OWNER’S MANUAL

• Safety
• Assembly
• Preventive Maintenance
& Troubleshooting
rev 05-02-08

1
 WARNING
Before assembling, operating, or maintaining a Designer
System® conveyor, read and understand this Manual.
Failure to follow instructions and safety precautions could
result in serious injury, death or property damage.

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 Table of Contents

Foreword ............................................................................................................. 5

For Your Records ............................................................................................... 5

Safety ......................................................................................................... 6
Installation Safety ...................................................................................................................... 6
Control Stations ........................................................................................................................ 6
Safety Inspections ..................................................................................................................... 7
Design Changes ........................................................................................................................ 7
Span Tech Parts ........................................................................................................................ 7
Major Causes of Conveyor-Related Injuries .............................................................................. 7
Prohibited Environments ........................................................................................................... 8
In Case of Fire ......................................................................................................................... 8
Maximum Load and Speed ....................................................................................................... 8
Designer System Operation ....................................................................................................... 9
Safety Signal Words - Definitions ............................................................................................ 10
Safety Labels .......................................................................................................................... 10
Illustrations of Labels (U.S. versions) ......................................................................................... 11
Illustrations of Labels (international versions) ....................................................................... 12

Assembly Guide ................................................................................................ 13

Introduction ............................................................................................................................ 13
Before You Begin .................................................................................................................... 14
List of Tools Required ............................................................................................................. 15
Getting Started ....................................................................................................................... 16
Pre-Assembly Checklist .......................................................................................................... 16
Step 1 - Uncrate and Lay Out Bed Sections ............................................................................ 17
Step 2 - Assemble Bed Sections ............................................................................................. 18
Step 3 - Install Center Support Rails ....................................................................................... 20
Step 4 - Install and Inspect Wearstrips .................................................................................... 22
Step 5 - Install Guide Rail and Return Chain Support Rail ........................................................ 25
Step 6 - Install Support Structures .......................................................................................... 27
Step 7 - Install Conveyor Chain .............................................................................................. 29
Step 8 - Install / Remove Gearmotor ....................................................................................... 33
Step 9 - Install Transfer Bridge - Gravity Roller Transfer ............................................................. 40
Step 10 - Install Transfer Bridge - MicroSpan Transfer ............................................................... 41
Pre-Operation Safety Checklist ............................................................................................... 43

(continued on next page)

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 Table of Contents (continued)

Preventive Maintenance and Troubleshooting ................................................. 45

Safety Guidelines and Information ............................................................................................ 45
Routine Preventive Maintenance ................................................................................................ 46
1 - Environmental Contamination Inspection ................................................................. 46
2 - Chain and Wearstrip Inspection .............................................................................. 47
3 - Drive / Idler Wearstrip and Side Plate Inspection .................................................... 48
4 - Foreign Object Interference Inspection ................................................................... 49
5 - Chain Slack and Sprocket Engagement Inspection .................................................. 50
6 - Lubrication and Lubricator Inspection ..................................................................... 51
7 - Measurement of Motor Current .............................................................................. 52

Preventive Maintenance Items Checklist ............................................................................... 53

Maintenance Procedures .................................................................................... 54

Part A: Preventing Environmental Contamination ....................................................................... 54
Part B: Cleaning ....................................................................................................................... 55
Part C: Wearstrip Installation .................................................................................................... 57
Part D: Overheated Wearstrips ................................................................................................ 63
Part E: Drives and Idlers .......................................................................................................... 64
Part F: Lubricator Adjustment .................................................................................................. 67
Part G: Powered Transfer Lubrication ...................................................................................... 68
Part H: Motor Amperage & Gearbox Temperature ................................................................... 69
Part I: Sprocket Orientation ..................................................................................................... 71
Part J: Sprocket Alignment ....................................................................................................... 72
Part K: Sprocket Installation .................................................................................................... 73
Part L: Chain-to-Sprocket Engagement and Chain Installation Direction ................................ 74
Part M: Sprockets Rubbing Side Plates .................................................................................... 75
Part N: Bound or Locked Idler Shaft ....................................................................................... 76
Part O: Broken or Bent Chain Rods ......................................................................................... 77
Part P: Chain Assembly ............................................................................................................ 78
Part Q: Center Support Rail ..................................................................................................... 79
Part R: Return Chain Support Rail ............................................................................................ 81
Part S: Direction of Bed Sections ............................................................................................. 82
Part T: Side Frame Alignment ................................................................................................... 83
Part U: Horizontal & Vertical Bend to Straight Bed Section Alignment ...................................... 84
Part V: Crossbars .................................................................................................................... 86
Part W: Chemical Contamination .............................................................................................. 87
Part X: Chain Pitch & Elongation ............................................................................................. 88

Chemical Compatibility Chart .......................................................................................................... 90

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Troubleshooting ................................................................................................. 98
Troubleshooting Diagnostic Chart ............................................................................................. 99

4
 Foreword

This manual has been prepared for those persons who will assemble,
operate, or maintain a Designer System® conveyor. It is important that all
persons responsible for the care and operation of this product READ and
UNDERSTAND the information contained in this publication.

This manual covers four major subject areas related to the Designer System®
family of conveyors:

1. Safety requirements and precautions.

2. Assembly of Designer System® conveyors.

3. Preventive Maintenance procedures for Designer System® conveyors.

4. Troubleshooting information and assistance.

For Your Records

Included with each conveyor system are the following papers; make sure you
have them all for your records:

• Final Bill of Materials

• Owner’s Manual (this document)
• Master Project Layout Drawings
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 Safety
Installation Safety
Installation of a Designer System® conveyor should be performed only by trained and experienced person-
nel who have read all of the literature that accompanied this shipment.

All electrical installations and wiring should conform to the National Electrical Code.

Each control station should be clearly labeled, and should be located so that the operation of the conveyor
is visible from the control station.

Guards, safety devices, and safety labels should be installed in the correct locations and maintained in good
repair.

Support systems for the conveyor should be securely anchored.

Control Stations

WARNING
Lockout the electrical power to the conveyor motor in accordance with OSHA regulations prior
to system maintenance. Failure to comply could result in serious injury or death.

The conveyor should not be started until all personnel in the area have been alerted by an automated signal
or by a designated person. Do not start equipment until all applicable personnel are aware of your intention
and are clear of components to be energized. Once personnel have been properly alerted, the conveyor
may be started.

Only trained and qualified personnel may perform maintenance or repair tasks on a control station.

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 Safety Inspections

Evaluation After Installation

After installation of the conveyor system, the user should perform an initial on-site safety evaluation. The
Pre-Operation Safety Checklist (page 43) should be used. Additional safety labels (if needed) should be
ordered at this time, before operations begin.

Pre-Operation Safety Checklist (form)

The Pre-Operation Safety Checklist is shown on page 43. All “No” entries on the evaluation require
corrective action.

User Safety Evaluation Log

The user should maintain an ongoing safety evaluation log. The log will consist of the most recent com-
pleted Pre-Operation Safety Checklists. User safety evaluations should be performed monthly.

Design Changes
Making changes to the equipment may create serious hazards. The user should not make changes which
affect the design, construction, installation, or handling requirements of the equipment without the written
consent of the manufacturer.

CAUTION
Do not mount brackets or other items on side frame that extend above or below the chain
surface, as this could create pinch points and the possibility of injury.

Span Tech Parts

Only parts supplied or authorized by Span Tech, LLC may be used on the conveyor system.

Major Causes of Conveyor-Related Injuries

The major causes of conveyor-related injuries include:
• Inability to rapidly halt conveyor motion
• Exposed drive components
• Shear points and pinch points caused by moving components, product, or product carriers
• Falling objects

The precautions, recommendations, and instructions provided in the Safety section (pages 6 through 11)
and throughout this Manual should be understood and followed, as a necessary part of a comprehensive
effort to minimize conveyor-related hazards.
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Prohibited Environments
In certain environments, Designer System® conveyors should not be used. If you are unsure of the safety
or suitability of your intended environment, contact a qualified Span Tech representative. Never use a
Designer System® conveyor in any of the following environments:

• Where chemicals that react with Celcon acetal copolymer are used
• Where machining chips are present
• Where fiberglass dust can come into contact with the conveyor
• Where broken glass occurs
• Where small metal particles are present
• Where strong acids or caustics are present
• Where ultraviolet light is present
• Where flammable materials are present (i.e. gasoline, solvents, etc.)

In Case of Fire

WARNING
The acetal material of the conveyor chain burns with a very hot, very faint flame. In case of
fire, use Water, Foam, CO2, or Dry Chemical extinguishers only. Use of other material will not
extinguish the fire and could result in serious injury, death or significant property damage.

If a Designer System® acetal conveyor chain were to catch fire, a blue flame would be barely visible, and
little or no smoke would be produced. In case of fire, immediately stop conveyor system operation. The
fire can then be extinguished using a water, foam, CO2, or dry chemical fire extinguisher. Report any fire to
the applicable Fire Department and plant management personnel immediately. Do not re-operate conveyor
until all repairs have been made.

Maximum Load and Speed

The maximum rated load capacity of any Designer System® conveyor is a function of the total load
(sum of the weights of the chain and conveyed product) and speed. Contact Span Tech for additional
information regarding load capacities.

NOTICE
Do not exceed Span Tech guidelines regarding maximum load and speed of conveyors and
related equipment. Failure to comply could result in premature component wear and conveyor
failure.
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 Designer System® Operation

WARNING
Before operating a Designer System® conveyor, read and understand this manual. Failure to
follow instructions and safety precautions could result in serious injury, death or property
damage.

Only trained employees should be permitted to operate a Designer System® conveyor. Personnel should
be trained to safely and properly operate the conveyor under normal conditions and emergency situations.

All personnel working in the vicinity of the conveyor should be instructed as to the location and operation of
normal and emergency stopping devices. In the case of an Emergency Stop, the conveyor controls should
be arranged so that manual reset or start must be accomplished from where the stop was initiated.

The conveyor should not be started until all personnel in the area have been alerted by a signal or by a
designated person. Use the Pre-Operation Safety Checklist on page 43 whenever conveyor is to be
started or restarted. Restart the conveyor system at the device or location from which it has been stopped.

The system should only be started with all safety devices, safety guards and safety labels in good repair and
in place.

Keep clear of the conveyor area when equipment is energized; conveyor may start at any time.

Keep obstructions away from all areas where the conveyor is loaded and unloaded.

Do not place articles or extremities into conveyor chain or frame while in operation.

Secure any loose clothing or hair; remove all jewelry, finger rings, pocket key rings, etc.

Watch for low clearance points and the potential for falling overhead objects.
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Safety Signal Words – Definitions

Below are signal words that are used in this manual and in the safety labels to identify different levels of risk.

• DANGER indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
• WARNING indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
• NOTICE deals with practices where property damage, inefficient work practices, and not injury, are
possible consequences.

• The SAFETY ALERT symbol (an exclamation point

within an equilateral triangle) indicates the need for
alertness to a potentially hazardous situation.

Safety Labels
Safety labels are not intended and must not be considered as substitutes for aggressive on-site safety
practices.

The following two pages feature illustrations of the safety labels provided with conveyors from Span Tech,
LLC. Page 11 shows labels formatted for use in the United States; page 12 shows labels formatted for
international use. Labels will become worn with normal conveyor use; these worn labels should be
promptly replaced with new labels obtained from Span Tech.

Span Tech replacement safety labels (U.S. versions) are provided as two gang labels; one having two
elements and the other having three elements. The part numbers for the two replacement safety labels are:

WARNING WARNING
To prevent serious injury or death:
To prevent serious injury
Part number (label 1): DS8008
· Do not operate or maintain this
conveyor until you have read all or death, do not operate
safety precautions in manual and with loose clothing, long
www.spantechllc.com on labels. hair, or loose jewelry.
· If manual is missing, obtain
replacement from Span Tech.
DS8008

WARNING WARNING WARNING

Fall Hazard Crush Hazard Burn Hazard
• Keep hands clear of moving
Do not stand on
components.
• Equipment starts auto-
If conveyor chain (acetal
plastic) catches on fire,
Part number (label 2): DS8009
conveyor. matically.
it burns with a very hot,
• Lock out / tag out equipment
before servicing. very faint flame.
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DS8009

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 Safety Labels – United States

WARNING
To prevent serious injury or death:
· Do not operate or maintain this
conveyor until you have read all
safety precautions in manual and
www.spantechllc.com on labels.
· If manual is missing, obtain
replacement from Span Tech.

WARNING
To prevent serious injury
or death, do not operate
with loose clothing, long
hair, or loose jewelry.

WARNING
Fall Hazard
Do not stand on
conveyor.

WARNING
Crush Hazard
• Keep hands clear of moving
components.
• Equipment starts auto-
matically.
• Lock out / tag out equipment
before servicing.

WARNING
Burn Hazard
If conveyor chain (acetal
plastic) catches on fire,
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it burns with a very hot,

very faint flame.
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 Safety Labels – International

The part number for the replacement

www.spantechllc.com international safety label is: DS8007
DS8007

Read Owner’s Manual

Entanglement Hazard.
Do not operate with loose clothing,
long hair, or loose jewelry.

Fall Hazard
Do not stand on conveyor.

Crush Hazard
Keep hands clear of moving components.

Lock out / tag out equipment before servicing.

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 Assembly Guide
Introduction
Span Tech has designed the Assembly Guide as a reference to assist you in assembling your new Span
Tech conveyor system. To ensure a smooth and efficient assembly process, it is important to take the time
to read this manual thoroughly, and to become familiar with the terminology and conveyor components.
Reviewing the Spare Parts Illustrations that have been supplied to you will also help you become familiar
with the various conveyor components and how they relate to each other. If a question arises during
assembly, feel free to contact Span Tech for technical assistance. (Contact information located on back
cover.) Keep in mind that each Span Tech conveyor system is customized, and no two installations will be
exactly the same.

WARNING
Before assembling a Designer System conveyor, read and understand this manual. Failure to
®

follow instructions and safety precautions could result in serious injury, death or property
damage.
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Before You Begin
Before starting assembly, the following two precautions must be addressed. These precautions are
very important.

NOTICE
Damage caused by a failure to follow the two precautions below will not be covered under the Span
Tech conveyor system warranty.

1. Remove Environmental Contaminants

Span Tech conveyor systems must be kept clean during installation to ensure proper operation. Environ-
mental debris can damage a conveyor. Examples of environmental contaminants include concrete dust,
sand, paper and wood dust, metal chips, glass, and ceramic dust. Construction in or near the assembly
area is a common source of these contaminants.

Avoid assembling the conveyor system when any type of construction is underway in the vicinity of the
assembly site. If construction work is to occur at any time after the conveyor system is installed, cover
the system completely to prevent contamination.

Do not place the conveyor components where they will be exposed to sunlight. UV (ultraviolet) rays will
cause deterioration of plastic components. If components must be stored outdoors, they must be protected
from both environmental dirt and sunlight.

