TR 0008 1 Whispersort FieldManual 1of3 Oct2007

TM
WhisperSort
Field Manual
P/N 0312996
TR-0008
WhisperSortTM
Field Manual
WhisperSort is a trademark of HK Systems, Inc., Hebron, Kentucky
The following information is proprietary information of HK Systems, Inc. and must not be used
except in connection with our work, nor in any manner disclosed to any third party without
HK Systems prior written consent. All rights of design and invention are reserved.
Recipient of this manual acknowledges that he/she will abide by the instructions contained in this
manual and in the training classes furnished by HK Systems. He/She will not tolerate any operation
that is contrary to these instructions. If the recipient observes equipment that presents a hazard,
he/she will promptly inform HK Systems so that a solution can be achieved.
Copyright 2001, 2003, 2004, 2007 by HK Systems, Hebron, Kentucky
P/N 0312996
TR-0008 October, 2007
WhisperSortTM Field Manual
WhisperSort
Chapter 1. Introduction
1.0
1.1
1.2
1.2.1
WhisperSort Overview ........................................................................................................................... 1-3

Product Summary....................................................................................................................................... 1-4
WhisperSort Documentation ................................................................................................................... 1-6
Bulletins ...................................................................................................................................................... 1-8
Chapter 2. Safety
2.0
2.1
2.2
2.3
2.4
2.4.1
2.5
2.5.1
2.5.2
2.5.2.1
2.5.2.2
2.5.2.3
2.6
2.6.1
2.6.2
2.7
2.7.1
2.7.2
2.8
2.8.1
Safety ............................................................................................................................................................ 3
Conveyor Safety Rules .................................................................................................................................. 4
Project Manual Safety Video and Safety Poster Introduction......................................................................... 5
Mechanical Maintenance Safety .................................................................................................................... 7
Electrical Maintenance Safety ....................................................................................................................... 7
Safety Guidelines .......................................................................................................................................... 7
Application Safety.......................................................................................................................................... 8
Headroom...................................................................................................................................................... 8
Guarding........................................................................................................................................................ 8
End Covers.................................................................................................................................................... 9
Bottom Covers............................................................................................................................................... 9
Finger/Hand Protection.................................................................................................................................. 9
Controls Safety .............................................................................................................................................. 9
Electrical Code .............................................................................................................................................. 9
Control Stations ........................................................................................................................................... 10
Safety Devices............................................................................................................................................. 10
Emergency Stops and Restarts ................................................................................................................... 10
Transfer, Loading, and Discharge Points..................................................................................................... 11
Safety Labels............................................................................................................................................... 12
Local Safety Considerations ........................................................................................................................ 13
Chapter 3. Mechanical Installation

3.0
3.1
3.2
3.3
3.4
3.4.1
3.4.1.1
3.4.2
3.5
3.6
3.6.1
3.6.2
3.7
3.8
3.8.1
3.8.2
3.8.3
3.8.4
3.8.5
3.8.6
3.8.7
Mechanical Installation ............................................................................................................................... 3-5

Supports ..................................................................................................................................................... 3-5
Inspection ................................................................................................................................................... 3-5
Layout......................................................................................................................................................... 3-5
Set Screw Retightening .............................................................................................................................. 3-6
General Guidelines for Fastener Tightening Torque................................................................................... 3-6
Torque Specifications for the Bolts used in Aluminum Extrusions .............................................................. 3-8
T-Bolts ........................................................................................................................................................ 3-9
Tools/Equipment Needed for Installation: ................................................................................................... 3-9
Preliminary Support Installation ................................................................................................................ 3-10
Intermediate Supports .............................................................................................................................. 3-11
Support Leg Weldment for Drive and Tail Sections .................................................................................. 3-12
Preliminary Sorter Installation................................................................................................................... 3-13
Installation Steps ...................................................................................................................................... 3-13
Step 1 Tail Assembly ............................................................................................................................. 3-14
Step 2 Intermediates ............................................................................................................................. 3-15
Step 3 Catenary..................................................................................................................................... 3-16
Step 4 Spur Sections ............................................................................................................................. 3-17
Step 5a Divert Module (Single-Sided Sorters) ....................................................................................... 3-19
Step 5b Divert Module (Dual-Sided Sorters).......................................................................................... 3-23
Step 6 Cam Guide ................................................................................................................................. 3-27
P/N 0312996
WhisperSort Field Manual
3.8.3
3.8.4
3.8.5
3.8.6
3.8.7
3.8.8
3.8.9
3.8.10
3.8.11
3.8.12
3.8.13
3.8.14
3.8.15
3.8.16
3.8.17
Step 3 Catenary..................................................................................................................... 3-16

Step 4 Spur Sections............................................................................................................. 3-17
Step 5a Divert Module (Single-Sided Sorters) ...................................................................... 3-19
Step 5b Divert Module (Dual-Sided Sorters)......................................................................... 3-23
Step 6 Cam Guide ................................................................................................................. 3-27
Step 7a Return Guide (Single-Sided).................................................................................... 3-34
Step 7b Return Guide (Dual-Sided) ...................................................................................... 3-37
Step 8 Side Guide Wearstrips, Wheel Track, and Wheel Cover........................................... 3-41
Step 9 Controls Tasks ........................................................................................................... 3-44
Step 10 Chain/Flight Assemblies .......................................................................................... 3-44
Step 11 Drive ......................................................................................................................... 3-47
Step 12 Load Belt Conveyor.................................................................................................. 3-48
Step 13 Installing Belt End Discharge Section..................................................................... 3-52
Step 14 Gravity Roller End Discharge................................................................................... 3-55
Step 15 Controls Tasks ......................................................................................................... 3-57
Chapter 4. Maintenance
4.0
MAINTENANCE ......................................................................................................................... 4-3
4.1
24-Hour Hotline Service ............................................................................................................. 4-3
4.1.1
Hotline Service Contract............................................................................................................. 4-3
4.1.2
Equipment Problems .................................................................................................................. 4-3
4.2
Equipment Warranty................................................................................................................... 4-4
4.3
Lubrication .................................................................................................................................. 4-5
4.4
Set Screw Retightening .............................................................................................................. 4-5
4.5
Drive and Take-Up Assembly (Discharge)................................................................................. 4-6
4.5.1
Phasing Sprocket Located on Drive Shaft.................................................................................. 4-6
4.5.2
Fixed Sprocket Located on Drive Shaft...................................................................................... 4-7
4.5.3
Pusher Out-of-Position Detector ................................................................................................ 4-7
4.5.4
Squaring the Drive Shaft ............................................................................................................ 4-8
4.6
Adjusting Belt End Discharge Section........................................................................................ 4-9
4.7
Adjusting Gravity Roller End Discharge ................................................................................... 4-12
4.8
Catenary Section ...................................................................................................................... 4-15
4.9
Chain Adjustment ..................................................................................................................... 4-16
4.10
Intermediate Sections............................................................................................................... 4-18
4.10.1
Side Guide Wear Strip and Aluminum Wheel Track Removal................................................. 4-19
4.10.2
Wearstrip Replacement ............................................................................................................ 4-19
4.10.3
Aluminum Wheel Track Replacement ...................................................................................... 4-20
4.10.4
Steel Wheel Track Adjustment ................................................................................................. 4-20
4.10.5
Pin Guides ................................................................................................................................ 4-20
4.11
Tail Section (In Feed) ............................................................................................................... 4-21
4.11.1
Cam Guide Ring Located on Tail Shaft.................................................................................... 4-22
4.11.2
Pin Guide Adjustment............................................................................................................... 4-23
4.11.3
Encoder .................................................................................................................................... 4-23
4.11.4
Replacement Procedure for Components Located on Tail Shaft............................................. 4-23
4.12
Divert Switch and Divert Guides............................................................................................... 4-24
4.12.1
Divert Control Module, Divert Proximity Sensor, and other Control Devices ........................... 4-24
4.12.2
Divert Signal ............................................................................................................................. 4-24
4.12.3
Switch Module .......................................................................................................................... 4-26
4.12.4
Divert Module............................................................................................................................ 4-29
4.13
Chain Flight Assembly.............................................................................................................. 4-30
4.14
Slat Removal and Pusher Replacement .................................................................................. 4-32
4.15
Pusher Assembly...................................................................................................................... 4-35
4.16
Crossover Switch Motor Replacement ..................................................................................... 4-36
4.17
Wheel and Side Guide Bearing Replacement.......................................................................... 4-39
2
P/N 0312996
Chapter 5. Electrical Controls Installation and Setup

5.0
5.1
5.2
Electrical Controls Installation and Setup ................................................................................................... 5-3

Critical Items Checklist (Controls Installation)............................................................................................. 5-3
Standard Offerings ..................................................................................................................................... 5-5
Chapter 6. DeviceNet Single-Sided Model 1

6.0
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
6.1.10
6.1.11
6.1.12
6.1.13
6.1.14
6.1.15
6.1.16
6.1.17
6.1.18
6.1.19
6.1.20
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8
6.3.9
6.3.10
6.3.11
6.3.12
6.3.13
6.3.14
6.3.15
6.4
6.4.1
6.4.2
6.4.3
DeviceNet Single-Sided Model 1 ............................................................................................................. 6-4

Installation Instructions ............................................................................................................................... 6-4
Controls Installation Overview .................................................................................................................... 6-4
Power Busway System ............................................................................................................................... 6-6
DeviceNet System ...................................................................................................................................... 6-8
DeviceNet Media and Connectors .............................................................................................................. 6-9
Divert Switch Assembly .............................................................................................................................. 6-9
Divert Control Module ............................................................................................................................... 6-10
Divert Control Module I/O Assignments.................................................................................................... 6-12
Long Range Jam Photoeye ...................................................................................................................... 6-13
Slack Chain and Shoe out of Position Sensors ........................................................................................ 6-14
Sorter Chain Oilers ................................................................................................................................... 6-15
Pin Greaser .............................................................................................................................................. 6-15
Induction Encoder..................................................................................................................................... 6-15
Sizing Divert Control Module Power Supplies........................................................................................... 6-15
End of Sorter Photoeye (Option) .............................................................................................................. 6-17
Divert Confirm Inductive Proximity Switch (Option) .................................................................................. 6-17
Dynamic Jam Photoeyes (Option) ............................................................................................................ 6-17
Full Lane Photoeyes (Option) .................................................................................................................. 6-18
Full Lane Photoeyes (Option) ............................................................................................................... 6-18
Induction Photoeye (Option) .................................................................................................................... 6-18
Broken Pin Assembly (Option).................................................................................................................. 6-18
Drawings................................................................................................................................................... 6-21
WhisperSort General Device Application .............................................................................................. 6-23
General Arrangement Overview ............................................................................................................... 6-25
Infeed ....................................................................................................................................................... 6-27
Intermediate.............................................................................................................................................. 6-29
Catenary ................................................................................................................................................... 6-31
Drive ......................................................................................................................................................... 6-33
Divert Switch............................................................................................................................................. 6-35
Broken Pin Kit........................................................................................................................................... 6-37
Reference Tables for Control Kits............................................................................................................. 6-39
Divert Switch Part Numbers...................................................................................................................... 6-39
Long Range Jam Photoeye Kit (Kit TRA03801-1) .................................................................................... 6-40
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)................................................ 6-41
Divert Confirm Proximity Switch Kit (Kit TRA03801-3).............................................................................. 6-41
Dynamic Jam Photoeye Kit (Kit TRA03801-4) .......................................................................................... 6-42
End-of-Sorter Photoeye Kit (Kit TRA03801-5) .......................................................................................... 6-43
Full Line Photoeye Kit (Kit TRA03801-6) .................................................................................................. 6-44
3/4 Full Line Photoeye Kit (Kit TRA03801-7) ............................................................................................ 6-45
Induction Photoeye Kit (Kit TRA03801-9) ................................................................................................. 6-46
DeviceNet Kit (Kit TRA03801-10) ............................................................................................................. 6-46
Power Busway Kit (Kit TRA03801-11) ...................................................................................................... 6-47
Divert Control Module Kit (Kit TRA03801-12) ........................................................................................... 6-47
Application Specific Quantities ................................................................................................................. 6-48
Broken Pin Detector Assembly ................................................................................................................. 6-49
Start Up and Test Procedures (DeviceNet Single-Sided) ........................................................................ 6-50
Sorter Power Check List ........................................................................................................................... 6-50
Sorter DCM DC Power Check List............................................................................................................ 6-51
Sorter DeviceNet System Check List........................................................................................................ 6-51
P/N 0312996
6.4.4
6.4.5
6.4.6
6.4.7
Chain Oiler ................................................................................................................................................6-52

Spray Oiler (Optional) ...............................................................................................................................6-52
Pin Greaser...............................................................................................................................................6-53
Start Up.....................................................................................................................................................6-53
Chapter 7. Discrete I/O Single-Sided Model 2

7.0
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.3.1
7.2.3.2
7.2.3.3
7.2.4
7.2.4.1
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
7.2.10
7.2.11
7.2.12
7.2.13
7.2.14
7.2.15
7.2.15.1
7.2.15.2
7.2.15.3
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
7.3.8
7.3.9
7.3.10
7.3.11
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.4.9
7.4.10
7.4.11
7.5
7.5.1
7.5.2
4
Discrete I/O Single-Sided Model 2 ...........................................................................................................7-5

Overview .....................................................................................................................................................7-5
Installation Instructions................................................................................................................................7-6
Controls Installation Overview.....................................................................................................................7-6
Divert Switch Assembly...............................................................................................................................7-7
Divert Control Module .................................................................................................................................7-8
Power and I/O Connections ........................................................................................................................7-9
Sorter DCM Operation ................................................................................................................................7-9
Manual Switch Operation of Divert Switches.............................................................................................7-10
Long Range Jam Photoeye.......................................................................................................................7-10
Long Range Jam Photoeye Alignment Procedure ....................................................................................7-11
Sorter Chain Oilers ...................................................................................................................................7-12
Pin Greaser...............................................................................................................................................7-12
Induction Encoder .....................................................................................................................................7-12
Sizing Divert Control Module Power Supplies ...........................................................................................7-13
End of Sorter Photoeye (Option) ...............................................................................................................7-14
Divert Confirm Inductive Proximity Switch (Option)...................................................................................7-14
Dynamic Jam Photoeyes (Option).............................................................................................................7-14
Full Lane Photoeyes (Option) ..................................................................................................................7-14
Full Lane Photoeyes (Option)................................................................................................................7-15
Induction Photoeye (Option) ....................................................................................................................7-15
Broken Pin Assembly (Option) ..................................................................................................................7-15
Mounting Location.....................................................................................................................................7-16
Operation ..................................................................................................................................................7-16
Mapping I/O ..............................................................................................................................................7-17
Drawings ...................................................................................................................................................7-18
WhisperSort General Device Application...............................................................................................7-20
General Arrangement Overview................................................................................................................7-22
Infeed ........................................................................................................................................................7-24
Intermediate ..............................................................................................................................................7-26
Catenary ...................................................................................................................................................7-28
Drive .........................................................................................................................................................7-30
Divert Switch .............................................................................................................................................7-32
Broken Pin Kit ...........................................................................................................................................7-34
Electrical Connections DCM Module......................................................................................................7-36
Electrical Connections Confirm Prox......................................................................................................7-38
Electrical Connections Broken Pin Module ............................................................................................7-40
Reference Tables for Control Kits (Discrete I/O Single-Sided).................................................................7-42
Divert Switch Part Numbers ......................................................................................................................7-42
Long Range Jam Photoeye Kit (Kit TRA03801-1).....................................................................................7-42
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA04031-2) ................................................7-43
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) ..............................................................................7-43
Dynamic Jam Photoeye Kit (Kit TRA03801-4) ..........................................................................................7-44
End-of-Sorter Photoeye Kit (Kit TRA04031-5) ..........................................................................................7-45
Full Line Photoeye Kit (Kit TRA04061-6) ..................................................................................................7-46
3/4 Full Line Photoeye Kit (Kit TRA04061-7) ............................................................................................7-47
Induction Photoeye Kit (Kit TRA03801-9) .................................................................................................7-48
Divert Control Module Kit (Kit TRA04031-10) ...........................................................................................7-49
Broken Pin Detector Assembly (Kit TRA03801-16L or 16R) .....................................................................7-49
Start Up and Test Procedures...................................................................................................................7-50
Sorter DCM DC Power Check List ............................................................................................................7-50
Chain Oiler ................................................................................................................................................7-50
P/N 0312996
7.5.3
7.5.4
7.5.5
Spray Oiler (Optional) ............................................................................................................................... 7-51

Pin Greaser .............................................................................................................................................. 7-51
Start Up .................................................................................................................................................... 7-52
Chapter 8. DeviceNet Dual-Sided Model 3

8.0
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.6.1
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.11.1
8.1.11.2
8.1.12
8.1.13
8.1.14
8.1.15
8.1.16
8.1.17
8.1.18
8.1.18.1
8.1.18.2
8.1.18.3
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8
8.2.9
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
8.3.9
8.3.10
8.3.11
8.3.12
8.3.13
8.3.14
8.3.15
DeviceNet Dual-Sided ................................................................................................................................ 8-5

Installation Instructions ............................................................................................................................... 8-5
Controls Installation Overview .................................................................................................................... 8-5
Power Busway System ............................................................................................................................... 8-7
DeviceNet System ...................................................................................................................................... 8-9
DeviceNet Media and Connectors .............................................................................................................. 8-9
Divert Switch Assembly ............................................................................................................................ 8-10
Divert Control Module ............................................................................................................................... 8-11
Divert Control Module I/O assignments .................................................................................................... 8-12
Slack Chain and Shoe out of Position Sensors ........................................................................................ 8-13
Sorter Chain Oilers ................................................................................................................................... 8-14
Pin Greaser .............................................................................................................................................. 8-14
Induction Encoder..................................................................................................................................... 8-14
Sizing Divert Control Module Power Supplies........................................................................................... 8-14
Sorter Power Supplies .............................................................................................................................. 8-15
Sizing Power Supplies for DCMs .............................................................................................................. 8-15
End of Sorter Photoeye (Option) .............................................................................................................. 8-16
Divert Confirm Inductive Proximity Switch (Option) .................................................................................. 8-17
Dynamic Jam Photoeyes (Option) ............................................................................................................ 8-17
Full Lane Photoeyes (Option) .................................................................................................................. 8-17
Full Lane Photoeyes (Option) ............................................................................................................... 8-18
Induction Photoeye (Option) .................................................................................................................... 8-18
Broken Pin Assembly (Option).................................................................................................................. 8-18
Mounting Location .................................................................................................................................... 8-19
Operation.................................................................................................................................................. 8-19
Mapping I/O .............................................................................................................................................. 8-19
Drawings................................................................................................................................................... 8-20
WhisperSort General Device Application .............................................................................................. 8-22
General Device Application (contd).......................................................................................................... 8-24
General Arrangement Overview ............................................................................................................... 8-26
Tail Section............................................................................................................................................... 8-28
Intermediate.............................................................................................................................................. 8-30
Catenary ................................................................................................................................................... 8-32
Drive ......................................................................................................................................................... 8-34
Divert Module ........................................................................................................................................... 8-36
Broken Pin Kit........................................................................................................................................... 8-38
Reference Tables for Control Kits............................................................................................................. 8-40
Divert Switch Part Numbers...................................................................................................................... 8-40
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)................................................ 8-40
Divert Confirm Proximity Switch Kit (Kit TRA03801-3).............................................................................. 8-41
Dynamic Jam Photoeye Kit (Kit TRA03801-4) .......................................................................................... 8-42
End-of-Sorter Photoeye Kit (Kit TRA03801-5) .......................................................................................... 8-43
Full Line Photoeye Kit (Kit TRA03801-6) .................................................................................................. 8-44
3/4 Full Line Photoeye Kit (Kit TRA03801-7) ............................................................................................ 8-45
Induction Photoeye Kit (Kit TRA03801-9) ................................................................................................. 8-46
DeviceNet Kit (Kit TRA03801-10) ............................................................................................................. 8-46
Divert Control Module Kit (Kit TRA03801-12) ........................................................................................... 8-48
Application Specific Quantities ................................................................................................................. 8-49
Broken Pin Detector Assembly (Kit TRA03801-16) .................................................................................. 8-49
Crossover Motor Kit (Kit TRA04021-17) ................................................................................................... 8-50
P/N 0312996
8.3.16
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
Divert Control Module Kit Set-Up Switch (Kit TRA04021-19) ...................................................................8-50

Start Up and Test Procedures...................................................................................................................8-51
Sorter Power Check List ...........................................................................................................................8-51
Sorter DCM DC Power Check List ............................................................................................................8-52
Sorter DeviceNet System Check List ........................................................................................................8-52
Chain Oiler ................................................................................................................................................8-53
Spray Oiler (Optional) ...............................................................................................................................8-53
Pin Greaser...............................................................................................................................................8-54
Start Up.....................................................................................................................................................8-54
Chapter 9. Discrete I/O Dual- Sided Model 4

9.0
9.1
9.2
9.2.1
9.2.2
9.2.3
9.2.3.1
9.2.3.2
9.2.3.3
9.2.3.4
9.2.4
9.2.5
9.2.6
9.2.7
9.2.7.1
9.2.7.2
9.2.8
9.2.9
9.2.10
9.2.11
9.2.12
9.2.13
9.2.14
9.2.14.1
9.2.14.2
9.2.14.3
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.3.7
9.3.8
9.3.9
9.3.10
9.3.11
9.4
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
9.4.8
9.4.9
6
Discrete I/O Dual-Sided Model 4..............................................................................................................9-5

Overview .....................................................................................................................................................9-5
Installation Instructions................................................................................................................................9-6
Controls Installation Overview.....................................................................................................................9-6
Divert Switch Assembly...............................................................................................................................9-7
Divert Control Module .................................................................................................................................9-8
Power and I/O Connections ........................................................................................................................9-8
Sorter DCM Operation ..............................................................................................................................9-10
Divert Confirmation Board.........................................................................................................................9-10
Manual Switch Operation of Divert Switches.............................................................................................9-11
Sorter Chain Oilers ...................................................................................................................................9-11
Pin Greaser...............................................................................................................................................9-11
Induction Encoder .....................................................................................................................................9-11
Sizing Divert Control Module Power Supplies ...........................................................................................9-12
Sorter Power Supplies ..............................................................................................................................9-12
Sizing Power Supplies for DCMs ..............................................................................................................9-12
End of Sorter Photoeye (Option) ...............................................................................................................9-13
Divert Confirm Inductive Proximity Switch (Option)...................................................................................9-14
Dynamic Jam Photoeyes (Option).............................................................................................................9-14
Full Lane Photoeyes (Option) ..................................................................................................................9-14
Full Lane Photoeyes (Option)................................................................................................................9-14
Induction Photoeye (Option) ....................................................................................................................9-14
Broken Pin Assembly (Option) ..................................................................................................................9-15
Mounting Location.....................................................................................................................................9-15
Operation ..................................................................................................................................................9-15
Mapping I/O ..............................................................................................................................................9-16
Drawings ...................................................................................................................................................9-17
WhisperSort General Device Application...............................................................................................9-18
General Arrangement Overview................................................................................................................9-20
Tail Section ...............................................................................................................................................9-22
Intermediate ..............................................................................................................................................9-24
Catenary ...................................................................................................................................................9-26
Drive .........................................................................................................................................................9-28
Divert Module............................................................................................................................................9-30
Broken Pin Kit ...........................................................................................................................................9-32
Electrical Connection Broken Pin Module .................................................................................................9-34
Electrical Connection DCM Module...........................................................................................................9-36
Electrical Connection Confirm Prox...........................................................................................................9-38
Reference Tables for Control Kits (Discrete I/O Dual-Sided) ...................................................................9-39
Divert Switch Part Numbers ......................................................................................................................9-39
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA04031-2) ................................................9-39
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) ..............................................................................9-40
Dynamic Jam Photoeye Kit (Kit TRA03801-4) ..........................................................................................9-41
End-of-Sorter Photoeye Kit (Kit TRA04031-5) ..........................................................................................9-42
Full Line Photoeye Kit (Kit TRA04061-6) ..................................................................................................9-43
3/4 Full Line Photoeye Kit (Kit TRA04061-7) ............................................................................................9-44
Induction Photoeye Kit (Kit TRA03801-9) .................................................................................................9-45
Divert Control Module (Kit TRA04061-12).................................................................................................9-46
P/N 0312996
9.4.10
9.4.11
9.4.12
9.4.13
9.5
9.5.1
9.5.2
9.5.3
9.5.4
9.5.5
Broken Pin Detector Assembly (Kit TRA03801-16L or TRA03801-16R) .................................................. 9-46

Crossover Motor (Kit TRA04021-17) ........................................................................................................ 9-47
Divert Control Module Kit Set-Up Switch (Kit TRA04061-19) ................................................................... 9-47
Divert Control Module Kit (Single) (Kit TRA04031-10).............................................................................. 9-48
Start Up and Test Procedures (Discrete I/O Single-Sided)...................................................................... 9-48
Sorter DCM DC Power Check List............................................................................................................ 9-49
Chain Oiler................................................................................................................................................ 9-49
Spray Oiler (Optional) ............................................................................................................................... 9-49
Pin Greaser .............................................................................................................................................. 9-50
Start Up .................................................................................................................................................... 9-50
Chapter 10 - DeviceNet Single-Sided Model 5

10.0
DeviceNet Single-Sided Model 5 ........................................................................................................... 10-5
10.1
Installation Instructions ............................................................................................................................. 10-5
10.1.1
Controls Installation Overview .................................................................................................................. 10-5
10.1.2
Power Busway System ............................................................................................................................. 10-7
10.1.3
DeviceNet System .................................................................................................................................... 10-9
10.1.4
DeviceNet Media and Connectors .......................................................................................................... 10-10
10.1.5
Divert Switch Assembly .......................................................................................................................... 10-10
10.1.6
Divert Control Module ............................................................................................................................. 10-11
10.1.7
Divert Control Module I/O Assignments.................................................................................................. 10-13
10.1.8
Terminal T2 - Inputs .............................................................................................................................. 10-14
10.1.9
Terminal T3 Outputs............................................................................................................................ 10-14
10.1.10
Long Range Jam Photoeye .................................................................................................................... 10-15
10.1.10.1
Long Range Jam Photoeye Alignment Procedure .................................................................................. 10-15
10.1.11
Slack Chain and Shoe out of Position Sensors ...................................................................................... 10-16
10.1.12
Sorter Chain Oilers ................................................................................................................................. 10-17
10.1.13
Pin Greaser ............................................................................................................................................ 10-17
10.1.14
Induction Encoder................................................................................................................................... 10-17
10.1.15
Sizing Divert Control Module Power Supplies......................................................................................... 10-17
10.1.15.1
Sorter Power Supplies ............................................................................................................................ 10-18
10.1.15.2
Sizing Power Supplies for DCMs ............................................................................................................ 10-18
10.1.16
End of Sorter Photoeye (Option) ............................................................................................................ 10-19
10.1.17
Divert Confirm Inductive Proximity Switch (Option) ................................................................................ 10-19
10.1.18
Dynamic Jam Photoeyes (Option) .......................................................................................................... 10-20
10.1.19
Full Lane Photoeyes (Option) ................................................................................................................ 10-20
10.1.20
Full Lane Photoeyes (Option) ............................................................................................................. 10-20
10.1.21
Sort Jam Photoeye (Option) purchase FULL Kit tra05261-6 ............................................................... 10-20
10.1.22
Induction Photoeye (Option) .................................................................................................................. 10-21
10.1.23
Sort Infeed Broken Pin Assembly Kit TRA03801-16 (Option)................................................................. 10-21
10.1.23.1
Mounting Location .................................................................................................................................. 10-22
10.1.23.2
Operation................................................................................................................................................ 10-22
10.1.23.3
Mapping I/O ............................................................................................................................................ 10-22
10.1.24
DCM Broken Pin Option ......................................................................................................................... 10-23
10.1.24.1
Single Sided Sorter (Kit TRA05261-20) .................................................................................................. 10-23
10.1.24.2
Dual Sided Sorter ................................................................................................................................... 10-23
10.1.25
Auto Calibration ...................................................................................................................................... 10-24
10.1.25.1
Concept .................................................................................................................................................. 10-24
10.1.25.2
Process .................................................................................................................................................. 10-24
10.1.25.3
One Time Physical Measurements ......................................................................................................... 10-25
10.1.25.4
Measurement 1:...................................................................................................................................... 10-25
10.1.25.5
Measurement 2 + the Return Switch Dimension..................................................................................... 10-25
10.1.25.6
Means..................................................................................................................................................... 10-25
10.1.25.7
Operation................................................................................................................................................ 10-26
10.1.25.8
Procedure ............................................................................................................................................... 10-26
10.2
Drawings................................................................................................................................................. 10-27
10.2.1
WhisperSort General Device Application ............................................................................................ 10-28
10.2.2
General Arrangement Overview ............................................................................................................. 10-30
10.2.3
Infeed ..................................................................................................................................................... 10-32
P/N 0312996
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
10.3
10.3.1
10.3.2
10.3.3
10.3.4
10.3.5
10.3.6
10.3.7
10.3.8
10.3.9
10.3.10
10.3.11
10.3.12
10.3.13
10.3.14
10.3.15
10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7
Intermediate ............................................................................................................................................10-34
Catenary .................................................................................................................................................10-36
Drive .......................................................................................................................................................10-38
Divert Switch ...........................................................................................................................................10-40
Broken Pin ..............................................................................................................................................10-42
Reference Tables for Control Kits (DeviceNet Single-Sided) .................................................................10-44
Divert Switch Part Numbers ....................................................................................................................10-44
Long Range Jam Photoeye Kit (Kit TRA03801-1)...................................................................................10-44
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2) ..............................................10-45
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) ............................................................................10-45
Dynamic Jam Photoeye Kit (Kit TRA03801-4) ........................................................................................10-46
End-of-Sorter Photoeye Kit (Kit TRA03801-5) ........................................................................................10-47
Full Line Photoeye Kit (Kit TRA03801-6) ................................................................................................10-48
3/4 Full Line Photoeye Kit (Kit TRA03801-7) ..........................................................................................10-49
Induction Photoeye Kit (Kit TRA03801-9) ...............................................................................................10-50
DeviceNet Kit (Kit TRA03801-10) ...........................................................................................................10-50
Power Busway Kit (Kit TRA03801-11).....................................................................................................10-51
Divert Control Module Kit (Kit TRA03801-12) .........................................................................................10-51
Power Busway Kit (Kit TRA03801-14).....................................................................................................10-52
Application Specific Quantities ................................................................................................................10-52
Broken Pin Detector Assembly ...............................................................................................................10-53
Start Up and Test Procedures.................................................................................................................10-54
Sorter Power Check List .........................................................................................................................10-54
Sorter DCM DC Power Check List ..........................................................................................................10-55
Sorter DeviceNet System Check List ......................................................................................................10-55
Chain Oiler ..............................................................................................................................................10-56
Spray Oiler (Optional) .............................................................................................................................10-56
Pin Greaser.............................................................................................................................................10-57
Start Up...................................................................................................................................................10-57
Chapter 11 DeviceNet Dual-Sided Model 6

11.0
11.1
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
11.1.6
11.1.7
11.1.7.1
11.1.7.2
11.1.8
11.1.9
11.1.10
11.1.11
11.1.12
11.1.13
11.1.14
11.1.15
11.1.16
11.1.17
11.1.18
11.1.19
11.1.19.1
11.1.20
11.1.21
11.1.21.1
11.1.21.2
8
DeviceNet Dual-Sided Model 6 ..............................................................................................................11-5

Installation Instructions..............................................................................................................................11-5
Controls Installation Overview...................................................................................................................11-5
Power Busway System..............................................................................................................................11-7
DeviceNet System.....................................................................................................................................11-9
DeviceNet Media and Connectors...........................................................................................................11-10
Divert Switch Assembly...........................................................................................................................11-11
Divert Control Module .............................................................................................................................11-12
Divert Control Module I/O assignments...................................................................................................11-13
Terminal T2 - Inputs................................................................................................................................11-14
Terminal T3 Outputs ............................................................................................................................11-15
Slack Chain and Shoe out of Position Sensors .......................................................................................11-15
Sorter Chain Oilers .................................................................................................................................11-16
Pin Greaser.............................................................................................................................................11-16
Induction Encoder ...................................................................................................................................11-17
Sizing Divert Control Module Power Supplies .........................................................................................11-17
Sorter Power Supplies ............................................................................................................................11-17
Sizing Power Supplies for DCMs ............................................................................................................11-17
End of Sorter Photoeye (Option) .............................................................................................................11-18
Divert Confirm Inductive Proximity Switch (Option).................................................................................11-19
Dynamic Jam Photoeyes (Option)...........................................................................................................11-19
Full Lane Photoeyes (Option) ................................................................................................................11-19
Full Lane Photoeyes (Option)..............................................................................................................11-19
Sort Jam Photoeye (Option) purchase FULL Kit TRA05261-6 .............................................................11-20
Induction Photoeye (Option) ..................................................................................................................11-20
Sorter Infeed Broken Pin Kit TRA03801-16 (Option)...............................................................................11-20
Mounting Location...................................................................................................................................11-21
Operation ................................................................................................................................................11-21
P/N 0312996
11.1.21.3
11.1.22
11.1.22.1
11.1.22.2
11.1.22.3
11.1.23
11.1.23.1
11.1.23.2
11.1.23.3
11.1.23.4
11.1.23.5
11.1.23.6
11.1.23.7
11.1.23.8
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7
11.2.8
11.3
11.3.1
11.3.2
11.3.3
11.3.4
11.3.5
11.3.6
11.3.7
11.3.8
11.3.9
11.3.10
11.3.11
11.3.12
11.3.13
11.3.14
11.3.15
11.3.16
11.4
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
11.4.7
Mapping I/O ............................................................................................................................................ 11-22

DCM Broken Pin Kit TRA05261-20 (Option)........................................................................................... 11-22
Single Sided Sorter................................................................................................................................. 11-22
Dual Sided Sorter ................................................................................................................................... 11-22
Broken Pin Code Operation.................................................................................................................... 11-23
Auto Calibration Information ................................................................................................................... 11-23
Concept .................................................................................................................................................. 11-24
Process .................................................................................................................................................. 11-24
One Time Physical Measurements ......................................................................................................... 11-24
Measurement 1....................................................................................................................................... 11-24
Measurement 2 + the Return Switch Dimension..................................................................................... 11-24
Means..................................................................................................................................................... 11-25
Operation................................................................................................................................................ 11-25
Procedure ............................................................................................................................................... 11-25
Drawings................................................................................................................................................. 11-26
WhisperSort General Device Application ............................................................................................ 11-28
General Device Application (contd)........................................................................................................ 11-30
Tail Section............................................................................................................................................. 11-32
Intermediate............................................................................................................................................ 11-34
Catenary ................................................................................................................................................. 11-36
Drive ....................................................................................................................................................... 11-38
Divert Module ......................................................................................................................................... 11-40
Broken Pin Kit......................................................................................................................................... 11-42
Reference Tables for Control Kits........................................................................................................... 11-44
Divert Switch Part Numbers.................................................................................................................... 11-44
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2).............................................. 11-44
Divert Confirm Proximity Switch Kit (Kit TRA03801-3)............................................................................ 11-45
Dynamic Jam Photoeye Kit (Kit TRA05261-4) ........................................................................................ 11-46
End-of-Sorter Photoeye Kit (Kit TRA03801-5) ........................................................................................ 11-47
Full Line Photoeye Kit (Kit TRA05261-6) ................................................................................................ 11-48
3/4 Full Line Photoeye Kit (Kit TRA05261-7) .......................................................................................... 11-49
Induction Photoeye Kit (Kit TRA05261-9) ............................................................................................... 11-50
DeviceNet Kit (Kit TRA03801-10) ........................................................................................................... 11-51
Power Busway Kit (Kit TRA03801-11) .................................................................................................... 11-51
Divert Control Module Kit (Kit TRA05281-12) ......................................................................................... 11-52
Power Busway Kit (Kit TRA03801-14) .................................................................................................... 11-52
Application Specific Quantities ............................................................................................................... 11-53
Broken Pin Detector Assembly (Kit TRA03801-16) ................................................................................ 11-53
Crossover Motor Kit (Kit TRA04021-17) ................................................................................................. 11-54
Divert Control Module Kit Set-Up Switch (Kit TRA05281-19) ................................................................ 11-54
Start Up and Test Procedures ................................................................................................................ 11-55
Sorter Power Check List ......................................................................................................................... 11-55
Sorter DCM DC Power Check List.......................................................................................................... 11-56
Sorter DeviceNet System Check List...................................................................................................... 11-56
Chain Oiler.............................................................................................................................................. 11-57
Spray Oiler (Optional) ............................................................................................................................. 11-57
Pin Greaser ............................................................................................................................................ 11-58
Start Up .................................................................................................................................................. 11-58
Chapter 12 Troubleshooting
12.0
Troubleshooting Guide ............................................................................................................................. 12-3
P/N 0312996
Chapter 13 Illustrated Parts List

The following engineering drawings are included as part of
this manual. If you want to print them out on
11 x 17 paper, select the Choose Paper Source by PDF
option on your Adobe Acrobat Print menu. This will print out
the rest of this manual on 8 x 11 paper and print the
engineering drawings on 11 x 17 paper.
General Arrangement Single Sided (TRA03861)
General Arrangement Dual Sided (TRA04321)
General Arrangement BOM & Qty Chart Dual Sided
(TRA04322)
Tail Assembly 42T Sprkt RH, LH & Dual (TRA03981)
Intermediate Assembly (TRA03581)
Intermediate Assembly Into Tail (TRA03641)
Catenary Assembly Section (TRA03511)
Drive Section RH & LH (TRA03651)
Drive Assembly SK9032 & SK9042 (TRA04231)
End Discharge Gravity Roller Assembly (TRA04891)
EndDischarge Gravity Roller Assembly (TRA04892)
Divert Module Single Sided (TRA04791)
Cross-Over Divert Module Dual-Sided (TRA04841)
Flight Chain Assembly (TRA04851)
Pusher Assembly (TRA03141)
Switch Assembly 20" Cross-Over (TRA04341)
Return Guide Assembly LH & RH (TRA03681)
Return Guide Assembly Dual Sided (TRA04391)
Switch Assembly 7" Rad Arm LH (TRA04761)
Switch Assembly RH W/7" Rad Arm (TRA04811)
Vertical Transition Assembly (TRA03991)
Pusher out of Place RH Assy Dual & RH Divert (TRA05171)
Pusher out of Place LH Assembly (TRA05172)
Broken Pin Detector Kit (TRA03881)
Broken Pin Prox Installation Kit Single Sided (TRA05291)
Appendix A. Busway
Appendix B. Lubrication
10
P/N 0312996
WhisperSort
Chapter 1
Introduction
WhisperSort
Chapter 1 - Introduction
Chapter 1 - Table of Contents

1.0
WhisperSort Overview ..........................................................................................................................1-3
1.1
Product Summary..................................................................................................................................1-4
1.2
WhisperSort Documentation..............................................................................................................1-6
1.2.1 Bulletins............................................................................................................................................1-8
P/N 0312996
1-1
WhisperSort
1-2
P/N 0312996
WhisperSort
1.0 WhisperSort Overview

HK Systems WhisperSort belongs to a family of conveyors generically known as
slat sorters. Rigid slats are affixed between two lengths of roller chain, forming a
moving platform capable of carrying a variety of products. These slats are constructed
extruded aluminum rectangular tubes.
Each pair of slats is equipped with a pusher that slides between
the slats (perpendicular to the direction of travel) to gently push
product off the sortation conveyor. Pushers are a high impact
plastic molded design with a gently sloped face and resilient
molded bumpers to prevent damage to product and equipment
in case a jam should occur. Pushers are maintained in position
on either side of the WhisperSort and are actuated and guided by electric switches
and guides located just below the surface of the slats.
HK Systems WhisperSort represents the next generation of slat sorters. The

installation of this conveyor indicates a serious commitment to efficiency and
excellence. Proper maintenance is imperative for the potential of the machine to be
realized.
WARNING: Before performing any maintenance, review the Safety

chapter of this manual.
P/N 0312996
1-3
WhisperSort
The WhisperSort is designed to accommodate higher operating speeds with increased

reliability. Depending on carton length, WhisperSort can sort at rates up to 200
cartons per minute. Speeds of 600 fpm (feet per minute) have been achieved with this
design.
The machine design provides for closer spacing of divert points. At divert points a
switch mechanism interrupts the guideway, collecting guide pins and activating
pushers. The cam followers on the pusher guide pins contact the divert guide causing
the pushers to be directed across the sorter at an angle, deflecting the product onto a
discharge lane.
Two endless chains are attached within the confines of each flight. These chains run
over large end sprockets that have been selected for low chordal action to provide
smoother operation. Conveyor and controls are arranged to feed product
automatically, efficiently, and smoothly onto the WhisperSort. A laser scanner reads
preprinted or labeled bar codes on the product and communicates through a PLC
(programmable logic controller) to the computer that governs shipping lane
assignments.
The conveyor system is arranged to feed a number of
conveyor lines onto one main conveyor onto which the
scanner is mounted.
The product is then automatically released from the
holding lines in a manner that creates a gap between
cartons. On high throughput systems a constant and
minimal distance between cartons is created.
Packages exit the sorter onto lanes at an angle, while
maintaining the same length/width orientation as the
package had upon entry to the sorter.
1.1 Product Summary

WhisperSort Single-Sided and Dual-Sided Sorters (Mechanical Components)
Effective Width (B/B)
24, 30, 36
Overall Width
46, 52, 58
Intermediate Sections
12, Odd lengths in 1 increments from 3 to 11
Carrying Surface
Flat Slat
Divert Angles
20, 30
Minimum Divert Centers (20) *
Single-Sided 24 B/B = 85, 30 B/B = 102.5, 36 B/B = 120

Dual-Sided 24 B/B = 123, 30 B/B = 139, 36 B/B = 154
Minimum Divert Centers (30) *
1-4
Single-Sided 24 B/B = 58, 30 B/B = 70, 36 B/B = 82
P/N 0312996
WhisperSort
WhisperSort Single-Sided and Dual-Sided Sorters (Mechanical Components)

Dual-Sided 24 B/B = 96, 30 B/B = 106, 36 B/B = 117
Divert Switch
Electric
Crossover Switch (Dual-Sided only)
Electric
Maximum Length
Dependent on loading and number of diverts
Drive Type
End-side mount, shaft mounted reducer, VFD control, drive sprocket 24

dia.
Drive HP and Take-up
7.5 to 40 HP shaft mounted gearmotor, catenary and end take-up
Speeds
200 FPM - 600 FPM
Infeed Idler
Idler sprocket 18 dia.
Infeed Belt
Slave driven from sorter (left or right hand)
Lubrication
Auto Oiler
Supports/Hangers
Standard with vibration pads on drive and idler
Paint
HK Standard Gray
Comments
50 Minimum length with catenary.

Live load is 100 lbs per foot.
Minimum elevation is 39 to top of slat.
350 FPM maximum using 30 divert.
600 FPM maximum using 20 divert.
Above 40 HP consult factory.
* Single-Sided Sorters - Minimum divert centers leave a 2 gap between the
aftersort spur rails. Dual-Sided Sorters Minimum adjustable divert centers
based on standalone crossover switch module. Closer fixed divert centers
can be obtained, contact engineering.
WhisperSort Single-Sided and Dual-Sided Sorters (Controls)

Divert Switch
Electric
Sorter Braking
Dynamic (optional)
Base Features
Divert control module, long range photoeye, divert control module, slack chain detector kit,
shoe-out-of-position kit (DeviceNet also includes DeviceNet kit, power busway sections/kits,
and 75 meter spool of network flat cable).
Option Kits
Divert confirm proximity switch, dynamic jam photoeye, induction photoeye (24 vdc), full-lane
photoeye, 3/4 full lane photoeye, no-sort photoeye, broken pin assembly.
User Supplied
Control panel, PLC (DeviceNet requires ControLogix PLC), UPS for sorter dc power supplies,
sorter VFD, motor disconnect, E-Stop circuits & materials.
Comments
P/N 0312996
Control devices are quick disconnect cables to DCM (Discrete I/O requires 15-conductor cables
to connect each DCM to the main panel).
1-5
WhisperSort
1.2 WhisperSort Documentation

Chapter 1. Introduction to WhisperSort
The first chapter introduces you to and gives an overview of WhisperSort along with a
product summary. The documentation is also outlined in this chapter.
Chapter 2. Safety
It is essential for safe and efficient system operation that
safety information and guidelines presented in this chapter are
properly understood and implemented. PLEASE READ
THIS CHAPTER CAREFULLY.
Chapter 3. Mechanical Installation
Mechanical installation instructions and adjustments are described here. Supports,
inspection, layout, set screw retightening and torque procedures, tools and equipment,
preliminary support and sorter installation and the actual installation steps are
described in detail.
1-6
P/N 0312996
WhisperSort
Chapter 4. Maintenance
One of the most important factors in the overall cost
effectiveness of your material handling system is that of
preventive maintenance; that is, eliminating the cause of
potential trouble before the trouble occurs. This chapter
contains preventive maintenance information for
conveyor mechanical equipment.
Chapter 5. Electrical Controls Installation and Setup
Electrical installation instructions and adjustments are described in this manual. There
are six WhisperSort models. Each is discussed in detail in a separate color-coded
chapter:
Chapter 7. Discrete I/O Single-Sided Model 2
Chapter 9. Discrete I/O Dual-Sided Model 4
Chapter 12. Troubleshooting
Despite the best operating techniques and preventive
maintenance programs, machines sometimes fail. This
chapter contains suggested methods to help determine
the cause or causes of the most commonly experienced
failures.
Chapter 13. Illustrated Parts List
This chapter identifies parts for each top level conveyor assembly.
Appendix A. Power Busway System
The Power Busway System supplies +48VDC and
+24VDC to the DCM modules. Power supplies are
located in the control panel. (Because of the detail,
a 22 x 34 version of this graphic is included in
the pocket of the binder.)
Appendix B. Lubrication Information
Some of the parts of the conveyer (i.e., chain oilers,
the pin greaser, the reducers, and bearings) need
lubrication from time to time. This chapter presents overviews and an MSDS for all
types of lubrication recommended.
P/N 0312996
1-7
WhisperSort
1.2.1
Bulletins
If we update any part of WhisperSort or if we discover a safety issue with any part of
the product, we will publish a bulletin explaining the update or issue. These topics
will be included in the next release of this manual. In the meantime, we will include
them in a section called Bulletins until the manual is updated.
1-8
P/N 0312996
WhisperSort
Chapter 2
Safety
WhisperSort
Chapter 2 - Safety

Safety............................................................................................................................................ 2-3
2.0
2.1 Conveyor Safety Rules................................................................................................................. 2-4
2.2 Project Manual Safety Video and Safety Poster Introduction...................................................... 2-5
2.3 Mechanical Maintenance Safety................................................................................................... 2-7
2.4 Electrical Maintenance Safety...................................................................................................... 2-7
2.4.1
Safety Guidelines ............................................................................................................ 2-7
2.5 Application Safety........................................................................................................................ 2-8
2.5.1
Headroom ........................................................................................................................ 2-8
2.5.2
Guarding.......................................................................................................................... 2-8
2.5.2.1 End Covers........................................................................................................... 2-9

2.5.2.2 Bottom Covers ..................................................................................................... 2-9
2.5.2.3 Finger/Hand Protection........................................................................................ 2-9
2.6 Controls Safety ............................................................................................................................. 2-9
2.6.1
Electrical Code ................................................................................................................ 2-9
2.6.2
Control Stations............................................................................................................. 2-10
2.7 Safety Devices............................................................................................................................ 2-10
2.7.1
Emergency Stops and Restarts ...................................................................................... 2-10
2.7.2
Transfer, Loading, and Discharge Points ...................................................................... 2-11
2.8 Safety Labels .............................................................................................................................. 2-12
2.8.1
Local Safety Considerations.......................................................................................... 2-13
P/N 0312996
2-1
WhisperSort
Chapter 2 - Safety
2-2
P/N 0312996
WhisperSort
Chapter 2 - Safety
2.0
Safety
It is essential for safe and efficient system operation that safety information and
guidelines presented here are properly understood and implemented. Follow
safety precautions for industrial work at all times. The information in this
chapter includes guidelines
specified in the latest issue of
American National Standard
Institute (ANSI) booklet entitled
Safety Standards for Conveyors
and Related Equipment B20.1. We have included additional precautions that are
to be observed in accordance with any ANSI regulations that are applicable.
With any piece of industrial equipment, conditions exist that might cause injury
to you or your co-workers. Because it is not possible to describe each potentially
hazardous situation that might develop, you must be alert at all times for unsafe
conditions. To avoid injury, use maximum possible care and common sense and
adhere to all safety standards.
Until you are appropriately trained, you are not authorized to operate, install,
maintain, or modify the system. See your supervisor about receiving this training
or authorization before you operate, install, maintain, or modify the material
handling system.
Take special care while maintaining and inspecting electrical equipment and
devices. All personnel working on or around the system should be aware of, and
adhere to, all CAUTION, DANGER, and WARNING
signs. These signs are posted to reduce the risk of injury to
all personnel. Never assume that the signs and notices are
applicable only to inexperienced personnel. Maintain signs
in a legible condition. Contact your supervisor to post
additional safety signs if you feel they are necessary.
P/N 0312996
2-3
WhisperSort
Chapter 2 - Safety
2.1
Conveyor Safety Rules

Follow these Conveyor safety rules, as well as specific regulations and guidelines
listed in this publication:
DO NOT touch moving Conveyor parts.
DO NOT walk, ride, or climb on the Conveyor.
DO NOT operate the Conveyor with chain guards or other protective guards
removed.
Keep jewelry, clothing, hair, etc., away from the Conveyor.
Know the location and function of all start/stop devices and keep those
devices free from obstruction.
Clear all personnel from the equipment before starting the Conveyor.
DO NOT attempt to clear product jams while the Conveyor is running.
Allow only trained and authorized personnel to maintain or repair Conveyor

equipment.
DO NOT load the Conveyor beyond specified design limits.
DO NOT attempt to make repairs to the Conveyor while it is running.
DO NOT modify equipment without checking with the manufacturer.
DO NOT operate or perform maintenance on equipment when taking any

type of drug, sedative, when under the influence of alcohol, or when
overfatigued.
Report any unsafe condition to your supervisor or maintenance staff.
Note: The safety procedures/policies listed in this chapter are not intended to
address fire-related considerations. Your system must comply with any
applicable national, state, and local codes.
When a Conveyor is stopped for maintenance or repair purposes, lock out or tag
out the starting devices, prime movers, or powered accessories in accordance
with a formalized procedure designed to protect everyone involved with the
Conveyor against an unexpected restart. Also, alert all personnel to the hazard of
stored energy, which can exist after the power source is locked out. For
additional information, refer to the latest issue of ANSI Z244.1, American
National Standard for Personnel Protection Lockout/Tagout of Energy Sources
Minimum Safety Requirements. Also, OSHA 29CRF Part 1910.147 Control
of Hazardous Energy Sources (Lockout/Tagout), which includes requirements
for release of stored energy.
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Chapter 2 - Safety
2.2
Project Manual Safety Video and Safety Poster Introduction

The Conveyor Equipment Manufacturers Association (CEMA) also provides
safety information related to conveyor systems.
Enclosed in this Project Manual are a Conveyor Safety
Video and Conveyor Safety Poster produced by
CEMA. These are provided by HK Systems as tools to
help you ensure worker safety and to enhance your
safety-training program.
The Conveyor Safety Video and the Conveyor Safety
Poster are designed to be used as a regular part of your
safety training and to be viewed and understood by all current and future
employees who are or may be near conveying equipment. The safety message is
communicated using high impact easy to understand instructional language and
graphical images.
The goal of the video is to alert and raise the level of awareness of operations
personnel, maintenance technicians, and management to safety hazards
commonly associated with the automated material handling conveyor equipment.
The safety poster highlights important safety labels and is intended to be posted
in public places as a day-to-day reinforcement of good safety practices.
Both the safety poster and the video can be purchased from CEMA
(www.cemanet.org). Visit their web site www.cemanet.org for additional
information or contact them at:
Conveyor Equipment Manufactures Association

6724 Lone Oak Blvd.
Naples FL 34109
Phone (941) 514-3470
An 11 x 17 color poster depicting various safety aspects related to working on
and around conveyor systems can be printed off the CEMA web site. This
should be displayed in a prominent or highly visible location. A copy of this
poster is shown here.
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2.3
Mechanical Maintenance Safety

Lubricate conveyors when they are not in
motion wherever practical. Only trained
personnel who are aware of the hazards
of the conveyors in motion should be
permitted to lubricate a conveyor that is
operating.
After you lubricate the conveyor, check
to make sure that none of the lubricants or other process liquids have spilled or
dropped onto the floor. These liquids create a hazardous condition. If you notice
a drip, install a drip pan or other means of eliminating the hazard.
2.4
Electrical Maintenance Safety

When an equipment problem occurs, the
first priority is to ensure that power is
disconnected from the affected area, as
well as from the control panel where
troubleshooting and repairs are
performed.
Once you verify that power is locked out, make sure you inform other personnel
in the area of the situation so they do not unexpectedly restore power.
After you inform your co-workers, recheck the power supply to ensure that
power is disconnected in the affected control panel. Remove fuses only with
insulated fuse pullers and check terminal strips for current-carrying wires.
Before you perform any repairs with an exposed conductor or terminal, use an
approved voltmeter to check for continuity to ground and continuity between
other current-carrying conductors.
2.4.1
Safety Guidelines
When you perform any kind of maintenance or repair
involving electrical components, follow the guidelines
listed below:
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NEVER reset a circuit breaker or replace an open

fuse before determining and correcting the cause
of the circuit interruption.
NEVER bypass or use a jumper to replace any

limit switch, fuse, circuit breaker, or other circuit
protection or safety device.
NEVER replace an open fuse with another that is

not rated at the proper current and voltage. Always double-check correct
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Chapter 2 - Safety
fuse specifications rather than replace the open fuse with one of the same
current and voltage rating.
2.5
NEVER rest tools on motors, transformers, terminal strips, or other control

panel or electrical components. All tools used should be kept in a tool box or
pouch.
NEVER restore power or restart equipment before verifying that all tools,
spare parts, etc., are removed from the work area and are safely stored.
NEVER restore power or restart equipment before verifying that ALL

personnel are aware of the condition and are safely clear of the equipment.
ALWAYS replace any safety devices and guards removed during

maintenance or repair before you restore power or restart equipment.
ALWAYS use extreme caution and follow recommended safety procedures

while you perform any electrical inspection or maintenance operations.
Application Safety
The equipment used in your system is designed to convey specified commodities
or materials within a certain rate and speed. It might not be possible to safely use
the equipment outside of the intended capacities or speeds. Check with your
supervisor if you have questions regarding the safe operation of the equipment at
other than the designed operating conditions.
2.5.1
Headroom
When equipment is installed above exit
passageways, aisles, or corridors, provide a
minimum clearance of 6 -8 inches (measured
vertically from the floor or walking surface to the
lowest part of the conveyors or guards). Where
system function will be impaired by providing the
minimum clearance of 6 -8 through an emergency exit, provide alternate
passageways. It is permissible, however, to allow passage under conveyors with
less than 6 -8 clearance from the floor for other than emergency exits if a
CEMA warning label is provided to indicate low headroom.
2.5.2
Guarding
If necessary to protect personnel from hazards, guard by location or position all
exposed moving machinery parts that present a hazard to personnel at their
workstations.
When a conveyor passes over a walkway, roadway, or work station, it is
considered guarded by location if all moving parts are at least 8 -0 above the
floor or walking surface or are otherwise located so that personnel cannot
inadvertently come in contact with hazardous moving parts.
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Although overhead conveyors may be guarded by location, spill guards, pan

guards, or equivalent shall be provided if material may fall off the conveyor and
endanger personnel.
When conveyors are installed below 8 -0 measured vertically from the floor or
walking surface to the lowest part of the conveyor, bottom guarding must be
provided.
2.5.2.1
End Covers
Tail assemblies and drive assemblies have
protective end covers. These covers should be
in place. Do not operate the conveyors without
them.
2.5.2.2
Bottom Covers
Bottom covers have been installed at various places. Do not operate the
conveyors without them.
2.5.2.3
Finger/Hand Protection
Finger/hand guards may be installed for safety reasons and
should be kept in place. If any are broken replace them
immediately. Do not operate the conveyors without them.
2.6
Controls Safety
2.6.1
Electrical Code
All electrical installations
and wiring must conform to
the National Electrical Code
(Article 670 and other applicable articles) published by the National Fire
Protection Association and approved by the American National Standards
Institute, Inc. Refer to their publications for additional information.
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2.6.2
Control Stations
Arrange control stations so that equipment
operation is visible from the stations, and clearly
mark or label each station to indicate its function.
The emergency stop devices installed with your
system are designed so that they cannot be
overridden from other locations.
Keep the area around your control station clear. Remove all miscellaneous
equipment (such as inactive and unused actuators, controllers, and wiring) from
control stations and panel boards, as well as obsolete diagrams, indicators,
control labels, and other material that might confuse the operator.
Keep the control station as well as the surrounding area neat and clean.
2.7
Safety Devices
All safety devices, including wiring of electrical safety devices, operate
in a "fail-safe" manner; that is, if power or the device fails, a hazardous condition
will not result.
2.7.1
Emergency Stops and Restarts

In case of an emergency stop, first determine the
cause of the stoppage and correct the situation
that warranted the stop. To resume operation
after a stoppage, manually reset or start at the
location where the emergency stop occurred.
When a Conveyor is stopped for maintenance or
repair purposes, all energy sources must be
locked out and tagged, including starting devices, prime movers, or powered
accessories, in accordance with a formalized procedure designed to protect
everyone which may be affected by the unexpected operation of the Conveyor.
Also, all forms of stored energy must be released to insure safe conditions. For
additional information, refer to the latest issue of ANSI Z244.1, American
National Standard for Personnel Protection -- Lockout/Tagout of Energy Sources
--- Minimum Safety Requirements. Also, OSHA 29CRF Part 1910.147 Control
of Hazardous Energy Sources (Lockout/Tagout), which includes requirements
for release of stored energy.
Note: Before you try to correct the situation, lock out or tag out the starting
device, unless it must be operated to determine the cause or to safely remove the
stoppage. For additional information, refer to the latest issue of ANSI Z244.1,
American National Standard for Personnel Protection Lockout/Tagout of
Energy Sources Minimum Safety Requirements.
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2.7.2
Transfer, Loading, and Discharge Points

Prevent free-falling material that might result from flooding, ricocheting, or
uncontrolled free-fall of material or product.
At transfer, loading, and discharge points, prevent unconfined and uncontrolled
free-fall of material resulting from flooding, ricocheting, overloading, trajectory,
leakage, or a combination thereof, if the material would create a hazard to
personnel.
WARNING: Failure to follow these rules can result in injury.
Note: The safety standards outlined in this section have NOT been exactly
duplicated from the latest issue of the ANSI booklet, Safety Standards for
Conveyors and Related Equipment B20.1. We recommend that all operators and
maintenance personnel review this booklet, which you can obtain by contacting
the American Society of Mechanical Engineers at the following address:
The American Society of Mechanical Engineers
United Engineering Center
345 East 47th Street
New York, NY 10017
Please also review Appendix A. Design and Safety Application of Spill Guarding
for Unit Handling Conveyors. The purpose of this document is to outline a
standardized approach to the selection and application of common

guardrail, safety netting, and accessories used to contain product (cartons
and totes excluding stacked loads) transported on unit handling
conveyors.
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2.8
Safety Labels
The following safety labels, as well as others, are used on HK Systems conveyor
equipment. Safety labels should be clean, legible, and in good condition.
Replace labels as needed. Make all employees aware of hazards, both labeled
and unlabeled.
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2.8.1
Local Safety Considerations

Many companies or operational practices require specific (local) safety
considerations. Make certain these considerations are posted or readily available
and that operators and maintenance personnel are aware of them. If in doubt, ask
your supervisor.
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Chapter 3
Mechanical Installation
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Chapter 3 Mechanical Installation
Chapter 3 Table of Contents

