IntelliROL IOM

INSTALLATION, OPERATION, MAINTENANCE
MANUAL
IntelliROL®
Motorized Roller Conveyor
IntelliROL®
Table of Figures .............................................................................................................. 3

Purpose ........................................................................................................................... 4
TGW Systems Equipment Warranty................................................................................ 5
Warnings and Safety Instructions .................................................................................... 6
Introduction to IntelliROL ............................................................................................... 11
Concept ...................................................................................................................... 11
Operation ................................................................................................................... 11
Feature/Benefits ......................................................................................................... 11
Application Options ....................................................................................................... 13
Application .................................................................................................................. 13
Definition of Terms ..................................................................................................... 13
Installation Arrangements.............................................................................................. 15
General ...................................................................................................................... 15
Driver Cards ............................................................................................................... 15
Drive / SLAVE Belt Break-in ....................................................................................... 15
Commissioning of Equipment ..................................................................................... 15
Precautions ................................................................................................................ 16
Receiving & Site Preparation ........................................................................................ 17
General ...................................................................................................................... 17
Preparation of Site...................................................................................................... 17
Parts Inventory & Identification ...................................................................................... 18
Dimensional Reference Points ................................................................................... 18
Basics of IntelliROL Installation ..................................................................................... 20
General ...................................................................................................................... 20
Elevations...................................................................................................................... 21
Component Orientation .............................................................................................. 21
Establishing Conveyor Flow ....................................................................................... 22
Supporting Arrangements ............................................................................................. 23
Floor Supports ............................................................................................................ 23
Anchoring ................................................................................................................... 23
Curve Support Points ................................................................................................. 25
Knee Braces ............................................................................................................... 25
Diagonal Sway Brace (floor support) .......................................................................... 26
CRUZ®channel to XenoROL Channel Connections .................................................. 27
Ceiling Hangers .......................................................................................................... 28
Sway Bracing (ceiling hanger) .................................................................................... 31
Anchoring ceiling hangers .......................................................................................... 31
Adjustable Channel Guard Rail to CRUZ®channel Options .......................................... 34
Air Supply Requirements............................................................................................... 35
General ...................................................................................................................... 35
Main Feeder ............................................................................................................... 35
Air Drops .................................................................................................................... 35
Low Pressure Switch .................................................................................................. 35
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Pneumatic Requirements ........................................................................................... 35

Electrical........................................................................................................................ 37
General ...................................................................................................................... 37
ITR Variations ............................................................................................................ 37
Straight Bed Construction .......................................................................................... 37
Curve Construction..................................................................................................... 38
UBT Construction ....................................................................................................... 38
Power Merge Construction ......................................................................................... 40
Wheel Divert Construction .......................................................................................... 40
Spur Construction....................................................................................................... 40
ITRHB Electrical Components .................................................................................... 41
ITRCB Electrical Components .................................................................................... 43
ITR Electrical Components ......................................................................................... 43
Typical Bed Description................................................................................................. 44
Electrical........................................................................................................................ 46
General ...................................................................................................................... 46
Conveyor Controls - Safety Guidelines ...................................................................... 47
Preventive Maintenance ................................................................................................ 48
General ...................................................................................................................... 48
Daily ........................................................................................................................... 48
Weekly ....................................................................................................................... 48
Air Systems ................................................................................................................ 48
Parts Identification ......................................................................................................... 50
CB-016 Drivercard......................................................................................................... 51
Transportation Straight Bed .......................................................................................... 52
Transportation Curve..................................................................................................... 54
Spur 30.......................................................................................................................... 58
Spur 45.......................................................................................................................... 64
Power Merge w/30 Degree Spur ................................................................................... 70
UBT ............................................................................................................................... 72
Accumulation Straight Bed (2 & 30 Zone) ..................................................................... 76
Accumulation Curve ...................................................................................................... 79
Induct Bed ..................................................................................................................... 82
Mission .......................................................................................................................... 85
Table of Figures
Figure 1 – UBT Sensor Location ................................................................................... 39
Figure 2 – HB-510 Drivercard ....................................................................................... 41
Figure 3 – HB 510 Communication Cable LH Flow ....................................................... 42
Figure 4 – HB-510 Communication Cable RH Flow ...................................................... 42
Figure 5 – CB-016 Drivercard ....................................................................................... 43
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Purpose
It is the intent of TGW Systems, through this manual, to provide information that acts as
a guide in the installation, operation and maintenance of TGW Systems IntelliROL
conveyors.
This manual describes basic installation practices, assembly arrangements, preventive

maintenance and assists in replacement parts identification.
This service manual is intended for use by personnel who are knowledgeable of
installation and safe working practices on conveyor systems.
Not all applications and conditions can be covered; therefore, this manual is to be used
ONLY as a guide.
If additional copies of this manual are needed or if you have any question concerning
the conveyor please contact your Business Partner or TGW Systems' Customer
Support at 231-798-4547 or Fax 231-798-4146.
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TGW Systems Equipment Warranty
TGW Systems warrants that the material and workmanship entering into its equipment is
merchantable and will be furnished in accordance with the specifications stated.
TGW Systems agrees to furnish the purchaser without charge any part proved defective within 2
years from date of shipment or before the equipment has forty-one hundred (4100) hours of
running use, whichever period is shorter, provided the purchaser gives TGW Systems
immediate notice in writing and examination proves the claim that such materials or parts were
defective when furnished. For drive components specific to XenoROL® (i.e. Xeno belts, slave
Xeno belts, drive spools, standard and speed-up, and spacers), this warranty shall be extended
to five years or ten thousand (10,000) hours of running use, whichever period is shorter,
provided the conveyors are applied, installed and maintained in accordance with TGW Systems
published standards. Other than the above, there are no warranties which extend beyond the
description on the face hereof. Consequential damages of any sort are wholly excluded.
The liability of TGW Systems will be limited to the replacement cost of any defective part. All
freight and installation costs relative to any warranted part will be at the expense of the
purchaser. Any liability of TGW Systems under the warranties specified above is conditioned
upon the equipment being installed, handled, operated, and maintained in accordance with the
written instructions provided or approved in writing by TGW Systems.
The warranties specified above do not cover, and TGW Systems makes no warranties which
extend to, damage to the equipment due to deterioration or wear occasioned by chemicals,
abrasion, corrosion or erosion; Purchaser's misapplication, abuse, alteration, operation or
maintenance; abnormal conditions of temperature or dirt; or operation of the equipment above
rated capacities or in an otherwise improper manner.
IMPORTANT
All equipment and components not manufactured by TGW Systems carry only such warranty as
given by the manufacturer thereof, which warranty TGW Systems will assign or otherwise make
available to Purchaser without recourse to TGW Systems, provided that such warranty is
assignable or may be made available.
For service on motors, reduction units, electrical components, controls, air or hydraulic
cylinders, contact the local authorized sales and service representative of respective
manufacturer. If none is available in your locality, contact the TGW Systems representative.
TGW Systems will not be responsible for units that have been tampered with or disassembled
by anyone other than the authorized representative of the respective manufacturer.
THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED

TO, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
EXTENDING BEYOND THOSE SET FORTH IN THIS STATEMENT OF WARRANTY.
Rev 08/22/2011
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Warnings and Safety Instructions
Failure to follow the instructions and cautions throughout this book, and warning labels
on the conveyor, may result in injury to personnel or damage to the equipment.
Your TGW Systems conveyor is powered by a motor and can be stopped only by
turning off electrical power to the motor. As with all powered machinery, the drive-
related components – including sprockets, chains, shafts, universal joints and
pneumatic devices – can be dangerous. We have installed or provided guards to
prevent accidental contact with these parts, along with warning labels to identify the
hazards.
Special attention must be paid to the following areas of this manual:
WARNING
 Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
 Indicates a situation which, if not avoided, could result in property
damage.
NOTE
This is where you will be notified of helpful information.
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WARNING
 After maintenance, REPLACE guards immediately.
 Keep ALL warning labels clean and clear of any obstructions.
 Never remove, deface or paint over WARNING or CAUTION
labels. Any damaged label will be replaced by TGW Systems
at no cost by contacting Lifetime Services.
 It is very important to instruct personnel in proper conveyor
use including the location and function of all controls.
 Special emphasis must be given to emergency stop
procedures.
 It is important to establish work procedures and access areas
which do not require any part of a person to be under the
conveyor.
 It should be required that long hair is covered by caps or hair
nets.
 Loose clothing, long hair and jewelry must be kept away from
moving equipment.
 Maintain enough clearance on each side of all conveyor units
for safe adjustment and maintenance of all components.
 Provide crossovers or gates at sufficient intervals where
needed to eliminate the temptation for personnel to climb over
or under any conveyor.
 Walking or riding on a moving conveyor must be prohibited.
 Before performing maintenance on the conveyor, make sure
the start-up controls are locked out and cannot be turned on
by any person other than the one performing the maintenance.
 If more than one crew member is working on the conveyor,
EACH CREW MEMBER MUST HAVE A LOCK ON THE
POWER LOCKOUT.
 All pneumatic devices must be de-energized and air removed
to prevent accidental cycling of the device while performing
general maintenance.
 Make sure all personnel are clear of all conveyor equipment
before restarting the system.
 Before servicing or performing any work in the motor control
panel, disconnect and lock out the main incoming service. If
only the panel disconnect is off, the incoming side will still be
hot.
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WARNING
 Before servicing or performing any work in the motor
control panel, disconnect and lock out the main
incoming service. If only the panel disconnect is off, the
incoming side will still be hot.
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Introduction to IntelliROL
Concept
Utilizing 24V DC motorized roller, this technology is the most revolutionary since the
advent of the line-shaft conveyor in the late-‘60s. Its impact is currently expanding
rapidly as more users and manufacturers begin to see the benefits of this technology.
TGW Systems’ experience with IntelliROL goes back to 1996 with a major tire handling
system.
This fast advancing technology uses a self-contained 24 volt DC motorized roller to

power a segment or zone of the conveyor. Rollers adjoining the motorized roller are
slave-driven with the same components TGW Systems developed in the ‘60s.
XenoROL® line-shaft driven live rollers and IntelliROL equipment both drive product
through the developed tangential force at the conveyor roller surface. The relationship
between tangential forces, product weight and product characteristics have been at the
root of TGW Systems conveyor technology for the past 30 years. This natural
extension places TGW Systems at the forefront of applying this technology.
Operation
The product-carrying rollers are slave-driven by a series of pre-tensioned belts to the
motorized roller in each zone. Since every motorized roller can be individually
controlled, every segment of the system becomes a potential zero-pressure zone.
Accumulation begins when an external signal “arms” the first sensor (discharge end).
External signals may originate from electrical controls, sensing devices, encoding
stations, manually activated switches, etc. The first product stops over the discharge
sensor which arms the next sensor in the zone upstream. When a product (armed from
the previous zone), stops the carrier rollers within its zone, all rollers in the zone stop.
As accumulation takes place from zone-to-zone, accumulated products are under zero-
pressure.
Feature/Benefits
 Flexible Modular design / easy to reconfigure
 Run on demand / less noise, wear, and energy consumption
 Non-contact zero-pressure / product protection
 Compact low profile / multi-level usage
 Reversible / less electrical hardware cost
 No scheduled maintenance / lower operating cost
 Low voltage / safety and lower cost
 Simple installation / lower cost
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 Soft start/stop / low G-forces

 Variable speed / versatility to suit each requirement
 Intelligent control capabilities / cost no greater than need
Most IntelliROL modules have a maximum depth profile of 6-3/8" T.O.R to bottom of
flange including a true vertical lift urethane belt transfer. A bi-directional urethane belt
transfer has a maximum rate of 30 cases per minute. Urethane belt transfer belts should
only run while transferring a load.
All curves except the minimum radius curve are based on TGW Systems’ true taper
roller for all widths.
IntelliROL optional run-on-demand software can selectively deactivate conveyor zones

when not carrying product. Because each IntelliROL module has its own drive and
control, any level of control sophistication is possible, including product-tracking,
diagnostics, and data collection.
The technology behind IntelliROL is growing and changing quickly. Most applications
use a 24 volt DC, 1.9" diameter, brushless motorized roller, and these rollers are the
basis of design for most IntelliROL modules. Special applications requiring slow speeds
and high torque may require the use of geared motorized rollers and 3-phase AC
voltage motorized rollers have been used in heavy duty applications.
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Application Options
Application
The application of IntelliROL breaks down into two areas. One is complete systems; the
other is the application of specific modules within a system that may be based on line-
shaft or some other conveyor technology.
TGW Systems has standard designs for straight bed sections for transportation or
zoned accumulation. Standard zone lengths are 24” or 36”. TGW Systems also offers
curves in 30°, 45°, 60° and 90°, 30° or 45° spurs, UBT transfers, three designs of
product stops, inclines and declines, gates, minimum radius curve, and anti-rollback
brakes (inclining). Many options are available including different roller centers,
bearings, roller coatings, etc.
Application Specific Modules may be used to solve certain requirements within a system
at a most cost-effective manner using IntelliROL conveyor.
Application Specific Module examples include:

 Short spurs
 Workstations
 Fill gaps between conveyors or devices
 Providing power to a lift bed
 Transfer car
 The bed of a turntable
 Gates
 Low Profile requirements over aisles, multi-level, etc.
In nearly all the above examples, space is a major consideration. Weight and balance
may even be a consideration on something like a scale, lift, or vertical conveyor.
Definition of Terms
Accumulation - Act of queuing, holding or backing up of product on a conveyor.
Carrying Roller - The conveyor roller upon which the object being transported is
supported. It has circumferential grooves near one end to allow the slave belts to ride
below the carrying surface.
Coefficient of Friction - A numerical expression of the ratio between the force of contact
between two surfaces and the resistant force tending to oppose the motion of one with
respect to the other.
Conveyor Width - The dimension outside to outside of frame rails. For the inside
dimension, the abbreviation "BF" (between frames) is used.
Crossmember - Structural member which is assembled between two side channels of a
conveyor bed.
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Frame - The structure which supports the components of a conveyor bed consisting of
formed channel rails bolted together with crossmembers.
Indexing Control - Maintains non-contact accumulation and functionality of gates,
transfers, curves, etc. by not allowing accumulation in these areas.
IntelliROL Non-Contact Accumulation - "Pure" zero-pressure accumulation which
guarantees that one product will not touch any other during accumulation, release, or
any time. (Requires product to be inducted singularly and be 3" to 4-1/2" shorter than
zone).
Roller Centers - Distance between center lines of adjacent rollers. For curves, roller
centers are measured at the inside radius.
Roller Groove - The groove that is fabricated into the carrying roller to provide a seat for
the slave belt below the carrying surface.
Singulation Release - A method of individual zone release that spaces product
approximately one zone length apart.
Slave Belt - An endless round belt manufactured from elastic material, typically
urethane, connecting a motorized roller or carrying rollers or other carrying rollers within
a zone.
Slug Release - Simultaneous release of several products.
Tapered Roller - A conical conveyor roller for use in a curve with end and intermediate
diameters proportional to their radius.
Zone - A portion of conveyor activated by a motorized roller that may be controlled by a
photoeye.
Zone Length - The distance between sensing devices (typically containing one
motorized roller).
Zero-Pressure Accumulation - The lack of force between products after accumulation.
(Industry standard)
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Installation Arrangements
General
IntelliROL conveyors are offered in four standard widths of 16BF, 22BF, 28BF, and
34BF with the overall conveyor width being 3.25" plus the BF. Standard available bed
lengths are multiples of the two standard zone lengths of 24" and 30", up to 10'.
Standard roller center distance is 3". Other roller centers and widths may be available.
Driver Cards
The driver cards that are supplied with each motorized roller are mounted inside the
side channel of a bed, opposite the slave O-ring side of the conveyor. These driver
cards condition the 24VDC power coming from a separate power supply. Standard
IntelliROL beds are prewired and tested prior to shipping. TGW provides an optional
plastic shroud that snaps into grooves in the 7.5” deep CRUZchannel to cover the driver
cards and wiring. These shrouds are translucent to allow monitoring of the LED
condition lights on the driver cards.
Drive / SLAVE Belt Break-in

The roller to roller round drive belts are installed under tension with predetermined initial
tension. After a time of static and running conditions, there is an initial tension drop in
the belt.
Run all IntelliROL conveyors 48 hours empty before running product. This will ensure
motorized rollers are not overloaded under the higher initial belt tension. This run time
is best accomplished during installation as soon as the power supplies are wired and
during the commissioning phase.
Commissioning of Equipment
Commissioning of the equipment can best be defined as the final adjustments and test
of the installed equipment required for its proper operation. The need for
commissioning is inherent, since the individual components of equipment are brought
together at the installation site to operate as a system.
Mechanical and electrical commissioning is most often carried out simultaneously.

