Friday, 06 November 2015 22:34

E-CART Power Supply: %Status lights


The Power Supply itself and the brake shopper have red and green status lights. The Power Supply lights up green if everything is ok and if it is on. The red light comes on if the Power Supply detected a short cut or an overload.

The brake shopper does show a green power light which can be seen through the front window of the power supply front cover. A red state light comes on if there is over power which gets directed into the resistor. The error light comes on if anything is not right with the circuit.

 

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Friday, 06 November 2015 21:17

E-CART Power Supply: %Connections


All terminals are located behind the cover in the front of the complete Power Supply housing. The AC power will enter and the 48V power cables will exit at the rear of the housing through the cable track connector. The AC power input is on the left of the mounting bolt (-X1 in the wiring diagram) and the complete right side of the terminal is used for outputs (-X2 and –X3 in the wiring).

Please refer to the wiring diagram in the Annex of that document for all terminal definitions.

E CART Power Supply Connections

 

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The operating company will have to supply AC power per the requirements to each Power Supply. For safety reasons, the Power Supply terminals are not equipped to be daisy chained at all. Either a power bus system or a dedicated secured power line sould be used to provide the required power.

The 48V DC output is normally connected and pre-wired to the track elements. Some of the connections might have to be connected after the system gets mechanically installed.

Using the remote shut down and the status control feature is optional. The required terminals are also called out on the electrical drawing. The remote shutdown can be used to negate the need of a big relay to switch the 460V because you can remotely switch off and on the Power Supply so that smaller switches will be sufficient. It is a regular input and can be connected with a PLC output.

The DC ok contact can be connected with an input at the main PLC and the signal drops if the 48V power is not provided anymore. That can be because of overload or any other reason.

Do not switch on AC power before checking that all 48V DC outputs are properly connected to the power rails and all connections are measured and checked.

 

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The Power Supplies get installed to the track with included mounting brackets. They can be moved around with restrictions to the cable lengths and the bolts required for leg supports or rail mounting. Generally the Power Supplies are installed in previously approved locations. If one gets added, it can be mounted to the required location.

Depending on the application, the mounting can be directly to the leg-set as well.

Please make sure that you keep at least 50 mm (2 inches) clearance underneath the Power Supply, so that no dust gets caught and the proper air flow will be given.

If the Power Supply doesn’t get sufficient air flow from the bottom, the Power Supply can overheat!!

 

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Friday, 06 November 2015 20:31

E-CART Power Supply: %Passive airflow


The Power Supply is designed to cool itself by generating an air exchange. The Power Supply heats up the air while going through and it exits at the top of the roof. The hot air pulls cool air through the open bottom of the Power Supply housing.

This system only works if the vents are open and not blocked by dust or other particles. Please ensure a good airflow.

There is no need for an external cooling system. The exiting air temperature should not exceed 50°C.

E CART Power supply Passive airflow

 

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To change the low profile drive motor, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the 456 mm long top rail extrusion above the drive station.
  3. Turn the fan of the drive motor in the direction of flow until a master link is visible.
  4. Remove the safety cover of the drive unit and unlock the ratchet unit manually. Lift the spring plates only as much as necessary to compress the spring with a suitable tool. Make sure that the tensioner is locked and stays in that position.
  5. Slightly raise the chain and open the master link.
  6. Place both ends of the chain right and left over the drive sprocket of the roller.
  7. Remove the mounting clamp of the drive motor, to take out the motor including the drive sprocket by raising the chain from the inside.
  8. Remove the washer and the bolt from the drive shaft with an Allen wrench (M6).
  9. Install the new motor and the drive sprocket (t = 28 mm) in reverse order if necessary. Position the drive sprocket that it lines up with the drive chain.
  10. Mount the clear front cover.
  11. Run the conveyor system and check the tension of the chain at the chain tensioner.

