To change the drive motor, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the chain from the drive sprocket.
  4. If the drive sprocket does have more than 18 teeth, please remove it from the motor shaft as described before (see other chapter). For smaller sprockets, the sprocket can remain on the output shaft.
  5. Release the motor clamping bolts and remove the motor backwards.
  6. If the drive sprocket is still installed, please mount it to the new motor according to the procedure of replacing the drive sprocket.
  7. Install the new motor and the drive sprocket, if required, in the reverse order as described. Make sure the drive sprocket is in the correct position: The center line of the chain has to be in one line.
  8. Re-tension the chain and reset the chain tensioner.
  9. Re-install the clear front cover.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  11. Check the chain tension after two hours of operation again.

    Drive Unit Replacing drive motor long tensioner

 
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To change the re-directional sprockets, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the re-directional sprocket attachment bracket by taking off all nine bolts.
  4. Unbolt the re-directional sprockets.
  5. For installation please proceed in reverse order. Pay attention to the correct flow of the chain and install the new re- directional sprockets with locking washers.
  6. Install and check all bolts to be tightened.
  7. Re-tension the chain and reset the chain tensioner.
  8. Re-install the clear front cover.
  9. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  10. Check the chain tension after two hours of operation again.

    Drive Unit Replacing re directional sprockets long tensioner

 
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To change the drive sprocket in a drive unit with long tensioner, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the chain from the drive sprocket.
  4. Release the mounting bolts of the drive sprocket with an Allen wrench (M6) and remove the bolts with the washer.
  5. Mount the feeding conveyor segment with the spacer strips to the base frame of the Swing Gate.
  6. Pull the drive sprocket of the motor shaft with a suitable puller. The spacer ring has to remain on the motor shaft because it will be used as a hard stop for the new sprocket to get the right alignment.
  7. Install the new drive sprocket in reverse order. If a drive sprocket with different diameter gets used, the drive chain length has to be checked and it needs to get shortened or lengthened if required. That should be done at an existing master link. Make sure that the drive sprocket is correctly positioned: The center line of the chain has to be in one line.
  8. Re-tension the chain and reset the chain tensioner.
  9. Install the clear front cover of the drive station.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  11. Check the chain tension after two hours of operation again.

    Drive Unit Replacing drive sprocket long tensioner

 
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A replacement of the entire chain is required when the chain is worn out, or worn beyond the limits of the chain tensioner. Signs for that are high soiling, non-moving chain links and rust at the chain, or seeing a red color code on the chain tensioner slider indicating that it is at the end of its travel.
 
To replace the chain in a drive unit with long tensioner, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the lower extrusion of the drive station by taking out the three attachment bolts.
  4. Remove the chain from the drive sprocket and pull the chain until a master link appears.
  5. Open the master link and connect the new with the old chain. Put the new chain on a clean surface to avoid new dirt and soiling of the chain.
  6. Pull at the open end of the old chain to get the new chain in the chain drive. If needed some chain has to be connected with additional master links.
  7. Place the chain around the chain tensioner and the drive sprocket and cut the chain so that it can be closed tightly with a master link.
  8. Re-tension the chain and reset the chain tensioner.
  9. Install the lower extrusion of the drive station and reinstall the clear front cover of the drive station.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to become shortened by another chain link.
  11. Check the chain tension after two hours of operation again.
 
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To shorten the drive chain, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the 228 mm long top rail extrusion above the drive station.
  3. Turn the fan of the drive motor in the direction of flow to drive the conveyor manually until a master link is visible (zinced).
    CAUTION: There is a residual danger because of the non covered chain drive.
  4. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  5. Open the master link, and pull the chain to tension and shorten the excessive chain.
  6. Re-connect both chain ends with the master link. Pay attention to the right orientation and to the style of the master link: The lock of the master link leads towards the bottom rail extrusion, the locking plate faces into the direction of the conveyor flow.
  7. Re-tension the chain and reset the chain tensioner.
  8. Mount the clear front cover and install the top rail extrusion piece. Please ensure that the chain guide and the guide strip are installed correctly. Install all chain covers correctly and completely again.
  9. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  10. Check the chain tension after two hours of operation again.

