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Attention
It is very important for the proper functioning of the Spiralveyor that maintenance is done
correctly and timely. In the enclosures of this manual you will find a maintenance log in
which all maintenance must be documented. Improper, insufficient or not documented
maintenance will void any warranty. The most important maintenance activity is to remove
chainoverlength.
This document contains maintenance schedules with instructions and intervals, supported
by video clips that can be found by following the website links provided in this document.
For any question regarding maintenance please contact our service department or your
local sales office.
© Nothing of this documentation may be reproduced in any form without the written permission of
the manufacturer.
2008/11/14 Page 3 of 75
1 Preface 5
1.1 Purpose of this manual 5
1.2 Structure of the manual 5
1.3 Requirements of the user 5
2 Technical specification 7
3 Introduction 9
3.1 Supplier’s information 9
3.2 Manufacturer’s declaration 10
3.3 Purpose of use 10
3.4 Operating conditions 10
3.5 Description of the Spiralveyor 11
3.6 Working principle 14
3.7 Control units 15
4 Safety 17
4.1 The most important safety conditions 17
4.2 Description of safety provisions 17
4.3 Safety measures to be taken 18
4.4 Explanation of symbols 18
5 Unload the Spiralveyor 20
5.1 Preparation 20
5.2 Unloading instructions 21
5.2.1. Unload the Spiralveyor from the truck at the rear side / from the container 21
5.2.2. Unload the Spiralveyor from the truck at the top 23
5.2.3. Unload the Spiralveyor from the truck at the side 24
5.2.4. Unload the Spiralveyor from a crate 25
5.2.5. Erecting the Spiralveyor 25
6 Mounting, installation, adjustment and commissioning 28
6.1 Provisions to be provided 28
6.2 Assembly 28
6.2.1. Motor reductor 28
6.2.2. Installing chain over length detection 30
6.2.3. Mounting B-guide 31
6.3 Validation 32
6.3.1. Dimension check Spiralveyor 32
6.3.2. Adjusting and setting the Spiralveyor 32
6.4 Integration in a (transport) system 34
6.4.1. Floor construction 34
6.4.2. Frequency control 35
6.4.3. Checklist integration 35
6.5 Reverse / adjust / set 36
6.5.1. Mechanical 36
6.5.2. Controls 37
6.6 Check / Shadow run 38
7 Technical maintenance 41
7.1 Troubleshooting-list 41
7.2 Maintenance schedule Spiralveyor 43
7.2.1. Checking conveyor plates 45
7.2.2. Checking chain tension and chain stretch 45
7.2.3. Checking side guide 46
7.2.4. Checking for skid 46
7.3 Maintenance procedures 47
7.3.1. Feature too move the slatbelt 47
7.3.2. Slatbelt service location 48
7.3.3. Replacing conveyor plates 48
7.3.4. Shorten chain 51
7.3.5. Align sprocket wheel 51
7.3.6. Replace reversing roller 52
7.3.7. Replace sprocket wheel 54
7.3.8. Lubricate the motor 55
8 Put out of comission 56
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8.1 Disconnect the power sources 56
8.2 Disassemble 56
8.3 Transport 56
8.4 Reuse 56
9 Sales offices AmbaFlex 58
Enclosures
I SEW Manufacturer’s declaration 59
II Spare parts list 60
II - A Article list 61
II - B SV-400 63
III Brakemotor 68
IV Electrical installation 72
IV - A Wiring diagram for chain overlength detection 73
V Maintenance Log 74
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1 Preface
This manual has been composed on the basis of the Technical Specification of the machine. This means
that this document is only valid for the Spiralveyor of the type and serial number mentioned on the cover of
the title page of this manual. Everything described in this manual may not be copied without written
permission from AmbaFlex. In this chapter the purpose, the set-up and the requirements of the user with
respect to this manual are explained in more detail.
1.1 Purpose of this manual
The purpose of this manual is to describe a number of operations that are intended for the user concerned.
Here it becomes clear how the user can work as well and as safely as possible. By making use of clear
illustrations and texts AmbaFlex wants to achieve a simple and safe way of working with the Spiralveyor.
This document contains remarks that point out a risky or specific situation to the user. In many cases this
situation is provided with one of the symbols given below.
General warning for danger!
Warning for electrical tension!
Attention, this is an important notice!
