Chain Conveyor Manual
GuttridgeLimited Page 1 of 60
Please read this manual before
commencing installation, operation
or maintenance
Installation, Operation and Maintenance Manual
Chain Conveyor
Machine No
Chain Conveyor Manual
GuttridgeLimited Page 2 of 60
GuttridgeLimited
Tel: +44 (0) 1775 765300 Fax: +44 (0) 1775 765301 Web: www.guttridge.co.uk Email: [email protected]
Wardentree Park, Spalding, Lincolnshire, PE11 3UU, ENGLAND
Chain Conveyor Manual
Revision 16 – 16/01/13
Copyright © 2010 Guttridge Limited, All Rights Reserved.
Chain Conveyor Manual
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Health and safety
Risk assessment requirements
Installation
It is the responsibility of the installation engineer in conjunction with the end user,
to carry out a risk assessment. This is to ensure that the installation, and access for
the subsequent operation and maintenance of the equipment, can be carried out in a
safe manner.
Operation and maintenance
It is the responsibility of the end user to carry out a risk assessment, to ensure the
safe operation and maintenance of the equipment.
Operation DO ensure all guards and access panels are fitted and in good condition.
DO ensure all safety devices and operating interfaces are working correctly.
DO ensure all electrical equipment is in good condition and electrical covers are
fitted.
DO NOT run the machine without the inlet and outlet apertures properly
connected to the mating equipment, or suitable guards or covers in place.
Maintenance DO ensure safe working access to the equipment, especially when working at
height.
DO ensure the machine is switched off and electrically isolated before carrying out
any maintenance work.
DO follow in house plant and maintenance procedures.
DO ensure any replacement parts that are fitted are of the correct type.
DO NOT modify any safety features fitted to this machine.
DO NOT modify guards.
declaration
The equipment conforms to all current EU directives and carries the marking.
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Explosive Atmospheres Assessment (ATEX)
The ATEX 137 Workplace Directive 1999/92/EC, (also known as the ‘Use’ Directive) is implemented by the Health and Safety Executive (HSE) as The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) in the UK.
This directive is concerned with the safety of the workplace and places responsibility on
the end user to risk assess their workplace and zone and mark hazardous areas according to their level of risk for gases and dusts. The zones correspond to the Group II
Categories 1-3 in the ATEX equipment directive and enable end users to correctly specify
to the manufacturers the intended use of ATEX products. Manufacturers can then supply
the right category of ATEX equipment (certified under 94/9/EC) to be used within these
zones.
See www.guttridge.co.uk/atex_information for further information.
Where a machine has been specified to be ATEX compliant, it must only be used in the ATEX zone specified at the time of ordering.
Alert symbols used in this manual
Where applicable the ATEX rating of the machine referred to in this manual can be determined from the identification label attached to the machine
Group II Zone
Category Gas Dust
0 20 1
1 21 2
2 22 3
This symbol is to warn of
a potential safety hazard
This symbol is to warn of
a potential electrical safety hazard
This symbol denotes an item or
operation that MUST be complied
with in order to ensure that ATEX
integrity is maintained
For illustration only.
ATEX label on subject machine may differ slightly
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How to use this manual
Purpose of this manual
This manual is provided as a guide to:
The equipment installer
Machine operatives
Maintenance personnel
on the best way to install, operate and maintain the equipment.
Competence
This manual assumes that the people who install, operate and maintain this equipment
have been adequately trained in general engineering installation, machine operation and
maintenance respectively, and are experienced and competent to carry out the work.
Scope of manual
All information in this manual is believed to be correct and is provided in good faith. If
you require further assistance please contact Guttridge Limited.
Layout of manual
Most pages in this manual refer to the machine or to a procedure in general terms.
However, where applicable, machine specific operating procedures, drawings or parts lists
will be included under particular section headings. In some cases a machine specific
appendix will be included with this manual.
Technical information or operating instructions for particular components on the machine
may also be included as an appendix to this manual.
Manual retention
This manual is an important document, and is an integral part of the machine, that should
remain with the equipment throughout its life.
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1. Machine Installation ...................................................................... 8
General ...................................................................................................... 8 1.1.
Joining casing sections together ................................................................ 8 1.2.
Alignment ................................................................................................. 12 1.3.
Lifting ....................................................................................................... 12 1.4.
Chain assembly and installation .............................................................. 12 1.5.
Shrouded (twin chain) conveyors ............................................................. 13 1.6.
Drop forged chain .................................................................................... 14 1.7.
Recycle cup fitment – Single Strand Chain Conveyor.............................. 15 1.8.
Recycle cup fitment – Shrouded Chain Conveyor ................................... 17
Chain tension ........................................................................................... 18 1.9.
Sprocket cleaner ...................................................................................... 19 1.10.
Cleaning flights ........................................................................................ 21 1.11.
Brush gear (optional) ............................................................................... 21 1.12.
Drives ....................................................................................................... 21 1.13.
Shaft mounted speed reducer (SMSR) .................................................... 22 1.14.
Motor/Gearboxes ..................................................................................... 23 1.15.
2. Electrical Installation .................................................................. 24
General .................................................................................................... 24 2.1.
Motors ...................................................................................................... 24 2.2.
Rotation sensor (optional) ........................................................................ 24 2.3.
Pressure switch (optional) ........................................................................ 25 2.4.
3. Drawings and illustrations .......................................................... 26
4. Commissioning run ...................................................................... 28
Starting .................................................................................................... 28 4.1.
Post commissioning checks ..................................................................... 30 4.2.
5. Operation ...................................................................................... 32
Standard operating principles .................................................................. 32 5.1.
Starting .................................................................................................... 32 5.2.
During operation ...................................................................................... 32 5.3.
Stopping ................................................................................................... 32 5.4.
Restarting ................................................................................................ 32 5.5.
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Bearings ................................................................................................... 32 5.6.
6. Maintenance ................................................................................. 33
General .................................................................................................... 34 6.1.
During operation ...................................................................................... 34 6.2.
Maintenance intervals .............................................................................. 35 6.3.
Bearings ................................................................................................... 35 6.4.
Bearing housing – removal and refitting ................................................... 36 6.5.
Lubrication of sealed for life bearings ...................................................... 36 6.6.
Taper lock bush ....................................................................................... 38 6.7.
V Belts ..................................................................................................... 39 6.8.
Drive chain ............................................................................................... 40 6.9.
Drive chain lubrication .............................................................................. 41 6.10.
Packing gland seals ................................................................................. 42 6.11.
Shaft mounted gear motor unit (GMU) removal ....................................... 44 6.12.
7. Trouble shooting .......................................................................... 45
8. Reference ...................................................................................... 46
9. Weights ......................................................................................... 47
10. Parts .............................................................................................. 48
Drive End assembly ................................................................................. 48 10.1.
Tension Section Assembly ....................................................................... 49 10.2.
Intermediate Section Assembly ............................................................... 50 10.3.
List of appendices Appendix 1 – Level/Over Pressure Sensing
Appendix 2 - Under Speed Monitoring
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1. Machine Installation
Please read these instructions completely before attempting to start installation. A layout
sketch marked 'CUSTOMER SITE COPY' is normally supplied with every machine, read it
in conjunction with these instructions. Check all items against delivery note.
General 1.1.
Where a machine has been specified to meet a specific ATEX standard, it should only be installed in the area it was designed for, as detailed on the machine identification label. Refer to page 4 for example.
Should a customer consider moving an ATEX compliant machine to a non-ATEX area, consideration should be given to removing all references to ATEX compliance, as subsequent maintenance levels could compromise the ATEX rating of the machine.
Unsupported spans should not exceed 6 metres.
Drive and tail ends should be bolted to rigid supports.
Heavy drive arrangements may need additional supports.
If additional outlets are fitted to a single span additional support may be required.
When bolting inlets and outlets into place take care to ensure that mating surfaces are flat,
true and straight, otherwise distortion may occur.
Equipment ordered and manufactured to operate at an angle must be fitted as ordered.
Failure to do so may mean the equipment will not function properly.
Before starting the equipment ensure that no personnel are working on the equipment and that no tools or loose items have been left in the casing or any other part of the machine.
The machine installer is responsible for ensuring that the machine is suitably earthed using appropriate flanges attachment points and a proven grounded earthing point.
Care should be taken to ensure that ALL parts of the machine are properly earthed and no potential difference (PD) is introduced by the use of sealants or jointing materials between sections or components.
Should a PD be identified or suspected, this can be eliminated by bonding each section of the machine to an adjoining section or by earthing that part of the machine to a proven grounded earthing point.
Joining casing sections together 1.2.
Before commencing, check section 10, along with any supplied drawings, to ensure sections
are assembled in the correct order. Sections are numbered at each end and these numbers
match the number on the adjoining section.
Remove casing lid to gain access to fittings.
1
6 1 2 2 3 3 4 4 5 5 6
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Casing sections and their components are precisely manufactured. This will ensure that all
sections align correctly when bolted together.
All sections of the machine must be fully supported during all stages of assembly. At no
point during the assembly process, must any section be supported solely by its attachments
to the adjacent section.
Before removing any temporary supports, ensure that all permanent supports are in
place and fully secured. Failure to do so could cause distortion of the casings, leading
to excessive noise and premature wear.
