Bump Turn

240BT
BUMP TURN
USER GUIDE AND PARTS MANUAL
PROPRIETARY AND CONFIDENTIAL NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN PERMISSION OF WALCO SYSTEMS
240BT_PM01_Rev A.doc
Copyright 2010 Walco Systems LLC
PRODUCT INFORMATION
Complete the following list. Provide this information when contacting customer support.
Model: 240BT Serial No:

If you have questions or concerns Contact
Technical Support: Walco Dealer: Phone: Or Walco Systems: Phone: (440) 937-0909 Web Site: www.walcosystems.com Mail: Walco Systems 1431-B Lear Industrial Pkwy Avon, Ohio 44011
No warranty (expressed or implied) can be made for its accuracy or completeness, nor is any responsibility assumed by the manufacturer or anyone connected with it for loss or damages suffered through reliance on any information contained in this guide or misuse of accompanying product. The manufacturer reserves the right to make changes at any time to this guide or accompanying product without obligation to notify any person or organization of such changes.
The information, specifications and illustrations in this guide are based on the latest information available at the time of printing. Walco Systems LLC reserves the right to make changes at any time without notice.
Copyright Information Copyright 2010 Walco Systems LLC All rights reserved.
Page 2 of 20
240BT_FED_PM01_Rev A.doc
TABLE OF CONTENTS
PRODUCT INFORMATION .............................................................................................................................. 2 SAFETY PRECAUTIONS................................................................................................................................... 4 GETTING STARTED .......................................................................................................................................... 6 PRODUCT OVERVIEW ........................................................................................................................................... 6 INSTALLATION ..................................................................................................................................................... 6 CONTROLS .......................................................................................................................................................... 7 Operator Control Panel functions .................................................................................................................. 7 Power Switch .............................................................................................................................................. 7 Stop Button ................................................................................................................................................. 7 Start Button ................................................................................................................................................. 7 Base Speed Potentiometer........................................................................................................................... 7 Conveyor Speed Potentiometer................................................................................................................... 7 TROUBLESHOOTING ....................................................................................................................................... 7 Base Does Not Power Up ............................................................................................................................... 7 Base will not start ........................................................................................................................................... 7 Vacuum Pump will not start............................................................................................................................ 7 PARTS MANUAL SECTION ............................................................................................................................. 8 BUMP TURN ASSEMBLIES .................................................................................................................................... 8 Cabinet............................................................................................................................................................ 8 Transport Frame............................................................................................................................................. 9 Transport Top ............................................................................................................................................... 10 CONVEYOR ASSEMBLIES .................................................................................................................................... 11 TOP ASSEMBLY .................................................................................................................................................. 11 RIGHT ANGLE KNOCK DOWN ASSEMBLY .......................................................................................................... 13 BELTING TABLE ........................................................................................... ERROR! BOOKMARK NOT DEFINED. ELECTRICAL PARTS LIST.................................................................................................................................... 14 MECHANICAL PARTS LIST.................................................................................................................................. 16 WIRING DIAGRAM.......................................................................................................................................... 19 TRANSPORT BASE .............................................................................................................................................. 19 CONVEYORS ....................................................................................................................................................... 20
Page 3 of 20
SAFETY PRECAUTIONS
READ AND UNDERSTAND THE SAFETY INSTRUCTIONS BEFORE SERVICING ANY EQUIPMENT.
Risk of electric shock.
Use extreme caution when working with circuits that have greater than 60 volts DC or 24 volts AC. Lockout-Tagout electrical power source before opening any electrical panels or covers.
Electric shock can cause injury.
Make sure power is off.

- This also helps prevent damage to print and computer systems.
Always disconnect equipment from its power source before servicing electrical system components.
Contacting electrical connections can cause injury.
Wear safety goggles and protective clothing.

- User and bystander - Even if your everyday glasses have impact resistant lenses, they may NOT be safety glasses, and may not provide adequate protection.
Do not position head directly over or in front of drying unit. Keep a dry chemical (Class B) fire extinguisher rated for paper and electrical fires in work area.
Fire can cause death or serious injury.
Risk of flying particles.

Wear safety goggles while using equipment.
- Rotating transport parts can cause flying particles and or objects. - Even if your everyday glasses have impact resistant lenses, they may NOT be safety glasses, and may not provide adequate protection. Flying particles and objects can cause eye injury.
Risk of electrical burns.

