System Plast Manual
Contents
1. Positioning Spacers Push Knob AA Piston Rod Spring Rod Sleeve Brackets F ES dl i 13500260 Range of travel Range of travel Largest container ne Smallest container Single side adjusting Double side adjusting 58 ENGINEERING MANUAL E M Edition 14 06 2006 Adjustable splicing clamp Required for adjustable curve product guides 190214 13500392 SpeedSet ENGINEERING MANUAL 39 60 Ga Ay 3 pad 4 a JU EM pl A P Ku A u C ENGINEERING MANUAL Roller side guides are recommended for shrink packs and carton packs They avoid scratches and other damage at the packs and at the same time they reduce backline pressure E M Edition 14 06 2006 CALCULATION Required data for chain calculation Chain and material specification Chain type Curve material Material straight upper part Material straight return part Productmaterial Product details and conveyor specification Products hour S EA Lubrication Number of tracks Height difference Power consumption Watt Conveyor layout from idler to drive A A A nian 10 Required operation data Please add a sketch of the conveyor layout Please describe operation conditions e g abrasive conditions environmental conditions special operation requirements in detail Please describe product features in detail2. OOJ SYSTEM JPLAST CONVEYOR COMPONENTS APPLICATIONS Inclined and declined conveyors Maximum angles Chain type ee Plastic chain belt High friction chains steel plastic 12 15 15 20 Dry run with steel chains is generally not recommendable Pollution on the chain as well as on the product surface influences the maximum angles negatively Drive construction Declines a tan critical angle coefficient of friction chain belt against product considering pollution gt 8 Soft start stop is reccomended nn lt 8 Soft start stop is recommended Dynamic tensioner is in both cases recommended Inclines Drive is normally located at the upper end Soft start stop is recommended er wee Integrated ve gt transfer Pr separate gt _ transfer amp e g with dead plate Hold down guide resp TAB chain 40 E ENGINEERING MANUAL E M Edition 14 06 2006 Curve construction in combination with inclines declines Sideflexing chains for Magnetic System can be used in inclined declined conveyors only under the following restrictions gt Incline is possible before a curve gt Decline is possible after a curve Otherwise the chain could be lifted out Example Recommendation install a separate drive for curving sections that are located between inclined declined sections sour and alcaline benzine fuel aqueous solutions oll and High fricti
3. SECTION 3 Y SECTION 1 wo SECTION 2 TABLE p Ke ANGLE FACTOR TURNING WITH TURNING COEFFICIENT OF FRICTION AN CLE DISK Ky 0 1 K 0 15 K L 0 20 K 0 25 K 0 30 K 0 35 K 0 40 15 115 1 03 1 04 1 06 1 07 1 08 1 10 1 12 30 1 15 1 05 1 08 1 10 1 14 1 17 1 20 1 21 45 1 15 1 08 1 13 1 17 1 22 1 28 1 32 1 37 60 1 15 1 11 1 17 1 23 1 30 1 37 1 44 1 51 75 1 15 1 14 1 22 1 30 1 39 1 48 1 58 1 69 90 1 15 1 17 1 27 1 37 1 48 1 60 1 73 1 88 120 1 15 1 23 1 37 1 51 1 69 1 87 2 08 2 28 150 1 15 1 30 1 48 1 69 1 92 2 19 2 50 2 86 180 1 15 1 37 1 60 1 87 2 19 2 56 3 00 350 Note that K angle eed is the same either for vertical or hori zontal curves as you will end of an inclined conveyor ind at the beginning and at the For the example shown in the picture below you must use the ves formula for sideflexing even Fin plan the conveyor has no cur Note that in the return section of an inclined conveyor it is pos sible to verify a negative pull that means that the chain moves due to gravity In this case instead of multiplying by the angle factor you must divide by it If the conveyor is not inclined part 3 of the formula will be equal to zero If the conveyor does not have the accumulation section part 2 of the formula will be equal to zero 64 ENGINEERING MANUAL Chain pull calculation elevators Elevating conveyors consist of two chains with rubber pads paral
4. add drawings sketches EZ Replacement of chain belts mp a Which chain belt was used before Did it work satisfactory or did problems occur SysCalc Please contact your Flexon System Plast partner or our technical support department ENGINEERING MANUAL 61 CX SYSTEM E PLAST CONVEVOR COMPONENTS Required data for belt calculation Belt and material specification Bettye Belt width Material straight upper part S Material straight return pat Product material Product details and conveyor specification Products hour a Product weight Belt speed Lubrication Diameter product mm Height difference Watt Centre drive yes no Section Length Accumulation Occupation _ Temperature Pa A Required operation data Please add a sketch of the conveyor layout Please describe operation conditions e g abrasive conditions environmental conditions special operation requirements in detail Please describe product features in detail add drawings sketches Replacement of chain belts Which chain belt was used before Did it work satisfactory or did problems occur Please contact your Flexon System Plast partner or our technical support department SysCalc 62 ENGINEERING MANUAL Conveyor calculation E M Edition 14 06 2006 If you do not have our calculation programme installed the following calculation guide will help you to
5. part Lubrication is not recommended and in most cases not required anyway Curve constructions should enable easy removement of debris Open design is recommended The chain should be removable out of the curve for cleaning purposes Inside guides can be made of plastic however stainless steel is recommended to avoid imbedding of dirt in the guides that would reduce the wear life of the chain Transfers Slave drive dead plate staggered conveyors ENGINEERING MANUAL 47 oF CONVEYOR COMPONENTS SYSTEM PLAST Gripper chains applications General instruction recommendations gt gt gt gt m Chains tracks must parallel before installing the chains The tolerance for the parallel adjustment of the tracks is lt 2mm Incorrect adjustment can lead to overloading and rapid wear It is very important to regard the orientation of the gripper ribs They must be bent backwards relative to the running direction of the chain The control system of the conveyor must assure that no backline pressure is created Backline pressure damages gripper chains The clearance between the chain tracks must be adjustable The gripping forces must be adjustment according to the product general rule as tight as the product can still be removed manually This is usually 5 to 10 mm less than the product width diameter It must be avoied that grippers touch each other e g by too tight adjustme
