IntelliSort HDS

Maintenance Manual

Publication No. 29157701

May 3, 2021
Legal Notices

Information in this document is subject to change without notice. No part of this document may be
reproduced or transmitted to parties other than the customer and the customer's employees in any form
or by any means, electronic or mechanical, for any purpose, without the express written consent of
Honeywell.

© 2016, 2021 Honeywell International Inc. All Rights Reserved

This document contains confidential proprietary information and trade secrets of Honeywell. This
document is distributed with the understanding that it will not be disclosed to any third party, in whole or
part, without the prior written consent of Honeywell.

Trademarks

OnTimeParts™ is a trademark of Honeywell International Inc.

Intelligrated® and IntelliSort® are registered trademarks of Honeywell International Inc.

Product and company names herein may be the trademarks of their respective owners.

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Table of Contents

1 SAFETY INSTRUCTIONS ................................................................................................... 1

1.1 Introduction ................................................................................................................ 1
1.2 For Your Safety ........................................................................................................ 2
1.3 ANSI Safety Statements ........................................................................................... 2
1.4 Standard Safety Conventions ................................................................................... 3
1.5 Safety Precautions ................................................................................................... 4
1.5.1 Guards and Guarding ........................................................................................ 4
1.5.2 Headroom ......................................................................................................... 5
1.6 Controls .................................................................................................................... 5
1.6.1 Control Stations ................................................................................................. 6
1.6.2 Safety Devices .................................................................................................. 7
1.7 Operation Safety Precautions ................................................................................... 7
1.8 Installation and Maintenance Safety ......................................................................... 8
1.9 Lockout/Tagout Guidelines ....................................................................................... 9
1.10 Safety Signs ......................................................................................................... 9

2 GENERAL DESCRIPTION .................................................................................................11

2.1 Introduction .............................................................................................................11
2.2 Idler Section with Infeed Belt ...................................................................................13
2.3 Pre-Sort Section ......................................................................................................14
2.4 Intermediate Section with Divert Switch ...................................................................16
2.4.1 Divert Switch Operation ....................................................................................16
2.4.2 Divert Switch Detail ..........................................................................................17
2.5 Intermediate Section with Catenary .........................................................................18
2.6 Carrying Chain and Drive Unit .................................................................................19
2.7 Divert Shoes and Flights .........................................................................................21
2.8 General Product Summary ......................................................................................22

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3 CONTROL DESCRIPTION .................................................................................................23
3.1 Introduction .............................................................................................................23
3.2 DCM Operation .......................................................................................................25
3.3 Connecting the DCM ...............................................................................................26
3.4 DCM Layout ............................................................................................................30
3.5 Oiler Control ............................................................................................................31

4 SERVICE AND REPAIR .....................................................................................................33

4.1 Introduction .............................................................................................................33
4.2 Flight Removal and Installation ................................................................................34
4.3 Chain Adjustment and the Catenary ........................................................................36
4.4 Chain Lubrication ....................................................................................................40
4.5 Chain Temperature .................................................................................................40
4.6 Chain Wear .............................................................................................................42
4.7 Cleaning the Divert and Crossover Switches ...........................................................43
4.8 Electric Switch Removal and Installation .................................................................44
4.9 Divert Actuator Assembly Replacement...................................................................45
4.10 Divert Switch Trigger Replacement ......................................................................46
4.11 Debris Detection Device Adjustment ....................................................................47
4.12 Chain Lubricator Adjustment ................................................................................48
4.12.1 Electric Pump Style Oiler ..............................................................................49
4.13 Carrying Flight Cleaning ......................................................................................51
4.14 Chain Track and Shoe Guidance Replacement ...................................................52
4.14.1 Replacing the Top Run Black UHMW Chain Track .......................................52
4.14.2 Replacing the Bottom Run Black UHMW Chain Track ..................................57

5 PREVENTIVE MAINTENANCE ..........................................................................................61

5.1 Introduction .............................................................................................................61
5.2 Maintenance Precautions ........................................................................................62
5.2.1 Cleaning and Inspection ...................................................................................63

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 5.3 IntelliSort HDS Conveyor Checklists........................................................................64
5.3.1 Daily Tasks.......................................................................................................64
5.3.2 Weekly Tasks ...................................................................................................65
5.3.3 Quarterly Tasks ................................................................................................67

6 REPLACEMENT PARTS ....................................................................................................71

6.1 Ordering Parts .........................................................................................................71
6.2 Illustrated Parts Lists ...............................................................................................71
6.2.1 Using the Illustrated Parts Lists ........................................................................71
6.2.2 Idler and Infeed ................................................................................................74
6.2.3 Pre-Sort Section ...............................................................................................79
6.2.4 Intermediates ...................................................................................................81
6.2.5 Catenary ..........................................................................................................87
6.2.6 Drive and Discharge Chute ..............................................................................91
6.2.7 Component Details ...........................................................................................94

7 TROUBLESHOOTING ......................................................................................................103
7.1 Introduction ...........................................................................................................103
7.2 Troubleshooting Help ............................................................................................110

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1 Safety Instructions
1
This chapter provides instructions for the safe and productive operation of the
equipment.

You must read and understand these precautions completely before operating,
setting up, installing, running, or performing maintenance on the equipment.
Failure to follow this instruction could result in death or serious injury.

1.1 Introduction
These safety procedures are to be used as a guide to supplement the following:

• All other information pertaining to the equipment.

• Local safety codes.

• Plant and shop safety rules and codes.

• Federal and state safety laws, regulations, and codes.

Note: Emphasis is placed on the latest edition of the Occupational Safety and
Health Standards, which is available from the Department of Labor, Washington,
D.C. These standards (found in Part 1910, Title 29 of the Code of Federal
Regulations) contain the current, general industry occupational safety and health
regulations set forth by federal legislation. Also, some of the information contained
in this section has been reprinted from ASME, B20.1 by permission of The
American Society of Mechanical Engineers. All rights reserved.

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Safety Instructions

1.2 For Your Safety

This manual contains important safety information concerning the use, maintenance,
installation, and operation of this equipment. Read and become familiar with the
contents of this manual before attempting to install, operate, or service this
equipment. It is necessary that all operators and maintenance personnel study the
applicable sections of this manual thoroughly before operating the equipment.

If you are unable to understand the contents of this manual, please bring it to the
attention of your supervisor or foreman. Failure to comply with the instructions and
warnings contained in this manual, and the warnings posted on the machine, could
result in death or serious injury. Do not operate this equipment unless you have
read and understood the contents of this manual.

1.3 ANSI Safety Statements

Safety statements contain information essential to the safety of personnel and
equipment. Throughout this manual, and on the equipment, you will find DANGER,
WARNING, and CAUTION signs. Pay particular attention to these because they
signal information that is important to your safety and to the correct operation of the
equipment.

Warning signs and labels posted on or near the equipment should not be removed,
painted over, or altered at any time. Reference: ANSI Z535.4. All safety devices,
warning lights, and alarms associated with the conveyor system must be regularly
tested (at least monthly) for proper operation and serviced as needed. If the original
safety item(s) become defective or damaged, refer to the conveyor parts list(s) of the
bill(s)-of-materials for replacement part numbers.

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 Safety Instructions

1.4 Standard Safety Conventions

This section includes information essential to the safety of personnel and equipment.
Throughout this manual, and on the equipment, you will find DANGER, WARNING,
and CAUTION signs. Pay particular attention to these because they signal
information that is important to your safety and to the correct operation of the
equipment.

Warning signs and labels posted on or near the equipment shall not be removed,
painted over, or altered at any time. Reference: ANSI Z535.4. All safety devices,
warning lights, and alarms associated with the conveyor system must be regularly
tested (at least monthly) for proper operation and serviced as needed. If the original
safety item(s) become defective or damaged, refer to the conveyor parts list(s) of
bill(s)-of-materials for replacement part numbers.

DANGER indicates a hazardous situation that, if not avoided will result in

immediate, serious personal injury or death.

A WARNING indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

A CAUTION indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

A NOTICE provides information that is considered important but is not hazard-

related. This includes messages that discuss property damage.

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Safety Instructions

Note: The term NOTE is used to call attention to useful information and is not a
safety notice. Information appearing in a NOTE provides additional information that
is helpful in understanding the item being explained.

1.5 Safety Precautions

The success of any safety program depends primarily on the attitudes and training of
the installation, maintenance, and operating personnel. The very nature of their work
makes it necessary that they develop a complete and firsthand knowledge of each
piece of equipment that is within their care. This familiarity enables them to recognize
the hazards resulting from improper usage.

1.5.1 Guards and Guarding

Where necessary for the protection of personnel from hazards, all exposed moving
machinery parts that present a hazard to employees at work stations or operator’s
stations shall be mechanically or electrically guarded, or guarded by location or
position.

Interfacing of Equipment
When two or more pieces of equipment are interfaced, special attention shall be given
to the interfaced area to ensure the presence of adequate guarding and safety
devices.

Guarding Exceptions
Wherever conditions prevail that would require guarding under these standards, but
such guarding would render the conveyor unusable, prominent warning means such
as signs or warning lights shall be provided in the area or on the equipment in lieu of
guarding.

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 Safety Instructions

Guarded by Location or Position

Remoteness from frequent presence of public or employed personnel shall constitute
guarding by location. Overhead conveyors, such as trolley equipment and hanger-
suspended tray conveyors, for which guarding would render the equipment unusable
or would be impractical, shall have prominent and legible warnings posted in the area
or on the equipment, and, where feasible, lines shall be painted on the floor
delineating the danger area.

When the equipment passes over a walkway, roadway, or work station, it is

considered guarded by location if all moving parts are at least 8 ft. (2.4 m) above the
floor or walking surface or are otherwise located so that the employee cannot
inadvertently come in contact with hazardous moving parts. Although overhead
conveyors may be guarded by location, spill guards, pan guards, or equivalent shall
be provided if the product may fall off the conveyor for any reason and endanger
personnel.

1.5.2 Headroom
When the equipment is installed above exit passageways, aisles, or corridors, there
shall be a minimum clearance of 6 ft. 8 in. (2.03 m) measured vertically from the floor
or walking surface to the lowest part of the equipment or guards. Where system
function will be impaired by providing the minimum clearance of 6 ft. 8 in. (2.03 m)
through an emergency exit, alternate passageways shall be provided. It is permissible
to allow passage under the equipment with less than 6 ft. 8 in. (2.03 m) clearance
from the floor for other than emergency exits if a suitable warning indicates low
headroom.

1.6 Controls
All electrical installations and wiring shall conform to the National Electrical Code
(Article 670 or other applicable articles) as published by the National Fire Protection
Association and as approved by the American National Standards Institute, Inc.

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1.6.1 Control Stations

Control stations should be arranged and located so that the operation of the affected
equipment is visible from them. Control stations shall be clearly marked or labeled to
indicate the function controlled.

Equipment that would cause injury when started shall not be started until employees
in the area are alerted by a signal, or by a designated person, that the equipment is
about to start. When the equipment would cause injury and is automatically controlled
or must be controlled from a remote location is started, an audible device shall be
provided which can be clearly heard at all points along the conveyor where personnel
may be present. The audible warning shall be actuated by the controller device
starting the equipment and shall continue for a required period of time before the
equipment starts. A flashing light or similar visual warning may be used in conjunction
with, or in place of, the audible device if a visual warning is more effective. Where
system function would be seriously hindered or adversely affected by the required
time delay, or where the intent of the warning may be misinterpreted (e.g., a work
area with many different pieces of equipment and allied devices), a clear, concise,
and legible warning sign shall be provided. The warning shall indicate that the
equipment and allied equipment may be started at any time, that danger exists, and
that personnel must keep clear. These warning signs shall be provided along the
equipment at areas not guarded by position or location.

