Montech - KTB KTBD

OPERATING INSTRUCTIONS
CONVEYORS
KTB; KTBD (End drive)
BA-100006 E
englisch, edition 11/2010
Operating instructions KTB / KTBD
Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Important information ............................................................................................ 3

Manufacturers declaration ............................................................................................3
Description of product and use .....................................................................................3
Factors which reduce the useful life...............................................................................3
Safety instructions ..........................................................................................................3
Additional information ...................................................................................................4
Scope of the operating instructions...............................................................................4
Technical data.................................................................................................................5
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
Commissioning........................................................................................................ 7
Mechanical design ..........................................................................................................7
Mounting instructions.....................................................................................................8
Pivoting of the drive unit................................................................................................9
Electrical connection ....................................................................................................10
Operation .....................................................................................................................12
Modes ...........................................................................................................................13
Program mode..............................................................................................................14
Exiting the program mode ...........................................................................................19
Error messages / Measures in case of malfunction .....................................................19
Direction of travel of the conveyor belt.......................................................................20
Setting the necessary pretension of the belt...............................................................21
Tracking ........................................................................................................................22
Changing the conveyor belt speed range ...................................................................23
Changing the installation side of the drive unit...........................................................23
Technical data for conveyor .........................................................................................24
Replacing endless belts ................................................................................................24
Replacing belts by welding the ends ...........................................................................25
3
3.1
3.2
3.3
3.4
Maintenance ......................................................................................................... 25
Repairs ..........................................................................................................................25
Replacing the drive roller .............................................................................................26
Replacing the gear motor ............................................................................................27
Replacing the control electronics / Protective cap ......................................................28
4
4.1
Exploded drawings / parts lists............................................................................ 29

KTB-K / KTBD-K with end drive ...................................................................................29
4.1.1
4.2
4.2.1
4.3
4.3.1
Parts list for KTB-K / KTBD-K with end drive........................................................................ 29
KTB-K conveyor end with deflection roller, single belt ...............................................30

Parts list for KTB-K conveyor end with deflection roller, single belt ................................... 30
KTBD-K conveyor end with deflection rollers, dual belt .............................................31

Parts list for KTBD-K conveyor end with deflection roller, dual belt ................................... 31
4.4
4.4.1
4.5
4.5.1
KTB drive unit for end drive, single belt ......................................................................32

Parts list for drive unit for end drive ..................................................................................... 33
KTBD drive unit for end drive, dual belt ......................................................................34

Parts list for drive unit for end drive ..................................................................................... 35
Environmental compatibility and disposal............................................................ 36
1 Important information
Conveyors as components of kits are not subject to the
EU-declaration of conformity (as per MRL Appendix II A)
EU Declaration of conformity (as per MRL Appendix II A)
1.1 Manufacturers declaration

Regulations and standards taken into account:
! Machine Directives 89/392/EEC, 91/368/EEC
! Low-voltage Directive 73/23/EEC EMC-Directive: Noise emissions EN 50081-2:1993, Noise
immunity EN 61000-6-2
Manufacturer:
Montech AG, Gewerbestrasse 12 CH-4552 Derendingen

Tel. +41 32 / 681 55 00, Fax +41 32 / 682 19 77
1.2 Description of product and use

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

! Direct irradiation with UV lamps.
! Queuing when transporting objects with sharp edges.
! Operating environment containing smoke, dust, steam or solvent vapours.
1.4 Safety instructions

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

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

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

Ambient tempertature
Rel. Humidity
Air purity
+10 to +40C
5% - 85% (without condensation)
normal workshop atmosphere
Noise level
< 55 dBA
Protection category of the drive unit
IP40
Motor
Type
brushless external rotor DC motor
Rated voltage
24 VDC
Operating voltage
18 to 28 VDC
Rated current
2.8 A
Max. current consumption
3.6 A (at start)
Rated output power
48 W
Speed range
200 to 3500 rpm
Total efficiency
70 %
Gear
Type
Version
two-stage spur gear