6. 2250 FT FTP2 With Positioner FG series 2250 FG FGP2 Closed or open surface PET Cans 2250 M FT Low friction FT series 2250 M FG Excellent stiffness Glass PET K330 1 pitch 2251 FTP2 With Positioner K330 Closed surface 2252 FTP2 Heavy duty design K325 Low friction Excellent stiffness 1 pitch 2120 FTP2 With Positioner K330 Closed surface 2121 FTP2 Low friction K325 Excellent stiffness 1 2 pitch Small transfer radius 42 ENGINEERING MANUAL E M Edition 14 06 2006 Optimised steel chains For maximum product stability e g PET bottles designer bottles and for critical applications e g inliners and pressureless combiners we offer the following chains For sideflexing applications Stainless stell chains for Magnetic System SPC 881 MO SPS 881 MO Design Features gt Optimized plate in terms of e Flat and smooth surface O Defined convex shape of plate Cn 7 R e Maximum closed plate surface ma For straight running applications Standard stainless stell chains Our staight running stainless stell chains offer design features as mentioned above in standard execution TRAVEL ma G gap 1 5 mm minimum For side transfer applications Stainless stell chains as described above in K330 83 8 mm width for 85mm track distance The gap between adjacent tracks is reduced by approx 50 compared to K325 82 5 mm cha
7. cleanliness of conveyor system 78 ENGINEERING MANUAL E M Edition 14 lt 06 2006 Installation procedure Check all sprockets idlers turn discs and rollers for proper elevation and alignment with regard to the conveyor tracks Check all wear strips carrying and return dead plates dividers and transfers mechanism for proper location elevation spacing and flatness Check all fasteners for proper tightness torque Fasteners used on wear strips and dead plates must have recessed heads Check all conveyor splice points for proper elevation alignment and fastening Inspect conveyor system for obstructions by pulling a short section of chain 1 metre trought the entire conveyor Check lubrication system if present Install conveyor chain assuring that the following has been done A Check for correct direction of chain travel B Assemble chain in 3 meters sections and avoied twisting or damaging the chain C Connect chain sections on the conveyor Insure that all pins and top plates are flush and propely secure D Adjust chain catenary sag to the proper elevation Note Readjustment is usually necessary following operation under loading conditions Although not to overload the chain Insure that lubricant is evenly dispersed through conveyor system See lubrication section for more information Start up conveyor by jogging and or using short running periods before loading the system Be alert to unusual
8. conveying e High mechanical wear EXTRA PLUS HB 100 EXTRA PLUS 50 Classic chains 20 E EXTRA PLUS HB MEXTRA PLUS CLASSIC CHAIN e Chemical influence EXTRA PLUS HB 100 EXTRA PLUS 70 Classic chains 20 E EXTRA PLUS HB MEXTRA PLUS CLASSIC CHAIN gt Life expectancy in case conveying e High mechanical wear EXTRA PLUS HB 100 100 EXTRA PLUS 50 80 Classic chains 30 60 40 20 0 E EXTRA PLUS HB MEXTRAPLUS CLASSIC CHAIN e Chemical influence EXTRA PLUS HB 100 100 EXTRA PLUS 70 30 Classic chains 30 60 40 20 0 E EXTRA PLUS HB S EXTRA PLUS CLASSIC CHAIN 46 ENGINEERING MANUAL E M Edition 14 06 2006 Crate conveying Usually single track stainless steel chains 71 2 wide are used for that purpose Two track 3 1 4 stainless steel chains installation is also possible Special plastic chains are available for conveying of heavy crates boxes and kegs especially in dirty environment under rough conditions PE ay iN wv x TRAVEL TRAVEL El mal al CC600 CC1400 For straight sections ferritic stainless steel profiles with a surface finish of max 1 6 um and a hardness of 25 HRC are recommended All edges should be chamfered To ensure proper operation and long wear life the CC chain should not be tensioned in the return
9. means were removed Other components This cleaning procedure is also applicable to other components of a conveyor which are not in direct conact with chains belts gt Basic construction pads pods clamps gt Product guides guide rails side brackets traverses clamps gt Drives supports sensors casing regard special instructions about cleaning electric devices 76 ENGINEERING MANUAL E M Edition 14 06 2006 Critical sections of a conveying line which need special attention regarding cleaness This list considers standard layouts conveying lines In those sections the danger of high wear is significant For this reason cleanness is essential to increase service life of all components and to avoid malfuctions as well as product scrap gt Return boxes all the way to the de cases or washer gt Return boxes all the way to the washer gt One way and return bottles in high speed section filler e labeller gt One way and return bottles in side transfer sections and pressure less combiners gt One way and return bottles in accumulation tables and buffer section in front of machines filler e labeller pasteurizer gt Create conveying in the dry end Generally it must be noticed that dry sections must be inspected very carefully regarding clean conditions In such sections no permanent cleaning by means of lubrication spray devices is taking place As a consequence out of insufficent cleaning wear at t
10. noises or actions If problem should occur refer to the trouble shooting guide ENGINEERING MANUAL 79 cx SYSTEM PLAST m mm ni CONVEYOR COMPONENTS Trouble shooting Chain belt jumps on sprocket or does not release well Improper catenary sag Check dimensions and adjust Replace sprocket Chain belt is elongated e g due to wear or Replace chain belt and sprocket overloading Check other components as well Wrong sprocket type Install correct sprocket Misaligned sprocket Check and adjust Improper sprocket position Check and adjust position Slip stick operation Slip stick Use lubrication Reduce chain belt tension by shortening the conveyor Return roller diameter too small Install larger rollers Chain belt catches the conveyor Remove obstructions Check return part as well Damaged chain hinges Possible ca Overloading Replace chain belt Check sprockets and other components as well Blocking and obstructions Check the complete conveyor Exceeding the minimum backflex radius Check conveyor construction Elongation Overloading Replace chain belt Check sprockets and other components as well Wear from dirt in hinges Improve cleaning Rapid curve wear Possible cause Remedy Use EXTRA curve Embedded abrasives Replacement Chain drifts sideways on sprocket shaft sprocket alignment Adjust or use collars Conveyors is not level Adjust 80 ENGINEERING M
