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Section 3: Conveyor Chain Installation & Maintenance
Section 3: Conveyor Chain Installation & Maintenance
Section 3
Conveyor Chain
Installation & Maintenance
Renold Conveyor Chain Catalogue I 53
Renold has, for many years, been a leader and Old Chain Still In Place Horizontal & Inclined Conveyors
innovator involved in the design and
On some installations where sprocket and track Where possible, chain should be fed on at the
manufacture of standard conveyor chain and
wear are minimal e.g. escalators, it is possible take-up end of the conveyor and pulled up to
the development of engineered products for
to replace the chain as the old chain is the drive end. When enough chain has been
such applications as escalators, travelators,
removed. installed to fill up to the drive, the chain can
sterilizers, cement conveyors, leisure rides and
Any fixtures, slats, steps, buckets etc., which then be inched over the drive sprocket and into
numerous other specialised systems for the
join two or more chains should be removed, the return tracks. Care should be taken to make
mechanical handling industry. We have a
except for enough to keep the chains at the sure that the chain is always restrained and
detailed understanding of the maintenance
correct spacing. The chains should then be cannot run back.
needs on such applications and can now offer
the manufacturers and operators of conveyor broken at the tension end by removing an NOTE: On horizontal conveyors, chain can be
systems the benefits of this knowledge. outer link or connecting link as necessary. fed into the return tracks either over the drive
Handling lengths of the new chains can then or take-up wheels.
Chain is one of the most widely used moving
be attached to the old chains using old
mediums in mechanical handling systems, On inclined conveyors the chain will need to be
connecting links if possible. Care should be
being robust and very adaptable, but it is also hauled up using a block and tackle, 'Tirfor' or
taken to ensure that the chains are in the
one of the most neglected components within winch (Fig. 1). Care should be taken to make
correct orientation. New fixtures should be
such equipment when general or routine sure that the chain is always restrained and
connected to the new chain or old fixtures
maintenance is carried out. In many cases this cannot run back. On twin strand conveyors
should be reconnected to maintain chain cross
product is attended to when problems occur, with slats/buckets etc., where access is
centres.
normally when the chain is already damaged available at the end of the conveyor, the chain
and the only real option is to fit a replacement The drive can then be used to inch the new handling lengths can be fully assembled with
to the system. chains on and the old chains off. slats/buckets etc. before being installed on the
Section 3
When the new chains have been fed onto the conveyor and then be drawn in as complete
This section has been designed with the
conveyor the next new handling lengths can be units.
manufacturer and operator in mind. It covers
the functional aspects of using Renold conveyor attached, this time using new connecting links.
chain and emphasizes the correct use of At the same time, the old chain can be
preventative maintenance procedures, which disconnected from the lower strands. Repeat
will ensure better machine performance, less until all the chain has been replaced.
down time, lower overall maintenance costs
and extended chain life.
No Chain in Place
Where the conveyor has no chain in situ, (i.e.
Installation of New Chain after refurbishing tracks etc., or a new
When installing a complete set of new chains conveyor), the method of installing chain
the method of installation depends on the should be decided according to conveyor layout,
state of the conveyor, i.e. if the old chain is still access available and equipment available. The
in place, or the chain has been removed to following notes are intended as a guide only.
allow refurbishing of the sprockets, tracks etc.
Fig. 1
54 I Renold Conveyor Chain Catalogue
Bucket Elevators The following points are also important and f) Check that the assembled joint flexes
should be adhered to:- freely. If it is tight, a light blow on the
On light duty elevators it may be possible, if
opposite end of the connecting pins should
access and space are available, to install the i) The necks of connecting pins should not be
free the joint.
chain from the top of the elevator and join the ground or filed to ease insertion into the
chain at the drive sprocket. chain plates, nor should the plate holes be
relieved. The press fit is an essential part of
On heavy duty elevators (usually twin strand) it Hollow Pin Connectors
the chain construction and should not be
may be necessary to fully or partially assemble a) Secure the chain on both sides of the
destroyed.
the chains and buckets in handling lengths and assembly point.
lift them up through the bottom of the casing ii) Do not apply heat to the connecting plates
(Fig. 2). When enough chain has been to ease insertion of the connecting pins. b) Unless the chain has to run unlubricated,
assembled to reach the drive sprockets it can This could seriously damage the material coat the hollow pins with grease or oil and
either be fed over the sprockets and driven properties. insert the pins into the two ends of the
down as more chain is installed and then chain.
