Belt diverter

Operation and maintenance manual

UM00003G01 (05/06/2008)

Ventomatic S.p.A > via G. Marconi, 20 > 24030 Valbrembo (Bg) Italy > tel +39 035 468 311 > fax +39 035 460 838
www.ventomatic.it
 We thank you for choosing a VENTOMATIC S.p.A. product.

This machine has been designed and manufactured using the most modern
processes and the best technologies available, in order to grant its reliability
during its lifetime while ensuring the utmost security to the operators.

The pictures and the drawings in the manual are for indication purposes
only, since they only represent a general reference, and are not necessarily
precise in every detail.

The dimensions and the technical specifications of the machine indicated

in the manual are not binding, and can be changed without warning by
VENTOMATIC S.p.A.

The drawings and all the other documents supplied together with the machine
belong to VENTOMATIC S.p.A. and cannot be handed over to any third party
without prior consent in writing by VENTOMATIC S.p.A.

The manual includes the instructions for all the accessories installed in the
basic version of the machine.

In order to ensure a proper and safe use of the machine, we recommend

you to carefully read and follow what is indicated in the manual.

All the documents included in the supply of the machine, and in particular
this manual, shall be properly kept for any further reference.

The product described in this manual has been manufactured using

the operation processes and modes according to the Quality System of
VENTOMATIC S.p.A.
Since January 2001 the Quality System of the company has been examined
and certified by Bureau Veritas Italia S.p.A to be complying to the requirements
of the standard ISO 9001.

This ensures that every phase of the production process – from the
formulation of the order up to the technical service following the supply
– is always monitored and kept under control, in order to ensure that the
product complies with the requirements of the customer and with its quality
standards.

© 2008 VENTOMATIC S.p.A all rights reserved.

It is strictly forbidden to totally or partially reproduce this manual without the
written consent of VENTOMATIC S.p.A

 MD00019G01
 General index

General index

General index 3

1 - Introduction 1-1

1.1 - Purpose of the manual_ _____________________________________ 1-2

1.2 - Manual’s addressees________________________________________ 1-3
1.3 - General prescriptions_______________________________________ 1-4
1.3.1 - Warnings and precautions....................................................................1-5
1.4 - List of enclosures_ ________________________________________ 1-6
1.5 - Warranty_ ______________________________________________ 1-6
1.6 - Test_ __________________________________________________ 1-6
1.7 - Service personnel__________________________________________ 1-6
1.8 - Communications with the customers’ office_ _______________________ 1-7
1.9 - Norms and reference documentation_ ____________________________ 1-7
1.10 - General notes upon delivery__________________________________ 1-7

2 - General instructions 2-1

2.1 - General safety instructions___________________________________ 2-2

2.2 - Start-up________________________________________________ 2-2
2.3 - Protections of the electric system______________________________ 2-2
2.4 - Improper use of the machine___________________________________ 2-3
2.5 - Safety devices_ ___________________________________________ 2-3
2.6 - Interventions on the machine_ _________________________________ 2-3
2.7 - Operators' clothing_________________________________________ 2-3
2.8 - Dismantling and disposal of the machine_ _________________________ 2-4

3 - Technical characteristics 3-1

3.1 - Description of the machine____________________________________ 3-2

3.2 - Belt diverter mod. DC/1_____________________________________ 3-3
3.3 - Belt diverter mod. DC/2_____________________________________ 3-4
3.4 - Belt diverter mod. DC/2S____________________________________ 3-5
3.5 - Belt diverter mod. DC/3_____________________________________ 3-6
3.6 - Proximity switches_________________________________________ 3-7
3.7 - Technical data_ ___________________________________________ 3-8

MD00019G01 
 General index

4 - Installation 4-1

4.1 - Unpacking and checking at the reception of the goods_ ________________ 4-2
4.2 - Checking of the installation requisites____________________________ 4-3
4.3 - Installation and assembling___________________________________ 4-4
4.3.1 - Positioning and mounting of the belt diverter........................................4-5
4.3.2 - Positioning and mounting of the chutes................................................4-6
4.4 - Electric connection_________________________________________ 4-6
4.5 - Pneumatic connection_ ______________________________________ 4-6

5 - Adjustment operations 5-1

5.1 - Adjustment of the ring belt___________________________________ 5-2

5.2 - Adjustment of the cylinder stroke_ _____________________________ 5-2

6 - Maintenance 6-1

6.1 - Routine maintenance________________________________________ 6-2

6.1.1 - General rules........................................................................................6-2
6.1.2 - Cleaning and checking at the end of the production..............................6-2
6.1.3 - Monthly checkout (400 hours).............................................................6-2
6.1.4 - Maintenance of the compressed air treatment group............................6-3
6.1.5 - Maintenance of the belt diverter...........................................................6-4
6.2 - Summary table of the maintenance operations_______________________ 6-4
6.3 - Tables of lubricants________________________________________ 6-5
6.3.1 - Table of lubricants for the reduction gears............................................6-5
6.3.2 - Table of lubricants for supports, bearings, guides and chains...............6-6
6.3.3 - Table of lubricants for the F.R.L. group..................................................6-6

This manual is composed of 38 pages

 MD00019G01
1 - Introduction

Index

1.1 - Purpose of the manual_ _____________________________________ 1-2

1.2 - Manual’s addressees________________________________________ 1-3
1.3 - General prescriptions_______________________________________ 1-4
1.3.1 - Warnings and precautions....................................................................1-5
1.4 - List of enclosures_ ________________________________________ 1-6
1.5 - Warranty_ ______________________________________________ 1-6
1.6 - Test_ __________________________________________________ 1-6
1.7 - Service personnel__________________________________________ 1-6
1.8 - Communications with the customers’ office_ _______________________ 1-7
1.9 - Norms and reference documentation_ ____________________________ 1-7
1.10 - General notes upon delivery__________________________________ 1-7

MD00047G04 1-1
 Chapter 1 - Introduction

1.1 - Purpose of the manual Please read carefully this handbook before you proceed in doing any kind
of intervention on the machine.

