TGW NBS BR Installation, Operation & Maintenance Manual

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INSTALLATION, OPERATION, MAINTENANCE

MANUAL

NBS®BR IOM

Narrow Belt Sorter – Low Friction Bearing Rail

P/N: 1116149

Revision Date: March 14, 2019

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NBS®-BR IOM

TABLE OF CONTENTS

CHAPTER 1: IOM INTRODUCTION .......................................................................................................................4

CHAPTER 2: TGW SYSTEMS POLICIES ..............................................................................................................5

CHAPTER 3: SAFETY ............................................................................................................................................6

3.1: TGW SAFETY RECOMMENDATION ........................................................................................................................6

3.2: CONVEYOR DESIGN AND SAFETY GUIDELINES.......................................................................................................7

3.2.1: CEMA Unit Handling Standard ....................................................................................................................8

3.3: WARNINGS AND SAFETY INSTRUCTIONS ................................................................................................................9

3.4: SAFETY WARNINGS .......................................................................................................................................... 10

3.5: TGW SYSTEMS CONVEYOR CONTROLS SAFETY GUIDELINES ............................................................................. 12

CHAPTER 4: NBS INTRODUCTION ................................................................................................................... 14

4.1: NBS 30 AND NBS 30 WAVE™ ........................................................................................................................ 15

4.2: NBS WAVE 200 .............................................................................................................................................. 15

4.3: NBS-90 & NBS90-SL ...................................................................................................................................... 16

4.4: PRODUCT DESCRIPTIONS .................................................................................................................................. 19

CHAPTER 5: NBS RECEIVING AND SITE PREPARATION .............................................................................. 20

5.1: PARTS INVENTORY & IDENTIFICATION ................................................................................................................ 21

CHAPTER 6: NBS APPLICATION & INSTALLATION DETAILS ....................................................................... 23

6.1: APPLICATION RULES & GUIDELINES ................................................................................................................... 23

6.2: PRODUCT ALIGNMENT ....................................................................................................................................... 26

CHAPTER 7: NBS INSTALLATION DETAILS .................................................................................................... 28

7.1: GENERAL ELECTRICAL REQUIREMENTS ............................................................................................................. 29

7.2: GEAR MOTOR ACTIVATION ................................................................................................................................ 31

7.3: ELEVATIONS ..................................................................................................................................................... 33

7.3.1: Straight and Level .................................................................................................................................... 34

7.4: SUPPORTING ARRANGEMENT ............................................................................................................................ 36

7.5: SUPPORTS & CONNECTIONS ............................................................................................................................. 36

7.6: ANCHORING ..................................................................................................................................................... 36

7.7: BED/SUPPORT CONNECTORS ............................................................................................................................ 37

7.8: INSTALL LOW FRICTION RAIL CONNECTORS ......................................................................................................... 38

7.9: RAILING ALIGNMENT PROCEDURE ..................................................................................................................... 38

7.10: CEILING SUPPORTED NBS CONVEYORS .......................................................................................................... 41

7.11: NBS BELT INSTALLATION ................................................................................................................................ 43

7.11.1: Belt Threading Instructions ..................................................................................................................... 44

7.11.2: Belt Tracking........................................................................................................................................... 47

7.11.3: Belt Specifications and Lacing ............................................................................................................... 48

7.11.4: Belt Lacing Information ........................................................................................................................... 49

7.12: NBS PNEUMATIC GENERAL GUIDELINES.......................................................................................................... 50

7.12.1: Air Regulator Lock Out Valve On and Off Position ................................................................................ 54

7.12.2: Air Line Connections .............................................................................................................................. 55

7.13: WAVE DIVERTER INSTALLATION ....................................................................................................................... 60

7.14: COMMISSIONING OF EQUIPMENT ..................................................................................................................... 63

CHAPTER 8: NBS MAINTENANCE .................................................................................................................... 65

8.1: GENERAL PREVENTIVE MAINTENANCE ............................................................................................................... 65

8.2: MAINTENANCE SCHEDULE ................................................................................................................................. 69

8.3: NBS TROUBLESHOOTING GUIDE ....................................................................................................................... 71

8.4: REPAIR PROCEDURES ...................................................................................................................................... 73

8.5: SENSING SWITCHES ......................................................................................................................................... 74

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8.6: NBS MAINTENANCE CHECKLIST ........................................................................................................................ 75

8.7: NBS 90 TRANSFER ROLLER ADJUSTMENT PROCEDURE ..................................................................................... 76

8.8: USING THE GATES 505C OR 507C SONIC METER .............................................................................................. 77

CHAPTER 9: NBS RECOMMENDED REPLACEMENT PARTS ........................................................................ 78

9.1: SPARE PARTS PRIORITY LEVEL EXPLANATIONS ................................................................................................. 78

9.2: NBS-BR END PULLEY ...................................................................................................................................... 79

9.2.1: Replacement Parts – NBS-BR End Pulley ............................................................................................... 80

9.3: NBS-BR INTERMEDIATE BED ............................................................................................................................ 81

9.3.1: Replacement Parts – NBS-BR Intermediate Bed..................................................................................... 81

9.4: NBS-BR DRIVE 3′ BED RH SHOWN .................................................................................................................. 82

9.4.1: Replacement Parts – NBS-BR Drive 3′ Bed RH Shown .......................................................................... 83

9.5: NBS-BR DRIVE 5′ BED RH SHOWN .................................................................................................................. 84

9.5.1: Replacement Parts – NBS-BR Drive 5' Bed RH & LH ............................................................................. 85

9.5.2: Replacement Parts – NBS-BR Drive 6' Bed RH & LH ............................................................................. 87

9.6: NBS-BR MANUAL AUXILIARY TAKE-UP ............................................................................................................. 88

9.6.1: Replacement Parts – NBS-BR Manual Auxiliary Take-Up ....................................................................... 89

9.7: NBS-BR LOW PROFILE AIR AUXILIARY TAKE-UP ............................................................................................... 90

9.7.1: Replacement Parts – NBS-BR Low Profile Air Auxiliary Take-Up ........................................................... 91

9.8: NBS 90-BR 24 TRANSFER ............................................................................................................................... 92

9.8.1: Replacement Parts – NBS90-BR-24 Transfer ......................................................................................... 93

9.9: NBS 90-BR 30 TRANSFER ............................................................................................................................... 94

9.9.1: Replacement Parts – NBS90-BR-30 Transfer ......................................................................................... 95

9.10: NBS90-BR SL 33 TRANSFER ......................................................................................................................... 96

9.10.1: NBS90-BR SL 33 Transfer ..................................................................................................................... 97

9.10.2: Replacement Parts – NBS 90-BR-SL 33 Transfer Power Take Off ....................................................... 98

9.11: NBS30-BR 3-ROW SORTER ASSEMBLY .......................................................................................................... 99

9.11.1: Replacement Parts – NBS30-BR 3-Row Sorter ................................................................................... 100

9.12: NBS30-BR 5-ROW SORTER ASSEMBLY ........................................................................................................ 101

9.12.1: Replacement Parts – NBS30-BR 5-Row Sorter ................................................................................... 102

9.13: NBS 30 WAVE™ SORTER ASSEMBLY .......................................................................................................... 103

9.13.1: Replacement Parts – NBS30-BR WAVE™ Sorter ............................................................................... 104

9.14: NBS30-BR 12-ROW ALIGNER ASSEMBLY ..................................................................................................... 105