joined at the bottom, or it can be secured at c) Place the loose plate over the ends of the
the top and the opposite side hauled up and Reconnecting Chain
hollow pins and support the chain on the
joined at the top and the bottom. The method of chain connection depends upon fixed plate side against the assembly force.
the type of connecting link used. The main ones
d) Progressively force the loose plate onto the
are either solid pin (i.e. No. 107, 58, 69, 86), or
Assembly & Installation hollow pin necks equally and alternately,
hollow pin (No. 107).
using a hollow punch and hammer, a
When assembling new chain or repairing
Whichever type is used, the following steps are hydraulic press or jack, or a bolt and spacer
existing chain, the following precautions are
Section 3
Fig. 2
Fig. 4
Renold Conveyor Chain Catalogue I 55
Section 3
This can be done with:-
Fig. 9
a) A hammer, working around the pin head. Fig. 8
(Care should be taken to hit the bearing pin
edge and avoid damaging the link plate)
(Fig. 6).
b) Work around the pin head with a
pneumatic hammer.
(Again avoid damaging the link plate).
c) A riveting punch and hammer,
progressively turning the punch after each
blow of the hammer to peen
completely around the bearing pin head
(Fig. 7). Use the factory riveted pins as a
guide to rivet spread.
Fig. 6
56 I Renold Conveyor Chain Catalogue
Performance Monitoring
The performance monitoring service offered by
Renold is designed to give customers peace of
mind in operating any chain system by
knowing the current condition of the chain and
sprockets.
Performance monitoring enables companies to
monitor the wear rates of chain and plan
replacements well ahead, thus avoiding
expensive breakdown and downtime and
ensuring that replacement chains can be
ordered in time to avoid delivery problems.
Renold Conveyor Chain Catalogue I 57
Section 3
necessary. be used in conditions where normal lubricants
Change oil, oil filter and clear the sump, if would be inadequate. (See Fig 11).
lubrication system fitted
Fig. 11
58 I Renold Conveyor Chain Catalogue
Section 3
It is important that lubricant is applied to the Lubricant should ideally be applied to the chain
10. Application Methods correct parts of a chain. To merely brush as it leaves the drive sprocket, i.e. at point of
Manual. By oil can, brush or aerosol, applied lubricant over the chain plates will prevent minimum tension. This will allow the lubricant
directly on the chain. Automatic. By drip feed, external corrosion but will not necessarily to penetrate into the bearing surfaces.
preferably one shot lubrication which deposits benefit the bearing surfaces. Lubricant should When a new set of chains has been installed, or
the correct amount of lubricant at the correct be applied between the inner and outer plates if the conveyor has been standing for a long
time in the correct place on the chain. It is above each pitch point, and between the inner time, it should be allowed to run unloaded for a
imperative that lubrication is accurately plates and roller if a roller is fitted. This should few hours after the lubricant has been applied
applied. Too much lubricant is as harmful as ensure that the lubricant flows into the bearing to allow it to work into the chain effectively.
too little. Incorrect application of lubricant will surfaces (Fig. 12).
result in irregular motion of the chain,
particularly at low speed or light loads due to
stick slip.
Fig. 12
Fig. 13
Renold Conveyor Chain Catalogue I 61
Inspection of chain should not be left until a Chain Allowable % Chain Allowable % An idea of the amount of roller wear can be
major breakdown has occurred. This may result Series Extension Series Extension obtained by measuring the clearance between
in expensive replacement of major parts and the bottom of the link plates and the track
long down time if the required new parts are surface and comparing the result with that
not readily available. BS Chains obtained on a new piece of chain. See Fig. 15.
On drive chain the major factor determining 3000lb 40.6 24000/30000lb 102 If the rollers have worn to the point where the
chain life is extension due to wear between the (13KN) P (107KN/134KN) P link plates are near to or are rubbing on the
bearing pin and bush. However, on a conveyor 4500lb 40.6 36000/45000lb 102 tracks, then replacement is necessary. If
chain the life may be determined by wear on (20KN) P (160KN/200KN) P standard chain is fitted it is not possible to
other components, depending on the 6000/7500lb 50.8 60000lb 127 replace just the rollers, therefore the complete
environment in which the chain is used. Where (27KN/33KN) P (267KN) P chain should be replaced. If outboard rollers are
accessible, the chain should be checked for fitted then it may be possible to replace the
12000/15000lb 76.2 90000lb 127
wear as follows:- (54KN/67KN) P (400KN) P rollers only.
