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CleanSweep® RM125
TECHNICAL DOCUMENTATION
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Technical Documentation
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CleanSweep® RM125
Table of contents
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CleanSweep® RM125
Table of figures
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CleanSweep® RM125
List of tables
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CleanSweep® RM125
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CleanSweep® RM125
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CleanSweep® RM125
Mayfran CleansweepRM conveyors are installed in applications chip-producing machine tools, etc.
They convey metal chips, scrap from a machnine tool to a chip container or a collecting conveyor. The conveyor is
designed with self cleaning maintenance screenbox cartridges used to clean the cooling lubricant applied in the
machining process. The finest chips are transported by means of a patented inner chip handling system in the same
chip tank or collecting conveyor as the coarse chips.
This operating manual provides instructions for care, maintenance, and spare part replacement.
The manual is not specific to a conveyor design, which can be designed as straight or have a bend and subsequent
ascending section.
The conveyed material and contaminated cooling lubricant continually fall to the conveying surface of the conveyor.
Finest dirt
discharge via
auger
Interchangeable
screen
The conveyed material is then continuously transported to the discharge opening. Long chips are discharged from the
steel belt. Small chips and fine dirt are discharged via the internal chip transport system. An interchangeable, low-
maintenance filter cardridge cleans the cooling lubricant before it is discharged in a coolant tank.
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1 Bear in mind that the conveyor is in continuous operation during machine production.
This operating manual must be available to the operator responsible for the conveyor and to the maintenance
personnel.
The guarantee is only valid if these requirements are strictly observed.
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CleanSweep® steel belt conveyors are usually delivered fully assembled. Depending on customer wishes or due to its
lengths, the conveyor can also be delivered in multiple parts.
The steel belt is then delivered on one or multiple pallets; small parts such as screws, belt joint, etc. are delivered in
separate crates / cartons.
4.2 TRANSPORT
1 Do not stand under suspended loads! The figures on this page should be considered examples.
The available load suspension devices must always be used for lifting and transporting.
p
Crane transport: Always use the available load suspension devices (M12x20mm).
The lifting eyes are not part of the delivery. Note that they are according to the local safety directive.
For the total weight please check order documents.
o Forklift transport: Always transport the conveyor packed on the wooden pallet and secured
against slipping or falling over.
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2 Work on the electrical system may only be performed by appropriately qualified experts in
observance of the locally applicable statutory regulations.
U Never stand or reach into the area of the chip discharge opening.
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6 COMMISSIONING
1
Ensure stable and secure machine setup.
Secure the system against sudden, unexpected operation.
Bear in mind the danger of entanglement of hands and loose clothing.
1. The conveyor must be aligned precisely. The deviation from the centre line may not exceed 2 mm on either side.
3. Before the conveyor belt is put into operation, the belt tension must be checked.
The belt tension is correct when it is possible to slighlty lift-up the steel belt from the track by 10-20 mm on the
discharge side in the bottom part. Should this not be the case, then please loosen or tighten the belt.
Make sure that the system is not switched on when checking the belt tension.
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4. The sidewings of the steel belt conveyor must run parallel to each other in the conveying direction. Excessive play
or bent side panels will lead to a jamming of the belt and hooking of the chips.
6. Is the current power supply according to the specification of the gear motor?
7. Is the conveyor (especially the overload protection device of the gearmotor) connected correctly to the machine
tool interface according specifications?
8. The conveyor should run without load for at least five hours.
During the run-in, ensure that the steel belt moves freely and do no bend anywhere.
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w
Close all gate valves and valves!
Remove all harmful substances!
Cooling lubricant may not be released into the environment!
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8 PREVENTIVE MAINTENANCE
8.1 GENERAL SERVICE POINTS
With the performance of regular maintenance (regular inspection, cleaning and maintnance intervals) according to
below guidelines, the Mayfran conveyor has a long service life with minimal wear. Please ensure that the steel belt
and chains are always lightly oiled.
The service intervals mentioned in this document are based on normal operating conditions and single shift usage
factors according to the table bleow. Service intervals should be adjusted accordingly when operating conditions and
usage factors change.
Oiling on a monthly basis is adequate for dry machining. If the belt is exposed to the elements, the maintenance work
must be especially diligent.
Check the belt regularly for damage in order to ensure that spare parts can be replaced in good time. Malfunctions
can be avoided as a result.
The maintenance of supplier components, such as pumps, cooling units, etc. must take place according to the
manufacturer's specifications.
