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OPERATING INSTRUCTIONS

CONVEYORS

KTB; KTBD (End drive)

BA-100006 E englisch, edition 11/2010

Operating instructions KTB / KTBD

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Contents

1 Important information ............................................................................................ 3 1.1 Manufacturer’s declaration ............................................................................................3 1.2 Description of product and use .....................................................................................3 1.3 Factors which reduce the useful life...............................................................................3 1.4 Safety instructions ..........................................................................................................3 1.5 Additional information ...................................................................................................4 1.6 Scope of the operating instructions...............................................................................4 1.7 Technical data.................................................................................................................5

2 Commissioning........................................................................................................ 7 2.1 Mechanical design ..........................................................................................................7 2.2 Mounting instructions.....................................................................................................8 2.3 Pivoting of the drive unit................................................................................................9 2.4 Electrical connection ....................................................................................................10 2.5 Operation .....................................................................................................................12 2.6 Modes...........................................................................................................................13 2.7 Program mode..............................................................................................................14 2.8 Exiting the program mode...........................................................................................19 2.9 Error messages / Measures in case of malfunction .....................................................19 2.10 Direction of travel of the conveyor belt.......................................................................20 2.11 Setting the necessary pretension of the belt...............................................................21 2.12 Tracking ........................................................................................................................22 2.13 Changing the conveyor belt speed range ...................................................................23 2.14 Changing the installation side of the drive unit...........................................................23 2.15 Technical data for conveyor .........................................................................................24 2.16 Replacing endless belts ................................................................................................24 2.17 Replacing belts by welding the ends ...........................................................................25

3 Maintenance ......................................................................................................... 25 3.1 Repairs ..........................................................................................................................25 3.2 Replacing the drive roller .............................................................................................26 3.3 Replacing the gear motor ............................................................................................27 3.4 Replacing the control electronics / Protective cap......................................................28

4 Exploded drawings / parts lists............................................................................ 29 4.1 KTB-K / KTBD-K with end drive ...................................................................................29 4.1.1 Parts list for KTB-K / KTBD-K with end drive........................................................................ 29 4.2 KTB-K conveyor end with deflection roller, single belt ...............................................30 4.2.1 Parts list for KTB-K conveyor end with deflection roller, single belt ................................... 30 4.3 KTBD-K conveyor end with deflection rollers, dual belt .............................................31 4.3.1 Parts list for KTBD-K conveyor end with deflection roller, dual belt ................................... 31


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4.4 KTB drive unit for end drive, single belt ......................................................................32 4.4.1 Parts list for drive unit for end drive ..................................................................................... 33 4.5 KTBD drive unit for end drive, dual belt ......................................................................34 4.5.1 Parts list for drive unit for end drive ..................................................................................... 35

5 Environmental compatibility and disposal............................................................ 36


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1 Important information

Conveyors as components of kits are not subject to the EU-declaration of conformity (as per MRL Appendix II A)

EU Declaration of conformity (as per MRL Appendix II A)

1.1 Manufacturer’s declaration

Regulations and standards taken into account: ! Machine Directives 89/392/EEC, 91/368/EEC

! Low-voltage Directive 73/23/EEC EMC-Directive: Noise emissions EN 50081-2:1993, Noise immunity EN 61000-6-2

Manufacturer: Montech AG, Gewerbestrasse 12 CH-4552 Derendingen Tel. +41 32 / 681 55 00, Fax +41 32 / 682 19 77

1.2 Description of product and use

Conveyors should be used for transporting solid objects which are not smaller than a minimum size. For example, they are not suitable for transporting sand, granules, chips, etc. Under no circumstances may the product-specific performance data shown on the identification plate be exceeded.

1.3 Factors which reduce the useful life

! Direct irradiation with UV lamps.

! Queuing when transporting objects with sharp edges.

! Operating environment containing smoke, dust, steam or solvent vapours.

1.4 Safety instructions

The safety instructions, especially those relating to the electrical connection, must be followed in all phases of commissioning, operation and service or repair work. Failure to follow these in-structions constitutes misuse of the conveyor and its components. Operation of a conveyor in an explosive atmosphere (inflammable gases, vapours or dust) can lead to their ignition and should therefore be avoided. Never carry out service or adjustment work alone. Another person who is able to switch off the mains and perform first aid must always be present. Moving the electromechanical drive unit on the chassis and dismantling the mechanical guards are permissible only if the conveyor is disconnected from the electrical supply.