Commissioning must simulate the actual operation of the system as close as possible to
demonstrate its ability to perform reliably at the specified rate in the prescribed
operational sequence.
During the Commissioning Phase, it is necessary to load the equipment with product to
be conveyed, which provides the means of detecting those areas requiring adjustment.
Personnel will be required to support operational functions and may serve as part of
operator training and familiarity with the system. During the commissioning activity,
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special attention should be directed toward personnel safety. No unnecessary risks

should be taken that would endanger the safety of any commissioning personnel. All
personnel must familiarize themselves with all safety features of the system such as
emergency stops and motor disconnects.
After commissioning, conduct operator training on all safety and operational aspects of
the system. This must include systems start-up, location of emergency stops and
familiarity with all operator controls.
Precautions
ULTRAVIOLET RAYS of sunlight will weaken polyurethane slave belts.
OILY OR WET CONDITIONS impair frictional drive characteristics between
polyurethane slave belts and roller grooves.
CORROSIVE SUBSTANCES will adversely affect various components, voiding the
warranty.
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Receiving & Site Preparation

General
IntelliROL conveyor is shipped in subassemblies. These subassemblies are packaged
to guard against damage in shipment when handled properly.
Examination immediately following unloading will show if any damage was caused
during shipment. If damage is evident, claims for recovery of expenses to repair
damage or replace components must be made against the carrier immediately. While
unloading, a check must be made against the Bill of Lading, or other packing lists
provided, to confirm full receipt of listed items.
CAUTION
 TAKE CARE DURING THE REMOVAL OF EQUIPMENT FROM THE
CARRIER.
 Remove small items and boxes first.
 Pull and lift only on the skid, not on the frame, crossmember or any part
of the equipment.
 Be sure the skid is free of other materials which may be on top of or
against the side of the skid to be removed.
Preparation of Site
After the conveyor is received, move it to the
installation site or designated dry storage area as
soon as possible. Clean up all packing material
immediately before parts get lost in it. Loose parts
should remain in the shipping boxes until needed.
Prior to starting assembly of the conveyor, carefully

check the installation path to be sure there are no
obstructions that will cause interference. Check for
access along the path needed to bring in bed sections and components closest to the
point where they are needed. It is often necessary to give the area along the system
path a general cleanup to improve installation efficiency, access and accuracy.
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Parts Inventory & Identification
Each subassembly is shipped completely

assembled except typical loose parts, which are
in boxes with the subassemblies. Segregate the
conveyor subassemblies by types for inventory
and ease of locating during installation.
An identification label is attached to the outside

of one side channel, close to one end of each
conveyor bed. This label contains: job number,
part number, order number, tag number (if
specified), assembler's initials and date of
Typical identification label location. manufacture. On supports, the tag is located on
the bottom side of the foot. On special devices it
is located on a convenient flat surface that is not
offensive to the appearance of the equipment but is still accessible for viewing. These
numbers can be cross-referenced against the packing list.
Loose parts are boxed and shipped separately. You should have all conveyor sections
and supports for a particular conveyor prior to installation. It is cost-effective to identify
and procure any missing parts before they are needed for assembly. Small items like
nuts and bolts are weigh-counted and packaged by size and type.
WARNING
 The Installation Supervisor must be experienced with
conveyor and qualified in the mechanics of the
equipment and enforce safe working procedures for the
protection of the crew, customer, and customer’s
property.
Dimensional Reference Points

The path of each conveyor in the system is determined by establishing a reference point
at each end. The center line of the conveyor is established and a chalk line is snapped
between these points.
Conveyors should be installed with the center line of the bed matching the center line of
the conveyor path within 1/8" of true center. Locate and mark the center of the
crossmembers at each end of the conveyor. Use a plumb line or other acceptable
means to ensure accuracy to the chalk line.
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Always carry out a thorough check for any obstructions such as building columns,
manholes, etc. It may be necessary to reroute the conveyor to avoid the obstruction. In
this case it would be advisable to begin installation at this point, using the obstruction as
a reference point (Datum), and install the sections in either direction as required.
All conveyor sections must be checked for squareness prior to installation as "racking"
or being knocked out of square may have occurred during shipping and handling.
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Basics of IntelliROL Installation
General
IntelliROL conveyor may be installed using any of the supporting arrangements
described under Support Arrangements in this manual. As each bed is installed in the
system, level the conveyor from side to side using a bubble level on the roller at each
support. The bubble location should be within the level indicator lines of the level. The
center line of the conveyor should not bow to the right or left more than 1/8 ” in either
direction from a center line drawn between the centers of the conveyor end assemblies.
A simple way to check this is to tie a nylon string around the center of the end roller, pull
it taut, and tie it to the center of the roller at the opposite end. Put a wood spacer under
the string at each end so it does not rest on the rollers. With the taut string centered on
each end and suspended above the rollers, check the center of the rollers at each
support relative to the string and adjust accordingly. (Note that this must be done after
side-to-side leveling of the conveyor at each support.)
When joining bed frames it is important to align the rollers and line-shaft. Care must be
taken to make sure the rollers are level (carrying surfaces) from bed to bed.
All bed frames should be checked for squareness. To check, measure diagonally from
corner to corner. Measure the opposite corners in the same manner. If the bed is
square, the two measurements will be the same within 1/16".
 
 
NOTE
Conveyor frames must always be installed in a straight line from end to end. After a
number of sections have been installed to the chalk line and leveled, check the
alignment of each line-shaft assembly. As the conveyor sections are bolted together,
the coupler sprockets may require adjusting. The edge of the 1" diameter lineshaft must
be 2" from the frame channel as an initial reference point.
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Elevations
All conveyors should be installed in accordance with the elevations shown on the
drawings. In addition, all conveyors must be level across the frame width and length (if
horizontal). Leveling of the frames is best done using a rotating laser level or a builder's
level.
After the first elevation is established at a critical point, the elevation of all other points
shall be relative to this first point. Normal practice is to dimension the layout and
measure elevations from the floor at each point of support.
As the conveyor system proceeds onto another floor or into another building or room, a
new elevation will be measured from the floor at that point. This new elevation will then
become the reference for subsequent elevations.
When installing an overhead system, the first elevation is measured from the floor and
becomes the reference elevation point until a change in elevation is shown on the
layout. Any new elevation is also measured from the floor and becomes the new
reference point. The process is repeated each time an elevation change occurs.
CAUTION
 Consult the building architect or a structural engineer regarding ceiling
loading or structural limitations of the building if any conveyor section is
ceiling hung.
Component Orientation
Using your conveyor system layout drawing and the
numbers on the I.D. tags on each component,
position and orient the conveyor sections. You must
know:
 The direction of product flow
 The elevation height
 Charge and discharge end beds
IMPORTANT! Do not make alterations to the

equipment without consulting with user's
representative and TGW Systems. Unauthorized
modifications to the equipment may impair its
function, create a hazardous condition, affect its useful life and/or void the warranty.
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Establishing Conveyor Flow

