GSi 2 Series User manual

Chain Conveyor
Installation and Operation Manual
MATERIAL HANDLING
PNEG-1043
En- Masse Chain Conveyors
Series 2 26” & 32” Tall

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
DANGERindicatesan imminentlyhazardous 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 apotentiallyhazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicatesa potentially hazardoussituation
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:
GSI Material 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
Care and Maintenance .......................................................16
Options.............................................................................17
Trouble Shooting Guide .......................................................21
Training Sign-Off Sheet ......................................................22
Warranty ..............................................................................23

6
Series 2 Chain Conveyors
Head Safety Decals
Head Section Decal Locations
3
1
2
4
Decal 3 Outside
Decal 4 Inside

7
Series 2 Chain Conveyors Tail Safety Decals
Tail Section Decal Locations
1
Decal 3 Outside
Decal 4 Inside
3
4

8
Series 2 Chain Conveyors
General Precautions
CAUTION:
!Do not operate the unit before reading
and understanding the operator’s manual.
!Keep all safety shields and devices in
place.
!Keep all covers in place.
!Make certain everyone is clear of the
equipment before operating.
!Keep hands, feet and clothing away from
movingparts.
!Shut off and lock out all power to adjust,
service, clean or unclog.
!Keep off the equipment at all times.
!Keep children, visitors and all untrained
personnel away from the machine while
in operation.
!Do not operate electric motor equipped
units until motors are properly grounded.
!Disconnect power on electrical driven
units before resetting motor overloads.
General Precautions
!!
!!
!Do 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.

9
Series 2 Chain Conveyors
Receiving Inspection
Carefullyinspecttheshipmentassoonasitisreceived.
Verify that the quantity of parts or packages actually
receivedcorrespondstothequantityshownonthepack-
ingslip. Anydiscrepanciesshouldbeclarifiedimmedi-
ately. Please remember that any damage or missing
partsmust be noted on thebill of ladingat thetime of
delivery. Report anydamage or shortageto thedeliv-
eringcarrier assoon as possible. GSI’s responsibility
fordamageto theequipment endswithacceptance by
thedeliveringcarrier.
Saveallpaperworkanddocumentationfurnished with
anyof the enmasse conveyorcomponents.
Pre-Installation Preparation
Familiarizeyourselfthoroughlywiththismanualandall
theconveyorparts. Readthe operatorsmanualandall
safetysignsbeforeusingorservicingequipment. Tak-
ing the time to do so will aid in the assembly of your
conveyor.
Removeanybandingandcratingmaterial. Arrangeall
theconveyorcomponents in suchafashion thatallare
easilyaccessible.
Locate sturdy items to serve as blocking (i.e. wood
blocks, saw horses, etc.). Blocking is used to sup-
port the conveyor sections above the ground to help
in assembly. Locate and place the conveyor sec-
tions on the blocking in order, starting with the head
section and concluding with the tail section.
Receiving Inspection

10
Series 2 Chain Conveyors
Thehead and tailsections ofthechain conveyorare shippedpre-assembleddirect fromthe factory. Intermedi-
atetrough sectionscome bothfactory pre-assembledor unassembled. Your orderwill serve as a reference to
howyourtrough section shouldarrive. Ifyou haveanyquestions,please refertoyour order confirmation.
HeadAssembly TailAssembly
IntermediateTroughAssembly
Installation
Typical Intermediate Trough Section Assembly

