TUBULAR DRAG CONVEYOR - Walter S. Reiss

Ideas that move

TUBULAR DRAG CONVEYOR

INSTALLATION,
OPERATION
&

MAINTENANCE
MANUAL

REV 9/07

All owners and operators should read this manual and/or be
instructed on safe operating and maintenance procedures before

attempting to uncrate, install, operate, adjust or service this
equipment

Following are symbols used in this manual along with a description of their meanings

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or severe
injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, will result in death or severe
injury

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor/moderate
injury and/or damage to equipment.

HAPMAN

TUBULAR DRAG CONVEYOR

Table of Contents

Definition of Warning Symbols.............................................................................. 2
Major Feature Index .............................................................................................. 4
1.0 - Warranty....................................................................................................... 5
2.0 - Introduction ................................................................................................... 6
3.0 - Safety Instructions ........................................................................................ 7
4.0 - Principles of Operation ................................................................................. 9
5.0 - Receiving your Equipment.......................................................................... 10
6.0-Storage ...................................................................................................... 10
7.0 - Conveyor Assembly and Erection............................................................... 10
8.0 - Tubular Chain Installation .......................................................................... 12
9.0 - Adjusting the Chain..................................................................................... 16
10.0- Adjusting the Sprocket.............................................................................. 17
11.0 - Adjusting the Chain Rotation .................................................................... 17
12.0- Starting and Adjusting............................................................................... 18
13.0- Suggested Conveyor Maintenance........................................................... 19
Tables

Maintenance Schedule ................................................................................. 20
Troubleshooting ........................................................................................... 21
Spare Parts List ........................................................................................... 21
Drive Identification (for servicing) ................................................................. 22
Lubrication - grease lubricated units ........................................................... 22
Lubrication - oil filled units ............................................................................ 23
Addendums
Electronic shear pin system ......................................................................... 25

Major Features Index

Typical Circuitry for Tubular Drag Configuration

1. Flighted Chain
2. Casing Flange or) Compression Coupling
3. Casing
4. Discharge Port
5. Drive Box (Optional, not shown)
6. Access Port
7. lnfeed Receiver
8. Vibrator (Optional
9. Reducer
I O.Take-up Adjustment
11. Idler Box

Note: The marker numerical designations listed in this
illustration are for reference purposes only within this
manual.

Drive Arrangements

1. Motor (position vanes)
2. Drive shaft
3. Take-up rod for drive
4. Traversing drive plate
5. Drive box
6. Hold down
7. Speed reducer*

*j fill plug (will be in the uppermost position)
*Oil level plug (will be in the middle position)

Note: The marker numerical designations listed in
above illustration is for reference purposes only within
this manual.

Drive Boxes Which May Be Used

k QRrent production drroe (Qect) The drive boxes shown are in order of evolution over the years. Early
B MIS production duve (Dodd) drives may have been belt/chain or direct drive. Each drive may have a
differing look and possibly differing lubrication requirements (detailed in
the back of this manual) but all perform in a similar manner.

C. Beginning production drive (Belt/chain or Direct)

REV 9/07 4

der Arrangement

There are 2 possible styles
Configuration I - WITH take-up

1. Shaft
2. Idler Bearing
3. Packing Gland
4. Hold Down
5. Take-up Rod
6. Slide Plate
7. Idler Box

der Arrangement

Configuration 2 - WITHOUT take-up

1. Shaft
2. Idler Bearing
3. Idler Box
4. Sprocket

Note: The marker numerical designations listed in
above illustrations are for reference purposes only
within this manual.

I O - WARRANTY

Equipment manufactured by Hapman is warranted to be free of defective material and workmanship
under the use and service quoted for a period of one year after date of shipment. This warranty is
void if serviced by anyone other than Hapman service personnel.

Hapman agrees to replace or repair any defective parts it has manufactured as covered under this
warranty. F.O.B. our plant, subject to inspection of the part in question by Hapman's personnel. No
article may be returned to Hapman without Hapman's written consent.

Parts supplied but not manufactured by Hapman are subject to the warranties extended to Hapman
by its suppliers. Hapman's liability is limited to such adjustment as the respective manufacturer
makes to the seller.

In no event shall Hapman be liable for costs incurred due to equipment malfunction such as
consequential damages, lost production or the expenses or losses incurred due to geographical
location or fault of the product, difficulty of access to the product as installed, or time urgency on the
part of the user and/or buyer of the equipment.

NOTICE:
While all information in this manual has been checked for accuracy, changes in design or
specifications may occur at any time in HAPMAN's continuing program of product improvement.
HAPMAN cannot assume responsibility for errors in the production of this manual, or for unsafe
operating practice of those employing HAPMAN equipment.

REV 9/07 5

BEFORE INSTALUNG, OPERATING OR MAINTAINING ANY EQUIPMENT, THE CONTENTS OF
THIS MANUAL SHOULD BE THOROUGHLY REVIEWED AND UNDERSTOOD.

Statements and instructions set forth herein are based upon the best information and practices known
to HAPMAN, but this may not be construed to suggest that every conceivable safety precaution is
contained herein. As a matter of practicality, HAPMAN cannot guarantee that actions in accordance
with such statements and instructions will result in the complete elimination of all hazards and thus
assumes no liability for accidents which may occur.

