point away from the conveyor. Reconnect tie rod and teach new home and extend positions.

Check conveyor path for obstructions.

Adjust sensor per drawing locations.

needed.

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Malfunction Probable Cause Corrective Action

Faulty selector switch Check selector switch and replace as

needed.

Figure 8 Control Unit 310/320 LEDs During Booting

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Figure 9 Control Unit 320 LEDs After Booting

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SIBAG HSDII Service Manual Troubleshooting

5.2.2 System Faults (Optional)

:NOTE: The following faults may be displayed if the HSDII is provided as part of

an integrated baggage handling system including operator workstations.

Malfunction Probable Cause Corrective Action

Diverter Failed to Extend Fault HSD was given a signal to

extend and failed to arrive at the extend position

Diverter Failed at Home Fault HSD was given a signal to

extend and remained in the home position

a. Check conveyor path for

obstructions.

b. Remove any lockout locks on the

diverter disconnect switches and return disconnects to ON position.

c. Place into MAN mode and

reposition paddles to verify proper

operation. d. Check incoming power supplies. e. Inspect for mechanical

obstructions. f. Ensure control signals to input

module(s) in associated MCP are

being received from diverter

sensors. g. Ensure input module(s) for

sensors are working correctly.

a. Check conveyor path for

obstructions. b. Remove any lockout locks on the

diverter disconnect switches and

return disconnects to ON position. c. Place into MAN mode and

reposition paddles to verify proper

operation. d. Check incoming power supplies. e. Inspect for mechanical

obstructions. f. Ensure control signals to input

module(s) in associated MCP are

being received from diverter

sensors. g. Ensure input module(s) for

sensors are working correctly.

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Malfunction Probable Cause Corrective Action

Diverter Failed to Retract Fault HSD was given a signal to

retract and failed to arrive at the home position

a. Check conveyor path for

obstructions.

b. Remove any lockout locks on the

diverter disconnect switches and return disconnects to ON position.

c. Place into MAN mode and

reposition paddles to verify proper

operation. d. Check incoming power supplies. e. Inspect for mechanical

obstructions. f. Ensure control signals to input

module(s) in associated MCP are

being received from diverter

sensors. g. Ensure input module(s) for

sensors are working correctly.

5.2.3 Servo Faults

Malfunction Probable Cause Corrective Action

A07441 Alert - Servo program reloaded "Teach" paddle positions. See section

4.5.3 Paddle Position.

F07452 Paddle jam or drag Check paddles or positioning

mechanism for obstructions. Reset fault.

F07464 Paddle jam or drag Check paddles or positioning

mechanism for obstructions; if fault cannot be reset, reinstall servo program.

Reset fault.

A07479 Alert - Paddle overtravel limit (-)

reached

A07480 Alert - Paddle overtravel limit (+)

reached

F07481 Paddle overtravel limit (-)

exceeded

Use paddle position controls to move paddle back to normal range.

"Teach" proper positions if necessary to maintain normal range.

Use paddle position controls to move paddle back to normal range.

"Teach" proper positions if necessary to maintain normal range.

Manually move paddles in to normal range.

Reset fault. "Teach" proper positions if necessary

to maintain normal range.

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Malfunction Probable Cause Corrective Action

F07482 Paddle overtravel limit (+)

exceeded

Manually move paddles in to normal range.

Reset fault. "Teach" proper positions if necessary

to maintain normal range.

F07490 Enable command removed during

paddle positioning stroke

Check for loose connection of auxiliary contact at main disconnect.

Reset fault

F07800 No power to Smart Line Module Check circuit breaker CB208.

Reset fault.

F07801 Motor drive overcurrent Check for obstructions to paddle

positioning mechanism or paddle belt drive.

Reset fault.

F07802 Three phase power missing Restore power.

Reset fault.

F07840 Infeed command to servo missing

due to paddle belt motor shut down

Check for continuity of thermal switch at paddle belt motor connector.

Reset fault (may be necessary to cycle e-stop as well).

F07841 Infeed command to servo lost

during operation due to paddle belt motor shut down

Check for continuity of thermal switch at paddle belt motor connector.

Reset fault (may be necessary to cycle e-stop as well).

F07900 Servo motor locked or stalled Clear paddle positioning mechanism.

Reset fault.

A13000 Alert - license discrepancy Older license. Will not interfere with

operation.

F30002 Servo overvoltage Replace Smart Line Module if problem

continuously repeats after reset. Reset fault.

F30003 Three phase power missing Restore power.

Reset fault.

F30005 Servo drive module overload Replace Double Motor Module if

problem continuously repeats after reset.

Reset fault.

F30021 Servo drive module ground fault Replace Double Motor Module if

problem continuously repeats after reset.

Reset fault.

F30600 E-stop fault Cycle both e-stop relays (CR265 and

CR267) together to reset. Reset fault.

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Malfunction Probable Cause Corrective Action

F30611 E-stop fault Cycle both e-stop relays (CR265 and

CR267) together to reset. Reset fault.