11
Series 2 Chain Conveyors
An en masse conveyor may be purchased with
unassembledtroughsections. Thefollowingrecommen-
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-
sibledamage. Remember to retain factory shipped hard-
ware for conveyor cover installation.
Take a moment to familiarize yourself with your trough
assembly. Install the slide rail returns so that the wide
ends of the rail returns face away from the discharge end
of the conveyor. The narrow end, therefore, will face
toward the discharge end.
Intermediate trough sections are supplied in standard
ten foot (10’) lengths. Depending on your application
and individual specifications however, shorter sections
mayberequired to accommodate adesiredoveralllength.
During assembly of each trough section to the next sec-
tion,carefully inspect each flange joint to ensurethatthe
inside bottom and side surfaces of the troughs 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
flightsandother potentialdamagetothe conveyor. Make
sure the conveyor is level in horizontal applications.
Proceed by attaching the head and tail assemblies using
the same alignment procedures and precautions noted
in the preceding paragraph.
Installation
Fasten covers to the enmasse conveyor with the 3/8”
and 1/2” hardware provided. Adequately tighten the
1/2” bolts and nuts so that the vertical cover seams are
in tight contact with each other.
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
Installationbelow.
Inlet Assembly and Installation
One inlet is typically provided per conveyor. GSI’s rec-
ommendation for inlet installation includes a minimum
distance of no less than 6” between the closest edge of
the inlet and the tail assembly. See detail on page 12.
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 order to seal the unit.
SimilarlyGSI recommendsthatif inlets are welded onto
theconveyor, this procedure should occur priortoinstal-
lation of motor and/or other electrical devices. By not
following this precaution, owner assumes all risks asso-
ciated with this type of installation.
Cover Assembly
Installation
Lay bottom plate weldment onto blocking material.
Next, loosely attach side weldments to bottom plate
with 3/8” hardware provided. Then fasten slide rail
return weldment to intermediate sides with the 1/2”
hardware.
Note: It is critical for straightness of the conveyor
that the sides and bottom flanges are aligned flush.
Also, it is important that the inside dimensions of
the box measure equidistant from side-to-side both
top and bottom of the trough box (Dimension A =
Dimension B). See diagram below.
After making sure the flanges are aligned, tighten all
hardware on the trough section. Abrasion Resisting
(A.R.)liners are installed with the 3/8” flat countersunk
hardware provided. Adequately tighten liners to con-
veyor sides. Check that the countersunk hardware is
not protruding above the surface of the A.R. liners.
Intermediate Trough Section Assembly
End View of Trough Section
(Liners not shown for clarity)

12
Series 2 Chain Conveyors
Inlet Assembly
Installation
Head Discharge End Tail End
Standard Inlet

13
Series 2 Chain Conveyors
DragChain AssemblyInstallation
All chain supplied with new conveyors will be
installed in a similar manner, regardless of type.
Correct total chain length has been determined for
your installation by GSI. The conveyor drag chain
is shipped in approximate 10 foot lengths with an
additional pre-cut short section if necessary (refer
to packing list). If welded chain (WH132, WH155
or WH157) has been supplied with the conveyor,
a minimum of five (5) feet of chain with cottered
pin connectors will be supplied. These pin con-
nectors and links may be removed as necessary for
chain take-up. The chain may be installed at any
time during conveyor assembly.
It is recommended however, that you position the
chain over the slide rail returns and the sprock-
ets in the head and tail assemblies. The UHMW
wear pads should be in front of the welded chain
flights in the direction of chain travel (see dia-
gram below). Connect chain lengths together
with connecting links and/or pins.
Installation
Rotate the chain, now on the sprockets, at least
onecompleterevolution. Checkto seethatthechain
and its wear pads are not catching on flanges or
rubbing on the trough liners. 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
the take-up head. The chain should be able to be
liftedslightly whensufficiently tightened. Afterthe
chain is tight, check that the head and tail shafts are
square to the box sides. If the shafts are not square,
loosen the tighter of the two take-up screws until
the shafts are square. Lock the take-up screws by
tighteningthe jamnuts.
Direction of Chain Travel
Bottom Run

