Modular Transfer Systems TSplus Lift-Transfer Unit Model EQ2/U3 Installation and Maintenance Publication Number: 8981 500 299 7/02 Lift-Transfer Unit
Table of contents IMPORTANT SAFETY INFORMATION .................. 3 For Lift And Lower Operation.................................. 14 Safety First ................................................................. 3 For Lift Only Operation ............................................. 14 Material Hazards: ...................................................... 3 Stop Rail Orientation ................................................. 16 Review All Safety Information: ...............................
IMPORTANT SAFETY INFORMATION IMPORTANT: This operation and installation manual should be reviewed with all equipment operators as part of your operator training program. SAFETY FIRST! Important safety information is contained throughout this manual to alert you to potentially dangerous situations and help prevent accidental injury and property damage.
IMPORTANT SAFETY INFORMATION WARNING! Please read all assembly, and maintenance instructions carefully before beginning set-up of the components in this document. Where appropriate, warning symbols have been included in this publication to alert you of potential or impending danger. • Be sure to read and observe all safety warnings in this document as well as those attached to the individual modules. Failure to do so could result in potential risks to your health and safety as well as those around you.
Introduction Like all Bosch flexible assembly systems, TSplus is constructed solely from standardized modules that are precisely matched to each other. One important benefit of this modular design is that you can interlink manual and automatic work stations freely, making TSplus suitable for virtually any assembly task. The EQ2/U3 Lift Transfer Unit (LTU) module allows you to transfer pallets laterally off of the main conveyor line.
Design and Detailed Description The EQ2/U3 includes a drive motor to power the toothed belts, two spring centered 3-position pneumatic cylinders, stop bar/guide bar, protective covers, pneumatic connections and mounting hardware. A proximity switch mounting bracket is also included. Due to the stroke, all three positions may not be sensed, as three proximity switches will not fit into the space available.
Application and Function The EQ2/U3 Lift Transfer Unit (LTU) is used to transfer pallets perpendicularly off the conveyer. It is used primarily at “corners” and “intersections”, but can also be used for pallet routing changes. “Corner Transfer” requires LTU operation in the “Pallet Stop” and “Transfer” positions as shown. Optional Cushioned “Intersection Transfer” requires LTU operaStop tions in the “Pallet Stop”, “Transfer” and “Clear” positions as shown.
Operation (Fig. 2) Pallet transfer from one parallel line to an adjacent line requires the use of a sending EQ2/U3 and a receiving EQ2/U3 located at each end of a set of track rollers or a transverse conveyor. The sending LTU waits in “Pallet Stop” mode below the transport surface level until a pallet passes over the LTU and is stopped by the stop rail or a cushioned stop triggering a proximity sensor that activates the LTU.
Attach LTU to Conveyor Section (Fig. 4 and 5) 1 Mark the location on the conveyor line where the LTU is to be installed. conveyor section profile SP/2. Hand tighten the M8 flange nut. 6 Attach supporting bar to mounting brackets using hardware previously removed. 2 Remove middle guard cover. 3 Remove mounting brackets (2 per side) from supporting bar on LTU and install in T-slot on conveyor section profiles. 4 Lower EQ2/U3 from above onto conveyor section profiles and set down on the four brackets.
Installing Proximity Switch (Fig. 6) 1 Install the proximity switch in the mounting bracket so that the sensing distance is approximately 2 mm (see inset). NOTE: Due to the stroke, all three positions can not be sensed, as three proximity switches will not fit into the space available. It is recommended that the center “Pallet Stop” position be sensed and the signal lost on the up and down stroke. Proximity Switch Exciter Proximity Switch Mounting Bracket 2 mm Proximity Switch Fig.
Checking and Adjusting Toothed Belt Tension NOTE: Incorrect toothed belt tension can lead to premature belt failure! Always check toothed belt tension prior to initial operation! Using a moderate amount of pressure, press upward on the belt for a deflection of approximately 10 mm (see inset 2) . To re-tension the toothed belt, loosen the 5 mm socket head cap screw on the return roller (see inset 1).
Initial Start-up For CE applications, refer to the next page for instructions on installing and connecting the terminal block. Before starting up the Lift Transfer Unit for the first time, recheck all mounting hardware for tightness. Delta Connection (Low Voltage) L2 (Blk/Yel)T4 T2 (Blu) NOTE: The customer assumes responsibility for the control system, and must provide an EMERGENCYOFF SWITCH in the EQ2/U3.
For CE Applications If a CE compliant module was ordered, an optional terminal block (Fig. 9) was included. Refer to the terminal box mounting instructions included with the terminal box. Blue #4-40 Screw Orange #4-40 Screw Terminal Block Assembly Instructions 1. Attach the terminal box to the motor according to the mounting instructions included with the terminal box. See Fig. 9.
Connect the Compressed Air Supply (Fig.s 10, 11, and 12) NOTE: Use a 5/3 way open center position control valve (not included) to direct airflow to the module. A 2-way valve will not work because the center position is lost and the upward flow cannot be controlled. The EQ2/U3 Tandem Lift Transfer Unit must be supplied with a filtered, regulated compressed air supply of 4–6 bar (58–87 psi). The customer must provide any necessary air preparation equipment.