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1.5 Additional information

The present Operating Instructions are intended to ensure proper and safe use of the conveyor. If information for your application is lacking, please contact the manufacturer. Additional information, e.g. on dismantling of the lateral guides, etc., can be found in the KTB or KTBD Assembly Instructions. These documents can be obtained from our homepage www.montech.ch. Identification plate

Montech AG Management

U. D .Wagner / Gianluca Aloisi

1.6 Scope of the operating instructions

Our products are continually updated to reflect the latest state of the art and practical experi-ence. In line with product developments, our Operating Instructions are continually updated. All Operating Instructions have an article number e.g. BA-100006. The article number and the date of edition are shown on the title page.


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1.7 Technical data

Ambient tempertature +10 to +40°C

Rel. Humidity 5% - 85% (without condensation)

Air purity normal workshop atmosphere

Noise level < 55 dBA

Protection category of the drive unit IP40

Motor

Type brushless external rotor DC motor

Rated voltage 24 VDC

Operating voltage 18 to 28 VDC

Rated current 2.8 A

Max. current consumption 3.6 A (at start)

Rated output power 48 W

Speed range 200 to 3500 rpm

Total efficiency 70 %

Gear

Type two-stage spur gear

Version L S

Gear ratio i = 59.19:1 i = 21.6:1

Permissible drive torque 1.6Nm 1.6Nm

Permissible current consumption at Vmax.

2A 2A

Output speed 3.4 ... 59.1 rpm 9.2 ... 162 rpm

Belt speed 0.4 to 7.6 m/min 1.2 to 21 m/min

Increments 0.1 m/min 0.2 m/min

Total efficiency 80%

Lubrication lifetime lubrication

Connection

Connecting cable 4-pin, coupling M12x1, angled at 90°

Cross-section 4 x 0.75 mm2

Length 5 m (standard) or 10 m; stripped cable end

Perm. voltage digital inputs +5 to 24 V (for anticlockwise or clockwise operation)


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The following information is shown on the identification plate attached to the drive unit:

Conveyor type

Belt type

Belt width [mm]

Belt length [mm]

Operating instructions

Order No.

Speed [m / min.]

Pretension [%]

Max. load [N]

Gradient [°]


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2 Commissioning

2.1 Mechanical design

The conveyors are shipped in units of max. 3 m length. If the total length of a conveyor exceeds the maximum transport length of 3 m, the individual parts should be assembled according to the following diagram. Total length of chassis Total length of chassis (in mm) L < 3000 lateral guide

chassis

3000< L ≤ 5000 lateral guide chassis

Svar Variable length of the lateral guides, min. = 500 mm, max. = 2000 mm Cvar Variable chassis length Cvar max. = 2853 or 1903 mm D Chassis joint for dismantling prior to shipping Prior to commissioning, the joints marked with (D) must be assembled. The conveyor must be supported at these points.

The conveyor should as far as possible be operated with ”front drive“, i.e. the output side of the conveyor is on the side of the driven roller and the objects being transported are moved by traction. In cases where the drive is arranged on the input side of the conveyor, i.e. ”rear drive“, the ob-jects being transported are moved under thrust so that the belt loading conditions are not op-timal, i.e. faults may occur in operation. In order to avoid this, the respective application must be discussed with Montech.

Cvar

Svar

Svar Svar

7 90

907

50

50

Lmax. 5000

Lmax. 3000

Svar 2000

2950

Cvar

D

Cvar

Svar


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2.2 Mounting instructions

When using the sliding sheet (10/20), we recommend binding the chassis (10/10) and the sliding sheet (10/20) with a double-sided adhesive tape (10/30). Before binding, clean the surfaces of the sliding sheet and chassis and degrease. Ensure that the adhesive tape or the adhesive tapes are uniformly distributed on the chassis. Our recommendation: Double-sided adhesive tape 25 mm x 55 m (Item No. 506333). KTB/TB-60 1 x Adhesive tape 25 mm width KTB/TB-80 2 x Adhesive tape 25 mm width KTB/TB-105 2 x Adhesive tape 25 mm width KTB/TB-140 3 x Adhesive tape 25 mm width KTB/TB-185 3 x Adhesive tape 25 mm width KTB/TB-250 4 x Adhesive tape 25 mm width


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2.3 Pivoting of the drive unit

The drive unit is pivotable through 270° and is thus optimally adapted to the space available. When the drive unit is at the top, (see following representation: Height of material conveyed) material with a maximum height of 40 mm can be conveyed.

