2035 TRACK, PART TR-471 AND PART TR-804

Two separate tracks are offered:
#2035 track, part TR-471 is available in 10'0" lengths only and formed from 3/16" pickled and oiled steel sheet with tan paint finish.

Capacity:
Maximum of 130# per foot with supports of 10'0" on centers.

Section Modules: .958
#2035 track, part TR-804 is available in 10'0" lengths only and formed from 11 Ga. pickled and oiled sheet steel with tan paint finish.

Capacity:
Maximum of 75# per foot with supports 10'0" on centers.

Section Modules: .571

The inside dimensions of the #TR-804 track are identical to those of the #TR-471 track.

Either track may be used in the inverted position with the slot at the top. In "Clean Room" applications this arrangement is particularly desirable because it prevents and soil from dropping from the track to the product. The non-standard inverted components are not shown in the Zig-Zag price list.

2035 WELDING JIGS, PART TR-155

the straight track and curves in most all systems are joined at erection by welding the joints. the welding jig, which is installed inside the track astride the joint, serves two purposes. It aligns the two ends when adjusted and the brass jig facing, at either side, prevents the weld flash from extending past the inner track walls. Without the jig, the weld flashes would cause a track obstruction which would be very difficult and costly to remove. While the device may be reused a number of times, repeated use does erode the brass facings. Therefore, it is recommended that at least the welding jigs are supplied with each system of 500 feet or less.

The jig is installed in the open end of the track and moved along to each new joint to be welded. It may be removed only at the drive unit or take-up. However, it is often taken out of the track at intermediate points by cutting off the adjusting bolt head and burning a hole in the top of the track.

2035 EXPANSION SLEEVE, PART TU-1114

This device is intended for use in the 2035 track in areas where temperature extremes are encountered and where no provision is made to accommodate expansion and contraction. Some ovens have an expansion joint at the mid-point. In such installations, an expansion sleeve should be installed in each conveyor track in line with the oven expansion joint. Uni-construction ovens do not have an expansion joint. Therefore, the expansion sleeves are not necessary. However, good conveyor practice dictates that the track in the oven be suspended from BR-1912 brackets, which will allow for some track movement throughout the temperature range.

2035 HORIZONTAL AND VERTICAL TRACK CURVES

All track curves are made of 3/16" H.R. pickled and oiled sheet steel. These do match up with the #TR-804, 11 Ga. straight track since all inside track dimensions are identical.

All changes in direction of the track, either horizontal or vertical, must be made with a curved section. While most stock curves are made in 45° degree and 90° radii, any degree turn may be accomplished by field cutting and /or welding together of stock curves.

there are two principle considerations governing the selection of curves; Product clearance and chain pull of the system (either 400# or 600#).

Relative to product clearance, it is often necessary to use curves with radii larger than 2'0" to provide close product centers on the straight conveyor while still having clearance at the horizontal and vertical curves. Curve layouts shown in "Step #3" will illustrate this point.

The chain pull of a given system will determine whether heat treated or untreated curves are required. The following chart is intended to provide a guide to the proper choice:

600# SYSTEMS

As indicated in the charts above, all curves for 400# chain pull systems are not heat treated.

Heat treated curves are required in all 600# systems where the horizontal or vertical curve radii is 2'0" to 3'0". Curves 3'0" radii and larger need not be heat treated.

Hardened curves are necessary in the 2'0" to 3'0" radii range because of the load imposed on the track by the conveyor chain wheels at 600# of chain pull. In a straight section of track, the wheel load is equal to only the sum of chain link, pendant, hook and product weights. When the track is bent or curved, the chain wheels have an additional radial load at the curved section as a result of the chain tension. At 400# of tension and 2'0" R., the wheel load resulting from tension is only 100#. At 600# of tension the wheel load is 150#. This diminishes in direct proportion to the increase in the curve radius as follows:

• 600# chain tension and 2'0" R. wheel loading = 150#
  
• 600# chain tension and 2'3" R. wheel loading = 133#
  
• 600# chain tension and 2'6" R. wheel loading = 120#
  
• 600# chain tension and 3'0" R. wheel loading = 100#
  

As evident, the limiting factor is the track, rather than the chain wheels. Therefore, if the wheel loading, as a result of chain tension, exceeds 100#, hardened curves must be used. If the 100# loading is exceeded with un-heat-treated curves, failure will occur as a result of peening of the track wear surface. the peening action removes metal in the form of flakes or slivers until the metal is too thin to resist the wheel load. This is most apparent at the track lips of the top vertical curves. With an overloaded condition, the lips will deform or roll downward until the chain finally emerges from the track.

