To change the drive sprocket in a drive unit with long tensioner, please proceed as follows:
  1. Disconnect the electrical and pneumatic supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the chain from the drive sprocket.
  4. Release the mounting bolts of the drive sprocket with an Allen wrench (M6) and remove the bolts with the washer.
  5. Mount the feeding conveyor segment with the spacer strips to the base frame of the Swing Gate.
  6. Pull the drive sprocket of the motor shaft with a suitable puller. The spacer ring has to remain on the motor shaft because it will be used as a hard stop for the new sprocket to get the right alignment.
  7. Install the new drive sprocket in reverse order. If a drive sprocket with different diameter gets used, the drive chain length has to be checked and it needs to get shortened or lengthened if required. That should be done at an existing master link. Make sure that the drive sprocket is correctly positioned: The center line of the chain has to be in one line.
  8. Re-tension the chain and reset the chain tensioner.
  9. Install the clear front cover of the drive station.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  11. Check the chain tension after two hours of operation again.

    Drive Unit Replacing drive sprocket long tensioner

 
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A replacement of the entire chain is required when the chain is worn out, or worn beyond the limits of the chain tensioner. Signs for that are high soiling, non-moving chain links and rust at the chain, or seeing a red color code on the chain tensioner slider indicating that it is at the end of its travel.
 
To replace the chain in a drive unit with long tensioner, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  3. Remove the lower extrusion of the drive station by taking out the three attachment bolts.
  4. Remove the chain from the drive sprocket and pull the chain until a master link appears.
  5. Open the master link and connect the new with the old chain. Put the new chain on a clean surface to avoid new dirt and soiling of the chain.
  6. Pull at the open end of the old chain to get the new chain in the chain drive. If needed some chain has to be connected with additional master links.
  7. Place the chain around the chain tensioner and the drive sprocket and cut the chain so that it can be closed tightly with a master link.
  8. Re-tension the chain and reset the chain tensioner.
  9. Install the lower extrusion of the drive station and reinstall the clear front cover of the drive station.
  10. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to become shortened by another chain link.
  11. Check the chain tension after two hours of operation again.
 
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To shorten the drive chain, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the 228 mm long top rail extrusion above the drive station.
  3. Turn the fan of the drive motor in the direction of flow to drive the conveyor manually until a master link is visible (zinced).
    CAUTION: There is a residual danger because of the non covered chain drive.
  4. Remove the clear front cover of the drive station and release the chain tensioner. Lock it in that position with an adequate device.
  5. Open the master link, and pull the chain to tension and shorten the excessive chain.
  6. Re-connect both chain ends with the master link. Pay attention to the right orientation and to the style of the master link: The lock of the master link leads towards the bottom rail extrusion, the locking plate faces into the direction of the conveyor flow.
  7. Re-tension the chain and reset the chain tensioner.
  8. Mount the clear front cover and install the top rail extrusion piece. Please ensure that the chain guide and the guide strip are installed correctly. Install all chain covers correctly and completely again.
  9. Run the conveyor system and check the tension of the chain at the chain tensioner. If the chain tensioner is almost at its far end, the chain has to be shortened by another chain link.
  10. Check the chain tension after two hours of operation again.

  11. Drive Unit Shortening drive chain long tensioner

 
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Thursday, 22 October 2015 22:55

Conveyor: %Changing an end roller


To change the end roller, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. If covers between rollers are installed, remove them by pushing them out from the bottom.
  3. Remove the chain covers between the two last rollers of the conveyor section, as described in the previous chapter.
  4. Remove the plastic chain end support.
  5. Loosen and remove the mounting bolts of the end roller. Relieve the end roller against the chain tension by hand to remove the bolts.
  6. Release the end roller by turning in slightly from the drive chain and remove the end roller sideways (the same way as the friction roller).
  7. Install the new end roller (please pay attention to the correct type of roller) in the reverse order. Insert the chain sprocket into the looped chain. The end roller must be pulled against the chain tension in position. If this is not possible, the chain tensioner must be released in the drive station. After the installation the chain tensioner has to be reset.

    Roller Changing end roller

Please use a self-locking nut for fastening the chain end support. Please check that no foreign material is remaining in the system and all covers are installed correctly before powering up the conveyor system.
 
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Thursday, 22 October 2015 22:53

Conveyor: %Changing a friction roller


To change or relocate a friction roller, please proceed as follows:
  1. Disconnect the electrical supply of the entire conveyor system and secure against reconnection.
  2. Remove the chain covers in the area around the roller(s) to be replaced or relocated.
  3. Loosen and remove the mounting bolts of the rollers (M8 socket head bolt with hexagon socket size 6 mm).
  4. To take the friction roller out, release the roller from the drive chain by twisting or sliding sideways. If relocation to an adjoining mounting position is planned, the roller can be shifted sideways.
  5. Remove the friction roller (aslope) upwards.
  6. Install the new roller in reverse order.

    Roller Changing friction roller

All chain covers must be installed completely and the roller must be checked for tight and correct installation after every change or relocation of a roller. Check the roller configuration and reposition more rollers, if necessary. Make sure that you install the correct roller type for that location.
 