Adjustment of the drive unit

Procedure:

! Switch off the motor ! Slacken the locking screw (650) ! Swivel the drive unit to the desired position ! Tighten the locking screw (650)

Adjustment of the belt pretension:

After fixing the drive unit in the final position, the belt tension should be adjusted again.

Procedure:

! Remove cover(20) by unscrewing the countersunk screw (200). ! Slacken the four fixing screws of the gear motor. ! Tension the belt by pulling the protective cap (110) by hand. ! Tighten the four fixing screws of the gear motor. ! Mount the cover (20) again. Height of material conveyed

max

. 40

270°


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2.4 Electrical connection

General safety instructions

The conveyor operator must have the electrical connection, commissioning, adjustment and maintenance and repairs carried out by qualified persons. Working on the electrical partscan be particularly dangerous. Never disconnect the electrical connections when the system is under voltage. In unfavorable cases, arcs may occur and harm persons and contacts. Warning plate for electrostatically sensitive components

Electrostatically sensitive components are present under the safety cover of the KTB /KTBD. The re-spective person must be properly earthed before carrying out maintenance work.

Voltage supply

A DC voltage of 24 V is required for supplying the motor. Higher voltages and AC voltages can damage the motor.

Earth connection

The earth connection of the conveyor must be electrically connected to the earth connection of the supply. If no earthing is performed, the control electronics of the conveyor may be damaged, rendering the warranty null and void.

Earth connection


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Connection to power unit

Power units of 20 to 28 VDC are permitted for supplying the conveyor. The rated power and the maximum motor speed are however reached only with a supply voltage of >24 VDC. The con-necting cable supplied has a length of 5m or 10 m. The connection cross-section is 4x0.75mm2. Other cables with standard M12 plugs can also be connected. However, a smaller connection cross-section and a long cable may result in a voltage drop which no longer guarantees opera-tion of the control or of the motor. There is also the danger that the cable will heat up to an im-permissible extent.

The drive unit must be correctly connected according to following representation. Connection errors may damage the control or the motor!

Jack assignment in the conveyor drive

Assignment of connecting cable supplied

+ 5...24V (S2)

+ 24VDC (supply)+ 5...24VDC (S1)

schwarz, + 5...24V (S1)

blau, -24V (Speisung)

weiss, + 5...24V (S2)

braun, + 24V (Speisung)

4, 5...24V (S1), black

3, GND (supply), blue

2, + 5...24V (S2), white

1, + 24V (supply), brown


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2.5 Operation

Control panel

Legend: Control panel

1) Reduce belt speed

2) Increase belt speed

3) Start / Counterclockwise operation

4) Stop

5) Start / Clockwise operation

6) Display

a) Display in operation: Belt speed in m/min.

b) Display when stationary: Mode / Programmed direction of travel

c) Display in program mode: Abbreviation for parameter

Note:

Clockwise operation is defined as running of the belt from left to right when facing the keypad – counterclockwise operation is operation in the opposite direction.

Switching on and off / Choice of direction of travel

By pressing the key (3) or key (5), the belt is switched on with the appropriate direction of travel. By pressing the key (4), the belt is stopped.

Adjusting the belt speed

When the belt is running, the belt speed can be adjusted by pressing the keys (1) or (2).

1 2 3 4 56

6a

6b

6c


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Coarse adjustment

By pressing the key (1) for at least 1 sec, the belt speed is continuously increased. The speed is reduced with the aid of key (2).

Precise adjustment

By briefly pressing the key (2), the belt speed is increased in each case by approx. 0.1 m/min in version (S) and by approx. 0.03m/min in version (L). By pressing the key (4), the belt speed is reduced by the corresponding step width.

Set belt speed during commissioning

The default speed during commissioning is in the following range: Version Belt speed [m/min.]

L 0.5 – 2.5 S 1.5 – 6.5

Action in the event of loss of power

The belt speed last set is retained during loss of power. For safety reasons, the belt remains switched off after a fault. It can be switched on again by pressing the keys (3) or (5).

2.6 Modes

The minidrive conveyor can be operated in three different modes:

1. Autonomous mode (A) The conveyor is operated alone. The belt is switched on and off on the keypad.

2. External mode (E)

The conveyor is used as part of a system. By externally switching the electrical supply on or off, the conveyor is directly switched on and off. The direction of travel is defined in advance by means of a parameter. By pressing the key (4) on the keypad, the conveyor can be stopped at any time. The belt can then be started again by pressing the appropri-ate key (3) or (5).

Attention: If there is a loss of power when the belt is stationary, the belt starts automatically after operating voltage is applied.


