UM Series Manual

UM SERIES
DATAR ENGINEERING & CONSULTANCY PVT.LTD.

OWNERS MANUAL
UM- SERIES
THE ILLUSTRATIONS IN THIS MANUAL ARE NOT TO SCALE OR DETAIL AND ARE FOR REFERENCE ONLY.
REGISTERED OFFICE:14,S.No. 128/4,Sanewadi, Off I.T.IRoad, Aundh,

Pune-411007, Maharashtra, India
Tel: 020-25885280 Fax: 020-25883213
Email: dale@pn2.vsnl.net.in
Website: www.datarengineering.com
DATAR ENGINEERING Page |1

SAFE. EFFICIENT. RELIABLE
UM SERIES
TABLE OF CONTENTS
SR.NO TITLE PAGE NO.

1 INTRODUCTION 5
2 SAFETY PRECAUTIONS 6
3 COMPONENT LOCATIONS 9
4 EQUIPMENT OVERVIEW 10
4.1 Mechanical Overview
4.2 Electrical Overview
5 VRC OPERATION
5.1 Sequence of Operation
5.2 Operation
6 MAINTENANCE & SERVICE

6.1 Servicing
6.2 Servicing Schedule
6.3 Essential Spare Parts Listing
7 VRC TROUBLESHOOTING
8 VRC PARTS
8.1 Safety Cam
8.2 Roller Chain
8.3 Electrical Switches and Controls
9 VRC ELECTRICAL DETAILS

9.1 Description
9.2 General Arrangement Drawing
9.3 Bill of Material
9.4 Control Circuit
9.5 Connection Details of Clip-on Terminal
10 IMPORTANT DOCUMENTS
10.1 DECON VRC GUARANTEE LETTER
10.2 DECON VRC TEST CERTIFICATE
10.3 INSTALLATION & COMMISIONING REPORT
10.4 VARIED EQUIPMENT CERTIFICATES

UM SERIES
1. INTRODUCTION
Your lifting unit is an industrial Vertical Reciprocating Conveyor (VRC). It will lift or lower
materials up to its rated capacity from one level to the next. Please be advised that this unit is for
materials only, no personnel must ride the VRC, it may result in injury or death.
The information and illustrations in this manual are intended only as an aid to understanding the
VRC‟s operations and maintenance requirements. It does not cover every possible contingency
or circumstances regarding non-standard options, installation, operation or maintenance.
DATAR ENGINEERING has an ongoing improvement program; therefore, we reserve the right
to change our product based upon these findings. In addition, the components may vary based
upon the equipment and options ordered. Please contact us if you have any questions.
WHAT DO I DO WHEN I HAVE A PROBLEM ? CALL US OVER TELEPHONE
* PARTS - As the manufacturer, we strongly suggest that you to keep a stock of standard
spare parts to cut downtime. You can buy spares directly from us.
* SERVICE - We have a team dedicated to assisting your maintenance personnel to
resolve questions and problems with the operation of the equipment.
* MODIFICATIONS -As your needs change, we have the expertise to work with you
in keeping the equipment up to your current production
expectations. Could you use another level ? Want a different
style gate ? Need to increase capacity ? Want to integrate it with
horizontal conveyors ? We have done it for others, let us help
you too.

UM SERIES
2. SAFETY PRECAUTIONS
There are two types of safety

Precautions in this manual –“WARNINGS” -------------------------------------------------
Apply to personnel danger, while ONLY PERSONNEL FAMILIAR
“CAUTION” applies to possible equipmentWITH THE LIFT EQUIPMENT AND
damage. But, remember, a condition which THESE INSTRUCTIONS SHOULD
can damage equipment could possibly OPERATE THE UNIT.
Result in injury to you. It is expected that -------------------------------------------------
you respect this possibility by using
additionalcaution under such conditions.
Whenever it is necessary to service the equipment, be sure to tag the control stations to alert
other people to your presence; and NEVER OPERATE THE LIFT WHEN PERSONNEL
ARE WITHIN THE ENCLOSURE AREA FOR ANY MAINTENANCE.
Use EXTREME CARE when trouble shooting and servicing electrical circuits because of
dangerous voltages. DO NOT WORK ON LIVE CIRCUIT. It is expected that such work will
be performed by qualified control electrician. Do not perform such electrical work without the
presence of another person capable of providing aid in the event of electrical shock.
SOME STANDARD PRECAUTIONS &WARNINGS :
 DO NOT OPERATE THE UNIT IF EITHER THE GATES OR INTER-LOCKS ARE

