GSi 2 Series User manual

Chain Conveyor
Installation and Operation Manual
PNEG-763
En- Masse Chain Conveyors
Series 212”-14”-20” Tall
DC-1058
Material Handling
PNEG-763

Series 2 Conveyors
3
This manual contains information that is important for you, the owner/operator, to know and
understand. This information relates to protecting personal safety and preventing
equipment problems. It is the responsibility of the owner/operator to inform anyone
operating or working in the area of this equipment of these safety guidlines.To help you
recognize this information, we use the symbols that are defined below.
Please read the manual and pay attention to these sections. Failure to read this manual
and it’s safety instructions is a misuse of the equipment and may lead to serious injury or death.
SAFETY GUIDELINES
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
NOTE indicates information about the equipment that you
should pay special attention to.

4
Series 2 Chain Conveyors
Use of the Equipment Information page will help you identify your equipment in the case that you need
to call your dealer or installer. This information should be filled out and kept on record.
Equipment Information
Model Number:__________________________
Serial Number:___________________________
Date Purchased:___________________________
Dealer/Distributor Name and Phone Number:
GSIMaterial Handling
1004 East Illinois Street
Assumption, Illinois 62510 USA
Phone: [phone]
FAX: [phone]
e-mail: [email protected]
Equipment Information

5
Series 2 Chain Conveyors
Table of Contents
Safety Guidelines ..................................................................3
Equipment Information .........................................................4
Safety Decal Locations........................................................6
General Precautions ............................................................8
Receiving and Pre-Installation ...............................................9
Installation ........................................................................10
Careand Maintenance .........................................................18
Options................................................................................19
TroubleShooting Guide ......................................................25
Training Sign-Off Sheet .....................................................26
Warranty.............................................................................27

6
Series 2 Chain Conveyors
Head Safety Decals
Head Section Decal Locations
1
1
1
1
Moving parts can crush
and cut. Keep hands
clear. Do not operate
without guards in place.
Failure to do so could
result in serious injury.
DC-972

7
Series 2 Chain Conveyors Tail Safety Decals
Tail Section Decal Locations
1
1
1
1
Moving parts can crush
and cut. Keep hands
clear. Do not operate
without guards in place.
Failure to do so could
result in serious injury.
DC-972

8
Series 2 Chain Conveyors
General Precautions
CAUTION:
wDo not operate the unit before reading
and understanding the operator’s manual.
wKeep all safety shields and devices in
place.
wKeep all covers in place.
wMake certain everyone is clear of the
equipment before operating.
wKeep hands, feet and clothing away from
moving parts.
wShut off and lock out all power to adjust,
service, clean or unclog.
wKeep off the equipment at all times.
wKeep children, visitors and all untrained
personnel away from the machine while
in operation.
wDo not operate electric motor equipped
units until motors are properly grounded.
wDisconnect power on electrical driven
units before resetting motor overloads.
General Precautions
wDo not repetitively stop and start the drive
in order to free a plugged condition. Jogging
the drive in this type of condition can damage
the conveyor and/or drive components.

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Series 2 Chain Conveyors
Receiving Inspection
Carefully inspect the shipment as soon as it is received.
Verify that the quantity of parts or packages actually
receivedcorrespondstothe quantityshown onthe pack-
ing slip. Any discrepancies should be clarified immedi-
ately. Please remember that any damage or missing
parts must be noted on the bill of lading at the time of
delivery. Report any damage or shortage to the deliv-
ering carrier as soon as possible. GSI’s responsibility
for damage to the equipment ends with acceptance by
the delivering carrier.
Save all paperwork and documentation furnished with
any of the chain conveyor components.
Pre-Installation Preparation
Familiarize yourself thoroughly with this manual and all
the conveyor parts. Read the operators manual and all
safety signs before using or servicing equipment. Tak-
ing the time to do so will aid in the assembly of your
conveyor.
Remove any banding and crating material. Arrange all
the conveyor components in such a fashion that all are
easily accessible.
Locate some sturdy items to serve as blocking (i.e.
wood blocks, saw horses, etc.). Blocking is used to
support the conveyor sections above the ground to
help in assembly. Locate and place the conveyor
sections on the blocking in order, starting with the
head section and concluding with the tail section.
Receiving Inspection

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Series 2 Chain Conveyors
The head and tail sections of the chain conveyor are shipped pre-assembled direct from the factory. Intermedi-
ate trough sections come both factory pre-assembled or unassembled. Your order will serve as a reference to
how your trough section should arrive. If you have any questions, please refer to your order confirmation.
Head Assembly Tail Assembly
Intermediate Trough Assembly
Installation
TypicalIntermediate TroughSection Assembly
withRoller Returns
*
* optional AR liner shown