3.0
MECHANICAL INSTALLATION..........................................................................................3-5
3.1 Supports..................................................................................................................................3-5
3.2 Inspection ...............................................................................................................................3-5
3.3 Layout.....................................................................................................................................3-5
3.4 Set Screw Retightening ..........................................................................................................3-6
3.4.1 General Guidelines for Fastener Tightening Torque.........................................................3-6
3.4.1.1 Torque Specifications for the Bolts used in Aluminum Extrusions.............................3-8
3.4.2 T-Bolts...............................................................................................................................3-9
3.5 Tools/Equipment Needed for Installation: .............................................................................3-9
3.6 Preliminary Support Installation ..........................................................................................3-10
3.6.1 Intermediate Supports......................................................................................................3-11
3.6.2 Support Leg Weldment for Drive and Tail Sections .......................................................3-12
3.7 Preliminary Sorter Installation .............................................................................................3-13
3.8 Installation Steps ..................................................................................................................3-13
3.8.1 Step 1 - Tail Assembly ....................................................................................................3-14
3.8.2 Step 2 - Intermediates......................................................................................................3-15
3.8.3 Step 3 - Catenary .............................................................................................................3-16
3.8.4 Step 4 Spur Sections.....................................................................................................3-17
3.8.5 Step 5a - Divert Module (Single-Sided Sorters) .............................................................3-19
3.8.6 Step 5b - Divert Module (Dual-Sided Sorters)................................................................3-23
3.8.7 Step 6 - Cam Guide .........................................................................................................3-27
3.8.8 Step 7a - Return Guide (Single-Sided)............................................................................3-34
3.8.9 Step 7b - Return Guide (Dual-Sided) ..............................................................................3-37
3.8.10 Step 8 Side Guide Wearstrips, Wheel Track, and Wheel Cover ..................................3-41
3.8.11 Step 9 - Controls Tasks ...................................................................................................3-44
3.8.12 Step 10 - Chain/Flight Assemblies..................................................................................3-44
3.8.13 Step 11 - Drive ................................................................................................................3-47
3.8.14 Step 12 Load Belt Conveyor ........................................................................................3-48
3.8.15 Step 13 Installing Belt End Discharge Section ...........................................................3-52
3.8.16 Step 14 Gravity Roller End Discharge ............................................................................3-55
3.8.17 Step 15 - Controls Tasks .................................................................................................3-57
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List of Figures
Figure 3-1. Torque Values for Bolts........................................................................................................ 3-8
Figure 3-2. T-Bolts Torqued to 220 Inch/Lbs ......................................................................................... 3-9
Figure 3-3 Intermediate Supports......................................................................................................... 3-11
Figure 3-4. Support Leg Weldment for Drive and Tail Sections Over 40".......................................... 3-12
Figure 3-5. General Assembly Layout (Single-Sided) ......................................................................... 3-13
Figure 3-6 General Assembly Layout (Dual-Sided)............................................................................. 3-14
Figure 3-7. Intermediate Assembly ...................................................................................................... 3-15
Figure 3-8. Catenary Section................................................................................................................ 3-16
Figure 3-9. Spur Mounting Bracket (Powered Roller) ......................................................................... 3-17
Figure 3-10. Spur Mounting Bracket (Skatewheel Spurs) ................................................................... 3-18
Figure 3-11 Aligning Divert Switches with the Spurs (Single-Sided) ................................................. 3-19
Figure 3-12. Mounting Divert Rail and Terminal Bracket (Single-Sided)........................................... 3-20
Figure 3-13. Mounting Divert Switch and Divert Rail (Single-Sided) ................................................ 3-21
Figure 3-14. Mounting the Divert Rail Support Bracket (Single-Sided) ............................................. 3-22
Figure 3-15. Aligning Divert Switches with the Spurs (Dual-Sided)................................................... 3-23
Figure 3-16. Dual-Sided Divert Module Subassemblies ...................................................................... 3-24
Figure 3-17. Loctite These Locations................................................................................................... 3-25
Figure 3-18. Mounting Divert Switches, Crossover Switch, and Divert Rails (Dual-Sided)............... 3-26
Figure 3-19. Single-Sided Cam Guide Mounting (Tail & Drive) (left hand shown) ........................... 3-27
Figure 3-20. Dual-Sided Cam Guide Mounting (Tail and Drive) (left hand shown) .......................... 3-28
Figure 3-21. Cutting Instructions for the Cam Guides Over the Drive ................................................. 3-29
Figure 3-22. Single-Sided Cam Guide Mounting (Intermediates) ....................................................... 3-30
Figure 3-23 Dual-Sided Cam Guide Mounting (Intermediates)........................................................... 3-31
Figure 3-24. Single-Sided Divert on Dual-Sided Sorter ...................................................................... 3-32
Figure 3-25. Cam Guide Offset ............................................................................................................ 3-33
Figure 3-26. Return Guide Field Mounting (Single-Sided) (See next figure for A, B, & X-X) ............ 3-34
Figure 3-27. Return Guide Mounting Details (Single-Sided) .............................................................. 3-35
Figure 3-28. Return Guide Mounting Clips (Single-Sided) ................................................................. 3-36
Figure 3-29. Return Guide Field Mounting (Dual-Sided) (See next figure for A, B, & X-X)............... 3-37
Figure 3-30. Return Guide Mounting Details (Dual-Sided)................................................................. 3-38
Figure 3-31. Return Guide Assembly (Dual-Sided).......................................................................... 3-39
Figure 3-32. Return Guide - Assembly (Dual-Sided) (contd)............................................................. 3-40
Figure 3-33. Wear Strip and Wheel Track Splice Details .................................................................... 3-41
Figure 3-34. Splice at 45 Degree Angle ................................................................................................ 3-42
Figure 3-35. Cutting the Wheel Track................................................................................................... 3-42
Figure 3-36. Flight Chain Assembly .................................................................................................... 3-44
Figure 3-37. Pusher .............................................................................................................................. 3-44
Figure 3-38. Coupler Links ................................................................................................................... 3-45
Figure 3-39. Drive Assembly ............................................................................................................... 3-47
Figure 3-40. Load Belt Conveyor (Plan View) .................................................................................... 3-49
Figure 3-41. Load Belt Conveyor (Side View) .................................................................................... 3-50
Figure 3-42. Load Belt Conveyor (End View)..................................................................................... 3-50
Figure 3-43. Drive Belt Tension Adjustment ....................................................................................... 3-51
Figure 3-44. Load Belt Conveyor (Reference Numbers) ..................................................................... 3-51
Figure 3-45. Belt End Discharge ........................................................................................................... 3-52
Figure 3-46. Adjusting Power Belt Sprocket ........................................................................................ 3-54
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Figure 3-47. Gravity Roller End Discharge .......................................................................................... 3-55

Figure 3-48. Adjusting Gravity Sprocket .............................................................................................. 3-57
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3.0 Mechanical Installation

The information in this manual was believed to be correct at the time it was
written. However, HK Systems conveyors are constantly being improved,
therefore the conveyors (and information) in this manual may not match the
conveyors in your installation in every respect.
Also, in some cases equipment supplied for a specific project may have been
modified to meet customer requirements, therefore specifications in this
manual may not match the actual equipment in the installation.
READ THESE INSTRUCTIONS BEFORE ATTEMPTING
INSTALLATION
3.1 Supports
Anchor all supports securely. Floor anchor bolts are to be
supplied by the installer.
It is essential that all bolts be kept tight after final adjustments
are made.
3.2 Inspection
Inspect equipment immediately upon arrival for possible damage or shortage
in transit.
3.3 Layout
Familiarize yourself with the components that make up your conveyor or
system of conveyors, then arrange all of the components in the proper
position in the area in which the conveyor is to be erected. At the same time,
confirm that the building dimensions and the locations of floor and wall
openings, beams, etc., agree with the specifications.
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3.4 Set Screw Retightening

After initial start-up of the conveyor/sortation system, all setscrews should be checked
and retightened if necessary. We recommend checking the set screws with a T-handle hex
wrench after the first 500 hours of operation initially, and then periodically thereafter.
The set screws provided by the factory have been pre-treated with an epoxy-based thread
locking compound. Do not apply excessive torque to check tightness. Breaking the
compound loose will compromise the locking feature. Replacement set screws should
only be installed after all residue has been removed from threaded holes. Refer to chart
below for recommended torque values to install or re-tighten set screws.
Setscrew Diameter
1/4
5/16
3/8
7/16
1/2
3.4.1
3-6
Hex Size
1/8
5/32
3/16
7/32
1/4
Recommended
Torque
Inch/Pounds
65
125
230
350
500
General Guidelines for Fastener Tightening Torque

The following industrial guidelines should be used for determining
tightening torque for different joint conditions. All material included in these
charts are advisory only, and its use by anyone is voluntary. These guidelines
do not replace any specified torque values, always use the specified torque
values. The joint conditions are lubricated, zinc plated & dry. The torque
values are based on a nut with the same grade.
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3.4.1.1 Torque Specifications for the Bolts used in Aluminum Extrusions

There are two types of bolts used in aluminum extrusions. The first is the
12mm hex head cap screw grade 5 bolt that connects the side frames to the
spreaders (see Figure 3-1). These bolts should be torqued to 310 in-lbs. The
second type of connection is the T-bolts used in all the frame rail and
spreader slots. The nuts for the T-bolt should be torqued to 220 in-lbs (see
Figure 3-2).
Figure 3-1. Torque Values for Bolts
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Figure 3-2. T-Bolts Torqued to 220 Inch/Lbs
3.4.2
T-Bolts
All T-bolts in the assembly (divert modules
and return guides) must be torqued to 220 in
lbs and must be double-nutted.
3.5 Tools/Equipment Needed for Installation:
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Fork truck with capacity to handle 4500 lb crates

Come-along (1)
Chain pulling bars (2)
Timing bar (1) Used for sprocket alignment (squareness)
Installation dollies (2) - Needed only if sorter is set on continuous
channels
Transit and/or chalk line
Torpedo level or equivalent
RC100 coupler links for flight chain assemblies (shipped loose)
Side guide (100 ft rolls) and wheel wearstrips (12 ft long)
Spare hitch pins and washers for attaching flight carriage to the RC100
chain.
Torque wrench
Slat tool
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3.6 Preliminary Support Installation

There are two methods for supporting a WhisperSort
conveyor:
1. Raised grid structures supported by columns that have
cross-members located at the joints of the
intermediate sections for floor supports.
2. Concrete floor or mezzanine.
Method #1: Using structures that have cross-members
located at the joints of the WhisperSort: Mount the
sorter on floor supports, which are bolted to the crossmember.
Method #2: Concrete floor or mezzanine:

1. Mount the sorter on floor supports located at the joints of the sorter
sections.
2. Anchor the heavy duty supports to the floor or mezzanine with concrete
anchor bolts.
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3.6.1
Intermediate Supports
The WhisperSort intermediate supports can be purchased in a range of
heights from 19 to 42 which allows a top-of-slat height range of 38 to
61. Each support leg has a leveling foot which is adjustable (see following
figure).
Note: The distance from the top of the frame to the top of the slat is 1 1/16.
Important: The supports must be located at the intermediate splices.
Figure 3-3 Intermediate Supports
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3.6.2
Support Leg Weldment for Drive and Tail Sections

Mount the drive and tail sections directly to the support structure if they are
between 38- 40. If they are higher than 40, install two support leg
weldments, one on each end of the drive and/or tail section. Connect the two
supports to each other with the angles which were relocated from the drive or
tail section. Weld the angle after final adjustment (see following figure).
Figure 3-4. Support Leg Weldment for Drive and Tail Sections Over 40"
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3.7 Preliminary Sorter Installation

It is wise to double-check the timing (phase, tooth alignment) of the drive
sprockets before installation even though it has been set at the factory before
shipment. Inspecting the timing requires the use of a timing bar (3/4-inch
diameter CRS shafting of adequate length to span the drive sprockets), a
plumb bob and a machinist scale. The timing bar fits into the bottom of a
tooth on each of the sprockets. The plumb bob is draped over the timing bar
and a measurement to the drive shaft is made at each end of the timing bar.
The measurements should be equal to within 1/64-inch. The measurement is
easier to make when the string is very close to the drive shaft.
3.8 Installation Steps
Figure 3-5. General Assembly Layout (Single-Sided)
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Figure 3-6 General Assembly Layout (Dual-Sided)
3.8.1
Step 1 - Tail Assembly

Place the tail assembly in the desired location (see following figure).
Figure 3-6. Tail Assembly
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The tail section of the WhisperSort is the first section to be installed. This
allows the chain to be pulled in the direction of chain travel, minimizing the
possibility of a jam occurring at a divert point (switch) during the chain
pulling process.
Since the sorter needs to be installed in a straight line, the tail section must be
square before proceeding with the next section.
3.8.2
Step 2 - Intermediates
Connect the first intermediate to the tail assembly.
Figure 3-7. Intermediate Assembly
Raise the intermediate section and set it on supports. Connect to the

preceding section using the coupling plates and hardware provided.
Connect all remaining intermediates. Use splice plates at the joints between
sections. As you install each new intermediate, make sure it is level and
square before installing the next intermediate.
Note: Odd length sections can be placed anywhere between the drive and
tail. However, depending on the divert locations, it may be possible to locate
the odd length(s) such that the need to move divert modules is minimized.
Consult your project drawings for divert locations.
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3.8.3
Step 3 - Catenary
Attach the catenary section. The catenary is the last section to be installed
before the drive section (see following figure).
Figure 3-8. Catenary Section
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3.8.4
Step 4 Spur Sections

Review the project layout drawings to verify the spur
locations. Connect the spur sections to the sorter at
the appropriate locations using the spur mounting
brackets (see Figure 3-9 and Figure 3-10).
Figure 3-9. Spur Mounting Bracket (Powered Roller)

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Figure 3-10. Spur Mounting Bracket (Skatewheel Spurs)
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3.8.5
Step 5a - Divert Module (Single-Sided Sorters)

This page describes where to mount the divert switches. The following
pages describe how to assemble and mount the divert switches.
Position the downstream edge of the 30 divert switch 1 7/16 upstream
from the inside edge of the spur side rail.
Position the downstream edge of the 20 divert switch 8 1/2 upstream from
the inside edge of the spur side rail.
Figure 3-11 Aligning Divert Switches with the Spurs (Single-Sided)
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Important Note: In most cases the single-sided divert module assembly is

preassembled at the factory. You can move this assembly without
disassembling it. Simply unbolt it, pick up the assembly from both ends,
move it to the desired location, and bolt it down again. Dont forget the clip
that holds the divert rail to the cross braces.
1. Position the divert rail terminal bracket and divert rail as described
previously.
2. If the correct location for the bracket is over a cross-tie, attach it with
T-bolts and the mounting clip. If the correct location is not over a crosstie, mount a cross-tie stub, attach the bracket as described.
Figure 3-12. Mounting Divert Rail and Terminal Bracket (Single-Sided)
3. Set the switch mounting bracket in place and loosely attach it to the
divert rail.
4. If the divert switch mounting bracket cannot be correctly placed because
the divert motor (which extends below the bracket) hits a cross-tie, move
the cross-tie to the next closest position upstream or downstream.
5. Attach the divert switch mounting bracket with the T-bolts and clip.
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6. Adjust the divert rail so it is flush or slightly recessed and tighten. It is

important that the shoe bearings not strike the end of the divert rail as
they pass through the divert switch onto the divert rail.
Figure 3-13. Mounting Divert Switch and Divert Rail (Single-Sided)
7. Attach the support bracket for the divert rail on a cross-tie near the center
of the divert rail. Mount the bracket 1 3/4 above the cross-tie using the
T-bolts.
8. Attach the mounting clip.
9. Install the cam guide (see Step 6 - Cam Guide on page 3-27).
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Figure 3-14. Mounting the Divert Rail Support Bracket (Single-Sided)
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3.8.6
Step 5b - Divert Module (Dual-Sided Sorters)

This page describes where to mount the divert module. The following pages
describe how to assemble and mount the divert module.
Position the downstream edge of the 30 divert module 1 7/16 upstream
from the inside edge of the spur side rail (see figure below).
Position the downstream edge of the 20 divert module 8 1/2 upstream from
the inside edge of the spur side rail (see figure below).
Figure 3-15. Aligning Divert Switches with the Spurs (Dual-Sided)
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Important Note: The dual-sided divert module is normally preassembled

inside an intermediate section at the factory. You can move this module and
the cam guide angles without disassembling it. Simply unbolt it, pick up the
module (giving adequate support so the rails dont bend), move it to the
desired location, and bolt it down again.
If the dual-sided divert module cannot be assembled inside an intermediate at
the factory then it is shipped loose as subassemblies.
Figure 3-16. Dual-Sided Divert Module Subassemblies
1. Position both divert rail terminal brackets in the desired location.

2. If the correct location for the brackets is over a cross-tie, attach them
with the T-bolts and the mounting clips. If the correct location is not
over a cross-tie, first mount cross-tie stubs then attach the brackets as just
described.
3. Loosely position the crossover switch.
4. Attach the downstream divert rails to the crossover switch mounting
bracket with the mounting bolts (Loctite 242 on Bolt 28 see Figure
3-17).
5. Bolt the crossover switch mounting bracket securely into place.
6. Loosely set the divert switches (on mounting brackets) in place.
Note: If a cross-tie interferes with the switch motor (on the underside of
the divert switch), move the cross-tie to the next closest position that is in
the same conveyor section.
7. Bolt the upstream divert rails to the crossover and Loctite.
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8. Secure the divert switch assemblies (on mounting brackets) with the
T-bolts and the mounting clips.
9. Install the cam guide (see Step 6 - Cam Guideon page 3-27).
Important Note: Use Loctite #24231 Blue on reference number 28.
Figure 3-17. Loctite These Locations
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The following figure shows the subassemblies after assembly with step-bystep instructions following the figure.
Figure 3-18. Mounting Divert Switches, Crossover Switch, and Divert

Rails (Dual-Sided)
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3.8.7
Step 6 - Cam Guide

Cam guides come in 12 lengths and are installed on the divert side (opposite
spur) and on both sides of single-sided sorters from the last divert to the
drive. Cam guides are required on both sides of dual-sided sorters. Start the
cam guide in the tail assembly at the point indicated Figure 3-19 and Figure
3-20.
Figure 3-19. Single-Sided Cam Guide Mounting (Tail & Drive) (left hand
shown)
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Figure 3-20. Dual-Sided Cam Guide Mounting (Tail and Drive) (left
hand shown)
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Space the mounting flats equally along the cam angle but no more than 4
apart. End the cam guide in the drive (just before the drive sprocket) at the
point indicated in Figure 3-19 and Figure 3-20. A mounting flat should be
within 1 foot of the end of any unsupported cam guide angle.
Figure 3-21. Cutting Instructions for the Cam Guides Over the Drive
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Install the cam guide between each divert switch throughout the length of the
intermediates. Cut the cam angle guide to length between switch assemblies.
Space the mounting flats equally along the cam angle but no more than 4
apart (see Figure 3-21).
At each end of the divert switch, mount the cam guide as shown in the
figures below.
Figure 3-22. Single-Sided Cam Guide Mounting (Intermediates)
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Figure 3-23 Dual-Sided Cam Guide Mounting (Intermediates)
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There may be cases when a dual-sided sorter has some single-sided diverts.
In these cases, install the cam guides on both sides of the sorter as described
in the guidelines for dual-sided sorters. At the single-sided divert location
mount the cam guide as shown in the following figure.
Figure 3-24. Single-Sided Divert on Dual-Sided Sorter
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If more than one cam guide is needed because one is not long enough, butt
the ends of the cam guides together and attach mounting flats near the ends.
Important: The downstream cam guide (in direction of cam travel) must be
offset slightly from the upstream cam guide so the cam bearing does not
strike the end of the downstream guide as it passes by.
Figure 3-25. Cam Guide Offset
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3.8.8
Step 7a - Return Guide (Single-Sided)

Install the return guide in the bottom side of the conveyor. The cross braces
are field installed and must be spaced differently for different width
conveyors. The entire return guide assembly butts up against the vertical
transition assembly in the tail.
Figure 3-26. Return Guide Field Mounting (Single-Sided) (See next figure for A, B, & X-X)
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Notice in the following figure that the return guide must be mounted a
specific distance from the side rails.
Figure 3-27. Return Guide Mounting Details (Single-Sided)
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Secure the middle of the return guide to each cross brace with mounting
clips.
Figure 3-28. Return Guide Mounting Clips (Single-Sided)
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3.8.9
Step 7b - Return Guide (Dual-Sided)

Install the return guide in the bottom side of the conveyor. One arm of the
guide is of different lengths for different width conveyors. The entire return
guide assembly butts up against the return switch assembly.
Figure 3-29. Return Guide Field Mounting (Dual-Sided) (See next figure for A, B, & X-X)
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Notice in the following figure that the return guide must be mounted a
specific distance from the side rails and must be correctly aligned with the
return switch.
Figure 3-30. Return Guide Mounting Details (Dual-Sided)
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The return guide must be field assembled as shown in the following figure.
Figure 3-31. Return Guide Assembly (Dual-Sided)
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The following figure shows the correct position and alignment for the return
guide.
Figure 3-32. Return Guide - Assembly (Dual-Sided) (contd)
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3.8.10 Step 8 Side Guide Wearstrips, Wheel Track, and Wheel Cover
Wheel tracks and side guide wearstrips are located at the top-left, top-right,
bottom-left, and bottom-right positions. There are four wheel track positions
and four side guide wearstrip positions per section. The wheel covers are
located at the top-left and top-right positions only.
Figure 3-33. Wear Strip and Wheel Track Splice Details
Side Guide Wearstrip Installation Instructions (See Figure 3-33)

1. The side guide wearstrip and groove in the aluminum rail must be
thoroughly cleaned and the temperature must be above 60 F for the
proper bonding of adhesive tape.
2. Apply a liberal amount of 3M Prep Solvent-70 cleaner to a Scotch Brite
pad (3M 7447 maroon recommended) and scrub the surface thoroughly.
3. Apply some more cleaner to a clean rag and wipe down the surface
turning the rag often to ensure that all dirt and oil has been removed.
4. After cleaning, use a clean dry rag to wipe down the surface, turning the
rag often to ensure that all residue has been removed and the surface is
dry.
5. Start the installation by peeling the back off one side of the tape and
applying it to the aluminum rail flush or just below the top edge. A roller
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is recommended to ensure even pressure is applied to the tape (15 PSI

recommended). Remove the remaining backing from the tape and install
the wearstrip by seating the bottom edge in the groove first and then
rotating it up against the tape. Use a roller to apply even pressure to the
wearstrip. Splices should be cut on a 45 bias.
Figure 3-34. Splice at 45 Degree Angle
Wheel Track Installation Instructions (See Figure 3-33)

1. The wheel track groove in the aluminum extrusion must be thoroughly
cleaned and the temperature must be above 60F for proper bonding of
the adhesive tape.
2. Apply a liberal amount of 3M Prep Solvent-70 cleaner to a Scotch Brite
pad (3M 7447 maroon recommended) and scrub the surface of the wheel
track groove in the aluminum extrusion thoroughly.
3. Next, apply some of this cleaner to a clean rag and wipe down the
surface, turning the rag often to ensure that all dirt and oil has been
removed.
4. After cleaning, use a clean dry rag to wipe down the surface again,
turning the rag often to ensure that all residue has been removed and the
surface is dry.
5. Start installation by cutting three 12 long pieces of the aluminum wheel
track. Cut one in half. These two pieces will be for the top run. Cut the
other two tracks to a dimension of 140 inches. These pieces are for the
bottom tracks. Butt the square end against the steel track (which is
already in the tail section) while holding the wheel track up at an angle.
Figure 3-35. Cutting the Wheel Track
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6. Begin peeling the backing off the wheel track adhesive, starting from the
end, and carefully lay the wheel track in the groove in the aluminum
extrusion.
7. Complete the bonding of the wheel track to the aluminum extrusion
surface using a roller. Extra care should be exercised to ensure that even
pressure is applied (15 psi recommended) and that straightness is
maintained. Continue installing each track section.
8. When an odd length section is used, the track may have to be cut to keep
the splice near the middle of each section.
9. Finish installing the track by measuring and cutting the last piece that has
a 90 cut to match the track in the drive for the top track and the catenary
for the bottom track.
Note: Level the aluminum wheel tracks between sections. Otherwise,

irregular wear patterns may cause erosion problems when spanning the joint
between two sections
Wheel Cover (See Figure 3-33)
The wheel cover comes in 12 long pieces that attach to the side frame.
Place the wheel cover on the side frame and hold in place. Slide the clip nut
over the edge of the frame at a mounting hole location. Pass a screw through
a lock washer, then through a flat washer, then through the hole in the wheel
cover, then into the clip nut. Tighten just enough to keep in place. Repeat
this process along the remainder of the length of the wheel cover. When all
screws are in place, tighten securely.
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3.8.11 Step 9 - Controls Tasks

Certain controls related tasks must be performed now, before the chain/flight
assemblies are installed (next step). Refer to the appropriate controls portion
of this installation document and complete all controls related tasks (Chapter
4) that require access to the interior area of the sorter.
3.8.12 Step 10 - Chain/Flight Assemblies

When the tail and all intermediates are installed and the control tasks are
completed for Step 9, it is time to install the chain flight assemblies.
Figure 3-36. Flight Chain Assembly
The chains have a special direction of travel. When they are on the top side
of the WhisperSort, the chain travel is the same as the carton flow. On the
bottom side, the chain travels opposite to the carton flow. Once the chain
travel is determined, it is easy to properly install the chain flights for the
correct direction of chain travel. The widest edge of the wedge-shaped
pusher is the leading edge in direction of chain travel.
Figure 3-37. Pusher
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To install the flight assemblies, follow the steps described below:

1. To make installation of the flight chains easier construct a 10-foot to 12foot long chain ramp. Fabricate the chain ramp from field steel (angles)
and install on the end of the catenary section. Set the elevation of the
ramp level with the top surface of the bottom wheel track.
2. On the first 10-foot section of chain, remove the first flight assembly side
plate by loosening the 5/16 slat bolts. Install a chain pulling bar in its
place.
Note: When you later reinstall the side plates and slats, apply Loctite
242 and tighten the 5/16 slat bolts to 20 ft-lbs. (See Section 4.14 in
Chapter 4 regarding Slat Removal and Pusher Replacement)
3. The chain flights are shipped in 10-foot lengths in a special crate. Install
the chain flights in the return track (lower level track) by raising the
entire crate each time a ten-foot section is removed from the crate. The
pusher pins must be face up since the flights travel upside-down in this
return track.
4. Pull each chain section from the crate onto the chain ramp and couple
them together using RC100 coupler links. The pins of the coupler link
MUST extend toward the outside of the sorter. Locate all pushers to one
side of the sorter when installing the chain (to eliminate pusher damage).
Pins on outside of sorter
Side Plates
Figure 3-38. Coupler Links
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5. Check the pushers for free travel across the slat. If a pusher does not
move freely across the slat, remove the pusher and inspect it for
obstructions or assembly errors. Check the slat for damage.
6. Double-check the pushers for correct direction of travel as previously
described.
7. Pull each section of chain, by hand, into the sorter onto the lower wheel
track. When an entire crate load is connected (approximately 70 feet of
chain), pull the whole section to the tail then up and around the tail
sprockets. When you have approximately 30 feet of chain on the top
level and 40 feet on the bottom level, tie the top chain off to the
WhisperSort frame. This will allow you access to connect the next 70foot section of chain to the preceding section. A nylon strap can be
stretched between the flights (top chain to bottom chain) to keep the
bottom chain from free rolling. Do not run the top chain past the bottom
chain. Do not pull the chain too quickly. Be sure to apply back pressure
on the chain assembly to eliminate the possibility of the chain
overrunning the pullers. If the chain overruns the puller, the chain is
likely to either bunch up at the tail sprocket or run out the end of the tail
section onto the floor.
8. Assemble the second and subsequent 70-foot crate loads of chain. Pull
each toward the tail section and couple to the preceding section. For ease
of pulling as well as for safety considerations, use a come-along to pull
the entire chain after each 70-foot chain section is coupled to the
previous section.
9. Installation of the chain will continue after the drive is installed (next
step).
Notes:
1. Do not pull the chain too quickly.
2. Never pull the chain opposite the direction of travel.
3. Apply back pressure to keep the chain from free rolling.
4. Always tie the chain off when you are not actively pulling in a
section.
When you have completely filled the top and bottom tracks and have the
chain tied off, you are ready to install the drive section.
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3.8.13 Step 11 - Drive

The drive assembly is installed next.
Figure 3-39. Drive Assembly
To install the drive assembly:

1. Move the chain support blocks out of the way.
2. Attach the support angles to the drive assembly.
3. Check the drive frame to be sure it is square.
4. Bolt the drive assembly to the catenary section.
5. Check the sprocket alignment (phase), which is the timing of teeth from
one drive sprocket to the other. (See Section 4.5.1 in Chapter 4
regarding Phasing Sprocket Located on Drive Shaft.)
6. Check the phase lock hubs to make sure they are tight.
7. Adjust the drive shaft take-up adjustments so that the shaft is as far
towards the catenary as possible. (See Section 4.9 in Chapter 4 regarding
Chain Adjustment.)
8. The drive is now ready to have the flight chains loaded into it. Load 20
feet of chain into the drive top and bottom tracks and around the drive
sprockets.
9. Attach a chain pulling bar to the last section of chain in the drive unit
(top side) and tie the chain off to the frame.
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10. Connect the bottom chains together. Attach a come-along to the chain
pulling bar and to a building header or the forks of a fork truck (to
provide a rigid base for pulling the slack chain out of the sorter). Pull the
slack out of the chain.
11. After pulling the slack out of the chain the last 10-foot section can be
shortened as needed. The chain must be shortened in increments of 5
(the approximate dimension of the flight assembly). Cut the chain so the
drive shaft and motor have sufficient take up for future adjustment.
Install the final coupler links.
12. Use the drive shaft take-up adjustments to square the drive shaft.
13. Use the drive shaft take-up adjustments to remove any excess slack in the
chain. (See Section 4.9 in Chapter 4 regarding Chain Adjustment.)
14. Check the entire sorter for any obstructions by free wheeling the sorter at
the drive section. (This is done by turning the fan on the motor.)
3.8.14 Step 12 Load Belt Conveyor

The load belt conveyor transfers product from the upstream conveyor to the
sorter. Assemble the load belt conveyor referring to the following figures for
part locations and reference numbers.
Install the drive belt and the conveyor belt (already installed when using
single-sided sorters). To install the drive belt and to tension both belts:
1. Loosen the conveyor belt.
2. Set the drive belt in place.
3. Tighten the drive belt. The correct tension, using the force deflection
method, is 9.2 to 13.8 pounds of force, applied to the center of the span,
to deflect the belt 0.43 inches (see Figure 3-41 and Figure 3-43.)
4. Tighten the conveyor belt.
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Figure 3-40. Load Belt Conveyor (Plan View)
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Figure 3-41. Load Belt Conveyor (Side View)
END VIEW "B-B"
BLA03443
Figure 3-42. Load Belt Conveyor (End View)
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Figure 3-43. Drive Belt Tension Adjustment
Figure 3-44. Load Belt Conveyor (Reference Numbers)
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3.8.15 Step 13 Installing Belt End Discharge Section

When the drive sprockets are moved on the sorter, the end discharge section
must be adjusted to match the movement of the drive sprockets. (The callouts
in the following figure correspond to the numbered installation steps that
follow.)
Figure 3-45. Belt End Discharge

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To install the belt end discharge section:

1. The end discharge belt should be installed with the top of the belt
2 9/16 below the top of the sorter slats. This should place the tip of
the transition flats 1 3/8 below the top of the sorter slats. The belt
section should be installed level. The belt section extends 48 from
the end of the sorter drive.
2. Move and tighten the sorter sprockets in the newly adjusted position
based on the chains in the sorter.
3. Loosen the bolts in the lower flange of the extending frame and the
top bolts in the slider bed (see Figure 3-44).
4. Use the adjusting screws on the side of the frame to evenly move the
extending frame. The bolts in the flange will have to be moved from
slot to slot as the frame extends.
5. Adjust the frame until the following three dimensions are met (see
Figure 3-46). If the bed was installed level, the elevation should still
be correct.
a. 7 from the center of the sorter sprocket to the end of the
transition flats.
b. From the top of the slats in the section down 1 3/8 to the
tips of the transition flats.
c. 5/16 between the slats around the sprocket and the bottom
of the transition flats.
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Figure 3-46. Adjusting Power Belt Sprocket
6. Retighten the section bolts, slider bed bolts and jam nuts on the
adjusting screws.
7. Check the belt tension and verify that the belt still conforms to the
pulleys. The belt tension should not change when extending the
section.
8. Run the discharge belt and check the belt tracking. There is a selftracking roller in the discharge belt. If belt tracking is required adjust
the roller clips on each side of the frame (see Figure 3-44).
9. Install the high guards with stiffener angles to sorter and the belt
section.
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3.8.16 Step 14 Gravity Roller End Discharge

The following steps are for installing the gravity roller end discharge. When
the drive sprockets are moved on the sorter, the end discharge section must
be adjusted to match the movement of the drive sprockets. (The callouts in
the following figure correspond to the numbered installation steps that
follow.)
Figure 3-47. Gravity Roller End Discharge
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To adjust the end discharge section:

1. First move and tighten the sorter sprockets in the newly adjusted
position.
2. Check the setting of the mounting angle on the drive section. The angle
should be 22 15/16 from the bottom of the drive section to the top of the
mounting angle.
3. Set the section in place with the adjusting clips mounted on this angle.
The other end of the section should be set to dimensions of 48 from the
end of the drive and 7 1/2 down from the top of the slat carrying surface
to the top end of the section.
4. Loosen the bolts holding the extending frame in place (24 places). Move
the frame in towards the sorter sprockets.
5. Loosen the bolts holding the end of the section near the sorter drive. This
will allow the end discharge section to move when the jack bolts are
rotated.
6. Extend the frame and raise or lower the section with the jack bolts until
the following three dimensions are met (see Figure 3-48).
transition flats.
b. From the top of the slats in the section down 1 3/8 to the tips of
the transition flats.
c. 1/4 between the slats around the sprocket and the bottom of the
transition flats.
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Figure 3-48. Adjusting Gravity Sprocket
7. Retighten the section bolts and jam nuts on the jack bolts.
8. Check the gap from the last roller in the extending frame to the rollers
mounted in the section. Rotate as many of the rollers/clips to the higher
position as needed to have rollers on 2 roller centers. The clips can be
moved to even out the last roller gap. (See Section 4.7 in Chapter 4 for
instructions on adjusting the gravity rollers.)
9. Install the high guards with stiffener angles to the sorter and the section.
3.8.17 Step 15 - Controls Tasks

Controls related tasks must be performed now. Go Chapter 5 to review the
controls installation and set up.
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Chapter 4
Maintenance
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Chapter 4 - Maintenance

4.0
MAINTENANCE....................................................................................................................4-3
4.1 24-Hour Hotline Service..........................................................................................................4-3
4.1.1
Hotline Service Contract .................................................................................................4-3
4.1.2
Equipment Problems .......................................................................................................4-3
4.2 Equipment Warranty ...............................................................................................................4-4
4.3 Lubrication ..............................................................................................................................4-5
4.4 Set Screw Retightening ...........................................................................................................4-5
4.5 Drive and Take-Up Assembly (Discharge) .............................................................................4-6
4.5.1
Phasing Sprocket Located on Drive Shaft.......................................................................4-6
4.5.2
Fixed Sprocket Located on Drive Shaft ..........................................................................4-7
4.5.3
Pusher Out-of-Position Detector .....................................................................................4-7
4.5.4
Squaring the Drive Shaft .................................................................................................4-8
4.6 Adjusting Belt End Discharge Section ....................................................................................4-9
4.7 Adjusting Gravity Roller End Discharge ..............................................................................4-12
4.8 Catenary Section....................................................................................................................4-15
4.9 Chain Adjustment..................................................................................................................4-16
4.10 Intermediate Sections ............................................................................................................4-18
4.10.1 Side Guide Wear Strip and Aluminum Wheel Track Removal.....................................4-19
4.10.2 Wearstrip Replacement..................................................................................................4-19
4.10.3 Aluminum Wheel Track Replacement ..........................................................................4-20
4.10.4 Steel Wheel Track Adjustment......................................................................................4-20
4.10.5 Pin Guides .....................................................................................................................4-20
4.11 Tail Section (In Feed)............................................................................................................4-21
4.11.1 Cam Guide Ring Located on Tail Shaft ........................................................................4-22
4.11.2 Pin Guide Adjustment ...................................................................................................4-23
4.11.3 Encoder..........................................................................................................................4-23
4.11.4 Replacement Procedure for Components Located on Tail Shaft...................................4-23
4.12 Divert Switch and Divert Guides ..........................................................................................4-24
4.12.1 Divert Control Module, Divert Proximity Sensor, and other Control Devices .............4-24
4.12.2 Divert Signal..................................................................................................................4-24
4.12.3 Switch Module ..............................................................................................................4-26
4.12.4 Divert Module ...............................................................................................................4-30
4.13 Chain Flight Assembly ..........................................................................................................4-31
4.14 Slat Removal and Pusher Replacement .................................................................................4-33
4.15 Pusher Assembly ...................................................................................................................4-36
4.16 Crossover Switch Motor Replacement ..................................................................................4-37
4.17 Wheel and Side Guide Bearing Replacement........................................................................4-40
4.18 Preventive Maintenance Schedule.........................................................................................4-41
4.18.1 Purpose ..........................................................................................................................4-41
4.18.2 Quick Reference Maintenance Schedule .......................................................................4-42
4.18.3 Daily ..............................................................................................................................4-42
4.18.4 Weekly...........................................................................................................................4-43
4.18.5 Monthly .........................................................................................................................4-44
4.18.6 Quarterly........................................................................................................................4-44
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List of Figures
4-6
Figure 4-2. Pusher Out-of-Position Detector (RH Drive shown)
4-7
Figure 4-3. Squaring the Drive Shaft
4-8
Figure 4-4. Adjusting Belt End Discharge
4-9
4-10
4-12
Figure 4-7. Adjusting Gravity Sprockets
4-14
4-15
Figure 4-9. Taking Up Chain Slack at the Drive Shaft
4-17
Figure 4-10. Intermediate Section
4-18
Figure 4-11. Wear Strip and Wheel Track Details
4-19
4-20
Figure 4-13. Tail Assembly (Dual-Sided Shown)
4-21
Figure 4-14. Cam Guide Ring and Tail Shaft (Dual-Sided Shown)
4-22
Figure 4-15. Pin Guide Adjustment Screws
4-23
Figure 4-16. Proximity Sensor Location on Divert Switch Assembly
4-25
Figure 4-17. Switch Assembly
4-26
Figure 4-18. Divert Rail Flush with Divider Block
4-28
Figure 4-19. Switch Module Alignment
4-29
Figure 4-20. Divert Module
4-30
Figure 4-21. Chain Flight Assembly
4-31
Figure 4-22. Hitch Pin and Washer
4-31
Figure 4-23. Flight Assembly
4-32
Figure 4-24. Slat Tool
4-33
Figure 4-25. Slat Removal and Pusher Placement
4-34
Figure 4-26. Pusher
4-35
Figure 4-27. Pusher Assembly Parts
4-36
Figure 4-28. Motor Replacement
4-37
Figure 4-29. Switch Arm
4-38
Figure 4-30. Crossover Switch
4-39
Figure 4-31. Wheel Assembly
4-40
Figure 4-32. Side Guide Bearing
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4.0 Maintenance
HK Systems conveyors are designed to operate with a minimum of maintenance.
Downtime on any part of a conveyor involves time and money. Certainly not all
breakdowns or failures can be detected before they occur; however, many can be
prevented if you follow a regular maintenance program. When you install new
equipment, you should establish a schedule of preventive maintenance.
The preventive maintenance procedures outlined in this chapter provide an easy
way to determine the operational status of the equipment. The preventive
maintenance procedures enable you to identify possible trouble areas so that the
suspect condition does not deteriorate to the point of equipment failure.
Always follow good conveyor safety practices. Never perform maintenance on a
running conveyor. Always replace guards and covers after maintenance.
4.1 24-Hour Hotline Service

Calls are received at the national service center. An HK Systems representative
logs the pertinent information of the call and routes the information to the
appropriate service technician. The service technician responds to the call. Later
the Service Center follows up on all calls to ensure resolution of all Customer
issues.
4.1.1
Hotline Service Contract

The service is available as part of an Asset Protection Plan Service contract.
Coverage is provided 24 hours per day / 7 days per week / 365 days per year.
Please contact HK Systems Customer Service at (800) 424-7365 for additional
information.
4.1.2
Equipment Problems
If you experience problems with your HK Systems equipment, please call our
hotline number at (800) 424-7365 with a description of the problem. One of our
highly trained professionals will direct your call to the proper channels.
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4.2 Equipment Warranty

A. HK SYSTEMS warrants that items supplied by HK SYSTEMS will
conform to the Agreement, shall be suitable for the intended use, and
shall be free of defects in material and workmanship at the time of
acceptance of the work for a period of (12) months or 2,000 hours of
operation, whichever comes first.
B. THERE ARE NO WARRANTIES, EXCEPT OF TITLE, EXPRESSED
OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR ANY PURPOSE EXCEPT
AS EXPRESSLY SET FORTH IN THIS ARTICLE.
C. HK SYSTEMS LIABILITY for breach of warranty or otherwise is
limited to the following actions:
1. Structural members: Defective or non-conforming structural
members will be repaired or replaced by HK SYSTEMS at
PURCHASERs site.
2. Items of HK SYSTEMS design or manufacture: Defective
components will be repaired or replaced when same are returned to
HK SYSTEMS, FOB HK SYSTEMS plant.
3. Items not of HK SYSTEMS design or manufacture: HK
SYSTEMS liability for defects in material or workmanship for
computer hardware, peripherals, software developed by third parties
or other items not designed or manufactured by HK SYSTEMS,
which are incorporated in the System, shall be limited to that of
vendor thereof.
4. HK SYSTEMS -developed software: HK SYSTEMS -developed
software is warranted to perform in accordance with the mutuallyapproved Software Functional Design Specification. HK
SYSTEMS liability for defects is limited to the correction of
demonstrable defects that are defined and documented by the
PURCHASER.
5. HK SYSTEMS -developed firmware: HK SYSTEMS liability for
defects are limited to the correction of demonstrable defects that are
defined and documented by the PURCHASER.
D. HK SYSTEMS shall be relieved of any obligations under the foregoing
warranty as to any items which: (1) Have not been properly maintained
or are not maintained to the current support level in accordance with HK
SYSTEMS and manufacturer's recommended procedures and written
instructions; (2) Have not been operated in accordance with HK
SYSTEMS or manufacturer's recommended procedures and written
instructions; (3) Have been modified by persons other than HK
SYSTEMS (except where prior approval has been granted by HK
SYSTEMS); (4) Differ from the operating conditions and methods
contemplated by the Agreement.
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E. HK SYSTEMS shall be given access to make warranty repairs.

F. PURCHASER shall notify HK SYSTEMS in writing of all warranty
claims, defining the nature, extent and effect of the defect.
4.3 Lubrication
The pillow block bearings in the drive section and the tail section are lubricated
with Shell Alvania #2 grease (Appendix B for the MSDS for this type of grease).
The recommended environmental conditions are 20F to 120F with only the
normal amount of dust found in a warehouse or manufacturing environment. Do
not expose the WhisperSort to water and do not wash down. Consult
HK Systems engineering department if you need to use the WhisperSort in
conditions that may extend outside this temperature range.
Refer to vendor documentation for any additional information regarding specific
recommendations by manufacturers of the components supplied with this
equipment. Also check motor/reducer nameplates as they sometimes provide
additional information regarding maintenance and lubrication. Lubrication
information can be found in Appendix.
4.4 Set Screw Retightening

After initial start-up of the conveyor/sortation system, all setscrews should be checked and
retightened if necessary. We recommend checking the set screws with a
T-handle hex wrench after the first 500 hours of operation initially, and then
periodically thereafter. The set screws provided by the factory have been pretreated with an epoxy-based thread locking compound. Do not apply
excessive torque to check tightness. Breaking the compound loose will
compromise the locking feature. Replacement set screws should only be
installed after all residue has been removed from threaded holes. Refer to chart below for
recommended torque values to install or re-tighten set screws.
Setscrew Diameter
Hex Size
Recommended
Torque
Inch/Pounds
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1/4
1/8
65
5/16
5/32
125
3/8
3/16
230
7/16
7/32
350
1/2
1/4
500
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4.5 Drive and Take-Up Assembly (Discharge)

The drive motor is located in this section. Motors are mounted by means of an inline shaft through a hollow reducer.
The oiler(s) (drip oiler and spray oiler) are located in this section. The oiler(s)
are set up with a timer in PLC logic to lubricate approximately one revolution of
the chain flights every eight hours of operation time. This is adjustable to meet
the requirements of the specific system.
Note: The oiling procedure in the preventive maintenance program is one of the
single most important maintenance functions associated with the WhisperSort.
Inadequate lubrication will increase chain wear which contributes to chain
stretch (see Section 4.18.4, Weekly Maintenance).
Flow control valves (drip oiler only) are provided for regulating oil flow to
brushes located on a cross-tie tube in the bottom area of the drive frame.
4.5.1
Phasing Sprocket Located on Drive Shaft

The teeth on this sprocket can be adjusted to line up with the opposing sprocket.
Loosening of the hardware, located on the side of the sprocket, will allow the
outside teeth to float around the hub which is secured to the shaft. Adjustment
bolts are attached which allow a controlled float of the sprocket teeth.
1. Be sure the drive shaft is square with the drive assembly housing (see Section
4.5.4, Squaring the Drive Shaft). If it is not, use the takeup screws in the
drive section to square the shaft.
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2. Place a section of chain flight assembly over the top of both drive sprockets.
3. If the drive shaft is known to be square with the frame (see 1 above), and the
sprocket teeth are aligned, the chain flight assembly will also be square with
the frame. Look down between the two top slats. If the teeth are in phase,
the slats will run parallel with the drive shaft, and the top tooth on each
sprocket will be in the same position relative to the frame. If the teeth are not
in phase, the flight assembly will be slightly cocked and the slats will not be
parallel with the shaft. The top tooth on each sprocket will also not be in the
same position relative to the frame.
4. If the teeth are not in phase, loosen the sprocket bolts on the phase sprocket
(opposite the motor). Loosen the setscrews on the adjustment bolts and then
use the adjustment bolts to rotate the sprocket until it is correctly positioned.
Tighten the sprocket bolts and the setscrews.
5. Recheck the sprocket position using the technique outlined in step 3 above.
4.5.2
Fixed Sprocket Located on Drive Shaft

This sprocket is secured to the shaft by a tapered bushing.
4.5.3
Pusher Out-of-Position Detector

This mechanical device (located in the drive section) pivots about a shaft and is
held in its normal position by the light force of a small magnet. A proximity
sensor is mounted through the frame, which detects the side of the device in its
normal position. The detector can be adjusted so that varying amounts of force
are required to trip it.
Figure 4-2. Pusher Out-of-Position Detector (RH Drive shown)
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4.5.4
Squaring the Drive Shaft

The drive shaft must be square! If it is not square:
1. Move the end discharge if it is in the way.
2. Loosen the pillow block bearing bolts.
3. Loosen the bolts on the gearmotor torque bracket.
4. Turn one of the takeup screws until the shaft is square.
5. Measure the new bearing location on both sides to verify the drive shaft is
square to the frame.
6. Retighten the bearings.
7. Move chain support blocks to meet centerline of sprocket
8. Retighten
Figure 4-3. Squaring the Drive Shaft
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4.6 Adjusting Belt End Discharge Section

When the drive sprockets are moved on the sorter, the end discharge section must
be adjusted to match the movement of the drive sprockets. (The callouts in the
following figure correspond to the numbered adjustment steps that follow.)
Figure 4-4. Adjusting Belt End Discharge
Adjustment when the sprockets are moved out to take up slack chain:
1. Before moving the sprockets, relocate the extending section. Loosen the
bolts in the lower flange and the top bolts in the slider bed.
2. Use the adjusting screws on the side of the frame to retract the extending
section. The bolts in the flange will have to be moved form slot to slot as
the frame retracts. Evenly, move the extending frame the desired distance
so the sprockets can be adjusted.
3. Move and tighten the sorter sprockets in the newly adjusted position (see
Section 4.9, Chain Adjustment.)
4. Use the adjusting screws to extend the frame until the following three
dimensions are met (see Figure 4-5). If the bed was installed level, the
elevation should still be correct.
transition flats.
b. From the top of the slats in the section, down 1 3/8 to the tips of
c. 5/16 between the slats around the sprocket and the bottom of
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5. Retighten the section bolts, slider bed bolts, and jam nuts on the
adjusting screws.
pulleys. The belt tension should not change when extending the section.
7. Run the discharge belt and check the belt tracking. There is a selftracking roller in the discharge belt. If belt tracking is required, adjust the
roller clips on each side of the frame.
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Adjustment when the chain is removed from the sorter and the sprocket is
moved back in:
8. First move and tighten the sorter sprockets in the newly adjusted position
(see Section 4.9, Chain Adjustment.)
9. Loosen the bolts in the lower flange of the extending frame and the top
bolts in the slider bed.
10. Use the adjusting screws on the side of the frame to move the extending
frame. The bolts in the flange will have to be moved from slot to slot as
the frame extends.
11. Adjust the frame until the following three dimensions are met (see Figure
4-5). If the bed was installed level, the elevation should still be correct.
a. 7 from the center of the sorter sprocket to the end of the transition
flats.
b. From the top of the slats in the section, down 1 3/8 to the tips of the
transition flats.
c. 15/16 between the slats around the sprocket and the bottom of the
transition flats.
12. Retighten the section bolts, slider bed bolts, and jam nuts on the
adjusting screws.
pulleys. The belt tension should not change when extending the section.
14. Run the discharge belt and check the belt tracking. There is a selftracking roller in the discharge belt. If belt tracking is required, adjust the
roller clips on each side of the frame.
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4.7 Adjusting Gravity Roller End Discharge

When the drive sprockets are moved on the sorter, the end discharge section must
be adjusted to match the movement of the drive sprockets. (The callouts in the
following figure correspond to the numbered adjustment steps that follow.)
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Adjustment when the sprockets are moved out to take up slack chain:
1. Before moving the sprockets, relocate the fill rollers/clips by rotating the
clips 180 and placing the roller into the lower position. These rollers are in
front of the extending frame weldment. Lower as many rollers as necessary
so the frame can slide back the desired distance.
2. Loosen the bolts holding the extending frame in place (24 places). Move the
frame out of the way so the sorter sprockets can be adjusted.
3. Move and tighten down the sorter sprockets in the newly adjusted position
(see Section 4.9, Chain Adjustment.)
4. Loosen the bolts on the sides of the high guards and the bolts holding the end
of the section near the sorter drive. This will allow the end discharge section
to move when the jack bolts are rotated.
5. Extend the frame and raise or lower the section with the jack bolts until the
following three dimensions are met (see Figure 4-7).
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7 from the center of the sorter sprocket to the end of the transition flats.
From the top of the slats in the section, down 1 3/8 to the tips of the
transition flats.
1/4 between the slats around the sprocket and the bottom of the
transition flats.
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Figure 4-7. Adjusting Gravity Sprockets
6. Retighten the section bolts, guard bolts, and jam nuts on the jack bolts.
mounted in the section. If there is room to rotate any of the rollers/clips to the
higher position do so. The rollers should be on 2 centers and the clips can be
moved to even out the last roller gap.
Adjustment when chain is removed from the sorter and the sprocket is
moved back in:
8. First move and tighten down the sorter sprockets in the newly adjusted
position (see Section 4.9, Chain Adjustment.)
9. Loosen the bolts holding the extending frame in place (24 places). Move the
frame in towards the sorter sprockets.
10. Loosen the bolts on the sides of the high guard and the bolts holding the end
of the section near the sorter drive. This will allow the end discharge section
to move when the jack bolts are rotated.
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11. Extend the frame and raise or lower the section with the jack bolts until the
following three dimensions are met.
7 from the center of the sorter sprocket to the end of the transition flats.
From the top of the slats in the section, down 1 3/8 to the tips of the
transition flats.
1/4 between the slats around the sprocket and the bottom of the
transition flats.
12. Retighten the section bolts, guard bolts, and jam nuts on the jack bolts.
mounted in the section. Rotate as many of the rollers/clips to the higher
position as needed to have rollers on 2 roller centers. The clips can be
moved to even out the last roller gap.
4.8 Catenary Section

The purpose of the catenary section is to maintain tension in the flight chain.
This unit is designed so that excessive chain slack can be detected using a
proximity sensor located on the side frame of the unit.
The return track located in this section dips down to allow the flight chain to
drop as the chain elongates
Viewing slots are provided on the side frame so a spot check of the sag can easily
be made.
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A proximity sensor is used to detect excessive chain sag and will shut the drive
down to prevent damage to the sorter.
CAUTION:
Slack-Chain Sensor: Be sure the Proximity Switches are flush
with plastic or (preferably) 1/32 recessed. If the sensors are
not mounted properly damage will occur to the sensor surface
when the sorter starts up.
Note: Failure to remove excess slack can cause further damage to the
WhisperSort.Chain Adjustment
4.9 Chain Adjustment

When excessive chain slack is detected, the WhisperSort will automatically
shut down. Use the drive shaft take-up screws to remove excess slack.
1. Move the end discharge conveyor before moving the drive shaft (see Section
4.6, Adjusting Belt End Discharge.)
2. Loosen the pillow block bearing bolts (see following figure).
3. Loosen the bolts on the gearmotor torque bracket.
4. Turn both takeup screws equally until the excess slack is removed.
5. Measure the new bearing locations on both sides to verify the drive shaft is
square to the frame.
6. Retighten the bearings and torque brackets bolts.
7. Adjust the chain support blocks until they are within 1 of the shaft
centerline (see following figure).
8. Reposition the end discharge conveyor (see Section 4.6, Adjusting Belt End
Discharge.)
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Figure 4-9. Taking Up Chain Slack at the Drive Shaft
Eventually the drive shaft may reach the end of its travel, making it impossible to
remove slack chain at the drive. If this occurs a section of the flight chain must
be removed in 5 increments. To do this:
1. Go to the drive section and, referring to the procedure above, move the chain
support blocks out of the way, adjust the drive shaft takeup screws in the
direction opposite to that which is described above. That is, adjust the drive
shaft takeup screws so as to cause the chain to have as much slack as
possible.
2. Go to the catenary section top run of the chain and locate a master link (they
occur every 10).
3. Secure straps and a come-along to the slats a few feet apart of each side of
the master link.
4. Remove the slats plates for every 5 which must be removed.
5. Cut the chain on both sides. With the come-along, pull the chains together
and reconnect using the RC100 master link. (Pins of the coupler link must
extend towards the outside of the sorter.)
6. Go back to the drive section and, following the procedure described above,
use the drive shaft takeup screws to remove any excess slack.
7. Double-check the drive shaft to be sure it is square.
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8. Adjust the chain support blocks until they are within 1 of the shaft
centerline.
9. Reposition the end discharge conveyor (see Section 4.6, Adjusting Belt End
Discharge.)
4.10 Intermediate Sections

The intermediate sections are lined with steel side guide wear strips and
aluminum wheel tracks. Both run the length of the sorter and are isolated from
the frame of the machine by structural bonding tape. Their purpose is to provide
a smooth and quiet wear surface for the bearings and wheels.
Replace the wear strips and/or aluminum wheel track if they show signs of
excessive wear or damage.
Figure 4-10. Intermediate Section
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4.10.1 Side Guide Wear Strip and Aluminum Wheel Track Removal
Removal of the side guide wear strips and wheel track can be done using a sharp
chisel and hammer. Start by prying up one end of the wearstrip/track. Use the
chisel to cut through the structural bonding tape and pry the remaining
wearstrip/track away from the frame. Scrape away as much of the tape as
possible with the chisel. Next, apply a liberal amount of 3M Prep Solvent-70
cleaner to a 3M 7447 Scotch-Brite pad to remove any remaining residue.
Figure 4-11. Wear Strip and Wheel Track Details
4.10.2 Wearstrip Replacement

1. Wearstrip and groove in aluminum rail must be thoroughly cleaned and the
temperature must be above 60 F for proper bonding of adhesive tape.
2. Apply a liberal amount of 3M Prep Solvent-70 cleaner to a 3M 7447 ScotchBrite pad and scrub the surface thoroughly.
3. Next, apply more cleaner to a clean rag and wipe down the surface turning
the rag often to ensure that all dirt and oil has been removed.
4. After cleaning, use a clean dry rag to wipe down the surface turning the rag
often to ensure that all residue has been removed and the surface is dry.
5. Start the installation by peeling the back off one side of the tape and applying
it to the aluminum rail flush or just below the top edge. A roller is
recommended to ensure even pressure is applied to the tape (15 PSI
recommended). Remove the remaining backing from the tape and install the
wearstrip by seating the bottom edge in the groove first and then rotating it
up against the tape. Use a roller to apply even pressure to the wearstrip.
Splices should be cut on a 45 bias.
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4.10.3 Aluminum Wheel Track Replacement

1. Track groove in aluminum rail must be thoroughly cleaned and the
temperature must be above 60 F for proper bonding of adhesive tape.
2. Apply a liberal amount of 3M Prep Solvent-70 cleaner to a 3M 7447 ScotchBrite pad and scrub the surface thoroughly.
3. Next, apply more cleaner to a clean rag and wipe down the surface turning
the rag often to ensure that all dirt and oil has been removed.
4. After cleaning, use a clean dry rag to wipe down the surface turning the rag
often to ensure that all residue has been removed and the surface is dry.
5. Start installation by cutting a 12' lg piece of track in half and butting the
square end against the steel track in the tail section. Starting from this end,
peel the backing off the tape and apply the track to the rail surface using a
roller. Extra care should be exercised to ensure even pressure is applied (15
PSI recommended) and straightness is maintained.
4.10.4 Steel Wheel Track Adjustment

Steel wheel tracks are located in the drive, catenary, and tail sections.
The steel tracks are adjusted as follows:
o
Loosen the mounting hardware located on the outside of each section.
Adjust one jackbolt located underneath the wheel track to align the
track with the aluminum wear strip in the intermediate.
4.10.5 Pin Guides

Pin guides are located at the switch entry and in the vertical transition assembly.
These guides capture and guide the pusher pins. Periodically check the guides
for excessive wear or damage and replace if needed.
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4.11 Tail Section (In Feed)
Figure 4-13. Tail Assembly (Dual-Sided Shown)
The sprocket configuration on the tail shaft is as follows:
One sprocket is the idler. This sprocket can rotate on the shaft. Set collars
are located on either side of sprocket to position the sprocket in place.
The second sprocket is fixed securely to the shaft by a taper-lock

compression fit.
Sprockets must be checked periodically for wear caused by misalignment. Set

screws and bushing bolts also need to be checked for proper tightness (see
Section 4.4, Set Screw Retightening.)
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4.11.1 Cam Guide Ring Located on Tail Shaft

The purpose of the cam guide ring located on the tail shaft is to guide the pushers
around the tail shaft. It is secured to the shaft by a taper lock bushing.
Figure 4-14. Cam Guide Ring and Tail Shaft (Dual-Sided Shown)
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4.11.2 Pin Guide Adjustment

Periodically check the pin guide to be sure it is correctly positioned. The pin
guide adjustment screws allow horizontal adjustment of the pin guide which
should be aligned with both the cam guide ring and the infeed guide to the
switch.
Figure 4-15. Pin Guide Adjustment Screws
4.11.3 Encoder
Encoders are shaft mounted with setscrews to hold them in place. The encoder
counts pulses in increments of 2.5 inches to help the PLC track product. Encoder
failure results in mis-sorts due to an inability to track to a divert station. If an
encoder fails - it must be replaced.
4.11.4 Replacement Procedure for Components Located on Tail Shaft
Use the following replacement procedure for components located on the tail
shaft:
1. Relieve tension in the chains.
Note: On long WhisperSorts, tying off of the chain is recommended.
2. Break flight chains by first locating the master links closest to tail
sprockets and then removing the flight slats above for accessibility.
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3. Remove master links and open flight chain in order to expose tail
assembly.
4. Remove side panels on the upper half of frame assembly.
5. Unbolt bearing blocks. Using a hoist or come-along, remove tail shaft
assembly. This allows access to make any necessary repairs.
4.12 Divert Switch and Divert Guides

