Ideas that move

TUBULAR DRAG CONVEYOR

INSTALLATION,OPERATION

&MAINTENANCE

MANUAL

REV 9/07

All owners and operators should read this manual and/or beinstructed on safe operating and maintenance procedures before

attempting to uncrate, install, operate, adjust or service thisequipment

Following are symbols used in this manual along with a description of their meanings

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or severeinjury.

WARNINGWARNING indicates a potentially hazardous situation which, if not avoided, will result in death or severe

injury

CAUTIONCAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor/moderate

injury and/or damage to equipment.

HAPMANTUBULAR DRAG CONVEYOR

Table of Contents

Definition of Warning Symbols.............................................................................. 2

Major Feature Index .............................................................................................. 4

1.0 - Warranty....................................................................................................... 5

2.0 - Introduction ................................................................................................... 6

3.0 - Safety Instructions ........................................................................................ 7

4.0 - Principles of Operation ................................................................................. 9

5.0 - Receiving your Equipment.......................................................................... 10

6.0-Storage ...................................................................................................... 10

7.0 - Conveyor Assembly and Erection............................................................... 10

8.0 - Tubular Chain Installation .......................................................................... 12

9.0 - Adjusting the Chain..................................................................................... 16

10.0- Adjusting the Sprocket.............................................................................. 17

11.0 - Adjusting the Chain Rotation .................................................................... 17

12.0- Starting and Adjusting............................................................................... 18

13.0- Suggested Conveyor Maintenance........................................................... 19

Tables

Maintenance Schedule ................................................................................. 20

Troubleshooting ........................................................................................... 21

Spare Parts List ........................................................................................... 21

Drive Identification (for servicing) ................................................................. 22

Lubrication - grease lubricated units ........................................................... 22

Lubrication - oil filled units ............................................................................ 23

Addendums

Electronic shear pin system ......................................................................... 25

Major Features IndexTypical Circuitry for Tubular Drag Configuration

1. Flighted Chain2. Casing Flange or) Compression Coupling3. Casing4. Discharge Port5. Drive Box (Optional, not shown)6. Access Port7. lnfeed Receiver8. Vibrator (Optional9. ReducerI O.Take-up Adjustment11. Idler Box

Note: The marker numerical designations listed in thisillustration are for reference purposes only within thismanual.

Drive Arrangements

1. Motor (position vanes)2. Drive shaft3. Take-up rod for drive4. Traversing drive plate5. Drive box6. Hold down7. Speed reducer*

*j fill plug (will be in the uppermost position)*Oil level plug (will be in the middle position)

Note: The marker numerical designations listed inabove illustration is for reference purposes only withinthis manual.

Drive Boxes Which May Be Used

The drive boxes shown are in order of evolution over the years. Earlydrives may have been belt/chain or direct drive. Each drive may have adiffering look and possibly differing lubrication requirements (detailed inthe back of this manual) but all perform in a similar manner.

C. Beginning production drive (Belt/chain or Direct)

k QRrent production drroe (Qect)

B MIS production duve (Dodd)

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der ArrangementThere are 2 possible styles

Configuration I - WITH take-up

1. Shaft2. Idler Bearing3. Packing Gland4. Hold Down5. Take-up Rod6. Slide Plate7. Idler Box

1. Shaft2. Idler Bearing3. Idler Box4. Sprocket

I O - WARRANTY

Equipment manufactured by Hapman is warranted to be free of defective material and workmanshipunder the use and service quoted for a period of one year after date of shipment. This warranty isvoid if serviced by anyone other than Hapman service personnel.

Hapman agrees to replace or repair any defective parts it has manufactured as covered under thiswarranty. F.O.B. our plant, subject to inspection of the part in question by Hapman's personnel. Noarticle may be returned to Hapman without Hapman's written consent.

Parts supplied but not manufactured by Hapman are subject to the warranties extended to Hapmanby its suppliers. Hapman's liability is limited to such adjustment as the respective manufacturermakes to the seller.

In no event shall Hapman be liable for costs incurred due to equipment malfunction such asconsequential damages, lost production or the expenses or losses incurred due to geographicallocation or fault of the product, difficulty of access to the product as installed, or time urgency on thepart of the user and/or buyer of the equipment.

NOTICE:While all information in this manual has been checked for accuracy, changes in design orspecifications may occur at any time in HAPMAN's continuing program of product improvement.HAPMAN cannot assume responsibility for errors in the production of this manual, or for unsafeoperating practice of those employing HAPMAN equipment.

der ArrangementConfiguration 2 - WITHOUT take-up

Note: The marker numerical designations listed inabove illustrations are for reference purposes onlywithin this manual.

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5

BEFORE INSTALUNG, OPERATING OR MAINTAINING ANY EQUIPMENT, THE CONTENTS OFTHIS MANUAL SHOULD BE THOROUGHLY REVIEWED AND UNDERSTOOD.

Statements and instructions set forth herein are based upon the best information and practices knownto HAPMAN, but this may not be construed to suggest that every conceivable safety precaution iscontained herein. As a matter of practicality, HAPMAN cannot guarantee that actions in accordancewith such statements and instructions will result in the complete elimination of all hazards and thusassumes no liability for accidents which may occur.