Remotely and automatically controlled equipment, and equipment where operator

stations are not manned or are beyond voice or visual contact from drive areas,
loading areas, transfer points, and other potentially hazardous locations on the
equipment path not guarded by location, position, or guards, shall be furnished with
emergency stop buttons, pull cords, limit switches, or similar emergency stop devices.
All such emergency stop devices shall be easily identifiable in the immediate vicinity
of such locations unless guarded by location, position, or guards. Where the design,
function, and operation of such equipment clearly is not hazardous to personnel, an
emergency stop device is not required. The emergency stop device shall act directly
on the control of the equipment concerned and shall not depend on the stopping of
any other equipment. The emergency stop devices shall be installed so that they
cannot be overridden from other locations.

Inactive and unused actuators, controllers, and wiring should be removed from control
stations and panel boards, together with obsolete diagrams, indicators, control labels,
and other material which may confuse the operator.

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 Safety Instructions

1.6.2 Safety Devices

All safety devices, including wiring of electrical safety devices, shall be arranged to
operate so that a power failure or failure of the device itself will not result in a
hazardous condition.

Emergency Stops and Restarts

The controls shall be arranged so that, in case of emergency stop, manual reset or
start at the location where the emergency stop was initiated shall be required of the
conveyor(s) and associated equipment to resume operation.

Before restarting the equipment that has been stopped because of an emergency, an
inspection of the conveyor shall be made and the cause of the stoppage determined.
The starting device shall be locked or tagged out before any attempt is made to
remove the cause of the stoppage, unless operation is necessary to determine the
cause or to safely remove the stoppage. Refer to American National Standard
Institute’s Control of Hazardous Energy - Lockout/Tagout and Alternative
Methods (ANSI Z244.1) and The Control of Hazardous Energy (Lockout/Tagout)
(OSHA Standard 29 CFR 1910.147).

1.7 Operation Safety Precautions

Only a trained person shall be permitted to operate a conveyor. Training shall include
instruction in operation under normal conditions and emergency situations.

Where safety is dependent upon stopping devices, starting devices, or both stopping
and starting devices, they shall be kept free of obstructions to permit ready access.

The area around loading and unloading points shall be kept clear of obstructions that
could endanger personnel.

No person shall ride on a conveyor under any circumstances.

Personnel working on or near a conveyor shall be instructed as to the location and

operation of pertinent stopping devices.

A conveyor shall be used to transport only material it is designed to handle safely.

Under no circumstances shall the safety characteristics of the conveyor be altered if

such alterations would endanger personnel.

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Safety Instructions

Routine inspections and preventive and corrective installation and maintenance

programs shall be conducted to ensure that all guards and safety features and
devices are retained and function properly.

Personnel should be alerted to the potential hazard of entanglement in conveyors

caused by items such as long hair, loose clothing, and jewelry.

Conveyors shall not be newly installed, maintained, or serviced while in operation

unless proper installation, maintenance, or service requires the conveyor to be in
motion. In this case, personnel shall be made aware of the hazards and how the task
may be safely accomplished.

1.8 Installation and Maintenance Safety

Installation and Maintenance shall be performed only by qualified and trained
personnel.

It is important to establish an installation and maintenance program to ensure that all

conveyor components are maintained in a condition which does not constitute a
hazard to personnel.

When a conveyor is stopped during installation or for maintenance, starting devices or

powered accessories shall be locked or tagged out in accordance with a formalized
procedure designed to protect all persons or groups involved with the conveyor
against an unexpected start. Personnel should be alerted to the hazard of stored
energy, which may exist after the power source is locked out. Refer to ANSI Z244.1-
1982, American National Standard for Personnel Protection – Lockout/Tagout
of Energy Sources – Minimum Safety Requirements, and OSHA Standard 29
CFR 1910.147, “The Control of Hazardous Energy (Lockout/Tagout).”

Replace all safety devices and guards before starting equipment for normal operation.

Conveyors shall not be lubricated while in operation unless it is impractical to shut

them down for lubrication. Only trained and qualified personnel who are aware of the
hazards of the conveyor in motion shall be allowed to lubricate a conveyor that is
operating.

Guards and safety devices shall be maintained in a serviceable and operational

condition. Warning signs shall be maintained in a legible and operational condition.
Examples of warning signs are shown later in this section.

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 Safety Instructions

It is the responsibility of the owner/user to add any additional protective components

that may be needed whenever changes or variations are made to any of the
equipment components or operational characteristics.

1.9 Lockout/Tagout Guidelines

Appropriate lockout and tagout policy and procedures shall comply with the Code of
Federal Regulations, 29 CFR 1910.147 and the minimum safety requirements
outlined in the current publication of the American National Standard Institute’s
Control of Hazardous Energy – Lockout/Tagout and Alternative Methods (ANSI
Z244.1).

Effective January 8, 1990, O.S.H.A. has designated the need for a ‘positive, lockable’
means to remove all energy sources from equipment prior to new installation(s) or
any maintenance. The electrical power to the equipment can be locked out at the
main disconnect switch, which is normally located on the electrical cabinet. When
this is done, residual energy remains for some time in the capacitors associated with
the electrical system. This residual energy is automatically depleted by features built
into the equipment. After locking out the main disconnect switch, wait at least 60
seconds before beginning any installation or maintenance procedures. This allows
the residual energy to diminish. (If an equipment-mounted plate indicates that you
should wait longer than 60 seconds, wait the recommended period of time before
beginning any installation or maintenance work.)

Whenever you need to install new equipment or perform maintenance on the

equipment, or whenever you need to shut it down for any other reason, a lockout
procedure must be followed. Your employer is required by O.S.H.A. to develop a
written lockout/tagout procedure for this equipment.

1.10 Safety Signs

In an effort to reduce the possibility of injury to personnel working around conveying
equipment, safety signs are placed at various points on the equipment to alert them
of potential dangers. Please check the equipment and note all safety signs. Make
certain all personnel are alerted to and obey these signs.

The following illustration shows pictograms designed by the Conveyor Equipment

Manufacturers Association (CEMA) Safety Committee as a service to the industry.
They also mirror, to the extent practical, the pictograms on the associated CEMA
Safety Labels placed on the equipment. CEMA Safety Posters are also available to
place in work areas and break areas to remind personnel of safe practices.

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Safety Instructions

Figure 1-1 CEMA Safety Pictograms

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2 General Description
2
2.1 Introduction
The IntelliSort® HDS is designed for applications requiring high rate positive sortation
of products. It is typically supplied with a flat extruded aluminum flight which acts as
the carrying surface.

The sliding shoe is actuated, or switched, under the carrying surface of the machine.
Once the sliding shoes are switched by the control system, products are diverted off
the machine to a chute. These sliding shoes are assembled in a flight and are
transported by a set of hardened industrial grade carrying chains. These carrying
chains contain roller bearings which reduce friction and optimize energy
requirements.

The sorter is shipped to the job site in several assemblies. Every sorter begins with a
feeding belt conveyor that is integrated with the sorter infeed terminal end, called the
idler. This is followed by a pre-sort section and then intermediate sorter sections
which contain the divert mechanisms. Divert mechanisms will be pre-engineered to
align with specified chute locations. Intermediate sections with a divert mechanism
come in 20° divert angles. Divert switches can be removed in intermediate sections,
as needed. Near the discharge end of the sorter, one of the intermediate sections will
include a catenary which is used to accommodate the excess slack in the chain. The
sorter ends with a large chute, which is integrated with the sorter discharge end,
called the drive.

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General Description

Figure 2-1 IntelliSort HDS

Do not touch the chains or belt while they are in motion. Keep clothing and jewelry
away from the rollers or belt. Failure to follow this instruction may result in serious
personal injury and/or equipment damage.

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 General Description

Figure 2-2 IntelliSort HDS General Layout

2.2 Idler Section with Infeed Belt

The idler section with infeed belt is located at the infeed end of the IntelliSort. The
general function of this section is to induct product onto the sorter. The infeed belt is
driven by the sorter drive using a Power Take-Off (PTO). The divert shoes are
guided from the bottom to the top of the infeed idler by a pin guide channel, into the
cam retainer, and to another pin guide channel on the top of the sorter. The pin guide
channels maintain the position of the divert shoes as they travel between divert
locations.

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General Description

Figure 2-3 Idler with Infeed Belt

2.3 Pre-Sort Section

In the pre-sort section, the setup switch selects shoes to enter on the correct side of
the cartons for left or right divert. The carton is then properly aligned to divert in
either direction. This section includes a calibration switch that is located on the
bottom side of the sorter that is used when the controller calibrates the sorter divert
switches. The pre-sort section is located directly after the idler and has no chutes.

The setup switch is used in conjunction with the pre-sort section to assign carton and
shoe relationships based on the side to which the carton will be diverted. The setup
switch is located on the bottom side of the sorter, upstream of the first divert.
IntelliSort HDS sorters require a setup eye that detects cartons at induction. The
setup switch and setup/induction photo-eye are equal distances from the sorter idler
roller. This positioning is critical because the shoes and cartons must meet at the
intersection of the sorter and induction belt.

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 General Description

When a carton is detected at the setup photo-eye, a carton marker is entered in the
first tracking array zone. The carton marker contains the information that the sorter
controller uses to divert the carton to the assigned chute. The assigned chute is
either on the left or right side of the sorter. The setup switch directs the assigned
shoes to the left or right, as required to divert the carton to the assigned lane.

Figure 2-4 Pre-Sort Section

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General Description

2.4 Intermediate Section with Divert Switch

2.4.1 Divert Switch Operation
The divert switch assembly is positioned in the middle of the sorter. The shoes move
down the pin guide track to each divert switch assembly. A pivoting divert blade
activated by a control signal is located in the divert switch assembly. When the divert
switch is not activated, the divert shoe will pass straight through the divert switch
assembly and continue down the middle of the sorter. When activated, the divert
blade will pivot into the divert position through the switch, guiding the shoe to the
divert location, along the soft touch rail, and then along the divert rail and into the re-
entry block. Some HDS configurations will not have a divert rail due to width and
divert angle, which means the path goes directly from the soft touch rail to the re-
entry block. The diverted shoes continue out of the re-entry block into the pin guide
and down the sorter. All shoes are returned to the infeed idler section where they are
positioned on the proper side of the sorter by the pre-sort section.

The control system determines how many, and which specific, shoes will be used to
divert an item. In general, one divert shoe is sent for every 5 in. of product length.
The lead edge of the divert shoe is timed to connect with the leading edge of the
product to be diverted. This timing and calibration process occurs during the
induction of the product where photo-eyes are used to identify the leading and
trailing edges of the product. The divert switch uses through-beam photo-eyes to
determine the exact position of the shoe prior to entering the divert switch assembly.
The signal from the photo-eye is used by the control system to coordinate the timely
diverting of both the shoe and the product through the divert switch assembly.

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 General Description

Figure 2-5 Intermediate Section with Divert Switch

2.4.2 Divert Switch Detail

The IntelliSort HDS is supplied with an electrically actuated divert switch. The divert
switch is actuated by a signal from a central control system. The central control
system maintains the signal to release the appropriate number of divert shoes
needed to guide the product onto predetermined chutes. The photo-eyes are used to
detect the guide pin on each divert shoe. Divert chutes are positioned at stationary
divert locations along the side of the IntelliSort HDS. As the sorter conveying surface
cycles around the conveyor, all shoes are returned to the middle of the flight
assembly prior to the pre-sort section. The shoes are returned to charge positions in
the pre-sort section.

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General Description

Figure 2-6 Divert Switch

2.5 Intermediate Section with Catenary

The catenary is where the carrying chains sag to their lowest point on their return
path below the sorter's carrying surface. The catenary is equipped with windows
through which maintenance personnel can gauge the amount of sag in the chains
and monitor the wear rate of the left and right chains to ensure consistent growth
rates.