Where bends occur in the tracks, extra care
ISO Chains should be taken with roller wear assessment as
Extension of Chain Pitch
less wear is allowable before the link plate
A direct measure of chain wear is the extension M40 76 MC224 128
P P edges contact the tracks. See Fig. 16.
in chain pitch due to the wear between bearing
pin and bush. This is caused by the chain M56 88 M315 168
P P
articulating under tension around the drive Fig. 15
sprockets and can usually be obtained by direct MC56 71 M450 180
Section 3
measurement as follows:- P P
M80 102 M630 203
Measure a length of chain over as many pitches
P P
as possible. The chain must be on a straight
section of track and under tension. This M112 97 M900 230
P P
measured length "M" can then be applied to
the following formula to obtain the percentage MC112 97
extension. P Fig. 16
Fig. 14
General
Fig. 18 General visual inspection of the chain should
be carried out with the forgoing to detect
broken components, broken or damaged
attachments, severe corrosion, seized joints or
any unusual occurrences. The causes of these
should be identified and rectified and damaged
chain replaced.
which creates a gap between the inner and a concavity or hooking of the tooth flank. If this
should be replaced. In certain circumstances it
outer plates). Again, this is usually a sign of is allowed to continue it will start to impede
may be possible to turn the chain over and
mis-alignment. In both cases, if the plate chain engagement/disengagement and on
wear the opposite face of the bush to extend
thickness has been reduced by more than 1/3 short pitch chains weaken the tooth.
the chain life. (In this case, advice from Renold
of its original thickness the chain strength is (See Fig. 22).
should be sought).
substantially reduced and the chain should be
replaced after first rectifying the mis-
alignments. Fig. 21
Fig. 19 Fig. 22
Fig. 23
Section 3
Measurement of Tooth Wear
Quite often it is only possible to make visual
inspection of the tooth gap. However, if the For most conveyor applications, the degree of
sprockets are accessible during routine wear should not exceed 8% to 10% of the
maintenance, then one of the following gearing (roller or bush) diameter. In some cases,
methods should be used to measure for wear. extended sprocket life can be obtained by
turning the sprockets round and allowing the
opposite face to wear (consult Renold for
i) Clean the tooth gap of oil, grease or any advice beforehand).
other matter and apply to the tooth gap an
"as new" template. (Fig. 24).
General
As a result of wear between the chain pin and
Fig. 24 bush, the distance between adjacent rollers
increases more at the outer links than at the
inner. In terms of sprocket engagement, this
causes a greater proportion of the chain pull to
be carried by the most highly loaded tooth. In
the extreme the full chain pull would be carried
by one tooth, with resulting accelerated tooth
wear. For this reason it is bad practice to run
worn chain on new sprockets or vice versa.
Tracks
Fig. 28
Tracks should be checked both individually and
across the set with a spirit level. This should be
carried out at regular intervals along the
conveyor, i.e. every 1.5m to 2m.
The transverse distance between tracks should
also be checked at similar distances along the
conveyor, and with reference to a centre line to
check for side bow.
At the ends of the conveyor, the transverse
centres of the tracks and sprockets should
match so that the chain has a smooth
transition from one to the other.
Shafts
The correct alignment of sprockets, shafts and
chain tracks is essential for smooth operation Fig. 30
of conveyors and satisfactory life of chain and
sprockets. The following checks should be
carried out before a new conveyor is run, after
chains and/or sprockets have been replaced, or
Section 3
Section 3
the sprocket can be dismantled and a new one
assembled around the shaft. This type of
sprocket is particularly useful on multi-strand
conveyors where long through shafts are used.
Considerable expense can be saved in sprocket
replacement time.
Fig. 33 Complete Chain Replacement
Sprockets with removable tooth segments are
If a chain is worn out and is to be replaced particularly useful where sprocket tooth wear is
entirely, then either the procedure on page 68 much more rapid than chain wear. With this
can be followed to remove each connecting link type of sprocket, segments of teeth can be
and thus each successive handling length, or replaced one at a time without having to
the chain can be cut through with a torch into disconnect or remove the chain from the
manageable sections for disposal. sprockets, thus considerable expense and
NOTE: When cutting the chain with a torch, the downtime can be saved.
necessary safety precautions should be
followed.