Electrical circuits can produce a short-circuit current high enough to weld jewelry to
metal. - Remove jewelry such as rings, bracelets and watches before working near electrical sources.
Keep personnel, clothing and other objects clear of electrical connections. Do not wear watches, rings when working around transport bases. Do not place tools on transport equipment.
Contacting electrical connections can cause injury.
Page 4 of 20
Risk of pinch or crush.

Moving parts can pinch or crush.
- Keep all persons clear from moving parts. - Stop equipment before making any adjustments. Moving parts and objects can cause injury.
Risk of injury.
Only qualified personnel should operate equipment. Do not operate equipment with damaged wires or cords. Do not operate equipment if damaged, until examined by a qualified service representative. Ensure transport base power is OFF before making adjustments. Verify all personnel are clear of moving parts before starting the machine. Never allow any personnel or personal items to come into contact with moving parts. Stop the machine before removing any jams. Lockout-Tagout electrical power source before servicing this machine.
Operation and service of equipment by anyone other than qualified personnel may result in injury.
Alteration or modifications to this equipment not expressly approved by the manufacture will void the manufactures liability.
Page 5 of 20
GETTING STARTED
The 240BT Bump Turn provides an inline solution for rotating products 90 degrees from their infeed orientation. This unit is capable of turning a large range of material sizes and thicknesses left or right. Easy integration coupled with versatility makes it the right choice for your turning application requirements.
Product Overview
Control Panel
Installation
Placing The 240BT
Place 240BT next to appropriate equipment. Leave a small gaps between 960VT and other equipment so the belts on the end of the roller DO NOT come in contact with anything.
WARNING:
Damage to belts may occur if they come in contact with any other equipment.
Leveling / Height Adjustment

Once the equitpment is in place the leveling pads need to be lowered. If the base needs to be raised to meet existing equipment height, use leveling pads to accomplish this. Turn the 1/2 hex bolts found inside the base at the four corners to adjust the cabinet height to desired level. Once proper height is established tighten lock nuts against cabinet base pan. The leveling pads will also insure cabinet stability. This will keep the cabinet from moving, allowing the belts to come into contact with other objects and getting damaged.
Page 6 of 20
CONTROLS
Operator Control Panel functions
Power Switch
This is the main Power switch for the machine.
Stop Button
This button stops the transport base. It also opens (OFF) the upstream inter-lock. NOTE: If a conveyor is connected to the base, Stop will stop it also.
Start Button
This button starts the transport base.
Base Speed Potentiometer

This POT controls the belt speed of the transport Base.
Conveyor Speed Potentiometer

This POT controls the belt speed of the take away Conveyor that is connected to the Base. It is independent of the transport section. Adjusting this speed will allow loosen or tighten the shingling or the conveyor.
TROUBLESHOOTING
Risk of electric shock
Use extreme caution when working with circuits that have greater than 60 volts DC or 24volts AC. Lockout-Tagout electrical power source before opening electrical panels or servicing equipment.
Electric shock can cause injury.

Electrical repairs should only be made by qualified personnel.
Base Does Not Power Up

Check the following: Make sure the Power Switch is in the ON position. Make sure outlet, the base is plugged into has power. Make sure the speed pot is not at minimum setting. Check fuse F1 is not blown. Relay K1 engages when power switch is turned on
Base will not start

Check the following: Make sure the Power Switch is in the ON position and the Base has Power. Start Was Pressed Make sure the Base speed pot is not at minimum setting. Make sure the downstream Device Interlock is active (If applicable) Check Line and Armature fuses on the Drive Board (located inside electrical panel) Make sure the drive belt is not broken
Vacuum Pump will not start

Check the following: Make sure the Power Switch is in the ON position and the Base has Power. Check fuse F2 is not blown.
Page 7 of 20
PARTS MANUAL SECTION