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SIBAG HSDII Service Manual Repair

6 Repair

This section provides removal and replacement procedures for spare parts and commonly replaced components and assemblies. Some parts are contained in assemblies. As you follow the removal steps to reach the part which is to be replaced, you have to remove other parts. Inspect these parts for wear or other problems and replace them at this time if worn.

:NOTE: Before removing any drive components; mark the precise mounting

point of all components on the shaft. Also mark the position of the bearing on the frame. This will minimize problems when re-aligning the components during assembly.

:NOTE: Use care when trying to reach a particular part, as damage can occur

to good parts.

In the procedure, when applicable, the number adjacent to the part referenced in that step refers to a Figure and Item number, as in Figure 5-(9). If the figure number is not repeated with an item number, it is understood that the item number refers to the last figure that was referenced.

Do not perform adjustments, maintenance, or other work on this equipment without following OSHA Lock-Out/Tag-Out requirements and state and local requirements. Failure to follow these requirements may result in death or serious injury and/or equipment damage.

Standard shop practices and safety procedures should be followed whenever parts are removed or replaced.

● Make certain the system is locked out and tagged out before performing any

maintenance activities.

● Secure all hardware during installation.

● Clean parts and assemblies after installation.

● Re-install all guards or covers removed after any maintenance activities

before starting the conveyor.

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6.1 Torque Values for Hardware

Table 18 Torque Values

Torque Torque Size Nm Lb

Hex Head Cap Screw Skwezloc Head Cap Screw

M8 24 18 lb ft 13 M4 7-8 65-70 lb in T-25

M10 48 35 lb ft 17 M5 9-10 80-90 lb in T-27

M12 83 61 lb ft 19 M6 18-20 160-180 lb in T-30

M14 132 97 lb ft 22 M8 40-45 360-400 lb in T-45

Socket Head Cap Screw Socket Head Flat Head Screw

M4 495 Ncm 44 lb in 3 M6 9 7 lb ft 4

M6 16.5 Nm 12 lb ft 5 M8 15 11 lb ft 5

M8 40 Nm 30 lb ft 6 M12 65 48 lb ft 8

Wrench Size (mm)

Size

Nm Lb

Wrench Size (mm)

6.2 Testing HSDII Operation

Test HSDII operation after repairing or replacing components as required:

1. Turn the mode switch to the MAN position

2. Turn the disconnect switch to the ON position.

3. Turn the PADDLE BELT selector switch to START.

4. The paddle belts should be operating and the HSDII can be cycled by turning the mode switch to MAN and turning the PADDLE RET/0/EXT selector switch to EXT and RET.

5. Reset encoder and setpoint settings if necessary. See section 4.5.3 Paddle

ion.

Posit

Use a current meter to check current draw and record the reading. Idling current should be less than the full load amps indicated on the motor nameplate.

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6.3 High Speed Diverter Top Level Assembly

Figure 10 HSDII Top Level Assembly

:NOTE: The repair procedures are identical for the 68.0020.100-XX (39 in wide)

(shown), 68.0020.101-XX (1050 mm wide), and 68.0020.150-XX (1200 mm wide) versions.

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6.3.1 Long Tie Rod

Removal [Figure 10 – Item (5)]

1. Remove bottom covers (7) and pivot area cover (41).

2. Remove drive frame cover (1).

3. Remove tie rod end bearing (Figure 11-5) clamps.

Pull tie rod ends from pivot arm posts (Figure 13-2 and Figure 17-2).

Remove tie rod assembly (Figure 10-5).

lternate Removal [Figure 10 – Item (5)]

Remove drive side tie rod end bearing clamp.

2. Pull drive side tie rod end from pivot arm post.

3. Remove screws and lockwashers securing transition pivot clamp weldment (Figure 17-2) and front clamp shell (Figure 17-3) to shaft.

. Remove shaft key (it may come off with clamp weldment).

5. Remove tie rod assembly with pivot clamp weldment attached (Figure 10-5).

acement [Figure 10 – Item (5)]

Repl

:NOTE: Measure length of long tie rod being replaced and set new tie rod

length the same.

1. Assemble tie rod onto both pivot clamp weldments (pivot arm posts).

2. Tighten tie rod end bearing clamps.

3. Check for paddle alignment and adjust tie rod length as necessary at loose

:NOTE: When in non-divert position, paddles should be parallel. :NOTE: When in divert position, each paddle centerline should align with pivot

axis of the paddle on the other side.

end. To align paddles:

a. Position drive side paddle so it is even with edge of cabinet in back of

control panel.

b. Transition side paddle should be parallel to edge of HSDII base.

c. Adjust transition side paddle position by manually turning long tie rod

until paddle is even and parallel with edge of HSDII base.

4. Tighten tie rod end jam nuts.

:NOTE: Apply loctite 242 to bearing-side tie rod ends prior to reassembly. Do

not use loctite on tube-side tie rod ends.