Unauthorised persons are not admitted!
Compliance with the operations described in this document is important in order to prevent dangerous
situations and unnecessary damage to the Spiralveyor. Carefully keep this document! It is recommended to
keep one copy near the machine and one copy with your technical documentation.
1.2 Structure of the manual
The user’s manual h
as been composed in such a way, that a number of operations can quickly and easily be
found. This manual will not describe operations that are not meant for the user. It does, however, indicate
what the user must do when carrying out a certain operation, for example calling in technical staff. The
user’s manual has been divided into three sections. These sections describe, among other things, the safety
and the operation of the Spiralveyor. AmbaFlex would like to point out to the user that section 4 safety [4
Safety] is to be read carefully.
1.3 Requirements of the user
The Spiralveyor may be operated by any adult person who has become acquainted with section 4 safety [4
Safety] and section 5 unload the spiralveyor [5 Unload the Spiralveyor]. If the user is not
technically qualified, he or she may not carry out any maintenance or repair activities on the Spiralveyor.
Maintenance activities on the Spiralveyor may only be carried out by a technically
qualified person.
2008/11/14 Page 7 of 75
2 Technical specification
Below the technical specification of the Spiralveyor with the corresponding type
and serial number is given. If
the user loads the Spiralveyor with weights, products or speeds not mentioned in the technical specification,
the guarantee will no longer be valid.
Introduction
Build up
Machine code SV-400-1300-719-S-4-B-26-TU-TPS4HF1
(500)
Base machine static parts
Frame
Outside dimension square 1980 mm
(562)
Diameter of the chain centre line (d2) 1300 mm
(561)
Belt width 400 mm
(560)
Spiralveyor type SV-400-1300
(153)
Pitch (z) 719 mm
(347)
Material Mild steel
(157)
Finishing Wet painted RAL colour 1015 gloss
(384)
Number of windings 4 windings
(160)
In / out feed configuration B
(162)
Lower end height Standard floor range mounted 600 mm (h1)
(171)
Upper end height Floor mounted 3800 mm (h3)
(348)
Height difference (h2) 3200 mm
(370)
Slope angle (a) 9,98 °
(371)
Column diameter 760 mm
(563)
Supports Standard floor mounting support frame
(175)
Feet Galvanised feet -70/+110 mm adjustable (AmbaFlex
model)
(178)
Base machine moving parts
Slat belt options
Slat type TPS Black POM
(186)
High friction insert ratio HF1 (100%)
(188)
Base chain Carbon steel
(193)
Belt guide rollers Carbon steel, ZZ-sealed
(429)
Shafts, sprockets and main bearings
Shafts, sprockets and bearings Carbon steel, ZZ seal
(196)
Shaft length 100 mm extended
(374)
Drive system
Position of the motor(s) on the shaft Motor positioned on the outer radius of the track
(205)
Motor orientation Vertically up
(208)
Mounting Drives supplied loose, to be mounted on site
(350)
Gear motor
Voltage 230-400V 3ph/50Hz, mass and zero, Europe
(368)
Mechanical isolation class IP54
(216)
Thermostatic isolation class ISO F
(367)
Special options Brake motor with 380 V brake voltage (with securable
manual brakelifter)
(467)
Speed and pull tension
SEW speed / pull combination SEW type KA47DT90L4; v= 26 m/min; 1,5 kW; 72 rpm;
199 Nm; fb 2 (row 676 )
(378)
Transport direction Up (TU)
(242)
Special Base Machine Options
Special static parts
Special vertical return channel 100 mm extra offset
(248)
Transport orientation Horizontally
(698)
Transport frames and options Standard transport frame
(700)
Accessories
Guide on the outside radius
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Guide plate B style plate guide, 100 mm effective height, stainless
steel
(281)
Spacers on the outside radius
Spacers for C, D or B guide 100 mm offset (plastic)
(770)
Maintenance features
Chain service location Chain service area in return channel
(735)
Chain overlength detection Chain overlength detection sensors
(736)
Chain overlength detection Connection box for chain overlength detection cables
(759)
Guarding
Under guarding Solid black polystyrene under the complete track
(683)
Spiralveyor system design
Machine capacity
Total track length 18,5 m
(558)
Minimum speed before overload (> 18 Hz) At maximum indicated throughput the machine will
overload below a speed of 9,4 m/min
(729)
Use
Operation environment Normal dust free operation, no wet cleaning
(564)
Additional supplies
Spare parts
Spare parts set Standard set included
(328)
Manuals
User manual supplied with machine 1 copies English language
(330)
User manual supplied with machine 1 copies Spanish language
(414)
Maintenance manual supplied with machine 1 copies English language
(334)
User manual supplied to purchase office 1 copies English language
(533)
User manual supplied to purchase office 1 copies Spanish language
(538)
Maintenance manual supplied to purchase
address
1 copies English language
(439)
All manuals on CD All manuals supplied to purchase address on 1 CD(s)
(728)
Identification marker
Type plate AmbaFlex
(480)
Sticker AmbaFlex
(481)
Product dimensions, weight & throughput
Rows Product name Length Width Height Weight Throughput
Single Closed cartons1 320 mm 190 mm 370 mm 18 kg 40 /min
Single Closed cartons2 380 mm 300 mm 400 mm 18 kg 40 /min
If the Spiralveyor is loaded with weights, products or speeds not mentioned in the
technical specification, the guarantee will no longer be valid.