L
i = 59.19:1
i = 21.6:1
1.6Nm
1.6Nm
2A
2A
3.4 ... 59.1 rpm
9.2 ... 162 rpm
Belt speed
0.4 to 7.6 m/min
1.2 to 21 m/min
Increments
0.1 m/min
0.2 m/min
Gear ratio
Permissible drive torque
Permissible current consumption at
Vmax.
Output speed
Total efficiency
Lubrication
80%
lifetime lubrication
Connection
Connecting cable
Cross-section
Length
Perm. voltage digital inputs
4-pin, coupling M12x1, angled at 90

4 x 0.75 mm
5 m (standard) or 10 m; stripped cable end

+5 to 24 V (for anticlockwise or clockwise operation)
The following information is shown on the identification plate attached to the drive unit:
Conveyor type
Belt type
Belt width
[mm]
Belt length
[mm]
Operating instructions
Order No.
Speed
[m / min.]
Pretension
[%]
Max. load
[N]
Gradient
[]
2 Commissioning
2.1 Mechanical design
The conveyors are shipped in units of max. 3 m length. If the total length of a conveyor exceeds
the maximum transport length of 3 m, the individual parts should be assembled according to the
following diagram.
Total length of chassis
Svar
Cvar
Total length of chassis (in mm)

L < 3000
lateral guide
chassis
90
Svar
3000< L 5000
Svar
Cvar
D
lateral guide
chassis
Svar
Svar
90
50
Cvar
Lmax. 3000
Svar
2000
50
D
Cvar
2950
Lmax. 5000
Variable length of the lateral guides, min. = 500 mm, max. = 2000 mm
Variable chassis length Cvar max. = 2853 or 1903 mm
Chassis joint for dismantling prior to shipping
Prior to commissioning, the joints marked with (D) must be assembled. The conveyor must be
supported at these points.
The conveyor should as far as possible be operated with front drive, i.e. the output side of the
conveyor is on the side of the driven roller and the objects being transported are moved by
traction.
In cases where the drive is arranged on the input side of the conveyor, i.e. rear drive, the objects being transported are moved under thrust so that the belt loading conditions are not optimal, i.e. faults may occur in operation. In order to avoid this, the respective application must be
discussed with Montech.
7
2.2 Mounting instructions

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

2.3 Pivoting of the drive unit

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

Slacken the locking screw (650)
Swivel the drive unit to the desired position
Tighten the locking screw (650)
Adjustment of the belt pretension:

After fixing the drive unit in the final position, the belt tension should be adjusted again.
Procedure:
!
!
!
!
!
Remove cover(20) by unscrewing the countersunk screw (200).

Slacken the four fixing screws of the gear motor.
Tension the belt by pulling the protective cap (110) by hand.
Tighten the four fixing screws of the gear motor.
Mount the cover (20) again.
max. 40
Height of material conveyed
270
2.4 Electrical connection

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

under the safety cover of the KTB /KTBD. The respective person must be properly earthed before
carrying out maintenance work.
Voltage supply
A DC voltage of 24 V is required for supplying the motor. Higher voltages and AC
voltages can damage the motor.
Earth connection
Earth connection
The earth connection of the conveyor must be electrically connected to the earth
connection of the supply. If no earthing is performed, the control electronics of
the conveyor may be damaged, rendering the warranty null and void.
10
Connection to power unit

Power units of 20 to 28 VDC are permitted for supplying the conveyor. The rated power and the
maximum motor speed are however reached only with a supply voltage of >24 VDC. The con2
necting cable supplied has a length of 5m or 10 m. The connection cross-section is 4x0.75mm .
Other cables with standard M12 plugs can also be connected. However, a smaller connection
cross-section and a long cable may result in a voltage drop which no longer guarantees operation of the control or of the motor. There is also the danger that the cable will heat up to an impermissible extent.
The drive unit must be correctly connected according to following representation.