IntelliSort HDS catenary sections are 21 in. deep. To ensure proper tension on the
chains, maintenance personnel must maintain the sag within the limits indicated.

Detailed checks and adjustment procedures are provided in the Chain Adjustment
and the Catenary section of the Service and Repair chapter.

Additional optional sensing equipment can be used in an HDS intermediate section

with catenary. The Chain Slack Detection Kit detects when the chain slack in the
catenary has reached its lowest allowable point and requires maintenance. The
Chain Jump Detection Kit detects the skipping of one chain, either the right- or left-
hand chain, over the tooth of its sprocket. The sprocket or chain would then need to
be re-clocked to ensure the sorter slats run perpendicularly in the machine relative to
the slat’s length.

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 General Description

Figure 2-7 Intermediate Section with Catenary

It is important to maintain chains in the recommended sag range. Failure to do so

could result in excessive sorter alarms, shutdown, or even mechanical damage.
Refer to the Chain Adjustment and the Catenary section in the Service and
Repair chapter for monitoring and maintenance instructions.

2.6 Carrying Chain and Drive Unit

Tension on the carrying chain is adjusted during installation and maintained by the
catenary take-up section. Carrying chains are driven by drive sprockets located on
the drive shaft. The drive shaft is driven by V-belts, which are installed from the drive
sheave on the motor to the drive sheave on the shaft mounted reducer. An AC motor
with constant velocity drives the reducer. The discharge belt is driven by a separate
AC motor and reducer.

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General Description

Figure 2-8 Carrying Chain

Figure 2-9 Drive Unit

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 General Description

2.7 Divert Shoes and Flights

IntelliSort HDS utilizes streamlined divert shoes and runs at 400 fpm. Appropriate
gap is required between cartons for effective sortation of the product; gap
requirements vary based on the product mix and the control system. Smooth sliding
divert shoes are attached to each flight and are capable of sliding freely on a fixed
divert angle. The patented soft touch diverting system minimizes shoe-to-carton
impact speed. The flights operate at right angles to the direction of divert travel and
function primarily to carry product quickly and seamlessly to the divert chutes,
allowing the sliding shoes to divert where appropriate. In all configurations, the divert
shoes travel down the middle of the sorter prior to sorting.

Figure 2-10 Flight Assemblies and Divert Shoes

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General Description

2.8 General Product Summary

Table 2-1 IntelliSort HDS General Product Summary

Application High density sliding shoe sortation of a wide variety of items from
a single induction conveyor to after-sort chutes.
Minimum Carton 0.1 lb.
Weight Requirement

Minimum Carton Size Less than 1/8 in. tall: must be at least 6 in. long
Requirements Greater than 1/8 in. tall: must be at least 4 in. long

Infeed Belt Widths 22 in.

Sorter Frame Widths 59 in. HDS DS

Frame: 48 in. center (20°) or 30 in. center (30°)
43 in. HDS SS
Frame: 43 in. center (20°)

Divert Angle Options 20° (48 in. divert centers)

30° (30 in. divert centers, DS only)
Carrying Surface Flat aluminum slats
Options

Operational 0°F to 120°F

Environment

Power Units Sorter motor up to 30 HP

Minimum Elevation 42 in.

Finish Powder-coated

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3
3.1 Introduction
There are several control devices used in conjunction with the IntelliSort HDS. The
typical components that are supplied with every sorter are listed below. Specific
requirements on each installation mean the actual devices used may be different
from the components listed.

You must read and understand these precautions completely before operating,
setting up, installing, running, or performing maintenance on the equipment.
Failure to follow this instruction could result in death or serious injury.

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Table 3-1 Electrical/Control Components

Function

Main Power Switches power to the drive motor(s) and the control unit. The
Disconnect (may fourth pole switches power to the control unit. Located in the
be 4-pole switch) control panel.

Motor Starter(s) Switches power to drive motor(s) via a motor disconnect switch
and Variable Frequency Drive. Contact status may be supplied to
control unit. Located in the control panel.

Motor Disconnect Switches power to the drive motor via the Variable Frequency
Drive. The contact status is typically supplied to the control unit.
Variable Frequency Provides smooth drive motor start-up. Typically wired between
Drive (VFD) drive motor and motor disconnect switch (one per motor).
Located near sorter drive or in the control panel.
Emergency Stop Used to drop power to the drive motor(s). The contact status is
Push Button/Pull typically supplied to the control unit. Located on the conveyor.
Cord

Divert Control Used to control voltage and starting sequence to each divert
Module (DCM) switch. Divert switches will not function without the use of the
DCM located on the conveyor.
Low Oil Reservoir The chain oiler may be supplied with a low level switch. When the
Switch oil reaches a low level, the switch is closed, indicating the oiler
needs lubrication added.
Photo-Eye (on divert Used to detect the presence of the divert shoe for synchronizing
switch assembly) divert switching. Located on each divert switch. Signal input to
the control unit. Photo-eyes are not adjustable.
Proximity Switch and Proximity switches may also be used for detecting divert shoe
Limit Switch “out of track,” discharge end “product jam,” or pop-up transition
belt out of position.
Induction Photo- Located on the conveyor to detect the leading/trailing edge of
Eye(s) product entering the conveyor. Initiates product tracking.

Product Jam Detect Located at extreme upstream end of each chute. Oriented
Photo-Eye perpendicular to product flow direction. Used with a 3- to 7-
second time delay. Product jam condition indicated when product
blocks entrance to chute for that period of time. Diverting to that
chute is inhibited and power to conveyor may be dropped.
Current Sensing Used to sense drive motor over-current condition as the result of
Relay (Over-Current a jam condition or mechanical/electrical problem. Power to the
Detection) conveyor is dropped. Contact status is supplied to the control
limit.

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3.2 DCM Operation

The electric switch DCM provides two basic functions on the sorter. The DCM
controls the voltage to the brushless rotary actuator that moves the divert switch
trigger. The DCM also handles the precise timing of switch actuation to ensure no pin
trigger impact. Once the DCM receives an enable signal from the control system, it
fires the trigger in the next gap between divert shoes. If the enable signal arrives at
the DCM while a shoe bearing is blocking the switch photo-eye, that shoe bearing
will be the first shoe diverted.

The enable signal from the control system should remain active until the last required
shoe has been diverted. Upon seeing the trailing edge of the first shoe bearing not to
be diverted, the DCM will return the trigger to its home, non-divert position.

Figure 3-1 Shoe Leaving Switch Photo-Eye

Note: To ensure proper voltage is supplied to the DCM, a constant voltage

transformer should be used in the electrical design of the system. A constant
voltage transformer recreates a well-regulated sinusoidal waveform that is isolated
from input disturbances including: impulses, brownouts, waveform distortion,
swells, and sags.

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3.3 Connecting the DCM

All wiring to the DCM is pre-connectorized prior to shipment of the DCM panels to
the jobsite.

Figure 3-2 DCM Board

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Figure 3-3 DCM Enclosure, Front View

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Figure 3-4 DCM Enclosure, Left View

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Figure 3-5 DCM Enclosure, Right View

Table 3-2 DCM Switch Connections

Port Device Notes

P1 Power Cable Requires 1.5 Amps at 120VAC (50/60Hz, this power should come
from a constant voltage transfer.

P2 Motor Cable Connect to electric switch motor connector

P3 Photo-Eye Connect to electric switch photo-eye connector

Cable

P4 I/O Cable Divert Enable requires a 24 VDC signal, has an input impedance
of 17,000 ohms, and requires 15mA to energize.
Photo-eye output/green activate button requires 24VDC and can
source up to 300mA.

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3.4 DCM Layout

The DCM board includes seven LEDs to indicate status and operation of the board.

Table 3-3 LED Description

LED Description
Label

PIN Indicates the state of the two photo-eyes installed for missing pin detection.
It will be on when either photo-eye is blocked by a pin. (This is an optional
feature and only functional when missing pin photo-eyes are connected.)
MISS Indicates the state of the missing pin signal to the control system. A pin is
assumed missing whenever the pin-to-pin period is 150% of the previous
measurement. The signal will be sent for 160ms whenever a missing pin is
detected.
PE Indicates the state of the switch photo-eye. The LED is on when the photo-
eye is blocked by a shoe bearing.
ENABLE Indicates the state of the divert signal from the control system.
CPU Blinks on and off when the DCM is powered to indicate the DCM is
operational.
DIVERT This LED is on when the divert coil of the actuator is energized.
RETRACT This LED is on when the retract coil of the actuator is energized.

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The DCM includes four jumpers that alter the operation of the board. All jumpers
should remain in their default position as supplied unless specifically instructed to
move by Honeywell engineering.

Table 3-4 Jumper Description

Jumper Description
Label

W1 Controls the timing of the switch activation. It affects the polarity of the
photo-eye signal sent back to the control system. When the jumper is set
to the “INV” position, the switch will fire when it sees the trailing edge of
the shoe bearing. When the jumper is set to the “REG” position, the switch
will fire when it sees the leading edge of the shoe bearing. This jumper
should normally be set to the “INV” position.
W2 Controls the motion profile during a divert and retract cycle. Some of the
jumper settings are in place to allow the same board to work for historical
revisions of the DCM board. The default position for this jumper is P1 for
the most current standard switch diagram.
W4 Should be connected across the two pins.
W5 Changes the timing relationship between detecting the bearing and firing
the switch. This jumper is on the board for future product development
purposes. This jumper should not be connected across the pins.

The DCM also includes a fuse. If this ever needs to be replaced, use a 250 volt,
3 amp, 216 series fuse.

3.5 Oiler Control

The IntelliSort HDS is supplied with an electric pump brush oiler. The electric pump
brush oiler should be cycled continuously at a rate of 100 revolutions ON, 100
revolutions OFF.

The length in feet of one sorter revolution can be found by counting the pushers.

Revolution length in feet = # sorter pushers x 0.42

To increase or decrease the flow of oil during an oiling cycle, adjust the set screws
on the solenoid valves as described in the installation chapter of this manual.

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4 Service and Repair
4
4.1 Introduction
This chapter contains instructions for removing, replacing, and adjusting various
components on the IntelliSort HDS. Be sure to follow all safety precautions and
Lockout/Tagout Procedures when servicing and repairing the conveyor.

Before performing any maintenance, follow the lockout/tagout procedure in

Chapter 1 Safety Instructions to ensure that equipment is safe to work on. Failure
to follow this instruction may result in serious personal injury and/or equipment
damage.

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4.2 Flight Removal and Installation

1. Remove the chain cover from the section(s) where you plan to remove the flight.
Using screwdrivers or pry bars, lift the chain up and away from the flights. This will
allow the chain pins to pull out of the flights. Grasp the flight to be removed and pull it
toward you, taking care not to let it fall into the sorter frame.

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2. Insert the replacement flight onto the chain pins on the far side of the conveyor.
(Make sure the sliding shoe faces the same direction as the other flights.) Use the
slots in the flight end caps to guide the other end of the flight onto the chain pins.

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3. Use screwdriver or pry bar to re-seat the chain in its resting position.

4.3 Chain Adjustment and the Catenary

The catenary is equipped with windows through which maintenance personnel can
gauge the amount of sag in the carrying chains and monitor the wear rate of the left
and right chains to ensure consistent growth rates.

To ensure proper tension on the chains, maintenance personnel must maintain the
sag within the limits described below. Failure to do so could result in excessive sorter
alarms, shutdown, or even mechanical damage.

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The approximate acceptable chain sag range, with the sorter running, depends on
catenary depth. All IntelliSort HDS sorters use a 21 in. catenary.

• For 21 in. catenary: -3.00 in. to +11.00 in. sag

The configuration of each sorter is different, so it may not be possible to achieve the
exact sag range of -3.00 in. to +11.00 in. On shorter sorters, removing 5 in. of chain
can have a more dramatic effect on elevation change in the catenary. In those
situations, it is better to have the chain too high rather than too low in the catenary.
Once the chain has worn such that it needs to be shortened, 5 in. of chain (one flight
assembly) will need to be removed from each side.