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Series 2 Chain Conveyors
An en masse conveyor may be purchased with
unassembled trough sections. The following recommen-
dations may prove useful in their assembly.
Before assembling conveyor trough sections together
remove covers. It is recommended that you store your
covers in a protected area in order to minimize any pos-
sible damage. Remember to retain factory shipped hard-
ware for conveyor cover installation.
Take a moment to familiarize yourself with your trough
assembly. If your conveyor is equipped with UHMW
roller returns, check that the rollers turn freely. If the
conveyor is equipped with slide rail returns, the wide
ends of the rail returns faceawayfromthedischarge end
of the conveyor. The narrow end, therefore, will face
toward the discharge end. See illustration on next page.
Intermediate trough sections are supplied in standard
ten foot (10’) lengths. Depending on your application
and individual specifications however, shorter sections
may be required to accommodate a given overall length.
During assembly of each trough section to the next sec-
tion, carefully inspect each flange joint to ensure that
the inside bottom and side surfaces of the trough are
flush. A chalk line is helpful during this phase of the
assembly to ensure the proper alignment of the trough
surfaces. The maximum run-out in any direction should
be +/- 1/4”. This proper alignment will minimize wear
on flights and other potential damage to the conveyor.
Make sure that the conveyor is level in horizontal appli-
cations.
Proceed by attaching the head and tail assemblies using
the same alignment procedures and precautions noted
in the preceding paragraph.
Installation
Lay bottom plate weldment onto blocking material.
Next, loosely attach side weldments to bottom plate
with 3/8” hardware provided. Then fasten UHMW
roller returns or slide rail return weldment to interme-
diate sides with the 5/16” whiz flange capscrews.
Note: When installing UHMW roller returns,
check that they are centered within the box. It is
importantthat theinside dimensionsof thebox are
equidistantfrom thebottom plateto theroller/slide
rail shafts (see diagram below).
It is critical for straightness of conveyor that the
sides and bottom flanges are aligned flush. After
making sure the flanges are aligned, tighten all hard-
ware on the trough section. When any optional Abra-
sion Resisting (A.R.) liners are ordered, they may be
installed with the 3/8” flat countersunk hardware pro-
vided. Adequately tighten liners to conveyor sides.
Check that the countersunk hardware is not protruding
above the surface of the A.R. liners.
Intermediate Trough Section Assembly

12
Series 2 Chain Conveyors
Installation
TypicalIntermediate TroughSection Assembly
withSlideRail Returns
Tail End
Head (Discharge) End
*
* optional AR liner shown

13
Series 2 Chain Conveyors
Inlet Assembly and Installation
One inlet is typically provided per conveyor. GSI’s
recommendation for inlet installation includes a
minimum distance of no less than 6” between the
closest edge of the inlet and the tail assembly.
The inlet can be attached with continuous weld
seams. If intermittently welded, it is important to
use caulking or sealing around the inlet area in or-
der to seal the unit.
Similarly GSI recommends that if inlets are welded
onto the conveyor, this procedure should occur prior
to installation of motor and/or other electrical de-
vices. By not following this precaution, owner as-
sumes all risks associated with this type of instal-
lation.
Before installing the covers, adhesive back foam
strip may be applied to provide a seal against the
elements. Starting at the tail assembly, place the
Tail Section Cover on top of the Tail Section
assembly. Apply the adhesive back foam strip to
the top surface of the protruding lip before install-
ing the next cover (see Cover Trough Assembly
diagram on page 14). This recommended installa-
tion sequence should ensure that water will shed
away from cover seam connections.
When an inlet is on the conveyor, a cover section
may have to be cut accordingly to accommodate
the inlet. For installation of an inlet, see Inlet
Assembly and Installation.
Cover Assembly
Installation
Installion

14
Series 2 Chain Conveyors
Cover Trough Assembly
Installation
Discharge End
Tail End
Standard Inlet
Adhesive Back Foam Strip