9.14.1: Replacement Parts – NBS30-BR 12-Row Aligner ............................................................................... 105

9.15: NBS30-BR WAVE™ ALIGNER ASSEMBLY .................................................................................................... 106

9.15.1: Replacement Parts – NBS30-BR WAVE™ Aligner.............................................................................. 106

9.16: WAVE CONTROL NBS-30 DUAL ETHERNET ................................................................................................... 107

9.16.1: Replacement Parts – Wave Control Dual Ethernet .............................................................................. 107

9.16.2: Replacement Parts – Photoeye ........................................................................................................... 107

9.17: WAVE CONTROL NBS-30 SINGLE ETHERNET ................................................................................................ 108

9.17.1: Replacement Parts – Wave Control Single Ethernet ........................................................................... 108

9.17.2: Replacement Parts – Photoeye ........................................................................................................... 108

WORKS CITED ................................................................................................................................................... 109

TGW SYSTEMS INFORMATION ....................................................................................................................... 110

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WARNING

Chapter 1: IOM INTRODUCTION

IOM Purpose

It is the intent of TGW Systems, through this manual, to provide information that acts as a guide in the installation, operation, and maintenance of TGW Systems conveyors.

This manual describes basic installation practices, assembly arrangements, preventive maintenance, and assists in replacement parts identification.

This service manual is intended for use by personnel who are knowledgeable of installation and safe working practices on conveyor systems.

Not all applications and conditions can be covered; therefore, this manual is to be used ONLY as a guide.

If additional copies of this manual are needed or if you have any question concerning the conveyor please contact your TGW Distributor or TGW Lifetime Services at 231-798-4547 or visit TGW at www.tgw-conveyor.com

for maintenance

videos and other application information.

Manual Structure

You should receive a separate documentation for each product line of TGW Systems implemented in your installation. You can identify the respective product line on the back of the folder or on the cover sheet of the IOM (Installation Operation Maintenance Manual)

• Pay attention to the safety instructions!

• Prior to working at or in the immediate vicinity of the system it is recommended that you make yourself familiar with the safety instructions included in the present document!

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TGW Systems warrants that the material and workmanship entering into its equipment is

charge any part proved defective within 2 years from

the purchaser gives TGW Systems immediate notice in writing and examination proves the claim that such materials or parts were defective when furnished. For drive components

(i.e. Xeno belts, slave Xeno

up, and

of running use, provided the conveyors are applied, installed and maintained in accordance with TGW Systems published standards. Other than the above,

end beyond the

The liability of TGW Systems will be limited to the

Systems under the warranties specified above is conditioned upon the equipment being installed,

Systems makes no warranties which extend to,

occasioned by chemicals, abrasion, corrosion or

misapplication, abuse, alteration, operation or maintenance; abnormal conditions of temperature or dirt; or operation of the equipment above rated capacities or in an otherwise improper

THERE ARE NO WARRANTIES, EXPRESSED OR

NOT LIMITED TO,

FOR A PARTICULAR PURPOSE, EXTENDING

Chapter 2: TGW SYSTEMS POLICIES

TGW Systems Equipment Warranty

merchantable and will be furnished in accordance with the specifications stated.

TGW Systems agrees to furnish the purchaser without

date of shipment provided

specific to XenoROL® belts, drive spools, standard and speedspacers), this warranty shall be extended to five years

there are no warranties which ext description on the face hereof. Consequential damages of any sort are wholly excluded.

replacement cost of any defective part. All freight and installation costs relative to any warranted part will be at the expense of the purchaser. Any liability of TGW

TGW Environment Standards

TGW equipment is designed to be installed in a clean, dry warehouse environment. Exposure to extreme humidly, direct sunlight, blowing dirt or rain can permanently damage some components of TGW conveyor. In particular, the curing agents in concrete are known to attack and degrade the urethane conveyor components.

When installing conveyor on a new construction site, be sure that the concrete is properly cured before setting conveyor on it. In addition, if conveyors are stored in the proximity of curing concrete, proper ventilation must be used to direct the curing agent fumes away from the conveyor.

Failure to comply with these guidelines will void the TGW warranty on any failed components that result from these environment issues.

Rev 03/01/2019

handled, operated, and maintained in accordance with the written instructions provided or approved in writing by TGW Systems.

The warranties specified above do not cover, and TGW

damage to the equipment due to deterioration or wear

erosion; Purchaser's

manner.

IMPLIED, INCLUDING, BUT WARRANTIES OF MERCHANTABILITY OR FITNESS

BEYOND THOSE SET FORTH IN THIS STATEMENT OF WARRANTY.

Rev 03/01/2019

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WARNING

Chapter 3: SAFETY

3.1: TGW SAFETY RECOMMENDATION

TGW Safety Recommendation

For additional safety information:

TGW agrees to the following safety instruction or guidelines listed within this manual. This is not to conflict with your state or legal requirements.

TGW Recommends for maintenance or repair purposes, to incorporate a lock out or tag procedure. To ensure all starting devices, prime movers, or powered accessories are off before attempting to maintenance or repair.

The procedures below are designed to protect everyone involved with the conveyor against an unexpected restart. To include understanding of potential hazard of stored energy, which can exist after the power source is locked out.

For additional information, refer to the latest issue of ANSI Z244.1, American National Standard for Personnel Protection − Lockout/Tagout of Energy Sources− Minimum Safety Requirements.

http://www.ansi.org/

OSHA 29CRF Part 1910.147 “Control of Hazardous Energy Sources (Lockout/Tagout)”, which includes

requirements for release of stored energy and OSHA Safety and Health Regulations for Construction

1926.555 Conveyors https://www.osha.gov/

Conveyor Design and Safety Guidelines

A safety risk evaluation is required for all of our standard equipment. The safety risk evaluation considers every potential hazard on the conveyor, weighs the probability and the severity of the potential injury, and addresses methods of mitigation to make the risk of injury either low or negligible. We use the ANSI B11 TR3 standards for all of our risk evaluation.

In addition, all of our equipment is designed to comply with the following national and industry standards:

• ANSI Z535.1 – Safety Color Code

• ANSI Z244.1 – Lockout/Tagout of Energy Sources

• ASME B15.1 – Safety standard for Mechanical Power

Transmission Apparatus

• ASME B20.1 – Safety standard for Conveyors and

Related Equipment

• CEMA – Safety Standards and Labels

• OSHA 1910.147 – The Control of Hazardous Energy

• OSHA 1910.212 - General Requirements for all

Machines

• OSHA 1910.95 – Occupational Noise Exposure

efinitions:

• ANSI = American National Standard Institute

• ASME = American Society of Mechanical Engineers

• CEMA = Conveyor Equipment Manufacturers

Association

• OSHA = Occupational Safety and Health

dministration

• Safety: Always lock out power source and follow recommended safety procedures.

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3.2: CONVEYOR DESIGN AND SAFETY GUIDELINES

ANSI Standards for Conveyors

It is essential for safe and efficient system operation that safety information and guidelines presented here are properly understood and implemented.

TGW recognizes American National Standard Institute (ANSI) booklet entitled Safety Standards for Conveyors and Related Equipment B20.1. For more information go to:

https://webstore.ansi.org/default.aspx

With any piece of industrial equipment, conditions exist that might cause injury to you or your co-workers. Because it is not possible to describe each potentially hazardous situation that might develop, you must be alert at all times for unsafe conditions. To avoid injury, use maximum possible care and common sense and adhere to all safety standards. Take special care while maintaining and inspecting electrical equipment and devices. All personnel working on or around the system should be aware of, and adhere to, all CAUTION, DANGER, and WARNING signs.