This manual, issued by the manufacturer, is an integral part of the machine

equipment.

The information contained herein is headed to qualified people, experienced

and with high technical preparation, to people aware of the laws and
regulations in force, who will be able to recognise and avoid possible dangers
during the transfer, installation, use and maintenance of the machine.

The aim of this manual is to describe the operation modes of the machine,
the use prescribed by the manufacturer and the precautions to be taken
to ensure a safe and proper handling, installation, use, operation and
maintenance of the machine.

Only if you observe the indications contained in this manual and in general
of all the documents included in the supply you can ensure the safety of the
operators, the economy of use, the proper operation of the machine as well
as a longer lifetime of the same.

It is necessary to carefully read and keep the whole documentation

provided in the supply.

VENTOMATIC S.p.A. declines any responsibility for damages to things or

people caused by an incorrect use of the machine, not foreseen in this
manual.

In order to simplify the consultation and improve the reading of the manual,
we have divided it into chapters and paragraphs, which are listed in the
general index.
Some parts of the texts have been highlighted in bold characters to underline
their importance, and they are preceded by the symbol shown below.

DANGER - ATTENTION: it’s absolutely necessary to be very careful in order

to avoid consequences that could cause physical damages to the user.

CARE - CAUTION: it’s absolutely necessary to be very careful in order to

avoid consequences that could cause damages to the goods (resources
and product).

Any remark you would like to make for our guidance is of great interest to
us, in order to improve services that VENTOMATIC S.p.A. usually offers to
its own customers.

1-2 MD00047G04
 Chapter 1 - Introduction

1.2 - Manual’s addressees The operators, depending on the tasks and different information requirements
(UNI 10653/2003) are divided into:

Addressee Information’s requirements

Homogeneous Addressee
H a n d l i n g To pack the equipment, check its right position into the
operators package, close it appropriately. Unpack the equipment in
accordance with the instructions indicated in the package.
If needed, these operations must be carried out by means
of lifting devices and in safe conditions for the people, for
the product and for the environment.
Carriers To load the packed machine on the means of transport
by using lifting devices, stow it adequately, transport it to
the place of destination and then unload it by carrying out
the above-mentioned operations in reverse order, always
in safe conditions for the people, for the product and for
the environment.
Sellers To illustrate the characteristics of the available products,
supplying to a potential customer all the indications for
the choice, giving all the information about the unsafe
conditions for the people, for the product and for the
environmental and supplying the addresses to carry out
all the operation that regards the product, the installation,
the use, the maintenance, the repairs, the disassemble
and the dismantling.
I n s t a l l a t i o n To install, by explicit and implicit authorisation of the
operators purchaser and with the collaboration of the dealer, the
equipment in safe conditions for people, for the product
and environment, by supplying the user with the necessary
instructions for use and maintenance.
Maintenance To carry on ordinary check, verification and adjustment
operators operations and, when it is necessary, also repairs
according to the maintenance schedule supplied by the
Manufacturer, always in safe conditions for the people,
for the product and for the environment.
Repairers To carry out the troubleshooting and check any anomalous
working of the machine by making use of the information
supplied by the user; they must carry out all necessary
repairs, replacement and adjustment operations, so that
the machine can work correctly in safe conditions for the
people, for the product and for the environment.
Dismantling To understand when it is necessary to dismantle the
operators machine, disassemble it, eventually selecting the relative
materials, disposing of the non-reusable materials
and recycling the others in safe conditions for the
environment.
Heterogeneous Addressee
Users To utilised the equipment in safe conditions for the people,
for the product and for the environment, to interpret an
elementary troubleshooting and the anomalous working
conditions and to carry out any simple operation of
adjustment, check, maintenance and repairs.

MD00047G04 1-3
 Chapter 1 - Introduction

1.3 - General prescriptions Always make sure that you have completely understood the content of this
manual. The inobservance of the specific indications included in this manual
exempts the manufacturer from any responsibility for damages to people
and/or things.
Before the installation, make sure that the safety rules and positioning
instructions have been complied with and that the machine works correctly;
check the environmental conditions (temperature, humidity, lighting, vibrations,
suspension powders) and the suitability of the installation place.
Delimit the operating areas and the user’s positioning and provide sufficient
spaces for production and maintenance, in accordance with the safety
prescriptions supplied by the manufacturer.
Always check that the environmental and productive conditions close to the
operating area do not hinder the control operations of the machine.
For fur ther information, directly contact the technical service or the
manufacturer and communicate all the information listed in chapter 1.8.
Before installing the machine, make sure that the bearing surface is suitable
to supporting the weight.
In case of incompatibilities, immediately inform the technical service.
Maintenance, lifting, installation, use and maintenance operations must be
carried on by skilled personnel provided with the necessary psycho-physical
requisites in compliance with the instructions supplied and the safety and
health rules in force.