11. oe S eo E bate O ae E I De ii T e of A o en m er 3 E a A oz B ao u S a _ __ E lt oa oceanie IS AA O AO Triethanolamin _ RA A O B a ei B A Oo E x Bs gt E bed O oo lt lt x B mi 2 3 B n n x s a x m E gt O 3 La Ss 5 of MM et m 3 gt S r 4 hops e SS oa ol I So o KS 7 3 A m 2 S R S s Data shown in the table was taken from laboratory tests performed on unstrained WABBREVIATION Good resistance samples and are merely indicative Chemical resistance under normal working HBC concentration L liquid O Fairly good resistance depending on use conditions Insufficient resistance not recommended SA saturated 5 solution Blank spaces No tests performed conditions can depend on various factors such as stress and temperature concentration of the chemical agent and duration of its effects 84 ENGINEERING MANUAL E M Edition 14 06 2006 wee To 1 H H CI ooo o SODIUMHIDROXINE ee eee Potassium HDROXINE nese eee AMMONIA nee eee supe aap e NITRICACID HYDROCHLORICACIO TT agne aog T acne agg tee e C O H H ee O HIDROGEN PEROXIDE 6 12 e ALCOHOL FOOD STABILIZERS tees tee FOOD OIS Te te COSMETIC PRODUCTS tee tee semea EEE Te Shore Seale A Shore ScaleD te e EMULSIFIED WATER 70 NE ES POLYGLICOL ME E MINERAL OIL 7h 23 C 24 h 70 C 0
12. of all components of a conveyor Long conveyors should be avoided in such cases Long conveyors result in high chain load which affects all components of the conveyor and reduces their wear life Conveyor speed Maximum m min Lubrication Type Dry Water amp soap Stainless steel straight 130 Stainless steel Magnet System 130 Plastic chains straight 80 lo 180 Plastic chains sideflexing Magnet System 2 180 Plastic belts straight 180 Under abrasive conditions the maximum speed is reduced ENGINEERING MANUAL 91 GYI SYSTEM JPLAST CONVEYOR COMPONENTS STM Safe Transfer Module Ss T Module Safe Transfer Module Sicherer Transfer Modul Features Merkmale v Safe and smooth Transfer v Sicherer und sanfter Transfer of instable products instabiler Produkte v Compact design one solid v Kompakte Ausf hrung einteilig piece no edges keine Kanten berg nge v Easy installation v Einfache Installation 52 ENGINEERING MANUAL E M Edition 14 06 2006 Application Example Anwendungs Beispiel Construction Konstruktion Oberteil Upper part Universal Unterteil Return part ENGINEERING MANUAL 53 SYSTEM CONVEYOR COMPONENTS PLAST Static electricity AS material has the following properties Surface resistivity 10 Ohm According to IEC60093 test method Volume resistivit
13. ANUAL E M Edition 14 06 2006 Cracked hinge eyes Stress corrosion caused by incompatible Replacement chemicals Check chemicals Chains for Magnetic System come out of curve Possible causes Remedy gt FJ Improper chamfering of the infeed Check and adjust rework Or other obstructions No controlled start up Install frequency inverter drives Curve not mounted level Check and adjust Rusted steel chain ssible cause temed Incompatible combination of chain material and Use only compatible chemicals chemicals Consider higher graded material May occur even with stainless steel Excessive chain belt wear ossib uses Improve cleaning Contact lubricant supplier Obstructions Check all sections Debris in return part Cleaning Install roller with larger diameter Sprockets don t slide on shaft when belt extends due to temperature increase P bl U S nemed Pollution Improve cleaninc Axial fixing incorrect Re adjust axial fixing according to temperature situation Rapid wear on sprockets Abrasive conditions Improve cleaning Use steel sprockets Please help us completing that list by informing us of your experiences ENGINEERING MANUAL 81 lI SYSTEM PLAST CONVEYOR COMPONENTS Replacement criteria Chains must be replaced when gt Pitch is elongated more than 3 gt Thickness of the plate is reduced to less than 50 g
14. C Note 23C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Aceticacd F S 10 MO 6 5 Don Oo x 20 20 6 Acetone 100 O 25 0 ie a W N PU A A A a R MA Be ee i a x A A x loll I eee u K ao i E 4 oe a oe AA te x EO o o 1 R x x I o O ale 7 io ea ee en i a g A _ 10 oo es om 6 B o o Mco e Ammonium chloride S 10 S 10 O S es SA O oe oc LE E e a E mu 1 O gt E 3 A a om et oR SE S _ we Benzene O W O a T Aaa u Sa A oF A SE G AA S ur og eae el DA DEA lhl 2 AS E o Butter 0 O E oe 10 lt S M xo 1 Me A z de MEE T S a E L o S co i gt conic a A a B s x s a w _ a OO oF N fle on 3 TS m T u T m7 O y S O mi AT MA s ae oe wa E m s sm a6 a A TMS S S mm x x 7 le OS a eee sw ke de e ee lt sE Ma it _ o Te J R 4 vic S S lt TF a sE S A mee rnes a E a B 4 S 5 E claw a O A a eepe T mr EL A mo Sa 3 A cio SS S s E a SS A x l n N OO x 7 ae nen wA 7 gt A gt e ee aes ae g io S a E a sm I o a lt z R HO lt el s x A Suc tha E a K x E e _ Ssk E S Se oo z lt oe m A E x SH n DD i E
15. E 40 80 sprockets idler wheels Expansion factors D LF XPG AR Acetal NG New Generation AS antistatic Acetal CR Polypropylene Approximate values 0 12 mm m C 0 18 mm m C 0 13 mm m C 0 15 mm m C Calculation Expected expansion mm width mm 1000 operation temperature C 21 C expansion factor CONVERSION FACTORS SI LENGTH meter 0 3048 foot centimeter 30 48 foot millimeter 304 8 foot meter 0 0254 inch centimeter 2 54 inch millimeter 25 4 inch meter 1609 34 mile kilometer 1 60934 mile meter 0 9144 yard gram g 28 3495 ounce avoirdupoids kilogram kg 0 0283495 ounce avoirdupoids kilogram kg 0 45359 pound avoirdupoids meter minute 0 00508 foot hour meter hour 0 3048 foot hour meter minute 0 3048 foot minute meter second m s 0 00508 foot minute meter minute 18 288 foot second meter second m s 0 3048 foot second newton N 9 80665 kilogram force newton N 9 80665 kilopound newton N 0 27801 ounce force newton N 4 44822 pound force newton meter N m 175 1268 pound inch newton meter N m 14 5939 pound foot 86 ENGINEERING MANUAL E M Edition 14 06 2006 NOTES ENGINEERING MANUAL 87
16. Sprockets and idler wheels must be conductive and grounded In case a system of rollers is used for the return of chain the same is applicable for the return rollers as for sprockets and idler wheels see 16 The resistance of the grounding must not exeed 1MOhm 10X60hm 10000000hm The resistance of the grounding must be checked by the assembly fitters prior to installing the chains During assembly installation of the chains sparks must be avoied Appropriate tools must be used Chain pin must be installed completely and carefully After the chais pin installation the chain links must be checked and in case of any damage be replaced Swarf and any other metallic or sparking objects must be removed from the conveyor prior to start up The total chain length of a grounding section must not exceed 333 chain links 54 ENGINEERING MANUAL E M Edition 14 06 2006 Product stability A product stands stabile even in case of large speed variation if C gt R Critical coefficient C B H Real coefficient R real friction coefficient measured for the application in question Raised edges however have to be avoided With the following formula the maximum admissible speed variation can be calculated Max admis speed variation MSV SQR 2 g SQR H2 B2 H SOR square root g gavitational acceleration H height of centre gravity B base radius G centre of gravity MSV indicates e g the max admissib