5. Replace drive frame cover.

6. Replace bottom covers and pivot area cover.

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:NOTE: Insert tabs of bottom cover into lower angles of conveyor assembly (6)

before attaching with hardware.

7. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.4 Tie Rod Assembly

Figure 11 Tie Rod Assembly

6.4.1 Tie Rods and Bearings

Removal [Figure 11 Tie Rods: Items (2) and (3) Bearings: Item (5)]

1. Remove bottom covers.

2. Remove tie rod assembly. See section 6.3.1 Long Tie Rod.

Measure and record overall length of tie rod and note original orientation of

3. hanger bearings (Figure 11-5).

Loosen hanger bearing hex nuts (4) or (6) to remove rods (2) or (3).

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Replacement [Figure 11 Tie Rods: Items (2) and (3) Bearings: Item (5)]

1. Replace threaded rods into bearings (inserting threads all the way until bottomed out) and loosely install hex nuts.

:NOTE: Apply loctite 242 to bearing-side threads of tie rods prior to reassembly.

Do not use loctite on tube-side tie rod ends.

2. Replace threaded rods with hex nuts into tie rod tube.

3. Adjust overall length of tie rod assembly and orientation of bearings according to notes made in Removal procedure.

4. Tighten hex nuts.

5. Replace tie rod assembly. See section 6.3.1 Long Tie Rod or 6.6.5 Short

e Rod.

6. Replace

bottom covers.

7. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.5 Conveyor Assembly

Figure 12 Conveyor Assembly

:NOTE: The repair procedures are identical for the 68.0020.000-63 (39 in wide)

(shown), 68.0020.000-67 (1050 mm wide), and 68.0020.001-13 (1200 mm wide) versions.

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SIBAG HSDII Service Manual Repair

6.5.1 Return Roller

Removal [Figure 12 – Item (3)]

1. Remove guards as necessary for access.

2. Remove two nuts and washers fastening conveyor roller mounting bracket (2) to conveyor frame weldment (1).

3. Support return roller (3) while removing screws.

4. Remove return roller from conveyor frame.

5. Remove mounting bracket from return roller shaft.

Replacement [Figure 12 – Item (3)]

Place mounting bracket on return roller shaft.

2. Hold return roller in place in conveyor frame weldment.

3. Replace screws in mounting bracket and through conveyor frame weldment.

4. Replace nuts and washers on screws and finger tighten.

5. Tighten screws. See Table 18 Torque Values.

Replace guards removed for access.

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6.6 Drive Subassembly

Figure 13 Drive Subassembly

6.6.1 Paddle Assembly (Drive Side)

Removal [Figure 13 – Item (1)]

1. Remove guards as necessary for access.

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2. Disconnect drive pulley cable.

3. Loosen shaft locking device (Figure 16-22).

:NOTE: See B-Loc manufacturer’s literature for additional instructions.

a. Remove eight screws and mark their original locations for replacement.

:NOTE: Be careful not to put a screw back into any one of these holes

while attempting to loosen the device.

b. Seven of these screws will be used to jack two conical halves of locking

device apart. See Figure 14. Set four screws in shallow (S) holes and

ighten screws sequentially to break loose top half of device.

c. Install three screws into mid-depth (M) holes and tighten screws

sequentially to break loose bottom half of device. See Figure 14.

You will hear popping sound indicating two halves have been released.

4. Slide paddle assembly (Figure 13-1) up to remove from shaft (7). This can be done usin

g wooden 2x4 board.

Figure 14 Jacking Two Conical Halves of Shaft Locking Device Apart (S=Shallow; M=Mid-Depth)

Replacement [Figure 13 – Item (1)]

1. Prepare shaft locking device to prevent it from walking and jamming paddle on shaft:

a. Leave one screw in jacking positing for upper half. See Figure 15.

Leave one screw in jacking position for lower half to keep sections

slightly separated.

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c. Insert remaining six screws into normal locking position, but DO NOT

tighten.

Figure 15 Preparing Shaft Locking Device for Replacement

2. Align keyway and set paddle assembly onto shaft.

:NOTE: Install paddle assembly against spacer (11).

3. Check paddle alignment:

● Vertical alignment should be within 1/8 inch (3 mm). Check with straight

edge across top or bottom of paddles.

● Gap between drive side and non-drive side paddles should be 1/4 inch (6

mm).

● Offset between paddle center lines should be within 1/4 inch (6 mm).

4. Move two locking device screws in jacking positions to locking positions.

5. Tighten all eight shaft locking device screws sequentially enough to secure paddle assembly in place.

6. Now tighten all eight shaft locking device screws to correct torque:

a. Set torque wrench initial setting to 32 lb ft (44 Nm).

b. Moving in circular pattern, tighten each of eight screws 1/4 turn.

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c. Once you can no longer tighten full 1/4 turn, go around couple more

times, tightening each screw.

d. Change torque wrench setting to 30 lb ft (41 Nm).

e. Moving in circular pattern, try to tighten each of eight screws. There

should not be any movement at this setting.

f. If there is still movement, repeat steps a through e.