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3. Control mode (S)

The motor control has two digital inputs for connecting a PLC. When the control voltage (5-24V) is applied, the belt begins to run in the appropriate direction. This mode is par-ticularly suitable for reversible operation and start/stop operation. By pressing the key (4), the belt can be stopped at any time by means of the keypad. The belt must then be started again by pressing the appropriate key (3) or (5) (starts only in the direction speci-fied by the control), unless the control signal has stopped in the meantime.

Limitations of start/stop operation

To limit the gear wear during start/stop operation, the following should be taken into account:

! The maximum permissible load must be limited to 50%.

! The maximum number of cycles is limited to 6 per minute (factory setting). Other possible steps are 15, 10, 6, 4, 3 and 2. If a start signal is given twice before the belt stops, the error message cYL appears in the control mode and the belt can be enabled again only after it has stopped.

2.7 Program mode

In the program mode, specific control parameters can be changed. Thus, the control can be op-timally adapted to the respective application.

Start program mode

By simultaneously pressing the keys (1) and (2) for 3 sec, the program mode is obtained. First, the parameter to be changed is selected and the parameter value is then input. Chapter: (Over-view of programming of control) shows the programming sequence in detail.


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Overview of programming of control

Mode of operation

Autonomous mode

External mode

Control mode

Duration cycle

Stationary Display

1) Press key when switching on 24 V operating voltage

Press for 3 sec.


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Press for 3 sec.

Display in Operation

Belt speed (m/min)

Run-up Ramp programmed

Decelerate Motor brake on

Factory parameter

Setting after reset (Belt speed = 0 m/min)


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Designation of the parameters

Code: Abbreviation for: Function:

SPE speed Speed

dIr direction Direction of travel

rAn ramp Run-up ramp

nod mode Mode

GEA gear Gear transmission

dIA diameter Diameter of drive roller

dIS display LED indicator

brA brake Motor brake

Locking of belt speed (SPE)

To prevent the belt speed from being changed by unauthorized persons, the set speed can be locked. ! FrE The belt speed is freely adjustable at all times

! Loc The belt speed is locked

Define direction of travel of conveyor (dIr)

For safety reasons, the direction of travel can be determined in the "autonomous mode". ! [ ] Direction of travel freely selectable

! [ Counterclockwise travel

! ] Clockwise travel

Set start-up ramp (rAn)

If soft starting of the conveyor is desired, the run-up time can be programmed. ! oFF Free run-up (load-dependent)

! 0.5 – 5.0 Run-up time in seconds (in steps of 0.5 seconds)

Anzeige: A raised dot lights up during run-up


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Set mode (nod)

Selection of mode (see section on modes). ! A Autonomous mode

! [ E External mode / Counterclockwise operation

! E ] External mode / Clockwise operation

! S Control mode

Actuation of control mode

Input S1

(Cable No. 4)

Input S2

(Cable No. 2)

Direction of travel

0 0 Stationary

1 0 Clockwise

0 1 Counterclockwise

Select gear transmission (GEA)

To ensure that the belt speed is correctly displayed, the correct gear transmission must be set (usually already programmed at the factory). ! 21.6 Gear transmission i=21.6:1

! 59.2 Gear transmission i=59.19:1

! 000 Prepared for further gear transmission

Change diameter of drive roller (dIA)

In the case of special belts, the diameter of the drive roller may be larger or smaller than 40 mm. To ensure that the belt speed is nevertheless correctly displayed, the corresponding diameter can be programmed in the range between 30 and 60 mm. ! 41 Standard value: Drive roller diameter 40 plus belt thickness 1 mm

! 30...60 Special diameter / In steps of 1 mm

Switch LED display on and off (dIS)

The LED display can be switched on and off. ! on The display is switched on

! oFF The display is switched off


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Switch motor brake on and off (brA)

The motor brake reduces the run-out distance of the belt. It functions only in the autonomous and control modes. ! oFF Motor brake off

! on Motor brake on

Display: A raised dot lights up during braking

2.8 Exiting the program mode

By pressing the key (4) for three seconds, it is possible to exit the program mode. The message End then appears for three seconds. If no operations are performed in the program mode for 30 seconds, the system automatically exits from the mode.

2.9 Error messages / Measures in case of malfunction

Message Cause Remedy

loc Belt speed locked Change parameter SPE to FrE

cYL Cycle time below permissible value ! Increase cycle time

! Contact factory to find whether a shorter cycle time is permissible un-der the given conditions / repro-gram factory parameter according to factory data

End ! Automatic exit from program mode after no changes were made for 30 sec.