NOT FUNCTIONING PROPERLY
 DO NOT DISCONNECT OR SERVICE MOTOR/BRAKE OR REDUCER - unless the
platform and chains are fully secured or lowered.
 DO NOT WALK OR WORK UNDER A RAISED PLATFORM.
 INSTRUCTIONS THAT INVOLVE ELECTRICAL WORK APPLY TO A
QUALIFIED CONTROLS ELECTRICIAN.
 PERSONNEL MUST NOT RIDE THIS EQUIPMENT.RIDING MAY RESULT IN
INJURY OR DEATH.
 DO NOT WORK ON THE POWER UNIT WITHOUT THE PLATFORM SECURED
AND BLOCKED IN PLACE.
 DO NOT EXCEED THE RATED CAPACITY.
 DECON HAS CAREFULLY DESIGNED AND BUILT THIS CONTROL PANEL.
ANY UN-AUTHORIZED CHANGES MAY VOID GUARANTEE.
 DO NOT ALLOW LOADS TO OVERHANG THE SIDES OF THE CARRIAGE.THIS
WILL RESULT IN DAMAGE TO THE EQUIPMENT AND MERCHANDISE.
 SERVICE MUST BE PERFORMED BY AUTHORISED PERSONNEL ONLY.READ
THE OWNER'S MANUAL BEFORE OPERATING THE EQUIPMENT.

UM SERIES
ELECTRICAL SAFETY PRECAUTIONS
 ALWAYS ASSUME THAT A CIRCUIT IS NOT SAFE UNTIL YOU ARE SURE
IT IS DEAD. Make sure that it cannot be energized after you start working on it.
Follow OSHA procedures after locking the control panel EVERYTIME you carry
out maintenance and servicing on the VRC unit. Put a lock / tag on disconnects,
breakers, and-or pulled fuses.
 USE A VOLTAGE TESTER ON CIRCUITS – DO NOT USE YOUR

FINGERS.Use Fuse Pullers to change a fuse; NEVER use fingers, pliers or
screwdrivers. Covers on exposed electrical devices or wires MUST be installed to
prevent personnel from injury or shock.
 All metal connection boxes, switch boxes, starting boxes, transformer shells must be
grounded to prevent personnel from injury or shock.
 When using a portable electric meter, DO NOT connect one wire and leave the
other wire dangling loose, it may result in shock or injury to personnel through the
device.
 Avoid powering on the circuit before making sure all is clear. Otherwise, it may
result in injury or shock to personnel and also may result in damage to the
equipment.
 Avoid accidental contact with equipment or conductors when the circuit is powered
on not known to be dead. If it is necessary to work on equipment while it is hot,
extra care must be taken. Always test and repair equipment indicating a warning of
unsafe conditions by giving a non-fatal shock. NEVER assume the equipment to be
safe because the shock was non-fatal, because the next shock may not be non-fatal.
 TAKE TIME TO BE CAREFUL! Following safety procedures and using common

sense will prevent incidences on injury, mutilation or shock.

UM SERIES
SAFETY PRECAUTIONS WHILE WORKING ON LIVE CIRCUITS OR

EQUIPMENT:
When electrical maintenance or repair work is required that prohibits de-energizing

the circuits involved, extreme cautionary measures must be taken. The work should
be accomplished only by qualified personnel who are aware of the dangers involved.
Every care must be taken to ensure the safety of the person carrying out the work
and to follow the safety procedures strictly. The following precautions MUST be
taken:
 The person carrying out the work must not wear watch, chain, rings, metal articles,
chains, or loose clothing which may make accidental contact with live parts or throw
some parts of his body into contact with live parts.
 Clothing and footwear must be as dry as possible
 Insulate the person from ground by covering any adjacent grounded equipment
with insulating material. Suitable insulating materials are dry wood, rubber mats,
dry canvas, dry phenolic material or even heavy, thick, dry paper. Be careful that it
has no holes and no conducting materials embedded in it. Cover sufficient area so
that enough space is available for the person’s movement.
 Cover working metal tools with insulating materials like insulating rubber tape as
much as practically possible.
 DO NOT stick a screwdriver or any metal tool directly into a hot fuse box.

UM SERIES
3. COMPONENT LOCATIONS
Figure 1 UM SERIES COMPONENT LOCATION
The main parts and assemblies of the VRC unit and their locations can be referred to as per the
schematic diagram above.
Typically the VRC “UM Series” unit consists of the following major components:
1. Outer Mesh Structure (or Lift Frame)

 VRC Carriage
 Drive Assembly.
 Guide Columns.
 Safety Cam Assembly.
 Carriage Guides.
 Lifting Chains.
 Electrical Control Panel and Switches.