Reconnect drive pulley cable plug.

8. Replace guards removed for access.

9. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.6.2 Shaft

Removal [Figure 13 – Item (7)]

1. Remove guards as necessary for access.

2. Remove paddle assembly (1). See section 6.6.1 Paddle Assembly (Drive Side), Removal.

Remove power cable.

4. Pry open plug with small screwdriver.

5. Each wire is numbered. Document number of each wire and its position in plug for replacement. The ground wire is not numbered, but its coloring makes it unique.

6. Remove plug.

7. Pull cable through shaft.

8. Remove paddle height spacer.

9. Remove screws and lockwashers securing pivot clamp weldment (2) and rear clamp shell (4) to shaft (7).

10. Remove shaft key (it may come off with clamp weldment).

11. Loosen set screw(s) located in shaft clamp collars of both bearings (15).

12. Remove shaft from drive weldment (13).

Replacement [Figure 13 – Item (7)]

Lubricate shaft ends with rust inhibiting lubricant.

2. Replace shaft into pivot bearings.

:NOTE: Install shaft with shoulder against inner race of bearings.

3. Insert both shaft clamp collars.

4. Tighten set screw(s) located in shaft clamp collars. See Table 18 Torque Values.

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:NOTE: Push pivot clamp assembly up against collar of upper bearing before

tightening.

5. Replace pivot clamp weldment, shaft key, and rear clamp shell around shaft and secure with screws (with Loctite 242) and lockwashers.

6. Replace paddle assembly. See section 6.6.1 Paddle Assembly (Drive Side), Replacem

ent.

7. Reattach plug to cable by partially joining plug base and plug cap to mid snap point.

8. Reinsert wires into plug in same positions as marked during removal procedure.

9. Push plug base and cap together to secure wires.

10. Reconnect plug on drive pulley cable.

11. Replace guards removed for access.

12. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.6.3 Servo Gearmotor

Removal [Figure 13 – Item (14)]

1. Remove guards as necessary for access.

2. Mark and disconnect servo gearmotor power and control cables.

3. Disassemble short tie rod assembly (5) by loosening threaded portion of rod until shaft can be removed.

4. Remove drip pan (Figure 10-39) beneath servo gearmotor.

:NOTE: Place supports underneath servo gearmotor to prevent it from falling

when motor mounting bracket (6) hardware is removed.

5. Remove hardware securing motor mounting bracket (6) to drive weldment (13).

6. Remove hardware securing angle weldment (12) to drive weldment (13).

The motor assembly is heavy. Use multipl e people and/or a lifting device to prevent injury.

7. Lower motor mounting bracket with servo gearmotor and angle weldment out of drive weldment.

8. Remove short tie rod assembly.

9. Remove screw, lockwasher, and hold-down washer (9) securing motor pivot arm (3) to servo gearmotor (14) shaft.

10. Remove four screws securing servo gearmotor to motor mounting bracket.

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Replacement [Figure 13 – Item (14)]

1. Fasten servo gearmotor to motor mounting bracket with four screws.

2. Replace motor pivot arm on servo gearmotor shaft and secure with screw, lockwasher, and hold-down washer.

The motor assembly is heavy. Use multipl e people and/or a lifting device to prevent injury.

3. Place motor mounting bracket and angle weldment with servo gearmotor into drive weldment, securing with screws and washers.

4. Reassemble short tie rod assembly.

5. Reconnect servo gearmotor power and control cables.

6. Replace drip pan.

7. Replace guards removed for access.

8. If servo gearmotor is new, zero (home) and retract positions will need to be programmed. See section 4.5.3.1 Setup of Position Setpoints: Quick Setup

Teach Functions.

Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.6.4 Pivot Bearings

Removal [Figure 13 – Item (15)]

1. Remove guards as necessary for access.

2. Remove paddle assembly (1). See section 6.6.1 Paddle Assembly (Drive Side), Removal.

Remove shaft (7). See section 6.6.2 Shaft, Removal.

Knock out roll pin.

5. Remove both screws; lockwashers, and hex nuts securing bearing flange block to bearing mount plate

6. Remove bearing.

Replacement [Figure 13 – Item (15)]

Clean inner face of bearing and shaft. Lubricate with rust inhibiting lubricant.

2. For bottom bearing, slide bearing onto shaft and secure to bearing mount plate with hardware and finger tighten. Orient bearing such that bearing collar is on top.

3. For top bearing, replace bearing and secure to bearing mount plate with hardware and finger tighten. Orient bearing such that bearing collar is on bottom.

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4. Replace shaft into upper pivot bearing. Install both pivot bearing’s shaft clamp collars. Insert shaft into bottom pivot bearing. See section 6.6.2 Shaft, Replacem

ent for details.

5. Align bearings with shaft so shaft is perpendicular to transport belt and tighten screws

6. Tighten set screws located in shaft clamp collars. See Table 18 Torque Values.

Drill through any bearing corner and insert roll pin to prevent bearing from shifting.