1-4 MD00047G04

1.3.1 - Warnings and precautions
MD00047G04
Chapter 1 - Introduction
Users, repairers and maintenance operators must be provided with a specific
knowledge as well as psycho-physical requisites in order to carry on the
above-mentioned operations.
When installing the machine, the customer must always check the correct
installation, working, and efficiency of control and safety systems (machine
supplied without electric board).
In case of anomalies in the machine, immediately stop the working cycle
and contact the technical service.
It is absolutely forbidden to operate on the machine wearing unsuitable
clothing (large or unbuttoned clothes, etc.) or personal objects (bracelets,
watches, rings, etc.).
Pay attention to the labels. In case of deterioration, replace them contacting
directly the technical service or the manufacturer.
Before starting a working cycle, make sure that neither the machine nor
its auxiliary components may cause dangerous situations to people and/or
things.
Preliminary starting, checks, starting of control units and any other operation
to be set by means of electric controls require competence, awareness and
prudence of the operator. In any case, it’s important to pay attention during
the control steps, operating carefully in the control devices, avoiding the
handing, at the same time, of tools and bulky objects. Keep the manufacturer’s
recommendations and the following instructions.
It is absolutely forbidden to place and/or abandon on the machine tools
and/or objects potentially dangerous for people’s health or for the damage
of the machine.
In order to have access to the parts of the machine under safety conditions,
stop the machine and disconnect the external power sources according to
the indications and the procedures prescribed by the manufacturer.
Any maintenance operation must be carried out by skilled technicians.
It is forbidden to modify or tamper with the machine. VENTOMATIC S.p.A.
declines any responsibility for any modification or tampering with the
machine.
It is absolutely forbidden to tamper equipment, controls and/or safety
devices.
Carefully read the “ATTENTION” sections of the manual.
1-5
 Chapter 1 - Introduction

1.4 - List of enclosures Attached to this manual the following documentation:

Electrical diagrams: necessary for advanced users for electric system
assistance.
Pneumatic diagram: necessary for advanced users for pneumatic system
assistance.
Spare parts catalogue: for original spare parts reordering.
Documentation of commercial available parts: containing all necessary
information pertaining to the commercial available parts, which have been
installed on the machine.
Lay-out designs: necessary for the installer to set the machine.

1.5 - Warranty The machine is covered by a warranty for manufacturing defects.

Refer to the purchase contract to obtain information about the duration of
the warranty period.

The warranty is valid only if the machine has been used in accordance with
the manufacturer’s instructions and has not been tampered.
The warranty includes the replacement of faulty parts (ex-works VENTOMATIC
S.p.A.).
The warranty is not valid if any repair operation is carried out by unauthorised
personnel.

1.6 - Test The positive test of the machine is carried out at VENTOMATIC S.p.A. before
the shipment of the machine.

1.7 - Service personnel The repair and special maintenance operations of the machine must be
carried out only by qualified personnel, that is by VENTOMATIC S.p.A., or
by personnel authorised by the company.
Information about the personnel qualified for such operations can be given
directly by VENTOMATIC S.p.A. by contacting the customer service office.

1-6 MD00047G04
 Chapter 1 - Introduction

1.8 -Communications with To solve any problem or doubt contact:

the customers ’ office VENTOMATIC S.p.A. - Customer’s office

A. Telephone:+39-035-468 311
B. Fax:+39-035-460 838
C. @Mail: service@ventomatic.it

In order to optimize the answer time and to find a solution appropriate and
punctual, is important to communicate the following information:

A. Customer’s information (Name, phone number, @mail address)

B. The order number;
C. Type of machine;
D. Problem description (specifically the par t of the machine
concerned);
E. Description of eventual tests done for the solution of the problem
achieve by the customer’s personal.

1.9 - Norms and reference The machine complies with the prescriptions included in the following
documents:
documentation
1. 89/392/CE Directive, modified by 91/368/CE, 93/44/CE, 93/68/CE
and 98/37/CE (“Machine Directive”).
2. UNI EN ISO 12100-1/2005: Safety of machinery - Basic concepts,
general principles for design - Part 1: Basic terminology, methodology.
3. UNI EN ISO 12100-2/2005: Safety of machinery - Basic concepts,
general principles for design - Part 2: Technical principles.
4. ­All the specific technical prescriptions of the sector that control the
activity of design, development, production, installation and maintenance of
the machine.

1.10 - General notes upon When receiving the machine make sure that:
• the supply corresponds to the order specifications;
delivery • all the components stated in the packing list are present;
• the machine has suffered no damages due to the transport or
other.

In case of damages or missing parts please inform immediately VENTOMATIC

S.p.A.

MD00047G04 1-7
 Chapter 1 - Introduction

1-8 MD00047G04
2 - General instructions

Index

2.1 - General safety instructions___________________________________ 2-2

2.2 - Start-up________________________________________________ 2-2
2.3 - Protections of the electric system______________________________ 2-2
2.4 - Improper use of the machine___________________________________ 2-3
2.5 - Safety devices_ ___________________________________________ 2-3
2.6 - Interventions on the machine_ _________________________________ 2-3
2.7 - Operators' clothing_________________________________________ 2-3
2.8 - Dismantling and disposal of the machine_ _________________________ 2-4

MD00274G00 2-1
 Chapter 2 - General instructions

2.1 - General safety The safety instructions listed herebelow shall be absolutely observed; this list
however is not exhaustive, and does not relieve the user from strictly knowing
instructions and applying the regulations in force in the country of use of the machine
pertaining to the accident prevention and the working safety.