Standard IntelliROL beds are supplied as either RH or LH flow. Looking down from
above and facing the IntelliROL bed with the slave O-rings on the opposite side and the
driver card close to you, with the product conveying to the right, the bed is considered a
RH flow bed. Using the same position as noted above and with the product conveying to
the right, the bed is considered a LH flow bed. The identification label described under
Parts Inventory & Identification has all of the information required to identify the piece of
equipment.
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Supporting Arrangements
Floor Supports
All IntelliROL bed side channels are punched to match hole spacing for TGW Systems
standard floor supports. Install bolts used to attach the standhead to the frame so the
nut is on the bottom. Standhead bolts should be left finger tight while the conveyor is
being assembled and aligned.
Floor supports are ordered by nominal height range, which is the dimension from the
floor to top of the support. Conveyor elevations are shown on the layout by top-of-roller
elevations. This difference must be recognized when setting the support elevations.
IntelliROL conveyor is 6 5/16” from top-of-support to top-of-rollers with a 7 1/2” deep
channel. (Rollers mounted low in frame.)
It is important that conveyor frames be installed level. Floor supports will accommodate
normal irregularities in the floor surface. Adjustment for elevation in floor supports is
accomplished with metal-on-metal bolt clamping force. To achieve the support’s stated
load rating, it is necessary to tighten the elevation adjustment bolts (3/8" diameter) to 23
lbs. of torque.
Supports should always be installed in the vertical position, and any variations due to
conveyor pitch or floor slope will be compensated for in the pivoting standhead of the
support.
Anchoring
Anchoring in concrete floors is accomplished by drilling into the floor and inserting the
suitable anchor bolt. The hole diameter and depth must be in accordance with the
anchor bolt manufacturer’s instructions.
Anchor intermediate floor supports with two anchor bolts, one through each support foot
plate using minimum 3/8" diameter anchor bolts. For floor supports over 5’ high or when
supporting drives, use 1/2" diameter anchor bolts. Stagger anchors from front hole on
one side to rear hole on opposite side. Anchor bolts for equipment subject to impact
loads should be a minimum of 1/2" diameter.
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WARNING
 Place a bolt through the frame and support immediately with
finger tight nut. This will prevent the frame from falling off the
support, if bumped, and causing injury.
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Curve Support Points

The curve illustration indicates proper support locations for curves of various degrees
and widths. The dots illustrate the support connecting point to the conveyor. The dark
line between dots indicates a full support
with crossmember or ceiling hanger cross
tube. A single dot on the outside center of
the curve indicates only the outer curve
rail is supported with either a ceiling
hanger drop at that point or a single leg
floor support.
If a full width support with crossmember is

supplied where only a dot is indicated,
use the full support. The illustration below
is minimum supporting arrangement.
Knee Braces
Stability along the conveyor length is
achieved with knee braces. Braces resist
stresses caused by direction of product
flow, drives, stops and starts. Every
support does not require bracing. Braces
are used at the ends of straight runs and approximately every 30' in between. Braces
should be located toward the discharge end (DOWNSTREAM) side putting them in
tension. Starting the conveyor puts opposite stresses on the supports, which is resisted
by installing a brace near the drive toward the receiving end (UPSTREAM).
For best results the angle between the knee brace

and frame should not exceed 45 degrees, or be
less than 30 degrees. On short supports where a
small angle results, the knee brace may need to
be shortened.
Type "C" braces (not shown) use two type

"B" braces overlapped and bolted
together for extended length when
conveyor height is 48" or more.
90480001Rev041012 25
IntelliROL®
Diagonal Sway Brace (floor support)

Floor support sway bracing consists of one 1-1/2"
x 1-1/2" structural angle and mounting hardware.
Application: Due to natural side to side movement

of line-shaft conveyor, a diagonal sway brace has
been designed to reduce side movement in the
standard floor support. Side movement is most
prevalent in long straight lines which are not side
braced by adjoining conveyors, curves, etc. or
where they cannot be braced to columns,
machinery, or other conveyors. This is more
noticeable when the conveyor elevation is greater
than its width. One brace can be mounted to
every third or fourth support diagonally across the
support with the low end on the opposite side of
every other brace (alternate orientation). The
holes in the support uprights need to be field
drilled.
If excessive oscillation persists after bracing has

been added, it may be the result of harmonics.
This can occur when the conveyor operating
speed generates vibrations with a frequency at or
near the conveyor’s natural frequency of its
structure. This rare condition normally occurs between 85 FPM and 120 FPM. It may be
minimized by adding more bracing or by either increasing or decreasing conveyor
speed.
Sometimes it is better not to add a brace at the drive location. Some experimentation
may be required.
90480001Rev041012 26
IntelliROL®
CRUZ®channel to XenoROL Channel Connections
ALIGN INSIDE SURFACES OF SIDE CHANNELS
7-1/2
6-3/8
9-3/8 9
P/N 80700120
3/8 HARDWARE (TYP)

KIT,CHANNEL CONN
P/N 92300009
9to7ChannelConn-89003
ALIGN INSIDE SURFACES OF SIDE CHANNELS
4-7/8 4-1/2 7-1/2

6-3/8
1-1/2
P/N 80700119
3/8 HARDWARE (TYP)
KIT,CHANNEL CONN
P/N 92300004
4to7ChannelConn-89003
90480001Rev041012 27
IntelliROL®
Ceiling Hangers
Drop rods and nuts are optional. The extension nut is welded into the angle hanger
upright during installation.
WARNING
 Consult the building architect or a structural engineer
regarding ceiling loading or structural limitations of the
building for sizing header steel.
Cross pipes, V-brackets and flat strap connectors are provided with ceiling hangers.
Threaded 3/4" rod and attaching nuts are available as an option. Bed connectors are
recommended with all ceiling hanger applications.
If hanger uprights are field fabricated, they should be a minimum of 1-1/2" x 1-1/2" x
3/16" angle.
90480001Rev041012 28
IntelliROL®
WARNING
 Consult your distributor or a structural engineer to
determine what size hangers should be used to support
your maximum anticipated load.
After hanger uprights are installed and the heavy extension nuts welded to angle
hangers, thread the drop rods into the extension nuts. Thread the jam nuts and stop
nuts on the drop rods far enough up the rods to allow installation and adjustment of the
cross pipe.
While still on the floor, loosely attach cross pipe, V-brackets, flat strap connectors and
bed connector to one end of a bed section. Hoist the bed section between the drop rods
guiding the rods through the mounting holes in the cross pipe. Thread the weld nuts on
the drop rods to support the bed. Weld the weld nuts to the drop rods to prevent
loosening. Hoist the next bed section into place and connect it using the flat strap
connectors and V-brackets. Level the bed lengthwise and side to side by threading the
90480001Rev041012 29
IntelliROL®
drop rods up or down by using a wrench on the weld nuts. Tighten the jam nuts against
the extension nuts and the stop nuts against the crosspipe. Continue for the length of
the conveyor.
90480001Rev041012 30
IntelliROL®
Sway Bracing (ceiling hanger)

1. Sway bracing should be a minimum of 1-1/2" x 1-1/2" x 3/16" angle.
2. Sway bracing is secured to the hanger upright near the conveyor support and
extended upward at an angle of approximately 30 degrees from the hanger upright. The
sway brace angle should not be over 45 degrees to the upright. When hangers are
installed adjacent to building columns, a horizontal brace may be installed securely to
the column.
3. Hanger uprights over 12’-0" in length must have horizontal bridging angles connected
between the upright and the sway brace at approximately the half-way point.
4. Sway bracing should be installed on every third hanger (maximum of 30’-0" centers).
5. If sway bracing cannot be placed on the outside of the uprights, alternate X-bracing
between every other pair of uprights.
6. Additional bracing should be used:

 Before and after curves
 At drives
 At product diverting points
Anchoring ceiling hangers
Open Building Steel