For further information regarding installation, operation and maintenance please contact the factoryservice department.

HAPMAN Customer Service6002 E. Kilgore Rd

Kalamazoo, MI 49048-2321 U.S.A.Ph one: 269-343-1675

U.S. Toll Free: 800-427-6260Fax: (269) 382 8266

e-mail: service@HAPMAN.com

2O NTRODUCflONThis manual provides instructions on how to install, operate and maintain the tubular drag conveyorsupplied by Hapman. A recommended spare parts list is provided to help determine which partsshould be kept on hand. This list is on page 15.

Assistance on part orders or service calls may be obtained from Hapman's service department. Seethe phone and fax numbers, address and E-mail address on the last page of this manual.

When calling or writing for parts or service, please reference the equipments serial number. Theserial number is stamped on the Hapman nameplate affixed to each piece of equipment. For futurereference, a space has been provided on the last page of this manual in order to record equipmentidentification information.

1.1 General Instructions

1, All guards, covers and safety devices must be in place before starting equipment for normaloperation.

2. Conveyors must be shut down for all types of maintenance, adjustments and lubrication.Power controls should be locked out while performing any of these functions.

3, Conveyor components should be maintained properly to avoid creating a hazard topersonnel. Included are such items as supports, ladders and platforms.

4. Guards and safety devices should be maintained in safe repair and hazard warning signs inlegible condition.

3.0 - SAFETY INSTRUCTIONS

CAUTIONAll Hapman furnished equipment must be installed, operated and

maintained in accordance with service instructions. Failure to follow theseinstruction may result in serious personal injury or property damage.

2.1 Do not attempt to install, connect power to, operate or service your Tubular Drag Conveyorwithout proper instructions, or until you have been thoroughly trained in its use by your employer.

2.2 Do not attempt to work on, clean, or service this conveyor until the power has been turned off andlocked out. If and when it is necessary to momentarily start and stop (jog) the conveyor, useextreme caution and ensure that all personnel are clear of the conveyor chain.

2.3 Do not manually override or electrically bypass any protective device.

2.4 Do not connect power to, or operate the conveyor unless all moving parts are covered and allcovers, guards, safety grids and maintenance panels are in place and securely fastened.

2.5 Do not abuse, overload, mistreat or misuse the conveyor or attempt to operate it when it is inneed of service, lubrication, maintenance or repair.

2.6 Never place any part of your body or loose clothing within the access chamber or feed hopper(s)while the drive unit is pulling the chain through the casing.

2.7 Never allow foreign objects (that could cause the chain to bind or otherwise damage the unit) toenter a conveyor casing through an access port or infeed receiver while conveyor is operating.

2.8 It is the owner's and employer's responsibility to adequately train the employee operator in theproper and safe use of conveyors. Written safety programs and formal instructions are essential.All new employees must be made aware of company policies and operating rules, especially theestablished safety and health procedures. Refresher training of experience employees in thepotential hazards of the job is important. Up-to-date training records must be maintained at thejob site.

2.9 All conveyor inlet and discharge openings and casing access panels must be completelyenclosed to prevent human access when the machine is running and remain enclosed until powerhas been turned off and locked out.

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2.10 Drive components, including the tension of the chain, must be inspected and adjustedperiodically, as required by operating conditions and the suggested maintenance schedule onpage 19. Check V-belt tension (if required), bearings, shafts and motor as appropriate to jobconditions.

2.11 High-voltage and rotating parts can cause serious or fatal injury. Installation, operation andmaintenance of electrical machinery must be performed only by qualified, trained andexperienced personnel. Make sure that the motor and frame are effectively grounded inaccordance with OSHA safety and health standards, the National Electric Code and local codes.

2.12 All electrical control panels and/or manual start-stop operation enclosures carry the potential forhazardous voltage. Follow local OSHA or corporate lockout] tagout procedures before doing anyservice work on tubeveyor, tubeveyor panels or electrical enclosures.

2.13 All protective covers, guards, grates, maintenance panels, switches and warning decal's must bekept in place and in good repair. Any equipment with damaged, malfunctioning, defective, ormissing protective devices must be taken out of service until such protective devices can berepaired or replaced.

2.13 Any equipment which is used in the processing of explosive materials in hazardousenvironments requires materials in hazardous environments requires an evaluation on the part ofthe user and operator of proper and adequate equipment enclosures. Do not use equipment inhazardous environments unless it has been properly equipped for the hazard.

2.14 It is ultimately the operators responsibility to implement the above-listed precautions and ensureproper use of the equipment, maintenance and lubrication. Keep these instructions and list ofwarnings with your machines at all times. Work safely at all times.

2.15 Basic DangerlWarning!Caution Areas for the Heavy-duty series tubular drag

A C

D E

4.0 - PRINCIPLES OF OPERATIONThe Hapman Tubular Drag Conveyor is similar to having a conveyor inside a pipeline. It is anenclosed loop conveyor system designed and engineered to your specific layout. It will handle a widerange of flowable materials. Essentially, the conveyor is a three to 12 inch diameter metal casingassembled from pre-engineered sections that are equipped with male and female flanges orcompression couplings. The conveyor circuitry can be designed around existing equipment. Usingsimple hangers or supports along the circuit, the conveyor is assembled before installing the chainthat is equipped with circular flights spaced evenly along the distance of the chain.