Connection errors may damage the control or the motor!
Jack assignment in the conveyor drive
+ 5...24V (S2)
+ 5...24VDC (S1)
+ 24VDC (supply)
Assignment of connecting cable supplied
schwarz,
+ 5...24V
(S1)
4, 5...24V
(S1), black
blau,
-24V(supply),
(Speisung)
3, GND
blue
2, + +
5...24V
(S2),
white
weiss,
5...24V
(S2)
1, + 24V
(supply),
brown
braun,
+ 24V
(Speisung)
11
2.5 Operation
Control panel
6a
6b
6c
6
Legend: Control panel

1)
Reduce belt speed
2)
Increase belt speed
3)
Start / Counterclockwise operation
4)
Stop
5)
Start / Clockwise operation
6)
Display
a)
Display in operation:
Belt speed in m/min.
b)
Display when stationary:
Mode / Programmed direction of travel
c)
Display in program mode:
Abbreviation for parameter
Note:
Clockwise operation is defined as running of the belt from left to right when facing the keypad
counterclockwise operation is operation in the opposite direction.
Switching on and off / Choice of direction of travel
By pressing the key (3) or key (5), the belt is switched on with the appropriate direction of travel.
By pressing the key (4), the belt is stopped.
Adjusting the belt speed
When the belt is running, the belt speed can be adjusted by pressing the keys (1) or (2).
12
Coarse adjustment
By pressing the key (1) for at least 1 sec, the belt speed is continuously increased. The speed is
reduced with the aid of key (2).
Precise adjustment
By briefly pressing the key (2), the belt speed is increased in each case by approx. 0.1 m/min in
version (S) and by approx. 0.03m/min in version (L). By pressing the key (4), the belt speed is
reduced by the corresponding step width.
Set belt speed during commissioning
The default speed during commissioning is in the following range:
Version
L
S
Belt speed [m/min.]

0.5 2.5
1.5 6.5
Action in the event of loss of power

The belt speed last set is retained during loss of power. For safety reasons, the belt remains
switched off after a fault. It can be switched on again by pressing the keys (3) or (5).
2.6 Modes
The minidrive conveyor can be operated in three different modes:
1. Autonomous mode (A)
The conveyor is operated alone. The belt is switched on and off on the keypad.
2. External mode (E)
The conveyor is used as part of a system. By externally switching the electrical supply on
or off, the conveyor is directly switched on and off. The direction of travel is defined in
advance by means of a parameter. By pressing the key (4) on the keypad, the conveyor
can be stopped at any time. The belt can then be started again by pressing the appropriate key (3) or (5).
Attention: If there is a loss of power when the belt is stationary, the belt starts
automatically after operating voltage is applied.
13
3. Control mode (S)

The motor control has two digital inputs for connecting a PLC. When the control voltage
(5-24V) is applied, the belt begins to run in the appropriate direction. This mode is particularly suitable for reversible operation and start/stop operation. By pressing the key
(4), the belt can be stopped at any time by means of the keypad. The belt must then be
started again by pressing the appropriate key (3) or (5) (starts only in the direction specified by the control), unless the control signal has stopped in the meantime.
Limitations of start/stop operation
To limit the gear wear during start/stop operation, the following should be taken
into account:
! The maximum permissible load must be limited to 50%.

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

In the program mode, specific control parameters can be changed. Thus, the control can be optimally adapted to the respective application.
Start program mode
By simultaneously pressing the keys (1) and (2) for 3 sec, the program mode is obtained. First,
the parameter to be changed is selected and the parameter value is then input. Chapter: (Overview of programming of control) shows the programming sequence in detail.
14
Overview of programming of control
Mode of operation
Stationary
Display
Press for
3 sec.
Autonomous mode
External mode
Control mode
Duration
cycle
1) Press key when switching on 24 V operating voltage
15
Press for
3 sec.
Display in
Operation
Belt speed
(m/min)
Run-up
Ramp programmed
Decelerate
Motor brake on
Factory parameter
Setting after reset

(Belt speed = 0 m/min)
16
Designation of the parameters

Code:
Abbreviation for: Function:
SPE
speed
Speed
dIr
direction
Direction of travel
rAn
ramp
Run-up ramp
nod
mode
Mode
GEA
gear
Gear transmission
dIA
diameter
Diameter of drive roller
dIS
display
LED indicator
brA
brake
Motor brake
Locking of belt speed (SPE)

To prevent the belt speed from being changed by unauthorized persons, the set speed can be
locked.
! FrE
The belt speed is freely adjustable at all times
! Loc
The belt speed is locked
Define direction of travel of conveyor (dIr)

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

Counterclockwise travel
Clockwise travel
Set start-up ramp (rAn)

If soft starting of the conveyor is desired, the run-up time can be programmed.
! oFF
Free run-up (load-dependent)
! 0.5 5.0 Run-up time in seconds (in steps of 0.5 seconds)