2. Handle the Conveyor Components Carefully

Span Tech conveyor systems should never be handled directly by a forklift or any other type of lift truck.
Your conveyor will arrive on skids. These skids should be moved as close as possible to the installation
area. Two or more able-bodied persons should be able to safely move any of the conveyor’s components
and field-broken assembly sections.

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 TOOLS REQUIRED

The following tools will be needed during installation of your conveyor system:

1/2” (or 13mm) electric drill

13/64” (.2040”) (5.5mm) drill bit

Ratchet, with 10mm socket and 1/2” (or 13mm) socket

1/2” (or 13mm) combination wrench

Hand-held countersink, or 3/8” – 1/2” (10mm – 13mm) drill bit

Flashlight or other portable light

At least four (4) saw horses, matched to the height of the conveyor to be installed

Felt tip marker

Centering punch

Flat screwdriver, small

Rubber mallet

Hammer

Tape measure
Figure 1A: Blade & Anvil pruning shears
Alignment tool (5/32” [4mm] or 3/16” [5mm]
recommended size – long tapered point assists in
aligning holes)

* Blade & Anvil type pruning shears (Figure 1A)

* Rivet Insertion Tool (Figure 1B)
Figure 1B: Rivet Insertion Tool
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* Supplied with Span Tech Tool Box

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Getting Started

Along with this Manual, you should have a schematic drawing of the conveyor system to be assembled.
Use the schematic to help prepare the installation site and to ensure that you have all of the required
components. Allow enough room in the work area to handle the components with ease. Remember, the
cleaner the installation site, the better the conveyor operation. Thorough preparation beforehand will
pay off during and after assembly.

Span Tech conveyor systems require a minimum of two (2) people for assembly. When the installation site
has been prepared and the all needed tools and personnel are present, assembly may begin. Span Tech
conveyor systems are designed and built to be field assembled with minimum effort.

NOTICE
Parts should never be forced together. If a problem arises, please call Span Tech for technical
assistance. It is better to take the time to make a telephone call than to risk damaging the conveyor
system.

PRE-ASSEMBLY CHECKLIST

No forklifts or lift-trucks are being (or have been) used to move any part of the conveyor.

All of the tools included in the “Tools Required” list (page 15) have been gathered and are readily
available.

All of the conveyor prints supplied are readily available for reference.

All of the conveyor components are clean.

The assembly area is roomy and clean.

There are at least two qualified people to do the assembly work.

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 STEP 1 — Uncrate and Lay Out Bed Sections

• Lay out the bed sections and components of the conveyor according to the schematic. While doing
this, make sure all bed sections and components are positioned right side up, and in the correct
direction according to chain flow, to avoid confusion and error during the actual assembly.

Notice that labels have been attached to the side frame, near the end of each bed section field break
(Figure 2). These labels indicate the bed section’s conveyor number, joint number, the top side of the
bed section, and the direction of chain flow. The joint number on the label of one bed section will
match the joint number on the label of the adjoining bed section. These labels should be removed after
assembly has been completed.

Joint Joint
label label

Connecting Strap

Figure 2: Conveyor Bed Section with joint labels

“Chain flow” refers to the direction in which the chain moves along the top of the conveyor. Most convey-
ors are designed with the chain “pulled” at the drive end, so that the chain flows from the idler to the drive.
The opposite is true for conveyors designed so that the chain is “pushed” at the drive end. The direction of
chain flow should be indicated on the schematic drawing, as well as on the label attached to each compo-
nent or field-broken bed section.

NOTICE
It is very important to keep your Span Tech conveyor system clean to ensure proper operation.
Keep this in mind when laying out the system.

Conveyors that will not fit onto one skid for shipping will be field-broken. The sections will have pre-
trimmed wearstrips, center support rails, and other accessories. These sections will only need to be
connected.

WARNING
Never step or walk on any part of the conveyor before, during, or after assembly. Doing so
could result in serious injury or damage to the conveyor system.
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STEP 2 — Assemble Bed Sections

Begin assembly at one end of the conveyor, and work toward the other end. If the system was not
shipped with the supports in place, assemble the bed sections on saw horses. The height of the saw
horses should place the conveyor at its final elevation. If you are assembling a relatively long system
and have only a limited number of saw horses, you can “leapfrog” the saw horses as you move along.

NOTICE
The adjoining bed sections must be bolted together using the steel connecting straps provided.

• Pull any trailing wearstrips at the ends of the bed sections away from the conveyor side frame1 so they
will not interfere while connecting the bed sections (Figure 3).

1
NOTE – If a wearstrip is accidentally removed, make
sure it is reinstalled and properly pinned to the side
frame as described in STEP 4 (beginning on page 22).

Wearstrip

Connecting Strap

Wearstrip

Figure 3: Overview of Bed Section assembly

• Remove the four bolts from the loose end of each connecting
strap.
• Loosen the four remaining, attached bolts on each connect-
ing strap.
• Bring the adjoining ends of the bed sections together,
lining up the side frames on both sides (Figure 4).

Bed
Sections
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Figure 4: Bring ends of Bed

Sections together

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 STEP 2 — Assemble Bed Sections (continued)

• Insert bolts through the connecting straps and holes in the

side frame. NOTE: You will need to leave one hole open,
so you can use an alignment tool to help align the frames.
After this step there should be four bolts in one end of the
strap and three bolts in the other end, with one open hole
(Figure 5). open hole
• Using a 1/2” (13mm) wrench, tighten the four bolts in one end
of the connecting strap (Figure 5).
• Insert an alignment tool into the open hole, and draw the two Connecting Strap
frames together (Figure 6). Ensure that the frames are
Figure 5: Tighten first four bolts
aligned (Figure 7) by feeling the connection with your
fingers.
• Tighten all remaining bolts. Install and tighten a bolt in the
empty hole.
• Push the wearstrips into position on the lips of the side
frames. Be sure the wearstrips are snug against the side
frames. Alignment
• Repeat assembly procedure for all remaining bed sections; tool
inspect all joints for correct and accurate alignment
(Figure 7).

Figure 6: Use alignment tool (in open

hole) to draw Bed Sections together

CORRECT INCORRECT
Side Frame alignment Side Frame alignments
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Figure 7: Side Frame misalignment illustrations

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STEP 3 — Install Center Support Rails

After the bed sections have been bolted together, the center support rails can be installed. The center
support rails (T-rails) provide support for the top chain in the product zone (Figure 8), thus preventing
the chain from bowing due to the product load. NOTE: As a rule of thumb, MonoSpan® conveyors
and MultiSpan® conveyors that are less than 13.21 inches (335.60 mm) wide do not require center
support rails.

This is the typical assembly

of center support rails for a Trailing
End Cha
field break location of a in F
conveyor bed section low

Leading
End

The T-rail is inserted into

Flo Center Support the crossbar slot and
w seated with a rubber
Rail
mallet. The self-locking
tab will lock the T-rail in
position.
Chamfered at
the end as shown

Crossbar

Figure 8: Overview of Center Support Rail assembly

• At field-break locations, insert the T-rail into the crossbar slot closest to the edge of the conveyor.
• Using a rubber mallet, tap the T-rail to fully seat it in the crossbar slot. The self-locking tab will lock the
T-rail in position (see Figure 8).
• At the next crossbar, insert the T-rail into the second
slot, so that the T-rail curves slightly. Use a rubber
mallet to seat the T-rail in its slot.
• Keep alternating between these two crossbar slots until
the entire T-rail is in place.
• Repeat the above steps for all adjacent T-rails, so that
the rails create a “wavy” pattern along the entire length
of the conveyor (Figure 9).
• Inspect entire Center Support Rail to ensure that it is
properly installed and secure at every crossbar.
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Figure 9: Typical Center Support Rail

layout

20
 STEP 3 — Install Center Support Rails (continued)

Center support rails should “snake” back and forth throughout the length of the conveyor to avoid wear in
one particular spot (Figure 9). The trailing end of a rail should extend beyond the leading end of the next
rail (as shown in Figure 8) so that support is not interrupted. As a general rule of thumb, MaxiSpan®
conveyors will have one center support rail weaving under each of the chain’s center links. MultiSpan®
conveyors will require a variable number of center support rails, depending on the specific chain pattern.
The number of center support rails for your system was specified at the time of purchase and should be
indicated on the schematic.

NOTICE
A center support rail should never be positioned under High Friction or roller type chain links.
If the chain includes High Friction or roller links, the rail should run under the acetal center
links only. This will reduce the chance of the rail coming into contact with High Friction or
roller links — a situation that can cause excessive drag and premature failure of the conveyor.

If it becomes necessary to cut and trim a center support rail, hold the trailing end in position and make a
mark at the intended cut location (refer to Figure 8). Use pruning shears to cut the center support rail
at the mark. Chamfer the end of the rail and install the rail, as illustrated and described above.
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STEP 4 — Install and Inspect Wearstrips
The wearstrip is one of the most important features of Span Tech's Designer System® conveyors. The conveyor
chain is designed with legs on the outer links that hook around the lips of the conveyor side frame. The lips of the
side frame have a Spanlon wearstrip fitted over them. The conveyor chain contacts this wearstrip, resulting in
smooth chain travel, reduced load on the motor, and the prevention of damage caused by the chain directly
contacting the metal side frame. Special care must be taken when installing the wearstrips.

NOTICE
Failure to read and follow these instructions could result in damage to the conveyor system.

Connecting Pre-Cut Wearstrips

If the conveyor system being installed has been field broken for shipping purposes, the wearstrips at the break
locations have already been properly trimmed according to the direction of chain flow and the environment in
which the system will operate. In this case, simply push the wearstrips into place on the frame lips and
proceed to the applicable wearstrip installation procedures, on page 24.

Before Cutting Wearstrips (if necessary)

Four factors must be considered before making cuts: temperature, cut angle, cut direction, and cut location.
TEMPERATURE: The temperature at which the wearstrip is installed in a conveyor, as well as the temperature
at which the conveyor will normally be operating, both need to be considered before the wearstrips are cut
and trimmed. Cooler operating temperatures cause the wearstrips to contract or become shorter. Warmer
operating temperatures cause the wearstrips to expand or become longer.

At Span Tech, conveyors are pre-assembled at an average room temperature of about 70° F (21° C). If the
conveyor is installed in a room with an average temperature of 20° F (- 6.7° C), the wearstrip will naturally
contract. When the wearstrip contracts, the gap between adjacent pieces gets wider. If the gap gets too wide,
the conveyor's chain could derail from the system. On the other hand, if the conveyor is installed in a room with
an average temperature of 100°F (37.8° C), the wearstrips will expand, causing the gap between adjacent pieces
to get smaller. A wearstrip could even start to overlap onto the next, possibly resulting in damage to the conveyor.

The gap between adjacent wearstrips should be maintained at or very near 1/4” (6.35mm). The Wearstrip Gap
Chart (below) indicates the gap that should be left between adjacent wearstrips at various installation tempera-
tures, as compared to various temperatures at which the conveyor will operate. Example: If the wearstrips are
installed in a conveyor at a room temperature of 60° F (15.5° C), but the conveyor will normally be operating in
a 100° F (37.8° C) environment, you should leave a 3/8” (9.5mm) gap between wearstrips as they are installed.
WEARSTRIP GAP CHART
NORMAL OPERATING TEMPERATURE
0° – 20°F 21° – 40°F 41° – 60°F 61° – 80°F 81° – 100°F 101° – 120°F
-17.8° – -6.7°C -6.1° – 4.4°C 5.0° – 15.5°C 16.1° – 26.7°C 27.2° – 37.8°C 38.3° – 48.9°C
0° – 20°F 1/4” 5/16” 7/16” 1/2” 9/16” 5/8”
INSTALLATION TEMPERATURE

-17.8° – -6.7°C 6.4mm 7.9mm 11.1mm 12.7mm 14.3mm 15.9mm

21° – 40°F 3/16” 1/4” 5/16” 3/8” 1/2” 9/16”
Wearstrip
-6.1° – 4.4°C 4.8mm 6.4mm 7.9mm 9.5mm 12.7mm 14.3mm
Gap 41° – 60°F 1/8” 3/16” 1/4” 5/16” 3.8” 1/2”
5.0° – 15.5°C 3.2mm 4.8mm 6.4mm 7.9mm 9.5mm 12.7mm
61° – 80°F 1/16” 1/8” 3/16” 1/4” 5/16” 3/8”
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16.1° – 26.7°C 1.6mm 3.2mm 4.8mm 6.4mm 7.9mm 9.5mm

81° – 100°F 0” 1/16” 1/8” 3/16” 1/4” 5/16”
27.2° – 37.8°C 0mm 1.6mm 3.2mm 4.8mm 6.4mm 7.9mm
101° – 120°F 0” 0” 1/16” 1/8” 3/16” 1/4”
38.3° – 48.9°C 0mm 0mm 1.6mm 3.2mm 4.8mm 6.4mm
22
 STEP 4 — Install and Inspect Wearstrips (continued)
CUT ANGLE: The ends of adjoining wearstrip sections should be trimmed at 60° angles, as shown in Figure 10.
This angle, in conjunction with the direction in which the angles are cut (discussed below), allows the chain to
travel smoothly over the wearstrip joint.

CUT DIRECTION: The direction in which The wearstrip ends

60° should be trimmed at
the conveyor chain will travel dictates the 60° angles
direction at which the wearstrip angles will
be cut. Figure 10 shows the correct Chain travel
direction
angles in relation to the direction of chain (top side of
conveyor)
flow. When making cuts, keep in mind
that the conveyor chain runs in the oppo-
site direction on the underside of the
frame.

NOTICE
NOTE: Since the
For bi-directional conveyors, the wearstrips chain travel direction
Chain travel
is reversed on the direction
should be cut “square” and positioned end- bottom side of the (bottom side
conveyor, the wear- of conveyor)
to-end (touching). strip trim angles are
also reversed.

Figure 10: Overview of Wearstrip assembly

NOTICE
Failure to cut the wearstrips at the proper angle, direction, and gap may cause the chain to catch at the
wearstrip joint and possibly derail from the conveyor.

CUT LOCATION: Wearstrip joints and conveyor bed section joints should never be located at the same
spot (Figure 11). The wearstrip should span across the side frame joint, and extend beyond the side frame
joint by at least 10” (254mm). Always be sure the wearstrip is firmly seated against the side frame as
shown (Figure 12), especially in horizontal and vertical bend locations.

The wearstrip should

be properly seated
NOTICE against the conveyor
Do not locate a side frame
Connecting
wearstrip joint at
side frames
the same location
as a side frame
joint, as this
may cause the
chain to derail.

Connecting
Strap
NO YES
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Figure 11: Do not locate wearstrip joint at bed Figure 12: Ensure wearstrip is correctly
section joint seated
23
STEP 4 — Install and Inspect Wearstrips (continued)
Installing Wearstrips

• Cut a 60° angle on the leading edge of the wearstrip (Figure

13). Make the first cut a little overlong, then trim as
needed. This will help to ensure that the wearstrip is not cut
too short on the first cut.