UM SERIES
4. EQUIPMENT OVERVIEW
MECHANICAL OVERVIEW
Each Series UM - VRC ( Vertical Reciprocating Conveyor ) has a main structural lift frame, a
drive base system at the top , a moving platform (carriage ), and interlocked safety gates or
doors. In addition, there is a control station on each level, a main control panel and various limit
switches. More information on the electrical components can be found in other areas within this
section of the manual.
LIFT FRAME: The lift frame is basically of modular design and consists of a standard BASE
& TOP Modules. And depending on the heights or floor involved – additional central modules
get fitted in between these basic top &bottom modules. The base module is bolted to the first
floor level or shop floor level. Other modules draw supports from other respective floor levels
depending on the location etc. (completely depending on each site & locational conditions).
TOP MODULE (DRIVE BASE): The drive base consists of a motor brake, gear reducer
(commonly referred to as reducer assembly ) ,drive sprockets and roller chain , a drive shaft,
bearing housings and support structure. Roller lift chains, connecting to extended tensioner
chains and chain tensioner assembly complete the components.

UM SERIES
One end of a lift chain connects to a block assembly bolted to the carriage. The lift chain engages
the lift sprocket at the top of the module, then connects to the smaller / or similar capacity
tensioner chain. Near the bottom of the base module, the tensioner chain goes around a small
sprocket and up, fastening to a bolt on the upper wheel block or to the carriage. The tensioner
sprocket is spring loaded by a chain tensioner maintaining tension on the main lifting chain /
tensioner chain combination. The tension is adjusted at the turnbuckleor threaded bolt at the
chain tensioner assembly.
Figure 2 CHAIN ATTACHMENT METHOD (Courtesy Pflow Industries USA)

UM SERIES
CARRIAGE AND GUIDE SHOES
The carriage consists basically of a tubular frame structure with a deck, up-rights, railings or
enclosure panels and guide shoe blocks.The shoes are bolted to the upright framing members so
that they ride within the inverted angle – so as to guide the carriage during travel.
Each wheel block has mounting block, a pin and wheel / bearings. The guide rollers or wheels
locate the wheel blocks within the track. There are eight nos. of top & bottom side wheel blocks
and four nos. of top & bottom central wheel blocks.
Also attached to the upright members are the safety cams with teeth cut into it and a slide shoe.
The shoe fits against the outside of the track, while the steel safety cam is pivoted on the
mounting block and is spring loaded. As the lift chain connects to this safety cam, all lifting
action is through it. Should the chain break or go slack, the cam will be pivoted by its spring into
a jam position with the track to stop the carriage from falling. The guide shoe on the outside of
the track helps to wedge the track between it and the cam teeth.
Figure 3 VRC CARRIAGE ASSEMBLY
DATAR ENGINEERING P a g e | 10
UM SERIES
MESH STRUCTURE / SAFETY GATES
To ensure safety at all levels to personnel - the openings at all floor levels are provided with
perforated type enclosures or cross bracing structure or mesh structure
(dependingon site location & operational requirements).The collapsible doors or other types of
door designs are provided on all other operating ends as per customer requirements and
depending on site conditions.
Safety gates depending on the installation or operational requirementare located at each level to
protect personnel when VRC is not at that level. These collapsible gates or access gates are inter-
locked with the carriage movement, thus if any doors are left open, the VRC will not operate.
Figure 4 MOTORIZED VERTICAL BI-PARTING DOOR
UM SERIES
DRIVE FRAME:
The drive assembly is the located on top of the VRC structure. It typically consists of SEW
Motor-Gearbox reducer assembly, drive shafts, bearing blocks, drive sprockets and the lifting
chain.
The Gearbox and sprockets are chosen on the basis of the speed requirement of the customer.
Figure 5 VRC DRIVE ASSEMBLY
UM SERIES
ELECTRICAL OVERVIEW
NOTE: This is only an overview of the electrical components included in the VRC and
includes standard information. For specific electrical wiring drawings, please refer to the
appropriate section of this manual.
All electrical components are operated by the MAIN CONTROL PANEL. The main Control
Panel uses a transformer to reduce the high voltage input required for the motor to the lower
voltage input required by the control panel. The gearbox-motor is protected against overloading
using overload relays.
PUSH BUTTON STATIONS are provided at each landing for the VRC. The location of these
stations is such that no person standing on the carriage can operate the VRC. Each control station
contains – UP, DOWN, and EMERGENCY STOP buttons.
The UP and DOWN buttons are momentary contact, hence allowing the operator to let go once
he has pushed the button. The EMERGENCY STOP button needs to be pushed in to activate the
emergency stop, and the VRC can only be operated again by pulling the button out to its initial
position.
There are typically 5 standard control switches in a 2-level VRC unit:
1. One each at every landing to stop the carriage.