Anzeige: A raised dot lights up during run-up
17
Set mode (nod)

Selection of mode (see section on modes).
! A
Autonomous mode
! [E
External mode / Counterclockwise operation
E]
External mode / Clockwise operation
Control mode
Actuation of control mode

Input S1
Input S2
Direction of travel
(Cable No. 4)
(Cable No. 2)
Stationary
Clockwise
Counterclockwise
Select gear transmission (GEA)

To ensure that the belt speed is correctly displayed, the correct gear transmission must be set
(usually already programmed at the factory).
! 21.6
Gear transmission i=21.6:1
! 59.2
Gear transmission i=59.19:1
! 000
Prepared for further gear transmission
Change diameter of drive roller (dIA)

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

The LED display can be switched on and off.
! on
The display is switched on
! oFF
The display is switched off
18
Switch motor brake on and off (brA)

The motor brake reduces the run-out distance of the belt. It functions only in the autonomous
and control modes.
! oFF
Motor brake off
! on
Display:
Motor brake on
A raised dot lights up during braking
2.8 Exiting the program mode

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

Message
Cause
Remedy
loc
Belt speed locked
Change parameter SPE to FrE
cYL
Cycle time below permissible value
! Increase cycle time

! Contact factory to find whether a
shorter cycle time is permissible under the given conditions / reprogram factory parameter according
to factory data
End
! Automatic exit from program mode after No action necessary

no changes were made for 30 sec.
! Program mode was exited after acknowledgement
rES
A reset was performed
No action necessary
blo
Motor does not rotate although a start sig- ! Reduce load

nal from the control is present.
! Remove blockage
! Conveyor may be blocked or overloaded ! Replace gear motor
! Motor or gear may be faulty
RESET funktion
If the control exhibits abnormal behavior during operation or during programming and this behaviour persists, the operating voltage should be switched off. The reset is performed by pressing the key (5) while simultaneously switching on the operating voltage. It should be noted that
the parameters are to be reprogrammed. The belt speed too must be reset.
19
2.10 Direction of travel of the conveyor belt

The direction of travel of the belt should be complied with when the belt ends were joined by
means of an overlapping weld joint (Thermofix).
Overlapped weld joint (Thermofix)
Position of the belt weld (Thermofix)
Longitudinal section
Plan view
In the case of zig-zag joints (Flexproof) or welded butt joints (Quickmelt), the direction of travel
of the belt is unimportant.
Flexproof and Quickmelt weld joints
Flexproof
Quickmelt
20
2.11 Setting the necessary pretension of the belt

The correct pretension for a conveyor belt is shown on the identification plate attached to the
belt drive (for example: 1.2%).
After the belt has been mounted, two measuring marks (M) are stuck on its upper surface in the
untensioned state, in such a way that they are a distance (L) of e.g. 500 or 1000 mm apart.
When the two tensioning screws (580) (See chapter: Tracking) are uniformly tightened, the two
measuring marks (M) move apart to a dimension (L) which corresponds to the required pretension Vnec.
Example:
L taut = L loose +
L loose
v ( %)
nec
100
When L loose = 100mm and v nec = 1.2%

L taut = 1000mm +
1000mm
1.2% = 1012mm
100%
Example of calculation of conveyor belt pretension
21
2.12 Tracking
The belt must always run centrally over the deflection roller and the drive roller. On no account
may the edges of the belt project over the ends of the rollers.
The running of the belt over the deflection roller can be corrected by slightly tightening or
slackening the hex screws (580) while the belt is running. The tracking over the drive roller is as a
rule ensured. If the tracking over the drive roller is nevertheless incorrect, the two tabs (40) can
be slightly moved.
Conveyor end with deflection roller
22
2.13 Changing the conveyor belt speed range

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

The drive unit of the minidrive conveyor with end drive is installed on the left or right, depending on the version ordered. If the installation side is to be changed subsequently, the tab on
drive side and the single tab must be replaced.
Article number:
Tab on drive side, complete
Single tab
Drive right
Drive left
48458
48161
48459
48468
Procedure:
! The procedure is the same as in the section Replacing the drive roller. It is also necessary
to slacken the threaded pin (360) so that the side part can be separated from the tab on the
drive side.
Changing the installation side of the drive unit
23
2.15 Technical data for conveyor