The chain is threaded over the drive sprocket and idler sprocket and the ends connected with a pinbefore the tension is adjusted. During operation, the chain is pulled through the casing and material isfed into the casing through an infeed hopper. As the flighted-chain moves inside the casing, the flightsdrag the material horizontally or vertically until it reaches the discharge port where the material isdischarged by gravity into some receiver. The flighted chain continues around the circuit to pick upmore material and prevents surging I flooding the conveyor line.

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5M RECEMNG YOUR EQUPMENTAs soon as the equipment is received, it should be carefully inspected to make certain it is in goodcondition and all items recorded on the packing list are received. All damages or shortages should benoted on the Bill of Lading. Purchaser should take immediate steps to file reports! claims with thecarrier.

Any damage incurred to a unit in transit is the responsibility of the common carrier since it is themanufacturer's policy to make shipments F.O.B, its factory. Ownership passes to the purchaserwhen the unit is loaded and accepted by the trucker. Any claims in transit damage or shortage mustbe brought against the carrier by the purchaser.

CAUT ONAll Hapman-fumished material handling equipment must be installed, operated and maintained inaccordance with service instructions. Failure to follow these instructions may result in a seriouspersonal injury or property damage.

6O STORAGEInside storage of equipment is recommended. If outdoor storage is required, precautions should betaken to protect all equipment from the elements.

CONVEYOR ASSEMBLY AND ERECTION

7.1 Inspect all components on arrival to make sure that there was no damage in shipment. Checkitems received against packing list and final layout drawings to determine whether all itemsneeded for complete installation are present. All necessary hardware for assembly should beincluded.

To avoid confusion when more than one conveyor is involved, separate components according toconveyor number. Lay the component on the floor in the area where the conveyor is to beinstalled. This will facilitate inspection and organizing components for installation.

7.2 Inspect (inside and out) the casing sections, elbows, receiving hoppers and discharge hoppersand remove any foreign objects before starting the erection process.

Chain for the conveyor is shipped in large boxlike containers. Depending on the type and size(length and diameter) of the chain, you may receive one or more containers of chain. The chainwill likely be shipped in approximately lOft sections that will conveniently fit in the shippingcontainers. Installation of the chain through the casing will be detailed later.

7,3 The Hapman conveyor casing is supplied in sections of approximately 1 O2O feet in length. Eachsection has "male" and "female" type flanged connections between which a gasket (shippedseparately) or compression coupling connection may be inserted. Always follow the match marksstamped on each flange and shown on the layout drawings as illustrated in Figure 15.

NOTE: DUE TO THE CUSTOM NATURES OF THESE CONVEYORS, THE FOLLOWING ARE GENERAL

GUIDELINES

7.4 Components, such as receiving and discharge hoppers which have a specific location relative toexisting equipment, should be installed first. Other components which require significant support

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should be installed next. These include the drive assembly, idler assembly and elbows. Thesecomponents should be securely positioned, but there should be enough play or slack in thecomponents to facilitate installing the casing.

Match Mark SymboUm Location As Shown On

Layout Drawing

Figure 15

Section atFlanged Connection

Female

/

ConveyorFlange

,

.

v;:;;

CasingbasKet

7.5 Locate the casing flange gaskets and place one on each male flange before making flangeconnections. Gasket dressings or pliable sealants may be used with the gaskets, if desired.Such dressings or sealants are to be supplied by customer.

7,6 As assembly of the conveyor circuit begins, two or more sections of the smaller (3" and 4"),casing may be assembled before elevating them into position. For larger casing sections (6" andlarger), it is advisable to install one section at a time using the appropriate (customer-supplied)hangers. (See Figure 16 for typical conveyor-supporting methods.) To aid in installing theconveyor chain in these larger casings, Hapman recommends inserting and connecting the chainin short section during the installation of each casing section (See Section 8.0 Tubular ChainInstallation).

7.7 It is very important to leave all flange bolts loose (finger tightened should be sufficient) until theentire conveyor circuitry is assembled. This will facilitate installation of the casing between theheavier - and location specific components that were installed first,

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Hgure 16TYPICAL SUPPORT METHODS FOR TUBULAR DRAG CONVEYOR

Supports can be tubing, pipe, angle, channel, etc.

Supports can betubing, pipe, angie,

channe', etc. Fleld WeldedFloor Bracket

Floor Openhig Support

U-bolt

Floor Mounted Supports

BeamClamp

StandardHanger

with Rod

PipeStrap

SingleHook

Supports from Existing Structures

7.8 With circuit assembly completed, tighten all hanger clamps and flange connections securely.

TUBULAR CHAN NSTALLATON

8.1 Basic Chain Types: Hapman Tubular Drag Conveyor chains are supplied in two basic designs:the offset-flight design; and the center-flighted design. The chain design used in your conveyor(s)was selected by the factory based on the application for the conveyor's intended use. See theparts list on your conveyor layout drawing, or examine the chain supplied to determine whichdesign you have. (See Figure 18 for basic designs.)