17. ck the condition of the chain belt regularly and replace links modules which are damaged Important in this matter is to try to find the cause of the damaged links modules Wear patterns or damage on a chain or belt can often lead to a problem area elsewhere in the conveyor It is very important to replace damaged modules in plastic belts and links in plastic chains as soon as possible since small damage could lead to bigger damage if it is not repaired If any damage is found such as pieces of plastic broken off or a wear pattern at the side of the belt the cause of the problem should be located ENGINEERING MANUAL 73 3 SYSTEM PLAST CONVEYOR COMPONENTS Cleaning instructions General remarks Cleaning of chains and belts is necessary for the following reasons gt Minimization of dirt debris gt Minimization of germ formation gt Minimization of product scarp gt Maximization of production stability continuity Clean operating conditions substantially improve gt Service life of chains and belts gt Service life of components e g wear strips and return part components gt Prevention of crashes caused e g by glass debris and wrapping debris gt Prevention of malfunctions caused e g by sticky residues Careful cleaning includes all components of a conveyor gt All components which are in direct contact with chains belts gt All components which affect indirectly the service life of chains b
18. de the conveyor run ning both carrying and return in several sections consisting of a straight part and a side lexing part proceeding in direction of product flow B Number the sections star ting from the motor gear in increasing order following the direction of product flow C Calculate the pull in point 1 using the formula shown above multiply the result by K jangle lados relative to the irst section see Table Add the pull of the pre AT 9 81 M W Lu K M La K3 K4 M La K M W Ly 1 The used symbols are AT pull increment of the section of chain in newtons Ly horizontal length of the section in metres Ly vertical height of the section in metres vious section to the increment obtained from the application of the formula to the second section and multiply the result by the angle factorrelative to the second section if there is a curve E Repeat step D for all 2 M conveyed product weight kilograms per metre of chain W lt choan weight kilograms per metre K coefficient of friction between chain flights and wear strips other sections untill the sprocket which is SECTION 4 3 L length in metres of the _ accumulating section on the conveyor M accumulated product weight e R per metre Ky coelficient of friction between chain flights and accumulated product the maximum point pull
19. design calculate your conveyor Chain pull calculation straight running conveyors This formula applies to strai ght running inclined straight running and straight running with an accumulation sec tion If the conveyor is not incli ned part 3 of the formula will be equal to zero If the conveyor does not have the accumulation sec tion part 2 of the formula will be equal to zero The used symbols are _ T chain pull al the sprocket in Newtons M conveyed product weight kilograms per metre of chain W choin weight eien per metre Cy horizontal length of the gt conveyor running pee C vertical height of Ihe conveyor running metres K coefficient of friction between chain flights and wear strips L length in metres of the accumulating section on the conveyor M accumulated product weight kilograms per metre Ky coefficient of friction between chain flights and accumulated product ENGINEERING MANUAL 63 2x3 SYSTEM PLAST m m m m mu CONVEYOR COMPONENTS Chain pull calculation sideflexing conveyors In case of sideflexing with or without incline with or without accumulation section the calculation is more com lex Fhe formula shown above allows the calculation of the pull increase relative to a section of the conveyor onl one way carrying or return including one curve The calculation proceeds as follows A Divi
20. duct and chain belt surfaces etc the coefficients are subject to variation Coefficients of friction are subject to permanent tests in our laboratories Coefficient of friction between chain and wearstrip Chain belt Lubrication Wearstrip material material Stainless steel Return Extra not Water amp soap applicable Oil 020 020 1019 LF Acetal D W ol 010 0 10 O10 XPG Acetal ol oo 0 10 oio 010 joi Coefficient of friction between chain and product Chain belt Lubrication Product material material Paper Metal Plastics aluminium New glass cartoon steel incl PET ceramics Stainless 0 35 steel 0 30 0 15 steel Speed Line 0 29 0 24 0 13 LF Acetal 0 20 D W 0 15 0 12 0 15 0 13 NG PBT v On foso foz oso 0 66 ENGINEERING MANUAL XPG Acetal Water amp soap 0 40 0 35 0 30 0 30 0 10 Parameters causing wear Operating conditions gt Load gt Speed gt Number of starts per hour e Starts with without load e Soft start frequency inverter controlled drive gt Product accumulation Conveyor control system PLC gt Lubrication gt Water quality e Concentration of chlorines e Water hardness e Contaminations e Capacity of water supply gt Lubricant e Suitability performance e Dosing Efficiency of nozzles Cleaning gt Cleaning agent e Frequency e Intensity e Rinsing gt Chemical attack Environment gt Temperature gt Humidity gt Wea
21. efore wear gt Extra cleaning required gt Slip stick effect possible gt Built up of electrostatic charges possible gt Higher noise level gt Not applicable for high speed applications Dirt and debris must be removed by cleaning to avoid increase of coefficient of friction and wear on all components of the conveyor ENGINEERING MANUAL 71 xII SYSTEM PLAST CONVEYOR COMPONENTS Cleaning Cleaning is most important in order to achieve gt Hygienic system gt Clean products gt Reduction of friction and wear gt Removal of abrasives Removal of remaining cleaning agents with flush water is recommended Cleaning dry running conveyors With dry running conveyors there is no continuous cleaning like with lubricated conveying All products beer or lemonade spilled on the chain belt will result in pollution of the containers increasing the friction and the risk of products toppling over Therefore dry running conveyors should be cleaned even more frequently than lubricated chains How often depends very much on the circumstances e g when liqueurs are bottled and spilled it might be necessary to clean every time the line stops for a few hours Cleaning stainless steel chains This type of chain will be lubricated in most cases Dirt etc is flushed away continuously Normally it is recommended to clean the chain regularly with hot water max 80 C or cold water with a cleaning agent to stop a
