7150_ZMC/ING_04 mod 14-01-2003 11:17 Pagina 3

ENGINEERING DATA

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CHAIN SELECTION - GENERAL CONSIDERATION

In order to ensure a correct approach to the selection of conveyor chains, the following points should be considered:

1) TYPE OF CONVEYOR
2) TOTAL LOAD TO BE CARRIED
3) CHAIN SPEED
4) CHAIN PITCH
5) TYPE OF ATTACHMENT
6) OPERATING CONDITIONS
7) LUBRICATION
8) CHAIN BREAKING LOAD

1) TYPE OF CONVEYOR

Conveyor chains are classified in two categories:

a) bush chains,
b) roller chains.
These two categories are further subdivided into conveyors that are:
a) horizontal,
b) inclined,
c) vertical,
d) combination.

2) TOTAL LOAD TO BE CARRIED

This is the weight of the carried material on the conveyor chain plus the weight of any attachments and / or carriers (i.e. slats, swing
trays, crossbars, fasteners, etc.).
It is essential that the load distribution is considered since the calculation factors for concentrated loads on a limited support surface are
different from those for a uniformly distributed load.

3) CHAIN SPEED
120
The chain speed, the distance travelled by the chain in a given Z=12
unit of time, is a fundamental factor in determining
the conveyor capacity. It is from this parameter that chain pitch 100
Z=10
and the diameter of the drive and driven wheels is derived.
Fig. 1
Fig. 1 illustrates this relationship.
80
Z=8

60
revolutions per minute [rpm]

Z=6

40
P•Z•n
V= [m/min]
1000
20
P = chain pitch [mm]
Z = number of teeth
n = revolution per minute of the wheel [rpm] 0 100 200 300 400 500 600

chain pitch [mm]

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The maximum recommended speed for conveyor chains is 60 metres per minute with an ideal speed range between 0 and 30 m/min.
Chain speed contributes greatly towards the condition known as Hunting or Surging.
Hunting (or Surging) is defined by irregular chain speed, a series of fast and slow chain surges. This condition can seriously compromise
the functionality of a chain conveyor, the main factors that can contribute to this effect are outlined in the following:
• The polygonal effect, due to the gearing of the chain with sprockets, (shown in in Fig. 2) can cause a small amount of chain surge.
This can be more marked on long pitch chain with number of teeth below 8.
• Cumulative effect of friction along the length of the conveyor (on the drive and return strands): intermittent contact between the chain
side plates and the track guides can cause the chain to surge.
• ‘Stick slip’ is a condition that can occur on slow running conveyors. It is often caused by over lubrication of the chain. The over
lubrication floods the chain track with oil or grease and lowers the rolling friction between the chain roller and the track. Once this rolling
friction becomes less than that of the rolling friction between the chain bush and the roller bore, the roller stops turning. The lubricant
then builds up at the pressure face between the bush and the roller bore creating a vacuum between the two surfaces. With the chain
track flooded with oil there is no available friction to turn the roller until the conveyor is stopped or the chain roller to track friction
increases. This condition of skidding rollers and rotating rollers can cause the chain speed to fluctuate up and down. Stick slip
conditions are more prevalent on lightly loaded conveyors as heavier loads will break the lubrication film on the chain track.
• Uneven loading of the conveyor, along its length, can also contribute towards the stick slip condition.
• On longer conveyors of 80 - 100 metres other factors must be taken into consideration, such as cumulative pitch tolerance.
Hunting / Surging of conveyors maybe eliminated by reducing the rolling friction of the chain. This can be achieved by the use of low
friction bushings in the roller bore or by introducing a bearing element into the roller / bush interface / as an alternative, twin track integral
ball bearings can be introduced. The additional advantage of this method is the overall reduction of the coefficient of friction of the
conveyor.This reduction can have a major influence on the selection of head shaft diameters and motor / gearbox sizes.
For further technical details please contact our technical department.
The following graph shows the speed variation due to the polygonal effect (%).

180/Z
100

14 Minimum speed of the chain

•

13
V2 - V1

12 r R
V2

2• π•r•n π•r•n
11 V1 = = [m/min]
12 6
10
=

9
Percentage variation of chain speed

8 180/Z Maximum speed of the chain

7
R 2• π•R•n π•R•n
6 r V2 = = [m/min]
5
12 6
R-r

0 5 10 15 20 25 30 35 40 45
Fig. 2
Number of teeth

n = rpm
Z = number of teeth of the wheel
R = pitch radius of the wheel [mm]

r = R • cos 180° [m]

Z

R-r = range of variation of the polygonal effect [mm]

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4) CHAIN PITCH

This is the distance expressed in millimetres or inches between two consecutive pin centres of the chain and is determined
by the following conveyor characteristics:
a) chain speed
b) diameter of drive and driven wheels
c) conveyor load distribution
d) spacing of attachments / carriers (i.e. slats, swing trays, crossbars, fasteners, etc).

5) CHAIN ATTACHMENTS

Slats / carriers are attached to the chain by means of angle iron sections welded to the chain plates or they
may be extensions of the chain plates. Chain attachments are defined by the dimensions, shape, number per linear metre,
and the type of material to be conveyed.