The minimum radius for any track curve is 2'0". The limitation is imposed of wheel loading and clearance of the vertical chain wheels at the inside wall of the horizontal curves. At 2'0" radius, the wheel clear, but at 1'6" radius the wheel faces bear on the track wall to increase the friction and drastically elevate the chain pull.

If it is necessary to use less than a 2'0" radius horizontal curve, as required in many oven applications, 24", 30" and 36" diameter traction wheel turns are available from stock. The traction wheel carries the chain around the curve as opposed to the chain wheels rolling around a track curve. Consequently, there is no peening action.

Bottom vertical traction wheel turns of 24", 30" and 36" diameter are also available on special order. However, top vertical traction wheel turns are not adaptable since the wheel face would interfere with the chain pendants, carriers and products.

All 600# curves are identified by a yellow label and letter "H" stampled on one end. The 400# curves have red labels.

2035 TAKE-UP FITTINGS

the take-up fittings are so designed because the unit includes only the two take-up sleeve assemblies, two support track sections, two hangers and two brackets. The curves, in which the radii may vary greatly, are not included.

One take-up is required for each system at a 180 degree track turn. The take-up sleeves are always installed parallel and usually 4'-0" apart on the centers. However, wider take-ups may be used to suit job conditions. If the take-up sleeves are to be spaced more than 14'-0" apart, additional support tracks and hangers must be provided.

The primary purpose of the take-up is to provide an easy method of keeping chain slack at a minimum. The chain develops slack or looseness as a result of normal wear in the various joints. This condition is first apparent at the "down stream" end of the drive unit or at the bottom of the first decline beyond the drive. The 18" adjustment in the take-up sleeves permits a number of movements before it is fully extended, and approximately 36" of chain can be removed from the system.

Two types of take-ups are offered. The screw type is preferred where the conveyor is not exposed to any appreciable variation in operating temperatures and in those cases where a track decline is located just "down stream" from the drive unit, it is necessary to prevent loose chain from accumulating at the outgoing end of the drive. The chain telescopes as it becomes slack, thereby moving the conveyor chain back into the Caterpillar drive chain. This, in turn, prevents the Caterpillar dogs from releasing the chain links easily. Considerable noise is created, and the drive will eventually jam.

Automatic type take-ups are advisable where operating temperatures are extreme. A good example is an oven. At 450° F., an oven chain length of 300'0" would expand or grow about 13". Therefore if all slack is removed from the chain at 70° F., it would be too loose when the oven reached 450° F. If a screw take-up is used and adjusted when the oven is a 450° F., the chain would then be under abnormal tension as the oven cooled to 70° F. Contraction would shorten the chain length to cause damage as a result of abnormal tension. The automatic type take-up will accommodate the variation and also maintain a constant chain tension.

In a level or monoplane system, the chain will gather or accumulate at the outgoing end of the drive, unless an automatic take-up is used.

Automatic take-ups are available in either spring or air cylinder types. Either will function properly. The air cylinder take-up, while more expensive, is capable of maintaining a constant chain tension as opposed to the spring unit which decreases tension as the springs are extended. Automatic take-ups are available only as fully framed units, not as "fittings."

2035 CONVEYOR CHAIN

CH-1974 Chain is all steel construction, natural finish, 600# chain pull capacity, 450° F., maximum operating temperature, ball bearing vertical and lateral wheels and a maximum load capacity of 75# @ 6" centers.

The chain is the major iten in a system, and every effort must be made to guard against those elements which are harmful.