Figure 4-1 Intermediate Section with Catenary

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Measure each chain separately, using the window on the corresponding side of the
catenary. The amount of sag is the distance from the 0 mark at the top of the
catenary window to the top of the chain.

Figure 4-2 Catenary Window

Keep in mind, removing 5 in. of chain will raise the catenary sag by approximately
8 to 10 in. Ensure there is enough sag before initiating the following procedure.

To reduce chain sag, adjust chain length as follows:

1. Turn the conveyor OFF and perform lockout/tagout.

2. Remove approximately 12 ft. of chain cover from both sides of the sorter, near or
above the catenary.

3. Remove the lockout/tagout.

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4. Slowly advance the sorter until the corresponding master links (chrome-plated chain
coupler) are positioned in the middle of the chain cover opening.

5. Turn the conveyor OFF and perform lockout/tagout.

6. Remove six or seven flight assemblies that are near the connecting link, as
described in the Flight Removal and Installation section.

7. Identify the four chain links that will be removed from each chain.

Note: Work on one chain at a time after this step.

8. Install 3/8 in. forged eyebolts with washers between the chain rollers approximately
30 in. from both sides of the links being removed. Make sure the master link is
between the eyebolts.

9. Connect a 1-ton minimum chain or cable puller (come-a-long) to the eyebolts, add
tension to the chain until the four links being removed are doubled over the adjacent
links in a manner that will allow a full flight to be removed.

10. Use an appropriate chain breaker (McMaster-Carr #6051K16 or Grainger #1A912) to

remove the chain links identified in Step 7.

11. Use the puller to create the necessary slack and reconnect the sorter chain with the
master link.

12. Make sure the drive shaft is square and the carrying flights are perpendicular to the
side frame, not skewed.

13. Remove the puller and eyebolts.

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14. Repeat Step 8 to 14 on the opposite side of the sorter.

15. Reinstall flights, chain covers, and guarding.

16. Restore power and slowly rotate the sorter to check operation.

17. Make sure that both sorter chains are properly lubricated.

18. Recalibrate the chain in the machine control HMI. Sorter recalibration is necessary to
ensure correct pusher to carton assignments.

Any time the chain has been altered it should be recalibrated in the machine
control HMI.

4.4 Chain Lubrication

Chain lubrication is the single most important preventive maintenance function on a
sliding shoe sorter. Be sure to follow the instructions provided in the Preventive
Maintenance chapter of this manual to ensure the chain oiler is properly filled and
functioning. While improper chain lubrication is not the only possible cause of chain
elongation due to pin and bushing wear, proper lubrication and application can
extend the life of a chain and save significant costs and downtime associated with
chain replacement.

4.5 Chain Temperature

An effective method of evaluating the lubrication being applied to the conveyor chain
is by checking the temperature of the left-hand and right-hand chains. The
temperature of the running chains should be initially checked after six hours of
operation.

To check the temperature of the chains:

• Take ambient temperature readings (temperature readings of steel objects in the

vicinity of the conveyor).

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• Take infrared thermometer readings of the chain at the idler end of the conveyor
with the thermometer as close to the chain as is safely possible. Measure the
temperature of the side plates of the chain, not the rollers.

• The chain temperature should be 5°F to 10°F (3°C to 6°C) higher than the
ambient temperature.

• If the temperature variance is greater than 10°F (6°C), the oiler system may need
to be adjusted to deliver more oil. Freezer applications give different readings
than room temperature environments.

• Each chain should be checked separately. Take the chain temperature at the
same place on both sides of the conveyor.

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4.6 Chain Wear

Chain wear is checked by measuring the elongation percentage over a new chain.
Chains should be replaced when they reach a 2.0% elongation over their original
length. Elongation can be checked by measuring the center-to-center distance over
25 extended pins (48 chain pitches). A brand new chain will measure 60 in. center-
to-center over 25 extended pins. At 2.0% elongation, a chain will measure 613/16 in.
center-to-center over 25 extended pins and should be replaced. For good statistical
data, this measurement should be checked on both sides of the sorter (LH and RH
chain) every 100 feet to ensure elongation on the entire chain.

Figure 4-3 Measuring Chain Elongation

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4.7 Cleaning the Divert and Crossover Switches

1. Make a window by removing approximately 15 flights in the conveyor to access the
divert switches.

2. Move the window to the location of a divert switch.

3. Use compressed air to blow out the debris in the switch mechanisms.

4. Wipe the switches with a clean, dry soft cotton towel to remove any oil or debris
which may have collected.

5. It may be necessary to use a mild detergent to remove all of the debris from the
switches.

Never use a solvent-based cleaner on the divert switches. Solvent-based cleaners

may damage the polymer materials in the switch and will destroy the photo-eye
lens cover. Failure to follow this instruction may result in equipment damage.

6. Look for loose or broken parts. Replace as required.

7. Examine the divert trigger, making certain it moves freely and returns to the straight
through position.

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4.8 Electric Switch Removal and Installation

Use the following procedure to remove and install the soft touch electrical switch.

Figure 4-4 Electric Switch

Note: If either the soft touch switch or DCM fail, replace both.

1. Turn the conveyor OFF and perform lockout/tagout.

2. Remove the flights at the switch location.

3. Disconnect the DCM cables from the actuator and photo-eye.

4. Remove (6) socket head cap screws and nuts that attach the switch to its mounting
plate.

5. Lift the switch out of the sorter.

6. Insert the replacement switch and reinstall the (6) socket head cap screws and nuts
that attach the switch to its mounting plate.

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7. Attach the DCM cables to the actuator and the photo-eye.

8. Restore power and test the divert switch operation.

4.9 Divert Actuator Assembly Replacement

The divert switch actuator assembly consists of the trigger, spacer block, and rotary
actuator.

1. Turn the conveyor OFF and perform lockout/tagout.

2. Make a window to access the divert switch by removing enough sorter flights.

3. Disconnect the cable connected to the DCM.

4. Remove the actuator assembly hardware.

Note: The screws were installed with Loctite 609 and torqued to 48 in-lbs at
assembly.

5. Remove the actuator assembly from the divert switch.

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6. Install the new actuator assembly into the divert switch.

a. Apply Loctite 609 to the mounting screw threads.

b. Install the screws and washers.

c. Torque the screws to 48 in-lbs.

7. Reconnect the cable to the DCM.

8. Restore power to the conveyor and test the divert switch operation.

4.10 Divert Switch Trigger Replacement

Figure 4-5 Divert Switch Trigger Replacement

Note: Apply Loctite 609 to screws prior to re-installation.

1. Turn the conveyor OFF and perform lockout/tagout.

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2. Create a working window by removing some flights from the sorter apron.

3. Remove the 1/4-20 x 11/2 in. screw and bridge.

4. Remove the 1/4-28 x 1/2 in. long screw.

5. Remove the 1 in. O.D. washer and lock washer.

6. Remove the trigger. There are notches on the bottom of the trigger for a small gear
puller, if necessary.

7. Install the new trigger and replace the washers.

8. Apply Loctite 609 to the screw and reinstall with 55 in-lbs of torque.

9. Replace the flights to the sorter apron.

10. Remove all tools from the conveyor.

11. Remove the lockout/tagout.

12. Restore power to the conveyor and test divert switch operation.

4.11 Debris Detection Device Adjustment

To adjust the debris detection device (DDD):

1. Loosen the bolts that attach the flipper blade to the shaft.

2. Adjust the flipper blade, as necessary, until it no longer interferes with any of the
moving components.

3. Tighten the bolts that attached the flipper blade to the shaft.

4. Adjust the limit switch, if necessary.

a. Adjust the trip arm bumper up or down to set the vertical position of the flipper
blade.

b. Loosen the limit arm switch.

c. Rotate the arm until the limit switch arm roller is in the normal operating position
when the DDD flipper blade is in the vertical position and the trip arm is
horizontal. (When debris comes into contact with the DDD flipper blade, the trip

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arm is moved off the limit switch roller arm and the limit switch is tripped. In this
condition, power is dropped to the drive motor.)

d. Tighten the limit switch arm.

4.12 Chain Lubricator Adjustment

Lubrication directly affects the life and performance of the sorter chains. Proper oil
flow and lubrication is the responsibility of the customer. Honeywell is not
responsible for chain damage due to lack of lubrication. Failure to follow this
instruction may result in equipment damage.

IntelliSort HDS conveyors are supplied with an automatic chain lubrication system.
The IntelliSort HDS conveyor uses an electrical pump style oiler. The oiler should
use 20 weight, non-detergent oil.

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4.12.1 Electric Pump Style Oiler

Never allow the pump to operate on an empty reservoir. If the reservoir should
ever run completely dry, be sure to re-prime the system until oil completely refills
the delivery tubing. Failure to follow this instruction may result in equipment
damage.

The electrical pump style oiler is controlled by the system level machine control to
adjust the run time delivery rate of oil to the chains. Oil is delivered through an
electric motor driven positive displacement pump. A green light will indicate when the
system is ON. The oiler has a low reservoir level alarm, which is fed back to the
machine control to alert maintenance that oil must be added to the reservoir.

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Oiler Brushes
1. The bristle tips of the oiler brush should be 1/16 in. lower than the top of the chain side
plates. Turn the 5/8 in. nylock nut to adjust the brush height.

2. Fill the oil reservoir with 20 WT NON-DETERGENT OIL.

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Electric Pump Oiler Priming Instructions

This procedure normally only needs to be completed during initial installation. If the
oiler has been running with an empty reservoir, perform the following steps:

1. After the oiler has been installed on the machine, fill the reservoir with 20 weight non-
detergent oil.

2. Use the MANUAL RUN button located on the side of the unit to run the pump. Run
the system until oil is delivered through the tubing and out of the brush.

4.13 Carrying Flight Cleaning

New flights should not require cleaning.

For regular maintenance, clean dirty flights with a suitable mild detergent:

1. Remove the flights from the sorter.

2. Dilute the mild detergent with water (30:1).

3. Dampen a cloth with the solution and wring out excess solution.

4. Replace the flights in the sorter.

Note: Do not lubricate the flights.

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4.14 Chain Track and Shoe Guidance Replacement

Tools needed for replacing the black UHMW chain track and shoe guidance:

• 5
/32 in. drill bit

• 10-24 tap

• Right angle drill

• Hand countersink

• Rubber mallet

• Permanent marker or grease pencil

• Knife

4.14.1 Replacing the Top Run Black UHMW Chain Track

Start from the drive and work toward the idler when replacing the top run.

To replace a top run UHMW chain track section:

1. Starting from the drive and working toward the idler, locate the expansion block for
the section being replaced and the expansion block in the following section.

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2. Insert the chain track tongue into the expansion block groove of the section being
replaced until it reaches the alignment notch. The UHMW chain track comes with a
tongue on each end (only one tongue is used per section). 6 in. of tongue should lay
on the UHMW chain track to allow expansion.

3. Adjust the expansion block so the top of the expansion block is even with the top
surface of the aluminum track support by loosening the nuts that connect the
expansion block to the side rail of the sorter.

4. Tighten nuts loosened in Step 3.

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5. Use a permanent marker or grease pencil to mark the UHMW chain track at the
drive-side edge of the following section’s expansion block and use a knife to cut the
track to fit.

Note: Intermediate section expansion blocks have a tongue. Make sure to mark
and cut at the expansion block edge and not the tongue edge.

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a. If connecting to an intermediate section, place the cut-end of the UHMW chain

track under the tongue of the next expansion block. Starting at the drive end, use
a rubber mallet to snap the UHMW chain track in place.

b. If connecting to the idler section, the cut-end of the UHMW chain track should be
flush with the idler section expansion block. Starting at the drive end, use a
rubber mallet to snap the UHMW chain track in place.