Labels or signs are posted to reduce the risk of injury to all personnel. Never assume that the signs and notices are applicable only to inexperienced personnel. Maintain signs in a legible condition. Contact your supervisor to post additional safety signs if you feel they are necessary.

https://www.ansi.org/

ANSI Conveyor Safety Rules

• Conveyor safety rules, as well as specific regulations

and guidelines listed in this publication:

• DO NOT touch moving Conveyor parts.

• DO NOT walk, ride, or climb on the Conveyor.

• DO NOT operate the

other protective guards removed.

Conveyor

with chain guards or

• Keep jewelry, clothing, hair, etc., away from the

Conveyor.

• Know the location and function of all start/stop devices

and keep those devices free from obstruction.

• Clear all personnel from the equipment before starting

the Conveyor.

• DO NOT attempt to clear product jams while the

Conveyor is running.

• Allow only trained and authorized personnel to maintain

or repair Conveyor equipment.

• DO NOT load the Conveyor beyond specified design

limits.

• DO NOT attempt to make repairs to the Conveyor while

it is running.

• DO NOT modify equipment without checking with the

manufacturer.

• DO NOT operate or perform maintenance on

equipment when taking any type of drug, sedative, when under the influence of alcohol, or when over fatigued.

• Report any unsafe condition to your supervisor or

maintenance staff.

CEMA Standards for Conveyors

The Conveyor Equipment Manufacturers Association (CEMA) provides safety information related to conveyor systems. There are Conveyor Safety Video and Conveyor Safety Poster produced by CEMA.

TGW recommends these videos for training and education purposes as part of a safe working environment around conveyor equipment. The videos introduce awareness of operations, personnel, maintenance technicians, and management to safety hazards commonly associated with the automated material handling conveyor equipment.

The safety posters reviews important safety labels and are intended to be posted in public places as a day-to-day reinforcement of good safety practices. These posters can be downloaded from the CEMA Website at

https://www.cemanet.org/safety-label-posters

information for both the safety poster and the videos can be purchased from CEMA. Visit their website –

https://www.cemanet.org/

For additional information or contact them at:

CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION 5672 Strand Ct., Suite 2 Naples, Florida 34110

239.514.3441

CEMA Safety Label Meanings

ANSI Z535.4 – Product Safety Signs and Labels

The word or words that designate a degree or level of hazard seriousness. The signal words for product safety signa are: DANGER, WARNING, and CAUTION.

DANGER -Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

WARNING – Indicates potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

or for more

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3.2.1: CEMA Unit Handling Standard

Shown below are some samples of labels applicable to conveyor standards.

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WARNING

CAUTION

3.3: WARNINGS AND SAFETY INSTRUCTIONS

Failure to follow the instructions and cautions throughout this manual and warning label on the conveyor may result in injury to personnel or damage to the equipment.

Your TGW Systems conveyor is powered by a motor and can be stopped only by turning off electrical power to the motor. As with all powered machinery, the drive-related components – including sprockets, chains, shafts, universal joints, and pneumatic devices – can be dangerous. We have installed or provided guards to prevent accidental contact with these parts, along with warning labels to identify the hazards.

• Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

Special attention must be paid to the following areas of this manual:

• Indicates a situation, which, if not avoided, could result in property damage.

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WARNING

3.4: SAFETY WARNINGS

• After maintenance, REPLACE guards immediately.

• Keep ALL warning labels clean and clear of any obstructions.

• Never remove, deface, or paint over WARNING or CAUTION labels. Any damaged

label will be replaced by TGW Systems at no cost by contacting Lifetime Services.

• It is very important to instruct personnel in proper conveyor use including the location and function of all controls.

• Special emphasis must be given to emergency stop procedures.

• It is important to establish work procedures and access areas, which do not require

any part of a person to be under the conveyor.

• It should be required that long hair is covered by caps or hairnets.

• Loose clothing, long hair, and jewelry must be kept away from moving equipment.

• Maintain enough clearance on each side of all conveyor units for safe adjustment and

maintenance of all components.

• Provide crossovers or gates at sufficient intervals where needed to eliminate the temptation for personnel to climb over or under any conveyor.

• Walking or riding on a moving conveyor must be prohibited.

• Before performing maintenance on the conveyor, make sure the start-up controls are

locked out and cannot be turned on by any person other than the one performing the maintenance.

• If more than, one crewmember is working on the conveyor, EACH CREW MEMBER MUST HAVE A LOCK ON THE POWER LOCKOUT.

• All pneumatic devices must be de-energized and air removed to prevent accidental cycling of the device while performing general maintenance.

• Make sure all personnel are clear of all conveyor equipment before restarting the system.

• Before restarting a conveyor which has been stopped because of an emergency, an inspection of the conveyor must be made and the cause of the stoppage determined. The starting device must be locked out before any attempt is made to correct the cause of stoppage.

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WARNING

• Before servicing or performing any work in the motor control panel, disconnect and lock out air and the main incoming service. If only the panel disconnect is off, the incoming side will still be hot.

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3.5: TGW SYSTEMS CONVEYOR CONTROLS SAFETY GUIDELINES

The following basic conveyor control safety guidelines are recommended by TGW Systems even though Business Partner may or may not purchase conveyor controls from TGW Systems. The items listed deal with applications of controls equipment. The actual installation of the equipment must always follow the National Electric Code and all other local codes.

Start-up Warning Horn

Ideally, all conveyors should be within sight of the conveyor start pushbutton. This allows the operator to verify that no one is touching the conveyor or would be in danger if the conveyor were to start up.

If it is not possible to see all of the conveyor being started from the start pushbutton location, then some form of audible warning device is required. It could be a horn, buzzer, bell, or anything unique to that conveyor for that location. It should be loud enough to be heard at any point on the conveyor system. It should sound for approximately five seconds after the start pushbutton is pushed, prior to the actual running of conveyor. Any auxiliary equipment such as vertical lifts, turntables, etc., should also be included in the warning circuitry.

Conveyors that stop and restart under automatic control could also require a horn warning prior to restarting. If it is not easy to distinguish the difference between a fully stopped conveyor system and a momentarily stopped conveyor section, then it is advisable to add a warning horn. All conveyor sections that stop and restart automatically should be marked with appropriate signs or labels.

Start Pushbuttons

Start pushbuttons should be the flush type or guarded such that inadvertently leaning against them will not actuate the conveyor. They should be provided with a legend plate clearly defining which conveyors will be started.

Stop Pushbuttons

Stop pushbuttons should be the extended type such that any contact with it is sufficient to stop the conveyor. They would also be provided with a legend plate clearly defining which conveyors will be stopped.

Operator Controls

Additional operator controls should be designed into the system with the same guidelines that go into start and stop pushbuttons, depending upon their function. Devices which are repeated on multiple control stations, such as emergency stops, should be located at the same relative location on each station (such as lower right corner).

Emergency Stops

All locations where an operator must work directly at the conveyor should be protected by an emergency stop. An operator should not have to move from where he is to actuate the emergency stop.

Conveyors in areas of high pedestrian traffic should also be protected by emergency stop devices.