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3 Introduction
This section deals with a number of general matters with respect to the Spiralveyor. This involves, among
other things, the purpose of use, the conditions of use and the working principle of the Spiralveyor. Should
you have any further questions on the safe operation of the Spiralveyor, you are requested to contact the
supplier.
3.1 Supplier’s information
This manual goes together with the Spiralveyor of the type mentioned on the order and on the title page of
this manual. This document was drawn up by:
AmbaFlex R&D BV
Date: 2002/06/20
Copyright: AmbaFlex - The Netherlands, 2000
The machine was produced by:
AmbaFlex Manufacturing BV Tel: +31 (0)299 27 44 49
De Corantijn 81 Fax: +31 (0)299 27 45 19
1689 AN Zwaag E-mail: manufacturing@ambaflex.com
The Netherlands www.ambaflex.com
In case of failures please contact the system integrator.
The Spiralveyor has been provided with the CE-mark. This means that the machine complies with the
applicable European guidelines with respect to safety and health. In the annex ‘Specification of the
guidelines’ the applicable guidelines are indicated in detail.
The guarantee conditions have been included in the order confirmation. AmbaFlex does not accept any
liability for unsafe situations, accidents and damages resulting from:
• Neglect of warnings or stipulations as displayed on the machine or in this documentation.
• For other applications or under other circumstances than those indicated in this documentation use
the order confirmation and the catalogue.
• Modifications on the machine. This also includes the use of other replacement parts than prescribed.
• Insufficient or incorrect maintenance.
AmbaFlex does not accept any liability for the consequential damage in case of failures of the machine, for
example damage of products, interruption of operation, etc.
2008/11/14 Page 10 of 75
3.2 Manufacturer’s declaration
The manufacturer:
AmbaFlex Manufacturing B.V.
De Corantijn 81
1689 AN Zwaag
The Netherlands
Hereby declares that the machine:
SPIRALVEYOR TYPE SV100, SV200, SV400, SV600, SV800
• is intended to be installed in a machine or integrated with other machines in the construction of a
machine governed by the provisions of the latest amendment of Directive 98/37/EC;
• and consequently does not comply with all the provisions of the aforementioned Directive.
and, moreover, declares that the aforementioned machine may not be put into service until the machine into
which the aforementioned machine is to be installed or incorporated is in accordance with the provisions of
the Directive 98/37/EC, and with the provisions of the national legislation introduced to implement this
Directive.
Done at Zwaag, 05 December 2002
Theo Ammeraal
Operations Manager
3.3 Purpose of use
The purpose of use of the Spiralveyor is to transport products / goods in vertical direction. This may be for
br
idging a difference in height or for functioning as buffer. It is not to be recommended to use the Spiralveyor
for transporting products with parts that are protruding or hanging loose, for transporting products that result
in a higher load than mentioned in the order and for transporting products with measures deviating from
those given in the technical specification (annex 2a) associated with the machine number. Apart from that it
is not allowed to walk, stand or sit on the Spiralveyor and to stick objects or body parts between the guards,
conveyor plates or other moving parts.
3.4 Operating conditions
The circumstances under which the Spiralveyor can be applied partly depend on the materials selected. Yet
AmbaFlex has defined a number of parameters within which the Spiralveyor would be allowed to function.