Figure 4-6 Snap Track In Place

6. In the center of the cut-end of the UHMW chain track (opposite end from where
tongue is inserted into expansion block), drill one 5/32 in. hole (or #25) 4 in. from the
cut and one 5/32 in. hole (or #25) 8 in. from the cut through the UHMW chain track
and aluminum track support. Countersink the UHMW chain track by using the 10-24
tap to tap both holes in the aluminum track support.

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7. Insert one #10-24 x 3/4 flat head screw into each hole drilled in Step 6.

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4.14.2 Replacing the Bottom Run Black UHMW Chain Track

Start from the idler and work toward the drive when installing the bottom run.

To replace a bottom run UHMW chain track section:

1. Starting from the idler and working toward the drive, locate the expansion block for
the section being replaced and the expansion block in the following section.

2. Insert the chain track tongue into the expansion block groove of the section being
replaced until it reaches the alignment notch. The UHMW chain track comes with a
tongue on each end (only one tongue is used per section). 6 in. of tongue should lay
on the UHMW chain track to allow expansion.

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3. Adjust the expansion block so the top of the expansion block is even with the top
surface of the aluminum track support by loosening the nuts that connect the
expansion block to the side rail of the sorter.

4. Tighten nuts loosened in Step 3.

5. Use a permanent marker or grease pencil to mark the UHMW chain track at the idler-
side edge of the following section’s expansion block and use a knife to cut the track
to fit.

Note: Intermediate section expansion blocks have a tongue. Make sure to mark
and cut at the expansion block edge and not the tongue edge.

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6. Place the cut-end of the UHMW chain track under the tongue of the next expansion
block. Starting at the idler end, use a rubber mallet to snap the UHMW chain track in
place.

7. In the center of the cut-end of the UHMW chain track (opposite end from where
tongue is inserted into expansion block), drill one 5/32 in. hole (or #25) 4 in. from the
cut and one 5/32 in. hole (or #25) 8 in. from the cut through the UHMW chain track
and aluminum track support. Countersink the UHMW chain track by using the 10-24
tap to tap both holes in the aluminum track support.

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8. Insert one #10-24 x 3/4 flat head screw into each hole drilled in Step 7.

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5 Preventive
Maintenance 5
5.1 Introduction

Before performing any maintenance or lubrication services, follow the

Lockout/Tagout procedure in the Safety Instructions chapter to ensure that the
equipment is safe to work on. Failure to follow this instruction may result in serious
personal injury and/or equipment damage.

The satisfactory performance and reliability of this equipment is dependent upon a

proficient preventive maintenance program with scheduled equipment inspections
under normal operating conditions. Accurate records of maintenance and repairs will
help to identify problem areas and repetitive problem patterns. It is imperative that
adequate records be kept in connection with the preventive maintenance program.
These records should contain the date of inspection, inspection results, equipment
services, repair history, part replacement history, and any other information that will
help to make the maintenance process more efficient and accurate. It is
recommended that each conveyor have its own record. Properly kept, the conveyor
record sheet will form a mechanical history of the equipment covered.

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Preventive Maintenance

Preventive maintenance consists of regular service (lubrication, adjustments,

cleaning, etc.). Part of preventive maintenance is becoming aware of potential
problems by simply using your senses. Use your eyes to see potential component
failure. Use your ears to listen for abnormal or louder than normal noises. Use your
nose to smell a motor running abnormally warm in time to prevent its burnout. These
sights, noises, and smells can be indicators of lack of lubrication, misalignment, or
other potential trouble. Ignore them and you will be replacing a control card,
motorized roller, or whatever does go out when a component is lacking proper
preventive maintenance.

Only qualified maintenance specialists should maintain the mechanical, electrical,

and pneumatic portion of the conveyor.

5.2 Maintenance Precautions

Read and understand these precautions completely before operating, setting up,
running, or performing maintenance on the equipment. Failure to follow this
instruction may result in serious personal injury and/or equipment damage.

• When testing operating performance, do not start the equipment until all
operations and maintenance personnel are notified and clear of the unit being
tested.

• Be certain that required safety guards are never removed without authorization.

• Never run the equipment under production conditions without safety guards in
place.

• Do not make any equipment repairs while the conveyor is running.

• Keep hands, hair, and clothing clear of any moving parts.

• Never attempt to clear load jams while equipment is running.

• Always use appropriate tools when making repairs or adjustments.

• Observe all warning labels and follow plant safety rules.

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 Preventive Maintenance

5.2.1 Cleaning and Inspection

Generally, there are many reasons for cleaning:

• To allow heat to dissipate (motors and gearboxes).

• To prevent wear on moving parts.

• To prevent binding.

• For proper operation.

• Operating personnel will most likely treat clean equipment with more care.

Any prescribed cleaning schedule should be modified as experience is gained. A

thorough inspection should be performed while cleaning problem areas.

The total value of inspection procedures is determined largely by the consistency

and regularity of the schedule. A definite interval of inspection must be established
and obeyed. This is usually easier to accomplish if a “round robin” system of
inspection is used. It is recommended that a general inspection that will ensure a
thorough examination of each component and assembly contained in the system be
done at least once for each thirty-day period of operation. Results of these general
inspections should be documented in the conveyor record of the unit inspected.

The probability of mechanical/electrical problems increase during periods of heavy

usage, so an additional inspection immediately before and after these periods is
recommended.

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5.3 IntelliSort HDS Conveyor Checklists

5.3.1 Daily Tasks
Table 5-1 Preventive Maintenance Daily Checklist

Daily Checklist

Task Date: Checked By: Changes/Repairs Made:

Check with Conveyor Running

Listen for abnormal noises that could
indicate worn bearings in rollers,
motors, reducers, etc.
Listen for abnormal noises that could
indicate misaligned timing belts or drive
belts.
Check for shoes making contact with
the UHMW transitions due to
misalignment, improper adjustment, or
wear.

Check with Conveyor Shut Down

Check for foreign material wrapped

around bearings, shafts, or rollers.
Remove all foreign material
immediately.
Check for shavings or belt dust under
the conveyor or shoes that would
indicate misaligned or damaged
components.
Check for carton dust preventing
proper operation of shoes.
Check for skewed slats that indicate
the jump of a sprocket tooth or uneven
stretching of the chain.
Check for oil leakage that would
indicate faulty motors, reducers, chain
oiler, bearings, or seals.
Ensure that all required guarding and
safety devices are in place and
functioning properly.

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5.3.2 Weekly Tasks

Table 5-2 Preventive Maintenance Weekly Checklist

Weekly Checklist

Task Date: Checked By: Changes/Repairs Made:

Check with Conveyor Running

Visually inspect for wear, improper
alignment, or buildup of foreign
materials and repair/clean as required.
Visually inspect all motors.
While inspecting shoes being diverted,
listen for any abnormal clicking sounds
at each divert switch location and
UHMW transition. If a clicking sound
happens at random, then the guide pin
of a divert shoe may be faulty. If the
sound happens continually at the same
divert switch, the divert switch may be
out of adjustment or improperly
synchronized (control timing). If the
sound happens continually at the same
UHMW transition, the UHMW transition
may be out of adjustment or worn.
Calibrate the sorter to check for correct
divert operation.
Check the oil level in the chain
lubricator reservoir. Add oil to the full
level. If the oil level has not changed
since the last check, check to make
sure the pump is operating correctly.
Lack of chain lubrication will allow the
chain to stretch and greatly reduce the
life of the chain. Use only 20wt non-
detergent oil, such as Mobile DTE
Heavy Medium ISO 68.
Check the tension of the carrying
chains by viewing their location in the
windows on the catenary. The chain
tension is correct if the carrying chain
is visible in the window. Adjustments
are made by removing chain links in 5
in. (2 links) segments. See the Chain
Adjustment and the Catenary section
in the Service and Repair chapter.

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Preventive Maintenance

Weekly Checklist

Task Date: Checked By: Changes/Repairs Made:

Check for uneven stretch of the

carrying chains by comparing their
locations in the windows on the
catenary. They should be at the same
position. Uneven chain stretch is a
result of insufficient lubrication. Make
sure the chains are being lubricated
properly.

Check with Conveyor Shut Down

Check the operation of the Emergency
Stop Pull Cord.
Check the operation of the Debris
Detection Device.
Check the operation of the Product jam
photo-eyes.
Check the operation of the long-range
photo-eye, if installed
Verify the divert switch access covers
are in place.
Check the operation of the Proximity
sensor at the infeed and discharge
ends.
Check the operation of any application
or site-specific safety device.
Make sure the carrying chains are
properly lubricated and that oil
applicator brushes are not worn out.
The brushes will appear wet with oil
when properly lubricated, but do not
over lubricate. Use only 20 wt. non-
detergent oil.
Make sure the fasteners on all photo-
eyes and reflectors are securely
attached. Check for proper operation of
the air pressure switch. Inspect
tightness and physical condition of all
wire/conduit fittings.

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Weekly Checklist

Task Date: Checked By: Changes/Repairs Made:

Inspect all divert shoes for any physical

damage. Replace any damaged shoes.
Verify the shoes slide freely on the
carrying flights. Fix any shoe binding
problems that are observed. Also look
for and correct any shoes that may
have jumped out of the pin track. The
typical causes of divert shoe binding
are dirty or bent carrying tubes, shoe
fasteners adjusted too tight, or
damaged guide pins or shoe bases.
Inspect the fasteners and the physical
condition of all structural items such as
frame supports, section joint fasteners,
guard rail, chain covers, and spur
conveyor mountings.

5.3.3 Quarterly Tasks

Table 5-3 Preventive Maintenance Quarterly Checklist

Quarterly Checklist

Task Date: Checked By: Changes/Repairs Made:

Check with Conveyor Shut Down

Check the flight assemblies for
cleanliness. The flights can be cleaned
with water and a cotton cloth. For
extremely contaminated flights, contact
Honeywell Customer Service.
If the shoe pads show unusual wear,
check position of the shoe return
wedge on the drive section. Replace
the pads as necessary.
Inspect the divert switches for
presence of any dirt or product
spillage. Clean each divert switch as
required. Check that the top of the
photo-eye is free of any contamination.

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Quarterly Checklist

Task Date: Checked By: Changes/Repairs Made:

Inspect the drive unit V-belts for proper

tension, wear, and alignment. Do not
over tighten the drive V-belt. The V-
belts are tensioned for 1/4 in. deflection
at their mid-point.
Check that all frame supports are in
good physical condition and have not
been damaged. Check that all
fasteners are securely tightened and
that none are missing.
Remove any build-up of dirt/dust
around the power unit motor vent
openings. Check that all mounting bolts
are securely tightened and that the
motor lead wires are securely
connected. Refer to the motor
lubrication plate or vendor’s instruction
tag(s).
During normal maintenance at the oil
change intervals, add grease to the
grease fitting on the floating sprocket
on the idler shaft.
Check the V-belts for wear and proper
tension.
Check the V-belt sheaves for tightness
to the motor and input shafts.
Check the electrical connections to the
motor.
Check the tightness of all pillow block
bearing mounting bolts, and the
general performance of the bearings.
Check the physical condition of the
black UHMW carrying chain tracks
mounted along each side of the sorter.
Check the height of the right and left
side black UHMW carrying chain
guides at points opposite each divert
switch.
Check tightness of the drive motor
mounting bolts.

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Quarterly Checklist

Task Date: Checked By: Changes/Repairs Made:

Inspect all plastic parts for signs of

unusual wear and deterioration.
Replace any worn plastic parts.
Check tightness of reducer mounting
bolts and torque arm (if equipped). For
information on changing oil, oil type,
and operating oil level, see reducer
checks below.
Check that warning signs and labels
posted on or near the conveyor
equipment are not removed, painted
over, or altered at any time. All safety
devices, warning lights, and alarms
associated with the conveyor system
should be regularly tested for proper
operation and serviced as needed.