! Program mode was exited after ac-knowledgement

No action necessary

rES A reset was performed No action necessary

blo Motor does not rotate although a start sig-nal from the control is present.

! Conveyor may be blocked or overloaded

! Motor or gear may be faulty

! Reduce load

! Remove blockage

! Replace gear motor

RESET funktion

If the control exhibits abnormal behavior during operation or during programming and this be-haviour persists, the operating voltage should be switched off. The reset is performed by press-ing the key (5) while simultaneously switching on the operating voltage. It should be noted that the parameters are to be reprogrammed. The belt speed too must be reset.


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2.10 Direction of travel of the conveyor belt

The direction of travel of the belt should be complied with when the belt ends were joined by means of an overlapping weld joint (Thermofix). Overlapped weld joint (Thermofix)

Position of the belt weld (Thermofix) Longitudinal section Plan view In the case of zig-zag joints (Flexproof) or welded butt joints (Quickmelt), the direction of travel of the belt is unimportant. Flexproof and Quickmelt weld joints Flexproof Quickmelt


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2.11 Setting the necessary pretension of the belt

The correct pretension for a conveyor belt is shown on the identification plate attached to the belt drive (for example: 1.2%). After the belt has been mounted, two measuring marks (M) are stuck on its upper surface in the untensioned state, in such a way that they are a distance (L) of e.g. 500 or 1000 mm apart. When the two tensioning screws (580) (See chapter: Tracking) are uniformly tightened, the two measuring marks (M) move apart to a dimension (L) which corresponds to the required preten-sion Vnec. Example: Example of calculation of conveyor belt pretension

)%(v100L

LLnec

looseloosetaut ∗+=

%2.1vandmm100LWhen necloose ==

mm1012%2.1%100mm1000

mm1000Ltaut =∗+=


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2.12 Tracking

The belt must always run centrally over the deflection roller and the drive roller. On no account may the edges of the belt project over the ends of the rollers.

The running of the belt over the deflection roller can be corrected by slightly tightening or slackening the hex screws (580) while the belt is running. The tracking over the drive roller is as a rule ensured. If the tracking over the drive roller is nevertheless incorrect, the two tabs (40) can be slightly moved. Conveyor end with deflection roller


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2.13 Changing the conveyor belt speed range

The belt speed is between 0.4 and 7.6 m/min in the case of version (L) and between 1.2 and 21 m/min in the case of version (S). The speed range can be changed by replacing the gear motor. Procedure: (see section: Replacing the gear motor). ! Reprogramming of the parameter GEA of the control electronics for correct display of the

belt speed (see section“Program mode“).

2.14 Changing the installation side of the drive unit

The drive unit of the minidrive conveyor with end drive is installed on the left or right, depend-ing on the version ordered. If the installation side is to be changed subsequently, the tab on drive side and the single tab must be replaced. Article number: Drive right Drive left Tab on drive side, complete 48458 48459 Single tab 48161 48468 Procedure: ! The procedure is the same as in the section „Replacing the drive roller“. It is also necessary

to slacken the threaded pin (360) so that the side part can be separated from the tab on the drive side.

Changing the installation side of the drive unit


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2.15 Technical data for conveyor

These are shown on the identification plate attached to the drive unit and must be taken into account when purchasing spare belts.

2.16 Replacing endless belts

The installation of endless belts is recommended when the conveyor is easily accessible or when the equipment needed for welding prepared endless belts is not available. Procedure: (See chapter: Replacing the gear motor) ! Stop the belt (key 4) and switch off mains voltage.

! Slacken the conveyor belt by alternately loosening the two screws (590) on the tensioning device.

! Remove the belt by first running it out on the drive side over the tab (40).

! Install the new belt by first placing the belt in the tensioning device and then drawing it over the tab (40).

! The drive unit is reinstalle in the reverse order.

! For pretensioning of the belt, see section "Setting the necessary pretension of the belt".

! For tracking of the belt, see section "Tracking". Changing of belts


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2.17 Replacing belts by welding the ends

Threading new belts into a conveyor with subsequent "welding" of the belt ends is recom-mended when the accessibility with regard to the operations described in the preceding section is greatly restricted. A prerequisite for this method of belt mounting is the availability of the necessary equipment for the "welding operation". Exact instructions for performing the "welding operation" can be requested when ordering new belts. Procedure: (See chapter: Replacing the gear motor) ! Switch off motor and disconnect from mains voltage

! Slacken the belt by alternately loosening the two screws (590).

! Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with adhesive tape). Attention should be paid to the position of the chamfered belt ends in rela-tion to the direction of travel (see section "Direction of travel of the belt"). The chamfered belt ends must be kept clean.