The assembly must be checked for trueness once all sections are joined.
Typical tightening sequence – Flanged joint
1
8
Typical tightening sequence - Fishplate joint
2
8
10
6
4
123
7
5
9
1
3
11
16
14 18
20
13
19 15
17
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Loosely bolt sections together.
For shrouded conveyors, bring flanges together with suitable sealing compound, (see figure
below for the type recommended by Guttridge Limited.) between the mating faces to ensure
a dust proof seal. Lids and other removable panels should be sealed using a suitable sealing
tape (see figure below for details of the type recommended by Guttridge Limited). This is
particularly important where the machine has been installed to comply with ATEX
standards.
For single strand chain conveyors, use the side and base fish plates, ensuring sealant and
sealing strips are applied as detailed in figure below. This is particularly important where
the machine has been installed to comply with ATEX standards.
On single strand chain conveyors of 300mm and above, potential bowing of trough lids is
reduced by the use of stiffening plates at the joints between each lid.
The stiffener plates themselves have a raised rib along their centre, to increase the stiffness
of the plate. The inner plate should be installed with the raised rib uppermost.
Install inner stiffener plate with raised rib
uppermost
Apply a suitable sealant between stiffener plates and lid sections to prevent
product leakage
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Indicates area to be sealed by a bead of sealing compound* along the full length of the joint between each casing.
*For NON-ATEX applications Guttridge recommend SIROFLEX® Polyflex HM. An equivalent may be used, providing the specification is identical.
*For ATEX rated machines Guttridge recommend SIROFLEX® SX High Temperature Silicone. An equivalent may be used, providing the specification is identical.
Indicates recommended position of sealing tape, such as that supplied with the machine* on joining plates and casing covers.
*For NON-ATEX applications Guttridge recommend LSP Ltd® single sided PVC foam sealant 20/25/50 Series. An equivalent may be used, providing the specification is identical.
*For ATEX rated machines Guttridge recommend LSP Ltd® LSP210 Silicone Sponge. An equivalent may be used, providing the specification is identical.
Casing sealing detail – single strand chain conveyor
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Care should be taken to ensure that ALL parts of the machine are properly earthed and no
potential difference (PD) is introduced by the use of sealants or jointing materials between
sections or components.
Should a PD be identified or suspected, this can be eliminated by bonding each section of
the machine to an adjoining section or by earthing that part of the machine to a proven
grounded earthing point.
Do not tighten all joining bolts on one side of the casing at once. Initial tightening
should be carried out sequentially, alternating from one side of the casing to the other,
tightening up the bolt diagonally/directly opposite the previously one each time, until all
bolts are tightened. Page 9.
Ensure the conveyor sections are correctly aligned then tighten all joining bolts to their final
torque.
Recheck alignment.
When refitting the casing lid, ensure the seals are in place and undamaged. This is
particularly important where the machine has been installed to comply with ATEX
standards.
Check the surface finish of the machine to ensure that it has not been damaged during the
assembly process. Where the paint surface has been broken or where bare metal has been
exposed, the finish should restored as soon as possible, especially where a machine is being
installed outside or in harsh conditions. This is particularly important where the
machine has been installed to comply with ATEX standards.
Alignment 1.3.
Once the conveyor has been fixed securely to its supports, ensure that it is not twisted as any
misalignment will cause excessive wear and noise.
Alignment checks can be carried out using a strong taut cord, spirit level or a laser level.
Lifting 1.4.
A fully assembled conveyor should not be lifted as a complete unit. If this is
unavoidable, the conveyor must be fully supported along its entire length, with the use of
bracing struts and spreader bars strongly recommended. Failure to do so, will damage the
conveyor.
Chain assembly and installation 1.5.
The importance of connecting and installing the chain correctly cannot be over emphasised. Failure to do so can lead to extensive damage to the equipment.
The chain is supplied in convenient lengths, pre-assembled with Polyethylene flights and
should be joined together with the connecting links provided, these are usually screwed
connecting links. If rivetted type (or any other type) of connection links have been supplied
these must be assembled using the correct tooling and methods.
Using the chain adjusters, adjust the tail end sprocket to its closest point towards the drive
end of the conveyor by moving chain adjusters (See Section 1.5). Where a sprocket cleaner
is fitted
Direction of travel - the polyethylene flights must face forward, 'pushed' by the chain
attachments. Please refer carefully to the sketch appended at the end of these instructions to
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check direction of travel. Damage will be caused if the chain is installed the wrong way
round.
Assemble the chain round both sprockets.
Pull the two ends together and join with a connecting link.
Examine the total length of chain at this stage to ensure it is straight and without kinks or
bent flights.
The bottom section of the chain always runs towards the drive end. On a standard single
chain conveyor the ‘L’ shaped flights (A) are installed in the trailing position. Flights with
special adaptors fitted, in either steel or plastic (B & C), are installed in the leading position
(pushing direction). See figure.
Shrouded (twin chain) conveyors 1.6.
The flight on a shrouded conveyor is fixed between the two roller chains which run at either
edge of the casing.
Shrouded conveyor flight attachment
A B C
Direction of travel
Flight orientation
Direction of travel
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Drop forged chain 1.7.
Where drop forged chain is fitted care needs to be taken when assembling sprockets to
ensure correct orientation and alignment across hub.
Plain connecting link.
When fitted to a shrouded chain conveyor the nuts must be on the inside of the chain towards the centre line of the conveyor
Flighted connecting link
For single pitch flights
Figure 1 – Chain connection links
Outlet
Rotation
Chain return bar
Note: Ensure sprocket
stripper correctly fitted
Direction of travel of chain and product on base
Ensure sprocket teeth are
correctly aligned across hub
Sensor (fitted to ATEX rated
conveyors only)
Drop forged chain sprocket installation
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Care should also be taken to ensure that the chain is correctly orientated when installed.
Recycle cup fitment 1.8.
Recycle cups should be fitted in accordance with the drawing below and taking note of the
following points:
Standard clearance between integral scraper and casing is 5mm.
Addition of a cleaning flight to the scraper reduces standard clearance to 2mm.
Clearance between cleaning flight and central wear strip is 2mm.
The outer face of the recycle cup, when fitted, should be slightly inside the width of the
integral scraper.
As standard, recycle cups when installed, are fitted at a chain joint. However, joining links
on chains fitted to 200mm conveyors do not have integral scrapers. In order to fit recycle
cups to these chains, the chain will need to be drilled every 20 feet to accept the flight and
cup assembly.
Direction of travel
Drop forged chain - twin strand Drop forged chain - single strand
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Direction of travel of chain on conveyor base
Cup shape may vary to increase clearances between chain, chain link pin or casing
Integral scraper
Recycle cup
Cleaning flight
Recycle cup fitment – Single Strand Chain Conveyor
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Recycle cup fitment – Shrouded Chain Conveyor
Direction of travel of
chain on conveyor base
Recycle Cup
Integral Scraper
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Chain tension 1.9.
Where a sprocket cleaner has been installed, BEFORE attempting to adjust the chain
tension, refer to section 1.10.
Slacken the four securing bolts on each of the two bearing housings BEFORE attempting
any adjustment on the chain tensioner. Slacken them only enough to allow the bearing
housing to move in the casing as the chain tensioner is adjusted.
Tension the chain by turning the adjuster nuts on the tail end EVENLY. The chain is at the
correct tension when a measurement of 10 to 30mm is achieved as detailed in the sketch
below. It must not be so slack so as to enable the chain to cling to the outfeed side of
the drive sprocket; this can cause excessive wear of the chain and sprockets, or in some
circumstances snap the chain. An over tensioned chain can cause damage to the chain and
sprockets and overload the bearings.
Correct tension is achieved when the distance between the bottom edge of a straight edge
and the top surface of the chain, at its lowest sag point, is 10 - 30mm. For conveyors of a
greater or lesser length, increase or decrease the chain lift measurement accordingly.
Chain tensioner
Bearing housing securing
bolts 4 off
Tighten
Slacken
Adjust chain tension by moving locknuts
Drive end sprocket
Straight edge
Chain support angle
Conveyor chain
10 to 30 mm
Chain tensioning check
Recycle cup fitment – Shrouded Chain Conveyor
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Once the chain tension has been set, check that the sprocket shaft has remained square to the
casing by measuring the final position of the bearing housing on each side of the casing and
ensuring that these have remained equal.
Once the chain tension has been adjusted and checked satisfactorily, tighten the four
securing bolts on each of the two bearing housings.
Where a sprocket cleaner is installed, refer to section 1.10 to ensure that this is correctly
adjusted.
Sprocket cleaner 1.10.
When required, a sprocket cleaner is installed to prevent product building up in the gap
between the sprocket teeth. This is to prevent over tensioning and possible chain breakage.
Before attempting to make any adjustments to the chain tension, the scraper bar(s) on
the sprocket cleaner assembly must be lossened off and moved clear of the centre hub.
This is particularly crucial where the sprocket assembly is being adjusted to reduce chain
tension (sprocket moving towards the drive end).
Failure to move the bar(s) clear of the sprocket centre hub will prevent correct adjustment of
the chain tension. It could also lead to excessive wear, overheating, or jamming/stalling of
the machine.