8. Replace paddle assembly. See section 6.6.1 Paddle Assembly (Drive Side), Replacem

ent.

:NOTE: Gap between drive side and non-drive side paddles should be 1/4 inch

(6 mm). If both bearings are being replaced, it may be necessary to move them around in the slot to achieve this gap.

9. Replace pivot clamp weldment, shaft key, and rear clamp shell around shaft against collar of upper bearing and secure with screws (with Loctite 242) and lockwashers. Replace drive pulley plug. See section 6.6.2 Shaft, Replacem

ent for details.

10. Replace guards removed for access.

11. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.6.5 Short Tie Rod

Removal [Figure 13 – Item (5)]

1. Remove drive frame cover (Figure 10-1).

Dismount pivot arm (Figure 13-2). Remove screws and lockwashers

2. secur shaft (7).

3. Remove tie rod end bearing (Figure 11-5) clamps.

Pull tie rod end from pivot arm posts (Figure 13-2 and Figure 13-3).

Remove tie rod assembly (Figure 13-5).

acement [Figure 13 – Item (5)]

Repl

Loosely assemble tie rod to pivot arm clamp weldment and motor pivot arm.

2. Check for paddle alignment and adjust tie rod length as necessary at loose end.

:NOTE: When in divert position, each paddle centerline should align with pivot

axis of the paddle on the other side.

ing pivot clamp weldment (2), shaft key, and rear clamp shell (4) to

3. Tighten tie rod end bearing clamps.

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4. Replace pivot clamp weldment and rear clamp shell around shaft against collar of upper bearing and secure with screws (with Loctite 242) and lockwashers. Move assembly up to upper bearing collar before tightening.

5. Replace drive covers.

6. Test HSDII operation. See section 6.2 Testing HSDII Operation.

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6.7 Paddle Assembly

Figure 16 Paddle Assembly

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6.7.1 Paddle Belt

Removal [Figure 16 – Item (13)]

1. Remove guards as necessary for access.

2. Remove top cover (9).

3. Loosen hardware securing both top and bottom clamp plate assemblies (4) and shaft clamp plates (5) to top drive plate (6) and bottom drive plate (7).

4. Loosen lower and upper tensioning nuts.

5. Move paddle drive pulley (11) toward center of paddle to loosen belt tension.

6. Remove paddle belt by sliding belt upward until completely off of paddle assembly.

Replacement [Figure 16 – Item (13)]

Slide belt downward into place on paddle assembly around drive pulley and nose roller (12).

2. Tension belt by moving drive pulley away from center of paddle. Keep drive pulley square.

3. Tighten upper and lower tensioning nuts evenly. Tension is correct when slack is removed and belt does not slip on drive pulley as it rotates. Tension should be equal across width of belt.

4. Track belt. See section 4.5.2 Paddle Belt Tracking.

Tighten screws, flat washers, and lockwashers fastening both top and

5. bottom shaft clamp plate assemblies to top and bottom drive plates.

6. Replace guards removed for access.

7. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.7.2 Paddle Nose Roller

Removal [Figure 16 – Item (12)]

1. Remove guards as necessary for access.

2. Remove paddle belt (13). See 6.7.1 Paddle Belt, Removal.

NOTE: For the drive side paddle assembly, it will be necessary to loosen and

raise the paddle assembly to remove the nose roller lower mount hardware unless a maintenance clearance hole has been provided in the frame.

3. Remove four screws securing top roller mounting plate (8) to top spacer (10) and weldment (1).

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4. Remove two screws securing paddle nose roller (12) to roller mounting plates (both top and bottom).

5. Remove nose roller.

Replacement [Figure 16 – Item (12)]

Place paddle nose roller into lower roller mounting plate.

2. Replace bottom screw (with Loctite 242) securing paddle nose roller to roller mounting plate.

3. Set upper roller mounting plate on spacer and paddle nose roller and secure to spacer with four screws (with Loctite 242).

4. Replace top screw (with Loctite 242) securing paddle nose roller to roller mounting plate.

5. Install and tighten paddle belt. See section 6.7.1 Paddle Belt, Replacement.

Replace guards removed for access.

7. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.7.3 Paddle Drive Pulley

Removal [Figure 16 – Item (11)]

:NOTE: Paddle must be in divert position.

1. Remove guards as necessary for access.

2. Remove paddle belt (13). See section 6.7.1 Paddle Belt, Removal.

Disconnect drive pulley electrical cable.

4. Loosen screws and washers securing bottom clamp plate assembly (4) to bottom shaft clamp plate (5).

5. Remove screws and washers securing top clamp plate assembly (4) to top shaft clamp plate (5).

6. Remove screws and washers securing top shaft clamp plate (5) to top drive plate (6).

7. Remove screws securing top drive plate (6) to v-groove spacer (2) and paddle weldment (1).

8. Remove clamp plate (5).

9. Remove top drive plate (6) and shaft clamp plate assembly (4).

10. Lift drive pulley (11) out of drive pulley spacer (16) and bottom drive plate (7).

Replacement [Figure 16 – Item (11)]

:NOTE: Unless otherwise indicated, refer to Figure 16.