6) OPERATING CONDITIONS

The environment in which the conveyor chain is to operate has an enormous influence on its design. The choice of material, quality of
materials, tolerances, production methods, anti corrosion treatments and safety factors are all dependent on the following:
- degree of cleanliness
- operating temperature
- presence of abrasive substances
- humidity / atmospheric substances
- presence of aggressive chemical substances
- etc.
Knowledge of the operating temperature is particularly important since it affects the breaking load of the chain
as demonstrated in Table 1:

TABLE 1

TEMPERATURE ADJUSTED WORK LOAD

-40° C ~ -20° C (Maximum allowable work load) x 0,25
-20° C ~ -10° C (Maximum allowable work load) x 0,30
-10° C ~ 160° C (Maximum allowable work load) x 1,00
160° C ~ 200° C (Maximum allowable work load) x 0,75
200° C ~ 300° C (Maximum allowable work load) x 0,50

For further information on other operational conditions, contact our Technical Office.

7) LUBRICATION

Lubrication of the conveyor chain is essential since it reduces wear and prevents corrosion and oxidation.
It also determines the friction factors and hence the chain pull.
See page 1.6.2 for more information on product, quality and usage.

8) BREAKING LOAD

Expressed in Newton’s this is the value given to the point at which the chain will fail in tensile pull.
The data given in the catalogue is based on tensile pull tests at ambient temperature.
The breaking loads given are an average value based on a number of tests.
The range variation, from average, should be considered as no more than 5%.

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CHAIN SELECTION - CHAIN PULL

Chain pull is that force required to move the chain, the connected mechanical parts and the load to be conveyed.
The chain pull required for a particular application is dependent on the following factors:

1) WEIGHT OF MATERIAL CARRIED

2) WEIGHT OF CHAINS AND SUPPORT ELEMENTS (SLATS, SWING TRAYS, CROSSBARS, FASTENERS, ETC.)
3) COEFFICIENT OF FRICTION
4) SERVICE FACTOR
5) GEARING FACTOR

The calculation of chain pull is carried out in two phases:

- the preliminary phase, a calculation which determines the type of chain required by the chain weight and the coefficient of friction.
- the second phase, a control calculation, confirms the preliminary chain weight and coefficient of friction by substituting
actual values of the identified chain.

1) WEIGHT OF MATERIAL CARRIED = P1 [kg]

See paragraph 2 of the chapter “Chain selection – General considerations”.

2) WEIGHT OF CHAINS = P [kg]

For the preliminary calculations this is the approximate weight of the entire chain circuit including any attachments
(slats, swing trays, crossbars, fasteners, etc.). For the control calculation it is the actual weight of the entire chain circuit.

3) COEFFICIENT OF FRICTION

The coeffficient of friction is the value that defines the force necessary to overcome resistance to movement when two bodies are in contact.
When operating in a “sliding” mode along a track, chains must overcome sliding friction “fr”. Typical values for sliding friction coefficients are
outlined in the following table.

TABLE 2

BODIES IN CONTACT fr dry surface fr lubr. surface

Steel chains on hardwood tracks 0,44 0,29
Steel chains on steel tracks 0,30 0,20
Steel chains on rough or rusty tracks 0,35 0,25
Steel chains on tracks of high density 0,18 0,05
very high molecular weight polyethlene

When running on rollers chains must overcome both sliding and rolling friction “fv”.
The value of the rolling coefficient in the preliminary calculation is assumed to be fv = 0.2, whilst in the control calculation its value is given as:

fv = C • d + b
D D
where
d = bush outside diameter [mm]
D = Roller outside diameter [mm] see catalogue.
b = Coefficient dependent on the type of materials used and the grade of machined surfaces.
= 1 - for steel roller on steel track with smooth surface
= 2 - for steel roller on steel track with rough surface
C = the sliding friction coefficient between bush and roller, outlined in the following table.

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TABLE 3
Dry Lubricated
BODIES IN CONTACT surface “C” surface “C”
Steel roller on steel bush 0,25 0,15
Roller with bronze bush on steel bush N/A 0,13
Nylon roller on steel bush 0,15 0,10
Important

It is important to note that in the initial stage of movement, the starting friction coefficient can be 1.5 to 3 times greater than
the dynamic friction coefficient.
As a general guide, in order to minimise initial friction, the external diameter of the roller should be at least 2.5 times greater than
the external diameter of the bush.

4) SERVICE FACTOR = FS

Chain pull must be multiplied by an adjustment coefficient (FS) to take account of operational conditions and characteristics
of the conveyors. FS values for the most common applications are outlined in the following table.

TABLE 4

OPERATING CONDITIONS FS
Load position
- Centred 1
- Not centred 1,2
Load characteristics
- Uniform: extent of overloading less than 5% 1
- With minor variations: extent of overloading 5 to 20% 1,2
- With major variations: extent of overloading 20 to 40% 1,5
Frequency of loaded starting/stopping
- Less than 5 per day 1
- From 5 per day to 2 per hour 1,2
- More than 2 per hour 1,5
Working environment
- Relatively clean 1
- Quite dusty or dirty 1,2
- Humid, very dirty or corrosive 1,3
Number of hours in use daily
- Up to 10 1
- More than 10 1,2

To obtain the total FS coefficient, (FS) value for each operational condition must be multiplied together.

5) GEARING FACTOR = FA

This is an adjustment coefficient made to the chain pull, which increases due to the additional friction caused by the rotation of the chain
on the drive and driven wheels.

FA = 1,05 for wheels mounted on brass bushes

= 1,03 for wheels mounted on bearings

The sum of all products obtained by multiplying FA for the chain pull in each gearing point determines the new total chain pull.
For the following examples the “FA” values will not be concidered.