2. One over travel protection.
3. Two on the Chain tensioner (slack or tight)
Units with more than two levels require additional switches at the intermediate levels.
Different types and styles of interlocks are supplied depending on the type of gate and onsite
conditions.
Figure 6 PUSH CONTROL STATION
UM SERIES
Figure 7 OVERTRAVEL LIMIT SWITCH (Courtesy Pflow Industries USA)
UM SERIES
5. SEQUENCE OF OPERATION
FOR THE LIFT TO WORK:
 ALL SAFETY DOORS OR GATES MUST BE CLOSED.

 LOADS MUST BE IN THE SPECIFIED LIMIT.
 LOADS MUST NOT OVERHAND THE LIMITS OF THE CARRIAGE
When the gates are closed and the up or down push button is pressed and the load is within limits
specified, the control circuit to the motor starter is completed. The coil magnetically closes the
high voltage contacts and the power circuit to the motor is completed to turn the motor in the
needed direction.
Now the brake is released,the motor turns the gears in the reducer which in turn rotate the drive
shaft. The sprockets on the shaft raise or lower the lift chain. As the lift chains are fastened to the
carriage, the carriage raises or lowers with its load.
When it arrives at the next level, the floor level limit switch is activated by the actuator plate or
cam on the carriage or the carriage, cutting power to the motor control circuit. The motor starter
contacts drop out, the motor stops, and the brake is applied, stopping the carriage.
(The OVER -TRAVEL LIMIT SWITCH is a safety device mounted directly above the upper
level floor level limit switch .The only time it should activate is if there is a failure of the upper
level limit switch. Again, activated by the top of the carriage, it will send a signal to shut the unit
down. Before reactivating the unit, find out why this occurred and correct the problem.)
Because the lift chains fastens to the carriage at one end and to the tensioner chain at the other,
which after being tensioned by the chain tensioner, fastens to the carriage at its other end, a
continuous loop is formed . The carriage raises or lowers as this loop is rotated by the lift
sprockets. A switch-activating block connected to the small tensioner sprocket which applies
tension to the tensioner chain is held in a relatively stationary position by the tension.
However, if the carriage encounters an object in its down travel, the lift chain on the load side of
the lift sprocket will slacken while tighteningon the non-load side. This raises the block which
will activate a slack chain switch circuit, cutting off the control circuit to the motor.
UM SERIES
DON’T RUN IT FURTHER IF…
If the carriage encounters an object in its up travel, or if the lift chain or tensioner chain breaks at
a point, the lift chain / tensioner chain on the non-load side will loosen .This lowers the block
which will activate a broken lift chain / tensioner chain switch circuit, cutting off the control
power to the motor and applying the brake. Refer to ``Troubleshooting„‟ for re-starting
instructions.
Switches at the chain tensioner sense a slack or broken lift chain or tensioner chain. When one of
these conditions occurs, the block on the chain tensioner sprocket spring rod is moved up or
down, activating the appropriate switch circuit.
Switches are mounted at each level gate. They are activated by various means, depending on the
installation, but are always inter-locked into the lift motors electrical circuit to signal the closed
condition of the gate.
CONTROL STATIONS AND PANEL:. A control station at each level contains push buttons
for moving the carriage up or down, and an emergency stop button. The up and down push
button switches are the momentary push and let go type. The red emergency stop switch is
momentary push to activated, but stays in until it is pulled back out.
The off condition will remain until the button is pulled out. But pulling the emergency button out
will not correct a problem which is occurred. The problem must be corrected before the controls
will operate again.
The main control panel normally contains a fuse transformer, instantaneous overload relay etc.
UM SERIES
HOW TO OPERATE
For safety and convenience, it is expected that clients post the following operating instructions at
each level of the lift.
If at any time proper operations or performance of your VRC is in question. DO NOT USE IT!
Notify your supervisor / superior or the proper maintenance personnel immediately. This lift is
designed for freight only.
WARNING
DO NOT RIDE ON THIS EQUIPMENT, RIDING MAY RESULT IN INJURY OR