15
Series 2 Chain Conveyors
DragChain AssemblyInstallation
Allchainsuppliedwithnewconveyorswillbeinstalled
inasimilar manner,regardlessof type. Correcttotal
chainlengthhasbeendeterminedforyourinstallation.
The 81X conveyor drag chain is shipped in
approximate10 footlengths withan additionalpre-
cutshort section,if necessary(referto packinglist).
The4"pitchchainisshippedwith(1)or(2)5'lengths
withcotteredlinksneeded forchain take-up.Always
installthesesectionsastheyarerequiredforshortening
thechain.
Position the chain over the roller return assemblies
and the sprockets in the head and tail assemblies.
The UHMW wear pads should be in front of the
weldedchain flights inthe directionof chaintravel
(see diagram below). Connect chain lengths
together with connecting links and/or pins. This
assembly also applies to conveyors with slide rail
returns.
Installation
Rotate the chain, now on the sprockets, at least
onecompleterevolution. Check tosee thatthechain
and its wear pads are not catching on flanges or
rubbingon the troughsidesdue tothe sprocketsnot
being centered within the box. Ensure a “break-
in” period whereby the chain is allowed to run and
seat itself. After running it for an adequate period
of time stop the machine, disconnect and lockout
the power source. Retighten as necessary and re-
move any excess chain portions. Repeat this pro-
cess as necessary.
Tighten the drag chain assembly using the take-up
screws located on each side of the tail section or on
thetake-up head. Onconveyors withroller returns,
thechainisatthe propertension whenamaximum of
1/2”deflectionoccursat apoint midwaybetween the
rollers(seediagrambelow). Onconveyorswithslide
railreturns,thechainshouldbeabletobeliftedslightly
whensufficiently tightened. Afterthechain istight,
check that the head and tail shafts are square to the
box sides. If the shafts are not square, loosen the
tighterof thetwo adjusterscrewsuntil theshafts are
square. Lock the adjuster screws by tightening the
hexnutsagainst thecross-ways “C”channel.
81X Chain Assembly
4” Pitch Roller Chain Assembly
Direction of Chain Travel
BottomRun

16
Series 2 Chain Conveyors
Installing Shaft Mount Reducers
Assemble torque arm bracket to conveyor per in-
stallation instructions found on page 19.
To aid in the installation of the reducer onto the shaft,
remove any protective coating film from shaft. Slide
the reducer onto the drive shaft extending from the
side of the conveyor head section. Using the instruc-
tionsandhardware suppliedwiththereducer, assemble
it to the conveyor drive shaft.
Assemble motor mount to the reducer. Refer to instal-
lation instructions provided with motor mount.
Install the rear panel of the drive guard before
mounting the sheaves. The rear panel has four (4)
mounting brackets with slotted holes. Attach the
lower brackets to the matching reducer assembly
bolts. Attach the upper brackets to the matching holes
in the front motor mount support.
Assemble the V-belt driven sheave to the input shaft
of the shaft mount reducer. Slide the sheave hub
onto the shaft and insert the square key. Attach the
hub sheave using the supplied retaining screws. The
retaining screws pass through the non-threaded holes
of the hub and into the sheave. Align the driver and
driven sheaves and tighten the retaining screws.
During tightening, it is possible for the sheave to
move out of alignment or become out of square. For
maximum V-Belt life, the driven sheave should re-
main both perpendicular to the drive shaft and aligned
with the drive sheave. Slip the V-belts over both
the driver and driven sheaves.
Install the front drive guard panel over the four
corner mounting studs. Secure with washers and
nuts provided.
Fill the shaft mount reducer with the manufacturer’s
recommended oil. A list of recommended oil can be
found in the gear reducer instructions.
Adjustment of V-belt tension is achieved by tighten-
ing the hex nuts located on the four (4) jackscrews
of the motor base. Adjust motor base equally at all
four bolts to maintain shaft alignment. Belts are
designed to fit loose upon installation. When the
V-belt tension is correct, tighten the top nut on the
jackscrews to lock the motor base in position.
Proper tension is 1/64” of deflection per one (1”)
inch of sheave centers on one side of belt, cen-
tered between sheaves.
Note: Too much tension shortens belt life. Check
belt tension frequently during the first 24-48 hours
of operation.
Installation

17
Series 2 Chain Conveyors
Motor
Connect the conveyor motor to a power source ac-
cording to the motor manufacturer’s instructions and
recommendations. To avoid injury it is recommended
that a certified electrician perform the motor wiring.
A shut off switch should be placed near the motor so
that the system may easily be shut down to help pre-
vent accidents during maintenance. It is important to
checkproper motorshaft rotationbefore installingdrive
belts
Welding
Welding on or to the conveyor may cause damage to
both the conveyor and its electrical system. If welding
is necessary, measures should be taken to protect the
conveyor. Should it be necessary to fasten anything to
theconveyor permanently,carefulconsideration should
be given to methods of maintenance, removal and re-
placement of the conveyor and/or its parts. (please
refer to Inlet Installation for GSI recommended guide-
lines).
Clearance
A clearance of at least the width of the conveyor is
recommended on all sides of the unit. Less clear-
ance may be acceptable however, serious consid-
eration must be given to methods of maintenance,
removal and replacement of the conveyor and/or
its parts.
Support
GSI’s recommended general guidelines in this area in-
clude adequate support for the conveyor assembly to
be installed at intervals no greater than 10 feet. It is
recommended that supports be installed at vertical por-
tions of flanges leaving bottoms of trough sections
clear. By attaching supports in this manner, the re-
movable bottoms are unobstructed for ease of re-
placement. Support legs are available as as option.
Discharge
The standard conveyor is constructed with one dis-
charge located at the drive end. If intermediate dis-
charges are to be used, the location(s) must be deter-
mined before proceeding with the conveyor assembly.
Intermediate discharges cannot be installed over a
trough joint; therefore, it may be necessary to position
a shorter trough section to serve as a spacer in order
to accommodate the placement of the discharge(s)
where they are required.
The owner assumes all responsibility for any alterations
to the equipment.
Installation