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8.2 Chain Construction: The unique sealed-pin design of the chain assures that the pin and bearingsurface are tightly sealed with elastomeric washers preventing wear and abrasion caused by theconveyed material, In addition, Hapman may specify a split flange rivetless chain (See Figures19) for your application.

8.3 Installing the Chain: The three and four-inch conveyor chain generally should be installed after allthe conveyor casing sections have been erected. The six-inch and larger conveyor chain shouldbe installed in relatively short lengths (as in each individual section of conveyor casing) duringerection.

8.4 Threading the Chain: Access to the casing may be through casing access ports, the drive box andidler box access opening, the receiving hopper and/or the discharge opening. Thread a ropethrough the casing from the highest elevation to the lowest elevation.

With the chain laid out on the floor in a single plane, tie one end of the rope to the leading end ofthe chain and pull the chain through the casing, around the elbows, and over the sprocket. Feedthe chain into the casing through an infeed hopper or other access opening. Always feed thechain in the same direction as it will be traveling when the system is operational. The direction offlow is noted on the conveyor layout drawing.

Figure 18CHAIN INSTALLATION - Typical Chain Construction & NomenclatureSEALED PIN CHAIN

Note: See Table 20-A for chain specifications.

Center

SeangWasher

Unk \____ /

Stee'Washer

Center Flighted Chain Center

SeaftngLink \

WasherSteel

Washer

Figure 19CHAIN INSTALLA11ON - Typical Chain Construction & NomenclatureDrop Forged Chain

Note: See Tab'e 20-B for chain specfficalions.

Center flighted Chain

Table 20-ASealed Pin Chain Specifications

ChainSize andSeries

25-3"

35 - 3"

35-4"

48-4"

64 - 6"

78 - 8*

AvaliableFlight

Diameters

2-3/8" & 2-3/4"

2-3/4"

3-3/4"

3-3/4" & 3-7/8"

5-5/8"

7/5/8"

FlightPitch

3"

6"

6"

6-9/16"

8"

8"

ChainPitch

1-1/2"

3"

3"

3-9/32"

4"

4"

Weightpertoot

(chainonly)

3.4 #

5.2 #

5.2 #

6.2 #

9.5#

9.5#

Ultimate Strengthand Maximum

Work Chain Pull

11,000-2,200#

15,000- 3,000 #

15,000- 3,000 #

19,600-3,900 #

44,000-8,800 #

44,000- 8,800 #

* - offset flights

Table 20-BDrop Forged Chain Specifications

______________________Weight

Chain Size Available Flight Flight Chain per Ultimate Strength

and Series Diameters Pitch Pitch foot and Maximum(chain Work Chain Pullonly) ______________________________

348-3"___________________

2-1/2" , 2-3/4"________

6"________

3" 2.25 # 24,000-4,800 #

348-4" 3-3/4" 6" 3" 2.25 # 24,000-4,800 #

458-4" 3-3/8", 3-5/8" 8" 4" 3.1 # 48,000-9,600#3-3/4" ______________________________

458-6" 5" , 5-5/8"________

8"________

4"_______

3.1 # 48,000-9,600 #

458-8"" 7-1/4" 8" 4" 3.1 # 48,000-9,600 #

458_10** 8-1/4" 8" 4" 3.1 # 48,000-9,600#

678- 10"" 9-1/8" 12" 6" 6,5 # 84,000- 16,900 #

* - offset flights

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8.5 Aligning the Chain: The simplest chain installation is when the chain travels through the circuit onthe same plane (like bicycle chain around two or more sprockets) allowing the chain openingbetween the side links to ride over the sprocket teeth un-impeded. When the circuitry of theconveyor (between the elbow and the sprocket) dictates a change in the plane of the chain, it willbe necessary to rotate (twist) the chain either clockwise or counterclockwise to properly positionthe chain openings to ride smoothly over the sprocket.

If the supplied chain is the offset- design, the force of gravity tends to roll the chain to a "heeldown" position. The chain should always be in the "heel down" position (toward the inside of theradius) when it moves around an elbow or sprocket. (See Figures 22-A and 22-B.) When it isnecessary to rotate the chain to "heel up" position to conform to chain installation instructions,rotate the chain in the "untwist" direction.

The installer should wear protective gloves when installing chain and especially when adding atwist to the chain. To induce a twist in the chain, firmly grab the leading end of the chain androtate the chain so it will smoothly interface with the sprocket. There is sufficient "play" in thechain's design to allow the chain to be rotated over the length of the straight section of the casing.

The twist of the chain must be performed before the chain is pulled around the bend of the casingbecause it cannot be rotated once it is in the bend. The chain twist should not exceed 360° inany one direction over the entire length of the chain's circuitry.

Figure 22-AHe&-Down Posflon of Chain - Around Bend

Figure 22-BHeel-Down Position of Chain - Around Sprocket

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Because of its design difference, the split flange chain is somewhat easier to twist than a sealed-pin construction type chain. Furthermore, twisting the chain is easier when the plane change(from elbow to sprocket) is only slight (15° to 45°) or when the length between plane changes islonger, rather than introducing a twist of a higher degree or shorter distance between planechanges. However, it is essential to match the plane of the chain with the plane of the sprocket,as noted on Figure 22-B.