A. The 450° F. (232° C.) operating temperature is maximum. If this is exceeded, hardness is reduced in certain critical parts, and chain life is greatly reduced.

B. Exceeding the recommended chain pull accelerates chain wear and is injurious to chain wheel bearings, track curves and drive unit.

C. Exposure to acidic solutions, corrosive vapors and liquids removes lubrications, corrodes bearings, pin joints, etc., to effectively shorten the useful life of the chain.

D. Abrasive laden air, such as in foundry applications and sand blast installations, are particularly injurious.

E. Vapor degreasers are often designed to allow the vapor level to extend above the conveyors. The chain is then completely stripped of lubricant of each complete circuit. An automatic mist spray oiler can be installed just "down stream" from the degreaser, but it is difficult to apply a sufficient amount of oil in just one pass. Rapid wear and short chain life is the result of inadequate lubrication.

Most of the above problems may be overcome by installing a "Protective system." However, if in doubt, consult the factory.

All conveyor chain is sold in 10'0" coils only. Each coil is coated with a preservative prior to placing in individual cartons.

2035 CHAIN LUBRICATORS

Proper lubrication greatly extends the useful life of the conveyor chain. Consequently, the best lubricator available is recommended.

The OPCO Model OP-41 chain and wheel oiler shown in the price list has been a reliable system for chain lubrication. It is intended to dispense oil of a viscosity similar to S.A.E. #20, and requires compressed air and electrical service. The lubrication should be suited to the operating conditions at the job site.

As indicated in the section covering conveyor chain, lubrication is one of the most important considerations insofar as conveyor chain life is concerned.

2035 ELECTRO-BRUSH OILERS

The #LU-669-A (110V.), #LU-670-A (230 V.) and #LU-671-A (460 V.) oilers are self contained. The oil flow is by gravity. The solenoid oil valve, which may be tied into the motor starting circuit, is opened when the conveyor starts and closed when it stops. There is an adjustment to regulate the oil flow. The brush type applicator depends on capillary action to flow the lubricant over all chain parts. In many situations, this lubrication is adequate, provided that some oil drainage is not objectionable. While the oiler operates only when the conveyor is running or when a timer permits it to do so, the lubricant will continue to bleed out of the brush for a period of time. This situation could be corrected by interrupting the oil flow some time prior to stopping the conveyor.

2LU-664-A BRUSH OILERS

This device is much the same as the Electro-Brush lubricators except that the oil flow is controlled by an "on-off" toggle at the top of the reservoir. It must be manually turned on and off. In certain applications it is adequate, providing that the user is careful to operate it often enough to thoroughly lubricate the chain.

LUBRICANTS

The choice of lubricant is governed partly by the applications. Therefore, the user is obligated to consult his supplier for a proper oil, based on the conditions to be encountered. In seeking this recommendation, attention must be given to temperature and the general operating environment. Ordinary petroleum derivatives leave a carbon residue when subjected to high temperatures. This is very harmful to chain wheel bearings. A high-temp synthetic type lubricant is suggested. In situations where the conveyor is exposed to high humidity, the oil should also contain a residue-free rust inhibitor. Moreover, the ideal oil in all circumstances should have a penetrate to carry the lubricant to all chain parts. The latter is especially beneficial when used with brush type lubricators.

If Molybdenum Disulfide based oils are used, the supplier must provide assurance that they "Moly" particles will stay in suspension and not settle out to clog tubes, brushes, orifices, etc.

A SAE #10 to #15 weight oil is best suited to all brush lubricators.

LUBRICATOR LOCATION

For ease of maintenance, the oiler should be located at the lowest track elevation. If drainage is objectionable, the oiler may then be placed in the return line or in an unloaded section of the conveyor.

2035 DRIVE UNITS

A wide variety of drive units is offered from factory stock to accommodate almost any system. Selection of the proper unit is relatively simple when the chain pull, conveyor speed and speed variation, if any, is known.

Variable conveyor speed is often times a requirement in systems involving washers, paint booth, dip tanks and ovens. In certain other installations, a fixed or constant speed is acceptable. To assist in the selection of the proper unit, the following stock drives are listed. All have 600# chain pull capacity.