For further information regarding installation, operation and maintenance please contact the factory
service department.

HAPMAN Customer Service
6002 E. Kilgore Rd

Kalamazoo, MI 49048-2321 U.S.A.
Ph one: 269-343-1675

U.S. Toll Free: 800-427-6260
Fax: (269) 382 8266

e-mail: [email protected]

2O NTRODUCflON

This manual provides instructions on how to install, operate and maintain the tubular drag conveyor
supplied by Hapman. A recommended spare parts list is provided to help determine which parts
should be kept on hand. This list is on page 15.

Assistance on part orders or service calls may be obtained from Hapman's service department. See
the phone and fax numbers, address and E-mail address on the last page of this manual.

When calling or writing for parts or service, please reference the equipments serial number. The
serial number is stamped on the Hapman nameplate affixed to each piece of equipment. For future
reference, a space has been provided on the last page of this manual in order to record equipment
identification information.

1.1 General Instructions

1, All guards, covers and safety devices must be in place before starting equipment for normal
operation.

2. Conveyors must be shut down for all types of maintenance, adjustments and lubrication.
Power controls should be locked out while performing any of these functions.

3, Conveyor components should be maintained properly to avoid creating a hazard to
personnel. Included are such items as supports, ladders and platforms.

4. Guards and safety devices should be maintained in safe repair and hazard warning signs in
legible condition.

3.0 - SAFETY INSTRUCTIONS

CAUTION

All Hapman furnished equipment must be installed, operated and
maintained in accordance with service instructions. Failure to follow these

instruction may result in serious personal injury or property damage.

2.1 Do not attempt to install, connect power to, operate or service your Tubular Drag Conveyor
without proper instructions, or until you have been thoroughly trained in its use by your employer.

2.2 Do not attempt to work on, clean, or service this conveyor until the power has been turned off and
locked out. If and when it is necessary to momentarily start and stop (jog) the conveyor, use
extreme caution and ensure that all personnel are clear of the conveyor chain.

2.3 Do not manually override or electrically bypass any protective device.

2.4 Do not connect power to, or operate the conveyor unless all moving parts are covered and all
covers, guards, safety grids and maintenance panels are in place and securely fastened.

2.5 Do not abuse, overload, mistreat or misuse the conveyor or attempt to operate it when it is in
need of service, lubrication, maintenance or repair.

2.6 Never place any part of your body or loose clothing within the access chamber or feed hopper(s)
while the drive unit is pulling the chain through the casing.

2.7 Never allow foreign objects (that could cause the chain to bind or otherwise damage the unit) to
enter a conveyor casing through an access port or infeed receiver while conveyor is operating.

2.8 It is the owner's and employer's responsibility to adequately train the employee operator in the
proper and safe use of conveyors. Written safety programs and formal instructions are essential.
All new employees must be made aware of company policies and operating rules, especially the
established safety and health procedures. Refresher training of experience employees in the
potential hazards of the job is important. Up-to-date training records must be maintained at the
job site.

2.9 All conveyor inlet and discharge openings and casing access panels must be completely
enclosed to prevent human access when the machine is running and remain enclosed until power
has been turned off and locked out.

REV 9/07 7

2.10 Drive components, including the tension of the chain, must be inspected and adjusted
periodically, as required by operating conditions and the suggested maintenance schedule on
page 19. Check V-belt tension (if required), bearings, shafts and motor as appropriate to job
conditions.

2.11 High-voltage and rotating parts can cause serious or fatal injury. Installation, operation and
maintenance of electrical machinery must be performed only by qualified, trained and
experienced personnel. Make sure that the motor and frame are effectively grounded in
accordance with OSHA safety and health standards, the National Electric Code and local codes.

2.12 All electrical control panels and/or manual start-stop operation enclosures carry the potential for
hazardous voltage. Follow local OSHA or corporate lockout] tagout procedures before doing any
service work on tubeveyor, tubeveyor panels or electrical enclosures.

2.13 All protective covers, guards, grates, maintenance panels, switches and warning decal's must be
kept in place and in good repair. Any equipment with damaged, malfunctioning, defective, or
missing protective devices must be taken out of service until such protective devices can be
repaired or replaced.

2.13 Any equipment which is used in the processing of explosive materials in hazardous
environments requires materials in hazardous environments requires an evaluation on the part of
the user and operator of proper and adequate equipment enclosures. Do not use equipment in
hazardous environments unless it has been properly equipped for the hazard.

2.14 It is ultimately the operators responsibility to implement the above-listed precautions and ensure
proper use of the equipment, maintenance and lubrication. Keep these instructions and list of
warnings with your machines at all times. Work safely at all times.

2.15 Basic DangerlWarning!Caution Areas for the Heavy-duty series tubular drag

A C
D E

4.0 - PRINCIPLES OF OPERATION

The Hapman Tubular Drag Conveyor is similar to having a conveyor inside a pipeline. It is an
enclosed loop conveyor system designed and engineered to your specific layout. It will handle a wide
range of flowable materials. Essentially, the conveyor is a three to 12 inch diameter metal casing
assembled from pre-engineered sections that are equipped with male and female flanges or
compression couplings. The conveyor circuitry can be designed around existing equipment. Using
simple hangers or supports along the circuit, the conveyor is assembled before installing the chain
that is equipped with circular flights spaced evenly along the distance of the chain.

