Bastian Solutions RLVAC Manuel

Installation and Maintenance Manual

Model: RLVAC

Effective February 2022

Rev. B

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

Contributions

ROLE

NAME

TITLE

Author

Ben Baker

Senior Design Engineer

Checker

Brad Paris

Senior Design Engineer

Approver

Sam Osterhout

Design Team Lead

Revisions

DATE

REVISION

DESCRIPTION

AUTHOR

11/18/2021

Initial Document Creation

Ben Baker

2/18/2022

Document Formatting Edits

Andrew W. Jones

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

Term and Acronym Definitions

TERM/ACRONYM DEFINITION

2 Groove

Roller format which uses O-Rings to transfer rotational motion from one roller to

another in DC conveyor.

Alternating current

Accumulation

The collection or staging of multiple cartons, cases, or totes of product on conveyor.

ATO

Assembled to Order; Orders consisting of standard products

Back pressure

Pressure against carton(s) in the direction of carton flow resulting from weight of

densely accumulated cartons.

Between frame; this refers to the distance between conveyor bed side frames.

BHCS

Button head cap screw

BOM

Bill of Materials

Carton or Case

Term for a conveyable item (cardboard box, tote, etc.)

Carriage bolt

CCW

Counter-clockwise

CDAC 1.0

Conveyor Director Control Card 1.0 - Bastian Solutions' dual zone control card designed

for zero pressure control of low-voltage (24V nominal) DC solenoids for belt-under

roller conveyor.

CDDC 1.0

Conveyor Director Control Card 1.0 - Bastian Solutions' dual zone control card designed

for zero pressure control of low-voltage (24V or 48V nominal) DC powered MDRs.

Center Drive

Drive format of AC conveyor where the drive unit is mounted underneath the

conveyor.

Clockwise

Direct current

Diffuse

A photoeye format that houses both the emitter and receiver and senses an object

when the light beam is reflected back to the sensor. This type of photoeye is a

standalone unit and does not use reflectors.

Discharge

The point where cartons, cases, or totes exit a conveyor or similar unit used in a

material handling system.

Divert

(noun) A conveyor unit used to change the direction of a carton, case, or tote in a

controlled manner. (verb) To change the direction of a carton, case, or tote in a

controlled manner.

Double-dispense

Event in which two or more cartons are dispensed when a single carton, case, or tote is

requested. This is generally a result of two cartons, cases, or totes being in full contact

just prior to reaching the dispensing point.

Drive Card

A control card used to power and control the logic of one or more zones of zero

pressure conveyor.

Drive Pulley

A motor-driven pulley used to transmit rotational energy to linear motion in AC belts.

Dutchman

A short, removable section of belt used to take up slack developed in AC belts after

they have stretched from long term use.

End stop

A plate mounted to the end of a conveyor with the intent of stopping and holding a

carton, case, or tote in position until removed by a user or diverted by a conveyor unit.

E-stop

A highly visible button or pull cable designed to shut down equipment in the case of an

emergency.

ETO

Engineered to Order; Orders requiring custom Engineering

FAT

Factory Acceptance Testing

Flange

A feature in sheet metal consisting of a face and bend connected to an existing face

along a straight edge.

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

Flash

Excess material left on a part by a molding or forming process, created by material

leaking between the separate parts of the mold.

Gapping

The separation of cartons, cases, or totes. Generally done by progressively increasing

the speed of consecutive zones or belts, forcing cartons, cases, or totes to "pull a gap."

Guide Rail

Mechanism used to maintain the desired position of conveyable cartons, cases, or

totes on their respective conveying surface.

HHCS

Hex head cap screw

Inner diameter of a circular, cylindrical or arced body.

Idler Roller

Conveyor roller that is unpowered and used to support a belt.

Infeed

The point where cartons, cases, or totes enter a conveyor or similar unit used in a

material handling system.

Live

A conveyor or zone which runs in response to a simple “enable” signal or runs

whenever power is applied, without any zero pressure accumulation logic.

LOTO Lockout Tagout

Mark Number

A numeric or alphanumeric term used to uniquely identify a conveyor bed or collection

of beds (of similar model type) within a material handling system.

Match

A mark made on mating conveyor assemblies to assist in identifying orientation and

placement within a system.

MDR

Motorized drive roller; DC powered conveyor roller with an internally mounted motor

which may be controlled via internal or external commutation.

Minimum Pressure

Allows cartons, cases, or totes to lightly touch with up to 2% back pressure while being

conveyed to eliminate product damage.

OAW

Overall width of any given conveyor bed, measured between the outside flanges of the

sideframes.

Outer diameter of a circular, cylindrical, or arced body.

O-Ring

A urethane ring or band with a circular cross section used for power transmission in DC

conveyor applications.