8.6 Closing the Loop: Before attempting to connect both ends of the chain, adjust the drive and idler(whichever one is most accessible) take-up bolts all the way in. In addition move the slide plateof the chain tensioner to its forward-most position.

Once this has been done and the chain has been fed through the casing and over both the driveand idler box sprockets, bring the leading and the trailing ends of the chain together and connectthem using the chain pins provided. If needed, twist one end of the chain or the other to align thechain pin holes. When closing the loop for offset flight design, the two flights of the two sectionsbeing joined must be in the same direction - either in the "heel-up" or "heel-down" position.

9M ADJUS11NG THE CHAN9,1 Removing the Slack: Starting at the least accessible take-up location - which is usually at the

drive assembly - remove slack in the chain by using a wrench to adjust the take-up rods whichmove the drive plate and tighten the conveyor chain. See Figure 23

Failure to remove excessive slack in the chain may cause operational problems with the chainjamming or jumping off the sprockets. The chain should be relatively loose in the normallyempty or "return" run the conveyor.

9.2 Jogging the Conveyor: Jog - quickly start and stop the drive by pushing the start then stop button- the conveyor to work out additional slack. Jogging will help to accumulate all the slack into onearea just below the drive sprocket.

Jog conveyor initially to check proper motor rotation. Run conveyor in only the direction indicatedby the arrows on the center line of the layout drawing.

9.3 Adjust Tensioner: Move the take-up on the drive box and/or idler box to adjust the chain forproper tension. To check the tension, remove an inspection opening on the empty or "return" runof the conveyor and lift or pull the chain. It should have about two inches of slack. You may haveto back off the take-up and remove a section of chain (one complete pitch) and start theadjustment procedure over again. If a piece of chain needs to be removed, the chain on either sideshould be secured to prevent it from slipping away until it can be joined again.

A WARNINGBefore jogging the conveyor, make certain that all foreign material is removed from inside thecasting and that all personnel are clear of the conveyor. Never put any part of the body(hands, feet, long hair) or clothing into the conveyor when the conveyor is to be jogged or run.

WARNNG

'

Exposed coveyorsand mova

pa1s can• cause sevm miury

L0CK OUT POWERbelora removcover o serrcng

10.0 - ADJUSTING THE SPROCKETThere could be one or several sprockets on a tubular drag conveyor that may need adjusting at thesame time. These are located in the drive box, idler box and corner turns.

First, remove the access cover and check the sprocket location on the shaft. The center of thesprockets should be in line with the center of the casing and the chain should run smoothly on and offthe sprocket.

If the sprocket is misaligned, loosen the set of screws on the sprocket and move the sprocket to theproper position. Tighten the set screws and check alignment again.

11.0- ADJUSTING THE CHAIN ROTATIONThe rotation of the chain is critical and the proper rotation is listed on the main layout drawing. Toadjust the rotation, open the inspection port in the area where the rotation is incorrect. Loosen thechain tension first then remove a chain pin so the chain may be rotated to its proper orientation.Secure the chain to keep it from slipping away during the twisting/rotating procedure.

If assistance is required to install or adjust the chain, call the Customer Service Department atHapman. (See inside cover.)

12O STARTNG AND ADJUSTNG12.1 Before Starting: Remove all access and/or inspection covers so any unusual or erratic operation

will be noticed immediately.

Operating this conveyor with these covers and guards removed presents a potential hazard.Take appropriate action to see that hands, arms, feet, or other body parts are kept clear of theaccess openings and moving chain.

A. Remove any foreign material that may have accumulated during installation fromconveyors.

B. Check the V-belt and roller chain tensions and correct if necessary.

12.2 Initial Starting, Chain Tension Adjustment And Breaking In

A. Start and run conveyor for several minutes while listening for any unusual noises andwatch for erratic operation of the chain.

B. The length of break-in period will vary with the size and complexity of the system.Generally speaking, it is advisable to run the conveyor empty for approximately 30-minutes.Check the tension after this 30-minute run. If significant tension adjustment is needed,make the adjustment* and run the conveyor empty for another 30-minutes.

*NOTE: Ideal chain adjustment is obtained by adjusting the take-up rods on the drive or idlerarrangement while the conveyor is running. Proper tension can be set by using an amp meterand setting the tension where the meter reads the lowest, steadiest amp reading.

C. Add material and run the conveyor listening for any unusual noises or erratic operation. Ifthe conveyor is running smoothly, continue to run product but check tension once everyeight hours of operation for the first 48-hours.

Note: If conveyor is noisy or running erratically, chain tension probably needs tightening. Atthis time adjustments should be made while conveyor is running and while listening to theconveyor for any change in operation.