DEATH.
WARNING
DO NOT WALK OR WORK UNDER RAISED PLATFORM
WARNING
DO NOT OPERATE THE LIFT IF EITHER THE GATES OR THE GATE INTELOCKS
ARE DAMAGED OR NOT FUNCTIONING PEOPERLY.
CAUTION
DO NOT EXCEED THE RATED LOAD CAPACITY FOR THE LIFT. EXCEEDING
THE CAPACITY WILL RESULT IN DANGEROUS OPERATING CONDITIONS.
Note : Carriage will not raise or lower when safety gates are open.
Note : If carriage stops during travel and will not raise or lower and the gates are closed,
contact your supervisor.
UM SERIES
To OPERATE:
Ensure all gates are closed.
Press and release the UP button to raise the carriage. The Carriage will stop when it
reaches the appropriate level.
When the carriage unit arrives at the appropriate level and comes to a complete stop,
proceed with the opening of the gate.
Push the EMERGENCY BUTTON TO STOP THE CARRIAGE BETWEEN LEVELS.

Note: THIS BUTTON WILL KEEP THE LIFT INOPERATIVE UNTIL THE BUTTON
IS PULLED BACK.
DO NOT ALLOW LOADS TO OVERHANG THE SIDES OF THE CARRIAGE. This will
result in damage to the equipment and merchandise.
UM SERIES
6. MAINTENANCE & SERVICING
SERVICING
WARNING : DO NOT DISCONNECT MOTOR OR BRAKE UNLESS PLATFORM AND

CHAINS HAVE BEEN SECURED
The lift requires consistent periodic attention, although servicing is minimal and basic. It
includes lubrication, minor adjustments, and inspection of key components. It is recommended
that you keep a record during inspection and make a periodic evaluation of lubricating needs to
reflect any increase in service. Refer to the schedule for service intervals and to the figure for
servicing locations.
CHAINS: During inspection, you don‟t want a brownish, rusty color in the joints, dull luster
pins, nor misalignment or wear indications between chains and sprockets. Chain lubricants are to
be low enough in viscosity to reach internal surfaces, but have enough body to keep a film under
bearing surfaces. They are also to be free from corrosive ingredients and do their job in your
ambient atmosphere, considering temperature, moisture and any fumes.
Normally, a good grade of non-detergents petroleum based oil meets these needs. But heavy duty
or severe use conditions might require Teflon or graphite – base lubricant. Check with your
lubricant supplier for your particular needs. Remember, the better the lubrication a chain is
given, the longer the chain life.
TENSIONER CHAINS: When inspecting the lift chains, also inspect the tensioner chains.
Look for signs of wear on the tensioner chain and the tensioner chain sprocket. Watch for signs
of rust or links that are bent or binding on tensioner chain. Check to make sure all connections
are tight.
LIST OF CHECKS (AT MONTHLY INTERVALS)
Check top drive assembly. It is important that both the chains are properly greased throughout its
length.
Check all wheel blocks or Wheel Shoes.
Check coupling & worm gears for any deterioration or damage.
Check oil in the gear box.
Check position & condition of the Limit switches. The 1st limit switch at the bottom level is
most important and must be activated when the platform is at the bottom level. Similarly the
over-run limit switch is important.
ELECTRICAL INTER-LOCKS
Check limit switches on doors at all the levels to ensure they are functioning electrically &
mechanically.
Similarly check all floor limit switches on the main I beam structure.
UM SERIES
MAINTENANCE SCHEDULE
Cycles/Days
Lubricate
Inspect
No. Of
Adjust
ITEM ACTION
01 2000/60 Motor / Brake See Bulletins
02 2000/60 Main Shaft Bearings Grease through fittings. Not

applicable since bearings
are grease packed
03 1000/30 Mounting Bolts Tighten all bolts & nuts
04 1000/30 Lift Roller Chains Coat with oil & inspect for
wear
05 2000/60 Safety Cam Assly Tighten all bolts & nuts

inspect for wear
06 2000/60 Guide Shoes Grease if required & inspect

for wear
UM SERIES
07 2000/60 Chain Inspect for wear or damage
08 2000/60 Chain Tensioners Inspect for tensioner wear.