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Thursday, 22 October 2015 22:52

Conveyor: %Adjustment of the friction rollers


Only KRUPS Standard Rollers with adjustable nut and silver or golden spring can be adjusted in their friction.
Rollers with a silver spring generate more friction than the gold spring rollers but share the same internal structure, allowing the spring to be changed to increase tension when needed. Warning: Too much friction can wear out the bottom of the pallet.
 
The friction rollers can be adjusted (increased or decreased) by turning the adjusting nut on the axis of the roller with an open-end wrench size 22 mm until the required transportation force is achieved. The adjustment range is predefined in all types of rollers because of the existing thread length.
Tightening the nut increases the friction and loosening reduces the friction.

Roller Adjustments

 
The rollers must have a low friction and low driving force in the accumulation areas to minimize the dynamic pallet pressure and to avoid the wear of the pallet bottom because of spinning rollers.
 
The rollers must have a higher friction and driving force in the area of corners, diverters and junctions to guarantee the transport of the pallet in those areas.
 
If a pallet hits a stop unit, the rollers should stop under the pallet to avoid wear.
 
The friction of the rollers is pre-set to the estimated total part weight but the friction must be adjusted to the actual pallet configuration and the working environment during the installation of the conveyor system.
The friction should be checked after approx. 100 hours.
 
The friction of the rollers should not be set higher than necessary for safe moving and departing of the pallets. This can avoid an unnecessarily high dynamic pressure and makes for a safer operation.
 
 
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Thursday, 22 October 2015 22:51

Conveyor: %KRUPS Stub Rollers


The stub rollers get used if free center access through the conveyor is necessary. The reason can be operations with tooling from underneath or the installation of components like lift and locates or rotates.
 
A continuous section with stub rollers should not exceed 1,000 mm in length. The driven stub rollers have to be arranged in a pitch of 57 mm to generate sufficient friction to transport the pallet safely. The pitch of the non-driven stub rollers can be 114 mm because they just support the pallet. If a stub roller area needs to be longer than 1,000 mm a friction roller, or at least a roller shaft, has to be installed to maintain the strength of the conveyor frame.
 
 
Name:
Stub roller, high friction, driven
Manufacturer Item No.:
72332
Feature:
Chain drive sprocket, full steel
Site of operation:
Drive side with free access

Roller Stub Roller driven steel

 
 
Name:
Stub roller, non-driven
Manufacturer Item No.:
52577
Feature:
No sprocket
Site of operation:
Non-driven side with free access

Roller Stub Roller non driven

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Thursday, 22 October 2015 22:51

Conveyor: %KRUPS Standard Rollers


The Standard Rollers can be used up to a total weight of 550 lbs. (250 kg) per pallet.
 
 
Name:
END-Roller, low friction (gold)
Manufacturer Item No.:
72297
Feature:
Gold spring
Site of operation:
In general roller conveyor system end roller with low friction

Roller heavy END Roller low friction

 
 
Name:
END-Roller, high friction (silver) 
Manufacturer Item No.:
68171
Feature:
Silver spring, black nut 
Site of operation:
End roller in the area of diverters or junctions with high friction

Roller heavy END Roller high friction

 
 
Name:
END-Roller, fixed driven 
Manufacturer Item No.:
68169
Feature:
Black retaining ring, no spring
Site of operation:
End Roller in the area of corners or divertes / junctions 

Roller heavy END Roller fixed driven

 
 
Name:
Roller, low friction (gold)
NOT usable as first or last roller of a driven section
Manufacturer Item No.:
72296
Feature:
Gold spring, silver nut
Site of operation:
In general roller conveyor system

Roller heavy Roller low friction

 
 
Name:
Roller, high friction (silver)
NOT usable as first or last roller of a driven section
Manufacturer Item No.:
68175
Feature:
Silver spring, silver nut
Site of operation:
Before and after corner and turn areas for incresed driving force

Roller heavy Roller high friction

 
 
Name:
Roller, fixed driven
NOT usable as first or last roller of a driven section
Manufacturer Item No.:
68172
Feature:
Silver retaining ring, no spring
Site of operation:
In coner and divert areas

Roller heavy Roller fixed driven

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Thursday, 22 October 2015 22:50

Conveyor: %KRUPS ECO Rollers


The ECO Rollers can be used up to a weight of 220 lbs. (100 kg) per pallet.
 
Name: 
END-Roller, friction
Manufacturer Item No.: 
68872
Feature: 
Spring with black washer
Site of operation: 
End roller on straight conveyor section

Roller ECO END Roller friction

 
 
Name:
END-Roller, fixed driven
Manufacturer Item No.:
68871
Feature:
Black retaining ring and no spring
Site of operation:
End roller in the area of a corner, diverter or junction

Roller ECO END Roller friction

 
 
Name:
Roller, friction
Manufacturer Item No.:
68874
Feature:
Spring with silver, zinced washer
Site of operation:
In general Roller Conveyor System

Roller ECO Roller friction

 
 
Name:
Roller, fixed-driven
Manufacturer Item No.:
68873
Feature:
Silver zinced retaining ring and no spring
Site of operation:
In coner and divert areas

Roller ECO Roller friction

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