Declaration of Incorporation

for an incomplete machine in accordance with Machine Directive 2006/42/EC, attachment II, no. 1 B

Manufacturer: WTT Fördertechnik GmbH

Wellershausen 3
42929 Wermelskirchen, Germany
Phone 0 21 96 / 942 0
Fax 0 21 96 / 942 89

herewith declares that the following product (equipment / machine / device)

Product name: Roller conveyor

Series / Type: 3.89.2.5-F S
Machine / series number: 2015 - 0474
Year of manufacture: 2016
complies with the following essential requirements of the Machinery Directive (2006/42/EC):
Attachment I, articles 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4 and 1.5.1.
The incomplete machine furthermore complies with all requirements of the Low Voltage (2006/95/EC) and
Electromagnetic Compatibility (2004/108/EC) directives.
The following harmonised standards were applied:
EN ISO 12100 Safety of machinery. Basic concepts, general principles for design –
Part 1: Basic terminology, methodology
EN 13857:2008 Safety of machinery – Safety distances to prevent danger zones from
being reached by the upper and lower limbs
EN 349:1993+A1:2008 Safety of machinery – Minimum gaps to avoid crushing of parts of the
human body
EN 619:2011-02 Continuous conveyer and systems – safety and EMC requirements for
mechanical conveyers of piece goods
The incomplete machine may be commissioned only when it has been determined that the machine into which
the incomplete machine is to be installed complies with the requirements of the Machinery Directive
(2006/42/EC).

The manufacturer undertakes to transmit electronically the special documentation on the incomplete machine to
national authorities if requested.
The special technical documentation belonging to the machine as per attachment VII part B was created.
The person responsible for the documentation was: R. Schwabe, Tel.: +49(0)2196 942-92
Wermelskirchen, den 3.5.2016

Signature______________________________________
Bodo Maleikat Managing director
 Installation instruction for an incomplete machine
in accordance with ATTACHMENT VI of the EC Machine Directive
2006/42/EG

Name: Conveyor unit

Order no.: K-2015-0474

Order no.: 395490

Year of manufacture: 2016

Customer:

Fabricator: WTT Fördertechnik GmbH

Wellershausen 3
D-42929 Wermelskirchen
Tel.: 0 21 96 / 942 0
Fax: 0 21 96 / 942 89

Page 1 of 18
Table of contents

1 Safety instructions and symbols used in this manual ........................................... 3

1.1 Danger ......................................................................................................................... 3
1.2 Warning ....................................................................................................................... 3
1.3 Caution ........................................................................................................................ 3
1.4 Note ............................................................................................................................. 3
2 Safety instructions .................................................................................................... 4
2.1 Operating instructions and safety instructions for conveyor belts ............................... 6
3 Technical data............................................................................................................ 7
3.1 Material to be conveyed .............................................................................................. 7
3.2 Electrical data: ............................................................................................................. 7
4 Scope of delivery ....................................................................................................... 8
4.1 Item 1 - 1 x Roller conveyor - series 3.89.2.5-F S ....................................................... 8
5 Technical description ................................................................................................ 9
5.1 Components ................................................................................................................ 9
5.1.1 Roller conveyor - series 3.89.2.5-F S .......................................................................... 9
6 Proper use ................................................................................................................ 10
7 Transport, installation, commissioning, dismantling and disposal ................... 11
7.1 Transport ................................................................................................................... 11
7.2 Installation ................................................................................................................. 11
7.3 Commissioning .......................................................................................................... 12
7.3.1 Measures to be taken priror to commissioning .......................................................... 12
7.3.2 Commissioning without load ...................................................................................... 12
7.3.3 Commissioning with load ........................................................................................... 12
7.4 Dismantling and disposal ........................................................................................... 12
8 Operation .................................................................................................................. 13
8.1 Decommissioning ...................................................................................................... 13
9 Measures to be taken in the event of malfunction ............................................... 13
10 Maintenance, service .............................................................................................. 14
10.1 Maintenance schedule............................................................................................... 14
10.2 Lubricants .................................................................................................................. 15
11 Residual risks .......................................................................................................... 16
12 Spare parts ................................................................................................................ 17
12.1 Instructions regarding the spare and wear parts ....................................................... 17
12.2 Spare and wear parts lists ......................................................................................... 18
13 Idex of appendices .................................................................................................. 18

Page 2 of 18
1 Safety instructions and symbols used in this manual

1.1 Danger
Instructions with this symbol must be strictly adhered to in order to prevent
injury to persons.

1.2 Warning
Instructions with this symbol must be adhered to in order to prevent damage to
persons, the environment or the processed product.

