HYTROL 36-CRRH Chain Driven Live Roller Installation Guide

HYTROL 36-CRRH Chain Driven Live Roller Installation

Product Information

The manual is for the installation, maintenance, and safety information of the Model 36-CRRH conveyor system. The recommended spare parts are highlighted in gray for easy identification. The manual is effective from November 2003 and supersedes the March 2000 version. The product comes with warning signs that are placed at various points to alert personnel of potential dangers. These signs include warnings against starting the conveyor until personnel are clear, servicing moving or energized equipment, climbing, sitting, walking, or riding on the conveyor, and exposed moving parts.

Product Usage Instructions

Before using the conveyor system, it is important to read and understand the warning signs placed on various points of the equipment. Ensure that personnel are alerted to and obey these warnings to reduce the possibility of injury.

Product Installation

When installing the conveyor system, follow the installation safety precautions provided in the manual. This includes receiving and uncrating the product, support installation, conveyor set-up, and electrical equipment installation.

Product Operation

Before starting the conveyor system, it is important to follow the operation safety precautions provided in the manual. This includes ensuring personnel are clear before starting the conveyor and following proper start-up procedures.

Product Maintenance

To ensure the longevity of the conveyor system, regular maintenance is necessary. Follow the maintenance safety precautions provided in the manual, which includes lubrication, drive chain alignment and tension, troubleshooting, and preventive maintenance checklist.

1. Replacement Parts

If any part needs replacement, follow the instructions on how to order replacement parts provided in the manual. The manual includes a model 36-CRRH parts drawing and parts list for easy identification of parts that need replacement.

Use code HYPMANUAL for free shipping on your first order at HytrolParts.com. For further assistance, contact support@hytrolparts.com or visit www.HytrolParts.com.

Warning Signs

In an effort to reduce the possibility of injury to personnel working around HYTROL conveying equipment, warning signs are placed at various points on the equipment to alert them of potential dangers. Please check equipment and note all warning signs. Make certain your personnel are alerted to and obey these warnings. Shown below are typical signs that are attached to this equipment.

WARNING!
DO NOT START CONVEYOR UNTIL PERSONNEL ARE CLEAR PLACED ON ALL POWERED CONVEYORS NEAR DRIVE AND/OR CONTROLS.

DANGER
Climbing, sitting,walking or riding on conveyor at any time will cause severe injury or death KEEP OFF PLACED ON 20 FT. INTERVALS,BOTH SIDES.

WARNING
Moving equipment can cause severe injury KEEP AWAY PLACED ON TERMINATING ENDS.

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, see the “Important Notice” attached to the crate.

INSTALLATION

Installation Safety
Precautions for Conveyors and Related Equipment

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. Wherever 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 mov-ing machinery parts that present a hazard to employees at their work station shall be mechanically or electrically guard-ed, or guarded by location or position.
When a conveyor passes over a walkway, roadway, or work station, it is considered guarded solely by location or posi-tion 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 haz- ardous moving parts.
Although overhead conveyors may be guarded by location, spill guard, pan guards, or equivalent shall be provided if the product may fall off the conveyor for any reason and if per-sonnel 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 con- veyor or guards.
Where system function will be impaired by providing the minimum clearance of 6 ft. 8 in. (2.032 m) through an emer-gency exit, 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.

Support Installation

1. Determine the chain guard side of conveyor and posi-tion drive section so guard is on desired side.
2. Refer to “Match-Mark” numbers on ends of conveyor sections (Figure 6A). Position them in sequence fol-lowing “Match-Mark” numbers.
3. Attach supports to both ends of drive section and to one end of intermediate or tail sections (Figure 6A). Hand tighten bolts only at this time.

Conveyor Set-Up

1. Mark a chalk line on floor to locate centerline of the conveyor.
2. Place the drive section in position.
3. Install remaining sections, placing end without sup-port on extended support of previous section (Figure 7A ). Check “Match-Mark” Numbers to see that adjoining sections are in proper sequence.
4. Fasten sections together with butt couplings and supports (Figure 7B). Hand tighten bolts.
5. Connect chains at section joints (Figure 7C).
6. Check to see that conveyor is level across width and length of unit. Shim supports if nescessary.
7. Tighten all butt coupling and support mounting bolts and lag conveyor to floor.
8. Install electrical controls and wire motor.

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 manufac-turer.

CONTROLS
Electrical Code: All motor controls and wiring shall conform to the National Electrical Code (Article 670 or other applica-ble articles) as published by the National Fire Protection Association and as approved by the American Standards Institute, Inc.
CONTROL STATIONS

• A) 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.

• B) 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 con-veyor 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 per-sonnel must keep clear. The warnings shall be provided along the conveyor at areas not guarded by position or loca-tion.

• C) 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 loca-tions 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 identifi-able 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 haz- ardous to personnel, an emergency stop device is not required.
  The emergency stop device shall act directly on the con-trol 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.