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CHAIN PULL CALCULATIONS

a) Horizontal conveyor with sliding chains

Fig. 3

T = 9,81 (P+P1) • fr • FS [N]

No. of chains

b) Horizontal conveyor with roller chains

Fig. 4

T = 9,81 (P+P1) • fv • FS [N]

No. of chains

c) Inclined conveyor with sliding chains

α
Fig. 5

T = 9,81 [cosα (P+P1) • fr + sinα • P1] • FS [N]

No. of chains

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d) Inclined conveyor with roller chains

Fig. 6

T = 9,81 [cosα (P+P1) • fv + sinα • P1] • FS [N]

No. of chains

e) Vertical elevator

Fig. 7

T = 9,81 (P/2+P) • FS [N]

No. of chains

N.B.:
For further technical assistance on vertical conveyors not covered in this catalogue,
please contact our technical office.

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SCRAPER CONVEYORS

To calculate the chain pull of scraper conveyors, additional parameters need to be considered:
fm = coefficient of friction between material to be moved and the side guides (table 5),
L = portion of loaded conveyor [m],
Q = mass of product to be transported [T/h],
H = height of side guide [m],
B = width between guides [m],
β = product depth normally not exceed 50-60 % of H,
3
γ = specific weight of material conveyed. [T/m ] (table 5),
v = chain speed. [m/sec].

TABLE 5 ** **
Spec. weight
3
Friction coefficient
MATERIAL CONVEYED γ. [T/m ] fm

Oats 0,45 0,7

Wheat 0,75 0,4
Corn 0,8 0,4
Dried barley 0,45 0,7
Rye 0,65 0,4
Rice 0,75 0,4
Linseed 0,7 0,4
Dried malt 0,4 0,4
Wheat flour 0,7 0,4
Corn flour 0,65 0,4
Refined powdered sugar 0,8 0,5
Cement 1,00 0,9
Anthracite coal in pieces 0,7 to 0,9 0,4
Coking coal 0,5 0,7
Dried clay 1,6 0,7
Ashes 0,6 0,6
KLINKER cement gravel 1,3 0,8

** indicative values

a) Horizontal conveyor with sliding chains and material

Fig. 8

T = 9,81 [(P • fr + P1 • fm) • FS] [N]

No. of chains

Where P1 can be calculated as follows:

a) P1 = H • B • L • β • γ • 1000 [kg]

b) P1 = L • Q [kg]
3,6 • v
If Q is unknown it can be calculated as follows: Q = H • B • β • γ • v • 3600 [T/h]

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b) Horizontal conveyor with roller chains and scraper bars

Fig. 9

T = 9,81 [(P • fr + P1 • fm) • FS] [N]

No. of chains
Where P1 can be calculated as follows:

a) P1 = H • B • L • β • γ • 1000 [kg]

b) P1 = L • Q [kg]
3,6 • v
If Q is unknown it can be calculated as follows: Q = H • B • β • γ • v • 3600 [T/h]

DETERMINING THE TYPE OF CHAIN TO USE

Having established the maximum chain pull, the maximum stress that chain components will be subjected to must then be considered.
It is generally accepted that a chain, working at 65% of the breaking load will be stressed beyond the ‘elastic limit’ of the side plate material.
In order to provide a sufficient margin of safety, the chain breaking load should therefore be at least 8 times the maximum working load.
This safety margin is known as the factor of safety.
It is essential that an adequate safety factor is provided and in cases where variations in chain pull values are difficult
to quantify, the Technical Office should be consulted.
In situations where high density loads are moved on small conveyor surface, the calculation of chain pull alone is not always sufficient
to identify chain type.
In these instances, the specific pressure values between the rollers/bushes and bushes/pins should also be considered.
If the specific pressure values exceed those listed in table 6-7, then a chain with greater contact surface between the rollers and bushes,
or bushes and pins must be considered.

Calculation of bearing pressure

a) roller loading = P kgf

L • Dr mm [ ]
2

b) pin pressure = T
Lb • Dp [ ]
kgf
mm
2

where:
P = load [kgf] supported by each roller
T = chain pull [kgf]
L = distance through roller bore [mm]
Lb = total bush length [mm]
Dr = diameter of roller bore [mm]
Dp = external diameter of pin [mm]

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MAXIMUM ALLOWABLE PRESSURES

TABLE 6
MATERIALS IN CONTACT Max. spec. Press.
BUSH PIN Kgf/mm2
Case-hardened steel Case-hardened steel 2,5
Case-hardened steel Hardened-tempered steel 2,1
Cast iron Case-hardened steel 1,75
Stainless steel Stainless steel 1,2
Bronze Case-hardened steel 1

TABLE 7
MATERIALS IN CONTACT Max. spec. Press.
ROLLER BUSH Kgf/mm2
Case-hardened steel Case-hardened steel 1
Hardened-tempered steel Case-hardened steel 1
Cast iron Case-hardened steel 0,70
Bronze Case-hardened steel 0,60
Polyethylene A.D. Case-hardened steel 0,1
Stainless steel Stainless steel 0,40
Cast iron Bronze 0,28

CALCULATION OF POWER REQUIRED AT HEAD SHAFT

Once the conveyor’s total chain pull has been determined, the following procedure for the calculation of shaft power requirements should be used:

Mt = T • dp [kgm] Mt = 716,2 • N [kgm]

2 n

where:
Mt = torque [kg m]
N = power [CV, Hp or KW]
n = head shaft rpm
T = total chain pull [kg]
dp = PCD of the drive sprockets [m]

From these two relationships it is concluded that:

T • dp = 716,2 • N
2 n

From which is derived

N = T • dp • n [CV]
2 • 716,2

or

N = T • dp • n [KW]
2 • 973.8

The usable power output of the motor must be determined taking into account losses from reduction devices, belts, etc.