Perform the following checks to the reducer:

Check the oil level in the reducers. Use

only Mobile SHC 634 Synthetic gear
lubricant. Also make sure the breather
cap was installed during setup and
installation.
Note: For operating temperatures of
40°F and above, use Mobile SHC 634.
For operating temperatures of 40°F
and below, use Mobile SHC 630.
Ensure that the reducer shaft set
screws are properly torqued.
Check the torque arm fittings for
tightness, wear, and level.

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Quarterly Checklist

Task Date: Checked By: Changes/Repairs Made:

Check the unit for oil leakage and find

the source of that leakage. The most
common leak points are pipe plugs, oil
seals, and the cover gasket. Rather
than waiting for parts during
unscheduled down time, you may wish
to order replacement parts when the
leaks are minor. Occasionally, the
breather plug is not properly located at
the highest point in the unit. Relocate
the breather plug, if required,
especially if the lubricant is foaming out
of the breather. Many leaks are caused
by overfilling the unit with oil. Check
the proper oil level. Do not let any leak
go unattended as loss of oil will
eventually cause a failure.
In accordance with the reducer
manufacturer’s recommendations,
change the reducer oil after an initial
operating period. Thereafter, change
the reducer oil on a regular schedule,
and follow the reducer manufacturer’s
recommendations.
For better drainage, drain the oil when
the unit is warm. Remove and examine
the magnetic drain plug for metal chips
and filings. An excessive amount of
metal filings signals internal problems.
Consult the manufacturer if you think
the amount is excessive. Small
amounts of metal filings are normal
and should simply be cleaned off prior
to reinstallation.
After draining, remove debris by
thoroughly flushing the inside of the
unit with clean oil. Remove and clean
the breather plug to ensure that the air
passage is clear. Reinstall the drain
plug and breather plug after using a
thread sealant.

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6
6.1 Ordering Parts
See the Ordering Replacement Parts Instruction Manual for help ordering new parts.

6.2 Illustrated Parts Lists

The following pages contain standard assembly and component part illustrations and
parts lists for your equipment. Colors used in these illustrations are for clarifications
only and may not match the paint colors of your equipment components. These
illustrations and listings were current at the time of the printing of this manual.

The assemblies and components listed in these parts lists may not be described
completely if they contain special modifications and/or enhancements. Use the part
numbers shown in these parts lists to make sure the correct replacement parts are
ordered.

Parts highlighted in gray are Recommended Spare Parts and may already be in your
parts inventory.

6.2.1 Using the Illustrated Parts Lists

The typical process for finding a part in the Illustrated Parts Lists:

1. Find the assembly containing the part.

2. Find the part number in the assembly’s illustration. Note the item number pointing to
it.

3. Find the item number in the SEQ column of the associated parts list.

4. Find the part number in the PART NO column.

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Replacement Parts

The IntelliSort HDS is engineered to the specific requirements of every project. Refer
to the Dashboard project files for each specific machine’s unique spare parts lists.

See the Ordering Replacement Parts Instruction Manual for ordering help.

Figure 6-1 IntelliSort HDS Sorter Layout

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Parts List Abbreviations

The following abbreviations are used in the parts lists:

Table 6-1 Parts List Abbreviations

20D 20 Degree Divert Angle ID Idler

30D 30 Degree Divert Angle KE Knife Edge

ADAPT Adaptor LHD Left Hand Divert

ASY Assembly LUBR Lubricator

BF Between Frame Width MS Medium Speed

(in inches)

CAT Catenary MTR Motor

CBTA Coupled Brushless Torque PE Photo-Eye

Actuator

CC Chain Care PTO Power Take Off

DCM Divert Control Module PULY Pulley

DDD Debris Detection Device RHD Right Hand Divert

DGE Dodge ROL Roller

DIV Divert RT Regular Touch

DR Drive SENS Sensor

DS Dual Sided SPKT Sprocket

ELEC Electric ST Soft Touch

ELEC SW Electric Switch SW Switch

GNECK Gooseneck URE Urethane

HS High Speed VFD Variable Frequency Drive

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6.2.2 Idler and Infeed

HDS Hitch Infeed
30518501 HDS HITCH INF ASY 22BF 120L

SEQ QTY PART NO DESCRIPTION

1 4 530125__ 530 PARCEL 2.75" DIAMETER ROLLER __"BF
2 1 531829__ 530 PARCEL ROLLER, RETURN 1.9"DIA ___BF
3 5 411466__ 200 KE ROLLER 2.25" TAPERED BRG ___BF
4 1 25083500 MLG-2T-PLUG, M12 8 PIN FEMALE AND M12 5 PIN
FEMALE TO M12 8 PIN MALE
5 1 25083400 MLG PRO 2.5MM SPACING, 145MM DET HT, 2 X AN + 2 X
I/O (IO-LINK), 2M RANGE, STD CONFIG

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HDS Idler Infeed Belt

30495001 HDS ID BELT XL FLIP-UP KE ASY 22BF

SEQ QTY PART NO DESCRIPTION

1 1 41146622 200 KE ROLLER 2.25" TAPERED BRG 21.50BF

2 1 531829215 530 PARCEL ROLLER, RETURN 1.9"DIA 21.50BF
3 1 53180705 530 PARCEL CROWNED ROLLER 4.00"DIA 22"BF
4 1 23096500 PROX SW M12X1 6MM RNG PNP N.O. SICK #IM12-06BPS-
ZC1
5 1 23320100 CABLE M12 THD 90DEG #22-4C 2M FEM W/FLYING LEADS
6 2 41054100 200 TAKE UP WELDMENT 8" ASSY
7 1 53012561 530 PARCEL 2.75" DIAMETER ROLLER 22.0"BF
8 1 30494201 HDSS MH-ID BELT XL KE BACK SLDR PAN 22BF

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Infeed Idler
305095 HDS ID ASY 22EW 59BF__-PTO

SEQ QTY PART NO DESCRIPTION

1 1 30407601 ISS MH-ID PULY BELT 8.50 OD LAT & FLAT 31.250B 22W
2 2 30404901 ISS MH-ID BRG PLATE PTO PULLEY
3 2 41006801 200 ANG SNUB ADJUSTER
4 2 22003000 BRG F4B-DL-115 (DGE# 128789)
5 1 22457500 BT SPKT P48-8M-50-2012 DODGE #112893

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SEQ QTY PART NO DESCRIPTION

6 1 22003800 BU TL 2012 1.938
7 1 22469800 BT DGE HT200 1512-8M-50 / GATES 1512-8MGT-50
8 1 22005400 BU TL 2517 1.938
9 1 22457900 BT SPKT DODGE P80-8M-50-2517 112897
10 1 30354600 ISS IDL TENSIONER SHV & SHAFT ASY
11 1 30406902 ISS MH-ID BLOCK ASY CHGD ID TOP LH
12 1 30407102 ISS MH-ID BLOCK ASY CHGD BOT 58R 36T LH
ISS BLOCK UHMW SUS SD SW PNGD HS/MS ID BOT
13 2 30463100
RAMP
14 1 30447102 ISS BLOCK UHMW SUS SD SW RET OUT 30DEG LHD
15 1 30406701 ISS MH-ID BLOCK UHMW PNGD BOT RAMP 36T
16 1 30447101 ISS BLOCK UHMW SUS SD SW RET OUT 30DEG RHD
17 1 30407101 ISS MH-ID BLOCK ASY CHGD BOT 58R 36T RH
18 3 30500300 HDSS MH-ID UHMW TOP FNL STRT
19 1 30406901 ISS MH-ID BLOCK ASY CHGD ID TOP RH
20 1 30225516 HDSS SHAFT IDLER ASY 22EW 59BF STYLE D

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Infeed Shaft
30225516 HDS SHAFT IDLER ASY 16EW 59BF CONFIG B

SEQ QTY PART NO DESCRIPTION

1 1 30219904 ISS SHAFT IDL 2 15/16 X 59BF
2 3 30220800 ISS PIN GUIDE CAM ASY IDL
3 1 30220000 ISS SPKT 100R36 ASY W/R1 BU
4 2 22499800 BRG DGE P2B-IP-215R
5 2 22001746 COLLAR 2 PC CLAMP-ON 2.938" ID
6 2 22006000 WASHER THRUST BRNZ OIL 2 15/16
7 1 30220300 ISS SPKT 100C36 ASY W/2.94 BU

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6.2.3 Pre-Sort Section

305441 – HDS SUS ASY 59BF LH-IND

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SEQ QTY PART NO DESCRIPTION

1 1 30500500 HDS SUS TOP FUNNEL UHMW ENTRY BLOCK 15' INNER
2 1 HDSS SUS TOP FUNNEL UHMW ENTRY BLOCK 15'
30500402
OUTER
3 1 30533503 HDS ST SUS RAIL KIT 57.01L (59B-20D)
4 1 30533512 HDS ST SNK RAIL KIT 58.5L (59B-20D)
5 1 3051300_ ISS FUTURE FILL BLOCK RT _HD
6 1 HDS SUS TOP UHMW CENTER MERGE FUNNEL BLOCK
3050060_
15' _H IND
7 1 30533511 HDS ST SNK RAIL KIT 39.875L (59B-20D)
8 1 30533505 HDS ST SUS RAIL KIT 36.16L (59B-20D)
9 1 30390304 ISS RT DIV RAIL ASY 41.96L (43B-30D)
10 1 30533102 HDS BLOCK UHMW DIV RE-RENTRY 20D LH
11 1 3050070_ HDS SUS TOP UHMW EXIT JUSTIFIER BLOCK 15' _H IND
12 1 30276502 ISS BLOCK UHMW RET IN 20DEG LHD
13 1 30533507 HDS ST SUS RAIL KIT 62.89L (59B-20D)
14 1 3050530_ HDS SUS BLOCK UHMW RE IN 20D _H IND
15 1 30276501 ISS BLOCK UHMW RET IN 20DEG RHD
16 1 30533506 HDS ST SUS RAIL KIT 25.55L (59B-20D)
17 1 30339600 ISS BLK UHMW SET-UP FUNNEL 20D
18 1 306524417 HDS PIN GUIDE EXTR KIT 13.78L
19 1 30276101 ISS BLOCK UHMW DIV RE-ENTRY 20D RHD
20 1 306524418 HDS PIN GUIDE EXTR KIT 15.98L
21 1 3051250_ ISS ELEC SW ASY 30D RT SUS _H
22 1 3051250_ HDS ELEC SW ASY 30D RT CAL _H
23 1 30533514 HDS ST SNK RAIL KIT 11.01L (59B-20D)
24 1 306524291 HDS PIN GUIDE EXTR KIT 14.94L
25 1 30533508 HDS ST SUS RAIL KIT 38.18L (59B-20D)
26 1 306524423 HDS PIN GUIDE EXTR KIT 128.54L
27 1 3050540_ ISS DR UHMW PNGD JOG BLOCK _H IND
28 1 306524233 HDS PIN GUIDE EXTR KIT 15.94L

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6.2.4 Intermediates
30 in. Divert Center Sections

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30 in. Divert Center Intermediate Assembly

30607__HDS IS ASY 59BF 30CTR _SP__._L

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SEQ QTY PART NO DESCRIPTION

1 1 30504402 HDS ELEC SW ASY SCKT ST LH
2 1 304525474 ISS PIN GUIDE EXTR KIT 15.88L
2 1 30504401 HDS ELEC SW ASY SCKT ST RH
4 1 304525474 ISS PIN GUIDE EXTR KIT 15.88L
3 1 30608202 HDS ST DIV BLK UHMW 30D LH
4 1 30608302 HDS BLOCK UHMW DIV RE-ENTRY 30D LH
7 1 30652464 HDS PIN GUIDE EXTR KIT 29.94L

Note: 2 switch pair and 3 switch pair sections use identical listed components.
QTY is per switch pair.