The following references are from the American Institute for Steel Construction manual
(AISC).
Welding of auxiliary steel (stringers or headers) to building steel is prohibited.
Drilling and bolting to building steel is not recommended and will be done only with the
customer's written permission.
Clamping of stringers or headers to building trusses will normally be done only at panel
points. Specific customer permission and load calculations by a qualified engineer are
necessary to safely clamp between panel points.
Headers when used for short spans, such as between roof purlins, will be securely
clamped to building steel. Stringers, when used between headers, may be welded or
bolted to the headers directly or with suitable angle clips.
Concrete Ceilings
Accomplish anchoring by drilling into the concrete ceiling and inserting suitable anchor
bolts. The hole diameter and depth must be in accordance with the lag bolt
manufacturer's instructions. Anchor each hanger with four bolts (two per upright)
minimum size 1/2" diameter. Consult your distributor or structural engineer to determine
your needs.
90480001Rev041012 31
IntelliROL®
WARNING
 Do not use explosive type anchors
For heavier concentrated loads like drives or points where movement or vibration can
occur, use 5/8" diameter through bolts with backup plates. If this is not permissible or
possible, then header steel must be installed using several anchor bolts to spread the
load.
Wood Joists/Beams
Hangers may be attached directly to the joists providing the load rating of the building
will permit. Attach hangers to the vertical side of the joist in two places, one above the
other, on each hanger upright. Anchoring is accomplished by drilling through the joist in
the upper position and using a 1/2" diameter through bolt with a backup plate or heavy
washer. A 1/2" diameter lag screw may be used in the lower position.
When a header is required to support the load, it must bridge across two or more joists.
This header will be attached to each joist in the manner specified in paragraph above.
Hanger uprights should then be bolted or welded securely to the headers.
90480001Rev041012 32
IntelliROL®
NOTE
Consult a structural engineer to determine which method should be used for your load
requirements.
Concrete/Masonry Walls
Equipment may be supported from concrete walls through use of suitable bolts and
anchors or by bolting through the wall if the condition of the wall or load dictates it. A
1/2" diameter through bolt should be used with a backing plate.
Ceiling-hung conveyor header steel should be installed well ahead of the conveyor
frame installation to minimize congestion.
90480001Rev041012 33
IntelliROL®
Adjustable Channel Guard Rail to CRUZ®channel Options
CAUTION
 Before adding X-braces between uprights, check for adequate product
clearance.
90480001Rev041012 34
IntelliROL®
Air Supply Requirements
General
Every conveyor system is unique, with its own specific requirements. Therefore, the
following is a general guide.
Main Feeder
Air velocity through the main feeder piping can be kept smooth with lower losses using
large diameter pipe with minimum bends and restrictions. Standard weight black pipe or
copper is suitable for plumbing the compressed air overhead to all points of use.
Air Drops
TGW Systems recommends using 3/4" pipe on air drops for high flow and low pressure
loss. The drop is terminated with a drain at the bottom. A tee located prior to the drain
branches off to the conveyor. This branch line must contain a lockout/shutoff. A shutoff
must also be located in the drop before the branch tee. OSHA Rule 29, CFR1910.147
requires energy sources (air drops) be turned off and capable of being locked or labeled
with a warning tag.
IMPORTANT! If your air compressor uses a synthetic oil, a coalescing filter plus a
regular filter of 5 micron is required. Synthetic oils will shrink the seals in pneumatic
devices and valving.
Low Pressure Switch

An air pressure switch is recommended to be installed into the pneumatic circuit to
detect a drop in air pressure below required levels. If pressure drops below
approximately 35 PSI, the conveyor system will shut off.
Pneumatic Requirements
 Regulator pressure set at 40-45 PSI.
 Maximum conveyor length each way from regulator is 100'. Locate regulator in
center of conveyor for maximum length.
 TGW Systems supplied low pressure regulator is required.
 Low pressure switch to be set at 35 PSI.
90480001Rev041012 35
IntelliROL®
 In high humidity or low temperature, use air dryer.

 Use 5 micron filter.
 Lockout/shutoff valve to be provided by air system installer.
90480001Rev041012 36
IntelliROL®
Electrical
General
The ITR product line is based on the following features and concepts:
 Itoh Denki motorized rollers and drivercards (CB-016 or HB-510) are standard.
 Cables are pre-engineered with the appropriate connectors.
 All channels are designed to accommodate any of the electrical variations.
 All CRUZchannels including C6 channels have welded connectors and CRUZbelt
tube crossmembers.
 AutoCAD blocks for the ITR product lines are available upon request.
ITR Variations
ITRHB – HB-510
 Standard product offered in Core Technologies.
 ZPA conveyor based on the Itoh HB-510 drivercard and FE-60 motorized roller.
 Can be a standalone conveyor. It does not require an input from a control panel,
etc. to operate.
 CRUZ channel with weld bed connectors and integrated photoeyes.
 24” and 30” zones with 3” centers are standard.
 A start signal can be used to activate the conveyor when using run on demand.
ITRCB – CB-016
 Standard product offered in Core Technologies.
 Transportation conveyor based on the Itoh CB-016 drivercard and FE-60
motorized roller.
 Each drivercard is wired to power, but requires a 24VDC run signal (provided by
others) to run each card.
 C6 channel with welded bed connectors.
 30” roller groups with 3” centers are standard.
Straight Bed Construction

 Straight bed, curve, & spur channels – CZ or C6.
 C6 channel standard has 1.625” flanges.
 C6 channel top flange are punched at ends for transition bezel (1120166) from
C6 to CRUZchannel.
 All channels come with a welded bed connector.
 Straight bed crossmembers are tube style as used in the CRUZbelt product line.
 Straight beds will be punched for HB-510 and CB-016 cards in every zone.
90480001Rev041012 37
IntelliROL®
 Straight beds with 30” zones will have holes for mounting the motorized roller
and mounting bracket in the middle of the zone and at the discharge end of the
zone for roller and belted versions respectively.
Curve Construction
 Inside radius standard will be 36”.
 Curve channels will be similar to NBC, notched with 10ga strips welded in.
 No tangents, arc only.
 All channels come with a welded bed connector.
 CB-016 and/or HB-510 cards located on the outer channel with an adapter plate
(CB-016 Plate: E0006531, HB-510 Plate: E0006532).
 Sensor location is 6” from the end of the zone.
UBT Construction
 3’-4” OAL is a standard.
 C6 channels are 10ga construction with welded bed connectors.
 Transfer belt centers are based on 4” as a standard.
 ERS or Pick Zone Module transfer belt centers are based on 3.25”.
 ERS or Pick Zone Module transfers require 1.75 diameter carrier rollers.
 For UBT’s with sensors, PE’s (ZL2) & reflectors are mounted in brackets at
corners of the transfer. As a standard, there will always be four PE’s and
reflectors. See Figure 8.1 for a view of the basic 4-sensor (bi-directional) UBT.
 UBT's are universal LH/RH. The power harness is installed for LH flow, but can
be reversed by cutting two wire ties and flipping cable end for end at installation.
90480001Rev041012 38
IntelliROL®
Figure 1 – UBT Sensor Location
90480001Rev041012 39
IntelliROL®
Power Merge Construction

 ITRCB is the only version of a standard power merge (Transportation only).
 The C6 channel with weld bed connectors are a standard.
 Standard spur angles are 30 & 45 degree RH/LH beds.
 Spur BF is 6” wider than abutting bed.
Wheel Divert Construction

 ITRCB is the only version of a standard wheel diverter (transportation only)
 Standard spur angle is a 30 degree RH/LH beds.
 Spur BF is 6” wider than abutting bed.
 Diverter has 4 independently acting rows. Each divert wheel row is controlled by
a separate solenoid. Having separate solenoids allows for independent control to
raise or lower each wheel row independently and increasing the throughput rate.
 Solenoids are included as a standard. 120 VAC or 24 VDC voltages are
available.
Spur Construction
 ITRCB is the only version of a standard spur. (transportation only).
 Standards created for 30 & 45 degree RH/LH spurs.
 Each spur has a conversion cable to allow for proper power and control signal
flow.
90480001Rev041012 40
IntelliROL®
ITRHB Electrical Components
Figure 2 – HB-510 Drivercard
A HB-510 item (includes hardware and 5-pin connector): 1137754

B Photoeye (ZL2 eye with 3-pin connector mounted to bracket with reflector in
bag): 1137686
C Power tap cable (for short distances < 6”): 1139543
D Scotchlok connectors (connect power tap to power harness): 3M567
E Power harness: See table below
F Cat5E Communication Cable
Table 1: Power Harness

Item No. Description
1102286 HARNESS,POWER,10AWG.10.5'
1102287 HARNESS,POWER,10AWG,8'
1102288 HARNESS,POWER,10AWG,5.5'
1102289 HARNESS,POWER,10AWG,3'
90480001Rev041012 41
IntelliROL®
Item No. Description

E0034025 CABLE,CAT5E 3” GRAY
E0034026 CABLE,CAT5E 5' GRAY
Figure 3 – HB 510 Communication Cable LH Flow
Figure 4 – HB-510 Communication Cable RH Flow
 Cat5E cable (Upstream cable goes in right side of card, and downstream cable
comes out the left side of the card, RH generally requires a longer cable). See
diagram below :
90480001Rev041012 42
IntelliROL®
ITRCB Electrical Components
Figure 5 – CB-016 Drivercard
A CB-016 item (with hardware): 1139716

B 5-Pin connector (for run signal connection): 733105
C Power tap cable (for short distances < 6”): 1139543
D Scotchlok connectors (connect power tap to power harness): 3M567
E Power harness – see power harness table
ITR Electrical Components

 Motor extension cables
Item No. Description Description 2 Description 3

CABLE,MOTOR ITOH M-F-EXT- USE W/ CB-016
1138704
EXTENSION,600MM 9PIN-600 OR HB-510
1138705
1138706
90480001Rev041012 43
IntelliROL®
Typical Bed Description