BWT=480 mm For Lift Only Operation Remove Quick Connect Fitting In Flow Control “C” And Install a Muffler. Quick Connect Fitting Quick Connect Fitting Flow Muffler Control C C B A Flow Control A 8 mm Push Type Fitting Flow Control B Fig. 11 BWT=640 mm For Lift Only Operation Remove Quick Connect Fitting In Flow Control “C” And Install a Muffler. Quick Connect Fitting C B A Quick Connect Fitting Flow Control C Muffler Flow Control A Flow Control B Fig.
Stop Rail Orientation (see Fig. 13) As delivered LTU stop rails are positioned so a pallet will not stop on the LTU when it is in the centered or home position. If your application requires, either stop rail can be repositioned to stop a pallet entering the LTU prior to lift and transfer. When total pallet payload exceeds 30 kg or 12 m/min you must use a cushioned stop to halt pallet travel. 1.
Installing Optional Cushioned Stop BWT = 480 and smaller (Fig. 15) Stop Tab 1. On side you are mounting the stop, position both stop blocks with the stop tab up. Cushioned Stop 2. Install stop bracket onto side of roller carrier as shown using the screws, lockwasher and hex nut included with cushioned stop. See Fig. 15. Stop Bracket Guard Plate 3. Attach guard plate to bottom of stop bracket as shown. 4. Mount cushioned stop to stop bracket with mounting hardware shown. 5.
Operating Instructions The TSplus conveyor is designed to transport Bosch WT2 workpiece pallets or WT2 workpiece pallet frames with integrated fixtures built into the pallet design. Since the conveyor is modular in design and part of a larger operating assembly system, it is the WARNING! • Use a qualified technician who is familiar with the control system during the initial start-up.
Maintenance WARNING! LOCK OUT all power supplies and release pressure from compressed air lines before beginning maintenance work of any type. The gearbox and motor used in the TSplus conveyor are maintenance-free. The following cleaning and adjustment procedures, however, will help keep your conveyor in almost new condition if performed on a regular basis. 1 Remove all dirt & grease.
Repair Replacing the Toothed Belt (Fig. 17 and 18) WARNING! LOCK OUT all power supplies and release pressure from compressed air lines before beginning maintenance work of any type. Toothed belts can be changed while the unit is installed! Always replace toothed belts in pairs to maintain smooth pallet flow. Always use genuine Bosch replacement belts only. 3 Remove faulty toothed belt. 4 Apply a thin coat of No. 10 machine oil to the new toothed belts.
BWT=480 mm Weld A P LL E T F W LO Apply Light Weight Machine Oil Stop Plate Toothed Belt Weld Stop Plate Fig. 17 BWT=640 mm Weld T E LL A P F W LO Apply Light Weight Machine Oil Toothed Belt Weld Stop Plate Fig.
Replacing Gear Box (Fig. 19) WARNING! LOCK OUT all power supplies and release pressure from compressed air lines before beginning maintenance work of any type. 1 Remove protective case (not shown). 2 Relax tension on toothed belt and move belt out of way. (See page 11) 3 Remove the C-clip from the hex shaft on the inside of the bearing block. NOTE: The Hex shaft subassembly is shown with the parts exploded for clarity in Fig. 19.
Replacing Motor (Fig. 20) 1 Remove protective case (not shown) 2 Be sure electric power supply is locked out and disconnect motor wiring. 3 Remove motor mounting bolts and lower motor from gearbox. 4 Apply anti-seize compound to new motor shaft and attach new motor to gearbox with the hardware you removed earlier. 5 Reconnect electrical wiring. CAUTION! Check motor for correct rotation before putting conveyor system back into operation.
Application Notes:
Installation of Protective Covers The protective cover assembly for the lift transfer unit with bottom mounted motor/gearbox is shown in Fig. 21. Note the orientation of the assembly. The cutout in sheet 1 is a clearance hole for the motor and must be oriented properly. 3 Side aluminum cover sheet Scope of Delivery: 6 Corner Bracket, RH (Qty. 2) 1 Bottom aluminum cover sheet with motor clearance hole 7 M6x20 Cap screw, lock washer, flat washer, M6x10mm T-nut (Qty.
Step by Step Assembly Instructions (Fig. 22) Note: All of the corner rail profiles (8 and 9) must be installed with the longer side on the bottom as shown in the inset. Make sure any protective film is removed from the aluminum sheets prior to assembly. Assembly hint: The four corner brackets hold the cover assembly firmly together, and the aluminum sheets fit snugly into them.
10 3 INSET 2a or 2c 1 8 8 2 3 1 4 8 2 2a 10 7 5 2 7 8 Flat Washer 9 3 Motor Clearance Hole 1 Alignment Nub 6 4 7 8 6 2 Flat Washer Lockwasher 9 7 M6 x 20 SHCS Fig.
Module Warranty BOSCH AUTOMATION PRODUCTS warrants to the original purchaser the modules manufactured by us to be free from defects in materials and workmanship under normal use and service. Our obligation under this warranty shall be limited to the repair or exchange of any part or parts which may thus prove defective under normal use and service within one (1) year from date of installation by the original purchaser.