Should the Spiralveyor still be applied beyond these limiting values, AmbaFlex cannot guarantee the good
functioning of the Spiralveyor.
Ambient temperature (in operation)
0 to +35°C
During transport / storage
-5 to +40°C
Relative air humidity (RH)
30% to 95%, not condensing
Lighting
Normal ambient lighting
Height
Up to max. 2000 m above sea level
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As a standard no lighting is installed on the Spiralveyor and this can neither be installed as an option.
Normal ambient lighting is sufficient to work safely with the Spiralveyor. The Spiralveyor is not intended for
use in the open air and besides the Spiralveyor is not suitable for an environment with a risk of explosion.
For use under deviating circumstances you may contact the supplier of the Spiralveyor.
3.5 Description of the Spiralveyor
The Spiralveyor is applied in a (transport) system with which various parcels / products can be transported
vertically along a relatively small surface. The Spiralveyor can be coupled to each transport system and be
built according to the customer’s needs.
Principle sketch Configuration options
The operating environment is to be adjusted to the presence of the Spiralveyor. This involves safety,
ambient climate and the integration of these. After integration / installation the Spiralveyor can no longer be
moved.
Dimensions of the Spiralveyor
De track width of the Spiralveyor is available in different conveyor-plate widths (see technical specification).
The height of the Spiralveyor is variable and depends on the calculated values allowed. The outside
diameter of the Spiralveyor may vary just like the height and further dimensions. These are variable and can
be adjusted to the customer and the use (see technical specification annex 2a).
Components Spiralveyor
The Spiralveyor consists of the following components:
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No.
Component
Description
1.
Frame
The basic frame of the Spiralveyor
consists of a central cylinder, a return
tray and an upper and lower end. The
materials of these components
depend on the configuration selected.
The return tray can be divided into a
vertical and a horizontal return tray.
Both the upper end and the lower end
may function as the input or output
part of the Spiralveyor.
2.
Conveyor belt
The conveyor belt consists of a chain
and conveyor plates with guide rollers.
The conveyor belt can have an
optional length and width. The
flexibility of the system enables
interconnection of all parts. The
conveyor belt rotates in a spiral form
around the central cylinder and is
guided on the plastic glide strips. The
conveyor belt is driven by the motor
reductor.
3.
Motor reductor
The motor reductor has been mounted
on the drive shaft of the conveyor belt.
On the driving shaft a chain wheel has
been mounted that is connected to the
chain of the conveyor belt.
Components Spiralveyor frame
1. Central cylinder column
2. Upper end
3. Lower end
4. Mounting frame
5. Return tray vertical
6. Return tray horizontal
7. Conveyor belt
Cylinder + mounting frame Lower end Upper end
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1. Vertical return tray
2. Horizontal return tray
Return trays
1. Conveyor plate
2. Chain
3. Link
Components conveyor belt
1. Motor reductor
2 Drive shaft
3. Chain wheel
4. Reaction arm
5. Reversing roller + guide belt
Drive
Explanation of machine terms
This manual contains a number of terms that will frequently be used. The most important terms will be
discussed below.
No.
Component
Description
1.
Conveyor plate
Narrow plastic plate (strips)
provided with a guide roller.
Conveyor plates are mounted in a
row on the basic chain and so form
the transport surface.
2.
Basic chain
This is a laterally flexible chain on
which the conveyor belt is
mounted.
3.
Mounting frame
The Spiralveyor is placed on an
underframe that is attached to the
floor surface.
4.
O-ring
In the Spiralveyor two types of O-
rings are used, being an O-ring
(optional) that ensures the driving
of the transition roller and an O-ring
placed around the reversing roller
that reduces the noise.
5.
Side guide (optional)
The side guide makes sure that the
products follow the track or
prevents them from falling off the
Spiralveyor.
6
Bottom plating
(optional)
The bottom plating avoids
exposure of the chain, so that
people or products cannot come in
contact with the moving part.
7.
Side plating (optional)
As an extra protection of the
environment side plating can be
chosen for the HS Spiralveyors that
completely guards the Spiralveyor.
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TPS-HF conveyor plate TPT-HF conveyor plate Side plating HS – Bookbinder
Synthetic black underguarding O-ring Side guide (D style guide rail)
The dimensions given are explained in short below.
