Operation, Maintenance and Parts Manual Manual · Before using the PowerTrax, please take time to review the drawings and instructions in this manual. PowerTrax Manual Warranty Summary

Best Diversified Products, Inc.107 Flint St.

Jonesboro, Arkansas 72401Phone: 870-935-0970

Toll Free: 800-327-9209Fax: 870-935-3661

Please read entire manual before operating conveyor.

Factory Order Number:_______________

Serial Number:______________________

Ship Date:__________________________

Manual

Diversified Products, Inc.PowerTrax

Operation, Maintenanceand Parts Manual

Please visit our website at www.bestconveyors.com and click on downloads forthe latest updates to this manual.

File Number E23049799053

July 23, 2003

Table of ContentsIntroduction.................................................................................................................3

Warranty......................................................................................................................3

UL Statement...............................................................................................................4

Safety Information........................................................................................................5

Operating Instructions..................................................................................................5

Standard Features and Options....................................................................................6

Troubleshooting/Maintenance.....................................................................................7-8

PowerTrax 24” Gravity Bed Parts List........................................................................10-11

PowerTrax 30” Gravity Bed Parts List........................................................................12-13

PowerTrax 24” Power Bed Parts List.........................................................................14-15

PowerTrax 30” Power Bed Parts List.........................................................................16-17

Accumulation Photo Eye Kit, 24”................................................................................18

Accumulation Photo Eye Kit, 30”................................................................................19

Photo Eye Package Stop Kit, 24”................................................................................20

Photo Eye Package Stop Kit, 30”................................................................................21

Wiring Diagram, Gravity Bed........................................................................................22

Wiring Diagram, Power Bed.........................................................................................23

Wiring Diagram, PowerTrax With Accumulation............................................................24

Wiring Diagram, Photo Eye Package Stop....................................................................25

Control Enclosure........................................................................................................26

3

Introduction

Thank you for purchasing the PowerTrax. The PowerTrax was carefully designed by engineers atBest Diversified Products, Inc. to make loading and unloading trailers safer, easier and faster. It hasvariable speed control and operates only when the switch is held down for safety. The durable allsteel construction chassis and the pneumatic slick wheels provide positive traction to travel easilyover dock levelers. An electrical brake can be installed to hold the PowerTrax on larger inclines. Itconveniently comes in 110V and 240V AC models. It also has built-in adjustable height capabili-ties.

The PowerTrax is available with gravity or powered rollers, so it works perfectly with any Best/Flex,gravity or power, conveyor system. It comes in 24” and 30” widths, but can be made to fit all ofBest’s expandable conveyors. It can be retrofitted or mounted to a complete system. The opticspackage can be added to the powered-roller PowerTrax.

Before using the PowerTrax, please take time to review the drawings and instructions in this manual.

PowerTrax Manual

Warranty Summary Statement

Your Best conveyor is protected by our premier warranty. Best Diversified Products, Inc. will replace,free of charge, parts that are damaged during the course of normal operation due to material or work-manship defects. This warranty extends for a period of two (2) years on all mechanical componentsand one (1) year on all electrical components, as measured from the date you take possession of yourconveyor.

This warranty does not cover damage due to accident, misuse, abuse, and negligence. This warrantydoes not cover damage due to improper operation or maintenance, connection to improper voltagesupply, or attempted repair/modification by anyone other than an authorized Best Diversified Products,Inc. service personnel.

For specific warranty information or assistance, please contact your Best Diversified Products, Inc.sales representative at 1-800-327-9209.

4

UL Statement

Underwriter’s Laboratories Certification Statement

Best conveyors have been thoroughly tested by Underwriter’s Laboratories, and have been found to meet their strict standards for Factory Automation Equipment. Our conveyors are certified to UL508 Standards when shipped from our plant. Our UL file number is E230497. All standards can be found on-line at www.ul.com. ANY MODIFICATION FROM ORIGIONAL FACTORY CONDITION OR REPAIRS NOT PERFORMED BY BEST DIVERSIFIED PRODUCTS’ TECHNITIONS OR CERTIFIED CONTRACTORS MAY VOID UL CERTIFICATION. For specific assistance regarding any UL issues, please contact your Best Diversified Products, Inc. sales representative at 1-800-327-9209.

5

Operating Instructions

1) Check the travel path and verify that it is clear.2) Select the appropriate speed by turning the knob next to the power switch (maximum speed is

approximately normal walking speed, or 50 feet per minute.3) Push and hold down the momentary rocker switch on top of the handle to move the

PowerTrax.4) When the switch is released, the PowerTrax will stop.5) Use the side handles and front handle to steer the PowerTrax

6) On the powered-roller models of PowerTrax, the roller speed and related functions are con-trolled on the conveyor system.

• Move the PowerTrax only by grasping the handles located on each side and at the front of theunit.

• Do not tape or in any way fix the RUN switch in the operating position.• Do not exceed the PowerTrax load capacity, as it may result in possible operator injury or

damage to the unit.• The PowerTrax should never be operated unmanned.• Keep long hair and loose clothing pulled up to prevent it from becoming caught in moving

parts. • Keep feet clear of the drive wheels at all times. • Broken or worn parts must be immediately replaced.

• Properly trained and qualified technicians must service the PowerTrax and its electrical sys-tems.

• Never service the PowerTrax with the power applied. Always disconnect power beforeservicing equipment.