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

The installation of endless belts is recommended when the conveyor is easily accessible or when
the equipment needed for welding prepared endless belts is not available.
Procedure: (See chapter: Replacing the gear motor)

! Stop the belt (key 4) and switch off mains voltage.
! Slacken the conveyor belt by alternately loosening the two screws (590) on the tensioning
device.
! Remove the belt by first running it out on the drive side over the tab (40).
! Install the new belt by first placing the belt in the tensioning device and then drawing it over
the tab (40).
! The drive unit is reinstalle in the reverse order.
! For pretensioning of the belt, see section "Setting the necessary pretension of the belt".
! For tracking of the belt, see section "Tracking".
Changing of belts
24
2.17 Replacing belts by welding the ends

Threading new belts into a conveyor with subsequent "welding" of the belt ends is recommended when the accessibility with regard to the operations described in the preceding section
is greatly restricted. A prerequisite for this method of belt mounting is the availability of the
necessary equipment for the "welding operation".
Exact instructions for performing the "welding operation" can be requested when ordering new
belts.
Procedure: (See chapter: Replacing the gear motor)
! Switch off motor and disconnect from mains voltage
! Slacken the belt by alternately loosening the two screws (590).
! Sever the defective belt and join one end of the old belt to the end of the new belt (e.g. with
adhesive tape). Attention should be paid to the position of the chamfered belt ends in relation to the direction of travel (see section "Direction of travel of the belt"). The chamfered
belt ends must be kept clean.
! Slowly pulling out the old belt automatically pulls the new one through the system.
! "Weld" the belt according to the manufacturer's instructions.
! Pretension the belt as under section "Setting the necessary pretension of the belt"
! Set the belt tracking as under section "Tracking".
3 Maintenance
Belt conveyors are maintenance-free when they are employed in accordance with their purpose
and are not exposed to any effects likely to shorten their service life.
The purpose and the factors likely to shorten the service life are mentioned in the declaration of
conformity.
When the belts are exposed to the action of dust, oily air, foreign matter, such as chips from
machine tools, etc., we recommend regular thorough cleaning of the belts, for example once a
week, with white spirit. The con-trol panel should be cleaned with industrial alcohol. Other solvents may damage the protective polyester film.
3.1 Repairs
The operating instructions contain the necessary spare parts lists and exploded drawings for
repairs in the mechanical part of the conveyor. The safety instructions must also be followed.
Repairs to the electrical part may be carried out only by the supplier. It is essential to follow the
safety instructions for electrical disconnection of components from the mains or from the motor
and for their reinstallation.
25
3.2 Replacing the drive roller

Replacing the drive roller
Procedure:
! Switch off motor
! Disconnect drive unit from mains
! Slacken the conveyor belt by alternately loosening the two screws (590).
! Remove the cover (20) by unscrewing the countersunk screw (200).
! Slacken and remove the toothed belt by loosening the four fixing screws (210) of the gear
motor.
! Loosen the threaded pin (350) and remove the cog wheel (130) from the drive shaft (50).
! Remove the single tab (40) by unscrewing the two fixing screws (230).
! Replace the drive roller with mounted self-aligning ball bearings
! The drive unit is reinstalled in the reverse order.
Correctly mount plate spring. The plate spring must not touch the inner race of the
self-aligning ball bearings. The toothed belt should be sufficiently tensioned by pulling the protective cap by hand.
26
3.3 Replacing the gear motor

Replacing the gear motor
Procedure:
! Stop conveyor and switch off mains voltage.
! Disconnect connecting cable (350) from drive.
! Remove the cover (20) by unscrewing the countersunk screw (200).
!
Unscrew the two fixing screws (130) of the protective cap (50).
! Carefully pull off the protective cap.

under the safety cover. The respective person
must be properly earthed before carrying out
maintenance work.
! Pull off the connection circuit baord (300) from the motor.
! Slacken and remove the toothed belt by loosening the four fixing screws (210) of the gear
motor.
! Loosen the threaded pin (350) and remove the cog wheel (140) from the drive shaft of the
gear motor (330).
! Remove the gear motor by unscrewing the four fixing screws (210).
! The drive unit is reinstalled in the reverse order. The toothed belt should be sufficiently tensioned by pulling the gear motor by hand.
27
3.4 Replacing the control electronics / Protective cap