Configuration input / output
The configuration of the Spiralveyor is available in different types with the corresponding input / output.
These configuration types are expressed in the letters A -
H. The correct configuration is selected dependent
on the system the Spiralveyor is integrated in.
It is possible to have a configuration with which the output side is placed in a certain angle. For this special
configuration please contact AmbaFlex in order to discuss the possibilities with respect to this.
3.6 Working principle
The purpose of the Spiralveyor is to transport products / goods vertically to bridge a difference of height or to
function as buffer zone.
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Principle sketch Spiralveyor
1. Conveyor belt
2. Upper end
3. Lower end
4. Return tray horizontal
5. Return tray vertical
6. Motor reductor
In most cases the Spiralveyor is integrated in a system. The input / output side of the Spiralveyor is
determined dependent on the system. In order to give a clear example, it is assumed that the input side is at
the lower end of the Spiralveyor and that the product will bridge a difference in height in order to continue the
required transport on the output side.
Input products Transport products Output products
1.
The product arrives at the input side of the Spiralveyor. The reduction motor drives the conveyor belt
with the required speed.
2. Subsequently, the product on the conveyor belt will bridge the height allowed by the Spiralveyor.
3. When the product arrives at the output side of the Spiralveyor it will continue its way in the system.
The conveyor belt will through the return tray (horizontal and vertical) go back to the starting point of
the input side.
3.7 Control units
As a standard the Spiralveyor is delivered without control. In this case we refer for operating instructions to
the system integrator / installer, who installs or has designed the control. Here it is obligatory to install an
operating switch at the
drive! With this switch the tension on the motor can be switched off in order to ensure
safely working on the machine. A control unit that obligatory should be present on the Spiralveyor is one of
multiple emergency stop switches.
Complete control panel
2008/11/14 Page 17 of 75
4 Safety
The Spiralveyor has been designed in such a way, that it can be used and maintained in a safe way. This
holds for the application, the circumstances and the instructions described in the manual. Any person
working with or on this machine should study the manual and follow the instructions. It is the responsibility of
the employer to make sure that the employee is familiar with and follows these instructions.
The company or the country in which the machine is used may require extra safety measures. This
particularly applies to the working conditions. This manual does not describe how these are to be complied
with. In case of doubt, consult your government or safety officer!
4.1 The most important safety conditions
At the moment that the Spiralveyor is going to be operated by a user, the following safety conditions mus
t be
met:
• Make sure that children or animals have no access to the machine and its surrounding area by, for
example, screening off the Spiralveyor with a fence.
• Only persons who have read and understood the operating instructions are allowed to operate,
maintain and clean the machine.
• Do not reach into the machine while it is running or on. Even if the machine is not running, it can be
‘on’, which means start operating automatically.
• Safety provisions, such as side plating, bottom plating, emergency stops and detectors may not be
removed or deactivated while the Spiralveyor is running.
• Provide good ambient lighting to enable the operator to work well and orderly with the Spiralveyor.
4.2 Description of safety provisions
As a standard the Spiralveyor is not provided with control and any safety provisions. Before putting the
Spiralveyor into operation some safety provisions are to be taken care of. The purpose of these safety
provisions is to protect the user, the product and the Spiralveyor against undesired situations (damage).
Without these safety provisions AmbaFlex cannot give a guarantee on any damage caused in absence of
these safety provisions.
The table below gives a general description of the safety provisions required. For the correct settings of
these safety devices / safety provisions we refer to paragraph 4.5 of the Technical Manual. Here it should be
noted that only technically qualified employees are allowed to work on the settings of the safety provisions!
Control
Remark
Emergency-stop switch
Each Spiralveyor is to be provided with one or more emergency-stop
switches that can be operated within reach of the user. The switch must
have the standard red colour. The emergency-stop switch must make
sure that the input and output tracks are switched off simultaneously.
Motor protection
The technical specification of the Spiralveyor is, among other things,
geared to the load given in the order confirmation. Should the
Spiralveyor (motor) be overloaded for certain reasons, this should be
detected. Without this protection there is a chance that the motor
reductor or other components of the Spiralveyor will be damaged.
If it cannot be made sure that there will be no product on the machine that exceeds the
minimum or maximum dimensions (see technical specification), the detector described
below must be installed on the Spiralveyor.