STOCK DRIVES

DR-1371, Drive unit, constant speed of 16 F.P.M. when used with 230/460 volt - 60 Hz. - 3 phase current.

DR-1372, Drive unit, constant speed of 45 F.P.M. when used with 230/460 volt - 60 Hz. - 3 phase current.

Multiple drive units must be used when conveyor chain pulls exceeds 600 pounds. They must be located from chain pull calculations as shown later in this manual.

Special drives for higher or lower speeds may be provided. Consult factory for each specific application.

The general speed formula for all drive units is:

*The 1.5 factor relates to the distance traveled for each revolution of the caterpillar drive sprockets which have 12 teeth x 1 1/2" pitch = 18" or 1.5 feet.

The standard A.C. inverter controls produce motor speeds from zero to 1750 R.P.M. with infinite adjustment. Motors are always started "softly" on a predetermined ramp from zero speed to "set" speed, but only 5 to 1 adjustment is available for constant operation. This means that motor speeds of 1750 R.P.M. to 350 R.P.M. are the only range usable for continuous duty. Do not attempt to operate drives below the lowest list speeds.

ELECTRICAL CHARACTERISTICS

All stock drive motors are dual wound for 230/460 volts, 60 hertz 3 phase. Motors with other electrical characteristics are available on special order. Please consult factory for price additions, if any, and delivery lead time.

DRIVE ADDITIONS

Various additions or modifications are available on special order. If the desired information is not in the price list, please consult the factory.

The price sheet lists electric clutch brakes and integral motor brakes. In situations where a conveyor is started and stopped three times a minutes, or less, an integral motor brake is acceptable. If the conveyor is to be started and stopped four times per minute or more often, an electric clutch and brake is necessary to prevent overheating of the motor. The electric clutch brake allows the motor to run continuously to eliminate the temperature problem. This applies to "indexing" applications where the motor is started "across the line" without variable speed controls.

DR-1373 SKELETON DRIVE UNIT

The P1373 skeleton drive unit is common to all drive units and provides all components except motor, speed reducer and chain drive from speed reducer to caterpillar shaft.

DRIVE SAFETY FEATURES

Caterpillar and drive chain guards are standard on complete drive units.

OVERLOAD PROTECTION

A torque limited of proper capacity is mounted on the speed reducer output shaft. In the event of a conveyor jam, the drive R sprocket, held between two friction discs, slips to protect the conveyor chain and driving mechanism.

REVERSING DRIVES

The drive may be reversed providing that the Caterpillar chain is free of slack and also that provisions have been made to ensure that the conveyor chain will not accumulate at either end of the drive. The latter condition can be met by elevating the drive about 18" and having a 5° track slope down and away at each end of the drive.

2035 A.C. INVERTER CONTROLS

The A.C. Inverter controls furnished with variable speed drive units are solid state, variable frequency, motor speed controls using solid state circuitry to convey 50 or 60 Hertz plant power to variable frequency power. A motor with a 60 Hertz speed of 1800 may be varied in speed in a 5 to 1 range (1800 to 360 R.P.M.) with constant torque.

These are industrial quality controls that include "soft" starting and stopping and electronic overload protection in addition to their variable speed function.

When two or more drive units are used on one conveyor, they must share the load to coordinate their operation. This is accomplished through the A.C. inverter control. The conveyor drive units must be located to have theoretical loading within 10% of one another. Then the controller can provide the load sharing characteristics required.

A complete description of the load sharing function is available from the factory upon request. It also describes methods for compensation for "out of balance" conditions.

CHAIN LOAD PENDANTS

The price list and the Zig-Zig catalog shows an assortment of pendants. It will be noted that pertinent dimensions and capacities are given.

A single 75# capacity pendant may be attached to the chain on 6" centers. The double suspension 150# capacity pendants are attached at two points, 6" apart. This then allows loads of 150# on 12" centers.

Pendant spacing is usually dependant on load clearance at the horizontal and vertical curves. This is discussed in "Step 3, System Design" section.