OSHA

Occupational Safety and Health Administration

Photoeye; Device used to detect the presence of an object by sensing a light beam.

Common types are diffuse, retroreflective, and through-beam.

PELV

Protected Extra Low Voltage, a voltage level (less than 60V DC or 25Vrms AC in the

context of EN 60204-1) that is low enough to be safe in the case of indirect or small

area direct contact. PELV circuits are required to be connected to earth ground.

Project Management (or Project Manager)

Purchase Order

Polytier

Heavy duty floor support with a wide stance, capable of supporting multiple levels and

types of conveyor.

PPE

Personal protective equipment

Prox Sensor

A sensor able to detect the presence of nearby objects without any physical contact.

Pulley

Mechanical device used to change the direction of the belt in a conveyor system, to

drive and/or tension the belt.

Reflector

A reflective component needed for retroreflective photoeyes to receive transmitted

light or radiation when no object is in front of the photoeye.

Retroreflective

Of or relating to a surface or device that reflects light or other radiation back to its

source.

Return Idlers

Belt-routing rollers on the underside of any given AC conveyor.

RLCAC

Roller Live Curve AC

RLSAC

Roller Live Spur AC

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

Roller

Powered or unpowered cylindrically-shaped material handling component used for

mechanical power transmission, a conveying surface, and/or support for a belted

conveying surface.

Shingling

Event in which surfaces of adjacent cartons, cases, or totes are forced to lift off the

conveyor due to elevated uneven carton, case, or tote back pressure.

Side Frame

Structural member used to support rotating components needed for conveyor beds.

Singulation

The active separation of cartons, cases, or totes.

Skatewheel

Small unpowered wheels used to replicate nearly frictionless guidance or support of

conveyable cartons, cases, or totes.

Skew

A format of conveyor where one end of all rollers are shifted to provide an angled

conveying surface for left or right justification of cartons, cases, or totes.

SKU

Stock Keeping Unit; Product and service identification code for a product (i.e. bar

code).

Slug Release

See Train Release.

Snub Roller

A roller or pulley mounted to increase the arc of contact between a belt and drive

pulley. Additionally, this can be used to change the direction of the return belt travel.

Splice Assembly

A five-component assembly-consisting of a plate (or formed plate), two bolts, and two

nuts-that is used to secure a piece of guide rail to an adjacent piece of guide rail, or a

side frame to an adjacent side frame. This is used to provide additional structural

rigidity and ensure relative position of components is maintained.

Spur

A format of DC conveyor used to create linear transitions into intersecting lines of

conveyor positioned at a non-perpendicular angle. Typically includes 30deg and 22deg

configurations.

Tail Pulley

A non-driven pulley located at the tail end of the conveyor.

Takeup Pulley

Pulley with an adjustable position used to eliminate unnecessary slack in a belt.

Takeup Screws

Adjustment screw used to adjust the position of a takeup pulley.

TOR

Top of roller; this refers to the elevation of the conveying surface with respect to the

floor on which the conveyor is sitting.

Track

To adjust the position of conveyor components in such a way that engourages proper

belt alignment on a system.

Tracking Bands

Thin plastic bands installed on head or secondary drive roller to help keep DC format

conveyor belts tracked.

Train Release

The release or activation of all zones in a line of accumulating conveyor at the same

time.

UHMW

Ultra-high molecular weight polyethylene plastic, used to reduce friction and wear.

Waterfall

Method of overlapping guide rail such that cartons, cases, or totes cannot catch on

downstream guide rail.

Wiz Nut

A serrated flange nut used to cut into the surface of the component it is tightened

against.

Zero Pressure

Condition where adjacent cartons, cases, or totes are not in contact with one another.

Zone

A section of conveyor that can be independently controlled for the purposes of zero

pressure accumulation.

ZPA

Zero Pressure Accumulation; a method of collecting, staging, and/or transporting

multiple cartons, cases, or totes on zoned conveyor without the products touching

each other.

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

Table of Contents

1Introduction........................................................................................................... 10

2OSHA and Safety .................................................................................................. 10

3Model: RLVAC....................................................................................................... 11

3.1 Overview ...............................................................................................................................11

3.2 Belt........................................................................................................................................11

3.3 Drive Section ........................................................................................................................11

3.4 Tails ......................................................................................................................................13

3.5 Intermediate Beds ................................................................................................................13

3.6 Skew Beds............................................................................................................................ 14

4Receiving............................................................................................................... 15

4.1 Mark Numbers ...................................................................................................................... 15

4.2 Skid Contents.......................................................................................................................15

4.3 Skid Documentation............................................................................................................. 16

5Installation............................................................................................................. 17

5.1 Layout................................................................................................................................... 17

5.2 Setting the Conveyor ...........................................................................................................17