Descriptions
Straight Bed:
BED, (i.)BF ITR (ii.)-C (iii.) - (iv.) - (v.) X (vi.)
(vii.),(viii),(ix.)MR,(x.)
__BF Width (16,22,28,34)
ITR__ ITR Variation (HB, CB, 2, T, K, DN, ER)
C_ Channel (Z or 6)
__ Rollers/Belt (R or B) and centers (3,2,etc)
__ Zone (24, 30, etc.) Do not use with ITRCB
__’_” OAL
__ Hand (RH/LH)
F_-__ Roller type & speed code (E-60 standard)
_MR Number of motorized rollers
Example: BED, 22BF ITRHB-CZ-R3-30 X 10’0”

RH, FE-60,4MR
(Cruz channel with 3”RC, 30” zone, 10’0” OAL, HB-510 card)
Curve:
CURVE, (i.)BF ITR (ii.)-C (iii.)- (iv.) (v.)
(vi.), (vii), (viii.)MR
__BF Width (16,22,28,34)
ITR__ ITR Variation (HB, CB, 2, T, K, DN, ER)
C_ Channel (Z or 6)
__ Angle (90, 60, 45, 30)
_Z Number of zones, Do not use with ITRCB
__ Hand (RH/LH)
Example: CURVE, 22BF ITRHB-CZ-60 1Z

RH, FE-60,2MR
(Cruz channel, 60˚ curve, 1 zone with 2 motorized rollers, HB-510 card)
UBT/Transfer: UBT, (i.)BF ITR (ii.)-C6X (iii.) BD (v.)
LH/RH, (vi.),(vii.)
__BF Width (16,22,28,34)
ITR__ ITR Variation (CB, 2, T, K, DN, ER)
90480001Rev041012 44
IntelliROL®
_’_” OAL (standard 3’4”, but 3’0” available as a special)

_S Number of strands (normally 6 (4”RC) or 5/7 (3.25”RC))
Example: UBT, 22BF ITRCB-C6X3’4” BD 6S

LH/RH, FE-60,3MR
Other Examples:
PM, 22BF ITRCB-C6-R3-30X7'6", RH, FE-60,5MR
WD, 22BF ITRCB-C6-R3-30X7'6", RH, FE-60,6MR, 4-ROW,
SPUR, 22BF ITRCB-C6-R3-45, RH, FE-60,2MR
Figures
Drive and Slave O-rings
Item # Description Centers Application

Straight Slave
E0005536 ORING,3/16 DIA X 9.5” HT BLUE 3 PM Slave
Spur Slave
Straight Slave
D0601626 ORINGS,3/16 DIA X 7-3/4” HT BLUE 2 PM Slave
Spur Slave
Straight Slave
1127703 ORING,3/16DIA X 11” HT BLUE 4 PM Slave
Spur Slave
1103665 ORING,3/16DIA X 13” HT BLUE N/A Spur (Twisted)
1102845 ORING,.210 DIA. X 11.5 HT RED N/A Curve Delta
1102748 ORING,.210 DIA X 9.4 HT RED 3 Curve Slave
1133173 ORING,88A .218 X 20-1/2, BLK N/A UBT (Twisted)
90480001Rev041012 45
IntelliROL®
Electrical
General
WARNING
 All electrical controls must be installed, wired and
connected by a licensed electrician only.
 All motor controls and wiring must conform to the
National Electrical Code as published by the National
Fire Protection Association and approved by the
American National Standards Institute, Inc. Since
specific electrical codes vary from one area to another,
be sure to check with proper authorities before starting.
The electrical voltage of motorized rollers will be stamped on a metal name plate affixed
to one end of the roller. This voltage should be checked to see that it matches the
output voltage of your power supply. Consult the appropriate TGW Systems wiring
diagram for the proper connections. If a single speed three phase motorized roller runs
the wrong direction, two leads must be switched to reverse rotation.
WARNING
 Do not connect the driver card to any other voltage than
the one listed on its name plate.
NOTE
All controls equipment is covered by the original manufacturer's equipment warranty.
WARNING
 All safety devices, including wiring of electrical safety
devices, shall be arranged to operate in a “fail safe”
manner. That is, if power failure or failure of the device
itself would occur, a hazardous condition must not
result.
90480001Rev041012 46
IntelliROL®
Conveyor Controls - Safety Guidelines

The following are basic conveyor controls safety guidelines for common controls
equipment.
START-UP WARNING HORN - If all conveyor being started cannot be seen from the
start pushbutton location, then an audible warning device is required. It could be a
horn, buzzer or bell. It must be loud enough to be heard at any point on the conveyor
being started. It should sound for a duration of five seconds after the start pushbutton is
pushed, prior to the conveyor starting. Any auxiliary equipment such as vertical lifts,
turntables, etc. must be included in the warning circuitry.
START PUSHBUTTON - Start pushbutton should be the flush type or guarded such that
inadvertently leaning against them will not actuate them. They should be provided with
a legend plate clearly defining which conveyors will be started.
STOP PUSHBUTTON - Stop pushbutton should be the extended type such that any
contact with it is sufficient to stop the conveyor. They should have a legend plate
defining which conveyors will be stopped.
EMERGENCY STOPS - All locations where high voltage motors are used and an
operator is working must be protected by an emergency stop.
Emergency stop devices should also protect high pedestrian areas where high voltage
motors are used. Actuating an emergency stop must dropout the start circuit and all
electrical power, requiring restarting the system using the start pushbutton provided.
All locations where low voltage motors are used (under 50 volts) and an operator is
working need to be evaluated on a case-by-case basis as to whether they require an
emergency stop circuit. This requirement also applies to high pedestrian areas.
90480001Rev041012 47
IntelliROL®
Preventive Maintenance
General
Preventive maintenance will save expensive downtime, wasted energy costs and
increase life of components. An accurate record keeping system will track component
servicing history.
Periodic maintenance intervals may vary with load, speed, hours of operation, ambient
temperature, humidity, etc. Intervals can be established by fairly frequent maintenance
at first, and then lengthens the intervals as justified by observation of need based on
history. The following schedule is based on 5 days per week, 8 hours per day operation
under normal conditions.
Daily
• Listen to everything for unusual noises or vibration.
• Visually inspect to see that conveyor sections are clear and free of debris.
• Check to see that all safety guards are in place.
• Check for loose bolts or parts.
• Listen for air leaks.
Weekly
• Check for proper PSI on air regulators.
• Check air filter bowls for accumulated water.
WARNING
 Prohibit walking or riding on conveyor by anyone.
 Care should be taken when servicing any conveyor to
prevent accidental injury.
 All moving parts are potentially dangerous.
Air Systems
The best preventive maintenance for any air operated device is clean air. Dirty air will
make pneumatic devices sticky, and they will not operate properly. To ensure the
continued performance of filters, monitor filter / regulator bowl drain every week. To
manually drain the bowl, push the push button at the bottom of the bowl. Let all
accumulated liquid drain until you hear air escaping.
90480001Rev041012 48
IntelliROL®
WARNING
 Do not perform maintenance on the conveyor until the
start-up controls, including motor safety switches, are
locked out and cannot be turned by any person other
than the one performing the maintenance.
 If more than one member of a crew is working on the
conveyor, EACH CREW MEMBER MUST HAVE A
LOCK ON THE POWER LOCK OUT. The air pressure
must be turned off to the work area. All pneumatic
devices must be de-energized to prevent accidental
cycling of the device.
 Check the loosened parts have been retightened and all
guards reinstalled.
 Make sure personnel are clear of all conveyor
equipment before restarting the system.
90480001Rev041012 49
IntelliROL®
Parts Identification
This section is used to identify parts that may require replacement during the life of the
conveyor.
Parts which specifically pertain to IntelliROL are included with illustrations.
A "Recommended Spare Parts List" is published for all conveyor orders of $20,000 or
more. This spare parts list is sent to the purchaser approximately (2) weeks after the
order is received. It includes part numbers, description, pricing and recommended
quantities to be kept on hand for maintenance.
If you are unable to locate this document another may be obtained by contacting the
TGW Systems Lifetime Services Department at 231-798-4547 or Fax 231-798-4549.
90480001Rev041012 50
IntelliROL®
CB-016 Drivercard
90480001Rev041012 51
IntelliROL®
Transportation Straight Bed
90480001Rev041012 52
IntelliROL®
TRANSPORATION STRAIGHT BED