The keypad with the control electronics is bonded into the protective cap. If the protective cap
is damaged or the electronics are faulty, only the whole unit can be replaced. If the control electronics no longer operates correctly, both the complete protective cap with keypad (50) and the
connection circuit board (300) must be replaced. Note: When purchasing new control electronics, it is always essential to specify the order number shown on the identification plate, so that
compatibility between motor and new control can be checked.
Procedure:
! Stop the belt and switch off the mains voltage.
! Disconnect the connecting cable (350) from the drive.
! Unscrew the two fixing screws (130).
! Carefully remove the protective cap.
under the safety cover. The respective person
must be properly earthed before carrying out
maintenance work.
! Pull off the connection circuit board (300) from the motor.
! Mount the new connection circuit board.
! Insert the new protective cap straight it is centered by the connection circuit board.
! Screw on the cap (50) with fixing screws (130)
! Reconnect the connecting cable (350)
! Perform a reset.
! Program the gear transmission.
! Set the speed.
! Reprogram parameters.
28
4 Exploded drawings / parts lists

4.1 KTB-K / KTBD-K with end drive
4.1.1
Parts list for KTB-K / KTBD-K with end drive
No. Designation
Order number
KTB-45K KTB-60K KTB-80K
10 Chassis aluminum
10
KTB-/
KTB-/
KTB-/
KTB-/
KTBD-105K KTBD-140K KTBD-185K KTBD-250K
48396/. 23584/. 23583/. 26330/.
21476/.
26331/.
37435/.
Chassis for sliding plate,

aluminum
58652/. 58653/. 58787/.
58788/.
58789/.
58790/.
Sliding plate stainless
58791/
58791/
58791/
0039/. 0059/. 0084/.
58791/
0119/.
58791/
0164/.
58791/
0229/.
20
Conveyor end with deflection

57972
roller, single belt
57973
57974
54874
57975
58700
58701
20
Conveyor end with deflection

roller, dual belt
54882
57989
58702
58703
30
KTBD-KR drive unit,

single belt
57976
57977
57978
57979
57980
58705
58708
30
KTBD-KL drive unit,

single belt
57981
57982
57983
57984
57985
58706
58709
30
KTBD-KR drive unit,

dual belt
54329
57986
58711
58714
30
KTBD-KL drive unit,

dual belt
57987
57988
58712
58715
50 Gear motor version S
50071
50071
50071
50071
50071
50071
50071
50 Gear motot version L
50072
50072
50072
50072
50072
50072
50072
60 Connecting cable 5m
520705
520705
520705
520705
520705
520705
520705
60 Connecting cable 10m
520706
520706
520706
520706
520706
520706
520706
29
4.2 KTB-K conveyor end with deflection roller, single belt
4.2.1
Parts list for KTB-K conveyor end with deflection roller, single belt
No. Sym. Designation
Order number
Mat.
KTB-45K KTB-60K KTB-80K KTB-105K KTB-140K KTB-185K KTB-250K
Conveyor end with deflec57972

tion roller, single belt compl.
57973
57974
54874
57975
58700
58701
Var.
10
Conveyor end
48535
48126
48536
48537
48130
50989
50985
Alu
20
Thrust piece
48127
48127
48127
48127
48127
48127
48127
Steel
30
Deflection roller compl.
48527
48488
48528
48529
48530
50990
50987
Var.
30
Conveyor-conveyor
element compl.
36546
36546
36546
36546
36546
36546
36546
Steel
These are wearing parts and available ex stock.