1. Place drive pulley in bottom drive plate and drive pulley spacer.

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2. Tighten screw and washer securing bottom clamp plate assembly to bottom shaft clamp plate.

3. Replace top drive plate onto v-groove spacer and paddle weldment and fasten with screws (with Loctite 242).

4. Fasten top shaft clamp plate to clamp plate assembly and install screws and washers into top drive plate and tighten.

5. Reconnect drive pulley electrical cable.

6. Install paddle belt and adjust tracking and tension. See section 6.7.1 Paddle Belt, Replacement.

6.8 Transition Subassembly

Figure 17 Transition Subassembly

:NOTE: The repair procedures are identical for the 68.0020.103-XX (39 in

wide), 68.0020.163-XX (1050 mm wide), and 68.0020.152-XX (1200 mm wide) versions.

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6.8.1 Paddle Assembly (Non-Drive Side)

Removal [Figure 17 – Item (1)]

1. Remove guards as necessary for access.

2. Disconnect drive pulley cable.

3. Loosen shaft locking device (Figure 16-22).

:NOTE: See B-Loc manufacturer’s literature for additional instructions.

a. Remove eight screws and mark their original location for replacement.

:NOTE: Be careful not to put a screw back into any one of these holes

while attempting to loosen the device.

b. Seven of these screws will be used to jack two conical halves of locking

device apart. See Figure 18. Set four screws in shallow (S) holes and

ighten screws sequentially to break loose top half of device.

c. Install three screws into mid-depth (M) holes and tighten screws

sequentially to break loose bottom half of device. See Figure 18.

You will hear popping sound indicating two halves have been released.

4. Slide paddle assembly (Figure 17-1) up to remove from shaft (4). This can be done usin

Figure 18 Jacking Two Conical Halves of Shaft Locking Device Apart (S=Shallow; M=Mid-Depth)

g wooden 2x4 board.

Replacement [Figure 17 – Item (1)]

1. Prepare shaft locking device to prevent it from walking and jamming paddle on shaft:

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a. Leave one screw in jacking positing for upper half. See Figure 19.

b. Leave one screw in jacking position for lower half to keep sections

slightly separated.

c. Insert remaining six screws into normal locking positions, but DO NOT

tighten.

Figure 19 Preparing Shaft Locking Device for Replacement

2. Align keyway and set paddle assembly onto shaft.

:NOTE: Install paddle assembly against spacer (9).

3. Tighten shaft locking device enough to secure paddle in place. See B-Loc manufacturer’s literature for additional instructions.

4. Check paddle alignment:

a. Vertical alignment should be within 1/8 inch (3 mm). Check with straight

edge across top or bottom of paddles.

b. Gap between drive side and non-drive side paddles should be 1/4 inch

(6 mm).

c. Offset between paddle center lines should be within 1/4 inch (6 mm).

5. Move two locking device screws in jacking positions to locking positions.

6. Tighten all eight shaft locking device screws sequentially enough to secure paddle assembly in place.

7. Now tighten all eight shaft locking device screws to correct torque:

a. Set torque wrench initial setting to 32 lb ft (44 Nm).

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b. Moving in circular pattern, tighten each of eight screws 1/4 turn.

c. Once you can no longer tighten full 1/4 turn, go around couple more

times, tightening each screw.

d. Change torque wrench setting to 30 lb ft (41 Nm).

e. Moving in circular pattern, try to tighten each of eight screws. There

should not be any movement at this setting.

f. If there is still movement, repeat steps a through e.

Reconnect drive pulley cable plug.

9. Replace guards removed for access.

10. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.8.2 Shaft

Removal [Figure 17 – Item (4)]

1. Remove guards as necessary for access.

2. Remove paddle assembly (1). See section 6.8.1 Paddle Assembly (Nonive Side), Removal.

Remove power cable.

4. Pry open plug with small screwdriver.

5. Each wire is numbered. Document number of each wire and its position in

plug for replacement. The ground wire is not numbered, but its coloring makes it unique.

6. Remove plug.

7. Pull cable through shaft.

8. Remove paddle height spacer.

9. Remove screws and lockwashers securing pivot clamp weldment (2) and

front clamp shell (3) to shaft (4).

10. Remove shaft key (it may come off with clamp weldment).

11. Loosen set screw(s) located in shaft clamp collars of both bearings (11).

12. Remove shaft from drive weldment (10).

Replacement [Figure 17 – Item (4)]

Lubricate shaft ends with rust inhibiting lubricant.

2. Replace shaft into pivot bearings.

:NOTE: Install shaft with shoulder against inner race of bearings.

3. Insert both shaft clamp collars.

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4. Tighten set screws located in shaft clamp collars. See Table 18 Torque Values.