For all other instances, emergency stops should be located throughout a system such that it is possible to shut down the system without having to walk too far. In these instances the emergency stop is used more to protect the equipment from damage than to protect personnel.

Emergency stops can be of the pushbutton or cable operated switch type. The pushbutton type should be a red, mushroom head maintained pushbutton which requires resetting after it is actuated. Cable operated switches should trip by pulling the cable, and require resetting at the switch.

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Actuating an emergency stop must drop-out the start circuit, requiring restarting the system using the start pushbuttons provided.

An emergency stop should normally stop all conveyors in the system. Very large systems may involve dividing a system into zones of control based on proximity of personnel, safety hazards, walls obstacles, etc.

Controls Logic

Solid state controls logic devices, such as programmable controllers are used extensively for conveyor control. They are very reliable, but a hardware failure or software bug would cause an output to function erratically. For this reason, start circuits, warning horn circuits, and emergency stops should usually be configured using conventional relay logic.

Safety Switches

All conveyor control cabinets and motors should be provided with safety (or disconnect) switches. These switches must have provisions for padlocking. As required for maintenance, equipment should be locked in the off position.

Special Devices

Special devices and equipment such as vertical lifts, turntables, high speed conveyors, etc., all have unique design and safety requirements. These should be looked at in each case to determine what the requirements might be.

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Chapter 4: NBS INTRODUCTION

NBS Concept

The TGW Systems NBS Narrow Belt Sorter technology was developed to provide an economic alternative to other sortation devices, as well as providing sorting options that were not easily available.

This technology is similar to sorters that use wide flat load carrying belts and pop-up wheels to divert product but has eliminated many of the high cost / maintenance features associated with these sorters.

Limitations on availability of bi-directional diverts, long divert lane center-line distances, as well as the high costs associated with the skilled labor required to install these wide belts have been addressed with this technology.

Features and Benefits

Features and benefits common to the NBS 30, NBS 90 low friction rail technologies include:

• Product is continuously carried on multiple narrow belts for smooth bump-free conveying and excellent tracking accuracy.

• Narrow belts slide on low friction roller bearing guides, resulting in reduced noise and virtually eliminating tracking problems.

• Multiple narrow belts are progressively guided through the sorter to minimize belt tracking issues

• Narrow belts run flat and straight through NBS modules without snubbing or back-wrapping resulting in reduced horsepower requirements.

• Simple user-friendly design allows ease of installation and maintenance.

• Compact modular design of modules allows closer divert/transfer lane center distances.

• Modularity and universal mounting of modules allows easy repositioning or reconfiguration in

the field.

• Gravity take-away or spurs may be used in many applications to lower initial costs.

• NBS technology costs less than conventional full width belt sorters in material as well as

installation costs.

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4.1: NBS 30 AND NBS 30 WAVE™

• Simple 30 degree diverter design means less maintenance and higher uptime.

• Diverters use proven true vertical lift for reliability, consistency, and low cost 3 rows and 5 rows

only.

• High friction, diverter wheels with precision bearings for positive quiet sorting

• Conveyor Action allows for close product centers and higher through put rates.

4.2: NBS WAVE 200

• Rates to 200 CPM with 18" long product at 425 FPM.

• Snubber roller has ABEC-1 precision bearings.

• Does NOT change product orientation when using a 30° spur take away conveyor.

• Maximum speed 425 FPM.

• Operating air pressure is 40 PSI with a maximum of 45 PSI

• Gap between products from the original 12” down to 6” recommended, with a tolerance of (± 3”).

• Products should be edge aligned to cover the first spur side divert wheels or approximately 1”off

the spur edge, and should contact the inside first wheel. (See above edge aligned drawing). Contact Engineering Support for application specific solutions.

• Distance between diverts - see NBS WAVE 200 Divert Bed page.

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4.3: NBS-90 & NBS90-SL

• Separate drive within the transfer module allows a space saving single or bidirectional unit NBS90 is driven with a MOVIMOT motor. NBS-SL is driven off the return side of the belt.

• Coated rollers allow positive product acceleration and transfer rate

• Pickup of product “on the fly” allows maximized sort rate

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KEY WORD

ABBREVIATION

DESCRIPTION

ALUMINUM RAIL

Original NBS UHMW belt guide holders

AIRBAG

Inflatable lifting device used in NBS30

BEARING

BRG

Low friction rotating or sliding device

BEAR RAIL

NBS-BR belt guides composed of small ball bearings BELT

BLT

Flexible load carrying surface or O-ring

BETWEEN-FRAME

The distance between conveyor side frames

BRACKET

BRKT

Attachment between a main and another part

CHANNEL

Structural side member of conveyor equipment

CONNECTOR

CONN

Holds two parts together (Mechanical or Electrical)

CONSTRUCTION ORDER

CO _ _ _ _ _

Item number of modified standard CROSSMEMBER

Holds channels apart

DIVERTER

NBS30 module

DRIVE

Power unit at the discharge end of NBS sorter

ELEVATION

Top-of belt height above base surface

ENCODER

Electrical distance counter used to track package END PULLEY

E-PULL

4” or 5" diameter roller at charge end of NBS sorter

EXTRUSION

Aluminum base that holds UHMW belt strips (See FEET PER MINUTE

FPM

Speed sorter belts are traveling

FILTER / REGULATOR

Combination air pressure air filter / regulator

FLOOR STAND

Name for conveyor bed support

FLOW CONTROL

Needle valve used to control airflow

GEARMOTOR

GEARMTR

One piece gear-reducer motor assembly

GUARD RAIL

Angle or channel used to keep product on NBS

GUARD

GRD

Any part used to protect area for safety reasons

IDLER

IDL

Un-driven pulley used as a tensioning device

ITEM NUMBER

IT #

TGW Systems part identification number

KEY

Square locking device used on rotating shafts

KIT

Group of several parts with a single item number

LACED

LCD

The condition of a correctly installed lacing

LACING

Type or method of joining belts together (splice)

LIFT FRAME

The lifting structure of a NBS90 transfer

LIFT TABLE

Assembly that guides the NBS30 wheels upward

LOCKNUT

Self-locking fastener that resists vibration

LOCTITE

A thread-locking adhesive that resists vibration

LOOSE PARTS

Individual parts that must be installed in the field

Definition of Terms

between steel side rails

location along the sorter length

ALUMINUM RAIL)