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LUBRICATION OF CHAINS

Chain lubrication is essential for the following reasons:

1) REDUCTION IN THE COEFFICIENT OF FRICTION

2) REDUCING CHAIN WEAR AND SAVING ENERGY
3) PREVENTION OF CORROSION
4) CORRECT FUNCTIONING OF THE CHAIN

1) REDUCTION IN THE COEFFICIENT OF FRICTION

Friction is defined as the mechanical resistance produced between two surfaces in motion against each other.
There are two basic types of Friction, Static and Dynamic.
Static friction Rs is the resistance given by a surface to relative movement when an external force is applied.
It can also be known as the breakaway friction. Experience shows that to obtain movement of a body of weight P rested on a plane,
the force necessary to move that body, F, is a product of the coefficient of static friction, µ and the weight of the body P.
Dynamic friction is the resistance given by a body already in motion, that is the resistance given to an external force exerted to overcome
the friction between two surfaces. The force required to keep a body in motion is always less than that to move a body from rest.
Dynamic friction Rd is a product of the coefficient of dynamic friction f and the weight of the body P.

Rs = P • µ (Kg)

Rd = P • f (Kg)

The value of both µ the coefficient of static friction and f the coefficient of dynamic friction are dependant on the quality of the surfaces in
contact, the type of contact (sliding or rolling), the relative speeds between the surfaces and the presence of lubrication.

Fig. 10 shows the influence of relative speed on the coefficient of friction. The curve is divided in three parts:
• part 1 shows friction at very slow speed, in this case the film of lubricant between the two surfaces
is not thick enough to prevent contact;
• part 2 is an intermediate condition;
• part 3 shows friction at higher speed when the film of lubricant is thick enough to ensure that motion takes
place without direct contact between the two surfaces.

Fig. 10

1
2 3
coefficient of friction (f)

speed (v)

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2) REDUCING CHAIN WEAR AND SAVING ENERGY

The absence of a lubricant film causes the rotating parts of the chain to come into direct contact with each other.
This in turn causes progressive wear of the mating surfaces, which results in premature failure of the chain.
Additional friction caused by premature wear results in an increase in chain pull, requiring a higher power input from the motor,
using more energy. The presence of a lubricant prevents metal to metal contact, increases the operating life of the chain and saves
a considerable amount of energy.

Figure 11 shows the percentage elongation of a chain, based on working hours and type of lubrication.

Key.
a) Percentage elongation of chains working with no pre lubrication or running lubrication.
b) Percentage elongation with pre lubrication but no further working lubrication.
c) Chain with pre lubrication and then only sporadic re lubrication.
This clearly shows that the lubrication periods are set at too great a time. Wear therefore occurs on a cyclic periods.
d) This curve indicates the unsuitability of lubricant used or the under lubrication of the chain.
e) Optimum lubrication.

a
2
elongation due to wear (%)

1
c

d
e
0
Fig. 11
time

3) PREVENTION OF CORROSION

Any non-protected metal is subject to oxidisation.

This phenomenon is exacerbated by environmental conditions, such as:
- high temperatures
- high humidity
- presence of aggressive chemical substances
Oxidisation or corrosion is a serious threat to chain life.
The presence of a lubricant film on the surface of the chain’s components, creating a barrier between the chain and the external
environment, prevents the formation of oxides and the onset of corrosion.
The effectiveness of this protection can be improved by the addition of corrosion inhibitors within the lubricant.

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4) CORRECT FUNCTIONING OF THE CHAIN

Adequate lubrication ensures continuous functioning of the chain and has the additional advantage of reducing operating noise.

CHOICE OF LUBRICANT

It is impossible to prescribe one lubricant for all applications. Many parameters determine the choice of lubricant;
but the most important one is operating temperature.
For practical purpose, operating temperature can be sub-divided as follows:

a) Low temperature - – 40°C to 15°C

b) Normal temperature - 15°C to 110°C
c) High temperature - 110°C to 250°C
d) Very high temperature - more than 250°C

A) LOW TEMPERATURE (– 40° C TO 15°C)

When operating temperatures fall below 0 degrees it is necessary to select the correct lubricant to keep the chain in good condition.
In very low operating temperatures synthetic oils, with low viscosities are often used. In applications that require no oil contamination or
fling off into the surrounding area it is best to apply greases in dispersions that will carry the grease into the round parts of the chain and
then dry to allow little or no dripping or fling off. For low temperature conditions we would recommend KLÜBERSYNTH UH14-68N or
ISOFLEX grease NBU 15. We do suggest that a lubrication company be contacted to get first hand technical knowledge before a final
decision is taken on which lubricant is used.

B) NORMAL TEMPERATURE (+ 15° C TO 110° C WITH POINTS UP TO 150° C)

The use of mineral oils is not recommended; specific lubricants for chains with additives to prevent dripping and improve capillarity are
more appropriate. One product which meets these requirements is the grease fluid STRUCTOVIS FHD (KLÜBER LUBRICATION), which has
an excellent adhesive capacity to minimise dripping and low surface tension which permits “sapping” of any drops of moisture which may
be present on the metallic surface. These attributes ensure maximum lubrication even in the most difficult conditions.

