installation, operation and maintenance manual chain conveyor … · 2019. 5. 17. · chain...

Chain Conveyor Manual

GuttridgeLimited of 60

Please read this manual before

commencing installation, operation

or maintenance

Installation, Operation and Maintenance Manual

Chain Conveyor

Machine No



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


Revision 16 – 16/01/13

Copyright © 2010 Guttridge Limited, All Rights Reserved.



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.



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

http://www.guttridge.co.uk/atex_information



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.



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.



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



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



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



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



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



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



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



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



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



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



Recycle cup fitment – Shrouded Chain Conveyor

Direction of travel of

chain on conveyor base

Recycle Cup

Integral Scraper



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



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



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



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



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



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



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.



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



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



Chain Conveyor Assembly

View A

View A

Chain Conveyor Assembly detailed

Drive ‘V’ belts



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.



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



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.



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.



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.



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)



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



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




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.



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



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.



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.



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



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



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.




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.



Packing gland seals

Pilot packing

Inner lock nut

Packing gland bush assembly

Outer lock nut

Packing gland bronze bush

Pilot packing joint alignment



Shaft mounted gear motor unit (GMU) removal 6.12.


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.



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



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



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


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


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



10. Parts

Drive End assembly 10.1.

Always quote the machine number when ordering spares.

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



Tension Section Assembly 10.2.

Always quote the machine number when ordering spares.



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



Intermediate Section Assembly 10.3.


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.



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



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



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



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



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.



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



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



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



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.



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.

installation, operation and maintenance manual chain conveyor … · 2019. 5. 17. · chain...

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