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KEY WORD

ABBREVIATION

DESCRIPTION

MODULE

MOD

A self-contained mechanical assembly

MOUNT

MNT

Part used to hold another, similar to a bracket

MOUNTING

MTG

Location and fasteners to attach a mount

MOTOR

MTR

Rotational power source usually using electricity

MUFFLER

Device used to reduce the noise of exhausted air

NATIONAL PIPE THREAD

NPT

Standard identifier for USA tapered pipe sizes ORDER NUMBER

11 _ _ _ _ _

Original factory order / tracking number

O-RING

Polyurethane cord belts of differing lengths

PHOTOEYE

Optical sensing device used for product control

PLATE

Flat piece of metal usually bolted on for strength

PROGRAMMABLE

CONTROLLER

PLC

Self-contained programmable control unit that can

PULLEY

Roller described by diameter and body length

REFLECTOR

Target used to reflect a light back to a photo eye

REGULATOR

REG

Air device that reduces pressure to usable level

ROLLER

Described by axle size and BF dimension

SCANNER

A device that recognizes products by bar codes

SCHEMATIC

Line drawing of a electrical or pneumatic circuit

SEAL

Sealing device on a rotating shaft or cylinder rod

SHAFT

Round steel rod described by diameter and length

SHEAVE

A grooved disc that guides a V-belt or O-ring

SHIM

Thin piece of metal, used to fill up a space

SKATEWHEEL

SKW

2” diameter X 5/8” wide X ¼” axle hole roller

SOCKET

SOC

Hex shaped hole in an Allen screw

SOLENOID

SOL

An electrically operated multi-position air valve

SPACER

Thick washer or tube that a fastener passes thru

SPLICE

Area where similar materials are joined together

SPRING

SPR

Coiled wire device used for un-powered return

SPROCKET

SPKT

Wheel with shaped teeth that engage roller chain

SPUR

Transition bed between a diverter and exit lane

STANDHEAD

Pivoting bracket that attaches support to the bed

STARTER

Electrical relay that energizes the drive motor

TAG

Number that identifies unit in system lay-out

TAKEUP

Assembly used to remove slack from a belt / belts

TEE

A part with three connections locations

TENSIONER

A pneumatic, spring, or static take-up device

TRANSFER

TRNS

NBS90 and NBS-SP module

LOGIC

control several input and output devices

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KEY WORD

ABBREVIATION

DESCRIPTION

ULTRA HIGH

UHMW

Industry standard term for the hard milky white VALVE

An air shut-off or switching device

VENT

Small hole in gearbox to allow air expansion

WEARSTRIP

Low-friction material used to reduce rubbing wear

WELDMENT

WLDMT

Any part that requires welding in its manufacture

VFD

Variable Frequency Drive for motor speed control

MOLECULAR WEIGHT

4.4: PRODUCT DESCRIPTIONS

Polyethylene used in wear strip applications

For the most current list of “Product Description” and “Terms and Abbreviations” Log into

www.tgw-conveyor.com

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and select Support/Engineering Support Documents.

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CAUTION

Chapter 5: NBS RECEIVING AND SITE PREPARATION

Receiving

TGW Systems NBS Narrow Belt Sorters are shipped in subassemblies. These subassemblies are packaged to guard against damage in shipment, when handled properly.

Examination immediately following unloading will show if any damage was caused during shipment. If damage is evident, claims for recovery of expenses to repair damage or replace components must be made against the carrier immediately. While unloading, a check must be made against the Bill of Lading, or other packing lists provided, to confirm full receipt of listed items.

• TAKE CAUTION DURING THE REMOVAL OF EQUIPMENT FROM THE CARRIER. Remove small items and boxes first. Pull and lift only on the skid, not on the frame, cross member or any part of the conveyor equipment.

Preparation of Site

After the conveyor is received, move it to the installation, or designated dry storage, area as soon as possible. Clean up all packing material immediately before parts get lost in it. Loose parts should remain in the shipping boxes until needed.

Prior to starting the assembly of the conveyor, carefully check the installation path to be sure there are no obstructions that will cause interference. Check for access along the path needed to bring in bed sections and components closest to the point where they are needed. It is often necessary to give the area, along the system path, a general cleanup to improve installation efficiency, access, and accuracy.

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WARNING

5.1: PARTS INVENTORY & IDENTIFICATION

Each subassembly is shipped completely assembled except the bed joint splice plate/nuts which are shipped with other loose parts. Identify and separate the sorter subassemblies by type or tag number, for inventory and ease of locating during installation.

An identification label is attached to the inside of one side channel or on a cross member, close to one end of each conveyor bed.

Labels may contain the following information:

Item number

• Item number

• Description

• Job Number

• Mfg. Number

• Date of manufacture

• Tag number (if specified)

• Assembler's clock number

• QR (Quick Response) Label

o Scan Code For IOM Manual

Scan the QR code to retrieve the IOM Manual, if nothing happens; check your scanner settings to make sure the QR Label setting is enabled.

On the supports, the tag is located on the bottom side of the foot.

On special devices, it is located on a convenient flat surface that is not offensive to the appearance of the equipment but is still accessible for viewing.

These numbers can be cross-referenced against the packing list.

Loose parts are boxed and shipped separately.

You should have all conveyor sections and supports for a particular conveyor prior to installation.

It is cost-effective to identify and procure any missing parts before they are needed for assembly.

Small items like nuts and bolts are weigh-counted and packaged by size and type.

• The Installation Supervisor must be experienced with conveyor, qualified in the mechanics of the equipment, and enforce safe working procedures for the protection of the crew, customer, and customer’s property.

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WARNING

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CAUTION

Chapter 6: NBS APPLICATION & INSTALLATION DETAILS

• NBS Selection Guidelines

• Use NBS when:

• Medium to high speed sortation is required

• Product may be same size and weight, or mixed

• Product weight: 1-75 lbs., 1500 lbs. total load

• Product size: 6" x 9" Min -- 28" x 28" Max

• Ambient temperature is +33° to 120°F

6.1: APPLICATION RULES & GUIDELINES

Matching conveyor rates before and after NBS sortation are vital to proper application decisions.

The take-away lanes from NBS can be either Skatewheel / gravity (used as a deceleration area), or powered conveyor, run at a speed which can receive products as fast as they are released from the NBS.

• The maximum divert rate for a NBS 30 is 100 CPM (18" X 18" cases moving at 300 feet per minute); NBS 30 WAVE is 200 CPM at 425 FPM; NBS 90 is 65 CPM single-direction, 55 CPM bi-directional.

• When feeding NBS sortation, use a split metering belt to singulate individual products with a minimum gap of 18". For NBS 30 WAVE, minimum gap is 6″.

• For NBS 30 and NBS 30 WAVE, align all products along the “Spur” side of the NBS sorter.

• The maximum length of an NBS sortation conveyor is 45' when using the 5' Drive Bed.

• The maximum length of an NBS sortation conveyor is 200' when using a 6' Drive Bed.

• The minimum length of an NBS sortation conveyor is 11'-6". (5' Drive Bed, 1'-6" End Pulley & 5'

Divert Bed)

• All units require 1/2” gap before and after the unit for maintenance access to the end covers.

• Maximum speed for NBS is 425 FPM.

• A VFD is required for all NBS sortation conveyors for speeds at 200 FPM and above.

• All product conveying on an NBS sortation conveyor cannot sag below the surface of the belts.

• The Gearmotors used for NBS drives are all VFD (variable frequency drive) rated.

• The use of a VFD (Variable Frequency Drive) is required for NBS drive motor control. Ignoring

this point will void the belt and motor manufacturer’s warranty.

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WARNING

• NBS 90 Transfer motors must be controlled to run on demand ONLY! Motors running continuously will cause component failure.

Elevation (Top-Of-Belt, TOB)

The minimum TOB to floor elevation at the discharge end of an NBS sortation line is 25". This elevation includes 23-1/2" for the drive unit at the discharge end, and 1-1/2" (minimum) for the NBS Low Elevation Support (LES) used on the drive unit. The length of the drive is based on the overall conveyor length: up to 45’ is a 5′ drive bed, and over 45′ is a 6′ drive bed. Extra room alongside the drive should be provided to allow maintenance personnel access to either side of the drive unit.

Divert Locations

• The leading edge of the first divert module must be a minimum 28" from the charge end of the sorter.

• The trailing edge of the last divert module must be a minimum 70" (5’ DR bed) or 80” (6’ DR bed) from the discharge end.