22. elts such as return shafts Upper side of chains belts Opposite side of chains belts e Wear strips rollers in the return part e Wear strips in the upper part Sprockets and idler e Shafts of return rollers and idler Return guide shoes Cleaning schedules depend on gt Production requirements gt Actual cleanness of chains belts gt Any case a conveyor should be cleaned before the first start up in order to remove all dirt debris residues from the assembly The same should be done when a conveyor is restarted after a longer period out of order We recommend permanent inspection of the actual cleanness of conveyors and chains belts If extraordinary cleaning is required this should be done without delay Regarding the choice of cleaning agents the followuing must be considered gt Chemical resistance of the chain belt materials gt Example pH 7 neutral is recommended recommended pH range4 10 Chlorine warm Ammoniac warm should only be used in very low concentrations lt 7 Only short contact time is allowed Strongly caustic agents e g phosphoric acid warm salt acid formic acid sulphuric acid warm saltpetre acid potassium hydroxide sodium hydroxide hydrogen peroxide warm and solvents like Acetone should be avoided with plastic chains belts Using cleaning agents the following should be considered gt In the actual catalogues gt On our internet site www systemplast co
23. er e brush hose pressure cleaner up to 80 bar gt If possible let the conveyor run Rinse it from all sides gt Sprockets idlers gt Upper chain belts guides gt Guides in the return part Repeat these steps until the favoured cleaning result is reached ENGINEERING MANUAL 75 xII SYSTEM PLAST CONVEYOR COMPONENTS Disinfection Is necessary to prevent alternating contamination of chains belts and product gt means disinfection agent and user manual of the supplier e brush pressure cleaner gt If possible let the conveyor run Disinfects it from all sides Make sure that all surface are convered with disinfection solution gt Sprockets idlers gt Upper chain belts guides gt Guides in the return part gt regards the recommended exposure time of the disinfection agent Rinsing gt means cold warm water up to 60 C regard recommendations of the cleaning agent supplier e brush hose pressure cleaner up to 80 bar gt If possible let the conveyor run Rinse it from all sides gt Sprockets idlers gt Upper chain belts guides gt Guides in the return part Drying blowing off Die to the fact that it most cases drying the conveyor completely is not possible it is recommended to remove at least big water residues Inspection gt Check the cleaning result carefully all components and repeat the procedure if necessary gt Before re starting the conveyor make sure that all cleaning
24. es are designed to operate under a continuous temperatu re of maximum 270 C Typical applications for HT profiles are Ovens cookers hot fill area steam chambers furnace discharge retorts fryers shrink tunnels pasturizers and steam boxes For use in high temperatures SPECIFICATIONS HI TEMP MATERIAL MATERIAL PROFILE Tensile Strength ASTM D 1457 N mm 12 6 500 Deformation under load ASTM D 621 3 8 7 47 37 120 C Coefficient of thermal expansion ASTM D 696 mm mm Cx10 12 62 120 150 C 7 47 150 270 C Coefficient of friction ASTM D 1894 0 04 Continuous service temperature 270 C For applications such as high conveyor speeds heavy loads or abrasive conditions Nylatron can be used at continuous temperatures up to 93 C VERSION WITH NYLATRON INSERT Nylatron 56 ENGINEERING MANUAL E M Edition 14 06 2006 57 ENGINEERING MANUAL Heavy duty SIDE GUIDE FOR LABELLING BOTTLE 13500250 Special product guides for labelled bottles avoiding scratches Installation example Adjusts to 3 container sizes SpeedSet brackets offer preset conveyor guide rail adjustability that is fast accurate without the need for tools A simple push on the end knob moves the pin clamp and guide rail Spacing blocks cut the length needed accurately hold the pin and guide rail in position
25. he following components can be observed gt curve guides gt wear strips gt chains belts gt return components Only due to the higher friction in such sections the wear rate is already higher compared to lubricated section If cleaned properly the service life of components can be increased significantly Additionally to regular cleaning cycles it is recommended to blow off particularly the curve guides in short intervals EXTRA curve guides with metal wear recommended anyway ENGINEERING MANUAL 77 OOJ SYSTEM CONVEYOR COMPONENTS PLAST Inspection procedure 00 N BM Ah M M A N O N Ww Inspect chains for unusual wear patterns nicks or damage Look for excessive gaps between chain flights Check conveying surface for flatness bent or broken flights Inspect hold down tabs or beveled sliding surfaces for excessive wear Review chain catenary sag for proper amount If take ups are used check that take up tension is not excessive Do not preload chain Check all idlers rollers turn discs and sprockets for freedom of rotation Examine sprockets for excessive wear Look for debris build up in sprocket tooth pockets Check for excessive guide ring wear Check all wear strips and fasteners for excessive wear Check all transfer points dead plates turn tables turn discs and sprockets for proper elevation and alignment Review function of lubrication system Inspect general
26. ide bow type Instruction for the assembling disassembling of the plate and the rubber GSI for light applications GS2 for heavy applications GS3 for special applications Picture 1 Connecting of two assembled Picture 2 Assembling of the plastic plate chains with a connecting link Step 1 heat to about 70 centigrade heating treatment time 20 sec Picture 3 Assembling of the plastic plate Picture 4 Disassembling of the rubber Step 2 Assembling in the show way Attention push out the pin in direction OUT Picture 5 Assambling of the rubber Picture 6 Cut the chain in the wished leght Attention assemble the pin in direction IN Attention use a compact base Lubrication You have to check the lubricationof the roller chain at regular intervals 50 ENGINEERING MANUAL E M Edition 14 06 2006 PRODUCT HANDLING se lg enti Conveyor length depends on ength m Stainless steel straight Approx 15 7 re Stainless steel sideflexing Approx 12 Plastic chains straight Approx 9 12 gt Product gt Load Plastic chains sideflexing Approx 9 12 gt Etc Only valid for standard conditions For long conveyors it is recommended to place curves close to the idler end in order to reduce chain load resulting in longer wear life A phenomenon called slip stick effect occurs unpredictably It depends on speed load construction and lubrication Pulsating dynamic forces are the result and affect the service life