D. Check chain tension again after 48 hours of continuous running, and again after one week,followed by another chain tension check after one month. After this, follow the suggestionsmaintenance procedures listed on page 19

E. Reinstall covers and guards after any tension adjustment is complete and unit is ready torun again.

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13O - SUGGESTED CONVEYOR MAINTENANCE

13.1 Overload I Jammed Mechanism:

Note: Mechanical shear pin protection is not included in these units. An optional overloadshock relay electrical shear pin system for overload and phase loss protection is availablefrom Hapman and is always suggested during the ordering process. If your conveyor wasnot ordered with this system, it is highly recommended that it be added on site!

A. With electrical shear pin protection - When the conveyor shuts down check the reset buttonlocated within the control panel and reset if necessary. If the problem persists contact Hapmancustomer service.

Note: These systems are preset to accommodate the material(s) which were originally specifiedto be conveyed. Deviation from the original material(s) specification can cause loss ofperformance and failure. See Addendum: "Electronic Shear Pin System" for installation andsafety procedures on page 23.

13.2 Adjusting Vibrator:

A. The hammer should rest lightly on flights when vibrator is turned off.

B. Adjust hammer position by changing the position of the hammer stud locking nuts. Do not operatevibrators unless these nuts are pulled up tight.

C. Adjust length and intensity of vibrating action by changing the position of the eccentrics withrespect to each other.

Maximum vibration is obtained by having all eccentrics in alignment.Minimum vibration is obtained by spacing them equally (1200 apart).

Figure 24

Underside view of hammerposition over flights

Table 29

Suggested Maintenance Schedule1 1 6 RECOMMENDED

ACTION TAKEN WEEK MONTH MONTHS LUBRICANTCheck ConveyorTension __________________________________ ________ __________

As Suggested by MotorGrease Motor ManufacturerCheck Reducer Oil X

__________

See Reducer Service BulletinLevel ____________________________

Grease Idler Box Pillow________ _________ __________

Shell Oil Co. Nerita 2 or EqualBlocks NLGI-2Check Vibrator

________ ________

x__________

Operation ____________________________

Grease Vibrator Pillow________ _________ __________

Shell Oil Co. Nerita 2 or EqualBlocks NLGI-2Grease Roller Turn

________ ________ __________

X Shell Oil Co. Alvania 2 orHaridshaft Equal

As Suggested by MotorGrease Vibrator Motor Manufacturer

Grease Reducer X

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Table 30

TroubeshootngEndosed Tubuar Drag Conveyor

PROBLEM POSSIBLE CAUSE SOLUTIONNoise in the drive box or idler box 1. conveyor chain is loose.

1. Adjust chain.2. Chain is tight.

2. Adjust chain.3. Chain rotation (twist) incorrect. 3. Put proper rotation in chain.4. Sprocket not centered.

4. Adjust sprocketNote: At times, you cannot prevent noise. In this case, check for wear on conveyor chains or sprockets.If there is none, let machine run.

_______________________ ____________________________Jamming

Material not conveying

Conveyor chain dislodged, orjumping off sprocket.

Wear in bends and flightswearing excessively

Chain jerking in casing

Table 31A

1. Too much material feed.2. Chain is tight or loose.3. Sprocket not adjusted tocenter of casing.4. Foreign object is machine5. Glazing in casing (build-up oninside walls).1. Bridging in hopper.

1. Conveyor chain loose.2. Chain rotation (twist) incorrect.

1. Conveyor chain tight.2. Wrong chain rotation.3. Abrasive material.1. Chain is tight or loose.2. Too much chain rotation(twist).3. Sprocket not adjusted tocenter of casing.4. Surge loading

1. Try restrictor in feed hopper.2. Adjust chain tension3. Adjust sprocket.4. Remove object.5. Install scraper flight (consultHapman)

1. Try vibrating the hopper(gitate the rnateriai)1. Adjust chain tension2. Adjust chain tension

nflihtosition1. Adjust chain tension.2. Adjust chain rotation.3. Consult Hapman.1. Adjust chain tension.2. Adjust chain rotation.3. Adjust sprocket.4. Make sure conveyor is controlfed. Call Customer Service.

Spare Parts UstTubuar Conveyor

Item Description

Chain Assembly

Unft Quantity

10 Ft.

Drive Shaft

Drive Sprocket 1

2

3

Idler Shaft

Idler Sprocket 1

4

5

6 Reducer

17 Motor

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DRIVE IDENTIFICATION & Lubrication Requirements

Hapman has engineered changes in the drives used on its tubular drag conveyors since theirintroduction in the 50's. Each drive has differing lubrication (either grease or oil) requirements asshown. Select your drive from the following illustrations.

A. Current production drive (Direct)

Cyclo LubricationThis is the round reducer portion between the motor and the square shaped Bevel Buddy Box "BBB"

The Cyclo has been grease lubricated with Shell Alvania #2 grease and should be replenished every6 months with quantities listed below. This done by the grease zerk located on the Cyclo portion. It isrecommended the unit be disassembled every 20,000 hours or 4-5 years to clean and repack withdesignated grease to prolong service life. Every six months replenish the Cyclo portion with thequantity of grease listed below for the Bevel Buddy Box model number shown.

Bevel BuddyBox l.D.