The chain is threaded over the drive sprocket and idler sprocket and the ends connected with a pin
before the tension is adjusted. During operation, the chain is pulled through the casing and material is
fed into the casing through an infeed hopper. As the flighted-chain moves inside the casing, the flights
drag the material horizontally or vertically until it reaches the discharge port where the material is
discharged by gravity into some receiver. The flighted chain continues around the circuit to pick up
more material and prevents surging I flooding the conveyor line.

REV 9/07 9

5M RECEMNG YOUR EQUPMENT

As soon as the equipment is received, it should be carefully inspected to make certain it is in good
condition and all items recorded on the packing list are received. All damages or shortages should be
noted on the Bill of Lading. Purchaser should take immediate steps to file reports! claims with the
carrier.

Any damage incurred to a unit in transit is the responsibility of the common carrier since it is the
manufacturer's policy to make shipments F.O.B, its factory. Ownership passes to the purchaser
when the unit is loaded and accepted by the trucker. Any claims in transit damage or shortage must
be brought against the carrier by the purchaser.

CAUT ON

All Hapman-fumished material handling equipment must be installed, operated and maintained in
accordance with service instructions. Failure to follow these instructions may result in a serious
personal injury or property damage.

6O STORAGE

Inside storage of equipment is recommended. If outdoor storage is required, precautions should be
taken to protect all equipment from the elements.

CONVEYOR ASSEMBLY AND ERECTION

7.1 Inspect all components on arrival to make sure that there was no damage in shipment. Check
items received against packing list and final layout drawings to determine whether all items
needed for complete installation are present. All necessary hardware for assembly should be
included.

To avoid confusion when more than one conveyor is involved, separate components according to
conveyor number. Lay the component on the floor in the area where the conveyor is to be
installed. This will facilitate inspection and organizing components for installation.

7.2 Inspect (inside and out) the casing sections, elbows, receiving hoppers and discharge hoppers
and remove any foreign objects before starting the erection process.

Chain for the conveyor is shipped in large boxlike containers. Depending on the type and size
(length and diameter) of the chain, you may receive one or more containers of chain. The chain
will likely be shipped in approximately lOft sections that will conveniently fit in the shipping
containers. Installation of the chain through the casing will be detailed later.

7,3 The Hapman conveyor casing is supplied in sections of approximately 1 O2O feet in length. Each
section has "male" and "female" type flanged connections between which a gasket (shipped
separately) or compression coupling connection may be inserted. Always follow the match marks
stamped on each flange and shown on the layout drawings as illustrated in Figure 15.

NOTE: DUE TO THE CUSTOM NATURES OF THESE CONVEYORS, THE FOLLOWING ARE GENERAL
GUIDELINES

7.4 Components, such as receiving and discharge hoppers which have a specific location relative to
existing equipment, should be installed first. Other components which require significant support

REV 9/07 10

should be installed next. These include the drive assembly, idler assembly and elbows. These
components should be securely positioned, but there should be enough play or slack in the
components to facilitate installing the casing.

Figure 15 Match Mark SymboU
m Location As Shown On
Section at
Flanged Connection Layout Drawing

Female / v;:;; Conveyor
Flange b, asKet. Casing

7.5 Locate the casing flange gaskets and place one on each male flange before making flange
connections. Gasket dressings or pliable sealants may be used with the gaskets, if desired.
Such dressings or sealants are to be supplied by customer.

7,6 As assembly of the conveyor circuit begins, two or more sections of the smaller (3" and 4"),
casing may be assembled before elevating them into position. For larger casing sections (6" and
larger), it is advisable to install one section at a time using the appropriate (customer-supplied)
hangers. (See Figure 16 for typical conveyor-supporting methods.) To aid in installing the
conveyor chain in these larger casings, Hapman recommends inserting and connecting the chain
in short section during the installation of each casing section (See Section 8.0 Tubular Chain
Installation).

7.7 It is very important to leave all flange bolts loose (finger tightened should be sufficient) until the
entire conveyor circuitry is assembled. This will facilitate installation of the casing between the
heavier - and location specific components that were installed first,

REV 9/07 11

Hgure 16
TYPICAL SUPPORT METHODS FOR TUBULAR DRAG CONVEYOR

Supports can be tubing, pipe, angle, channel, etc.

U-bolt

Supports can be Fleld Welded
tubing, pipe, angie, Floor Bracket

channe', etc.

Floor Mounted Supports Floor Openhig Support

Pipe
Strap

Beam
Clamp

Standard
Hanger
with Rod

Single
Hook

Supports from Existing Structures

7.8 With circuit assembly completed, tighten all hanger clamps and flange connections securely.

TUBULAR CHAN NSTALLATON

8.1 Basic Chain Types: Hapman Tubular Drag Conveyor chains are supplied in two basic designs:
the offset-flight design; and the center-flighted design. The chain design used in your conveyor(s)
was selected by the factory based on the application for the conveyor's intended use. See the
parts list on your conveyor layout drawing, or examine the chain supplied to determine which
design you have. (See Figure 18 for basic designs.)