C) HIGH TEMPERATURE (FROM 110° C TO 250° C)

The use of synthetic oils is necessary in this temperature range because their thermal stability is superior to that of mineral oils.
Oils containing combinations of solid pigments with a graphite or molybdenun disulphide base are recommended because they provide
emergency lubrication and increase the maximum specific pressure value. Additionally these oils contain additives to prevent the formation
of sludge. The synthetic oil SYNTHESCO (KLÜBER LUBRICATION) is recommended since it has less tendency to smoke (NON-toxic).

D) VERY HIGH TEMPERATURES

In these temperature conditions, a fluid lubricant is ineffective. A solid lubricant suspended in a synthetic “vehicle” should be used.
The synthetic solution evaporates and leaves the lubrication place. A certain quantity of smoke generation is inevitable in this case.
The application must be carried out when the chain is cold.
WOLFRAKOTE TOP FLUID S (KLUBER LUBRICATION) is recommended.

CLEANING OF CHAINS

The cleaning of chains and tracks along with the correct lubrication of the chain can give vastly improved chain life. In certain conditions re
lubrication of a chain without first cleaning the chain and tracks can be detrimental to the running of the conveyor, and will render re lubri-
cation completely ineffectual.
It is recommended that chains be cleaned in the following circumstances:

• Before periods of extended downtime. It is advisable to clean the chains before applying a suitable protective product.
• When the chains reach a point that they are so contaminated that the dirt build up cannot be removed by normal methods.

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(i.e. flushing with lubricant, brushing or washing down.) At this point it is recommended that the chain be removed from the conveyor
thoroughly cleaned, dipped in a lubricant bath, and allowed to soak for at least 6 hours, before being put back on the conveyor.
• If a reaction takes place between the grease used by the manufacturer and the product used for re lubrication the chains must be
removed from the system, degreased and re lubricated before being put back into service.

NOTE.
When washing chains with water or water/detergent mix products it is essential that the chains are re-lubricated with a product that will
displace moisture and penetrate into the round parts.

Suggested procedure for cleaning chains.

1) Remove chain from conveyor.

2) Remove all surface dirt and oil/grease, with rags or brushes
3) Wash the chain with a solvent/lubricant mix. Paying attention to remove all contamination from the round parts.
(i.e. ensure all round parts rotate freely and all links articulate.)
4) Immerse the cleaned chain in a suitable lubricant bath for a minimum of 6 hours.

INITIAL LUBRICATION

For the initial lubrication of the chains the special lubricant STRUCTOVIS FHD of KLÜBER LUBRICATION is used.
The viscous structure of this chain oil distinguishes itself clearly from traditional chain lubricants by the following characteristics:

- high adhesion (anti drop)

- water-repellent
- very good wear protection
- excellent ageing stability
- very good temperature stability up to 150°C

STRUCTOVIS FHD - Chemical physical properties

Density at 20°C [g/cm3] DIN 51757 Approx. 0,890
Kinematic viscosity [mm2/sec] DIN 51561
at 40° C 145
at 50° C 86
at 100° C 15
Viscosity index ISO 2909 100
Flash point (°C) DIN 51376 >250
Pourpoint (°C) DIN ISO 3016 -12

Since 1979, KLÜBER Lubrication Italia has been subsidiary of the German company KLÜBER Lubrication München KG,
which is represented world-wide through 14 productions plants and more than 50 sales offices.

Thanks to a large choice of special lubricants, KLÜBER Lubrication Italia offers solutions for all requirements of lubrication.

KLÜBER Lubrication Italia has the DIN ISO 9002 and DIN ISO 14001 certificates and the EC eco-audit validations EMAS.

KLÜBER Lubricants are also available throughout Europe.

KLÜBER Lubrication Italia s.a.s.

Via Monferrato, 57
20098 S.Giuliano Milanese (MI)
Tel. 02-98213.1 - Fax 02-98.28.15.95
klita@klueber.com

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LUBRICATION SYSTEM LUBRICANT

Automatic lubricant distribution is always recomended, because it ensures

optimum lubricant dosage. This avoids accidental dry operation and pre-
vents over-lubrication and consequent dripping. The lubricant, whether
sprayed or atomized, must reach the flanks of the rollers and between the
plates of the pins to ensure an even distribution to all parts of chain.
Provided a suitable lubricant is used, it is not necessary for the chain to be
soaked, merely dampened. Lubrication frequencies or quantities cannot be
given here, every case should be individually assessed.

CONCLUSION

The lubrication discussion is by no means exhaustive, and is offered merely as a method of highlighting the importance of the correct
lubrication of moving parts. Regretably, this subject is often either ignored or underestimated, but to ensure chain longevity,
smooth and quiet running at minimum power consumption, it is crucial.

CHAIN IDENTIFICATION

To avoid misinterpretation, a standard terminology for chain identification is proposed. To demonstrate this terminology, the type of chain
and the type of attachment are considered separately.

TYPE OF CHAIN

a) Each chain type is assigned a number, which identifies all the chain characteristics such as: pitch, internal width,
roller diameter, etc.

Example:

Chain No. 352 - No. C2080H - No. 400C

b) The series not unified in inches DIN 8167 and series DIN 8165 chains are additionally identified by a letter (A) for the bush solution,
(B) for the small roller, (C) for the large roller, or (D) for the flange roller and by a number which specifies chain pitch.
(A single chain type can be almost any pitch).

Examples:

a) chain No. Z40-A-101,6

means:
Z40 = solid-pin chains, series BS 4116
A = bush chain
101,6 = pitch of 101,6 mm.

b) chain No. MC112-D-200

means:
MC112 = chain with hollow pins, series DIN 8167
D = flange roller
200 = pitch of 200 mm

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c) Special chains not listed in the catalogue, are classified by pitch, internal width, roller diameter
and the relevant design number.