LHYJS-2B1 45Y

LHYJS-2B165Y

LHYJS-2C1 55Y

LHYJS-2C145Y

LHYJS-2C1 65Y

Oz. grease

Bevel Buddy

Oz. greaseNo. for Cyclo

Box l.D.

No. for Cyclo4 oz.

LHYJS-2C175Y

9 oz.

6 oz.

LHYJS-D4165Y

6 oz.

4 oz.

LHYJS-2D175Y

9 oz.

4 oz.

LHYJS-E4175Y

9 oz.

6 oz.

LHYJS-2E175Y

9 oz.

Bevel Buddy Box LubricationThis is the square shaped portion with the shaft running through it. This has been filed with uShellAlvania EP R00" or equivalent and can be changed every 4-5 years or (20,000 hours) to providelonger service life. This is a pourable grease and has the viscosity like that of molasses. It isrecommended to drain during warm weather or when the unit is warm from running.

Note: Weekly inspection for leakage, loose fasteners, excessive heat, etc. should be done to assuretrouble free operation.

B. Mid production drive (Direct)

C. Beginning production drive (Belt/chain or OWed)

On oil lubricated units the reducers ordered from the factory will be filled to the proper level withlubricant, but before operation the supplied vent plug must be placed in the proper (highest possible)location!

Vent Plug Location On Oil Filled Drive Box

Before installing the vent plug, refer to the instruction tag and determine the proper position accordingto reducer mounting specification. The position and number of these (vent/fill) plugs will varied oneach unit and should accommodate the final orientation of the unit. After the installation of the ventplug, the unit is ready for use.

Grove Gear recommends changing oil every six months or 2,500 hours of service under Class Iservice. If service is more severe, the oil should be changed more frequently.

To assist in proper selection of replacement lubricant, the following oils are recommended for theambient temperature specified.

uii LUDICtlOflS u 0 be use

15° to 60° F Ambient

a #i i emperaiure

50° to 125° F Ambient

uggestedManufacturer

Listing

TemperatureAGMA Compounded

No.7Recommended Oilfor this temperature

TemperatureAGMA Compounded

No.8Recommended Oilfor this temperature

Amoco Oil Co. Worm Gear Oil Cylinder Oil #680

Chevron USA Cylinder Oil #460X Cylinder Oil #680X

Exxon Co. USA Clyesstic TK-460 Clyesstic TK-680

Gulf Oil Corp. Senate 460 Senate 680D

Mobil Oil Corp. 600W Super Extra Helcia Super

Shell Oil Co. Valvata Oil J460 Valvata Oil J680

Sun Oil Co. Gear Oil 7C Gear Oil 8C

Texaco Honor Cylinder Oil 650T Cylinder Oil

Union Oil of CA Steaval A Worm Gear Lube 140

Note: For temperature ranges not shown and synthetic lubrication contact factory

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Capac

Unit Size

ities For Oil LubricWorm Over

Worm OverMount

MountOz.

Oz.________

ated DriveVerticalOutputMount

Oz.

Boxes

"J" MountOz.

_______________

1100________

3 4 4 3

1133 5 7 6 7

1154 10 14 13 12

1175 15 18 16 16

1206 21 25 23 24

1238 25 30 26 25

1262 45 49 46 47

1300 55 61 58 60

1325 73 89 74 75

1425 135 127 120 126

1525 200 216 216 216

1600 310 330 320 325

1700 563 625 332 585

1800 768 822 460 800

11000 1152 1280 640 1200

Addendum: Electronic Shear Pin SystemHapman provides a non-mechanical electronic shock relay, as an option, to help prevent damageto the conveyor. If your conveyor is equipped with one, please follow safety and maintenanceprocedures to assure continued performance of your conveyor.

Safety Precautions To Follow Before ProceedingUSE CARE TO PREVENT INJURY.COMPLY WITH THE FOLLOWING TO AVOID SERIOUS PERSONAL INJURY:

A WARNING1. Disconnect power. Always lock out power switch before installing, removing, or servicing unit.

Comply with Occupational Safety and Health Standards 1910.147 "The Control of HazardousEnergy (Lock Out/Tag Out)" or Corporate lockoutltagout procedures.

2. Install in proper enclosure in accordance with NEMA 250-1997 "Enclosures for ElectricalEquipment (1 000 Volts Maximum)" and NFPA496 1998 Edition "Purged and Pressurized

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Enclosures for Electrical Equipment, 1998 edition'. When revisions of these standards arepublished, the updated edition shall apply.

3. Guards must be provided on all power transmission and conveyor applications in accordance withprovisions of ASME B 15. 1-1996 "Safety Standards for Mechanical Power TransmissionApparatus and ASME B20,1-1996' Safety Standard for Conveyors and Related Equipment", orother applicable standards. When revisions of these standards are published, the updated editionshall apply.