REV9IO7 12

8.2 Chain Construction: The unique sealed-pin design of the chain assures that the pin and bearing
surface are tightly sealed with elastomeric washers preventing wear and abrasion caused by the
conveyed material, In addition, Hapman may specify a split flange rivetless chain (See Figures
19) for your application.

8.3 Installing the Chain: The three and four-inch conveyor chain generally should be installed after all
the conveyor casing sections have been erected. The six-inch and larger conveyor chain should
be installed in relatively short lengths (as in each individual section of conveyor casing) during
erection.

8.4 Threading the Chain: Access to the casing may be through casing access ports, the drive box and
idler box access opening, the receiving hopper and/or the discharge opening. Thread a rope
through the casing from the highest elevation to the lowest elevation.

With the chain laid out on the floor in a single plane, tie one end of the rope to the leading end of
the chain and pull the chain through the casing, around the elbows, and over the sprocket. Feed
the chain into the casing through an infeed hopper or other access opening. Always feed the
chain in the same direction as it will be traveling when the system is operational. The direction of
flow is noted on the conveyor layout drawing.

Figure 18
CHAIN INSTALLATION - Typical Chain Construction & Nomenclature
SEALED PIN CHAIN

Note: See Table 20-A for chain specifications.

Center Seang Center Flighted Chain Center Seaftng
Link \ Washer
Washer Steel
/Unk \____ Washer
Stee'
Washer

Figure 19
CHAIN INSTALLA11ON - Typical Chain Construction & Nomenclature
Drop Forged Chain

Center flighted Chain

Note: See Tab'e 20-B for chain specfficalions.

Table 20-A

Sealed Pin Chain Specifications

Chain Avaliable Flight Chain Weight Ultimate Strength
Size and Flight Pitch Pitch per and Maximum
toot Work Chain Pull
Series Diameters
(chain
only)

25-3" 2-3/8" & 2-3/4" 3" 1-1/2" 3.4 # 11,000-2,200#

35 - 3" 2-3/4" 6" 3" 5.2 # 15,000- 3,000 #

35-4" 3-3/4" 6" 3" 5.2 # 15,000- 3,000 #

48-4" 3-3/4" & 3-7/8" 6-9/16" 3-9/32" 6.2 # 19,600-3,900 #

64 - 6" 5-5/8" 8" 4" 9.5# 44,000-8,800 #

78 - 8* 7/5/8" 8" 4" 9.5# 44,000- 8,800 #

* - offset flights

Table 20-B

_________ Drop Forged Chain Specifications _____________

Weight Ultimate Strength
and Maximum
Chain Size Available Flight Flight Chain per Work Chain Pull
and Series Diameters Pitch Pitch foot
(chain __________________

____________ ___________________ ________ ________ only) 24,000-4,800 #

348-3" 2-1/2" , 2-3/4" 6" 3" 2.25 #

348-4" 3-3/4" 6" 3" 2.25 # 24,000-4,800 #

458-4" 3-3/8", 3-5/8" 8" 4" 3.1 # 48,000-9,600#
3-3/4"
____________ ________ ________ _______ __________________
5" , 5-5/8"
458-6" 8" 4" 3.1 # 48,000-9,600 #

458-8"" 7-1/4" 8" 4" 3.1 # 48,000-9,600 #

458_10** 8-1/4" 8" 4" 3.1 # 48,000-9,600#

678- 10"" 9-1/8" 12" 6" 6,5 # 84,000- 16,900 #

* - offset flights

REV 9/07 14

8.5 Aligning the Chain: The simplest chain installation is when the chain travels through the circuit on
the same plane (like bicycle chain around two or more sprockets) allowing the chain opening
between the side links to ride over the sprocket teeth un-impeded. When the circuitry of the
conveyor (between the elbow and the sprocket) dictates a change in the plane of the chain, it will
be necessary to rotate (twist) the chain either clockwise or counterclockwise to properly position
the chain openings to ride smoothly over the sprocket.
If the supplied chain is the offset- design, the force of gravity tends to roll the chain to a "heel
down" position. The chain should always be in the "heel down" position (toward the inside of the
radius) when it moves around an elbow or sprocket. (See Figures 22-A and 22-B.) When it is
necessary to rotate the chain to "heel up" position to conform to chain installation instructions,
rotate the chain in the "untwist" direction.
The installer should wear protective gloves when installing chain and especially when adding a
twist to the chain. To induce a twist in the chain, firmly grab the leading end of the chain and
rotate the chain so it will smoothly interface with the sprocket. There is sufficient "play" in the
chain's design to allow the chain to be rotated over the length of the straight section of the casing.
The twist of the chain must be performed before the chain is pulled around the bend of the casing
because it cannot be rotated once it is in the bend. The chain twist should not exceed 360° in
any one direction over the entire length of the chain's circuitry.

Figure 22-A
He&-Down Posflon of Chain - Around Bend

Figure 22-B
Heel-Down Position of Chain - Around Sprocket

REV9IO7 15

Because of its design difference, the split flange chain is somewhat easier to twist than a sealed-
pin construction type chain. Furthermore, twisting the chain is easier when the plane change
(from elbow to sprocket) is only slight (15° to 45°) or when the length between plane changes is
longer, rather than introducing a twist of a higher degree or shorter distance between plane
changes. However, it is essential to match the plane of the chain with the plane of the sprocket,
as noted on Figure 22-B.

8.6 Closing the Loop: Before attempting to connect both ends of the chain, adjust the drive and idler
(whichever one is most accessible) take-up bolts all the way in. In addition move the slide plate
of the chain tensioner to its forward-most position.

Once this has been done and the chain has been fed through the casing and over both the drive
and idler box sprockets, bring the leading and the trailing ends of the chain together and connect
them using the chain pins provided. If needed, twist one end of the chain or the other to align the
chain pin holes. When closing the loop for offset flight design, the two flights of the two sections
being joined must be in the same direction - either in the "heel-up" or "heel-down" position.

9M ADJUS11NG THE CHAN

9,1 Removing the Slack: Starting at the least accessible take-up location - which is usually at the
drive assembly - remove slack in the chain by using a wrench to adjust the take-up rods which
move the drive plate and tighten the conveyor chain. See Figure 23

Failure to remove excessive slack in the chain may cause operational problems with the chain
jamming or jumping off the sprockets. The chain should be relatively loose in the normally
empty or "return" run the conveyor.

9.2 Jogging the Conveyor: Jog - quickly start and stop the drive by pushing the start then stop button
- the conveyor to work out additional slack. Jogging will help to accumulate all the slack into one
area just below the drive sprocket.

Jog conveyor initially to check proper motor rotation. Run conveyor in only the direction indicated
by the arrows on the center line of the layout drawing.

9.3 Adjust Tensioner: Move the take-up on the drive box and/or idler box to adjust the chain for
proper tension. To check the tension, remove an inspection opening on the empty or "return" run
of the conveyor and lift or pull the chain. It should have about two inches of slack. You may have
to back off the take-up and remove a section of chain (one complete pitch) and start the
adjustment procedure over again. If a piece of chain needs to be removed, the chain on either side
should be secured to prevent it from slipping away until it can be joined again.

A WARNING

Before jogging the conveyor, make certain that all foreign material is removed from inside the
casting and that all personnel are clear of the conveyor. Never put any part of the body
(hands, feet, long hair) or clothing into the conveyor when the conveyor is to be jogged or run.

WARNNG

Exposed coveyors
and mova pa1s can
•' cause sevm miury
L0CK OUT POWER
belora remov
cover o serrcng

10.0 - ADJUSTING THE SPROCKET

There could be one or several sprockets on a tubular drag conveyor that may need adjusting at the
same time. These are located in the drive box, idler box and corner turns.

First, remove the access cover and check the sprocket location on the shaft. The center of the
sprockets should be in line with the center of the casing and the chain should run smoothly on and off
the sprocket.

If the sprocket is misaligned, loosen the set of screws on the sprocket and move the sprocket to the
proper position. Tighten the set screws and check alignment again.

11.0- ADJUSTING THE CHAIN ROTATION

The rotation of the chain is critical and the proper rotation is listed on the main layout drawing. To
adjust the rotation, open the inspection port in the area where the rotation is incorrect. Loosen the
chain tension first then remove a chain pin so the chain may be rotated to its proper orientation.
Secure the chain to keep it from slipping away during the twisting/rotating procedure.

If assistance is required to install or adjust the chain, call the Customer Service Department at
Hapman. (See inside cover.)

12O STARTNG AND ADJUSTNG

12.1 Before Starting: Remove all access and/or inspection covers so any unusual or erratic operation
will be noticed immediately.

Operating this conveyor with these covers and guards removed presents a potential hazard.
Take appropriate action to see that hands, arms, feet, or other body parts are kept clear of the
access openings and moving chain.

A. Remove any foreign material that may have accumulated during installation from
conveyors.

B. Check the V-belt and roller chain tensions and correct if necessary.
12.2 Initial Starting, Chain Tension Adjustment And Breaking In

A. Start and run conveyor for several minutes while listening for any unusual noises and
watch for erratic operation of the chain.

B. The length of break-in period will vary with the size and complexity of the system.
Generally speaking, it is advisable to run the conveyor empty for approximately 30-minutes.
Check the tension after this 30-minute run. If significant tension adjustment is needed,
make the adjustment* and run the conveyor empty for another 30-minutes.

*NOTE: Ideal chain adjustment is obtained by adjusting the take-up rods on the drive or idler
arrangement while the conveyor is running. Proper tension can be set by using an amp meter
and setting the tension where the meter reads the lowest, steadiest amp reading.

C. Add material and run the conveyor listening for any unusual noises or erratic operation. If
the conveyor is running smoothly, continue to run product but check tension once every
eight hours of operation for the first 48-hours.

Note: If conveyor is noisy or running erratically, chain tension probably needs tightening. At
this time adjustments should be made while conveyor is running and while listening to the
conveyor for any change in operation.

D. Check chain tension again after 48 hours of continuous running, and again after one week,
followed by another chain tension check after one month. After this, follow the suggestions
maintenance procedures listed on page 19

E. Reinstall covers and guards after any tension adjustment is complete and unit is ready to
run again.

REV 9/07

13O - SUGGESTED CONVEYOR MAINTENANCE

13.1 Overload I Jammed Mechanism:

Note: Mechanical shear pin protection is not included in these units. An optional overload
shock relay electrical shear pin system for overload and phase loss protection is available
from Hapman and is always suggested during the ordering process. If your conveyor was
not ordered with this system, it is highly recommended that it be added on site!

A. With electrical shear pin protection - When the conveyor shuts down check the reset button
located within the control panel and reset if necessary. If the problem persists contact Hapman
customer service.

Note: These systems are preset to accommodate the material(s) which were originally specified
to be conveyed. Deviation from the original material(s) specification can cause loss of
performance and failure. See Addendum: "Electronic Shear Pin System" for installation and
safety procedures on page 23.

13.2 Adjusting Vibrator:

A. The hammer should rest lightly on flights when vibrator is turned off.

B. Adjust hammer position by changing the position of the hammer stud locking nuts. Do not operate
vibrators unless these nuts are pulled up tight.

C. Adjust length and intensity of vibrating action by changing the position of the eccentrics with
respect to each other.

Maximum vibration is obtained by having all eccentrics in alignment.
Minimum vibration is obtained by spacing them equally (1200 apart).

Figure 24

Underside view of hammer
position over flights

Table 29

Suggested Maintenance Schedule

ACTION TAKEN 11 6 RECOMMENDED

Check Conveyor WEEK MONTH MONTHS LUBRICANT

Tension _______ ________ __________ ___________________________

Grease Motor As Suggested by Motor

Check Reducer Oil __________ Manufacturer

Level ________ X __________ See Reducer Service Bulletin
________ __________
Grease Idler Box Pillow _________ ____________________________

Blocks ________ Shell Oil Co. Nerita 2 or Equal

Check Vibrator NLGI-2
Operation
Grease Vibrator Pillow x

Blocks ________ _________ __________ ____________________________

Grease Roller Turn Shell Oil Co. Nerita 2 or Equal
Haridshaft
________ ________ __________ NLGI-2
Grease Vibrator Motor Shell Oil Co. Alvania 2 or
X Equal

As Suggested by Motor

Manufacturer

Grease Reducer X

REV 9/07 20

Table 30

Troubeshootng
Endosed Tubuar Drag Conveyor

PROBLEM POSSIBLE CAUSE SOLUTION

Noise in the drive box or idler box 1. conveyor chain is loose. 1. Adjust chain.

2. Chain is tight. 2. Adjust chain.

3. Chain rotation (twist) incorrect. 3. Put proper rotation in chain.

4. Sprocket not centered. 4. Adjust sprocket

Note: At times, you cannot prevent noise. In this case, check for wear on conveyor chains or sprockets.

If there is none, let machine run. _______________________ ____________________________
Jamming
1. Too much material feed. 1. Try restrictor in feed hopper.

2. Chain is tight or loose. 2. Adjust chain tension

3. Sprocket not adjusted to 3. Adjust sprocket.

center of casing. 4. Remove object.

4. Foreign object is machine 5. Install scraper flight (consult

5. Glazing in casing (build-up on Hapman)

inside walls).

Material not conveying 1. Bridging in hopper. 1. Try vibrating the hopper

(gitate the rnateriai)

Conveyor chain dislodged, or 1. Conveyor chain loose. 1. Adjust chain tension

jumping off sprocket. 2. Chain rotation (twist) incorrect. 2. Adjust chain tension

nflihtosition

Wear in bends and flights 1. Conveyor chain tight. 1. Adjust chain tension.

wearing excessively 2. Wrong chain rotation. 2. Adjust chain rotation.

3. Abrasive material. 3. Consult Hapman.

Chain jerking in casing 1. Chain is tight or loose. 1. Adjust chain tension.

2. Too much chain rotation 2. Adjust chain rotation.

(twist). 3. Adjust sprocket.

3. Sprocket not adjusted to 4. Make sure conveyor is control

center of casing. fed. Call Customer Service.

4. Surge loading

Table 31A

Spare Parts Ust
Tubuar Conveyor

Item Description Unft Quantity
10 Ft.
Chain Assembly 1

2 Drive Shaft 1
1
3 Drive Sprocket

4 Idler Shaft

5 Idler Sprocket

6 Reducer

7 Motor

REV 9/07 21

DRIVE IDENTIFICATION & Lubrication Requirements

Hapman has engineered changes in the drives used on its tubular drag conveyors since their
introduction in the 50's. Each drive has differing lubrication (either grease or oil) requirements as
shown. Select your drive from the following illustrations.

A. Current production drive (Direct)

Cyclo Lubrication
This is the round reducer portion between the motor and the square shaped Bevel Buddy Box "BBB"

The Cyclo has been grease lubricated with Shell Alvania #2 grease and should be replenished every
6 months with quantities listed below. This done by the grease zerk located on the Cyclo portion. It is
recommended the unit be disassembled every 20,000 hours or 4-5 years to clean and repack with
designated grease to prolong service life. Every six months replenish the Cyclo portion with the
quantity of grease listed below for the Bevel Buddy Box model number shown.

Bevel Buddy Oz. grease Bevel Buddy Oz. grease
Box l.D. No. for Cyclo Box l.D. No. for Cyclo

LHYJS-2B1 45Y 4 oz. LHYJS-2C175Y 9 oz.

LHYJS-2B165Y 6 oz. LHYJS-D4165Y 6 oz.

LHYJS-2C1 55Y 4 oz. LHYJS-2D175Y 9 oz.

LHYJS-2C145Y 4 oz. LHYJS-E4175Y 9 oz.

LHYJS-2C1 65Y 6 oz. LHYJS-2E175Y 9 oz.

Bevel Buddy Box Lubrication
This is the square shaped portion with the shaft running through it. This has been filed with uShell
Alvania EP R00" or equivalent and can be changed every 4-5 years or (20,000 hours) to provide
longer service life. This is a pourable grease and has the viscosity like that of molasses. It is
recommended to drain during warm weather or when the unit is warm from running.

Note: Weekly inspection for leakage, loose fasteners, excessive heat, etc. should be done to assure
trouble free operation.

B. Mid production drive (Direct)
C. Beginning production drive (Belt/chain or OWed)

On oil lubricated units the reducers ordered from the factory will be filled to the proper level with
lubricant, but before operation the supplied vent plug must be placed in the proper (highest possible)
location!

Vent Plug Location On Oil Filled Drive Box

Before installing the vent plug, refer to the instruction tag and determine the proper position according
to reducer mounting specification. The position and number of these (vent/fill) plugs will varied on
each unit and should accommodate the final orientation of the unit. After the installation of the vent
plug, the unit is ready for use.

Grove Gear recommends changing oil every six months or 2,500 hours of service under Class I
service. If service is more severe, the oil should be changed more frequently.

To assist in proper selection of replacement lubricant, the following oils are recommended for the
ambient temperature specified.

uii LU DICtlOflS u 0 be use a #i i emperaiure

uggested 15° to 60° F Ambient 50° to 125° F Ambient
Manufacturer Temperature Temperature

Listing AGMA Compounded AGMA Compounded
No.7 No.8

Recommended Oil Recommended Oil
for this temperature for this temperature

Amoco Oil Co. Worm Gear Oil Cylinder Oil #680

Chevron USA Cylinder Oil #460X Cylinder Oil #680X

Exxon Co. USA Clyesstic TK-460 Clyesstic TK-680

Gulf Oil Corp. Senate 460 Senate 680D

Mobil Oil Corp. 600W Super Extra Helcia Super

Shell Oil Co. Valvata Oil J460 Valvata Oil J680

Sun Oil Co. Gear Oil 7C Gear Oil 8C

Texaco Honor Cylinder Oil 650T Cylinder Oil

Union Oil of CA Steaval A Worm Gear Lube 140

Note: For temperature ranges not shown and synthetic lubrication contact factory

REV 9/07 23

Capac ities For Oil Lubricated Drive Boxes

Unit Size Worm Over Worm Over Vertical "J" Mount
Mount Mount Output Oz.
_______ Oz. Oz. Mount
________
1100 ________ ________ Oz.
3
3 4 4

1133 5 7 6 7

1154 10 14 13 12

1175 15 18 16 16

1206 21 25 23 24

1238 25 30 26 25

1262 45 49 46 47

1300 55 61 58 60

1325 73 89 74 75

1425 135 127 120 126

1525 200 216 216 216

1600 310 330 320 325

1700 563 625 332 585

1800 768 822 460 800

11000 1152 1280 640 1200

Addendum: Electronic Shear Pin System

Hapman provides a non-mechanical electronic shock relay, as an option, to help prevent damage
to the conveyor. If your conveyor is equipped with one, please follow safety and maintenance
procedures to assure continued performance of your conveyor.

Safety Precautions To Follow Before Proceeding
USE CARE TO PREVENT INJURY.
COMPLY WITH THE FOLLOWING TO AVOID SERIOUS PERSONAL INJURY:

A WARNING

1. Disconnect power. Always lock out power switch before installing, removing, or servicing unit.
Comply with Occupational Safety and Health Standards 1910.147 "The Control of Hazardous
Energy (Lock Out/Tag Out)" or Corporate lockoutltagout procedures.

2. Install in proper enclosure in accordance with NEMA 250-1997 "Enclosures for Electrical
Equipment (1 000 Volts Maximum)" and NFPA496 1998 Edition "Purged and Pressurized

REV 9/07 24

Enclosures for Electrical Equipment, 1998 edition'. When revisions of these standards are
published, the updated edition shall apply.

3. Guards must be provided on all power transmission and conveyor applications in accordance with
provisions of ASME B 15. 1-1996 "Safety Standards for Mechanical Power Transmission
Apparatus and ASME B20,1-1996' Safety Standard for Conveyors and Related Equipment", or
other applicable standards. When revisions of these standards are published, the updated edition

shall apply.

Electronic Shear Pin Features Fail safe protection
Electronic shear pin function • Easy wiring
Independent setting of start and trip delay
Overload and phase loss protection Maintenance free
Visual selling and trip indicator • No mechanical connection needed

How It Works
Two of three phases of the motor current are monitored by integral current transformers (External
current transformer are required for current more than 60 Amps). The internal solid-state circuitry
compares the monitored motor (or load currents with preset current level. When motor current
exceeds the preset trip current level, the red LED illuminate and indicated that an overload has been
detected. The relay will trip after the preset trip time (SHOCK TIME) and the LED remains illuminated
indicating an overload trip has occurred until the relay is reset by pushing the RESET button
interrupting the power supply. If the motor current drops back down below the preset current level
before the preset trip time delay has elapsed, the TSB-SS will return to normal condition. With the
visual aid of the LED flashing when motor current becomes 100% of the preset current, actual load
current can be determined without aid of an ammeter. The TEST button provides the means of testing
service worthiness and integrity. The internal relay is energized in a normal operating condition. In the
event of a SHOCK RELAY failure or a power failure, the internal relay changes back to the non-
energized state. Since the TSB-SS has a definite time characteristics, the start trip delay may be
adjusted with a minimum setting of 0.2 through a maximum of 30 seconds. The trip time adjustment
range is from 0.2 through 10 seconds. The relay may be used as an electronic shear-pin by selling
the SHOCK TIME to minimum. If the TSB-SS trips, always investigate to determine the cause and

correct prior to restarting.

How To Set Up The System
1. When installing, set the start delay timer (START TIME knob) to the known motor run-up time or

the maximum if the time is not known.

2. Set the trip delay timer (SHOCK TIME knob) to the desired trip time.

3. Set the load current (CURRENT knob) at the rated full load or the desired value.

4. With connections made and the control power on, depress the TEST button and hold. Verify the
red LED illuminates and the internal relay should switch contacts after the sum of start time and
shock time. Once verified, reset by depressing the RESET button.

5. Start the equipment and notice the run-up time, then slowly turn the CURRENT know counter
clock-wise until the LED flashes. This indicates 100% of the load current. Set the CURRENT knob
to the desired trip setting. A setting of 110% of the running current is commonly used.

6. Reset the START TIME knob to match the normal run-up time

7. Periodic testing by using the TEST button is suggested to ensure the full protection through
preventive maintenance.

REV 9/07 25

Figure 25 Figure 26
Construction Dimension - Units in mm (1 inch = 25.4mm)

CT 030

Figure 27
Wiring - Typical Installation

THREE PHASE MOTOR
1o ol UTep ph*ses of the mows are passed
throuqh the Shock Rc4ays CT pn the swic dNection

1 A transfaniier rnsy be required, dependinq on the voltaqe of Motor. TSB-SS and MC

FIgure 28
TSB - SS Model Identification

TSB-SS-05 05 O.5-5Amp
30 3-3OAmp
Current Range 60 5-6OAmp
Model: Shock Relay SS model Over 60 to 600 Amp: 05 Type is fitted
with External CT

REV 9/07 26

Specifications TSB-SS
Model Name Range
0.5- 5A (6.5A)
Current Selling Type 3 - 30A (35A)
05 5 - 60A (70A)
05 Type is Fitted with External CT
30 0.2 - 30 sec
0.2 - 10 sec
): Max Limit 60 ±10%
100-600 ±15%
Definite
Time Setting Starting Trip Delay Start Time 90 - 25OVAC, 50/60Hz
Trip Time Shock Time 600VAC, 50/60Hz
2 Integral Current Transformer
Accuracy Current 1-SPDT (1-C)
Time 3A/25OVAC, Resistive
Normally Energized
Time Characteristic 10,000,000 Operations
100,000 Operations
Control Power Supply Manual or Electrical (Interrupt Power Supply)
-20 - +60 C (-4- +158°F)
Rated Voltage -30- +70 C (-22- +176°F)
45- 85% RH without Condensation
Current Selling Over 10 MO with 500 VDC Megger
AC 2000V, 5mA, 60Hz, 1mm
Mode AC 1000V, 5mA, 60Hz, 1mm
AC 2000V, 5mA, 60Hz, 1mm
Output Relay Rating 2.70 VA (0.35W)
11.00 VA (1.2W)
Status 35mm DIN rail or Panel
54 x 60 x 65mm
Expected Output Relay Life Mechanical Less than 159g (0.35LBS) without External CT
Electrical

Reset

Temperature Operating
Storage
Ambient Environment

Humidity

Insulation Between casing and circuit

Between casing and circuit

Dielectric Strength Between contacts

Between Circuits

Power Consumption 1 15VAC
23OVAC

Mounting

Dimension (W x H x D / Including Integral CT Windows)

Weight

Electric rotating machinery and high voltage can cause serious or fatal injury if improperly installed,
operated or maintained. Responsible personnel should be familiarized with NEMA MG2: Safety
Standards for ConstruCtion and Guide for Selection, Installation and Use of Electric Motors and
Generators: National Electric Code and all local safety requirements. When servicing, all power
sources to the motor and to any accessory devices should be de-energized and disconnected and all
rotating parts should be at a standstill.

REV 9/07 27

Record Of Important Information For This Machine

Serial Number
Model Number

For Operational Information In This Plant Contact

Name
Department I Phone Number______________________________________

Notes

HAPMA 28

6002 E Kilgore Road• Kalamazoo, MI 49048
Ph 269-343-1675 800-427-6260 Fax 269-349-2477 • www.hapman.com

REV 9/07