Adjust Switch.
09 2000/60 Chain Sprockets for main Inspect for wear. Tighten

drive shaft screws
10 1000/30 Electrical Switching Inspect for proper

devices & gate interlocks operations. Adjust switches.
1. Use Non Detergent, Petroleum Base Sae-30 Oil

2. Use Lithium Axle Grease
3. Observe Cycle Or Days Schedule Based On Whichever Comes First
UM SERIES
ESSENTIAL SPARE PARTS FOR VERTICAL RECIPROCATING CONVEYOR
The following list can be used as a guide regarding spare parts for your VRC. Convenience and
minimal down time are two good reasons to maintain an inventory of spare parts. Critical spare
parts can be bought directly from Datar Engineering. Please feel free to call us regarding any
questions and recommendations.
Sr. No. Part Description Quantity

1 Sprockets 2 Nos.
2 Drive Chain Loop Assembly 2 Sets
3 Guide Shoe Assembly 4 Nos.
4 Floor Limit Switches 2 Nos.
5 Door Limit Switches 2 Nos.
6 Chain Tensioner Assembly 2 Nos.
7 Bearings for Drive Assembly 4 Nos.
8 Safety Cam Assembly (LHS and RHS) 2 Nos.
9 Sundry Electrical Components for main control panel. 6 Nos.
UM SERIES
7. TROUBLE SHOOTING
------------------------------------------------------------------------------------------------------------------------------------------
When the VRC won‟t operate, do a systematic search for the problem to lessen down time.
This section contains a description of scenarios regarding operating malfunctions and their
solutions. If you need clarifications or further assistance, please contact us.
During repairing or adjustment procedures listed in the trouble shooting, please follow all
safety regulations as highlighted earlier.
A] WHEN CONTROLS DO NOT START THE VRC MOTOR
PROBLEM SOLUTION
Safety Gate Close Gate
Main Disconnect Off Enquire whether there is a reason before
turning on.
Slack Lift Chain / Tensioner Chain Tighten Tensioner Turnbuckle / Bolt
Broken Lift Chain / Tensioner Chain Repair or replace is necessary
Control Fuse is blown Replace fuse after determining cause
Guide Shoes Adjust and Tighten, or replace if needed.
Power circuit between disconnect and starter is Check situation
dead
WARNING: DANGEROUS HIGH VOLTAGE POTENTIAL EXISTS. TAKE EXTREME

CAUTION!
B] LIFT MOTOR STARTS FOR 3 seconds AND THEN STOPS
PROBLEM SOLUTION
Relay Trip Lighten Load
CAUTION: DO NOT EXCEED LIFT CAPACITY. Higher load draws a current which is
higher than the relay sensitivity setting.
UM SERIES
C] MOTOR HUMS BUT DOES NOT ROTATE SHAFT
PROBLEM SOLUTION
Load is greater than VRC rated capacity Lighten Load
Object encountered Remove object and repair if necessary
Drive component interference Remove and repair if necessary
Improper operation of Brake-motor or reducer Contact Datar Engineering.
Single Phasing Check incoming main leads. Repair if needed.
WARNING: DANGEROUS HIGH VOLTAGE POTENTIAL EXISTS. TAKE EXTREME

CAUTION!
D] CARRIAGE STOPS BEFORE DESTINATION IS REACHED
PROBLEM SOLUTION
Safety gate has been opened Close gate. Check to see why this has
happened.
Object Encountered Identify problem. Repair/ Replace as needed.
Drive component interference Repair / Replace as needed.
Slack Lift / Tensioner Chain Tighten Chain
Broken Lift / Tensioner Chain Repair / Replace chain.
E] CARRIAGE FAILS TO STOP
PROBLEM SOLUTION
Travel Limit Switch Failure Adjust or Replace Limit Switch
Brake Failure Determine cause and correct
F] CARRIAGE RAISES BUT WILL NOT LOWER
PROBLEM SOLUTION
Mechanical Interference Identify problem. Remove and repair as needed
G] CARRIAGE LOWERS BUT STOPS EARLY
PROBLEM SOLUTION
Debris in pit Clear Pit
UM SERIES
H] ROUGH OR NOISY OPERATION
PROBLEM SOLUTION
Interference between chain and guards or Determine cause and correct
guides
Shaft or idler sprocket bearings. Inspect, lubricate and replace.
Motor or reducer Determine cause and correct
Travel Interference Remove interference or replace
Drive component interference Identify. Repair or replace.
Wheel guide rollers worn Inspect, lubricate or replace if necessary.
Determine why they are worn.
Carriage is not level. Determine cause and correct.
Inpect whether chain lengths are equal.
Check for improper or excessive eccentric
loading.
Check for interference on guide columns.
UM SERIES
8. VRC CRITICAL PARTS
A] SAFETY CAM ASSEMBLY
Vertical Reciprocating Conveyors manufactured by Datar Engineering have an additional safety