18
Series 2 Chain Conveyors
WARNING!
Before any maintenance is per-
formed to the conveyor, power must be shut off
and locked out to prevent accidental start up!
The care and maintenance section is provided with the
intention of helping to extend the useful life of the unit.
Like all equipment, the useful life of the conveyor is
greatly reduced if not used wisely and well maintained.
Please follow the next few simple steps to ensure
the safety and longevity of your equipment.
wCheck all bearings and moving parts daily
during use.
wLubricate bearings according to bearing
manufacturer’s recommendations.
wFollow manufacturer’s recommendations for
gear reducer lubrication and maintenance.
wInspect the V-belts periodically for proper
tension and wear. V-belts should be
replaced as necessary. If replacement or
tension adjustment is required, please refer to
the Shaft Mount Reducer Assembly Section
on page 16.
wThe Drag Chain and Sprockets should be
checked periodically for wear, damage and
proper adjustment. Any broken or bent
paddles should be replaced or straightened.
Should adjustment or replacement of the
drag chain be required, refer to the
Assembly Section on page 15.
Care and Maintenance Storage
If the unit is to be inactive for an extended period,
the following procedures are recommended.
wThoroughly clean the unit.
wLoosen the drag chain tension. Doing so
relieves the stress placed on the bearings
and shafts of the drive and tail sections.
wLubricate drag chains, shafts and drive
components with a good grade of light
machine oil.
Care and Maintenance

19
Series 2 Chain Conveyors Options
Drill the four holes in the conveyor’s bottom to
accomodate the 5/8” hardware provided. Attach the
torque arm bracket to the conveyor using four 5/8”
hardware. Under any circumstances, do not use
the 3/8” bolts previously removed from the con-
veyor bottom to attach the torque arm to the con-
veyor.
Install shaft mount reducer to head shaft per instruc-
tions on page 16.
Next, match the size of the hardware to the reducer
manufacturer’s torque arm. Use this hardware to at-
tachthe torque armto thebracket. Adequately tighten
all hardware.
Inspection Ports
After determining location(s) of inspection port(s)
on conveyor, cut an 8 3/16” square hole in the
cover for each inspection port.
Insert inspection port into hole until its frame is flush
to the cover. Weld inspection port to conveyor
cover. Additional caulking may be required to
ensure that water will shed from the inspection
port.
When a drive package is ordered with the conveyor
system, a torque arm bracket is provided.
The torque arm bracket is pre-punched for ease of
installation to the unit. Begin installation of this option
by first determining the location of the torque arm
bracket relative to the range of extension allowed by
the shaft mount reducer’s torque arm. The bracket
will extend on the same side of the conveyor as the
head shaft. Remove the four bolts necessary from the
bottom of the conveyor plate.
Torque Arm Bracket Installation

20
Series 2 Chain Conveyors
Plug Relief Door
Next, use two (2) machine screws, nuts and washers
to fasten the limit switch to the clip. The limit switch
can be installed with its conduit port facing either to
the left or to the right. Do not tighten these machine
screws at this time.
Adjust the limit switch so that the roller actuator keeps
sufficient tension against the Plug Relief Door. The
roller actuator will fit into one of the pre-punched slots
in the Plug Relief Door lid. After the limit switch is
properly positioned, tighten the two machine
screws.
A NEMA 4 limit switch is shown below. A NEMA
9 limit switch is should be used in extremely dirty,
dusty conditions and/or in enclosed environments.
Options
Remove cover plate from head section end channel.
When installing Plug Relief Door, be certain that the
unit’s offset bottom lip is inserted inside the conveyor.
Use the existing hardware from the cover plate to at-
tach the Plug Relief Door to the head section. The
bolts should be inserted from inside the conveyor to
the outside.
Liberally apply the provided sealant around the Plug
Relief Door. Follow label directions on sealant car-
tridge.
Attach limit switch clip to the Plug Relief Door with the
hardware provided. Refer to the illustration below for
correct orientation.
Note: The limit switch clip must be oriented as
shown for proper engagement between limit
switch and Plug Relief Door.
Plug Relief Door