ATTENTION! In order to safely use the machine it is absolutely necessary

to strictly adhere to the working safety instructions ruled out by the laws
in force in every country.

All the operations on the machine must be carried out only by high-qualified
technicians.

Never carry out any operation while the machine is running.

When the plant is running, never put any object, tool, hand or other parts of
your body into any moving part.

Always disconnect the electric and pneumatic supply before carrying out
any operation on the machine.

The area around the machine must be clean, clear and well-lit.

2.2 - Start-up

ATTENTION! It is strictly forbidden to start the belt diverter before the plant
into which it has been installed has been declared complying with the
safety rules in force in the country of use; for this reason the construction
electrician/installer shall foresee the proper personal or general protection
devices in order to avoid any damage to people or things.

2.3 - Protections of the The electric system has been designed and manufactured so as to protect
the operators from electric shocks, and to protect the whole machine from
electric system overheating or any other dangerous condition.

2-2 MD00274G00
 Chapter 2 - General instructions

2.4 - I mproper use of the The machine shall not be used for purposes different from those it has been
destined to (see chapter 3). Each time the machine is used for any other
machine purpose it could cause dangers, since the safety foreseen at a design level
cannot be guaranteed.

2.5 - Safety devices The machine is installed on a belt conveyor, which in turn is part of a bags-
feeding system composed of various belt conveyors.
The belt diverter is not equipped with specific safety devices; the safety of
the operators and of the maintenance operators shall be granted by the safety
devices adopted on the feeding system which the machine is part of.

2.6 - I nterventions on the All the routine maintenance operations (cleaning, adjustments, removal or
arrangement of the bags) shall be carried out according to the safety measures
machine adopted and foreseen for the protection of the area.

2.7 - Operators' clothing All the people working with the machine shall be properly trained on the correct
working methods, and shall be informed about the type and the operation
of the safety devices.
All the operators shall read this manual carefully.

The operators must not wear fluttering clothes that could get caught in the
moving parts of the machine.

ATTENTION! Do not get your clothes near the moving elements.

The operator shall wear the accident prevention clothing foreseen in the working
area, such as protective glasses, gloves, shoes and headsets, according to
the laws in force in the country where the machine is installed.

MD00274G00 2-3
 Chapter 2 - General instructions

2.8 - Dismantling and Useful information for the disposal of the machine and its components.

disposal of the machine The dismantling shall be carried out by skilled personnel, equipped with
personal and general protection devices, according to the accident prevention
laws and the environment protection regulations.

Construction material:
• steel, aluminium, cast iron;
• copper and silver for the electric components;
• rubber, nylon, PVC, resins and fibers.

To our knowledge no component is harmful or toxic.

It is necessary to be extremely careful when disposing of the gearmotors,

since they are full with oil.
Do not abandon them in the environment, and do not dispose of them as
waste.

ATTENTION! All the machines and components, after exceeding their

useful lifetime, shall be disposed of according to the laws in force in the
countries of use.

2-4 MD00274G00
3 - Technical characteristics

Index

3.1 - Description of the machine____________________________________ 3-2

3.2 - Belt diverter mod. DC/1_____________________________________ 3-3
3.3 - Belt diverter mod. DC/2_____________________________________ 3-4
3.4 - Belt diverter mod. DC/2S____________________________________ 3-5
3.5 - Belt diverter mod. DC/3_____________________________________ 3-6
3.6 - Proximity switches_________________________________________ 3-7
3.7 - Technical data_ ___________________________________________ 3-8

MD00020G01 3-1
 Chapter 3 - Technical characteristics

3.1 - Description of the The function of the belt diverters is to deviate the bags passing on the belt
conveyors; they allow the deviation of the bag, conveying it onto another
machine belt conveyor placed at a lower level. The installation of a belt diverter on a
transport line allows to change the flow of bags towards the various loading
and palletization points.
The belt diverter consists of a frame onto which two vertical drums (one
motorized and one idle) are installed, pulling a ring belt. The belt diverter is
perpendicular in respect to the belt of the belt conveyor, so that while the
bag is moving on the conveyor it meets the belt diverter, which deviates it
towards the edge and then towards the sloping chute.
The belt diverter carries out two functions: it turns the bag and conveys it
onto the chute.
The chute can be executed in two versions: one version is fixed, while the other
has a mobile final section. In its upper position the mobile chute allows the
passage of the bags onto the lower belt, while in its lower position it allows
the bags to be conveyed from the upper belt to the lower belt.

The four configurations for the belt diverter are the following:
• DC/1;
• DC/2;
• DC/2S;
• DC/3.

DC/1 DC/2

DC/2S DC/3

3.1

3-2 MD00020G01
 Chapter 3 - Technical characteristics

3.2 -
Belt diverter mod. The belt diverter mod. DC/1 conveys the bag in one direction only in respect
to the line it comes from, since it is equipped with a fixed position that does
DC/1 not allow other deviations.
The belt diverter (Pos.1 Fig.3.2) is connected to the fixed frame (Pos.2 Fig.3.2)
by means of a screw coupling (Pos.3 Fig.3.2), which allows to correctly
adjust the position the diverter.