Once the required chain tension has been achieved, the scraper bar(s) should be adjusted to
achieve a minimum clearance (dimension x) between the end of the bar and the face of the
sprocket hub.
Care should be taken to ensure that a clearance is achieved and that the bar(s) will not be in
contact with the hub when the machine is running.
Scraper bar
contact face
Sprocket cleaner assembly with single scraper bar
Scraper bar
adjustment bolts x 2 Mounting
bolts
Mounting
bolts
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Conveyor chain
tensioning
adjuster
Sprocket cleaner
mounting
bolts
Scraper bar adjustment
bolts
(inside casing)
Ensure scraper bar(s) NOT in
contact with hub following
adjustment
x
Sprocket
centre hub
Sprocket cleaner adjustment
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Cleaning flights 1.11.
Where a wear strip is fitted in the bottom of conveyor, an extended flight is fitted at every
tenth flight to sweep the bottom of the conveyor.
Brush gear (optional) 1.12.
Brush gear is located at the outlet position to ensure that the product is swept off the chain
and flights when the outlet is open.
It should be set to penetrate the chain and flights by 1.5 to 2mm. Insufficient penetration
will lead to ineffective cleaning of the chain. Excessive penetration will lead to excessive
wear on the brush gear
When the outlet slide is closed the brush is retracted mechanically or pneumatically. This
sequence of operation must be checked for correct operation before the machine is run.
Failure to do so could lead to blockage of the conveyor or damage to the brush gear.
Slide closed – brush gear retracted
Slide open – brush gear extended
Recommended pneumatic supply pressure is between 6 & 7bar Max Air consumption on cylinder extension is 39269mm3 (39.7cm3)
Drives 1.13.
The standard drive is a shaft mounted speed reducer, which is driven by a motor via a V
belt. (See Section 6.8 for adjustment).
Another option is a direct drive motor/gearbox linked via a flexible coupling.
Brush penetration setting
Brush set to penetrate chain by
1.5 to 2mm
Loosen locknuts x 3 evenly to ensure brush remains square to belt during adjustment
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Shaft mounted speed reducer (SMSR) 1.14.
Before running the machine, ensure the speed reducer is filled with the correct lubricant to
the required level. The following charts give details for standard vertical set up.
To identify the type of speed reducer, refer to speed reducer plate as illustrated below.
When checking oil levels this is best done with the speed reducer swung into the horizontal
position.
Synthetic and food grade lubricants can be used but these must NOT be mixed with the
standard mineral oils normally used.
For further information refer to manufacturer’s website. (See Section 8). Or contact
Guttridge Limited for advice.
Approximate oil quantities in litres for speed reducer orientated as per fig 10
Speed reducer size B C D E F G H
Ratio 5:1 0.3 0.5 0.9 1.7 2.6 3.2 5.3
Ration 13 & 20:1 0.4 0.6 0.9 1.8 2.6 3.2 5.5
Recommended oil BP ENERGOL GR-XP or equivalent Speed reducer oil capacity
Recommended Mineral Oil Lubricant Viscosities
5:1 Ratio Speed Reducer 13:1 and 20:1 Ratio Speed Reducer
I.S.O. Viscosity Grade
Ambient Temp
°C
-10 to +5 6 to 25 26 to 40
0-100 rev/min
101-200 rev/min
201-400 rev/min
0-20 rev/min
21-50 rev/min
51-120 rev/min
B - T B - T B - D E - T B - T B - E F - T B - E F - T
100 100 100 68 150 150 150 100 100 460 320 320 220 680 680 460 460 320 800 680 680 460 800 800 800 680 460
Mobil SHC XMP 320 Synthetic oil is suitable for all ambient temperatures and all speeds
Oil viscosities
Product code 116E2002
E refers to the type of
speed reducer
20 refers to the ratio
Drain
Level
Fill
Speed Reducer Lubrication
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Motor/Gearboxes 1.15.
Before running the machine ensure gearboxes are filled with the correct lubricant to the
correct level.
Depending on the type of drive unit specified, the gearbox may be a sealed for life unit or
require regular checking of the lubrication medium. Always check the separately supplied
component manual for any commissioning and maintenance requirements.
The oil level is dependent on gearbox type and orientation. For further information refer to
the gearbox manufacturer’s website (See Section 8). Or contact Guttridge Limited for
advice.
Gearboxes normally come filled with a standard mineral oil with a viscosity ISO VG 220,
which is suitable for ambient conditions of 0˚C - 40˚C.
Below is a table of commonly available oils. Others brands can be used.
Synthetic and food grade lubricants can be used but these must NOT be mixed with the
standard mineral oils normally used.
Under filling can lead to bearing or gear failure. Over filling may lead to over heating or oil
seal failure.
Mineral Synthetic
BP Energol GR-XP 220
BP Enersyn SG-XP 220
Mobilgear 630
Shell Omala 220
Shell Tivela WB
Kluberoil GEM 1-220
Klubersynth GH 6-220
Optimol Optigear BM 220
Fuchs Renolin CLP 220
Lubricant specification
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2. Electrical Installation
General 2.1.
All work must be carried out by a qualified electrician, to current regulations and codes of
practice.
Where a machine is being installed to comply with ATEX standards, all electrical
components and connections should be checked to ensure that they are in compliance with
the required standards BEFORE they are first operated.
The cable entry devices used shall be suitable for the equipment, the cable and conditions of
use and shall be certified under EC Type Examination Certificate to Directive 94/9 EC.
Motors 2.2.
Make sure the local mains voltage and frequency match the motor plate. For additional
information refer to manufacturer’s website. (See Section 8)
Wire the motors in to suitable starters, (or the control equipment supplied with the machine
if ordered specially).
The starters should then be wired into suitably located isolators.
At this stage the thermal overloads in the starter must be checked and reset if necessary.
The motor should only be inverter driven if specified when ordered; otherwise this could
lead to poor start up performance or overheating of the motor.
If the motor runs in the wrong direction it will damage the chain.
Before running the motor ensure the drive is disconnected. If the drive is not to be
disconnected, ensure that no personnel are working on the equipment and that the equipment
will not be damaged by foreign objects or by incomplete assembly of other parts.
Rotation sensor (optional) 2.3.
The rotation sensor is fitted to the tail shaft to detect slow or non-rotation of the shaft; under
these conditions it will stop the drive motor.
It should be wired so that the electrical signal from the rotation sensor is used to stop the
drive motor and generate a warning signal. This will prevent severe blockage and/or
damage to the conveyor.
It should be wired so that to restart the machine, a restart switch must be activated. Under
no circumstances should it be wired to start automatically.
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Pressure switch (optional) 2.4.
The pressure switch is fitted at the drive end to detect pressure due to a build back of
product at the discharge.
It should be wired so that the electrical signal from the pressure switch is used to stop the
drive motor and generate a warning signal. This will prevent severe blockage and/or
damage to the conveyor.
It should be wired so that to restart the machine, a restart switch must be activated. Under
no circumstances should it be wired to start automatically.
To check pressure switch operation apply a light pressure ensuring that the machine stops.
Beware of moving parts when accessing the pressure switch.
BL15/S - IP65 Diaphragm Switch - NON-ATEX application
Coote Pressure Switch BL15/S (sealed) is fitted where a higher level of moisture protection
for the switch is required.
Neither switch is suitable for fitment where the machine is required to comply with the ATEX standard.
The switch consists of a micro-switch operated by a diaphragm through a lever system. The
unit is robust, being constructed in a cast aluminium Housing. It is reliable in service and,
due to the design of the housing, the diaphragm cannot be overstressed by the pressure of
material.
Electrical connections
Normally open
Normally closed
Common
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3. Drawings and illustrations
Chain drive
Multi position geared motor with chain drive (cover removed)
Coupled drive
In line geared motor unit connected to drive shaft via flexible coupling (cover removed)
Direct drive
Geared motor fitted directly to shaft
Drive types
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Chain Conveyor Assembly
View A
View A
Chain Conveyor Assembly detailed
Drive ‘V’ belts
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4. Commissioning run
Starting 4.1.
Before starting the equipment for the first time:
Ensure that no one is working on the equipment
Ensure that no tools or loose items are left in the casing that could cause damage
Ensure that no foreign objects can fall in to the inlets thereby causing blockages, overheating or sparking
The table below contains a list of items to be checked once the machine is in place and in
some cases, before it is started. This list is only for guidance. The commissioning
engineer should ensure that all aspects of the machine have been checked to his satisfaction,
before it is started for the first time and before it is released to the customer for use.