• The leading edge of a 30° spur mounts 5-1/2" ahead (upstream) of the center line of the second row of wheels on a NBS 30 divert. (Reference drawing)

• The location of a divert lane is centered or slightly downstream of the centerline of the transfer rollers in a NBS 90.

• Set spur height to be level with the 3 approximately 3/8" above the belts, reference drawing.

• One NBS 90 transfer with rollers up to 45" in length can transfer to two or four separate lanes.

• A single-direction transfer to two lanes one side is called a "Dual Transfer"

• A bi-direction transfer to two lanes each side is called a "Quad Transfer"

or 3rd thru last row of wheels on the sorter/divert

Available Drive Selections

• 2 HP @ 120, 150, 180 FPM

• 2 HP @ 200, 220, 250, 300 FPM

• 3 HP @ 180, 200, 220, 250, 300 FPM

• 5 HP @ 250, 300 FPM

• 7.5 HP @ 300, 325, 375, 425 FPM

Sorter Nominal Widths (Number of belts)

• 18" with 4 Belts on 3-1/2" Centers

• 25" with 6 Belts on 3-1/2" Centers

• 32" with 8 Belts on 3-1/2" Centers

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SPUR LOCATION (Both NBS 30 and Wave Divert)

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Correct alignment – product contacts the first spur side divert wheels.

6.2: PRODUCT ALIGNMENT

Products should be edge aligned to cover the first spur side divert wheels or approximately 1” off the spur edge, and should contact the inside first wheel.

Shown is 6” box approximately 1” off edge aligned on an NBS30

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Wrong alignment - missed contact with the first spur side divert wheels.

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WARNING

Chapter 7: NBS INSTALLATION DETAILS

General Procedures

The following procedures are to be used as guidelines only. Specific installation methods will vary somewhat depending on available equipment on site and each installer's preferences based on experience.

Dimensional Reference Points

The path of each conveyor in the system is determined by establishing a reference point at each end. The centerline of the conveyor is established and a chalk line is snapped between these points.

Conveyors should be installed with the centerline of the bed matching the centerline of the conveyor path within 1/8" of true center. Locate and mark the center of the crossmembers at each end of the conveyor. Use a plumb line or other applicable device to ensure accuracy to the chalk line.

Always carry out a thorough check for any obstructions such as building columns, manholes, etc. It may be necessary to reroute the conveyor to avoid the obstruction. In this case it would be advisable to begin installation at this point, using the obstruction as a reference point (Datum), and install the sections in either direction as required.

All conveyor sections must be checked for squareness prior to installation as "racking" or being knocked out of square may have occurred during shipping and handling.

• The Installation Supervisor must be experienced with conveyor and qualified in the mechanics of the equipment and enforce safe working procedures for the protection of the crew, customer, and customer's property.

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WARNING

7.1: GENERAL ELECTRICAL REQUIREMENTS

• All electrical controls must be installed, wired, and connected by a licensed electrician only.

• All motor controls and wiring must conform to the National Electrical

The electrical voltage of the motor will be stamped on the metal nameplate. This voltage should be checked to see that it matches your available voltage. Many motors, both single phase and three phase, are dual voltage. Consult the wiring diagram on the motor for the proper connections. If a three-phase motor on a single direction conveyor runs the wrong direction, two of the three leads must be switched to reverse rotation.

Code as published by the National Fire Protection Association and approved by the American National Standards Institute, Inc. In addition, since specific electrical codes vary from one area to another, be sure to check with the proper authorities before starting the electrical wiring.

• Do not connect the motor to any other voltage than stamped on its metal nameplate.

Consult the wiring diagram on the inside cover of the starter and push-button station for the proper electrical connections.

Three-phase drives require transformers to reduce the push-button and control circuit to 115 volts. If primary voltage is changed, the transformer must be changed according to the wiring diagram found on the transformer.

NOTE:

All control equipment is covered by the original manufacturer's equipment warranty.

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WARNING

NEMA type enclosure ratings are as follows:

NEMA 1 - Indoor use; Provides protection against contact with internal components. Suitable for use

in warehouse and distribution environments.

Gasketed

NEMA 1 - Same use as NEMA 1, but with additional protection against dust and dirt.

NEMA 3 - Outdoor use, designed to keep out rain and dust.

NEMA 4 - Indoor and outdoor use, designed to keep out rain and dust.

NEMA 12 - Indoor use: Provides protection against dust, dirt and oil, and drippings of noncorrosive

liquids suitable for use in industrial environments.

NEMA 13 - Indoor use: Provides protection against dust, dirt, sprayed oil and noncorrosive liquids.

• All safety devices, including wiring of electrical safety devices, shall be arranged to operate in a “fail safe” manner. That is, if power failure or failure of the device itself would occur, a hazardous condition must not result.

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WARNING

7.2: GEAR MOTOR ACTIVATION

PRIOR to systems activation - Please inspect the gear unit for a vent and if applicable to the product remove the rubber sealing plug to activate. The vent is designed to allow excessive pressure to escape. Each gear unit should have a yellow instruction tag as shown below. The tag can be removed after the plug is removed.

Note: The rubber sealing plug is in place for shipping and storage purpose only.

• In order for the gear motor to release pressure, the vent must be activated by removing the rubber sealing plug PRIOR to gear unit start up.

Please check you gear unit for a vent and if applicable to your product, remove the sealing plug to activate. “https://www5.nord.com

” Operation Manual for Gear Units (B1000).

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Sealing Plug

The Yellow Tag may

Sealing Plug

Vent & Sealing Plug

Note: Yellow tags may be tucked out of sight. Please inspect all motors for a vent and remove sealing plug, if present, to activate.

The following pictures are examples showing where vent plugs may be located depending on the product line and motor position.

be hidden or possibly

missing. Check motor for a vent and remove sealing plug to activate.

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may be hard to see

depending on the product line and motor location.

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CAUTION

7.3: ELEVATIONS

All top-of-belt (TOB) heights should be installed in accordance with the elevations shown on the drawings. In addition, all sortation devices must be level across both the frame width and length. Leveling of the frames is best done using a rotating laser level along the length of the conveyor and a builder's level across the width.

After the first elevation is established at a critical point, the elevation of all other points shall be relative to this first point. Normal practice is to dimension the layout and measure elevations from the floor at each point of support.

As the conveyor system proceeds onto another floor or into another building or room, a new elevation will be measured from the floor at that point. This new elevation will then become the reference for subsequent elevations.

When installing an overhead system, the first elevation is measured from the floor and becomes the reference elevation point until a change in elevation is shown on the layout. Any new elevation is also measured from the floor and becomes the new reference point. The process is repeated each time an elevation change occurs.

• Consult the building architect or a structural engineer regarding ceiling loading or structural limitations of the building if any conveyor is ceiling hung.

Component Orientation

Using your conveyor system layout drawing and the numbers on the I.D. tags on each component, position and orients the conveyor sections. You must know:

• The direction of product flow

• The elevation height

• The drive is positioned at the discharge end

• The end pulley is positioned at the charge end

IMPORTANT!

Do not make alterations to the equipment without consulting with user's representative and TGW Systems. Unauthorized modifications to the equipment may impair its function, create a hazardous condition, affect its useful life, and/or void the warranty.

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7.3.1: Straight and Level

Sorters must be installed straight and level.