3.2

MD00020G01 3-3
 Chapter 3 - Technical characteristics

3.3 -
Belt diverter mod. The belt diverter mod. DC/2 deviates the bag laterally; when it is in rest
position, it lets the bag continue its path straight onto the belt on which it
DC/2 is moving.
As shown in fig. 3.3, the belt diverter rotates around a pivot (Pos.1 Fig.3.3)
from the running position (Pos.2 Fig.3.3) to the rest position (Pos.3 Fig.3.3).
When the belt diverter is in running position the bags are conveyed onto the
chute and onto the lower belt conveyor, while when the belt diverter is in rest
position the bags continue their straight path.
The rotation is driven by a pneumatic actuator (Pos.4 Fig.3.3) operated by a
solenoid valve; a sensor controls its correct positioning.

3.3

3-4 MD00020G01
 Chapter 3 - Technical characteristics

3.4 -
Belt diverter mod. The belt diverter mod. DC/2S allows the flow of bags in two directions: to the
right (Pos.1 Fig.3.4) and to the left (Pos.2 Fig.3.4) in respect to the direction
DC/2S they are coming from. This type of configuration requires a supporting frame
for the diverter with four bearings on the ground. Unlike the DC/2 model, the
rotation pivot is positioned in the middle (Pos.3 Fig.3.4) and not at the end.
The rotation angle of 90° allows the deviation of the bag to the right or to the
left in respect to the running direction of the main belt. The change of position
of the belt diverter corresponds to the rotation direction.
The rotation is driven by a pneumatic actuator (Pos.4 Fig.3.4) operated by a
solenoid valve; a microswitch controls its correct positioning.

3.4

MD00020G01 3-5
 Chapter 3 - Technical characteristics

3.5 -
Belt diverter mod. The belt diverter mod. DC/3 allows the flow of bags in three directions: straight
(Pos.1 Fig.3.5), to the right (Pos.2 Fig.3.5) and to the left (Pos.3 Fig.3.5).
DC/3 This type of configuration requires a supporting frame for the diverter with
four bearings on the floor.
Unlike the belt diverter mod. DC/2S, this model is characterised by a further
position (rest position), which allows the bag to continue its straight path.

3.5

3-6 MD00020G01
 Chapter 3 - Technical characteristics

3.6 - Proximity switches The machine is equipped with photocells and proximity switches having the
following functions:
1. proximity switch rest position (DC/2);
2. proximity switch running position (DC/2);
3. proximity switch belt diverter to the right (DC/2S);
4. proximity switch belt diverter to the left (DC/2S).
5. proximity switch rest position (DC/3);
6. proximity switch belt diverter to the right (DC/3);
7. proximity switch belt diverter to the left (DC/3);
8. proximity switch rotation control of the belt diverter.

8
1
2

6
5

3.6

MD00020G01 3-7
 Chapter 3 - Technical characteristics

3.7 - Technical data

The standard version of the belt diverters can handle bags having the following characteristics:

Material of the bag paper (raffia, plastic)

Dimensions of the full bag
Length see the order confirmation
Width see the order confirmation
Speed
Speed of the belt diverter 1,9 m/s
Speed of the belt conveyor on which the belt diverter is installed 1 m/s
Compressed air
Pressure 6 bar
Filter 25 micron
Dew point 5°C
Maximum oil concentration 0,05 mg/m3
Electric power
Electric power installed 0,75 Kw.
Noise level
Noise level equivalent to the weighed acoustic pressure A at 1 meter lower than 62,5 dBA
Max. instantaneous weighed acoustic pressure C in the working places lower than 80 dB/20uPa
Working temperatures
Max. relative humidity allowed 80%
Min. ambient temperature allowed (storage) -20° C
Max. ambient temperature allowed (storage) +50° C
Min. ambient temperature allowed (operation) -10° C (*)
Max. ambient temperature allowed (operation) +40° C
Max. production time allowed (without pauses) 22 hrs

(*) The machine will operate at this minimum temperature but not necessarily at its normal production capacity. The minimum
temperature for a normal production is +5°C.

3-8 MD00020G01
4 - I n s ta l l at i o n

Index

4.1 - Unpacking and checking at the reception of the goods_ ________________ 4-2
4.2 - Checking of the installation requisites____________________________ 4-3
4.3 - Installation and assembling___________________________________ 4-4
4.3.1 - Positioning and mounting of the belt diverter........................................4-5
4.3.2 - Positioning and mounting of the chutes................................................4-6
4.4 - Electric connection_________________________________________ 4-6
4.5 - Pneumatic connection_ ______________________________________ 4-6

MD00021G01 4-1
 Chapter 4 - Installation

4.1 - Unpacking and checking The belt diverter is generally shipped inside a container or in cases together
with other components of the plant.
at the reception of the The unpacking operations shall be carried out close to the installation
place.
goods The personnel in charge of the handling, lifting and positioning operations
must be specifically trained, in order to avoid any incorrect operation while
moving heavy loads.
It will be necessary therefore to assign such operations to skilled personnel
(slingers, crane and truck operators, etc.) and provide on the ground a
person in charge of the signals, should the overall dimensions hinder a good
visibility to the operator.
The containers containing the machineries are marked with the anchor points
to be used for their lifting.
Outside the containers bear all the information useful to identify their content
and handle them safely.