Bump Turn Assemblies
Cabinet
Page 8 of 20
Transport Frame
Page 9 of 20
Transport Top
Page 10 of 20
Conveyor Assemblies Top Assembly
Belting Table
WALCO P/N 210-28 210-28-1 210-27 210-27-1 210-13 210-13-1 210-29 210-29-1 Model 480VSC 4ft 480VSC 4ft 720VSC 6ft 720VSC 6ft 960VSC 8ft 960VSC 8ft 1200VSC 10ft 1200VSC 10ft Belt Width 3" Wide 8" Wide 3" Wide 8" Wide 3" Wide 8" Wide 3" Wide 8" Wide
Page 11 of 20
Motor Leg
Page 12 of 20
Right Angle Knock Down Assembly
Page 13 of 20
PARTS LISTS
Electrical Parts List
Electrical
PART NO.
130-01 130-03 130-04 130-05 130-06 130-07 130-08 130-09 130-10 130-11 130-12 130-13 130-14 130-15 130-16 130-17 131-01 131-02 131-03 131-04 131-05 131-06 131-07 131-08 131-09 132-01 132-02 132-03 132-04 132-05 132-06
DESCRIPTION
Ckx Speed Encoder 24VAC Transformer Dryer Product Sensor (IDEC) Inkjet Product Sensor (Banner) Relay DPDT 120VAC Relay DPDT 24VAC Relay Socket Ckx Out Amplifier Board Ckx DPDT Relay Terminal Block Gray Terminal Block GND Terminal Block Fused Solid State Relay Rotary Speed Encoder Xi Jet HP 5K OHM 2Watt POT 5K OHM 2Watt 10 Turn POT Fuse MDL 8A Fuse MDL 5A Fuse AG 4A Fuse AG 12A Fuse AG 8A Fuse AG 4A Fuse AG 2.5A Fuse MDL 10A Fuse MDL 6A Stand Alone Motor Controller DC Motor Controller HP Resistor 1/4hp HP Resistor 1/2hp HP Resistor 1/6hp Speed Following Board
Page 14 of 20
Electrical
PART NO.
133-01 133-02 133-03 133-04 133-05 133-06 133-07 133-08 133-09 134-01 134-02 134-03 134-04 134-05 134-06 134-07 134-08 134-09 134-10 134-11 134-12 134-13 134-14 134-15
DESCRIPTION
Eaton Contact Block NC Eaton Contact Block NO SW PB, 22 mm, momentary, red, 1 N.C. contact (STOP) SW PB, 22mm, momentary, black, 1 N.C. 1 N.O. contact (JOG) SW PB, 22mm, momentary, green, 1 N.O. contact (START) SW, 22mm, selector, 1 N.O. contact (ON/OFF) Pushbutton, 22 mm, twist-to-release, red, 1 N.C. contact Pushbutton, 35 mm, twist-to-release, red, 1 N.C. contact N.O. Contact Plug 9 Position Plug 4 Position Receptacle 9 Position Receptacle 4 Position Connector Back Shell 17 Connector Back Shell 11 Connector Female Disconnect (AWG):22-18 Connector Female Disconnect (AWG):16-14 Circular Connectors Signal Pin CNT 22-18tin Size 16 Male Circular Connectors Signal Pin CNT 22-18tin Size 16 Female Spade Connector Wire Nut Wire Strain Relief .17 Wire Strain Relief .23 Motor Con Box
Page 15 of 20
Mechanical Parts List