Fig. 35
conditions a harder material can be used. assembled on the end of the A chains and correct use of any tools are followed.
the Y on the B chains. Do not remove the 9. Never reuse individual components.
iii) Wear strips should be flat and level when tags until the ends are joined correctly.
installed (check with a spirit level). If this is 10. Never reuse a damaged chain or chain part.
not the case then chain life will be reduced c) When handling chains, great care should
and conveyor operation could be impaired. be taken so that the chains do not get a
(See Fig. 30). permanent twist or side bow. This will have
an adverse affect on chain operation
iv) Joints in wear strips or tracks should be and life.
smooth so that no sharp edges protrude.
d) When chains are supplied with
v) Weld spatter, slag, metal filings, scale etc. attachments as handed strands (i.e. right
should be eliminated from the conveyor. hand and left hand) make sure that
vi) Chain entry and exit points should be the chains are connected in the correct
radiused to allow smooth transfer of chains orientation.
from sprockets to tracks. e) Make sure that connecting links are
vii) Non metallic materials such as low friction installed with the connector on the correct
plastics can be used where chains are side of the chain.
sliding on the chain plate edges, but should
not be used where severe impact loads or
abrasive conditions exist.
Renold Conveyor Chain Catalogue I 67
EXCESSIVE WEAR IN THE ROLLER BORE HIGH UNIT LOAD DISTRIBUTE LOAD - ALTER PITCH
TWISTED SLATS OR CARRIERS RECTIFY & CHECK FOR FLATNESS
PACKING OF ABRASIVE PARTICLES MINIMISE CHAIN/MATERIAL
CONTACT - CONSIDER CHAIN AS
PULLING MEDIUM ONLY
UNSATISFACTORY ROLLER BORE IMPROVE LUBRICATION; CHANGE
LUBRICATION AND CORROSION TO GREASE GUN DESIGN IF POSSIBLE
FRACTURED BUSHES SPEED TOO HIGH FOR PITCH CHAIN OF SHORTER PITCH BUT
EQUIVALENT STRENGTH
HEAVY SHOCK LOAD APPLIED INVESTIGATE ON-LOADING IN
ATTEMPT TO MINIMISE SHOCK
CORROSION PITTING CONSIDER SPECIAL MATERIALS OR
IMPROVE LUBRICATION
Section 3
FRACTURED PLATE OVERLOAD ABOVE MAXIMUM INVESTIGATE FOR FOREIGN
FRACTURED BEARING PIN BREAKING STRENGTH OBJECTS CAUSING JAMS
ELONGATED HOLES
PROTECT CHAIN - SHEAR PIN DEVICE
REVIEW LOADING
ROLLER FLATTING DUE TO SKIDDING TOO LIGHTLY LOADED SYSTEM INCREASE LOAD WITHIN LIMITS OF
CHAIN
HEAVY LOAD WHERE FRICTION BETWEEN INCREASE CHAIN SIZE IF NO LOAD
BUSH AND ROLLER BORE OVERCOMES REDUCTION POSSIBLE
LEVER EFFECT OF FRICTION AT ROLLER
PERIPHERY
EXCESSIVE LUBRICANT ON TRACK CLEAN AND SCOUR TRACK
CANTING OF CHAIN DUE TO LOAD STRENGTHEN CARRYING MEDIUM
UNEVEN RUNNING HEAVY LOAD AND LOW SPEED SEE "ROLLER FLATTING".
CAUSING ROLLERS TO "STICK - CONSIDER ADDITIONAL DRIVE POINT.
SLIP" CHECK SURGE AT DRIVE DUE TO
INADEQUATE POWER RESERVE OR
SHAFT/BEARING RIGIDITY
VERY LIGHT LOAD AND LUBRICANT GUIDES TO BE CLEANED TO
ON TRACK CAUSING ROLLERS TO REMOVE EXCESS LUBRICANT AND
"STICK - SLIP" CHAIN LUBRICATED ON ROUND
PART CONTACT POINTS ONLY
POLYGONAL ACTION OF CLOSELY INCREASE SPROCKET CENTRES
SPACED WHEELS IN COMPLEX OR REPOSITION SPROCKETS
CIRCUIT