1.3 Caution
Instructions with this symbol must be adhered to in order to prevent damage to
the processed product.

1.4 Note

Page 3 of 18
2 Safety instructions

Caution!
Have you read the operating manual – in particular chapter 2 "Safety
instructions"?
If not, you may not operate the unit.

Caution!
Prior to carrying out any maintenance or cleaning work, switch the unit off at
the main switch.
Maintenance, cleaning and repair work should only be carried out by
authorised specialist technicians.

Caution!
Only suitably trained, authorised and reliable personnel may operate the unit.
Ensure that all personnel working on or at the unit have read and fully
understood the operating manual, in particular the safety instructions and
sections referring to residual risks.

Caution!
Modifications to and deactivation of safety devices can lead to serious injury.
Never modify or deactivate the safety devices without the explicit consent of
the manufacturer.
Extensions and modifications to the unit may only be carried out by suitably
trained and authorised personnel.

Caution!
Do not touch energised machine components! Risk of electrocution!

Caution!
The unit must be installed by trained and authorised specialist personnel.

Protect the environment!

The handling and disposal of detergents is governed by statutory
regulations.
Dispose of cloths contaminated with detergents through an authorised waste
collector. For more information, contact the local authorities (water
management bureau or trade supervisory office)
Page 4 of 18
Prevent detergent from spilling!
Take preventive measures to limit damage in the event of spillage of
detergent (e.g. collecting or binding of spilt liquid).

Caution!
To dismantle and dispose of the unit, employ only suitably trained and
authorised specialist personnel.

Protect the environment!

The handling and disposal of dismantled unit parts is governed by statutory
regulations.

Page 5 of 18
2.1 Operating instructions and safety instructions for conveyor belts

The signs described below are affixed on the materials handling technology and contain
the most important safety and operating instructions.

These signs are an integral part of the materials handling equipment and may not be
removed.

Signs that have become illegible must be replaced without delay.

Factory type plate, containing the

following details:
- Conveyor type
- Year of manufacture
- Bearing capacity
- Operating voltage

Prohibition sign

Direction of conveyance
sign

Page 6 of 18
3 Technical data

3.1 Material to be conveyed

Material to be conveyed: Foam blocks

Dimensions: Length: L= 350 - 650 mm

Width: B= 300 - 550 mm
Weight: max. 50 kg

Conveying Directions: lengthways

Continuous operation: 8h , 5 days / week

Special Features: Dry and dusty

Installation location: dry operation in enclosed spaces, environmental

temperature + 10°C to + 40°C

Floor structure at site: We presume that it is possible to attach to the

Floor using normal fixing dowels, and that there is
no underfloor heating, or floor containing
magnesite, etc.

3.2 Electrical data:

Operating voltage U = 400 V+N+PE - 50 Hz
Drive Fabricat SEW, Type of protection IP54

Without electric control systems and without required logic elements and without these
dislocation.

Page 7 of 18
4 Scope of delivery

4.1 Item 1 - 1 x Roller conveyor - series 3.89.2.5-F S

Conveyor length: L= 4.975 mm

Installation length: IL = 2.900 mm
Speed: v= 6 m/min; 50Hz
Driven: P= 0,55 kW with TH

Page 8 of 18
5 Technical description

5.1 Components

5.1.1 Roller conveyor - series 3.89.2.5-F S

The roller conveyor consists mainly of:
- Supporting construction
- Side plates of L-profile 135/51/20/5
- supporting rollers with precision grooved ball-bearings, on one side with steel
simply sprocket
- drive, return- and tension station
- geared motor
- height adjustable support legs
Protective devices for drive and chain drive, fitted in conformance with the accident
prevention regulations

Page 9 of 18
6 Proper use

The conveyor units should be used only to transport the materials described
in section "Material to be conveyed"!