Example:

chain pitch 150 X 23 X 45 in design n. 001954

Any deviation from the production standard must be followed by precisely defined characteristics.

Examples:

a) chain N° 500 zinc-plated

b) chain N° 500 with hardened and tempered plates
c) chain N° 500 with 20 mm diameter rollers

TYPE OF ATTACHMENT

Attachments are defined by dimensional characteristics from a standard table or, in the case of special attachments,
by a precisely detailed drawing.
The chain identifing code also includes the attachment code and specifies how the attachment is to be put into position,
how many holes it must have, etc. as follows:

A = for single-sided bent attachment

M = for single-sided vertical attachment
K = for double-sided bent attachment
MK = for double-sided vertical attachment
1 = for single-holed attachment
2 = for double-holed attachment
3 = for triple-holed attachment
01 = for attachment every pitch
02 = for attachment every 2 pitches
10 = for attachment every 10 pitches
0X = for attachment every X pitches

Examples:

a) chain No. 500A202

means:
chains type 500 single-sided attachments, with two holes, every 2 pitches

b) chain No. 703K304

means:
chain type 703, double-sided attachments, with 3 holes, every 4 pitches

c) chain No. M160C125A203

means:
chain series M …, single-sided attachments, with 2 holes, every 3 pitches

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Special attachments, or those which depart from the catalogue norm, are identified with the same classification criteria,
but must always include the drawing number:

Example:
Chain No. 704A1-01, drawing N° 001988

When the attachments are required at even pitch intervals (02-04-06 etc.), they will be assembled on the external link of the chain unless
otherwise specified.

The following pages illustrate the most common attachment assembly combinations.

M1-01 MK1-01

M2-01 MK2-01

M1-02 MK1-02

M2-02 MK2-02

M1-03 MK1-03

M2-03 MK2-03

M1-04 MK1-04

M2-04 MK2-04

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7150_ZMC/ING_04 mod 14-01-2003 11:17 Pagina 21

A1-01 K1-01

A2-01 K2-01

A3-01 K3-01

A1-02 K1-02

A2-02 K2-02

A3-02 K3-02

A1-03 K1-03

A2-03 K2-03

A3-03 K3-03

A1-04 K1-04

A2-04 K2-04

A3-04 K3-04

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7150_ZMC/ING_04 mod 14-01-2003 11:17 Pagina 22

CONVERSION FACTORS
Measure LENGTH multiplying by to obtain Measure
m metre 39,3701 inch in
m metre 3,28084 foot ft
m metre 1,09361 yard yd
cm centimetre 0,393701 inch in
cm centimetre 0,032808 foot ft
mm millimetre 0,039370 inch in
mm millimetre 0,003280 foot ft
in inch 25,4 millimetre mm
in inch 2,54 centimetre cm
in inch 0,0254 metre m
ft foot 304,8 millimetre mm
ft foot 30,48 centimetre cm
ft foot 0,3048 metre m
mi mile 1,60934 kilometre km
mi mile 1609,344 metre m
km kilometre 0,621371 mile mi

Measure AREA multiplying by to obtain Measure

2 2
m square metre 1550 square inch in
2 2
m square metre 10,7639 square foot ft
2 2
m square metre 1,19599 yard square yd
2 2
cm square centimetre 0,001076 square foot ft
2 2
cm square centimetre 0,155 square inch in
2 2
mm square millimetre 0,00155 square inch in
2 -5 2
mm square millimetre 0,000010 (1,07639x10 ) square foot ft
2 -4 2
in square inch 0,000645 (6,64516x10 ) square metre m
2 2
in square inch 6,4516 square centimetre cm
2 2
in square inch 645,16 square millimetre mm
2 2
ft square foot 0,092903 square metre m
2 2
ft square foot 929,03 square centimetre cm
2 2
ft square foot 92903 square millimetre mm

Measure VOLUME multiplying by to obtain Measure

3 3
m cubic metre 61023,7 cubic inch in
3 3
m cubic metre 35,3147 cubic foot ft
3
m cubic metre 219,969 UK gallon (imperial) UK gallon
3
m cubic metre 264,172 USA gallon gal (U.S. liquid)
3 3
l (dm ) litre 61,0237 cubic inch in
3 3
l (dm ) litre 0,035314 cubic foot ft
3
l (dm ) litre 0,219969 UK gallon (imperial) UK gallon
3
l (dm ) litre 0,264172 USA gallon gal (U.S. liquid)
3 3
cm cubic centimetre 0,061023 cubic inch in
3 -5 3
cm cubic centimetre 0,000035 (3,53147x10 ) cubic foot ft
3 3
ft cubic foot 0,028316 cubic metre m
3 3
ft cubic foot 28,3168 litre l (dm )
3 3
ft cubic foot 28316,8 cubic centimetre cm
3 -5 3
in cubic inch 0,000016 (1,63871x10 ) cubic metre m
3 3
in cubic inch 0,016387 litre l (dm )
3 3
in cubic inch 16,3871 cubic centimetre cm
3
UK gallon UK gallon (imperial) 0,004546 cubic metre m
3
UK gallon UK gallon (imperial) 4,54609 litre l (dm )

Measure ANGLES multiplying by to obtain Measure

° degree (angle) 0,017453 radian rad
rad radian 57,2958 degree (angle) °

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7150_ZMC/ING_04 mod 14-01-2003 11:17 Pagina 23