feature called as “SAFETY CAM”. This is essentially a device which comes into the picture
regarding safety in case of breaking of the main lifting chain.
The safety cam assembly is mounted on the VRC carriage. It consists of a wheelblock, a central
guide roller and 2 lateral guide rollers. It also contains the safety cam device with teeth cut into it
and a shoe. The shoe fits on the outside of the track, while the central guide roller and lateral
guide rollers fit in the guide columns and are essential in guiding the carriage along the guide
columns.
Figure 8 SAFETY CAM ASSEMBLY (Courtesy of Pflow Industries USA)
The lifting chain connects through this safety cam, and hence all lifting occurs through this
safety cam.
In the event of breaking of the lifting chain, the cam will be pivoted by it‟s spring into a jamming
position with the guide column face, thereby supporting the full weight of the carriage, and thus
preventing accidents.
UM SERIES
Figure 9 SAFETY CAM OPERATION (Courtesy Pflow Industries USA)
Routine inspection of the safety cam assembly is highly recommended since it is a major safety
device in the Vertical Reciprocating Conveyor.
VISUAL INSPECTION
The Safety cam must be periodically checked for signs of rust or corrosion on the teeth, and
other signs of visual wear and tear.
ROTATION
Make sure that the safety cams rotate perfectly by slackening the chains.
For any additional support, kindly contact us.
UM SERIES
B] LIFTING CHAIN
Your VRC is an electro-mechanically driven unit and employs roller chains as the main lifting
element.
The certificate for the lifting chain is attached at the end of this manual.
The chain-loop assembly is shown in the following schematic.
Figure 10 CHAIN LOOP ASSEMBLY (Courtesy of Pflow Industries USA)
UM SERIES
C] ELECTRICAL SWITCHES
Appropriate switches, either limit or micro, provide carriage and gate position information to the
electrical circuit of the lift motor. Their function is level info, over-travel limiting , gate closed , slack lift
chain / tensioner chain sensing.
At each level a travel limit switch is bracket mounted to the lift upright frames. An actuator or cam plate
on the side of the carriage activates the switch when it comes in contact with the switch-activating arm.
The mounting position of the switch is adjustable.
The gravity type over travel limit switch is mounted on the top drive module. It is actuated when the
upper wheel block shoe or carriage or a separate cam/bolt device contacts its actuator arm. This safety
gravity limit switch comes into action only when the top floor limit switch fails. It is thus imperative that
before the lift is reactivated - the floor limit switch needs to be replaced or attended to - as the case may
be.
UM SERIES
9. VRC ELECTRICAL DETAILS
ELECTRICAL INSTALLATION:
Following is a description of the electrical installation requirements of Vertical Reciprocating

Conveyors („UM‟ Series design – Electro-Mechanical).It is intended as a guide and does not
include added optional equipment. The schematic diagram is also entailed herein (it may be for
single floor – but for floors more than one – the same is duplicated at other levels and holds
good).
Except for the main disconnect, required wire and conduit / cable trays as required;
DatarEngineering – provides the other electrical inclusive of main control panel, control stations
& cabling etc.
MAIN DISCONNECT: Required as per standard. Should be fused type disconnect and located
within a few meters of the VRC. To be provided by the clients so that we can tap the power
source.
MAIN CONTROL PANEL: All electrical components will be tied into this panel. Panel is
supplied by us. Location is to be determined at site mutually. Normally the main control panel is
located near the electrical disconnect.
MOTOR/BRAKE UNIT: The standard unit is supplied by us and will have a brake rewired to
the motor so that only motor needs to be wired.
PUSH BUTTON STATIONS: One push button station is normally supplied for each level.
These are mounted by an electrician.
CONTROL SWITCHES:The standard two level lift incorporates normally four control
switches – one switch at each level to stop the carriage, one over-travel switch, and one chain
tensioner switches.These switches are supplied by us and require field mounting and wiring.
Lifts servicing more than two levels require additional switches for each intermediate level.
GATE INTER-LOCKS: All gates or doors accessing the lift must have electric contacts to
prevent the lift from operating. There are many types and styles of inter-locks which might be
supplied depending on the type of gates or doors and on site conditions.
OPTION AND ACCESSORIES: Lifts with carriage lights, power gates, horns etc., all require
electrical installations and will increase installation times and costs.
UM SERIES
10. ESSENTIAL DOCUMENTS AND CERTIFICATES
The following documents and certificates are attached herewith:
1. Datar Engineering Guarantee Letter.