Assembly Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Cabinet Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Frame Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top WALCO P/N 110-01 110-03 110-07 114-04 150-12 150-15 150-23 150-40 370-22 370-CA-240 370-CA-Electrial Small 110-10 110-14 111-03 111-05 113-03 113-07 113-08 114-09 150-01 150-21 150-37 150-38 210-08 210-23 230-05 250-01 250-02 270-02 310-13 310-AR-12D 310-AR-12I 350-02 390-02 390-04 390-05 390-13 110-02 110-15 111-02 111-03 111-04 111-06 111-12 112-01 SW Part Description Hex Nut 1/2-13 Hex Nut 10-32 Hex Cap Screw 1/2-13 x 6" Button Head Screw 10-32 x 3/8" Swivel Caster Compression Door Latch Swivel Leveling Pad Electrical Panel Hinge Cabinet Door Pan Small 240 Feed/Inkjet/dryer Small Electrical panel assembly Flat washer 1/4" Split Lock washer 1/4" Socket Head Cap Screw 1/4-20 x 3/4" Socket Head Cap Screw 1/4-20 x 7/8" Brass Tip Set Screw 1/4-20 x 1/2" Brass Tip Set Screw 1/4-28 x 1/4" Socket Head Set Screw 1/4-20 x 1 1/2" Button Head Screw 10-32 x 1 1/4" Collar Bearing 5/8 ID Thumb Screw Belt Guide Belt Guide Pin Belt Guide Collar 1/2" ID Heat Belts w/o Holes 3/4" x 51 1/2" 50-1/4" long x 2-1/2" Timing Belt 225L050 Timing Pulley 10L050 1/2" Bore Timing Pulley 12L050 5/8" Bore DC Motor - 1/6 HP 1750 RPM 240 Motor Mount Roller Assembly 12" Drive Roller Assembly 12" Idle Frame Non-Vacuum 24" Belt Guide Shaft 12.5 Drive Shaft 5/8 x 16.5 Shaft Frame Stiffener 12.5" Shaft Idler Roller 13.5 Bases Hex Nut 1/4-20 1/4 Nylon Washer Socket Head Cap Screw 1/4-20 x1" Socket Head Cap Screw 1/4-20 x 3/4" Socket Head Cap Screw 1/4-20 x 5/8" Socket Head Cap Screw 1/4-20 x 1/4" Socket Head Cap Screw 10-32 x 1/2" Machine Flat Head Screw 10-32 x 1/2"
Page 16 of 20
Assembly Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Bump Turn Top Conveyor Knock Down Conveyor Knock Down Conveyor Knock Down Conveyor Knock Down Conveyor Knock Down Conveyor Knock Down Conveyor Knock Down Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg
WALCO P/N 114-02 114-07 150-03 150-14 150-18 150-19 150-28 150-36 310-07 310-151 310-152 310-18 310-19 310-20 310-32 310-43 310-44 330-40 390-14 150-47 150-48 310-133 310-134 310-150 310-153 390-20 110-01 110-02 110-07 110-08 110-10 110-14 111-02 114-02 150-01 150-12 150-23 230-06 250-02 250-05
SW Part Description Button Head Screw 1/4-20 x 5/8" Button Head Screw 8-32 x 1/2" Flange Bushing 1/2" ID Shaft Collar 1/2" ID Brass Tip Knob Assembly 1/4-20 Fluted Knob 1/4-20 1" Extension Spring Flat Bearing 1/4" ID Infeed/Outfeed Roller Arm Bump Turn Rail Bump Turn Rail Nose Infeed Guide Arm Infeed Side Guide 1 Infeed Side Guide 2 IJ Infeed Shaft Post Infeed Shaft Pivot Block Infeed/Outfeed Roller Table Top 240 Bump Turn Shaft Infeed/Outfeed Post 23.5" Collar 3/8 Fluted Knob 1/4-20 1/2" Conveyor Knock Down Roller Bearing Block Conveyor Knock Down Roller Mounting Post Conveyor Knockdown Conveyor Knock Down Bridge Conveyor Straight Away Shaft 3/8" Hex Nut 1/2-13 Hex Nut 1/4-20 Hex Cap Screw 1/2-13 x 6" Hex Cap Screw 1/4-28 x 5/8" Zinc Flat washer 1/4" Split Lock washer 1/4" Socket Head Cap Screw 1/4-20 x1" Button Head Screw 1/4-20 x 5/8" Collar Bearing 5/8 ID Swivel Caster Swivel Leveling Pad Timing Belt Conveyor Timing Pulley 12L050 5/8" Bore Timing Pulley 24L050 3/4" Bore
Page 17 of 20
Assembly Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Motor Leg Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top Conveyor Top
WALCO P/N 270-03 270-10 310-29 310-49 310-51 370-06 370-CAConvLegMotor 390-03 110-01 110-02 110-07 110-10 110-14 114-02 150-01 150-12 150-21 150-23 150-37 150-38 310-21 310-28 310-50 310-68 370-05 370-09 370-CAConvLegw/oMotor 390-01 390-12
SW Part Description DC Motor - 1/4 HP 62 RPM Straight Gear Drive Straight Gear Drive Motor Bracket Idle Roller Hub Conveyor Driver Block Conveyor Roller Conveyor End Cap Outfeed Conveyor Leg with motor Assembly Drive Shaft 5/8 x 15.5 Hex Nut 1/2-13 Hex Nut 1/4-20 Hex Cap Screw 1/2-13 x 6" Flat washer 1/4" Split Lock washer 1/4" Button Head Screw 1/4-20 x 5/8" Collar Bearing 5/8 ID Swivel Caster Thumb Screw Belt Guide Swivel Leveling Pad Belt Guide Pin Belt Guide Collar 1/2" ID Conveyor Stop Plate Drive Roller Hub Conveyor Idler Block Conveyor Idler Roller Conveyor End Cap Conveyor Top 96" (8ft) Conveyor Leg with w/o motor Assembly Belt Guide Shaft 15.5" Conveyor Shaft Idler Roller 15.5" Conveyor
Page 18 of 20
WIRING DIAGRAM
Transport Base
A- A+
F2 F1
Conveyor 1 Motor Control Board
Drive Motor Control Board
Conveyor 2 Motor Control Board
A-
A-
I2
K3
K2
K1
P1
P1
L2
L2
L2
P2
P2
P2
P1
A+
B L1 W
P3 3
L1
L1
I1
P3
P3 3
X2
24V AC Transformer
3 2
X1
H1
H4
Power Cord
Pin1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9
1 3 4 2
Conveyor Connector
Drive Motor
NC NO NO
Power Sw
Stop Sw
Start Sw
Base Speed Pot
Conv. 1 Speed Pot
Conv. 2 Speed Pot NAME DATE 7/28/10 7/28/10
Walco Systems LLC