Not available ex stock individually (upon request).
Price-listed items available ex stock.
30
4.3 KTBD-K conveyor end with deflection rollers, dual belt
4.3.1
Parts list for KTBD-K conveyor end with deflection roller, dual belt
Order number
Mat.
KTBD-105K KTBD-140K KTBD-185K KTBD-250K
Conveyor end with deflection roller,

54882
dual belt complete
57989
58702
58703
Var.
10
Conveyor end
48537
48130
50989
50985
Alu
20
Thrust piece
48127
48127
48127
48127
Steel
30
Deflection roller complete
54316
54317
58716
58717
Var.
30
Conveyor-conveyor element compl. 36546
36546
36546
36546
Steel

31
4.4 KTB drive unit for end drive, single belt
32
4.4.1
Parts list for drive unit for end drive
Order number
Mat.
KTB-45 KTB-60 KTB-80 KTB-105 KTB-140 KTB-185 KTB-250

KR/KL KR/KL KR/KL KR/KL KR/KL KR/KL KR/KL
Drive unit for end drive right

57976 57977 57978 57979
(KR) one belt complete
57980
58705
58708
Var.

57981 57982 57983 57984
(KL) one belt complete
57985
58706
58709
Var.
10
Tab, drive side ri. compl. (KR) 48458 48458 48458 48458
48458
48458
48458
Var.
10
Tab, drive side le. compl. (KL) 48459 48459 48459 48459
48459
48459
48459
Var.
20
Tab, single ri. (KR)
48161 48161 48161 48161
48161
48161
48161
Alu
20
Tab, single le. (KL)
48468 48468 48468 48468
48468
48468
48468
Alu
30
Sliding block
21913 21913 21913 21913
21913
21913
21913
Steel
40
Cheesehead screws M6x12
504644 504644 504644 504644 504644 504644 504644 Steel
50
Ribbed washer M6
505255 505255 505255 505255 505255 505255 505255 Steel
60
Side part
48153 48153 48153 48153
48153
48153
48153
Alu
70
Cover
48157 48157 48157 48157
48157
48157
48157
Alu
80
Countersunk screw M4x25
506370 506370 506370 506370 506370 506370 506370 Steel
90
Threaded pin M3x6
506368 506368 506368 506368 506368 506368 506368 Steel
100
Edged adjusting pin 6x20
508116 508116 508116 508116 508116 508116 508116 Steel
110
Protective cover complete
48445 48445 48445 48445
48445
48445
48445
Var.
120
Cog wheel for gear motor,

complete
48106 48106 48106 48106
48106
48106
48106
Alu
130
Cog wheel for drive roller
48109 48109 48109 48109
48109
48109
48109
Alu
140
Toothed belt
506367 506367 506367 506367 506367 506367 506367 PUR
150
Spring wedge 3x3x16
506714 506714 506714 506714 506714 506714 506714 Steel
160
Plate spring 29.7/17.3x1.55 506369 506369 506369 506369 506369 506369 506369 Steel
170
Locking part complete
48469 48469 48469 48469
180
501646 501646 501646 501646 501646 501646 501646 Steel
190
505328 505328 505328 505328 505328 505328 505328 Steel
200
Spring washer M4
504382 504382 504382 504382 504382 504382 504382 Steel
210
U-washer M4
506097 506097 506097 506097 506097 506097 506097 Steel
220
Drive rolls complete
48531 48479 48532 48533
48469
48534
48469
50988
48469
50984
Steel
Var.

33
4.5 KTBD drive unit for end drive, dual belt
34
4.5.1
Parts list for drive unit for end drive
Order number
Mat.
KTBD-105 KTBD-140 KTBD-185 KTBD-250

KR/KL
KR/KL
KR/KL
KR/KL

(KR) double belt compl.
54329
57986
58711
58714
Var.

(KL) double belt compl.
57987
57988
58712
58715
Var.
10
Tab, drive side ri. compl. (KR)
48458
48458
48458
48458
Var.
10
Tab, drive side le. compl. (KL)
48459
48459
48459
48459
Var.
20
Tab, single ri. (KR)
48161
48161
48161
48161
Alu
20
Tab, single le. (KL)
48468
48468
48468
48468
Alu
30
Sliding block
21913
21913
21913
21913
Steel
40
504644
504644
504644
504644
Steel
50
Ribbed washer M6
505255
505255
505255
505255
Steel
60
Side part
48153
48153
48153
48153
Alu
70
Cover
48157
48157
48157
48157
Alu
80
Countersunk screw M4x25
506370
506370
506370
506370
Steel
90
Threaded pin M3x6
506368
506368
506368
506368
Steel
100
Edged adjusting pin 6x20
508116
508116
508116
508116
Steel
110
Protective cover complete
48445
48445
48445
48445
Var.
120
Cog wheel for gear motor
48106
48106
48106
48106
Alu
130
Cog wheel for drive roller, com48109