Width & Item #
Balloon Description 16 BF 22 BF 28 BF 34 BF
4 DRIVERCARD,ITOH CB-016S7 1116036
HARNESS, POWER BROWN & BLUE14 AWG 3'-0" L 5'-6" L 8'-0" L 10'-6" L
--- WITH MALE/FEMALE CONN (NOT BF
SPECIFIC) 1102289 1102288 1102287 1102286
CABLE,MOTOR EXTENSION REFERENCE MOTOR EXTENSION CABLE
---
,600, 1200, OR 2700 MM LONG TABLE
CONNECTOR,IDC SCOTCHLOK 567
12 3M567
10-12AWG RUN,14-18AWG TAP
19 ORING,3/16DIA X 9.5" HT BLUE E0005536
ROLLER,ITR BF 2G ITOH
22 1138722 1138723 1138729 1138725
21 ROLLER, ITR 1.9PLTD PRBG E0002412 E0002413 E0002414 E0006220
90480001Rev041012 53
IntelliROL®
Transportation Curve
RH FLOW
LH FLOW MIRROR IMAGE
LH CURVE
FLOW PWR CABLE
LH FLOW
RH FLOW
ITR 90 CURVE TRANS
90480001Rev041012 54
IntelliROL®
RH CURVE
LH CURVE MIRROR IMAGE
LH CURVE
FLOW PWR CABLE
LH CURVE
RH CURVE
LH CURVE
RH CURVE
ITR 60 TRANS CURVE
90480001Rev041012 55
IntelliROL®
LH CURVE
FLOW PWR CABLE
LH FLOW
RH FLOW
90480001Rev041012 56
IntelliROL®
TRANSPORTATION CURVE
Width & Item #
SPECIFIC) 1102289 1102288 1102287 1102286
---
,600, 1200, OR 2700 MM LONG TABLE
CABLE,CAT5E __FT GRAY REFERENCE COMMUNICATION CABLE
---
TABLE
12 3M567
19 ORING,.210 DIA X 9.4 HT RED 1102748
ORING,.210 DIA. X 11.5 HT RED
18 1102845
MARKED WITH 1 BLACK STRIPE
22 1138722 1138723 1138724 1138725
ROLLER, W TT ITR 2GRV PRBG

21 E0009900 E0009901 E0009902 E0009903
90480001Rev041012 57
IntelliROL®
Spur 30
SEE POWER
HARNESS CHART
90480001Rev041012 58
IntelliROL®
SEE POWER
HARNESS CHART
90480001Rev041012 59
IntelliROL®
LH FLOW SHOWN
RH FLOW MIRROR IMAGE
SEE POWER
HARNESS CHART
90480001Rev041012 60
IntelliROL®
LH FLOW SHOWN
RH FLOW MIRROR IMAGE
SEE POWER
HARNESS CHART
90480001Rev041012 61
IntelliROL®
90480001Rev041012 62
IntelliROL®
SPUR-30
Width & Item #
SPECIFIC) 1102289 1102288 1102287 1102286
12 3M567
10-12AWG RUN,14-18AWG TAP,3M
18 ORING,3/16DIA X 13" HT BLUE 1103665
---
,600, 1200, OR 2700 MM LONG TABLE
22 ROLLER,ITR BF 2G ITOH 1138722 1139545
23 ROLLER, 16 BF ITR SPUR 2G ITOH 1126586 1126586 1126586 1126586
ROLLER,ITR 3-3/8"BF PRBG
24 1143248 1143248 1143248 1143248
NO AXLE
25 1130834 1130834 1130834 1130834
NO AXLE
ROLLER,6-27/32BF ITR 1.9PLTD
20-01 1131620 1131620 1131620 1131620
PRBG
20-02 1131621 1131621 1131621 1131621
PRBG
20-03 1143250 1143250 1143250 1143250
PRBG
20-04 1131622 1131622 1131622 1131622
PRBG
20-05 1131623 1131623 1131623 1131623
PRBG
20-06 NA 1131624 1131624 1131624
PRBG
20-07 NA 1143251 1143251 1143251
PRBG
20-08 NA 1131625 1131625 1131625
PRBG
20-09 NA NA 1143252 1143252
PRBG
20-10 NA NA 1131627 1131627
PRBG
20-11 NA NA 1131628 1131628
PRBG
20-12 NA NA 1131629 1131629
PRBG
20-13 NA NA NA 1143252
PRBG
20-14 NA NA NA 1131627
PRBG
20-15 NA NA NA 1131628
PRBG
20-16 NA NA NA 1131629
PRBG
90480001Rev041012 63
IntelliROL®
Spur 45
LH SPUR SHOWN
RH SPUR MIRROR IMAGE
SEE POWER
HARNESS CHART
90480001Rev041012 64
IntelliROL®
LH SPUR SHOWN
SEE POWER
HARNESS CHART
90480001Rev041012 65
IntelliROL®
LH SPUR SHOWN
SEE POWER
HARNESS CHART
90480001Rev041012 66
IntelliROL®
LH SPUR SHOWN
RH SPUR OPPOSITE
90480001Rev041012 67
IntelliROL®
90480001Rev041012 68
IntelliROL®
SPUR-45
Width & Item #
---
WITH MALE/FEMALE CONN (NOT BF SPECIFIC) 1102289 1102288 1102287 1102286
12 3M567
18 ORING,3/16DIA X 13" HT BLUE 1103665
ORING,3/16DIA X 9.5" HT BLUE E0005536
---
,600, 1200, OR 2700 MM LONG TABLE
22 1138723 1138723 1138723 1138723
PM486FE-60-544-D-24-FB-P2-KF
ROLLER,ITR SPUR 2G ITOH
23 1126586 1126586 1126586 1126586
PM486FE-60-393-D-24-P2-OS-KF
20-01 E0003268 E0003268 E0003268 E0003268
NO AXLE
20-02 1144370 1144370 1144370 1144370
PRBG
20-03 1144371 1144371 1144371 1144371
PRBG
20-04 1144372 1144372 1144372 1144372
PRBG
20-05 NA 1144373 1144373 1144373
PRBG
20-06 NA 1144374 1144374 1144374
PRBG
20-07 NA NA 1144375 1144375
PRBG
20-08 NA NA 1144376 1144376
PRBG
20-09 NA NA NA 1144377
PRBG
20-010 NA NA NA 1144378
PRBG
90480001Rev041012 69
IntelliROL®
Power Merge w/30 Degree Spur
90480001Rev041012 70
IntelliROL®
POWER MERGE W/30 DED SPUR

Width & Item #
SPECIFIC) 1102289 1102288 1102287 1102286
CONN,ITOH CB-016 WAGO & HDWE
1104417
2-PIN + 5-PIN PAIR
12 3M567
3M562
ORING,3/16DIA X 13" HT BLUE 1103665
ORING,3/16DIA X 9.5" HT BLUE E0005536
---
,600, 1200, OR 2700 MM LONG TABLE
ROLLER, ITR_BF 2G ITOH 1138722 1138723 1138724 1138725
1139545
PM486FE-60-322-D-24-FB-P2-KF
23 ROLLER, 16BF ITR SPUR 2G ITOH 1126586 1126586 1126586 1126586
24 1143248 1143248 1143248 1143248
NO AXLE
25 1130834 1130834 1130834 1130834
NO AXLE
20-01 1131620 1131620 1131620 1131620
PRBG
20-02 1131621 1131621 1131621 1131621
PRBG
20-03 1143250 1143250 1143250 1143250
PRBG
20-04 1131622 1131622 1131622 1131622
PRBG
20-05 1131623 1131623 1131623 1131623
PRBG
20-06 NA 1131624 1131624 1131624
PRBG
20-07 NA 1143251 1143251 1143251
PRBG
20-08 NA 1131625 1131625 1131625
PRBG
20-09 NA NA 1143252 1143252
PRBG
20-10 NA NA 1131627 1131627
PRBG
20-11 NA NA NA 1131628
PRBG
20-12 NA NA NA 1131629
PRBG
90480001Rev041012 71
IntelliROL®
UBT
90480001Rev041012 72
IntelliROL®
90480001Rev041012 73
IntelliROL®
UBT
Width & Item #
SPECIFIC) 1102289 1102288 1102287 1102286
---
,600, 1200, OR 2700 MM LONG TABLE
7 3M567
24 1120174
8 ORING,.210 DIA X 9.5" HT RED E0002442
ORING,88A .218 X 20-1/2,BLK
11 1133173
HD
ORING,3/16DIA X 8.688 HT BLUE
18 1137420
,FOR ITR 2.625CTRS,20% STRETCH
ORING,3/16DIA X 7-3/4" HT BLUE
17 1142656
ITR 2"CTR
VALVE,SMC 4WAY 24VDC W/FITT &
12 1139102
2M CABLE,ITR UBT/ERS
VALVE,SMC 4WAY 24VDC DIN CONN
13 1139436
SMC, 24V
14 AIRBAG,FIRESTONE 90000025
BELT,83A .188 X .468 X 1132754 1132755 1132756 1132757