4.12.1 Divert Control Module, Divert Proximity Sensor, and other Control Devices
An electric limited-angle DC brushless motor is used to operate the switch
module. The divert proximity sensor controls the timing of the switching action.
4.12.2 Divert Signal
The divert signal is controlled by the programmable logic controller (PLC) and
communicated to the divert control module (DCM).
1. Before the product has been scanned the tracking induction photoeye is
flagged by a case. This starts the tracking procedure. Pulses generated by
the sorter tail shaft encoder (1 pulse = 2.5) are counted by the PLC.
2. A barcode scanner scans the case sending the data the PLC. The PLC sends
the barcode ID to the supervisory computer. The supervisory computer
returns the case destination to the PLC.
3. Pointers are then set for distance measurements between the tracking eye
and the divert destination.
4. When the pointer value is reached, the PLC signals the divert control
module. (Divert Signal = 1 = divert position, Divert Signal = 0 = straight
position).
5. The divert control module board has on-board software (installed by the
vendor) which controls the action of the divert switch. Once the divert signal
changes, the on-board software monitors the divert proximity sensor for the
next shoe pin. When the shoe pin is detected the on-board software activates
the necessary signal(s) for the switching action.
6. A faulty DCM board will result in divert switch failure. Replace the DCM
board.
Note: Ensure that the divert proximity sensor is in the correct location. See
figure below. Place the sensor in the upstream location (A=1). Connect the
female end of the cable to the proximity sensor and the other end to the DCM I/O
block.
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Note: When the divert proximity sensor fails, diverting will not take place.
Replace the proximity sensor.
Note: Flickering of the divert proximity sensor output LED located on the
proximity sensor may occur if the proximity sensor is located too far back from
the inside surface of the pin guide. The proximity sensor should be positioned
against the recessed surface of the pin guide.
For all DeviceNet components (DCM board, Shoe out of Position, Slack
Chain, and End of Sort Photoeye, follow the DeviceNet troubleshooting guide
book for network and module LED fault status.
For all other NON-DeviceNet control devices such as divert confirm proximity
sensor, full and lane PEs, dynamic jam PEs, long range jam PE and others,
component LED indicators are provided along with LED indicators on the DCM
board. Also, signal status of these components can also be monitored in a static
state over DeviceNet using RSNetworx.
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4.12.3 Switch Module

Switch modules are designed for easy replacement. Before removing the switch,
disconnect the electric power. Quick-release connections are supplied for the
motor and proximity sensor.
Figure 4-17. Switch Assembly
To replace a switch module:

1. Create a window in the flight above the switch and remove the mounting
bolts.
2. There are two washers under the two bolts toward the middle of the
sorter. Pry the switch off the location pins and collect these washers.
Once the hardware is removed, the switch module will lift out easily.
3. When inserting the new switch line up the location pin. Place the
washers under the switch plate (only on the two bolts towards the middle
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of the sorter) then insert the mounting bolts. Lightly tap the switch plate
onto the mounting pins.
4. Tighten the mounting bolts.
5. Check and make sure the infeed is lined up with the feed block.
6. Check the divert rail so it is flush or slightly recessed from the divider
block on the exit of the switch (see following figure).
7. Reconnect the motor and proximity sensor. Make sure the wire is out of
the way and secure to the frame.
8. Close the window in the flights (see Section 4.14, Slat Removal and
Pusher Replacement.)
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Figure 4-18. Divert Rail Flush with Divider Block
4.12.3.1 Divert Arm Settings in the Nondivert Mode

The back surface of the divert arm and the straight surface of the divert block
(see Figure 4-19) should be aligned when the motor is on and in the straight
through position. There should be no obstructions in the pin path. The pin
should travel freely from entrance to exit. Adjustments can be made by shimming
the bumper. Peel layers to adjust the shim thickness. The shim is laminated in
0.003 thick layers and is located between bumper and plate.
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4.12.3.2 Divert Arm Settings in the Divert Mode

Check the height of the divert arm; it should be flush with the top of divert block
(see following figure). Adjust if necessary.
With the motor driving the curved surface of the switch arm into the divert
position, the curve surface and the pin guide surface should be aligned (see
following figure). The pin should travel freely from entrance to the diverted
path. Adjustments can be made by shimming the bumper behind the arm.
Figure 4-19. Switch Module Alignment
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4.12.4 Divert Module

The divert module consists of a switch module and a divert guide rail. The divert
guide rail is located immediately after each switch module and is used to guide
the pusher across the top of the WhisperSort for a smooth push of product off
the side of the sorter.
Figure 4-20. Divert Module
The divert module is positioned by removing the bolts and sliding along the
continuous slots in the aluminum extrusions. Carefully lift the entire assembly if
necessary to clear cross-ties.
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4.13 Chain Flight Assembly

The chain flight assembly consists of a series of flights attached to two strands of
RC100 chain with extended pins.
Figure 4-21. Chain Flight Assembly
Roller
Chain
Extended Pin
of RC100
Washer
Hitch Pin
Figure 4-22. Hitch Pin and Washer
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Flight Assembly
Each flight assembly consists of two tubular slats and a pusher mounted between
two side plates. The side plates contain wheels to carry the load and side guide
bearings to maintain direction. The slats are bolted to the carriers with four
special clamp screws that have a thread-locking strip. The slats are removable
for easy access to inside of sorter.
Slats can be removed by loosening the clamp screws in the side plates.
Flight side plates are connected to the RC100 chain by a washer and hitch
pins through extended roller chain links.
Hitch pins are located every 10 inches or at every other flight assembly.
Figure 4-23. Flight Assembly
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4.14 Slat Removal and Pusher Replacement

Removal of slats is often required during general maintenance and preventive
maintenance inspections. Remove slats from the side plates by loosening the
four clamp screws (two per side) and lifting the slats out. To replace the pusher,
two of the clamp screws have to be removed from the side plate. The pusher can
then slide off the end of the slats (see Section 4.15, Pusher Assembly.)
Slat removal and installation procedure:
1. Insert the slat tool into the slot between the two slats that are being removed
and rotate 90 (see Figure 4-24). The tool should be near the end of the slats
where the bolts are being removed. Back off the screws far enough so the
neck of the screw can slide out through the keyholes in the side plates.
Figure 4-24. Slat Tool
2. Move the slat tool to the other end of the slats and repeat step 1.
3. Remove the pair of slats and the pusher.
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4. To install the slats, first back out the clamp screws 3 to 4 additional turns.
Brush off any loose Loctite.
5. Place clamp screws of the two slats with a pusher assembly between them
into the keyholes in the side plates. Check that the groove in the slats are on
the bottom and not seen. Check that the pusher is in the correct orientation.
6. Insert the slat tool onto the slats. Place two drops of Loctite #242 onto the
threads of each clamp screw near the end of the slats. Tighten the screws into
the slats. Torque each clamp screw to 20 ft-lbs.
7. Move the slat tool to the other end of the slats and repeat step 6.
Figure 4-25. Slat Removal and Pusher Placement
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The pushers have to be checked for free travel across the slat. If a pusher does
not move freely across the slat, remove the pusher and inspect it for obstructions
or assembly errors. Check the slat for damage.
The clamp screws should be replaced after five uses. Each time the screw is
removed, make a mark on the screw with a paint marker to keep track of the
number of uses.
If a pusher needs to be replaced, only the screws on one side plate need to be
removed.
1. Just past the pusher, insert the slat tool into the slot between the two slats that
are being removed and rotate 90. Back off the screws far enough so the neck
of the screws can slide out through the keyholes in the side plate.
2. Lift up the slats and remove the pusher.
3. Replace the pusher. Check the orientation of the pusher.
4. Back out the clamp screws three to four additional turns. Brush off any loose
loctite.
5. Place clamp screws of the two slats back into the keyholes in the side plate.
6. With the slat tool still on the slats, place two drops of loctite #242 onto the
threads of each clamp screw near the end of the slats. Tighten the screws into
the slats. Torque each clamp screw to 20 ft-lbs.
7. Check that the pusher moves freely across the slats.
Figure 4-26. Pusher
The widest edge of the wedge-shaped pusher is the leading edge in direction of
chain travel.
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4.15 Pusher Assembly

Figure 4-27 shows the parts to the pusher assembly.
Figure 4-27. Pusher Assembly Parts
1. Push the bumpers (item 2 and 3) in until the knobs on top of the bumpers are
locked in the holes on the top of the pusher body.
2. Slide item 7 into the pusher body (item 1). Tabs on the pusher body hold the
sides of item 7.
3. Use a new coated shoulder bolt in item 6.
4. Place the disc spring and washer on the shoulder bolt. Make sure the raised
center section of the spring disc is toward the head of the shoulder bolt.
5. Place the washer (item 10), bearing (item 9), and bearing adapter (item 8) on
the pin (item 11).
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6. Hold the pin assembly under the pusher body and position the bearing
adapter so the key will engage in the pocket in item 7.
7. Insert the shoulder bolt assembly and screw the shoulder bolt into the pin.
Make sure not to cross-thread the assembly.
8. Torque the shoulder bolt to 80 inch-pounds.
4.16 Crossover Switch Motor Replacement

To replace a crossover switch:
1. First, create a window in the slats over the switch motor that will be replaced.
2. Disconnect the wire.
3. Remove the existing motor from the crossover switch by removing the four
top bolts and disconnecting the quick-release connection at the end of the
wire.
4. Pry the motor to loosen the locating pin from the plate.
5. Pull the motor out of the bottom of the switch. The switch arm will exit
through the keyhole in the plate.
6. Remove the switch arm and key from the motor.
7. Prepare the new motor to be mounted into the switch (see Figure 4-28).
Figure 4-28. Motor Replacement
To prepare the new motor:

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7. Insert location pins in the new motor.
Remove the screws from the switch arm and brush off the dry loctite
from the screws.
Place some paper towels around the shaft so that no loctite runs down in
the bearings.
Place a drop of loctite #242 on each of the four switch arm screws.
Place the key in the motor shaft.
Place the switch arm on the motor shaft so that the keyseat in the switch
arm is aligned with the key.
Place the arm clamp over the shaft and insert the screws.
The switch arm should be position 2.18 above the top of the motor (see
Figure 4-29).
Figure 4-29. Switch Arm
Evenly tighten the screws to 33 in-lbs.

Wipe off all excess loctite and remove the paper towels.
8. Brush off the loctite from the motor mounting screws and place loctite #242
on the screws.
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9. Install the new motor from under the switch plate. Place the locating pins
over the holes in the plate and lightly tap the motor to engage the pins (see
Figure 4-30).
10. Insert the motor mounting screws and tighten. Wipe off any excess loctite.
11. Check that the arm freely moves side to side and is not rubbing on the switch
parts.
12. Check that the top of the arm is flush with the top of the switch parts. Adjust
if necessary.
13. Reconnect the motor wire and secure the wire to the cross members with wire
ties as needed.
14. With control power on, check that the motor functions correctly.
15. Close the window in the flights (see Section 4.14, Slat Removal and Pusher
Replacement.)
Figure 4-30. Crossover Switch
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4.17 Wheel and Side Guide Bearing Replacement

To replace the wheel (see Figure 4-31):
1. Unscrew and remove the old wheel
2. Insert the wheel mounting screw through the wheel and wheel hub.
3. Insert the wheel mounting screw through the hole in the side plate.
4. Install the Nylock nut on the wheel mounting screw.
5. Torque the wheel mounting screw to 20 ft-lbs.
Figure 4-31. Wheel Assembly
To replace the side guide bearing (see Figure 4-32):

1. Unscrew and remove the old side guide bearing.
2. Insert the side guide bearing mounting screw through the bearing and
washer.
3. Insert the side guide bearing mounting screw through the hold in the tab on
the side plate. The screw is inserted from the bottom of the tab.
4. Install the Nylock nut on the side guide bearing mounting screw on the top of
the side plate tab.
5. Torque the side guide bearing mounting screw to 20 ft-lbs.
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Figure 4-32. Side Guide Bearing
4.18 Preventive Maintenance Schedule

HK Systems equipment is designed to operate with a minimum of maintenance.
Downtime on any piece of equipment involves time and money. Certainly not all
breakdowns or failures can be predicted before they occur; however, many can
be prevented if you follow a regular maintenance program. When you install
new equipment, you should establish a schedule of preventive maintenance.
The preventive maintenance procedures outlined in this manual provide an easy
means of determining the operational status of the equipment. The preventive
maintenance procedures enable you to identify possible trouble areas so that the
suspect condition does not deteriorate to the point of equipment failure.
Notes:
Always follow good safety practices.
Never perform maintenance on a running conveyor.
Always replace guards and covers after maintenance.
The maintenance schedule should be modified to suit the operating conditions of

individual applications.
4.18.1 Purpose
The objective of the preventive maintenance schedule is to ensure that the
equipment performs at maximum efficiency over a long period of time. An
effective maintenance schedule also helps to eliminate costly repairs. Do not
assume that trouble will not occur and therefore pass over inspection items.
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Standardized procedures ensure effective control over maintenance operations,

and enable you to compare equipment in order to evaluate the maintenance
program. Preventive maintenance procedures are applicable to all equipment
locations.
Note: Replace any faulty parts immediately during scheduled inspections and
maintenance.
4.18.2 Quick Reference Maintenance Schedule
Action Required
Check chain slack at catenary
Check oil level in chain oilers
Check oil level in spray oilers
Check grease level in pin greaser
Check switch assemblies for wear
Inspect gearmotor fasteners
Check gearmotor oil and amperage
Inspect wear strips
Check position and movement of
switch arms
Check condition and position of
switch bumpers
Check grease and temperature of
pillow block bearings
Inspect sprockets and chains
Inspect load belt and sprockets
Interval (operating hours)

Weekly Monthly Quarterly
9
9
9
9
9
9
9
9
9
9
9
9
9
Note: Please refer to the text on the pages that follow this table for further
explanation of some of the maintenance items in this table. For instructions on
gearmotor maintenance, refer to the vendor documentation.
4.18.3 Daily
Walk around and generally inspect the entire conveyor. Listen for unusual noise
and/or erratic operation. Pay particular attention to condition of the flight slats
and pushers. Efficient operation requires the flight slats to be free of any buildup of dirt or dust. If required, clean and polish with a cloth and a nonresidual
solvent such as lacquer thinner if the work area is well ventilated.
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4.18.4 Weekly
Drip Oiler
1. Check the oil level of the automatic chain oilers located on both sides of the
drive section.
2. Clean and adjust the applicator brushes on each side inside the drive section.
3. Top off reservoir as needed with clean Vulcan chain lubrication (Aries
Series).
Note: The oiler is controlled by the PLC, which allows the oil to flow for
approximately one complete revolution of the chains after every 8 hours of
operation. Inspect both sides of the RC100 chains and be sure they are well
lubricated.
Spray Oiler
1. Verify that the appearance of the chain is slightly wet with oil with no visible
rust.
2. Make sure that the oil is spraying properly from the nozzles.
3. Top off the reservoir as needed with Powerflow Hydraulic Oil ISO-68AW.
4. Loosen drain plug to remove any air trapped in the pumps.
5. Adjust the air pressure to 50 PSI. Set the stroke length to maximum by
turning knob clockwise.
6. Adjust air metering screw to turn open.
7. Turn unit on by supplying power to the solenoid valve.
8. Set pump cycles/min per chart by adjusting pulse generator.
Note: The Lubricator should run anytime the Whispersort is running.
Catenary Section
Visually inspect the catenary portion of the return flight chain run for excessive
slack. This observation should be made as the sorter is starting until top speed is
achieved.

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4.18.5 Monthly
Inspect all switch assemblies for proper operation and wear. Replace if
excessive wear is evident.
Note: Switch assemblies are easily removed and replaced as an assembly.
At least one complete assembly of each type should be available at all times
as a spare to allow for the service of individual switches.
Inspect fasteners at the motor and gearbox for tightness.
Inspect gearmotor for oil leaks and proper amperage (amp reading can be
made at variable drive controller).
Inspect all wheel guide wear strips and bearing guide wear strips along the
length of the conveyor. Replace if required. There is one wheel track wear
strip and one bearing guide wear strip on the top left, top right, bottom left,
and bottom right of the sorter.
Check the position of the divert proximity sensor so that a consistent signal is
received for each passing pusher. Proximity sensor must be flush against the
protective guard.
Check the switch arm to be sure it is securely attached to motor shaft and at
the correct elevation.
Check bumpers to see that they are in good conditions and the switch arm is
slightly (1/64" to 1/32") behind incoming guides when in position against the
bumper.
Check switch arm to see that it can be moved easily by hand with power
turned off.
Check grease and temperature of the pillow block bearings in the drive
assembly (2 bearings) and tail assembly (2 bearings).
4.18.6 Quarterly
Check all sprockets and chains for alignment, lubrication, and wear. Correct as
necessary.
CAUTION: Avoid over lubrication. Over lubrication shortens

the life span of the bearings. Check MSDS sheets in Chapter 6 for
information about lubrication.
Inspect load belt and sprockets for proper alignment. Adjust if necessary.
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Chapter 5
Electrical Controls Installation and Setup
WhisperSort
Chapter 5 Controls Overview

5.0
Electrical Controls Installation and Setup ................................................................................ 5-3
5.1 Critical Items Checklist (Controls Installation)............................................................................ 5-3
5.2 Standard Offerings ....................................................................................................................... 5-5
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5-2
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5.0
Electrical Controls Installation and Setup

There are six WhisperSort models. Each model is described in detail in the
following chapters. An overview of the model, installation instructions,
drawings, referent tables, and start-up and test procedures are included for each.
Model 1 DeviceNet Single-Sided (see Chapter 6)

Model 2 Discrete I/O Single Sided (see Chapter 7)
Model 3 DeviceNet Dual-Sided (see Chapter 8)
Model 4 Discrete I/O Dual-Sided (see Chapter 9)
Model 5 DeviceNet Single Sided (see Chapter 10)
Model 6 DeviceNet Dual-Sided (see Chapter 11)
This chapter contains commonalities among the six models. For specifics of your
model, refer to the appropriate chapter.
5.1 Critical Items Checklist (Controls Installation)

Please read through these important cautions. They apply to all four WhisperSort
models.
Important Please Read !

SLACK-CHAIN SENSOR
Be sure the Proximity Switches are flush with plastic or (preferably) 1/32 recessed.
CAUTION: If the sensors are not mounted properly damage will occur to the
sensor surface when the sorter starts up.
POWER BUSWAY
1. Install the power rails under the sorter so that the label on the front of the power rail faces the outside of
the sorter.
2. After inserting the busway splices, hand tighten the splice screws on the bottom.
CAUTION: Over tightening can cause the busway to bow causing intermittent power connection.
3. Be sure there is enough clearance so that no obstacles exert pressure on the busway or power jack after
installation. Also, allow enough clearance to insert and remove power jack from busway.
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4. Once the busway rail and DCMs

are installed, insert the DCM power
connector into the busway rail.
Squeeze clamp to side of power
connector, insert sideways into rail,
and twist to the right (ON ).
Releasing clamp locks connector into
rail. To remove, squeeze clamp and
twist to left ( OFF) and pull down from rail. Installing the connector differently than
described above will cause damage to the power jack connections.
5. Remove power connector T1 at each divert control module before applying power to the Busway. (This
should have been done at the factory). Reconnect T1 with power OFF - after DC power and polarity
have been checked.
CAUTION: Damage can occur to the DCM control board if the DC polarity is incorrect.
6. The power busway is rated for 60 amps. HK Systems limits the maximum current on the busway to 50
amps. If there are more than 16 dual sections on a sorter there must be two separate busways. There is a
second busway power feed box supplied if the number of dual sections is greater than 16.
CROSSOVER SORTER CENTER PROXIMITY SENSORS

DO NOT activate both center sensors at the same time. Under normal operating conditions both sensors
will never activate at the same time. This can only be done manually.
CAUTION: Activating both sensors at the same time will cause damage to the DCM module control
board.
DIVERT CONTROL MODULE DEVICENET TIMER SETTINGS
The controls engineer should check the following parameter settings for each DCM board to ensure proper
operation at high speeds.
Parameters 258 through and including 263 should have a timer setting of 80.
LEFT-HANDED SORTER REVERSING DIVERT SWITCH ACTION
A left hand sorter is a single-sided sorter that diverts product to the left side. Reverse the electric motor
wires on the DCM board (connector T3, terminals 7 and 8). Move the brown/green wire to terminal 8 and
the gray wire to terminal 7.
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5.2 Standard Offerings

These features are standard with all six WhisperSort models, unless specifically
noted.
Component Features
1. All sorter electrical components are quick disconnecting components, except
for the load belt induction photoeye, sorter shaft encoder, oils, sorter motor,
and busway power feed.
2. All field mounted component kits come with all the necessary parts and
hardware to mount and connect components to sorter.
Standard Components
Factory mounted
Sorter Motor
Chain Oilers
Drip
Spray (optional)
Pin Greaser (for speeds above 350 fpm)
Divert Switch Assembly
Shaft Encoder
Field installed
Long Range Jam Photoeye

Divert Control Module and Bracket
Slack Chain Sensor
Shoe out of Position Sensor
DeviceNet Flat Cable and Bases
Power Busway components
Options
Field installed
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Divert Confirm Proximity Switch and Cable

Dynamic Jam PE and Cable
End of Sorter Photoeye and Cable
Full Lane Photoeye and Cable
Lane Photoeye and Cable
Induction Photoeye and Cable
Broken Pin Module
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User Supplied
5-6
Sorter Control Panel

Controller ControLogix PLC, DeviceNet Card, and I/O cards if
required, DC Power Supplies,
Uninterrupted Power Supply (UPS) for Sorter DC power supplies,
Sorter Motor Variable Frequency Drive,
E-Stop materials and circuits
Sorter Motor Disconnect
Manual Jogging Pushbutton Station
RSLinx & RSNetworx for DeviceNet
RSLogix 5000 for ControLogix PLC
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Chapter 6
DeviceNet Single-Sided Model 1
WhisperSort
Chapter 6 DeviceNet Single-Sided Model 1

6.0 DeviceNet Single-Sided Model 1................................................................................................... 6-5
6.1 Installation Instructions ..................................................................................................................... 6-5
6.1.1
Controls Installation Overview.......................................................................................... 6-5
6.1.2
Power Busway System ...................................................................................................... 6-7
6.1.3
DeviceNet System ............................................................................................................. 6-9
6.1.4
DeviceNet Media and Connectors................................................................................... 6-10
6.1.5
Divert Switch Assembly.................................................................................................. 6-10
6.1.6
Divert Control Module .................................................................................................... 6-11
6.1.7
Divert Control Module I/O Assignments ........................................................................ 6-13
6.1.8
Long Range Jam Photoeye .............................................................................................. 6-14
6.1.9
Slack Chain and Shoe out of Position Sensors ................................................................ 6-15
6.1.10 Sorter Chain Oilers .......................................................................................................... 6-16
6.1.11 Pin Greaser ...................................................................................................................... 6-16
6.1.12 Induction Encoder ........................................................................................................... 6-16
6.1.13 Sizing Divert Control Module Power Supplies ............................................................... 6-16
6.1.14 End of Sorter Photoeye (Option)..................................................................................... 6-18
6.1.15 Divert Confirm Inductive Proximity Switch (Option)..................................................... 6-18
6.1.16 Dynamic Jam Photoeyes (Option)................................................................................... 6-18
6.1.17 Full Lane Photoeyes (Option) ........................................................................................ 6-19
6.1.18 Full Lane Photoeyes (Option) ..................................................................................... 6-19
6.1.19 Induction Photoeye (Option) .......................................................................................... 6-19
6.1.20 Broken Pin Assembly (Option) ....................................................................................... 6-19
6.2 Drawings ......................................................................................................................................... 6-22
6.2.1
WhisperSort General Device Application.................................................................... 6-24
6.2.2
General Arrangement Overview...................................................................................... 6-26
6.2.3
Infeed............................................................................................................................... 6-28
6.2.4
Intermediate..................................................................................................................... 6-30
6.2.5
Catenary........................................................................................................................... 6-32
6.2.6
Drive ................................................................................................................................ 6-34
6.2.7
Divert Switch................................................................................................................... 6-36
6.2.8
Broken Pin Kit................................................................................................................. 6-38
6.3 Reference Tables for Control Kits................................................................................................... 6-40
6.3.1
Divert Switch Part Numbers............................................................................................ 6-40
6.3.2
Long Range Jam Photoeye Kit (Kit TRA03801-1) ......................................................... 6-41
6.3.3
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2) ................. 6-42
6.3.4
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) .............................................. 6-42
6.3.5
Dynamic Jam Photoeye Kit (Kit TRA03801-4) .............................................................. 6-43
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6.3.6
End-of-Sorter Photoeye Kit (Kit TRA03801-5) ..............................................................6-44
6.3.7
Full Line Photoeye Kit (Kit TRA03801-6)......................................................................6-45
6.3.8
3/4 Full Line Photoeye Kit (Kit TRA03801-7)................................................................6-46
6.3.9
Induction Photoeye Kit (Kit TRA03801-9) .....................................................................6-47
6.3.10 DeviceNet Kit (Kit TRA03801-10) .................................................................................6-47
6.3.11 Power Busway Kit (Kit TRA03801-11) ..........................................................................6-48
6.3.12 Divert Control Module Kit (Kit TRA03801-12)..............................................................6-48
6.3.14 Application Specific Quantities .......................................................................................6-49
6.3.15 Broken Pin Detector Assembly........................................................................................6-50
6.4 Start Up and Test Procedures (DeviceNet Single-Sided) .......................................................6-51
6.4.1
Sorter Power Check List ..................................................................................................6-51
6.4.2
Sorter DCM DC Power Check List..................................................................................6-52
6.4.3
Sorter DeviceNet System Check List...............................................................................6-52
6.4.4
Chain Oiler.......................................................................................................................6-53
6.4.5
Spray Oiler (Optional) .....................................................................................................6-53
6.4.6
Pin Greaser.......................................................................................................................6-54
6.4.7
Start Up ............................................................................................................................6-54
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List of Figures
Figure 6-1. Busway Voltages .........................................................................................................................6-8
Figure 6-3. Proximity Sensor Location on Divert Switch Assembly ...........................................................6-11
Figure 6-4. WhisperSort General Device Application (Drawing TRA03801) ........................................6-24
Figure 6-5. General Arrangement Overview (Drawing TRA03803) ...........................................................6-26
Figure 6-6. Infeed (Drawing TRA03804) ....................................................................................................6-28
Figure 6-7. Intermediate (Drawing TRA03805)...........................................................................................6-30
Figure 6-8. Catenary (Drawing TRA03806) ................................................................................................6-32
Figure 6-9. Drive (Drawing TRA03807)......................................................................................................6-34
Figure 6-10. Divert Switch (Drawing TRA03808) ......................................................................................6-36
Figure 6-11. Broken Pin Kit (Drawing TRA03809) ....................................................................................6-38
Figure 6-12. Divert Switch Part Numbers ....................................................................................................6-40
Figure 6-13. Kit TRA03801-1......................................................................................................................6-41
Figure 6-14. Kit TRA03801-2......................................................................................................................6-42
Figure 6-15. Kit TRA03801-3......................................................................................................................6-42
Figure 6-16. Kit TRA03801-4......................................................................................................................6-43
Figure 6-17. Kit TRA03801-5......................................................................................................................6-44
Figure 6-18. Kit TRA03801-6......................................................................................................................6-45
Figure 6-19. Kit TRA03801-7......................................................................................................................6-46
Figure 6-20. Kit TRA03801-9......................................................................................................................6-47
Figure 6-21. Kit TRA03801-10....................................................................................................................6-47
Figure 6-22. Kit TRA03801-11....................................................................................................................6-48
Figure 6-23. Kit TRA03801-12....................................................................................................................6-48
Figure 6-24. Kit TRA03801-14....................................................................................................................6-49
Figure 6-25. Application Specific Quantities ...............................................................................................6-49
Figure 6-26. Broken Pin Detector Assembly ...............................................................................................6-50
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6-4
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6.0

This section contains installation instructions, control wiring drawings, reference
tables for control kits, and start-up and test procedures for the DeviceNet SingleSided model.
The drawings span facing pages. That is, when this manual is placed in a threering binder, each drawing is split and occupies both a left-hand page and a righthand page.
The kit tables identify all of the parts that are included in each kit.
The kit installation instructions refer to the drawings and describe how to install
the controls system.
6.1
Installation Instructions
The following instructions describe how to install the control wiring and the
control wiring kits.
6.1.1
Controls Installation Overview

Note: For left-hand sorters see Divert Control Module on page 6-11.
(A left hand sorter is a single-sided sorter that diverts product to the left side.)
1. Install the power busway.
2. Connect the round cable to the divert switch proximity sensor (kit
TRA03801-12).
3. Mount the divert control module (DCM) to the DCM bracket. (kit
TRA03801-12).
4. Mount the DCM assembly on the same side of the sorter that the divert
switch assembly in located. The I/O breakout module on the DCM assembly
should be located within 6 inches (downstream) of the divert switch motor
location. This is to ensure that all cables reach the I/O breakout module.
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5. Mount Shoe out of Position and Slack Chain inductive proximity

switches and cables.
CAUTION:
with plastic or (preferably) 1/32 recessed. If the sensors are not
mounted properly damage will occur to the sensor surface when
the sorter starts up.
6. Mount the long range photoeye.

7. Mount all other option kits.
8. Run the DeviceNet flat cable from the control panel along the sorter. Cable
should be run on the same side as the DCMs.
9. Attach all DeviceNet IDC bases for all DeviceNet components mount
within 1 meter of the DeviceNet component maximum cable lengths of
DeviceNet components is two meters.
10. Connect all DeviceNet components to IDC bases.
11. Connect all other control devices to the DCM I/O breakout block.
12. Mount and wire the induction photoeye and WhisperSort shaft encoder.
13. Connect wires from the control panel to the sorter 460Vac motor and 120Vac
oilers. Run these wires in the same conduit unless otherwise specified by the
customer.
oilers. For convenience and cost, these wires can be run in the same conduit.
Keep high-voltage wires separate from DCM signal cables by 6.
15. Supply 120 VAC 60 Hz to the lubricating unit of the pin greaser to supply
the drip oilers.
16. If using a spray oiler, adjust the nozzles horizontally to spray the lubricant
between the side plate and the roller.
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6.1.2
Power Busway System

Note: Refer to the following figure during busway assembly. A larger version of
the figure is in Appendix A. A much larger version (22 34 ) is in the pocket in
the back of the binder.
Important: Remove power connector T1 at each divert control module before

applying power to the system.
The purpose of the busway is to supply +48VDC and +24VDC to the DCM
modules. Power supplies are located in the control panel.
P/N 0312996
Power rails come in 20-foot sections. Install the power rails under the
sorter so that the label on the front of the power rail faces the outside of the
sorter. Power rail should always be mounted to the sorter on the same side
as the divert switch assembly.
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Splice the power rails together using bus connectors. The bus connectors are
inserted into each end of the power rail sections. Allen head screws on the
bus connectors are tightened to ensure good electrical connection between
the bus connector and the power rail.
Busway rail is supported with clips every 10 feet.
Hanger brackets at each splice support the 20-foot sections.
The power feed box can be installed on either end of the power rail assembly
or a middle power feed (included) can be used to connect power to the
middle of the power rail if the control panel is in the middle of the sorter.
Power connections at the power feed (ends or middle feeds), need to be
connected so that the power on the conductors in the busway are as shown in
figure below.
Label must be on
outside of sorter
Figure 6-1. Busway Voltages

Note: Label on busway must face outside of sorter.
6-8
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Once the busway rail and DCMs are installed, insert the DCM power connector
into the busway rail. Squeeze clamp to side of power connector, insert sideways
into rail, and twist to the right (ON ). Releasing clamp locks connector into
rail. To remove, squeeze clamp and twist to left ( OFF) and pull down from
rail.
6.1.3
DeviceNet System
Note: All DeviceNet components communication method must be set to Change
of State (COS).
All DCMs plus Slack Chain and
Shoe Out of Position are controlled
via DeviceNet. DeviceNet
components are connected (via
DeviceNet media) to the DeviceNet
scanner card in the control panel.
P/N 0312996
All DeviceNet components on the

sorter require commissioning
(node number, baud rate setting, configuration, and node mapping in the
network scanner card).
The divert control modules node and baud rate is switch settable. An eight
position piano switch located on the DCM board sets the node and baud rate.
The baud rate is 125k. Switches 7 and 8 OFF.
The DCM modules can be set to any node number. Usually the 1st DCM is
node one, second DCM is node two and so on.
Node switches are binary (Switch ON = 1) The combination of binary
values of the switches in the ON position = the node number.
Switch 1 binary 1
Switch 2 binary 2
Switch 3 binary 4
Switch 4 binary 8
Switch 5 binary 16
Switch 6 binary 32
Other DeviceNet components on the sorter:
1. Slack Chain and Shoe out of Position inductive proximity switches
2. No sort photoeye
All DeviceNet components communication method must be set to Change of
State (COS).
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6.1.4
DeviceNet Media and Connectors

Kwiklink flat cable and micro connector bases are DeviceNet media components
that connect DeviceNet components to the network scanner card.
Kwiklink cable is run from the sorter control panel along the side frame of the
sorter. The flat cable is secured on the side of the sorter that the DCM modules
are mounted. The DCM brackets are notched for the flat cable to pass behind the
DCM bracket. Factory punched holes in the side frame of the sorter secure the
flat cable ties and bases. The flat cable is terminated at the far end of the cable
with an IDC termination base. Each DeviceNet component is connected to a
base installed onto the flat cable.
Note: A termination resistor is required on both ends of the flat cable. Resistor
Value = 120 ohms. Resistors are installed across the blue and white conductors
of the flat cable. Total network resistance should be 60 ohms with both resistors
installed when measuring across the blue and white flat cable conductors. If the
network scanner card is at one end of the flat cable, insert a 1/8 watt 120 ohm
resistor to the network scanner card connector across the blue and white wires.
If the network scanner card is in the middle of the network, use one IDC
termination base at each end of the flat cable. (No resistor would be required on
the network scanner card).
6.1.5

The divert switch assembly consists of a DC brushless limited angle motor and
an inductive proximity switch sensor and cable.
Prior to a package being diverted, the controller sends a divert enable signal via
DeviceNet to the DCM. Once enabled, the DCM software monitors the divert
inductive proximity switch input that detects pusher shoe pins. When the
proximity switch detects a pin, the DCM turns ON the divert switch signal that
activates the motor to the divert position. The motor is maintained in the divert
position until the divert enable signal is removed by the Controller. When the
pin is detected by the proximity switch, a signal is sent to the DCM. The DCM
returns the motor to the straight position.
Manual Operation of Divert Switches Use Divert Right Pushbutton
The manual pushbutton performs the same action as the associated controller
divert enable signal. With the sorter running, press the manual pushbutton to
activate the switch. Release it to return the switch to the straight position. The
manual switch overrides the controller divert enable signal.
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Note: The Divert Switch and the Divert Inductive Proximity Switch are
assembled in the factory. The divert proximity cable comes with the Divert
Control Module Kit Kit # TRA03801-12.
Divert Inductive Proximity Sensor Location
The sensor is located in the upstream location (A=1). Connect the female end of
the cable to the inductive proximity sensor and the other end to the DCM I/O
block.
6.1.6
Divert Control Module

Note: For left hand sorters reverse the electric motor wires on the DCM board
(connector T3, terminals 7 and 8). Move the brown/green wire to terminal 8 and
the grey wire to terminal 7. (A left hand sorter is a single-sided sorter that
diverts product to the left side.)
The divert control module (DCM) consist of the following components
DCM board
Prewired busway power connector and cable
Prewired DeviceNet cable
Prewired multiport connector
The DCM board connects
The DeviceNet network via J1
DC power via T1
Inputs via T2
Outputs via T3
The board connectors silk-screened nomenclature refer to some signals which
are not used on the single sided sorter. Refer to all signals with RT in the
signal description.
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There is one spare output on T3 and one spare input on T2, along with +24Vdc
and 24Vcom terminals.
Mount the DCM enclosure to the DCM bracket and then to the sorter side frame.
Mount the bracket as close to the switch assembly as possible so that the motor
cable can reach the I/O block.
Note: Before applying busway DC power to DCMs unplug connector T1 on all
DCM boards. Check each (unplugged) connector (at the unplugged connector)
for proper voltages. This ensures proper power connections from the control
panel through the busway rail, through the DCM connector to T1.
T1-1
T1-2
T1-3
T1-4
+48Vdc
48V COM
+24Vdc
24V COM
The DCM multiport module connects external NON-DeviceNet components

to DCM input circuits.
Divert inductive proximity switch
Full lane photoeye
Full lane photoeye
Confirm inductive proximity switch
Dynamic jam PE
1 spare input
1 spare output
Divert motor connections
Each port on the multiport module has two I/O points. When multiple I/O is
required from one connector, use a splitter.
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6.1.7
Divert Control Module I/O Assignments

DCM Produced Data
Bit #
0
1
2
3
4
5
6
7
8
9
10
11
12
N/A
*Divert Prox Sw.
Pin Present = +24Vdc at DCM
N/A
Full Line PE
Full = Bit OFF at PLC
N/A
Full Line PE
N/A
*Confirm Prox Sw.
N/A
N/A
N/A
N/A
+24Vdc spare input, or Dynamic
Signal = Bit ON at PLC
Jam, or Long Range Jam PE
(connected to tail DCM)
13
N/A
14
N/A
15
Confirm Signal Right
Confirm = Bit ON at PLC
* Reserved for DCM Board CCO Logic NOT CONTROLLED VIA
DEVICENET
FULL and FULL eyes are 42GTU9000 Allen Bradley timer eyes
Input bit numbers are same for all DCM modules
Bit #
0
N/A
1
N/A
2
N/A
3
N/A
4
N/A
5
N/A
6
* Divert Switch Signal
7
* Straight Switch Signal
8
N/A
9
N/A
10
N/A
11
N/A
12
N/A
13
+24Vdc spare output B
14
N/A
15
Divert Switch Enable Signal
* Reserved for DCM Board CCO Logic NOT CONTROLLED VIA
DEVICENET
Output bit numbers are same for all DCM modules
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6.1.8

The purpose of the long-range photoeye is to detect packages that have somehow
been removed from their intended path of travel.
Note: The photoeye is not required when a high-side guard is used.
The Jam PE (source / receive) is mounted on the extreme ends of the sorter, and
is connected to the first and last divert control module I/O Blocks. This is NOT a
DeviceNet component. A splitter is required to connect the photoeye to the I/O
block connector that the divert proximity switch sensor shares.
6.1.1.8 Long Range Jam Photoeye Alignment Procedure

The WhisperSort Long Rang Photoeyes are infrared long range source / receive
units. These units are connected to the last DCM QD I/O Block at the ends of the
sorter.
1. The alignment procedure is a multi step procedure that breaks up the sorter
into quarters, aligning the Source PE (if required) each time the Receive eye
is plugged into a DCM I/O Block Port at distances , , , and final
mounting location away from the Transmit PE.
2. Disconnect the Receive PE from the DCM I/O Block Port, and its mounting
bracket. (Leave the mounting bracket secured to the sorter).
3. Mount and secure the Transmit PE at the same height as the Receive PE
measure from the sorter side frame. Tighten Transmit PE mounting bracket
so the movement / alignment of the Source PE is difficult but achievable. Realigning is done by moving the Source PE very small distances with your
hands.
4. Apply power to the sorter and align / point the Transmit PE toward the area
where the Receive PE is located at the end of the sorter.
5. Plug the Receive PE into a DCM I/O Block spare port located approximately
the distance from the Source PE.
6. Hold the Receive PE at the approximate height / location of the Source /
Receive PE.
7. Monitor the LEDs on the Receive PE to ensure the Source PE is correctly
aligned. If the LEDs are not ON, (on the Receive PE), re-align the Source
PE.
8. Move the Receive PE to the way point from the Source PE. Re-align the
Source PE if required.
9. Move the Receive PE to the way point. Re-align the Source PE if required.
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10. Move the Receive PE to the location at the end of the sorter and secure in
bracket. Re-align the Source PE if required.
Note: The area of the Source PE beam is approximately 1-1/2 in diameter at 300
feet.
6.1.9
Slack Chain and Shoe out of Position Sensors

Slack chain detection and shoe out of position sensors are Allen Bradley
DeviceNet components that need to be commissioned and mapped much like the
divert control modules.
The slack chain sensor must be configured via
DeviceNet for normally closed operation.
When slack in the chain occurs, the output
from the sensor goes from 1 to 0.
The shoe out of position sensor must be
configured via DeviceNet for normally open
operation. The sensor normally senses a plate,
and when a shoe out of position knocks the
plate away from the sensor the output goes
from 1 to 0.
In the RSNetworx For DeviceNet software
change the communications mode to Change of State (COS) with node
numbers set to 55 and 56 accordingly.
CAUTION:
P/N 0312996
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6.1.10 Sorter Chain Oilers

There are two types of oilers: Drip and Spray.
DripOiler
There are two chain drip oilers one for each side of the
sorter. The drip oiler coil is 120Vac. The control signal
for the oilers originates at the sorter control panel. A
+24Vdc relay may be used if AC I/O is not available. An
oiler control signal can be run to the control panel in the
480Vac conduit. Drip oilers are mounted at the factory.
Spray Oiler
The spray oiler is optional. If used, the nozzle must be
placed so that the tip is approximately to 1 away
from the chain side bars. The oil and air lines must be
tied to cross members so that they are clear of the
moving flights. Adjust the nozzles horizontally to
spray the lubricant between the side plate and the
roller. Use Powerflow Hydraulic oil ISO-68A2.
6.1.11 Pin Greaser

The pin greaser is used to supply lubricant to the oilers. Supply
120 VAC 60 Hz to the lubricating unit. The operating current
must be 1.0A. The unit should operate only when WhisperSort
is running. The program is retained if the power is removed or
lost.
6.1.12 Induction Encoder

The sorter induction encoder is factory mounted on the tail section. This is NOT
a DeviceNet component. It is field wired to the sorter control panel +24Vdc
input card. The output from the encoder (+24Vdc) is 1 pulse per 2.5 of travel.
6.1.13 Sizing Divert Control Module Power Supplies

Note: To prevent damage to shoes/pins during power outage or dips, the sorter
DC power supplies should be powered from a uninterrupted power source
(UPS).
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6.1.1.13 Sorter Power Supplies

The main control panel uses the following power supplies:
1. DeviceNet +24Vdc power supply.
2. Holding voltage (+HV) regulated (+24Vdc) Used for holding voltage of
divert switches and control devices wired back to the main control panel.
3. +48Vdc regulated Used at DCM for divert motor pulsed voltage. The
DCM board regulates the +48Vdc down to +24Vdc for control devices
connected to divert control module I/O block.
6.1.2.13 Sizing Power Supplies for DCMs
There are two DC power supplies required for the DCMs.
+HV regulated (+24Vdc) used for divert switch.

+48Vdc regulated.
Calculating the Holding Voltage Power Supply Current

Important: Use +24Vdc Power Supply.
Holding current per divert motor is approximately 1.0 amp.
1. Count the number of divert points.
2. Multiply the number in step one by 1.0. This is your total holding current.
Calculating the +48Vdc Power Supply
The +48Vdc power supply serves two purposes:
1. Supplies starting pulse for the divert motor.
2. The +48Vdc is regulated down on the DCM board to +24Vdc for control
devices connected to the DCM I/O block. The pulse duration is
approximately 40ms and during this period the current draw for the divert
motor is 2 amp. The maximum number of diverts to be activated
simultaneously during this 40ms period could be 3 diverts. Therefore, the
total amount of current draw from the +48Vdc power supply for 40ms is 6
amps. So, the +48Vdc power supply must be sized for 12 amps + the current
consumed by all control devices connected to the DCM I/O block. (See
below.)
Most of the DCM board circuits and indicators are powered from the DeviceNet
power supply. Therefore, calculate the current consumed by control devices
connected to all DCM I/O blocks.
Count the number control devices connected to the DCM I/O blocks.
P/N 0312996
Divert proxs
6-17
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Confirm proxs
Full line PEs
Full line PEs
Jam PEs
Example:
WhisperSort with 20 diverts using divert confirm prox, 1 full line, no fulls,
no jam PEs
20 divert switch inductive proximity switches, 20 divert confirm inductive
proximity switches, 20 full line PEs
Multiply the total number of control devices times 40ma
60 0.040 = 2.4 amps
Add 12 amps to the control device current derived above (6 + 2.4 amps = 8.4
amps).
Multiply 8.4 amps 1.25 = 9.65 amps. Round up the current to the next highest
power supply available.
6.1.14 End of Sorter Photoeye (Option)

The end of sorter photoeye is a DeviceNet component that needs to be
commissioned and mapped. The photoeye is a light energized polarized
retroflective unit. The purpose is to detect non-sorted packages. The output
comes on when the photoeye beam is broken. Set to COS, node # 57).
6.1.15 Divert Confirm Inductive Proximity Switch (Option)

The divert confirm sensor gives positive confirmation that the divert shoe was
diverted and consequently the package. The sensor is connected to the DCM I/O
block. Kit comes with sensor and cable. Route the cable along the aluminum
support members using the Bosch ties to the DCM I/O block. The divert confirm
pulse width at the PLC is a minimum of 200 milliseconds.
6.1.16 Dynamic Jam Photoeyes (Option)

Dynamic Jam Photoeyes are located every 5 zones. The PLC uses the tracking
file to determine when a package should be passing a Jam photoeye. If a package
is not detected by a Jam photoeye in an expected time and/or package count, the
sorter will shut down with a Jam error. Jam photoeyes are connected to the DCM
I/O block.
6-18
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6.1.17 Full Lane Photoeyes (Option)

Full lane photoeyes are located at the infeed end of each divert lane (distance
from photoeye to main sort line is determined by engineer). The full lane
photoeyes must have a timer feature. Allen Bradley series 9000, 42GTU-9200QD. Since the DCM I/O is configured for change of state (COS), the full lane
photoeye signal occupies much of the network bandwidth with packages passing
the photoeye all the time. Therefore, the photoeye timer is set to allow the
longest package to pass without activating the sensor. Only when there is a
FULL condition (sensor blocked and timer times out) will the sensor output go
OFF.

Full lane photoeyes are located downstream of the FULL LANE sensor
(distance from sorter is determined by engineer). The full lane photoeyes must
have a timer feature. Allen Bradley series 9000, 42GTU-9200-QD. Since the
DCM I/O is configured for change of state (COS), the full lane photoeye signal
occupies much of the network bandwidth with packages passing the photoeye all
the time. Therefore, the photoeye timer is set to allow the longest package to
pass without activating the sensor. Only when there is a FULL condition
(sensor blocked and timer times out) will the sensor output go OFF.
6.1.19 Induction Photoeye (Option)

The induction photoeye (Allen Bradley RightSight Photoeye, part number:
42EF-P2MPB-F4) is not a DeviceNet component. The mounting location on the
load belt is determined by the engineer. The signal is discretely wired back to the
sorter control panel (with the encoder power/signal) to a DC input card in the
PLC rack.
6.1.20 Broken Pin Assembly (Option)

Sorter shoes that travel along the side of the sorter are guided down and across
(divert) the sorter by a pin attached to the underside of the shoe. If there is an
obstruction in the path of the shoe pin, the pin is designed to break away from the
shoe to prevent damage to the slat and associated components. Consequently, if
a pin is missing from a shoe, and that shoe is assigned to a divert package, the
shoe will not divert, and the package being diverted may not divert properly.
Missing pins need to be detected so the sorter can shut down, and the shoe and/or
pin replaced.
P/N 0312996
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The Broken Pin Assembly detects missing pins. An Allen Bradley Compact I/O
Block with DeviceLogix program monitors two inductive proximity switches on
five inch centers, the same centers as the shoe pins. If at any time one but not
both of the pins are detected, the I/O Block output signals the PLC. The PLC
then shuts down the sorter so the shoe can be repaired.
The Broken Pin Assembly uses 4 screws to secure a non-metallic enclosure

to the tail section (input side) of the sorter.
Quick disconnect cables pre-wired to the enclosure connect two 18mm
inductive proximity switches to the I/O block.
For a WhisperSort using DeviceNet controls, a DeviceNet cable is pre-wired
to the enclosure, and must be connected to an IDC base that is attached to the
DeviceNet Network Flat Cable. The missing pin output signal is sent to the
sorter controller via DeviceNet.
The Broken Pin kit TRA03801-16 comes complete with the following (all
components are mounted in the field.):
6.1.1.20
Mounting Location
6.1.2.20
Mechanical Assembly includes two mounted 18mm inductive proximity

switches
Broken Pin enclosure, pre-wired to DeviceNet Cable, Inductive Prox Cables
(2)
Mounting hardware
DeviceNet IDC base and hardware (do not connect if Non-DeviceNet
WhisperSort, use discrete output)
Mount Broken Pin Assembly at the infeed of the sorter see mechanical
drawing TRP10991.
Mount the Broken Pin Enclosure on the outside of the sorter against the side
frame near the mechanical assembly.
Operation
There are several input points that are selectable by the sorter controller. The
input bit/point that is selected depends on the speed of the sorter.
For speed selection the input bit or point should be held high all the time.
The reset fault from PLC is a momentary pulse (1 second).
Note: reset fault refers to broken pin being detected output ON
6-20
Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
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Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
300-400
< 300
10
Fault Output
Reset Fault
6.1.3.20
15
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Up-stream Prox
Down-Stream Prox
Mapping I/O
For a DeviceNet WhisperSort map I/O at unused high number node.
In the DeviceNet canner card scanlist, double click on the broken pin module and
set up the following:
COMMUNICATIONS TYPE Set to COS
PRODUCED AND CONSUMED DATA
Set Inputs Size to 4 Bytes

Set Output Size to 2 Bytes
ENABLING LOGIC MODULE Open RSLogix for DeviceNet
P/N 0312996
Open operating network

Double click on Broken Pin Module icon
Open DeviceLogix
Start Logic Editor
Drop down Edit Window in Logic Editor
Click on Recovery Mode
Enable
Click OK
Close out window
6-21
WhisperSort
6.2 Drawings
A series of two page controls drawings follows this page. The page on the left
and the page on the right are two halves of one drawing. Each drawing shows
one section of the WhisperSort (infeed, drive, etc) with numbered callouts.
The numbered callouts match the tables which follow the drawings. Each table
identifies the parts for a particular electrical control kit. The quantity column
(QTY REQ.) in the tables indicates the original quantity in the kit.
Note: Each drawing shows an assembly but each table matches a kit.
6-22
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P/N 0312996
6-23
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6.2.1
WhisperSort General Device Application
Figure 6-3. WhisperSort General Device Application (Drawing TRA03801)
6-24
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6-25
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6.2.2
General Arrangement Overview
Figure 6-4. General Arrangement Overview (Drawing TRA03803)
6-26
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6-27
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6.2.3
Infeed
Figure 6-5. Infeed (Drawing TRA03804)
6-28
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6-29
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6.2.4
Intermediate
Figure 6-6. Intermediate (Drawing TRA03805)
6-30
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6-31
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6.2.5
Catenary
Figure 6-7. Catenary (Drawing TRA03806)
6-32
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6-33
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6.2.6
Drive
Figure 6-8. Drive (Drawing TRA03807)
6-34
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P/N 0312996
6-35
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6.2.7
Divert Switch
Figure 6-9. Divert Switch (Drawing TRA03808)
6-36
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6-37
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6.2.8
Broken Pin Kit
Figure 6-10. Broken Pin Kit (Drawing TRA03809)

6-38
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6.3 Reference Tables for Control Kits

6.3.1
Divert Switch Part Numbers
Figure 6-11. Divert Switch Part Numbers
6-40
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6.3.2
Long Range Jam Photoeye Kit (Kit TRA03801-1)
Figure 6-12. Kit TRA03801-1
P/N 0312996
6-41
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6.3.3
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)
6.3.4
Divert Confirm Proximity Switch Kit (Kit TRA03801-3)
6-42
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6.3.5
Dynamic Jam Photoeye Kit (Kit TRA03801-4)
P/N 0312996
6-43
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6.3.6
End-of-Sorter Photoeye Kit (Kit TRA03801-5)
6-44
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6.3.7
Full Line Photoeye Kit (Kit TRA03801-6)
P/N 0312996
6-45
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6.3.8
3/4 Full Line Photoeye Kit (Kit TRA03801-7)
6-46
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6.3.9
Induction Photoeye Kit (Kit TRA03801-9)
6.3.10 DeviceNet Kit (Kit TRA03801-10)
P/N 0312996
6-47
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6.3.11 Power Busway Kit (Kit TRA03801-11)
6.3.12 Divert Control Module Kit (Kit TRA03801-12)
6-48
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6.3.14 Application Specific Quantities
Figure 6-24. Application Specific Quantities
P/N 0312996
6-49
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6.3.15 Broken Pin Detector Assembly
Figure 6-25. Broken Pin Detector Assembly
6-50
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6.4 Start Up and Test Procedures (DeviceNet Single-Sided)

After mounting and connecting all components the following checklist needs to
be completed before power is applied to the sorter components.
1. Disconnect DCM power connectors T1 from all DCMs.
2. All control devices are mounted securely.
3. All wiring is terminated properly.
4. Check continuity on the network cable between communication wires (blue
and white) - should be 60 ohms. If not check for termination resistors and /
or short circuit. To find a short circuit on the network cable measure
between the blue and white wires. The closer you get to the short your
meter will read closer and closer to zero ohms.
5. Check for short circuits from power wiring to ground.
6. Check all inductive proximity switches check mounting. Ensure that all
proximity face surfaces are clear of the pusher pin path.
7. For the oilers, fill the reservoir (with 20-weight non-detergent motor oil for
the drip oilers and Powerflow Hydraulic oil ISO-68A2 for the Spray oilers),
and adjust the flow controls to a slow drip when the solenoid is activated.
The reservoir should drip continuously, but not enough to begin filling the
sight glass.
6.4.1
Sorter Power Check List

1. Check DeviceNet switch settings for correct settings node number and
baud rate settings.
2. Ensure all DCM T1 connectors are disconnected from the board.
3. Check the power busway conductor continuity from the power feed to the
other end of the power busway (4 conductors).
Jumper two conductors together at the power feed box and check
continuity at the other end of the busway between the jumpered
conductors.
Jumper the other two conductors and perform the same check.
Remove all jumpers when check is complete.
4. Check to make sure that DC power connections are correct.
P/N 0312996
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6.4.2
Sorter DCM DC Power Check List

1. Check all DC power supplies in the sorter control panel (+48Vdc and
+24Vdc).
2. Check the power busway power feed for the correct DC voltages.
3. Check each DCM for the correct DC voltages on connector T1. DO NOT reconnect connector T1 to the DCM board until all voltages have been checked
and power has been removed from the power busway.
4. After power checks are complete, remove power from the sorter control
panel and insert all DCM T1 connectors.
5. Apply power to the control panel.
6. Check all DeviceNet components module and network status LEDs.
Module LED should be solid green and the Network LED should be blinking
green, unless the node already has been entered into the network scanner
scanlist.
6.4.3
Sorter DeviceNet System Check List

1. Check to make sure that RSNetworx and RSLinx are installed on your PC.
2. Once the PLC has been setup for operation, the EDS files can be installed in
the DeviceNet scanner card using EDS Wizard under tools.
3. For Allen Bradley components, inductive proximity switches for Shoe out
of Position and Slack Chain, and No Sort Photoeye, EDS files can be
found on the internet. (AB.com).
Note: These EDS files are probably already in the RSNetworx software
package.
4. For the divert control module EDS file (EDS file: CDN128-2), contact the
Controls Engineering Department at HK Systems, Inc. in Hebron, Kentucky
(1-800-354-9795).
5. After EDS files are installed, open RSNetworx (new network) and go online.
All DeviceNet components should appear on screen.
6. Click on network scanner card and enter all DeviceNet components into
network scan list.
7. Configure all DeviceNet components for change of state (COS) operation.
8. When mapping DeviceNet components map in the M file. It is easier to
track nodes if DCM 1 is in word 1, DCM 2 is in word 2, etc. (The produced
and consumed data for the DCMs is 1 word.) Auto Mapping can be used to
expedite mapping process.
6-52
P/N 0312996
WhisperSort
9. Once mapping is completed, bits can be set and control devices activated to
ensure component operation. Click on DeviceNet Icon in RSNetworx to
monitor component operation.
10. Save RSNetworx files when complete.
6.4.4
Chain Oiler
The chain oiler is located in the drive section of the WhisperSort. It oils the
chain for one revolution every 8 hours of operating time.
Fill the reservoir with 20-weight non-detergent motor oil, and adjust the flow
controls to a slow drip when the solenoid is activated. The reservoir should drip
continuously, but not enough to begin filling the sight glass.
The PLC monitors the running time of the WhisperSort and activates the
solenoid every 8 hours of run time for one complete sorter revolution.
6.4.5
Spray Oiler (Optional)

Fill the reservoir with Powerflow Hydraulic Oil ISO-68AW. Loosen the drain
plug to remove any air trapped in the pumps and adjust the air pressure to 50 PSI.
Set the stroke length to the maximum by turning the knob clockwise. Adjust the
air metering screw to turn open. Turn the unit on by supplying the power to the
solenoid valve. Set the pump cycles/min per chart (see below) by adjusting the
pulse generator. The lubricator should run any time the WhisperSort is running.
Pump Cycles/Min
Overall Length (Ft)
Speed
P/N 0312996
30 150
151 300
301 and Greater
501-600
FPM
12
401-500
FPM
10
350-400
FPM
6-53
WhisperSort
6.4.6
Pin Greaser
Supply 120 VAC 60 Hz to the lubricating unit. The operating current must be
1.0A. The unit should operate only when Whispersort is running. The program is
retained if the power is removed or lost.
Fill the unit with grease before operating. The program settings for the first hour
of operation are:
P1=0
P2=20
P3=3
The program settings after the first hour of operation are:
P1=2
P2=0
P3=1
6.4.7
Start Up
Before start up, determine the direction of travel. Next, set up the controls. The
WhisperSort is equipped with a variable speed control to facilitate an initial
slow speed start up. The acceleration ramp on the controller should be set at
approximately 30 seconds and the speed at approximately 50 fpm on all sorters.
Then, track the induction belt as soon as possible to prevent damage to the belt.
When the sorter is running at a slow speed, a visual and audible inspection of the
sorter is made. Minor adjustments, if required, are to be made at this time. The
final step is to bring the sorter up to full speed using the speed setting on the
variable speed controller and verify the induction belt tracking.
When start up is complete, the remaining flight assemblies are installed using the
5/16 slat bolts. With the closing of the open window, the installation of the
WhisperSort is complete.
6-54
P/N 0312996
WhisperSort
Chapter 7
Discrete I/O Single-Sided Model 2
WhisperSort
Chapter 7 Discrete I/O Single-Sided Model 2

7.0
Discrete I/O Single-Sided Model 2 ............................................................................................ 7-5
7.1 Overview ...................................................................................................................................... 7-5
7.2 Installation Instructions ................................................................................................................ 7-6
7.2.1
7.2.2
Divert Switch Assembly.................................................................................................... 7-7
7.2.3
Divert Control Module ...................................................................................................... 7-8
7.2.3.1 Power and I/O Connections............................................................................................. 7-9
7.2.3.2 Sorter DCM Operation .................................................................................................... 7-9
7.2.3.3 Manual Switch Operation of Divert Switches............................................................... 7-10
7.2.4
Long Range Jam Photoeye .............................................................................................. 7-10
7.2.4.1 Long Range Jam Photoeye Alignment Procedure......................................................... 7-11
7.2.5
Sorter Chain Oilers .......................................................................................................... 7-12
7.2.6
Pin Greaser ...................................................................................................................... 7-12
7.2.7
Induction Encoder ........................................................................................................... 7-12
7.2.8
Sizing Divert Control Module Power Supplies ............................................................... 7-13
7.2.9
End of Sorter Photoeye (Option)..................................................................................... 7-14
7.2.15.1 Mounting Location........................................................................................................ 7-16
7.2.15.2 Operation....................................................................................................................... 7-16
7.2.15.3 Mapping I/O .................................................................................................................. 7-17
7.3 Drawings .................................................................................................................................... 7-18
7.3.1
7.3.2
7.3.3
Infeed............................................................................................................................... 7-24
7.3.4
Intermediate..................................................................................................................... 7-26
7.3.5
Catenary........................................................................................................................... 7-28
7.3.6
Drive ................................................................................................................................ 7-30
7.3.7
Divert Switch................................................................................................................... 7-32
7.3.8
Broken Pin Kit................................................................................................................. 7-34
7.3.9
Electrical Connections DCM Module .......................................................................... 7-36
7.3.10 Electrical Connections Confirm Prox........................................................................... 7-38
7.3.11 Electrical Connections Broken Pin Module ................................................................. 7-40
7.4 Reference Tables for Control Kits (Discrete I/O Single-Sided)................................................ 7-42
7.4.1
P/N 0312996
7-1
WhisperSort