NOTICE
Ensure that the angles are cut correctly with regard to rstr
ip
Wea
the direction of chain flow. Refer to Figure 10 on
Shears
previous page.

Figure 13: Cut wearstrip at 60° angle

• Slide the wearstrip into the conveyor side frame (Figure 14).

For straight sections, each wearstrip section will need to be

approximately two feet long. Both ends of each wearstrip
section must be cut at a 60° angle. The correct gap must be
provided between consecutive pieces of wearstrip; refer to the
Wearstrip Gap Chart and other information on page 22.
ip
rstr
• Once the wearstrip is properly seated against the side frame, Wea e
fram
use a flashlight or other portable light to locate the side Side

frame’s mounting hole (Figure 15).

• Drill a 13/64“ (5.5mm) hole through the leading edge of the Figure 14: Slide wearstrip into side
wearstrip (Figure 15). frame
• Load one of the supplied plastic rivets into the Rivet Insertion
Tool (Figure 16), and install the rivet to attach the wearstrip
to the side frame (Figure 17). Only one rivet is required for
each two-foot section of wearstrip.
• Ensure that the rivet is fully installed and is firmly against the
surface of the wearstrip.

Plastic Rivet Insertion

rivet Tool

Wearstrip

Drill Wearstrip

Rivet
Insertion
Tool
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Figure 15: Use light to locate Figure 16: Load plastic rivet Figure 17: Install rivet to secure
hole; drill hole in wearstrip into Rivet Insertion Tool wearstrip

24
 STEP 5 — Install Guide Rail and Return Chain Support Rail
If the conveyor system being assembled includes guide rails and/or return chain support rails, a continuous
and smooth rail connection is required.

Guide Rail

Guide rail is designed to guide the product as it travels along the conveyor chain. At field-break loca-
tions, connect the rails with a splice sleeve (Figure 18). This sleeve envelops the metal backing of both
ends of the rails. To remove a guide rail after the splice sleeve has been installed, slide the sleeve along
the rail as necessary.

To remove guide rail, slide

Slide the splice sleeve onto the end the splice sleeve out of the
of one of the guide rails. Then, align way.
the adjoining sections and slide the
sleeve onto the other rail.

Figure 18: Installing and removing splice sleeve

Chamfering the leading edge of the guide rail at each splice location (Figure 19) will lessen the possibility of
product hang-ups.

Chamfer leading end

Ch
ain
flo
w

Figure 19: Chamfer Guide Rail’s leading edge

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25
STEP 5 — Install Guide Rail and Return Chain Support Rail (continued)

Return Chain Support Rail

Return chain support rail (Figure 20) is used on conveyors more than 24” (609mm) wide. It supports the
weight of the return chain (on the bottom side of the conveyor) to prevent it from sagging. When return
chain support rail is required, there will be at least two return chain support crossbars on the conveyor.
Any splices in the return rail should be located as close to a support as possible. Field break locations are
connected in the same manner as the guide rail. The illustration in Figure 20 shows how standard return
chain support rails are assembled.

Round Guide Rail

(stainless steel
backed)

Return chain
support clip angle
Hex head cap
screw
Return chain
support crossbar

Nyloc nut

Figure 20: Overview of Return Chain Support Rail assembly

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26
 STEP 6 — Install Support Structures

NOTICE
To avoid binding and possible damage to the conveyor system, do not tighten or anchor any
support structure to the floor until the entire conveyor system has been assembled and properly
positioned.

The specific procedure for the installation of the support structure depends upon the type of structure
specified for the conveyor being installed. Two common support styles are shown below (Figure 21).
The distance between support structures should never exceed 12 ft (3.66m).

2” x 2” Stainless Aluminum Ceiling

Steel Tubing Support Channel Support Support

Figure 21: Support Structure styles

The support structure units, regardless of style, will be bolted to the conveyor bed's framing at the crossbar
locations. Prior to shipping, matching pairs of numbered “Support” labels (Figure 22) have been affixed to
the equipment as an assembly aid. One label is affixed to each support structure; the corresponding
numbered label is affixed to the conveyor side frame to indicate the correct attachment location for the
support.

SUPPORT SUPPORT

1 1
(remove after assembly) (remove after assembly)

Number on the Support Structure will match

Number on the conveyor Side Frame
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Figure 22: “Support” labels

27
STEP 6 — Install Support Structures (continued)

Upon completion of support structure installation, ensure that the conveyor system is level. Any minor
elevation adjustments that may be required (usually due to an uneven floor) can be accomplished using
the conveyor support structure’s adjustable feet. Figure 23 illustrates some examples of various styles
of adjustable feet. If greater elevation adjustments are required, it may be necessary to actually shorten
or lengthen the support legs.

Figure 23: Types of adjustable feet

Sway Braces

The amount of sway bracing necessary will depend upon the design of the specific conveyor system
being installed. The location of the sway braces can be found on the schematic (plan view). The
symbol shown in Figure 24 indicates the location of a diagonal sway brace. All sway braces, and the
hardware required to attach them to the support structures, are supplied with the system. One end of
each sway brace is bolted to the conveyor side frame; the other end is bolted to a support leg.

Diagonal Diagonal
Sway Brace Symbol Sway Brace

Figure 24: Sway Brace symbol and illustration

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28
 STEP 7 — Install Conveyor Chain

General Notes Regarding Conveyor Chain

The chain has been assembled at Span Tech according to specification. To maximize ease of handling, the
chain has been packed in lengths of no more than 15 ft (4.57m).

NOTICE
Do not unpack the chain until you are ready to install it, to avoid the possibility of exposing the
chain to damaging contaminants.

Your Span Tech conveyor will typically be equipped with MonoSpan®, MultiSpan®, or MaxiSpan® con-
veyor chain. The type of chain depends upon the application for which the conveyor system has been
specified. Before attempting to install a Span Tech conveyor chain for the first time, it is recommended that
you take a few moments to become familiar with the chain links and how they interact with each other.
Illustrations of the three basic chain types are shown below (Figures 25, 26, 27). Use the information in
the illustrations to determine the chain orientation and direction of chain flow.

Direction of Chain Link

Chain Travel

Chain Rod

Lock Tab

Figure 25: MonoSpan® chain assembly

Chain Rod Chain Rod

Direction of Direction of
Chain Travel Chain Travel

Chain Link

Lock Tab Lock Chain Link

Tab

Figure 26: MultiSpan® chain assembly Figure 27: MaxiSpan® chain assembly

Chains are constructed of interconnecting links. The links are installed on chain rods that have been cut
according to the specified chain width. The rods are held in place by lock tabs that fit into slots in the
chain’s side links. The illustrations above show the relationship of the various chain components.
rev 05-02-08

NOTICE
The chain, like all of the conveyor components, must be kept clean during installation to ensure
proper operation. Dust and environmental debris can damage the chain and void the warranty.
29
STEP 7 — Install Conveyor Chain (continued)

Chain Installation

• Before installing the chain, check for any pre-installed accessories on the conveyor (guide rails, etc.) that could
make it difficult to load the chain, and remove them if necessary. It may also be necessary to disengage the
gearmotor from the drive shaft so that the chain will feed around the drive sprockets (refer to STEP 8 –
Installing / Removing Gearmotors).
• Start at the “Idler” end of the conveyor when installing the chain (Figure 28).
• Pull the unanchored ends of the wearstrip sections nearest the idler away from the frame. This will expose
both of the side frame lips on the top side of the conveyor, and provide enough clearance to install the
chain.
• Ensuring that you have the chain right side up and in the correct direction of flow, start feeding the chain
(from the chain’s leading end) onto the exposed lips of the side frame. Work the tab legs on each side of
the chain down onto the lips of the side frame by shifting the chain from side-to-side.
• As the chain legs enclose the side frame lips, push the chain forward onto the wearstrip. If working with a
wide chain, this process may require two people. Chain installation should not require excessive force.

Direction of chain flow

Toward the conveyor 2. Install chain here,
drive unit working it from side-
to-side and feeding it TIP:
forward. Feed a chain rod through the nose of the
leading links before installing a section of
1. Pull away the unanchored ends chain. This will prevent the center links
of the top wearstrips closest to from falling down into the bed section and
the idler unit to expose the hanging at the crossbars.
conveyor side frame.

NOTE
If a wearstrip is accidentally
removed, reinstall it, ensuring that
the wearstrip lock tab securely pins
the wearstrip to the side frame.
Idler unit

Figure 28: Chain installation

• If the first roll of chain does not reach the drive end of the conveyor, push it ahead and load another roll of
chain. After the second roll of chain has been loaded, join the two sections with a chain rod and install the
chain lock tabs (refer to Figures 31 and 32, on page 31).
• Continue loading sections of chain until the leading end reaches the drive.
• When the chain has reached the drive end of the conveyor, engage the chain with the drive sprockets (Figures
29 and 30, on page 31). Ensure that the chain links and sprocket teeth are aligned across the chain width.
For MonoSpan® or MultiSpan® chains:
•• The sprocket tooth should engage the chain directly behind a connecting rod.
rev 05-02-08

For MaxiSpan® chains:

•• The larger sprocket tooth should engage the chain directly behind a connecting rod.
30
 STEP 7 — Install Conveyor Chain (continued)

Chain Travel Direction Chain Travel Direction

Figure 29: Sprocket engaging MonoSpan® or Figure 30: Sprocket engaging MaxiSpan® chain
MultiSpan® chain

• Feed the chain around the drive by either (A) pulling the end of the chain around, or (B) rotating the
drive shaft by hand. DO NOT push the chain into the drive sprocket(s) as the compressed chain will
not engage the sprocket(s) properly. If done correctly, the chain will feed smoothly.
• Continue to load and join all of the remaining sections of chain.
• Push in the wearstrips that were pulled out.
• Feed the chain around the idler sprocket(s), then join the ends of the chain to complete the loop, as
follows:
•• Insert the chain rod on one side, and reconnect each link as you push the rod through (Figure 31).
•• If connecting High Friction chain, it may help to use a small amount of soapy water on the chain
rod so that it slides through more easily.
•• Once the rod is in place, insert the lock tabs into the side links (Figure 32). The lock tabs must
snap up into the chain link. The lock tabs will slide easily into the cavity of the chain if they are
inserted at a slight angle.

Chain rods

Chain links Side Side

link link

Lock tab
Lock tab
Chain (installed)
rod
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Figure 31: Insert chain rod through links Figure 32: Insert lock tab
31
STEP 7 — Install Conveyor Chain (continued)

WARNING
Remove all foreign objects, such as tools or hardware, from the chain and conveyor bed sec-
tions before energizing or operating the conveyor. Failure to comply could result in serious
injury or equipment damage.

Chain Slack

If the chain slack is correct, you should be able to pull three rows of links together with your thumb and
forefinger, just after the drive unit on the return side (Figure 33). If you cannot pull three rows to-
gether, the chain is too tight. If you can pull more than three rows together, the chain is too loose.

Chain slack is adjusted by adding or removing rows of links, as follows:

• Using a small flat screwdriver, break the

chain loop by removing the lock tab at FOR “PULLED” CHAINS
each end of a chain rod.
Chain in tension
• Remove the chain rod.
• Push the chain apart, then remove the
wearstrip sections as described in the
“Chain installation” procedure (page 30). 3 links
Drive
sprocket
• Add or remove a row of chain links as
required.
Loose
• Replace the wearstrips. Chain
Sectio
n (retu
rn cha
• Reconnect the chain loop. in)

• Repeat the above process as necessary

until chain slack is correct. It may be
necessary to remove chain slack after the
system has been started at least once.
FOR “PUSHED” CHAINS
Loose Chain Section (return chain)

3 links
Drive
sprocket

Chain
in ten
sion

Figure 33: Chain slack illustration for “Pulled” and

“Pushed” chains
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32
 STEP 8 — Install / Remove Gearmotor

Span Tech conveyor systems are typically supplied with SEW Eurodrive gearmotors. General instructions
concerning the installation and removal of SEW Eurodrive gearmotors are provided in this section.

WARNING
Starting devices, prime movers, and powered accessories should be locked and tagged follow-
ing OSHA regulations before assembly, maintenance, or repair tasks are performed on any
conveyor system. Only trained and qualified personnel who are aware of all safety hazards and
how to avoid them should be allowed to perform maintenance procedures. Failure to comply
could result in serious injury or death, or equipment damage.

Gearmotors are heavy! Two persons should participate in any gearmotor removal or installa-
tion. Failure to comply could result in serious injury or equipment damage.

NOTICE
Users of motors other than SEW
Eurodrive should refer to motor
manufacturer’s documentation. Shaft Sleeve
(if required)

Eurodrive
Gearmotor

Drive Shaft

Extractor
(Internal Gear
Flat Puller)
Washer

Retainer Washer

Retainer Bolt

Figure 34: SEW Eurodrive gearmotor assembly

Eurodrive Gearmotor Installation Torque

Arm
Bracket
• Assemble the components as follows; refer Keys
to the exploded view in Figure 34.
•• Apply a liberal amount of anti-seize
compound to the outside of the drive
Shaft
shaft (Figure 35).
•• Verify that the key is in place on the
drive shaft (Figure 35).
rev 05-02-08

Figure 35: Apply anti-seize compound

33
STEP 8 — Install / Remove Gearmotor (continued)

•• Insert the extractor into the same end of the

gearbox into which the drive shaft will be inserted
(Figure 36). The extractor bolt should “bottom
out” on the retaining ring in the gearbox.
•• Gently slide the gearbox onto the drive shaft, Gearbox
and align the keyways together. The gearbox
should slide all the way to the torque arm bracket
(Figure 37).
•• Install and tighten the retaining bolt on the end Extractor
of the shaft (Figure 38).
•• Install and tighten the four bolts that hold the
gearmotor to the torque arm bracket (Figure
39). Figure 36: Insert extractor
•• Install the plastic end cap that protects the end
of the drive shaft.