ATTENTION! The capacity of the lifting devices must correspond to the

weight of the different parts to be handled (including the safety margins)
and to the capacity increase foreseen by the safety norms.

ATTENTION! The containers shall be handled and opened in the presence

of personnel authorized by VENTOMATIC S.p.A.

Once the containers have been correctly positioned, unpack as follows:

A. make sure that the content of the containers corresponds to what

indicated in the shipment documents;
B. visually check the soundness of all the electric components;
C. should any component/part be missing, immediately stop the
unpacking operations and inform VENTOMATIC S.p.A.;
D. if the plant has been damaged during the transport, immediately
inform the Insurance company and stop the unpacking operations until you
are authorized by the company itself to proceed.

ATTENTION! The manufacturer declines any responsibility for damages

to the machines due to incorrect handling operations carried out by
unqualified personnel or with the help of unsuitable means.

4-2 MD00021G01
 Chapter 4 - Installation

4.2 - Checking of the Except for specific layout indications, the foundations or the structures
of the plant must be arranged according to the drawings supplied by the
installation requisites manufacturer.
The area required for the assembling depends on the lifting and handling
means provided by the purchaser.
The room shall be foreseen with the connections for the power supply and
the compressed air.

ATTENTION! The position and size of the connections are set out by the
manufacturer and are shown in the layout enclosed.

ATTENTION! The surface of the area housing the belt diverters must be
perfectly plane and suitable to bear the specific load of the supports (see
the layout enclosed).

ATTENTION! The purchaser is responsible for arranging the area of the

plant according to the safety norms and requisites in force.

MD00021G01 4-3
 Chapter 4 - Installation

4.3 - I nstallation and The personnel in charge of the handling, lifting and positioning of the modules
must be specifically qualified in order to avoid any incorrect operation while
assembling moving heavy loads.
It will be necessary therefore to assign such operations to skilled personnel
(slingers, crane and truck operators, etc.) and provide on the ground a
person in charge of the signals, should the overall dimensions hinder a good
visibility to the operator.
The belt diverter shall be installed and mounted by skilled technicians,
appointed or determined by the manufacturer, under the supervision of a
person in charge appointed by VENTOMATIC S.p.A.
The assembling shall comply with the drawings and diagrams supplied by
the manufacturer.
In order to have a correct view of the weights of the machine, please refer
to the PACKING LIST.
Before proceeding with the transport of the machine, check the overall
dimensions and the general weights of the machine, and then use suitable
lifting and transport means.

IL010010000

4-4 MD00021G01
 Chapter 4 - Installation

4.3.1 - Positioning and mounting
of the belt diverter
For the positioning of the belt diverters please refer to the layout drawings
attached to the documentation.
For the installation you shall locate the area of the belt conveyor in which
the belt diverter is going to be installed; in this area the belt-supporting
rollers (Pos.1 Fig.4.1) have been replaced by a plate made of a sheet (Pos.2
Fig.4.1), whose function is to avoid belt depressions due to deviated bags
or to shakings.
The belt diverters mod. DC/1 and DC/2 are erected on a three-upright frame.
Such uprights shall be fastened to the structure of the belt conveyor by means
of supporting plates. After leveling them, fix the uprights by means of the
suitable bolts supplied together with the machine (Pos.3 Fig.4.1).
The belt diverters mod. DC/2S and DC/3S are erected on a four-upright frame:
such uprights rest on the floor and are equipped with a supporting plate with
adjustment bolts (Pos.4 Fig.4.1) so to obtain a correct leveling.

For the geometric positioning proceed as follows:

• align the geometric axis of the chute with the geometric axis of the
lower belt conveyor;
• place the belt diverter in working position (completely outside), except
for the model DC/1;
• adjust the distance between the lower rim of the belt diverter and the
belt of the belt conveyor, which shall be about 5 mm. (Pos.5 Fig.4.1).

ATTENTION! Check the flatness of the frames by means of a spirit level.

2
5

4
1

4.1

MD00021G01 4-5
 Chapter 4 - Installation

4.3.2 - Positioning and mounting
of the chutes
The chute is mainly fastened to the frame of the belt conveyor, which is fixed
with bolts to the supporting sheet of the belt (Pos.1 Fig.4.2).
The inclination of the chutes is about 35°, and the height difference between
the lower belt and the upper belt can go from 350 mm. (minimum) to 1200
mm. (maximum) (Pos.2 Fig.4.2).

1 2

350-1200
35
4.2

4.4 - Electric connection

ATTENTION! The electric line which the belt diverter shall be connected to
shall comply with the norms in force and must have a correct earthing. Do
not use the earth cable to bypass different voltages, since the electronic
devices of the machines might be subject to disturbances.

ATTENTION! The connection must be carried out only by qualified

technicians being familiar with the accident prevention laws.

The filter-reducer-lubricator group (F.R.L. group) for the treatment of the

4.5 - Pneumatic connection compressed air is positioned on the frame of the belt diverter. Connect the
supply network to the inlet of the air treatment group.
The air feeding pressure shall be minimum 6 bar.