7.4.2
Long Range Jam Photoeye Kit (Kit TRA03801-1)..........................................................7-42
7.4.3
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA04031-2)..................7-43
7.4.4
Divert Confirm Proximity Switch Kit (Kit TRA03801-3)...............................................7-43
7.4.5
Dynamic Jam Photoeye Kit (Kit TRA03801-4)...............................................................7-44
7.4.6
7.4.7
7.4.8
7.4.9
7.4.11 Broken Pin Detector Assembly (Kit TRA03801-16L or 16R) ........................................7-49
7.5 Start Up and Test Procedures......................................................................................................7-50
7.5.1
7.5.2
Chain Oiler.......................................................................................................................7-50
7.5.3
7.5.4
Pin Greaser.......................................................................................................................7-51
7.5.5
Start Up ............................................................................................................................7-52
7-2
P/N 0312996
WhisperSort
List of Figures
Figure 7-1. Proximity Sensor Location on Divert Switch Assembly .............................................................7-8
Figure 7-3. General Arrangement Overview (Drawing TRA04033) ..........................................................7-22
Figure 7-4. Infeed (Drawing TRA04034) ...................................................................................................7-24
Figure 7-5. Intermediate (Drawing TRA04035)..........................................................................................7-26
Figure 7-6. Catenary (Drawing TRA04036) ...............................................................................................7-28
Figure 7-7. Drive (Drawing TRA04037).....................................................................................................7-30
Figure 7-8. Divert Switch (Drawing TRA04038) .......................................................................................7-32
Figure 7-9. Broken Pin Kit (Drawing TRA04039) .....................................................................................7-34
Figure 7-10. Electrical Connections - DCM Module (TRA04041).............................................................7-36
Figure 7-11. Electrical Connections Confirm Prox (TRA04042) ............................................................7-38
Figure 7-12. Electrical Connections Broken Pin Module (TRA04043)...................................................7-40
Figure 7-13. Divert Switch Part Numbers ...................................................................................................7-42
Figure 7-14. Kit TRA03801-1.....................................................................................................................7-42
Figure 7-15. Kit TRA04031-2.....................................................................................................................7-43
Figure 7-16. Kit TRA03801-3.....................................................................................................................7-43
Figure 7-17. Kit TRA03801-4.....................................................................................................................7-44
Figure 7-18. Kit TRA04031-5.....................................................................................................................7-45
Figure 7-19. Kit TRA04061-6.....................................................................................................................7-46
Figure 7-20. Kit TRA04061-7.....................................................................................................................7-47
Figure 7-21. Kit TRA03801-9.....................................................................................................................7-48
Figure 7-22. Kit TRA04031-10...................................................................................................................7-49
Figure 7-23. Kit TRA03801-16L or 16R .................................................................................................... 7-49
P/N 0312996
7-3
WhisperSort
7-4
P/N 0312996
WhisperSort
7.0

tables for control kits, and start-up and test procedures for the Discrete I/O
Single-Sided model.
7.1 Overview
The WhisperSort Discrete I/O version eliminates some of the discrete wiring of
control devices located on the sorter. DCM field wiring between the main panel
and the DCM is still required. Control devices connected to the DCM use quick
disconnect micro connectors / cables.
DCM Standard Drawings
Divert Control Module Drawings TRP11091 and TRP11092 show the DCM
module, control devices and associated connections.
Most sorter control devices are connected to the DCM/s. Other control devices
are hardwired back to the sorter control panel.
All Control Device components are +24Vdc with the exception of the oiler/s
(120Vac).
The control signal for the oiler/s can be run in the same conduit as the 480Vac
motor power cable.
Limited Angle Electric Motor
The electric motor is a limited angle motor. The poles in the motor are aligned
such that the rotation of the motor is 90 degrees from pole to pole. Therefore,
when a positive DC voltage is applied to the motor coil, the shaft of the motor
rotates 90 degrees. There are two separate coils to common. Only one coil is
energized at a time. One coil for Divert position and the other for Straight
position.
P/N 0312996
7-5
WhisperSort

Factory Installation
A complete intermediate section is assembled in the factory, including the Divert
Switch assembly. Included in the Divert Switch assembly is the switch
motor/cable and Divert Inductive Proximity Switch.
Field Installation
DCM modules, all control devices and QD cables are installed in the field. All
control devices located on the sorter have QD connectors. The DCM interfaces
to all control devices through an I/O breakout block factory wired to the DCM.
7.2 Installation Instructions

7.2.1

1. Connect the round cable to the divert switch proximity sensor kit
TRA04031-10.
2. Mount the divert control module (DCM) to the DCM bracket - kit
TRA04031-10.
CAUTION:
7. Connect control devices to the DCM I/O breakout block.
7-6
P/N 0312996
WhisperSort

10. Run multi-conductor round cable from the sorter control panel to each DCM.
Use Belden Cable 8623 or equivalent. The number of conductors will vary
per application. A minimum of 5 conductors is required.
the drip oilers.
7.2.2

Prior to a package being diverted, the controller sends a divert enable signal to
the DCM. Once enabled, the DCM monitors the divert inductive proximity
switch input that detects pusher shoe pins. When the proximity switch detects a
pin, the DCM turns ON the divert switch signal that activates the motor to the
divert position. The motor is maintained in the divert position until the divert
enable signal is removed by the Controller. When the pin is detected by the
proximity switch, a signal is sent to the DCM. The DCM returns the motor to the
straight position.
Manual Operation of Divert Switches Use Divert Pushbutton
block.
P/N 0312996
7-7
WhisperSort
7.2.3

DCM board
DC power via T1
IO via T2
T1-1
T1-2
T1-3
T1-4
+24 VDC
24V COM
+48 VDC
48V COM
The DCM multiport module connects external components to DCM input

circuits.
Full lane photoeye
Full lane photoeye
Dynamic jam PE
1 spare input
1 spare output
7-8
P/N 0312996
WhisperSort

7.2.3.1 Power and I/O Connections
Terminal
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
#
1
2
3
4
5
6
7
8
9
10
11
Signal
Terminal
T2
T2
T2
T2
#
16
15
14
13
Signal
T2
12
T2
T2
T2
T2
T2
T2
T2
T2
T2
T2
T2
11
10
9
8
7
6
5
4
3
2
1
Power
X
X
X
X
Description
+24Vdc Holding Voltage
24V common
+48Vdc
48V common
Divert Prox Signal to PLC
Divert Signal from PLC
Divert Confirm Signal to PLC
Full Line Signal to PLC
Fill Line Signal to PLC
Input to PLC
Output from PLC
Power
Description
N/C
Spare Output
Spare Input
Full Lane Signal
Tied on board to Motor Common (DO
NOT USE)
Motor Straight Signal
Motor Divert Signal
Divert Prox Signal
Full Line Eye Signal
Divert Confirm
N/C
N/C
N/C
N/C
24Vdc common
+24Vdc
7.2.3.2 Sorter DCM Operation

The PLC monitors the package length and assigns the appropriate number of
shoes to a particular package to be sorted. Just before the package reaching its
sort point, the controller sends a Divert Enable Signal to the DCM. The DCM
board circuits monitor the Divert Proximity Switch Input for the next pusher shoe
pin to be detected. When the Divert Proximity Switch Input goes low to high
(0V to +24Vdc), the DCM circuits turn ON the divert switch signal which fires
the divert switch to the divert position. The divert switch is maintained in the
divert position until the Divert Enable Signal is removed by the Controller. When
the Divert Enable Signal goes from high to low (+24Vdc to 0V), the DCM
circuits look for the next pusher shoe pin to turn ON the Straight switch signal to
fire the divert switch to the straight position.
P/N 0312996
7-9
WhisperSort

Confirmation of the divert shoes is accomplished by using the Divert
Confirmation Board located in the Sorter Control Panel. (See Drawing
TRP04042 for detailed hookup). The Divert Confirm Proximity Switch Output
is Normally Open. When the Proximity Switch sees a pin, the output goes high
(+24Vdc) for approximately 4ms at maximum sorter speed of 600fpm. This
signal is connected to the Divert Control Module board that sends the signal to
the Divert Confirm Board (HK# B00013) that extends the signal. The Divert
Confirm Board is located in the Sorter Control Panel.
Sorter divert points have inductive proximity switches to detect when a pusher or
number of pushers have been diverted. This gives positive identification that the
DCM diverted the shoe. The Confirm Prox detects the pin on a shoe as the pin
passes across the sorter. The Normally Open Prox is tied to DCM confirm line
input. The output of the Confirm Line from the DCM is one conductor of a
multi-conductor cable routed back to the Sorter Control Panel. All Confirm
Signals from the Sorter are terminated to a terminal strip inside the sorter control
panel. The confirm signals are then wired to the Confirmation Board. The sorter
encoder signal also terminates at the Confirmation Board. All Confirm Signals
going to the Confirmation Board are high (+24VDC), unless a pin is present, then
the input signal goes to 0V.
A number of shoes are diverted at a time. The purpose of the Confirmation
Board is when the input shoe pin pulses are present, the output for that particular
divert point on the Confirmation Board goes to +24VDC until no more pulses are
present.
The Confirmation Board circuit monitors the sorter encoder pulses that are
always present. There should never be more than two sorter wheel prox signals
for every pusher pin pulse. If there are three consecutive sorter wheel prox
signals with no shoe pin signal present then the Confirmation Board Output
Signal goes from +24VDC to 0V. As soon as another pusher pin pulse is present
the Confirmation Board Output Signal goes to +24VDC.
7.2.3.3 Manual Switch Operation of Divert Switches
The Switch, when depressed performs the same action as the associated
Controller Divert Enable Signal. Manual Switch Depressed = Switch is diverted
until Manual Switch is released. When released the Switch goes back to the
straight position.
Note: Manual Switch overrides the Controller Divert Enable Signal
7.2.4

7-10
P/N 0312996
WhisperSort

NOTE: The photoeye is not required when a high-side guard is used.
is connected to the first and last divert control module I/O Blocks. This is not a
7.2.4.1 Long Range Jam Photoeye Alignment Procedure
sorter.
hands.
Receive PE.
PE.
feet.
P/N 0312996
7-11
WhisperSort
7.2.5
Sorter Chain Oilers

DripOiler
There are two chain drip oilers one for each side of the sorter.
The drip oiler coil is 120Vac. The control signal for the oilers
originates at the sorter control panel. A +24Vdc relay may be
used if AC I/O is not available. An oiler control signal can be
run to the control panel in the 480Vac conduit. Drip oilers are
mounted at the factory.
Spray Oiler
placed so that the tip is approximately to 1 away from
the chain side bars. The oil and air lines must be tied to
cross members so that they are clear of the moving flights.
Adjust the nozzles horizontally to spray the lubricant
between the side plate and the roller. Use Powerflow
Hydraulic oil ISO-68A2.
7.2.6
Pin Greaser
The pin greaser is used to supply lubricant to the oilers.
Supply 120 VAC 60 Hz to the lubricating unit. The operating
current must be 1.0A. The unit should operate only when
WhisperSort is running. The program is retained if the power
is removed or lost.
7.2.7
Induction Encoder
The sorter induction encoder is factory mounted on the tail section. This is not a
DeviceNet component. It is field wired to the sorter control panel +24Vdc input
card. The output from the encoder (+24Vdc) is 1 pulse per 2.5 of travel.
7-12
P/N 0312996
WhisperSort
7.2.8
Sizing Divert Control Module Power Supplies

The Main Control Panel uses the following power supplies:
+24Vdc Regulated used for holding voltage of Divert Switches.

+48Vdc Regulated used at DCM for Divert Motor pulsed voltage, Circuit
Board Power, and control devices power wired back to the Main Control
Panel.

Note: Use +24Vdc Power Supply
The holding current per divert motor is approximately 1.0 amp
1. Count the number of divert points
2. Multiply the result from step one by 1. This is the total holding current.
3. Multiply the result from step 2 by 1.25. This is the size of the 24Vdc supply.
Example:
Number of diverts = 25
1 amp 25 diverts = 25 amps
25 amps 1.25 = 31.25 amps
The Divert Control Module board uses the +48Vdc to pulse the divert switch
motor for 40ms. During this period the current draw for the divert motor is
2 amps. The maximum number of diverts being activated during the 40ms period
will probably never be more than 3 diverts. Therefore, the total current draw for
the divert pulse is 6 amps.
1. Allow 6 amps for the divert pulse
2. Count the number of control devices on the sorter and allow 60ma per device
3. Count the number of divert modules on the sorter and allow 100ma per module
for board current
Example:
25 Divert Control Modules
The control devices for each control module include a Divert Prox, Divert
Confirm Prox, and Full Lane PE (3 control devices).
60ma 3 control devices per DCM 25 DCM = 4.5 amps
100ma 25 Divert Control Module boards = 2.5 amps
Find the total of the following:
P/N 0312996
7-13
WhisperSort

Control Device Current (4.5 amps)
Divert Control module Board Current (2.5 amps)
Divert Pulse Current (6.0 amps)
4.5 + 2.5 + 6 = 13 amps
13 amps 1.25 = 16.25 amps
The +48Vdc power supply must be sized at or above 16.25 amps
Note: The control device current may vary depending on manufacturer
7.2.9
End of Sorter Photoeye (Option)

The photoeye is a light energized polarized retroflective unit. The purpose is to
detect non-sorted packages. The output comes on when the photoeye beam is
broken.
HK Divert Confirm Board (typically located in the Sorter Control Panel) is
ordered separately. HK part number: B00013. A Divert Confirm Board has 16
inputs, one per Divert Confirm Proximity Sensor. The output of the Divert
Confirm Board is an extended pulse of the Divert Confirm proximity sensor
signal.

support members using the Bosch ties to the DCM I/O block.

I/O block.

from sorter is determined by engineer).
7-14
P/N 0312996
WhisperSort

have a timer feature.

The induction photoeye is an Allen Bradley RightSight Photoeye, part number:
42EF-P2MPB-F4. The mounting location on the load belt is determined by the
engineer. The signal is discretely wired back to the sorter control panel (with the
encoder power/signal) to a DC input card in the PLC rack.

pin replaced.
both of the pins are detected, the I/O block output signals the PLC. The PLC
P/N 0312996

For Non-DeviceNet WhisperSorts using discrete cable/wiring, the output
signal is wired back to the sorter controller I/O card. The output signal (pin
missing) is +24Vdc.
7-15
WhisperSort

7.2.15.1
Mounting Location
7.2.15.2

switches
(2)
Mounting hardware
drawing TRP10991.
Operation
There are several input points that are selectable by the Sorter Controller. The
input Bit/Point that is selected depends on the speed of the sorter.

Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
300-400
< 300
10
Fault Output
Reset Fault
7-16
15
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Up-stream Prox
Down-Stream Prox
P/N 0312996
WhisperSort

7.2.15.3
Mapping I/O
For a DeviceNet WhisperSort map I/O at unused high number node

P/N 0312996

Open DeviceLogix
Start Logic Editor
Enable
Click OK
Close out window
7-17
WhisperSort
7.3 Drawings
7-18
P/N 0312996
WhisperSort
P/N 0312996
7-19
WhisperSort
7.3.1
7-20
P/N 0312996
WhisperSort
P/N 0312996
7-21
WhisperSort
7.3.2
7-22
P/N 0312996
WhisperSort
P/N 0312996
7-23
WhisperSort
7.3.3
Infeed
Figure 7-4. Infeed (Drawing TRA04034)
7-24
P/N 0312996
WhisperSort
P/N 0312996
7-25
WhisperSort
7.3.4
Intermediate
7-26
P/N 0312996
WhisperSort
P/N 0312996
7-27
WhisperSort
7.3.5
Catenary
CAUTION:
7-28
P/N 0312996
WhisperSort
P/N 0312996
7-29
WhisperSort
7.3.6
Drive
7-30
P/N 0312996
WhisperSort
P/N 0312996
7-31
WhisperSort
7.3.7
Divert Switch
Figure 7-8. Divert Switch (Drawing TRA04038)
7-32
P/N 0312996
WhisperSort
P/N 0312996
7-33
WhisperSort
7.3.8
Broken Pin Kit
7-34
P/N 0312996
WhisperSort
P/N 0312996
7-35
WhisperSort
7.3.9
Electrical Connections DCM Module
Figure 7-10. Electrical Connections - DCM Module (TRA04041)
7-36
P/N 0312996
WhisperSort
P/N 0312996
7-37
WhisperSort
7.3.10 Electrical Connections Confirm Prox
Figure 7-11. Electrical Connections Confirm Prox (TRA04042)
7-38
P/N 0312996
WhisperSort
P/N 0312996
7-39
WhisperSort
7.3.11 Electrical Connections Broken Pin Module
Figure 7-12. Electrical Connections Broken Pin Module (TRA04043)
7-40
P/N 0312996
WhisperSort
P/N 0312996
7-41
WhisperSort
7.4 Reference Tables for Control Kits (Discrete I/O Single-Sided)

7.4.1
7.4.2
Long Range Jam Photoeye Kit (Kit TRA03801-1)
7-42
P/N 0312996
WhisperSort
7.4.3
7.4.4
P/N 0312996
7-43
WhisperSort
7.4.5
7-44
P/N 0312996
WhisperSort
7.4.6
P/N 0312996
7-45
WhisperSort
7.4.7
7-46
P/N 0312996
WhisperSort
7.4.8
P/N 0312996
7-47
WhisperSort
7.4.9
7-48
P/N 0312996
WhisperSort
7.4.11 Broken Pin Detector Assembly (Kit TRA03801-16L or 16R)
Figure 7-23. Kit TRA03801-16L or 16R
P/N 0312996
7-49
WhisperSort
7.5 Start Up and Test Procedures

1. Disconnect DCM power connectors from all DCMs.
6. For the oilers, fill the reservoir with 20-weight non-detergent motor oil, and
adjust the flow controls to a slow drip when the solenoid is activated. The
reservoir should drip continuously, but not enough to begin filling the sight
glass.
7.5.1

1. Before applying power disconnect all DCM T1 connectors.
+24Vdc).
3. Check the power feed for the correct DC voltages.
7.5.2
Chain Oiler
7-50
P/N 0312996
WhisperSort

7.5.3

Pump Cycles/Min
Overall Length (Ft)
Speed
7.5.4
30 150
151 300
301 and Greater
501-600
FPM
12
401-500
FPM
10
350-400
FPM
Pin Greaser
of operation are:
P1=0
P2=20
P3=3
P1=2
P2=0
P3=1
P/N 0312996
7-51
WhisperSort
7.5.5
Start Up
The WhisperSort is equipped with a variable speed control to facilitate an
initial slow speed start up. At start up, the acceleration ramp on the controller
should be set at approximately 30 seconds and the speed at approximately 50 fpm
on all sorters. As soon as direction of travel has been established, tracking of the
induction belt should be done to prevent damage to the belt.
variable speed controller and the induction belt tracking verified.
7-52
P/N 0312996
WhisperSort
Chapter 8
DeviceNet Dual-Sided Model 3
WhisperSort
Chapter 8 DeviceNet Dual-Sided - Model 3

8.0
DeviceNet Dual-Sided................................................................................................................... 8-5
8.1.1
8.1.2
Power Busway System ...................................................................................................... 8-7
8.1.3
DeviceNet System ............................................................................................................. 8-9
8.1.4
DeviceNet Media and Connectors..................................................................................... 8-9
8.1.5
Divert Switch Assembly.................................................................................................. 8-10
8.1.6
Divert Control Module .................................................................................................... 8-11
8.1.6.1 Divert Control Module I/O assignments ..................................................................... 8-12
8.1.7
Slack Chain and Shoe out of Position Sensors ................................................................ 8-13
8.1.8
Sorter Chain Oilers .......................................................................................................... 8-14
8.1.9
Pin Greaser ...................................................................................................................... 8-14
8.1.10 Induction Encoder ........................................................................................................... 8-14
8.1.11 Sizing Divert Control Module Power Supplies ............................................................... 8-14
8.1.11.1
Sorter Power Supplies ............................................................................................. 8-15
8.1.11.2
Sizing Power Supplies for DCMs............................................................................ 8-15
8.1.12 End of Sorter Photoeye (Option)..................................................................................... 8-16
8.1.18.1
Mounting Location .................................................................................................. 8-19
8.1.18.2
Operation ................................................................................................................. 8-19
8.1.18.3
Mapping I/O ............................................................................................................ 8-19
8.2 Drawings .................................................................................................................................... 8-20
8.2.1
8.2.2
General Device Application (contd) .............................................................................. 8-24
8.2.3
8.2.4
Tail Section...................................................................................................................... 8-28
8.2.5
Intermediate..................................................................................................................... 8-30
8.2.6
Catenary........................................................................................................................... 8-32
8.2.7
Drive ................................................................................................................................ 8-34
8.2.8
Divert Module ................................................................................................................. 8-36
8.2.9
Broken Pin Kit................................................................................................................. 8-38
8.3 Reference Tables for Control Kits.............................................................................................. 8-40
8.3.1
8.3.2
Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2) ................. 8-40
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8.3.3
Divert Confirm Proximity Switch Kit (Kit TRA03801-3)...............................................8-41
8.3.4
Dynamic Jam Photoeye Kit (Kit TRA03801-4)...............................................................8-42
8.3.5
8.3.6
8.3.7
8.3.8
8.3.9
DeviceNet Kit (Kit TRA03801-10) .................................................................................8-46
8.3.13 Application Specific Quantities .......................................................................................8-49
8.3.14 Broken Pin Detector Assembly (Kit TRA03801-16).......................................................8-49
8.3.15 Crossover Motor Kit (Kit TRA04021-17) .......................................................................8-50
8.3.16 Divert Control Module Kit Set-Up Switch (Kit TRA04021-19) ....................................8-50
8.4 Start Up and Test Procedures......................................................................................................8-51
8.4.1
Sorter Power Check List ..................................................................................................8-51
8.4.2
8.4.3
Sorter DeviceNet System Check List...............................................................................8-52
8.4.4
Chain Oiler.......................................................................................................................8-53
8.4.5
8.4.6
Pin Greaser.......................................................................................................................8-54
8.4.7
Start Up ............................................................................................................................8-54
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List of Figures
Figure 8-1. Busway Voltages .........................................................................................................................8-8
Figure 8-2. Proximity Sensor Location on Divert Switch Assembly ...........................................................8-11
Figure 8-4. General Device Application (contd) (Drawing TRA04012) ...................................................8-24
Figure 8-6. Tail Section (Drawing TRA04014) ...........................................................................................8-28
Figure 8-10. Divert Module (Drawing TRA04018) .....................................................................................8-36
Figure 8-11. Broken Pin Kit (Drawing TRA04019) ....................................................................................8-38
Figure 8-13. Kit TRA03801-2......................................................................................................................8-40
Figure 8-14. Kit TRA03801-3......................................................................................................................8-41
Figure 8-15. Kit TRA03801-4......................................................................................................................8-42
Figure 8-16. Kit TRA03801-5......................................................................................................................8-43
Figure 8-17. Kit TRA03801-6......................................................................................................................8-44
Figure 8-18. Kit TRA03801-7......................................................................................................................8-45
Figure 8-19. Kit TRA03801-9......................................................................................................................8-46
Figure 8-20. Kit TRA03801-10....................................................................................................................8-46
Figure 8-21. Kit TRA03801-11....................................................................................................................8-47
Figure 8-22. Kit TRA03801-12....................................................................................................................8-48
Figure 8-23. Kit TRA03801-14....................................................................................................................8-48
Figure 8-24. Application Specific Quantities ...............................................................................................8-49
Figure 8-25. Broken Pin Detector Assembly (Kit TRA03801-16) .............................................................8-49
Figure 8-26. Crossover Motor Kit (Kit TRA04021-17) ..............................................................................8-50
Figure 8-27. Divert Control Module Kit Set-Up Switch (Kit TRA04021-19 .............................................8-50
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8.0
DeviceNet Dual-Sided
The following topics/pages contain control wiring drawings, control kit tables,
and kit installation instructions.

8.1.1

1. Install the power busway on the left side of the sorter (based on direction of
travel).
TRA04021-12.
TRA04021-12.
4. Mount the DCM assembly on the left side (based on direction of travel) of
the sorter. The I/O breakout module on the DCM assembly should be
located within 6 inches (downstream) of the divert switch motor location.
This is to ensure that all cables reach the I/O breakout module.
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Note: There are pre-drilled holes for cable clamps, bases, inserts, and
hardware.
DeviceNet components is 2 meters.
customer.
the drip oilers.
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8.1.2
Power Busway System


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sorter. Mount the power rail on the left side (based on direction of travel) of
the sorter.
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bus connectors need to be tightened to ensure good electrical connection

between the bus connector and the power rail.

the figure below.
Label must be on
outside of sorter


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rail.
8.1.3
DeviceNet System
of State (COS).
All DCMs plus Slack Chain and Shoe Out of Position are controlled via
DeviceNet. DeviceNet components are connected (via DeviceNet media) to the
DeviceNet scanner card in the control panel.
8.1.4
All DeviceNet components on the sorter require commissioning (node

number, baud rate setting, configuration, and node mapping in the network
scanner card).
Switch 1 binary 1
Switch 2 binary 2
Switch 3 binary 4
Switch 4 binary 8
Switch 5 binary 16
Switch 6 binary 32
2. No sort photoeye
State (COS).
DeviceNet Media and Connectors

Kwiklink flat cable and micro bases are DeviceNet media components that
connect DeviceNet components to the network scanner card.
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flat cable ties and IDC bases. The flat cable is terminated at the far end of the
cable with a IDC termination base. Each DeviceNet component is connected to
an IDC base installed onto the flat cable.
8.1.5

Place the sensor in the upstream location (A=1) with sorter speeds equal to or
greater than 350 fpm. Connect the female end of the cable to the inductive
proximity sensor and the other end to the DCM I/O block.
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8.1.6

DCM board
DC power via T1
Inputs via T2
Outputs via T3
panel through the busway rail, through the DCM connector to T1. Note the
voltage polarity.
T1-1
T1-2
T1-3
T1-4
P/N 0312996
+48Vdc
48V COM
+24Vdc
24V COM
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The DCM multiport module connects external NON-DeviceNet components to

DCM input circuits.
Divert inductive proximity switch (2)
Full lane photoeye (2)
Confirm inductive proximity switch (2)
Dynamic jam PE (1)
1 spare input
1 spare output
Divert motor connections (2)
Crossover motor and proximity switches
8.1.6.1 Divert Control Module I/O assignments
DCM Produced Data
Bit #
0
1
2
3
4
5
6
7
8
9
10
11
12
13
* Divert Prox Switch Left

* Divert Prox Switch Right
Full Line Photoeye Left
Full Line Photoeye Right
3/4 Full Line Left
Full Line Photoeye Right
Confirm Prox Switch Left
Confirm Prox Switch Right
Crossover Prox Left
Pin Present = +24 Vdc at DCM
Crossover Prox Right
Pin Present = +24 Vdc at DCM
Jam Photoeye Left
Jam Photoeye Right
Jam = Bit OFF at PLC
Spare Input
+24Vdc spare input, or Dynamic
Jam, or Long Range Jam PE
(connected to tail DCM)
14
Confirm Left to PLC
15
Confirm Right to PLC
* Reserved for DCM Board CCO Logic
FULL and FULL eyes are 42GTU9000 Allen Bradley timer eyes.
Input bit numbers are same for all DCM modules
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Bit #
0
N/A
1
N/A
2
N/A
3
N/A
4
N/A
5
N/A
6
* Divert Switch Signal
7
* Straight Switch Signal
8
N/A
9
N/A
10
N/A
11
N/A
12
+24Vdc spare output
13
+24Vdc spare output
14
Divert Switch Enable Signal Left
15
Divert Switch Enable Signal Right
* Reserved for DCM Board CCO Logic
Output bit numbers are same for all DCM modules
8.1.7
Slack Chain and Shoe out of Position Sensors

The slack chain sensor must be configured via DeviceNet for normally closed
operation. When slack in the chain occurs, the output from the sensor goes from
1 to 0.
The shoe out of position sensor must be configured via DeviceNet for normally
open operation. The sensor normally senses a plate, and when a shoe out of
position knocks the plate away from the sensor the output goes from 1 to 0.
In the RSNetworx For DeviceNet software change the communications mode
to Change of State (COS) with node numbers set to 55 and 56 accordingly.
CAUTION:
Be sure the Proximity Switches are flush with plastic or
(preferably) 1/32 recessed. If the sensors are not mounted
properly damage will occur to the sensor surface when the sorter
starts up.
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8.1.8
Sorter Chain Oilers

DripOiler
Spray Oiler
moving flights. Adjust the nozzles horizontally to spray
the lubricant between the side plate and the roller. Use
Powerflow Hydraulic oil ISO-68A2.
8.1.9
Pin Greaser
lost.


(UPS).
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+48Vdc regulated.

1. Count the number of divert points, crossover motors, and return switches.
2. Multiply the number in step one by 1. This is your total holding current.
Note: The maximum capacity of the busway is 60 amps. If a dual-sided
sorter exceeds 50 divert switches (including crossover motors), install a
second busway and feed.
below.)
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Divert proxs
Confirm proxs
Full line PEs
Full line PEs
Jam PEs
Example:
no jam PEs
120 0.040 = 4.8 amps
Add 6 amps to the control device current derived above
(6 + 4.8 amps = 10.8 amps).
Multiply 10.8 amps 1.25 = 11 amps. Round up the current to the next highest

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support members using the Bosch ties to the DCM I/O block. The divert confirm
pulse width at the PLC is a minimum of 200 milliseconds.

I/O block.

from sorter is determined by engineer). The full lane photoeyes must have a
timer feature. Allen Bradley series 9000, 42GTU-9200-QD. Since the DCM I/O
is configured for change of state (COS), the full lane photoeye signal occupies
much of the network bandwidth with packages passing the photoeye all the time.
Therefore, the photoeye timer is set to allow the longest package to pass without
activating the sensor. Only when there is a FULL condition (sensor blocked and
timer times out) will the sensor output go OFF.
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have a timer feature. Allen Bradley series 9000, 42GTU-9200-QD. Since the
the time. Therefore, the photoeye timer is set to allow the longest package to
pass without activating the sensor. Only when there is a FULL condition
(sensor blocked and timer times out) will the sensor output go OFF.

The induction photoeye is not a DeviceNet component. Allen Bradley
RightSight Photoeye, part number: 42EF-P2MPB-F4. The mounting location on
the load belt is determined by the engineer. The signal is discretely wired back to
the sorter control panel (with the encoder power/signal) to a DC input card in the
PLC rack.

pin replaced.
8-18

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switches.
(2).
Mounting hardware.
WhisperSort, use discrete output).
8.1.18.1 Mounting Location
drawing TRP10991.
8.1.18.2 Operation
Note: reset fault refers to broken pin being detected output ON.
Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
300-400
< 300
10
Fault Output
Reset Fault
15
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Up-stream Prox
Down-Stream Prox
8.1.18.3 Mapping I/O

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8.2 Drawings
8-20
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8.2.1

8-22
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8.2.2
General Device Application (contd)
Figure 8-4. General Device Application (contd) (Drawing TRA04012)
8-24
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8-25
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8.2.3
8-26
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8.2.4
Tail Section
Figure 8-6. Tail Section (Drawing TRA04014)
8-28
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8-29
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8.2.5
Intermediate
8-30
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8-31
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8.2.6
Catenary
8-32
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8-33
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8.2.7
Drive
8-34
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8-35
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8.2.8
Divert Module
Figure 8-10. Divert Module (Drawing TRA04018)
8-36
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8-37
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8.2.9
Broken Pin Kit
8-38
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P/N 0312996
8-39
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8.3.1
8.3.2
8-40
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8.3.3
P/N 0312996
8-41
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8.3.4
8-42
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8.3.5
P/N 0312996
8-43
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8.3.6
8-44
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8.3.7
P/N 0312996
8-45
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8.3.8
8.3.9
DeviceNet Kit (Kit TRA03801-10)
8-46
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8.3.10
Power Busway Kit (Kit TRA03801-11)
P/N 0312996
8-47
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8.3.11
Divert Control Module Kit (Kit TRA03801-12)
8.3.12
Power Busway Kit (Kit TRA03801-14)
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8.3.13
Application Specific Quantities
8.3.14
Broken Pin Detector Assembly (Kit TRA03801-16)
Figure 8-25. Broken Pin Detector Assembly (Kit TRA03801-16)
P/N 0312996
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8.3.15
Crossover Motor Kit (Kit TRA04021-17)
Figure 8-26. Crossover Motor Kit (Kit TRA04021-17)
8.3.16
Divert Control Module Kit Set-Up Switch (Kit TRA04021-19)
Figure 8-27. Divert Control Module Kit Set-Up Switch (Kit TRA04021-19
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glass.
8.4.1
Sorter Power Check List

baud rate settings.
2. Ensure all DCM T1 connectors are disconnect from the board.
conductors.
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8.4.2

+24Vdc).
scanlist.
8.4.3
Sorter DeviceNet System Check List

package.
(1-800-354-9795).
network scan list.
track nodes if DCM 1 is in word 1, DCM 2 is in node 2, etc. (The produced
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8.4.4
Chain Oiler
8.4.5

Pump Cycles/Min
Overall Length (Ft)
Speed
P/N 0312996
30 150
151 300
301 and Greater
501-600
FPM
12
401-500
FPM
10
350-400
FPM
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8.4.6
Pin Greaser
of operation are:
P1=0
P2=20
P3=3
P1=2
P2=0
P3=1
8.4.7
Start Up
on all sorters. As soon as direction of travel has been established tracking of the
induction belt should be done as soon as possible to prevent damage to the belt.
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Chapter 9
WhisperSort
Chapter 9 Discrete I/O Dual-Sided
Discrete I/O Dual-Sided Model 4

9.0
Discrete I/O Dual-Sided Model 4............................................................................................... 9-5
9.1 Overview ...................................................................................................................................... 9-5
9.2.1
9.2.2
9.2.3
9.2.3.1
9.2.3.2
9.2.3.3
9.2.3.4
9.2.4
9.2.5
9.2.6
9.2.7
9.2.7.1
9.2.7.2
9.2.8
9.2.9
9.2.10
9.2.11
9.2.12
9.2.13
9.2.14
Controls Installation Overview.............................................................................. 9-6

Divert Switch Assembly ........................................................................................ 9-7
Divert Control Module........................................................................................... 9-8
Power and I/O Connections........................................................................................... 9-8
Sorter DCM Operation ................................................................................................ 9-10
Divert Confirmation Board.......................................................................................... 9-10
Manual Switch Operation of Divert Switches ............................................................. 9-11
Sorter Chain Oilers .............................................................................................. 9-11

Pin Greaser........................................................................................................... 9-11
Induction Encoder................................................................................................ 9-11
Sizing Divert Control Module Power Supplies ................................................... 9-12
Sorter Power Supplies ................................................................................................. 9-12
Sizing Power Supplies for DCMs................................................................................ 9-12
End of Sorter Photoeye (Option) ......................................................................... 9-13

Divert Confirm Inductive Proximity Switch (Option)......................................... 9-14
Dynamic Jam Photoeyes (Option) ....................................................................... 9-14
Full Lane Photoeyes (Option)............................................................................. 9-14
Full Lane Photoeyes (Option).......................................................................... 9-14
Induction Photoeye (Option) .............................................................................. 9-14
Broken Pin Assembly (Option)............................................................................ 9-15
9.2.14.1 Mounting Location..................................................................................................... 9-15

9.2.14.2 Operation.................................................................................................................... 9-15
9.2.14.3 Mapping I/O............................................................................................................... 9-16
9.3 Drawings .................................................................................................................................... 9-17
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.3.7
9.3.8
9.3.9
9.3.10
9.3.11
9.4
WhisperSort General Device Application........................................................ 9-18

General Arrangement Overview .......................................................................... 9-20
Tail Section .......................................................................................................... 9-22
Intermediate ......................................................................................................... 9-24
Catenary ............................................................................................................... 9-26
Drive .................................................................................................................... 9-28
Divert Module...................................................................................................... 9-30
Broken Pin Kit ..................................................................................................... 9-32
Electrical Connection Broken Pin Module .......................................................... 9-34
Electrical Connection DCM Module ................................................................... 9-36
Electrical Connection Confirm Prox.................................................................... 9-38
Reference Tables for Control Kits (Discrete I/O Dual-Sided) .................................................. 9-39
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9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
9.4.8
9.4.9
9.4.10
9.4.11
9.4.12
9.4.13
9.5
Start Up and Test Procedures (Discrete I/O Single-Sided) ........................................................9-48
9.5.1
9.5.2
9.5.3
9.5.4
9.5.5
9-2
Divert Switch Part Numbers ................................................................................ 9-39

Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA04031-2) ..... 9-39
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) .................................. 9-40
Dynamic Jam Photoeye Kit (Kit TRA03801-4) .................................................. 9-41
End-of-Sorter Photoeye Kit (Kit TRA04031-5) .................................................. 9-42
Full Line Photoeye Kit (Kit TRA04061-6).......................................................... 9-43
3/4 Full Line Photoeye Kit (Kit TRA04061-7) ................................................... 9-44
Induction Photoeye Kit (Kit TRA03801-9) ......................................................... 9-45
Divert Control Module (Kit TRA04061-12) ....................................................... 9-46
Broken Pin Detector Assembly (Kit TRA03801-16L or TRA03801-16R)......... 9-46
Crossover Motor (Kit TRA04021-17) ................................................................. 9-47
Divert Control Module Kit Set-Up Switch (Kit TRA04061-19)......................... 9-47
Divert Control Module Kit (Single) (Kit TRA04031-10) ................................... 9-48
Sorter DCM DC Power Check List ..................................................................... 9-49
Chain Oiler........................................................................................................... 9-49
Spray Oiler (Optional) ......................................................................................... 9-49
Pin Greaser........................................................................................................... 9-50
Start Up ................................................................................................................ 9-50
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List of Figures
Figure 9-1. Proximity Sensor Location on Divert Switch Assembly .............................................................9-7
Figure 9-2. WhisperSort General Device Application (Drawing TR04061)................................................9-18
Figure 9-4. Tail Section (Drawing TRA04064) ...........................................................................................9-22
Figure 9-8. Divert Module (Drawing TRA04068) .......................................................................................9-30
Figure 9-9. Broken Pin Kit (Drawing TRA04071) ......................................................................................9-32
Figure 9-10. Electrical Connection Broken Pin Module (Drawing TRA04075)..........................................9-34
Figure 9-11. Electrical Connection DCM Module (Drawing TRA04072)...................................................9-36
Figure 9-12. Electrical Connection Confirm Prox (Drawing TRA04074) ...................................................9-38
Figure 9-14. Kit TRA04031-2......................................................................................................................9-39
Figure 9-15. Kit TRA03801-3......................................................................................................................9-40
Figure 9-16. Kit TRA03801-4......................................................................................................................9-41
Figure 9-17. Kit TRA04031-5......................................................................................................................9-42
Figure 9-18. Kit TRA04061-6......................................................................................................................9-43
Figure 9-19. Kit TRA04061-7......................................................................................................................9-44
Figure 9-20. Kit TRA03801-9......................................................................................................................9-45
Figure 9-21. Kit TRA04061-12....................................................................................................................9-46
Figure 9-22. Kit TRA03801-16L or TRA03801-16R ..................................................................................9-46
Figure 9-23. TRA04021-17..........................................................................................................................9-47
Figure 9-24. Kit TRA04061-19....................................................................................................................9-47
Figure 9-25. Kit TRA04031-10....................................................................................................................9-48
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9.0

9.1 Overview
Over the years the Transort product controls have consisted of divert control
modules (DCM) and other control devices. Control devices were either
hardwired to the DCMs and / or wired directly to the Transort control panel.
Whether a single or crossover Transort, there is a multi-conductor cable
connected to between each DCM and the Transort control panel. These cables
plus the wiring of the control devices along the Transort made the installation
and commissioning period long and drawn out. In addition, the DCM Modules
were expensive to install.
The WhisperSort Discrete I/O version eliminates some of the discrete wiring of
control devices located on the sorter. DCM field wiring between the main panel
and the DCM is still required. Control devices connected to the DCM use quick
disconnect micro connectors / cables. Discrete I/O connections to control
devices reduce the installation and commissioning time, saving time and money.
DCM Standard Drawings
Drawing TRA04061 shows the DCM module, control devices and associated
connections.
Most sorter control devices are connected to the DCM/s. Other control devices
are hardwired back to the sorter control panel.
All Control Device components are +24Vdc with the exception of the oiler/s
(120Vac).
The control signal for the oiler/s can be run in the same conduit as the 480Vac
motor power cable.
P/N 0312996
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Limited Angle Electric Motor
Further savings have been achieved by replacing the Pneumatic Danfoss
Actuator. Eliminating air brings significant savings. The electric motor is a
limited angle motor. The poles in the motor are aligned such that the rotation of
the motor is 90 degrees from pole to pole. Therefore, when a positive DC
voltage is applied to the motor coil, the shaft of the motor rotates 90 degrees.
There are 2 separate coils to common. Only one coil is energized at a time. One
coil for Divert position and the other for Straight position.
Factory Installation
A complete intermediate section is assembled in the factory, including the Divert
Switch and Center Switch assemblies. Included in the Switch assemblies are the
switch motor/cable and Divert Inductive Proximity Switch.
Field Installation
DCM modules, all control devices and QD cables are installed in the field. All
control devices located on the sorter have QD connectors. The DCM interfaces
to all control devices through an I/O breakout block factory wired to the DCM.

9.2.1
9-6

TRA04061-12.
TRA04061-12.
7. Connect control devices to the DCM I/O breakout block.
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10. Run multi-conductor round cable from the sorter control panel to each DCM.
Use Belden Cable 8623 or equivalent. The number of conductors used can
vary per application.
the drip oilers.
9.2.2

Prior to a package being diverted, the controller sends a divert enable signal to
the DCM. Once enabled, the DCM monitors the divert inductive proximity
switch input that detects pusher shoe pins. When the proximity switch detects a
pin, the DCM turns ON the divert switch signal that activates the motor to the
divert position. The motor is maintained in the divert position until the divert
enable signal is removed by the Controller. When the pin is detected by the
proximity switch, a signal is sent to the DCM. The DCM returns the motor to the
straight position.
Manual Operation of Divert Switches Use Divert Pushbutton
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9.2.3

DCM board
Pre-wired multi port connector
DCM Board Terminals
Terminals T1 & T2 - DC power and PLC I/O
Terminal T3 & T4 interfaces to I/O blocks
Refer to Drawing TRP11142 for DCM board to I/O Block connections
The DCM multi port modules connects external components to DCM input
circuits.
Divert inductive proximity sensors
Full lane photoeyes
Full lane photoeyes
Confirm inductive proximity sensors
Dynamic Jam Sensors
1 spare input
1 spare output
Divert and Crossover motors
9.2.3.1 Power and I/O Connections

Terminal
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
9-8
#
1
2
3
4
5
6
7
8
9
10
Signal
Power
X
X
X
X
Power / Signals TO/FROM PLC

+24Vdc Holding Voltage
24V common
+48Vdc
48V common
Full Left to PLC
Full Left to PLC
Divert Right Proximity to PLC
Spare Output from PLC
Spare Input to PLC
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Terminal
T2
T2
T2
T2
T2
T2
#
1
2
3
4
5
6
Signal
Power
Signals TO/FROM PLC

Divert Right Enable from PLC
Divert Left Enable from PLC
Confirm Left to PLC
Confirm Right to PLC
Full Line Left to PLC
Full Line Right to PLC
Terminal
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
T3
#
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
I/O Block Signals

Full Right
Full Left
Divert Right Proximity Sensor
Divert Left Proximity Sensor
Full Line Right
Full Line Left
Confirm Right
Confirm Left
Terminal
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
T4
#
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
I/O Block Signals
24V Common
24Vdc
Spare Output
Spare Input
Crossover Right Proximity Sensor
Crossover Left Proximity Sensor
Crossover Motor
Crossover Motor
24V Common
Right Motor Straight
Right Motor Divert
24V Common
Left Motor Straight
Left Motor Divert
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9.2.3.2 Sorter DCM Operation
The PLC monitors the package length and assigns the appropriate number of
shoes to a particular package to be sorted. Just before the package reaching its
sort point, the controller sends a Divert Enable Signal to the DCM. The DCM
board circuits monitor the Divert Proximity Switch Input for the next pusher shoe
pin to be detected. When the Divert Proximity Switch Input goes low to high
(0V to +24Vdc), the DCM circuits turn ON the divert switch signal which fires
the divert switch to the divert position. The divert switch is maintained in the
divert position until the Divert Enable Signal is removed by the Controller. When
the Divert Enable Signal goes from high to low (+24Vdc to 0V), the DCM
circuits look for the next pusher shoe pin to turn ON the Straight switch signal to
fire the divert switch to the straight position.
Confirmation of the divert shoes is accomplished by using the Divert
Confirmation Board located in the Sorter Control Panel. (See Drawing
TRA04074 for detailed hookup). The Divert Confirm Proximity Switch Output
is Normally Open. When the Proximity Switch sees a pin, the output goes high
(+24Vdc) for approximately 4ms at maximum sorter speed of 600fpm. This
signal is connected to the Divert Control Module board that sends the signal to
the Divert Confirm Board (HK# B00013) that extends the signal. The Divert
Confirm Board is located in the Sorter Control Panel.
9.2.3.3 Divert Confirmation Board
Sorter divert points have inductive proximity switches to detect when a pusher or
number of pushers have been diverted. This gives positive identification that the
DCM diverted the shoe. The Confirm Prox detects the pin on a shoe as the pin
passes across the sorter. The Normally Open Prox is tied to DCM confirm line
input. The output of the Confirm Line from the DCM is one conductor of a
multi-conductor cable routed back to the Sorter Control Panel. All Confirm
Signals from the Sorter are terminated to a terminal strip inside the sorter control
panel. The confirm signals are then wired to the Confirmation Board. The sorter
encoder signal also terminates at the Confirmation Board. All Confirm Signals
going to the Confirmation Board are high (+24VDC), unless a pin is present, then
the input signal goes to 0V.
A number of shoes are diverted at a time. The purpose of the Confirmation
Board is when the input shoe pin pulses are present, the output for that particular
divert point on the Confirmation Board goes to +24VDC until no more pulses are
present.
The Confirmation Board circuit monitors the sorter encoder pulses that are
always present. There should never be more than two sorter wheel prox signals
for every pusher pin pulse. If there are three consecutive sorter wheel prox
signals with no shoe pin signal present then the Confirmation Board Output
Signal goes from +24VDC to 0V. As soon as another pusher pin pulse is present
the Confirmation Board Output Signal goes to +24VDC.
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9.2.3.4 Manual Switch Operation of Divert Switches
The Switch, when depressed performs the same action as the associated
Controller Divert Enable Signal. Manual Switch Depressed = Switch is diverted
until Manual Switch is released. When released the Switch goes back to the
straight position.
Note: Manual Switch overrides the Controller Divert Enable Signal
9.2.4
Sorter Chain Oilers

DripOiler
Spray Oiler
placed so that the tip is approximately to 1 away from
the chain side bars. The oil and air lines must be tied to
cross members so that they are clear of the moving
flights. Adjust the nozzles horizontally to spray the
lubricant between the side plate and the roller. Use
9.2.5
Pin Greaser
lost.
9.2.6
Induction Encoder
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9.2.7
Sizing Divert Control Module Power Supplies

(UPS).


+48Vdc regulated.

below.)
9-12
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Divert proxs
Confirm proxs
Full line PEs
Full line PEs
Jam PEs
Example:
20 diverts using divert confirm prox, 1 full line, no fulls, no jam PEs
120 0.040 = 4.8 amps
(6 + 4.8 amps = 10.8 amps).
9.2.8
End of Sorter Photoeye (Option)

The photoeye is a light energized polarized retroflective unit. The purpose is to
detect non-sorted packages. The output comes on when the photoeye beam is
broken.
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9.2.9
Divert Confirm Inductive Proximity Switch (Option)

HK Divert Confirm Board (typically located in the Sorter Control Panel) is
ordered separately. HK part number: B00013
A Divert Confirm Board has 16 inputs, one per Divert Confirm Proximity
Sensor. The output of the Divert Confirm Board is an extended pulse of the
Divert Confirm proximity sensor signal.
9.2.10
Dynamic Jam Photoeyes (Option)

I/O block.
9.2.11
Full Lane Photoeyes (Option)

from sorter is determined by engineer).
9.2.12
Full Lane Photoeyes (Option)

have a timer feature.
9.2.13
Induction Photoeye (Option)

The induction photoeye is an Allen Bradley RightSight Photoeye, part number:
42EF-P2MPB-F4. The mounting location on the load belt is determined by the
engineer. The signal is discretely wired back to the sorter control panel (with the
encoder power/signal) to a DC input card in the PLC rack.
9-14
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9.2.14
Broken Pin Assembly (Option)

pin replaced.
both of the pins are detected, the I/O block output signals the PLC. The PLC

For Non-DeviceNet WhisperSorts using discrete cable/wiring, the output
signal is wired back to the sorter controller I/O card. The output signal (pin
missing) is +24Vdc.
9.2.14.1
Mounting Location
9.2.14.2

switches
(2)
Mounting hardware
drawing TRP10991.
Operation
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Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
300-400
< 300
10
15
Fault Output
Reset Fault
9.2.14.3
Up-stream Prox
Down-Stream Prox
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Mapping I/O
For a DeviceNet WhisperSort map I/O at unused high number node

9-16

Open DeviceLogix
Start Logic Editor
Enable
Click OK
Close out window
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9.3 Drawings
The numbered callouts match the tables that follow the drawings. Each table
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9.3.1
Figure 9-2. WhisperSort General Device Application (Drawing TR04061)
9-18
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9-19
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9.3.2
9-20
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9-21
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9.3.3
Tail Section
9-22
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9-23
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9.3.4
Intermediate
9-24
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9-25
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9.3.5
Catenary
9-26
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9-27
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9.3.6
Drive
9-28
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9-29
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9.3.7
Divert Module
9-30
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9-31
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9.3.8
Broken Pin Kit
9-32
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9-33
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9.3.9
Electrical Connection Broken Pin Module
Figure 9-10. Electrical Connection Broken Pin Module (Drawing TRA04075)
9-34
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9-35
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9.3.10
Electrical Connection DCM Module
Figure 9-11. Electrical Connection DCM Module (Drawing TRA04072)
9-36
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9-37
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9.3.11
Electrical Connection Confirm Prox
Figure 9-12. Electrical Connection Confirm Prox (Drawing TRA04074)
9-38
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9.4 Reference Tables for Control Kits (Discrete I/O Dual-Sided)

9.4.1
9.4.2
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9.4.3
9-40
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9.4.4
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9-41
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9.4.5
9-42
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9.4.6
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9-43
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9.4.7
9-44
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9.4.8
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9.4.9
Divert Control Module (Kit TRA04061-12)
9.4.10
Broken Pin Detector Assembly (Kit TRA03801-16L or TRA03801-16R)
Figure 9-22. Kit TRA03801-16L or TRA03801-16R
9-46
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9.4.11
Crossover Motor (Kit TRA04021-17)
Figure 9-23. TRA04021-17
9.4.12
Divert Control Module Kit Set-Up Switch (Kit TRA04061-19)
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9.4.13
Divert Control Module Kit (Single) (Kit TRA04031-10)
9.5 Start Up and Test Procedures (Discrete I/O Single-Sided)

1. Disconnect DCM power connectors from all DCMs.
glass.
9-48
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9.5.1

1. Before applying power disconnect all DCM T1 connectors.
+24Vdc).
3. Check the power feed for the correct DC voltages.
and power has been removed.
9.5.2
Chain Oiler
9.5.3

Pump Cycles/Min
Overall Length (Ft)
Speed
501-600
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30 150
151 300
301 and Greater
12
9-49
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FPM
9.5.4
401-500
FPM
10
350-400
FPM
Pin Greaser
of operation are:
P1=0
P2=20
P3=3
P1=2
P2=0
P3=1
9.5.5
Start Up
on all sorters. As soon as direction of travel has been established, tracking of the
induction belt should be done to prevent damage to the belt.
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Chapter 10
WhisperSort

10.0 DeviceNet Single-Sided Model 5 ............................................................................................. 10-5
10.1 Installation Instructions .............................................................................................................. 10-5
10.1.1 Controls Installation Overview........................................................................................ 10-5
10.1.2 Power Busway System .................................................................................................... 10-7
10.1.3 DeviceNet System ........................................................................................................... 10-9
10.1.4 DeviceNet Media and Connectors................................................................................. 10-10
10.1.5 Divert Switch Assembly................................................................................................ 10-10
10.1.6 Divert Control Module .................................................................................................. 10-11
10.1.7 Divert Control Module I/O Assignments ...................................................................... 10-13
10.1.8 Terminal T2 - Inputs..................................................................................................... 10-14
10.1.9 Terminal T3 Outputs .................................................................................................. 10-14
10.1.10
Long Range Jam Photoeye .......................................................................................... 10-15
10.1.10.1 Long Range Jam Photoeye Alignment Procedure.................................................... 10-15
10.1.11
Slack Chain and Shoe out of Position Sensors............................................................ 10-16
10.1.12
Sorter Chain Oilers...................................................................................................... 10-17
10.1.13
Pin Greaser .................................................................................................................. 10-17
10.1.14
Induction Encoder ....................................................................................................... 10-17
10.1.15
Sizing Divert Control Module Power Supplies ........................................................... 10-17
10.1.15.1 Sorter Power Supplies.............................................................................................. 10-18
10.1.15.2 Sizing Power Supplies for DCMs ............................................................................ 10-18
End of Sorter Photoeye (Option)................................................................................. 10-19
10.1.16
10.1.17
Divert Confirm Inductive Proximity Switch (Option) ................................................ 10-19
10.1.18
Dynamic Jam Photoeyes (Option)............................................................................... 10-20
10.1.19
Full Lane Photoeyes (Option) .................................................................................... 10-20
10.1.20
Full Lane Photoeyes (Option) ................................................................................. 10-20
10.1.21
Sort Jam Photoeye (Option) purchase FULL Kit tra05261-6 .................................. 10-20
10.1.22
Induction Photoeye (Option)...................................................................................... 10-21
10.1.23
Sort Infeed Broken Pin Assembly Kit TRA03801-16 (Option).................................. 10-21
10.1.23.1 Mounting Location................................................................................................... 10-22
10.1.23.2 Operation.................................................................................................................. 10-22
10.1.23.3 Mapping I/O............................................................................................................. 10-22
DCM Broken Pin Option............................................................................................. 10-23
10.1.24
10.1.24.1 Single Sided Sorter (Kit TRA05261-20).................................................................. 10-23
10.1.24.2 Dual Sided Sorter ..................................................................................................... 10-23
Auto Calibration .......................................................................................................... 10-24
10.1.25
10.1.25.1 Concept .................................................................................................................... 10-24
10.1.25.2 Process ..................................................................................................................... 10-24
10.1.25.3 One Time Physical Measurements........................................................................... 10-25
10.1.25.4 Measurement 1:........................................................................................................ 10-25
10.1.25.5 Measurement 2 + the Return Switch Dimension ..................................................... 10-25
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10.1.25.6 Means........................................................................................................................10-25
10.1.25.7 Operation ..................................................................................................................10-26
10.1.25.8 Procedure ..................................................................................................................10-26
10.2 Drawings ...................................................................................................................................10-27
10.2.1 WhisperSort General Device Application ..................................................................10-28
10.2.2 General Arrangement Overview ....................................................................................10-30
10.2.3 Infeed .............................................................................................................................10-32
10.2.4 Intermediate ...................................................................................................................10-34
10.2.5 Catenary .........................................................................................................................10-36
10.2.6 Drive ..............................................................................................................................10-38
10.2.7 Divert Switch .................................................................................................................10-40
10.2.8 Broken Pin .....................................................................................................................10-42
10.3 Reference Tables for Control Kits (DeviceNet Single-Sided) .................................................10-44
10.3.1 Divert Switch Part Numbers ..........................................................................................10-44
10.3.2 Long Range Jam Photoeye Kit (Kit TRA03801-1)........................................................10-44
10.3.3 Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)................10-45
10.3.4 Divert Confirm Proximity Switch Kit (Kit TRA03801-3).............................................10-45
10.3.5 Dynamic Jam Photoeye Kit (Kit TRA03801-4).............................................................10-46
10.3.6 End-of-Sorter Photoeye Kit (Kit TRA03801-5) ............................................................10-47
10.3.7 Full Line Photoeye Kit (Kit TRA03801-6)....................................................................10-48
10.3.8 3/4 Full Line Photoeye Kit (Kit TRA03801-7)..............................................................10-49
10.3.9 Induction Photoeye Kit (Kit TRA03801-9) ...................................................................10-50
10.3.10
DeviceNet Kit (Kit TRA03801-10) .............................................................................10-50
10.3.11
Power Busway Kit (Kit TRA03801-11) ......................................................................10-51
10.3.12
Divert Control Module Kit (Kit TRA03801-12) .........................................................10-51
10.3.13
Power Busway Kit (Kit TRA03801-14) ......................................................................10-52
10.3.14
Application Specific Quantities ...................................................................................10-52
10.3.15
Broken Pin Detector Assembly....................................................................................10-53
10.4 Start Up and Test Procedures....................................................................................................10-54
10.4.1 Sorter Power Check List ................................................................................................10-54
10.4.2 Sorter DCM DC Power Check List................................................................................10-55
10.4.3 Sorter DeviceNet System Check List.............................................................................10-55
10.4.4 Chain Oiler.....................................................................................................................10-56
10.4.5 Spray Oiler (Optional) ...................................................................................................10-56
10.4.6 Pin Greaser.....................................................................................................................10-57
10.4.7 Start Up ..........................................................................................................................10-57
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List of Figures
Figure 10-1. Busway Voltages .....................................................................................................................10-8
Figure 10-2. Proximity Sensor Location on Divert Switch Assembly .......................................................10-11
Figure 10-3 WhisperSort General Device Application (Drawing TRA05261) ....................................10-28
Figure 10-4 General Arrangement Overview (Drawing TRA05263) .......................................................10-30
Figure 10-5 Infeed (Drawing TRA05264) ................................................................................................10-32
Figure 10-6 Intermediate (Drawing TRA05265).......................................................................................10-34
Figure 10-7 Catenary (Drawing TRA05266) ............................................................................................10-36
Figure 10-8 Drive (Drawing TRA05267)..................................................................................................10-38
Figure 10-9 Divert Switch (Drawing TRA05268) .................................................................................... 10-40
Figure 10-10 Broken Pin Kit (Drawing TRA05269) ................................................................................10-42
Figure 10-11 Divert Switch Part Numbers ................................................................................................10-44
Figure 10-12 Kit TRA03801-1..................................................................................................................10-44
Figure 10-13 Kit TRA03801-2..................................................................................................................10-45
Figure 10-14 Kit TRA03801-3..................................................................................................................10-45
Figure 10-15 Kit TRA03801-4..................................................................................................................10-46
Figure 10-16 Kit TRA03801-5..................................................................................................................10-47
Figure 10-17 Kit TRA03801-6..................................................................................................................10-48
Figure 10-18 Kit TRA03801-7..................................................................................................................10-49
Figure 10-19 Kit TRA03801-9..................................................................................................................10-50
Figure 10-20 Kit TRA03801-10................................................................................................................10-50
Figure 10-21 Kit TRA03801-11................................................................................................................10-51
Figure 10-22 Kit TRA03801-12................................................................................................................10-51
Figure 10-23 Kit TRA03801-14................................................................................................................10-52
Figure 10-24 Application Specific Quantities ...........................................................................................10-52
Figure 10-25 Broken Pin Detector Assembly ...........................................................................................10-53
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10-4
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10.0 DeviceNet Single-Sided Model 5

tables for control kits, and start-up and test procedures for the DeviceNet SingleSided model.