Gearbox

Retaining bolt

Torque
Arm
Bracket

Gearbox

Shaft

Figure 37: Slide gearbox onto drive shaft Figure 38: Install and tighten retaining bolt

Mounting
bolt

Gearbox

Torque
Arm
Bracket
rev 05-02-08

Figure 39: Install and tighten four mounting

bolts

34
 STEP 8 — Install / Remove Gearmotor (continued)

Eurodrive Gearmotor Removal

• Remove the plastic end cap from the gearbox to

expose the end of the drive shaft (Figure 40).
• Using a 13mm wrench, remove the four bolts
that hold the gearmotor to the torque arm
bracket (Figure 41). End
cap
• Using a 1/2” (13mm) socket, remove the retaining
bolt from the end of the shaft (Figure 42).
• If the gearbox will not slide off, insert extractor bolt
(see Table A, below) into the gearbox extractor,
located at the end of the drive shaft (Figure 43).
• Continue turning this threaded rod until the gear-
box is driven off the drive shaft. Figure 40: Remove end cap

Gearbox Retaining bolt

Mounting
bolts

Torque
Arm
Bracket Conveyor
chain

Gearbox

Figure 41: Remove four mounting bolts Figure 42: Remove retaining bolt

MOTOR EXTRACTOR EXTRACTOR

SIZE (METRIC) (ENGLISH)
WA20 M12 x 1.75 x 75 1/2-13 x 3”
WA30 M12 x 1.75 x 75 1/2-13 x 3”
SA37 M12 x 1.75 x 140 1/2-13 x 5-1/2”
SA47 M20 x 2.5 x 150 3/4-10 x 6”
SA57 M20 x 2.5 x 150 3/4-10 x 6”
SA67 M20 x 2.5 x 190 3/4-10 x 7-1/2”
Table A: Extractor Bolt sizes (NOTE: motor sizes Extractor bolt
refer to SEW Eurodrive motors)
rev 05-02-08

Figure 43: Insert extractor bolt to drive gearbox

off shaft
35
STEP 8 — Install / Remove Gearmotor (continued)

For Keyed Drives: see Figure 44

NOTICE
Be sure that the key is the correct size, and is well-
seated into the drive shaft keyway and the gearbox
keyway.

Be sure that the drive shaft runs all the way through
the gearbox housing.

Be sure that the key is correctly positioned.

Key

Drive Shaft
keyway

Gearbox keyway

Gearbox housing

Figure 44: Illustration of keyed drive assembly

rev 05-02-08

36
 STEP 8 — Install / Remove Gearmotor (continued)

Proper alignment of gearbox on drive shaft for remote drives: see Figure 45

Remote Box
Driven Sprocket
(22 Teeth)

Support
Bracket Chain

Idler
Sprocket

Drive Sprocket
(19 Teeth)

NOTICE
The Drive Sprocket, Driven Sprocket,
and Idler Sprocket must all be in
alignment, or the chain will not engage
the sprockets correctly.

Driven Sprocket

YES NO
Idler Sprocket

Drive Sprocket
rev 05-02-08

Figure 45: Remote drive alignment illustration

37
STEP 8 — Install / Remove Gearmotor (continued)

Gearbox Mounting Positions

A gearbox (gearmotor) can be mounted in any of several orientations with respect to the conveyor.
Always refer to specific job prints for the proper mounting orientation. The following photographs and
illustrations (Figures 46, 47, 48) show examples of different mounting positions.

NOTICE
The gearmotor is only allowed to be Conveyor chain
installed in the mounting position
indicated by the job-specific drawings Side Frame
provided with the conveyor. The oil
checking and drain screws, and the Motor
breather valves, must be freely acces-
sible. Also check that the oil fill is as
specified for the mounting position.
SEW-Eurodrive supplies gear units
filled with the required oil volume, and Gearbox
with the breather valve installed and
activated according to the particular
mounting position. Adjust the lubri-
cant fill volumes and the position of
the breather valve accordingly, in the
event of a change of mounting
Figure 46: Hollow shaft gearmotor, horizontally mounted
position.

Motor

Gearbox

Motor

Gearbox
rev 05-02-08

Figure 47: Hollow shaft gearmotors, mounted to vertical drive shafts (Wedge
conveyor)

38
 STEP 8 — Install / Remove Gearmotor (continued)

Remote Box

Driven Sprocket
22 Teeth

Support
Bracket Chain

Idler
Sprocket

Drive Sprocket 19
Teeth

Figure 48: Remote gearbox mounting position (typical)

Gearbox Breather Valve (Vent Plug)

Location

A breather valve (Figure 49) should always be

installed in the provided hole in the upward face
of the gearbox.

NOTICE
The gearbox will leak oil if the breather
valve is not installed, or if it is installed
in an incorrect location.
rev 05-02-08

Figure 49: Breather Valve

39
STEP 9 — Install Transfer Bridge: Gravity Roller Transfer

Gravity Roller Transfer Bridge Installation: see Figure 50

• Install the roller bridge assembly, so that the bridge assembly rods rest in the notches in the side plate.
• Remove the screw that attaches the safety cable to the side plate.
• Insert the screw through the safety cable eyelet, and reinstall it in its original location.
• Repeat above Steps for the other side of the transfer.

NOTE
The non-rigid mounting design allows the
bridge to pop out in the event of a product
jam, preventing damage to the equipment.
This design is also a safety feature, pro-
tecting employees from harm should they
Bridge
become caught between the transfer roll- Assembly
ers and the conveyor. Rods

Rollers
Bridge
Transfer Plate
Safety Cable Notches

Roller Bridge
Assembly

Transfer Side
Plate CAUTION
The safety cable is designed to prevent the
unit from falling in the event that the
bridge becomes dislodged from the frame.
Transfer
Side Plate
Do not operate the unit without the safety
cable properly attached. Failure to comply
could result in injury or equipment
Safety Cable damage.
Safety Cable Screw
Eyelet
rev 05-02-08

Figure 50: Transfer Bridge assembly illustration - Gravity Roller Transfer

40
 STEP 10 — Install Transfer Bridge: MicroSpan Transfer

MicroSpan Transfer Bridge Installation: see Figures 51, 52, 53

• Install the MicroSpan bridge assembly. The bridge assembly side plates (shaded grey in the illustration
below) are positioned outboard of the frame assembly’s side plates (see Inset “A”).

Front View Front View - with

Bridge Assembly
Bridge INSET Installed
Assembly
“A”

Bridge
Assembly

Transfer
Frame
Assembly Transfer
Frame
Assembly

Grasp bridge
Bridge assembly
using pop-up
Assembly handles

Transfer
Frame
Assembly Installed

refer to
Figure
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52

Figure 51: Transfer Bridge installation - MicroSpan Transfer

41
STEP 10 — Install Transfer Bridge: MicroSpan Transfer (continued)

• Ensure that Transfer Bridge’s

support rods are correctly
installed into Frame Rod Holddown Clip
(UHMW-PE)
Assembly’s seating pockets holds Transfer
(Figure 52). Bridge snug in
position

NOTICE
If the actual MicroSpan Transfer Side Plate
(steel)
assembly does not match the supports weight of
Transfer Bridge
illustrations shown in Figures 51, 52,
and 53, the Transfer’s side plates
need to be adjusted so that the
Transfer bridge is seated correctly.

NOTICE Figure 52: Transfer Bridge installation - seating pockets

There should be 1mm (0.04”)
clearance between the top land of a
gear tooth and the bottom land of the
tooth it meshes with on the mating
gear (see Figure 53 detail).
1mm (0.04”)
clearance

rev 05-02-08

Figure 53: Detail of MicroSpan Transfer drive gear assembly

42
 R

Side-Flexing Continuous Conveyors

PRE-OPERATION SAFETY CHECKLIST

Date: Project No.

Time: Conveyor No.
Evaluator:

Safety Evaluation Questions YES NO* N/A

1. Are all safety devices installed and in good repair?
2. Are all safety labels and placards installed where needed and in
good repair? (order more if needed)
3. Are control stations in proper working order, and in locations from
which the conveyor is visible?
4. Are Emergency Stops / stations in proper working order?
5. Are warning signals or procedures, intended to inform personnel
that the conveyor is about to start, in working order?
6. Are conveyor chain links in good repair, with no unbroken links?
7. Are all conveyor chain link Lock Tabs properly in place?
8. Are the wearstrips (and associated components) in good repair?
9. Is the conveyor chain properly lubricated?
10. Is the drive motor amperage correct?
11. Is the support structure in good repair (and anchored, if appli-
cable)?
12. Have all personnel working in the conveyor area been thoroughly
trained on Emergency Stop locations and procedures?
Additional Comments:
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* All items marked “No” require corrective action before operation.

43
this page intentionally left blank

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44
 Preventive Maintenance and Troubleshooting
Safety Guidelines
and Information

WARNING
Failure to comply with the safety precautions and instructions provided in this manual could
result in serious injury, death, or property damage.

• Read and follow all operating and product safety instructions.

• Read and observe all safety labels and warnings.
• Use proper lockout and tagout procedures following OSHA regulations prior to conveyor system mainte-
nance.
• Only use parts supplied or authorized by Span Tech, LLC.
• In case of fire, use only water, foam, CO2 or dry chemical extinguishers.
• Never climb or walk on the conveyor system unless necessary and authorized for maintenance purposes.
• Only authorized and trained personnel may perform maintenance on a conveyor’s electrical control panel.
• Do not start conveyor until all personnel are clear.
• Keep clear of the conveyor area when equipment is energized; conveyor may start at any time.
• Do not place articles or extremities into conveyor chain or frame while in operation.
• Secure any loose clothing or hair; remove all jewelry, finger rings, pocket key rings, etc.
• Do not remove any guards or safety devices unless necessary and authorized for maintenance purposes.
• Restart the conveyor system at the device or location from which it has been stopped.
• Watch for low clearance points and the potential for falling overhead objects.
• Keep extremities clear from shear points and conveyor chain.
• Do not use Designer System® conveyors in prohibited environments. (Refer to page 8 for information on
prohibited environments. Refer to page 46 for information on abrasive materials and contaminants.)
rev 05-02-08

45
 Routine Preventive Maintenance
Each conveyor system should be inspected according to the following procedures, and the results of
each inspection recorded on the “Preventive Maintenance Items Checklist” provided on page 53. While
the Designer System® conveyor is a complex engineered system, routine maintenance can be covered in
only seven (7) basic steps. Each of these items should be checked to ensure a long, reliable conveyor life.
If you have questions regarding any topic or problem not covered in this guide, feel free to contact Span
Tech® for technical assistance.

Consistent preventive maintenance is a necessary safety practice. Regularly performed, preventive

maintenance practices can help prevent damage to equipment and injury to personnel.

WARNING
Starting devices, prime movers, and powered accessories should be locked and tagged follow-
ing OSHA regulations before maintenance or repair tasks are performed on any conveyor
system. Only trained and qualified personnel who are aware of all safety hazards and how to
avoid them should be allowed to perform maintenance procedures. Failure to comply could
result in serious injury or death, or serious equipment damage.

1. Environmental Contamination Inspection – MONTHLY

• Inspect conveyor and its components for signs of contamination from environmental debris. If contami-
nation is present, do not operate the conveyor until a thorough cleaning has been performed to remove
the contamination.

Some components in a conveyor, especially the chain and wearstrips, can become contaminated by
harsh or abrasive materials. Over time, small abrasive particles can become embedded in a conveyor’s
plastic parts. This leads to excessive friction between the chain and wearstrip, and can ultimately
reduce performance. A common source of abrasive contamination is construction occurring in the area
of an exposed conveyor. Drilling, grinding, sawing, sanding, and other processes produce airborne
abrasive dust which can build up on a conveyor.

Examples of abrasive materials include:

• Ceramic dust • Paper/wood dust • Broken glass particles

• Metal chips • Sand • Crumbs
• Concrete dust • Medical tablet dust • Corn meal
• Sugar

Sources of contamination include:

• Construction • Airborne delivery • Manufacturing processes

• Product flaking • Product spillage • Overhead equipment
rev 05-02-08

Most abrasive contaminants can be removed by wiping down the top and bottom sides of the wearstrips,
using a cloth moistened with rubbing alcohol.
46
 2. Chain and Wearstrip Inspection – MONTHLY

The wearstrip is one of the most important features of a Span Tech conveyor system. The conveyor chain
is designed with legs on the outer (side) links that hook around the lips of the conveyor side frame. Typi-
cally, a Spanlon wearstrip is fitted over the lips of the side frame. The conveyor chain contacts the wear-
strip resulting in smooth chain travel, reduced load on the motor, and prevention of chain damage which
could be caused by direct metal contact. A derailed chain is most often caused by wearstrip problems.
Special attention must be given to the installation, maintenance, and repair of the wearstrips.

• Inspect the conveyor chain for broken links. Damage to chain can occur by dropping a heavy item on the
chain links, or by a process jam. Promptly replace any broken links. The links immediately before and
after the broken links should also be replaced due to possible material fatigue.
• Inspect the chain link Lock Tabs. It is very important to
verify that all chain link Lock Tabs are properly in place. If
not broken, snap any loose tabs back into place using a flat
screwdriver. If broken, replace immediately.
• Inspect the leg and foot tab of the side links for wear. See
illustrations below. If leg or foot tab measures less than
dimensions shown in right-hand columns above, link is
excessively worn and should be replaced.
Inspect Chain for broken links

Normal side link Side link w/ worn leg

7.80mm MonoSpan < 6.85mm

8.40mm MultiSpan < 7.15mm
8.40mm MaxiSpan < 7.15mm Inspect chain link Lock Tabs for proper fit

• Inspect wearstrips to verify that all are in place and

Normal side link Side link w/ worn foot tab
are properly installed. The wearstrip sections must
not overlap. The ends of the wearstrip sections
must be cut at the correct angle for the chain travel
direction, and the gap width between sections must
be sized according to temperature. NOTE: For
bidirectional conveyors, the wearstrips should be
4.00mm MonoSpan < 2.00mm
cut “square” and positioned end to end (touching).
4.00mm MultiSpan < 2.00mm
4.15mm MaxiSpan < 2.15mm • Inspect wearstrips for signs of overheating.
rev 05-02-08

47
3. Drive / Idler Wearstrip and Side Plate Inspection – MONTHLY

• Inspect the drive / idler wearstrips (often called “horseshoes”) for excessive wear or improper instal-
lation. Ensure that the drive / idler wearstrips are correctly cut, pressed completely onto the Side
Plates, and correctly pinned. The wearstrips must not be disengaged from the ends of the Side Plates.

• Inspect Side Plates for damage or excessive wear.

• Inspect for loose or missing fasteners in the drive and idler units.

The drive / idler wearstrip is a key element in the design of the drive and idler units. This curved
wearstrip guides the chain around the side plates, and carries the load as the chain travels around the
sprockets.

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48
 4. Foreign Object Interference Inspection – MONTHLY

Interference from foreign objects is a primary cause of excessive wear on the chain surface. Interfer-
ence can also result in broken chain links and rods, and damage to the drive and idler sprockets. If the
drag becomes great enough, the motor current will increase and the Side Plates can fail. Interference
can be prevented or corrected by removing all foreign objects from the vicinity of the conveyor, and by
adjusting the position of any components or accessories which may come into contact with the chain.

• Inspect chain for any foreign objects that may be interfering with chain movement. Adjacent ma-
chines or conveyors must not be in contact with the moving chain.

• Ensure that no interference is occurring at the loading or unloading points of the conveyor system.

• Inspect transfer devices to ensure that components (transfer plates, transfer fingers, etc.) are not
contacting the moving conveyor chain.

• Ensure that all guide rails, guide rail brackets, raised side walls, chain support rails, drip tray brack-
ets, and other accessories and components are clear of the conveyor chain.