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Customer Machine Serial Number Customer’s Machine Number
Site Machine size Product being handled Throughput
Item Action Comment (if
required) Checked
1 Check major component instruction manuals for any commission checks required
2 If machine ATEX rated check installed location is the correct one and is safe to operate machine in
3 Check supply voltage/current is the correct one for the machine being commissioned
4 Check casing alignment along its full length in both front and side vertical planes
5 Check conveyor chain tension and that chain is running in the correct direction (Page 13 of manual)
6 Check cleaning flights are in place (if required) and adjusted to scrape bottom of conveyor
7 Check sprocket position and grub screws are correctly fitted
8 Check gear box oil type and level and that breather has been fitted
9 Check tension gear locknuts
10 Check drive belt or chain tension and condition. Check chain is correctly lubricated
11 Check that all taperlocks are secured correctly
12 Check packing gland seals
13 Check all casing seals in place
14 Check that drive motor has been wired correctly to ensure that conveyor rotates in the correct direction
15 Check all tools and foreign objects have been removed from internal areas and moving parts of the machine
16 BEFORE starting machine check all covers and guards or inlets/outlets in place and
that no moving parts are accessible
17 BEFORE starting machine check that all personnel in the vicinity are aware. For large machines it may be necessary to post warning signs
18 BEFORE starting machine ensure that any follow on machinery is running
19 Once started check that machine runs quietly and without any unusual noises such as rubbing or grinding that may be caused by misalignment
20 Check normal running speed of machine is as per specification sheet
21 During running check that any emergency stop buttons or switches operate correctly
22 If explosion panels fitted check that any micro-switches fitted shut down the machine when operated
23 Check that any safety interlocks close down the machine when operated and that power cannot be restored until the interlocks are correctly reset
24 Where a machine has been installed to an internal ATEX rating check all bearings for signs of overheating and carryout initial bearing running temperature recording
25 Using a sufficient quantity of sacrificial product, run the machine for several minutes to clear any foreign material that may be present
The checks listed above have been completed and the machine is cleared for operation
Name of Commissioning Engineer Signature Date
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When the conveyor is started for the first time it should run quietly, any noise above the
sound of the drives should be investigated immediately and corrected before proceeding.
Where a machine has been installed specifically to meet the ATEX standard, a 30
minutes ‘safe’ running period MUST be completed. A safe running period is when the
machine is run without any ATEX class hazard present i.e. no product in the machine and
the surrounding operating to be free from potentially explosive atmosphere.
During the 30 minute ‘safe’ running period, the machine should be visually inspected for
any signs of a potential ignition source being generated i.e. loose wiring connections causing
arcing, component mis-alignment causing sparking or obvious over-heating.
After the 30 minutes initial running period, all areas of the machine should be examined for
signs of excessive wear, binding, arcing or over-heating and appropriate rectification action
taken.
Where any rectification is carried, a further safe running period should be completed to
ensure that the problem has been rectified satisfactorily.
Before operating with production materials, it is recommend that the machine is run for a
few minutes with a sacrificial waste material, to ensure that the conveyor is purged of all
foreign matter.
In order to ensure that the machine remains safe for use within the ATEX zone for which it
was designed, the end user will need to monitor the running temperature of all bearings on a
regular basis.
It is not possible for Guttridge Limited to know what the actual machine operating
conditions will be at all times, e.g. ambient temperature, temperature of product, actual
loading on machine parts when operating at maximum capacity.
The end user will need to measure the normal running temperatures of all bearings in order
to have a start point by which to monitor future bearing performance. The end user is
therefore advised to carryout this monitoring at the earliest opportunity. Any bearing
showing signs of over heating should be replaced immediately.
Once the operating temperatures for all bearings have been identified and confirmed as
acceptable, the end user will need to determine, based on the usage of the machine, how
often these temperatures will need to be monitored and ensure maintenance staff of made
aware of this requirement.
Post commissioning checks 4.2.
See section 6, Routine Maintenance table for details.
Chain Conveyor Manual
GuttridgeLimited Page 31 of 60
The machine referred to in this manual has been designed to operate to the specification detailed by the end user when the machine was ordered. This will have included:
Type of material to be conveyed Electrical supply voltage(s) Systems of control Maximum throughput Machine operating environment Hours of operation Sensing and monitoring systems Safety features
Where the machine supplied has been specified to be ATEX compliant the end user will also need to ensure that the replacement item or material is to an identical specification in all respects. Components and materials supplied to ensure ATEX compliance include:
Drive belt(s) Sealing strip material Sealing compounds Bearing lubrication medium Electrical components
Should an end user consider changing ANY of the above specifications they should contact Guttridge Limited for advice BEFORE doing so.
Chain Conveyor Manual
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5. Operation
Standard operating principles 5.1.
The chain conveyor consists of a chain(s), with flights attached, encased in a metal casing.
The conveyor chain is driven by a motor and speed reducer via V belts. Product is fed into
the top of the conveyor at the tail end of the machine and is pulled by the flighted chain
along the bottom of the casing until it is discharged at outlet(s), situated on the underside of
the conveyor.
Starting 5.2.
Before starting the machine check that no one is working on the machine and that all guards
and covers are in place.
Ensure the conveyor and the follow on machinery are running BEFORE feeding product.
Failure to do so could lead to machine overload and subsequent damage.
During operation 5.3.
Running the conveyor without product loaded will reduce wear strip and conveyor chain life
and should not be done unnecessarily.
Maintaining an even flow of product ensures the conveyor performs to its optimum.
Do not use flood feed operation unless this has been specified at the design stage.
If during the operation of the machine there are any unusual noises, vibrations or smells,
clear the machine of product, and then stop the machine to investigate the cause. This is
particularly crucial where the machine has been installed to comply with ATEX
standards, as unusual noises or smells could be a symptom of component failure
leading to risk of explosion.
Stopping 5.4.
Machines are designed to stop and start under normal working load. If the machine is
overloaded under stop and start conditions it could damage the equipment.
Restarting 5.5.
If the machine is stopped due to an emergency, a breakdown or the operation of the pressure
switch or rotation sensor, it may be necessary to remove product from the casing manually
before restarting. The machine must be isolated from the power supply before any such
clearance is attempted.
Bearings 5.6.
All bearings should be monitored to ensure that they remain serviceable and not liable to
compromise the ATEX integrity of the machine. This is particularly important where the
machine, even when stationary, is subject to high levels of vibrations from surrounding
machinery or plant.
Bearing should also be checked for serviceability where the rotating parts of the machine
have been subjected to a shock loading caused by jamming or overloading of the chain
during operation.
Chain Conveyor Manual
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6. Maintenance
Items marked are vital to ensuring ATEX integrity
Post commissioning checks after 2/3 hours
Item Action Ref
Conveyor chain Check tension 1.9
Drive belt(s) or chain(s) Check tension 6.11 6.12
Packing gland seals Check for leaks and tighten if required 6.14
Seals and gaskets Check for any leaks or damage especially around covers, access panels or removable parts
Earthing and bonding points Check security
Major components Check component instruction manual for any commissioning checks required
Post commissioning checks after one week or 50 hours if sooner
Machine Check all parts secure and in sound condition
Packing gland seals Check for leaks and tighten if required 6.14
Seals and gaskets Check for any leaks or damage especially around covers, access panels or removable parts
Bearing and running parts
Check for signs of overheating or binding that could lead to component failure and subsequent risk of explosion. Any bearing showing signs of over heating should be replaced immediately
Daily
Area around machine Clean to ensure safe working for personnel
Guards and covers
Check in place and that all safety warnings and signs are in place and visible.
Monthly
Packing gland seals Check for leakage and tighten or repack as required 6.14
Motor fan cover Clean
Sensor systems (where fitted) Check the operation
All guards Ensure in good condition and correctly fitted
All electrical cabling, covers and junction boxes
Check undamaged and in a safe condition
All earthing and bonding points Check for security and condition to ensure that earth continuity is maintained
Bearings and running parts
Check for signs of overheating or binding, that could lead to the generation of high temperatures or sparks. Any bearing showing signs of overheating should be replaced immediately
1.4 1.8 6.5 6.7 6.9
Bearings Check running temperatures against those recorded during the commissioning phase. (dependant on frequency requirements determined by end user)
Chain Conveyor Manual
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General 6.1.
The wide range of environmental conditions and modes of operation that may apply to a
particular machine installation, mean that it is only possible to give general guidance on
maintenance periods and practices. The end user should ensure that where applicable,
maintenance timescales and activities are adapted to suit the local conditions. Please
contact Guttridge Ltd for advice.
Regular maintenance ensures that this equipment will continue to perform to its optimum
level.
It is good practice to keep both the machine and the area around it clean and tidy; this
helps in the identification of machine faults and makes for a safer working
environment.
Rigorous housekeeping is particularly crucial where the machine has been installed to
comply with the ATEX standards. Any accumulation of dust could compromise the
explosion protection concept of the machine.
During operation 6.2.
Any defects in machine operation such as those indicated below must be reported to
machine maintenance personnel.
Listen for any unusual noises; this could indicate a problem with the machine in
particular loose flights, a damaged or misaligned chain, worn bearings or slipping
drive belts.
Feel outside casings for vibration. Do not place hands near moving parts.
Drive chain and sprockets Check condition. Lubricate using suitable lubricant 6.12
Every 6 months
Complete monthly checks
Gearbox Check oil level and top up if required 1.8
Gearbox breather Clean 1.8
Conveying chain and sprockets Check condition. Re-tension as required
Electrical installations Check in good condition and functioning correctly 6.9 6.10
Annually
Complete all above checks
Gearbox oil Change 1.8
Wear strips (where fitted) Check condition. Replace if worn
Brush gear (where fitted) Check for correct operation 1.11
Flange bearings Check condition. If required by local procedures, lubricate with an appropriate grease or replace bearing. See table for recommended bearing replacement timescales.