10.1.1 Controls Installation Overview

1. Install the power busway.
2. Connect the round cable to the divert switch proximity sensor (kit
TRA05261-12).
3. Mount the divert control module (DCM) to the DCM bracket. (kit
TRA05261-12).
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CAUTION:

DeviceNet components is two meters.
customer.
the drip oilers.
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10.1.2 Power Busway System


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sorter. Power rail should always be mounted to the sorter on the same side
as the divert switch assembly.
10-7
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bus connectors are tightened to ensure good electrical connection between

the bus connector and the power rail.

figure below.
Label must be on
outside of sorter


10-8
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rail.
10.1.3 DeviceNet System

of State (COS).
All DCMs plus Slack Chain and
Shoe Out of Position are controlled
via DeviceNet. DeviceNet
components are connected (via
DeviceNet media) to the DeviceNet
scanner card in the control panel.
P/N 0312996
All DeviceNet components on the

sorter require commissioning
(node number, baud rate setting, configuration, and node mapping in the
network scanner card).
Switch 1 binary 1
Switch 2 binary 2
Switch 3 binary 4
Switch 4 binary 8
Switch 5 binary 16
Switch 6 binary 32
2. No sort photoeye
State (COS).
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10.1.4 DeviceNet Media and Connectors

Kwiklink flat cable and micro connector bases are DeviceNet media components
that connect DeviceNet components to the network scanner card.
flat cable ties and bases. The flat cable is terminated at the far end of the cable
with an IDC termination base. Each DeviceNet component is connected to a
base installed onto the flat cable.
10.1.5 Divert Switch Assembly

10-10
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block.
10.1.6 Divert Control Module

Note: For left hand sorters reverse the electric motor wires on the DCM board
(connector T3, terminals 7 and 8). Move the brown/green wire to terminal 8 and
the grey wire to terminal 7. (A left hand sorter is a single-sided sorter that
diverts product to the left side.)
DCM board
DC power via T1
Inputs via T2
Outputs via T3
The board connectors silk-screened nomenclature refer to some signals which
are not used on the single sided sorter. Refer to all signals with RT in the
signal description.
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panel through the busway rail, through the DCM connector to T1.
T1-1
T1-2
T1-3
T1-4
+48Vdc
48V COM
+24Vdc
24V COM
The DCM multiport module connects external NON-DeviceNet components

to DCM input circuits.
Full lane photoeye
Full lane photoeye
Dynamic jam PE
2 spare inputs
1 spare output
Each port on the multi port module has two I/O points. When multiple I/O is
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10.1.7 Divert Control Module I/O Assignments

Produced Data
Parameter
Description
Bit #
0
1
2
3
Divert Left Prox Sensor

Divert Right Prox Sensor
Full Lane Right
273
274
0=Disable, 1=Off Delay, 2=On Delay

Time Delay In Ms, Range = 5 To 10000
4
5
Full Right
277
278

289
290

6
7
8
9
10
11
Broken Pin Fault

0
0
0
12
13
14
15
Spare Input 1
Spare Input 2
Jam Right
Enabled Via Auto Calibrate Start

Confirm Right
DCM Consumed Data
Description
Bit #
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Broken Pin Fault Reset

0
Sorter Speed 250-300 Fpm
BPF Enable Input 1
BPF Enable Input 2
0
Auto Calibrate Start
Auto Calibrate Reset
0
Spare Output 1
Spare Output 2
Bit Selects Parameter With Preset Value Of 137ms

Set Bit To Enable Input For Broken Pin Feature
Set Bit To Receive Divert Prox Signals
Reset Bit To Disable Divert Prox Signals
Divert Right Enable Signal
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10.1.8 Terminal T2 - Inputs

All timers settable range: 0 to 10000ms in increments of 1ms
PIN #
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Divert Left Prox

Divert Right Prox
Full Lane Left
Full Lane Right
Full Left
Full Right
Confirm Left Prox
Confirm Right Prox
Crossover Left Prox
Crossover Right Prox
Jam Left
Jam Right
Spare Input 1
Spare Input 2
N/C
N/C
BD NAME
DIV LT P
DIV RT P
FULL LT
FULL RT
F LT 3/4
F RT 3/4
CONF LT
CONF RT
XLT PROX
XRT PROX
JAM LT
JAM RT
24V IN
24V IN
FACTORY SETTING (0,1,2)
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
1 - 5000
1 - 5000
1 - 5000
1 - 5000
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
1 - 5000
1 - 5000
0 - 5000
0 - 5000
10.1.9 Terminal T3 Outputs

PIN #
1. +24Vdc
2. 24V common
3.
4. Divert Left
5. Sraight Left
6. 24V common
7. Divert Right
8. Straight Right
9. 24V common
10.
11. Crossover Mtr Left
12. Crossover Mtr Right
13. Spare Output 1
14. Spare Output 2
15. 24V common
16. 24V common
10-14
Bd Name
24Vdc
24V COM
SPARE
LT DIV
LT STR
LT COM
RT DIV
RT STR
RT COM
SPARE
X LT
X RT
24V OUT
24V OUT
24V COM
24V COM
P/N 0312996
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10.1.10 Long Range Jam Photoeye

is connected to the first and last divert control module I/O Blocks. This is NOT a
10.1.10.1
Long Range Jam Photoeye Alignment Procedure

sorter.
hands.
Receive PE.
PE.
P/N 0312996
10-15
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feet.
10.1.11 Slack Chain and Shoe out of Position Sensors

The slack chain sensor must be configured via
DeviceNet for normally closed operation.
When slack in the chain occurs, the output
from the sensor goes from 1 to 0.
The shoe out of position sensor must be
configured via DeviceNet for normally open
operation. The sensor normally senses a plate,
and when a shoe out of position knocks the
plate away from the sensor the output goes
from 1 to 0.
In the RSNetworx For DeviceNet software
change the communications mode to Change of State (COS) with node
numbers set to 55 and 56 accordingly.
CAUTION:
10-16
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DripOiler
Spray Oiler
moving flights. Adjust the nozzles horizontally to
spray the lubricant between the side plate and the
roller. Use Powerflow Hydraulic oil ISO-68A2.
10.1.13 Pin Greaser

lost.

The sorter induction encoder is factory mounted on the tail section. This is NOT
a DeviceNet component. It is field wired to the sorter control panel +24Vdc
input card. The output from the encoder (+24Vdc) is 1 pulse per 2.5 of travel.

(UPS).
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10-17
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10.1.15.1
Sorter Power Supplies

10.1.15.2
Sizing Power Supplies for DCMs


+48Vdc regulated.

1. Count the number of divert points.
2. Multiply the number in step one by 1.0. This is your total holding current.
below.)
10-18
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Divert proxs
Confirm proxs
Full line PEs
Full line PEs
Jam PEs
Example:
no jam PEs
60 0.040 = 2.4 amps
Add 12 amps to the control device current derived above (12 + 2.4 amps = 14.4
amps).


P/N 0312996
10-19
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I/O block.

from photoeye to main sort line is determined by engineer. Since the DCM I/O is
configured for change of state (COS), the full lane photoeye signal occupies
Therefore, the sensor input parameter timers must be set to allow the longest
package to pass without activating the sensor. Only when there is a FULL
condition (sensor blocked and timer times out) will the sensor input to the PLC
be set.

be set.
10.1.21 Sort Jam Photoeye (Option) purchase FULL Kit tra05261-6

Lane Jam photoeyes are located at the infeed end of each divert lane. Since the
the time. Therefore, the sensor input parameter timers must be set to allow the
longest package to pass without activating the sensor. Only when there is a JAM
be set.
10-20
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The induction is not a DeviceNet component. The mounting location on the load
belt is determined by the engineer. The signal is discretely wired back to the
sorter control panel (with the encoder power/signal) to a DC input card in the
PLC rack.
10.1.23 Sort Infeed Broken Pin Assembly Kit TRA03801-16 (Option)

pin replaced.

P/N 0312996

switches
(2)
Mounting hardware
10-21
WhisperSort
10.1.23.1
Mounting Location
drawing TRP10991.
10.1.23.2
Operation
There are several input points that are selectable by the sorter controller. The
input bit/point that is selected depends on the speed of the sorter.

Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
300-400
< 300
10
Fault Output
Reset Fault
10.1.23.3
15
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Up-stream Prox
Down-Stream Prox
Mapping I/O
10-22

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Open DeviceLogix
Start Logic Editor
Enable
Click OK
Close out window
10.1.24 DCM Broken Pin Option

10.1.24.1 Single Sided Sorter (Kit TRA05261-20)
For a Single Sided Sorter it is necessary to install Broken Pin Kit TRA05261-20
(see drawing TRA05269) directly across from any DCM Proximity Sensor. The
Broken Pin Kit proximity sensor cable is routed across the sorter to the DCM I/O
block and connected to Port 5 or IN2. IN2, DCM Consumed Data bit 7, (BPF
Enable Input 2) must be enabled so the DCM code recognizes this input to be used
for the Broken Pin Fault feature.
10.1.24.2 Dual Sided Sorter
For the Dual Sided Sorter it is NOT necessary to install the Broken Pin Kit
TRA05261-20. The DCM board monitors both the Divert Right and Left Divert
Proximity Sensors to detect a broken pin.
The Broken Pin Fault Code monitors 2 sensor inputs, and the Divert Left and
Right Proximity Sensors. The 2 sensor inputs are disabled from the factory. If
these inputs are used to detect Broken Pins, DCM consumed data bits 6 and/or 7
must be set.
Enabling a SPEED RANGE DCM Consumed Data bits 2,3,4, or 5 (depending
on sorter speed) activates the Broken Pin Feature. If one of the speed range bits
are NOT set, the Broken Pin Code is NOT activated.
Broken Pin PLC code sequence:
1. Sorter Control Panel Start Button (momentary pulse) sets DCM Consumed
Data bit 0 (Broken Pin Fault Reset) ACTION: Sets the Broken Pin Fault
Bit to 0.
2. Sorter Control Panel Start Button (momentary pulse) Unlatches DCM
Consumed Data bits 2,3,4, or 5 (Speed Bits) ACTION: Disables the Broken
Pin Code.
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3.
Sorter at speed: When the Sorter is at speed latch one of the DCM
Consumed Data bits 2,3,4 or 5 speed bits. Setting a speed bit enables the
Broken Pin Code. The speed bit should be set only when the sorter is at
speed. Otherwise, a fault will occur during acceleration or deceleration.
Note: Setting any of the DCM Consumed Data bits 2,3,4 or 5 enables the Broken
Pin Code
Broken Pin Code Operation
Once the sorter is at speed and a speed bit is enabled, a timer starts after each
pin is detected. This timer is reset every time a pin is detected. If a pin is
missing, the timer times out and DCM Product Data bit 6 (Broken Pin Fault) is
set, and the Broken Pin Fault LED on the DCM board is illuminated.
10.1.25 Auto Calibration

Bits are provided to START and STOP the Auto Calibration process. These bits
add the Divert Proximity Sensors to the COS mask so they can be read by the
PLC. The Sorter speed must be slow for accurate detection of the divert
proximity signals.
Note: The actual Auto Calibrate PLC code is provided by the end users controls
person.
10.1.25.1
Concept
Auto calibration; the process of using a pusher shoe and an encoder in
conjunction with a programmable controller to automatically determine and
record (pointer valves) the position of each divert switch.
10.1.25.2
Process
The auto calibration process is initiated during initial startup (or at any time after
startup) by pressing an auto calibrate illuminated pushbutton. Invoking auto
calibrate suspends induction, clears the sorter then begins the calibration process.
The auto calibrate light flashes for the duration. When all divert pointer values
are determined (as compared to PLC mapping table) or the marker shoe reaches
the last divert control module an indicating light continuously illuminates
signaling completion and the sorter is ready to return to auto operation or a fault
condition is annunciated. The set point determination program must be
completed for all divert points (PLC pointer table rebuilt) or the fault condition
resolved before auto operation can be restored. Depressing the system start
10-24
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button resets the calibration program, sounds the startup alarm and enables
induction to automatically resume.
10.1.25.3
One Time Physical Measurements

During the initial Sorter setup two measurements are required. These
measurements are used to determine the pointers for the first divert switch, and
for a dual sided sorter, the return switch pointer. These pointer values are entered
into the PLC code and remain a constant unless one or both of the following
change. 1) The induction package sensor location changes and/or 2) the location
of the first divert switch inductive proximity switch changes. If either or both of
these locations change, measurements of the new location/s is required, and the
new pointer values calculated and re-entered into the PLC code.
10.1.25.4
Measurement 1:
First divert switch inductive proximity switch to induction belt package sensor.
This measurement is used to determine the pointer location of the first divert
switch.
10.1.25.5
Measurement 2 + the Return Switch Dimension

Measure from the end of the Sorter identified in the pictorial below, to the
induction belt package sensor. Contact product engineering for the Dual Sided
Sorter Return Switch dimension. (The Return switch dimension is the same for
all dual sided sorters). Add both dimensions to arrive at the Return Switch
pointer value.
10.1.25.6
Means
The WhisperSort DeviceNet Divert Control Module uses Change of State (COS)
communications between the Divert Control Module board and the PLC. The
Divert Proximity Signals are not enabled in the COS mask during sorter
operation in order to keep the communications bandwidth low. During the AutoCalibration period this Divert Proximity signal is enabled in the COS mask.
DCM consumed data bit 9 starts Auto Calibration and enables the Divert
Proximity Signals in the COS mask.
DCM consumed data bit 10 disables the Divert Proximity Signals in the COS
mask.
During Auto Calibration the sorter needs to run at a very slow speed (25 fpm).
The low speed ensures that all divert proximity switch signals to be received by
the PLC via COS.
An Encoder pulsing on 2.5 increments provides tracking accuracy.
P/N 0312996
10-25
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The PLC has the capacity to maintain two distance measuring tables each equal
to 700 feet X 12/2.5 and encode (64-single sided/128 dual sided) divert switch
set points. The first table contains the current working pointer data. The second is
reserved to record the new pointer readings.
10.1.25.7
Operation
The PLC diverts a group of shoes at the first divert switch , then lets one (1) shoe
through (pointer shoe) then diverts all other shoes. The PLC waits for the single
shoe to signal each divert proximity switch location. This process continues until
all switch positions are calibrated.
Dual Sided sorter calibration same as above
10.1.25.8
Procedure
Initial Sorter Set-up (Steps 1 and 2)
1. Measure distance infeed end of sorter to the induction belt package sensor.
(Enter in PLC)
2. Measure from the first divert switch proximity switch to the induction belt
package sensor. (Enter in PLC)
3. Depress Auto-Calibration button on Control Panel
4. Sorter slows to Auto-Calibration speed of 25 fpm
5. PLC diverts a group of shoes at first divert switch
6. PLC sends one (1) shoe through first divert switch
7. PLC diverts all other shoes at first divert switch
8. PLC receives each divert switch sensor signal and records the pointer value.
9. The Auto-Calibration is complete when the last divert control proximity
sensor signal is received.
For a 700 foot Sorter, from the time the Auto-Calibration button is
depressed to the time the process is complete should take less than 60
minutes.
10-26
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10.2 Drawings
P/N 0312996
10-27
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10.2.1 WhisperSort General Device Application
Figure 10-3 WhisperSort General Device Application (Drawing TRA05261)
10-28
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P/N 0312996
10-29
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10.2.2 General Arrangement Overview
Figure 10-4 General Arrangement Overview (Drawing TRA05263)
10-30
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P/N 0312996
10-31
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10.2.3 Infeed
TRAVEL
121
120
DCM MODULE
(KIT # TRA05261-12)
121
120
115 118 119

114
CONTINUED ON
DWG# TRA05265
KWIKLINK
MICRO BASE
113
MPIS BLOCK
SEE DWG# TRA05261CONTROL CABLES
FOR CONNECTIONS FROM DEVICES
TO MPIS BLOCK
123 122
NOTE 1
128B 128A 128 127 126
BUSWAY MTD CLIP

& T - BOLT KIT
(KIT # TRA03801-14)
STAR JACK
BUS CONNECTOR
END POWER FEED111

(KIT # TRA03801-11)
DCM
POWER FEED
TO MCP
112A
133 124 125
UNIVERSAL BUS DUCT
112B
112C
112D
NOTES:
1) SET NODE AND BAUD RATE DIP SWITCHES
Figure 10-5 Infeed (Drawing TRA05264)
10-32
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BROKEN PIN
DETECTOR
(KIT # TRA03801-16)
MOUNT WITH EXISTING
GUARD BOLT
142
KWIKLINK
MICRO BASE
141
140
137
139
132
138
131
LONG RANGE
JAM PE
RECEIVER
(KIT # TRA03801-1)
2
10
14
15
13
12
11
12
8
3
PANDUIT
FLAT CABLE
CLAMP
130
130
130
129
135
131 132
DEVICENET
FLAT CABLE
TO MCP
ROUTE CABLE TO
FIRST DCM MPIS BLOCK
P/N 0312996
SHAFT MT
TRACKIN
ENCODE
TO MCP
10-33
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10.2.4 Intermediate
Figure 10-6 Intermediate (Drawing TRA05265)
10-34
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P/N 0312996
10-35
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10.2.5 Catenary
Figure 10-7 Catenary (Drawing TRA05266)

10-36
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P/N 0312996
10-37
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10.2.6 Drive
Figure 10-8 Drive (Drawing TRA05267)
10-38
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P/N 0312996
10-39
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10.2.7 Divert Switch
Figure 10-9 Divert Switch (Drawing TRA05268)
10-40
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P/N 0312996
10-41
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10.2.8 Broken Pin

TRAVEL
146
MOUNT KIT TRA05261-20

SO INDUCTIVE PROX
IS LOCATED DIRECTLY
ACROSS FROM SWITCH
INDUCTIVE PROX
+/- 1/4"
ROUTE INDUCTIVE PROX

CABLES TO MPIS BLOCK
CONNECTION DETAILS
ON DWG #TRA05261
SECURE CABLE WITH
BOSCH CABLE CLAMPS
116
DIVERT
PIN PROX
DIVERT
SWITCH
117
ROUTE ALL DEVICE

CABLES TO MPIS BLOCK
CONNECTION DETAILS
ON DWG #TRA05261
113
DCM MODULE
MPIS BLOCK
Figure 10-10 Broken Pin Kit (Drawing TRA05269)

10-42
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136
135
LONG RANGE
JAM
RECEIVER
BROKEN PIN
DETECTOR
(KIT # TRA03801-16)
P/N 0312996
10-43
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10.3 Reference Tables for Control Kits (DeviceNet Single-Sided)

10.3.1 Divert Switch Part Numbers
Figure 10-11 Divert Switch Part Numbers
10.3.2 Long Range Jam Photoeye Kit (Kit TRA03801-1)
Figure 10-12 Kit TRA03801-1
10-44
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10.3.3 Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)
10.3.4 Divert Confirm Proximity Switch Kit (Kit TRA03801-3)
P/N 0312996
10-45
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10.3.5 Dynamic Jam Photoeye Kit (Kit TRA03801-4)
10-46
P/N 0312996
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10.3.6 End-of-Sorter Photoeye Kit (Kit TRA03801-5)
P/N 0312996
10-47
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10.3.7 Full Line Photoeye Kit (Kit TRA03801-6)
10-48
P/N 0312996
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10.3.8 3/4 Full Line Photoeye Kit (Kit TRA03801-7)
P/N 0312996
10-49
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10.3.9 Induction Photoeye Kit (Kit TRA03801-9)
10-50
P/N 0312996
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P/N 0312996
10-51
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Figure 10-24 Application Specific Quantities
10-52
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10.3.15 Broken Pin Detector Assembly
Figure 10-25 Broken Pin Detector Assembly
P/N 0312996
10-53
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7. For the oilers, fill the reservoir (with 20-weight non-detergent motor oil for
the drip oilers and Powerflow Hydraulic oil ISO-68A2 for the Spray oilers),
and adjust the flow controls to a slow drip when the solenoid is activated.
The reservoir should drip continuously, but not enough to begin filling the
sight glass.
10.4.1 Sorter Power Check List

baud rate settings.
2. Ensure all DCM T1 connectors are disconnected from the board.
conductors.
10-54
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10.4.2 Sorter DCM DC Power Check List

+24Vdc).
scanlist.
10.4.3 Sorter DeviceNet System Check List

package.
(1-800-354-9795).
network scan list.
track nodes if DCM 1 is in word 1, DCM 2 is in word 2, etc. (The produced
P/N 0312996
10-55
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10.4.4 Chain Oiler

10.4.5 Spray Oiler (Optional)

Pump Cycles/Min
Overall Length (Ft)
Speed
10-56
30 150
151 300
301 and Greater
501-600
FPM
12
401-500
FPM
10
350-400
FPM
P/N 0312996
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10.4.6 Pin Greaser

of operation are:
P1=0
P2=20
P3=3
P1=2
P2=0
P3=1
10.4.7 Start Up
Before start up, determine the direction of travel. Next, set up the controls. The
WhisperSort is equipped with a variable speed control to facilitate an initial
slow speed start up. The acceleration ramp on the controller should be set at
approximately 30 seconds and the speed at approximately 50 fpm on all sorters.
Then, track the induction belt as soon as possible to prevent damage to the belt.
variable speed controller and verify the induction belt tracking.
P/N 0312996
10-57
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10-58
P/N 0312996
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Chapter 11
WhisperSort

11.0 DeviceNet Dual-Sided Model 6 ............................................................................................... 11-5
11.1 Installation Instructions .............................................................................................................. 11-5
11.1.1 Controls Installation Overview............................................................................ 11-5

11.1.2 Power Busway System......................................................................................... 11-7
11.1.3 DeviceNet System................................................................................................ 11-9
11.1.4 DeviceNet Media and Connectors ..................................................................... 11-10
11.1.5 Divert Switch Assembly .................................................................................... 11-11
11.1.6 Divert Control Module....................................................................................... 11-12
11.1.7 Divert Control Module I/O assignments............................................................ 11-13
11.1.7.1 Terminal T2 - Inputs ..................................................................................... 11-14
11.1.7.2 Terminal T3 Outputs.................................................................................. 11-15
11.1.8 Slack Chain and Shoe out of Position Sensors .................................................. 11-15
11.1.9 Sorter Chain Oilers ............................................................................................ 11-16
11.1.10 Pin Greaser....................................................................................................... 11-16
11.1.11 Induction Encoder............................................................................................ 11-17
11.1.12 Sizing Divert Control Module Power Supplies ............................................... 11-17
11.1.13 Sorter Power Supplies...................................................................................... 11-17
11.1.14 Sizing Power Supplies for DCMs .................................................................... 11-17
11.1.15 End of Sorter Photoeye (Option) ..................................................................... 11-18
11.1.16 Divert Confirm Inductive Proximity Switch (Option)..................................... 11-19
11.1.17 Dynamic Jam Photoeyes (Option) ................................................................... 11-19
11.1.18 Full Lane Photoeyes (Option)......................................................................... 11-19
11.1.19 Full Lane Photoeyes (Option)...................................................................... 11-19
11.1.19.1 Sort Jam Photoeye (Option) purchase FULL Kit TRA05261-6 ................ 11-20
11.1.20 Induction Photoeye (Option) .......................................................................... 11-20
11.1.21 Sorter Infeed Broken Pin Kit TRA03801-16 (Option) .................................... 11-20
11.1.21.1 Mounting Location ....................................................................................... 11-21
11.1.21.2 Operation ...................................................................................................... 11-21
11.1.21.3 Mapping I/O.................................................................................................. 11-22
11.1.22 DCM Broken Pin Kit TRA05261-20 (Option) ................................................ 11-22
11.1.22.1 Single Sided Sorter ....................................................................................... 11-22
11.1.22.2 Dual Sided Sorter.......................................................................................... 11-22
11.1.22.3 Broken Pin Code Operation .......................................................................... 11-23
11.1.23 Auto Calibration Information .......................................................................... 11-23
11.1.23.1 Concept ......................................................................................................... 11-24
11.1.23.2 Process .......................................................................................................... 11-24
11.1.23.3 One Time Physical Measurements................................................................ 11-24
P/N 0312996
11-1
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11.1.23.4 Measurement 1.............................................................................................. 11-24

11.1.23.5 Measurement 2 + the Return Switch Dimension .......................................... 11-24
11.1.23.6 Means............................................................................................................ 11-25
11.1.23.7 Operation ...................................................................................................... 11-25
11.1.23.8 Procedure ...................................................................................................... 11-25
11.2 Drawings ...................................................................................................................................11-26
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7
11.2.8
WhisperSort General Device Application...................................................... 11-28

General Device Application (contd)................................................................. 11-30
Tail Section ........................................................................................................ 11-32
Intermediate ....................................................................................................... 11-34
Catenary ............................................................................................................. 11-36
Drive .................................................................................................................. 11-38
Divert Module.................................................................................................... 11-40
Broken Pin Kit ................................................................................................... 11-42
11.3 Reference Tables for Control Kits ............................................................................................11-44
11.3.1
11.3.2
11.3.3
11.3.4
11.3.5
11.3.6
11.3.7
11.3.8
11.3.9
11.3.10
11.3.11
11.3.12
11.3.13
11.3.14
11.3.15
11.3.16
Divert Switch Part Numbers .............................................................................. 11-44

Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2) ... 11-44
Divert Confirm Proximity Switch Kit (Kit TRA03801-3) ................................ 11-45
Dynamic Jam Photoeye Kit (Kit TRA05261-4) ................................................ 11-46
End-of-Sorter Photoeye Kit (Kit TRA03801-5) ................................................ 11-47
Full Line Photoeye Kit (Kit TRA05261-6)........................................................ 11-48
3/4 Full Line Photoeye Kit (Kit TRA05261-7) ................................................. 11-49
Induction Photoeye Kit (Kit TRA05261-9) ....................................................... 11-50
DeviceNet Kit (Kit TRA03801-10) ................................................................... 11-51
Power Busway Kit (Kit TRA03801-11) .......................................................... 11-51
Divert Control Module Kit (Kit TRA05281-12) ............................................. 11-52
Power Busway Kit (Kit TRA03801-14) .......................................................... 11-52
Application Specific Quantities ....................................................................... 11-53
Broken Pin Detector Assembly (Kit TRA03801-16) ...................................... 11-53
Crossover Motor Kit (Kit TRA04021-17) ....................................................... 11-54
Divert Control Module Kit Set-Up Switch (Kit TRA05281-19).................... 11-54
11.4 Start Up and Test Procedures....................................................................................................11-55
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
11-2
Sorter Power Check List .................................................................................... 11-55

Sorter DCM DC Power Check List ................................................................... 11-56
Sorter DeviceNet System Check List ................................................................ 11-56
Chain Oiler......................................................................................................... 11-57
Spray Oiler (Optional) ....................................................................................... 11-57
Pin Greaser......................................................................................................... 11-58
P/N 0312996
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11.4.7
Start Up .............................................................................................................. 11-58
P/N 0312996
11-3
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List of Figures
Figure 11-1. Busway Voltages..................................................................................................................... 11-9
Figure 11-3. Proximity Sensor Location on Divert Switch Assembly....................................................... 11-12
Figure 11-4. WhisperSort General Device Application (Drawing TRA05281).................................... 11-28
Figure 11-5. General Device Application (contd) (Drawing TRA05282)............................................... 11-30
Figure 11-6. Tail Section (Drawing TRA05284)....................................................................................... 11-32
Figure 11-7. Intermediate (Drawing TRA05285) ...................................................................................... 11-34
Figure 11-8. Catenary (Drawing TRA05286)............................................................................................ 11-36
Figure 11-9. Drive (Drawing TRA05287) ................................................................................................. 11-38
Figure 11-10. Divert Module (Drawing TRA05288)................................................................................. 11-40
Figure 11-11. Broken Pin Kit (Drawing TRA05289) ................................................................................ 11-42
Figure 11-12. Divert Switch Part Numbers................................................................................................ 11-44
Figure 11-13. Kit TRA03801-2 ................................................................................................................. 11-44
Figure 11-14. Kit TRA03801-3 ................................................................................................................. 11-45
Figure 11-15. Kit TRA05261-4 ................................................................................................................. 11-46
Figure 11-16. Kit TRA03801-5 ................................................................................................................. 11-47
Figure 11-17. Kit TRA05261-6 ................................................................................................................. 11-48
Figure 11-18. Kit TRA05261-7 ................................................................................................................. 11-49
Figure 11-19. Kit TRA05261-9 ................................................................................................................. 11-50
Figure 11-20. Kit TRA03801-10 ............................................................................................................... 11-51
Figure 11-21. Kit TRA03801-11 ............................................................................................................... 11-51
Figure 11-22. Kit TRA05281-12 ............................................................................................................... 11-52
Figure 11-23. Kit TRA03801-14 ............................................................................................................... 11-52
Figure 11-24. Application Specific Quantities .......................................................................................... 11-53
Figure 11-25. Broken Pin Detector Assembly (Kit TRA03801-16) ......................................................... 11-53
Figure 11-26. Crossover Motor Kit (Kit TRA04021-17) ......................................................................... 11-54
Figure 11-27. Divert Control Module Kit Set-Up Switch (Kit TRA05281-19......................................... 11-54
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11.0


11.1.1 Controls Installation Overview

1. Install the power busway on the left side of the sorter (based on direction of
travel).
TRA05281-12.
TRA05281-12.
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Note: There are pre-drilled holes for cable clamps, bases, inserts, and
hardware.
DeviceNet components is 2 meters.
customer.
the drip oilers.
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11.1.2 Power Busway System


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sorter. Mount the power rail on the left side (based on direction of travel) of
the sorter.
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bus connectors need to be tightened to ensure good electrical connection

between the bus connector and the power rail.
11-8

the figure below.
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Label must be on
outside of sorter


rail.
11.1.3 DeviceNet System

of State (COS).
All DCMs plus Slack Chain and Shoe Out of Position are controlled via
DeviceNet. DeviceNet components are connected (via DeviceNet media) to the
DeviceNet scanner card in the control panel.
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All DeviceNet components on the sorter require commissioning (node

number, baud rate setting, configuration, and node mapping in the network
scanner card).
Switch 1 binary 1
Switch 2 binary 2
Switch 3 binary 4
Switch 4 binary 8
Switch 5 binary 16
Switch 6 binary 32
2. No sort photoeye
State (COS).
11.1.4 DeviceNet Media and Connectors

Kwiklink flat cable and micro bases are DeviceNet media components that
connect DeviceNet components to the network scanner card.
flat cable ties and IDC bases. The flat cable is terminated at the far end of the
cable with a IDC termination base. Each DeviceNet component is connected to
an IDC base installed onto the flat cable.
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11.1.5 Divert Switch Assembly

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11.1.6 Divert Control Module

DCM board
DC power via T1
Inputs via T2
Outputs via T3
panel through the busway rail, through the DCM connector to T1. Note the
voltage polarity.
T1-1
T1-2
T1-3
T1-4
11-12
+48Vdc
48V COM
+24Vdc
24V COM
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The DCM multiport module connects external NON-DeviceNet

components to DCM input circuits.
Divert inductive proximity switch (2)
Jam photoeye (2)
Confirm inductive proximity switch (2)
Dynamic jam PE (1)
2 spare inputs
2 spare outputs
Divert motor connections (2)
Crossover motor and proximity switches
11.1.7 Divert Control Module I/O assignments

Produced Data
Parameter
Description
271
272

273
274
275
276
277
278

287
288
289
290

Bit #
0
1
2
Divert Lt Prox Sensor

Divert Rt Prox Sensor
Full Lane Lt
Full Lane Rt
Full Lt
Full Rt
6
7
8
9
10
Broken Pin Fault

0
0
0
Jam Lt
11
Jam Rt
12
13
14
15
Spare Input 1
Spare Input 2
Confirm Rt
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DCM Consumed Data

Bit #
0
Broken Pin Fault Reset
1
0
2
3
4
5
6
BPF Enable Input 1
7
BPF Enable Input 2
8
0
9
Auto Calibrate Start
10
Auto Calibrate Reset
11
0
12
Spare Output 1
13
Spare Output 2
14
15
Divert Rt Enable Signal
Description

Set Bit To Receive Divert Prox Signals
Reset Bit To Disable Divert Prox Signals
11.1.7.1 Terminal T2 - Inputs

All timers settable range: 0 to 10000ms in increments of 1ms
Pin #
Signal ID
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
DIV LT P
DIV RT P
FULL LT
FULL RT
F LT 3/4
F RT 3/4
CONF LT
CONF RT
XLT PROX
XRT PROX
JAM LT
JAM RT
24V IN
24V IN
Divert Lt Prox
Divert Rt Prox
Full Lane Lt
Full Lane Rt
Full Lt
Full Rt
Confirm Lt Prox
Confirm Rt Prox
Crossover Lt Prox
Crossover Rt Prox
Jam Lt
Jam Rt
Spare Input 1
Spare Input 2
N/C
N/C
11-14
(0 Disable, 1 Off Delay, 2 On Delay) Factory Setting
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
1
1
1
1
5000
5000
5000
5000
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
Disable/OFF/ON
1
1
0
0
5000
5000
5000
5000
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11.1.7.2 Terminal T3 Outputs

PIN #
Signal ID
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
24Vdc
24V COM
+24Vdc
24V common
SPARE
Divert Left
Sraight Left
24V common
Divert Right
Straight Right
24V common
SPARE
Crossover Mtr Left
Crossover Mtr Right
Spare Output 1
Spare Output 2
24V common
24V common
LT DIV
LT STR
LT COM
RT DIV
RT STR
RT COM
X LT
X RT
24V OUT
24V OUT
24V COM
24V COM
11.1.8 Slack Chain and Shoe out of Position Sensors

The slack chain sensor must be configured via DeviceNet for normally closed
operation. When slack in the chain occurs, the output from the sensor goes from
1 to 0.
The shoe out of position sensor must be configured via DeviceNet for normally
open operation. The sensor normally senses a plate, and when a shoe out of
position knocks the plate away from the sensor the output goes from 1 to 0.
In the RSNetworx For DeviceNet software change the communications mode
to Change of State (COS) with node numbers set to 55 and 56 accordingly.
CAUTION:
Be sure the Proximity Switches are flush with plastic or
(preferably) 1/32 recessed. If the sensors are not mounted
properly damage will occur to the sensor surface when the sorter
starts up.
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DripOiler
Spray Oiler
moving flights. Adjust the nozzles horizontally to spray
the lubricant between the side plate and the roller. Use
11.1.10 Pin Greaser

lost.
11-16
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(UPS).
11.1.13 Sorter Power Supplies

11.1.14 Sizing Power Supplies for DCMs


+48Vdc regulated.

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below.)
Divert proxs
Confirm proxs
Full line PEs
Full line PEs
Jam PEs
Example:
no jam PEs
120 0.040 = 4.8 amps
(6 + 4.8 amps = 10.8 amps).

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I/O block.

be set.

be set.
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11.1.19.1 Sort Jam Photoeye (Option) purchase FULL Kit TRA05261-6

Lane Jam photoeyes are located at the infeed end of each divert lane. Since the
the time. Therefore, the sensor input parameter timers must be set to allow the
longest package to pass without activating the sensor. Only when there is a JAM
be set.

The induction photoeye is not a DeviceNet component. The mounting location
on the load belt is determined by the engineer. The signal is discretely wired
back to the sorter control panel (with the encoder power/signal) to a DC input
card in the PLC rack.
11.1.21 Sorter Infeed Broken Pin Kit TRA03801-16 (Option)

pin replaced.
11-20

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switches.
(2).
Mounting hardware.
WhisperSort, use discrete output).
11.1.21.1 Mounting Location
drawing TRP10991.
11.1.21.2 Operation
Note: reset fault refers to broken pin being detected output ON.
Sorter Speed
FPM
DeviceNet
Consumed
Bit
Discrete
Input Point
Bit
400-600
300-400
< 300
10
Fault Output
Reset Fault
P/N 0312996
15
DeviceNet
Produced
Bit
Discrete
Output
Point Bit
Up-stream Prox
Down-Stream Prox
11-21
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11.1.21.3 Mapping I/O



Open DeviceLogix
Start Logic Editor
Enable
Click OK
Close out window
11.1.22 DCM Broken Pin Kit TRA05261-20 (Option)

11.1.22.1 Single Sided Sorter
For a Single Sided Sorter it is necessary to install Broken Pin Kit TRA05261-20
(see drawing TRA05269) directly across from any DCM Proximity Sensor. The
Broken Pin Kit proximity sensor cable is routed across the sorter to the DCM I/O
block and connected to Port 5 or IN2. IN2, DCM Consumed Data bit 7, (BPF
Enable Input 2) must be enabled so the DCM code recognizes this input to be
used for the Broken Pin Fault feature.
11.1.22.2 Dual Sided Sorter

For the Dual Sided Sorter it is NOT necessary to install the Broken Pin Kit
TRA05261-20. The DCM board monitors both the Divert Right and Left Divert
Proximity Sensors to detect a broken pin.
The Broken Pin Fault Code monitors 2 sensor inputs, and the Divert Left and
Right Proximity Sensors. The 2 sensor inputs are disabled from the factory. If
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these inputs are used to detect Broken Pins, DCM consumed data bits 6 and/or 7
must be set.
Enabling a SPEED RANGE DCM Consumed Data bits 2,3,4, or 5 (depending
on sorter speed) activates the Broken Pin Feature. If one of the speed range bits
are NOT set, the Broken Pin Code is NOT activated.
Broken Pin PLC code sequence:
1. Sorter Control Panel Start Button (momentary pulse) sets DCM Consumed
Data bit 0 (Broken Pin Fault Reset) ACTION: Sets the Broken Pin Fault
Bit to 0.
2. Sorter Control Panel Start Button (momentary pulse) Unlatches DCM
Consumed Data bits 2,3,4, or 5 (Speed Bits) ACTION: Disables the Broken
Pin Code.
3. Sorter at speed: When the Sorter is at speed latch one of the DCM
Consumed Data bits 2,3,4 or 5 speed bits. Setting a speed bit enables the
Broken Pin Code. The speed bit should be set only when the sorter is at
speed. Otherwise, a fault will occur during acceleration or deceleration.
Note: Setting any of the DCM Consumed Data bits 2,3,4 or 5 enables the Broken
Pin Code ONLY ONE of the speed bits should be set.
11.1.22.3 Broken Pin Code Operation

Once the sorter is at speed and a speed bit is enabled, a timer starts after each
pin is detected. This timer is reset every time a pin is detected. If a pin is
missing, the timer times out and DCM Product Data bit 6 (Broken Pin Fault) is
set, and the Broken Pin Fault LED on the DCM board is illuminated.
11.1.23 Auto Calibration Information

Bits are provided to START and STOP the Auto Calibration process. These bits
add the Divert Proximity Sensors to the COS mask so they can be read by the
PLC. The Sorter speed must be slow for accurate detection of the divert
proximity signals.
Note: The actual Auto Calibrate PLC code is provided by the end users controls
person.
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11.1.23.1 Concept
Auto calibration; the process of using a pusher shoe and an encoder in
conjunction with a programmable controller to automatically determine and
record (pointer valves) the position of each divert switch.
11.1.23.2 Process
The auto calibration process is initiated during initial startup (or at any time after
startup) by pressing an auto calibrate illuminated pushbutton. Invoking auto
calibrate suspends induction, clears the sorter then begins the calibration process.
The auto calibrate light flashes for the duration. When all divert pointer values
are determined (as compared to PLC mapping table) or the marker shoe reaches
the last divert control module an indicating light continuously illuminates
signaling completion and the sorter is ready to return to auto operation or a fault
condition is annunciated. The set point determination program must be
completed for all divert points (PLC pointer table rebuilt) or the fault condition
resolved before auto operation can be restored. Depressing the system start
button resets the calibration program, sounds the startup alarm and enables
induction to automatically resume.
11.1.23.3 One Time Physical Measurements
During the initial Sorter setup two measurements are required. These
measurements are used to determine the pointers for the first divert switch, and
for a dual sided sorter, the return switch pointer. These pointer values are entered
into the PLC code and remain a constant unless one or both of the following
change. 1) The induction package sensor location changes and/or 2) the location
of the first divert switch inductive proximity switch changes. If either or both of
these locations change, measurements of the new location/s is required, and the
new pointer values calculated and re-entered into the PLC code.
11.1.23.4 Measurement 1
First divert switch inductive proximity switch to induction belt package sensor.
This measurement is used to determine the pointer location of the first divert
switch.
11.1.23.5 Measurement 2 + the Return Switch Dimension
Measure from the end of the Sorter identified in the pictorial below, to the
induction belt package sensor. Contact product engineering for the Dual Sided
Sorter Return Switch dimension. (The Return switch dimension is the same for
all dual sided sorters). Add both dimensions to arrive at the Return Switch
pointer value.
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11.1.23.6 Means
The WhisperSort DeviceNet Divert Control Module uses Change of State (COS)
communications between the Divert Control Module board and the PLC. The
Divert Proximity Signals are not enabled in the COS mask during sorter
operation in order to keep the communications bandwidth low. During the AutoCalibration period this Divert Proximity signal is enabled in the COS mask.
DCM consumed data bit 9 starts Auto Calibration and enables the Divert
Proximity Signals in the COS mask.
DCM consumed data bit 10 disables the Divert Proximity Signals in the COS
mask.
During Auto Calibration the sorter needs to run at a very slow speed (25 fpm).
The low speed ensures that all divert proximity switch signals to be received by
the PLC via COS.
An Encoder pulsing on 2.5 increments provides tracking accuracy.
The PLC has the capacity to maintain two distance measuring tables each equal
to 700 feet X 12/2.5 and encode (64-single sided/128 dual sided) divert switch
set points. The first table contains the current working pointer data. The second is
reserved to record the new pointer readings.
11.1.23.7 Operation
The PLC diverts a group of shoes at the first divert switch , then lets one (1) shoe
through (pointer shoe) then diverts all other shoes. The PLC waits for the single
shoe to signal each divert proximity switch location. This process continues until
all switch positions are calibrated.
Dual Sided sorter calibration same as above
11.1.23.8 Procedure
Initial Sorter Set-up (Steps 1 and 2)
1. Measure distance infeed end of sorter to the induction belt package sensor.
(Enter in PLC)
2. Measure from the first divert switch proximity switch to the induction belt
package sensor. (Enter in PLC)
3. Depress Auto-Calibration button on Control Panel
4. Sorter slows to Auto-Calibration speed of 25 fpm
5. PLC diverts a group of shoes at first divert switch
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6. PLC sends one (1) shoe through first divert switch

7. PLC diverts all other shoes at first divert switch
8. PLC receives each divert switch sensor signal and records the pointer value.
9. The Auto-Calibration is complete when the last divert control proximity
sensor signal is received.
For a 700 foot Sorter, from the time the Auto-Calibration button is
depressed to the time the process is complete should take less than 60
minutes.
11.2 Drawings
The numbered callouts match the tables that follow the drawings. Each table
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11.2.1 WhisperSort General Device Application
11-28
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11-29
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11.2.2 General Device Application (contd)
\
Figure 11-4. General Device Application (contd) (Drawing TRA05282)
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11-31
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11.2.3 Tail Section
11-32
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11-33
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11.2.4 Intermediate
11-34
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P/N 0312996
11-35
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11.2.5 Catenary
11-36
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P/N 0312996
11-37
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11.2.6 Drive
11-38
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P/N 0312996
11-39
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11.2.7 Divert Module
11-40
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P/N 0312996
11-41
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11.2.8 Broken Pin Kit
11-42
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P/N 0312996
11-43
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11.3.1 Divert Switch Part Numbers
11.3.2 Slack Chain/Shoe Out of Position Proximity Switch Kit (Kit TRA03801-2)
REF
#
QTY.
REQ.
VENDOR
PART NO.
HK SYSTEM
PART #
11-44
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11.3.3 Divert Confirm Proximity Switch Kit (Kit TRA03801-3)
P/N 0312996
11-45
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11.3.4 Dynamic Jam Photoeye Kit (Kit TRA05261-4)
11-46
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11.3.5 End-of-Sorter Photoeye Kit (Kit TRA03801-5)
P/N 0312996
11-47
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11.3.6 Full Line Photoeye Kit (Kit TRA05261-6)
11-48
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11.3.7 3/4 Full Line Photoeye Kit (Kit TRA05261-7)
P/N 0312996
11-49
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11.3.8 Induction Photoeye Kit (Kit TRA05261-9)
11-50
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P/N 0312996
11-51
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11.3.14 Broken Pin Detector Assembly (Kit TRA03801-16)
Figure 11-24. Broken Pin Detector Assembly (Kit TRA03801-16)
P/N 0312996
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11.3.15 Crossover Motor Kit (Kit TRA04021-17)
Figure 11-25. Crossover Motor Kit (Kit TRA04021-17)
11.3.16 Divert Control Module Kit Set-Up Switch (Kit TRA05281-19)
Figure 11-26. Divert Control Module Kit Set-Up Switch (Kit TRA05281-19)
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glass.
11.4.1 Sorter Power Check List

baud rate settings.
2. Ensure all DCM T1 connectors are disconnect from the board.
conductors.
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11.4.2 Sorter DCM DC Power Check List

+24Vdc).
scanlist.
11.4.3 Sorter DeviceNet System Check List

package.
4. For the divert control module EDS file (EDS file: 0316992.eds), contact the
(1-800-354-9795).
network scan list.
track nodes if DCM 1 is in word 1, DCM 2 is in node 2, etc. (The produced
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11.4.4 Chain Oiler

11.4.5 Spray Oiler (Optional)

Pump Cycles/Min
Overall Length (Ft)
Speed
P/N 0312996
30 150
151 300
301 and Greater
501-600
FPM
12
401-500
FPM
10
350-400
FPM
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11.4.6 Pin Greaser

of operation are:
P1=0
P2=20
P3=3
P1=2
P2=0
P3=1
11.4.7 Start Up
on all sorters. As soon as direction of travel has been established tracking of the
induction belt should be done as soon as possible to prevent damage to the belt.
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Chapter 12
Troubleshooting
WhisperSort
Chapter 12 - Troubleshooting

12.0
Troubleshooting Guide.....................................................................................................................12-3
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12.0 Troubleshooting Guide

If you experience problems with your sorter, refer to the troubleshooting guide in
this chapter to assist you in correcting those problems. The following table is
designed to help you pinpoint the source of possible problems, as well as to
provide you with information on how to correct them. If your problem is not
listed, or if you require further explanation, please contact our Customer Service
department.
Always follow good conveyor safety practices.
Never perform maintenance on a running conveyor.
Always replace guards and covers after maintenance.
Note: You must have a basic knowledge of conveyor equipment operation and/or
maintenance to properly use and understand the information presented in the
following table.
Where applicable, follow specific manufacturers recommendations for
individual components supplied as part of the material handling system.
Problem
Possible Cause
Correction
Excessive noise in the divert

switch
Excessive noise in drive
section
Switch arm out of alignment

or bumpers worn out.
Side bearing wear strip out of
alignment.
Wheel track out of alignment.
Drive shaft out of square.
Excessive catenary chain
slack.
Sprocket teeth out of time
with each other.
Sprockets misaligned
UHMW track out of
alignment.
Tail shaft out of square.
Side bearing wear strip out of
alignment.
Wheel track out of alignment.
Adjust or replace bumpers.
Excessive noise in tail section
Erratic shoe count

during divert
P/N 0312996
Sprockets misaligned
Faulty divert module board.
Realign side bearing wear strip

with catenary.
Realign wheel track with catenary.
Square drive shaft to frame.
Tighten chain.
Reset sprocket teeth with phasing
sprocket and tighten chain.
Align sprockets.
Realign track with intermediate.
Square shaft to frame.
Realign side bearing wear strip
with catenary.
Realign wheel track with the first
section.
Align sprockets.
Replace board.
12-3
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Problem
Possible Cause
Correction
WhisperSort will not run
Power interrupted due to

drive overload.
Drive fault.
Jam at discharge.
Shoe out of position.
Check control panel.
Drive fault
Divert pin breaks
Noisy switches
Chain slack detection in

catenary
Obstruction in pin path.
Product jam.
Switch out of adjustment.
Divert module control board
failure.
Proximity sensor failure or
out of position.
Damage to machined items
located in switch.
Loose hardware.
Reset processor.
Clear jam and restart.
Replace defective shoe and reset
deflector bar.
Adjust chain tension.
Remove obstruction.
Clear jam and reset processor.
Check switch hardware.
Replace board.
Be sure the proximity sensor is in
the proper location and that the
hardware is secure.
Check alignment and replace
damaged parts.
Tighten hardware and check motor
operation.
NOTE: Please refer to the vendor documentation (or to the

information plate which is attached to the motor or reducer)
for troubleshooting gearmotors.
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Chapter 13
Illustrated Spare Parts
When ordering spare parts,

due to our continuous improvement initiatives,
please check the Recommended Spare Parts List
that was generated with your order, or contact
HK Systems, for verification of part numbers.
WhisperSort

General Arrangement Dual Sided (TRA04321)
General Arrangement BOM & Qty Chart Dual Sided (TRA04322)
Intermediate Assembly (TRA03581)
Intermediate Assembly Into Tail (TRA03641)
Drive Section RH & LH (TRA03651)
End Discharge Gravity Roller Assembly (TRA04891)
EndDischarge Gravity Roller Assembly (TRA04892)
Pusher Assembly (TRA03141)
Return Guide Assembly LH & RH (TRA03681)
Return Guide Assembly Dual Sided (TRA04391)
Switch Assembly 7" Rad Arm LH (TRA04761)
Switch Assembly RH W/7" Rad Arm (TRA04811)
Vertical Transition Assembly (TRA03991)
Pusher out of Place RH Assy Dual & RH Divert (TRA05171)
Pusher out of Place LH Assembly (TRA05172)
Broken Pin Detector Kit (TRA03881)
Broken Pin Prox Installation Kit Single Sided (TRA05291)
P/N 0312996
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Chapter 13 - Illustrated Parts List
13-2
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13.0 Illustrated Parts List

This chapter of the manual identifies WhisperSorts top level assemblies.
P/N 0312996
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Chapter 13 - Illustrated Parts List
13-4
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MATERIAL LIST FOR:
B/B (EW + 22)
11
12
14
13
SEE FORMULA
2
17
18
REF
F
G
M6-1 NUT CLIP P/N 0314867 (REF)
SEE SHT 7 FOR

INSTALLATION
INSTRUCTIONS
31
23
42
SEE CHART
SEE CHART
TRP10291
11
12
VIEW "Y-Y"
ENLARGED 30X
WSHR LOCK M6
W07861
EA
WSHR FLAT M6
B20555
17
18
CUT WEARSTRIP @ 45^
TRACK ENDS ARE PRE-CUT @ 45^
45%%
45%%
23
REF 22 SPLICE DETAIL
ENLARGED 30X
W07630
TRP10281
22
0317033
*
EA
24
25
26
TRP12811
27
SEE NOTE 3
EA
TRP12391
0315322
EA
29
0315958
30
0315873
20
EA
EA
32
0317245
0314876
EA
EA
TRP12811
CHAIN PULLER BAR
B01500
3M PREP SOLVENT-70 CLEANER GAL
EA
TRP12391
T-HANDLE SLAT FIXTURE
EA
28
31
TRP13031
TRP12241
GRAVITY SPUR MTG BRACKET
WEARSTRIP SIDE .020 X 1 X 100
ALUM WHEEL TRACK W/ TAPE X 12
EA
TRA04791
TRP10281
MOUNTING BRACKET POWER SPURS
EA
SEE CHART
DIVERT MODULE KIT
GUIDE ANG CAM 144" LG
EA
WSHR FLAT 3/8
BRKT SPUR MTG
EA
TRP12241
EA
TRP13032-144
NUT NYLOCK 3/8-16
EA
23
BOLT CRG 3/8-16X1
EA
SEE FORMULA
NOTES:
DETAIL "B"
EA
SEE CHART
20
T-BOLT M8X1.25X24MM W/ 2 NUTS
3M 7447 SCOTCH-BRITE PAD 20 CT

COTTER PIN RC100 CONN LINK
TAPE 3M 4941 VHB .045X3/4X108
1)
SEE DRAWING TRA04321 FOR GENERAL ARRANGEMENT OF DUAL-SIDED SORTER.
2)
SEE THE FOLLOWING DRAWINGS FOR GENERAL ARRANGEMENT OF ELECTRICAL COMPONENTS:

TRA03801 (DEVICENET); TRA04031 & TRA04041 (DISCRETE WIRED)
ENLARGED 8X
L.H. SLAVE DRIVE
G 3)
(SHOWN)
REF 27 NOT REQD FOR SORTERS UNDER 50 FT LG. FOR SORTERS OVER 50 FT LG, SUPPLY
P/N B01503 FOR 46 B/B, P/N B01504 FOR 52 B/B, & P/N B01505 FOR 58 B/B.
20^ SPUR REF
L 4)
SEE SHT 2 FOR OPTIONAL MATERIAL.
20
B
E
TRAVEL
LOAD BELT (REF)
SEE DWG #TRA03863 & 4
21
PLAN VIEW
FOR DETAILS
LOAD BELT (REF)
16 - 9" TAIL ASSEMBLY (REF 1)
4-9"
12-0"
TAIL INTERMEDIATE W/SWITCH
** SIDE DISCHARGE
(ODD LENGTH = 1FT - 11FT
INTERMEDIATE
TAIL SECT.
**
19-0" DRIVE ASSEMBLY (REF 6)
SORTERS OVER
12-0" CATENARY SECTION
IN 1FT INCREMENTS)
7-0" DRIVE SECT
H
NOT REQD FOR SORTERS
UNDER 50 FT LG
(REF 5)
50 FT LG REQUIRE
FIXED DIVERT IN
CATENARY SECTION
CHR930004
L01793
CHR930005
2:19:42 PM
CHR930009
Y
C
ECO #TR21-137
NOTE: ADD (2) SUPPORT LEGS

UNDER TAIL SECTION PER DWG
TRP12161 FOR ELEVS OVER 40"
TR7-1057
SEE SHTS 3 THRU 8
5/9/07
RTS
TR7-1072
SEE SHTS 3 & 4
7/12/07
RTS
OR
PAINT NOTE:
TOLERANCES
DATE
OR
BOM NUMBER:
DWN
K.DAY
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
05/25/2001
SCALE
3/8" = 1-0"
ALL PARTS MUST BE FREE

OF BURRS AND SHARP EDGES

UNDER DRIVE SECTION PER DWG
CAD/CAM DRAWING DO NOT MANUALLY CHANGE

DASH
NEXT ASSY
NUMBER
NUMBER
THIRD ANGLE PROJECTION
NOTICE: "THIS DRAWING AND THE DATA SHOWN

THEREON ARE PROPRIETARY AND CONFIDENTIAL
AND ARE NOT TO BE USED NOR REPRODUCED
FOR ANY PURPOSE WITHOUT THE EXPRESSED
WRITTEN CONSENT OF HK SYSTEMS INC."
BY
GENERAL ARRANGEMENT
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
WHISPERSORT - SINGLE SIDED
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03861
D-SIZE
DRAWING TITLE:
CHKD
BY
(UNLESS OTHERWISE NOTED)

U.S. CUSTOMARY UNITS
REVISION
OR
ELEVATION VIEW
OF
MICROSTATION
38
MIN ELEV
18
FOR DETAILS
12-0" TYP
REV
17
12-0" TYP
ECO NUMBER
16
O.A.L.
15
TRAVEL
SEE DWG. #BLA03441
10
R.H. DRIVE (SHOWN)
FOR DETAILS
10/1/2007
ENLARGED 30X
N36625
EA
TRP10291
TRP13381
SCR HHC M6-1 X 20 MM FTHD
14
L
22
EA
TRA04851
COVER WHEEL 12 LG
EA
21
31
TRA03681
FLIGHT CHAIN ASSY 120" LG
19
32
ENLARGED 4X
GUIDE RETURN ASSY
TRA03651
SHHD-00-00
burleson
DETAIL "A"
EA
W09148
16
CHART ON DWG
*SEE
TRA03862 FOR QTY
SHHD SUPPORT ASSY
EA
TRA03581
TRA03651
DRIVE SECT W/CATENARY & SWITCH
13
0312815
TRA03581
TRA03581
MTG PLATE FOR CAM GUIDE ANGLE
0314868
TRA03981
DRIVE SECT W/O CATENARY
15
EA
DRWNG NUM
EA
EA
TRP13381
15
3/4
EA
DESCRIPTION
SECT SORTER INTRM W/ SWITCH
EA
UM
TAIL ASSY W/INTER & SWITCH
SECT SORTER INTRM 144" LG
EA
*
SEE CHART
10
SECT SORTER INTRM ODD LENGTH
EA
SEE FORMULA
EA
SEE FORMULA
LENGTH
EA
SEE FORMULA
QTY
SEE CHART
22
L
7 5/16
SEE CHART
18
OPTIONAL BOTTOM COVER REF 45
GEN ARRANGEMENT-SINGLE SIDED WHISPERSORT
REV REF# PART NUMBER

16
OPTIONAL CATCH SCREEN

REF 41 (SEE SHT 3)
43
\\hebfil04\tech-pub$\product documentation\whispersort_tr08\1-whispersort_oct2007\ch13-illuspartslist\microstation\cp_tra03861.dgn
REF
1 1/16
QTY PER SORTER OVER 50 FT LG (O.A.L. IN FT)
3
L
MATERIAL LIST FOR:

REF #2
(O.A.L. - 35.75)/12 - (QTY REF #3 + QTY REF #4)

(ROUND UP) NOTE: ALWAYS 0 OR 1
REF #3
(O.A.L. - 35.75)/12 - QTY REF #4
41
SEE CHART
42
(ROUND DOWN)
NO. OF DIVERTS - 2 OR (O.A.L. - 35.75)/12
REF #5
QTY = 0
QTY = 1
REF #7
QTY OF REF #2 + QTY OF REF #3 + QTY OF REF #4 + 1
REF #9
(((O.A.L. - 3) X 2 + 6.25)/10) + 1 (ROUND UP)
20^ SPUR
(ROUNDED DOWN) WHICHEVER IS LESS
REF #6
REF #10
QTY OF REF #21 X 3
REF #11
O.A.L./6 (ROUND UP)
REF #12
QTY OF REF #11 X 9
REF #13
QTY OF REF #12
REF #19
30^ SPUR
B/B
DWG & PART NO.
DWG & PART NO.
46
TRP10831
TRP10811
52
TRP10831
TRP10821
58
TRP10811
TRP10831
SEE CHART
43
0317277
44
C00933
QTY
LENGTH
10
EA
QTY OF REF #12

QTY OF REF #10 X 2 + QTY OF REF #45 X 6
REF #16
QTY OF REF #10 X 2 + (NO. OF DIVERTS X "Q") FOR SKATEWHEEL SPURS OR
REF #2 & #3
L
L
POWERED SPURS + QTY OF REF #42 X 4

QTY OF REF #10 X 2 + (NO. OF DIVERTS X "Q") + QTY OF REF #42 X 4
REF #18
QTY OF REF #17
REF #19
NO. DIVERTS (X 2 FOR 20^ 58" B/B ONLY)
REF #8
B/B
QTY OF REF #10 X 2 + (NO. OF DIVERTS X ("Q" - (2 X "R"))) FOR
REF #17
REF #7
REF #9
RH
LH
SEE CHART
46
SEE CHART
3**
47
SEE CHART
QTY
LENGTH
EA
EA
2**
UM
DESCRIPTION
REF #21
CATENARY BOTTOM COVER
NO. OF DIVERTS - 2 - QTY OF REF #4
OPTIONAL ITEMS
REF 42
REF 45
REF 46
REF 47
"A"
PART NO.
PART NO.
PART NO.
PART NO.
TRA03581-46XX
SHHD-46XX
TRA03681-46R
TRA03681-46L
TRA04851-46
46
TRA03863-001
24
TRP15021-46
TRP15031-46
TRP15041-46
TRP15051-46
52
TRA03581-52XX
SHHD-52XX
TRA03681-52R
TRA03681-52L
TRA04851-52
52
TRA03863-002
30
TRP15021-52
TRP15031-52
TRP15041-52
TRP15051-52
58
TRA03581-58XX
SHHD-58XX
TRA03681-58R
TRA03681-58L
TRA04851-58
58
TRA03863-002
30
TRP15021-58
TRP15031-58
TRP15041-58
TRP15051-58
(QTY = 0 IF LESS THAN 0)
(ROUND UP)
((O.A.L. - 35.75) X 4 + 60)/100
REF #23
((O.A.L. - 35.75) X 4 + 60)/12
REF #24
NO. DIVERTS X "R" (NOT REQD FOR SKATEWHEEL SPURS)
NOTE: MUST BE IN 2 INCH INCREMENTS ONLY
(ROUND UP)
(20" MIN, 42" MAX)

SUPPORT HEIGHT = TOP OF SORTER - 19"
(ROUND UP)
REF #25
NO. DIVERTS X "R" (NOT REQD FOR POWERED SPURS)
REF #31
((O.A.L. - 35.75) X 4 + 60)/108
REF #32
QTY OF REF #7 X 4
(ROUND UP)
"XX" = INTERMEDIATE LENGTH (FT)

ODD LENGTH (FT) = (O.A.L. - 35.75 OR 23.75) 12 X (QTY OF REF #3 + QTY OF REF #4)
MUST BE IN 1 FT INCREMENTS ONLY (1 FT MIN)
REF #41
((O.A.L. - 9.5) X 2)/9.75
REF #42
((O.A.L. - 9.5)/3) + 1
REF #43
QTY OF REF #42 X 3
(O.A.L. - 27.25)/4
REF #
REF #2
SORTER W/
SORTER W/O
B/B
CATENARY
CATENARY
46
38-9"
26-9"
52
41-9"
29-9"
58
43-9"
31-9"
USE 35.75 FOR SORTERS OVER 50 FT LG
USE 23.75 FOR SORTERS UNDER 50 FT LG
QTY OF REF #42 - 1
MINIMUM OVERALL LENGTH
"XX" = SUPPORT HEIGHT (INCHES)
SEE SHT 5 OR 6 FOR DIMS
REF #22
REF #44
46
(O.A.L. - 6.75 - (2.5 X NO. DIVERTS) + (DIM "G" + DIM "D"
REF #45
TRP15051
- DIM "C")/12 - 2)/12
TRP15041
** QTY OF REF 46 IS 1 & QTY OF REF 47 IS 0 W/O CATENARY
PART NO.
TRP15031
CATENARY/TAIL BOTTOM COVER
G
REF #20
DRAWING NUMBER
INTERMEDIATE BOTTOM COVER
EA
REF 41
B/B
TRP15021
OPTIONAL BOTTOM COVER
45
DRAWING NUMBER
CABLE TIE NYLON 7" LG
REF #14
REF #15
DESCRIPTION
SCR SELF DRILL & TAP 1/4 X 3/4
EA
* SEE CHART FOR QTY
UM
SHEET EXPANDED METAL X "A"
CATCH SCREEN SUPPORT ANGLE
EA
MATERIAL LIST FOR:
FT
(ROUND UP)
(ROUND UP)
ITEM #1 P/N DESIGNATION:

TRA03981- XX
E
(ROUND UP)
XX
P
SPECIFY FOR PIN LUBRICATOR
(REQD FOR SPEEDS OVER 350 FPM)
QTY PER SORTER UNDER 50 FT LG (O.A.L. IN FT)
TRA04791- XX XX X
(L) LH SLAVE DRIVE

(R) RH SLAVE DRIVE
(O.A.L. - 23.75)/12 - (QTY REF #3 + QTY REF #4)

(L) LEFT DIVERT

(R) RIGHT DIVERT
REF #3
REF #4
(O.A.L. - 23.75)/12 - QTY REF #4
(ROUND DOWN)
(L) LH DIVERT/LH TAIL ASSY
NO. OF DIVERTS - 1 OR (O.A.L. - 23.75)/12
(R) RH DIVERT/RH TAIL ASSY
(20) 20^ DIVERT
(ROUNDED DOWN) WHICHEVER IS LESS
(30) 30^ DIVERT

(20) 20^ DIVERT
REF #5
QTY = 1
REF #6
QTY = 0
REF #7
QTY OF REF #2 + QTY OF REF #3 + QTY OF REF #4
REF #9
(((O.A.L. - 3) X 2 + 6.25)/10)
(46) 46" B/B
(52) 52" B/B

(58) 58" B/B
REF #10
QTY OF REF #21 X 3
REF #11
O.A.L./6 (ROUND UP)
REF #12
QTY OF REF #11 X 9
REF #13
QTY OF REF #12
REF #14
QTY OF REF #12
REF #15
REF #16
QTY OF REF #10 X 2 + (NO. OF DIVERTS X "Q") FOR SKATEWHEEL SPURS OR
B
L
L
(L) LEFT DIVERT
QTY OF REF #10 X 2 + (NO. OF DIVERTS X "Q") + QTY OF REF #42 X 4
REF #18
QTY OF REF #17
(20) 20^ DIVERT
NO. DIVERTS (X 2 FOR 20^ 58" B/B ONLY)
(30) 30^ DIVERT
NO. OF DIVERTS - 1 - QTY OF REF #4
(46) 46" B/B
(O.A.L. - 6.75 - (2.5 X NO. DIVERTS) + (DIM "G" + DIM "D"
(52) 52" B/B
- DIM "C")/12 - 2)/12
(58) 58" B/B
(ROUND UP)
SEE SHT 5 OR 6 FOR DIMS
REF #22
((O.A.L. - 23.75) X 4 + 36)/100
REF #23
((O.A.L. - 23.75) X 4 + 36)/12
REF #24
NO. DIVERTS X "R" (NOT REQD FOR SKATEWHEEL SPURS)
REF #25
NO. DIVERTS X "R" (NOT REQD FOR POWERED SPURS)
REF #31
((O.A.L. - 23.75) X 4 + 36)/108
REF #32
QTY OF REF #7 X 4
((O.A.L. - 9.5) X 2)/9.75
((O.A.L. - 9.5)/3) + 1
REF #43
QTY OF REF #42 X 3
REF #44
QTY OF REF #42 - 1
REF #45
(O.A.L. - 15.25)/4
20^ DIVERT (20)

30^ DIVERT (30)
NO CATENARY (LEAVE BLANK)
GEARBOX:
(N) NORD - STANDARD
(E) EURODRIVE - OPTIONAL
LEFT DIVERT (L)

RIGHT DIVERT (R)
G
(ROUND UP)
LEFT HAND DRIVE (L)

RIGHT HAND DRIVE (R)
(ROUND UP)
QTY "R"
QTY "Q"
(ROUND UP)
DIVERT ANGLE
(ROUND UP)
(ROUND UP)
(PER CHART ABOVE)
END DISCHARGE (E)
(H THRU N) HORSEPOWER P/N CODE
SIDE DISCHARGE W/ FIXED DIVERT (S)
DIVERT ANGLE
B/B
20^
30^
B/B
46
10
46
52
10
52
58
14
10
58
20^
(J THRU R) SPEED P/N CODE
(PER CHART ABOVE)
30^
2:19:46 PM
REF #41
REF #42
B/B (46, 52 & 58)
(R) RIGHT DIVERT
REF #17
REF #21
TRA03651-XX XX X X X X X X
TRA03581- XX XX X
POWERED SPURS + QTY OF REF #42 X 4
REF #19
ITEM #5 & #6 P/N DESIGNATION:
QTY OF REF #10 X 2 + (NO. OF DIVERTS X ("Q" - (2 X "R"))) FOR
REF #20
(46) 46" B/B
(58) 58" B/B
(ROUND UP)
(ROUND UP)
ECO #TR21-137
TR6-1074
REVISED QTY FOR REF 15-18; ADDED REF 31,32, & 41-45
11/16/06
RTS
TR7-1057
SEE SHTS 3 THRU 8
5/9/07
RTS
TR7-1072
SEE SHTS 3 & 4
7/12/07
RTS
PAINT NOTE:
TOLERANCES
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
K.DAY
05/25/2001
SCALE

DRAWING TITLE:
CHKD
BY
DATE
GENERAL ARRANGEMENT BOM & QTY CHART
APPD
PRODUCT OR MODEL:
WEIGHT:
BY
N/A

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT - SINGLE SIDED
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03862
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
(30) 30^ DIVERT
(52) 52" B/B
10/1/2007
REF #4
burleson
REF #
MATERIAL LIST FOR:
B/B (EW + 22)

16

REF 41 (SEE SHT 3)
11
12
14
13
SEE FORMULA
17
SEE CHART
3
4
43
22
REF
7 5/16
M6-1 NUT CLIP P/N 0314867 (REF)
SEE SHT 7 FOR

INSTALLATION
INSTRUCTIONS
34
42
SEE CHART
TRP10291
11
TRP13381
12
VIEW "Y-Y"
DETAIL "A"
22
WSHR LOCK M6
WSHR FLAT M6
18
24
25
45%%
D
D
D
ENLARGED 30X
DETAIL "B"
*
*
SEE FORMULA
TRP10281
0317033
EA
EA
EA
EA
L39998
EA
SEE CHART
TRA04841
GUIDE ANG CAM 144" LG
TRP10281
WEARSTRIP SIDE .020 X 1 X 100
ALUM WHEEL TRACK W/ TAPE X 12
TRP13031
MOUNTING BRACKET POWER SPURS
EA
WSHR FLAT 3/8
BRKT SPUR MTG
CROSSOVER DIVERT MODULE KIT
EA
TRP12391
26
NUT NYLOCK 3/8-16
EA
TRP13032-144
BOLT CRG 3/8-16X1
EA
TRP12241
GRAVITY SPUR MTG BRACKET
EA
TRP12391
LOCTITE #24231 50 ML BOTTLE
SEE FORMULA
28
TRP12811
29
EA
EA
SEE NOTE 3
31
ENLARGED 30X
32
0315958
33
0315873
20
EA
EA
0315322
34
35
EA
0317245
0314876
SINGLE DIVERT MODULE KIT
EA
EA
TRP12811
CHAIN PULLER BAR
B01500
12INTERMEDIATE W/ SGL DIVERT
TRA03581
3M PREP SOLVENT-70 CLEANER GAL
EA
TRA04791
T-HANDLE SLAT FIXTURE
EA
30
ENLARGED 8X
SEE FORMULA
L.H. SLAVE DRIVE

(SHOWN)
(TYP. BOTH ENDS)
27
3M 7447 SCOTCH-BRITE PAD 20 CT

COTTER PIN RC100 CONN LINK
TAPE 3M 4941 VHB .045X3/4X108
20^ SPUR REF
27
TRAVEL
B
B
LOAD BELT (REF)
B
R.H. DRIVE (SHOWN)
FOR DETAILS
10
15
16
NOTES:
17
FOR DETAILS
LOAD BELT (REF)
1)
SEE DRAWING TRA03861 FOR GENERAL ARRANGEMENT OF SINGLE-SIDED SORTER.
2)
SEE THE FOLLOWING DRAWINGS FOR GENERAL ARRANGEMENT OF ELECTRICAL COMPONENTS:
SEE DWG. #BLA03441
21
PLAN VIEW
TRA04011 & TRA04021 (DEVICENET); TRA04061 & TRA04071 (DISCRETE WIRED)
FOR DETAILS
D 3)
REF 29 NOT REQD FOR SORTERS UNDER 50 FT LG. FOR SORTERS OVER 50 FT LG, SUPPLY
P/N B01503 FOR 46 B/B, P/N B01504 FOR 52 B/B, & P/N B01505 FOR 58 B/B.
O.A.L.
16 - 9" TAIL ASSEMBLY (REF 1)
12-0" TYP
4-9"
12-0"
TAIL SECT.
TAIL INTERMEDIATE W/SWITCH
**
12-0" TYP
19-0" DRIVE ASSEMBLY (REF 6)
**
(ODD LENGTH = 1FT - 11FT
INTERMEDIATE
12-0" CATENARY SECTION
IN 1FT INCREMENTS)
MUST BE A FULL 12 INTERMEDIATE

TO INSTALL THE RETURN GUIDES
NOT REQD FOR SORTERS

UNDER 50 FT LG
7-0" DRIVE SECT

(REF 5)
END DISCHARGE
DRIVE SECTION
ONLY (NO FIXED
DIVERT IN
CATENARY).
CHR930004
L01793
CHR930005

UNDER TAIL SECTION PER DWG
ECO #TR1-1041
TR7-1057
SEE SHTS 3 THRU 8
5/10/07
RTS
TR7-1072
SEE SHTS 3 & 4
7/12/07
RTS
OR
PAINT NOTE:
TOLERANCES
REV
DATE
REVISION
OR

UNDER DRIVE SECTION PER DWG
BOM NUMBER:
DWN
BREWER T.
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
4/1/02
SCALE
3/8"=1-0"

DRAWING TITLE:
CHKD
BY
GENERAL ARRANGEMENT
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT - DUAL SIDED
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04321
D-SIZE
BY

ECO NUMBER
OR
ELEVATION VIEW
OF
10/1/2007
2:22:18 PM
TRAVEL
CHR930009
MICROSTATION
38
MIN ELEV
burleson
EA
SEE CHART
TRP12241
W07630
22
23
N36625
TRP13381
45%%
C
C
20
EA
B20555
17
23
SCR HHC M6-1 X 20 MM FTHD
EA
TRACK ENDS ARE PRE-CUT @ 45^
EA
TRP10291
COVER WHEEL 12 LG
W07861
TRA04851
EA
14
21
CUT WEARSTRIP @ 45^
FLIGHT CHAIN ASSY 120" LG
H
34
TRA04391
EA
35
ENLARGED 4X
GUIDE RETURN ASSY
MTG PLATE FOR CAM GUIDE ANGLE
TRA03651
SHHD-00-00
0312815
TRA03581
TRA03651
SHHD SUPPORT ASSY
W09148
19
ENLARGED 30X
TRA03581
13
16
EA
0314868
12INTERMEDIATE
DRIVE SECT W/CATENARY & DIVERT
EA
EA
TRA03981
TRA03581
DRIVE SECT W/O CATENARY
EA
DRWNG NUM
15
SEE CHART ON DWG

TRA04322 FOR QTY
EA
DESCRIPTION
12INTERMEDIATE W/CROSS DIVERT
EA
UM
TAIL/INTERMEDIATE W/ DIVERT
EA
SEE CHART
ODD LENGTH INTERMEDIATE
EA
*
SEE CHART
15
3/4
*
*
SEE FORMULA
10
23
OPTIONAL BOTTOM COVER REF 45
EA
SEE FORMULA
LENGTH
EA
SEE CHART
QTY
SEE FORMULA
18
D
D
18
GEN ARRANGEMENT - DUAL SIDED WHISPERSORT
REF
1 1/16
QTY PER SORTER OVER 50 FT LG (O.A.L. IN FT)
REF #2
REF #3
(O.A.L. - 35.75)/12 - (QTY OF REF #4 + QTY OF REF #30)
REF #4
QTY "Q"
(ROUND DOWN)
20^
30^
B/B
46
10
46
OR (O.A.L. - 35.75)/12 (ROUND DOWN) WHICHEVER IS LESS

QTY = 0
REF #6
QTY = 1
REF #7
QTY OF REF #2 + QTY OF REF #3 + QTY OF REF #4 + QTY OF REF #30 + 1
REF #9
(((O.A.L. - 3) X 2 + 6.25)/10) + 1
10
58
QTY OF REF #21 X 3
REF #11
O.A.L./6 (ROUND UP)
REF #12
QTY OF REF #11 X 9
REF #13
QTY OF REF #12
REF #14
QTY OF REF #12
20^
30^
52
14
58
10
ITEM #5 & #6 P/N DESIGNATION:

TRA03651-XX XX X X E X X X
B/B (46, 52 & 58)
REF #16
QTY OF REF #10 X 2 + (NO. OF CROSSOVER DIVERTS X (2 X "Q")) + (NO.
20^ DIVERT (20)

30^ DIVERT (30)
SINGLE DIVERTS X "Q") FOR SKATEWHEEL SPURS OR QTY OF REF #10 X 2 +
REF #3
(O.A.L. - 23.75)/12 - (QTY OF REF #4 + QTY OF REF #30)
(NO. CROSSOVER DIVERTS X ((2 X "Q") - (4 X "R"))) + (NO. SINGLE DIVERTS
NO. OF CROSSOVER DIVERTS - (NO. OF CROSSOVER DIVERTS IN REF 1)
QTY = 1
REF #6
QTY = 0
REF #7
QTY OF REF #2 + QTY OF REF #3 + QTY OF REF #4 + QTY OF REF #30
REF #9
(((O.A.L. - 3) X 2 + 6.25)/10)
REF #10
QTY OF REF #21 X 3
REF #11
O.A.L./6 (ROUND UP)
REF #12
QTY OF REF #11 X 9
REF #13
QTY OF REF #12
REF #14
QTY OF REF #12
REF #15
REF #16
QTY OF REF #10 X 2 + (NO. OF CROSSOVER DIVERTS X (2 X "Q")) + (NO.
(NO. CROSSOVER DIVERTS X ((2 X "Q") - (4 X "R"))) + (NO. SINGLE DIVERTS

X ("Q" - (2 X "R"))) FOR POWERED SPURS + QTY OF REF #42 X 4
+ (NO. OF SINGLE DIVERTS X "Q") + QTY OF REF #42 X 4
REF #18
QTY OF REF #17
REF #19
NO. CROSSOVER DIVERTS X 2 (X 4 FOR 20^, 58" B/B ONLY)

+ NO. SINGLE DIVERTS (X 2 FOR 20^, 58" B/B ONLY)
GEARBOX:
(N) NORD - STANDARD
REF #17

LEFT HAND DRIVE (L)
NO. OF CROSSOVER DIVERTS - (NO. OF CROSSOVER DIVERTS IN REF 1 & 6)

- QTY OF REF #4
(ROUND UP)
SINGLE DIVERTS X "Q") FOR SKATEWHEEL SPURS OR QTY OF REF #10 X 2 +
LEFT DIVERT (L)

RIGHT DIVERT (R)
DUAL DIVERT (D)
QTY OF REF #10 X 2 + (NO. OF CROSSOVER DIVERTS X (2 X "Q"))
REF #20
REF #5
X ("Q" - (2 X "R"))) FOR POWERED SPURS + QTY OF REF #42 X 4

REF #17
(ROUND DOWN)
REF #2
REF #4
(ROUND UP)
REF #15
QTY PER SORTER UNDER 50 FT LG (O.A.L. IN FT)
(O.A.L. - 23.75)/12 - (QTY OF REF #3 + QTY OF REF #4 + QTY OF REF #30)

OR (O.A.L. - 23.75)/12 (ROUND DOWN) WHICHEVER IS LESS

52
REF #5
QTY "R"
DIVERT ANGLE
B/B
NO. OF CROSSOVER DIVERTS - (NO. OF CROSSOVER DIVERTS IN REF 1 & 6)
REF #10
REF #
(O.A.L. - 35.75)/12 - (QTY OF REF #3 + QTY OF REF #4 + QTY OF REF #30)

DIVERT ANGLE
QTY OF REF #10 X 2 + (NO. OF CROSSOVER DIVERTS X (2 X "Q"))

+ (NO. OF SINGLE DIVERTS X "Q") + QTY OF REF #42 X 4
REF #18
QTY OF REF #17
REF #19
NO. CROSSOVER DIVERTS X 2 (X 4 FOR 20^, 58" B/B ONLY)

+ NO. SINGLE DIVERTS (X 2 FOR 20^, 58" B/B ONLY)
(PER CHART ABOVE)
NO. OF CROSSOVER DIVERTS - (NO. OF CROSSOVER DIVERTS IN REF 1)
REF #20
END DISCHARGE
- QTY OF REF #4
(PER CHART ABOVE)

REF #21
((2 X (O.A.L. - 6.75 - (NO. OF CROSSOVER DIVERTS X DIM "C"/12)))
REF #22
(O.A.L. - 35.75) X 4 + 60)/100
NOTE: DO NOT USE SIDE DISCHARGE
(O.A.L. - 35.75) X 4 + 60)/12
REF #24
NO. CROSSOVER DIVERTS X 2 X QTY "R" + NO. SINGLE DIVERTS X QTY "R"
(ROUND UP)
D
NOT REQD FOR SKATEWHEEL SPURS
REF #25
NOT REQD FOR POWERED SPURS
REF #26
QTY = 1 IF QTY OF REF #20 IS GREATER THAN 0
REF #27
NO. OF SINGLE DIVERTS - (NO. OF SINGLE DIVERTS IN REF 1 & 6)
REF #30
- QTY OF REF #30
REF #22
(O.A.L. - 23.75) X 4 + 36)/100
- NO. OF SINGLE DIVERTS X 3.5)/12 (ROUND UP)
(ROUND UP)
REF #23
((2 X (O.A.L. - 6.75 - (NO. OF CROSSOVER DIVERTS X DIM "C"/12)))
W/ DUAL-SIDED SORTER
- NO. OF SINGLE DIVERTS X 3.5)/12 (ROUND UP) SEE SHT 5 OR 6 FOR DIM "C"
REF #21
NOT REQD FOR SKATEWHEEL SPURS
NOT REQD FOR POWERED SPURS
REF #23
(O.A.L. - 23.75) X 4 + 36)/12
REF #24
QTY = NO. SINGLE DIVERTS - (NO. OF SINGLE DIVERTS IN REF 1 & 6)
REF #25
REF #27
NO. OF SINGLE DIVERTS - (NO. OF SINGLE DIVERTS IN REF 1)
REF #30
- QTY OF REF #30
REF #34
((O.A.L. - 35.75) X 4 + 60)/108

QTY OF REF #7 X 4
REF #41
((O.A.L. - 9.5) X 2)/9.75

((O.A.L. - 9.5)/3) + 1
REF #43
QTY OF REF #42 X 3
REF #44
QTY OF REF #42 - 1
REF #45
(O.A.L. - 27.25)/4
(ROUND UP)
IF QTY OF REF #20 = 0
H
DUAL DIVERT
REF #42
OR (O.A.L. - 23.75)/12 - REF #4 (ROUND DOWN) WHICHEVER IS LESS
TRA03581- XX XX D
REF #35
QTY = NO. SINGLE DIVERTS - (NO. OF SINGLE DIVERTS IN REF 1)
OR (O.A.L. - 35.75)/12 - REF #4 (ROUND DOWN) WHICHEVER IS LESS

IF QTY OF REF #20 = 0
(ROUND UP)
REF #26
SEE SHT 5 OR 6 FOR DIM "C"
(ROUND UP)
(ROUND UP)
(ROUND UP)
(20) 20^ DIVERT

(30) 30^ DIVERT
(46) 46" B/B
(ROUND UP)
REF #34
((O.A.L. - 35.75) X 4 + 60)/108
REF #35
QTY OF REF #7 X 4
REF #41
((O.A.L. - 9.5) X 2)/9.75
REF #42
((O.A.L. - 9.5)/3) + 1
REF #43
QTY OF REF #42 X 3
REF #44
QTY OF REF #42 - 1
REF #45
(O.A.L. - 15.25)/4
(ROUND UP)
(ROUND UP)
(ROUND UP)
(ROUND UP)
(52) 52" B/B

(58) 58" B/B
H
MATERIAL LIST FOR:
41
TRA03981- XX
XX
E
42
TRA03581- XX XX X
D
SEE CHART
SEE CHART
43
0317277
44
C00933
QTY
LENGTH
10
FT
EA
DESCRIPTION
DRAWING NUMBER
CATCH SCREEN SUPPORT ANGLE
EA
UM
SHEET EXPANDED METAL X "A"

TRP15021
SCR SELF DRILL & TAP 1/4 X 3/4
EA
CABLE TIE NYLON 7" LG
(46) 46" B/B

(L) LEFT DIVERT
(L) LH SLAVE DRIVE
(52) 52" B/B
(R) RIGHT DIVERT
(R) RH SLAVE DRIVE
(58) 58" B/B
MATERIAL LIST FOR:
OPTIONAL BOTTOM COVER

(A) LH DIVERT/DUAL TAIL ASSY
D
(B) RH DIVERT/DUAL TAIL ASSY
(20) 20^ DIVERT
45
SEE CHART
(30) 30^ DIVERT
46
SEE CHART
3**
47
SEE CHART
(D) DUAL DIVERT/DUAL TAIL ASSY
QTY
LENGTH
EA
EA
2**
UM
DESCRIPTION
DRAWING NUMBER
INTERMEDIATE BOTTOM COVER

CATENARY/TAIL BOTTOM COVER
EA
CATENARY BOTTOM COVER
TRP15031
TRP15041
TRP15051
(46) 46" B/B

** QTY OF REF 46 IS 1 & QTY OF REF 47 IS 0 W/O CATENARY
* SEE CHART FOR QTY
(20) 20^ DIVERT
(52) 52" B/B
(30) 30^ DIVERT
(58) 58" B/B

REF #2 & #3
B/B
TRA04841- XX XX
DWG & PART NO.
DWG & PART NO.
46
TRP10831
TRP10811
52
TRP10831
TRP10821
58
TRP10811
TRP10831
SORTER W/
SORTER W/O
CATENARY
CATENARY
47-9"
REF #7
REF #8
REF #9
35-9"
TRA04791- XX XX X
NOTE: SAME FOR ALL B/BS
46
TRA03581-46XX
SHHD-46XX
TRA04391-46
TRA04851-46
52
TRA03581-52XX
SHHD-52XX
TRA04391-52
TRA04851-52
58
TRA03581-58XX
SHHD-58XX
TRA04391-58
TRA04851-58
"XX" = SUPPORT HEIGHT (INCHES)
(L) LEFT DIVERT
NOTE: MUST BE IN 2 INCH INCREMENTS ONLY
(R) RIGHT DIVERT

H
(20) 20^ DIVERT

REF 41
(30) 30^ DIVERT
OPTIONAL ITEMS
REF 42
REF 45
REF 46
PART NO.
REF 47
B/B
PART NO.
"A"
PART NO.
46
TRA03863-001
24
TRP15021-46
TRP15031-46
TRP15041-46
PART NO.
TRP15051-46
(58) 58" B/B
52
TRA03863-002
30
TRP15021-52
TRP15031-52
TRP15041-52
TRP15051-52
58
TRA03863-002
30
TRP15021-58
TRP15031-58
(46) 46" B/B

(52) 52" B/B
TRP15051-58
SEE SHTS 3 & 4
7/12/07
(58) 58" B/B
PAINT NOTE:
TOLERANCES
RTS
USE 23.75 FOR SORTERS UNDER 50 FT LG
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
BREWER,T.
4/1/02
SCALE

DRAWING TITLE:
CHKD
BY
DATE
GENERAL ARRANGEMENT BOM & QTY CHART
APPD
PRODUCT OR MODEL:
WEIGHT:
BY
N/A

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT - DUAL SIDED
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04322
D-SIZE
USE 35.75 FOR SORTERS OVER 50 FT LG
ECO #TR1-1041
TR7-1072
SUPPORT HEIGHT = TOP OF SORTER - 19"
"XX" = INTERMEDIATE LENGTH (FT)

ODD LENGTH (FT) = (O.A.L. - 35.75 OR 23.75) 12 X (QTY OF REF #3 + QTY OF REF #4 + QTY OF REF #30)
MUST BE IN 1 FT INCREMENTS ONLY (1 FT MIN)
(30) 30^ DIVERT
PART NO.
TRP15041-58
(20" MIN, 42" MAX)
(20) 20^ DIVERT
(46) 46" B/B

(52) 52" B/B
B/B
2:22:23 PM
MINIMUM OVERALL LENGTH
30^ SPUR
OF
MICROSTATION
REF #19
20^ SPUR
REF #
10/1/2007
burleson
(REF. #3, #45-56)

REF# 01
REF# 02
REF# 16
REF# 18
REF# 19
SINGLE
DUAL
SIDED
SIDED
24
46
TRP11521-46
TST00002-2446
TRP12171-46
30
52
TRP11521-52
TST00002-3052
TRP12171-52
36
58
TRP11521-58
TST00002-3658
TRP12171-58

01
2. SEE SHT 3 FOR DUAL ASSY & PIN GUIDE DETAIL
02
SEE CHART
03
TRP11671
3. SEE SHT 4 FOR DUAL RETURN SWITCH DETAIL &
16
ENLARGED END VIEW FOR RH ASSY

4. SEE DWG TRP15041 FOR OPTIONAL BOTTOM COVER
SEE DWG.
SEE DWG.
TRA03641
TRA03991
04
05
MANUFACTURING NOTE:
C 2.
SEE PIN GUIDE SHT 3
57
18
OPTIONAL BROKEN PIN

DETECTOR KIT - SEE DWG.
TRA03881 FOR DETAILS
33
35
58
22
17
14
LENGTH
EA
EA
1
1
B17948
SPRKT 100C42H W/2.938B BRZ BSH
2.50
COLLAR SET 2 15/16 MODIFIED

IN
EA
TSORT 16 GA SHIM
EA
TSORT 10 GA SHIM
P02165
EA
ANGLE MTG TRANSORT TAIL
EA
PAD ISOLATION 3-HOLE TSORT
13
TRP11631
TRP11611
EA
CHAIN SUPPORT GUIDE RH 42T IDL
TRP11611
15
TRP11621
EA
CHAIN SUPPORT GUIDE LH 42T IDL
TRP11621
EA
SEE CHART
18
B51115
GUIDE WHEEL SIDE 42T IDLER
EA
SEE CHART
19
SEE CHART
20
TRP11641
EA
EA
24
LH SLAVE DRIVE
SHAFT DETAIL
PROX SW.
45
(OPTIONAL)
B/B
B/B-6
TRAVEL
C
S05465
EA
SIDE PANEL 42T IDLER
62
63
64
EA
NUT HX HVY NYLOCK 1/2-13
S06605
39
33
35
26
35
2 1/4
15
31
W07670
W09370
N36625
S05450
22
36
S05910
38
W09350
39
(REF)
1 1/16
61
62
63
APPLY VIBRA-TITE (#C00008) TO THESE

BOLTS DURING FINAL ASSEMBLY
64
EA
NUT MF 3/8HX #21NE1420 NYL ZP
EA
20
13
33
*
*
EA
EA
R63160
EA
14
REF
W07650
EA
19
59
35
N.S.
F.S.
22
SEE DETAIL 2 (SHT 2)
RIVET .125 X .462 LG #AAP-45
EA
"A"
TRP11821
TRP11831
EA
"A"
TRP11811
EA
"B"
EA
"B"
EA
B46037
51
0312815
"B"
TRP11811
SUPPORT CHANNEL MTG BRKT
TRP11821
SUPPORT CHANNEL ADJUSTING BRKT
TRP11831
BOLT EYE CARR LANE CL-39-EB
EA
T-BOLT KIT BOSCH 10MM ZP

EA
EA
W08100
55
S06933
56
P08136
EA
6x"A"
EA
3X"A"
S04310
58
TRP11801
ADJUSTABLE PIN GUIDE
EA
"C"
N36630
EA
4
S05600
PIN GROOVED 1/4 X 1 1/4
SCR HHC 1/2-13 X 4 FTHD
EA
WSHR 1/4 SAE
SCR SHC 1/4-20 X 1 3/4 BLK OX
EA
N36060
59
WSHR CUT 1/2
PIN GUIDE SUPPORT CHANNEL
EA
50
57
NUT HEX 3/8
NUT CLIP M6-1 AU-VE-CO #16842
EA
TRP11801
53
1/2 X 1 3/4
WASHER LOCK 1/2
SCREW HHC 3/8 X 2 FULL THREAD
0314867
SCREW HHC
EA
52
35
SCREW HHC 3/8 X 1 500/BOX
EA
N36030
54
15
WASHER LOCK 3/4
SCREW HHC 3/8 X 4 1/2 FULL THD
49
57
42 3/16 (REF)
TRAVEL
EA
EA
S04200
41
47
17
WASHER CUT 3/4
16
37
46
NUT HEX 3/4-10
EA
S04268
SCR HHC 3/4-10 X 4 1/2 LG
EA
34
48
WHISPERSORT TAIL ASSY
144 TAIL INTERMEDIATE SECTION
EA
N36105
44
WHEEL COVER (REF)
30
45
TRP11681
N32861
43
40
16-9"
ENCODER COVER
28
40
3 11/16
61
EA
SCR HHC 1/2-13 X 1-1/2 GRD5 ZP
35
3
5 1/4 REF
NOTE: ATTACH LUBE LINE TO

CROSS TIES W/ TIE WRAPS
SCR HHC 3/8-16 X 1 1/4
ENCODER HOHNER 8807-0102-0021
EA
42
OPT. PIN LUBRICATOR REQD

FOR SPEEDS OVER 350 FPM
EA
36
TRP11691
S05896
EA
TRP11681
33
TRP11641
WSHR CUT 3/8
27
32
0313897
29
TRA03991
EA
25
TO FIRST
TRA03641
TRACK WHEEL TAIL 42T IDLER
23
26
INT ASSY / TAIL SECT.
VERT. TRANSITION ASSY
TRP11691
TRP12171
BSHG "E" 2 15/16 BORE
EA
EA
TRP11631
END COVER TAIL ASSY
EA
W07630
22
BROKEN PIN
14
17
47 1/4
SQ 3/4 X 3/4 X 10 CR C1018
S73358
A17779
TRP11651
BRG PB 2 15/16
S73362
12
TRP11671
EA
10
11
TRP11521
TST00002
SPRKT 100E42H QD2 HUB W/0 BSHG
09
16
DRAWING NUMBER
GUIDE CAM RING ASSY 42T QD BSH
EA
DESCRIPTION
EA
EA
K15081
UM
TRANSORT TAIL SHAFT ASSY
C25075
21
41
TAIL FRAME WELDMENT 42T SPKT
EA
"A"
TRP11651H
08
- FLOOR STOCK, QUANTITIES AS REQUIRED.
QTY
0313907
07
*
,A, B, & C - SEE CHART FOR QUANTITY..
**
3. TIGHTEN CROSS TIE BOLTS TO 310 IN-LBS
1.
RH SLAVE DRIVE (SHOWN)

POSITION KW ON THIS SIDE
FOR RH SLAVE DRIVE
SEE CHART
06
1. SEE SHT 2 FOR LH ASSY & FINISHED ASSY PART NUMBERS
3 11/16
B/B
MATERIAL LIST FOR: TAIL ASSY 42T SPRKT RH, LH & DUAL
ENGINEERING NOTES:
FOR VARIOUS B/Bs CHART
EFF.
WIDTH
EA
NUT HEX 1/2-13
SCR HHC 3/8-16 X 3 1/2
60
ADDITIONAL MATERIAL FOR:

61
SEE CHART
OPTIONAL PIN LUBRICATOR
EA
LUBRICATOR PIN LINCOLN QLS 301
110 VAC C/W TUBING & FITTINGS
16
62
TRP13141
63
ZL4840
64
C00939
EA
EA
LUB PUMP MTG BRKT
TRP13141
LUB GREASE VALVO LITH EP 609
PRODUCT TRAVEL
PRODUCT TRAVEL
P/N: N01286
CHR930004
**
EA
CABLE TIE TB TY528M 14.19 LG
SEE SHEET 4 FOR ADDITIONAL PARTS REQUIRED ONLY FOR DUAL SIDED WHISPERSORT
36
35
SEE NOTE 4
42
21
21
35
29
36
30
31
C
(2)
3/16
1 1/2 - 6
27
28
44
37
11
38
WHISPERSORT TAIL ASSEMBLY / R.H. DIVERT / R.H. SLAVE DRIVE (AS SHOWN)
ECO #TR1-1041
TR7-1057
5/10/07
ECO NUMBER
REV
SEE SHT 4
6/20/07
DATE
REVISION
0315508
OPTIONAL PIN LUBRICATOR SETUP INSTRUCTIONS
12
3. UNIT SHOULD OPERATE ONLY WHEN WHISPERSORT IS RUNNING.

4. PROGRAM IS RETAINED IF POWER IS REMOVED OR LOST.
5. FILL UNIT WITH GREASE BEFORE OPERATING.
6. PROGRAM SETTINGS. P1=0, P2=20, P3=3 FIRST HOUR OF OPERATION
PAINT NOTE:
7. PROGRAM SETTINGS. P1=2, P2=0, P3=1 AFTER FIRST HOUR OF OPERATION
BOM NUMBER:
DWN
BY
FRACTIONS
.XX
.XXX
.XXXX
REF 35 WAS 26; P/N FOR REF 39 WAS S05510

F
DUAL SIDED
2. SUPPLY 120VAC 60Hz TO LUBRICATING UNIT. OPERATING CURRENT 1.0A
SEE SHEET 4
FOR VIEW C-C
DRILL n.129 HOLES IN SIDE PANELS

FOR RIVETS @ ASSY
TOLERANCES
RTS
REF 33 WAS FLOOR STOCK; DELETED REF 34; QTY FOR
TR7-1061
42
SEE DWG. TRA03982 FOR L.H. DIVERT ASSY & TRA03983 FOR DUAL DIVERT ASSY
REMOVED CHART/NON-HARDENED P/NS FOR REF 4 & 5;
0315360
1. SEE LINCOLN INSTALLATION AND OPERATION INSTRUCTION FOR FURTHER DETAILS
10
SHIMS
A
QTY
SINGLE SIDED
32
SEE DETAIL 4 (SHEET 2)
WELD ONLY AFTER

ALIGNMENT/LEVELING
(2) PLACES
REF 64
PART NO.
24
SEE DETAIL 3 (SHEET 2)
REF 61
SORTER TYPE
+
- 1/32"
+
.015
+
.005
+
.0010
-
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
3/11/02
SCALE
DRAWING TITLE:
CHKD
BY
TAIL ASSY 42T SPRKT RH, LH & DUAL
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1"=1-0"
ANGLES (TOTAL RUNOUT)

MACHINING
1/2 ^
FABRICATING
1^
RTS

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03981
D-SIZE
2:20:11 PM
18
LH SLAVE DRIVE SHAFT SHOWN

POSITION KW ON THIS SIDE FOR
LH SLAVE DRIVE
42
OF
MICROSTATION
TOP OF
SLATS
(REF)
19 1/16
\\hebfil04\tech-pub$\product documentation\whispersort_tr08\1-whispersort_oct2007\ch13-illuspartslist\microstation\cp_TRA03981.DGN
10/1/2007
7
PART NUMBERS OF COMPONENT PARTS
burleson
ASSY. P/N DESIGNATION:
ENGINEERING NOTES:
TRA03981- XX
XX
1. SEE SHT 1 FOR RH ASSY & BILL OF MATERIALS
LH SLAVE DRIVE (SHOWN)

FOR LH SLAVE DRIVE

46" B/B (46)
17
52" B/B (52)
SEE PIN GUIDE DETAIL

SHEET 3
(L) LH SLAVE DRIVE

(R) RH SLAVE DRIVE
58" B/B (58)
3 11/16
57
58
20^ DIVERT (20)
18
14
35
OPTIONAL BROKEN PIN

DETECTOR KIT - SEE DWG.
TRA03881 FOR DETAILS
33
(A) LH DIVERT/DUAL TAIL ASSY
(5 1/4)
n.129 THRU
nu.25w.125
5/16 X 30^
BEVEL @ ASSY
41
(B) RH DIVERT/DUAL TAIL ASSY
UHMW/ALUM
EXTRUSION
20
B/B-6
SQUARE END
B/B
RH SLAVE DRIVE
SHAFT DETAIL
(D) DUAL DIVERT/DUAL TAIL ASSY
20
47 1/4
BROKEN PIN
FLIGHT
TRAVEL
FLIGHT
TRAVEL
FLIGHT
TRAVEL
TRAVEL
TO FIRST
PROX. SW.
13
(OPTIONAL)
FLIGHT
TRAVEL
13
SIDE GUIDE DETAIL 1 (TOP VIEW)
TYPICAL FOR FLIGHT TRAVEL SHOWN

BEVEL OPP HAND FOR OPP SIDE
(R) RH DIVERT/RH TAIL ASSY
30^ DIVERT (30)
22
36
35
35
26
33
39
63
64

RH SLAVE DRIVE SHAFT SHOWN

RH SLAVE DRIVE
40
17
16-9"
FLIGHT
TRAVEL
N.S.
F.S.
22
WHEEL COVER (REF)
20
19
35
42 3/16 (REF)
59
61
62
63
64
(REF)
13
REF

FLIGHT
TRAVEL

BEVEL OPP HAND FOR OPP TRAVEL

BEVEL OPP HAND FOR OPP SIDE
15
FLIGHT
TRAVEL
19
1 1/16
57
33
FLIGHT
TRAVEL
SEE DETAIL 1
35
n.129 THRU
nu.25w.125
19
17
18
TRAVEL
SEE DETAIL 2
20
TOP OF SLAT (REF)
B
16
(SEE DETAIL
ON SHT 4)
41
13
B
A
PRODUCT TRAVEL
PRODUCT TRAVEL
25
P/N: N01286
42
32
35
21
24
31
12
36
SEE DETAIL 3
21
FLOOR ELEV
SEE DETAIL 4
10
(2)
A
11
42
SHIMS
38
37
44
28
27
3/16

FOR RIVETS @ ASSY
WELD ONLY AFTER

ALIGNMENT/LEVELING
(2) PLACES
1 1/2 - 6
SET COLLAR EACH

SIDE OF SPROCKET
1 3/4
(TYP)
2:20:16 PM
1/2
29
3 1/4
(REF)
30
TOP OF
SLATS
(REF)
19 1/16
42
35
(NOT SHOWN)
36
20 23/32
CHR930004
39 (+/- 1 1/4)
22
62
REF
61
UHMW/ALUM
EXTRUSION
3/16 X 45^
BEVEL @ ASSY
32
n.129 THRU
nu.25w.125
REF
15
3/16 X 45^
BEVEL @ ASSY
1 1/16

( 1/2 )
30 15/16
5 1/4 REF
2 1/4
3 11/16
( 1/2 )
(L) LH DIVERT/LH TAIL ASSY
1 3/4
(TYP)
VIEW "A-A"
ECO #TR1-1041
D
SEE SHT 1
11/30/06
RTS
SEE SHT 1
5/10/07
RTS
TR7-1061
SEE SHT 4
6/20/07
RTS
PAINT NOTE:
TOLERANCES
+
- 1/32"
+
.015
+
.005
+
.0010
-
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
3/11/02
SCALE
DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1"=1-0"

MACHINING
1/2 ^
FABRICATING
1^
ECO NUMBER
BOM NUMBER:
BY
FRACTIONS
.XX
.XXX
.XXXX

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03982
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
TR6-1074
TR7-1057
burleson
SEE DWG. TRA03981 FOR R.H. DIVERT ASSY & TRA03983 FOR DUAL DIVERT ASSY
10/1/2007
WHISPERSORT TAIL ASSEMBLY / L.H. DIVERT / L.H. SLAVE DRIVE (AS SHOWN)
A
ENGINEERING NOTES:
RH SLAVE DRIVE (SHOWN)

FOR RH SLAVE DRIVE
24
40
35
50
48
48
45
22
35
8
2 1/4
33
14
61
46
5 1/4
58
18
3 11/16
57
1/16
56
41
B/B
TRAVEL
B/B-6
54
47
1/16
LH SLAVE DRIVE
SHAFT DETAIL
53
51
36
46
51
47
35
51
44
44
45
61
62
63
64
15
61
C
ENLARGED DETAIL ADJUSTABLE PIN GUIDE

(FOR LH WHISPERSORT TAIL SHOWN)
3 11/16
7 5/16 ( C OF CROSSTIES FOR

L
RETURN SWITCH)

2 1/4

4
33
35
26
35
22
36
17
LH SLAVE DRIVE SHAFT SHOWN

LH SLAVE DRIVE

57
15
20
61
62
63
64
TRAVEL
59
33
35
REF
19
42 3/16 (REF)
18
13
N.S.
F.S.
22
35
REF

1 1/16
(REF)
1 1/16

WHEEL COVER (REF)
C
IMPORTANT!
THREAD FITTING FOR OPTIONAL PIN
LUBRICATOR INTO TAPPED HOLE
LOCATED CLOSEST TO SIDE FRAME
IN BOTTOM OF PIN GUIDE REF 46
17
20
TOP OF SLAT (REF)
36
42
21
36
29
30
31
32
1
21
24
WELD ONLY AFTER

ALIGNMENT/LEVELING
(2) PLACES
35
28
44
1 3/4
10
9
37
2
7
FLOOR ELEV
(2)
27
13
25
SET COLLAR EACH

SIDE OF SPROCKET
1/2
SEE RETURN SWITCH

SHT 4
TOP OF
SLATS
(REF)
19 1/16
42
(NOT SHOWN)
B
41
11
38
20 23/32
35
VIEW B-B ON
SHEET 4
30 15/16
CHR930004
32
PRODUCT TRAVEL
P/N: N01286
(SEE DETAIL
ON SHT 4)
REF
PRODUCT TRAVEL
39 (+/- 1 1/4)
1 3/4
SHIMS
3/16
(TYP)
12
3 1/4
REF
16
2:20:22 PM
16-9"
39
REF
40
5 1/4 REF
(TYP)
1 1/2 - 6
42
\\hebfil04\tech-pub$\product documentation\whispersort_tr08\1-whispersort_oct2007\ch13-illuspartslist\microstation\cp_TRA03983.dgn
50

FOR RIVETS @ ASSY
SEE SHT 1
5/10/07
RTS
SEE SHT 4
6/20/07
RTS
PAINT NOTE:
TOLERANCES
+
- 1/32"
+
.015
+
.005
+
.0010
-
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
3/11/02
SCALE
DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1"=1-0"

MACHINING
1/2 ^
FABRICATING
1^
REV
BOM NUMBER:
BY
FRACTIONS
.XX
.XXX
.XXXX

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03983
D-SIZE
REV
WHISPERSORT
2
OF
burleson
TR7-1061
MICROSTATION
TR7-1057
ECO NUMBER
SEE DWG. TRA03981 FOR R.H. DIVERT ASSY & TRA03982 FOR L.H. DIVERT ASSY
ECO #TR1-1041
10/1/2007
DUAL SIDED WHISPERSORT TAIL ASSEMBLY / R.H. SLAVE DRIVE (AS SHOWN)
A
B/B
REF# 301
REF# 317
QTY REF# 316
QTY REF# 318
24
46
0312816
TRA04301
30
52
0312817
TRA04271
36
58
0312818
TRA04311
SEE RETURN
SWITCH DETAIL
317
320
316
318
309
SPKT CENTERLINE
COMPONENT PARTS FOR VARIOUS B/Bs CHART

EFF.
WIDTH
ADJUST CAM GUIDE SO CAM & PIN ASSY

PASS THROUGH WITHOUT OBSTRUCTION
301
302
303
19
319
D
40 1/4
48
34 1/2

C
301
302
306
309
316 OR 318
311
TRP13201
312
S06933
313
314
315
P08136
317
318
319
320
EA
EA
10
EA
17
EA
309
319
VIEW B-B FROM TRA03983
C
312
313
REF
2 1/16
B/B
5 1/4
17
20
41
3
13
B/B-6
39
312
314
313
305
306
307
308
309
(BOTTOM VIEW SHOWN FOR CLARITY)
312
313
314
311
312
313
314
305
306
307
308
309
40
25
B
SET COLLAR EACH

SIDE OF SPROCKET
(2)
REF
3 1/4
28
304

M6-1 X 20 MM HHCS
P/N 0314868 (REF)
3/4 (REF)

M6 LOCK WASHER
P/N W09148 (REF)
M6 FLAT WASHER
P/N W07861 (REF)
REF
RETURN SWITCH DETAIL
ENGINEERING NOTES:
WHEEL COVER P/N

TRP10221 (REF)
27
REF
2:20:27 PM
REF
1/2
44
20 23/32 (REF)
32
REF
39 (+/- 1 1/4)
30 15/16
(NOT SHOWN)
TRP11941
304
311
310
CAM GUIDE
SCR SFHC 3/8-16 X 2-1/2
314
TOP OF
WHEEL TRACK
WHEEL COVER (REF)
1 1/16
19
DUAL SIDED RETURN SWITCH
TRP11881
5 1/4
316
320
TRA04261
CAM GUIDE
RETURN GUIDE ASSEMBLY RH
EA
310
315
RETURN GUIDE ASSEMBLY LH
* FLOOR STOCK - QTY AS REQD

** SEE CHART
OPTION. BROKEN
PIN DETECT. KIT
SEE DWG
TRA03881
FOR DETAILS
MAKE THE JOINT OF RAIL #315

FLUSH OR SLIGHTLY RECESSED
BEHIND SWITCH GUIDE BLOCK
NUT HEX 1/4-20 NYLOCK ESNA REG
**
S04125
EA
TRP11941
0312815
TRP13201
**
SEE CHART
BLOCK BROKEN PIN PROX MTG
EA
D
TRP12751
EA
TRP11881
WSHR LOCK 3/8"
EA
TRA04261
PIN ROLL 1/4 X 1/2
BLOCK DIVERT MODULE ENTRY
EA
TRP11841
TRA04761
SCR SHC 3/8-16X1 BLK OX
EA
EA
EA
N36630
316
EA
14
WSHR LOCK M12
SWITCH ASSY LH 20 DEG
EA
W09330
DRAWING NUMBER
B/B
B/B-10 1/2
N36625
DESCRIPTION
SCR HHC M12X1.75X50 FTHD GRD5
EA
B/B-6
35
P08311
UM
RETURN SWITCH MOUNTING BRACKET
TRP12751
BOSCH 45X90 3 842 992 433/--MM
EA
EA
310
TO FIRST BROKEN
PIN PROX. (OPTION.)
EA
16
S06971
308
EA
16
TRA04761-20
307
LENGTH
W09159
TRP11841
305
24 11/16 C
S09088
304
QTY
SEE CHART
303
10 3/4
MATERIAL LIST FOR: ADDITIONAL PARTS FOR DUAL SIDED WHISPERSORT
13/16 (REF)
FLOOR ELEV
41
1 3/4
(TYP)
VIEW C-C FROM SHEET 1

11
DETAIL B
8 X SCALE
1 3/4
(TYP)
ECO #TR1-1041
TR7-1057
SEE SHT 1
5/10/07
RTS
TR7-1061
P/N FOR REF 319 WAS S04110 (2" LG)
6/20/07
RTS
PAINT NOTE:
TOLERANCES
+
- 1/32"
+
.015
+
.005
+
.0010
-
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
3/11/02
SCALE
DRAWING TITLE:
CHKD
BY
TAIL ASSY 42T SPRKT RH, LH, & DUAL
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1"=1-0"

MACHINING
1/2 ^
FABRICATING
1^
ECO NUMBER
BOM NUMBER:
BY
FRACTIONS
.XX
.XXX
.XXXX

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03984
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
ENLARGED END VIEW (2X)
11
10/1/2007
burleson
7
PART NUMBERS & QUANTITIES OF
5 1/4 CAM GUIDE

RING CENTERLINE
MATERIAL LIST FOR:

LENGTH
REF #1
REF #2
REF #3
REF #4
REF #5
REF #6
REF #7
REF #11
(FT)
PART & DWG #
PART #
PART #
QTY
QTY
QTY
QTY
QTY

E/W
B/B
REF #4
HK P/N
TRP13361
TRP09271-12
TRP09281-12
16
TRP13371
TRP09271-24
TRP09281-24
20
24
46
0312816
TRP09661
TRP09271-36
TRP09281-36
24
30
52
0312817
36
58
0312818
TRP09671
TRP09271-48
TRP09281-48
28
TRP09681
TRP09271-60
TRP09281-60
32
10
TRP09611
TRP09271-72
TRP09281-72
36
10
TRP09691
TRP09271-84
TRP09281-84
40
12
SEE CHART
QTY
LENGTH
UM
DESCRIPTION
DRWNG NUM
FORMED SIDE RAIL
SEE CHART
SEE CHART
UPPER FRAME RAIL EXTRUSION
TRP09271
SEE CHART
LOWER FRAME RAIL EXTRUSION
TRP09281
SEE CHART
5
6
0312815
S09088

W09159
TRP09861
TRP09701
TRP09271-96
TRP09281-96
44
12
12
12
TRP09711
TRP09271-108
TRP09281-108
48
12
12
14
10
TRP09721
TRP09271-120
TRP09281-120
52
16
16
16
10
11
TRP09731
TRP09271-132
TRP09281-132
56
16
16
16
12
TRP09601
TRP09271-144
TRP09281-144
60
16
16
18
NO1286
0314867
WSHR LOCK M12

SPLICE PLATE
CHR930004
11
BOSCH 45X90 3 842 992 433/--MM
INTERMEDIATE ASSEMBLY 144" LONG
TRP09861
NPL PRODUCT TRAVEL

2
LBL SAFETY CEMA 04
+
+SEE

CHART FOR QTY
FINISHED ASSY P/N (INTERMEDIATE ONLY): TRA03581-XX XX

B/B
1 1/4 (REF)
B
46, 52, OR 58 B/B
LENGTH (FT)
SEE DETAIL B
2
FINISHED ASSY P/N (12 INTERMEDIATE W/ DIVERT MODULE): TRA03581-XX XX X

46, 52, OR 58 B/B
11
3 1/8
5
5 1/2
6 3/8
1 3/8
R, L, OR D
20 OR 30 DEG
NOTE: SEE DWG TRA04841 FOR DUAL-SIDED DIVERT MODULES

& DWG TRA04791 FOR SINGLE-SIDED DIVERT MODULES
C
1 25/32
3 17/32
TIGHTEN CROSS TIE

BOLTS TO 310 IN-LBS
17 1/4
1
WHEEL COVER P/N
TRP10221 (REF)
M6-1 X 20 MM HHCS
P/N 0314868 (REF)
DIVERT MODULE ASSY

MOUNT TO INTERMEDIATE FOR SHIPPING
PURPOSES ONLY
3/4 (REF)
M6 LOCK WASHER
P/N W09148 (REF)
M6 FLAT WASHER
P/N W07861 (REF)
1
3/4
REF
13/16 (REF)
DETAIL A
11
(ENLARGED)
DETAIL B
8 X SCALE
2 3/4
LENGTH (FT)
(SEE CHART)
1 1/4 REF
B/B
TRAVEL
1 1/4 REF
18
PRODUCT TRAVEL
PRODUCT TRAVEL
P/N: N01286
B/B + 3
10
SECTION X-X
ECO #TR21-137
TR6-1074
ADDED NOTE FOR CROSS TIE BOLT TORQUE
11/30/06
PAINT NOTE:
TOLERANCES
RTS
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY
DWN

K. DAY
BY
DATE
SUPERSEDES:
MATERIAL:

DASH
NEXT ASSY
NUMBER
NUMBER
03/05/2001
SCALE
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DRAWING TITLE:
CHKD
BY
INTERMEDIATE ASSEMBLY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1 1/2"=1-0"
WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03581
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
burleson
10/1/2007
2:19:03 PM
CHR930004
MATERIAL LIST FOR:

ITEM #115 PART NUMBERS
20^ SWITCH DIVERT
E
H
30^ SWITCH DIVERT
INTERMEDIATE ASSEMBLY 144" LONG

QTY
LENGTH
UM
DESCRIPTION
DRWNG NUM
101
TRP10251-L
EA
FORMED SIDE RAIL INT-TO-TAIL L
TRP10251
102
TRP10251-R
EA
FORMED SIDE RAIL INT-TO TAIL R
TRP10251
103 TRP09271-144
104
B/B
LEFT HAND
RIGHT HAND
DUAL
LEFT HAND
RIGHT HAND
DUAL

46"
TRA04791-4620L
TRA04791-4620R
TRA04841-4620
TRA04791-4630L
TRA04791-4630R
TRA04841-4630
52"
TRA04791-5220L
TRA04791-5220R
TRA04841-5220
TRA04791-5230L
TRA04791-5230R
TRA04841-5230
58"
TRA04791-5820L
TRA04791-5820R
TRA04841-5820
TRA04791-5830L
TRA04791-5830R
TRA04841-5830
TRA03641- XX XX X
TRP09281-67
105
106
(D) DUAL DIVERT
107
(20) 20^ DIVERT
144.00
67.00
SEE CHART
IN
IN
UPPER FRAME RAIL EXTRUSION
TRP09271
LOWER FRAME RAIL EXTRUSION
TRP09281
EA
BOSCH 45X90 3 842 992 433/--MM
(L) LEFT DIVERT
S09088
108
109
110
EA
16
EA
W09159
2
B20552
EA
EA
16
TRP09851
WSHR LOCK M12
BUTT CPLG (INT-TO-DRIVE/TAIL)
EA
TRP09851
BOLT CRG 5/16-18X3/4 SHORTNECK
(52) 52" B/B

(58) 58" B/B
B/B
1 1/4 (REF)
G
REF #105
111
N33211
P/N
112
N01286
46
0312816
113
30
52
0312817
36
58
0312818
E/W
B/B
24
G
E
CHR930004
114
115
0314867
SEE CHART
EA
EA
2
NUT FLANGE 5/16 (LOCKNUT)

NPL PRODUCT TRAVEL
EA
18
EA
EA
N01286
LBL SAFETY CEMA 04
CHR930004
DIVERT MODULE ASSEMBLY
SAME AS PART NUMBER
SEE DETAIL B
77
3 1/8
67
103
114
106
5 1/2
6 3/8
105
1 3/8
1 25/32
3 17/32
107 108
102
WHEEL COVER P/N
TRP10221 (REF)
115
TRAVEL
M6-1 X 20 MM HHCS
P/N 0314868 (REF)
8 3/32
3/4 (REF)
M6 LOCK WASHER
P/N W09148 (REF)
M6 FLAT WASHER
P/N W07861 (REF)
106
1 3/4
104
105
13/16 (REF)
114
1 1/2 REF
DETAIL A
(ENLARGED)
DETAIL B
8 X SCALE
TRAVEL
144
18
27
A
1 1/4 REF
B/B
45
WAS 36
36
18
WAS 36
1 1/4 REF
106
A
109
102
101
18
PRODUCT TRAVEL
PRODUCT TRAVEL
P/N: N01286
CHR930004
111
B/B + 3
113
SECTION X-X
112
A
ECO #TR21-137
TR2-1103
UPDATED CHART FOR REF 115 (NEW DIVERT MODULES)
3/10/04
PAINT NOTE:
TOLERANCES
RTS
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY
DWN

KOENINGER, T
BY
DATE
SUPERSEDES:
MATERIAL:

DASH
NEXT ASSY
NUMBER
NUMBER
03/05/2001
SCALE
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DRAWING TITLE:
CHKD
BY
DATE
INTERMEDIATE ASSY INTO TAIL SECTION
APPD
PRODUCT OR MODEL:
WEIGHT:
BY
1 1/2"=1-0"
WHISPERSORT 42T TAIL ASSY
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03641
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
2:19:06 PM
110
(30) 30^ DIVERT

(46) 46" B/B
44
10/1/2007
0312815
burleson
(R) RIGHT DIVERT
WHEEL COVER P/N

TRP10221 (REF)
101
144
3/4 (REF)
M6 LOCK WASHER
P/N W09148 (REF)
M6 FLAT WASHER
P/N W07861 (REF)
F
130
13/16 (REF)
122
111
B/B (46", 52", 58")
TRAVEL
ENLARGED VIEW "X-X"

8 X SCALE
111
127
102
125
C
123
PRODUCT
TRAVEL
i
RETURN
TRAVEL
118
114
103
(N.S.)
126
(N.S.)
125
(F.S.)
103
129
4" TO 7" CHAIN SAG
WHEN RUNNING
(SHOWN @ 4 1/2 ")
128
127
102
BEVELS ON UHMW WEARSTRIPS

NOTE! THERE IS NO SCALE TO THIS VIEW
104
126
(F.S.)
102
(N.S. & F.S.)
118
112
119
(BOTH SIDES)
LOCATE PROXIMITY
AS SHOWN
105
109
117
118
114
118
124
120
15 3/16
INTERMEDIATE SECTION
B
PRODUCT TRAVEL
23 3/4
TOP OF TRACK
4 1/2
117
DRIVE
SECTION
14 13/16
(REF. DWG. TRA03581)
PRODUCT TRAVEL
P/N: N01286
108
118
119
SEE DWG TRP15041 & TRP15051

FOR OPTIONAL BOTTOM COVERS
120
6 1/4

101
107
113
117
118
TRA03511- XX XX X F
(BOTH SIDES)
115
106
116
120
110
111
107
SPECIFY FOR FIXED

DIVERT ONLY
SLOT TO VIEW BOTTOM

OF WHEEL ON FLIGHT
ASSY. @ 4" CHAIN SAG.
121
SLOT TO VIEW BOTTOM

OF WHEEL ON FLIGHT
ASSY. @ 7" CHAIN SAG.
(L) LEFT DIVERT
2:18:59 PM
120
(R) RIGHT DIVERT
TIGHTEN CROSS TIE

BOLTS TO 310 IN-LBS
(D) DUAL DIVERT
(20) 20^ DIVERT

(30) 30^ DIVERT
(46) 46" B/B
(52) 52" B/B
SEE DRAWING TRA03512 (SHEET 2 OF 2) FOR PARTS LIST.
(58) 58" B/B
ECO #TR21-137
TR3-1020
REVISED VIEW "X-X" FOR NEW CLIP-ON NUT
2/13/03
RTS
TR2-1103
SEE SHEET 2
3/10/04
RTS
TR4-1083
ADDED (4) SCREWS TO WEARSTRIP REF 102
5/5/05
RTS
TR6-1074
ADDED NOTES FOR CROSS TIE BOLT TORQUE & OPTIONAL
11/30/06
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
RTS
ECO NUMBER
REV
DATE
REVISION
BY
BY

Koeninger,T.
BY
SUPERSEDES:
MATERIAL:
SEE MATERIAL LIST

APPROVED
DWN
DATE
BOTTOM COVERS
CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DASH
NEXT ASSY
NUMBER
NUMBER
DRAWING TITLE:
CHKD
BY
11/17/00
DATE
SCALE
APPD
CATENARY ASSEMBLY SECTION 144"

WEIGHT:
PRODUCT OR MODEL:
BY
1 1/2"=1-0"
WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03511
D-SIZE
OF
MICROSTATION
10/1/2007
122
burleson
M6-1 X 20 MM HHCS
P/N 0314868 (REF)
MATERIAL LIST FOR:

B
101
TRP09291
102
TRP09321
103 TRP09311-1
104
EFF.
WIDTH
B/B
24
46
30
36
105
REF# 111
PART NUMBER
TRP09831
0312816
107
TRP09351
52
0312817
108
TRP09361
58
0312818
109
TRP09371
110
111
112
N01286
COUPLING PLATE
TRP09831
S05465
W09330
W09159
122
0314867
124
TRP09351
0312815
SCREW HHC 3/8 X 1 (500/BOX)
EA
32
EA
18
123 TRP09271-144
TRP09341
EA
*
EA
WASHER CUT 3/8

WASHER LOCK M12
EA UPPER FRAME RAIL EXTRUSION
30
EA
TRP09271
D
125 TRP09311-2
EA WEARSTRIP - CATENARY
TRP09311
EA MTG. CHNL. - SWITCH - CATENARY
TRP09371
126 TRP09311-3
TRP09311
127 TRP09311-4
TRP09311
EA
B/B
EA
116
W07630
SCR SFHC 3/8-16 X 1 1/4
NUT HEX 3/8-16 HEAVY NYLOK
115
S05450
EA
EA
DRWNG NUM
TRP09361
119
LENGTH UM DESCRIPTION
32
32
121
EA
S04114
N36034
120
TRP09851
FLAT TRACK - CATENARY
117
QTY
EA MTG. ANGLE - SWITCH - CATENARY
32
B20555
TRP09321
BUTT COUPLING
EA CURVED TRACK - CATENARY
114
118
TRP09311
EA
EA
CHR930004
TRP09291
S09088
DRWNG NUM
EA WEARSTRIP - CATENARY - MAIN
SEE CHART
113
LENGTH UM DESCRIPTION
TRP09341
3
EA SIDE RAIL - CATENARY - 144" LG
106
QTY
TRP09851
CATENARY SECTION 144" LG.
SCR HHC M12X1.75X50 FTHD

EA
LABEL - DIRECTION OF TRAVEL
EA LABEL - WARNING DO NOT RIDE

EA
EA
*
BOSCH 45X90 #3842992433
N01286
CHR930004
129
130
333096
N36005
SEE CHART
EA
EA
SCR SFHC 1/4-20 X 1
NUT HEX 1/4-20 HEAVY NYLOK
EA DIVERT MODULE ASSEMBLY
SAME AS PART NUMBER
131
BOLT CARRIAGE - 3/8-16 X 1
132
SCREW HHC 3/8 X 1 1/4 LG
EA
128
133
WASHER LOCK 3/8
* = FLOOR STOCK - QTY AS REQD
ITEM #130 PART NUMBERS

20^ SWITCH DIVERT
30^ SWITCH DIVERT
20^ FIXED DIVERT
30^ FIXED DIVERT
B/B
LEFT HAND
RIGHT HAND
46"
TRA04791-4620L
TRA04791-4620R
52"
TRA04791-5220L
58"
TRA04791-5820L
DUAL
LEFT HAND
RIGHT HAND
DUAL
LEFT HAND
RIGHT HAND
LEFT HAND
RIGHT HAND
TRA04841-4620
TRA04791-4630L
TRA04791-4630R
TRA04841-4630
TRA04791-4620LF
TRA04791-4620RF
TRA04791-4630LF
TRA04791-4630RF
TRA04791-5220R
TRA04841-5220
TRA04791-5230L
TRA04791-5230R
TRA04841-5230
TRA04791-5220LF
TRA04791-5220RF
TRA04791-5230LF
TRA04791-5230RF
TRA04791-5820R
TRA04841-5820
TRA04791-5830L
TRA04791-5830R
TRA04841-5830
TRA04791-5820LF
TRA04791-5820RF
TRA04791-5830LF
TRA04791-5830RF
NOTES:
1.) SEE DRAWING TRA03511 (SHEET 1 OF 2) FOR PLAN VIEW,
ELEVATION VIEW AND ASSY P/N DESIGNATION FOR
TR4-1083
QTY FOR REF 117 & 118 WAS 24
TR6-1074
SEE SHT 1
5/5/05
RTS
11/30/06
RTS
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY
DWN

Koeninger,T.
BY
DATE
SUPERSEDES:
MATERIAL:
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^

DASH
NEXT ASSY
NUMBER
NUMBER
DRAWING TITLE:
CHKD
BY
11/17/00
DATE
SCALE
APPD
CATENARY ASSEMBLY SECTION 144"

WEIGHT:
PRODUCT OR MODEL:
BY
1 1/2"=1-0"
WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03512
D-SIZE
REV
WHISPERSORT
2
OF
burleson
ECO #TR21-137
MICROSTATION
10/1/2007
2:19:01 PM
CATENARY SECTION ASSEMBLY.
41
47
70
71
68
69
13
27
28
07
12
29
37
1. ADJUSTMENT SCREWS ON REF #19 ARE FACED TOWARD CENTER OF DRIVE ASSY.
30
46
34
79
79
65
41
3. SEE DWG. TRA03652 FOR BILL OF MATERIAL..