• Inspect entire conveyor for bolts, fasteners, tools, and other debris.
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49
5. Chain Slack and Sprocket Engagement Inspection – MONTHLY

Over time, normal wear and elongation of chain links can contribute to an increase in chain slack. An
improper amount of slack in the chain can lead to excessive motor current. It can also cause the chain
to “jump teeth” on the sprockets. Chain slack can be adjusted by removing or adding rows of chain
links.

• Check the overall amount of slack in the chain (3 to 4 links compression recommended).

• Check for excessive chain slack immediately after the drive sprockets.

• Ensure that the sprocket teeth are not engaging or contacting any High Friction chain links.

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50
 6. Lubrication and Lubricator Inspection – EVERY 15 DAYS

Conveyor Systems WITH Lubricators:

• Check the adjustment of wearstrip lubricators.

• Check the fill level of the lubricator reservoir; add

lubricant if needed.

Conveyor Systems WITHOUT Lubricators:

• Manually lubricate wearstrips, as follows:

•• Where your operation and product allow, use

SpanLube silicone oil (Span Tech part Lubricate the conveyor wearstrip with
number DS0000). SpanLube greatly re- silicone oil
duces the chain tension and lowers friction by
lubricating the area where the wearstrips and
side links meet.
•• With the conveyor STOPPED, lightly drip oil
in the area where the conveyor chain and
wearstrip meet on the bottom side of the
conveyor. The chain will then distribute
sufficient lubrication to the rest of the system.
•• Do not use silicone oil if your product will be
contaminated by the oil. Once silicone oil is
applied, it is very difficult to remove.

Powered Roller Transfers:

• Inspect the oil level sight glass on the Transfer Chassis

oil reservoir. Refill with lubricant as needed.

Gearmotor Lubrication:

• Inspect the lubricant levels in the motor gearboxes,

following the guidelines recommended by the manufac-
turer. Refer to manufacturer’s documentation. Bottle of SpanLube
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51
7. Measurement of Motor Current – MONTHLY

• Measure the current requirements for all 3-phase AC

drive motors. Compare the measured value to the
value shown on the motor’s specification plate.
Keep a log of the measured values.

NOTICE
Excessive amperage indicates a problem in the
system that should be immediately diagnosed and
corrected by qualified personnel. Failure to comply
could result in damage to equipment and system
Checking drive motor amperage
downtime.

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52
 Preventive Maintenance Items Checklist

Environmental Contamination Inspection (PAGE 46).

Chain and Wearstrip Inspection (PAGE 47).

Drive / Idler Wearstrip (“Horseshoe”) and Side Plate Inspection (PAGE 48).

Foreign Object Interference Inspection (PAGE 49).

Chain Slack and Sprocket Engagement Inspection (PAGE 50).

Lubrication and Lubricator Inspection (PAGE 51).

Measurement of Motor Current (PAGE 52).

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53
 Maintenance Procedures
The following section (pages 54 through 90) provides complete information for 24 specific maintenance
tasks and topics. Refer to the Table of Contents (page 4) for a listing of all 24 procedures.

WARNING
Starting devices, prime movers, and powered accessories should be locked and tagged follow-
ing OSHA regulations before maintenance or repair tasks are performed on any conveyor
system. Only trained and qualified personnel who are aware of all safety hazards and how to
avoid them should be allowed to perform maintenance procedures. Failure to comply could
result in serious injury or death, or serious equipment damage.

Part A: Preventing Environmental Contamination

Some components in a conveyor, mainly the chain and wearstrip, can become contaminated if subjected to
harsh abrasive materials. Over time, small abrasive particles can become embedded in a conveyor’s chain
and/or wearstrip. This leads to excessive friction between the chain and wearstrip, and can ultimately result
in performance problems.

Construction in the area of an exposed conveyor is a common source of abrasive contamination. Drill-
ing, grinding, sawing, sanding, etc. produces airborne abrasive dust which can build up on nearby
conveyors.

Some examples of abrasive materials are:

• Ceramic dust • Metal chips • Concrete dust • Corn meal
• Paper/wood dust • Sand • Medical tablet dust • Sugar
• Crumbs • Broken glass particles
If construction is to be carried out anywhere near a conveyor, first remove the conveyor chain and store it
in an airtight plastic bag(s). When the construction has been completed, clean all areas of the conveyor
frame. If possible, wash the conveyor frame down with water. Then, reinstall the chain.

If the dust produced by construction is not cleaned off the conveyor, it can become embedded in the
chain and/or wearstrip, leading to permanent damage.

Contamination can also result from an unforeseen environmental condition such as build up of residue
from the customer’s product, etc.

Exposing a conveyor to certain harsh chemicals may also contaminate conveyor components. Refer to the
Chemical Compatibility Chart (pages 90-97) for data concerning the effect of various chemicals on
plastic conveyor components. Also refer to Part W on page 87 for additional information.

NOTICE
rev 05-02-08

Do not run a conveyor that has been exposed to contaminating materials. The conveyor
should be thoroughly cleaned to remove the contamination. Failure to comply could result in
damage to equipment. (See Part B, page 55, for recommended cleaning procedures.)
54
 Part B: Cleaning

Cleaning Conveyors
The components in Designer System® products are made from a variety of metal, plastic, and composite
materials. Care should be taken to remove soils with the least corrosive detergent possible. It is very
important to keep your Span Tech conveyor system clean to ensure proper operation.
NOTICE
NOTICE
Using a higher than recommended concentration of detergent is not beneficial and can harm
the conveyor system.

Recommended General Cleaning Procedure for Conveyors:

1. Water is the most important cleaning agent. It should be used to remove 85% - 90% of all foreign
material on a conveyor system. For the best results in dissolving soils, keep the water temperature
between 90°F - 135°F (32°C - 57°C).

2. When necessary, the conveyor system should be foamed, scrubbed, or soaked with an inhibited
alkaline detergent at the recommended concentration. Facilities that must meet USDA requirements will
clean with this detergent on a daily basis. All other facilities should clean with detergent quarterly.

3. It may be necessary to open the chain and remove soils from the conveyor’s wearstrips, sprockets,
center support rails, and return chain support rails by hand washing.

4. Remove the chain from the conveyor to use high pressure spray.

5. Never allow detergents to dry on the conveyor.

6. Soil and detergent should be completely rinsed from the conveyor with plain water. For rinsing, the
water temperature should be kept between 70°F - 90°F (21°C - 32°C).

7. Facilities meeting USDA requirements should apply a recommended concentration of mild citric acid
once a month to remove any dried soap or mineral deposits from the system. Rinse the mild citric acid
solution away from the system with plain water.

NOTICE
Reference the Chemical Compatibility Chart (pages 90-97) to determine a component’s level of
resistance to specific chemicals.

Components made of acetal and nylon materials are not resistant to organic or mineral acids
such as phosphoric acid, sulfuric acid, nitric acid, hydrochloric acid, etc.

Components made of acetal material are not resistant to hypochlorite solutions.

rev 05-02-08

Contact with non-resistant materials by acids or hypochlorite solutions can result in damage to
components and system downtime.
55
Part B: Cleaning

Cleaning Powered Transfer Units

Cleaning the Chassis:

1. Remove the transfer bridge from the chassis.

2. Lightly hose the contaminated area of the chassis. Hot water may be used.

NOTICE
Never use high-pressure spray to clean a transfer unit chassis. Bearing failure will occur.

3. Use a soft - bristled brush to apply cleaning solution. A mild dish detergent is recommended.

4. Rinse off the cleaning solution before it dries.

5. Operate the transfer unit until it is completely dry.

Cleaning the Transfer Bridge:

1. Remove the transfer bridge from the chassis.

2. Lightly hose the contaminated area of the bridge. Hot water may be used.

NOTICE
Never use high-pressure spray to clean a transfer unit bridge. Bearing failure will occur.

3. Use a soft-bristled brush to apply cleaning solution. A mild dish detergent is recommended.

4. Rinse off the cleaning solution before it dries.

5. Reinstall the transfer bridge, and operate the transfer unit until it is completely dry.
rev 05-02-08

56
 Part C: Wearstrip Installation
The wearstrip is one of the most important features of Span Tech's Designer System® conveyors. The conveyor
chain is designed with legs on the outer links that hook around the lips of the conveyor side frame. The lips of the
side frame have a Spanlon wearstrip fitted over them. The conveyor chain contacts this wearstrip, resulting in
smooth chain travel, reduced load on the motor, and the prevention of damage caused by the chain directly
contacting the metal side frame. Special care must be taken when installing the wearstrips.

NOTICE
Failure to read and follow these instructions could result in damage to the conveyor system.

Connecting Pre-Cut Wearstrips

If the conveyor system being installed has been field broken for shipping purposes, the wearstrips at the break
locations have already been properly trimmed according to the direction of chain flow and the environment in
which the system will operate. In this case, simply push the wearstrips into place on the frame lips and
proceed to the directions for pinning wearstrip.

Before Cutting Wearstrips (if necessary)

Four factors must be considered before making cuts: temperature, cut angle, cut direction, and cut location.

TEMPERATURE: The temperature at which the wearstrip is installed in a conveyor, as well as the temperature at
which the conveyor will normally be operating, both need to be considered before the wearstrips are cut and
trimmed. Cooler operating temperatures cause the wearstrips to contract or become shorter. Warmer operating
temperatures cause the wearstrips to expand or become longer.

At Span Tech, conveyors are pre-assembled at an average room temperature of about 70° F (21° C). If the
conveyor is installed in a room with an average temperature of 20° F (–7° C), the wearstrip will naturally con-
tract. When the wearstrip contracts, the gap between adjacent pieces gets wider. If the gap gets too wide, the
conveyor's chain could derail from the system. On the other hand, if the conveyor is installed in a room with an
average temperature of 100° F (38° C), the wearstrips will expand, causing the gap between adjacent pieces to
get smaller. One wearstrip could even start to overlap onto the next, possibly resulting in damage to the conveyor.

The gap between adjacent wearstrips should be maintained at or very near 1/4” (6.4mm). The Wearstrip Gap
Chart (below) indicates the gap that should be left between adjacent wearstrips at various installation tempera-
tures, as compared to various temperatures at which the conveyor will operate. Example: If the wearstrips are
installed in a conveyor at a room temperature of 60° F (15.5° C), but the conveyor will normally be operating in
a 100° F (38° C) environment, you should leave a 3/8” (9.5mm) gap between wearstrips as they are installed.
WEARSTRIP GAP CHART
NORMAL OPERATING TEMPERATURE
0° – 20°F 21° – 40°F 41° – 60°F 61° – 80°F 81° – 100°F 101° – 120°F
-17.8° – -6.7°C -6.1° – 4.4°C 5.0° – 15.5°C 16.1° – 26.7°C 27.2° – 37.8°C 38.3° – 48.9°C
0° – 20°F 1/4” 5/16” 7/16” 1/2” 9/16” 5/8”
INSTALLATION TEMPERATURE

-17.8° – -6.7°C 6.4mm 7.9mm 11.1mm 12.7mm 14.3mm 15.9mm

21° – 40°F 3/16” 1/4” 5/16” 3/8” 1/2” 9/16”
Wearstrip
-6.1° – 4.4°C 4.8mm 6.4mm 7.9mm 9.5mm 12.7mm 14.3mm
Gap 41° – 60°F 1/8” 3/16” 1/4” 5/16” 3.8” 1/2”
5.0° – 15.5°C 3.2mm 4.8mm 6.4mm 7.9mm 9.5mm 12.7mm
61° – 80°F 1/16” 1/8” 3/16” 1/4” 5/16” 3/8”
rev 05-02-08

16.1° – 26.7°C 1.6mm 3.2mm 4.8mm 6.4mm 7.9mm 9.5mm

81° – 100°F 0” 1/16” 1/8” 3/16” 1/4” 5/16”
27.2° – 37.8°C 0mm 1.6mm 3.2mm 4.8mm 6.4mm 7.9mm
101° – 120°F 0” 0” 1/16” 1/8” 3/16” 1/4”
38.3° – 48.9°C 0mm 0mm 1.6mm 3.2mm 4.8mm 6.4mm
57
Part C: Wearstrip Installation
Cut Angle

The ends of adjoining wearstrip sections should be trimmed at 60° angles, as shown in Figure 10. This angle, in
conjunction with the direction in which the angles are cut (discussed below), allows the chain to travel smoothly
over the wearstrip joint.
The wearstrip ends
60° should be trimmed at
Cut Direction 60° angles

The direction in which the conveyor chain Chain travel

direction
will travel dictates the direction at which (top side of
conveyor)
the wearstrip angles will be cut. Figure 1
shows the correct angles in relation to the
direction of chain flow. When making
cuts, keep in mind that the conveyor chain
runs in the opposite direction on the
underside of the frame.
NOTE: Since the Chain travel
chain travel direction
NOTICE is reversed on the
bottom side of the
direction
(bottom side
conveyor, the wear- of conveyor)
For bi-directional conveyors, the wearstrips strip trim angles are
also reversed.
should be cut “square” and positioned end-
to-end (touching). Figure 1: Overview of Wearstrip assembly

NOTICE
Failure to cut the wearstrips at the proper angle, direction, and gap may cause the chain to catch at the
wearstrip joint and possibly derail from the conveyor.

Cut Location

Wearstrip joints and conveyor bed section joints should never be located at the same spot (Figure 2). The
wearstrip should span across the side frame joint, and extend beyond the side frame joint by at least 10”
(254mm). Always be sure the wearstrip is firmly seated against the side frame as shown (Figure 3),
especially in horizontal and vertical bend locations.
The wearstrip should
be properly seated
against the conveyor
NOTICE side frame
Connecting Do not locate a
side frames wearstrip joint at
the same location
as a side frame
joint, as this
may cause the
chain to derail.

Connecting NO YES
Strap
rev 05-02-08

Figure 2: Do not locate wearstrip joint at bed section Figure 3: Ensure wearstrip is correctly
joint seated
58
 Part C: Wearstrip Installation

Replacing Wearstrip
If a wearstrip becomes worn or damaged, it should be replaced.

WARNING
Starting devices, prime movers, and powered accessories should be locked and tagged follow-
ing OSHA regulations before maintenance or repair tasks are performed on any conveyor
system. Only trained and qualified personnel who are aware of all safety hazards should be
allowed to perform maintenance procedures. Failure to comply could result in personal injury
or death, or severe equipment damage.

• TURN OFF and LOCK OUT the conveyor.

• Remove the chain from the area where the wearstrip is to be replaced.
• Remove the rivets from the wearstrip to be replaced.
• Pull the wearstrip off of the lip of the conveyor side frame, and install a new wearstrip following the
procedures outlined in this section.

Replacing Wearstrip in Straight Bed Sections

Each wearstrip in straight bed sections should be about 24” (610mm) long. Each section of wearstrip
should be pinned with two rivets at its leading end. The end that the chain first contacts while running is the
leading end of the wearstrip. Use a 13/64” (5.5mm) drill bit to drill wearstrip rivet holes as needed.