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8.2 MAINTENANCE
1 Drive unit
2 Shaft bearing
4 Frame bracket
5 Torque arm
The connection takes place by means of a standard M12x1 plug-type connector (DIN 43650 / ISO 4400) or an
appropriate plug socket as follows:
Number 1 2 3 4
Connection COM in brown NC (normally closed) in white M12x1 plug NO (normally open) in black
Gear
Type Gear oil quantity Manufacturer
unit
2. Re-check the belt tension and tighten as necessary on regular basis, see chapter 6 ‘Commissioning’.
3. Remove the chain guard and check whether there is recongnisable wear or signs of rubbing on the rollers, side
panes, and chains. If this is the case please refer to chapter 11 ‘Elemination of faults’.
4. The drive bearings are provided with life-long grease lubrication for normal loads.
5. Check the correct fixation and position of the brushes and wipers of the inner handling system. See Chapter 9.2.
6. The specified conveying capacity of chips can only be achieved if the conveyor runs continuously. This means that
the conveyor must always be operated simultaneaously with the machine tool.
2. Check the bottom plate at the discharge opening and the returning steel belt for chip accumulations. If chips
have accumulated, the respective positions need to cleaned.
3. The inner chip handling system (especially the auger discharge funnel) must be free of chip accumulations
and cleaned on regular basis. See chapter 9.3
4. The inner filter cartridge(s), especially the coolant exit openings must be inspected for chip accumulation and
cleaned as necessary on regular basis. See chapter 9.8
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CleanSweep® RM125
Activity Operating
Component Service activity Remark
sequence hours*
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9 REPLACEMENT OF COMPONENTS
An overview and list of the main components of the CleanSweep® RM125 are provided in chapter 12.1 'CleanSweep®
RM125 main components'.
1 Belt axle
2 Rubber wiper
4 Roller block
5 Belt plate
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The stell belt comprises special cleats which are composed of a combination of brushes and wipers and which can be
adjusted form the upper side of the belt.
Adjustment is carried out by handpressing the brush or wiper down to the inner chip handling plate in the charge
section of the conveyor. Fixate the bruch or wiper by tightening the bolts firmly and mark their location with a water/oil
proof marker.
The brushes and wipers must be inspected for wear, adjusted as necessary, and possibly replaced on regular basis.
The auger and the discharge channel of the CleanSweep conveyor must be inspected periodically for material
accumulation and cleaned as necessary (Figure 4: Removal of the steel belt, position 3).
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CleanSweep® RM125
1 Worm bearing
3 Auger channel
4 Drive unit
5 Bearing shaft
8 Shaft
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The electrical connections must be removed by authorised, qualified personnel for the removal of the gear motor. The
torque support bolt must be loosened for removal of the drive unit (see Figure 4: Removal of the steel belt, position 7).
The removal of the drive shaft takes place complete with bearing and chain wheels.
For this purpose, the belt and the drive motor must be removed as described under chapter 9.1 (Removal of the steel
belt) and 9.2 (Replacement and adjustment of brushes and wipers).
Now the belt of the drive bearings must be loosened and the shaft can be removed (see chapter Figure 4: Removal of
the steel belt, position 15).
The fastening bolts can be loosened from the drive shaft by turning it anti-clockwise with an Allen key. Now the
bearings can be pulled off of the drive shaft by hand (see Figure 4: Removal of the steel blet, position 5).
The filter cartridge must be inspected for material accumulation or wear and cleaned or replaced as necessary. The
filter cartridge is represented in Figure 6: CleanSweep® RM125 main components, position 4 and must also be
removed as necessary.
9.9 ASSEMBLY
Prior to assembly, it must be ensured that all damaged or worn parts have been replaced. Assembly takes place in the
reverse order of the removal.
The side panels of the belt must overlap in the conveying direction.
1
For the tension of the belt, it must be ensured that both tensioning stations are tightened evenly so
that the drive shaft is perpendicular to the conveyor frame.
Uneven belt tension leads to increase wear of chains, chain guides, chain wheels, and tracks.
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The following points must be taken into consideration for simple cleaning:
1. Switch off the conveyor.
6. Ensure the correct running direction of the belt prior to machine start-up.
More-intensive cleaning can take place after the entire belt has been removed.
Then the belt (on both sides) and the inner sides of the frame can be cleaned with a high pressure cleaner.
The belt can be re-installed after it has been cleaned (see chapter 9.9 Assembly).
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11 ELIMINATION OF FAULTS
Excessive wear of the outer sides of the Bent frame or poorly Align the belt and the frame as
side panels. aligned drive shaft. necessary.
The overload coupling is not Run the conveyor until the overload
Error message from the microswitch of the
in the correct or normal coupling jumps back to the correct
overload protection coupling
position. position.
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1 Auger bearing
3 Auger channel
4 Filter cartridge
5 Drive unit
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CleanSweep® RM125
http://www.mayfran.com
sales@mayfran.eu
www.mayfran.nl
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