:NOTE: Push pivot clamp assembly up against collar of upper bearing before

tightening.

5. Replace pivot clamp weldment, shaft key, and front clamp shell around shaft against collar of upper bearing and secure with screws (with Loctite 242) and lockwashers.

6. Replace paddle assembly. See section 6.8.1 Paddle Assembly (Non-Drive Side), Replacement.

Reattach plug to cable by partially joining plug base and plug cap to mid snap point.

8. Reinsert wires into plug in same positions as marked during removal procedure.

9. Push plug base and cap together to secure wires.

10. Reconnect plug on drive pulley cable.

11. Replace guards removed for access.

12. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.8.3 Pivot Bearings

Removal [Figure 17 – Item (11)]

1. Remove guards as necessary for access.

2. Remove paddle assembly (1). See section 6.8.1 Paddle Assembly (Non-

ive Side), Removal.

Remove shaft. See section 6.8.2 Shaft, Removal.

Knock out roll pin.

5. Remove both screws; lockwashers, and hex nuts securing bearing flange block to bearing mount plate.

6. Remove bearing.

Replacement [Figure 17 – Item (11)]

Clean inner face of bearing and shaft. Lubricate with rust inhibiting lubricant.

2. For bottom bearing, slide bearing onto shaft and secure to bearing mount plate with hardware and finger tighten. Orient bearing such that bearing collar is on top.

3. For top bearing replace bearing and secure to bearing mount plate with hardware and finger tighten. Orient bearing such that bearing collar is on bottom.

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4. Replace shaft into upper pivot bearing. Install both pivot bearing’s shaft clamp collars. Insert shaft into bottom pivot bearing. See section 6.8.2 Shaft, Replacem

ent for details.

5. Align bearings so shaft is perpendicular to transport belt and tighten screws.

6. Tighten set screws located in shaft clamp collars. See Table 18 Torque Values.

Drill thru any bearing corner and insert roll pin to prevent bearing from shifting.

8. Replace paddle assembly. See section 6.8.1 Paddle Assembly (Non-Drive Side), Replacement.

:NOTE: Gap between drive side and non-drive side paddles should be 1/4 inch

(6 mm). If both bearings are being replaced, it may be necessary to move them around in the slot to achieve this gap.

9. Replace pivot clamp weldment, shaft key, and front clamp shell around shaft against collar of upper bearing and secure with screws (with Loctite 242) and lockwashers. Replace drive pulley plug. See section 6.6.2 Shaft, Replacem

ent for details.

10. Replace guards removed for access.

11. Test HSDII operation. See section 6.2 Testing HSDII Operation.

6.8.4 Transition Rollers

:NOTE: Paddle may need to be in the divert position.

Removal [Figure 17 – Item (6)]

1. Press in on spring loaded end of roller (6) to compress internal spring.

2. Remove roller.

Replacement [Figure 17 – Item (6)]

:NOTE: Orient roller so spring-loaded shafts will be depressed on end farthest

from paddle pivot.

1. Place one end of roller in roller mounting hole in transition weldment (10).

2. Compress internal roller spring and place other end of roller in opposite roller mounting hole.

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6.9 Control Panel

:NOTE: The repair procedures are identical for the 68.0020.212 (US) (shown),

and 68.0020.215 (international) versions.

Figure 20 Control Panel, Inside

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6.9.1 Motor Power Cable

Removal [Figure 20]

1. Remove servo gearmotor access panel.

2. Turn off motor safety disconnect switch and apply lockout/tagout.

3. Open diverter control panel enclosure door.

4. Loosen captive Torx screw holding motor power cable in place.

5. Unplug motor power cable from servo motor module (52) in diverter control panel.

6. Unscrew Torx screw and remove ground wire.

7. Disconnect motor power cable from servo gearmotor (Figure 13-14).

acement [Figure 20]

Repl

Connect motor power cable to servo gearmotor.

2. Connect ground wire in diverter control panel enclosure.

3. Plug motor power cable into servo motor module in diverter control panel and tighten captive Torx screw.

4. Close diverter control panel enclosure door.

5. Replace servo gearmotor access panel.

6.9.2 Motor Control Cable

Removal [Figure 20]

1. Remove servo gearmotor access panel.

2. Turn off motor safety disconnect switch and apply lockout/tagout.

3. Open diverter control panel enclosure door.

4. Disconnect motor control cable from top of servo power module (51) in diverter control panel.

5. Disconnect motor control cable from servo gearmotor (Figure 13-14).

acement [Figure 20]

Repl

Connect motor control cable to servo gearmotor.

2. Connect motor control cable into servo power module in diverter control panel.

3. Close diverter control panel enclosure door.

4. Replace servo gearmotor access panel.

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6.9.3 Servo Control Unit and Memory Module

Removal [Figure 20 Servo Control Unit: Item (48) Memory Module: Item (49)]

1. Turn off motor safety disconnect switch and apply lockout/tagout.

2. Open diverter control panel enclosure door.

Power is still applied to the servo control module through a secondary circuit.