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Height / width detector
The product that is put into the Spiralveyor may not get stuck as a result
of a too high / wide or twisted product. In order to ensure that products
fit in the Spiralveyor and will not get stuck, the input of the SV can be
checked for height / width. This detection must take place well before
the Spiralveyor prior to putting the product on the Spiralveyor. The
maximum dimensions of the product are given in the technical
specification (see annex 2a).
Mechanical
Remark
Transition guard
At the transition between the Spiralveyor and a connected conveyor a
guard must have been placed, so that persons are kept at a reaching
distance from the transition.
If the Spiralveyor has not been provided with bottom plating, a fence is to be placed
around the Spiralveyor. This is to keep people at a safe distance.
Fence
The bottom and side platings give sufficient protection to
ensure safe operation of the Spiralveyor. If the Spiralveyor
has not been provided with bottom plating, placing a fence
around the Spiralveyor is obligatory to prevent persons
from getting into contact with the Spiralveyor.
Fence at the top of the Spiralveyor
The cover at the top of the column is not meant and rated
for people access or storage of any material. If a walkway
or mezzanine is present and the top of the column is
accessible, a fence must be placed to prohibit access to
the top cover. The purpose of the cover is to close the
Spiralveyor column and prevent dirt to fall into it.
Only technically qualified employees are allowed to change the settings of the safety
provisions.
4.3 Safety measures to be taken
For a safe operation of the Spiralveyor a number of safety measures are to be taken. These include the
following measures:
• Clean floor surface -
With a clean floor surface the operator will not be hindered while operating the
Spiralveyor. This can prevent tripping or slipping, so that the operator does not unexpectedly come
into contact with the Spiralveyor.
• Hearing protection - Different tests have shown that the Spiralveyor does not produce more than
the legally stipulated 85 dB(A). If the operator works in a room in which the noise exceeds the legal
85 dB(A) also caused by Spiralveyor, the operator should wear hearing protection. Apart from that
the Spiralveyor can be provided with a sound shield that will reduce the noise.
4.4 Explanation of symbols
Just like in the manual, symbols are used that have been placed on the Spiralveyor in order to point the
attention of the user to certain situations or provide certain information on components of the Spiralveyor.
2008/11/14 Page 19 of 75
No.
Description
Picture
1.Type plate Spiralveyor
This contains the name and
the address of AmbaFlex.
Apart from that the CE-mark,
series or type indication, serial
number and the year of
construction of the Spiralveyor.
2.Rotation direction
On the Spiralveyor an arrow
indicates the rotation direction
of the conveyor belt. This is
important for the electrical
connection of the motor.
3.Type plate motor
This contains the name and
the address of the motor
supplier. Apart from that the
CE-mark, kind of motor oil,
series or type indication, serial
number and the year of
construction of the motor.
2008/11/14 Page 20 of 75
5 Unload the Spiralveyor
This section describes the steps that are required for unloading the Spiralveyor. It is recommended to make
use of the devices described in § 3.1. When using this or another device this device is expected to be
provided with a quality mark.
The operations concerned are to be carried out calmly in order to be able to carefully
monitor any movement of the Spiralveyor.
5.1 Preparation
Before starting the unloading a good preparation is required. The appropriate devices must be available.
Apart from that the first transport check is an important part of the unloading, as in case of damage this
should be mentioned on the delivery note in relation to guarantee and the like.
Device(s) required
The weight of the Spiralveyor may vary and for the correct weight we refer to the technical specification of
the Spiralveyor. For a safe unloading of the Spiralveyor from the container / truck it is advised to use the
following devices:
Fork-lift truck Crane Hoist
Jack Transport roller Pump carriage
A fork-lift truck, crane and hoist must have a minimum hoisting capacity of 1.5x the weight of the Spiralveyor
(see technical specification). When putting the Spiralveyor upright it must be secured to the hoisting device
to prevent shifting. A hoist can be used if at the place of putting upright there is no room for a crane or a fork-
lift truck.
The devices used must have been approved and be provided with a quality label.
The first transport check
After arrival of the Spiralveyor a transport check is to be carried out. The check can be carried out at the
moment the Spiralveyor has been unloaded from the container or the truck. The technical specification gives
the dimensions to be checked. Is the spiral delivered undamaged and is it the correct Spiralveyor?
/