• D) 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

• A) All safety devices, including wiring of electrical safety devices, shall be arranged to operate in a “Fail-Safe” man-ner, that is, if power failure or failure of the device itself would occur, a hazardous condition must not result.
• B) 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 associat-ed equipment to resume operation.
• C) 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

Operation Safety Precautions

• A) Only trained employees shall be permitted to operate conveyors. Training shall include instruction in operation under normal conditions and emergency situations.
• B) Where employee safety is dependent upon stopping and/or starting devices, they shall be kept free of obstructions to permit ready access.
• C) The area around loading and unloading points shall be kept clear of obstructions which could endanger personnel.
• D) 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 verti-cal conveyor. Owners of conveyors should affix warning devices to the conveyor reading Do Not Ride Conveyor.
• E) Personnel working on or near a conveyor shall be instructed as to the location and operation of pertinent stopping devices.
• F) A conveyor shall be used to transport only material it is capable of han-dling safely.
• G) Under no circumstances shall the safety characteristics of the convey-or be altered if such alterations would endanger personnel.
• H) Routine inspections and preventive and corrective maintenance pro-grams shall be conducted to insure that all safety features and devices are retained and function properly.
• I) Personnel should be alerted to the potential hazard of entanglement in conveyors caused by items such as long hair, loose clothing, and jewelry.
• J) As a general rule, conveyors should not be cleaned while in operation. Where proper cleaning requires the conveyor to be in motion and a haz-ard exists, personnel should be made aware of the associated hazard.

Conveyor Start-Up

Before conveyor is turned on, check for foreign objects that may have been left inside 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

Maintenance Safety Precautions

• A) Maintenance, such as lubrication and adjustments, shall be per-formed only by qualified and trained personnel.
• B) 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.
• C) 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 per-son or groups involved with the conveyor against an unexpected start.
• D) Replace all safety devices and guards before starting equipment for normal operation.
• E) 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.

WARNING SIGNS
Maintain all warning signs in a legible condition and obey all warnings. See Page 3 of this manual for examples of warning signs.

Lubrication

The drive chain is pre-lubricated from the manufacturer by a hot dip-ping 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 gener-ously lubricate the chain. The proper viscosity of lubricant greatly affects its ability to flow into the internal areas of the chain. Refer to the table below for the proper viscosity of lubricant for your application.

Ambient Temperature

Degrees F

| SAE| ISO
---|---|---
20-40| 20| 46 or 68
40-100| 30| 100
100-120| 40| 150

The drive chain’s lubrication requirement is greatly affected by the operating conditions. For harsh conditions such as damp environ-ments, dusty environments, excessive speeds, or elevated tempera-tures, 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 lubrica-tion intervals accordingly.

Drive Chain Alignment and Tension

The drive chain and sprockets should be checked periodi-cally for proper tension and alignment. Improper adjustment will cause extensive wear to the drive components.

TO MAKE ADJUSTMENTS

1. Remove chain guard.
2. Check sprocket alignment by placing a straightedge across the face of both sprockets (Figure 12A). Loosen set screws and adjust as needed. Re-tighten set screws.
3. To adjust chain tension, loosen bolts that fasten motor ing angles, both sides of the conveyor. Tighten take-up bolts until desired chain tension is reached. (Fig
4. Lubricate chain per lubrication instructions.
5. Replace chain guard so that it does not interfere with drive.

CAUTION!
Never remove chain guards while the conveyor is run-ning. Always replace guards after adjustments are made.

Trouble Shooting

The following charts list possible problems that may occur in the operation of a powered conveyor.

TROUBLE SHOOTING DRIVES

Conveyor will not start or motor quits fre- quently.

| ****

1. Motor is overloaded or drawing too much current.

| ****

1)   Check for overloading of conveyor.

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

Drive chain and sprockets wear excessively.

| 1)   Lack of lubrication on chain causing chain stretch which creates improper chain to sprocket mesh.

2)   Sprockets are out of alignment.

3)   Improper chain tension.

| 1)   Replace chain and sprockets. Provide adequate lubrication.

2)   Align sprockets. (See “Drive Chain Alignment and Tension”).

3)   See “Drive Chain Alignment and Tension”.

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

2)   Loose set screw.

| 1)   Replace bearing.

2)   Tighten set screw.

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.

Preventive Maintenance Checklist

The following is a general maintenance checklist which covers the major components of your conveyor. This will be helpful in establishing a standard maintenance schedule.

MOTOR

| Check Noise|  |  |
Check Temperature|  |  |
Check Mounting Bolts|  |  |

REDUCER

| Check Noise|  |  |
Check Temperature|  |  |
Check Oil Level|  |  |

DRIVE CHAIN

| Check Tension|  |  |
Lubricate|  |  |
Check for Wear|  |  |

SPROCKETS AND ROLLERS

| Check Sprocket Alignment|  |  |
Check for Wear|  |  |
Check Noise (Bearings)|  |  |
Check Bearing Lubrication|  |  |
STRUCTURAL| General Check: All loose bolts, etc., tightened|  |  |

REPLACEMENT PARTS

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 Distributor.
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.

Model SC Diverter Parts Drawing

Model SC Diverter Parts Drawing & List

for Information on How To Order Replacement Parts

Recommended Spare Parts Highlighted in Gray

“Building Relationships One Conveyor Part at a Time” support@hytrolparts.com | www.HytrolParts.com
Use code HYPMANUAL for free shipping on your first order at HytrolParts.com

References

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

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