Safety Information

6

• Parallel Shaft DC Drive MotorHP Rating: ¼ hpMaximum Safe Torque: 250.0 in/lbs.Maximum Voltage: 90VMaximum Amperage: 2.2A

• Solid State DC Motor Speed ControllerHP Rating: 1 hp at 115V and 2 hp at 230V ACMaximum Voltage: 90VMaximum Amperage: 11.0A

• Speed of the unit is 0 to 50 feet per minute

• Roller Bed Speed (1.9” rollers)Motor speed is 0 to 120 feet per minute

• Chassis is all steel construction.• Wheels are 12” x 4” pneumatic slicks in back and 8” swivel casters in front.• Standard height adjustment is 27 to 37 inches.• Emergency Stop Switch

Standard Features

1) Manual Package Stop – Manually stops packages at the end of the roller bed.2) Optics – Electronically stops packages at the end of the roller bed.

Options

7

PowerTraxTroubleshooting Guide

Motor Controller and Motor

Symptom Possible Cause Corrective Action1. Motor does not run; power ON 1. Power Switch in Off position, 1. Move power switch to ON indicator not lit. Or AC voltage not brought to position.

L1, L2 terminals in controller. Correct wiring to controller.

2. Blown Fuse 2. Replace line fuse with 12 Amp rated 3AB-type fuse. If blew due to miss wiring, speed control module may be defective.

3. Speed control knob set to 0 3. Turn knob CW to start motor

4. Defective motor 4. Check the defective motor, worn brushes, etc. Replace motor.

5. Plug-In Horespower Resistor not 5. Install proper size Plug-in installed. Horespower Resistor.

2. Motor hums, or runs at very low 1. Low voltage. 1. Check line voltage at controller and rewire speed (with control knob set at rewire as required. high number) or motor slows down substantially when load is applied.

2. Overload condition; control in 2. Reduce loading; CL trimpot setting current limit mode (CL) may have to be increased. (trimpot not set correctly).

3. Plug-In Horsepower Resistor 3. Install proper size resistor. not correct size.

4. Incorrect wiring. Armature and 4. Correct wiring (armature has shunt connections interchanged. lower resistance than field). (shunt motor only).

3. Erratic motor performance 1. Defective motor, worn brushes etc. 1. Repair motor.

2. Overload condition. 2. Remove overload.

3. Plug-In Horsepower Resistor 3. Replace with proper size. wrong size.

4. IR comp and/or CL trimpots 4. Readjust trimpots. not set properly.

5. Defective speed control module. 5. Replace module.

4. Motor continues to run when 1. Min speed trimpot not set to full 1. readjust min. trimpot. speed control knob is set to 0. CCW position.

2. IR comp trimpot set too high. 2. Lower IR comp trimpot setting.

5. Motor will not run in either 1. Incorrect wiring or faulty reversing 1. Correct wiring. forward or reverse direction. switch.

2. Defective APRM. 2. Replace APRM.

8

PowerTraxTroubleshooting Guide (Cont.)

6. No Braking action in brake mode. 1. Incorrect wiring. 1. Correct wiring.

2. Defective brake resistor. 2. Replace resistor.

3. Defective APRM. 3. Replace APRM.

7. Motor runs in wrong direction. 1. Armature leads reversed. 1. Reconnect armature leads.

The PowerTrax is virtually maintenance free, however, we do recommend the following:

• Keep the PowerTrax clean and free of debris, dirt and grease accumulation.

• Inspect belts for wear (in power applications). Replace excessively worn belts.

• Make sure photoeyes are clean and unobstructed (in Accumulation and Photo Eye Package Stop applications).

• Test all EMERGENCY STOP pushbuttons to verify proper operation.

• Check the chain tension.

All of the above maintenance inspections should be conducted daily.

Maintenance Schedule

9

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18

Accumulation Photo Eye Kit, 24”

Located in PowerTrax Electrical Enclosure

Item Part # Description

24" Photo Eye Kit 8-

061031 10010 SCREW HHC 1/4-20X3/4 42 10532 SCREW, #6X1/2 PAN HD 03 10576 BOLT CAR 1/4-20X 3/4" 44 11110 LOCKNUT NYL 1/4 85 11278 NUT MACH SCREW #12-24 06 12000 WASHER FLAT 1/4" 47 15016 TERM RING .25STUD 16-14GA 18 15017 TERM FEM DISC 16-14 .25TA 69 15025 CABLE TIE 7 3/8L, 3/16W 410 15026 WIRE NUT (YELLOW) HI-Y 311 15037-5 CORD ELECT 16/5 SO 612 15048 ENCLOSE 6X4X4 SCREW W/CVR 113 15050-2 PHOTO-EYE DEFUSED 18MM 314 15054 COMP FIT C&I#SLRN-3/4 NPT 315 15055 NUT COMP FIT 3/4" NPT 316 15062 TW LK MA 5 PR (#2021P) 117 15063 TW LK FM 5 PR (#2021C) 118 1-90024 22AWG/3C CABLE 319 8-61024 CHANNEL PHOTO-EYES 24" 120 8-61025 CHANNEL PHOTO-EYES 30" 021 8-61030 ANGLE CHANNEL MT 2

Photo Eye Kit Parts Quantity

19

Accumulation Photo Eye Kit, 30”






20

Photo Eye Package Stop Kit, 24”






21

Photo Eye Package Stop Kit, 30”






22

Wiring Diagram, Gravity Bed PowerTrax

23

Wiring Diagram, Power Bed PowerTrax

24

Wiring Diagram, PowerTrax With Accumulation

25

Wiring Diagram, Photo Eye Package Stop

Control Enclosure

AA

2

6

89

73

1

11

5

10

4

11

13

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30

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22

mm

41

30

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31

30

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06

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,

22

mm

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22

mm

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Notes

Best Diversified Products, Inc.107 Flint St.

Jonesboro, Arkansas 72401Phone: 870-935-0970

Toll Free: 800-327-9209Fax: 870-935-3661

Call Best Customer Service

99053

Documents

Operation, Maintenance and Parts Manual Manual · Before using the PowerTrax, please take time to review the drawings and instructions in this manual. PowerTrax Manual Warranty Summary