14
Series 2 Chain Conveyors
InstallingShaft Mount Reducers
Assemble torque arm bracket to conveyor per in-
stallation instructions found on page 17.
Toaidin theinstallationofthe reducerontotheshaft,
removeanyprotectivecoating filmfromshaft. Slide
the reducer onto the drive shaft extending from the
sideofthe conveyor headsection. Usingthe instruc-
tionsandhardwaresuppliedwiththereducer,assemble
ittothe conveyor driveshaft.
Assemblemotormounttothereducer. Referto instal-
lationinstructionsprovidedwithmotormount.
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. Attachtheupperbracketstothematching holes
inthe front motormount support.
AssembletheV-beltdrivensheavetotheinputshaftof
theshaftmountreducer. Slidethesheave hub ontothe
shaftandinsert thesquarekey. Attachthehubsheave
usingthesuppliedretainingscrews. Theretainingscrews
pass through the non-threaded holes of the hub and
intothe sheave. Align the driver and driven sheaves
andtightentheretainingscrews. Duringtightening,itis
possible for the sheave to move out of alignment or
become out of square. For maximum V-Belt life,
the driven sheave should remain both perpendicu-
lar 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.
Filltheshaftmountreducerwiththemanufacturer’s
recommended oil. A list of recommended oil can
be found in the gear reducer instructions.
AdjustmentofV-belttension is achievedbytighten-
ing the hex nuts located on the four (4) jackscrews
of the motor base. Adjust motor base equally at all
fourjackscrews 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

15
Series 2 Chain Conveyors
Motor
Connect the conveyor motor to a power source ac-
cordingtothe motormanufacturer’sinstructions and
recommendations. To avoidinjuryitisrecommended
thata certifiedelectrician perform the motor wiring.
Ashut offswitch shouldbe placednear themotor so
thatthe system may easily beshut downto help pre-
ventaccidentsduring maintenance. Itisimportantto
checkpropermotorshaftrotationbeforeinstallingdrive
belts
Welding
Welding on or tothe conveyor maycause damage to
boththeconveyoranditselectricalsystem. Ifwelding
isnecessary,measuresshould betaken to protectthe
conveyor. Shoulditbenecessarytofastenanythingto
theconveyorpermanently,carefulconsiderationshould
begivento methodsofmaintenance, removaland re-
placement of the conveyor and/or its parts. (please
refertoInletInstallationforGSIrecommendedguide-
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’srecommendedgeneralguidelinesinthisareain-
cludeadequate supportfor theconveyor assemblyto
be installed at intervals no greater than 10 feet. It is
recommendedthatsupportsbeinstalledatverticalpor-
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 an option.
Discharge
The standard conveyor is constructed with one dis-
charge located at the drive end. If intermediate dis-
chargesare tobe used,the location(s) must be deter-
minedbeforeproceedingwiththeconveyorassembly.
Intermediate discharges cannot be installed over a
troughjoint;therefore,itmaybenecessarytoposition
a shorter trough section to serve as a spacer in order
to accommodate the placement of the discharge(s)
wheretheyare required.
Theownerassumesallresponsibilityforanyalterations
totheequipment.
Installation

16
Series 2 Chain Conveyors
WARNING!
Beforeanymaintenanceis per-
formedtothe conveyor,powermustbeshut off
andlocked out topreventaccidental start up!
Thecareandmaintenancesection isprovidedwiththe
intentionofhelpingtoextendtheusefullifeoftheunit.
Like all equipment, the useful life of the conveyor is
greatly reducedifnotusedwiselyandwellmaintained.
Please follow the next few simple steps to insure the
safetyandlongevityofyourequipment.
!!
!!
!Checkallbearingsandmovingpartsdaily
duringuse.
!!
!!
!Lubricate bearings according to bearing
manufacturer’srecommendations.
!!
!!
!Followmanufacturer’srecommendations for
gear reducer lubrication and maintenance.
!!
!!
!Inspect the V-belts periodically for proper
tension and wear. V-belts should be
replacedas necessary. If replacementor
tensionadjustmentis required, pleasereferto
theShaftMountReducerAssembly Section
on page 14.
!!
!!
!The Drag Chain and Sprockets should be
checkedperiodicallyfor wear, damage and
properadjustment. Any broken orbent
paddlesshould bereplacedor straightened.
Shouldadjustmentorreplacementof the
dragchain berequired, referto the
AssemblySection on page13.
Careand Maintenance Storage
If the unit is to be inactive for an extended period,
the following procedures are recommended.
!!
!!
!Thoroughlycleantheunit.
!!
!!
!Loosenthedrag chaintension. Doingso
relievesthestress placedonthe bearings
andshaftsof the driveandtail sections.
!!
!!
!Lubricatedragchains,shafts and drive
componentswithagood grade oflight
machineoil.
Care and Maintenance