4. SEE DWG. TRA04231 & TRA04241 FOR DRIVE MOUNTING USING NORD GEARMOTORS.
5. SEE DWG. TRA04211 & TRA04221 FOR DRIVE MOUNTING USING SEW-EURODRIVE GEARMOTORS.
67
37
65
D
44
60
8. FIELD CUT WHEEL COVER #TRP10221 X 12-0" LG. AS REQD. (TYP. BOTH SIDES).
B/B - 6 = C/L TO C/L CHAIN
41
15
19
77
23
08
41
37
04
08
38
33
20
39
77
41
06
40
32
04
39
37
41
38
14
36
30
B/B + 12 3/8
36
B/B
53
7. SEE SHTS 3 & 4 FOR OTHER END VIEWS OF SIDE DISCHARGE & END DISCHARGE ASSEMBLIES.
WHEEL COVER P/N

TRP10221 (REF)
M6-1 X 20 MM HHCS
P/N 0314868 (REF)
3/4 (REF)
M6 LOCK WASHER
P/N W09148 (REF)
21
M6 FLAT WASHER
P/N W07861 (REF)
13/16 (REF)
44
67
C
9 3/16
DETAIL B
35
47
65
46
34
40
30
41
41
37
36
14
78
07
12
13
27
28
29
17
18
43
44
8 X SCALE
DETAIL "A"
SPROCKET NOT SHOWN
37
72
(END DISCHARGE)
84 (SEE NOTE #8)

54 (SEE NOTE #8)
ONLY FOR USE

WITHOUT CANTENARY
(SIDE DISCHARGE)
30 (REF.)
B/B
5 1/4
79
(F.S.)
78
(N.S.)
20
45
23
43
26
64
25
39
41
38
40
30
32
31
(N.S.)
37
9
1 1/16
42
(F.S.)
(REF.)
2 1/16
63
41
91
9
SEE DETAIL "A"
6
TRAVEL
14
36
NEXT SECTION (REF.)
19
43
90
(2)
43
45
17
18
44
17
18
TOP OF SLAT
T.O.F.
92
Made In U.S.A.
Protected by one or more of the following UNITED STATES Patents:
5,595,279
86
29
28
27
07
37
35
60
(2)
(2)
12
13
SECTION "B-B"
SPLICE PLATE ASSY
49
49
33
10
46
47
10
39
40
41
(2)
40
92
20 1/4
3/16
KA87
DRIVE MOUNTING SEE DWG. #TRA04211
KA97
}
}
SEW-EURODRIVE
GMTRS
9/22/06
RTS
REVISED VIEWS OF REF 60 & ADDED NOTE
1/19/07
JJW
SEE SHEET 2
4/03/07
JG
SEE SHEET 2
5/10/07
DATE
REVISION
FOR SK9052AZD
1 1/2 -6
REVISED VIEW OF REF 26; RELOCATED REF 25 & 64
REV
FOR
FOR
FOR SK9042AZD
ECO NUMBER
KA77
FOR KA107
SEE DWG. TRA03653 FOR OPPOSITE HAND
FOR
FOR SK9032AZD
TR6-1058
TR7-1057
FOR RH DIVERT PLACE STOP BRACKET

AND MAGNET THIS SIDE (REF 60)
NOTES:
41
R.H. DIVERT/L.H. DRIVE (AS SHOWN)
TR6-1012
TR7-1043
40
REF.
90
WELD ONLY AFTER

ALIGNMENT/LEVELING
(2) PLACES
33
WHISPERSORT DRIVE ASSY. - SIDE DISCHARGE W/FIXED DIVERT
34
48
37
86
41
65
41
LOCATION. (REF.)
60
PAINT NOTE:
TOLERANCES
BOM NUMBER:
DWN
WATFORD,D.
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
APPROVED
BY
BY
DRAWING TITLE:
CHKD
BY
04/18/01
DATE
SCALE
APPD
1 1/2"=1-0"

WHISPERSORT DRIVE SECTION RH & LH

WEIGHT:
PRODUCT OR MODEL:

DASH
NEXT ASSY
NUMBER
NUMBER

SIDE & END DISCHARGE
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03651
D-SIZE
BY

CHANGED
SUPERSEDES:
MATERIAL:
NORD
GMTRS
FOR SK9062AZD
OF
MICROSTATION
85
37
PROXIMITY SWITCH
89
2:19:09 PM
88
1/2
(2)
87
EC0 #TR21-137
54
SHIP LOOSE
04
55
NOTE: SHIMS
NOT SHOWN
65
& CABLE MOUNTING
(REF.)
26
REF.
30 15/16
94
(F.S.)
32 (REF)
37
39 (+/- 1 1/4 ADJ.)
24
95
2 13/16
85
D
93
65
12 15/16
TRANSORT
N01482
(REF.)
UHS conveyor
P/N
66
13 3/4 (NTS)
TOP OF TRACK
18
13 1/8
19 1/16
TOP OF SLAT
20 13/16
TOP OF PUSHER
40
10/1/2007
35
40
NOTES:
33
burleson
40
ENGINEERING NOTE:
QTY
LENGTH
4
UM
DESCRIPTION
DRWNG NUM
81
FOR WHISPERSORT DRIVE SECTION COMPLETE WITH DRIVE,

THE ASSY PART NO. FROM THE CHART BELOW MUST BE
SPECIFIED ON THE BOM ALONG WITH THE GEARMOTOR REQD.
04
83
05
MANUFACTURING NOTES:
D
1.
85
W07610
86
W09310
87
88
*- FLOOR STOCK, QUANTITIES AS REQUIRED.
EA
EA
W07650
TRP10541
92
EA
2
S05130
*
EA
0313862
E
TRP10541
J
TBG PLASTIC .25 O.D X .04 WALL
EA
DRIVE TOP COVER
EA
TRP10471
WASHER LOCK 3/8
EA
TSD00212
TSD00213
EA
TRANSORT DR SHIM 16 GA
TSD00212
EA
TRANSORT DR SHIM 10 GA
TSD00212
G13146
EA
SUPPORT CHAIN (LH)
G13145
EA
SUPPORT CHAIN (RH)
EA
SCR HHC M6-1 X 20 MM
CHR930001
EA
WARNING LABEL
CHR930001
95
CHR930009
EA
WARNING LABEL
CHR930009
17
18
TRP10461
BRG. PILLOW BLOCK 3.438 BORE
IN
TRP10231
DRIVE END COVER
14
94
* IF NO CATENARY, REF 60 IS SAME HAND AS DRIVE HAND
24
DRWNG NUM
BSHG TAPERLOCK #E-3.438 W/KEY
EA
DESCRIPTION
15
1. FOR KA77 & KA87 DRIVE MATERIAL LIST (SEE DWG. TRA04211#)
5. REF NOS 5, 9, 17, 18, 43, & 45 NOT REQD FOR END DISCHARGE SORTERS.
EA
W09330
13
TRP04881
2. FOR KA97 & KA107 DRIVE MATERIAL LIST (SEE DWG. TRA04221#)
4. FOR SK9052AZD & SK9062AZD DRIVE MATERIAL (SEE DWG. #TRA04241).
EA
UM
TRANSORT DR FR WLDMT
11
SCR HHC 1/4-20 X 3/4
DRIVE OPENING GUARD
SEE CHART
12
CHR930005
LENGTH
EA
074472
10
3. FOR SK9032AZD & SK9042AZD DRIVE MATERIAL (SEE DWG. #TRA04231).
0313861
07
09
WSHR CUT 1/2
WARNING LABEL
EA
06
QTY
SEE CHART
08
HK SYSTEM LOGO "WHISPERSORT"

EA
SEE CHART
SCR HHC 1/2-13 X 2 GRD5
EA
TRP04881
WSHR CUT 1/4"

WSHR LOCK 1/4"
NUT HX HVY NYLOCK 1/2-13
CHR930005
93
EA
EA
N32861
91
GENERAL NOTES:
B
S05896
89
90
2. USE NYLOC NUTS IN PLACE OF FLANGE NUTS WHEREVER POSSIBLE.
*
*
WHISPERSORT RH & LH DR ASSY/ SIDE DISCHA
82
84
F
MATERIAL LIST FOR:
16
0314868
W09148
19
TRP11601-H
EA
EA
WSHR LOCK M6
SPRKT ADJ. PHASE W/ "E" BUSH
TRP11601
(3.438 DIA. BORE W/KEY) HT
6. REF 50 NOT REQD FOR SORTERS UNDER 50 FT LG.
20
S000296
21
R63160
EA
SPRKT 100E60H W/O BUSHING
EA
RIVETS .125 X .462 LG #AAP-45
22
END DISCHARGE CHART
23
SEE CHART
S04268
24
RH DIVERT
LH DIVERT
REF. #5
EFF.
WIDTH
REF. #9
B/B
REF. #60
DUAL & RH DIVERT
25
LH DIVERT
24
46
TRA05131-46R
TRA05131-46L
TRP10461-46
TRP10471-46
24
46
TRA05171-46R
TRA05171-46L
30
52
TRA05131-52R
TRA05131-52L
TRP10461-52
TRP10471-52
30
52
TRA05171-52R
TRA05171-52L
36
58
TRA05131-58R
TRA05131-58L
TRP10461-58
TRP10471-58
36
58
TRA05171-58R
TRA05171-58L
TSD00225
26
28
W07680
W09380
30
32
TSD00232
33
TSD00533
A
NORD GEARMOTOR SIZE/RPM &
34
PART NO.
L
7.5
10
15
20
25
30
40
7.5
10
15
20
25
30
40
(FPM)
P/N
CODE
200
250
H
042/32
052/32
0313200
0313209
042/44
052/44
052/44
052/48
052/55
062/38
087/32
087/35
107/35
107/35
107/35
0313235
0313260
0313268
0313277
0313285
0313294
062/46
062/46
077/43
087/40
097/42
107/42
107/42
0313228
0313236
0313286
0313295
0313303
107/41
052/64
0313269
0313278
052/48
052/48
062/53
062/46
077/50
087/48
097/51
107/48
107/48
107/48
0313229
0313237
0313244
0313262
0313270
0313279
0313287
0313296
0313304
0313221
0313213
0313261
052/55
052/55
062/53
0313000
0313238
0313245
062/53
0313251
077/56
0313263
077/56
0313271
097/56
G13071
S05480
W07630
43
44
47
W09350
48
S05450
107/56
107/56
107/61
49
TRP10781
0313305
0313311
50
SEE CHART
052/64
052/64
052/64
062/64
062/64
077/68
077/65
087/70
087/71
107/67
107/67
107/67
0313230
0313239
0313246
0313252
0313264
0313272
0313280
0313289
0313298
0313306
0313312
450
0313205
500
550
042/76
062/73
062/73
062/73
062/73
077/75
077/73
087/78
087/79
097/71
097/71
107/78
0313240
0313247
0313253
0313265
0313273
0313290
0313299
0313307
0313313
062/78
052/78
062/78
077/85
077/86
077/86
097/79
097/79
097/79
107/78
0313215
042/89
0313216
032/96
0313208
0313223
032/84
042/89
0313207
600
0313214
032/84
0313206
042/76
032/96
0313217
0313231
0313281
A21727
54
P18570
55
0313232
0313248
0313254
0313266
0313274
0313282
0313291
0313300
0313308
0313313
57
042/89
052/90
052/90
052/90
062/91
077/85
087/89
087/89
087/91
097/93
107/89
107/89
58
0313225
0313233
0313242
0313249
0313255
0313266
0313275
0313283
0313292
0313309
0313314
052/102
052/102
062/91
062/91
062/91
077/97
077/97
077/97
097/93
097/101
0313226
0313234
0313243
0313250
0313255
0313267
0313276
0313284
0313293
0313302
0313310
EA
1
WASHER LOCK 1/2

SCREW HHC 3/8-16 X 1
PAD - WHISPERSORT TRACK
EA
56
EA
EA
S05115
0313224
097/93
EA
EA
NUT HEX M6-1
SCREW HHC 1/2 X 1 3/4
TRP10781
CATENARY W/SWITCH
TRA03511
52
052/78
0313301
EA
51
052/78
0313241
WSHR FLAT M6
EA
0313297
SCR HHC 1/4-20 X 1 FTHD
EA
107/56
NUT HEX 3/8
WASHER CUT 3/8
EA
0313288
0313222
EA
SCR HHC 3/8-16 X 1 1/2
EA
12
P02165
NUT MF 3/8 NYL
EA
EA
10
N40210
53
032/72
0314867
S05910
EA
TSD00034
PAD ISOLATION
SCREW HHC 3/8 X 2 FULL THREAD
W07861
45
TSD00533
TSORT SUPPORT ANGLE
SCREW HHC 3/8-16 x 5 FULL THR.
EA
S05145
46
TSD00232
N36030
40
EA
41
42
062/31
0313227
0313220
052/55
0313212
042/65
0313204
0313219
0313211
032/61
0313203
400
052/32
0313218
0313210
042/50
0313202
350
F
0313201
300
WEAR STRIP RH 56 LG
CURVE RETURN TRACK
EA
S04200
39
SPEED
TSD00030
TSD00231
EA
N36625
38
WASHER CUT 7/8

WASHER LOCK 7/8
WEAR STRIP LH 56 LG
EA
EA
TRP14901
TRACK TRANSORT 56 1/2 LG
EA
S05632
37
NOM.
EA
P02165
36
PART NO.
EA
TSD00225
SCR HHC 7/8-9 X 4 1/2
EA
TSD00034
35
SEW - EURODRIVE GEARMOTOR SIZE/RPM &
EA
TSD00231
OILER MTG BRKT
LEXAN ACCESS COVER
TSD00030
31
EA
0313832
TSD00223
SCR HHC 3/8-16 X 4 1/2 FTHD
EA
29
OILER APPLICATOR BRKT "OAB"
EA
TRP14901
27
EA
S08838
APPL TRICO 36051 EVEN-FLO
PLATE SPLICE WHEEL TRACK TSORT

EA
EA
SCREW HHC 1/4 X 5/8
SCR SELF TAP 1/4-20X1/2 TYPE D
59
*
097/93
60
SEE CHART
EA
PUSHER OUT OF PLACE ASSY.
61
0313315
62
NOTE:
1)
63
B26350
64
L40011
MULTIPLY RPM BY 6.25 TO DETERMINE ACTUAL FPM SPEED
65
L
DRIVE ASSEMBLY P/N:
S05435
EFF.
WIDTH
B/B
REF# 04
PART NUMBER
24
46
TRP10231-46
TSD00223-2446
30
52
TRP10231-52
TSD00223-3052
36
58
TRP10231-58
TSD00223-3658
REF# 23
PART NUMBER
REF# 50
PART NUMBER
J
B/B (46, 52 & 58)
20^ DIVERT (20)

30^ DIVERT (30)
BRKT APPLICATOR MNTH #36024
EA
*
LUBRICATOR TRICO 36011-01-B
EA
B17915
69
TRP14001
70
EA
2
SCREW HHC 3/8 X 3/4
TRP13791
EA
4
W07690
72
SCREW SELF TAP 3/8 X 3/4
EA
N36125
71
SEE DWG.
TRA03511
S11328
68
J
EA
66
67
TRA03651-XX XX X X X X X X
COMPONENT PART NUMBER FOR VARIOUS B/Bs CHART
TAKE-UP ASSY
TAKE-UP SCREW
EA
EA
EA
TRP14001
NUT HEX 1-8
WSHR FLAT 1" ZP
COUPLING DRIVE(NO CANTENARY)
73
74
75
GEARBOX:
(N) NORD - STANDARD
76
77

LEFT HAND DRIVE (L)
78
TRP10261R
EA
PANEL SIDE RH 38 LG
TRP10261
79
TRP10261L
EA
PANEL SIDE LH 38 LG
TRP10261
10:30:54 AM
LEFT DIVERT (L)

RIGHT DIVERT (R)
DUAL DIVERT (D)

(PER CHART ABOVE)
L
(E) END DISCHARGE
SEE SHT 5 FOR ADDITIONAL MATERIAL REQD FOR OPTIONAL SPRAY OILER
NOTE: REF 8, 25, & 64 NOT REQD W/ SPRAY OILER.
(S) SIDE DISCHARGE (W/FIXED DIVERT)
(PER CHART ABOVE)
NOTE: DO NOT USE SIDE DISCHARGE
REDUCE QTY OF REF 53 & 63 TO 2.
ITEM 72 TO BE USED ONLY WHEN SORTER DOES NOT HAVE A CANTENARY
W/ DUAL-SIDED SORTER
A
ECO #TR21-137
L
REVISED P/N FOR REF 26 & 92; DELETED REF 66; ADDED
9/22/06
TR6-1012
REVISED P/N CHART FOR REF 60
1/19/07
REVISED NOTE (SPRAY OILER WAS REQD OVER 350 FPM)
4/03/07
JG
TR7-1057
REMOVED CHART/NON-HARDENED P/NS FOR REF 19 & 20
5/10/07
RTS
ECO NUMBER
REV
DATE
REVISION
BOM NUMBER:
DWN
WATFORD,D.
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
JJW
TR7-1043
PAINT NOTE:
TOLERANCES
RTS
MANUFACTURING NOTE 2
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
APPROVED
BY
BY
DATE
SCALE
APPD
1 1/2"=1-0"

BY

WEIGHT:
PRODUCT OR MODEL:
BY

CHANGED
SUPERSEDES:
MATERIAL:
DRAWING TITLE:
CHKD
04/18/01

DASH
NEXT ASSY
NUMBER
NUMBER

DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03652
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
TR6-1058
u:\dms\burleson\copy\cp_TRA03652.DGN
B/B
REF. #60
10/10/2007
EFF.
WIDTH
REF. #60
burleson
SIDE DISCHARGE CHART
REF. #60
B/B
ENGINEERING NOTES:
SEE DETAIL "A"
20
19
1. SEE DWG. TRA03652 FOR BILL OF MATERIAL.
TOP OF SLAT
T.O.F.
27
07
M
L
37
65
FOR LH DIVERT PLACE

STOP BRACKET AND
MAGNET THIS SIDE
(REF 60)
41
60
1/2
REF.
49
40
33
PRODUCT TRAVEL
P/N: N01286
DRIVE/CATENARY ASSY VIEW

(L.H. DRIVE FAR SIDE - R.H. DRIVE NEAR SIDE)
FOR DUAL AND RH DIVERT PLACE

STOP BRACKET AND MAGNET THIS SIDE (REF 60)
7-0" (DRIVE ASSEMBLY)
50
30 15/16 (REF.)
28
12"-0" (CATENARY SECTION)
(REF.)
29
32 (REF)
39 (+/- 1 1/4 ADJ.)
13 3/4 (NTS)
19-0"
13
PRODUCT TRAVEL
12
END VIEW
(REDUCED SCALE)
(FROM DWG. TRA03651)
WHISPERSORT DRIVE ASSY. - END DISCHARGE

M
DUAL, R.H. OR L.H. DIVERT / L.H. DRIVE
B/B
B/B
WHEEL COVER PER TRP10221
(REF.)
20
20
3 7/8
9
SEE DETAIL "A"
19
19
ON DWG. TRA03651.
1 1/16
WHEEL COVER PER TRP10221

(REF.)
44
TOP OF PUSHER
TOP OF SLATS
TOP OF SLATS
29
07
27
13
28
29
07
27
33
40
60
49
FOR LH DIVERT PLACE

STOP BRACKET AND
MAGNET THIS SIDE
(REF 60)
41
65
60
49
41
33
40
65
37
28
12
1 3/4
13
32 (REF)
12
32 (REF)
T.O.F.
13 3/4 (NTS)
13 3/4 (NTS)
T.O.F.
END VIEW
37
END VIEW

WHISPERSORT DRIVE ASSY. - END DISCHARGE
F
L.H. DIVERT / R.H. DRIVE
DUAL, R.H. OR L.H. DIVERT / R.H. DRIVE
SEE DWG. TRA03651 FOR OPPOSITE HAND
ECO #TR21-137
TR7-1057
SEE SHEET 2
5/10/07
PAINT NOTE:
TOLERANCES
RTS
BOM NUMBER:
DWN
WATFORD,D.
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
SUPERSEDES:
MATERIAL:
04/19/01
SCALE

ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY

BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1 1/2"=1-0"
CHANGED
DRAWING TITLE:
CHKD

DASH
NEXT ASSY
NUMBER
NUMBER

DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03653
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
10/10/2007
FOR LH DIVERT PLACE

STOP BRACKET AND
MAGNET THIS SIDE
(REF 60)
FOR DUAL AND RH DIVERT PLACE

STOP BRACKET AND MAGNET THIS SIDE
(REF 60)
10:30:58 AM
burleson
B/B
SEE DETAIL "A"
5 1/4
18
17
44
19
20
43
TOP OF SLAT
13 3/4 (NTS)
T.O.F.
12
13
28
29
07
27
39 (+/- 1 1/4 ADJ.)
32 (REF)
49
REF.
(REF.)
1/2
30 15/16
(REF.)
L
41
40
33
37
65
60
FOR RH DIVERT PLACE

STOP BRACKET AND
MAGNET THIS SIDE
(REF 60)
END VIEW
ENGINEERING NOTES:
R.H. DIVERT / R.H. DRIVE
1. SEE DWG. TRA03652 FOR BILL OF MATERIAL.
B/B
SEE DETAIL "A"
6
20
5 1/4
19
43
44
17
18
TOP OF SLAT
27
07
1/2
49
(REF.)
30 15/16
32 (REF)
REF.
39 (+/- 1 1/4 ADJ.)
60
65
37
33
40
41
10:31:00 AM
FOR LH DIVERT PLACE

STOP BRACKET AND
MAGNET THIS SIDE
(REF 60)
END VIEW
TR7-1043
SEE SHEET 2
4/3/07
TR7-1057
SEE SHEET 2
5/10/07
PAINT NOTE:
TOLERANCES
JG
REV
DATE
REVISION
BOM NUMBER:
DWN
R. SKANSE
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
2/14/03
SCALE
1 1/2"=1-0"

DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
L.H. DIVERT / L.H. DRIVE
ECO #TR3-1020

DASH
NEXT ASSY
NUMBER
NUMBER

DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03654
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
u:\dms\burleson\copy\cp_TRA03654.dgn
28
10/10/2007
29
burleson
13
(REF.)
12
13 3/4 (NTS)
T.O.F.
MATERIAL LIST FOR:

1. MOUNT LUBRICATOR ON SAME SIDE AS DRIVE.
SHOP & INSTALLATION NOTES:
2. SEE DWG TRA03656 FOR SCHEMATIC DIAGRAM & INSTALLATION NOTES.
QTY
L
108
110
112
LENGTH
UM
DESCRIPTION
DRWNG NUM
101
102
0316781
EA
1/8" OD NYLON TUBING

106
OPTIONAL SPRAY OILER
UNIST SPRAY CHAIN OILER
AIR/OIL SYSTEM CONSISTS OF:
(REF.)
PUMP PACKAGE W/ FILTER REG

23
120V SOLENOID, 1/8 " TUBING
(4) SPRAY NOZZELS
RC100 CHAIN
NOZZLES (4)
(REF.)
D
53
63
103
104
C
L RC100 CHAIN
108
N36630
112
NOZZLE MTG BRKT
EA
N36000
113
114
EA
TRP14911
SCR HHC 1/4-20 X 1-1/4
EA
NUT NYLOC 1/4-20
111
L
SHIP LOOSE
S04650
110
109
TRP14911
107
2 1/2
105
106
B/B
EA
NUT HEX 1/4-20
115
116
0316794
EA
LUB POWER-FLO ISO-68AW 5 GA
FOR BOTH
117
BRUSH &
SPRAY
119
OILER
L
85
92
EA
HARNESS STRAP
B20555
EA
*
SPRAY OILER MTG BRKT

EA
TRP12521
BOLT CRG 3/8-16 X 1
122
123
M18992
124
125
121
TRP12521
120
S90005
118
EA
MUFFLER PIAB N125FF 1/8" NPT
126
127
128
129
37
119
41
102
120
7 5/8
110
1/8"" OD NYLON TUBING
102
SPRAY OILER
119
(REF.)
85
92
110
TRAVEL
For Best Results, Use
9303-016
9303-009
Coolube 2210
F12B-02S01
014
UNIST
106
L
37
23
41
48
108
110
112
L
R
UHS conveyor
R
TRANSORT
102
Made In U.S.A.
5,595,279
P/N
N01482
AIR/OIL SPRAY NOZZLES
9303-006
1/2" TO 1"
BETWEEN SPRAY NOZZLE
AND CHAIN
2 9/16
SK9062
3 1/2
11 1/4
123
102
53
63
41
(REF.)
CHAIN LUBE SYSTEM W/ AIR/OIL SPRAY NOZZLE

TR6-1012
SEE SHEETS 1 THRU 4
1/19/07
JJW
TR7-1043
SEE SHEET 2
4/03/07
JG
SEE SHEET 2
5/10/07
RTS
TR7-1057
PAINT NOTE:
TOLERANCES
REV
DATE
REVISION
BOM NUMBER:
DWN
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
R. SKANSE
3/17/04
SCALE
3/16"=1"

DRAWING TITLE:
CHKD
BY
OPTIONAL SPRAY OILER
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT DRIVE SECTION
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03655
D-SIZE
REF DWG TRA04611
ECO TR2-1103
OF
MICROSTATION
burleson
37
RC100 CHAIN
10/10/2007
10:31:02 AM
120
119
INSTALLATION NOTES:
PUMP CYCLES/MIN
1.) VERTICALLY PLACE NOZZLE SO THE TIP IS APPROXIMATELY
OVERALL LENGTH (FT)
1/2 TO 1" AWAY FROM THE CHAIN SIDE BARS.

SPEED
2.) TIE OIL AND AIR LINES TO CROSS MEMBERS SO THAT

THEY ARE CLEAR OF THE MOVING FLIGHTS
30 - 150
151 - 300
301 AND GREATER
501-600 FPM
12
401-500 FPM
10
350-400 FPM
3.) ADJUST NOZZLES HORIZONTALLY TO SPRAY

LUBRICANT BETWEEN SIDE PLATE AND ROLLER
4.) USE POWERFLOW HYDRAULIC OIL ISO-68AW (P/N XXXX)
0PERATION:
L
1.) FILL RESIVOIR WITH RECOMMENDED OIL

2.) LOOSEN DRAIN PLUG TO REMOVE ANY AIR TRAPED IN THE PUMPS
POWER REQUIREMENTS
AIR
50 PSI
3.) ADJUST AIR PRESSURE TO 50 PSI

120/60, 110/50,
10.9 VA HOLDING
AIR VALVE
4.) SET STROKE LENGTH TO MAXIMUM BY TURNING KNOB CLOCK WISE.

5.) ADJUST AIR METERING SCREW TO 1/4 TURN OPEN.
6.) TURN UNIT ON BY SUPPLYING POWER TO THE SOLENOID VALVE.
7.) SET PUMP CYCLES/MIN PER CHART BY ADJUSTING PULSE GENERATOR.
7.) LUBRICATOR SHOULD RUN ANYTIME THE WHISPERSORT IS RUNNING.
LOW LEVEL SWITCH

C
PULSE GENERATOR ADJUSTMENT (CYCLES PER MIN.)
For Best Results, Use
9303-016
9303-009
Coolube 2210
F12B-02S01
014
UNIST
AIR CONTROL ADJUSTMENT SCREW

MAC 120V SOLENOID
ECO TR2-1103
TR6-1058
CHAIN OILER CHANGED FROM BIJIR TO UNIST
6/22/06
MPC
TR6-1012
SEE SHEETS 1 THRU 4
1/19/07
JJW
TR7-1043
SEE SHEET 2
4/03/07
JG
TR7-1057
ECO NUMBER
REV
SEE SHEET 2
5/10/07
DATE
REVISION
PAINT NOTE:
TOLERANCES
BOM NUMBER:
DWN
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
APPROVED
BY
BY
3/17/04
SCALE

DRAWING TITLE:
CHKD
BY
OPTIONAL SPRAY OILER SCHEMATIC
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1/2" = 1"

CHANGED
SUPERSEDES:
MATERIAL:
R. SKANSE

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT DRIVE SECTION
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA03656
D-SIZE
REF DWG TRA04641
OF
MICROSTATION
burleson
PUMP STROKE LENGTH ADJUSTMENT
10/10/2007
10:31:05 AM
DRAIN/PRIME PLUG
9303-006
1/4" NPT AIR INLET
NOTE:
20 13/16 REF.
B/B
BOLT MOTOR MTG. ANGLES TO GEARMOTOR

BEFORE MOUNTING GEARMOTOR TO SHAFT.
15 1/2
46
END OF SHAFT
SHOULDER TO END OF SHAFT
6 1/8
S05910
47
W09350
TSD002GA
261
TSD002GF
282
APPLY ANTISEIZE COMPOUND

TO SHAFT BEFORE
INSTALLING GEARMOTOR
TOP OF TUBE
2.000 (REF)
292
500
S05633
EA
EA
NUT HEX 5/8
WASHER FLAT 1/2
EA
EA
NUT HEX 1/2
SCREW HHC 3/4-10 x 2 GRD5
W07670
EA
WASHER FLAT 3/4
294
W09370
EA
WASHER LOCK 3/4
N36105
500
0315906
EA
TRP11761
WASHER LOCK 5/8
293
295
B
SK9032 DRIVE SHAFT 3.437 DIA.
TSD002GF
SCREW HHC 5/8 X 4
EA
N36060
TSD002GA
KA77 MOTOR MTG ANG
EA
N36090
W07650
291
DRAWING NUMBER
WASHER LOCK 1/2
EA
DESCRIPTION
KA77 MOTOR BASE WLMT
EA
UM
SCREW HHC 1/2 X 1 3/4
EA
SB
W09360
290
SEE B/M FOR GEARMOTOR

HP AND OUTPUT RPM
EA
SEE CHART
289
C
L
SHAFT PER DWG. TRP11761 (REF.)
LENGTH
S06435
288
QTY
256
286
A
SK9032AZD DRIVE MOUNTING
(REF.)
INSERT BOLT AS SHOWN. (NUT TO OUTSIDE)
MATERIAL LIST FOR:
EA
NUT HEX 3/4-10
SCR SHC 5/8-11 X 3 GRD 5
9.84 (REF.)
289
288
286
261
A
SK9032
SK9032
291
290
47
46
38 (MIN. ELEV.)
282
EFF.
WIDTH
B/B
REF# 282
PART NUMBER
24
46
TRP11761-2446
30
52
TRP11761-3052
36
58
TRP11761-3658
256
295
C
256
294
293
292
261
MATERIAL LIST FOR:
NOTE:
22 11/16 (REF.)
B/B

17
(REF.)

END OF SHAFT
6 13/16
TSD002GB
268
TSD002GM
283
SEE CHART
C
L
2.375 (REF)

HP AND OUTPUT RPM
700
DRAWING NUMBER
EA
EA
TSD002GM
288
W09360
EA
WASHER LOCK 5/8
N36090
S05633
EA
EA
NUT HEX 5/8
293
W07670
EA
WASHER FLAT 3/4
W09370
EA
WASHER LOCK 3/4
N36105
298
S06350
W09346
299
700
EA
EA
N36033
S00181
EA
4
1
WASHER LOCK M24
EA
NUT HEX 3/4-10
SCREW HHC 5/8 X 2
SCREW HHC M24 X 160MM
EA
TRP11771
294
S00167
TSD002GB
KA87 MOTOR MTG ANG
WASHER FLAT 5/8
297
DESCRIPTION
EA
296
TOP OF TUBE
UM
295
SB
W07660
292
LENGTH
287
289
TO SHAFT BEFORE
QTY
257
EA
NUT HEX M24
SCR HHC 3/4-10 X 3 1/2 GRD 5
298
297
268
A
SK9042
289
288
287
SK9042
296
295
257
294
293
B/B
REF# 283
PART NUMBER
24
46
TRP11771-2446
30
52
TRP11771-3052
36
58
TRP11771-3658
2:22:11 PM
257
EFF.
WIDTH
292
268
ECO #TR1-1101
TR3-1063
UPDATED VIEWS/DIMS; P/N FOR REF 500 WAS 0312217
6/5/03
TR5-1120
P/N FOR REF 500 WAS S12451
8/4/05
PAINT NOTE:
TOLERANCES
RTS
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
BREWER,T.
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
2/13/02
SCALE
1 1/2"=1-0"

DRAWING TITLE:
CHKD
BY
WHSPRST DR ASSY/ SK9032 & SK9042
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
& P/N FOR REF 700 WAS 0312207

DASH
NEXT ASSY
NUMBER
NUMBER

NORD SHAFT MTD. GEARMOTORS
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
TRNSRT
TRA04231
D-SIZE
SEE DWG TRA04211 FOR SEW-EURODRIVE GEARMOTORS.
OF
MICROSTATION
11.81 (REF.)
299
38 (MIN. ELEV.)
283
10/1/2007
burleson
3
MATERIAL LIST FOR:
NOTE:
25 7/16
REF.
B/B

A
19 1/2
(REF.)
258
TSD002GC
260
TSD002GE
284
SEE CHART
2.750 (REF)

HP AND OUTPUT RPM
EA
W09360
EA
WASHER LOCK 5/8
N36090
S05633
EA
EA
W07670
EA
WASHER FLAT 3/4
W09370
EA
WASHER LOCK 3/4
EA
296
S06350
EA
298
W09346
EA
N36033
S00167
700
S00181
EA
1
NUT HEX 3/4
SCREW HHC 5/8 X 2

WASHER LOCK M24
EA
TRP11751
NUT HEX 5/8
293
300
TSD002GE
294
N36105
TSD002GC
KA97 / KA107 MOTOR MTG ANG
288
299
DRAWING NUMBER
WASHER FLAT 5/8
C
L
TOP OF TUBE
EA
DESCRIPTION
EA
295

TO SHAFT BEFORE
UM
292
LENGTH
SB
W07660
289
9 3/16
QTY
287
END OF SHAFT
NUT HEX M24
EA
SCR HHC 3/4-10 X 3 1/2 GRD 5
284
13.78 (REF.)
298
299
300
A
SK9052
260
SK9052
289
288
287
38 (MIN. ELEV.)
700
296
EFF.
WIDTH
B/B
REF# 284
PART NUMBER
24
46
TRP11751-2446
30
52
TRP11751-3052
36
58
TRP11751-3658
C
258
295
260
294
293
292
258
MATERIAL LIST FOR:

NOTE:
26 13/32
REF.
B/B

A
21 7/16
(REF.)
END OF SHAFT
SHOP FILL SEALANT
@ EXPOSED KEYWAY
SEE CHART
EA
1
WASHER FLAT 5/8
288
W09360
EA
WASHER LOCK 5/8
N36090
S05633
EA
EA
W07670
EA
WASHER FLAT 3/4
W09370
EA
WASHER LOCK 3/4
EA
296
S06350
EA
298
W09346
EA
N36033
S00167
1
EA
NUT HEX 3/4
SCREW HHC 5/8 X 2

WASHER LOCK M24
EA
TRP11741
NUT HEX 5/8
293
299
TSD002GE
294
N36105
TSD002GD
EA
NUT HEX M24
301
800
S00181
EA
SCR HHC 3/4-10 X 3 1/2 GRD 5
285
EFF.
WIDTH
B/B
REF# 285
PART NUMBER
24
46
TRP11741-2446
30
52
TRP11741-3052
36
58
TRP11741-3658
2:22:13 PM
SK9062
288
DRAWING NUMBER
KA97 / KA107 MOTOR MTG ANG
EA
260
289
DESCRIPTION
SK9062
296
UM
W07660
300
300
287
LENGTH
SB
287
295
800
299
285
TOP OF TUBE

HP AND OUTPUT RPM
298
TSD002GE
QTY
38 (MIN. ELEV.)
301
260
C
L
3.250 (REF)

TO SHAFT BEFORE
TSD002GD
292
A
(REF.)
259
289
11 1/8
REDUCER FRAME TO END OF SHAFT
17.72 (REF.)
259
260
292
295
294
WELDMENT @ ASSY. (TYP.)

1/4
1-6
ECO# TR1-1101
TR3-1063
UPDATED VIEWS/DIMS; REMOVED REF 301; P/N FOR
6/5/03
PAINT NOTE:
TOLERANCES
RTS
+
- 1/32"
+
.015
+
.005
+
.0010
-
REV
DATE
REVISION
DWN
BREWER,T.
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
2/13/02
SCALE
DRAWING TITLE:
CHKD
BY
WHSPRST DR ASSY/ SK9052 & SK9062
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1 1/2"=1-0"

MACHINING
1/2 ^
FABRICATING
1^
ECO NUMBER
BOM NUMBER:
BY
FRACTIONS
.XX
.XXX
.XXXX
REF 700 WAS 0312207

DASH
NEXT ASSY
NUMBER
NUMBER

NORD SHAFT MTD. GEARMOTORS
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
TRNSRT
TRA04241
D-SIZE
SEE DWG TRA04221 FOR SEW-EURODRIVE GEARMOTORS.
OF
MICROSTATION
259
293
10/1/2007
burleson
MATERIAL LIST FOR:

8
45
11
12
1 3/8

7
15
[ 24 7/8 ]
( 21 7/8 )
17
16
C
TRP13431
TRP13431L
EA
END DISCHARGE SIDE FRAME LH
TRP13431
SEE CHART
45
0315748
[ 54 ]
[ 24 7/8 ]
17
18
EA
60
TRP13451
ROLLER MTG FLAT

EA
TRP13461
RLR 1 3/8 X 18GA 5/16 HEX
TRP13471R
EA
DISCHARGE ADJUSTING CLIP RH
TRP13471
14
TRP13471L
EA
DISCHARGE ADJUSTING CLIP LH
TRP13471
15
TRP13491
EA
16
TRP13611-4
17
TRP13611-5
0315660
19
S07810
20
W09152
N33212
23
S05955
TRP13611
EA
TRANSITION FLAT 5" CTR
TRP13611
TORSION SPRING #LT-040H-6-L MW
EA
8
6
BOLT CRG 3/8-16 X 1 LG
NUT FLG 3/8-16 WHIZ-LOCK
EA
SCR HHC 1/2-13 X 2 1/2 LG FTHD
EA
N33150
WSHR LOCK M8 DIN 127
EA
EA
N34625
S04179
SCR HHC M8X1.25 30MM
EA
EA
TRP13491
TRANSITION FLAT 4" CTR
EA
B20555
22
FILL PLATE GRAVITY DISCHARGE

EA
NUT 1/2-13 JAM
SCR SFHC 1/4-20 X 1 1/4 LG
EA
NUT ELASTIC STOP NE 1/4-20

TRP13921
28
TRP13921L
EA
END DRIVE GUARD RAIL LH
TRP13921
29
TRP13941R
EA
GRAVITY DISCHARGE GUARD RAIL R
TRP13941
30
TRP13941L
EA
GRAVITY DISCHARGE GUARD RAIL L
TRP13941
S07007
32
N33212
33
37
EA
SCR HHC 3/8-16 X 1 1/2 LG
10
EA
NUT FLG 3/8-16 WHIZ-LOCK
W07630
18
0315750
35
36
B20550
SEE CHART
SEE CHART
38
S05645
39
TRP13931
40
EA
EA
EA
EA
GUARD RAIL STIFFENER 30"
EA
N36000
EA
NUT HEX 1/4-20
43
W09310
EA
WSHR LOCK 1/4
44
W07610
S07030
EA
24
EA
TRP13931
SCR HHC 1/4-20 X 3/4 GRD5 ZP
42
45
TRP13501
SCR HHC M6 X 25
TSD00211
SCR HHC 3/8-16 X 5
EA
LOW PRO
DRIVE END COVER GRAVITY DISCHA
12
S05131
BOLT CRG 3/8-16 X 3/4
DISCHARGE SUPPORT ANGLE
4
4
WSHR 3/8 FLAT
T-BOLT M6 X 14mm #8981019577
EA
S06761
41
EA
EA
WSHR CUT 1/4
SCR SHC M6X1X12mm BLK OX
* SEE CHART FOR QTY
28
SEE CHART
TRP13441
13
34
1 3/8
1
45
ROLLER MTG SIDE ANGLE
ROLLER MTG CENTER CHANNEL
EA
EA
TRP13391
END DRIVE GUARD RAIL RH
2
1
EXTENDING FRAME WELDMENT
EA
15
EA
B
25
CONN LINK BOSCH #3842521216
TRP13921R
26
T-BOLT M6 X 14mm #8981019577
EA
TRP13461
31
TRAVEL
TRP13451
GUSSET BOSCH #3842523528 W/FAS
EA
27
( 21 7/8 )
16
TRP13441
EA
BOSCH 30X60 #3842922926/XXmm
BOSCH 30X30 #3842990720/1219.2
18 7/8
TYPICAL
5 FOR
48 B/B
16
SEE CHART
26
**
0315750
25
0315749
12
EA
EA
24
42
16
2
3
21
( 48 )
16
0315744
18
DRWNG NUM
1 1/2
DESCRIPTION
END DISCHARGE SIDE FRAME RH
10
45
UM
EA
11
18 7/8
5 FOR
48 B/B
4
4
TYPICAL
16
LENGTH
QTY
TRP13431R
25
26
END DISCHARGE GRAVITY ROLLER ASSY
** NOTE: BOX & BAG LOOSE ITEMS FOR FIELD INSTALLATION ITEMS 27 THRU 44
SEE SHEET 2 FOR INSTALLATION
ASSEMBLY P/NS:
PART NUMBER
A= 1418A ALUM ROLLER W/ GRAVITY BRG
B= STEEL ROLLER W/ ABEC GRAVITY BRG
B/B = 42 FOR EW = 24"

48 FOR EW = 30"
54 FOR EW = 36"
NOTE: ASSEMBLE TO THE

10 7/16 DIM
(CAN EXTEND TO 20 11/16)
16
B/B
SORTER
EFFECTIVE
B/B
WIDTH
TRA04891-42X
42
46
24 BB
TRA04891-48X
48
52
TRA04891-54X
54
58
REF #12
REF #3
REF #16 REF #17 REF #18
REF #8
REF #36
REF #37
TRA04891-XXA
TRA04891-XXB
R68055-18.87
0315752
24
TSD00211-2446
TRP13501-46
QTY.
QTY.
QTY.
0315745
TRP13391-42
30 BB
0315746
TRP13391-48
R68055-21.87
0315753
30
TSD00211-3052
TRP13501-52
36 BB
0315747
TRP13391-54
R68085-24.87
0315754
36
TSD00211-3658
TRP13501-58
48
C
18
11
12
45
18
TYP
10
19
2:23:23 PM
20
4
4
5
14
21
22
19
20
11
12
19
20
21
22
13
5
5
23
TR5-1066
TR7-1002
ECO NUMBER
24
CHANGED TRANSITION FLAT PART NUMBERS
11/15/04
JJW
CHANGED GUARD RAIL, ADD ROLLER OPTION, WAS SPDS
4/12/05
JJW
CHANGED BOM ITEM 21, 27-30, 32-33, 35, 39-44
UPDATED VIEWS FOR 10 GA FRAME & ADDED REF 45
CHANGED DIM TO ASSEMBLE EXTEND FRAME
REV
3/22/07
DATE
REVISION
24
NOTE: BREAK OFF TABS ON GUSSET MOUNTING TO CROSS RAIL
23
BOM NUMBER:
DWN
BY
JJW
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
APPROVED
BY
BY
J.Wilkins
9/3/04
SCALE
3/8" = 1"

24
DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04891
D-SIZE
22
BY

CHANGED
SUPERSEDES:
MATERIAL:
21
23
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
14
OF
MICROSTATION
13
10/1/2007
burleson
SEE DRAWING TRA04891 FOR BILL OF MATERIALS
11
SORTER
B/B
B/B
24
EFFECTIVE WIDTH
PRODUCT AREA
EFFECTIVE
WIDTH
9
11
39
41
42
43
44
84
48
TOP OF SLATS TO TRANSITION FLAT END

SPKT CENTERLINE TO TRANSITION FLAT
N.S.
32
35
27
29
N.S.
30
F.S.
TRAVEL
F.S.
28
1 3/8
END OF TRANSITION FLAT

30 1/16
C
7
1/4
C
40
BETWEEN SLAT AND

TRANSITION FLAT
32
31
33
TOP OF CARRYING SURFACE
B
7 1/2
UHS conveyor
R
TRANSORT
Made In U.S.A.
T.O.R.
5,595,279
P/N
N01482
34
35
32
36
38
32
33
22 15/16
A
A
CHANGED TRANSITION FLATS AND MTG DIM
11/15/04
JJW
CHANGED GUARD RAIL, ADD ROLLER OPTION, WAS SPDS
4/12/05
JJW
TR7-1002
LOWERED DISCHARGE SECTION 5/16" @ INFEED END & 2"
3/22/07
JJW
PAINT NOTE:
TOLERANCES
@ DISCHARGE END (DIMS WERE 13/32, 6-5/8, 1-1/16, 5-1/2,
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
9/3/04
SCALE
1/8" = 1"

DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

DATE
REVISION
DWN
DATE
& 22-1/2)
ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA04892
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
A
TR5-1066
burleson
10/1/2007
2:23:27 PM
37
13
1.)
13
14
FIELD INSTALL WHEN SHIPPING DIVERT MODULE LOOSE (SEE NOTE 1)
10
5
D
15
16
17
WHEN POSSIBLE, SHIP DIVERT MODULE COMPLETELY ASSEMBLED TO WHISPERSORT

INTERMEDIATE SECTION. IF DIVERT MODULE MUST SHIP LOOSE, SUB-ASSEMBLIES
"A" & "B" & LOOSE SHIP ITEMS ARE TO BE BOXED FOR FIELD ASSEMBLY (INCLUDE
COPY OF DRAWING).
2.)
OPTIONAL DIVERT CONFIRM PROX KIT TRA03801-3 (SHIPPED LOOSE)
3.)
SEE SHEET 2 FOR ASSEMBLY PART NUMBERS AND BILL OF MATERIAL

D
4
FIELD MOUNT TO A CROSS TIE NEAR
THE MIDDLE OF THE DIVERT RAIL
21
11
12
13
9
10
SEE DETAIL B
USE OTHER SET OF HOLES
FOR 30^ ASSY
4
2
B/B-2 1/2
16
17
10
15
16
17
19
SEE NOTE 2
FOR 30^ ASSY
16
15
18
SEE DETAIL C
20
2
22
23
24
25
13
10
14

FOR 30^ ASSY
SUB-ASSY "B"
4 13/16
16
15
RH DIVERT MODULE (SHOWN)
18
20
RH FIXED DIVERT DETAIL

7
SEE SHT 2 FOR LH ASSY
FIELD NOTE: MOVE CROSS TIE IN SECTION

IF IT INTERFERS WITH THE SWITCH MOTOR
15
16
18
20
INSERT GROOVED END OF PIN ITEM #20 INTO ENTRY BLOCK ITEM #3
LEAVING 1/4-3/8" BELOW THE SURFACE OF THE BLOCK
22
23
24
25
21
15
16
SEE NOTE 2
17
B
1
4
11
16
17
12
13
21
19
9
5
29
13
14
2
21
22
(FIELD ASSY)
1 3/4
10
MAKE THE DIVERT RAIL FLUSH

OR SLIGHTLY RECESSED
15
16
NOTE FOR SWITCH ASSY ONLY

THESE TWO BOLTS HAVE WASHER
BETWEEN SWITCH PLATE
AND MOUNTING BRACKET
17
DETAIL A
ISOMETRIC
TR2-1103
CHGD DWG TO STD (WAS SPDS); SEE SHEET 2
3/2/04
RTS
TR6-1074
ADDED REF 30; REVISED T-BOLTS TO SHOW DOUBLE NUTS
11/1/06
RTS
26
13
DETAIL C
ISOMETRIC
ISOMETRIC
REV
DATE
REVISION
BOM NUMBER:
DWN
M.Carr
BY
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
28
FIELD INSTALL TO SECTION CROSS TIE HOLES

WHEN CROSS TIE IS NOT PRESENT
BY
DATE
SCALE
APPD
DIVERT MODULE
WEIGHT:
PRODUCT OR MODEL:
BY

DASH
NEXT ASSY
NUMBER
NUMBER

SINGLE-SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04791
D-SIZE
DRAWING TITLE:
CHKD
10/14/03
1 1/2"=1-0"

27
14
(FIELD ASSY)
DETAIL B
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-

ECO NUMBER
(FIELD ASSY)
22
FIELD MOUNT TO A CROSS TIE NEAR

6
A
30
5
2:23:04 PM
30
OF
MICROSTATION
12
10/1/2007
11
NOTES:
SUB-ASSY "A"
SEE DETAIL A
burleson
MATERIAL LIST FOR:

A
SUB-ASSY "B"
SEE CHART
SEE CHART
16
17
EA
19
S08000
20
P08136
29
W09734
QTY
TRP12111
EA
DIVERT CAM GUIDE SS DIVERT
TRP12121
TRP12061
TRP10411
13
N36625
EA
1
N36630
EA
EA
W08100
N36625
EA
21
22
**
23
**
24
**
26
**
27
**
EA
S09088
0314876
NUT ELASTIC STOP NE 5/16-18
EA
EA
WSHR CUT 5/16
BOSCH 45X90 3 842 992 453/381m
EA
EA
WSHR LOCK M12

4
TRP10321
SCR HHC 5/16-18 X 1 1/4
EA
W09159
30
EA
TRP12151
0314165
DRWNG NUM
BOLT CRG 3/8-16X1
EA
W07620
DESCRIPTION
MTG CLIP FOR BOSCH 10mm T-SLOT
N33105
UM
SUPPORT BRKT FOR DIVERT RAIL
EA
S05335

EA
EA
7
TRP10321
28
**
LENGTH
0312815
25
**
QTY
WSHR 1/4 SAE
LOOSE SHIP ITEMS
EA
B20555
BOLT CRG 3/8-16X1
SCR HHC 1/4-20X1 FTHD
TRP12151
TRP10411

EA
TRP12061
DIVERT RAIL MTG CLIP
EA
*
S05145
14
DIVERT RAIL TERMINAL BRACKET
EA
B20555
**
DRWNG NUM
SEE CHART
13

FOR 30^ ASSY
DESCRIPTION
UM
DIVERT GUIDE MTG ANGLE SS
MATERIAL LIST FOR:
**
LENGTH
EA
17
**
WSHR SS 1.000 X .442 X .098
16
SEE SHEET 1 FOR RH ASSY
EA
DIVERT GUIDE SUB-ASSEMBLY "B"
SEE CHART
15
LH DIVERT MODULE (SHOWN)
SCR SHC 1/4-20 X 3 1/2
14
SUB-ASSY "A"
EA
***
WSHR 1/4 SAE
EA
MOUNT TO A CROSS TIE NEAR

EA
***
MATERIAL LIST FOR:

FOR 30^ ASSY
EA
WSHR LOCK 3/8"
*
3
TRP12731
EA
W08100
S06933
SAME AS P/N
EA
TRP12051
SAME AS P/N
PIN ROLL 1/4 X 1/2
EA
N36630
18
EA
DRWNG NUM
SENSOR GUARD BLOCK
S05145
DESCRIPTION
SWITCH ASSEMBLY
EA
UM
EA
N36625
15
B/B-2 1/2
EA
W09330
13
SWITCH MTG BRACKET
EA
***
S06971
12

FOR 30^ ASSY
P08311
11
D
LENGTH
EA
TRP12731
10
4 13/16
QTY
SEE CHART
SWITCH/FIXED DIVERT SUB-ASSEMBLY "A"
NOTE: SEE SHEET 1 FOR RH ASSEMBLY, DETAILS, & NOTES
** BAG & TIE TO DIVERT MODULE WHEN SHIPPING ASSEMBLED TO INTERMEDIATE (ALWAYS SHIP LOOSE)
*** NOT REQD FOR FIXED DIVERT. SUPPLY (1) REF 4 , (3) REF 19 & (2) REF 29S
FOR EACH SWITCH SUB-ASSY.
NOTE: SUB-ASSIES A & B SHIP LOOSE WHEN NOT ASSEMBLED TO INTERMEDIATE
LH FIXED DIVERT DETAIL

REF #3
SWITCH
DIVERT
HAND
FIXED DIVERT
REF #2
DIVERT
ANGLE
REF #1
SWITCH
FIXED DIVERT
A
20
R
TRP12751
REF #5
46
TRP12111-4620
TRP12121-4620R
52
TRP12111-5220
TRP12121-5220R
58
TRP12111-5820
TRP12121-5820R
46
TRP12111-4630
TRP12121-4630R
52
TRP12111-5230
TRP12121-5230R
REF #6
TRP12051-R
A
30
FINISHED P/N: TRA04791-XX XX X F
TRA03621-20R
TRA04811-20
B/B
TRA04811-30
TRA03621-30R
58
TRP12111-5830
TRP12121-5830R
46
TRP12111-4620
TRP12121-4620L
52
TRP12111-5220
TRP12121-5220L
58
TRP12111-5820
TRP12121-5820L
46
TRP12111-4630
TRP12121-4630L
52
TRP12111-5230
TRP12121-5230L
58
TRP12111-5830
TRP12121-5830L
TRP09811
46, 52, OR 58 B/B
20
TRA03621-20L
TRA04761-20
20 OR 30 DEGREE DIVERT ANGLE
2:23:06 PM
SEE SHEET 1 FOR RH ASSY
TRP12051-L
A
30
R OR L (RH OR LH DIVERT)
TRA04761-30
TRA03621-30L
SPECIFY FOR FIXED DIVERT ONLY

A
A
A
CHGD DWG TO STD (WAS SPDS); ADDED P/NS FOR REF 2
3/2/04
TR6-1074
QTY FOR REF 21 WAS 9; ADDED REF 30
11/1/06
PAINT NOTE:
TOLERANCES
RTS
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
M.CARR
BY
DATE
SCALE
APPD
3/8=1

DRAWING TITLE:
CHKD
10/14/03
DIVERT MODULE
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
P/N FOR REF 1 WAS TRP13111-L, -R

DASH
NEXT ASSY
NUMBER
NUMBER

SINGLE-SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA04792
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
TR2-1103
10/1/2007
burleson
NOTES:
FOR 30^ ASSY
1.)
SEE DETAIL A
SEE DETAIL C
SEE DETAIL B
1/32
GAP
WHEN POSSIBLE, SHIP DIVERT MODULE COMPLETELY ASSEMBLED TO WHISPERSORT

INTERMEDIATE SECTION (SEE OVERALL PLAN VIEW). IF DIVERT MODULE MUST SHIP
LOOSE, SUB-ASSEMBLIES "A" THRU "E" & LOOSE SHIP ITEMS ARE TO BE BOXED FOR
FIELD ASSEMBLY (INCLUDE COPY OF DRAWING).
2.)
OPTIONAL DIVERT CONFIRM PROX KIT TRA03801-3 (SHIPPED LOOSE)
3.)
LOCTITE #242 BLUE (PART NO. L39998) REQD ON #22 & #28 IN TAPPED HOLES
4.)
SEE SHEET 2 FOR ASSEMBLY PART NUMBERS AND BILL OF MATERIAL

D
4 13/16
28
SEE NOTE 2
29
30
15
16
SUB-ASSY "E"
SUB-ASSY "A"
34
B/B-2 1/2
B/B-2 1/2
SUB-ASSY "D"
SUB-ASSY "B"
REF
11
26
27
42
35
39
40
(FIELD ASSY)
(FIELD ASSY)
4 13/16
38
DETAIL C
ISOMETRIC
26
1/32
17
27
FIELD INSTALL TO SECTION CROSS TIE HOLES

WHEN CROSS TIE IS NOT PRESENT
SUB-ASSY "C"
GAP
7
18
26
OVERALL PLAN VIEW
27
10
12
FIELD NOTE: MOVE CROSS TIE IN SECTION

IF IT INTERFERS WITH THE SWITCH MOTOR
19
13
20
5
29
30
31
21
22
33
28
30
INSERT GROOVED END OF PIN ITEM #33 INTO ENTRY BLOCK ITEM #5
LEAVING 1/4-3/8" BELOW THE SURFACE OF THE BLOCK
34
10
26
15
27
1
FOR 30^ ASSY
6
24
29
30
25
26
28
30
32
SEE NOTE 4
19
20
21
26
22
27
41
2
35
11
(FIELD ASSY)
10
23
MAKE THE DIVERT RAIL FLUSH