27. ins to a minimum in order to avoid toppling products ENGINEERING MANUAL 43 2x5 SYSTEM PLAST CONVEYOR COMPONENTS HB pins for extended wear life standard pins Generally both are Chemical suitable Resistant Regular applications e Clean environment proper cleaning e Abrasive environment dirt like crate and lubrication conveyors return bottles e LOW speed and load e High speed and short conveyor like e Regular cleaning with aggressive in filler area chemicals e High speed and load e Low speed high load like in accumulation areas and full crate transport 44 ENGINEERING MANUAL Life time expectancy Mass conveying e High mechanical wear EXTRA PLUS HB EXTRA PLUS Classic chains e Chemical influence EXTRA PLUS HB EXTRA PLUS Classic chains Pressureless inlining e High mechanical wear EXTRA PLUS HB EXTRA PLUS Classic chains e Chemical influence EXTRA PLUS HB EXTRA PLUS Classic chains 100 30 100 80 30 E M Edition 14 06 2006 100 80 60 40 20 0 s MEXTRA PLUS HB S EXTRA PLUS CLASSIC CHAIN MEXTRA PLUS HB S EXTRA PLUS CLASSIC CHAIN M EXTRA PLUS HB S EXTRA PLUS CLASSIC CHAIN E EXTRA PLUS HB S EXTRA PLUS CLASSIC CHAIN ENGINEERING MANUAL 45 5x5 SYSTEM PLAST m m m m mu nn CONVEYOR COMPONENTS Have duty single line
28. le speed of a bottle being conveyed onto a dead plate without tilting Noise reduction Measures gt Use curves instead of dead plate transfer gt Install flow control devices like frequency controlled drives to adjust the conveyor speed according to actual requirements e g accumulation stop gt Cover guiderails with plastics gt Use plastic sprockets and idlers gt Use plastic wearstrips in combination with steel chains gt Use return part rollers with a larger diameter than 60 mm gt Apply lubrication gt Use Magnetic Corner Tracks in EXTRA execution with profiled stainless steel sheet metal insert or Nolu S material ENGINEERING MANUAL 939 XS SYSTEM PLAST al CONVEYOR COMPONENTS Product guides The conical guide rail incorporates two outstanding materials stainless steel and UHMW The stainless steel sheath provides rigid streamlined support for heavy loads at any speed plus a solid connecting point for holding the rail in place with clamps and brackets The UHMW guiding surface is available in a wide selection of shapes The very low friction characteristics of UHMW allow containers to move at high speed with a minimum of drag container damage and noise Materials are approved by the FDA and accepted for use in USDA inspected facilities METAL PROFI LE l Zinc plated steel Metal profile is typically in stainless steel AISI 304 AISI 316 on the request used for its excellent resistance t
29. lel running and assembled symmetrically one in front of the other The product does not lay on a horizontal plane but is held between the pads The formula shown above allows the calculation of the pull increase relative to a section of the conveyor only one way carrying or heoi including one curve The calculation proceeds as follows A Divide the conveyor _ running both carrying and return in several sections consisting of a straight part and a aliasing part proceeding in direction of product flow Power absorption The following formula gives the power absorbe by the chain itself on continuous operation To chose the power of the E M Edition 14 06 2006 AT 9 81 M Ko 2W Lu Ki 1 dla a e Lv 2W Lv The used symbols are AT chain pull increment in one section in newtons M conveyed product weight kilograms per metre o chain W chain weight kilagrams per metre B Number the sections starting from the motor gear in increasing order following the direction of product flow C Calculate the pull in point 1 using the formula shown above multiply the result by Ke angle factor rolera to the first section see Table p or devide by Ke if the pull is negative D Add the pull of the previous section to the increment obtained from the application motor you should consider a starts and stops factor and transmission efficiency General
30. lt A S S MATA se m 4 EE SS gt S gt S E a E S S cA a srs 7 z ao _ O z L ae p mu u 5S S s s S 3 i sE BSR ie S Tun B ENGINEERING MANUAL 83 YS SYSTEM PLAST CONVEYOR COMPONENTS ae POLYAMIDE POLYPROPYLENE ACETAL RESIN POLYETHYLENE BRASS RUBBER STAINLESS STEEL PA PP POM PE NBR CHEMICAL OT NI VITON AISI 304 AGENT E E C E G C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Note 23 C Magnesium chloride S10 ORM cA B Le os SA ORM O _Methyl acetate e 100 weh T IE LA D Methylacohol ie _ I a Mativlenechionde 1009 Mo Eco 79 MO A u o J _ 1 gt o ot Mineral oil o O O o O m K a A oG Mn oo i e K Wo Mn x L E raa ee CT om S S oe B x E S 4 B as oo n O re ell k E a o Coen TU m ereo S ii HI eo w B 9 I 4 H a eee K A AI AA m E ea IN Cu ee e zA SS no WW i 3 sao 9 a ST o a O CUA a _ E UE gt or e E S m o rn ui 3 E O e Mi B a 7 m 3 E o n M aa as O i n ee A u a oa nena eee o a W ae fa S o oei om R o x 7 re gt 8 ta i ATA TA o Be S aede E mE B G sI 5 R a va en N Eee S S O hs alas EN iti mi er a eepe Oo em MU x B fF 3 TJ on m er m 3 cineca D E E SS JA _ Po oe sa om A
31. ly a power of 1 5 times higher is needed KW Tmax N speed m min 60000 horizontal length of the section metres Ly vertical height of the section metres K coefficient of friction between chain flights and wear strips of the formula to the second section and multiply the result by the angle factor relative to the second section if there is a curve or divide if the pull is negative E Repeat step D for all other sections untill the sprocket which is the maximum point pull The pull obtained is to e considered as the total pull on the pair of chains that form the elevating conveyor with continuous operation and 2 times higher with frequent stars and stops Anyway the correct amp coefficient of friction between rubber and product in mos cases a precautionary value of 0 25 can be used Kg mesh load factor of the rubber pad on a particular product With U 0 25 KG 4 12 SECTION 6 y MOTOR ASS x SECTION 1 SECTION 5 J SECTION 4 SECTION 2 O SECTION 3 choice of the motor depends also on its kind rige air hydraulic and the type of transmission friction reducer ENGINEERING MANUAL 65 SYSTEM PLAST CONVEYOR COMPONENTS Coefficients of friction Below listed coefficients can be used as a guideline Dependent on environmental and application requirements temperatures lubricant material combinations dirt debris pro