Replacing Wearstrip in Horizontal Bends

Each wearstrip in a horizontal bend should run continuously,

without a break. If the bend is too large for this, use two
wearstrip sections, joining them in the center of the bend.
The ends of the wearstrips should run out at least 10”
(254mm) onto the straight bed sections attached to the
bend. As shown in Figure 4, all wearstrips in horizontal
bends are pinned with single plastic rivets.

It is critical, especially in bends, that the wearstrips are

completely seated against the side frame before they are Figure 4
pinned. The following section thoroughly explains the best
way to install wearstrip in horizontal bends.
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59
Part C: Wearstrip Installation

Installing New Wearstrip in Horizontal Bends

1. Using the Rivet Insertion Tool provided, install rivets in

the straight bed section coming out of the bend (inside,
outside, top, and bottom). Refer to Figure 5.

Figure 5

2. When Step 1 has been completed, push the wearstrip

into the inside of the bend until the wearstrip is com-
pletely bottomed out against the side frame. Refer to
Figure 6.

INSET A

Push wearstrip into the curve from this

end (as shown) while also pushing it
into the bend to ensure that the
wearstrip is properly seated against
NO YES the side frame throughout the bend
(see INSET A at left).
Figure 6

3. When the wearstrip is completely bottomed out against

the side frame, use a clamping device to hold it in
position. Refer to Figure 7.
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Figure 7

60
 Part C: Wearstrip Installation

4. Push the wearstrips into the outside of the bend until the
wearstrip is completely bottomed out against the side
frame. Refer to Figure 8.

INSET A

NO YES Pull on the wearstrip in the direction

shown while pushing it into the curve,
to ensure that it is properly seated against
the side frame throughout the bend
(see INSET A at left).

Figure 8

5. When the wearstrip is completely bottomed out against

the side frame, use a clamping device to hold it in
position. Refer to Figure 9.

Figure 9

6. A single wearstrip rivet must be installed in every hole

throughout the bend. Drill the necessary holes (13/64”
[5.5mm] drill bit) in the wearstrip, and install the
wearstrip rivets. Refer to Figure 10. Remove the
clamping devices after all rivets have been installed.
rev 05-02-08

Figure 10
61
Part C: Wearstrip Installation

7. Trim the ends of the horizontal bend wearstrips to form

the proper gap and angle in relation to the ends of the
straight section wearstrips. Drill all the holes for the
wearstrip rivets in the wearstrips. Then install the
wearstrip rivets to finish the job. Refer to Figure 11.

Trim all wearstrips

Drill all holes in the

wearstrips and install
the wearstrip rivets

Figure 11

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62
 Part D: Overheated Wearstrips

Wearstrips may overheat for various reasons, including: the conveyor is overloaded; the lip-to-lip width of
the conveyor is over tolerance, especially in bends; the conveyor has become contaminated; or the
wearstrips have expanded and overlapped.

Overheating Wearstrips in Horizontal Bends

The wearstrips in a bend will usually begin to overheat in the area we call the “hot spot.” As the conveyor
chain travels around a curve, friction can cause heat to build up around the curve’s outside radius. The hot
spot is the area where the most friction is produced.
Hot
Spot
“Pulled” Conveyors Top View

The hot spot in the curve of a “pulled” conveyor is located

on the top outside of the curve, in the spot just before the
chain exits the curve (Figure 12).
Figure 12

“Pushed” Conveyors Hot

Spot
Bottom View
The hot spot in the curve of a “pushed” conveyor is
located on the bottom outside of the curve, in the spot just
before the chain exits the curve (Figure 13).

As heat builds up in the wearstrip, it begins to melt. The

Figure 13
running chain will redistribute the melted wearstrip for-
ward to a cooler area of wearstrip. This is a gradual process, but the effect can be seen over time.

The wearstrip may be turning slightly yellow in color. This is another noticeable indication that the wearstrip
is overheating.

Correcting Overheated Wearstrip

Overheated wearstrip is usually the result of a bigger
problem in the conveyor. This must be found and cor-
rected, so that new wearstrips will not overheat.

NOTICE
Plastic wearstrip begins to overheat at 140° -
150° F (60° C - 65.5°C). Overheated wearstrip
can cause shedding chain, distortion or melting
of wearstrip, or other damage. Any section of
wearstrip that shows the signs of overheating
rev 05-02-08

should be completely replaced with a new section

of wearstrip. Figure 14: Examples of overheated wearstrip

63
Part E: Drives and Idlers

Assembly of DRIVE / IDLER UNITS with STAINLESS STEEL

“HORSESHOES”
(standard as of October, 2004):

Stainless Steel Drive Side Plate

Horseshoe
Santoprene Shield

Crescent Ring
Drive Side Cap
Shaft

Bearing

O-Ring

Slotted FHS

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64
 Part E: Drives and Idlers

Installing New (Stainless Steel) Drive / Idler Wearstrips

“Horseshoes”
1. While holding the Drive Side Plate with the inboard side toward you (Figure 15), begin at right and work
counterclockwise around the curve as you fit the horseshoe to the Plate (if you are left-handed, you may
want to reverse this direction). Ensure that the four tabs are aligned with the recessed notch at the end of
the Drive Side Plate (Figure 16).

Work counterclockwise around

the curve

Inboard side Recesse

d notch
of Drive Side Plate

Start
here
Inner tabs

Outer tabs

Figure 15 Figure 16

2. Once the horseshoe is fitted onto the Drive Side Plate, attach a clamp to hold it in position (Figure 17).

3. Using a 7/64” (3mm) drill bit, drill two pilot holes into the Drive Side Plate, through the existing holes in the
horseshoe’s mounting ear (Figure 18).

Horseshoe
Drive Side Plate Clamp
(inboard side)
Horseshoe
mounting
Clamp
ear

Figure 18

Figure 17

4. Install two Phillips pan head screws into the pilot holes, and tighten. Remove the clamp.
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65
Part E: Drives and Idlers

5. Manually fit the horseshoe around the curve of the Drive Side Plate (Figure 19).

6. Manually adjust the horseshoe, making sure that the two outer tabs are positioned on one side, and the two
inner tabs are positioned on the other side of the recessed notch (Figure 20).

recessed
notch
Inner tabs

Outer tabs

Inboard
side
of Drive
Side Plate

Figure 19 Figure 20

7. When the horseshoe is in position, clamp the mounting ear to the Drive Side Plate.

8. Place a chisel at an angle against the clamped mounting ear (Figure 21), and tap with a hammer to achieve
as snug a fit as possible between the curve of the horseshoe and the end of the Drive Side Plate.

snug
fit
Clamp around
curve
Horseshoe

Figure 21
Figure 22

9. Using a 7/64” (3mm) drill bit, drill two pilot holes into the Drive Side Plate, through the existing holes in the
horseshoe’s mounting ear.
rev 05-02-08

10. Install two Phillips pan head screws into the pilot holes, and tighten. Remove the clamp.

11. Inspect the completed assembly (Figure 22).

66
 Part F: Lubricator Adjustment

Adding the Lubricant

Fill the lubricator at the top of the reservoir as shown in
Figure 23. Span Tech recommends using SpanLube
(Span Tech part number DS0000).

Adjusting the Lubrication Feed Rate

Control the flow rate of the lubricant by turning the
adjustment knobs located at the top of the feed valves
(Figure 24). Turning the knob clockwise slows the flow
rate. Turning the knob counterclockwise increases the
flow rate.
Figure 23

Feed Rate Guidelines

Where the lubricant is fed to the outside of a bend, adjust
the oil flow to approximately one drop every five minutes. Feed Rate
Adjustment
Knobs
If the lubricant is fed to the inside of a bend, set the flow
to dispense one drop every fifteen minutes.

When lubricating a straight conveyor, the flow rate should

be set to feed one drop of lubricant every ten to fifteen
minutes, depending on the length of the conveyor. Gen-
erally, the longer the conveyor length, the faster the flow Figure 24
rate of the lubricant.
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67
Part G: Powered Transfer Lubrication

Checking the Oil Level

Check the oil level in each powered transfer unit periodically. Refer to
Figure 25.
D
Be sure the transfer is not operating when checking the oil level. The oil
level in the sight glass will not be true when the transfer is in operation.
C
B
Locate the oil level sight glass (A), on the inside face of the transfer
chassis.
A
When looking straight at the oil level sight glass, the line indicating the oil
level (C) should line up with the small dot (B) stamped to the left side of Figure 25
the sight glass.

Adding Oil
If the oil level line is below the dot, oil should be added.

Unscrew the ventilation plug (D) near the top left side of the sight glass using a 5/8 inch wrench.

Span Tech uses SpanLube food grade conveyor lubricant (Span Tech part number DS0000) in all current
powered transfers.

Add enough oil through the open hole to bring the oil level line even with the dot.

Replace the ventilation plug and continue normal transfer operation.

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68
 Part H: Motor Amperage & Gearbox Temperature

3-Phase AC Motor Amperage

WARNING
Only trained and authorized personnel should perform this procedure. Failure to comply with
these instructions and safety precautions could result in serious injury or death.

Use a clamp-on type multimeter to measure the

actual running amperage of a 3-phase AC motor.

Hold the clamp around each of the motor’s three

power leads (excluding the ground lead) individually
as shown in Figure 26. Record the amperage
reading for each lead. You should get the same
value for each of the three leads.

Compare the actual amperage recorded from above

Figure 26
with the maximum amp. rating of the motor. The
maximum amp. rating is engraved on the motor plate
(Figure 27).

The motor is overloaded if the measured readings

exceed the motor’s maximum amp. rating, shown in
bold in Figure 28.
Figure 27
Excessive chain pull can overload a motor. Find and
correct the problem(s) in the conveyor that may be
causing the excessive chain pull. Check the motor
amperage again to see if the corrections brought the Type

S.O.

readings back into range (below the maximum amp. V Hz

rating). A Code NEMA Conn

Nom Eff% Dia.
Hp S. F. Duty Design
Letter
rpm Ins Maximum C
Class Ambient

NOTICE Brake V Torque lb - ft Control

When a conveyor is running 125 FPM (38.1 Figure 28

MPM) or faster and will not be controlled by an
inverter or an electric soft-start, the Z-fan op-
tion should be used on the SEW Eurodrive
gearmotor. The Z-fan is a cast iron fan that
replaces the plastic fan normally installed on the
gearmotor. The Z-fan adds mass to the motor
armature causing the motor to accelerate more
slowly to full speed when started across the line.
rev 05-02-08

The Z-fan helps reduce the initial shock on the

conveyor at start-up.

69
Part H: Motor Amperage & Gearbox Temperature

Gearbox Temperature
Measure the actual running temperature of the
gearbox. If using an infrared pyrometer, aim at the
surface of the gearbox while holding the thermom-
eter about 1 ft. (30cm) away as shown in Figure 29.
A laser beam sight is available so you can see the
exact point at which the pyrometer is aimed. Simply
press and hold the applicable button on the handle.

If the gearbox is painted a dark color, the emissivity

value on the pyrometer, shown in Figure 30, should
be set at 1.00. If the gearbox is painted white or a
very light color, the emissivity value should be 0.80. Figure 29
If your infrared pyrometer has an emissivity setting,
adjust the emissivity as necessary.

Compare this temperature to the maximum or minimum temperature rating for

Current
the gearbox. The gearbox manufacturer has this information. Have the infor- Emissivity
mation on the gearbox plate, shown in Figure 31, ready before contacting the
manufacturer.

If the actual running temperature of the gearbox is above its maximum or below
its minimum temperature rating, gearbox failure is inevitable unless it is brought
Emissivity
into range. Adjustment

The problem could be caused by any one or more of the following:

Figure 30
• Excessive chain pull resulting in extremely high torque require-
ments. Find and correct the problem(s) in the conveyor that
may be causing the excessive chain pull. Check the gearbox
running temperature again to see if the corrections brought the
temperature back into range.
• The gearbox may be leaking or out of oil. Be sure the vent plug
is installed in the proper position.
Figure 31
• The ambient temperature may be above or below the
unit’s rated operating parameters. Be sure the ambient
temperature falls between the minimum and maximum
ambient temperature values engraved on the gearbox Type

S.O.
plate, shown in bold in Figure 32. In rpm Out rpm

• The gearbox could have failed, or could have been

Hp Torque lb-in

Service
rev 05-02-08

Ratio Factor

damaged in some way. Mounting

Position
Lubrication
A Mobil C C
Product
See Operating Instructions for Lubrication Details Min Amb Max Amb

Figure 32
70
 Part I: Sprocket Orientation

MonoSpan and MultiSpan

MonoSpan and MultiSpan sprockets (Figure
33) will engage the chain properly when
rotating in either direction.
Chain Travel
Direction
Chain T ravel

The MonoSpan sprocket can be assembled to

Direction

the shaft in either direction.

A MultiSpan conveyor usually has more than

one sprocket common to a shaft. All the Figure 33
sprockets common to a shaft should be
installed in the same direction so that the
sprocket teeth will line up across the drive /
idler (see Figure 35).
Half-teeth
correctly
The sprockets used with the MultiSpan® mated
conveyor system each consist of two sprocket
halves, assembled and installed onto the
conveyor’s Drive and Idler shafts. Because
the sprocket has an odd number of teeth (21),
the two sprocket halves are not symmetrical.
The sprocket halves must be oriented to
properly mate the half-teeth (Figure 33A) in
order to fit together correctly.
Figure 33A
MaxiSpan
MaxiSpan sprockets (Figure 34) are not
symmetrical and will not engage the chain
properly unless they are installed in the correct
direction.

The teeth on a MaxiSpan sprocket are in pairs, Chain Travel

each having one smaller tooth and one larger Direction

tooth.

The sprockets should be installed so that the

smaller tooth engages the chain before the
larger tooth. Figure 34
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All the sprockets common to a shaft should be

installed so that the sprocket teeth will line up
across the drive / idler (see Figure 36)
71
Part J: Sprocket Alignment

Ensure that the teeth of all the sprockets that are common to one shaft are in alignment across the shaft.

Figure 35: Correct MultiSpan Sprocket Alignment Across Drive / Idler Shafts

Figure 36: Correct MaxiSpan Sprocket Alignment Across Drive / Idler Shafts
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72
 Part K: Sprocket Installation

Hex Head Sprocket

Sprocket Installation Notes Cap Screw Shear Pin

Be sure the sprocket halves are seated down Flat Washer MonoSpan / MultiSpan
Sprocket Top
onto the reinforcement plate and sprocket key.
They should fit snug on the shaft when the
bolts are tightened.
Keystock

Be sure the shear pin is seated in the provided

Sprocket
slot in the reinforcement plate. The sprocket Reinforcing Plate
should not rotate or move from side-to-side
on the shaft.

Once the sprockets are installed, be sure they

MonoSpan / MultiSpan
are perpendicular to the shaft. Sprocket Bottom

Be sure the outer sprockets do not rub against Figure 37 MonoSpan / MultiSpan Sprocket
the drive / idler side plates. Assembly

Hex Head
Replace any sprocket that is noticeably Cap Screw
Sprocket
warped. This can easily be seen by rotating Shear Pin
the shaft several times while looking straight
down into the drive / idler. Flat Washer MaxiSpan
Sprocket Top

Be sure the half-tooth on the top sprocket half

matches up with the half-tooth on the bottom
sprocket half (Figure 33A). Keystock

Sprocket
Be sure all sprockets are installed in the Reinforcing Plate

correct rotational direction.

Be sure the sprockets are in alignment across

the drive / idler shaft. MaxiSpan
Sprocket Bottom

Figure 38 MaxiSpan Sprocket Assembly

NOTICE
Use low-strength Loctite (#222) when installing Shear Pin.
rev 05-02-08

73
Part L: Chain-to-Sprocket Engagement and Chain
Installation Direction
The chain links should always engage the sprocket(s) teeth as shown in Figures 39 and 40. The nose of
the chain links should always point in the direction of chain travel.

Chain Travel Chain Travel

Direction Direction

The chain rod is cradled

between the small and large
sprocket teeth with the
smaller tooth leading.

Direction of Direction of
Chain Travel Chain Travel

Figure 39: MonoSpan / MultiSpan Chain to Figure 40: MaxiSpan Chain to Sprocket
Sprocket Engagement Engagement

Sprockets should not engage or contact High Friction chain links as shown in Figure 41.

Sprockets should not engage or contact rollers or tubes in the chain as shown in Figure 42.

NO NO
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Figure 41 Figure 42

74
 Part M: Sprockets Rubbing Side Plates

Sprockets should not rub against the drive / idler side plates (Figure 43).

To check for rubbing, rotate the drive / idler shaft by hand. If a sprocket is rubbing against the inner
surface of one or both of the drive / idler side plates at any point, you should be able to see it, feel it, and/or
hear it.

As shown in Figure 44, there should be a minimum clearance of 0.075” (2mm) between the surfaces of the
outer sprocket(s) and the drive / idler side plates.

YES There should be a minimum

of 2mm between

NO surfaces on each side.

Figure 43: Illustration of a Sprocket Rubbing Figure 44: Correct Clearance Between Sprockets
Against a Drive / Idler Side Plate and Drive / Idler Side Plates
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75
Part N: Bound or Locked Idler Shaft

A bound or locked idler shaft in a conveyor increases the torque required to keep it in operation. Ulti-
mately, this results in motor overload and failure.

Possible Causes of Bound or Locked Idler Shafts

• The Idler’s outer sprockets are rubbing against the side plates.
• Bearing failure.

Correcting Bound or Locked Idler Shafts

• Loosen the bolts in the sprocket that is rubbing against the side plate. Place a shim plate 0.075” (2mm)
thick between the side plate and the sprocket, as shown in Figure 45, and tighten the sprocket bolts.
Remove the shim plate. While turning the shaft several times, make sure the sprocket is no longer rubbing
against the side plate. If this does not help the problem, replace the rubbing sprocket with a new one.
• Replace bearing.

Figure 45
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76
 Part O: Broken or Bent Chain Rods

Bent chain rods, like those illustrated in Figure 46, are often the result of heavy loads concentrated in the
center of the chain. This can distort the chain and change how the side links contact the wearstrip. Badly
bent chain rods will cause accelerated wear to both the wearstrip and the chain’s side links. Bent chain
rods can also increase the amount of torque required to run the conveyor, which in turn can stress the
conveyor’s motor.

Figure 46 Figure 47

Though not as common, certain applications can cause the chain rods in a conveyor to bend upward like
those illustrated in Figure 47. This can happen in roller or tube top type chains where there is an open
space between consecutive chain rods. When the product is placed onto the conveyor in a way that its
edge can catch under the chain’s rollers or tubes, as shown in Figure 48, the chain can be lifted upward.
This can eventually lead to bent or broken chain rods.

Figure 49 is a photographed example of bent chain rods.

Product placed on the conveyor off a

Inc decline can get caught momentarily
om between rollers / tubes, thus bending
ing the chain rods.
Pr
od
uc
t

Chain Flow

Roller or Tube Top Chain Figure 49: Bent Chain Rods

Figure 48
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77
Part P: Chain Assembly

Figures 50, 51 and 52 show how each of the Designer System® chains are assembled.

Direction of
Chain Travel
Direction of Chain Link
Chain Travel

Chain Rod

Lock Tab

Figure 50: MonoSpan Chain Assembly Figure 51: MultiSpan Chain Assembly

Direction of
Every side link in a conveyor’s chain should have a Chain Travel
lock tab.

The lock tab is inserted in the opening in the side link

after the chain rod has been installed as shown in
Figure 53.

Always check your conveyor chain for any missing,

broken, or loose lock tabs, and replace those found.
Figure 52: MaxiSpan Chain Assembly

Figure 53: Chain Lock Tab Assembly Figure 54

Figure 54 is a photographed example of worn lock tabs that should be replaced.

rev 05-02-08

78
 Part Q: Center Support Rail

The center support rails provide support for the top chain in the product zone, thus preventing the chain
from bowing due to the product load.

As a rule, all widths of MaxiSpan conveyors require center support rails.

MultiSpan conveyors that are 13.21” (335.6mm) or wider require center support rails.

MonoSpan conveyors do not require center support rails.

General Notes About Center Support Rail

• Center support rails should “snake” back and forth

throughout the length of the conveyor, as shown in Figures
Center support rails
55 and 56, to avoid wear in one particular spot under the should “snake” back and
forth (as shown)
chain. throughout the conveyor.
This is done to avoid wear
in one spot of the chain.
NOTICE
Figures 55 and 56 are shown as typical examples;
actual layout and appearance of center support
rails for specific applications may vary. Figure 55

• As a general rule of thumb, MaxiSpan conveyors

will have one center support rail weaving under
each of the chain’s center links.
• MultiSpan conveyors will require a varying number
of center support rails depending on the specific
chain pattern and width. In this case, refer to job
prints to determine the number and location of the
center support rails.

NOTICE
A center support rail should never be positioned
Figure 56
under High Friction or roller type chain links.
If the chain includes High Friction or roller links,
the rail should run under the acetal center links Trailing
Cha
End
only. This will reduce the chance of the rail com- in F
low

ing into contact with High Friction or roller links

— a situation that can cause excessive drag and
premature failure of the conveyor. Leading
End
rev 05-02-08

At field break locations, the trailing end of a center

support rail should extend beyond the leading end, as Figure 57: Center Support Rail at Field Break
shown in Figure 57, so that support is not interrupted. location
79
Part Q: Center Support Rail

Center Support Rail Installation

1. Hold the trailing end of the center support rail in posi-

tion and make a mark at the location it should be cut. Flo Center
w Support
2. Use pruning shears to cut the center support rail at the Rail
mark.
3. Using the pruning shears, chamfer the end of the rail. Chamfered at
end as shown
4. At field-break locations, insert the T-rail into the
crossbar slot closest to the edge of the conveyor.
5. Using a rubber mallet, tap the T-rail to fully seat it in the
crossbar slot. The self-locking tab will lock the T-rail Crossbar
in position (Figure 59).
6. Inspect entire Center Support Rail to ensure that it is Figure 58
properly installed and secure at every crossbar.
The T-rail is inserted
into the crossbar slot
NOTICE and seated with a
rubber mallet. The
If the center support rail is not completely seated self-locking tab will
lock the T-rail in
in the crossbar slot, the rail will push up against position.
the chain causing various problems such as ad-
ditional chain pull, wear on the chain links, and
increased wear of the wearstrips.

Figure 59

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80
 Part R: Return Chain Support Rail

Return chain support rail (Figure 60) is used on conveyors more than 24” (609mm) wide. It supports the
weight of the return chain to prevent it from sagging.

General Notes About Return Chain Support Rail

• When return chain support rail is required, there should be at least two return chain support crossbar
assemblies on the conveyor.
• The return rail itself is simply round guide rail, so connection of consecutive rails are made with splice
sleeves in the same manner as guide rail connections are made. Splice sleeves should never be loose.
• Any splices in the return rail should be located as close to a support structure as possible.
• When the return rail reaches the drive / idler of a conveyor, it should be angled downward following the
angle present under drives / idlers. This prevents interference between the return rail and the chain.
• All splices should be clean and smooth to eliminate catch points.
• The return rail should be completely seated in the return chain support clip.
• The return chain support clip should grip the rail firmly to hold it in position.
• Be sure the return chain support crossbar is not bent or damaged.

Round Guide Rail

Stainless Steel
Backed

Return Chain
Support Clip Angle
Hex Head
Cap Screw
Return Chain
Support Crossbar
rev 05-02-08

Nyloc Nut

Figure 60: Return Chain Support Rail Assembly

81
Part S: Direction of Bed Sections

When installing a conveyor bed section, the The upper lips of the crossbars
are bent in the direction of chain flow
upper lips of the crossbars should bend in the when the bed section is installed properly
direction of chain flow as illustrated in Figure
61.
Dire
ctio
no
f Ch
ain
Flo
w

Figure 61: Correct Bed Section Installation

Direction

If the upper lips of the crossbars in a bed

Dire
section are bent in the opposite direction as ctio
no
f Ch
the chain flow, the bed section is installed ain
Flo
backward as illustrated in Figure 62. The w

only exception to this is in a conveyor that will

run in both directions.

If the upper lips of the crossbars

are bent opposite to the direction of
chain flow, the bed section is
installed backwards.

Figure 62: Incorrect Bed Section Installation

Direction

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82
 Part T: Side Frame Alignment

Inspect the areas along a conveyor where bed sections join. The ends of the side frames should be aligned as
illustrated in Figure 63 for smooth transition of the plastic wearstrips over the adjoining lips.

Figure 64 illustrates examples of misaligned side frames where bed sections join. If misalignment is discovered,
loosen the eight bolts at the connecting strap. Realign the adjoining side frames, and retighten the connecting
strap bolts.

Figure 63: Correct Side Frame Alignment

rev 05-02-08

Figure 64: Examples of Misaligned Side Frame

83
Part U: Horizontal & Vertical Bend to Straight Bed
Section Alignment
Figure 65 illustrates how horizontal bends connect to straight bed sections.

Figure 65

Inspect the areas where bed sections join. The ends of the side frames should be aligned as illustrated in
Figure 63 (preceding page) for smooth transition of the plastic wear-strips over the adjoining lips.

Figure 64 (preceding page) illustrates examples of misaligned side frames where bed sections join. If
misalignment is discovered, loosen the eight bolts at the connecting strap. Realign the adjoining side frames,
and retighten the connecting strap bolts.

Figure 66 illustrates how vertical bends connect to

straight bed sections.

Figure 66
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84
 Part U: Horizontal & Vertical Bend to Straight Bed
Section Alignment
Additional Inspection Tips:

• Be sure all connecting strap bolts are installed and tightened.

• Be sure the correct lip-to-lip width across the conveyor is maintained throughout the connection areas.
• Be sure the transition of the wearstrip across the side frame joints is smooth.
• Be sure the plastic vertical bend side frames are cut at the correct angle.
• Be sure the proper connecting straps are used.
• Be sure to install the correct number of crossbars in the vertical bend area, and be sure they are installed in
the proper locations. Refer to Figure 67 for information concerning crossbars in vertical bends.
• Be sure all center support railing is seated and pinned in the vertical bend area. The leg of the center
support railing may need to be notched to conform to the bend angle so it will seat properly in the crossbar
slot.

CONVEYOR VERTICAL NUMBER OF LOCATION OF

TYPE(S) BEND ANGLE CROSSBARS CROSSBARS

MonoSpan, MultiSpan, MaxiSpan All Angles 0 NA

MonoSpan, MultiSpan, MaxiSpan 0° - 19° 0 NA

There should be one crossbar at the end of each

MonoSpan, MultiSpan, MaxiSpan 20° - 39° 2
of the attached straight bed sections.
There should be one crossbar at the end of each
MonoSpan, MultiSpan, MaxiSpan 40° - 59° 3 of the attached straight bed sections, and one crossbar
in the center of the vertical bend.
There should be one crossbar at the end of each
MonoSpan, MultiSpan, MaxiSpan 60° - 90° 4 of the attached straight bed sections, and two crossbars in
the vertical bend positioned at the innermost holes.

Figure 67: Vertical Bend Crossbars

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85
Part V: Crossbars

Inspect the conveyor’s crossbars. Replace any bent, damaged, or missing crossbars.

Refer to the job layout print that shows your conveyor(s) in a plan view to determine the correct quantity
and placement of the crossbars. Figure 68 explains how crossbars are depicted on the job print.

Plastic Crossbar
(No Longer Used)

On the job print (plan view), these hidden lines Stainless Steel
spanning the conveyor width indicate the Crossbar
location of each required crossbar

Figure 68 Figure 69

Figure 69 illustrates the two types of crossbars that the bed sections of a conveyor could have. The
plastic style crossbars were installed in earlier conveyor models, and are no longer used.

Earlier drive / idler units were built with two plastic crossbars as shown in Figure 70.

Old style Drive / Idler unit Web should

with two plastic crossbars always face UP
(No Longer Used) in MonoSpan
Drive / Idler units.

Figure 71

Figure 70

The plastic crossbars have been replaced by one

piece stainless steel crossbars. Figure 71 illustrates
the proper installation of the crossbar in a MonoSpan
Web should face DOWN
drive / idler unit. Figure 72 illustrates proper cross- if Center Support Rails are required.
bar installation in MultiSpan and MaxiSpan drive / Otherwise the web should face UP.
rev 05-02-08

idler units.
Figure 72

86
 Part W: Chemical Contamination

Certain harsh chemicals can rapidly deteriorate plastic components and lead to premature failure. Different
chemicals change the properties of the plastic components in different ways. For instance, the appearance
of a chain that has been exposed to a certain chemical may not change, but the chain may have become
brittle causing the links to break easily. Exposure to another chemical may change the appearance of the
chain links.

A conveyor system can often be exposed to harsh chemicals during a cleaning process. Contact a Span
Tech customer service representative to obtain Span Tech’s recommended cleaning procedures.

Plastic components can be molded from polypropylene material which can withstand exposure to a wider
range of chemicals than some of the standard materials used in normal environment applications. Polypro-
pylene components are often used when a customer’s product contains harsh chemicals.

To determine the resistance of various plastics used in Span Tech conveyor systems to specific chemicals,
refer to the Chemical Compatibility Chart (pages 90 through 97).

As an example of chemical contamination, Figures 73 and 74 are photographs showing a drive unit that
was exposed to and severely damaged by sulfuric acid (battery acid). Compare the photograph in Figure
75 to that in Figure 76. The link in Figure 75 is new and has not been exposed to any contaminants. The
link in Figure 76 was immersed in bleach containing 5.5% sodium hypochlorite for a period of one week.
Notice the damage caused by the bleach.