! Slowly pulling out the old belt automatically pulls the new one through the system.

! "Weld" the belt according to the manufacturer's instructions.

! Pretension the belt as under section "Setting the necessary pretension of the belt"

! Set the belt tracking as under section "Tracking".

3 Maintenance

Belt conveyors are maintenance-free when they are employed in accordance with their purpose and are not exposed to any effects likely to shorten their service life. The purpose and the factors likely to shorten the service life are mentioned in the declaration of conformity. When the belts are exposed to the action of dust, oily air, foreign matter, such as chips from machine tools, etc., we recommend regular thorough cleaning of the belts, for example once a week, with white spirit. The con-trol panel should be cleaned with industrial alcohol. Other sol-vents may damage the protective polyester film.

3.1 Repairs

The operating instructions contain the necessary spare parts lists and exploded drawings for repairs in the mechanical part of the conveyor. The safety instructions must also be followed. Repairs to the electrical part may be carried out only by the supplier. It is essential to follow the safety instructions for electrical disconnection of components from the mains or from the motor and for their reinstallation.


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3.2 Replacing the drive roller

Replacing the drive roller

Procedure:

! Switch off motor

! Disconnect drive unit from mains

! Slacken the conveyor belt by alternately loosening the two screws (590).

! Remove the cover (20) by unscrewing the countersunk screw (200).

! Slacken and remove the toothed belt by loosening the four fixing screws (210) of the gear motor.

! Loosen the threaded pin (350) and remove the cog wheel (130) from the drive shaft (50).

! Remove the single tab (40) by unscrewing the two fixing screws (230).

! Replace the drive roller with mounted self-aligning ball bearings

! The drive unit is reinstalled in the reverse order.

Correctly mount plate spring. The plate spring must not touch the inner race of the self-aligning ball bearings. The toothed belt should be sufficiently tensioned by pull-ing the protective cap by hand.


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3.3 Replacing the gear motor

Replacing the gear motor

Procedure:

! Stop conveyor and switch off mains voltage.

! Disconnect connecting cable (350) from drive.

! Remove the cover (20) by unscrewing the countersunk screw (200).

! Unscrew the two fixing screws (130) of the protective cap (50).

! Carefully pull off the protective cap.

Electrostatically sensitive components are present under the safety cover. The respective person must be properly earthed before carrying out maintenance work.

! Pull off the connection circuit baord (300) from the motor.

! Slacken and remove the toothed belt by loosening the four fixing screws (210) of the gear motor.

! Loosen the threaded pin (350) and remove the cog wheel (140) from the drive shaft of the gear motor (330).

! Remove the gear motor by unscrewing the four fixing screws (210).

! The drive unit is reinstalled in the reverse order. The toothed belt should be sufficiently ten-sioned by pulling the gear motor by hand.


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3.4 Replacing the control electronics / Protective cap

The keypad with the control electronics is bonded into the protective cap. If the protective cap is damaged or the electronics are faulty, only the whole unit can be replaced. If the control elec-tronics no longer operates correctly, both the complete protective cap with keypad (50) and the connection circuit board (300) must be replaced. Note: When purchasing new control electron-ics, it is always essential to specify the order number shown on the identification plate, so that compatibility between motor and new control can be checked.

Procedure:

! Stop the belt and switch off the mains voltage.

! Disconnect the connecting cable (350) from the drive.

! Unscrew the two fixing screws (130).

! Carefully remove the protective cap.

Electrostatically sensitive components are present under the safety cover. The respective person must be properly earthed before carrying out maintenance work.

! Pull off the connection circuit board (300) from the motor.

! Mount the new connection circuit board.

! Insert the new protective cap straight – it is centered by the connection circuit board.

! Screw on the cap (50) with fixing screws (130)

! Reconnect the connecting cable (350)

! Perform a reset.

! Program the gear transmission.

! Set the speed.

! Reprogram parameters.


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4 Exploded drawings / parts lists

4.1 KTB-K / KTBD-K with end drive

4.1.1 Parts list for KTB-K / KTBD-K with end drive

No. Designation Order number

KTB-45K KTB-60K KTB-80K KTB-/ KTBD-105K

KTB-/ KTBD-140K

KTB-/ KTBD-185K

KTB-/ KTBD-250K

10 Chassis aluminum 48396/…. 23584/…. 23583/…. 26330/…. 21476/…. 26331/…. 37435/….

10 Chassis for sliding plate, aluminum

- 58652/…. 58653/…. 58787/…. 58788/…. 58789/…. 58790/….