Any other use is deemed to be unintended use, and is therefore forbidden!

Proper use of the conveyor technology also includes:

 Operation of the conveyor technology in accordance with this

operating manual.
 Compliance with the safety instructions.
 Execution of specified set up work.
 Execution of specified maintenance and service measures.
 Compliance with the technical data.

Improper use is:

 Operation and execution of maintenance and service measures by

personnel who have not been instructed and trained in operation,
service, and maintenance of the device.
 Unauthorized conversions or modifications.
 Operation with material to be conveyed other than that material
specified under proper use.
 Operation with non-functioning safety devices and sensors.
 Operation of the materials handling equipment if there are apparent
malfunctions.

Use only original spare parts or standard parts approved by the

manufacturer.
When replacing parts, always adhere to the dismantling and installation
instructions of the manufacturer or parts supplier.

Always comply with the instructions regarding the operation, maintenance

and repair of the unit as specified in this operating manual.

Page 10 of 18
7 Transport, installation, commissioning, dismantling and disposal

7.1 Transport
Each conveyor is one transport unit.
It can thus be easily transported with a fork-lift truck or manual lifting platform to the
location of installation.
Use only suitable transport and lifting gear with the necessary capacity.

7.2 Installation
Caution!
The unit must be installed by trained and authorised specialist personnel.

Risk of injury!
The securing straps are taut! When opening the straps, wear protective
gloves and goggles.

The installation location must be planar and able to take a load.

Page 11 of 18
7.3 Commissioning

7.3.1 Measures to be taken priror to commissioning

- Remove any foreign objects

- Are all elements properly aligned?
- Are all safety devices mounted and working properly?
- Are all emergency-stop buttons and other switching elements working properly?
- Check the oil fill level of the gear units
- Check the motors' direction of rotation
- Check the chain tension

7.3.2 Commissioning without load

- General function check of the materials handling equipment

- Switch on the conveyor and let it run without material to be conveyed
- Check for clean running
- Note any unusual noises

7.3.3 Commissioning with load

- General function check of the materials handling equipment

- Check the run of the material to be conveyed
- If needed correct the height of the unit
- Adjust the limit switches, light barriers, end-stops etc.
- Check movement of all transport variants

7.4 Dismantling and disposal

Caution!
To dismantle and dispose of the unit, employ only suitably trained and
authorised specialist personnel.

Protect the environment!

The handling and disposal of dismantled unit parts is governed by statutory
regulations.

Page 12 of 18
8 Operation

Readiness for operation is established by switching on the main switch.

The materials handling equipment should only be operated if all instructions

regarding “safety” and “proper use” have been complied with followed.

Detailed instructions on the use and operation of the equipment are to be found in the
control system documentation.

8.1 Decommissioning

At the end of a shift or during breaks, always shut down the materials
handling equipment in order to prevent unauthorised operation.

To do this, lock operating switch and shut down the unit at the main switch.

9 Measures to be taken in the event of malfunction

Basic instructions

Caution!
Prior to carrying out any maintenance or cleaning work, switch the unit off at the
main switch.
Maintenance, cleaning and repair work should only be carried out by authorised
specialist technicians.

Caution!
Do not touch energised machine components! Risk of electrocution!

Page 13 of 18
10 Maintenance, service

Comply with all safety instructions when performing maintenance work!

Caution!
Prior to carrying out any maintenance or cleaning work, switch the unit off at
the main switch. Maintenance, cleaning and repair work should only be
carried out by authorised specialist technicians.

The Maintenance intervals specified in this manual apply for materials

handling equipment in single-shift operation. If operated in multiple shifts or
under extreme conditions, adjust the maintenance intervals accordingly.