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48 in. Divert Center Sections

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48 in. Divert Center Intermediate Assembly

30544__HDS IS ASY 59BF 20D 48CTR_SP__._L

SEQ QTY PART NO DESCRIPTION

1 1 30504502 HDSS ST DIV BLK UHMW 20D LH

2 2 303903101 HDS ST DIV RAIL ASY 34.06L (59B-20D)
3 1 30533102 HDS BLOCK UHMW DIV RE-ENTRY 20D LH
304525416 ISS PIN GUIDE EXTR KIT 17.31L
4 1 304525329 ISS PIN GUIDE EXTR KIT 19.94L
5 1 304525414 ISS PIN GUIDE EXTR KIT 30.50L
6 1 30533101 HDS BLOCK UHMW DIV RE-ENTRY 20D RH
304525416 ISS PIN GUIDE EXTR KIT 17.31L

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SEQ QTY PART NO DESCRIPTION

7 1 30504501 HDSS ST DIV BLK UHMW 20D RH

8 1 30504401 HDS ELEC SW ASY SCKT ST RH
304525415 ISS PIN GUIDE EXTR KIT 13.875L
9 1 30504402 HDS ELEC SW ASY SCKT ST LH
304525415 ISS PIN GUIDE EXTR KIT 13.875L

Note: 2 switch pair and 3 switch pair sections use identical listed components.
QTY is per switch pair.

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6.2.5 Catenary
Electric Oiler Catenary
305411 HDS CAT ASY 21.5DP 144.00L

SEQ QTY PART NO DESCRIPTION

1 1 30378101 ISS BLOCK ASY CHGD CAT OUT 48R RH

2 1 30378102 ISS BLOCK ASY CHGD CAT OUT 48R LH
3 2 30376607 ISS W/STRIP CAT 21.5DP CC 20D-21.5DP 45.25L RH
4 2 30379302 ISS CH CARE CAT BLOCK FLIGHT CATCHER 64.50L
5 2 30376608 ISS W/STRIP CAT 21.5DP CC 20D-21.5DP 45.25L LH
6 1 30376702 ISS GD BLK CAT-IN UHMW CHAIN LH
7 1 30376701 ISS GD BLK CAT-IN UHMW CHAIN RH

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Catenary Assembly
30608501 – HDS IS CAT ASY 59BF 30CTR 30D 2SP ELEC OILER

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SEQ QTY PART NO DESCRIPTION

30504402 HDS ELEC SW ASY SCKT ST LH
1 3
304525474 ISS PIN GUIDE EXTR KIT 15.88L
30504401 HDS ELEC SW ASY SCKT ST RH
2 3
304525474 ISS PIN GUIDE EXTR KIT 15.88L
3 4 30608302 HDS BLOCK UHMW DIV RE-ENTRY 30D LH
30652464 HDS PIN GUIDE EXTR KIT 29.94L
4 3 30608202 HDS ST DIV BLK UHMW 30D LH
5 1 306524353 HDS PIN GUIDE EXTR KIT 120.94L
6 1 306524443 HDS PIN GUIDE EXTR KIT 7.00L
7 1 30504501 HDS ST DIV BLK UHMW 20D RH
8 1 303903109 HDS FUNNEL LH RAIL ASY 41.80L (59B-20D)
9 1 303903115 ISS RT ISS DSD-DIV EXIT RAIL ASY 33.31L (59B-30D)
10 3 30608201 HDS ST DIV BLK UHMW 30D RH
11 8 306524475 HDS PIN GUIDE EXTR KIT 13.50L
12 5 30608301 HDS BLOCK UHMW DIV RE-ENTRY 30D RH
30652464 HDS PIN GUIDE EXTR KIT 29.94L

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30544401 – HDS IS CAT ASY 59BF 20D 48CTR 2SP ELEC OILER

SEQ QTY PART NO DESCRIPTION

30504402 HDS ELEC SW ASY SCKT ST LH

1 2
304525415 ISS PIN GUIDE EXTR KIT 13.875L
30504401 HDS ELEC SW ASY SCKT ST RH
2 2
304525415 ISS PIN GUIDE EXTR KIT 13.875L
3 6 303903101 HDS ST DIV RAIL ASY 34.06L (59B-20D)
30533102 HDS BLOCK UHMW DIV RE-ENTRY 20D LH
4 3
304525416 ISS PIN GUIDE EXTR KIT 17.31L
5 6 304525414 ISS PIN GUIDE EXTR KIT 30.50L
6 1 304525231 ISS PIN GUIDE EXTR KIT 60.94L
7 1 304525427 ISS PIN GUIDE EXTR KIT 128.54L
8 1 304525300 ISS PIN GUIDE EXTR KIT 46.94L
30533101 HDS BLOCK UHMW DIV RE-ENTRY 20D RH
9 4
304525416 ISS PIN GUIDE EXTR KIT 17.31L
10 2 30504501 HDSS ST DIV BLK UHMW 20D RH
11 2 30504502 HDSS ST DIV BLK UHMW 20D LH

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6.2.6 Drive and Discharge Chute

Drive Assembly
305100__HDS DR ASY 59BF__-DR

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SEQ QTY PART NO DESCRIPTION

SPLIT TAPER SHEAVE – REFERENCE ORIGINAL ORDER

1 1 VARIES
DOCUMENTATION FOR SPECIFIC CONFIGURATION
2 1 VARIES BELT – REFERENCE ORIGINAL ORDER
DOCUMENTATION FOR SPECIFIC CONFIGURATION
SPLIT TAPER SHEAVE – REFERENCE ORIGINAL ORDER
3 1 VARIES
DOCUMENTATION FOR SPECIFIC CONFIGURATION
VARIES MOTOR – REFERENCE ORIGINAL ORDER
4 1
DOCUMENTATION FOR SPECIFIC CONFIGURATION
5 1 30548102 HDS DIS CHUTE TRANS PLT DURASURF LH
6 1 30548101 HDS DIS CHUTE TRANS PLT DURASURF RH
ISS DR SHAFT ASY – SEE SHAFT DRIVE ASSEMBLY
7 1 302254__
SECTION
8 1 30376201 ISS GD BLK DR-CAT UHMW CHAIN RH
9 2 302175240 ISS AL CH TRACK 21.88L
10 1 30424701 ISS MH-DR BLOCK UHMW CHGD TOP BASE ASY RH
11 1 306524378 HDS PIN GUIDE EXTR KIT 11.94L
12 1 30339600 ISS BLK UHMW SET-UP FUNNEL 20D
13 1 30556600 HDS DR UHMW PNGD CAM FD BLOCK
14 1 30424702 ISS MH-DR BLOCK UHMW CHGD TOP BASE ASY LH
15 1 30376202 ISS GD BLK DR-CAT UHMW CHAIN LH

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 Replacement Parts

Shaft Drive Assembly

302254__ ISS SHAFT DRIVE ASSY _.___TP__EW 59BF

SEQ QTY PART NO DESCRIPTION

30218110 ISS SHAFT DR 3 7/16 X 1.938 59BF

1 1 30218111 ISS SHAFT DR 3 7/16 X 2.438 59BF
30218112 ISS SHAFT DR 3 7/16 X 3.438 59BF
2 2 30219200 ISS PIN GUIDE CAM ASY DR
3 1 30218200 ISS SPKT 100A48 ADJ ASY W/R2 BU
4 2 22499900 BRG DGE P2B-IP-307R (#069423)
5 1 30219600 ISS SPKT 100R48 ASY W/R1 BU

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Replacement Parts

6.2.7 Component Details

Switch Assembly
305044__HDSS ELEC SW ASY SCKT ST _H

SEQ QTY PART NO DESCRIPTION

1 1 7085897 PE,CONNECTOR ASSY,AB
2 1 30453802 ISS ELEC SW BRIDGE 20/30 ST LH
3 1 30504302 HDS ELEC SW BLOCK ASY SCKT ST LH
4 1 30453801 ISS ELEC SW BRIDGE 20/30 ST RH
5 1 30504301 HDS ELEC SW BLOCK ASY SCKT ST RH
6 1 30453401 ISS ELEC SW BLADE 20/30 ST RH
7 1 30453301 ISS ELEC SW BTA ACTUATOR ASY RH
8 2 7085793 GUARD,FRMD,CBTA,16 GA
9 1 30453402 ISS ELEC SW BLADE 20/30 ST LH
10 1 30453302 ISS ELEC SW BTA ACTUATOR ASY LH

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 Replacement Parts

DCM Enclosure
23433500 – DCM ELECTRIC ENCLOSURE WITH UL508A STICKER BASIC UNIT

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Replacement Parts

DCM Board
23434000 – DCM BOARD W/MISSING PIN DETECT UR LISTED

Note: Panel assembly 23433500 includes all required cables and DCM board
23434000. If desired, the DCM circuit board can be replaced independently.

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 Replacement Parts

DDD Kit
305057__HDS DDD KIT 59BF 20D 48CTR___LS-_

SEQ QTY PART NO DESCRIPTION

1 1 22612702 WHEEL PLASTIC 2.5 O.D. BUSHING REMOVED

2 1 30295804 ISS DDD SHAFT 1" DRILLED 59BF
3 1 23086800 LIMIT SWITCH AB 802T-AP
4 2 22596600 BRG DGE F2B-SC-100 SERIES 205 #124173
5 1 0165431 LIMIT SWITCH ROLLER ARM AB 802T-W2B
6 1 30295900 ISS DDD SWITCH TRIGGER MACH 5/8DIA

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Replacement Parts

Aluminum Flight Assembly

30424523 – ISS FLIGHT ASY SLAT ZGS-LS 59BF 20D DS

SEQ QTY PART NO DESCRIPTION

1 1 30424301 ISS PUSHER ASY SLAT ZG-LS 20D DS

2 1 30227903 ISS ENDCAP ASY SLAT ZG RH
3 1 30227904 ISS ENDCAP ASY SLAT ZG LH

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 Replacement Parts

Electric Oiler
30456600 – ISS STANDARD CHAIN OILER

SEQ QTY PART NO DESCRIPTION

1 1 30456000 ISS STANDARD OILER POLE LIGHT

2 1 30293001 ISS OILER 2QT RESERVOIR W/39" LEADS

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Replacement Parts

Chain Jump Detection Kit

30642200 – HDS CAT SPCL CHAIN JUMP DETECTION KIT

SEQ QTY PART NO DESCRIPTION

1 1 30353802 ISS DIVERT CONFIRM MOUNTING BLOCK LH
2 1 306524233 HDS PIN GUIDE EXTR KIT 15.94L
3 2 30353801 ISS DIVERT CONFIRM MOUNTING BLOCK RH
4 1 30641002 HDS ST DIV BLK UHMW 20D W/ SNSR MNTG LH
5 2 303903115 ISS RT ISS DSD-DIV EXIT RAIL ASY 33.31L (59B-30D)
6 1 30641001 HDS ST DIV BLK UHMW 20D W/ SNSR MNTG RH
7 3 23096700 PHOTO EYE 24VD A-B #42KB-T1LPSQ-Y3 W/PICO QD
8 1 30641502 HDS DIVERT CONFIRM MOUNTING BLOCK SHORT LH

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 Replacement Parts

Chain Slack Detection Kit

30630301 – ISS SPCL CHAIN SLACK DETECTION KIT 15.625 TALL

SEQ QTY PART NO DESCRIPTION

1 1 30630401 ISS SPCL CAT WINDOW 12.50 TALL

2 1 30381701 ISS LABEL CHAIN HEIGHT 21.5DP
3 1 25617200 PROXIMITY SWITCH M30X1 20MM SENSE RANGE SICK
MODEL IME30-20BPSZC0S (SICK P/N 1071293)

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7 Troubleshooting
7
7.1 Introduction

Before performing any maintenance or lubrication services, follow the

lockout/tagout procedure in the Safety Instructions chapter to ensure that the
equipment is safe to work on. Failure to follow this instruction may result in serious
personal injury and/or equipment damage.