  12. Drive Unit Replacing drive motor low profile

 
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To change the re-directional sprockets of a low profile drive unit, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the 456 mm long top rail extrusion above the drive station.
  3. Turn the fan of the drive motor in the direction of flow until a master link is visible.
  4. Remove the safety cover of the drive unit and unlock the ratchet unit manually. Lift the spring plates only as much as necessary to compress the spring with a suitable tool. Make sure that the tensioner is locked and stays in that position.
  5. Remove the oil pan underneath the drive station.
  6. Open the chain at the master link.
  7. Remove the drive motor as described in a previous Chapter.
  8. Remove the upper (2x), and the lower (2x) re-directional sprockets.
    Please pay attention to the existing chain alignment!
  9. Install the drive motor in reverse order.
  10. Pay attention to the correct orientation and the type of master link. Close the master link.
  11. Install the removed top rail extrusion piece. Please ensure that the chain guide strip is installed correctly. Install all chain covers correctly and completely again. Remove the tool, mentioned in step 4, which was used to compress the spring and make sure that the spring tensioned the chain correctly.
  12. Re-install the clear front cover.
  13. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  14. Check the chain tension after two hours of operation again.
 
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To change the drive sprocket of a low profile drive unit, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the 456 mm long top rail extrusion above the drive station.
  3. Turn the fan of the drive motor in the direction of flow until a master link (zinced) is visible.
  4. Remove the safety cover of the drive unit and unlock the ratchet unit manually. Lift the spring plates only as much as necessary to compress the spring with a suitable tool. Make sure that the tensioner is locked and stays in that position.
  5. Slightly raise the chain and open the master link.
  6. Place both ends of the chain right and left over the sprocket of the roller.
  7. Remove the mounting clamp of the drive motor, to take the motor including the drive sprocket out, by raising the chain from the inside.
  8. Remove the bolt and the washer of the drive shaft with an Allen wrench (M6).
  9. Pull the drive sprocket (t = 28 mm) with a suitable puller off the motor shaft. The spacer ring has to remain on the motor shaft because it will be used as a hard stop for the new sprocket to get the right alignment.
  10. Install the new drive sprocket in reverse order. If a drive sprocket with different diameter gets used, the drive chain length has to be checked and it needs to get shortened or lengthened if required. That should be done at an existing master link. Make sure that the drive sprocket is correctly positioned: The center line of the chain has to be in line with the drive sprocket teeth.
  11. Install the clear front cover.
  12. Run the conveyor system and check the tension of the chain at the chain tensioner.
 
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A replacement of the entire chain is required when the chain is worn out, or worn beyond the limits of the chain tensioner. Signs for that are high soiling, non-moving chain links and rust at the chain, or seeing a red color code on the chain tensioner slider indicating that it is at the end of its travel.
 
To replace the chain of the low profile drive unit, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the 456 mm long top rail extrusion above the drive station.
  3. Remove the safety cover of the drive unit and unlock the ratchet unit manually. Lift the spring plates only as much as necessary to compress the spring with a suitable tool. Make sure that the tensioner is locked and stays in that position.
  4. Turn the fan of the drive motor in the direction of flow until a master link (zinced) is visible.
  5. Open the master link and connect the new to the old chain. Put the new chain on a clean surface to avoid new dirt and soiling of the chain.
  6. Turn the fan of the drive motor until the conveyor sections are fully equipped with the new chain.
  7. Conncect both chain ends with a master link.
  8. Install the removed top rail extrusion piece. Please ensure that the chain guide strip is installed correctly. Install all chain covers correctly and completely again. Remove the tool, mentioned in step 3, which was used to compress the spring and make sure that the spring tensioned the chain correctly.
  9. Install the clear front cover.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner.
 
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To shorten the drive chain of a low profile drive unit, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the safety cover of the drive unit and unlock the ratchet unit manually. Lift the spring plates only as much as necessary to compress the spring with a suitable tool. Make sure that the tensioner is locked and stays in that position.
  3. Remove the 456 mm long top rail extrusion above the drive station.
  4. Turn the fan of the drive motor in the direction of flow to drive the conveyor manually until a master link (zinced) is visible.
    CAUTION: There is a residual danger because of the non covered chain drive.
  5. Open the master link, and pull the chain until the chain is tensioned and shorten the excessive chain.
  6. Re-connect both chain ends with the master link. Pay attention to the right orientation and to the style of the master link: The lock of the master link leads towards the bottom rail extrusion, the locking plate faces into the direction of the conveyor flow.
  7. Install the removed top rail extrusion. Please ensure that the chain guide strip is installed correctly. Install all chain covers correctly and completely again. Remove the tool, mentioned in step 2, which was used to compress the spring together and make sure that the spring tensioned the chain correctly.
  8. Mount the drive station front cover, run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  9. Check the chain tension after two hours of operation again.

  10. Drive Unit Shortening drive chain low profile

 
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