DESIGNED: DRAWN: CHECK: ENG. APPR. MFG. APPR. Comments: Dual Convayor drive
Fuses
F1 - 5 MDL F2 - 5 MDL
PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WALCO SYSTEMS LLC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WALCO SYSTEMS LLC IS PROHIBITED.
RCS RCS
1431-B Lear Industrial PKWY Avon, Ohio 44011 (440) 937-0909
Drive Controller Board

Armature - 43AG Line - 12 AG Relays K1 - 120V DPDT K2 - 24V DPDT K3 - 24V DPDT
Wiring Diagram:
Modified 240BT for Fedelity AddresserBased
SIZE: DWG. NO. Rev.
FedelityAddresserBased.vsd
Scale:8.5 x 11 Weight:
A
Sheet: 1 of 2
Conveyors
Conveyor 2
Conveyor 1
Conveyor 1 Connector
Drive Motor
Drive Motor
NO
Stop Button
Walco Systems LLC

NAME DATE 7/28/10 7/28/10
PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WALCO SYSTEMS LLC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WALCO SYSTEMS LLC IS PROHIBITED.
DESIGNED: DRAWN: CHECK: ENG. APPR. MFG. APPR.
RCS RCS
1431-B Lear Industrial PKWY Avon, Ohio 44011 (440) 937-0909
Wiring Diagram:
Modified 240BT for Fedelity AddresserBased
SIZE: DWG. NO. Rev.
Comments: Dual Convayor drive
FedelityAddresserBased.vsd
Scale: 8.5 x 11 Weight: Sheet: 2 of 2

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Bump Turn

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240BT

USER GUIDE AND PARTS MANUAL

Copyright 2010 Walco Systems LLC

Model: 240BT Serial No:

Make sure power is off.

Wear safety goggles and protective clothing.

Risk of flying particles.

Risk of electrical burns.

Risk of pinch or crush.

Leveling / Height Adjustment

Base Speed Potentiometer

Conveyor Speed Potentiometer

Electric shock can cause injury.

Base Does Not Power Up

Base will not start

Vacuum Pump will not start

PARTS MANUAL SECTION

Conveyor Assemblies Top Assembly

Right Angle Knock Down Assembly

Mechanical Parts List

Conveyor 1 Motor Control Board

Drive Motor Control Board

Conveyor 2 Motor Control Board

Base Speed Pot

Conv. 1 Speed Pot

Conv. 2 Speed Pot NAME DATE 7/28/10 7/28/10

Walco Systems LLC

PROPRIETARY AND CONFIDENTIAL

1431-B Lear Industrial PKWY Avon, Ohio 44011 (440) 937-0909

Drive Controller Board

Walco Systems LLC

PROPRIETARY AND CONFIDENTIAL

DESIGNED: DRAWN: CHECK: ENG. APPR. MFG. APPR.

1431-B Lear Industrial PKWY Avon, Ohio 44011 (440) 937-0909

Comments: Dual Convayor drive

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