4-6 MD00021G01
5 - Adjustment o p e r at i o n s

Index

5.1 - Adjustment of the ring belt___________________________________ 5-2

5.2 - Adjustment of the cylinder stroke_ _____________________________ 5-2

MD00022G01 5-1
 Chapter 5 - Adjustment operations

5.1 - Adjustment of the ring To adjust the ring belt of the belt diverter proceed as follows:
• loosen the fastening screws (Pos.1 Fig.5.1) of the idle support;
belt • act on the tie rods (Pos.2 Fig.5.1) until the tension achieved is
correct;
• then tighten the stop nuts.

The slightly convexed shape of the idle drum and of the motorized drum
keeps the belt perfectly on the guide (Pos.3 Fig.5.1).

3
2

5.1

5.2 - Adjustment of the To adjust the cylinder stroke correctly, act on the screw connecting the rear
fork and the frame (Pos.1 Fig.5.2).
cylinder stroke

5.2

5-2 MD00022G01
6 - Maintenance

Index

6.1 - Routine maintenance________________________________________ 6-2

6.1.1 - General rules........................................................................................6-2
6.1.2 - Cleaning and checking at the end of the production..............................6-2
6.1.3 - Monthly checkout (400 hours).............................................................6-2
6.1.4 - Maintenance of the compressed air treatment group............................6-3
6.1.5 - Maintenance of the belt diverter...........................................................6-4
6.2 - Summary table of the maintenance operations_______________________ 6-4
6.3 - Tables of lubricants________________________________________ 6-5
6.3.1 - Table of lubricants for the reduction gears............................................6-5
6.3.2 - Table of lubricants for supports, bearings, guides and chains...............6-6
6.3.3 - Table of lubricants for the F.R.L. group..................................................6-6

MD00024G01 6-1

6.1 - Routine maintenance
6.1.1 - General rules
6.1.2 - Cleaning and checking at
the end of the production
6.1.3 - Monthly checkout
(400 hours)
6-2
Chapter 6 - Maintenance
VENTOMATIC S.p.A. declines any responsibility if the maintenance cycles
indicated in this manual and in the documentation enclosed are not properly
followed, if the maintenance is assigned to unskilled personnel or if
procedures or lubricants having characteristics non compatible with those
indicated by us are used.
The systematic control of the operation of some of the most important
elements of the machine can avoid operation faults in the future, and helps
in keeping the machine at its maximum operational levels.
DANGER - ATTENTION! The maintenance operations shall be carried out
by operators skilled in their specific sector, having proper experience,
technical training and knowledge of the relevant regulations. The
maintenance operations shall be carried out with the machine properly
isolated at an electric and pneumatic level.
ELECTRIC DISCONNECTION:
• press the emergency pushbutton;
• turn the main switch to OFF and lock it by means of a padlock.
PNEUMATIC DISCONNECTION:
• press the pushbutton of the progressive starter installed on the F.R.L.
group.
Once the plant has been stopped, clean with a jet of compressed air all the
components of the plant, in detail:
• kinematic motion groups;
• instruments;
• photocells and reflection units;
• signals.
ATTENTION! Do not use water jets.
Every month you shall check that:
• no oil leaks from the reduction gears and that the oil level is stable
within its allowed limits;
• the dust, dirt or rust laying on the motion groups do not hinder their
movement, uselessly overloading the movers;
• no component shows clear wear signs;
• the bearings slide properly.
MD00024G01
 Chapter 6 - Maintenance

6.1.4 - Maintenance of the The belt diverter is foreseen with a compressed air treatment group called
filter-reducer-lubricator group (F.R.L. group), which is connected to the supply
compressed air treatment group network of the plant.

The maintenance operations on the F.R.L. group are the following:

1

• check the F.R.L. group;

• check that no clogging has occurred and
- every 16 hours -
drain the condensate on the regulator of the F.R.L.
group;
• check the presence of lubricant in the cups
- every 400 hours -
of the F.R.L. group;
• clean the filtering element of the F.R.L.
- every 2400 hours - group with solvent and with a jet of compressed
air;
A
• clean the transparent cup with water and
B soap.
- every 4800 hours -
Note: Take great care, since alcohol, diluents or
acetone may damage it irreparably.

CONTROL OF THE F.R.L. GROUP:

2
1. Drain the condensate (Pos.1 Fig.6.1)
• Put a can under the washout valve A.
• Unlock the valve by turning it in the direction of the arrow and press
it to the top; keep it pressed until the condensate has been fully drained.
• Lock again the valve.

D 2. Top up the lubricant (Pos.2 Fig.6.1)

C • Unscrew the cup B or the plug C.
• Top up the lubricant until you reach the maximum level.
• Screw again the cup B or the plug C.
• Check the oil level through the inspection windows of the cup B.

3. Adjust the lubrication (Pos.3 Fig.6.1)

• Check the quantity of oil distributed by the feeder by carrying out
a series of cycles with the machine working idling. It should be about 5/6
drops per hour.
3 • If necessary act on knob D to adjust such quantity.

4. Clean the filter (Pos.4 Fig.6.1)

• Remove the cup E and disassemble the filter.
• Clean it by means of compressed air and if necessary wash it with
4 petrol or trichlorethylene.