5.3 Pressure Assembly Installation........................................................................................... 18

5.4 Leveling and Straightening.................................................................................................. 19

5.5 Installing the Belt .................................................................................................................20

5.5.1 Belt Routing: Screw Takeup Drive ...................................................................................... 21

5.5.2 Belt Routing: Pneumatic Takeup Drive................................................................................ 23

5.5.3 Belt Routing: Skewed Beds ................................................................................................24

5.5.4 Belt Hot Splicing ................................................................................................................. 25

5.6 Installing Return Rollers ......................................................................................................30

5.7 Belt Tracking Zones ............................................................................................................. 31

5.8 Drive Pressure Adjustment.................................................................................................. 34

5.9 Power Take-Off..................................................................................................................... 35

5.10 Electrical Installation............................................................................................................35

5.10.1 AC Motor Installation ..........................................................................................................35

5.11 Accessories.......................................................................................................................... 36

5.12 Belt Tensioning and Tracking.............................................................................................. 36

5.12.1 Screw Takeup Drives .........................................................................................................36

5.12.2 Pneumatic Takeup Drives................................................................................................... 38

5.12.3 Belt Tracking Principles ......................................................................................................39

6Maintenance and Operation................................................................................. 42

6.1 Safety During Operation ...................................................................................................... 42

6.2 Maintenance Schedule......................................................................................................... 42

6.3 Fastener Torque ................................................................................................................... 44

6.4 Belt Replacement .................................................................................................................44

6.5 Screw Takeup Drive ............................................................................................................. 45

6.5.1 Drive Motor Replacement ...................................................................................................45

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

6.5.2 Drive Pulley Replacement................................................................................................... 46

6.5.3 Takeup Pulley Replacement ............................................................................................... 47

6.5.4 Takeup Spring or Guide Tube Replacement ....................................................................... 47

6.5.5 Idler Roller Replacement .................................................................................................... 48

6.5.6 Bearing Replacement and Maintenance ............................................................................. 48

6.6 Pneumatic Takeup Drive...................................................................................................... 48

6.6.1 Drive Motor Replacement ...................................................................................................48

6.6.2 Drive Pulley Replacement................................................................................................... 49

6.6.3 Takeup Pulley Replacement ............................................................................................... 50

6.6.4 Takeup Chain and Sprocket Replacement and Maintenance .............................................. 51

6.6.5 Idler Roller Replacement .................................................................................................... 52

6.6.6 Bearing Replacement and Maintenance ............................................................................. 52

6.6.7 Air Cylinder Replacement ................................................................................................... 53

6.6.8 Air Regulator Replacement and Maintenance ..................................................................... 53

6.7 Tail ........................................................................................................................................54

6.7.1 Tail Pulley Replacement ..................................................................................................... 54

6.7.2 Tail Snub Replacement ......................................................................................................54

6.7.3 Bearing Replacement and Maintenance ............................................................................. 55

6.7.4 Roller Replacement ............................................................................................................55

6.7.5 Band Replacement .............................................................................................................55

6.8 Modules ................................................................................................................................55

6.8.1 Bed Roller Replacement.....................................................................................................56

6.8.2 Pressure Roller Replacement .............................................................................................56

6.8.3 Pressure Spring Replacement ............................................................................................ 56

6.8.4 Guide Bushing Replacement .............................................................................................. 56

6.9 Skew Beds............................................................................................................................ 57

6.9.1 Skew Roller and Band Replacement................................................................................... 57

6.9.2 Routing Roller Replacement ...............................................................................................57

6.10 Accessories.......................................................................................................................... 57

6.10.1 PTO ...................................................................................................................................57

6.10.2 Tracking Zones...................................................................................................................57

6.10.3 Return Roller Replacement................................................................................................. 58

7Troubleshooting and Repair................................................................................ 59

8Appendix 1: Standard Gearmotor Options......................................................... 62

9Appendix 2: General Arrangement Drawings .................................................... 64

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

List of Figures

Figure 1: RLVAC Overview.................................................................................................................... 11

Figure 2: Screw Takeup Drive Overview ................................................................................................12

Figure 3: Pneumatic Takeup Drive Overview ......................................................................................... 13

Figure 4: RLVAC Intermediate Bed Exploded View ................................................................................ 14

Figure 5: Mark Number Stickers.............................................................................................................15

Figure 6: Skid Sticker.............................................................................................................................16

Figure 7: Floor Support and Splice Plate Installation .............................................................................. 18

Figure 8: Pressure Assembly Installation Detail...................................................................................... 19

Figure 9: Skew Transition Pressure Assembly Detail ............................................................................. 19

Figure 10: Tail Belt Routing ...................................................................................................................21

Figure 11: Belt Lacing............................................................................................................................ 21

Figure 12: Screw Takeup Drive Overview .............................................................................................. 22