3. Turn off circuit breaker CB204 inside diverter control panel to remove power from servo control module.

4. Remove preconfigured memory module (card) (49) from servo control unit (48).

5. Remove servo control unit operator panel by depressing locking tabs on top and bottom.

6. Remove wire harnesses from control unit.

7. Unscrew Torx screw and remove green ground wire.

8. Lift servo control unit upwards and separate from the smart line servo power module (51) to remove.

Replacement [Figure 20 Servo Control Unit: Item (48) Memory Module: Item (49)]

1. Lower servo control unit in enclosure and slide downward into notches on side of smart line servo power module.

2. Reconnect green ground wire.

3. Reconnect wire harnesses to servo control unit.

4. Set dipswitches on new servo control unit to match the settings from the old unit.

5. Reinstall servo control unit operator panel.

6. Reinstall existing preconfigured memory module into servo control unit. If it is necessary to reprogram a new memory module, see section 6.9.4 Reprogram Servo Control Module.

Turn on circuit breaker CB204 inside diverter control panel to restore power to servo control module.

8. Close diverter control panel enclosure door.

9. Remove lockout/tagout and turn motor disconnect switch on.

10. Test HSDII operation. See section 6.2 Testing HSDII Operation.

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6.9.4 Reprogram Servo Control Module

There are two typical scenarios for the process of reprogramming the servo control module. In one scenario, a replacement Compact Flash (CF) card is shipped with the HSDII application pre-loaded onto the card. The other scenario is that the application files are delivered electronically and that the existing CF card will be reused.

The reprogramming procedure is essentially identical for both scenarios. The only difference is the preparation of the CF card for those installations where the existing CF card will be reused. For these installations, a computer with a CF card reader and access to the delivered HSDII application files is required to complete this procedure.

The Sinamics servo consists of four components: control unit, memory module (CF card), smart line module, and motor module (Figure 21). Each of the servo m

odules contains LEDs that are used to identify faults and aid in reprogramming

the memory module.

Figure 21 Sinamics Control Unit and Modules

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[Figure 20 – Item (49)]

1. Turn off motor safety disconnect switch and apply lockout/tagout.

2. Open diverter control panel enclosure door.

Power is still applied to the servo control module through a secondary circuit.

3. Turn off circuit breaker CB204 inside diverter control panel to remove power from servo control module.

4. Remove preconfigured memory module (card) (49) [Compact Flash (CF) card] from servo control unit (48).

a. If the CF card is being discarded and new card is being used for the

reprogramming, go to Step 8.

b. If the CF card is being reused for the reprogramming, continue with

Step 5.

5. Using computer with external CF card reader and access to HSDII application files, view memory module card contents. Figure 22 shows t

ypical file structure loaded on CF card.

Figure 22 Memory Module Card Files

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6. Except for KEYS folder, completely delete all existing folders and files on CF card. Be sure to retain KEYS folder. It contains information unique to CF

card that must be retained.

7. Install HSDII application files onto CF card. If application files were delivered as ZIP file, be sure to extract contents of ZIP file onto CF card. CF card

should now include application files and KEYS folder as shown in Figure 22.

Insert memory module card into servo control module card slot.

The following steps require power to the unit and lockout/tagout to be removed. Use extreme caution when working inside the control panel enclosure while power is applied.

9. Remove lockout/tagout and turn disconnect switch on door of diverter control panel to ON position. Make sure mode switch is in SERVICE mode.

10. Turn on circuit breaker CB204 to restore power to servo module.

11. Control module performs initial boot up, which can take several minutes.

During boot-up, control unit DP1 LED flashes yellow slowly, approximately

once per second (Figure 23).

Figure 23 Servo Component LEDs

12. After several seconds, control unit operator panel displays fault “1650”. Green light appears on motor module.

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13. When control unit DP1 LED flashes faster, approximately twice per second,

initial boot-up is complete.

14. Reboot control module by turning off, then turning on circuit breaker CB204.

15. Operator panel displays same pattern as initial boot-up, except that when this boot-up is complete, the control unit, smart line module, and motor module RDY LEDs will remain continuously lit green. At this point, boot-up is complete.

16. Operator panel screen turns to status “0”. As screen changes through its display cycle it should also show two alerts:

● A31811 = Unrecognized Encoder Alert (will clear after the next reboot

of the servo control module)

● A07441 = Parameter Setting Alert (telling user to teach paddle

positions)

:NOTE: If alert A13000 displays, ignore it. It is an older license verification

message that is no longer relevant.

17. Set home and extend position positions. See section 4.5.3 Paddle Position. A07441 Par

ameter Setting Alert will go away.

18. Adjust paddle belt speed. See section 4.5.4 Setting Paddle Belt Speed.

Change mode switch to MAN to test HSDII operation. Paddles should now

19. cycle between previously taught positions. Paddle belts should also operate normally.

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Siemens HSDII Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual