Monogram-Martinsville, VA

X-RAY INFEED CONVEYOR

04/07/2020

1389 Cormorant Ave - PO Box 889

Detroit Lakes, MN 56502
Phone: 218-844-4437
Fax: 218-844-0358
  

It is the responsibility of the purchaser of this equipment to train operating

personnel in the proper manner of operation. It is furthermore understood that Friesen’s
Incorporated assumes no responsibility for injury, disability, or death resulting from
improper operation of, removal of, or bypassing of any electrical or mechanical safety
devices incorporated in the design and manufacturing of this equipment.

Operator and maintenance personnel shall read and understand all these precautions,
warnings and dangers completely before operating, setting up, running, or performing
maintenance on the equipment. Fatal injury may result if the previous instructions are
not completely followed!

Whenever you are calling Friesen’s Inc. about your equipment, PLEASE
have the Serial Number available. The Serial Number is located on each
piece of Friesen’s equipment. All our records are filed under that Serial
Number. This will help us serve you as quickly and efficiently as possible.

 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
  

SAFETY WARNING
Please follow these safety rules when operating equipment

1. KEEP HANDS AWAY from the moving parts at all times

2. DO NOT operate the machine until you have complied with all local
safety regulations

3. DO NOT operate the machine in a careless manner

4. DO NOT jog the machine when fully loaded

5. DO NOT overload the machine

6. DO NOT reach into machine while in operation

7. DO NOT reach into the machine when not in operation, unless the
power has been disconnected and locked out

8. NEVER bypass or route around safety limit switches.

9. DO NOT operate the machine until guards and covers are in place

10. DO NOT use for any purpose other than its intended use

11. DO NOT under any circumstances enter this machine

 

 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
  

Friesen’s Incorporated conveyors have been designed to meet a variety of applications

in the food processing industry. Every effort is made to design these systems to be as
easily maintained as possible in its application.

In the food processing industry an area of utmost importance is that of sanitation.

Keeping that process straightforward and effective is factored into the design of this
equipment. In each system we design and build there are a variety of options and
additions that can be on each of these products. It is important that the plant sanitation
team is aware of proper safety and cleaning procedures for the conveyors.

General Conveyor Sanitation Procedure and Guidelines

1. Follow all Lock Out – Tag Out procedures as established in plant operation
policies.
2. Wear all appropriate personal protection equipment.
3. Use chemical agents appropriate for your operations and chemically compatible
with any of the belting or materials in your conveyor.
4. Relieve tension on conveyor belt; remove guards, scrapers, side walls or any
other devices that would interfere with the cleaning process.
5. If equipped, raise hoppers away from belts where appropriate and lock into
cleaning position.
6. If equipped, raise belt lifters into place and lock into cleaning position.
7. Thoroughly clean and rinse conveyor starting at highest point and working
downward.
WARNING:
During the sanitation process the belt can NOT be run. Running the conveyor
with the take up open and belt lifts up will cause irreversible damage to the
belting.

8. All guide strips must be attached firmly back into place. These may come loose
in the cleaning process.
9. Return all guards, scrapers, sidewalls, belt lifters, hoppers, etc. (where
applicable) to the operating position. Conveyor should NEVER be operated
WITHOUT ALL safety guarding installed and functioning correctly.
10. Return tension to the belts.
11. Avoid leaving any cleaning solutions on the belt.
12. Belts MUST be down into the carry ways before operating conveyor.
13. Hold-downs on radius belts must be firmly engaged into hold-down slot.
 

 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
  

General Conveyor Start-Up Procedure and Guidelines

 

Prior to operations start up an inspection should be made to ensure that tools and
personnel are clear of the belt and the belt lifts are in the down position. The take ups, if
equipped, need to be closed and ensure that the belting is engaged into the drive. All
conveyors have motor disconnects mounted in close proximity to the drive motor and
gearbox. Ensure that these are in the on position. Ensure that the E-Stops are pulled
out and in the run position. Once the pre-op checks have been made start the
conveyors and visually ensure the belts are tracking and engaged in the drives. The
conveyor is now ready for the daily production run.

 
 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
  

WARRANTY / LIMITATION OF LIABILITY POLICY

 

Friesen’s Inc. Custom Manufactured Specialty Equipment is warranted against defective

materials and workmanship for a period of one year or 2,080 hours from the date of acceptance.
Commercial components used in the manufactured equipment are subject to the original
manufacturer’s warranty policies and agreements.

The seller’s warranty is limited to repair or replacement of defective product(s) manufactured at

Friesen’s, Inc., for which Friesen’s, Inc. will issue written authorization for return of product,
freight prepaid. Friesen’s, Inc. obligation to repair or replace defective products hereunder shall
arise only if:

A. Friesen’s, Inc. technician(s) determine by inspection that such product(s) are defective in
material or workmanship.
B. Friesen’s, Inc. has received written notification from purchaser of the defect within the
warranty period.
C. Purchaser has notified Friesen’s, Inc. in writing of the defect immediately upon
discovery thereof, warranty further shall not apply to any product which has been
subject to misuse, improper operating conditions, faulty installations, negligence or
accidents. All products repaired or replaced under warranty will carry the remainder of
the warranty left on such product(s). All various catalog components used in the
manufacturing will be subject to the components manufacturing warranty(s).

Except as otherwise agreed, Friesen’s, Inc. shall not be liable for special incidental or
consequential damages arising out of the use of, or inability to use, any product sold by
Friesen’s, Inc. Including without limitation, damage, or loss of other property or equipment, loss
of profit or revenue, or claims of customer(s) for any such damage or loss.

 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
  

 
Preventative Maintenance Schedule
 

Schedule
Component Action Weekly Monthly Quarterly
Check noise
Motor Check temperature
Check mounting bolts
Check noise
Gear
Check temperature
Reducer
Check oil level
Check noise
Bearings Check mounting bolts
Lubricate
Check for wear
Belt Check for damage
Check tension
Belt
Sprockets Check for wear
Lubricate
Chain Drive Check for noise
Check for wear
Check for noise
Belt Drive Check for wear
Check tension
Check for wear
V-Belt Drive Check sheave alignment
Check tension
Check for damage
Structural
Check for loose bolts
Check oil level
Power Unit
**Change filter Every 100 Hours of Use
Note: All components may not apply to all conveyors
** Or when indicator shows it is required
 

 
 
Phone: (218) 844‐4437    PO Box 889 
Toll Free: (800) 955‐6058    1389 Cormorant Avenue 
Fax: (218) 844‐0358    Detroit Lakes, MN 56502 
 8 7 6 5 4 3 2 1
SPARE PART NUMBER
ITEM # SPARE (Serial # - Part #) DESCRIPTION QTY.
1 Recommended =90372 - 000883 Sterling Motor 1/2 HP 1
2 Recommended =90372 - 001851 Winsmith S17 5:1 1
1.000" Bore - 205 Series - SS 3-Bolt Flange
3 Recommended =90372 - 004337 2
Bracket Bearing - L3-type Seal - Stand Off
1100 Series 3.1" (16T) Sprocket 1.5" SQR F
4 Recommended =90372 - 006435 3
F 7
58 Bore EZ Track
5 Recommended =90372 - 026827 RFID Safety Actuator 2
48
6 Recommended =90372 - 026828 RFID Safety Sensor 2
7 Recommended =90372 - 124050 Belt: 1100 Series Radius FlushGrid 10" Wide 1
38 35 Fabricated =90372 - 024722 Idler Shaft 11-10-3-1 2
36 Fabricated =90372 - 081351 Driveshaft S17-11-10-0.190TG-205 1
5
37 Fabricated =90372 - 081369 Shaft 11-10-3-0.75 2
6 38 Fabricated =90372 - 115365 Air Manifold 1
39 =90372 - 000055 STD Hex Shoulder Bolt 1
1
47
40 =90372 - 000061 Mennekes Disconnect 1
E
41 =90372 - 000649 Threaded Rod 1"-8 x 9" Long 4 E
2 Shaft Cap 1/2" ID 1.5" OD 0.1345" Thk -
42 =90372 - 001408 1
Gearbox
Lock Pin Hex Bolt - 0.375" Hex X 5/16"-18
43 =90372 - 002418 1
42 Thread
3 44 =90372 - 005035 Pin - 0.5" X 3" 1
Shoulder Bolt 18-8 SS 1/2" Diameter x 5/16"
45 =90372 - 029004 2
Long Shoulder, 3/8"-16 Thread
46 46 =90372 - 041748 Pneumatic Enclosure: 24-2S-.375-V 1
47 =90372 - 049294 Tote 1
48 =90372 - 078932 SS Air Hose Coupling 1
49 =90372 - 081374 Torque Arm 1
D
50 =90372 - 086103 Snub Shoe 1 D
51 =90372 - 124040 Carryway Bed 2 1
52 =90372 - 124054 Acetal Shoe 3
45
53 =90372 - 125794 Cognex Camera 1
54 =90372 - 125798 Carryway Bed 1
51 40 55 =90372 - 127731 Return Shoe 2
56 =90372 - 127732 Return Shoe 1
50 41
57 =90372 - 127827 UHMW Bed 1
58 =90372 - 127878 Hood Weldment Piece 1

37

C C
5

36 6

44
4 43
52
54
39

49 35
55
57

56

55
53 B
B

A
A
Friesen’s equipment is used by a variety of different industries
each requiring varying levels of sanitation. Even though
Friesen’s equipment is designed to be readily sanitized, it is
the client’s responsibility to determine to what extent of Spare part numbers are made up of a serial
DRAWN BY

NV *Full Assembly - 90372 - X-Ray

disassembly the equipment must be taken to ensure proper Infeed Conveyor
number followed by a part number.
DATE
sanitation. All parts, guarding and safeties removed or altered 4/7/2020
124039
DWG. REV
NO.
during maintenance or the sanitation process must be returned
to their original locations or conditions prior to operating the Parts can be ordered by using the complete SCALE
1:6
1

91673-Spare Parts
Sheet:

equipment. spare part number or by using the last six digits. SHEET 3 OF 3

SIZE D
8 7 6 5 4 3 2 1
 0
RESET
AM

MM
 Installation Instructions
SensaGuard™ Rectangular Flat Pack - 440N-Z21SS2*
IMPORTANT: SAVE THESE INSTRUCTIONS FOR FUTURE USE.

ENGLISH: This instruction sheet is available in multiple languages at www.rockwellautomation.com/literature. Select

publication language and type "SensaGuard" in the search field.
Operating Characteristics
GERMAN: Dieses Instruktionsblatt kann in mehreren Sprachen unter www.rockwellautomation.com/literature gelesen
werden. Bitte Ihre Sprache anwählen und "SensaGuard" im Suchfeld eintippen. Sensing Distance
FRENCH: Ces instructions sont disponibles dans différentes langues à l'adresse suivante
www.rockwellautomation.com/literature. Sélectionner la langue puis taper “SensaGuard” dans le champ de
recherche. Assured Make 15 mm
ITALIAN: La presente scheda d'istruzione è disponibile in varie lingue sul sito www.rockwellautomation.com/literature.
Selezionare la lingua desiderata e digitare "SensaGuard" nel campo di ricerca. Assured OFF 35 mm
SPANISH: Puede encontrar esta hoja de instrucciones en varios idiomas en www.rockwellautomation.com/literature.
Seleccione el idioma de publicación y escriba "SensaGuard" en el campo de búsqueda.
PORTUGUESE: Esta folha de instruções está disponível em várias línguas em www.rockwellautomation.com/literature. Typical Misalignment (±7 mm in both axes)
Seleccione a língua de publicação e entre com "SensaGuard" no espaço de busca.
POLISH: Ta kartka z instrukcjami jest dostepna w wielu jezykach na stronie: www.rockwellautomation.com/literature Repeat Accuracy 10% of sensing range
Wybierz jezyk publikacji i wpisz w polu poszukiwania "SensaGuard".

Max. output current (all outputs) 200 mA

Installation Instructions Input Current 50 mA (no load supply current)
Installation must be in accordance with the following steps and
Operational Current, Min. ≥1 mA DC
stated specifications and should be carried out by suitable
competent personnel. The unit is not to be used as a mechanical Off-state Current <0.5 mA DC
stop. Guard stops and guides must be fitted. Adherence to the
recommended maintenance instructions forms part of the Unlimited. See Unit Response Time
Max. no. of switches, connected in series
warranty. section on page 5.

This device is intended to be part of the safety related control 24V DC +10%/-15%
Operating Voltage
system of a machine. Before installation, a risk assessment should Class 2 SELV power supply
be performed to determine whether the specifications of this Frequency of operating cycle 1 Hz
device are suitable for all foreseeable operational and
environmental characteristics of the machine to which it is to be 54 ms first switch,
Response Time (Off)
fitted. Refer to Technical Specifications below for certification 18 ms for each additional switch
information and ratings. Case Material Valox® DR 48
The presence of spare actuators compromise the Actuator Material Valox® DR 48
integrity of the safety systems. Personal injury or
ATTENTION death, property damage or economic loss can
result. Appropriate management controls, Outputs
working procedures and alternative protective
measures should be introduced to control their (guard door closed, actuator in place)
use and availability.
Outputs Description Status

Safety 2 x PNP, 0.2 A max. ON (+24V DC)

WARNING Do not defeat, tamper, remove or bypass this unit.
Severe injury to personnel could result. The sensor Auxiliary 1 x PNP, 0.2 A max. OFF (0V DC)
MUST be connected to a Class 2 SELV 24V DC,
+10%/-15% power supply.
Environmental

Technical Specifications Operating Temperature [C (F)] -10…+55 ° (14…131 °)

Operating Humidity 5…95% relative
Type 4 Interlocking Device per ISO 14119 (Low Coding)
Safety Classification PLe, Cat 4 per ISO 13849-1 Washdown Rating NEMA 3, 4X, 12, 13, IP69k
SIL CL3 per IEC 62061 and IEC 61508 IEC 68-2-27 30 g, 11 ms/IEC 68-2-6
Shock & Vibration
CSA 22.2 No. 14, ISO 13849-1, ISO 14119, IEC 60947-5-3, 10…55 Hz
Standards
IEC 61508, IEC 62061, and UL508 IEC 61000-4-3
Radio Frequency
Certifications TÜV, CE Marked for all applicable directives, cULus IEC 61000-4-6

Functional Safety Data PFHD: 1.12 - 10-9

Protection
Short-circuit Incorporated
Current Limitation Incorporated
Overload Incorporated
False Pulse Incorporated
Transient Noise Incorporated
Reverse Polarity Incorporated
Overvoltage Incorporated
Thermal Shutdown/Restart Incorporated

Electrical Life 10 x 106

Dimensions [mm (in.)]

18.54
(0.73)
10.67
(0.42)
24.99 20.65 18.54 24.99 20.65 4.57
(0.984) (0.813) (0.73) (0.984) (0.813) (0.18)

88.14 68.31 77.98 88.14 57.96 82.55

(3.47) (2.689) (3.07) (3.47) (2.282) (3.25)
72.9 62.53
(2.87) (2.462)
77.98
(3.07)

10.66 4.57 4.57

(0.42) Ø5.08 (0.18) Ø5.08 (0.18)
(Ø0.2) (Ø0.2)
7.11
(0.28)
6.78
(0.267) 4.57
(0.18)
4.57
(0.18)

13.41
(0.528)

9.96 QD
(0.392) CONNECTOR
VERSION

M12 x 1

¯ 9.7
(¯ 0.38)

Mode of Operation Mounting Information

Use non-removable screws, bolts, or nuts to mount the switch and
Status indicators: actuator. Do not over torque the mounting hardware.
• “Status/Diag” LED illuminates green: Door/guard closed, Position the switch and actuator so they are aligned with each
safety outputs active. other.
• “Status/Diag” LED illuminates red: Door/guard open,
safety outputs off. Mount the switch and actuator to removable guard, door, or gate.
• “Status/Diag” LED flashes red: Unit failure. See Diagnostic Keep the switch and actuator within the sensing range shown in
section on page 4. the sensing/misalignment curve.
• “Status/Diag” LED flashes green: Safety inputs off.
• “Status/Diag” LED flashes amber: Sensor is approaching Nut Torque Specification
max. sensing distance. (-N and -N9 models only) Switch/Actuator: 2.26 N•m (20 in•lb)

2
Minimum Distance Between Sensors Sensor Actuator
50 50

40 40

30 30

Misalignment (mm)
23
20 20
ASSURED
10 SENSING 10
DISTANCE

200.00 mm 0 0

10 10

20 20
23
30 30

40 40

50 50

10

15

20

25

30

35
0

5
Assured Make: 15 mm
Sensing Distance** (mm)
Misalignment Curve
Assured OFF: 35 mm

** when the actuator approaches the sensor in the

Sensor Actuator x-direction and is misaligned in the z-direction.

SIDE
LOBES
z
Misalignment (mm)

ASSURED
SENSING
DIS TANC E
x

Sensor Actuator
SIDE
LOBES
Wiring Diagram
10

15

20

25

30

35
0

Assured Make: 15 mm

8-Pin Unit
Assured OFF: 35 mm
Sensing Distance* (mm)
* when the actuator approaches the sensor in the x-direction or
from above (z-direction) and is misaligned in the y-direction
Pin Number Wire Color Signal
Actuator
1 White Aux. Outputs
2 Brown +24V
3 Green NA
z
4 Yellow OSSD 2, +24V Input
5 Grey OSSD 1
x y 6 Pink OSSD 2
Sensor Actuator 7 Blue 0V
Allow a minimum spacing of 9 mm (0.35 in.) if the 8 Red OSSD 1, +24V Input
actuator and sensor faces approach laterally (from
the y-direction). This will prevent false triggering Recommended mating cable, 2 m (6.5 ft)—889D-F8AB-2.
IMPORTANT due to the side lobe areas. Replace the 2 with 5 (5 m) or 10 (10 m) for standard cable lengths.
To ensure proper functioning of margin indication
(non-safety), z-direction approach is not
recommended for -N and -N9 models. Brown
Green
White

2 1
3 8 7 Blue
4 6
Red 5
Pink
Yellow
Grey

3
5-Pin Unit

Pin Number Signal

1 +24V
2 OSSD 1
3 0V
4 OSSD 2
5 Aux.
Recommended cordset, 2m (6.5 ft) - 889D-F5AC-2. Replace the
2 with 5 (5 m) or 10 (10 m) for standard cable lengths.
Note: If the user does not require the Auxiliary signal, a 4-pin
cordset (889D-F4AC-2) can be used.
Recommended patchcord for use with ArmorBlock® Guard
Safety I/O, 2 m (6.5 ft) - 889D-F4ACDM-2. Replace the 2 with
0M3 (0.3 m), 1 (1 m), 5 (5 m), or 10 (10 m) for standard cable
lengths.
Note: Do not use a 5-pin patchcord with the ArmorBlock.

2
3 5 1
4

Diagnostic
Unit Indicators (per IEC 60073)

State Status Troubleshooting

Off Not Powered NA

Red Not Safe, OSSD not active NA
Green Safe, OSSD active NA
Power up test or OSSD Check 24V DC or OSSD
Device Green Flash
inputs not valid inputs (yellow and red wire)
Output
LED Recoverable fault —check
1 Hz Flash Recoverable Fault
OSSD outputs are not
Red Flash 4 Hz Flash Non-recoverable
shorted to GND, 24V DC or
Fault
each other. Cycle power.
Amber Flash Sensor is reaching max.
1 Hz Flash margin indicator
(-N & -N9 sensing distance; realign
Safe, OSSD active
models only) sensor with actuator

IMPORTANT
Refer to Technical Specifications (page 1) for
certification information and ratings.

4
Troubleshooting
Series Circuit
RTN
24VDC
Power
Supply+24
Actuator 1 Actuator 2 Actuator 3 Actuator 4 Actuator 5
1606
-XL120D

Switch 1 Switch 2 Switch 3 Switch 4 Switch 5

Blu Blu Blu Blu Blu

te

te

te

te
e

hi
e

hi
e

hi
e

hi
e

W
White

Brown

Brown

Brown

Brown

Brown
Gray

Gray

Gray

Gray

Gray
Pink

Red

Red

Red

Red
Red

Pink

Pink

Pink

Pink
Yel

Yel

Yel

Yel
Yel

+24 V +24 V +0 V +0 V +0 V
+24 V +24 V +0 V +0 V +0 V

Actuator 1 is in sensing range. Actuator 2 is in sensing range. Actuator 4 is in sensing range. Actuator 5 is in sensing range. OSSD’s are OFF
Actuator 3 is in sensing range.
Recoverable fault Switch Switch Switch Switch
Switch 4 is functioning properly
. 5 is functioning properl y .
1 is functioning properly 2 is functioning properly 3 has fault.
OSSDs are energize to 24 V OSSDs are energize to 24 V Series inputs are 0 V . Series inputs are 0 V .
See TableAbove—Red LED is flashing OSSDs are de-energized to 0V . OSSDs are de-energized to 0V.
Green LED is ON. Green LED is ON.
Green LED is Flashing to indicate Green LED is Flashing to indicate
Series inputs are not 24V. Series inputs are not 24V.

IMPORTANT
Refer to Technical Specifications (page 1) for
certification information and ratings.

Unit Response Time (does not include safety control system response time)
RT
24V DC
Power +24
Supply
A1 S11 S52 S12 13 23 33 41
1606
e
e

Pink
e
Red Pink
Blu
Blu

Blu
Actuator 1

Actuator 2

Actuator 3

Gray Yel Gray

Sensor 1

Sensor 2

Sensor 3

White White White MSR127TP

Red Pink Red
Yel Gray Yel
n

n
ow

ow

Brown
Br

Br

S21 S22 S34 A2 14 24 34 42

Initial Conditions: Actuator 1 is moved out of Sensor 2 drops the 24 volts Sensor 3 drops the 24 volts
OFF All actuators are in sensing sensing range. (red and yellow) from Sensor 1 (red and yellow) from Sensor 2
distance. OSSD outputs. OSSD outputs.
Green LED flashes. Green LED flashes.

0 ms 54 ms 72 ms 90 ms

Actuator 1 is out of sensing Actuator 1 is moved into sensing Sensor 2 OSSD inputs (red and yellow) Sensor 3 OSSD inputs (red and
ON range. range. transition to 24V DC from Sensor 1 yellow) transition to 24V DC from
Actuator 2 and 3 are in Sensor 1 OSSD outputs are OSSD outputs. Sensor 2 OSSD outputs.
sensing range. energized. Sensor 2 OSSD outputs are energized Sensor 3 OSSD outputs are
energized.

0 ms 360 ms 378 ms 396 ms

IMPORTANT
Refer to Technical Specifications (page 1) for
certification information and ratings.

5
Application Wiring Examples
+24V DC +24V DC

SensaGuard SensaGuard SensaGuard SensaGuard

Unit 1 Unit 1 Unit 2 Unit 3

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown
Blue
Gray
Pink
Yellow
Red
Brown
A1 S11 S52 S12 13 23 33 41 A1 S11 S52 S12 13 23 33 41
Reset Reset

MSR127RP MSR127RP

S21 S22 S34 A2 14 24 34 42 S21 S22 S34 A2 14 24 34 42

K1 K2 K1 K2

GND GND
MSR127RP with 1 sensor, monitored manual reset, driving 100S or 700S safety controllers. MSR127RP with 3 sensors in series, monitored manual reset, driving 100S or 700S safety controllers

+24V DC +24V DC

SensaGuard SensaGuard SensaGuard GuardShield SensaGuard

Unit 1 Unit 2 Unit 3 Unit 1

Blue
Gray
Pink
Yellow
Red
Brown
Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink

Brown

A1 S11 S52 S12 13 23 33 41

A1 S11 S52 S12 13 23 33 41 Reset
MSR127TP
MSR127RP
S21 S22 S34 A2 14 24 34 42
S21 S22 S34 A2 14 24 34 42

K1 K2
K1 K2 GND
GND MSR127RP with 1 sensor, automatic reset, driving 100S or 700S safety controllers
MSR127RP with 3 sensors and 1 440L light curtain in series, monitored manual reset, driving 100S or 700S safety relays.
Note: Light curtain must be last (farthest from MSR127).

+24V DC +24V DC

SensaGuard SensaGuard SensaGuard SensaGuard SensaGuard SensaGuard

Unit 1 Unit 2 Unit 3 Unit 1 Unit 2 Unit 3 GuardShield
Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink
Yellow
Red
Brown

Blue
Gray
Pink

Brown
A1 S11 S52 S12 13 23 33 41 A1 S11 13 41
S52 S12 23 33

MSR127TP MSR127TP
S21 S22 S34 A2 14 24 34 42
S21 S22 S34 A2 14 24 34 42

K1 K2 K1 K2
GND GND
MSR127TP with 3 sensors in series, automatic reset, driving 100S or 700S relays. MSR127TP with 3 sensors and 1 440L light curtain in series, automatic reset, driving 100S or 700S safety contactors.
Note: Light curtain must be last (farthest from MSR127)

IMPORTANT
Refer to Technical Specifications (page 1) for
certification information and ratings.

6
Application Wiring Examples
+24V DC +24V DC

Brown
Brown
SensaGuard SensaGuard

Yellow
Brown

Red
K1 K1

Green
White
Blue
889D-F4AC-* 889D-F8AB-*
K2 K2

Yellow
Brown

Red
Reset Reset

Green

White
White

White
889D-F5AC-*

Black

Black
889D-F8AB-*

Grey

Grey

Grey
Blue
Blue

Blue

Pink

Pink
SensaGuard SensaGuard

S12 S22 S32 S42 A1 13 23 S34 S12 S22 S32 S42 A1 13 23 S34
LOGIC 0 LOGIC 0
1 1
2 2
8 3 8 3
7 4 7 4
DI 6 5 DI 6 5
440R-D22R2 440R-D22R2
Gate S11 S21 L11 L12 A2 14 24 Y32 Gates S11 S21 L11 L12 A2 14 24 Y32
Open Open
K1 K2 K1 K2
24V Com 24V Com
Note: The Green wire is connected to the housing of the Stainless Steel
SensaGuard only; it has no connection for plastic SensaGuard.

24V DC 24V DC
Brown

Reset Reset

Blue Yellow
White Brown

Grey Red
Green
Grey

White
Blue

889D-F5AC-* 889D-F8AB-*
Black

Pink
SensaGuard Integrated Latch SensaGuard Integrated Latch

S12 S22 S34 A1 13 23 S12 S22 S34 A1 13 23

RESET 0 RESET 0
AM AM
SI MM SI MM
440R-S12R2 440R-S12R2
S11 S21 Y32 L11 A2 14 24 Gate S11 S21 Y32 L11 A2 14 24
Gate
Open Open
K1 K2 K1 K2
24V DC Com 24V DC Com

IMPORTANT
Refer to Technical Specifications (page 1) for
certification information and ratings.

7
List of Recommended Safety Control Interfaces
GSR DI, GSR DIS, GSR SI, CR30, MSR126, MSR127, MSR131, MSR138, MSR211, MSR221, MSR121, MSR320, SmartGuard™, 1791DS/ES
CompactBlock™ Guard Safety I/O, 1732DS/ES ArmorBlock Guard Safety I/O. Relay must have OSSD (light curtain) inputs.

Check the machine is

isolated and stopped
whenever the interlocked
guard door is open.
IMPORTANT: After
installation and
commissioning, the
actuator, switch and switch
lid fixing screws should be
coated with tamper evident
varnish or similar compound.

Maintenance
Monthly
Check the correct operation of the switching circuit. Also check for signs of abuse or tampering. Inspect the switch casing for damage.

Repair
If there is any malfunction or damage, no attempts at repair should be made. The unit should be replaced before machine operation is
allowed.

Declaration of Conformity
This is to declare that the products shown in this document conform with the Essential Health and Safety Requirements (EHSRs) of the
European Machinery Directive. These products also conform to EN 60947-5-3, EN ISO 14119, and have Third Party Approval.
For a comprehensive certificate please visit: www.ab.com/safety.

Allen-Bradley, CompactBlock, Rockwell Software, and SensaGuard are trademarks of Rockwell Automation, Inc.

Rockwell Automation maintains current product environmental information on its website at

http//www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page

Publication 440N-IN008B-EN-P — December 2014 — 10000979555 Ver 00 PN-243696

Supersedes Publication 440N-IN0008A-EN-P — May 2012 Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
 Conveyor Belting
Installation, Maintenance
& Troubleshooting Manual

Copyright ©2015 Intralox, Inc.

 TABLE OF CONTENTS

TABLE OF CONTENTS
TABLE OF CONTENTS .................3 Mini Rib
Nub Top™
EQUIPMENT INSTALLATION Perforated Flat Top
OVERVIEW.....................................7 Perforated Flat Top Round Hole
Overview ..................................................7 Roller Top
Shaft Installation ......................................7 Rounded Friction Top
Sprocket Installation .................................7 Tough Flat Top
Wearstrip Installation .............................10
SERIES 800-2 ..............................39
Belt Installation .......................................11
Open Hinge Cone Top™
Wide Belt Installation .............................13
Open Hinge Flat Top
Finger Transfer Plates Installation .........14
SeamFree™ Open Hinge Cone Top™
Dead Plate Installation ...........................15
SeamFree™ Open Hinge Flat Top
Abrasion Resistant Rod Installation .......17
SeamFree™ Open Hinge Nub Top™
STRAIGHT RUNNING SERIES 800-3 ..............................43
Flush Grid
SERIES 100-1...............................21
Flush Grid Nub Top™
Flush Grid
Raised Rib SERIES 800-4 ..............................45
Perforated Flat Top Round Hole Plus
SERIES 200-1...............................23
Raised Rib
Open Grid
Flush Grid SERIES 850-1 ..............................47
Open Hinge SeamFree™ Minimum Hinge Cone Top™
SeamFree™ Minimum Hinge Flat Top
SERIES 400-1...............................27
SeamFree™ Minimum Hinge NubTop
0.85 in Diameter Transverse Roller Top
Ball Belt SERIES 888-1 ..............................49
Flush Grid Medium Slot
Non Skid Medium Slot SSL
Raised Rib Large Slot SSL
Roller Top
SERIES 900-1 ..............................51
Transverse Roller Top™
Flat Top
SERIES 400-2...............................31 Flush Grid
Open Hinge Flush Grid with Insert Rollers
Flush Grid Nub Top™
SERIES 400-3...............................33
Intralox® Diamond Friction Top
0º, 30º, 45º, 60º & 90º Angled Roller™ Intralox® Flat Friction Top
SERIES 550-1...............................35 Mesh Top™
Tight Transfer Flat Top Mold to Width 29mm Square Friction Top
Mold to Width Flat Top
SERIES 800-1...............................37 Mold to Width Flush Grid
Cone Top™ Mold to Width Raised Rib
Flat Top Nub Top™
Mesh Top™

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 3

TABLE OF CONTENTS

ONEPIECE™ Live Transfer Flat Top Intralox® Flat Friction Top

ONEPIECE™ Live Transfer Flush Grid Mold to Width Flat Top
Open Grid Mold to Width Square Friction Top
Perforated Flat Top Mold to Width Oval Friction Top
Raised Rib ONEPIECE™ 9.3 in (236mm) Live Transfer
Square Friction Top Flat Top
ONEPIECE™ Live Transfer Flat Top
SERIES 900-2 .............................. 53
Oval Friction Top
Open Flush Grid Non Skid
SERIES 1000-1 ............................ 59 Roller Top™
Flat Friction Top Square Friction Top
Flat Top ProTrax™ with Tabs
Insert Roller SERIES 1500-1 ............................ 73
Mold to Width Flat Top Flush Grid
SERIES 1100-1 ............................ 61 Flush Grid with Contained Edge
38 & 46mm Wide SERIES 1600-1 ............................ 81
Cone Top™ Mesh Top™
Embedded Diamond Top
Mesh Nub Top™
Flush Grid Mini Rib
Flush Grid Friction Top Mold to Width Open Hinge Flat Top
Flush Grid Friction Top No Indent
Nub Top™
Flush Grid Mold to Width Open Hinge Flat Top
Flush Grid Nub Top™ Raised Open Grid
ONEPIECE™ Live Transfer Flush Grid
SERIES 1650-1 ............................ 83
SERIES 1100-2 ............................ 63
SeamFree™ Minimum Hinge Flat Top
Flat Top
Perforated Flat Top SERIES 1700-1 ............................ 85
Flush Grid
SERIES 1200-1 ............................ 65
Flush Grid Nub Top
Flat Top
Flush Grid SERIES 1700-2 ............................ 87
Non Skid Transverse Roller Top
Non Skid Raised Rib
SERIES 1800-1 ............................ 89
Raised Rib
Flat Top
SERIES 1400-1 ............................ 69 Mesh Top
3.25 in Mold to Width Flat Friction Top with
SERIES 1900-1 ............................ 91
Tabs
6 in Flat Top Mold to Width Self-Clearing Raised Rib
Edge SERIES 4400-1 ............................ 93
Embedded Diamond Top Transverse Roller Top
Flat Top
Flat Top Easy Release PLUS SERIES 4500-1 ............................ 95
Flat Top Easy Release Traceable Polypro- Dual Stacked Angled Roller™
pylene Flush Grid
Flush Grid Left/Right Roller Top

4 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TABLE OF CONTENTS

SERIES 4550-1.............................97 SERIES 2400-2 ..........................125

Dual Stacked Angled Roller™ Radius with Edge Bearing
SERIES 7000-1.............................99 SERIES 3000-1 ..........................127
Transverse Roller Top Knuckle Chain
Mesh Top
SERIES 7050-1...........................101
Dual-Stacked Transverse Roller Top SERIES 4000-1 ..........................129
S4009 Flat Top
SERIES 9000-1...........................103
S4009 Flush Grid
Flush Grid S4014 Flat Top
SERIES 10000-1.........................105 S4090 Sideflexing Flat Top
Bricklay Flat Top S4091 Sideflexing Flat Top
Bricklay Non Skid Raised Rib S4092 Sideflexing Flat Top
Bricklay Non Skid Perforated S4092 Sideflexing Square Friction Top
SERIES 10000-2.........................107 SPIRAL
MTW Flat Top
SERIES 2600-1 ..........................133
RADIUS Spiralox® (1.0, 1.1, 1.6, 2.0. 2.2, 2.5, & 3.2)
Radius
SERIES 2100-1...........................113 Spiralox® Rounded Friction Top
ZERO TANGENT™ Radius Flat Top
SERIES 2700-1 ..........................137
SERIES 2200-1...........................115 Spiralox® (1.6, 2.2 & 2.7) Radius
Radius Flush Grid Dual Turning 2.0
Radius Flush Grid High Deck
Radius Flush Grid (2.6) with Insert Rollers SERIES 2800-1 ..........................141
Radius Friction Top Spiralox® Direct Drive
Spiralox® G-Tech 1.6 Radius
SERIES 2200-2...........................117 Spiralox® G-Tech 2.2 & 3.2
Radius with Edge Bearing Spiralox® G-Tech Rounded Friction Top
Radius Flush Grid High Deck with Edge
Bearing SERIES 2850-1 ..........................143
Spiralox® Direct Drive
SERIES 2300-1...........................119
Flush Grid Nose-Roller Tight Turning SERIES 2900-1 ..........................145
Spiralox® Direct Drive
SERIES 2400-1...........................121 Spiralox® 1.6
Radius Flat Top
Radius Flush Grid (1.7 & 2.2) PREVENTIVE MAINTENANCE .147
Radius Flush Grid (2.4 & 2.8) with Insert TROUBLESHOOTING ...............149
Rollers
Radius Flush Grid High Deck
Radius Friction Top (2.2)
Radius Raised Rib
0.4 in High Radius Friction Top

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 5

 EQUIPMENT INSTALLATION OVERVIEW

EQUIPMENT INSTALLATION OVERVIEW

Overview
Before installing an Intralox belt, the shafts, sprock-
ets, and various other components must be
installed.

Shaft Installation
• Use the triangulation method to check shaft
alignment and ensure the shafts are parallel even
when the conveyor frame is not square.

all pilot holes aligned

• When installing sprockets with a number of
teeth unevenly divided by 4 on a square shaft,
ensure the sprocket alignment notches are
aligned on the same side of the shaft.

If AD and BC are equal, and AB and CD are

equal, then the shafts are square with each
other.
Notches aligned
• Align the shafts in the same relative position
for the entire length of the conveyor so the belt
tracks properly.
Sprocket Alignment
Notch
Sprocket Installation
Sprocket Alignment
• Align sprocket teeth in the same position.
Inspect by looking down the shaft.
• Ensure the pilot holes on all sprockets with an
uneven number of teeth are aligned on the same
side of the shaft.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 7

EQUIPMENT INSTALLATION OVERVIEW

Center Sprocket Offset

Sprocket Positions on the Shaft
Series Number of Offset Max.
Links Sprocket
NOTE Spacing
This information does not apply to Series 888, in mm in mm
Series 2600, Series 2700, Series 2800, or even 0 0 6 152
100
Series 2900. See those specific sections on odd 0.12 3 6 152
the following pages for more information. 200 even/odd 0 0 7.5 191
200 RR even/odd 0.09 2.3 7.5 191
even 0 0 6 152
400
• Lock one sprocket each on the drive and idle odd 0.16 4 6 152
shafts to maintain proper lateral tracking. 400 RT,
See bottom of chart.
ARB, TRT
even 0 0 5 127
550
A odd 0.5 12.7 5 127
800 even/odd 0 0 6 152
800
Angled EZ even/odd 0.16 4 6 152
Cleana
even 3 76 6 152
800 RR
odd 0 0 6 152
850 even/odd 0 0 6 152
A-Locked Sprocket See Medium Slot (without Stainless
Steel Links) Sprocket Installation on
• Position the locked sprockets in the same page 50 and Medium and Large Slot
888
location on each shaft. (with Stainless Steel Links) Sprocket
• Ensure the non-locked sprockets on the shaft Installation on page 50 or contact
Customer Service.
are free to move with the elongation and contrac-
even 0 0 4 102
tion of the belt. 900
odd 0.16 4 4 102
• If there are only two sprockets per shaft, only See Locked Sprocket Location on
900 OFG
lock the sprockets on the drive journal side. page 55 or contact Customer Service.
even 0 0 6 152
• See the following chart for center sprocket 1000
odd 0.25 6.44 6 152
offset and maximum sprocket spacing informa-
even (whole) 0 0 4 102
tion.
odd (whole) 0.5 12.7 4 102
1100b even/odd (0.5
in 12.7 mm 0.25 6.35 4 102
increments)
even (whole) 0.19 4.8 4 102
1100 EZ odd (whole) 0.31 7.9 4 102
Tracking even/odd (0,5
Sprockets in 12.7 mm 0.06 1.52 4 102
increments)
See Locked Sprocket Loca-
1200 tion on page 66 or contact 6 152
Customer Service.
even 0 0 6 152
1400
odd 0.5 12.7 6 152
See Locked Sprocket Loca-
A-Centerline of Belt B-Centerline of Sprocket 1400 FG tion on page 70 or contact 6 152
C-Offset D-Sprocket Width Customer Service.

8 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 EQUIPMENT INSTALLATION OVERVIEW

Center Sprocket Offset Center Sprocket Offset

Series Number of Offset Max. Series Number of Offset Max.
Links Sprocket Links Sprocket
Spacing Spacing
in mm in mm in mm in mm
See Locked Sprocket Loca- Number of
1500 tion on page 74 or contact 6 152 rollers per
Customer Service. row
1600 even/odd 0 0 4 102 even 0 0 6 152
400 RT,
1650 c even/odd 0.25 6.4 4 102 ARB, TRT odd 1 25.4 6 152
even 0.5 12.7 5 127
1700
odd 0 0 5 127 a. 6, 10, 16 tooth sprockets can be placed on belt center-
1800 even/odd 0 0 6 152 line.
See Locked Sprocket Loca- b. The 8 and 12 tooth steel sprockets can be placed on
belt centerline.
1900 tion on page 91 or contact 3 76
c. 20 tooth sprocket has 0 offset.
Customer Service.
d. When determining number of links, drop the 0.5 link.
2100 even/odd 1.97 50 3.94 100 e. Assuming belt is running in preferred direction.
0.25 6.4 to
even to the the 4 102 Center Sprocket Offset for Roller Belts
left left
2200d 0.25 6.4 to Series Number of Offset Max.
odd to the the 4 102 Rollers Sprocket
right right Spacing
even 0 0 6 152 in mm in mm
2300
odd 1.5 38 6 152 even 0 0 6 152
400
0.125 3.2 to odd 1 25.4 6 152
even to the the 6 152 even 0 0 6 152
left left 4500
2400 d.e odd 1 25.4 6 152
0.125 3.2 to even 0 0 6 152
odd to the the 6 152 4550
odd 1 25.4 6 152
right right
Divisible by 4 1 25.4 6 152
2600 even/odd 0 0 8 203 7000a Not divisible by 4 0 0 6 152
2700 even/odd 0 0 8 203
Divisible by 8 1 25.4 6 152
even 0 0 6 152 7050
2800 Not divisible by 8 0 0 6 152
odd 0.5 12.7 6 152
4400 even/odd 0.5 12.7 9 229
a. Number of rollers = belt width in inches - 1 (belt width in
4500 even/odd 0.5 12.7 6 152 mm/25.4 - 1)
even 0.5 12.7 4 102
9000
odd 0 0 4 102
0.25 6.3 to
10000 even 5.91 150
to left left
Hinge
Drive 0.25
6.3 to
(preferred) odd to 5.91 150
right
right
0.25
6.3 to
10000 even to 5.91 150
right
Center right
Drive 0.25 6.3 to
odd 5.91 150
to left left

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Man- 9

EQUIPMENT INSTALLATION OVERVIEW

Wearstrip Installation Flat and Angle Wearstrips

Plastic wearstrip installation should allow for ther- 1. Bevel cut the opposing ends of the wearstrips.
mal expansion and contraction. • A 30º angle with the horizontal and a 0.30 in
(8 mm) clearance gap usually works best.
Flat Finger-Joint Wearstrips • In extreme conditions, a 60° angle is needed.
The clearance must be determined by thermal
1. Starting at the idle end of the conveyor, cut the
expansion calculations.
tongues from the first wearstrips and bevel the lead-
ing edges. 2. Place the wearstrips in position and stagger the
wearstrip joint locations for smooth belt operation.
2. Place the wearstrips in position.
3. Drill a 1/4 in (6 mm) hole in the wearstrips and
3. Drill a 1/4 in (6 mm) hole in the wearstrip and
frame at the idle end of the conveyor.
frame.
4. Using the plastic bolt and nut, fasten the wear-
strips to the frame.
NOTE
Before mounting, ensure there is proper 5. Drill slotted holes through the wearstrips and
clearance between the tongues and grooves. frame every 2 ft. (0.61 m) to 5 ft. (1.52 m) on center-
Ensure all tongues point in toward the lines, working toward the drive end of the conveyor.
idle shaft. 6. Cut off the excess wearstrips at the drive end and
fasten the wearstrips to the frame.
4. Using the plastic bolt and nut, fasten the wear-
strips to the frame.
5. Continue this process, working toward the drive
end of the conveyor.
6. Cut off the excess wearstrips at the drive end and
fasten the wearstrips to the frame.

A-Operating temp. of 100º F (37º C) or more

B-Operating temp of 100º F (37º C) or less

A-Idle End B-Drive End *Minimum

10 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 EQUIPMENT INSTALLATION OVERVIEW

Belt Installation Standard Belt Installation

1. If there is a shaft take-up, move the adjustment to
Preparation the relaxed or loose-belt position.
The following procedures are basic instructions for 2. Feed the belt down the carryway from the con-
installing Intralox belting. Not all conveyors are veyor drive end.
alike. Each conveyor frame and each application
may have special considerations. Review the follow-
ing information before installing or replacing a belt.

• In most retrofits, Intralox belting can run

directly on the same carryways as the replaced
belt.
• Ensure carryways are clean, in good condition,
not grooved from belt wear, and free of debris.
• Ensure the existing wearstrip material is com-
patible with the new belt. 3. Center the belt on the conveyor frame, noting the
• Replace damaged, worn, or incompatible wear- location of the locked sprocket.
strips as needed. 4. Ensure there is space between the belt edges and
the conveyor frame to accommodate belt expan-
Top & Bottom Inspection sion.
If belt geometry is not symmetrical on top and bot-
tom, a dedicated top (product conveyance surface)
and bottom (sprocket driving surface) must be
determined before installation. Some distinguishing
features on open area belts are:

• The bottom side has geometry designed for

the sprocket tooth to engage (drive bar, drive
pockets).
• The top side has a closed hinge and the bot-
tom side has an open hinge design.
• Center bars/spines are wider on the top side
than the bottom side.
• The end of the rod is usually more exposed on measure distance between belt edge and
the bottom side. conveyor frame
If still unclear, refer to the belt drawing for the spe-
cific series and style in the Intralox Conveyor Belting 5. Wrap the belt around the idle sprockets, ensuring
Engineering Manual. the sprockets remain aligned and in position. The
two outboard sprockets must engage the belt 1.5 in
(38 mm) to 2 in (51 mm) in from the outer belt
edges.

NOTE
For Series 1100, the two outboard sprockets
must engage 1 in (25.4 mm) in from the outer
belt edges.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Man- 11

EQUIPMENT INSTALLATION OVERVIEW

8. Push the belt ends together to engage the links

and ensure the edges are properly aligned.

6. Once wrapped around the idle sprockets, feed the

belt down the returnway until it reaches the drive
sprockets.

9. Clip the rod at an angle to make insertion easier.

7. Wrap the belt around the drive sprockets, keep-

ing the drive end and idle end locked sprockets in
the same lateral position. 10. After any final adjustments, align the hinges
and insert the rod (see specific instructions for your
belt style).
NOTE
Ensure the belt engages the drive and idle end
locked sprocket in the same position. Failure to
do this causes belt mistracking.

Checking the Installation

1. Jog the conveyor slowly or manually push the
belt forward so the drive shaft revolves several
times.
2. While the belt moves, ensure the drive and idle
shaft sprockets fully engage the belt and the belt
tracks properly.

Keep hands and fingers clear of

moving parts

12 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 EQUIPMENT INSTALLATION OVERVIEW

3. If the sprockets engage the belt properly and the

belt tracks properly, ensure the shaft bearings and Break-in Period
conveyor frame are aligned properly. The break-in period usually occurs during the first
several days of operation. Depending on the appli-
• If the belt and sprockets do not engage the
cation and environment, belts elongate from 0.5%
belt, repeat the Sprocket Installation and Belt
to 1% of their total length during the break-in
Installation procedures in this section.
period.
• If the belt does not track properly, check the
sprocket positions on both shafts. See Sprocket If belt elongation is excessive, remove one or more
Installation in this section. rows of modules to maintain proper catenary sag
and belt tension.
Catenary Sag
1. If needed, add or remove belt rows or adjust the Wide Belt Installation
take-up to ensure the proper amount of catenary
sag for belt tension. Installing belting on wide conveyors is more diffi-
cult than on narrow conveyors. Using the conveyor
motor to pull the belt may ease installation.

NOTE
If needed, belt pullers can be purchased
from Intralox. Contact Customer Service
for more information.

A-Drive Sprocket
B-Catenary Sag: set up at 1 in (25.4mm) to 6
in (152mm) during operational temperature
Roller Diameter: Min. 2 in (51mm) for 0.6 in
and 1.0 in pitch belts.
Min. 4 in (102mm) for 1.25 in, 1.5 in, 2.0 in,
and 2.5 in pitch belts.
*For all series except 100, 400, and 1200,
these series should have rollers spaced from
48 in (1219mm) to 60 in (1524mm)
1. Place supports across the width of the belt
between the shoes or rollers to prevent the belt from
NOTE forming catenary sags before the belt ends are
For additional information regarding the calcu- joined.
lation of proper catenary sag, see the Design
Guidelines in the Intralox Conveyor Belting 2. Starting at the idle end, slide the belt over the car-
Engineering Manual. ryway.
3. Wrap the belt around the drive sprockets.
4. Once wrapped around the drive sprockets, use
2. Once the belt is properly tensioned and running
the motor, if possible, to pull the belt down the car-
smoothly, secure the rod in place (see specific
ryway.
instructions for your belt style).
5. While pulling the belt down the carryway, feed
the belt manually through the returnway and con-
tinue adding sections of belt.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Man- 13

EQUIPMENT INSTALLATION OVERVIEW

6. When the belt in the returnway reaches the idle

end of the conveyor, pull it up and wrap it around
the idle sprockets. Pull up enough belt to prevent it
from slipping back.
7. Lock the idle shaft in place to prevent the belt
from moving.
8. When the belt is the proper length and the belt
ends are close, align the hinges.
9. Insert a rod to join the belt ends (see specific 1. Install Finger Transfer Plates using only Intralox
instructions for your belt style). plastic bolts in the Plate slots.
10. Once the belt is joined, reverse the motor run- 2. Do not attempt to over tighten Plates. The loose
ning direction and pull the belt tight. fitting allows lateral movement of Plates, which is
required for belt expansion and contraction.
11. Return the motor to the normal running direc-
tion.
12. Adjust the take-up (if provided) and add or NOTE
remove belt rows to achieve proper catenary sag. Finger Transfer Plate slots allow limited expan-
sion. If the installation involves wide belts with
13. Remove the supports added in step 1. large temperature variations, contact Intralox
14. After any final adjustments, secure the rod in Customer Service.
place (see specific instructions for your belt style).
15. Once the belt is closed, run the conveyor to
ensure the belt tracks properly.

Finger Transfer Plates

Installation

NOTE
Intralox Finger Transfer Plates work in conjunc-
tion with Raised Rib belts.

Proper Finger Transfer Plate installation is required

for trouble-free operation. Proper installation is
especially critical for installations with high tem-
perature variations, which cause significant thermal
expansion of belts.

Finger Transfer Plates are manufactured with slots

for Intralox plastic shoulder bolts.
For an even number of finger transfer plates,
locate from the centerline of the belt. Straddle
NOTE the centerline for an odd number of plates.
ONLY use Intralox plastic shoulder bolts. Any The finger transfer plate must be level with the
other shoulder bolts may damage equipment belt +0.03 in (0.8 mm), -0.00 with hinge rod at
top dead center.

14 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 EQUIPMENT INSTALLATION OVERVIEW

Dimensional Requirements for Finger Transfer Plate Installation

Two-Material
Standard Glass Handling
S100 & S400 S1200 S900 S1900 S400 S1200 S1900
S2400 6 in 4 in
152 mm 102 mm
Retrofit
in mm in mm in mm in mm in m in mm in mm in mm in mm
m
F 2.38 61 3.50 89 3.50 89 3.50 89 2.38 61 3.50 89 3.50 89 3.50 89 3.50 89
G 0.19 5 0.31 8 0.31 8 0.25 6 0.19 5 0.31 8 0.31 8 0.31 8 0.31 8
H 5.83 148 7.25 184 7.25 184 6.50 165 5.83 148 6.11 155 8.26 210 8.26 210 6.11 155
I 3.96 101 5.91 150 5.91 150 5.92 150 3.94 100 5.91 150 5.91 150 5.91 150 5.91 150
J 2.50 64 3.00 76 3.00 76 3.00 76 2.18 55 3.00 76 3.00 76 3.00 76 3.00 76
K 0.74 19 1.45 37 1.45 37 1.45 37 0.90 23 1.45 37 1.45 37 1.45 37 1.45 37
L 2.00 51 2.00 51 2.00 51 2.00 51 2.00 51 5.50 140 5.50 140 5.50 140 5.50 140
Spacing at Ambient Temperatures
PP PP PP
3.979 5.952 Composite Endur- 5.952 Composite Endur-
S PP AC AC
(101.1) (151.2) PP alox™ PP (151.2) PP alox™ PP
5.981 5.975 3.976
AC PE 6.000 6.000 PE 6.000 6.000
(151.9) (151.8) (101.0)
3.976 5.933 (152.4) (152.4) 5.933 (152.4) (152.4)
(101.0) (150.7) (150.7)

Dead Plate Installation

Dead Plates with Gap
1. For proper Dead Plate installation, position the
belt so a rod is directly above the centerline of the
shaft.
2. Mount the Dead Plate using the minimum gap
shown in the tables. The minimum gap prevents
contact between the belt and the Dead Plate during
operation.

1–Dead Plate Top Surface; typically 0.031 in

(0.8 mm) above the belt surface for product
transfer onto the belt and 0.031 in (0.8 mm)
below the belt for product transfer off the belt.
2–Dead Plate Gap

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Man- 15

EQUIPMENT INSTALLATION OVERVIEW

Dead Plate Gap Dead Plate Gap

Sprocket Description Gap Sprocket Description Gap
Pitch Diameter No. of in mm Pitch Diameter No. of in mm
in mm Teeth in mm Teeth
Series 100 Series 1000
2.0 51 6 0.134 3.4 3.1 79 16 0.029 0.7
3.5 89 11 0.073 1.9 4.6 117 24 0.020 0.5
6.1 155 19 0.041 1.0 6.1 155 32 0.015 0.4
Series 200 Series 1100
4.0 102 6 0.268 6.8 1.6 41 8 0.058 1.5
6.4 163 10 0.160 4.1 2.3 58 12 0.040 1.0
10.1 257 16 0.100 2.5 3.1 79 16 0.029 0.7
Series 400 3.5 89 18 0.026 0.7
4.0 102 6 0.268 6.8 3.8 97 20 0.024 0.6
5.2 132 8 0.200 5.1 4.6 117 24 0.020 0.5
9 (Flush 5.1 130 26 0.018 0.4
5.8 147 Grid 0.178 4.5 6.1 155 32 0.015 0.4
Acetal) Series 1200
6.4 163 10 0.160 4.1 6.5 165 14 0.081 2.1
7.8 198 12 0.130 3.3 7.9 201 17 0.067 1.7
13 (Flush 10.2 259 22 0.052 1.3
8.4 213 Grid 0.121 3.1
Series 1400
Acetal)
3.9 99 12 0.066 1.7
10.1 257 16 0.100 2.5
5.1 130 16 0.050 1.3
Series 550 5.7 145 18 0.044 1.1
2.4 61 24 0.028 0.7 6.7 170 21 0.038 1.0
3.2 81 32 0.021 0.5
Series 1500
Series 800 2.3 58 14 0.028 0.7
4.0 102 6 0.268 6.8 2.7 69 17 0.023 0.6
5.2 132 8 0.200 5.1 3.8 97 24 0.017 0.4
6.5 165 10 0.158 4.0 5.7 145 36 0.011 0.3
7.7 196 12 0.132 3.4
Series 1600
10.3 262 16 0.098 2.5
2.0 51 6 0.134 3.4
Series 850 3.2 81 10 0.079 2.0
4.0 102 6 0.268 6.8 3.9 99 12 0.066 1.7
5.2 132 8 0.200 5.1 6.4 163 20 0.039 1.0
6.5 165 10 0.158 4.0
Series 1650
7.7 196 12 0.132 3.4
2.0 51 6 0.134 3.4
10.3 262 16 0.098 2.5
3.2 81 10 0.079 2.0
Series 900 3.9 99 12 0.066 1.7
2.1 53 6 0.147 3.7 1.0
3.1 79 8 0.095 2.4 6.4 163 20 0.039
3.5 89 10 0.084 2.1
Series 1700
4.1 104 12 0.071 1.8
5.8 147 12 0.224 5.7
5.1 130 15 0.057 1.4
6.7 170 14 0.210 5.3
5.8 147 17 0.050 1.3
7.7 196 16 0.199 5.0
6.1 155 18 0.047 1.2
6.8 173 20 0.042 1.1 Series 1800
9.8 249 28 0.029 0.7 5.0 127 6 0.150 3.8
6.5 165 8 0.108 2.8

16 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 EQUIPMENT INSTALLATION OVERVIEW

Dead Plate Gap

Dead Plates without Gap
Sprocket Description Gap
In some installations, the tip of the Dead Plate may
Pitch Diameter No. of in mm need to contact the belt rather than maintain a gap.
in mm Teeth To do this, hinge the Dead Plate support so the
8.1 206 10 0.091 2.3 Dead Plate moves as the belt passes.
10.5 267 13 0.074 1.9

Series 1900 NOTE

6.7 170 10 0.164 4.2 There is a small oscillating motion that may
10.6 269 16 0.102 2.6 cause tipping for sensitive product containers.
Series 2200
3.9 99 8 0.150 3.6
5.3 135 11 0.108 2.8
6.3 160 13 0.091 2.3
Abrasion Resistant Rod
7.7 196 16 0.074 1.9 Installation
Series 2400
The Intralox Abrasion Resistant rods enhance the
2.0 51 6 0.134 3.4
3.9 99 12 0.065 1.7
performance of Intralox belts in abrasive or gritty
5.1 130 16 0.050 1.3 environments. These rods are held in place on both
6.4 163 20 0.039 1.0 ends by short rods made of Abrasion Resistant plas-
tic with preformed heads called rodlets.
Series 2600 & 2700 Spiralox®
5.2 132 8 0.200 5.1
See specific series sections for instructions regard-
6.5 165 10 0.158 4.0
ing Abrasion Resistant Rod installation.
Series 2800 Spiralox®
6.3 160 13 0.091 2.3
Series 3000
5.2 132 8 0.200 5.1
6.5 165 10 0.158 4.0
7.7 196 12 0.132 3.4
Series 4000
3.9 99 12 0.066 1.7
5.1 130 16 0.050 1.3
5.7 145 18 0.044 1.1
6.7 170 21 0.038 1.0 
Series 7000
8.3 211 8 0.318 8.1
10.3 262 10 0.253 6.4
Series 9000
6.5 164 20 0.040 1.0
8.1 205 25 0.032 0.8

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Man- 17

 SERIES 1100-1

SERIES 1100-1
5. Ensure the rod is fully inserted.
Belts Covered in Section
38 & 46mm Wide
Cone Top™
Embedded Diamond Top
Flush Grid
Flush Grid Friction Top
Flush Grid Friction Top No Indent
Flush Grid Mold to Width
Flush Grid Nub Top™ Remove the Rod
ONEPIECE™ Live Transfer Flush Grid 1. Insert a screwdriver between two flush edges.
2. Twist the screwdriver to bend and push the rod
Headless Rod through the retention feature and out of the belt.

Insert the Rod

1. Cut rods 0.3 in (8 mm) shorter than the overall
belt width.
2. Join belt ends together so the hinges are aligned.
3. Insert the rod through the hinges as far as possi-
ble.

3. Use a screwdriver to push the rod out from the

opposite belt edge.

4. Use a screwdriver to push the rod past the reten-

tion feature.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 61

SERIES 1100-1

Splicing Original Edge Splicing Old Edge (Version 2)

(Version 1) with New Edge with New Edge (Version 3)
(Version 3) 1. Get 2 headless rods of the same material as the
existing installed rods.
1. Get 2 headed rods of the same material as the
existing installed rods. 2. Cut the new 0.18 in (4.6 mm) diameter rods
0.3 in (8 mm) shorter than the belt width.
2. Cut the new 18 in (4.6 mm) diameter headed
rods1 0.25 in (6 mm) shorter than the belt width. 3. Bring the two belt ends close together, but do not
join them.
3. Bring the two belt ends close together, but do not
join them. 4. Cut off the lip on the old belt (Version 2).

4. On the old belt (Version 1), locate the flexible

edge member that points toward the edge member
on the new belt (Version 3).
5. Cut off half of the flexible edge member on the
old belt.

5. Join the belt ends together so the hinges are

aligned.
6. Insert one of the pre-cut, headless rods as far as
possible.
6. Repeat Steps 4 & 5 on the opposite belt edge.
7. Use a screwdriver to push the rod past the reten-
7. Join the belt ends together so the hinges are
tion feature and fully into the belt.
aligned.
8. Insert one of the pre-cut, headed rods into the
belt from the side opposite the newly cut, flexible
edge member (side B).
9. Use a screwdriver to push the rod head past the
edge of the older module.

1. Contact Intralox Customer Service for headed rods.

62 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 SERIES 1100-2

SERIES 1100-2
Belts Covered in Section Remove the Rod
1. On the bottom of the belt, grip the rod in the
Flat Top opening near the belt edge.
Perforated Flat Top

Headless Rod
Insert the Rod
1. Cut rods 0.3 in (8 mm) shorter than the overall
belt width.
2. Join belt ends together so the hinges are aligned.
3. Insert the rod through the hinges as far as possi- 2. Push the rod slightly to the side and past the
ble. retention feature.

4. Use a screwdriver to push the rod past the reten-

tion feature.

3. Once past the belt edge, pull the rod out to open
the belt.

5. Ensure the rod is fully inserted.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 63

SERIES 1100-2

Splicing Original Edge Splicing Old Edge (Version 2)

(Version 1) with New Edge with New Edge (Version 3)
(Version 3) 1. Get 2 headless rods of the same material as the
existing installed rods.
1. Get 2 headed rods of the same material as the
existing installed rods. 2. Cut the new 0.18 in (4.6 mm) diameter rods
0.3 in (8 mm) shorter than the belt width.
2. Cut the new 18 in (4.6 mm) diameter headed
rods1 0.25 in (6 mm) shorter than the belt width. 3. Bring the two belt ends close together, but do not
join them.
3. Bring the two belt ends close together, but do not
join them. 4. Cut off the lip on the old belt (Version 2).

4. On the old belt (Version 1), locate the flexible

edge member that points toward the edge member
on the new belt (Version 2).
5. Cut off half of the flexible edge member on the
old belt.

5. Join the belt ends together so the hinges are

aligned.
6. Insert one of the pre-cut, headless rods as far as
6. Repeat steps 4 & 5 on the opposite belt edge. possible.
7. Join the belt ends together so the hinges are 7. Use a screwdriver to push the rod past the reten-
aligned. tion feature and fully into the belt.
8. Insert one of the pre-cut, headed rods into the
belt from the side opposite the newly cut, flexible
edge member (side B).
9. Use a screwdriver to push the rod head past the
edge of the older module.

1. Contact Intralox Customer Service for headed rods.

64 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE
Perform the following procedures at the frequency indicated to maintain the Intralox belting system. Initially,
performing this inspection on a monthly basis will enable you to spot any wear trends and develop a feel for the
operational characteristics of the conveyor.

Repair or replace any damaged components and repair any faulty processes.

Contact Intralox (the nearest Intralox office or Customer Service Representative) regarding any problems not
explained here.

Biannually
Quarterly

Annually
Monthly
Tech.
Maintenance Procedure to Perform
Initials

General/Safety Inspection
Inspect the belt for missing or damaged belt modules. Repair or replace parts
x
as needed.
Inspect sprockets for mistracking or movement on the shaft. Repair or replace
x
parts as needed to prevent premature belt and sprocket wear.
Inspect the conveyor for missing or damaged return rollers, shoes, and wear-
strips. Repair or replace any parts as needed to prevent premature belt and x
sprocket wear.
Inspect the belt for missing, damaged, or protruding belt rods. Repair or
x
replace parts as needed.
Inspect all incoming power sources to the equipment (air hoses, fittings, con-
x
nections) for good working condition. Repair or replace parts as needed.
Secure any misaligned or loose components, fasteners, etc. Repair or replace
x
parts as needed.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 147

 TROUBLESHOOTING

TROUBLESHOOTING
This guide is designed to assist in diagnosing and resolving mechanical problems on conveyors using an
Intralox belting system. If you require further help, contact the nearest Intralox office listed on the back cover.

Straight Running Belts

Problem Possible Cause Solution
Belt not Incorrect belt 1. Ensure the belt returnway allows recommended catenary
engaging tension around drive sag.
drive sprockets 2. Re-space rollers to get proper sag and bypass the slider bed
sprockets returnway to get proper sag.
3. Contact Intralox Customer Service for further assistance.
Incorrect A or B Compare existing shaft location to that recommended for A
dimension and B Conveyor Frame dimensions in the Intralox Engineering
Manual. Adjust the drive shaft as necessary to meet these
dimensions.
Incorrect belt 1. Ensure the belt returnway provides recommended catenary
returnway design sag.
2. Re-space rollers to get proper sag and bypass the slider bed
returnway to get proper sag.
3. Contact Intralox Customer Service for further assistance.
Sprockets not Ensure sprockets are timed identically and all sprocket teeth
aligned correctly on line up when looking down the shaft.
shafts See Sprocket Installation on page 7 for more information.
Insufficient belt wrap Move the return roller nearest the drive shaft so 180º or more
around drive of belt wraps around the drive sprockets.
sprockets Contact Intralox Customer Service for further assistance.
Belt not Drive and idle shafts 1. Adjust shafts to be plumb, level, and square.
tracking not plumb, level, 2. Ensure sprockets are held in place with shaft collars.
properly and square
Conveyor frame 1. Square the Conveyor frame.
and/or components 2. Check shaft alignment after adjusting the frame.
not level or square 3. Re-plumb, level, and square the shafts if needed.
Return rollers not Adjust return rollers to be level or square with conveyor frame.
level and square to
conveyor frame

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 149

TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Belt not Sprockets not Ensure sprockets are timed identically and all sprocket teeth
tracking aligned correctly on line up when looking down the shaft.
properly shafts See Sprocket Installation on page 7 for more information.
Locked sprockets 1. Realign the locked sprockets.
on drive and idle 2. Ensure the drive shaft sprocket is aligned with the idle shaft
shafts are not sprocket.
properly aligned See Sprocket Installation on page 7 for more information.
Material build-up on Clean the bottom of the belt to remove any debris that could
bottom of belt interfere with sprocket tooth engagement. Consider installing
interfering with in-place brushes, scrapers, scrolls or other devices to prevent
proper sprocket future build up.
tooth engagement
Belt improperly With the exception of Series 200, all belt edges should be flush
installed when spliced properly. See belt series and style instructions for
specific splicing instructions.
Retainer rings 1. Install the retainer rings so the locked sprockets on the drive
improperly installed and idle shafts are aligned.
or missing 2. Replace any missing retainer rings.
Excessive Belts, sprockets or • Eliminate or reduce belt, sprocket, and wearstrip exposure to
belt wear wearstrip exposed abrasive material.
to abrasive material • Use pressurized air to blow debris from equipment or wash
off equipment regularly.
Incorrect wearstrip To ensure wearstrip material is correct for the application, con-
material tact Intralox for assistance in wearstrip selection.
Binding of belt in 1. Square and level the conveyor frame.
conveyor frame 2. Remove any obstructions causing the belt to rub or bind.

150 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Excessive Uneven or incorrect • Add support under belt loading area.
belt wear product loading • Consider adding a chute to orient conveyed material so it
travels in the same direction as the belt and at a similar speed.
• Consider adding a side guide to the opposite side of the belt
for side-loaded conveyors.
Contact Intralox Customer Service for assistance.
Excessive belt Reduce belt speed if possible. High speed belts, especially those
speed with short shaft centers, wear faster than belts at lower speeds.
Incorrect wearstrip Contact Intralox Customer Service for assistance.
spacing Wearstrip spacing varies with the load on the belt, belt style,
and temperature.
Sharp corners on Bevel or radius the leading edge of carryway and returnway
carryway or wearstrips and slider beds for smooth belt travel.
returnway
wearstrips
Excessive Sprockets exposed • Eliminate or reduce sprocket exposure to abrasive material.
sprocket to abrasive material • Use pressurized air to blow debris from equipment or wash
wear off equipment regularly.
• Abrasive resistant sprockets are available for several belt
series. Contact Intralox Customer Service for assistance.
Incorrect tension on 1. Ensure the belt is properly tensioned around the drive
belt sprockets.
2. Ensure the belt returnway allows recommended catenary
sag.
3. Re-space rollers to get proper sag and bypass the slider bed
returnway to get proper sag.
4. Contact Intralox Customer Service for further assistance.
Excessive belt Reduce belt speed if possible. High speed belts, especially those
speed with short shaft centers, wear faster than belts at lower speeds.
Drive and idle shafts • Adjust shafts to be plumb, level, and square.
not plumb, level, • Ensure sprockets are held in place with shaft collars.
and square
Insufficient number The conveyor may require a more even load distribution
of sprockets among sprockets. Contact Intralox Customer Service for assis-
tance.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 151

TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Excessive Locked sprockets 1. Realign the locked sprockets.
sprocket on drive and idle 2. Ensure the drive shaft sprocket is aligned with the idle shaft
wear shafts are not sprocket.
properly aligned See Sprocket Installation on page 7 for more information.
Sprockets not Ensure sprockets are timed identically and all sprocket teeth
aligned correctly on line up when looking down the shaft.
shafts See Sprocket Installation on page 7 for more information.
Incorrect A or B Compare existing shaft location to that recommended for A
dimension and B Conveyor Frame dimensions in the Intralox Engineering
Manual. Adjust the drive shaft as necessary to meet these
dimensions.
Shaft deflection or 1. Inspect shaft for deflection or twisting.
twisting 2. Replace any bent or twisted shafts.
Wide belts may require an intermediate bearing. Contact
Intralox Customer Service for assistance.
Excessive Belt contacting • Square and level the conveyor frame.
belt edge obstructions on • Remove any obstructions causing the belt to rub or bind.
wear or conveyor belt, • Ensure locked sprockets are secure.
damage returnway, frame or • Ensure sprockets are square.
adjacent equipment
Belt improperly • Realign the locked sprockets.
aligned and not • Align the drive shaft sprocket with the idle shaft sprocket. See
tracking correctly Sprocket Installation on page 7 for more information.
• Level and square the conveyor frame.
• Remove any obstructions causing the belt to rub or bind.
• Square the sprockets.
Thermal expansion Ensure there is a 0.25 in (6.4 mm) minimum clearance on each
is causing belt edge side of the belt when the belt is under full thermal expansion
to rub on conveyor (highest temperature).
frame
Conveyor frame not • Square and level the conveyor frame.
square or level • Remove any obstructions causing the belt to rub or bind.
• Ensure locked sprockets are secure.
• Ensure sprockets are square.

152 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Excessive Shafts not properly • Adjust shafts to be plumb, level, and square
belt edge locked in place with • Ensure sprockets are held in place with shaft collars.
wear or shaft collars,
damage allowing the shafts
to migrate to one
side
Belt improperly With the exception of Series 200, all belt edges should be flush
installed when spliced properly. See belt series and style instructions for
specific splicing instructions.
Belt edge not guided Consult Intralox Customer Service for assistance. Because
through a Intralox belts are buoyant in most solutions, it is necessary to
submerged control the belt course to prevent edge wear.
application
Sprockets Drive and idle shafts • Adjust shafts to be plumb, level, and square.
move not plumb, level, • Ensure sprockets are held in place with shaft collars.
laterally to and square
center or
edge of belt Retainer rings 1. Install the retainer rings so the locked sprockets on the drive
improperly installed and idle shafts are aligned.
or missing 2. Replace any missing retainer rings.
Locked sprockets 1. Realign the locked sprockets.
on drive and idle 2. Ensure the drive shaft sprocket is aligned with the idle shaft
shafts are not sprocket.
properly aligned See Sprocket Installation on page 7 for more information.
Sprockets not Ensure sprockets are timed identically and all sprocket teeth
aligned correctly on line up when looking down the shaft.
shaft See Sprocket Installation on page 7 for more information.
Material build up on Clean the bottom of the belt to remove any debris that could
bottom of belt interfere with sprocket tooth engagement. Consider installing
preventing proper in-place brushes, scrapers, scrolls or other devices to prevent
tooth engagement future build up.
Belt improperly With the exception of Series 200, all belt edges should be flush
installed when spliced properly. See belt series and style instructions for
specific splicing instructions.
Shaft deflection or 1. Inspect shaft for deflection or twisting.
twisting 2. Replace any bent or twisted shafts.
Wide belts may require an intermediate bearing. Contact
Intralox Customer Service for assistance.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 153

TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Belt rod Rods not properly See belt series and style instructions for specific splicing
pushing out installed instructions.
of belt
Drive and idle shafts • Adjust shafts to be plumb, level, and square.
not plumb, level, • Ensure sprockets are held in place with shaft collars.
and square
Sideguard Sideguards • Remove side guard travel obstructions.
wear or contacting conveyor • Square and level the conveyor frame.
damage frame, returnway or • Remove any obstructions causing the belt to rub or bind.
(including adjacent equipment • Secure locked sprockets.
breakage) • Square sprockets.
Uneven or incorrect • Add support under belt loading area.
product loading • Consider adding a chute to orient conveyed material so it
travels in the same direction as the belt and at a similar speed.
• Consider adding a side guide to the opposite side of the belt
for side-loaded conveyors.
Contact Intralox Customer Service for assistance.
Flight wear or Flights contacting • Remove debris blocking the flight travel.
damage obstructions on • Square and level the conveyor frame.
conveyor frame, • Remove any obstructions causing the belt to rub or bind.
returnway or • Secure locked sprockets.
adjacent equipment • Square sprockets.
Uneven or incorrect • Add support under belt loading area.
product loading • Consider adding a chute to orient conveyed material so it
travels in the same direction as the belt and at a similar speed.
• Consider adding a side guide to the opposite side of the belt
for side-loaded conveyors.
Contact Intralox Customer Service for assistance.
High impact in Add an impact plate or chute above the belt to absorb initial
infeed area shock and reduce or eliminate belt impact. Mount the impact
plate at an angle so product travels gently onto the belt.
Improper flight Ensure return rails support flighted belts on both sides of the
support on belt along the returnway and as needed across the belt width.
returnway Contact Intralox Customer Service for assistance.
Impact Uneven or incorrect • Add support under belt loading area.
damage to product loading • Consider adding a chute to orient conveyed material so it
belt travels in the same direction as the belt and at a similar speed.
• Consider adding a side guide to the opposite side of the belt
for side-loaded conveyors.
Contact Intralox Customer Service for assistance.

154 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Impact Unsuitable belt Ensure belt material is appropriate for application. See Belt
damage to material Selection Process in the Intralox Engineering Manual or contact
belt Intralox Customer Service for assistance.
Application is Contact Intralox Customer Service for assistance.
outside the
performance range
of a plastic conveyor
belt
Finger Incorrect finger • Ensure finger transfer plates are not tightened down too
transfer plate transfer plate firmly on the mounting support surface.
damage mounting • Ensure the finger transfer plates are mounted straight, level,
and not bent or twisted.
• See the Design Guidelines in the Intralox Engineering Manual
for correct dimensional information and installation informa-
tion.
Excessive heat at If belts in a high heat area expand beyond the range allowed by
finger transfer plate the slotted holes on the finger transfer plates, contact Intralox
area Customer Service for assistance.
Raised Rib belt not Correct belt tracking. See Belt not tracking properly on
tracking properly page 149.
Material build up • If possible, eliminate the source of the material build up.
between raised ribs • Routinely inspect and clean any unpreventable debris from
the belt.
Incorrect A or B Compare existing shaft location to that recommended for A
dimensions and B Conveyor Frame dimensions in the Intralox Engineering
Manual. Adjust the drive shaft as necessary to meet these
dimensions.
Shaft deflection or 1. Inspect shaft for deflection or twisting.
twisting 2. Replace any bent or twisted shafts.
Wide belts may require an intermediate bearing. Contact
Intralox Customer Service for assistance.
Sprockets not Ensure sprockets are timed identically and all sprocket teeth
aligned correctly on line up when looking down the shaft.
shafts See Sprocket Installation on page 7 for more information.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 155

TROUBLESHOOTING

Straight Running Belts

Problem Possible Cause Solution
Belt develops Incorrect total belt • Inspect catenary sag at the belt’s coldest operating tempera-
excessive length ture.
catenary sag • If needed, remove rows of modules to shorten the belt and
remove excess catenary sag.

NOTE
Some belts can only be shortened in two row increments.

Insufficient belt If the excess catenary sag is due to thermal expansion from
tension in high heat operational temperatures and is not excessive when cold, add-
applications ing a take-up/tensioning device on the conveyor to compensate
for the thermal growth may be necessary. Contact Intralox for
assistance.
Elongation of belt • Belts elongate during the initial break-in period. This is a nat-
due to initial start-up ural part of the belt adjusting to the application and is more
situation or heavy noticeable with heavy loads.
loads • Allow the belt to adjust to operating conditions before short-
ening.
• Monitor the belt during this break-in to avoid binding or
catching.

Radius Belts
Problem Possible Causes Solutions
Belt not Incorrect belt Series 2200 and Series 2400 require little tension, but belt length
engaging tension/wrap changes and the dynamics of the returnway can cause the belt
with drive around drive to skip off the sprockets. A snub roller is recommended to keep
sprockets sprockets the belt wrapped at least 180° around the sprocket.
Adjustments are If excess belt slack after the drive sprockets causes the belt to
needed o belt length bounce off the drive sprockets, installing a snub roller may pre-
due to changes in vent this. A vertical belt take-up before the first turn may also
temperature, load, be needed.
or wear

156 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TROUBLESHOOTING

Radius Belts
Problem Possible Causes Solutions
Belt not The straight section Ensure the straight section is at least 1.5 times the belt width.
engaging of belt from curve to
with drive drive shaft is less
sprockets than 1.5 times the
belt width causing
the belt to have
different pitches at
the two belt edges,
which causes the
belt to walk to the
outside of the last
curve.
Unsupported belt Install a guide rail on the outside edge of the belt leading to the
edge leading to the drive shaft to prevent the belt from walking toward the outside
drive sprockets of the last turn.
Returnway section Ensure both the carryway and returnway are vertically parallel.
not vertically parallel
with carryway
section, which
forces the sprocket
rotation to be out of
line with the belt
travel.
Locked sprockets Ensure only one method of tracking is used—either locked
and hold down sprockets or hold down guides.
guides are over-
constraining the
belt. NOTE
DO NOT use a hold down AND locked sprockets on
Series 2200 or 2400 belts.

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 157

TROUBLESHOOTING

Radius Belts
Problem Possible Causes Solutions
Excessive PV value of guide 1. Check the temperature of the guide rail wearstrip in the tran-
wear on the rail wearstrip sition between straight and turning sections. A sharp rise in
guide rail material is temperature indicates the wearstrip material is insufficient for
wearstrip, exceeded. the application.
especially in 2. Install guide rail wearstrips with a higher PV.
turns.
NOTE
Eventually, the guide rail wearstrip stops wearing and the
belt edge begins to wear. It is better to replace wearstrips
than belts.

Not enough belt • Prior to belt installation, manually pass a piece of belt through
clearance through all sections and wearstrips to ensure adequate clearance.
the section. If the • Ensure Intralox recommended clearance is maintained.
belt is bound Contact Intralox Customer Service for further assistance.
through a section,
additional
compressive and
tensile loads are
applied to the
wearstrip.
Wearstrips in the 1. Check the temperature of the guide rail wearstrip in the turn.
turn not smooth or A higher temperature on these wearstrips indicates the wear-
even strip is not smooth.
2. Replace guide rail wearstrips as needed.
3. Ensure all wearstrips form a smooth arc for any turn.

158 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 TROUBLESHOOTING

Radius Belts
Problem Possible Causes Solutions
Excessive Unsupported belt Install a guide rail on the outside edge of the belt leading to the
sprocket edge leading to the drive shaft to prevent the belt from walking toward the outside
wear drive sprockets. of the last turn.
Returnway section Ensure both the carryway and returnway are vertically parallel.
not vertically parallel
with carryway
section, which
forces the sprocket
rotation to be out of
line with the belt
travel.
Locked sprockets Ensure only one method of tracking is used—either locked
and hold down sprockets or hold down guides.
guides are over-
constraining the
belt. NOTE
DO NOT use a hold down AND locked sprockets on
Series 2200 or 2400 belts.

Excessive A catch point on the • Remove any catch points and sharp leading edges from all
belt edge guide rail wearstrips guide rail wearstrips.
wear or or hold down • Ensure there is clearance between the outer hold down wear-
damage wearstrip is strips and the belt when the belt is at maximum operating tem-
snagging an edge. perature.
• Ensure outer hold down wearstrips do not catch the belt.
Inappropriate guide • Check the guide rail wearstrip for wear. Wearstrips with little
rail wearstrip wear may have too high a PV value for the belt.
material. • Replace any acetal, nylon, PTFE, etc. wearstrips with a plain or
lubricated UHMW wearstrip.

NOTE
Eventually, the guide rail wearstrip stops wearing and the
belt edge begins to wear. It is better to replace wearstrips
than belts.

Belt rod Rods not correctly Reinstall the rod. See belt series and style instructions for spe-
moving out of installed. cific splicing instructions.
belt

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual 159

TROUBLESHOOTING

Radius Belts
Problem Possible Causes Solutions
Belt rod A snag or wear • Inspect the belt for signs of damage.
moving out of damaged the rod. • Replace any damaged belt edge modules or rods.
belt. • Repair any snags on the conveyor frame.
If Series 2200 or Always use a blunt cut on rods. An angled cut can cause the rod
2400 belt, the rod tip tip to move past the retention feature.
has a sharp angle.

160 Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

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Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

A subsidiary of Laitram, L.L.C. Intralox is a registered trademark of
Laitram, L.L.C. All rights reserved worldwide. Intralox, L.L.C. manufactures
products under one or more of the following U.S. patents: 5,072,640 -
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5,361,893 - 5,372,248 - 5,377,819 - 5,507,383 - 5,544,740 - 5,597,063 -
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7,537,106 - 7,540,368 - 7,575,113 - 7,588,137 - 7,607,533 - 7,617,923.
Other U.S. and foreign patents pending.
Notice: The information contained in this manual is provided only as an
aid and service to our customers. Intralox, L.L.C. does not warrant the
accuracy or applicability of such information and, Intralox, L.L.C. is
specifically not responsible for property damages and/or personal injury,
direct or indirect, for damages and/or failures caused by improper machine
design, application, installation, operation, abuse and/or misuse of its
products, whether or not based on information contained herein.
Caution: Intralox, L.L.C. does not warrant that the design and/or
operational function of any machine that incorporates and/or intends to
incorporate Intralox, L.L.C. products, conform to any local, state, and/or
federal regulations and standards relating to public safety, worker safety,
safety guards, sanitation safety, fire safety, or any other safety regulations.
ALL PURCHASERS AND USERS SHOULD CONSULT THEIR
APPROPRIATE LOCAL, STATE AND FEDERAL SAFETY REGULATIONS
AND STANDARDS.
© 2015 Intralox, L.L.C. 5001534-English (update 12/1/15)

Intralox Conveyor Belting Installation, Maintenance & Troubleshooting Manual

 Installation &
Installation & Lubrication
Lubrication
Shaft Tolerances
Shaft Tolerances
Shaft Diameter Shaft Tolerance
Shaft
1/2" -Diameter
1 15/16" Shaft Tolerance
Nominal to - .0005"
1/2"
2" - 31 3/16"
15/16" Nominal to - .0005"
.0010"
2" - 3 3/16"
3 1/4" - Up Nominal to - .0010"
.0015"
3 1/4" - Up Nominal to - .0015"

For maximum life, IPTCI recommends a fit as close to nominal as possible. Turned and ground shafting is also beneficial as it tends
INFORMATION

to be
For rounder,life,
maximum straighter and free of burrs
IPTCI recommends or other
a fit as close flaws.
to nominal as possible. Turned and ground shafting is also beneficial as it tends
INFORMATION

to be rounder, straighter and free of burrs or other flaws.

Mounting Instructions
Mounting
When mounting, Instructions
always clean shafting and bearing bore. Then, having coated the shaft with a light oil, slide the bearing unit on the
shaft tomounting,
When its correct position.
always It may
clean be necessary
shafting and bearing to use a soft
bore. Then,mallet and/or
having pipe,
coated theon the with
shaft inneraring
lightonly, to reach
oil, slide the correct
the bearing unitposition.
on the
TECHNICAL

Nevertopound
shaft on, orposition.
its correct apply pressure
It may beto,necessary
the outsidetoring!
use Once
a soft the bearing
mallet unit
and/or is inonposition,
pipe, the innerprecise alignment
ring only, to reachcan
thebecorrect
achieved by
position.
TECHNICAL

first fixing
Never poundtheon,
housing in place,
or apply thento,simultaneously
pressure the outside ring!rotating
Once and tapping unit
the bearing the shaft with a soft
is in position, mallet.alignment
precise This shouldcanbe
beaccomplished
achieved by
before
first anythe
fixing locking collar
housing or set screw
in place, is tightened. rotating and tapping the shaft with a soft mallet. This should be accomplished
then simultaneously
before any locking collar or set screw is tightened.
When mounting a locking collar bearing, use a spanner wrench or punch to lock the collar in place — always in the direction of
shaft rotation.
When mountingThen tightencollar
a locking set screw.
bearing,Dousenot ause locking
spanner collar bearings
wrench or punch for bi-directional
to lock the collar applications.
in place — always in the direction of
shaft rotation. Then tighten set screw. Do not use locking collar bearings for bi-directional applications.
When mounting set screw locking bearings we recommend the following torque settings:
When mounting set screw locking bearings we recommend the following torque settings:
Mild steel set screws - for standard bearing inserts 400 series stainless set screws for
- for SUC & CUC bearing Inserts
Mild steel set screws - for standard bearing inserts
Max. Recommended Torque SUC,series
400 SUCX, SSB, SNA
stainless set & CUC
screws bearing
- inserts
for SUC
Max. Recommended &Torque
CUC bearing Inserts
Set Screw Size Set Screw Size
(in./lbs.) Torque
Max. Recommended (in./lbs.) Torque
Max. Recommended
Set Screw Size Set Screw Size
10-32 (in./lbs.)
28 (in./lbs.)
1/4 -28 54
10-32
1/4 - 28 28
66 1/4 -28 54
5/16 - 24 110
1/4 --28
5/16 24 66
126 5/16 - 24 110
3/8 - 24 205
5/16 - 24
3/8 - 24 126
228 3/8 - 24 205
7/16--24
3/8 20 228
306
7/16 - 20
1/2 - 20 306
330
1/2 - 20 330

Lubrication
Lubrication
All IPTCI bearing units are factory prelubricated and, therefore, do not require supplemental grease before service life begins.
Relubrication,
All when
IPTCI bearing administered
units are factory correctly, can and,
prelubricated increase the lifedoofnot
therefore, a bearing
require substantially.
supplementalIPTCI
grease recommends the life
before service following
begins.
general guidelines
Relubrication, whentoadministered
maximize your bearingcan
correctly, life: increase the life of a bearing substantially. IPTCI recommends the following
general guidelines to maximize your bearing life:
Environmental Interval NOTE:
RPM Temperature
Condition
Environmental Overlubrication is a major cause of bearing
RPM Temperature Interval NOTE:
100 32° F -120° F Clean
Condition 6-12 months failures. Please is
Overlubrication relubricate conservatively
a major cause of bearing
100
500 32°
32° FF -120°
-150° FF Clean
Clean 6-12 months
2-6 months when unsure
failures. of relubricate
Please bearing requirements.
conservatively
500 32° FF --150° when unsure of bearing requirements.
1,000 32° 210° FF Clean
Clean 2-6 months
2 weeks to 2 months When selecting a bearing lubricant, IPTCI
1,000
1,500 32° F -210°
Over 210°FF Clean
Clean 2 weeks
Daily to to weekly
2 months suggests
When any lithium-based
selecting NLGI #2 IPTCI
a bearing lubricant, grease.
1,500
Any Over -150°
32°F 210° FF Clean
Dirty Daily totoweekly
Weekly monthly For operating
suggests temperatures NLGI
any lithium-based higher#2than 210° F,
grease.
Any 32°F -150° F Dirty Weekly to monthly please
For consulttemperatures
operating IPTCI. higher than 210° F,
Any Over 150° F Dirty Daily to 2 weeks please consult IPTCI.
Any
Any Over 150°
Any Temp. F Dirty
Very Dirty Daily
Dailytoto2weekly
weeks
Any
Any Any
Any Temp.
Temp. Very Dirty
Extremely Dirty Daily
Daily toto weekly
weekly
Any Any Temp. Extremely Dirty Daily to weekly

88
88
3 Phase AC Induction Motors

INSTALLATION AND OPERATION MANUAL

January 22, 2018

Indianapolis, Indiana (800) 866-7973

e-mail: sales@sterlingelectric.com
www.sterlingelectric.com
 7997 Allison Avenue, Indianapolis, IN 46268 (800) 866-7973 FAX (317) 872-0907
Website: www.sterlingelectric.com email:sales@sterlingelectric.com

INSTALLATION AND OPERATION OF

STERLING 3-PHASE AC INDUCTION MOTORS

DANGER
ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THE
EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL, ADJUST, OPERATE, AND/OR SERVICE THIS
EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE TO
OBSERVE THIS CAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

SELECTION INFORMATION

Buyer shall be solely responsible for determining the adequacy of the product for any and all
uses to which buyer shall apply the product. The application by buyer shall not be subject to
any implied warranty of fitness for a particular purpose. Information contained in this manual is
considered correct at the time of publication and is subject to change without notice.

Read ALL instructions prior to operating unit. Improper maintenance or operation may cause
injury to personnel or reducer failure.

SAFETY ALERT

WARNING: For safety, purchaser or user should provide protective guards over all shaft
extensions and any moving apparatus mounted thereon. The user is responsible
for checking all applicable safety codes in his area and providing suitable guards.
Failure to do so may result in bodily injury and/or damage to equipment.

WARNING: Make certain that the power supply is disconnected before attempting to service
or remove any components. Lock out the power supply and tag it to prevent
unexpected application of power.

WARNING: Lifting devices supplied with motors (Frame 180T and larger) are for lifting and
placing the motor only. Do not use lifting devices to lift any other objects or
additional weight such as gear reducers, pumps, skids, etc. Using lifting devices
to lift other objects or additional weight may cause lifting devices to fail and
resulting in death, serious personal injury or property damage.

CAUTION: Test run unit to verify operation. If the unit tested is a prototype, that unit must
be of current production.

WARNING: For motors to be used in hazardous locations, check National Electric Code,
NEMA, and UL (Underwriters Laboratory) standards to make sure that explosion-
proof motors are not required. Note that UL labeling (certification) is required in
some hazardous locations.

CAUTION: Rolled Steel motors and Stainless Steel motors are designed to run at elevated
temperatures. Avoid physical contact. Use gloves and/ or other protective
clothing or gear when working in the proximity of these motors while they are in
operation.

1
 IMPORTANT INFORMATION

In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will
include the following language in a conspicuous place and in a conspicuous manner in a
written agreement covering such sale:

The manufacturer makes no warranty or representations, expressed or

implied, by operation of law or otherwise, as to the merchantability or
fitness for a particular purpose of the good sold hereunder. Buyer
acknowledges that it alone has determined that the goods purchased
hereunder will suitably meet the requirements of their intended use. In no
event will manufacturer be liable for consequential, incidental or other
damages.

Resellers/Buyers agree to also include this entire document including the warnings above
in a conspicuous place and in a conspicuous manner in writing to instruct users on the
safe usage of the product.

This instruction manual should be read together with all other printed information such as
catalogs, supplied by Sterling Electric.

RECEIVING
1. Check nameplate data.

2. Check whether any damage has occurred during transportation. If there is evidence
of rough handling or potential damage in shipment, file a claim immediately with the
carrier. Notify your Sterling Electric sales representative.

3. Turn motor shaft by hand to check that it turns freely.

NOTE: Large motors may have a shaft locking device to aid in the protection of
the bearings during shipment. This locking device needs to be removed
before the motor is put into service.

INSTALLATION

Location and Mounting Position

A. The location for installing motors should be accessible and allow routine
inspection, cleaning, and maintenance.

B. ODP (Open Drip Proof) motors are designed for installation in a well-ventilated
area where the atmosphere is reasonably free of dirt and moisture.

C. TEFC (Totally Enclosed Fan Cooled) or TENV (Totally Enclosed Non

Ventilated) motors may be installed where dirt, moisture and corrosion are
present, or in outdoor locations. For locations were motors will be exposed to
washdown or severe weather, washdown duty motors are recommended.

WARNING: For locations considered hazardous or flammable, check National Electric

Code, NEMA, and UL standards to make sure that explosion-proof motors
are not required. Note the UL labeling (certification) is required in some
hazardous locations.
2
 D. All general purpose and washdown duty cast iron motors and general purpose
rolled steel motors are configured for horizontal foot mounting (F-1 or F-2) as
standard. For all other mounting positions including vertical, ceiling, or wall
mount, consult factory.

E. All stainless steel and rolled steel washdown duty motors can be mounted in
any position as long as the condensation drain plugs are removed in the
proper location and the supplied T-drains are installed. Failure to do so will
void the warranty. Please refer to the condensation drain instructions supplied
with the motor.

Environment

A. Temperature
1. For standard motors, ambient operating temperature is normally
within the range of –15 to 40°C (5 to 104°F).

2. In case of excessive ambient temperature, or excessive heat,

protective measures, such as forced cooling or heat insulating should
be applied or the load should be reduced.

3. If the ambient temperature is too low, space heaters may need to be

added to the motor.

B. Ventilation
1. All motors will require the free circulation air whether the enclosure is
ODP, TEFC, or TENV. If the motor is installed in poorly ventilated
area, steps may have to be taken to guard the motor against over-
heating which may include de-rating the motor or reducing the load.

2. For ODP motors with internal fans and TEFC motors with external
fans, a clearance of at least (8) inches from ventilation ports is
required around motor to assure proper airflow.

C. Humidity
1. If the motor is installed outdoors or in very damp or wet environments,
steps may have to be taken to guard the motor against excessive
moisture or a washdown duty motor should be used.

D. Dust
1. ODP Enclosure
A large accumulation of dust on windings and cooling ducts will result
in over-heated windings leading to insulation breakdown. In severe
cases, dust accumulated on the rotor, not evenly distributed, can
cause vibration. If dust particles get into the bearings, the lubricant
should be changed as soon as possible to prevent damage.

2. TEFC Enclosure
A large accumulation of dust on the fame, fins, and other surfaces will
greatly reduce heat dissipation. If the dust accumulated on cooling
fans or transmission device is not evenly distributed poor balance and
vibration can occur.

3
 3. TENV Enclosure
A large accumulation of dust on the frame and other surfaces will
greatly reduce heat dissipation.

E. Gases and Steam

1. If corrosive, flammable, or other chemical gases, or steam exist in the
environment, motors of explosion-proof type or corrosion protective
motors should be chosen; particular attention should be placed on
motor selection, when flammable gases, dust, or steam, which are all
liable to fire hazard, exist.

WARNING: For hazardous locations, check National Electric Code, NEMA, and UL
standards to make sure the explosion-proof motors selected are
satisfactory. Note UL labeling (certification) is required in some hazardous
locations.

Foundation

A. The ground footing or foundation on which motors are installed must be hard
and stable and not susceptible to vibration from surrounding equipment. If not,
vibration may become excessive, especially when coupled to machines such
as crushers and reciprocating compressors. Vibration of a large amplitude
while the motor is running can bring about the following failures:
1. The service life of bearings may be reduced.

2. Parts may come loose or become displaced.

3. Cooling fans or other parts on rotor may fail due to material fatigue.

4. The insulation on the windings could be damaged.

B. Severe vibration from the environment may induce vibration on motors causing
some damage. Depression on roller bearings can occur during idle periods
(when the motors are not running).

Power Supply

A. Nameplate voltage and frequency must agree with power supply. Motor will
operate satisfactorily on line voltage within 10% of nameplate value or
frequency within 5%. The combined variation is not to exceed 10%. 230 volt
motors can be used on 208 volt network systems, but with slightly modified
performance characteristics.

B. Dual voltage motors can be connected for the desired voltage by following the
connection diagram on the nameplate. For motors capable of alternate
starting methods such as part winding start and wye start-delta run, the proper
connections are located on a connection diagram inside the conduit box cover
or consult factory.

C. Wiring of motor and motor control, overload protection and grounding should
be in accordance with the National Electric Code and/or local building codes.

4
 D. The following are the connection diagrams for STANDARD 3-phase general
purpose 9-lead and 12-lead dual voltage motors. For all other connections
such as two speed motors, 1-phase motors, alternate starting methods, etc.,
consult factory.

9 LEADS 12 LEADS

Thermal Protection

The motor nameplate will indicate whether the motor is thermally protected.
These are Normally Closed (NC) “Klixons” that open when a predetermined
temperature is reached breaking continuity. Thermal protection leads are
labeled P1 and P2 and are to be connected in series with the motor magnetic
starter holding coil or magnetic starter assembly. For inverter duty motors
used with VFD (Variable Frequency Drive) controllers, connect to interlock
circuitry so that the contact will open to stop the controller in the event that the
motor overheats.

Altitude

If the motor location is more than 3300 feet above sea level, the operating
temperature of the motor will be 5 to 10°C higher. The motor may require de-
rating to allow for this additional heating. Consult factory.

Alignment Procedures

Since poor alignment will bring about vibration and early bearing failure it is
essential to be accurate when doing alignment of the motor to the driven
equipment. The following steps should be taken to obtain proper alignment to the
driven equipment.
1. Use a level instrument to adjust the level mounting plate or surface to
which the flange of the motor will mount.

2. Check the (up and down) endplay of the shaft of driven machine.

3. Mount the motor on the mounting plate and/or driven equipment. Install
mounting bolts but do not tighten. Mounting hardware should be grade 5
or higher.

4. Check angular alignment by using a feeler gauge between coupling hubs

at four points, 90 degrees apart. Position the motor to obtain best
possible alignment and correct coupling hub separation. Consult factory,
equipment supplier, or coupling manufacturer for proper values.

5
 5. Check the offset alignment between the two shafts. Use a dial indicator
mounting on one hub (motor side, for example), with the dial indicator
button contacting the alignment surface of the opposite hub. Rotate the
opposite shaft slowly by hand and take a reading on at least four equally
spaced points. Move motor until the indicator movement does not
exceed 0.002 in. Transfer indicator to opposite hub and recheck.
Recheck angular alignment as described above.

6. After each corrective adjustment is made, connect the couplings and

tighten the motor and mounting plate bolts. Recheck the alignment and
correct if necessary.

Belts

A. V-Belt Sheave Pitch Diameters should not be less than the NEMA
recommended values. Refer to NEMA MG1-14.41.

B. Tighten belts only enough to prevent belt slippage. Belt speed should not
exceed 5000 feet per minute.

START UP

1. If the motor has become damp or has been in storage for a prolonged period of time,
measure the insulation resistance of the stator winding. For motors rated 600V and
below the minimum resistance should not be less than 1 megaohm.
If the insulation resistance measures less than the desired value, in may be necessary
to dry the windings, especially if the motor has been stored in a damp location. In
drying, DO NOT exceed 90°C (194°F).

2. Disconnect load and start motor. Check direction of rotation. Interchange any two
line leads to reverse rotation on 3-phase motors.

3. Connect the motor to load referring to procedures above for mounting and alignment.
The motor should start up quickly and run smoothly. If not, shut power off at once.
Recheck the assembly including all connections before restarting.

4. Operate under load for at least one hour. Observe whether any unusual noise or
heating has developed and check operating current against nameplate data.

5. If excessive vibration is noted, check for loose mounting bolts, too flexible of a motor
support structure, or transmitted vibration from adjacent machinery. Recheck the
coupling alignment between the motor and the driven equipment.

6
 MAINTENANCE
A. Inspection
Inspect motor at regular intervals.
Keep motor clean and ventilating openings clear of any obstructions. Double
check the mounting bolts and couplings to ensure that they are tight and
properly adjusted.
Check belt tension and adjust of necessary.

B. Lubrication
Motors in storage longer than 2 years should have the bearings inspected
and/or replaced before putting the motor into service.

Motors with pre-lubricated double sealed bearings (bearing suffix LL, VV, or
UU) or double shielded bearings (bearing suffix ZZ) do not need to be re-
lubricated and are considered lubricated for life. However, it is recommend
changing bearings at times shown, but if not changeable, you can re-lubricate
by removing seal plate, cleaning and refilling the bearing and bracket cavity
with the recommended grease.

Motors with re-greasable bearings have sufficient lubrication from the factory
for storage up to 2 years. However, bearings should be re-lubricated when the
motor is initially put into service and at the intervals shown below thereafter, or
whenever the motor has been inoperable for more than 2 months.

FREQUENCY OF RELUBRICATION

MOTOR FRAME TYPE OF SERVICE

RPM VS. HP STANDARD HEAVY DUTY
8 HR/DAY 24 HR/DAY
143T - 286TS * *
3600 1.5 - 30
324TS - 445TS 6 MONTHS 2 MONTHS
40 - 150
143T - 256T * *
1 - 20
1800 284T - 326T 4 YEARS 18 MONTHS
25 - 50
364T-445T 9 MONTHS 3 MONTHS
60 - 150
143T - 256T * *
.75 - 10
1200 284T - 326T 4 YEARS 18 MONTHS
15 - 30
364T - 445T 1 YEAR 4 MONTHS
40 - 125
* Motors of this size normally do not have bearings that can be re-lubricated.
These bearings should be replaced at least every 5 years for 8 hr/day service, or
every 2 years for 24 hr/day service.

7
 C. Instructions for lubricating
Motors with re-greasable type bearings are to be lubricated using the following
steps. See the figure below for reference.

Item Description Item Description

Number Number
1 Grease Fitting 8 Roller Bearing
2 Grease Fitting Extension Pipe 9 Motor Shaft
3 Outer Bearing Cap 10 Grease Relief Cover Plate
4 Bearing Lock Washer 11 Cover Plate Thumb Screw
5 Bearing Lock Nut 12 Bolt
6 Motor End Bracket 13 Outer Bearing Cap
7 Inner Bearing Cap

1. Remove plastic cap covering grease fitting on both end brackets.

2. Remove pipe plug or cover plate opposite grease fitting for grease relief.

3. Be sure fittings are clean and free from dirt.

4. Using a low-pressure grease gun, pump in the recommended grease

until new grease appears at the grease relief hole.

5. After relubricating, allow motor to run for 10 minutes to purge any excess
grease before replacing any pipe plugs or cover plates in the end
brackets.

6. Remove discharged grease from relief area, clean area thoroughly, and
replace pipe plugs or cover plate.

D. Recommended Greases
Unless special grease is specified on the motor nameplate, standard Sterling
Electric motors use lithium based NLGI grade #3 bearing grease. Use the
following compatible grease: Shell Alvania R3, BP Energrease LS3, Castrol
Spheerol MP3, Esso Beacon 3, Gulf Gulfcrown Grease No.3, Texaco Multifak
Premium 3, Mobil Mobilux EP3, Kluber Centoplex 3.

8
 E. Lubrication Amounts
The following replenishment amounts are for motors with provisions for re-
greasable bearings. Typically smaller motors (250 and below) do not have this
feature.

NEMA Frame Size Volume (fl-oz)

280T 1.13
320T 1.13
360T 1.87
400T 1.87
440T 1.87

CAUTION: The amount of grease in the bearings is critical. Too little grease or too
much grease will cause excessive wear, noise, and elevated running
temperatures leading to premature bearing failure and possible permanent
motor damage. Refer to motor nameplate or table above for amount and
type of grease, or consult factory.

REPLACEMENT PARTS

A. Sterling Electric motors use commercially available bearings and seals (where
appropriate) that can usually be sourced locally. For all other items or items
that are not readily available, consult factory.

B. When ordering replacement parts, include the unit model number, serial
number, item number and description (from parts list), and the quantity
required.

WARRANTY

Generally, Sterling Electric will correct by repair or replacement any defect in material and
workmanship when properly used for a period of one year after installation, or 18 months
after shipment, whichever one comes first. Sterling Electric is not responsible for
apparatus returned without proper authorization and identification, improper handling or
storage, misapplication of the motor or the driven equipment or device. Sterling Electric,
as a motor manufacturer, sells quality motors that are warranted to perform at a given
load condition with performance characteristics in accordance with NEMA Standards.
Sterling Electric is not responsible for the application, installation, or proper maintenance
of the motor. Proper application, and whether a given motor is suited for a given
application, is the responsibility of the purchaser and/or user of the motor. Refer to the
complete Conditions of Sale and Warranty available from any Sterling Electric authorized
distributor or factory representative.

9
 TROUBLE SHOOTER’S GUIDE BASED ON SYMPTOMS

SYMPTOMS CAUSE RESULT REMEDY

1. Motor does a. Incorrectly connected. a. Burnout a. Connect correctly per
not start. diagram on motor.
b. Incorrect power supply. b. Burnout b. Use only with correct rated
power supply.
c. Fuse out, loose or open c. Burnout c. Correct open circuit
connection. condition.
d. Open control circuit. d. None d. Correct open circuit
condition.
e. Rotating parts of motor e. Burnout e. Check and correct:
may be jammed 1. Bent shaft
mechanically. 2. Broken housing
3. Damaged bearing
4. Jammed or broken fan
5. Foreign material in motor
f. Driven machine may be f. Burnout f. Correct jammed condition.
jammed.
g. No power supply. g. None g. Check voltage at motor and
work back to power supply.
2. Motor starts, but a. Same as 1-a, b, c above.
does not come up
to speed.
b. Overload b. Burnout b. Reduce load to bring
current to rated limit. Use
proper fuses and overload
protection.
3. Motor noisy a. Same as 1-a, b, c above.
electrically
SYMPTOMS CAUSE RESULT REMEDY
4. Motor runs hot. a. Same as 1-a, b, c above.
Exceeds rating.
b. Overload b. Burnout b. Reduce load.
c. Impaired ventilation. c. Burnout c. Remove obstruction.
d. Frequent start or stop. d. Burnout d. 1. Reduce number of starts
or reversals.
2. Secure proper motor for
this duty.
e. Imbalance in voltage or e. Burnout e. Check and correct power
frequency of power supply.
supply.
5. Motor noisy a. Misalignment of coupling a. Bearing failure, broken a. Correct misalignment.
mechanically or sprocket. shaft, burnout due to
rotor drag.
b. Mechanical unbalance of b. Same as 5-a b. Find unbalanced part, then
rotating parts. rebalance.
c. Lack of or improper c. Bearing failure c. Use correct lubricant, and
lubricant. replace parts as necessary.
d. Foreign material in d. Same as 5-c d. Clean out or replace
lubricant. bearing.
e. Overload e. Same as 5-c e. Remove overload condition.
Replace damaged parts.
f. Shock load. f. Same as 5-c f. Correct causes and replace
damaged parts.
g. Mounting acts as g. Annoying g. Isolate motor from base.
amplifier
of normal noise.
h. Rotor dragging due to h. Burnout h. Replace bearings, shaft or
worn bracket as needed.
bearings, shaft or
bracket
6. Bearing a. Same as 5-a, b, c, d, e a. Burnout, damaged a. Replace bearings and follow
failure above. shaft or housing 5-a, b, c, d, e above.
b. Entry of water or foreign b. Same as 6-a b. Replace bearings and shield
material into bearing above against entry of foreign
housing. material (water, dust, etc.)
Use proper motor.

10
 TYPICAL BURNOUT PATTERNS

SYMPTOM CAUSED BY APPEARANCE

1. Shorted coil a. Moisture, chemicals, foreign a. Black or burned coil with remainder
material in motor, damage of winding good.
winding.
2. 100% Burnout a. Overload. a. Burned equally all around winding.
b. Stalled. b. Burned equally all around winding.
c. Impaired ventilation. c. Burned equally all around winding.
d. Frequent reversal or starting. d. Burned equally all around winding.
e. Incorrect power. e. Burned equally all around winding.
3. Single phase a. Open circuit in one line. The most a. If 1800 RPM motor-four equally
condition. common causes are loose connection, burned groups at 90 intervals.
one fuse out, loose contact in switch
or contactor. b. If 1200 RPM motor-six equally
burned groups at 60 intervals.

c. If 3600 RPM motor-two equally

burned groups at 180 apart.

NOTE: If WYE connected each burned

group will consist of two adjacent phase
groups. If DELTA connected each
burned group will consist of one phase
group.
4. Other a. Improper connection. a. Irregular burned groups or spot
burns.
b. Ground b. Badly damaged burn spot.

11
 PARTS LIST ** TOTALLY ENCLOSED FAN COOLED (T.E.F.C.)

ITEM DESCRIPTION ITEM DESCRIPTION

1 Wound Stator w/Frame 9 Lead Seal

2 Rotor Assembly 10 Wave Washer 56 - 320T
3 Rotor Core Bearing Shim 360T - 440T
4 Shaft 11 Slinger
5 Bracket, Drive End 12 Outside Fan
6 Bracket, Opp. Drive End 13 Fan Cover
7 Bearing, Drive End 14 Conduit Box Assembly
8 Bearing, Opp. Drive End 15 Lifting Eye

BEARINGS

FRAME T-SERIES T-SERIES E-SERIES E-SERIES N,R-SERIES N,R-SERIES S,X,D-SERIES S,X,D-SERIES

7 8 7 8 7 8 7 8
56 6205ZZ* 6204ZZ 6205LL 6204LL
140T 6205LL 6205LL 6205ZZ 6205ZZ 6205LL 6204LL
180T 6206LL 6206LL 6207ZZ 6206ZZ 6306LL 6206LL**
210T 6208LL 6208LL 6308ZZ 6208ZZ 6308LL 6306LL
250T 6309LL 6309LL 6310ZZ 6208ZZ 6309LL 6309LL
280T 6311CLL 6311CLL 6310ZZ 6210ZZ 6311LL 6311LL
280TS 6311C3LL 6311C3LL 6310C3 6210C3 6311C3LL 6311C3LL
320T 6312C3 6312C3 6312ZZ 6212ZZ
320TS 6312C3 6312C3 6312C3 6212C3
360T 6314 6314 NU215 6312
360TS 6314C3 6314C3 6312C3 6312C3
400T 6316 6316 NU218 6313
400TS 6316C3 6316C3 6313C3 6313C3
440T NU316 6316 NU220 6315
440TS 6316C3 6316C3 6313C3 6313C3
* N-Series footed models with non-C-face output end have 6204ZZ bearings on both ends.
** 2P (3600RPM) 180T X-Series stainless steel motors and D-Series rolled steel motors have 6305LL bearing at position 8.

12
 PARTS LIST ** OPEN DRIP PROOF (O.D.P)

ITEM DESCRIPTION ITEM DESCRIPTION

1 Wound Stator w/Frame 9 Lead Seal

2 Rotor Assembly 10 Wave Washer 56 - 320T
3 Rotor Core Bearing Shim 360T - 440T
4 Shaft 11 Slinger
5 Bracket, Drive End 14 Conduit Box Assembly
6 Bracket, Opp. Drive End 15 Lifting Eye
7 Bearing, Drive End 16 Air Deflector
8 Bearing, Opp. Drive End

BEARINGS

FRAME E-SERIES E-SERIES J-SERIES J-SERIES C,P-SERIES C,P-SERIES

7 8 7 8 7 8
56 6204ZZ 6203ZZ
140T 6205ZZ 6205ZZ
180T 6306ZZ 6206ZZ
210T 6308ZZ 6208ZZ 6308ZZ 6208ZZ
250T 6309ZZ 6208ZZ 6309ZZ 6208ZZ
280T 6312ZZ 6211ZZ 6312ZZ 6211ZZ
280TS 6311C3 6311C3 6311C3 6311C3
320T 6313 6312 6313 6312
320TS 6312C3 6312C3 6312C3 6312C3
360T 6314 6314 6314 6314
360TS 6313C3 6313C3 6313C3 6313C3
400T 6317 6317 6317 6317
400TS 6313C3 6313C3 6313C3 6313C3
440T NU318 6318 NU318 6318
440TS 6313C3 6313C3 6313C3 6313C3

13
 Engineering Service Bulletin 21
Installation, Operation and Lubrication Instructions

Stainless Conveyor Drive

Stainless Conveyor Drive, Operation and Lubrication Instructions

I. INSTALLATION
1. Shaft Alignment and Loading if tight initially. Doweling the motor and speed reducer to the base plate
will help ensure that alignment is maintained.
A. The various drive components (motor, speed reducer, couplings,
sprockets, sheaves, gears, etc.) should be aligned as accurately as D. Excessive thrust or overhung loads on the input or output shafts of
possible to guard against unusual stresses and overloads imposed by a gear reducer may cause premature failures of the bearings and/or
misalignment. shafts. Mount gears, pulleys and sprockets as close to the housing as
possible to minimize such loads. Do not exceed catalog loads.
B. The Winsmith Stainless Conveyor Drive is designed for direct motor
mounting to the input flange and shaft . If other input arrangements are
required, contact the Winsmith Factory. If the output shaft is to be directly
2. Mounting Positions
connected to the driven shaft, flexible couplings should be used. It should Single reduction reducers are designed to accommodate most standard
be remembered that even flexible couplings have limited ability to mounting positions. To minimize bacteria traps, mounting holes are
accommodate misalignment. Care must be taken at installation to ensure provided only on the bottom of the housing closest to the output shaft.
that shaft alignments are within the limits recommended by the coupling Figure 1 illustrates the utility plug locations for each mounting
manufacturer. Use of a rigid coupling to connect speed reducer shafts to orientation. Contact Winsmith for mounting orientations not shown in
other drive components is not recommended. Figure 1. All standard single reduction models are equipped with an
internal splash shield located near the worm. This shield deflects the oil
C. A common base plate supporting the motor and reducer is not
from the vent, preventing leakage when the vent plug is adjacent to the
usually required, but will help preserve the original alignment between
worm (as on the worm over gear traditional mounting). When this location
reducer and motor shafts. If a structural steel base is used, the plate
is used as a drain (as on the inverted mounting), drainage will be better
should be at least equal in thickness to the diameter of the bolts used to
facilitated if done at or near the operating temperature. Filling from this
fasten the speed reducer to the base plate. Also, for sufficient rigidity, the
location is not recommended, as the shield will impede the oil flow rate.
design in general should be substantial enough to minimize flexing under
Bearings are splash lubricated, provided the input speed is 1160 RPM or
vibration. After the first week or two of operation all of the fasteners used
greater. Contact a local Winsmith sales representative when input speeds
to mount the reducer and motor, pedestal, etc., to the base plate should
fall below 1160 RPM.
be retightened. Vibration tends to loosen the fasteners even
 Stainless Conveyor Drive
lubricant to a “universal” level. Consequently, the oil level as
received may be slightly above or below the level plug shown
3. Venting
in Figure 1. This fill level will work for any of the orientations
During operation, the heat generated by the gearbox will cause the air shown in Figure 1 and does not need to be adjusted.
and lubricant inside the reducer to expand. An optional vent can be used
to equalize the resulting pressure. The location of the vent on the housing
2. Ambient Temperature
depends on the model and mounting position. Before putting the reducer If the ambient temperature during operation is outside of -18 to 130
into service, review Figure 1 and locate the vent as shown for the degrees F, please contact a local Winsmith sales representative.
appropriate model and mounting position. To prevent loss of oil during
shipment, the vent plug location is blocked with a hex head plug, 3. Initial Start-Up
which must be removed and replaced with the supplied vent prior to
During the initial start-up operation, a break-in period is necessary
operation. For intermittent duty, or severe environment applications,
before the reducer reaches maximum operating efficiency. Winsmith
where the operating temperature does not rise more than 20 to 40
recommends a gradual application of load during the first several hours
degrees F, internal pressure build-up is minimal and venting is not
after start-up. The reducer may run hot during this initial break-in period.
recommended. Caution! Current venting technology may not
This is normal.
completely keep out all contaminants, therefore WINSMITH
recommends monitoring the condition of the oil and replacing it as
necessary (see section II #4 Oil Change Instructions). 4. Oil Change Instructions
When changing the oil for any reason, use only Mobil Glygoyle 460 or
4. C-Flange Motor Mounting Procedures other compatible PAG (Polyalkylene glycol) synthetic lubricants. If another
A. Check motor and reducer mounting registers for nicks that would oil type is used (PAO, Mineral Oil, etc.), the housing(s) must be drained
interfere with assembly. Remove if necessary. Remove protective plastic and thoroughly flushed with a light flushing oil prior to refilling. Do not
plug from reducer input shaft. The bore has been coated with an anti- mix different lubricants in the reducer. Lubricant incompatibility may
seize compound. Verify the white rubber face seal is present on the input result in premature failure. Note: When changing oil, carefully inspect
flange. Align the motor shaft and key with keyway in bore and slide motor used oil to be sure there are no metal shavings, fragments or other signs
up to flange. Note: An input bushing with key may be installed in worm of excessive wear.
bore to reduce the possibility of fretting corrosion. Position the motor The oil level should be checked after a short period of operation and
conduit box as desired. Using the stainless steel fasteners supplied, adjusted if necessary. Each housing of a double reduction model should
secure the motor to the reducer. Draw down evenly so as not to bend the be drained and filled independently when changing the oil. Visit our
motor shaft. Tighten the fasteners to the appropriate torque per the size website, www.WINSMITH.com, for a detailed flushing procedure.
and the material of the fastener.
In many light duty, relatively clean ambient conditions, the life of Mobil
B. Winsmith stainless steel reducers are designed to utilize a rubber Glygoyle 460 is extended to the point where a reducer can operate for
seal on the flange face between the reducer and the input motor. This the AGMA/ISO specified "Normal" reducer life of 25,000 hours without
seal is designed for severe environmental conditions and is necessary to ever changing the lubricant.
minimize the risk of water and/or other contamination within the reducer.
This seal should be replaced whenever the motor is replaced. Note: The “Normal” reducer life of 25,000 hours specified in AGMA 6034-
B92 and ISO TR 14521 is highly application dependent. In Winsmith’s 100
years of experience, we have found that the actual service life of many of
II. LUBRICATION & MAINTENANCE our reducers exceeds 25,000 hours by several multiples. Under severe
1. Factory Filling conditions (rapid temperature changes, moist, dirty, or corrosive
environments) it may be necessary to change the oil at intervals of 1-3
Winsmith Stainless Conveyor Drives are factory filled
months. Periodic examination of oil samples taken from the reducer will
with Mobil Glygoyle® 460 (PAG) lubricant. The use of
help establish the appropriate interval.
other lubricants may result in substantially lower torque
capacity and is not recommended by Winsmith. If other The oil change procedure for all Winsmith speed reducers is similar. The
lubricants are used, a thorough flushing procedure appropriate oil fill, drain, and level plugs are identified in Figure 1. Please
is required. note that these locations are unique for each operating position shown.

NOTE: Winsmith Conveyor Drives are factory filled with *Glygoyle is a registered trademark of Exxon Mobil Corporation or one of its subsidiaries.
After draining the old lubricant, new lubricant should be added to the
appropriate level plug shown. It is important to clean the threads of oil Note: Initial operating temperatures may be higher than normal during
plugs and apply thread sealant proir to re-installation. the break-in period of the gear set. However, continuous operation above
212°F (as measured on the external housing) may cause damage to seals
Mounting Position and Lubricant Levels for Single
or other components and reduce the reducer operating life. Excessive oil
Reduction Models
temperatures may be the result of one or more of the following factors:
Optimal lubricant level information for single reduction models is shown
A. Overloads
in Figure 1. Lubricant levels are critical to the proper operation of all
speed reducers. If a speed reducer was ordered and supplied for a Overloads may be due to the original reducer selection being too small for
specific mounting position, it should not be changed without contacting the application, or increased loads on the speed reducer to a point where
Winsmith. Altering the mounting position from that which was specified its rating is exceeded after it has been in service for a period of time.
may result in inadequate lubrication. Contact a local Winsmith sales Always check the speed reducer rating when increasing driven loads or
representative with questions regarding proper lubricant selection increasing the horsepower rating of the motor or other prime mover.
and level. B. Overfilling or Under-filling
If a speed reducer is overfilled with oil, the energy used in churning the
5. Long Term Storage or Infrequent Operation
excessive oil can result in overheating. If this occurs, shut down the drive,
If a speed reducer is to stand idle for an extended period of time, either remove the oil level plug and allow the oil to drain until oil ceases to drain
prior to installation or during use, it is recommended that the reducer be from the level hole, reinstall the oil level plug and restart the drive. If the
filled completely with oil to protect interior parts from rust corrosion due speed reducer is under-filled, the resultant friction can cause overheating
to internal condensation. Remember to drain the oil to the proper level and possible damage. If this occurs, check the gearing for excessive wear
before placing the speed reducer in service. A long-term storage option is and then fill the speed reducer to the oil level plug hole.
available on new reducers. Contact a local Winsmith sales representative
C. Inadequate Cooling
for details.
In order to dissipate internally generated heat, the speed reducer must be
6. Low Input Speeds (Under 1160 RPM) installed in such a way that air can circulate freely. Tightly confined areas
(inside cabinets, etc.) should be avoided. If this is not possible, forced air
When input speeds are less than 1160 RPM, grease fittings will be
cooling by means of a separate blower should be used. If possible the use
required to lubricate any bearings not partially covered by the normal oil
of a fan-cooled motor is recommended to increase airflow.
level. Such reducers are considered non-standard and require factory
modification. If this low speed operating condition exists and reducers are
8. Surface Treatments
without the appropriate grease fittings, please contact a local Winsmith
sales representative. Do Not Paint Reducer! All exterior 300 series stainless steel surfaces
have been passivated; no further treatment is required. Washing the
7. Oil Temperature reducers can effectively clean the surface. Do not use steel wool pads as
they can induce rust. Thorough rinsing to remove any industrial solvent
Speed reducers in normal operation can generate temperatures up to
residue is highly recommended. Care should be exercised when rinsing
212°F (as measured on the external housing) depending on the type of
with high-pressure techniques to avoid prolonged wash-down of vents
reducer and the severity of the application (loading, duration of service,
and seals. Drying after wash-down is recommended to prevent mineral
ambient temperatures).
deposits. Abrasive techniques should be avoided especially on the
optional #4 pharmaceutical surface finish units.
FIGURE 1 KEY
F &V F&L F&V
V V
L
L

F&L

D D D D

- Contact Winsmith for mounting orientations not shown in Figure 1 or when input speeds are less than 1160 RPM.
 Product Information/Cautions
CAUTIONS/WARNINGS NOT A SUPPORT STRUCTURE
Winsmith products, and associated equipment and machinery, are intended for selection and use by A speed reducer must never be used as an integral component of a machine superstructure or support
trained and skilled persons capable of determining their suitability for the specific application or use. frame that would subject it to additional loads other than properly rated loads transmitted through
Proper selection, installation, operation and maintenance, including implementation of adequate the shafts.
safety precautions, are the responsibility of the purchaser or user. The following safety precautions,
MOUNTING POSITION
as well as additional safety precautions that may be required for the specific application or use, are
The speed reducer should be mounted in one of the mounting positions shown in the catalog.
the responsibility of the purchaser or user. FAILURE TO OBSERVE REQUIRED SAFETY PRECAUTIONS
Different mounting positions should not be used without contacting Winsmith as this may result in
COULD RESULT IN SERIOUS INJURY TO PERSONS OR PROPERTY OR OTHER LOSS.
improper lubrication.
LOCK-OUT/TAG-OUT
OVERHEAD MOUNTING
It is EXTREMELY IMPORTANT that all equipment or machinery does not unexpectedly start. To prevent
Mounting of a speed reducer in overhead positions may be hazardous. Use of external support rails
this possibility, all electrical or other input power sources must be turned off, and properly locked
or structure is strongly recommended for any overhead mounting.
out. Tag out procedures must be followed before working on or near the reducer or any associated
equipment. Loads on the input and output shafts should be disconnected prior to working on any LIFTING EYEBOLTS
reducer. Failure to observe these precautions may result in serious bodily injury and/or property Any lifting supports or eyebolts provided on the speed reducer are supplied with the purpose of
damage. vertically lifting only the speed reducer, without any other attachments or motors. Inspect such
supports and bolts before each use.
GROUNDING
Be sure the reducer and associated equipment are properly grounded and otherwise installed in PROPERLY SECURE MOUNTING BOLTS
accordance with all electrical code requirements. Proper mounting bolts and proper torques must be applied and maintained to insure the speed
reducer is securely mounted to the desired machinery. Inspect regularly as machine vibration may
PROTECTIVE GUARDING/LOOSE CLOTHING, ETC.
loosen fasteners.
Always ensure there is proper protective guarding over all rotating or moving parts. Never allow
loose clothing, hair, jewelry and the like to be worn in the vicinity of rotating or moving parts or THREAD LOCKING COMPOUND
machinery. The purchaser or user is responsible for complying with all applicable safety codes. Proper thread locking compound should be appropriately applied to the cleaned threads of all
Failure to do so may result in serious bodily injury and/or damage to properly or other loss. mounting bolts connecting or securing the speed reducer to equipment and any drive, accessories, or
brake components attached to the speed reducer. If, at any time after installation a factory supplied
SELECTION & INSTALLATION
assembly or construction bolt is removed, care must be taken to thoroughly clean off the old thread
This speed reducer and associated equipment must be selected, installed, adjusted and maintained by
locking compound and new appropriate thread locking compound must be applied. Failure to
qualified personnel who are knowledgeable regarding all equipment in the system and the potential
properly apply new thread locking compound on all mounting or reducer construction bolts may
hazards involved.
result in serious injury or death from falling mechanical components.
CONSULT CATALOG RATINGS
REDUCER SURFACE IS HOT
Load, torque and other requirements must not exceed the published ratings in the current catalog
Operating speed reducers generate heat. Surface temperatures may become hot enough to cause
and/or on the speed reducer nameplate. The reducer selected must be consistent with all service
severe & burns. Proper personal protective equipment should be used.
factors for the application. See Winsmith catalogs and www.WINSMITH.com.
NOISE
BRAKE TORQUE LOADS
Operating speed reducers may generate high noise levels. Use appropriate hearing protection and
Whenever a brake or any other stopping force is involved in an application, braking torque loads
avoid extended exposure to high noise levels.
imposed on the speed reducer must not exceed the allowable load ratings.
LUBRICANTS HOT AND UNDER PRESSURE
NOT A BRAKE
The temperature of lubricants inside a speed reducer may be very high. The reducer should be
Speed reducers should never be used to provide the function of a fail safe brake or an assured safe
allowed to cool to ambient temperature before removal of any vent, drain, level, or fill plugs, and
locking device. Speed reducers must never be used to replace a brake or a critical braking
before removing seals or bearing covers. Speed reducers without a pressure vent may also be under
application function.
great internal pressure, Slowly loosen the lubricant fill plug above the lubricant level to vent any
EXCESS OVERHUNG LOADS internal pressure before further disassembling.
Excessive overhung loads on the input or output shafts of a speed reducer may cause premature
LUBRICANT CONTACT
failures of the bearings and/or shafts. Mount gears, pulleys and sprockets as close to the housing as
Contact with lubricants can present safety concerns. Proper personal protective equipment should be
possible to minimize such loads. Do not exceed catalog ratings.
used whenever handling speed reducer lubricants. Consult the lubricant Safety Data Sheet (SDS)
EXCESS THRUST LOADS which is often available on the lubrication manufacturer's website.
Excessive thrust loads on the input or output shafts of a gear reducer may cause premature failure
FDA, USDA, AND NSF APPLICATIONS
of bearings. Do not exceed catalog ratings.
Factory supplied lubricants may not be suitable or safe for applications involving food, drugs and
ALIGNMENT similar products. This includes applications subject to FDA, USDA, NSF or other regulatory jurisdiction.
Properly align any input and output power transfer elements connected to the speed reducer. Even Consult the lubricant supplier or Winsmith for acceptable lubricants.
slight misalignments in a rigid mounting system may cause binding, large vibration forces or
INSPECTION AND LUBRICATION
excessive overhung loads, leading to premature bearing, shaft, or speed reducer failure. Use of
Ensure proper operation by regularly inspecting the speed reducer and following all maintenance,
flexible couplings that allow the reducer and connected transfer elements to self-align during
operation and lubrication guidelines.
operation will compensate for minor misalignments.

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SPRINGVILLE, NEW YORK 14141-1197
PHONE: 716/592-9310
FAX: 716/592-9546 PWS-198989-April 1/15
www.WINSMITH.com Printed in U.S.A.