Sliding plate stainless - 58791/ 0039/….

58791/ 0059/….

58791/ 0084/….

58791/ 0119/….

58791/ 0164/….

58791/ 0229/….

20 Conveyor end with deflection roller, single belt

57972 57973 57974 54874 57975 58700 58701

20 Conveyor end with deflection roller, dual belt

- - - 54882 57989 58702 58703

30 KTBD-KR drive unit, single belt

57976 57977 57978 57979 57980 58705 58708

30 KTBD-KL drive unit, single belt

57981 57982 57983 57984 57985 58706 58709

30 KTBD-KR drive unit, dual belt

- - - 54329 57986 58711 58714

30 KTBD-KL drive unit, dual belt

- - - 57987 57988 58712 58715

50 Gear motor version S 50071 50071 50071 50071 50071 50071 50071

50 Gear motot version L 50072 50072 50072 50072 50072 50072 50072

60 Connecting cable 5m 520705 520705 520705 520705 520705 520705 520705

60 Connecting cable 10m 520706 520706 520706 520706 520706 520706 520706


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4.2 KTB-K conveyor end with deflection roller, single belt

4.2.1 Parts list for KTB-K conveyor end with deflection roller, single belt

No. Sym. Designation Order number Mat.

KTB-45K KTB-60K KTB-80K KTB-105K KTB-140K KTB-185K KTB-250K

◘ Conveyor end with deflec-tion roller, single belt compl.

57972 57973 57974 54874 57975 58700 58701 Var.

10 ◊ Conveyor end 48535 48126 48536 48537 48130 50989 50985 Alu

20 ◊ Thrust piece 48127 48127 48127 48127 48127 48127 48127 Steel

30 ● Deflection roller compl. 48527 48488 48528 48529 48530 50990 50987 Var.

30 ◊ Conveyor-conveyor element compl.

36546 36546 36546 36546 36546 36546 36546 Steel

● These are wearing parts and available ex stock. ◊ Not available ex stock individually (upon request). ◘ Price-listed items available ex stock.


31

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4.3 KTBD-K conveyor end with deflection rollers, dual belt

4.3.1 Parts list for KTBD-K conveyor end with deflection roller, dual belt


KTBD-105K KTBD-140K KTBD-185K KTBD-250K

◘ Conveyor end with deflection roller,dual belt complete

54882 57989 58702 58703 Var.

10 ◊ Conveyor end 48537 48130 50989 50985 Alu

20 ◊ Thrust piece 48127 48127 48127 48127 Steel

30 ● Deflection roller complete 54316 54317 58716 58717 Var.

30 ◊ Conveyor-conveyor element compl. 36546 36546 36546 36546 Steel



32

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4.4 KTB drive unit for end drive, single belt


33

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4.4.1 Parts list for drive unit for end drive


KTB-45KR/KL

KTB-60KR/KL

KTB-80KR/KL

KTB-105KR/KL

KTB-140 KR/KL

KTB-185 KR/KL

KTB-250KR/KL

◘ Drive unit for end drive right (KR) one belt complete

57976 57977 57978 57979 57980 58705 58708 Var.

◘ Drive unit for end drive right (KL) one belt complete

57981 57982 57983 57984 57985 58706 58709 Var.

10 ◊ Tab, drive side ri. compl. (KR) 48458 48458 48458 48458 48458 48458 48458 Var.

10 ◊ Tab, drive side le. compl. (KL) 48459 48459 48459 48459 48459 48459 48459 Var.

20 ◊ Tab, single ri. (KR) 48161 48161 48161 48161 48161 48161 48161 Alu

20 ◊ Tab, single le. (KL) 48468 48468 48468 48468 48468 48468 48468 Alu

30 ◊ Sliding block 21913 21913 21913 21913 21913 21913 21913 Steel

40 ◊ Cheesehead screws M6x12 504644 504644 504644 504644 504644 504644 504644 Steel

50 ◊ Ribbed washer M6 505255 505255 505255 505255 505255 505255 505255 Steel

60 ◊ Side part 48153 48153 48153 48153 48153 48153 48153 Alu

70 ◊ Cover 48157 48157 48157 48157 48157 48157 48157 Alu

80 ◊ Countersunk screw M4x25 506370 506370 506370 506370 506370 506370 506370 Steel

90 ◊ Threaded pin M3x6 506368 506368 506368 506368 506368 506368 506368 Steel

100 ◊ Edged adjusting pin Ø6x20 508116 508116 508116 508116 508116 508116 508116 Steel

110 ● Protective cover complete 48445 48445 48445 48445 48445 48445 48445 Var.