35
___", BF ITR2 UBT 35-1/2" 45-3/4" 56" 66"
SPRING,EXT 3/4OD X 2"LG .075W
15 90800263
LOOPS MUST BE INLINE +/- 20
2 PCB, DB, PE, EXTENSION 1138198
PCB, DB, PE, 4A
4 1138197
8 STATION
FUSE,HOLDER IN-LINE,CARTRIDGE
9 1102222
5X15MM AND 5X20MM FUSES,HHT
FUSE,4A,125V,CARTRIDGE,GMA
10 1102221
5 X 20MM, BUSSMANN,GMA-4A
---
,600, 1200, OR 2700 MM LONG TABLE
23 ROLLER,ITR_BF NG ITOH 1138739 1138740 1138741 1138742
25 ROLLER,ITR_BF 2G ITOH 1138722 1138723 1138724 1138725
ROLLER,CARRIER DRIVE
22 1132730
ITR2 UBT 4"C
PE,REFLEX TYPE ZL2 PNP,LIGHT
6 1138113
OPERATE,2M CABLE
9A PE,REFLECTOR 4-3/8" X 1-1/8" 400004
90480001Rev041012 74
IntelliROL®
UBT – Cont.
Width & Item #
9B TAPE,FORM DBL SIDED 1" SQUARE E0005429
26 CONN,FEMALE 5 POLE PIN 733105

90480001Rev041012 75
IntelliROL®
Accumulation Straight Bed (2 & 30 Zone)
90480001Rev041012 76
IntelliROL®
90480001Rev041012 77
IntelliROL®
ACCUMULATION STRAIGHT BED (24 & 30 ZONE)

Width & Item #
4 DRIVERCARD,ITOH HB-510P 1101261
SPECIFIC) 1102289 1102288 1102287 1102286
---
,600, 1200, OR 2700 MM LONG TABLE
6 PE,REFLEX TYPE ZL2-P2400S11
1137687
PNP,DARK OPERATE,700MM CABLE
9A PE,REFLECTOR 4-3/8" X 1-1/8" 400004
TAPE,FOAM DBL SIDED 1"SQUARE
9B E0005429
POLYETHYLENE
12 3M567
22 1138722 1138723 1138729 1138725
90480001Rev041012 78
IntelliROL®
Accumulation Curve
ACCUMULATION CURVE
Width & Item #
4 DRIVERCARD,ITOH HB-510P 1101261
---
WITH MALE/FEMALE CONN (NOT BF SPECIFIC) 1102289 1102288 1102287 1102286
PE,REFLEX TYPE ZL2-P2400S11
6 1137687
PNP,DARK OPERATE,700MM CABLE
9A PE,REFLECTOR 4-3/8" X 1-1/8" 400004
9B E0005429
POLYETHYLENE
12 3M567
CABLE,CAT5E __FT GRAY REFERENCE COMMUNICATION CABLE
---
TABLE
---
,600, 1200, OR 2700 MM LONG TABLE
ORING,.210 DIA. X 11.5 HT RED
18 1102845
MARKED WITH 1 BLACK STRIPE
19 ORING,.210 DIA X 9.4 HT RED 1102748
22 1138722 1138723 1138724 1138725
ROLLER, W TT ITR 2GRV PRBG

21 E0009900 E0009901 E0009902 E0009903
90480001Rev041012 79
IntelliROL®
Induct Bed
SEE POWER
HARNESS CHART
90480001Rev041012 80
IntelliROL®
LH SPUR SHOWN
90480001Rev041012 81
IntelliROL®
INDUCT BED
Width & Item #
SPECIFIC) 1102289 1102288 1102287 1102286
---
,600, 1200, OR 2700 MM LONG TABLE
PE,REFLEX TYPE ZL2-P2465S12
6 1138113
PNP,LIGHT OPERATE,2M CABLE
9A PE,REFLECTOR 4-3/8" X 1-1/8" 400004
9B E0005429
POLYETHYLENE
12 3M567
PCB, DB, PE, 4A
29 1138197
8 STATION
FUSE,HOLDER IN-LINE,CARTRIDGE
38 1102222
5X15MM AND 5X20MM FUSES,HHT
FUSE,4A,125V,CARTRIDGE,GMA
39 1102221
5 X 20MM, BUSSMANN,GMA-4A
22 1138722 1138723 1138724 1138725
ROLLER,ITR BF 2G CTD ITOH
32 1140375 1140376 1140377 1140378

ROLLER, ITR 1.9CTD PRBG
31 1134693 1132204 1131724 1140369
1/16" PVC SLV
90480001Rev041012 82
IntelliROL®
90480001Rev041012 83
IntelliROL®
Mission
To meet or exceed all customer expectations by providing the highest quality products
and services, on time, at exceptional value, in an environment which promotes safety
and personal development.
TGW Systems Inc.

6870 Grand Haven Road
Spring Lake, MI 49456-9652 USA
231.798.4547
Sales Fax 231.798.4146 or Corp Fax 231.798.8322
Email: usinfo@tgw-group.com
Web Site: www.tgw-group.com
Regional sales offices and authorized Business Partners located throughout the United
States and Canada.
Licensees and Business Partners in Europe, South America and Southeast Asia.
90480001Rev041012 84

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INSTALLATION, OPERATION, MAINTENANCE

Table of Figures .............................................................................................................. 3

Pneumatic Requirements ........................................................................................... 35

This manual describes basic installation practices, assembly arrangements, preventive

TGW Systems Equipment Warranty

THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED

Warnings and Safety Instructions

Special attention must be paid to the following areas of this manual:

This fast advancing technology uses a self-contained 24 volt DC motorized roller to

 Soft start/stop / low G-forces

IntelliROL optional run-on-demand software can selectively deactivate conveyor zones

Application Specific Module examples include:

Drive / SLAVE Belt Break-in

Mechanical and electrical commissioning is most often carried out simultaneously.

special attention should be directed toward personnel safety. No unnecessary risks

Receiving & Site Preparation

Prior to starting assembly of the conveyor, carefully

Parts Inventory & Identification

Each subassembly is shipped completely

An identification label is attached to the outside

Dimensional Reference Points

Basics of IntelliROL Installation

IMPORTANT! Do not make alterations to the

Establishing Conveyor Flow

Curve Support Points

If a full width support with crossmember is

For best results the angle between the knee brace

Type "C" braces (not shown) use two type

Diagonal Sway Brace (floor support)

Application: Due to natural side to side movement

If excessive oscillation persists after bracing has

CRUZ®channel to XenoROL Channel Connections

ALIGN INSIDE SURFACES OF SIDE CHANNELS

3/8 HARDWARE (TYP)

ALIGN INSIDE SURFACES OF SIDE CHANNELS

4-7/8 4-1/2 7-1/2

Sway Bracing (ceiling hanger)

6. Additional bracing should be used:

Anchoring ceiling hangers

Open Building Steel

Adjustable Channel Guard Rail to CRUZ®channel Options

Air Supply Requirements

Low Pressure Switch

 In high humidity or low temperature, use air dryer.

Straight Bed Construction

Figure 1 – UBT Sensor Location

Power Merge Construction

Wheel Divert Construction

ITRHB Electrical Components

Figure 2 – HB-510 Drivercard

A HB-510 item (includes hardware and 5-pin connector): 1137754

Table 1: Power Harness

Item No. Description

Figure 3 – HB 510 Communication Cable LH Flow

Figure 4 – HB-510 Communication Cable RH Flow

ITRCB Electrical Components

Figure 5 – CB-016 Drivercard