  11. Drive Unit Shortening drive chain long tensioner

 
Freigegeben in L - Conveyor
Thursday, 22 October 2015 22:55

Conveyor: %Changing an end roller


To change the end roller, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. If covers between rollers are installed, remove them by pushing them out from the bottom.
  3. Remove the chain covers between the two last rollers of the conveyor section, as described in the previous chapter.
  4. Remove the plastic chain end support.
  5. Loosen and remove the mounting bolts of the end roller. Relieve the end roller against the chain tension by hand to remove the bolts.
  6. Release the end roller by turning in slightly from the drive chain and remove the end roller sideways (the same way as the friction roller).
  7. Install the new end roller (please pay attention to the correct type of roller) in the reverse order. Insert the chain sprocket into the looped chain. The end roller must be pulled against the chain tension in position. If this is not possible, the chain tensioner must be released in the drive station. After the installation the chain tensioner has to be reset.

    Roller Changing end roller

Please use a self-locking nut for fastening the chain end support. Please check that no foreign material is remaining in the system and all covers are installed correctly before powering up the conveyor system.
 
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Thursday, 22 October 2015 22:53

Conveyor: %Changing a friction roller


To change or relocate a friction roller, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the chain covers in the area around the roller(s) to be replaced or relocated.
  3. Loosen and remove the mounting bolts of the rollers (M8 socket head bolt with hexagon socket size 6 mm).
  4. To take the friction roller out, release the roller from the drive chain by twisting or sliding sideways. If relocation to an adjoining mounting position is planned, the roller can be shifted sideways.
  5. Remove the friction roller (aslope) upwards.
  6. Install the new roller in reverse order.

    Roller Changing friction roller

All chain covers must be installed completely and the roller must be checked for tight and correct installation after every change or relocation of a roller. Check the roller configuration and reposition more rollers, if necessary. Make sure that you install the correct roller type for that location.
 
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Thursday, 22 October 2015 22:52

Conveyor: %Adjustment of the friction rollers


Only KRUPS Standard Rollers with adjustable nut and silver or golden spring can be adjusted in their friction.
Rollers with a silver spring generate more friction than the gold spring rollers but share the same internal structure, allowing the spring to be changed to increase tension when needed. Warning: Too much friction can wear out the bottom of the pallet.
 
The friction rollers can be adjusted (increased or decreased) by turning the adjusting nut on the axis of the roller with an open-end wrench size 22 mm until the required transportation force is achieved. The adjustment range is predefined in all types of rollers because of the existing thread length.
Tightening the nut increases the friction and loosening reduces the friction.

Roller Adjustments

 
The rollers must have a low friction and low driving force in the accumulation areas to minimize the dynamic pallet pressure and to avoid the wear of the pallet bottom because of spinning rollers.
 
The rollers must have a higher friction and driving force in the area of corners, diverters and junctions to guarantee the transport of the pallet in those areas.
 
If a pallet hits a stop unit, the rollers should stop under the pallet to avoid wear.
 
The friction of the rollers is pre-set to the estimated total part weight but the friction must be adjusted to the actual pallet configuration and the working environment during the installation of the conveyor system.
The friction should be checked after approx. 100 hours.
 
The friction of the rollers should not be set higher than necessary for safe moving and departing of the pallets. This can avoid an unnecessarily high dynamic pressure and makes for a safer operation.
 
 
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Thursday, 22 October 2015 22:47

Conveyor: %Replacing the pallet stop insert


Please position and secure the pallet upside down for a better handling.
 
To change the pallet stop insert, please proceed as follows:
  1. De-install and remove the attachment bolts and the lock washers of the stop insert.
  2. Remove the stop insert with the return stop flapper with suitable tools.
  3. Insert the new stop insert and the return stop flapper in the intended opening. Make sure that the PU damping strips are inserted and the stop insert is even on the bottom of the cutout.
  4. Insert and tighten the attachment bots with the lock washers. Make sure that the heads of the screws are not protruded beyond the stop insert but also that the bolts are not too tight because it is just bolted into a plastic thread.
  5. Check the function of the return stop flapper and its movement.

    Pallet Replacing stop insert

 
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For working on the side guide rollers, a free access has to be given to the attachments of the side guide rollers. Please remove attached top plates or any structure on top of the pallet, if necessary.
 
To change the side guide rollers of a pallet, please proceed as follows:
  1. Remove the clamping bolts of the hold down device and remove those.
  2. Drive out the shaft of the roller with a pin punch of 3 mm until the side guide roller can be removed.
  3. Install the new side guide roller in the reverse order as described above. Make sure that the axis is not set up too low, the roller is flexible and can rotate freely and the bolts of the hold down device are not tightened too much, because it is just bolted into a plastic thread.

    Pallet Replacing side guide roller

 
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