Electronic Shear Pin FeaturesElectronic shear pin function

Fail safe protectionIndependent setting of start and trip delay

• Easy wiringOverload and phase loss protection

Maintenance freeVisual selling and trip indicator

• No mechanical connection needed

How It WorksTwo of three phases of the motor current are monitored by integral current transformers (Externalcurrent transformer are required for current more than 60 Amps). The internal solid-state circuitrycompares the monitored motor (or load currents with preset current level. When motor currentexceeds the preset trip current level, the red LED illuminate and indicated that an overload has beendetected. The relay will trip after the preset trip time (SHOCK TIME) and the LED remains illuminatedindicating an overload trip has occurred until the relay is reset by pushing the RESET buttoninterrupting the power supply. If the motor current drops back down below the preset current levelbefore the preset trip time delay has elapsed, the TSB-SS will return to normal condition. With thevisual aid of the LED flashing when motor current becomes 100% of the preset current, actual loadcurrent can be determined without aid of an ammeter. The TEST button provides the means of testingservice worthiness and integrity. The internal relay is energized in a normal operating condition. In theevent of a SHOCK RELAY failure or a power failure, the internal relay changes back to the non-energized state. Since the TSB-SS has a definite time characteristics, the start trip delay may beadjusted with a minimum setting of 0.2 through a maximum of 30 seconds. The trip time adjustmentrange is from 0.2 through 10 seconds. The relay may be used as an electronic shear-pin by sellingthe SHOCK TIME to minimum. If the TSB-SS trips, always investigate to determine the cause andcorrect prior to restarting.

How To Set Up The System1. When installing, set the start delay timer (START TIME knob) to the known motor run-up time or

the maximum if the time is not known.

2. Set the trip delay timer (SHOCK TIME knob) to the desired trip time.

3. Set the load current (CURRENT knob) at the rated full load or the desired value.

4. With connections made and the control power on, depress the TEST button and hold. Verify thered LED illuminates and the internal relay should switch contacts after the sum of start time andshock time. Once verified, reset by depressing the RESET button.

5. Start the equipment and notice the run-up time, then slowly turn the CURRENT know counterclock-wise until the LED flashes. This indicates 100% of the load current. Set the CURRENT knobto the desired trip setting. A setting of 110% of the running current is commonly used.

6. Reset the START TIME knob to match the normal run-up time

7. Periodic testing by using the TEST button is suggested to ensure the full protection throughpreventive maintenance.

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Figure 25

ConstructionCT

Figure 26

Dimension - Units in mm (1 inch = 25.4mm)

030

Figure 27

Wiring - Typical Installation

THREE PHASE MOTOR1o ol UTep ph*ses of the mows are passed

throuqh the Shock Rc4ays CT pn the swic dNection

1 A transfaniier rnsy be required, dependinq on the voltaqe of Motor. TSB-SS and MC

FIgure 28

TSB - SS Model Identification

TSB-SS-05

Current Range

Model: Shock Relay SS model

05 O.5-5Amp30 3-3OAmp60 5-6OAmpOver 60 to 600 Amp: 05 Type is fittedwith External CT

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SpecificationsModel Name TSB-SS

Type Range

Current Selling 05 0.5- 5A (6.5A)

30 3 - 30A (35A)

): Max Limit 60 5 - 60A (70A)

100-600 05 Type is Fitted with External CT

Starting Trip Delay Start Time 0.2 - 30 secTime Setting

Trip Time Shock Time 0.2 - 10 sec

Current ±10%Accuracy

Time ±15%

Time Characteristic Definite

Control Power Supply 90 - 25OVAC, 50/60Hz

Rated Voltage 600VAC, 50/60Hz

Current Selling 2 Integral Current Transformer

Mode 1-SPDT (1-C)

Output Relay Rating 3A/25OVAC, Resistive

Status Normally Energized

Mechanical 10,000,000 OperationsExpected Output Relay Life

Electrical 100,000 Operations

Reset Manual or Electrical (Interrupt Power Supply)

Operating -20 - +60 C (-4- +158°F)

Ambient EnvironmentTemperature

Storage -30- +70 C (-22- +176°F)

Humidity 45- 85% RH without Condensation

Insulation Between casing and circuit Over 10 MO with 500 VDC Megger

Between casing and circuit AC 2000V, 5mA, 60Hz, 1mm

Dielectric Strength Between contacts AC 1000V, 5mA, 60Hz, 1mm

Between Circuits AC 2000V, 5mA, 60Hz, 1mm

1 15VAC 2.70 VA (0.35W)Power Consumption

23OVAC 11.00 VA (1.2W)

Mounting 35mm DIN rail or Panel

Dimension (W x H x D / Including Integral CT Windows) 54 x 60 x 65mm

Weight Less than 159g (0.35LBS) without External CT

Electric rotating machinery and high voltage can cause serious or fatal injury if improperly installed,operated or maintained. Responsible personnel should be familiarized with NEMA MG2: SafetyStandards for ConstruCtion and Guide for Selection, Installation and Use of Electric Motors andGenerators: National Electric Code and all local safety requirements. When servicing, all powersources to the motor and to any accessory devices should be de-energized and disconnected and allrotating parts should be at a standstill.

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Record Of Important Information For This Machine

Serial Number

Model Number

For Operational Information In This Plant Contact

Name

Department I Phone Number______________________________________

Notes

HAPMA6002 E Kilgore Road• Kalamazoo, MI 49048

Ph 269-343-1675 800-427-6260 Fax 269-349-2477 • www.hapman.com

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