6.8
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Take care not to touch, with the bare hand, any areas of the machine that may
be hot.
Look to ensure all electrical switches and cut outs function properly and are in
good condition.
Look to make sure all outlets are clear and product is flowing freely.
Look to make sure all guards are securely fitted and are in good condition.
Excessive bearing wear can lead to bearing failure causing rapid overheating or
sparking. Likewise, prolonged belt slippage could lead to the generation of high
temperatures. Any such occurrence could compromise the ATEX integrity of
the machine.
Ensure the machine is switched off and electrically isolated before carrying out any maintenance work
Maintenance intervals 6.3.
The above intervals are based on a 10 hour day operation 5 days a week. If the equipment
is run more often than this, maintenance intervals should be adjusted to suit.
Where ambient temperatures are outside the normal operating range of 5ºC to 30ºC, it may
be necessary to vary the maintenance intervals.
Bearings 6.4.
In order to maintain the ATEX integrity of the machine, it is vital that the condition of all
bearings is monitored on a regular basis. It is also critical that all maintenance requirements
detailed above are carried out in order to ensure that the machine remains safe to operate.
Table below should be referred to as a guide to when bearing assemblies should be replaced.
Size of Machine Recommended replacement period
200 5 years or 12,500 hours
250 5 years or 12,500 hours
300 5 years or 12,500 hours
400 5 years or 12,500 hours
Recommended bearing life
Notes:
These recommended bearing lives have been calculated based on a standard machine running
for 10 hours a day 5 days a week, 50 weeks of the year and within relatively standard
conditions.
Where a machine is being used in excess of the figures given above or at maximum capacity
for extended periods of time, end users should consider shortening the bearings replacement
period accordingly. If in any doubt about how to assess bearing life under such conditions
end users should contact Guttridge Limited.
Notwithstanding the above guidelines, it is crucial that end users establish the bearing
operating temperatures during the commissioning phase and continue to monitor these at
regular intervals throughout the life of the machine.
Chain Conveyor Manual
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Always isolate the machine to prevent accidental start up
All bearings should be monitored to ensure that they remain serviceable and not liable to
compromise the ATEX integrity of the machine. This is particularly important where the
machine, even when stationary, is subject to high levels of vibrations from surrounding
machinery or plant.
Bearing should also be checked for serviceability where the rotating parts of the machine
have been subjected to a shock loading caused by jamming or overloading of the chain
during operation.
Bearing housing – removal and refitting 6.5.
Flange mounted bearing housings are fitted as standard.
Securing of the bearing to the shaft is achieved by the use of two grub screws in the bearing
inner ring. These locate in to dimples on the drive or tail shaft.
Removal
Ensure that both grub screws have been removed before attempting to remove bearing from
shaft.
Refitting
Ensure flange mounting bolts are fully tightened before any attempt is made to secure
bearing to shaft.
Check that a grub screw hole aligned before refitting the grub screws.
Clean both inside of flange bearing inner ring, grub screw holes and shaft before refitting
bearing to shaft.
Tighten each grub screw progressively until the recommended torque loading is achieved.
The table below is for guidance only.
Lubrication of sealed for life bearings 6.6.
Flange bearings are normally fitted with sealed for life bearings that contain their own
lubrication medium and therefore do not require any further lubrication during the life of the
bearing (see information on the recommended life cycle of bearings).
The lip seal or seals (on double sealed bearings) are designed to prevent the ingress of
external contamination in the first instance and not as a specific means of sealing in the
lubrication medium.
However, some flange bearing housings also have a threaded drilling that allows for the
installation of a grease nipple.
mm Thread Tightening torque – Nm 1
2.5 M5 3.6
3 M6 x 0.75 6
4 M8 x 1 14
5 M10 x 1.25 26
6 M12, M12 x 1.25 42 1
Tightening torques are valid for original INA grub screws only
Chain Conveyor Manual
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Where a grease nipple has been installed and a re-greasing schedule introduced, the
end user should ensure that maintenance personnel are aware of the correct re-
greasing method to be employed. The following points should also be noted:
1. When first installed the spaces within the bearing is not completely filled. SKF bearings
have only 30% of the internal space occupied by grease. INA bearing will probably have
a similar arrangement.
2. Excessive greasing (over-packing) of the bearing can lead to over-heating of the bearing
during operation.
3. If excessive pressure or rate of flow is applied to the grease as it is injected into the
bearing housing the lip seals, that are designed to prevent any ingress of contaminants,
may become distorted or damaged. In extreme cases the internal bearing components
may also become displaced resulting in bearing failure.
4. Mixing of grease type and makes should be avoided as this could lead to an adverse
chemical reaction that leads to a breakdown of the lubricant and subsequent bearing
failure.
5. Excessive greasing could lead to product contamination or damage to non-metallic parts
of the machine e.g. drive belts, conveyor belt.
Where an end user is considering the introduction of grease nipples and a re-greasing
schedule, they are strongly advised to contact Guttridge Limited for advice.
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GuttridgeLimited Page 38 of 60
Taper lock bush 6.7.
Taper lock bushes are used to secure sprockets and pulleys to shafts. Basic removal and
fitting details are detailed below.
To remove taper lock bush
1. Slacken screws in hub. Remove one screw, place it in the half threaded hole and tighten
until taper lock separates. It may be necessary to tap the outer hub to free it from the
inner.
2. Remove assembly from the shaft.
Fitting taper lock bush
1. Ensure all mating surfaces are clean and oil free, particularly the protective film on new
components.
2. Insert inner bush into the hub so that the holes line up.
3. Lightly oil the screws and place loosely in threaded holes on both sides.
4. If a key is to be fitted, place it in the shaft keyway before fitting bush. It must be a
parallel key and side fitting only, it must have TOP CLEARANCE.
5. Ensure shaft is clean and fit to shaft as one unit. Position it on the shaft to get correct
alignment, allow for the fact that the hub will draw slightly up the bush when fully
tightened.
6. Tighten the screws gradually and alternately to ensure the hub remains square on the
bush when fully tightened.
7. Give the bush a firm tap with a soft hammer or drift, retighten screws. Repeat until all
screws are fully tightened.
8. Fill empty holes with grease to prevent ingress of dirt. This will also make removal at a
later date easier.
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Always isolate the machine to prevent accidental start up Take care not to trap fingers between belts and pulleys
V Belts 6.8.
To replace and adjust V belts
1. Remove guard.
2. Slacken the locking nuts on the torque arm and turn adjuster to loosen belts.
3. Remove old belts.
4. Replace with belts of the correct type. Do not mix belt types or old with new.
Note: Where a machine has been specified to be ATEX compliant, replacement belts
MUST be to the same standard as originally supplied. Standard profile SPZ,
construction to FRAS (Fire Resistant and Anti-Static)1.
5. Put new belts onto pulleys ensuring that you do not force them on, as this could damage
them and cause them to twist when running.
6. Turn the adjuster on the torque arm until there is approximately 15mm deflection on the
belt, at the midpoint between the pulleys, when applying a reasonable force by hand.
7. 15mm deflection is for a belt with a one metre span. Any reduction or increase in span
length, should be reflected by a corresponding reduction or increase in deflection
measurement.
Over tensioned belts could damage the belts or bearings.
Under tensioned belts could cause slippage, which can cause the conveyor to stall or the
belts to become overheated and damaged.
8. Tighten all locking nuts and replace the guard.
1 ISO 4184 – DIN 2215 – BS 3790 – RMA IP20
Fenner Classic V-Belts have specially treated jackets to give superior anti-static, heat and oil-resistant properties. All Fenner Classic V-Belts are static conductive to ISO 1813 and conform to the anti-static specification of the American Petroleum Institute.
1m span (typical)
15mm deflection (typical)
V belt tensioning
Chain Conveyor Manual
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Drive chain 6.9.
Always isolate machine drive to prevent accidental start up
Take care not to trap fingers between chains and sprockets
Drive chain and sprocket condition should be checked as follows:
1. No excessive play between links.
2. Not kinked.
3. Free from rust.
4. Sprockets not dog toothed.
5. Sprockets secure.
6. Replace as required.
Setting chain tension
1. Slacken locking bolts in the motor mounting
slide and adjust chain tension by moving the
tension plate, using the adjuster nut.
2. Do not slacken locking bolts excessively as this
could cause the gearbox alignment to change
excessively.
3. Do not remove bolts completely as this will
cause the gearbox to be come detached from the
mounting plate.
4. Ensure locking bolts are retightened evenly to
avoid distorting the casing or misaligning the
gearbox.
5. Correct tension is achieved when movement at
the midway point between sprockets is between
15 and 20mm.
6. Check tension at other positions in the drive to ensure it is not over tight.
7. DO NOT OVERTENSION CHAIN, as this can lead to premature wear of chains,
sprockets or bearings.
8. Lubricate with good quality chain lubricant.
Drive chain adjustment
15-20mm
Adjuster nut
Locking bolts 4 off
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Drive chain lubrication 6.10.
All drive chains are fitted with the manufacturer’s anti-corrosion treatment applied only.
Therefore, an appropriate lubricant must be applied before the machine is first
operated.