Figure 13: Screw Takeup Drive Belt Routing.......................................................................................... 22

Figure 14: Pneumatic Takeup Drive Overview........................................................................................ 23

Figure 15: Pneumatic Takeup Drive Belt Routing ................................................................................... 24

Figure 16: Skewed Bed Belt Routing......................................................................................................24

Figure 17: Belt Splice Alignment ............................................................................................................ 27

Figure 18: Completed Belt Splice........................................................................................................... 28

Figure 19: Return Roller Module Installation Detail................................................................................. 30

Figure 20: Pressure Roller Locations for 2”RC Pressure Modules .......................................................... 32

Figure 21: Pressure Roller Locations for 3”RC Pressure Modules .......................................................... 33

Figure 22: RLVAC Intermediate Bed Tracking Roller Details .................................................................. 34

Figure 24: Screw Takeup Drive Belt Routing..........................................................................................37

Figure 25: Tension Indicators.................................................................................................................38

Figure 25: Belt Tracking by Adjusting Snub Rollers ................................................................................ 41

Figure 26: Chain Pitch Measurement ..................................................................................................... 51

Figure 27: General Arrangement, RLVAC Bed Section, Sheet 1 of 2...................................................... 65

Figure 28: General Arrangement, RLVAC Bed Section, Sheet 2 of 2...................................................... 65

Figure 29: General Arrangement, RLVAC Tail, Sheet 1 of 1................................................................... 65

Figure 30: General Arrangement, Belt Under Roller AC, Pneumatic Takeup Drive, Sheet 1 of 1............. 65

Figure 31: General Arrangement, Belt Under Roller AC, Screw Takeup Drive, Sheet 1 of 1.................... 65

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

List of Tables

Table 1: Reference Documents ...............................................................................................................9

Table 2: Belt Hot Splicing Tools .............................................................................................................25

Table 3: Belt Hot Pressing Parameters .................................................................................................. 27

Table 4: Return Roller Positions for Intermediate Beds .......................................................................... 31

Table 5: Pneumatic Takeup Pressure Settings....................................................................................... 39

Table 6: Recommended Preventative Maintenance Schedule................................................................ 43

Table 7: Fastener Standard Torque Values............................................................................................ 44

Table 8: Troubleshooting Guide ............................................................................................................. 59

Table 9: Standard Gearmotors with 1.250in Output................................................................................ 62

Table 10: Standard Gearmotors with 1.500in Output.............................................................................. 63

Table 11: RLVAC General Arrangement BOM ....................................................................................... 64

Reference Documents

Table 1: Reference Documents

MANUFACTURER

MANUAL

Bastian Solutions

Conveyor Director AC User Manual

Bastian Solutions

Side Cover and Guiderail Installation Manual

Bastian Solutions

Support Installation Manual

Bastian Solutions

RLCAC Installation and Maintenance Manual

Bastian Solutions

RLSAC Installation and Maintenance Manual

Habasit Holding

AG Habasit Fabric Conveyor Belts Installation and Maintenance Guide (6040)

ABB Motors and

Mechanical Inc Dodge Quantis RHB Installation and Maintenance Instructions (499322)

ABB Motors and

Mechanical Inc

Instruction Manual for DODGE® Setscrew, Eccentric Collar, D-Lok, H-E Series,

E-Z Kleen, Ultra Kleen and Food Safe Mounted Ball Bearings (MN3016)

ProCal

Innovations, LLC

(PCI)

INSTALLATION INSTRUCTIONS: XT®, QD®, HE & TAPERLOCK® BUSHINGS

(31905)

Installation and Maintenance Manual: RLVAC

Published February 2022

Rev. B

1 Introduction

Thank you for choosing Bastian Solutions Conveyor. The following manual serves as a guide for

installation, part replacement, and general maintenance for your material handling equipment. It is

important to read the manual and follow any instructions as it provides important safety information for

personnel and will maximize the longevity of the conveyor.

The information contained in this manual applies only to the products described. Uses, activities, or

processes related to installing or maintaining the equipment that are not explicitly described in this

manual are considered out of scope. Please contact Bastian Solutions Conveyor for any questions or

support that is not clearly addressed in this document. Bastian Solutions Conveyor is not responsible for

misuse of the equipment described in this manual or misuse of information in this manual. If you have any

questions, contact Bastian Solutions Conveyor Customer Service or Support at

ConveyorSupport@BastianSolutions.com.

2 OSHA and Safety

Bastian Solutions Conveyor is not responsible for ensuring that conveyors used in a system abide by

OSHA standards. Safety is of primary importance to our company, but as a product distributor we ask that

system integrators and end users conform with all applicable OSHA standards. We encourage that all

warnings in this manual are followed to avoid unnecessary risk.

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