HYTROL CT-3000 Transfer Manual Instruction Manual

HYTROL CT-3000 Transfer Manual

INTRODUCTION

This manual provides guidelines and procedures for installing, operating, and maintaining your conveyor. A complete parts list is provided with recommended spare parts highlighted in gray. Important safety information is also provided throughout the manual. For safety to personnel and for proper operation of your conveyor, it is recommended that you read and follow the instructions provided in this manual.

Receiving and Uncrating

1. Check the number of items received against the bill of lading.
2. Examine condition of equipment to determine if any damage occurred during shipment.
3. Move all crates to area of installation.
4. Remove crating and check for optional equipment that may be fastened to the conveyor. Make sure these parts (or any foreign pieces) are removed.

NOTE: If damage has occurred or freight is missing, Contact your Hytrol Integration Partner.

How to Order Replacement Parts

Included in this manual are parts drawings with complete replacement parts lists. Minor fasteners, such as nuts and bolts, are not included.
When ordering replacement parts:

1. Contact Dealer from whom conveyor was purchased or nearest HYTROL Integration Partner.
2. Give Conveyor Model Number and Serial Number or HYTROL Factory Order Number.
3. Give Part Number and complete description from Parts List.
4. Give type of drive. Example—8” End Drive, 8” Center Drive, etc.
5. If you are in a breakdown situation, tell us.

HYTROL Serial Number
(Located near Drive on Powered Models).

Installation

GUARDS AND GUARDING
Interfacing of Equipment. When two or more pieces of equipment are interfaced, special attention shall be given to the interfaced area to insure the presence of adequate guarding and safety devices.

Guarding Exceptions. Whenever conditions prevail that would require guarding under these standards, but such guarding would render the conveyor unusable, prominent warning means shall be provided in the area or on the equipment in lieu of guarding.

Guarded by Location or Position. Where necessary for the protection of employees from hazards, all exposed moving machinery parts that present a hazard to employees at their work station shall be mechanically or electrically guarded, or guarded by location or position.

• Remoteness from frequent presence of public or employed personnel shall constitute guarding by location.
• When a conveyor passes over a walkway, roadway, or work station, it is considered guarded solely by location or position if all moving parts are at least 8 ft. (2.44 m) above the floor or walking surface or are otherwise located so that the employee cannot inadvertently come in contact with hazardous moving parts.
• Although overhead conveyors may be guarded by location, spill guards, pan guards, or equivalent shall be provided if the product may fall off the conveyor for any reason and if personnel would be endangered.

HEADROOM

• When conveyors are installed above exit passageways, aisles, or corridors, there shall be provided a minimum clearance of 6 ft. 8 in. (2.032 m) measured vertically from the floor or walking surface to the lowest part of the conveyor or guards.
• Where system function will be impaired by providing the minimum clearance of 6 ft. 8 in. (2.032 m) through an emergency clearance, alternate passageways shall be provided.
• It is permissible to allow passage under conveyors with less than 6 ft. 8 in. (2.032 m) clearance from the floor for other than emergency exits if a suitable warning indicates low headroom.

Operation

• Only trained employees shall be permitted to operate conveyors. Training shall include instruction in operation under normal conditions and emergency situations.
• Where employee safety is dependent upon stopping and/or starting devices, they shall be kept free of obstructions to permit ready access.
• The area around loading and unloading points shall be kept clear of obstructions which could endanger personnel.
• No person shall ride the load-carrying element of a conveyor under any circumstances unless that person is specifically authorized by the owner or employer to do so. Under those circumstances, such employee shall only ride a conveyor which incorporates within its supporting structure platforms or control stations specifically designed for carrying personnel. Under no circumstances shall any person ride on any element of a vertical conveyor.
• Personnel working on or near a conveyor shall be instructed as to the location and operation of pertinent stopping devices.
• A conveyor shall be used to transport only material it is capable of handling safely.
• Under no circumstances shall the safety characteristics of the conveyor be altered if such alterations would endanger personnel.
• Routine inspections and preventive and corrective maintenance programs shall be conducted to insure that all safety features and devices are retained and function properly.
• Personnel should be alerted to the potential hazard of entanglement in conveyors caused by items such as long hair, loose clothing, and jewelry.
• Conveyors shall not be maintained or serviced while in operation unless proper maintenance or service requires the conveyor to be in motion. In this case, personnel shall be made aware of the hazards and how the task may be safely accomplished.
• Owners of conveyor should insure proper safety labels are affixed to the conveyor warning of particular hazards involved in operation of their conveyors.

CAUTION! Because of the many moving parts on the conveyor, all personnel in the area of the conveyor need to be warned that the conveyor is about to be started.

Maintenance

• All maintenance, including lubrication and adjustments, shall be performed only by qualified and trained personnel.
• It is important that a maintenance program be established to insure that all conveyor components are maintained in a condition which does not constitute a hazard to personnel.
• When a conveyor is stopped for maintenance purposes, starting devices or powered accessories shall be locked or tagged out in accordance with a formalized procedure designed to protect all persons or groups involved with the conveyor against an unexpected start.
• Replace all safety devices and guards before starting equipment for normal operation.
• Whenever practical, DO NOT lubricate conveyors while they are in motion. Only trained personnel who are aware of the hazard of the conveyor in motion shall be allowed to lubricate.