Chain lubricants
Recommended lubricant is a penetrating non-mineral oil which lubricates the chain pins and
frees seized chain. It forms a dry film which will not attract dust and dirt, and is also non-
drip.
Chain drives should be protected against dirt and moisture and be lubricated with good
quality non-detergent mineral based oil. A periodic cleaning and re-oiling is desirable.
Heavy oils and greases are generally too stiff to enter the chain working surfaces and
should not be used.
Care must be taken to ensure that the lubricant reaches the bearing areas of the chain. This
can be done by directing the oil into the clearances between the inner and outer link plates,
preferably at the point where the chain enters the sprocket on the bottom strand.
The table below indicates the correct lubricant viscosity for various ambient temperatures
Ambient Temperature Lubricant Rating
Celsius SAE BS4231
-5 to +5 20 46 to 68
5 to 40 30 100
40 to 50 40 150 to 220
50 to 60 50 320
For the majority of applications in the above temperature range, a multi-grade SAE 20/50 oil would be suitable
Use of grease
As mentioned above, the use of grease is not recommended. However, if grease lubrication
is essential, the following points should be noted:
Limit chain speed to 4 m/s.
Applying normal greases to the outside surfaces of a chain only seals the bearing surfaces
and will not work into them. This causes premature failure. Grease has to be heated until
fluid and the chain is immersed and allowed to soak until all air bubbles cease to rise. If
this system is used, the chains need regular cleaning and re-greasing at intervals
depending on the drive's power and speed. It should also be noted that temperatures
above 80°C will cause damage to many greases and reduce their effectiveness.
Abnormal ambient temperatures
For elevated temperatures up to 250°C, dry lubricants such as colloidal graphite or M0S2 in
white spirit or poly-alkaline glycol carriers are most suitable.
Conversely, at low temperatures between -5°C and -40°C, special low temperature initial
greases and subsequent oil lubricants are necessary. Lubricant suppliers will give
recommendations.
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Always isolate the machine to prevent accidental start up
Packing gland seals 6.11.
To adjust packing gland seals
1. If the seals have hardened or the product has been leaking for a long time tightening
the gland could damage the shaft.
2. Slacken inner lock nuts on the packing gland bush assembly equally (2 to 3 flats) then
tighten outer lock nuts.
3. Adjustment is best done in small steps as over tightening can cause the pilot packing to
pinch the shaft and stall the machine.
Repacking gland - quick method
1. Release locknuts and move packing gland bush assembly out as far as possible.
2. Remove the pilot packaging material and fit new material of the correct type and size.
See parts list.
3. Adjust inner and outer locknuts EVENLY to ensure pilot packing contacts the shaft
squarely.
4. Adjust until pilot packing lightly compresses against the shaft.
5. Tighten locknuts.
6. After 2/3 hours check for leakage. Tighten if required.
Repacking gland
1. If it is not possible to remove the pilot packing as above or the product has been leaking
for some time and caused a build up on the shaft, proceed as follows:
2. Remove flanged bearing assembly.
3. Release locknuts and remove packing gland bush assembly.
4. Remove the pilot packing.
5. Clean the shaft and packing gland assembly.
6. Replace bronze bush if worn.
7. Fit new pilot packing of the correct type and size. Ensure joints are staggered to prevent
leakage (See figure below).
8. Refit packing gland sealing bush assembly.
9. Adjust inner and outer locknuts EVENLY to ensure pilot packing contacts the shaft
squarely.
10. Adjust until pilot packing lightly compresses against the shaft.
11. Tighten locknuts.
12. Refit flanged bearing assembly.
13. After 2/3 hours check for leakage. Tighten if required.
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Packing gland seals
Pilot packing
Inner lock nut
Packing gland bush assembly
Outer lock nut
Packing gland bronze bush
Pilot packing joint alignment
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Shaft mounted gear motor unit (GMU) removal 6.12.
Always isolate the machine to prevent accidental start up
Warning – The GMU may be extremely heavy and must be properly supported before any attempt is made to remove the torque arm securing bolt.
Where it is not possible to use the GMU lifting eye to take the weight of the unit, support should be placed underneath. Care must be taken to ensure that any support is stable and strong enough to take the full weight of the unit once it is disconnected from the drive shaft.
Warning – With the torque arm securing bolt removed the GMU will rotate downwards. Depending on the drive arrangement this could occur rapidly and could cause the machine conveying system to rotate. Do not allow personnel to work on any other part of the machine unless full safeguards are in place
Lifting eye
Drive shaft end
cover
Plastic cap
Torque arm securing bolt
1. Stepped bush 2. Spring washer 3. Socket headed
cap screw
1. Refer to local manual handling guidance to determine need for mechanical assistance due to weight of GMU.
2. Remove the drive shaft cover plate by removing the two retaining bolts.
3. Carefully remove the plastic cap covering the cap screw. Avoiding using any sharp tools as this may damage the cap.
4. Remove the socket headed cap screw, spring washer and stepped bush.
5. Recheck that the weight of the GMU is fully supported and that it cannot rotate unexpectedly once the torque arm securing bolt is removed.
6. Check that other personnel are not working on the machine and could be injured by any movement of the conveying system.
7. Remove torque securing bolt.
8. Carefully rotated the GMU until the torque arm is clear of the bracket.
9. Slide GMU off of the drive shaft.
10. Caution – Even where the GMU has not rotated with the torque arm bolt removed, once it is disengaged from the keyway on the drive shaft, it will be free to rotate under its own weight. Care must be taken to avoid injury due to the uncontrolled rotation of the unit.
11. Refitting is the reverse of the above. Ensure that the key is fully located in the keyway. Apply a suitable lubricant to the shaft. Ensure circlip (where used) is correctly located inside gearbox. Where the GMU is installed on a bucket elevator, care must be taken not to damage any installed backstop.
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7. Trouble shooting
Fault Possible cause Solution
Motor fails to start
No power Check power supply
Isolator switch operative Release isolator
switch button
Faulty start switch Repair/replace
switch
Rotation sensor
operative
Rectify cause and
reset
Pressure sensor/switch
has operated
Clear blockage
Motor running, but no material present at outlet
No materials being fed
in
Restart material flow
Drive belts broken or
slipping
Replace or re-
tension
Other outlet open Close other outlet
Knocking noise from chain casing
Loose or damaged flight
contacting the casing.
Fix or straighten
Conveyor not straight Straighten conveyor
Bearing failure
Bearings are supplied sealed for life. Where
the end user decides to introduce lubrication,
local procedures will be required to ensure
adequate maintenance processes and intervals
are introduced.
Loss of lubrication Replace bearing
Misaligned shaft Replace bearing
Low material throughput
Brush gear not retracted Reset brush gear
Inadequate material feed Increase material
feed
Other outlet partially
open
Close other outlet
Trouble shooting chart
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8. Reference
Motors and gearbox
Manufacturer Web site
ABB www.ABB.com
SEW www.sew-eurodrive.com
NORD www.nord.com
CEG www.ceg.it
Fenner www.fptgroup.com
Rossi www.rossimotorid.it
Bonfiglioli www.bonfoglioli.com
Pujol www.pujol.com
Flender www.flender.com
David Brown Radicon www.Textron.com
Motovario www.motovario.com
Renold www.renold.com
Bearings
Manufacturer Web site
SKF www.skf.com
INA www.ina.de
RHP www.eu.nsk
Manufacturer reference
Chain Conveyor Manual
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9. Weights
All weights given are only approximate and are based on a ‘typical’ standard machine
installation. End users must check the specification of the particular machine installed to
determine its actual weight, before selecting and using any form of lifting equipment to
assemble or dismantle their machine. Please contact Guttridge Limited for assistance if more
detailed information is required. Please quote the machine number in any
communications.
Machine Section Wt in Kgs
Component Size Wt in Kgs
200CC Intermediate 108
Tail 87
Drive 108
plus
Motor (Kw)
1.1 1.5 2.2 3.0 4.0 5.5 7.5 11.0
13 16 21 24 32 40 50 72
SMSR(size)
C20 D20 E20 F20
15 21 31 45
250CC Intermediate 128
Tail 114
Drive 108
plus
Motor(Kw)
1.1 1.5 2.2 3.0 4.0 5.5 7.5 11.0
13 16 21 24 32 40 50 72
SMSR(size)
C20 D20 E20 F20 G20 H20 J20
15 21 31 45 69 92
133
300CC Intermediate 160
Tail 150
Drive 142
plus
Motor(Kw)
1.1 1.5 2.2 3.0 4.0 5.5 7.5 11.0
13 16 21 24 32 40 50 72
SMSR (size)
D20 E20 F20 G20 H20 J20 K20 L20 S20
15 21 31 45 92
133 385 545 197
Basic weights
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10. Parts
Drive End assembly 10.1.
Always quote the machine number when ordering spares.
