PHOSPHATE AND E-COAT CONVEYORS

PHOSPHATE AND E-COATCONVEYORSLESSONS LEARNED AND MAINTENANCE TIPS

CONCERN # 1: Poor LightingNormally there is no lighting over the Inline Drives. Only the Master Drive and the Take Up Platforms have Task Lighting.Few locations that have lighting installed over the Inline Drives, dont have the lighting in working condition. Normally bulbs are burned out. Occasionally, bulbs as well as Ballasts are burned out.

View of drive with lights off

Close up view of drive with lights off

Inline Drive with Lights On

Lube Line not connected to Roller

Drive Shaft View with Lights On

Typical Shroud View

Typical Shroud Close Up View

Shroud and Carrier without Lighting

Shroud with OHPF Carrier & Lighting

Access to Cat Chain through cutout

CONCERN # 2: Poor AccessTypically the access to Inline Drive Cat Chains is restricted by the Drip Pan

Access restricted by the Drip Pan

Recommended Drip Pan shape for the Inline Drive Areas

CONCERN # 3: Cat Chain and Back Up Bar Failure & Chain WearTypically the Cat Chains and the Back UP Bars fail due to lack of lubrication.The Conveyor Chain will last ten years with proper lubrication (DTP Chain lasted from 2000 through 2010, it was kept well lubed. KTP chain is more than seven years old). Keep turn wheels and roller nests greased. Check for play in the bearings while greasing.

Cat Chain not getting lubed

Cat Chain Lubricator not working

CONCERN # 4: Take Up JamsTypically Take Up travel path is restricted by some mechanical obstruction.

Loose Parts can possibly cause jams

Parts left in TU travel zone

Load Cell to measure chain tension

Load Cell requires Custom Clevis

Take Up Tension Read Out

CONCERN # 5: Jams caused by improper job spacing, wrong switch settings and repeated resets Job spacing shorter than intendedSwitch Arms turned such that the drive would never shutdown on over-torqueRepeated resets without checking the reason for the stoppage

Check orientation of Torque Overload Switch at each drive

Check the job spacing if chain separates

Dont push reset more than once

Example of repeated resets5:29PM:Initial VFD Fault5:31PM:Second VFD Fault5:33PM: Inline Drive # 2 Torque Overload Fault5:40PM:Take Up Extended Fault

SUMMARYInstall lighting over the drives.If lighting is installed, periodically check to ensure that it stays in working condition.Install lighting for the Cat Chain areas.Provide opening/s in the shroud or drip pan to have easy access to the Cat Chain. Grease the slides every two weeks and move the Cat Chain Assembly back and forth.

SUMMARYKeep the Cat Chains well lubricated. Do NOT store loose chain, trolleys or other spare parts in the path of Take Up travel. Periodically review the TU Air Pressure Gage that is working properly. Check the program and ensure that it annunciates and records the Low Air Pressure and Auto Lube Not Working faults.

SUMMARYIf the system faults, do NOT press the reset button more than once. Check the entire system for a mechanical jam, fix the problem and then re-start the system. Repeated resets will most likely compound the problem.