10.1 Maintenance schedule

Interval
Assembly Task Instructions
t w m v h j
Roller conveyor
Visual inspection for Repair the damage
Roller conveyor x
external damage If necessary, fit replacement parts
Screwed connections Check for firm seat x Tighten if necessary
Check lubricant / change x Change lubricant after 10,000 hours
Spur gear motor
lubricant of operation or after 2 years

Work instructions and specifications

in accordance with maintenance
manual lubrication
https://www.sew-
eurodrive.de/os/dud/?tab=documents&co
untry=de&language=de_DE
Apply lubricant with brush
Chain
or spray
x Oil, viscosity class SAE 40 Ⓗ
Chain wheels Check for wear x Replace if necessary
There is danger of accident
Protective cladding Check for firm seat x if operated without
protective cladding!
t = daily, w = weekly, m = monthly, v = every 3 months, h = every 6 months, j = annually
Ⓐ Ⓑ Ⓒ Ⓓ Ⓔ Ⓕ Ⓖ Ⓗ = Lubrication details are in the next 2 sections

When adding or changing fluid, use only an equivalent product

Page 14 of 18
10.2 Lubricants

Ref.
Rolith in
SHELL MOBIL ESSO BP KLÜBER CHEMICALS accordanc
e with DIN
Ⓐ Shell Mobilux 3 BEACON 3 BP Energrase CENTOPLEX 3 K3K-20
Alvania R3 LS3 DIN 5 1825

Shell Mobilux FIBRAX EP BP Energrease MICROLUBE GPOOG-10

Alvania GLOO EP 004 370 PR-EPOO GBOO GOH
Ⓒ GPOON-10
BP Energrease DIN 51 825
LS-EPOO
Shell Mobilgear CAZARK1 BP Energol POLYLUB BCV
Malleus GL 95 OGL 007 (OG1C-30) WRL HVT50 DIN 51513
Ⓓ
A-SPRAY
Shell
Malleus OHG
Ⓔ Shell DTE 46 NUTO H 46 Energol HLP 46
Tellus 46 HLP 46 DIN 51524/2

Ⓕ Shell Mobilgear SPARTAN BP Energol KLÜBEROIL CLP 220

Omala Oil 220 630 EP 220 GR-XP 220 GEM 1-220 DIN 51 517

Ⓖ Shell Mobilgear BP Energol KLÜBEROIL VG 680

Omala Oil 680 636 GR-XP 680 GEM 1-680

Ⓗ Structovis HD Kettenspray-
Nass
K-AE59

Page 15 of 18
11 Residual risks

Description of risk Measures to reduce risk

Severe crushing injuries can occur through
moving the conveyor device for repair and
maintenance tasks.
Instruct personnel on the potential
risks
Prohibition signs on the materials
handling equipment (see
operating and safety instructions)

Page 16 of 18
 12 Spare parts

12.1 Instructions regarding the spare and wear parts

Ensure that your spare parts stock is complete

This ensures This prevents

- fast repair - prolonged downtime

- low repair costs - high repair costs
- high availability of the lift

For fast and efficient handling of your order, please provide the following information:

1. Designation of the equipment

2. Year of manufacture
3. OC no.
4. OC item
5. Equipment item
6. Order quantity
7. Additionally the Designation and possibly Drawing no./Item no.
8. Manufacture no.
9. Dispatch address

Spare and replacement parts list

Page1 from 1 page
Designation:
Roller conveyor series 3.89.2.5-F S
OC no.: 2015/0474

Drawing OC
no.: ENG-1604-000046 item: 1
Machine
Item no. Designation Drawing no. / Item no. Quantity V
item
1 Spur geared motor 7 1
RF47 DRS71M4 TH ES7C
0,55kW;21U/min;230/400V;50Hz;
IP54;M1/0°;Fl.140; Ø30x60;ISOF

2 Motor sprocket 3.2.1.3.1.Kf.46/4 8 1

5/8”; z=13; Ø30 with groove

Page 17 of 18
12.2 Spare and wear parts lists

Item Name Series / Type Draving no. sheet

1 Roller conveyor 3.89.2.5-F S ENG-1604-000046 6

The specified replacement and wear parts lists with drawings are provided in the
Appendix!

13 Idex of appendices

- Spare and replacement parts lists with drawings

- Manufacturer's Declaration
- You will find the documentation for the motors under
https://www.sew-eurodrive.de/os/dud/?tab=documents&country=de&language=de_DE

Page 18 of 18