Item Description Qty
Item Description Qty
1 Drive End Side Plate Assembly – RH 1 7.2 Drive End Chain Support Wear Strip 1
2 Drive End Side Plate Assembly – LH 1 7.3 Rivet Countersunk 9
3 Drive End Frame Assembly 1 8 Spacer Tube 120 Long 3
4 Drive End Overflow Plate – Pressure Pad 1 9 Spacer Tube 85 Long 3
5 Drive Lid – Plain End 1 10 Tie Bar 3
6 Drive Base Plate Assembly 1 11 Outlet Flange Assembly 1
6.1 Drive Base Plate 1 12 Nut, Nyloc 18
6.2 Drive End Base Wear Strip 1 13 Nut, Plain 16
6.3 Rivet, contersunk 6 14 Washer, Flat 58
7 Drive End Chain Support Assembly 1 15 Washer, Spring 6
7.1 Drive End Chain Support 1 16 Packing gland assy (not shown) 2
Drive end parts list
16
Chain Conveyor Manual
GuttridgeLimited Page 49 of 60
Tension Section Assembly 10.2.
Always quote the machine number when ordering spares.
Item Description Qty
Item Description Qty
1 Bearing Spacer Plate 2 16.1 Packing Gland Assy (not shown)
2
2 Lid Fishplate 1 17 Bearing Backing Plate Assy 2
3 Base Fishplate 1 18 Tension Plate Adjuster 2
4 Side Fishplate 2 19 Tail End Base Plate Assy 1
5 Spacer Tube – 120 Long 2 19.1 Tension Base Plate 1
6 Spacer Tube – 85 Long 2 19.2 Tension Base Wear Strip 1
7 Tie Bar 2 19.3 Rivet, Countersunk 10
8 Tension Side Plate – Standard O/B LH 1 20 Inlet Flange Assy 1
9 Tension Side Plate – Standard O/B RH 1 21 Bearing Cap 2
10 Tension Side Plate – Std O/B Tension 1 22 Bearing 2
11 Tension Lid – Sprocket End 1 23 Sprocket 1
12 Tension Lid Plate – Inlet 1 24 Setscrew 16
13 IB/OB Tension Channel Assembly 1 25 Nut, Plain 8
14 Tension Plate – Bearing 2 26 Washer, Flat 8
15 Tension Chain Support Assy 1 27 Washer, Spring 8
15.1 Chain Support Angle 1 28 Nut, Nyloc 2
15.2 Tension Chain Support Assembly 1 29 Nut, Plain 8
15.3 Rivet, Countersunk 6 30 Washer, Spring 4
16 Tail Shaft 1
Outboard tension section assembly parts list
16.1
Chain Conveyor Manual
GuttridgeLimited Page 50 of 60
Intermediate Section Assembly 10.3.
Item Description Qty
1 Intermediate Chain Support Assy 1
1.1 Chain Support Angle 1
1.2 Intermediate Chain Support Wear Strip 1
1.3 Rivet, Countersunk 19
2 Lid Fishplate 1
3 Base Fishplate 1
4 Side Fishplate 2
5 Spacer Tube – 120 Long 5
6 Spacer Tube – 85 Long 5
7 Tie Bar 5
8 Intermediate Side Plate 2
9 Intermediate Lid 1
10 Intermediate Base Plate Assy 1
10.1 Intermediate Base Wear Strip 1
10.2 Intermediate Base Plate 1
10.3 Rivet, Countersunk 19
11 Nut, Plain 20
12 Washer, Flat 30
13 Washer, Spring 20
14 Rivet 30
15 Collar 30
Intermediate section assembly parts list
Always quote the
machine number
when ordering
spares.
Chain Conveyor Manual
GuttridgeLimited Page 51 of 60
Accuracy of information provided
This data sheet gives technical information for a component fitted to materials handling equipment manufactured by Guttridge Limited.
Every effort has been made to ensure that the technical information is accurate. However, it is in general a duplication of the information supplied to us by the original equipment manufacturer and is therefore only offered in good faith and cannot be guaranteed.
Users should ensure that the information provided in a particular section applies to their specific installation before disturbing or adjusting their equipment. If there is any doubt, please contact Guttridge Limited for advice and assistance.
Appendix 1 – Level/Over Pressure Sensing
BL15/S - IP65 Diaphragm Switch - NON-ATEX application
General Pressure sensing systems are fitted to machines where a requirement exists for monitoring the
level of product in a particular part of the machine to prevent jamming, product backup or
over pressure.
A pressure switch BL15 (standard for dry moisture free conditions) BL15/S (sealed) is fitted
to machines that are NOT required to comply with the ATEX standard.
The switch consists of a microswitch operated by a neoprene rubber diaphragm through a
lever system. The design of the housing means that the diaphragm cannot be overstressed by
pressure of product.
In normal service, the factory setting for the switch is suitable for all applications. Re-
adjustment should only take place if this setting has been disturbed or a non-standard setting
is required. Please contact Guttridge Limited for advice if a non-standard setting is being
considered.
A pressure switch BL15/S – IP65 is fitted where a higher level of moisture protection for the
switch is required.
Installation
When installing a machine with the BL15/S fitted, users must observe the following points:-
1. A final check should be made after wiring installation has been completed to ensure
that the cover plate is fully tightened on to the seal.
BL15 Pressure Switch
Chain Conveyor Manual
GuttridgeLimited Page 52 of 60
2. In the event of cover plate removal, a new seal should always be fitted on re-assembly.
The condition of the ‘O’ rings fitted under the five fixing screws should also be
checked for soundness.
3. Cable entry to the switch must be through a gland which provides a minimum
protection to IP 65.
4. These switches should not be used in areas where combustible gases may be present.
5. Where switches are used in dust laden atmospheres, sparking is highly unlikely to
occur from the aluminium body, care should be taken by users to avoid possible
sparks caused by dropping on to or striking other metal objects.
6. Should the micro-switch plate inside the housing be removed, it should be re-
assembled ensuring that the small ‘O’ rings fitted to each of the two fixing screws are
checked and replaced if deformed or damaged. The ‘O’ rings should be positioned
adjacent to the body with a plain washer between the ring and the mounting plate.
These instructions must be observed to ensure the compliance of the switch to the IP65
standard.
Re-adjustment of factory setting
Re-adjustment should only be undertaken if the factory setting has been disturbed or if the
requirement is other than standard. Users are requested to contact Guttridge Limited for
advice and assistance before proceeding with any internal adjustment of the switch.
CD1TZ(A) or CE1TZ(A) Switch - ATEX application
A CD1 or CE1 capacitance sensor switch is fitted where a machine is required to be ATEX
compliant.
Installation
The sensor will normally be fitted in the same position as the BL15 diaphragm switch, via a
30mm dia mounting hole in the casing or lid or by the use of an adaptor plate.
In the interests of operator safety the switch unit must be isolated from the
electrical supply before carrying out any work on the switch
CD1TZ(A) Sensor
Chain Conveyor Manual
GuttridgeLimited Page 53 of 60
A LED gives indication of the output state. Sensitivity of the unit can be adjusted using the
potentiometer located on the rear of the unit.
Calibration Calibration of the unit is carried out by use of the sensitivity potentiometer and monitoring of
the Red LED.
Ensure that the sensor is clear of product and installed as detailed above.
Turn the sensitivity potentiometer anti-clockwise to reduce sensitivity to the minimum. The
maximum number of turns required should be four. Do not apply excessive force to the
adjusting screw or it may become damage making further adjustment difficult.
Now turn the sensitivity potentiometer adjusting screw clockwise slowly whilst monitoring
the Red LED. As soon as the Red LED illuminates stop.
Finally, turn the sensitivity potentiometer adjustment screw back in an anti-clockwise
direction 45 degrees making sure the Red LED goes off.
CD1TZ(A) - LED and potentiometer
Sensitivity
Potentiometer
Red LED sensing
indication
CD1/CE1 Adjustment when used for
proximity/motion monitoring
≤ 12mm typical
(25mm maximum)
Sensor
Casing
CD1/CE1 Adjustment when used for level
sensing
≥ 50mm
Sensor
Casing
Chain Conveyor Manual
GuttridgeLimited Page 54 of 60
Step 1 Step 2
Step 3 Step 4
CD1TZ(A) & CE1TZ(A) Calibration
Specification
CD1TR(A) & CE1TR(A) Relay o/p CD1TZ(A) & CE1TZ(A) 2 wire o/p
Supply 12-204V dc 50/60 Hz 24-240 ac 24-240V dc/ac 50/60 Hz
Current consumption
30mA Min. 1.6mA, Vdrop 8V max.
Operating range Typically 25mm Typically 25mm
I/P Rating IP65 IP65
Output Single pole change over contact rated @
3A 240V ac non-ind 2 wire FET rated@200mA max.
Output mode CD1TR(A) output Normally Off
CE1TR(A) Output Normally On
CD1TZ(A) output Normally Off
CE1TZ(A) Output Normally On
Time delay N/A N/A
Cable 2 metres 5 core PVC 2 metres 2 core PVC
Sensitivity 0.2-10 Picofarad. 0.2-10 Picofarad.
LED indication Red LED indicating output state.
LED ‘On’ with output (On) energised.
Red LED indicating output state.
LED ‘On’ with output (On) energised.
Weight 215 gms. 190gms
Approval/ Certification
BAS02ATEX1127X
II 1D T100oC Tamb -15oC to 50oC IP65
CD1/CE1 Specification
X4 max
45o
≥ 50mm
Chain Conveyor Manual
GuttridgeLimited Page 55 of 60
Appendix 2 - Under-speed Monitoring
General
An under-speed monitoring system is fitted to the non-drive end of the machine. The system
comprises of:
A WHIRLIGIG® unit containing a signal generator to transmit shaft rotation data.