Safety Guards
Maintain all guards and safety devices IN POSITION and IN SAFE REPAIR.

Safety Labels
In an effort to reduce the possibility of injury to personnel working around HYTROL conveying equipment, safety labels are placed at various points on the equipment to alert them of potential hazards. Please check equipment and note all safety labels. Make certain your personnel are alerted to and obey these warnings. See Safety Manual for examples of warning labels.

REMEMBER Do not remove, reuse or modify material handling equipment for any purpose other than it’s original intended use.

Location

1. Refer to building layout for obstructions such as machines, columns, walls, openings, etc. Check to see that conveyor layout drawings correspond with building layout.
2. Determine direction of product flow. Figure 4A indicates the flow as related to the drive.
3. Refer to “Match-Mark” numbers on ends of conveyor sections (Figure 4A). Position them in this sequence near area of installation.

Conveyor Installation

1. The model CT-3000 is typically a component of a conveyor and is not a stand alone device, therefore follow conveyor set-up and installation procedures outlined in the installation manual for the particular model of conveyor the CT-3000 is contained within.
2. A Conveyor-to-Conveyor CT-3000 will have two sections (infeed/discharge) that must be coupled together located within two parallel lines of conveyor.
3. Install conveyors containing transfer components. Ensure proper distance between lines for CT-3000 has been established prior to lagging to floor/surface.
4. Fasten sections together at coupling channels.
5. Check for proper alignment of chain guide wearstrips. Install transfer chain using the connector links provided. NOTE: Chain tension has been pre-determined at the factory. Refer to “Maintenance” section for periodic chain tension adjustment procedures.

CT-3000 Set-Up

1. Connect main air supply line to filter/regulator and set to 75 psi. (Fig 4B) NOTE: See Packing List for maintenance instructions and how to adjust the filter/regulator, if supplied.
2. Provide electrical power to motor and up/down proximity switches (if provided) at conduit boxes located on the CT-3000 base channel under the drive side of the conveyor.
3. Provide electrical power to the solenoids on the air valve located on the CT-3000 base channel adjacent to the conduit boxes for the motor/proximity switches.

Electrical Equipment

WARNING! Electrical controls shall be installed and wired by a qualified electrician. Wiring information for the motor and controls are furnished by the equipment manufacturer.

CONTROLS
Electrical Code: All motor controls and wiring shall conform to the National Electrical Code (Article 670 or other applicable articles) as published by the National Fire Protection Association and as approved by the American Standards Institute, Inc.
“Building Relationships One Conveyor Part at a Time”

CONTROL STATIONS

• Control stations should be so arranged and located that the operation of the equipment is visible from them, and shall be clearly marked or labeled to indicate the function controlled.
• A conveyor which would cause injury when started shall not be started until employees in the area are alerted by a signal or by a designated person that the conveyor is about to start.

When a conveyor would cause injury when started and is automatically controlled or must be controlled from a remote location, an audible device shall be provided which can be clearly heard at all points along the conveyor where personnel may be present. The warning device shall be actuated by the controller device starting the conveyor and shall continue for a required period of time before the conveyor starts. A flashing light or similar visual warning may be used in conjunction with or in place of the audible device if more effective in particular circumstances.

Where system function would be seriously hindered or adversely affected by the required time delay or where the intent of the warning may be misinterpreted (i.e., a work area with many different conveyors and allied devices), clear, concise, and legible warning shall be provided. The warning shall indicate that conveyors and allied equipment may be started at any time, that danger exists, and that personnel must keep clear. The warnings shall be provided along the conveyor at areas not guarded by position or location.

• Remotely and automatically controlled conveyors, and conveyors where operator stations are not manned or are beyond voice and visual contact from drive areas, loading areas, transfer points, and other potentially hazardous locations on the conveyor path not guarded by location, position, or guards, shall be furnished with emergency stop buttons, pull cords, limit switches, or similar emergency stop devices.

All such emergency stop devices shall be easily identifiable in the immediate vicinity of such locations unless guarded by location, position, or guards. Where the design, function, and operation of such conveyor clearly is not hazardous to personnel, an emergency stop device is not required.

The emergency stop device shall act directly on the control of the conveyor concerned and shall not depend on the stopping of any other equipment. The emergency stop devices shall be installed so that they cannot be overridden from other locations.

• Inactive and unused actuators, controllers, and wiring should be removed from control stations and panel boards, together with obsolete diagrams, indicators, control labels, and other material which serve to confuse the operator.

SAFETY DEVICES

• All safety devices, including wiring of electrical safety devices, shall be arranged to operate in a “Fail-Safe” manner, that is, if power failure or failure of the device itself would occur, a hazardous condition must not result.
• Emergency Stops and Restarts. Conveyor controls shall be so arranged that, in case of emergency stop, manual reset or start at the location where the emergency stop was initiated, shall be required of the conveyor(s) and associated equipment to resume operation.
• Before restarting a conveyor which has been stopped because of an emergency, an inspection of the conveyor shall be made and the cause of the stoppage determined. The starting device shall be locked out before any attempt is made to remove the cause of stoppage, unless operation is necessary to determine the cause or to safely remove the stoppage.