When troubleshooting equipment problems, it is essential to completely understand

how the system functions during normal operation. Thoroughly review the
operational description, the circuit drawings, and the electrical diagrams sent with
your equipment. Once the system operation is understood, it is usually best to start
at the problem, and then work back to the source.

Procedures are discussed at length in the following pages; however, certain

guidelines should be followed for all troubleshooting problems:

1. Locate the problem.

2. Listen and observe.

3. Identify the problem as electrical or mechanical.

4. Determine symptoms through observations.

5. Think and act with caution and clear thinking.

6. List short- and long-term solutions.

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Troubleshooting

7. Select a solution or possible solutions.

8. Implement and document one solution at a time.

Table 7-1 Troubleshooting Chart

Symptom Probable Cause Corrective Action

Motor will not No line voltage. Check emergency stops and reset.
start or it is slow Check fuses and wiring for open circuit. Replace fuses or
to start repair wiring as necessary.
Check thermal overload protection device and reset as
necessary.
Check limit switches, starter, and relays for defective
contacts or mechanical fault. Replace as necessary.
Check for supply voltage at source and correct fault as
necessary.
Check control circuit voltage and correct fault as
necessary.
Low line voltage Check for proper supply voltage and proper motor wiring.
Correct as necessary.
Conveyor overloaded Remove load from conveyor and reset.
or jammed
Check for foreign material in chain or sprockets and
remove.
Check chain tension and correct as necessary.
Defective motor Verify proper wiring, voltage, and overload. Correct as
necessary. Replace motor with spare.

Motor repeatedly Defective wiring or Check electrical circuits and panels for loose or defective
stalls electrical components wiring. Correct as necessary.
Check for loose or defective relays, switches, etc. Correct
as necessary.
Motor runs Overload Check for sluggish or seized bearings or obstructions.
excessively hot Check all rollers for free rotation.
(over 130°F)
Lack of lubrication in Replace reducer with spare and clean motor as
reducer. necessary.
Ventilating holes in Clean ventilating holes or replace motor as necessary.
motor obstructed or
excessive dust in motor
Defective bearing in Replace motor or reducer with spare.
motor reducer

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 Troubleshooting

Symptom Probable Cause Corrective Action

Motor emits Lack of lubrication in Replace reducer with spare.

excessive noise, reducer
hum, or vibration Worn or damaged Replace motor or reducer with spare.
motor or reducer
Defective bearing Replace motor or reducer with spare.
Loose mounting Check motor and reducer for loose mounting hardware.
Oil leakage from Worn or damaged Replace reducer with spare.
reducer bearing or seals or
cracked housing
Loose drain plug Tighten or replace plug.
Conveyor does Clutch unit is not Adjust clutch unit as instructed in manufacturer’s manual
not start or stop engaging properly provided.
quickly enough.
There is a delay
between signal
and function.

Excessive chain Sorter chain is too tight Add or remove chain links as necessary. (Always add
wear or too loose and remove in pairs.)
Sprockets are Re-align with straight edge across the face of both
misaligned sprockets.
One sprocket is loose Locate, align, and tighten loose sprocket.
Insufficient lubrication Lubricate as instructed.

Excessive noise Refer to “Excessive See Corrective Actions for excessive chain wear listed
chain wear” listed above.
above
Dirty chain Remove and clean chain in solvent, clean sprockets,
replace chain, and lubricate as instructed.
Chain is rubbing guard Check for obstruction and adjust as necessary.

Chain is pushing Insufficient tension Adjust as instructed.

Conveyor/Drive Inspect conveyor for obstructions and correct as
overload necessary.

Broken chain Frozen pulley or Inspect source of problem and correct as necessary.
sprocket shaft
Product not Defective photo-eye Replace photo-eye.
discharging or
conveyor has
dead zone

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Troubleshooting

Symptom Probable Cause Corrective Action

Noisy divert Divert shoe binding Adjust shoe fasteners.

switch Flight assemblies Clean flights.
contaminated
Divert shoes Switch binding Align, adjust, or replace switch block.
jump when misaligned or damaged
diverting Guide pin damaged Replace guide pin.
Pin guide track Align pin track.
misaligned
Divert switch not Spur lane full Clear lane.
working Photo-eye defective Replace photo-eye.
Broken wire or loose Repair or replace.
connection
DCM board defective Replace DCM board.

Sorter is running Sorter in calibrate mode Exit calibrate mode in control system.
at the proper Control system failure Troubleshoot control system per control supplier’s
speed, but all instructions.
divert switches
are not working +24 VDC supply Check +24 VDC power supply and wiring.
voltage logic
See “Divert switch not working” Symptom.
Loss of 110 VAC for Check 110 VAC wiring and control unit.
solenoid valves
DCM board defective Replace DCM board.
Broken wire or loose Repair or replace.
connection
First divert switch Remove blockage.
photo-eye blocked or
Replace photo-eye and run calibration as necessary.
defective
Induction Sorter not at proper First proximity switch defective and/or auxiliary contact on
conveyor speed motor starter defective.
inoperative PTO belt disconnected Reconnect or replace belt.

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Symptom Probable Cause Corrective Action

Conveyor takes Variable Frequency Check VFD manufacturer’s instructions for proper
too long to reach Drive (VFD) adjustments. Correct VFD adjustments as necessary.
speed (sorter misadjusted or Replace VFD if defective.
under-speed defective.
error detected) Carrying chains are not Check for automatic oiler operation. Make adjustments to
sufficiently lubricated ensure correct oil distribution.
The carrying chains are Check the carrying chain tension and make appropriate
over-tensioned adjustments.
Missing pin on divert Replace as necessary.
shoe
Blocked or defective Remove blockage or replace as necessary.
photo-eye in first divert
switch
Overcurrent sensor is Check that the sensor is adjusted properly.
tripping
Lubricate the carrying chain properly.
Check that the carrying chain tension is not too high.
Check that debris or product is not binding the sorter.
Check that the drive motor, reducer, and sprockets are
rotating freely.
Repair or replace as necessary.

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Troubleshooting

Symptom Probable Cause Corrective Action

Drive motor does Tripped safety device Check if the debris detector has been tripped. Remove
not run any internal debris and reset the detector. Verify that the
limit switch is actuated. If it is not actuated, replace the
limit switch.
Check if there is a product jam on the conveyor. Clear the
jam. Verify the position and operation of the jam and
long-range photo-eyes.
Check if the emergency stop has been tripped. Find and
resolve the cause of the emergency. Reset the
emergency stop, verify the safe operation of the system,
and restart.
Electrical power circuits Check for loose connections or faulty wiring. Tighten or
critical issue repair as necessary.
Check if the motor is operating properly. Replace as
necessary.
Check that the motor disconnect switch is on and not
defective.
Refer to the manufacturer’s instructions for
troubleshooting the VFD.
Check if the motor overcurrent sensor has tripped. If it
has, check the motor’s wiring for the source of the
overcurrent. Repair as necessary.
Check the motor contactor for proper operation. Replace
as necessary.
Check that the main power switch is on. Turn on if
necessary.
Check that the motor start push button is on. Turn on if
necessary.
Recirculation is not Check if recirculation conveyor is powered or full. Switch
running on power and remove product as necessary.
Check if recirculation conveyor’s drive motor or other
component is defective. Replace as necessary.

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Symptom Probable Cause Corrective Action

Conveyor shuts A safety device has See “Drive motor does not run” Symptom.
off automatically been tripped
during normal Low oil level in the Check the oil level and refill if necessary. Use only the
operation automatic oiler recommended oils.
reservoir
Electrical power circuit See the “Electrical power circuits critical issue” Probable
or device problem Cause of the “Drive motor does not run” Symptom.
Recirculation or Clear the full conveyor and/or troubleshoot the
overflow conveyor is full appropriate power unit.
or non-operational
Sort control unit failure Verify that the control unit is not inhibiting motor power
due to possible control unit failure/wiring problems.
Check for control unit failures/wiring problems and repair
as necessary.
Sorter is running Sorter in calibrate mode Exit calibrate mode using sorter HMI.
at the proper Induction not enabled Enable induction using sorter HMI.
speed, but no
product is Induction conveyor not Power the induction conveyor.
inducted powered

Single Take-away lane is full Clear take-away lane

inoperative divert or not powered
Power the take-away lane.
switch
Bad divert switch Replace divert switch.
Bad DCM Replace DCM.
Divert photo-eye is Remove blockage
blocked or defective
Replace photo-eyes and run calibration as necessary.
Wiring between DCM Repair/replace.
and switch is broken or
restricted See the “Divert switch not working” Symptom

Divert shoes are Flight assemblies Clear debris from flights.

noisy at one or contaminated
more divert Divert shoe binding Adjust shoe fastener
switches
Pin track misaligned Align track.
Product Check for read error Replace defective photo-eye
recirculates or is Assigned lane is full Remove product.
sent to “error
lane” Assigned lane is not Power the assigned lane.
powered.

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Troubleshooting

7.2 Troubleshooting Help

If you need further assistance, please visit our website at www.intelligrated.com or
call our Lifecycle Support Services (LSS) at (877) 315-3400.

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Index

DCM enclosure, 95
A DDD, 47
DDD kit, 97
abbreviations, 73
debris detection device. See DDD
after-sort, 22
aluminum flight assembly, 98 divert
ANSI, 2–3, 7–9 actuator assembly, 45
blade, 16
ASME, 1
switch, 11, 16, 17, 43
switch trigger, 46
B divert control module. See DCM
brush, 50 drive assembly, 91
drive shaft, 19
C drive unit, 11, 19

calibration gate, 14
E
carrying chain, 11, 19
catenary, 11, 18, 36, 87, 88 electric oiler, 99, 100, 101
central control system, 17 electric oiler catenary. See catenary
chain electric switch, 44
adjustment, 36 electrical components, 24
measurment, 36 emergency restart, 7
recalibration, 40 emergency stop, 7
sag, 37
temperature, 40 F
wear, 42
chain lubricator, 40, 48 flight assembly, 11, 21
chain track, 52–60 cleaning, 51
checklist installation, 34
daily, 64 removal, 34
quarterly, 67
weekly, 65 G
cleaning, 63
guard, 4
Code of Federal Regulations, 1
control components, 24
H
control stations, 6
controls, 5 headroom, 5
crossover switch, 43 hitch infeed, 74

D I
DCM, 25–31 idler, 11, 13
jumper description, 31 idler infeed belt, 75
LED description, 30 illustrated parts lists, 71–72
switch connections, 29 infeed belt, 13
DCM board, 96 infeed idler, 76

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infeed shaft, 78 pin guide, 13, 16
inspection, 63 power take-off, 13
intermediate assembly, 82, 85 precautions, 62
intermediate section, 11, 16 pre-sort section, 11, 14, 79
product summary, 22
L PTO, 13
Lifecycle Support Services, 110
lockout/tagout, 9
S
safety
M devices, 7
lockout/tagout, 9
maintenance precautions, 4, 7
daily, 64 signs, 9
precautions, 62 setup switch, 14
quarterly, 67 shaft drive assembly, 93
weekly, 65
shoe, 11, 16, 21
soft touch, 21, 44
O
sorter, 11
oil, 50 spur, 17
oiler, 31, 49 switch assembly, 94
oiler brush, 50
oiler priming, 51 T
OSHA, 1, 8, 9
trigger, 46
troubleshooting
P
chart, 104
photo-eye, 14, 16, 17 help, 110

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