An under-speed monitoring unit (Rotamatic or Rotaslip) to capture and monitor the
shaft rotation data.
Operation
Once setup, the unit will monitor the speed of the machine and depending on the specific
machine requirements, either shut down the machine or cause an alarm signal/light to be
activated.
Installation
WHIRLIGIG® unit
The WHIRLIGIG® unit is attached to the end of the shaft being monitored by a threaded stud
using a suitable thread locking adhesive. A flexible strap is provided to secure it to the fixed
structure of the machine being monitored.
The WHIRLIGIG® unit has a mounting plate on to which the underspeed monitoring unit is
either bolted directly or attached by the use of a mounting bracket, depending on the type
fitted. See figure below.
Do not remove the WHIRLIGIG® unit cover. The rotating components under the cover could cause serious injury.
Chain Conveyor Manual
GuttridgeLimited Page 56 of 60
Sensor
2mm gap (approx)
Whirligig
Monitored shaft
Flexible strap
Whirligig to sensor unit gap
Rotamatic PU1DR
Rotaslip PU1DR
Rotamatic PU1DR unit
When fitting to a WHIRLIGIG® unit, correct fitment is achieved when a gap of approximately
2mm is set between the sensor face of the monitoring unit and the WHIRLIGIG® cover.
Where the PU1DR is fitted without a WHIRLIGIG®, the snout of the unit should not be
mounted flush with surrounding metal, as this will cause the sensor to ‘latch on’ permanently.
The sensor snout should be mounted proud of the surrounding metal by at least 10mm and
have as much air gap around it as possible. Refer to table for set up dimensions.
Range for setting up (without Whirligig)
A =
12mm max for ferrous target 20mm dia.
A =
6mm max for non-ferrous target 200mm dia.
B =
15mm minimum
Standard set up dimensions
Rotaslip PU1TZ(A) & PU1TR(A)
A
B
B
A
Shaft being monitored
sensor
Setup details
sensor
Chain Conveyor Manual
GuttridgeLimited Page 57 of 60
When fitting to a WHIRLIGIG® unit, correct fitment is achieved when a gap of approximately
2mm is set between the sensor face of the monitoring unit and the WHIRLIGIG® cover.
Where the unit is fitted without a WHIRLIGIG®, the Rotaslip should be mounted adjacent to
the target. Ideally, the target should be of ferrous metal but non-ferrous metal will be
detected at short range.
Maximum range for ferrous and non-ferrous materials is 12mm and 5 mm respectively with a
30mm diameter circular target. Smaller targets may be used, but the operating distance will
need to be reduced accordingly. See Error! Reference source not found. for standard
dimensions.
When mounted against a solid steel shaft, the target bolt head should protrude from the shaft
at least 15mm, otherwise the sensor will not be able to distinguish the target from the shaft
and the red input light will stay on permanently.
Calibration
Rotamatic PU1DR unit
Two LED’s are provided for information purposes. The input LED is red and flashes every
time a target passes the face of the sensor. The output LED is tri-coloured. Under normal
running, the output LED is a static green. Under fault conditions the colour may be orange or
red (see table for fault codes).
Output LED Fault codes
Orange Programming not accepted, unit has defaulted back to previous programme settings and requires reprogramming
Red Follow procedure for ‘Recalibration to a different setting’. If the output LED remains red contact Guttridge Limited
LED fault codes
The unit is factory set to a speed of 10PPM and a start up time of 5 seconds. If the time
delay required is greater than 5 seconds, see Recalibration for a different setting section
below, otherwise proceed as follows.
12mm Max
15mm Min
sensor Shaft
Standard set up dimensions
Ferrous stud or bracket
30mm dia
Magnetic auto-calibration point
CAL MAG
Chain Conveyor Manual
GuttridgeLimited Page 58 of 60
1. Apply power to both the machine and the PU1DR.
2. Once the machine has reached the normal running speed, place the calibration
magnet on the ‘Cal’ point.
3. Now count the number of flashes made by the green LED to set the start delay
required in seconds, 1 flash = 1 second delay.
4. Remove the ‘Cal’ magnet as soon as the required number of flashes has occurred.
The green output LED will echo the setting in seconds.
5. At the same time automatic calibration to 20% below the normal operating speed
will take place.
Recalibration for a different setting
If the unit is to be used for a slower speed or with a longer time delay than previously set, the
unit may trip out before it can be calibrated. To avoid this occurring use the following
procedure:
1. Whilst holding the magnet on the Cal point, apply power to the machine.
2. Once the machine has reached normal speed remove the Cal magnet.
3. Wait for the green LED to illuminate permanently and then recalibrate as above.
Specification - PU1DR
Supply 24-240V ac, 12-240 dc
Current consumption 50mA maximum
Operating temp -40oC to +70
oC
Operating speed 10 -3,600 pulses per minute
Enclosure Polycarbonate / ABS blend
Protection IP66
Repeat accuracy Better than 2% of working speed over entire range
Output Voltage free relay contact rated 3A 240V ac non-inductive
Output state Relay normally energised with shaft rotating at correct speed
(fail safe).
Start-up delay Programmable delay 0 – 30 seconds initiated by application
of supply
Termination Supplied with 2 metres PVC cable
LED indication LED indication of input pulses and output relay energised
Weight 350gms
Calibration Automatic. Initiated by magnet
Sensing range 15mm maximum ferrous targets
Target If not used in conjunction with Whirligig. Metal protrusion
(ideally min 30mm dia.)
Rotamatic specification details
Chain Conveyor Manual
GuttridgeLimited Page 59 of 60
Rotaslip PU1TZ(A) and PU1TR(A) unit
Two LED’s are provided for information purposes. The input LED is red and flashes every
time a target passes the face of the sensor. The output LED is green. Under normal running,
the output LED is a static green and the output LED is on (energised). With an under-speed
condition both the input and output LED’s will be off (de-energised).
The unit is factory set to a speed of 10PPM and a start up time of 5 seconds. If the time
delay required is greater than 5 seconds, see Recalibration for a different setting section
below, otherwise proceed as follows:
1. Apply power to both the machine and the Rotaslip.
2. Once the machine has reached the normal running speed, place the calibration
magnet (supplied with unit) on the ‘Cal’ point.
3. Now count the number of flashes made by the green LED to set the start delay
required in seconds, 1 flash = 1 second delay.
4. Remove the ‘Cal’ magnet as soon as the required number of flashes has occurred.
The green output LED will echo the setting in seconds.
5. At the same time automatic calibration to 20% below the normal operating speed
will take place.
Recalibration for a different setting
If the unit is to be used for a slower speed or with a longer time delay than previously set, the
unit may trip out before it can be calibrated. This can be avoided by applying power whilst
holding the magnet on the Cal point and removing the magnet only when the machine has
reached normal speed. Wait for the green LED to illuminate permanently and then
recalibrate as above.
Chain Conveyor Manual
GuttridgeLimited Page 60 of 60
Item Specification
Sensor type PU1TZ(A) PU1TR(A)
Supply 24-240V ac/dc 12-240V dc or 24-240V ac
Supply rating 2VA 2VA
Output FET S.P.C.O. relay
Switching capacity 200mA max 3A 240V non-inductive maximum
Saturation voltage 6 volts max (output on) N/A
Ambient temp -15oC to +50oC -15oC to +50oC
Output state Normally closed (volt drop 6 volts max)
above set speed. Normally open (leakage current 1.6mA max).
Normally open. Closed above set speed.
Calibration Automatic. Initiated by magnet Automatic. Initiated by magnet
Sensing range Nominally 12mm on ferrous metal, 5mm
on non-ferrous at 25oC Nominally 12mm on ferrous metal, 5mm
on non-ferrous at 25oC
Input pulse range 10 to 3600 p.p.m. 10 to 3600 p.p.m.
Repeat accuracy 1% 1%
Start up delay Adjustable to 0 – 60 seconds Adjustable to 0 – 30 seconds
Operating settings Automatic calibration by applying
magnet to cal point Relay de-energised at 20% under set speed
Automatic calibration by applying magnet to cal point Relay de-energised at 20%
under set speed
Enclosure Moulded nylon. DIN threaded 30mm by
1.5mm pitch Moulded nylon. DIN threaded 30mm by
1.5mm pitch
Protection IP65 IP65
Relative humidity 90% RH 90% RH
LED indication Target Detected and Output Target Detected and Output
Cable Supplied with 5 metres 2 core 600/1000v
flame retardant to EN60332-1 Supplied with 5 metres 5 core 600/1000v
flame retardant to EN60332-1
Rotaslip specification details
Testing both types of sensor
The system can be tested by placing a thin metal plate between the sensor and the cover of the
WHIRLIGIG®. When installing other industry standard sensors, a small gap should be left
between the sensor and the WHIRLIGIG® cover for this purpose.
Note When installing or using either type of sensor in an exterior location, a suitable UV shield
should be fitted over the unit. If located in an area with high risk of impact additional
guarding/protection MUST be fitted.