32. m documenti chemicalpg htm gt In the Engineering Manual In case of doubts question don t hesistate calling us 74 ENGINEERING MANUAL E M Edition 14 06 2006 Cleaning process Selection of the best suitable cleaning process can only be done by the plant operator according to the special requirements and circumstances of his production unit We are only able to give general recommendation based on our experience In any case our recommendation must be checked carefully by the plant operator reading applicability Pre cleaning gt Stop conveyor remove debris e g broken glass wrapping piecies cords wood piecies Also in the return part gt means cold warm water up to 60 C brush hose pressure cleaner up to 80 bar gt If possible let the conveyor run Clean it from all sides driet dirt germ sticky dirt gt Sprockets idlers gt Upper chain belts guides gt Guides in the return part Cleaning gt means cleaning solution and user manual of cleaning agent supplier e brush perssure cleaner to apply the cleaning solution gt If possible let the conveyor run Clean it from all sides Make sure that all surface with cleaning solution gt Sprockets idlers gt Upper chains belts guides gt Guides in the return part gt regards the recommended exposure time of the cleaning agent Rinsing gt means cold warm water up to 60 C regard recommendations of the cleaning agent suppli
33. nd remove any form of bacteria growth There are often positions where product beer or soft drinks is spilled on the chain In these positions the lubrication will not function optimally and a more frequent cleaning could be required e g once every week It could be necessary to use a brush in addition to the hot water or cleaning agent to remove e g broken grass etc 72 ENGINEERING MANUAL E M Edition 14 06 2006 Cleaning plastic chains For lubricated plastic chains almost the same counts as for stainless steel chains But when using cleaning agent attention should be given to its compatibility with the chain material With respect to cleaning it is obvious that the Magnet System offers great advantages because the chain can be taken out of the curve and cleaning takes less time than with conventional curve systems Cleaning plastic belts Basically cleaning of plastic belts is not different from cleaning plastic chains Again the chemical resistance of the materials against the cleaning agents must be checked beforehand Flat Top belts have to be cleaned from the top and underside Flush Grid belts can be cleaned very effectively due to the open area Water can be sprayed through the belt to clean it Inspection A good condition of the line can be maintained when people recognise initial signs of wear failure and react accordingly Generally all components of a conveyor should be checked at once Che
34. nt Touching grippers loose their elasticity what can result in damage as weel as production stand still A tensioning system is strongly recommended Overstressing the chain by too strong tension must be avoided It is of major importance to avoid touching products If products touch each other while being clamped by the gripper chains they cause damage It is e g recommended to set the speed of the feeding conveyor a little slower than the speed of the gripper conveyor This ensures a gap between the products which is necessary Summary of recommendations e Continuous operations no start stop e Run the gripper elevator empty before a line stop e Use frequency controlled drivers with soft start stops e If lubrication is necessary PermaLub devices are preferred grease lubrication is not recommended because the grease binds dirt and creates wear e Continuous inspection is strongly recommended e Avoid e Too tight adjustment of the tracks e Misaligned tracks and or sprockets wheels e Touching products e Collision points with parts of the conveyor construction ENGINEERING MANUAL E M Edition 14 06 2006 Orientation of gripper ribs Elevator Crate turner ENGINEERING MANUAL 49 YI SYSTEM PLAST CONVEYOR COMPONENTS Gripper chain assembly instruction SIDEFLEXING PLASTIC PLATE TOP CHAINS WITH GRIPPERN SNAP ON BASE ROLLER CHAIN 19 05 mm 3 4 inch pich s
35. o corrosion and long lasting attractive appearance Galvanized steel can be ordered as an economical alternative to stainless steel 304 Stainless steel STANDARD VERSION Natural UHMW The manufacturing process allows the use of UHMW without additives or other processing chemicals The result is a material that resists abrasion better is more color stable less prone to yellowing and of uni Polyethylene form consistency Available in two colors black and white un SELF LUBRICATED VERSION Nolu S UHMW Battleship grey color A lubricant system is added to our standard UHMW during processing to give it reduced friction while maintaining all other physical properties The coefficient of friction Nolu S Polyethylene material is ca 35 lower as standard The PV limit for chain is at least 2 times Kae the standard value for UHMW VERSION WITH IMPROVED ELECTROSTATIC CONDUCTIVITY Static Dissipating UHMW Special formulation retains the low friction and Polyethylene wear characteristics of UHMW while effectively reducing problems caused by K static Color black Antistatic Polythylene Specific electrical resistance 10 10 10 10 102 10 10 10 10 102 10 10 Ohm x cm A A PA Metals Pure compressed Conductive Antistatic Plastic Carbon black Compounds Compounds Standard UHMW VERSION FOR HIGH TEMPERATURE High temperature Special developed material to operate under high tempera Y tures The HT profil
36. on inserts of our chains have a abrassion Shore A hardness of 70 4 Applicable temperature range 40 to 80 C Accumulation of products most of the applications Accumulation of products results in increased load on the chain as well as in increased wear on chain belt and product LBP Low Back Pressure chains belts are recommended to avoid these effects With low noise accumulation rollers the friction and other negative resulting effects are reduced to a minimum For the return part construction flat surfaces or guide shoes are recommended Roller or serpentine wearstrips are not possible Frequent and thorough cleaning of LBP chains belts is recommended to make sure that the accumulation rollers run free Otherwise the advantages of this construction get lost Example ENGINEERING MANUAL 41 xl SYSTEM JPLAST CONVEYOR COMPONENTS Pressureless combiner K330 83 8mm width is recommended because the gap between adjacent chains belts is reduced to the minimum Production tolerances as well as temperature elongation must be considered Suitable chains belts K325 82 5 width is necessary for sloped Usually pressureless combiners have a track pitch of 85 mm pressure less combiners Characteristics Suitable for Stainless steel chains Extremely close Glass tolerances in terms of PET Flatness surface finish SPEED LINE no sharp edges Plastic chains LF XPG NG Low friction K330