Figure 73 Figure 74
rev 05-02-08

Figure 75: New Uncontaminated Link Figure 76: Bleach Contaminated Link

87
Part X: Chain Pitch & Elongation

Stretched Chain Links

The links in a chain can stretch after a prolonged period of conveyor operation. This stretch is minimal and
is usually not significant in shorter conveyors.

Profile of a new Profile of a stretched

In longer conveyors, however, this stretching can Chain Link Chain Link
produce a functionally significant increase in the
amount of overall chain slack. The pitch of con-
secutive chain links may also change, which in turn
can affect how the chain links engage and mesh
with the sprockets. This can cause the chain to
(Illustration exaggerated to emphasize difference)
jump the sprocket teeth and can also accelerate
sprocket wear. Figure 77

Figure 77 illustrates an exaggerated comparison of

a new chain link to a stretched chain link.

Chain Pitch
Chain Pitch
Chain pitch refers to the distance from one point on a chain link
to the same point on the next chain link, when the chain is fully
extended (Figure 78).

A conveyor’s chain pitch can change over time. Various factors

can play a part in increasing the chain pitch in a conveyor chain. Figure 78
The changes in chain pitch are usually dependent on the amount
of chain pull involved. As the chain pull increases, the chain pitch increases by a greater amount and at a
faster rate. Conveyors that run at low speeds with large loads may experience a faster growth in chain
pitch. A conveyor that has a relatively complex layout, including horizontal and/or vertical bends, requires a
great amount of driving torque which may also affect the chain pitch.

When a conveyor’s chain pitch has changed significantly, the result is apparent. The sprocket teeth may be
excessively worn or broken, the chain may be jumping the sprocket teeth, the drive/idler wearstrips may be
damaged, or the chain links may be breaking. Correcting these symptoms will not solve the overall prob-
lem. The chain itself must be replaced. To determine if a conveyor’s chain pitch is out of the allowable
range, the chain pitch must be measured correctly. The chain’s elongation percentage can then be deter-
mined and compared to the maximum recommended allowance.
rev 05-02-08

88
 Part X: Chain Pitch & Elongation

Procedure for Finding a Chain’s Elongation Percentage

Find a fully extended length of chain along the conveyor that includes at least ten links. Measure from one
end of this length of chain to the other, beginning at some point on the first side link and ending at the same
point on the last side link (see Figure 79).

Figure 79

Use this distance to calculate the chain’s elongation percentage, by the following formula:

Distance Measured – (Normal Pitch* x No. of Links Measured)

% Elongation = x 100
Normal Pitch* x No. of Links Measured

* Normal Pitch for MonoSpan chain = 0.984” (25mm)

* Normal Pitch for MultiSpan chain = 0.984” (25mm)
* Normal Pitch for MaxiSpan chain = 1.969” (50mm)

If the elongation percentage calculated is greater than 4% for MonoSpan and MultiSpan chain, or 2% for
MaxiSpan chain, the conveyor’s chain should be replaced.
rev 05-02-08

89
 Chemical Compatibility Chart

The following multi-page chart (pages 90-97) provides chemical compatibility information for a variety of
materials used in Designer System® conveyor components. The information is based on testing of the
component materials’ compatibility with a wide range of chemical reagents.

The materials used in Designer System® conveyors include the following:

• Acetal – Chain links, MaxiSpan chain rods, chain lock tabs

• LDPE – Drive/idler hole plugs
• Nylon – Wearstrip rivets
• Polypropylene – Drive/idler side plates, vertical bends
• Polyurethane – High Friction chain links
• Santoprene 55 – High Friction chain links
• Santoprene 87 – High Friction chain links, drive/idler bearing shields
• Spanlon – Wearstrips
• Super Tough Nylon – Sprockets
• UHMW-PE – Center Support Rails, Guide Rails

rev 05-02-08

90
 rev 05-02-08

Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Acetaldehyde A LR A NR

Acetic Acid (5%-10%) A A LR A LR A A LR A

Acetic Acid (50%-75%) NR A NR A A A NR

Acetic Acid (80%-95%) NR LR NR A NR A A NR A

Acetic Acid - Glacial NR NR A NR A A NR

Acetic Anhydride NR A NR

Acetone A NR A A NR A A

Acetophenone A A LR
Acetyl Chloride NR NR

Acetylene A A A

Adipic Acid A
Allyl Alcohol NR LR LR

Aluminum Chloride A A A A A A

Aluminum Fluoride A A
Aluminum Hydroxide A A

Aluminum Sulfate A A A A A

91
Alums A A A
Ammonia A A A A

Ammonium Acetate A

Ammonium Carbonate A A A
Ammonium Chloride A A A A A

Ammonium Fluoride A A

Ammonium Hydroxide VLR A NR A

Ammonium Nitrate A A A

Ammonium Sulfate A A A

Amyl Acetate A NR A LR NR
Amyl Alcohol A A LR A LR LR

Aniline LR A LR A NR A A A

Antifreeze A A A A
Aqua Regia NR LR

Barium Chloride A A A A

Barium Hydroxide A A
Beer A A A A

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

 Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Benzaldehyde A A A NR

Benzene A NR A LR NR LR
Benzoic Acid LR A VLR A VLR

Benzyl Alcohol A LR A LR A

Bleach A LR LR A
Borax A A A

Boric Acid A A A A A

Brake Fluid A A A A A A A
Bromine NR NR NR NR NR

Butane A A A

Butanol A A LR
Butyl Acetate A LR A NR NR A A

Butyl Alcohol A A A LR A

Butyric Acid NR NR A A
Calcium Chloride A A A A A A A A A

Calcium Hydroxide A A A

92
Calcium Hypochlorite A NR A
Calcium Nitrate A A A

Calcium Sulfate A A A

Carbon Dioxide A A A A
Carbon Disulfide A NR A NR LR

Carbon Monoxide A A A

Carbon Tetrachloride A NR A NR NR LR
Chlorine NR NR NR LR NR NR

Chloroacetic Acid NR NR NR A NR

Chloroform LR NR A VLR NR LR
Chlorosulfonic Acid NR NR NR NR

Chromic Acid (10%-20%) NR A NR A

Chromic Acid NR A A NR A
Citric Acid A A A A A

Clorox NR A NR

Copper Chloride A A VLR A

Copper Sulfate A A A A A

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

rev 05-02-08
 rev 05-02-08

Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon

Corn Oil VLR A A

Cottonseed Oil A A A
Cresol A NR A NR NR

Crude Oil A A A

Cyclohexane A A NR NR VLR A
Cyclohexanol A A A A A

Cyclohexanone A NR A LR NR

Decalin A A NR
Detergent A A A A A A A A A

Dibutyl Phtalate A LR A A LR

Diesel Fuel A A A
Diethyl Ether A LR LR A A

Dimethyl Formamide A NR A A

Dioctyl Phthalate A LR A LR A A
Dioxane A A A VLR A

Ethanol A A A LR A A A A

93
Ethyl Acetate A LR A A NR A
Ethyl Alcohol A A LR A LR

Ethylene Chloride A NR A NR

Ethylene Dichloride A VLR A LR LR

Ethylene Glycol A A LR A LR A A A

Ethylene Oxide A A A

Ferric Chloride A A A A A
Ferric Sulfate A A A A

Ferrous Sulfate A A

Ferrous Chloride A A A A
Fluoboric Acid A NR NR

Fluorine NR A NR NR NR

Fluorosilicic Acid A NR A NR
Formaldehyde (@37%) A A A A LR

Formic Acid (80%-85%) NR A NR A NR NR

Freon 12 A LR
Furfural A NR NR

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

 Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Gasoline A NR A LR A

Glycerin A A A A A A A
Heptane A NR A NR A

Hexane A A A A VLR A

Hydraulic Fluid A A A
Hydrobromic Acid NR A NR A NR

Hydrochloric Acid NR A NR A NR A A A NR A

Hydrocyanic Acid NR NR NR A
Hydrofluoric Acid NR A VLR A LR NR A

Hydrogen Peroxide NR A NR LR NR A

Hydrogen Sulfide A A A A
Hypochlorous Acid NR A NR NR

Isooctane A A NR VLR A A

Isopropyl Alcohol A LR A LR LR
Kerosene A A LR LR A

Lactic Acid LR A A A LR

94
Lestoil (@ 2%) A VLR NR
Magnesium Chloride A A A A A

Magnesium Sulfate A A A

Maleic Acid LR A
Methyl Ethyl Ketone LR NR A A NR VLR A A

Mercury A A A A A

Methanol A A A A LR a A
Methyl Alcohol A A LR A LR LR

Methyl Chloride A LR A NR

Methyl Isobutyl Ketone A A NR

Methylene Chloride LR LR A NR NR

Milk A A A A A A

Mineral Oil A LR A A A A
Motor Oil A A A A A

Naphtha (VMP) A A A A LR

Naphthalene A NR A A
Natural Gas A A

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

rev 05-02-08
 rev 05-02-08

Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Nitric Acid (@ 10%) NR NR A NR A

Nitric Acid (@ 70%) NR A NR VLR NR LR

Nitrobenzene A NR LR A A A

Oleic Acid A LR A A A

Oleum NR NR NR NR
Oxalic Acid NR A A A

Ozone VLR LR LR NR A

Perchloric Acid NR A NR
Perchloroethylene LR A NR NR

Petroleum Ether A NR A VLR LR A

Phenol NR NR NR A NR NR
Phosphoric Acid (@ 10%) VLR A NR A NR

Phosphoric Acid (@ 85%) NR A NR A NR A

Potassium Bicarbonate A A A A
Potassium Bromide (sat.) A A A A

Potassium Carbonate A A A A

95
Potassium Chloride A A A A
Potassium Dichromate A A LR A A

Potassium Hydroxide A A VLR A A A A

Potassium Nitrate A A A A A
Potassium Permanganate A A NR A

Potassium Sulfate A A A A A

Propane A A A A A
Pyridine LR A A NR A A

Silicone Oil A A A A

Soap Solution A A A A A
Sodium Bicarbonate A A A A A

Sodium Bisulfite NR A A A

Sodium Carbonate A A A A A
Sodium Chloride A A A A A A A A

Sodium Hydroxide (@10%) A A A A

Sodium Hydroxide A A A A A A A
Sodium Hypochlorite (@15%) VLR A NR A A

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

 Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Sodium Sulfate A A A

Sodium Sulfide A A A A A
Stannic Chloride A A LR A

Stannous Chloride NR A A

Stearic Acid A A A
Styrene A A LR

Sulfur A A LR

Sulfur Dioxide, Dry NR A

Sulfur Dioxide, Moist NR A

Sulfuric Acid (@ 3%) A

Sulfuric Acid (@ 10%) LR A VLR A NR

Sulfuric Acid (@ 30%) NR A VLR A NR A

Sulfuric Acid (@ 98%) NR LR NR VLR A A NR A

Sulfurous Acid (conc.) A LR NR

Tannic Acid LR A NR A NR

Tartaric Acid LR A A A

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Tetrachloroethylene A A
Tetrahydrofuran LR NR A LR

Tetralin A A LR

Toluene A NR A NR NR NR VLR A A LR
Transformer Oil A LR A A LR A

Trichloracetic Acid NR NR A NR

Trichloroethane A LR NR
Trichloroethylene NR NR LR NR NR NR NR A LR

Tricresyl Phosphate A A NR

Triethanolamine A A A A
Trisodium Phosphate A A LR

Turpentine A LR LR A NR VLR

Unocal Drillube 100 A A A A NR

Urea A A A

Vaseline A A A

Vegetable Oils A A A A
Vinegar A A A

A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant

rev 05-02-08
 rev 05-02-08

Reagent Acetal LDPE Nylon 66 Polypropylene Polyurethane Santoprene Santoprene Spanlon Super Tough UHMW-PE
55 87 Nylon
Wax A A

Wines A A A A A A
Xylene A NR A VLR NR NR VLR LR

Zinc Chloride NR A VLR A A A A A NR A

Zinc Oxide A A
Zinc Sulfate A A A A

NOTE: This is not an exclusive list. If an unlisted or untested chemical is in question, have a qualified testing laboratory run a test using
conveyor components to determine the chemical’s effect.

NOTE: All tests performed to produce the given results were conducted in an ambient temperature of 70°F (21°C).

SOURCES: Plastics Design Library (William Andrew, Inc.)

Santoprene Thermoplastic rubber - fluid resistance (Advanced Elastomer Systems)
Engineering Plastics for Industry (Solidur Plastics Company)

97
A = Acceptable LR = Limited Resistance VLR = Very Limited Resistance NR = Not Resistant
 Troubleshooting
Diagnostic Chart

The following diagnostic chart (page 99) is designed to serve as a troubleshooting aid when attempting to
solve problems with a conveyor system. Some obvious defects in the conveyor system, uncovered while
investigating the conveyor and environment, may not be shown directly on the chart. The corrective action
for these defects should be included in the plans for the corrective repairs.

If you find problem descriptions and/or probable causes that should be added to this chart, be sure to let
the Span Tech customer service manager know, so that it can be included on future charts.

rev 05-02-08

98
 Troubleshooting Diagnostic Chart
PROBLEM DESCRIPTION
NOTICE

Excessive wear on the outside (product) chain surface

While this chart contains a comprehen-

Chain disengaging from the conveyor side frame

Wearstrip becomes detached from side frame

sive set of problem descriptions and

Wearstrip in curve discolored on outer edge

Excessive wear on the inside chain surface

No clearance between chain and wearstrip

probable causes, it cannot replace a thor-

Breaking drive and / or idler side plates

Excessive wear on side link chain legs

Excessive wear on side link chain feet
ough examination and investigation of

Breaking drive and / or idler sprockets

Chain jumping teeth on sprockets

the conveyor system. The intended use

Motor running at high amperage

Product will not incline / decline

of this diagnostic chart is to assist
troubleshooters in reviewing the results
of their investigation.

Breaking chain links

Breaking chain rods
Contamination of the chain and/or wearstrips

Interference from foreign objects

Improper sprocket assembly

Misalignment of sprockets

Improper sprocket / chain engagement

Idler sprockets not rotating freely

Improper wearstrip installation

Overlapping wearstrip

Damaged wearstrip
PROBABLE CAUSES

Broken drive / idler wearstrip

Missing wearstrip

Broken chain links / rods / lock tabs

Improper amount of chain slack

Backward chain installation

Improper center support rail installation

Improper return chain support installation

Misaligned conveyor bed sections

Damaged conveyor side frame

Missing crossbars

Bound idler shaft

Loose and / or missing fasteners

rev 05-02-08

Chemical contamination

Chain’s % elongation exceeded

99
 ®

Span Tech LLC

1115 Cleveland Avenue
P. O. Box 369
Glasgow, KY 42142
(270) 651-9166
rev 05-02-08

general_info@spantechllc.com
www.spantechllc.com

100