CONVERSION FACTORS
Measure TORQUE multiplying by to obtain Measure
Nm newton metre 0,101972 kilogram-force metre kgf m
Nm newton metre 0,737562 pound force foot lbf ft
Nm newton metre 8,85075 pound force inch lbf in
kgf m kilogram-force metre 9,80665 newton metre Nm
kgf m kilogram-force metre 7,23301 pound force foot lbf ft
kgf m kilogram-force metre 86,7962 pound force inch lbf in
lbf in pound force inch 0,112985 newton metre Nm
lbf in pound force inch 0,0115212 kilogram-force metre kgf m
lbf ft pound force foot 1,35582 newton metre Nm
lbf ft pound force foot 0,138255 kilogram-force metre kgf m

Measure FORCE AND WEIGHT FORCE multiplying by to obtain Measure

N newton 0,101972 kilogram force kg
N newton 0,224809 pound force lbf
kgf kilogram force 9,80665 newton N
kgf kilogram force 2,20462 pound force lbf
lbf pound force 4,44822 newton N
lbf pound force 0,453592 kilogram kgf
ton f (UK) ton-force UK 9964,02 newton N
ton f (UK) ton-force UK 1016,05 kilogram force kgf
ton f (US) ton-force US 8896,44 newton N
ton f (US) ton-force US 907,185 kilogram force kgf
tf ton-force metric 9806,65 newton N
tf ton-metric force 1000 kilogram-force kgf

Measure MASS/WEIGHT multiplying by to obtain Measure

kg kilogram 2,20462 pound lb
-4
kg kilogram 0,000984 (9,84207x10 ) ton UK (long ton) ton UK
kg kilogram 0,001102 ton US (short ton) ton US
kg kilogram 0,001 ton metric t
lb pound 0,453592 kilogram kg
ton UK ton UK (long ton) 1016,05 kilogram kg
ton US ton US (short ton) 907,185 kilogram kg
t ton metric 1000 kilogram kg

Measure DENSITY multiplying by to obtain Measure

3 3
kg/m kilogram per cubic metre 0,62428 pound per cubic foot lb/ft
3 -5 3
kg/m kilogram per cubic metre 0,000036 (3,61273x10 ) pound per cubic inch lb/in
3
kg/m kilogram per cubic metre 0,001 kilogram per litre kg/l
3 3
lb/ft pound per cubic foot 16,0185 kilogram per cubic metre kg/m
3 3
lb/in pound per cubic inch 27679,9 kilogram per cubic metre kg/m
3
kg/l kilogram per litre 1000 kilogram per cubic metre kg/m
3
kg/l kilogram per litre 62,428 pound per cubic foot lb/ft
3
kg/l kilogram per litre 0,036127 pound per cubic inch lb/in
3
lb/ft pound per cubic foot 0,016018 kilogram per litre kg/l
3
lb/in pound per cubic inch 27,6799 kilogram per litre kg/l

Measure WEIGHT FOR UNIT OF LENGTH multiplying by to obtain Measure

kg/m kilogram per metre 0,671972 pound per foot lb/ft
lb/ft pound per foot 0,13826 kilogram force per metre kg/m

Measure POWER multiplying by to obtain Measure

Hp horsepower 746 watt W
CV horsepower metric 735,499 watt W
W watt 0,001340 horsepower Hp
W watt 0,001359 horsepower metric CV

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7150_ZMC/ING_04 mod 14-01-2003 11:17 Pagina 24

CONVERSION FACTORS
Measure POWER multiplying by to obtain Measure
kW kilowatt 1000 watt W
kW kilowatt 1,34048 horsepower Hp
kW kilowatt 1,35962 horsepower metric CV
Hp horsepower 0,746 kW kilowatt kW
CV horsepower metric 0,735499 kW kilowatt kW