Refer to ANSI Z244.1-1982, American National Standard for Personnel Protection – Lockout/Tagout of Energy Sources – Minimum Safety Requirements and OSHA Standard Number 29 CFR 1910.147 “The Control of Hazardous Energy (Lockout/Tagout).”

OPERATION

Conveyor Start-Up
Before conveyor is turned on, check for foreign objects that may have been left inside the conveyor during installation. These objects could cause serious damage during start-up.
After conveyor has been turned on and is operating, check motors, reducers, and moving parts to make sure they are working freely.

CAUTION! Because of the many moving parts on the conveyor, all personnel in the area of the conveyor need to be warned that the conveyor is about to be started.

MAINTENANCE

Lubrication
The drive chain is pre-lubricated from the manufacturer by a hot dipping process that ensures total lubrication of all components. However, continued proper lubrication will greatly extend the useful life of every drive chain.
Drive Chain lubrication serves several purposes including:

• Protecting against wear of the pin-bushing joint
• Lubricating chain-sprocket contact surfaces
• Preventing rust or corrosion

For normal operating environments, lubricate every 2080 hours of operation or every 6 months, whichever comes first. Lubricate with a good grade of non- detergent petroleum or synthetic lubricant (i.e., Mobile 1 Synthetic). For best results, always use a brush to generously lubricate the chain. Refer to the table above for the proper viscosity of lubricant for your application.

The drive chain’s lubrication requirement is greatly affected by the operating conditions. For harsh conditions such as damp environments, dusty environments, excessive speeds, or elevated temperatures, it is best to lubricate more frequently. It may be best, under these conditions, to develop a custom lubrication schedule for your specific application. A custom lubrication schedule may be developed by inspecting the drive chain on regular time intervals for sufficient lubrication. Once the time interval is determined at which the chain is not sufficiently lubricated, lubricate it and schedule the future lubrication intervals accordingly.

Trouble Shooting

The following chart list possible problems that may occur in the operation of a powered conveyor.
TROUBLE SHOOTING DRIVES

2)  Check heater or circuit breaker and change if necessary.

Drag chain and sprockets wear excessively.

| 1)  Lack of lubrication on chain may have caused chain to stretch and create an improper chain to sprocket mesh.

2)  Sprockets are out of alignment.

3)  Loose chain.

| 1)  Replace chain and sprockets. NOTE: If problem reoccurs, a chain take-up may be required.

2. Align drive sprockets with fixed idlers.

3. Tighten chain.

Loud popping or grinding noise.| 1)  Defective bearing.

2)  Loose set screws in bearing.

3)  Loose drive chain.

| 1)  Replace bearing.

2. Tighten set screw.

3. Tighten chain.

Motor or reducer overheating.

| 1)  Conveyor is overloaded.

2)  Low voltage to motor.

3)  Low lubricant level in reducer.

| 1)  Check capacity of conveyor and reduce load to recommended level.

2)  Have electrician check and correct as necessary.

3)  Relubricate per manufacturer’s recommendations. For HYTROL reducer, refer to separate manual.

Transfer raises too slowly.| 1) Air pressure is too low.| 1) Adjust pressure at FR (80 psi. max)
Transfer descends too slowly.| 1)  Flow-controls not set properly.

2)  Quick-exhaust valve not functioning.

3. Air-line restriction.

| 1)  Open flow-control mufflers attached to quick-exhaust valves located on runner channel.

2)  Check to make sure flow-control muffler located on air-valve is not restricted/closed off.

3)  Make sure air-lines between air-valve and air-actuators is not pinched or binding.

Chain Tension Adjustment

NOTE: Chain tension should be pre-set at factory. However, during normal operation, chain may stretch enough to require adjustment.

1. Remove chain guard.
2. To adjust chain tension, loosen the two bolts that are securing the sprocket and take-up angle to the carriage weld listed on Figure 6A. Tighten take-up bolts until desired tension is reached. Make sure all strands are adjusted the same, then retighten mounting bolts.
3. Lubricate chain per lubrication instructions.
4. Replace chain guard.

Chain should be about a 1/2” from the chain guide when lifted. When released, it should fall back into place with decent force. If chain can’t be lifted, then there’s too much tension on it. If it doesn’t fall back into place with force, then the chain is too loose.

CAUTION! NEVER remove chain guards while the conveyor is running. Always replace guards after adjustments are made.

Transfer Plumbing Diagram

Single Pneumatic Schematic

Transfer Assembly

Transfer Linkage Rod Assembly

Filter Regulator Assembly

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References

• Hytrol Conveyor Parts & Accessories – HytrolParts.com
• Hytrol Conveyor Parts & Accessories – HytrolParts.com
• Hytrol Conveyor Parts & Accessories – HytrolParts.com

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