28
29
34
NOTE FOR SWITCH ASSY ONLY
THESE TWO BOLTS HAVE WASHER
BETWEEN SWITCH PLATE
AND MOUNTING BRACKET
30
DETAIL A
ECO #TR2-1103
TR6-1074
ISOMETRIC
ADDED REF 42; REVISED T-BOLTS TO SHOW DOUBLE NUTS
11/1/06
PAINT NOTE:
TOLERANCES
RTS
DATE
REVISION
37
14
DETAIL B
BOM NUMBER:
DWN
BY
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
R. SKANSE
3/5/04
SCALE
1/8" = 1"


DASH
NEXT ASSY
NUMBER
NUMBER

DRAWING TITLE:
CHKD
BY
CROSS-OVER DIVERT MODULE
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
DUAL-SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04841
D-SIZE
REF DWG TRA04331 (REV A)
BY

REV
36
ISOMETRIC
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
26
FIELD NOTE: MOVE CROSS TIE IN SECTION IF THERE IS

INTERFERENCE WITH THE CROSS-OVER SWITCH MOTOR
12
A
2:23:12 PM
42
OF
MICROSTATION
11
27
10/1/2007
26
burleson
18
MATERIAL LIST FOR:

1
24
SEE DETAIL A
25
26
SEE DETAIL B
26
10
12
28
29
TRP12751
SEE CHART
SEE CHART
***
13
SEE CHART
22
S02037
23
P08311
24
29
30
28
32
29
30
DIVERT GUIDE TO BE FLUSH

FROM SWITCH BLOCK
30
20
21
22
DIVERT GUIDE TO BE FLUSH

FROM SWITCH BLOCK
33
26
36
37
P08136
41
W09734
20
21
22
29
30
32
26
27
0314231
26
EA
36
37
EA
QTY
1
4
EA
4
4
CROSS-OVER SWITCH SUB-ASSY "C"

10
23
13
28
29
QTY
SEE CHART
***
15
SEE CHART
***
16
TRP12061
EA
1
29
30
31

FOR 30^ ASSY
33
SEE CHART
26
LH DIVERT SWITCH SUB-ASSY "B"
26
27
A
**
SEE NOTE 2
28
29
17
30
35
**
39
SEE DETAIL C
11
14
29
30
4 13/16
40
A
42
S09088
0314876
QTY
BOLT CRG 3/8-16X1
LENGTH
EA
EA
14
WSHR 1/4 SAE
EA
2
BOLT CRG 3/8-16X1
WSHR 1/4 SAE
MTG CLIP FOR BOSCH 10mm T-SLOT
EA
4
TRP10321
BOSCH 45X90 3 842 992 453/381m

EA
TRP10281
EA
DRWNG NUM
EA
EA
DESCRIPTION
EA
16
UM
FORMED ANG CAM GUIDE
EA
W09159
TRP12061
TRP10411
EA
14
0314165
DIVERT RAIL MTG CLIP
LOOSE SHIP ITEMS
0312815
TRP10321
TRP12011
EA
W08100
34
38
**
15
B20555
S05145
**
**
16
11
27
30
**
N36625
28
DIVERT CAM GUIDE "B" LH
DIVERT RAIL TERMINAL BRACKET

18
EA
EA
MATERIAL LIST FOR:
TRP11991
TRP12011
EA
DRWNG NUM
DIVERT CAM GUIDE "B" RH
EA
W08100
DESCRIPTION
EA
*
*
UM
DIVERT GUIDE MTG ANGLE "B"
EA
N36630
30
WSHR CUT 3/8 ZP
LENGTH
EA
B20555
29
30
SCR SBHC 3/8-16 X 2 BLK OX
EA
DIVERT GUIDE SUB-ASSEMBLIES "D" & "E"
14
S05145
SAME AS P/N
SAME AS P/N
EA
28
DRWNG NUM
ADAPTER SHOULDER 3/8"BR SB0001
N36625
DESCRIPTION
SWITCH ASSY CROSS-OVER
EA
SEE CHART
27
UM
CHANNEL X-MODULE CENTER MTG
EA
W07630
26
WSHR SS 1.000 X .442 X .098
LENGTH
EA
TRP10411
SCR SHC 1/4-20 X 3 1/2

EA
11
17
WSHR 1/4 SAE
EA
CROSS-OVER SWITCH SUB-ASSEMBLY "C"
MATERIAL LIST FOR:
BOLT CRG 3/8-16X1
EA
S02006
WSHR LOCK 3/8"
EA
1-4/20 X 1

EA
N36625
G01101
08P03781
EA
PIN ROLL 1/4 X 1/2
EA
SEE CHART
SCR SBHC
EA
SEE CHART
GD PROX SWITCH X-OVER
MATERIAL LIST FOR:
TRP12001
EA
19
DIVERT CAM GUIDE "A" LH
BALLUFF 18mm INDUCT PROX
EA
S08000
33
EA
S06933
32
RH DIVERT SWITCH SUB-ASSY "A"
31
TRP12001
EA
TRP11981
DIVERT CAM GUIDE "A" RH
W08100
31
DIVERT GUIDE MTG ANGLE "A"
PLATE MTG TAPPED PROX SWITCH
N36630
30
TRP12731
EA
TRP12751
SENSOR GUARD BLOCK
EA
S05145
29
19
TRA04761
EA
B20555
28
TRP12051
SWITCH ASSEMBLY LH
N36625
27
29
W09330
26
SWITCH MTG BRKT LH
EA
EA
S06971
25
EA
EA
G01101
08P03781
TRP12051
TRA04811
***
0312931
DRWNG NUM
SWITCH ASSEMBLY RH
EA
12
DESCRIPTION
EA
EA
1
10
20
UM
SWITCH MTG BRKT RH
***
TRP12731
21
***
SEE CHART
19
LENGTH
EA
***
TRP12051-L
30
QTY
***
SEE CHART
27
23
TRP12051-R
DIVERT SWITCH SUB-ASSEMBLIES "A" & "B"
EA
WSHR LOCK M12

NOTE: SEE SHEET 1 FOR OVERALL PLAN VIEW, DETAILS, & NOTES
** BAG & TIE TO DIVERT MODULE WHEN SHIPPING ASSEMBLED TO INTERMEDIATE (ALWAYS SHIP LOOSE)
28
4 13/16
SEE NOTE 2
*** (1) REF #1 REQD FOR SUB-ASSY "A" & (1) REF #3 REQD FOR SUB-ASSY "B".
SEE CHART FOR QTY OF REF #2, 4, 12, 13, 14, & 15.
16
FINISHED P/N: TRA04841-XX XX
26
27
DIVERT
ANGLE

FOR 30^ ASSY
20
LH DIVERT GUIDE SUB-ASSY "E"
30
SUB-ASSY "A"
SUB-ASSY "B"
REF #2 (QTY=1)
REF #4 (QTY=1)
TRA04811-20
TRA04811-30
TRA04761-20
REF #8
TRA04341
TRA04761-30
TRA04351
20 OR 30 DEGREE DIVERT ANGLE
SUB-ASSY "A"
SUB-ASSY "B"
SUB-ASSY "D"
SUB-ASSY "E"
REF #12 (QTY=1)
REF #13 (QTY=1)
REF #14 (QTY=1)
REF #15 (QTY=1)
TRP12001-4620L
TRP12011-4620R
TRP12011-4620L
TRP10281-4
TRP12001-5220R
TRP12001-5220L
TRP12011-5220R
TRP12011-5220L
TRP10281-5
TRP12001-5820R
TRP12001-5820L
TRP12011-5820R
TRP12011-5820L
TRP10281-6
TRP11991-4630
TRP12001-4630R
TRP12001-4630L
TRP12011-4630R
TRP12011-4630L
TRP10281-1
TRP11981-5230
TRP11991-5230
TRP12001-5230R
TRP12001-5230L
TRP12011-5230R
TRP12011-5230L
TRP10281-2
TRP11981-5830
TRP11991-5830
TRP12001-5830R
TRP12001-5830L
TRP12011-5830R
TRP12011-5830L
TRP10281-3
B/B
REF #7
REF #10
REF #11
46
TRP12101
TRP11981-4620
TRP11991-4620
TRP12001-4620R
52
TRP12131
TRP11981-5220
TRP11991-5220
58
TRP12141
TRP11981-5820
TRP11991-5820
46
TRP12101
TRP11981-4630
52
TRP12131
58
TRP12141
ECO #TR2-1103
TR6-1074
QTY FOR REF 34 WAS 20; ADDED REF 42
11/1/06
PAINT NOTE:
TOLERANCES
RTS
DATE
REVISION
BOM NUMBER:
DWN
BY
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
R. SKANSE
3/5/04
SCALE
1/8" = 1"

DRAWING TITLE:
CHKD
BY
CROSS-OVER DIVERT MODULE
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

REV

DASH
NEXT ASSY
NUMBER
NUMBER

DUAL-SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04842
D-SIZE
REF DWG TRA04332 (REV A)
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
REF #18
OF
MICROSTATION
46, 52, OR 58 B/B
RH DIVERT GUIDE SUB-ASSY "D"
2:23:14 PM
17
10/1/2007
burleson
MATERIAL LIST FOR:

CONVEYOR EFF
TRANSORT
SLAT LENGTH
REF #2
TRA03141
WIDTH
B/B
"L"
PART NUMBER
SEE CHART
24
46
42.500
TRP09121-46
30
52
48.500
TRP09121-52
36
58
54.500
TRP09121-58
14
D
LENGTH
EA
48
EA
48
UM
DESCRIPTION
DRWNG NUM
PUSHER ASSEMBLY
TRA03141
SLAT EXTRUSION
EA
TRP09121
WHEEL FLIGHT
TRP12501
TRP11901-R
24
EA
SIDE PLATE WELDMENT RH
TRP11901
TRP11901-L
24
EA
SIDE PLATE WELDMENT LH
TRP11901
0312192
TRP09181
C19325
W07635
TRP09191
13
14
15
16
EA
EA
48
12
48
96
10
11
15
QTY
24
TRP12501
6
*
FLIGHT CHAIN ASSEMBLY
EA
48
EA
N36625
96
TRP09201
48
TRP10161
R63137
B48150
WSHR FLAT SAE 3/8 (.406X.812X.
EA
EA
48
SCREW WHEEL MTG
EA
EA
48
EA
TRP10161
BSHG DRIVE TRANSORT FT
18
W09730
24
EA
19
P08170
24
EA
2
TRP10171
SIDE PLATE SPACER
C11870
L34125
EA
TRP09201
WHEEL HUB
RIVET 3/16X.575 STEEL 3/8 HEAD
17
20
TRP09191
NUT HEX 3/8-16 NYLOCK
EA
96
C19325
SCR SIDE GD BRG MTG TSORT FT-3
48
TRP09181
CLIP STABILIZER TRANSORT FT
EA
48
TRP10171
BRG 6201-2RSVC3SR12 ABEC1
SCR CLAMP 5/16-18X1 14 LNG-LOK
B48150
CHAIN RC-100 TSORT FT
C11870
WSHR SS .875OD X .391ID X .051

PIN HITCH "WW" CLIP #13
EA
CPLG LINK
SEE SHEET 2 FOR FLIGHT CHAIN ASSY WITH ITEMS 17, 18, 19 & 20.
DETAIL A
NOTE: APPLY LOCTITE 242 TO THREADS ON ITEM # 7 PER INSPECTION SHEET(SLAT BOLT ASSEMBLY AND TEST.XLS)
FINISHED ASSY P/N: TRA04851-XX
(ENLARGED)
C
(ITEMS 2 & 7 HIDDEN FOR CLARITY)
46, 52, OR 58 B/B

"L" .010
TRAVEL
1
1
2
TIGHTEN NUT TO
240 in-lb TORQUE
(20 ft-lbs)
3
10
10
2
TORQUE TO
240 in-lbs
(20FT-LBS)
11
11
B
9
6
6
12
12
12
TIGHTEN NUT TO
16
240 in-lb TORQUE

(20 ft-lbs)
16
13
13
5
4
TR6-1037
UPATED VIEW TO SHOW NEW SLAT PROFILE
3/30/06
TR7-1092
ADDED LOCTITE NOTE
9/5/07
PAINT NOTE:
TOLERANCES
MPC
REV
DATE
REVISION
BOM NUMBER:
DWN
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
CO
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
R. SKANSE
3/8/04
SCALE
FULL

DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04851
D-SIZE
REF DWG TRA04281
ECO #TR2-1103
OF
MICROSTATION
2:23:17 PM
FLIGHT ASSEMBLY
10/1/2007
burleson
NOTES:
1.) CHAIN (REF #17) MUST BE ASSEMBLED IN PAIRS (CHAIN ENDS MUST MATCH)
1 3/4
REF.
17
C
C
3
END VIEW "X-X"
120 REF
118 3/4
3 3/4
(11) SPCS @ 10 = 110
1 1/4
REF
TRAVEL
1 1/4
REF
X
19
17
2:23:20 PM
X
18
USE PRE-WIRED
MATCHED PAIRS
20
CPLG LINK SEE NOTE #2
SHOP NOTE!!!
ECO #TR2-1103
TR6-1037
UPATED VIEW TO SHOW NEW SLAT PROFILE
3/30/06
TR7-1092
SEE SHEET 1 FOR REVISION INFO
9/5/07
PAINT NOTE:
TOLERANCES
MPC
REV
DATE
REVISION
BOM NUMBER:
DWN
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
CO
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
R. SKANSE
3/8/04
SCALE
1/2" = 1"

DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04852
D-SIZE
REF DWG TRA04282
OF
MICROSTATION
10/1/2007
1 1/16
SEE SHEET 1 FOR FLIGHT ASSY
burleson
WHISPERSORT B/B - 3 1/2
1 3/4
2.) BAG AND WIRE TIE THE CHAIN COUPLER LINKS (REF #20) TO THE CHAIN
MATERIAL LIST FOR:

1
TRP08591
QTY
LENGTH
EA
UM
DESCRIPTION
DRWNG NUM
PUSHER BODY
TRP08591
TRP08601
EA
BUMPER PUSHER RH 21^
TRP08601
TRP08611
EA
BUMPER PUSHER LH 21^
TRP08611
0312030
EA
0312028
EA
S11360
EA
TRP08621
WSHR .875 X .327 X .125 SS
SPRING DISC SCHNORR #007400
.906 X .323 X .028 X .059

D
7
8
TRP08641
TORQUE TO 80 IN-LBS
6 3/16
B29505
EA
EA
10
0312029
11
TRP08631
EA
SCR SHSS 8 X 50 W/ PRECOTE 80

SPRING PUSHER PRE-LOAD
TRP08621
BEARING ADAPTER PUSHER
TRP08641
BRG 40MM OD X 17MM ID X 12MM W
EA
B29505
WSHR .876 X .471 X .049 SS
EA
PUSHER PIN
TRP08631
REF
.10
.04
1.28
REF
7 1/4 REF
NOTE!
NYLOK PRECOTE 80
TO BE PRE-APPLIED
TO THREADS OF
SHOULDER SCR (#6)
(SLAT)
5 1/16
REF
(SLAT)
1.69
2.43
3.30
9/32
REF
8
9
9
1 11/32 REF
.87
11
10
11
2 1/2
FRONT
REF
10:02:35 AM
10
3 11/16 REF
LEFT
A
ECO #TR21-137
PAINT NOTE:
TOLERANCES
TR6-1012
REF #7 CHANGED - UPDATED VIEWS
1/22/07
JJW
TR2-1103
ADDED PRECOTE DESCRIPTION TO ITEM #6
11/14/03
JJW
TR2-1103
CHANGED TORQUE FROM 120 TO 80 IN-LBS
11/14/03
JJW
TR1-1073
P/N 0312028 (REF #5) WAS SCHNORR #004400
08/30/2001
TAK
ECO NUMBER
REV
DATE
REVISION
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
APPROVED
BY
BY
DWN
BY
DATE

SUPERSEDES:
MATERIAL:

DASH
NEXT ASSY
NUMBER
NUMBER
KOENINGER, T
09/22/2000
SCALE
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DRAWING TITLE:
CHKD
BY
PUSHER ASSEMBLY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
FULL
FLIGHT ASSEMBLY
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03141
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
u:\dms\burleson\copy\TRA03141PusherAssembly.dgn
1.22
REF
10/2/2007
TOP
burleson
.10
.04
MATERIAL LIST FOR:

108
114
EA
MTG BLOCK - ENTRY GUIDE RH
TRP11961
103
TRP11961-L
EA
MTG BLOCK - ENTRY GUIDE LH
TRP11961
A00002
109
B53820
110
113
105
102
115
S10006
116
0312999
DIVERT MOTOR ASSY

SWITCH ARM
EA
4
WASHER LOCK 3/8
SCR SHC #8-32 X 3/4 SS

KEY - 1/8 SQ. X 3/4 LG
118
S06950
EA
SCR SHC 5/16-18 X 3/4
119
W09320
EA
WASHER LOCK 5/16
EA
120
S06924
121
W09310
122
P08311
SCR SHC 1/4-20 X 1/2
EA
B53820
SCR FHSC 1/4-20 X 1 BLK OX
EA
A00002
WASHER LOCK #10
EA
A00001
SCR SHC 3/8-16 X 3/4 BLK OX
EA
EA
TRP11971
SCR SHC #10-32 X 3/4 BLK OX
EA
P08136
EA
EA
EA
TRP12021
MTG BLOCK - V-GUIDE - 20^
BUMPER - CROSS-OVER SWITCH
S04149
BLOCK - X-SWITCH V-GUIDE - 20^
EA
TRP12091
ARM CLAMP - CROSS-OVER SWITCH
EA
4
W09330
114
110
EA
S06970
117
111
W09160
112
1
1
S06902
BASE PLATE - 20^ X-SWITCH
EA
0312978
111
117
EA
A00001
108
TRP11971
106
103
DRWNG NUM
104
DESCRIPTION
TRP11961-R
TRP12021
EA
UM
102
107
109
LENGTH
D
107
QTY
TRP12091
105
115
101
104
116
SWITCH ASSY - 20^ CROSS-OVER
EA
WSHR LOCK 1/4

PIN ROLL 1/4 X 1/2
117
115
117
102
101
117
116
108
104
107
101
106
105
109
112
36%%d
120
121
113
A
119
118
112
113
122
B
118
119
103
114
121
111
106
122
120
110
NOTES:
1.) LOCTITE #242 REQUIRED ON
2:22:54 PM
ALL THREADED FASTENERS.
106
ECO #TR1-1041
TR2-1144
ITEM #110 WAS S06932; QTY OF ITEMS #112 & 113
12/19/02
TR4-1083
ADDED REF 120-122 (HARDWARE WAS INCLUDED W/ MOTOR)
5/5/05
PAINT NOTE:
TOLERANCES
TB
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
WAS 7; ADD ITEMS #118 & 119

RTS
ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY
DWN
BY
DATE

SUPERSEDES:
MATERIAL:

DASH
NEXT ASSY
NUMBER
NUMBER
BREWER,T.
4/23/02
SCALE
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1/2" = 1"
DUAL DIVERT WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA04341
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
10/1/2007
burleson
MATERIAL LIST FOR:

B
6 1/16 REF
2
1/8
19
SEE CHART
SEE CHART
SEE CHART
SEE CHART
NOTES:
1) SHIP IN TWO (2) PIECES
2) BAG & TIE REF #5 (2), #6 (2), #7, #8, #10, #11,
3) REF #9 SHIP LOOSE
LH ASSY
RH ASSY
REF #2
REF #4
TRP09981-L
TRP10021-L
TRP09981-R
TRP10021-R
FINISHED P/N: TRA03681-XX X

46, 52, 58 B/B
R OR L
+
+SEE CHART FOR QTY
E
REF #1
REF #3
B/B
24
46
TRP10011-46L
TRP10011-46R
30
52
TRP10011-52L
TRP10011-52R
36
58
TRP10011-58L
TRP10011-58R
TRP09941-58L
LH ASSY
RH ASSY
LH ASSY
DESCRIPTION
DRWNG NUM
EA
RETURN GUIDE EXIT WELDMENT
TRP10011
TRP09981
+
++
+ FLOOR STOCK - QTY AS REQD
S09088
RETURN GUIDE EXIT FLAT
TRP10021
**
EA
EA
EA
14
TRP13291
EA
16
17
S05100
18
W09310
19
20
EA
5
N33105
EA
SCR HHC 1/4-20 X 1/2
EA
EA
WSHR LOCK 1/4

WSHR FLAT SAE 1/4
**
EA
EA
WSHR FLAT 5/16
RETURN GUIDE MOUNTING BRACKET
+
+QUANTITIES
REF #9
NUT ELASTIC STOP 5/16-18
EA
**
TRP13291
BOLT CRG 5/16-18 X 3/4
EA
**
W07620
TRP10331
SCR SFHC #10-32X1 1/4
RETURN GUIDE MOUNTING CLIP
**
0314876
WSHR LOCK M12
EA
W08100
TRP15191
EA
MERGE GUIDE BLK RET GUIDE SS
B20552
BOSCH 45X90 3 842 992 433/--MM
*
EA
"A"
"B"
176 29/32
153 15/16
45 7/8
204 5/8
181 21/32
73 19/32
232 11/32
209 3/8
101 5/16
RH ASSY
HK P/N
REF #7
REF #9
REF #10
REF #11
REF #19
REF #20
TRP09941-46L
TRP09941-46R
0312816
24
24
19
TRP09941-52L
TRP09941-52R
0312817
24
24
21
TRP09941-58R
0312818
28
28
23
TRP15191
"C"
12
E
TRP10321
EA
S04163
MTG CLIP FOR BOSCH 10MM T-SLOT
EA
W09159
TRP10331
21
EA
13
22
TRP09941
EA
SEE CHART
15
EA
RETURN GUIDE ENTRY FLAT
0312815
11
12
E/W
UM
RETURN GUIDE ENTRY WELDMENT
**
TRP10321
10
(ENLARGED)
LENGTH
EA
S05145
#19 (2), & #20
QTY
N36630
(DO NOT SPLICE AT DETAIL "A" WHEN SHIPPING)
DETAIL A
REF
RETURN GUIDE ASSEMBLY
13
14
TOP VIEW LH ASSY
2
8
14
17
18
19
USE LOCTITE #242 BLUE (P/N L39998) ON THREADS
PRODUCT
RETURN
TRAVEL
TRAVEL
5
"B" REF
22
16
B
15
16
21
15
C
21
15
19
16
F)
21
32
5/
5 1
(RE
22
12
13
"A" REF
TOP VIEW RH ASSY

22
22
"C" REF
2:19:12 PM
12
107 15/16 REF
QTY OF REF 8 WAS 4; REVISED VIEWS OF REF 22
7/11/07
PAINT NOTE:
TOLERANCES
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
KOENINGER, T
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
03/07/2001
SCALE
1 1/2"=1-0"

DRAWING TITLE:
CHKD
BY
RETURN GUIDE ASSEMBLY LH & RH
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-

DASH
NEXT ASSY
NUMBER
NUMBER

SINGLE SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03681
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
TR7-1072
burleson
ECO #TR21-137
10/1/2007
FRONT VIEW RH ASSY

A
MATERIAL LIST FOR:

TRA04381
N36630
**
6
7
D
2) BAG & TIE REF #5 (2), #6 (2), #7, #8, #10, #11,
1/8
#12, & #19 (2)
REF
19
6 1/16 REF
C
B
DETAIL A
(ENLARGED)
E/W
B/B
REF #1
REF #2
REF #4
REF #9
QUANTITY
HK P/N
REF #7 & #12
24
46
TRP10011-46L
TRP09941-46L
TRA04401
0312816
30
52
TRP10011-52L
TRP09941-52L
TRA04371
0312817
36
58
TRP10011-58L
TRP09941-58L
TRA04411
0312818
31 1/2
27
S09088
13
14
15
16
17
S05100
18
W09310
19
20
B20552
TRP15191
EA
**
**
NUT ELASTIC STOP 5/16-18

SCR HHC 1/4-20 X 1/2
EA
**
EA
EA
TRP13291
BOLT CRG 5/16-18 X 3/4
EA
WSHR FLAT 5/16
RETURN GUIDE MOUNTING CLIP

EA
W08100
WSHR LOCK M12
EA
EA
N33105
BOSCH 45X90 3 842 992 433/--MM
**
2
TRP10321
EA
W07620
TRP13291
EA
TRA04381
SEE CHART
EA
EA
20
0314876
TRP10011
TRP09941
W09159
12
DRWNG NUM
RETURN GUIDE ASSY DUAL SIDE RH
EA
20
DESCRIPTION
RETURN GUIDE ENTRY FLAT
EA
EA
UM
RETURN GUIDE ASSY DUAL SIDE LH
EA
10
WSHR LOCK 1/4

WSHR FLAT SAE 1/4
RETURN GUIDE MOUNTING BRACKET
TRP15191
+
+SEE CHART FOR QTY
+
++
+FLOOR STOCK
17
0312815
11
B
EA
SEE CHART
10
3) REF #9 SHIP LOOSE
EA
**
TRP10321
RETURN GUIDE ENTRY WELDMENT
EA
S05145
LENGTH
EA
1
SEE CHART
(DO NOT SPLICE AT DETAIL "A" WHEN SHIPPING)
SEE CHART
1)SHIP IN THREE (3) PIECES
QTY
NOTES:
D
SEE CHART
RETURN GUIDE ASSY DUAL SIDE
18
27
19
USE LOCTITE #242 BLUE

(P/N L39998) ON THREADS
27
TAIL SECTION BOTTOM SWITCH
27
END OF TAIL SECTION
4 13/32
7
12
14
D
13/16
10
13
11
10
15
16
11
13/16
DETAIL A
8
3
20
12
C
TORQUE T-BOLTS TO 220 IN-LBS
35
16
14
12
10
11
B
12
10
11
TORQUE BOLTS TO 310 IN-LBS
4 13/32
17
18
19
USE LOCTITE #242 BLUE

(P/N L39998) ON THREADS
10
11
PUSHER CAM/PIN MUST BE ABLE
TO PASS THROUGH GUIDE OPENING
CENTERED ON THE 35" DIMENSION
TOP VIEW
TORQUE BOLTS TO 310 IN-LBS
(SHOWING ONLY THE BOTTOM CROSS-TIES)

10 11/16
2:22:58 PM
(52 B/B SHOWN)
FINISHED P/N: TRA04391-XX

ECO #TR1-1041
TR7-1072
46, 52, 58 B/B
POSITION OF BOTTOM CROSS-TIES
QTY OF REF 8 WAS 9; QTY OF REF 15 & 16 WAS 6; QTY
7/11/07
PAINT NOTE:
TOLERANCES
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
J.Wilkins
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
05/24/02
SCALE
1 1/2"=1-0"

DRAWING TITLE:
CHKD
BY
RETURN GUIDE ASSY DUAL SIDE
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
OF REF 20 WAS 2; REVISED VIEWS OF REF 3, 4, & 20

DASH
NEXT ASSY
NUMBER
NUMBER

DUAL SIDED WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04391
D-SIZE
OF
MICROSTATION
10/1/2007
15
burleson
13
18 1/4
1 3/8
16 3/4
9
B
30
31
3
SWITCH ASSEMBLY LH
QTY
0312978
S06924
W09310
P08311
C10001
19
W09141
TRP10551
TRP08651
11
27
14
21/32
EA
EA
TRP12741
13
33
EA
SWITCH BUMPER
TRP08651
SCREW SHC 1/4-20 X 3/4
EA
TRP10551
BUMPER MTG BLOCK
BLOCK PIN GUIDE ENTRANCE LH
TRP08671
WSHR #8-32 LOCK SS
EA
S06933
C10001
SCR #8-32 X 3/4 SHC SS
EA
TRP12851
SWITCH ARM CLAMP
EA
SO6925
12
36
SWITCH ARM LH 7" RADIUS
EA
4
9
26
32
S10006
10
34
22
PIN ROLL 1/4 X 1/2
EA
TRP12741
SCR SHC 1/4-20X1 3/4
PLATE PIN GUIDE MTG
TRP08671
15
N36630
EA
16
R59385
EA
BALLUFF RETAINER BES-18-BS-1
17
20
21
3 15/32 A
2.61
20^
6 1/4
18
S12123
19
W09150
TRP12761
21
S06022
24
25
14
15
S06020
10
30
31
16
18
9 9/32
19
TRP13071
WSHR LOCK 1/4"
EA
1
S73326
PROX BALLUFF BES-516-326G-S4-C
EA
SCR 1/4-20 X 5/8 SHC LOW HD
SHIM BUMPER .032 X.003 LAMINAT
DIVERTER BLADE LH
EA
TRP12871
KEY 1/8 SQ X 3/4 LG C1018
35
S06946
EA
SCR SFHC 1/4-20 X 3/4
NOTES:
25
8 31/32
1.)
11
ADJUST ARM TO BE
FLUSH W/ BLOCK
20
0312999
36
PEEL LAYERS TO
SHIM BUMPERS
SEE DETAIL
EA
1
TRP12871
34
EA
0312931
33
28
SWITCH MTG PLATE
EA
S73326
32
EA
4
TRP12891/TRP13151
1/4" X 1 1/4" GROOVED PIN
29
31
1
WSHR LOCK 3/8"
TOP DIVERTER BLOCK LH
EA
TRP12831
EA
EA
TRP12761
SCR SELF TAP FL HD #10X3/4 ZP
BOTTOM DIVERTER BLOCK LH
W09310
WASHER LOCK NO8

PLATE PROX MTG
EA
TRP13071
30
12
EA
W09330
28
13
EA
P08136
27
EA
SEE CHART
26
C
S06970
SCREW SHC 8-32 X 1 1/4 L
EA
TRP12831
23
EA
20
22
1 9/32
PLEASE NOTE TOLERANCE BLOCK
2.)
DIMENSIONS ARE FOR REFERENCE ONLY
3.)
FOR RH ASSY, SEE DWG
4.)
LOCTITE #242 BLUE (PART NO. L39998) REQD ON ALL THREADED FASTENERS
5.)
INSERT GROOVED END OF ALL PINS (ITEM #26) INTO BOTTOM DIVERTER BLOCK (ITEM #22) &
21
PIN GUIDE BLOCK (ITEM #12) LEAVING 3/8-1/2" MAXIMUM ABOVE THE SURFACE OF THE BLOCKS
12
2 3/4
B
ALIGN CURVE ON ARM
WITH THIS EDGE
26
(4 49/64 )
26
23
24
26
15
C
B
10
28
EVENLY TIGHTEN THE 2 BOLTS OVER THE KEY FIRST, THEN EVENLY TIGHTEN THE OTHER
2 BOLTS WHEN ASSEMBLING SWITCH ARM TO MOTOR (TORQUE 33 INCH-LBS & SEE NOTE #4)
PART NUMBER CHART
DIV. ANGLE
ITEM #25 P/N
ASSEMBLY P/N
20^ ASSY
TRP12891
TRA04761-20
30^ ASSY
TRP13151
TRA04761-30
A
TR2-1103
CHGD DWG TO STD (WAS SPDS); ADDED P/NS FOR 30^
3/2/04
FRACTIONS
.XX
.XXX
.XXXX
35; UPDATED ALIGNMENT DETAIL & DIMS

TR5-1001
ADDED PROX SWITCH DIM. & BOLT TIGHTENING NOTE
1/4/05
JJW
TR6-1074
QTY OF REF 2 WAS 4; DELETED REF 29
11/1/06
RTS
ECO NUMBER
REV
DATE
REVISION
PAINT NOTE:
TOLERANCES
RTS
ASSY; REVD REF 1; ADDED REF 2, 3, & 4; DELETED REF
APPROVED
BY
BY
BOM NUMBER:
DWN
BY
SUPERSEDES:
MATERIAL:
SEE MATERIAL LIST

DASH
NEXT ASSY
NUMBER
NUMBER
ALIGNMENT DETAIL
A
DATE

MACHINING
1/2 ^
FABRICATING
1^
CHANGED
ALIGN THIS EDGE WITH

THE STRAIGHT BACK ON ARM
N/A
+
- 1/32"
+
.015
+
.005
+
.0010
-
2:23:00 PM
14
M. CARR
CHKD
10/8/2003
DATE
SCALE
APPD
DRAWING TITLE:
BY
SWITCH ASSEMBLY 7" RAD ARM LH

WEIGHT:
PRODUCT OR MODEL:
BY
1/2" = 1"
DIVERT SWITCH ASSEMBLY
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA04761
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
13
10/1/2007
18
WSHR LOCK 1/4
EA
EA
DRWNG NUM
SCR SHC 1/4-20 X 1/2
EA
DESCRIPTION
DIVERT MOTOR ASSY
EA
UM
burleson
16
EA
TRP12851
LENGTH
MATERIAL LIST FOR:
MATERIAL LIST FOR:

104
EA
MTG BLOCK - ENTRY GUIDE RH
TRP11961
103
TRP11961-L
EA
MTG BLOCK - ENTRY GUIDE LH
TRP11961
B53820
110
111
113
S10006
116
0312999
102
P08136
EA
118
S06950
119
W09320
120
S06924
121
122
W09310
P08311
SCR SHC #8-32 X 3/4 SS
EA
WASHER LOCK 3/8
EA
KEY - 1/8 SQ. X 3/4 LG

EA
SCR SHC 5/16-18 X 3/4
EA
WASHER LOCK 5/16
EA
6
SCR SHC 1/4-20 X 1/2
EA
B53820
WASHER LOCK #10
EA
A00002
EA
B C
111
EA
A00001
SCR SHC #10-32 X 3/4 BLK OX
EA
W09330
115
SWITCH ARM
BUMPER - CROSS-OVER SWITCH
S06925
117
DIVERT MOTOR ASSY W/FASTENERS
EA
TRP12041
ARM CLAMP - CROSS-OVER SWITCH
EA
4
S06970
114
C
105
TRP12031
MTG BLOCK - V-GUIDE - 30^
EA
EA
W09160
112
117
EA
TRP12081
BLOCK - X-SWITCH V-GUIDE - 30^
S06902
BASE PLATE - 30^ X-SWITCH
EA
A00001
109
EA
0312978
A00002
TRP12041
108
103
DRWNG NUM
107
109
DESCRIPTION
TRP11961-R
TRP12031
EA
UM
102
106
107
LENGTH
114
116
QTY
TRP12081
105
115
D
101
104
121
108
EA
WSHR LOCK 1/4

PIN ROLL 1/4 X 1/2
110
116
115
117
106
107
108
101
102
104
117
105
117
109
112
60%%d
101
113
120
121
114
121
118
119
112
122
113
A
118
119
110
103
120
122
121
111
106
NOTES:
1.) LOCTITE #242 REQUIRED ON
3/8 REF
TR2-1144
ITEM #110 WAS S06932; QTY OF ITEMS #112 & 113
12/19/02
TR4-1083
TR6-1086
ECO NUMBER
REV
ADDED REF 120-122 (HARDWARE WAS INCLUDED W/ MOTOR)

CHNG ITEM 114 & CHNG QTY ITEM 117 & 121.
5/5/05
1/4/07
DATE
REVISION
PAINT NOTE:
TOLERANCES
TB
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
WAS 7; ADD ITEMS #118 & 119

RTS
JJW
APPROVED
BY
BY
DWN
BY
DATE

SUPERSEDES:
MATERIAL:

DASH
NEXT ASSY
NUMBER
NUMBER
BREWER,T.
4/24/02
SCALE
SEE MATERIAL LIST

CHANGED
BOM NUMBER:
N/A
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DRAWING TITLE:
CHKD
BY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY
1/2" = 1"
DUAL DIVERT WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA04351
D-SIZE
REV
WHISPERSORT
2
OF
burleson
ECO #TR1-1041
MICROSTATION
10/1/2007
2:22:56 PM
ALL THREADED FASTENERS.
18 1/4
1 3/8
16 3/4
QTY
0312978
S06924
W09310
P08311
10
30
31
12
S10006
W09141
TRP10551
10
TRP08651
15
EA
EA
TRP08651
SCREW SHC 1/4-20 X 3/4
BLOCK PIN GUIDE ENTRANCE RH
TRP08671
TRP10551
BUMPER MTG BLOCK
EA
WSHR #8-32 LOCK SS
SWITCH BUMPER
EA
S06933
14
EA
C10001
SCR #8-32 X 3/4 SHC SS
EA
TRP12841
SWITCH ARM CLAMP
EA
TRP12781
13
14
PIN ROLL 1/4 X 1/2
SWITCH ARM RH 7" RADIUS
EA
SO6925
12
13
EA
DRWNG NUM
WSHR LOCK 1/4
EA
DESCRIPTION
SCR SHC 1/4-20 X 1/2
EA
UM
DIVERT MOTOR ASSY
EA
4
2
C10001
11
EA
TRP12841
LENGTH
EA
TRP12781
SCR SHC 1/4-20X1 3/4
PLATE PIN GUIDE MTG
TRP08671
15
N36630
EA
16
R59385
EA
BALLUFF RETAINER BES-18-BS-1
17
A
1 9/32
6 1/4
3 15/32
2.61
20^
2.85
30^
18
S12123
19
W09150
TRP12761
21
S06022
22
25
A
C
18
19
36
27
S06020
S73326
16
18
30
9 9/32
19
EA
EA
TRP12861
0312999
SWITCH MTG PLATE
TRP13071
WSHR LOCK 1/4"
SCR 1/4-20 X 5/8 SHC LOW HD
SHIM BUMPER .032 X.003 LAMINAT
EA
S73326
PROX BALLUFF BES-516-326G-S4-C
EA
DIVERT BLADE RH
EA
TRP12861
KEY 1/8 SQ X 3/4 LG C1018
35
36
S06946
EA
SCR SFHC 1/4-20 X 3/4
* FLOOR STOCK
31
25
8 31/32
11
NOTES:
1.)
ADJUST ARM TO BE
FLUSH W/ BLOCK
20
TRP12881/TRP13161
1/4" X 1 1/4" GROOVED PIN
EA
33
26
EA
0312931
WSHR LOCK 3/8"
TOP DIVERTER BLOCK RH
TRP12821
EA
32
34
22
BOTTOM DIVERTER BLOCK RH
29
31
33
34
TRP12761
SCR SELF TAP FL HD #10X3/4 ZP
EA
EA
W09310
WASHER LOCK NO8

PLATE PROX MTG
EA
*
TRP13071
30
32
EA
P08136
28
16
EA
W09330
27
EA
SEE CHART
26
21/32
S06970
SCREW SHC 8-32 X 1 1/4 L
EA
TRP12821
24
21
EA
20
23
20
PLEASE NOTE TOLERANCE BLOCK
2.)
DIMENSIONS ARE FOR REFERENCE ONLY
3.)
FOR LH ASSY, SEE DWG
4.)
LOCTITE #242 BLUE (PART NO. L39998) REQD ON ALL THREADED FASTENERS
5.)
INSERT GROOVED END OF ALL PINS (ITEM #26) INTO BOTTOM DIVERTER BLOCK (ITEM #22) &
21
12
2 3/4
PIN GUIDE BLOCK (ITEM #12) LEAVING 3/8-1/2" MAXIMUM ABOVE THE SURFACE OF THE BLOCKS
ALIGN THIS EDGE WITH

THE STRAIGHT BACK ON ARM
26
(4 49/64 )
26
23
24
26
15
10
28
EVENLY TIGHTEN THE 2 BOLTS OVER THE KEY FIRST, THEN EVENLY TIGHTEN THE OTHER
2 BOLTS WHEN ASSEMBLING SWITCH ARM TO MOTOR (TORQUE 33 INCH-LBS & SEE NOTE #4)
2
1
PART NUMBER CHART

DIV. ANGLE
ITEM #25 P/N
ASSEMBLY P/N
20^ ASSY
TRP12881
TRA04811-20
30^ ASSY
TRP13161
TRA04811-30
ALIGN CURVE ON ARM

WITH THIS EDGE
A
TR2-1103
CHGD DWG TO STD (WAS SPDS); REVISED REF 1; ADDED
3/2/04
FRACTIONS
.XX
.XXX
.XXXX
REF 35; UPDATED ALIGNMENT DETAIL & DIMS

TR5-1001
ADDED PROX SWITCH DIM. & BOLT TIGHTENING NOTE
1/4/05
JJW
TR6-1074
QTY OF REF 2 WAS 4; DELETED REF 29
11/1/06
RTS
ECO NUMBER
REV
DATE
REVISION
APPROVED
BY
BY
DWN
BY
DATE
SUPERSEDES:
MATERIAL:
SEE MATERIAL LIST

MACHINING
1/2 ^
FABRICATING
1^
CHANGED
BOM NUMBER:
N/A
+
- 1/32"
+
.015
+
.005
+
.0010
-

DASH
NEXT ASSY
NUMBER
NUMBER
ALIGNMENT DETAIL
A
PAINT NOTE:
TOLERANCES
RTS
REF 2, 3, & 4; CORRECTED DWG FOR REF 22; DELETED
M. CARR
CHKD
10/8/2003
DATE
SCALE
APPD
DRAWING TITLE:
BY
SWITCH ASSEMBLY RH W/7" RAD ARM

WEIGHT:
PRODUCT OR MODEL:
BY
1/2" = 1"
SWITCH ASSEMBLY
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
REV
WHISPERSORT
TRA04811
D-SIZE
2:23:09 PM
14
OF
MICROSTATION
13
10/1/2007
28
burleson
SWITCH ASSEMBLY RH
PEEL LAYERS TO
SHIM BUMPERS
SEE DETAIL
MATERIAL LIST FOR:
MATERIAL LIST FOR:

201
B/B
202
SEE CHART
TRP11011L
203
204
TRP11031
"A"
PIN GD GRAY
215
TRP11071
EA
PAD WHISPERSORT TRACK X 21.125
TRP11071
208
TRP11081
EA
TRP11081
TRP11011R
08P01181
S06942
N36630
213
S06912
214
N38736
215
0312815
216
EA
EA
08P01181
BOLT SQ HD 1/4-20X1 1/4
NUT #10-32 NYLOCK ZP
SCR HHC M12X1.75X50 FTHD GRD 5
EA
WSHR LOCK M12
VERTICAL TRANSITION ASSY
217
REF. #201
B/B
EFF. WIDTH
DIVERT
24"
46"
"B"
"C"
"D"
"E"
RH
LH
TRA03991L-52
LH
TRA03991R-58
RH
LH
RH
TRA03991R-52
SINGLE SIDED
204
"A"
52"
30"
"F"
0312816
TRA03991L-46
205
TRP11011
SCR SHC #10-32 X 1 1/4 BLK OX
EA
"F"
EA
"C"
W09159
ANG FRMD PIN GD MT RH
EA
"C"
TRP11061
PIN GD TAIL .375 SLOT X 18.38L
EA
"B"
S09088
217
EA
EA
"B"
212
"E"
"A"
TRA03991R-46
208
TRP11051
207
ASSEMBLY No.
TRP11031
WHEEL TRACK 126.60 LG
203
216
207
TRP11021
(18)
206
TRP11011
CHNL PIN GD MTG
EA
EA
DRWNG NUM
ANG FRMD PIN GD MT LH
EA
DESCRIPTION
EA
201
215
EA
UM
BOSCH 45X90 3 842 992 433/--MM
211
209
EA
TRP11061
210
202
LENGTH
"A"
TRP11051
206
209
203
QTY
"D"
TRP11021
205
RH, LH & DUAL VERT TRANSITION ASSY
0312817
204
36"
58"
0312818
TRA03991D-46
24"
46"
0312816
TRA03991D-52
30"
52"
0312817
TRA03991D-58
36"
58"
0312818
DUAL SIDED
THESE 2 SPREADERS ARE

IN THE WELDED FRAME ASSY
VIEW "X-X"
211
DUAL
TRA03991L-58
12
12
212
(ENLARGED)
B
216
NOTES:
217
1.)
211
213
212
213
WORK THIS DWG WITH DWG TRA03981 FOR RH DIVERT ASSY,

TRA03982 FOR LH DIVERT ASSY, & TRA03983 FOR DUAL ASSY.
201
214
214
CHAIN
209
TRAVEL
210
3/16
3/16 X45^
X 45^
BEVEL @ ASSY
45^
6 X
3/1
BEVEL @ ASSY
215
208
207
206
LH DIVERT ASSEMBLY VIEW
CHAIN
202
RH DIVERT ASSEMBLY VIEW
ECO # TR1-1041
TR1-1041
CHGD TO STD DWG (WAS SPDS)
7/5/02
RTS
TR2-1124
ADDED ITEMS 216 & 217
9/30/02
JJW
TR3-1155
CORRD CHART, NOTE, & ASSY VIEWS FOR DIVERT HAND
11/18/03
RTS
TR4-1085
ECO NUMBER
REV
REVD VIEWS OF REF 202 & 209 (WERE FORMED ANGLES)
11/30/04
DATE
REVISION
PAINT NOTE:
TOLERANCES
BOM NUMBER:
DWN
K. DAY
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
APPROVED
BY
BY
SCALE
3/16" = 1"

DRAWING TITLE:
CHKD
BY
VERTICAL TRANSITION ASSEMBLY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

CHANGED
SUPERSEDES:
MATERIAL:
09/27/2001

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT 42T TAIL ASSY
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03991
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
2:20:29 PM
TRAVEL
10/1/2007
burleson
MATERIAL LIST FOR:

100
SEE CHART
101
104
W07640
105
W09340
106
M00150
107
108
B44160
EA
1
112
B20550
113
N36625
WASHER CUT 7/16

D
SCREW RHM #10-32 X 3/4
EA
SEE CHART
TRP14351
WASHER LOCK 7/16
EA
TRP14321
TSD002EB
MAGNET #5688K52 BUTTON TYPE
EA
1
W09160
110
111
EA
N35886
109
EA
DRWNG NUM
SCREW HHC 7/16 X 3/4
EA
DESCRIPTION
STOP BRACKET
EA
UM
PUSHER INNER SHAFT
EA
S10797
PUSHER OUT OF PLACE BRKT
EA
S05720
LENGTH
EA
TRP14351
103
QTY
SEE CHART
102
PUSHER OUT OF PLACE ASSY END DISCHARGE
NUT HEX #10-32

WASHER LOCK #10
BSHG BRONZE FLNG FB1215-8 1"LG
EA
PUSHER STRIKE FLAT
EA
EA
TRP14341
BOLT CRG 3/8-16 X 3/4

NUT NYLOK 3/8-16 (ZP)
9 7/8
9 7/8
111
112
113
111
109
112
113
108
107
106
106
107
108
109
102
110
105
102
103
104
104
110
103
110
101
100
105
5/32
5/32
B
B
11/64
REF.
"A"
11/64
REF.
"A" + 11/32 (REF.)
PUSHER OUT OF PLACE RH ASSY

DUAL & RH DIVERT - END DISCHARGE
PART NUMBER & VALUE FOR VARIOUS B/Bs CHART
B/B
"A"
REF# 100
PART NUMBER
REF# 101
PART NUMBER
REF# 111
PART NUMBER
TRA05171-46R OR L
24
46
45 1/2
TRP14321-46
TSD002EB-2446
TRA05171-52R OR L
30
52
51 1/2
TRP14321-52
TSD002EB-3052
TRP14341-52E
TRA05171-58R OR L
36
58
57 1/2
TRP14321-58
TSD002EB-3658
TRP14341-58E
TRP14341-46E
ECO# TR6-1012
PAINT NOTE:
TOLERANCES
BOM NUMBER:
DWN
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
REV
DATE
REVISION
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
J.Wilkins
1/15/07
SCALE
1/2=1

DRAWING TITLE:
CHKD
BY
PUSHER OUT OF PLACE RH ASSY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
WHISPERSORT
TRA05171
D-SIZE
OF
REV
MICROSTATION
EFF.
WIDTH
2:23:30 PM
ASSY.
PART NUMBER
10/1/2007
burleson
9 7/8
9 7/8
111
112
113
111
109
112
113
108
107
106
106
107
108
109
102
110
110
105
104
103
110
102
103
104
101
100
105
5/32
5/32
B
B
11/64
REF.
"A"
11/64
REF.
"A" + 11/32 (REF.)
PUSHER OUT OF PLACE LH ASSY
BOM NUMBER:
DWN
BY
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
REV
DATE
REVISION
APPROVED
BY
BY
1/15/07
SCALE
1/2=1

DRAWING TITLE:
CHKD
BY
PUSHER OUT OF PLACE LH ASSY
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

CHANGED
SUPERSEDES:
MATERIAL:
J.Wilkins

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
WHISPERSORT
TRA05172
D-SIZE
OF
REV
burleson
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
SEE SHT 1 FOR RH ASSY, BOM, & CHARTED VALUES
ECO# TR6-1012
MICROSTATION
10/1/2007
2:23:31 PM
LH DIVERT END DISCHARGE
MATERIAL LIST FOR:

C
1
2
TRP12731
TRP11871
QTY
0312931
S06939
N36630
EA
S05227
DRWNG NUM
TRP12731
TRP11871

NUT HEX 1/4-20 NYLOCK
EA
DESCRIPTION
PROX BALLUF BES-516-326-G-S4-C
EA
4
UM
SENSOR GUARD BLOCK
EA
W07610
MTG. PLATE - PROXIMITY SWITCH
EA
LENGTH
EA
BROKEN PIN DETECTOR KIT
EA
WASHER FLAT 1/4

D
SCR HHC 1/4-20 X 2 3/4
NOTES:
1.)
SEE DETAIL "A"
2.)
KIT CAN BE ASSEMBLED AS RH OR LH - SEE SCHEMATIC BELOW

REF 1 & 4 NOT REQD FOR DUAL DIVERT.
REDUCE QTY OF REF 5 BY 3.
SEE DWG. TRA03982 FOR LOCATION

C
ADJUST BOTH PROXs TO

BE RECESSED AS SHOWN
2
4 5
3
3
1
1/16
1/32
D
1
"
E T A IL "A
B
2
RETURN SWITCH (REF)

ADJUSTABLE PIN GUIDE (REF)
2:20:08 PM
(LOOKING DOWN FROM ABOVE)

4 5
7
6 (2)
5
ECO #TR21-137
TR1-1073
PROX WAS P/N P00002
8/30/01
TR1-1041
RE-DESIGNED TO ELIMINATE HANDED PARTS
5/6/02
TR2-1103
REVISED REF 1 (P/N WAS TRP10401) & ADDED NOTE 2
3/16/04
PAINT NOTE:
TOLERANCES
TAK
RTS
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
REV
DATE
REVISION
DWN
DATE
CHANGED
APPROVED
BY
BY
SUPERSEDES:
MATERIAL:
Koeninger,T.
BY
DATE
SCALE
APPD
Half

DRAWING TITLE:
CHKD
06/08/01
BROKEN PIN DETECTOR KIT

WEIGHT:
PRODUCT OR MODEL:
BY

ECO NUMBER
BOM NUMBER:
BY
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
TB

DASH
NEXT ASSY
NUMBER
NUMBER

WHISPERSORT
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
TRA03881
D-SIZE
REV
WHISPERSORT
2
OF
MICROSTATION
10/1/2007
burleson
MATERIAL LIST FOR: BROKEN PIN PROX INSTALLATION KIT

10
6
3
13
14
15
12
13
16
11
20
12
13
15
16
18
SEE CHART
TRP12751
SEE CHART
DRAWING NUMBER
TRP15201
EA
BLOCK PIN GUIDE ENTRANCE
TRP12751
TRP12741/81
EA
PROX SWITCH 18MM BALLUFF
R59385
EA
RETAINER BALLUFF BES-18-BS-1
TRP12761
TRP15211
EA
PIN GUIDE SHIM PLATE
TRP15211
TRP08671
EA
PIN GUIDE MTG PLATE
TRP08671
S12123
EA
W09150
13
N36630
14
S08000
EA
5
15
W08100
16
P08136
SCR SHC 1/4-20 X 1-3/4
EA
EA
NUT NYLOK 1/4-20

SCR SHC 1/4-20 X 3-1/2
EA
EA
WSHR FLAT 1/4 SAE
PIN GROOVED 1/4 X 1-1/4
17
0312815
EA
18
0314876
EA
20
21
22
23
TRP10321
TRP12731
EA
1
0312209
0312932
EA
1
0312212
SENSOR GUARD BLOCK

EA
1
EA
TRP10321
TRP12731
CABLE 5 METER
EA
WSHR LOCK #8
SCR SELF TAP FLAT HD #10 X 3/4
EA
TRP12761
SCR SHC #8-32 X 1-1/4
EA
S06933
PROX MTG PLATE
EA
2
S06022
12
19
VIEW "A-A"
EA
DESCRIPTION
0312931
11
17
UM
BROKEN PIN PROX MTG BRKT
10
LENGTH
EA
19
QTY
SPLITTER
BOSCH CABLE CLAMP
NOTE: INCLUDE COPY OF DWG W/ KIT
KIT P/N
DIVERT HAND
REF 1 P/N
REF 3 P/N
TRA05291-L
LEFT
TRP15201-L
TRP12781
TRA05291-R
RIGHT
TRP15201-R
TRP12741
B
19
13
14
15
20
18
4
11
12
13
15
16
17
10
12
13
16
2:24:49 PM
A
ECO TR7-1044
BOM NUMBER:
DWN
R. SKANSE
BY
ANGLES
(TOTAL RUNOUT)
MACHINING
1/2 ^
FABRICATING 1^
DATE
REV
DATE
REVISION
APPROVED
BY
BY
SCALE
3/16" = 1"

DRAWING TITLE:
CHKD
BY
BROKEN PIN PROX INSTALLATION KIT
DATE
APPD
WEIGHT:
PRODUCT OR MODEL:
BY

CHANGED
SUPERSEDES:
MATERIAL:
5/18/07

DASH
NEXT ASSY
NUMBER
NUMBER

SINGLE-SIDED WHISPERSORT LH/RH
DATE
PROJECT NAME:
PROJECT NO:
CODE:
HKS DRAWING NO:
SHT
WHISPERSORT
TRA05291
D-SIZE
OF
REV
MICROSTATION
PAINT NOTE:
TOLERANCES
FRACTIONS +
- 1/32"
+
.XX
.015
+
.XXX
.005
.XXXX +
.0010
-
ECO NUMBER
10/1/2007
burleson
WhisperSort
Appendix A
Power Busway System
WhisperSort
Appendix B
Lubrication Information
WhisperSort
Appendix B - Lubrication
Appendix B - Table of Contents

Lubrication
Chain Oilers Aries Series Antiwear Hydraulic Oils
Pin Greaser Valvoline Multi-Purpose Greases
Reducers Shell Omala Fluids HD
Bearings Shell Avania Greases EP
P/N 0312996
6-1
WhisperSort
Appendix B - Lubrication
6-2
P/N 0312996
Customer Service
If your material handling solution was provided through a Distributor/Integrator, HK Systems requests
that you initially contact the designated distributor contact. In the event that you require additional
assistance, please feel free to contact the HK Systems 24-Hour-Hotline number below.
For material handling solution provided by HK System, use the numbers below for your customer
service needs.
HK Systems intends to provide customer support services, which will help maximize the level of your
system's performance and reliability. To ensure this, HK Systems will:
Isolate and correct reported problems with HK Systems products.
Provide telephone assistance designed to quickly diagnose and resolve problems with HK
Systems hardware and software products.
Provide solutions, whenever necessary, which will help to minimize the impact of a problem
affecting your operation.
Share technical data learned from other HK Systems installations, which can be applied to your
system.
Assist in obtaining the highest quality of service for equipment and software provided by third
party vendors, which is incorporated into your system.
Check for the symptoms of developing problems that may create system failures.
Provide technical assistance to help prevent minor problems from growing into major problems.
Important Phone Numbers

24-Hour-Hotline
Customer Service Manager
Spare Parts Coordinator
Technical Specialist
Field Supervisor
Account Executive
800- 424-7365
859-334-2652
859-334-2478 or 859-334-2418
859-334-2591
859-334-2593
859-334-2880 or 859-334-2064
Customer Responsibilities
HK Systems suggests you consistently follow the preventive maintenance guidelines. We value your
role in helping to maintain high system reliability and prevent problems that may affect your operation.
To minimize disruptions to your production, HK Systems recommends that you be responsible for the
following preventive maintenance functions:
1.
Maintain adequate personnel training. This requires on-going training during system installation
and regular safety and maintenance instruction after your system is in full operation.
2.
Make a first-level problem diagnosis. Supply sufficient data to identify the general problem
areas. Isolate the problem if possible (i.e. hardware, operating software, application software,
power, environmental, etc.).
3.
HK Systems technical analysts may ask you to supply additional information or data to aid them
in determining and correcting the problem.
4.
Where possible, keeping safety in mind, attempt to develop "work-around" procedures until the
problem can be corrected.
5.
Sufficient access to the system must be given HK Systems personnel.
6.
Maintain all equipment in accordance with all manufacturer's recommendations.
7.
Make no changes in the equipment and/or software design or operation without the approval of
HK Systems. Unauthorized changes can void your Warranty.
8.
Customer is responsible for parts which require regular replacement during normal preventive
maintenance.
Obtaining Warranty Replacement Parts

During the warranty period, parts which fail (through no fault of our customer) will be replaced
pursuant to the terms of the contract. Please provide us with all information regarding the nature of the
failure, part number, if available, any circumstances surrounding the failure and whether or not you
have a spare in stock. In most cases, we will require that the part be returned to HK Systems for
warranty disposition, or to a vendor for disposition or repair. If an immediate replacement part is
required before warranty disposition, HK Systems may require a purchase order for shipment of the
part. The P.O. will be credited if the part is warranted after disposition.
Requests for replacement parts can be made through Customer Service. Part Specialists are available
through 1-800-424-7365. Fax number is 859-334-2515.

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TM

WhisperSort is a trademark of HK Systems, Inc., Hebron, Kentucky

Copyright 2001, 2003, 2004, 2007 by HK Systems, Hebron, Kentucky

TR-0008 October, 2007

WhisperSortTM Field Manual

WhisperSort Overview ........................................................................................................................... 1-3

Chapter 3. Mechanical Installation

Mechanical Installation ............................................................................................................................... 3-5

WhisperSort Field Manual

Step 3 Catenary..................................................................................................................... 3-16

WhisperSortTM Field Manual

Chapter 5. Electrical Controls Installation and Setup

Electrical Controls Installation and Setup ................................................................................................... 5-3

Chapter 6. DeviceNet Single-Sided Model 1

DeviceNet Single-Sided Model 1 ............................................................................................................. 6-4

WhisperSort Field Manual

Chain Oiler ................................................................................................................................................6-52

Chapter 7. Discrete I/O Single-Sided Model 2

Discrete I/O Single-Sided Model 2 ...........................................................................................................7-5

WhisperSortTM Field Manual

Spray Oiler (Optional) ............................................................................................................................... 7-51

Chapter 8. DeviceNet Dual-Sided Model 3

DeviceNet Dual-Sided ................................................................................................................................ 8-5

WhisperSort Field Manual

Divert Control Module Kit Set-Up Switch (Kit TRA04021-19) ...................................................................8-50

Chapter 9. Discrete I/O Dual- Sided Model 4

Discrete I/O Dual-Sided Model 4..............................................................................................................9-5

WhisperSortTM Field Manual

Broken Pin Detector Assembly (Kit TRA03801-16L or TRA03801-16R) .................................................. 9-46

Chapter 10 - DeviceNet Single-Sided Model 5

WhisperSort Field Manual

Chapter 11 DeviceNet Dual-Sided Model 6

DeviceNet Dual-Sided Model 6 ..............................................................................................................11-5

WhisperSortTM Field Manual

Mapping I/O ............................................................................................................................................ 11-22

WhisperSort Field Manual

Chapter 13 Illustrated Parts List

Chapter 1 - Table of Contents

1.0 WhisperSort Overview

HK Systems WhisperSort represents the next generation of slat sorters. The

WARNING: Before performing any maintenance, review the Safety

The WhisperSort is designed to accommodate higher operating speeds with increased

1.1 Product Summary

12, Odd lengths in 1 increments from 3 to 11

Minimum Divert Centers (20) *

Single-Sided 24 B/B = 85, 30 B/B = 102.5, 36 B/B = 120

Minimum Divert Centers (30) *

Single-Sided 24 B/B = 58, 30 B/B = 70, 36 B/B = 82

WhisperSort Single-Sided and Dual-Sided Sorters (Mechanical Components)

Crossover Switch (Dual-Sided only)

Dependent on loading and number of diverts

End-side mount, shaft mounted reducer, VFD control, drive sprocket 24

Drive HP and Take-up

7.5 to 40 HP shaft mounted gearmotor, catenary and end take-up

200 FPM - 600 FPM

Idler sprocket 18 dia.

Slave driven from sorter (left or right hand)

Standard with vibration pads on drive and idler

50 Minimum length with catenary.

WhisperSort Single-Sided and Dual-Sided Sorters (Controls)

1.2 WhisperSort Documentation

Chapter 2 - Table of Contents

2.5.2.1 End Covers........................................................................................................... 2-9

Conveyor Safety Rules