Measure PRESSURE multiplying by to obtain Measure

2 -7 2
Pa (N/m ) pascal 0,00000010 (1,01972x10 ) kilogram force per square millimetre kgf/mm
2 -5 2
Pa (N/m ) pascal 0,000010 (1,01972x10 ) kilogram force per square centimetre kgf/cm
2 -5
Pa (N/m ) pascal 0,00001 (10 ) bar bar
2 -6
Pa (N/m ) pascal 0,000009 (9,86923x10 ) atmosphere atm
2 2
Pa (N/m ) pascal 0,020885 pound per square foot lbf/ft
2 -4 2
Pa (N/m ) pascal 0,000145 (1,45038x10 ) pound per square inch lbf/in (psi)
2 2
Mpa (N/mm ) megapascal 0,101972 kilogram force per square millimetre kgf/mm
2 2
Mpa (N/mm ) megapascal 10,1972 kilogram force per square centimetre kgf/cm
2
Mpa (N/mm ) megapascal 10 bar bar
2
Mpa (N/mm ) megapascal 9,86923 atmosphere atm
2 2
Mpa (N/mm ) megapascal 20885,4 pound per square foot lbf/ft
2 2
Mpa (N/mm ) megapascal 145,038 pound per square inch lbf/in (psi)
2 2
kgf/cm kilogram force per square centimetre 98066,5 pascal Pa (N/m )
2 2
kgf/cm kilogram force per square centimetre 0,098066 megapascal Mpa (N/mm )
2 2
kgf/cm kilogram force per square centimetre 14,2233 pound force per square foot lbf/in (psi)
2 2
kgf/cm kilogram force per square centimetre 2048,16 pound force per square inch lbf/ft
2
kgf/cm kilogram force per square centimetre 0,980665 bar bar
2
kgf/cm kilogram force per square centimetre 0,967841 atmosphere atm
2 2
kgf/mm kilogram force per square millimetre 9806650 Pascal Pa (N/m )
2 2
kgf/mm kilogram force per square millimetre 9,80665 megapascal Mpa (N/mm )
2 2
kgf/mm kilogram force per square millimetre 1422,33 pound force per square inch lbf/in (psi)
2 2
kgf/mm kilogram force per square millimetre 204816 pound force per square foot lbf/ft
2
kgf/mm kilogram force per square millimetre 98,0665 bar bar
2
kgf/mm kilogram force per square millimetre 96,7841 atmosphere atm
2 2
lbf/ft pound force per square foot 47,8803 pascal Pa (N/m )
2 -5 2
lbf/ft pound force per square foot 0,000047 (4,78803x10 ) megapascal Mpa (N/mm )
2 2
lbf/ft pound force per square foot 0,000488 kilogram force per square centimetre kgf/cm
2 -6 2
lbf/ft pound force per square foot 0,000004 (4,88243x10 ) kilogram force per square millimetre kgf/mm
2 -4
lbf/ft pound force per square foot 0,000478 (4,78803x10 ) bar bar
2 -4
lbf/ft pound force per square foot 0,000472 (4,72541x10 ) atmosphere atm
2 2
lbf/in (psi) pound force per square inch 6894,76 pascal Pa (N/m )
2 2
lbf/in (psi) pound force per square inch 0,006894 megapascal Mpa (N/mm )
2 2
lbf/in (psi) pound force per square inch 0,070307 kilogram force per square centimetre kgf/cm
2 -4 2
lbf/in (psi) pound force per square inch 0,000703 (7,0307x10 ) kilogram force per square millimetre kgf/mm
2
lbf/in (psi) pound force per square inch 0,068947 bar bar
2
lbf/in (psi) pound force per square inch 0,068046 atmosphere atm
2
bar bar 100000 Pascal Pa (N/m )
2
bar bar 0,1 megapascal Mpa (N/mm )
bar bar 0,986923 atmosphere atm
2
atm atmosphere 101325 Pascal Pa (N/m )
2
atm atmosphere 0,101325 megapascal Mpa (N/mm )
atm atmosphere 1,01325 bar bar

Measure FLOW RATE BY MASS multiplying by to obtain Measure

kg/sec kilogram per second 60 kilogram per minute kg/min
kg/sec kilogram per second 3600 kilogram per hour kg/h
kg/sec kilogram per second 132,277 pound per minute lb/min
kg/sec kilogram per second 7936,64 pound per hour lb/h
kg/sec kilogram per second 3,6 ton per hour t/h

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CONVERSION FACTORS
Measure FLOW RATE BY MASS multiplying by to obtain Measure
kg/sec kilogram per second 3,54314 British ton per hour ton UK/h
kg/sec kilogram per second 3,96832 ton USA per hour ton US/h
kg/min kilogram per minute 0,016666 kilogram per second kg/sec
-4
kg/h kilogram per hour 0,000277 (2,77778x10 ) kilogram per second kg/sec
lb/min pound per minute 0,00755987 kilogram per second kg/sec
-4
lb/h pound per hour 0,000125 (1,25998x10 ) kilogram per second kg/sec
t/h ton per hour 0,277778 kilogram per second kg/sec
ton UK/h British ton per hour 0,282235 kilogram per second kg/sec
ton US/h ton USA per hour 0,251996 kilogram per second kg/sec

Measure SPEED multiplying by to obtain Measure

m/sec metre per second 39,3701 inch per second in/sec
m/sec metre per second 2362,2 inch per minute in/min
m/sec metre per second 3,28084 foot per second ft/sec
m/sec metre per second 196,85 foot per minute ft/min
m/sec metre per second 3,6 kilometre per hour km/h
m/sec metre per second 2,23694 mile per hour mi/h
m/min metre per minute 0,016666 metre per second m/sec
m/min metre per minute 0,656168 inch per second in/sec
m/min metre per minute 39,3701 inch per minute in/min
m/min metre per minute 0,054680 foot per second ft/sec
m/min metre per minute 3,28084 foot per minute ft/min
m/min metre per minute 0,06 kilometre per hour km/h
m/min metre per minute 0,037282 mile per hour mi/h
in/sec inch per second 0,0254 metre per second m/sec
-4
in/min inch per minute 0,000423 (4,23333x10 ) metre per second m/sec
ft/sec foot per second 0,3048 metre per second m/sec
ft/min foot per minute 0,00508 metre per second m/sec
km/h kilometre per hour 0,2778 metre per second m/sec
mi/h mile per hour 0,44704 metre per second m/sec
in/sec inch per second 1,524 metre per minute m/min
in/min inch per minute 0,0254 metre per minute m/min
ft/sec foot per second 18,288 metre per minute m/min
ft/min foot per minute 0,3048 metre per minute m/min
km/h kilometre per hour 16,6667 metre per minute m/min
mi/h mile per hour 26,82240 metre per minute m/min

Measure TEMPERATURE Applying the following formula to obtain Measure

°C degrees Celsius (tC x 1,8) + 32 tC=temperature °C degrees Fahrenheit °F
°F degrees Fahrenheit 5/9x(tF-32) tF=temperature °F degrees Celsius °C
K kelvin tK-273,15 tK= temperature K degrees Celsius °C

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