2. Datar Engineering Vertical Reciprocating Conveyor Certificate.
3. VRC Installation and Commisioning Report.
4. SEW Eurodrive Gearbox-Motor Certificate.
5. TI Diamond Chain Certificate.
6.

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UM SERIES

DATAR ENGINEERING & CONSULTANCY PVT.LTD.

REGISTERED OFFICE:14,S.No. 128/4,Sanewadi, Off I.T.IRoad, Aundh,

DATAR ENGINEERING Page |1

SR.NO TITLE PAGE NO.

6 MAINTENANCE & SERVICE

9 VRC ELECTRICAL DETAILS

DATAR ENGINEERING Page |2

WHAT DO I DO WHEN I HAVE A PROBLEM ? CALL US OVER TELEPHONE

* SERVICE - We have a team dedicated to assisting your maintenance personnel to

resolve questions and problems with the operation of the equipment.

in keeping the equipment up to your current production

expectations. Could you use another level ? Want a different

style gate ? Need to increase capacity ? Want to integrate it with

horizontal conveyors ? We have done it for others, let us help

DATAR ENGINEERING Page |3

There are two types of safety

SOME STANDARD PRECAUTIONS &WARNINGS :

 DO NOT OPERATE THE UNIT IF EITHER THE GATES OR INTER-LOCKS ARE

DATAR ENGINEERING Page |4

ELECTRICAL SAFETY PRECAUTIONS

 USE A VOLTAGE TESTER ON CIRCUITS – DO NOT USE YOUR

 TAKE TIME TO BE CAREFUL! Following safety procedures and using common

DATAR ENGINEERING Page |5

SAFETY PRECAUTIONS WHILE WORKING ON LIVE CIRCUITS OR

When electrical maintenance or repair work is required that prohibits de-energizing

 Clothing and footwear must be as dry as possible

DATAR ENGINEERING Page |6

Figure 1 UM SERIES COMPONENT LOCATION

1. Outer Mesh Structure (or Lift Frame)

DATAR ENGINEERING Page |7

DATAR ENGINEERING Page |8

Figure 2 CHAIN ATTACHMENT METHOD (Courtesy Pflow Industries USA)

DATAR ENGINEERING Page |9

CARRIAGE AND GUIDE SHOES

Figure 3 VRC CARRIAGE ASSEMBLY

MESH STRUCTURE / SAFETY GATES

Figure 4 MOTORIZED VERTICAL BI-PARTING DOOR

Figure 5 VRC DRIVE ASSEMBLY

There are typically 5 standard control switches in a 2-level VRC unit:

1. One each at every landing to stop the carriage.

Figure 6 PUSH CONTROL STATION

Figure 7 OVERTRAVEL LIMIT SWITCH (Courtesy Pflow Industries USA)

FOR THE LIFT TO WORK:

 ALL SAFETY DOORS OR GATES MUST BE CLOSED.

DON’T RUN IT FURTHER IF…

DO NOT RIDE ON THIS EQUIPMENT, RIDING MAY RESULT IN INJURY OR

DO NOT WALK OR WORK UNDER RAISED PLATFORM

Ensure all gates are closed.

Push the EMERGENCY BUTTON TO STOP THE CARRIAGE BETWEEN LEVELS.

6. MAINTENANCE & SERVICING

WARNING : DO NOT DISCONNECT MOTOR OR BRAKE UNLESS PLATFORM AND

LIST OF CHECKS (AT MONTHLY INTERVALS)

01 2000/60 Motor / Brake See Bulletins

02 2000/60 Main Shaft Bearings Grease through fittings. Not

03 1000/30 Mounting Bolts Tighten all bolts & nuts

05 2000/60 Safety Cam Assly Tighten all bolts & nuts

06 2000/60 Guide Shoes Grease if required & inspect

07 2000/60 Chain Inspect for wear or damage

08 2000/60 Chain Tensioners Inspect for tensioner wear.

09 2000/60 Chain Sprockets for main Inspect for wear. Tighten

10 1000/30 Electrical Switching Inspect for proper

1. Use Non Detergent, Petroleum Base Sae-30 Oil

ESSENTIAL SPARE PARTS FOR VERTICAL RECIPROCATING CONVEYOR