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Discharge end product flow

Discharge end drive bed with product flow

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WARNING

7.4: SUPPORTING ARRANGEMENT

Floor Supports

Install bolts used to attach the standhead to the frame so the nut is on the bottom. Standhead bolts should be left finger tight while the conveyor is being assembled and aligned.

Floor supports are ordered by nominal height range, which is the dimension from the floor to top of the support. Conveyor elevations are shown on the layout by top-of-belt elevations. The difference between top of belt (TOB) and top of support is 7-5/8". This dimension must be subtracted from the TOB height to set support height.

It is important that conveyor frames be installed level. Floor supports will accommodate normal irregularities in the floor surface. Adjustment for elevation in floor supports is accomplished with metalon-metal bolt clamping force. To achieve the support's stated load rating, it is necessary to tighten the elevation adjustment bolts (3/8" diameter) to 23 ft. /lbs. of torque.

Supports should always be installed in the vertical position, and any variations due to conveyor pitch or floor slope will be compensated for in the pivoting stand-head of the support.

7.5: SUPPORTS & CONNECTIONS

Roll Formed (RF) supports replace all existing TGW conveyor floor supports.

For details on Supports & Connections see Support & Connections IOM (#1200485) at

https://www.tgw-conveyor.com/support/iom-manuals/supports-and-connections

7.6: ANCHORING

Anchoring in concrete floors is accomplished by drilling into the floor and inserting the suitable anchor bolt. The hole diameter and depth must be in accordance with the anchor bolt manufacturer's instructions.

Anchor intermediate floor supports with two anchor bolts, one through each support footplate using at a minimum 3/8" diameter anchor bolts. For floor supports over 5' high or when supporting drives, use 1/2" diameter anchor bolts.

Stagger anchors from front hole on one side of the support, to rear hole on opposite side. Anchor bolts for equipment subject to impact loads should be a minimum of 1/2" in diameter.

• Place a bolt through the frame and support immediately with finger tight nut. This will prevent the frame from falling off the support, if bumped, and causing injury.

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7.7: BED/SUPPORT CONNECTORS

NBS can ONLY be supported at bed joints. Install the sortation conveyor (drive bed thru end pulley) on supports. Leave approximately 1/16″ gap between low friction rail joints. The conveyor must be level and straight. Adjoining beds are connected using 3/8″ thick by 10″ nut plate, 3/16″ thick by 10″ clamping plate and 3/8″ hardware. These parts are shipped with other loose parts. Insert 10″ nut plate halfway into the formed channel end of each bed.

Mount standhead support with two 3/8-16 x 1″ hex head bolts with flat and lock washers. After that mount 10″ clamp plate to channel ends with four 3/8-16 x 1″ hex head bolts with nut, flat and lock washers (see picture below). It can be seen that a crossmember could be moved into the recessed area of the standhead support bracket if needed.

Maintaining the rigidity and flatness of the conveying surface is the end result of proper support installation.

Low Friction Rail Overlapping Splice Connection Kit#1108930

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M5 Hex head bolt

M5 Nylon locking nut ½” dia. Connecting spacer P/N# 1109054

7.8: INSTALL LOW FRICTION RAIL CONNECTORS

Install low friction rail connectors at all rail joints. Each low friction rail connection consists of a M5 hex head bolt, a M5 nylon locking nut, and a ½″ dia. connecting spacer. These parts are bagged with the quantity required for each bed, and shipped with other loose parts.

P/N# 1101993

P/N# 1101984

7.9: RAILING ALIGNMENT PROCEDURE

Install rail connector by placing the connector between the offset rails at the joint. Slide mounting screw thru rails and spacer and place nut on the other end. Do not tighten connector hardware at this time.

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CAUTION

Installation of the connecting spacers requires an alignment tool (TGW Kit part no.1113691). The tool is used to ensure a smooth straight transition from bed to bed with each job and should be shipped with the loose parts for the end pulley assembly.

Place top plate of rail alignment tool between guide covering bearings at the joint. Slide the bottom nut plate under the low friction rail with the nuts facing down. Thread (2) 3/8-16 x 2″ hex head screws thru top plate and into the bottom nut plate and snug hardware to clamp plates to rail.

• Do not over tighten clamp plates to the rails as this may crush and permanently damage the rails.

The rail assemblies are built with a 1″ offset and are mounted flush to the charge end of the bed. The offset extends beyond the discharge end of the bed allowing an overlap with the up stream bed. There should be approximately a 1/16″ gap between the low friction rails at the joints. Tighten M5 hardware for rail connector. After connector hardware is snug, remove alignment tool and repeat process for each rail joint.

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The low friction rail belt guides are installed at the factory with clamping plates which hold them down to the top surface of their mounting crossmembers. These crossmembers have a built in locating feature for ensuring the correct placement of the across the width of the conveyor.

A splice kit consisting of spacers and M5 hardware is provided with each bed and it is used to connect the rails at the overlap. A 9/16″ socket wrench, 8mm socket wrench, and an 8mm box wrench are recommended for this installation.

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CAUTION

7.10: CEILING SUPPORTED NBS CONVEYORS

The NBS conveyor is designed to ALWAYS be supported at the bed joints. For ceiling hanging applications, an NBS ceiling hanger kit MUST be used at the bed joints as shown in the diagrams below. The end pulley and drive beds show connection locations for the specific ceiling hanger kit designed for those locations. Along with the ceiling hangers, cross bracing is required for all hangers. This ceiling hanging method provides the lateral conveyor rigidity.

Deviation from this ceiling hanging requirement will void the warranty of the NBS sorter.

• Deviation from this ceiling hanging requirement will void the warranty of the NBS sorter.

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WARNING

Ceiling hanger diagrams are a guide to establish a final support design.

Consult structural engineer for actual application.

• Consult structural engineer for actual application.

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PLEXIGLASS COVER

BELT THREADING LABEL BELT TRACK

COVER

7.11: NBS BELT INSTALLATION

Pre-Installation

Belts, as shipped from TGW Systems, are cut to length with lacing installed. Rolls of belting should be stored laying on the edge on a pallet. Never leave a belt where it may absorb moisture. Remove any tight shipping banding immediately upon arrival. Lacing pins are taped inside the lacing on each belt.

The NBS conveyor should be completely installed and aligned before belt installation.

Remove the plexiglass side covers from the sides of the drive frame, exposing the take-up pulleys. Switch the take-up air switch to the un-tensioned position, raising the take-up pulleys on the 5′ drive bed and retracting the take-up pulleys on the 6′ drive bed to the minimum take-up position. Replace all covers and guards.

Then remove the covers between the belt tracks so that the belt guides are exposed. Do the same for each NBS 30 diverter.

Remove the O-rings from the O-ring driven gap roller.

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GAP ROLLER

7.11.1: Belt Threading Instructions

Because NBS uses multiple narrow belts of long length, it will be most efficient to have two people working together during the threading process.

The belting must be uncoiled and laid out flat on the sorter, with the smooth red urethane surface down contacting the bearing assemblies on the rails. The belts must not be allowed to twist along their length as they are installed.

BELT ORIENTATION MARK (Smooth Side Down)

Start at the charge end (farthest from the drive) and feed all of the belts through together at the same time. Start the belts down between the gap roller and the end pulley. Guide the belts under the 5" diameter end pulley and up and over the 2.5" diameter snub roller, before passing through the crossmember mounted belt guides.