120 ● Cog wheel for gear motor, complete

48106 48106 48106 48106 48106 48106 48106 Alu

130 ● Cog wheel for drive roller 48109 48109 48109 48109 48109 48109 48109 Alu

140 ● Toothed belt 506367 506367 506367 506367 506367 506367 506367 PUR

150 ◊ Spring wedge 3x3x16 506714 506714 506714 506714 506714 506714 506714 Steel

160 ◊ Plate spring Ø29.7/17.3x1.55 506369 506369 506369 506369 506369 506369 506369 Steel

170 ◊ Locking part complete 48469 48469 48469 48469 48469 48469 48469 Steel



200 ◊ Spring washer M4 504382 504382 504382 504382 504382 504382 504382 Steel

210 ◊ U-washer M4 506097 506097 506097 506097 506097 506097 506097 Steel

220 ● Drive rolls complete 48531 48479 48532 48533 48534 50988 50984 Var.



34

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4.5 KTBD drive unit for end drive, dual belt


35

®

4.5.1 Parts list for drive unit for end drive


KTBD-105KR/KL

KTBD-140KR/KL

KTBD-185KR/KL

KTBD-250 KR/KL

◘ Drive unit for end drive right (KR) double belt compl.

54329 57986 58711 58714 Var.

◘ Drive unit for end drive right (KL) double belt compl.

57987 57988 58712 58715 Var.

10 ◊ Tab, drive side ri. compl. (KR) 48458 48458 48458 48458 Var.

10 ◊ Tab, drive side le. compl. (KL) 48459 48459 48459 48459 Var.

20 ◊ Tab, single ri. (KR) 48161 48161 48161 48161 Alu

20 ◊ Tab, single le. (KL) 48468 48468 48468 48468 Alu

30 ◊ Sliding block 21913 21913 21913 21913 Steel

40 ◊ Cheesehead screws M6x12 504644 504644 504644 504644 Steel

50 ◊ Ribbed washer M6 505255 505255 505255 505255 Steel

60 ◊ Side part 48153 48153 48153 48153 Alu

70 ◊ Cover 48157 48157 48157 48157 Alu

80 ◊ Countersunk screw M4x25 506370 506370 506370 506370 Steel

90 ◊ Threaded pin M3x6 506368 506368 506368 506368 Steel

100 ◊ Edged adjusting pin Ø6x20 508116 508116 508116 508116 Steel

110 ● Protective cover complete 48445 48445 48445 48445 Var.

120 ● Cog wheel for gear motor 48106 48106 48106 48106 Alu

130 ● Cog wheel for drive roller, com-plete

48109 48109 48109 48109 Alu

140 ● Toothed belt 506367 506367 506367 506367 PUR

150 ◊ Spring wedge 3x3x16 506714 506714 506714 506714 Steel

160 ◊ Plate spring Ø29.7/17.3x1.55 506369 506369 506369 506369 Steel

170 ◊ Locking part complete 48469 48469 48469 48469 Steel



200 ◊ Spring washer M4 504382 504382 504382 504382 Steel

210 ◊ U-washer M4 506097 506097 506097 506097 Steel

220 ● Drive rolls complete 55305 55306 57012 57013 Var.



36

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5 Environmental compatibility and disposal

Materials used

! Aluminum

! Steel

! Copper

! ABS acrylonitrile-butadiene/styrene

! PUR polyurethane

! POM polyoxymethylene

! PS polystyrene

! Polyethylene

! Polyester

! Various electronics components

! Gear lubricant Klüber STABURAGS NBU 12/300 KP

Surface treatment

! Anodizing of aluminum

! Chemical nickel-plating of steel

! Painting of metal

Shaping processes

! Profile pressing of aluminum

! Machining of aluminum, steel and POM

! Thermoforming of ABS

! Injection molding of ABS

! Die-casting of aluminum

! Vulcanization of PUR

Emissions while operating

Keine

Disposal

Conveyors that are no longer fit for operation should not be disposed of as complete units but should be dismantled into parts and recycled according to the kind of material. The kind of ma-terial used for each part is shown in the spare parts lists. Materials which cannot be recyled should be disposed of appropriately. In particular, it should be noted that the gear lubricant must be disposed of separately.

MONTECH AG Gewerbestrasse 12, CH-4552 Derendingen Fon +41 32 681 55 00, Fax +41 32 682 19 77 [email protected], www.montech.com

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