plete
48109
48109
48109
Alu
140
Toothed belt
506367
506367
506367
506367
PUR
150
Spring wedge 3x3x16
506714
506714
506714
506714
Steel
160
Plate spring 29.7/17.3x1.55
506369
506369
506369
506369
Steel
170
Locking part complete
48469
48469
48469
48469
Steel
180
501646
501646
501646
501646
Steel
190
505328
505328
505328
505328
Steel
200
Spring washer M4
504382
504382
504382
504382
Steel
210
U-washer M4
506097
506097
506097
506097
Steel
220
Drive rolls complete
55305
55306
57012
57013
Var.

35
5 Environmental compatibility and disposal

Materials used
! Aluminum
! Steel
! Copper
! ABS acrylonitrile-butadiene/styrene
! PUR polyurethane
! POM polyoxymethylene
! PS polystyrene
! Polyethylene
! Polyester
! Various electronics components
! Gear lubricant Klber STABURAGS NBU 12/300 KP
Surface treatment
! Anodizing of aluminum
! Chemical nickel-plating of steel
! Painting of metal
Shaping processes
! Profile pressing of aluminum
! Machining of aluminum, steel and POM
! Thermoforming of ABS
! Injection molding of ABS
! Die-casting of aluminum
! Vulcanization of PUR
Emissions while operating
Keine
Disposal
Conveyors that are no longer fit for operation should not be disposed of as complete units but
should be dismantled into parts and recycled according to the kind of material. The kind of material used for each part is shown in the spare parts lists. Materials which cannot be recyled
should be disposed of appropriately. In particular, it should be noted that the gear lubricant
must be disposed of separately.
36
MONTECH AG
Gewerbestrasse 12, CH-4552 Derendingen
Fon +41 32 681 55 00, Fax +41 32 682 19 77
info@montech.com, www.montech.com

Montech - KTB KTBD

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OPERATING INSTRUCTIONS

Operating instructions KTB / KTBD

Important information ............................................................................................ 3

Exploded drawings / parts lists............................................................................ 29

Parts list for KTB-K / KTBD-K with end drive........................................................................ 29

KTB-K conveyor end with deflection roller, single belt ...............................................30

KTBD-K conveyor end with deflection rollers, dual belt .............................................31

Operating instructions KTB / KTBD

KTB drive unit for end drive, single belt ......................................................................32

KTBD drive unit for end drive, dual belt ......................................................................34

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

Operating instructions KTB / KTBD

1.1 Manufacturers declaration

Montech AG, Gewerbestrasse 12 CH-4552 Derendingen

1.2 Description of product and use

1.3 Factors which reduce the useful life

1.4 Safety instructions

Operating instructions KTB / KTBD

1.5 Additional information

U. D .Wagner / Gianluca Aloisi

1.6 Scope of the operating instructions

Operating instructions KTB / KTBD

1.7 Technical data

Protection category of the drive unit

brushless external rotor DC motor

Max. current consumption

3.6 A (at start)

Rated output power

200 to 3500 rpm

two-stage spur gear

3.4 ... 59.1 rpm

9.2 ... 162 rpm

0.4 to 7.6 m/min

4-pin, coupling M12x1, angled at 90

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

Operating instructions KTB / KTBD

Operating instructions KTB / KTBD

Total length of chassis

Total length of chassis (in mm)

Operating instructions KTB / KTBD

2.2 Mounting instructions

1 x Adhesive tape 25 mm width

Operating instructions KTB / KTBD

2.3 Pivoting of the drive unit

Switch off the motor

Adjustment of the belt pretension:

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

Height of material conveyed

Operating instructions KTB / KTBD

2.4 Electrical connection

Electrostatically sensitive components are present

Operating instructions KTB / KTBD

Connection to power unit

The drive unit must be correctly connected according to following representation.

Jack assignment in the conveyor drive

Assignment of connecting cable supplied

Operating instructions KTB / KTBD

Legend: Control panel

Reduce belt speed

Increase belt speed

Start / Counterclockwise operation

Start / Clockwise operation

Belt speed in m/min.