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RETURN ROLLER

CROSS MEMBER BELT GUIDE

DIVERT WHEELS

UNDER THESE ROLLERS

All belts must pass over return rollers positioned not more than 9′ apart to minimize belt sag and through holes in crossmembers.

NBS 30 diverts use the moving narrow belts to drive the pop-up divert wheels. The narrow belts must pass over the first

2.5″ dia. roller in the diverter, under the next three, five or six rollers, depending on the number of rows in the diverter, which

power the divert wheels over the last 2.5″

dia. roller and then between the belt guides, as they exit the diverter.

NBS 90 transfer rollers fit up between the narrow belts.

Thread the belts through the drive unit using the diagram on the side of the unit as a guide. The red urethane surface of the belt should be down contacting the drive pulley and bearings in the rails.

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Mesh the loops of the lacing on one end of the belt with the loops on the other, so the sides of the belt are even, and install the lacing pin.

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NBS Encoder Assembly at Charge End of Sorter

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Snubber Roller

Tracking Plate

Drive Pulley Tracking

7.11.2: Belt Tracking

Prior to belt tracking, all guards, plates, and bottom pans must be re-installed. With the guards in place, switch the take-up air switch to the tensioned position, moving the take-up pulleys to tension the belts. At this time you can "bump" the motor to be sure rotation is correct, the belts are running smoothly and maintaining their position.

Most NBS conveyors do not require belt tracking. However, each conveyor should be checked at the charge and discharge ends to be sure the belts are floating in a neutral position not crowding the sides of the low friction rail guide tracks.

If the belts are out of their grooves or riding hard to one side adjustment can be made on the driven pulley jackscrew after loosening the four bolts holding the drive pulley 1-7/16″ bearing at the discharge end. The snubber roller in the end pulley assembly is used to track the belts at the charge end.

After running for a few hours inspect rail joints for belt wear at these points. All beds come from the factory with the ends of the rails pre-flared, but if belt dust occurs at the joints, additional flaring the rails outwards may be necessary.

To do this simply clamp pliers to the guide portion of the rail on the end and twist outward away from the belt. A slight amount of flare is all that should be necessary to prevent belt wear at the joints.

Once the belt is tracking properly verify that all of the bottom pans, guards and access covers on the drive bed, end pulley, and all diverts have been reinstalled.

Flared Rail Ends (Outwards)

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CAUTION

7.11.3: Belt Specifications and Lacing

Belting:

Endurethane 150 2-ply

Width: 1-1/4" +0/-1/16"

Thickness: .203" +/- .015 with a hidden lace

Lace: Clipper U3RTS w/#2 point

Lacing pin: DSS093 (Dura Stainless Steel) x 1-1/8" +/- 1/32" long .093 “WHITE DURA PIN COATING” .048 304 stainless steel core

• Only use the specified lacing and pin. Any substitution will result in premature belt failure.

For field repair, lacing can be done without hidden lace without damage to the unit. Belts without hidden lace may make additional noise as the lace passes thru snubbed areas. See diagram below. Belts must have six (6) hooks on one side and seven (7) hooks on the other for maximum strength.

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7.11.4: Belt Lacing Information

Belt Replacement Lengths

Replacement belts may be ordered by the original part number marked on the belt or belt length. The item belt length can be determined by the following information.

• The 5' drive bed requires, 10'-8" (128")

• The 6’ drive bed requires, 16’0” (192”)

• The 18" end pulley bed, 3'-0" (36")

• NBS 30 diverters require, 3/8" each

• NBS 30 WAVE diverters require, 3/8" each

• NBS 90 SL transfers require, 3/8" each

• Auxiliary take-up requires, 1'4" (16")

• All other beds require 2 times their length.

Nominal Widths (Number of Belts)

• 18" with 4 Belts on 3-1/2" Centers

• 25" with 6 Belts on 3-1/2" Centers

• 32" with 8 Belts on 3-1/2" Centers

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CAUTION

7.12: NBS PNEUMATIC GENERAL GUIDELINES

Every conveyor system is unique, with its own specific requirements. Therefore, the following is a general guide.

Main Feeder

Air velocity through the main feeder piping can be kept smooth with lower losses using large diameter pipe with minimum bends and restrictions. Standard weight black pipe or copper is suitable for plumbing the compressed air overhead to all points of use.

Air Drops (NBS30-3R, NBS30-5R, and NBS90, and NBS90-SL)

TGW Systems recommends using 3/4" pipe on air drops for high flow and low pressure loss. The drop is terminated with a drain at the bottom. A tee located prior to the drain branches off to the conveyor. This branch line must contain a lockout/shutoff. A shutoff must also be located in the drop before the branch tee. OSHA Rule 29, CFR1910.147 requires energy sources (air drops) be turned off and capable of being locked or labeled with a warning tag.

Air Drops (NBS30 WAVE, and NBS30 Aligner)

The NBS WAVE and aligner require higher air capacity than the NBS30 or NBS90 divert. As six rows of divert wheels must fire within a fraction of a second, the “burst” air capacity must be adequate or sluggish and inconsistent divert action will result. TGW Systems recommends the following minimum air plumbing for the WAVE divert and aligner.

A 1″ air drop and ¾″ black pipe or copper header for every 5 WAVE diverts. 3/8″ polyethylene tubing and be plumbed to each divert from the ¾″ header provided the length doesn’t exceed 5′. Do not plumb more than one divert with 3/8″ poly tube.

A 1″ air drop and ¾″ black pipe or copper header for each pre-aligner. 3/8″ polyethylene tubing can be run from the ¾″ header to each solenoid bank on the pre-aligner. The length of the poly tube must not exceed 5′.

TGW Systems can provide a standard ¾″ filter regulator for each drop. The part number is 1103388.

NOTE: The NBS pneumatic system does not require lubrication. Lubrication may affect valve action and cause sluggish or erratic operation.

IMPORTANT! If your air compressor uses synthetic oil, a coalescing filter plus a regular filter of 5 micron is required. Synthetic oils will shrink the seals in pneumatic devices and valves.

• All airlines must be thoroughly blown out (of all debris) and the regulator must be set as required before connecting air to the NBS.

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CAUTION

• NBS 30 WAVE™ diverters must not be operated above 55 PSI. Exceeding this may damage unit.

Air Supply Requirements NBS30-3R, NBS30-5R, NBS90

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Air Supply Requirements NBS90-SL

Air Supply Requirements NBS30 WAVE, NBS30 ALIGNER

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Pneumatic Pressure Requirements

• Maximum conveyor length each way from regulator is 80'.

• Locate regulator in center of conveyor, if possible, for maximum efficiency.

• Overhead feeder line pressure to be 100 PSI minimum.

• Low pressure switch should be set at 10 PSI below the operating air pressure for the specific

device noted below.

• In high humidity or low temperature, use air dryer.

• Use 5 micron filter.

• Lockout/shutoff valve to be provided by air system installer.

Regulators pressure set to unit requirements:

• 5’ drive with air take-up 50-55 PSI

• 6’ drive with air take-up 80-85 PSI (Requires separate shop air drop)

• 30º 3 row /5 row sorter 50-55 PSI

• 30º WAVE sorter/aligner 40-45 PSI

• 90º transfer 50-55 PSI

• 90° SL transfer 40-45 PSI

Pneumatic Volume Formulas

NBS 30 3-Row Diverters are actuated by a single air bag.