6.1

MD00024G01 6-3
 Chapter 6 - Maintenance

6.1.5 - Maintenance of the belt The maintenance operations on the belt diverter are the following:
diverter
• check the tension and the adjustment of
- every 400 hours -
the ring belt;
• check the oil of the reduction gears and
their level,
- every 800 hours - • check the wear of the ring belt (superficial
indentations, deep cuts and so on), and if
necessary replace it;
• check the operation of the pneumatic
actuators;
- every 4800 hours - Note: It is necessary to have a kit of seals
available for each pneumatic actuator (see the
spare parts catalogue).
- every 12000 hours - • change the oil of the reduction gears.

6.2 - Summary table of the The table below summarizes the maintenance operations that shall be carried
out on the plant. The meaning of the letters and of the indications used in the
maintenance operations table are listed here below:
A. Intervention: Reset of the level
B. Intervention: Lubrication
C. Intervention: Oil check
D. Intervention: Oil change
E. Intervention: Inspection of the operation
(*) For the type of lubricant, please refer to the paragraph indicated.

Frequency (hrs)
Par.
Reference

Section of the
Component Lub.
Quantity

12000
2400

4800

9600

machine
400

800
16

(*)

F.R.L. group 6.3.3 Varies E C E E 6.1.4

Belt diverter Ring belt E 6.1.5
Reduction gears 6.3.1 Varies E 6.1.5
Pneumatic actuators E 6.1.5

6-4 MD00024G01
 Chapter 6 - Maintenance

6.3 - Tables of lubricants The following tables list:

1. The lubricants for the reduction gears (see par. 6.3.1)

2. The lubricants (grease) for the following elements (see par. 6.3.2):
• supports;
• bearings;
• guides;
• chains.

3. The lubricants for the F.R.L. group (see par. 6.3.3)

The abbreviations, the meaning of the shading and the indications used in
the table are listed here below:
CLP = mineral oil.
CLP PG = polyglycol (reduction gear W approved USDA-H1).
CLP HC = synthetic hydrocarbons.
HLP = hydraulic oil.
= synthetic lubricant (= grease for lubricants with synthetic
basis).
= mineral lubricant (= grease for lubricants with mineral basis).

1. ambient temperature;
2. type of lubricant as per DIN (ISO);
3. viscosity class ISO or class NLGI;
4. at low temperatures, critical behaviour at start-up.

6.3.1 - Table of lubricants for For the reduction gears use the lubricants (type OIL) listed below:
the reduction gears

1)
Mobil
®
Oil .3) ISO,NLGI
°C -50 0 +50 +100 2)DIN (ISO)
Standard Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin Spartan
-10 +40 CLP(CC) VG 220 Meropa 220 EP 220
630 220 GEM 1-220 BG 220 GR-XP 220 1100/220 BM 220 CLP 220
Mobil Shell Tivela Klübersynth Aral Degol BP Enersyn Tribol Synlube Optiflex A
-25 +80 CLP PG VG 220 SG-XP 220
Glygoyle 30 S 220 GH 6-220 GS 220 800/220 CLP 220 220
Mobil Shell Omala Klübersynth Aral Degol Tribol Pinnacle Optigear Syn- Renolin Unisyn
-40 +80 VG 220 thetic A 220 CLP 220
SHC 630 HD 220 EG 4-220 PAS 220 1510/220 EP 220
CLP HC
4) -40 +40 Mobil Shell Omala Klübersynth Pinnacle
VG 150
SHC 629 HD 150 EG 4-150 EP 150
VG 150 Mobilgear Shell Omala Klüberoil Aral Degol BP Energol Tribol Optigear Renolin Spartan
-20 +25 CLP (CC) GR-XP 100 Meropa 150 EP 150
VG 100 627 100 GEM 1-150 BG 100 1100/100 BM 100 CLP 150
-30 +10 VG 68-46 Mobil Shell Tellus Klüberoil Aral Degol Tribol Rando EP Optigear Renolin Esso Automatic
IL007080000

HLP (HM) VG 32 Trasmission Fluid

D.T.E. 13M T 32 GEM 1-68 BG 46 1100/68 Ashless 46 32 B 46 HVI
4) Mobil Klüber-Summit Cetus
-40 +10 CLP HC VG 32 HySyn FG-32
SHC 624 PAO 46
4) -40 -20 VG 22 Mobil Shell Tellus Isoflex BP Energol Rando
HLP (HM) VG 15 T 15 MT 30 ROT HLP-HM 15 HDZ 15
D.T.E. 11M

MD00024G01 6-5
 Chapter 6 - Maintenance

6.3.2 - Table of lubricants for For the bearings, the supports, the chains and the guides use the lubricants
(type GREASE) listed below:
supports, bearings, guides and
chains

1)
Oil 3) ISO,NLGI Mobil ®

°C -50 0 +50 +100 2) DIN (ISO)

IL007090000
Esso
-25 +80 3 Unirex N3
DIN 51 502
Centoplex 2 Multifak EP 2
-25 +60 2-3 Mobilux EP2 Alvania R2 Beacon 2
Centoplex 2 EP Grease L2

6.3.3 - Table of lubricants for The table below lists the lubricant (type OIL) to be used for the F.R.L.
group:
the F.R.L. group

1)

IL007110000
Mobil
®
Oil 3) ISO,NLGI
°C -50 0 +50 +100 2)DIN (ISO)
Mobil Shell Crucolan Rando Renolin ESSO
-10 +40 (FD 22) HD 22
DTE 22 Tellus 22 22 MR 5 Spinesso 22

6-6 MD00024G01