37. r increasing media abrasives gt Corrosion gt Cleanness e Soil e g from construction work Conveyor components gt Material quality gt Construction gt Dimensional accuracy of Wear strips e Sprockets e Idlers e Return rollers e Shaft alignment Conveyor construction gt Choice of chain belt suitability of selected chain belt for the application gt Catenary design Tensioner gt Sprocket construction e Tooth geometry e Pitch line clearance e Number of teeth polygon effect gt Return part construction e Smooth feed in e Sliding rolling gt Mounting of wear strips e Flatness e Chamfers e Raised portions Extension compensation gaps gt Lubrication system gt Cleaning system Changed modified conditions gt Changed operating conditions gt Modification of conveyor or it s parts components e Maintenance e Overhaul ENGINEERING MANUAL 67 E M Edition 14 06 2006 SYSTEM E PLAST mu m m mu ni CONVEYOR COMPONENTS Forces on the chain Start up Tension LER BERS SSL LES ELE LEE REE Time Working cycle Tension Force on chain link Tension 68 ENGINEERING MANUAL Time E M Edition 14 06 2006 Forces in the curve F2 F1 e Ha F1 IW gt PV a 80 PV pressure x velocity a 60 5 4 PV W P N mm xv m s Q 40 P f F1 F2 A A contact surface 20 PV is a material property and indicates the wea
38. r resistance AE A G 1 00 V 0 172 0 104 0 07 0 085 01 The higher the PV the higher the PV generated heat the higher the wear being a function of the heat Different pressure and different velocities lead to different wear rates The effect is amplified dynamic operating conditions as shown above ENGINEERING MANUAL 69 CX SYSTEM PLAST CONVEYOR COMPONENTS Experimental results of wear tests NG against Acetal The diagrams show the wear rate in 0 00 over the test duration in h Test performed under dry run conditions Tested with 1 5 PET bottles Tested with 1 glass bottles v man XP i NG w lt LF dR 4 7 ES 0 y D H0 530 209 2 id 100 300 16 u 00 bah ARI Test station 70 ENGINEERING MANUAL xP NG LF E M Edition 14 06 2006 MAINTENANCE Lubrication Synthetic lubricants offer gt Concentration independent on water properties e g hardness gt Less foam gt No slippery factory floors gt Less bacteria growth Soap based lubricants offer gt Best possible lubrication because lubricant sticks to the chain Lubrication suppliers advice is strongly recommended Aspects of dry running conveyors gt Savings on investment lubrication system lubricant water treatment etc gt No packaging damage gt Increased coefficient of friction and ther
39. t The surface becomes very unflat uneven or rough dependant on application gt Side of sideflexing chains is worn to such an extent that the pin is exposed gt Chain jumps on the sprocket Chains of inliners pressureless combiners should be changed all at once Belts must be replaced when gt Thickness of the plate is reduced by 1 mm from the top and from the underside gt The surface becomes very unflat uneven or rough dependant on application gt Belt jumps on the sprocket gt Asa guideline 3 elongation is tolerable When replacing chains belts it is recommended to replace wearstrips and sprockets idlers as well Replacement of Dual Magnetic Corner Tracks In case of multitrack curves check all tracks Curve is worn when the edge o the chain plate reaches the inner side of the curve Sprockets and idlers must be replaced when gt Teeth show hooked shape and chain releases not well gt Teeth are damaged gt Chain jumps on sprocket gt Bore of idlers is worn out and idler starts oscillating gt Hub or keaway are damaged gt New chain is installed Wearstrips must be replaced when gt Thickness is reduced to less than 50 gt Dirt or debris is embedded gt Fixing bolts protrude 82 ENGINEERING MANUAL E M Edition 14 lt 06 2006 T Er ACETAL RESIN POLYETHYLENE BRASS RUBBER STAINLESS STEEL CHEMICAL PA PP POM PE OT NI NBR VITON AISI 304 AGENT C C C E
40. we OIL 7 h 23 C 24 h 70 C PI TOLUENE 1h 223 C eee je sn Fr a aa Data shown in the table was taken from laboratory Leganda tests performed on unstained samples and are INSUFFICIENT RESISTANCE merely indicative Chemical resistance under normal working conditions can depend on various factors such as stress and temperature concentration of the chemical agent and duration of iss effects LIMITED GOOD EXELLENT ENGINEERING MANUAL 85 xo SYSTEM PLAST AA AAA P mm ni CONVEYOR COMPONENTE APPLICATION TEMPERATURES Carbon Steel Ferritic Stainless Steel Standard Extra Stainless Steel Extra Extra Plus Stainless Steel Extra Plus Austenitic Stainless Steel Austic Acetal Resin Low Friction Acetal Resin Extra Performance New Generation Anti Static Acetal Resin High Temperature Resistance Splecial Chemical Resistance steel chains roller chains steel chains steel chains steel chains steel chains roller chains plastic chains plastic chains plastic chains plastic chains plastic chains plastic chains plastic chains N B R Rubber NBR 40 110 rubber pad gripper E P D M Rubber EPDM rubber pad gripper Polyamide PA 10 80 sprockets idler wheels Reinforced Polyamide PA FV 20 120 sprockets idler wheels Polypropylene PP 5 100 sprockets idler wheels Reinforced Polypropylene PP FV 10 110 sprockets idler wheels Polyethylene P
41. y 10 Ohm m General instructions recommendations gt gt gt Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y gt Caution Already during transportation of the chains electric charge can be generated what can cause sparks Before carrying the chains into an explosion hazardous area any electric charge must be dissipated from the chain Disharging can be done for example by brushing the chains with a grounded and conductive wire brush The chains must be grounded respectively included in the potentialequalisation of the plant It must be assured on site that the electric charge is dissipeted to the ground preventing any damage Grounding of the chains can be achieved by appropriate wear strips and by appropriate sprockets and idler wheels By means of conductive and grounded wire brushes electric charge can be removed directly from the surface of the chains Wear strips must be conductive and grounded Damage at chains wear caused by wear strips must not exceed the admissible limits Caution Wear at chains must not lead to lay open the metallic pin which might scratch over other metallic surfaces and generate sparks Sliding properties of wear strips must admit save operation of the chains Chain breakages must be avoided Caution Chains breakages can cause impact sparks Construction layout and control system of the conveyors must permit a save operation of the chains The chain speed must not exeed 1 m s
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