17
Series 2 Chain Conveyors Options
Set the torque arm bracket in place and attach with
the 5/8” hardware previously removed from the
bottom plate of the conveyor. Four (4) 5/8” bolts
and nuts are required to fasten the torque arm
bracket to the conveyor.
Install shaft mount reducer to head shaft per in-
structions on page 14.
Next, match the size of the hardware to the reducer
manufacturer’storquearm. Use this hardwareto at-
tachthetorquearmtothebracket. Adequatelytighten
allhardware.
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
optionby firstdetermining thelocation ofthe torque
arm bracket relative to the range of extension al-
lowedby theshaft mount reducer’s torque arm. The
bracket will extend on the same side of the con-
veyoras the head shaft. Removethe 5/8” bolts nec-
essary from the bottom of the conveyor head bot-
tom plate.
TorqueArmBracketInstallation
TorqueArm Bracket
InspectionPorts
After determining location(s) for the inspection
port(s) on conveyor, cut an 11-3/4” square hole in
the cover for each inspection port. Cut the square
opening so that it is centered over the peak of the
conveyor cover.
Position the inspection port over the square hole
until its frame is flush to the cover. Weld inspec-
tion port to conveyor cover. Additional caulking
may be required so that water will shed from the
inspection port.

18
Series 2 Chain Conveyors
Note: Thelimit switchbracketmust beoriented
as shown for proper engagement between limit
switchand Plug Relief Door.
Attach the bracket to the hood cover with two (2)
5/16” bolts and nuts where two pre-punched holes
are located. Two pairs of pre-punched holes are
provided on the removable head hood cover - one
pair on the left side and one pair on the right side
of hood cover. Next, use two (2) #10 machine
screws, nuts and washers to fasten the limit switch
to the bracket. The limit switch can be installed
eitherto the left or to the right. Donot tighten these
machine screws at this time.
Adjustthelimitswitch sothattheactuator armkeeps
sufficient tension against the Plug Relief Door.Af-
ter the limit switch is properly positioned, tighten
the two machine screws.
Options
GSI Series 2 26” and 32” tall enmasse conveyors
come equipped with a head discharge plug relief
door as a standard feature. A NEMA 4 heavy duty
limit switch is standard on the relief door.
However, in extremely dirty, dusty conditions and/
orin enclosed environments, a NEMA9 heavy duty
limit switch should be used on the plug relief door.
The NEMA 9 limit switch is available as an added
option.
The optional NEMA 9 limit switch (GSI part num-
ber CE-00504) attaches to the same universal
bracket on the front of the head assembly as the
standardNEMA 4 limit switch.The same hardware
is used for both limit switches.
Plug Relief Door
Standard Plug Relief Door Limit Switch Optional NEMA 9 Limit Switch
GSI part # CE-00504

19
Series 2 Chain Conveyors
SlackChainAssembly
The GSI Group offers a slack chain detector
system as an option for its 26” and 32” tall Series
II enmasse conveyors. Depending on working
conditions and/or environment, either a NEMA 4
or a NEMA 9 limit switch is available.
Begininstallationofoptionalslackarmassemblyby
first cutting a 12” x 5” rectangular hole in the head
section cover; see illustration below.
Next, center the slack chain assembly over the
rectangular opening. Mark the locations for the
four (4) 7/16” diameter holes. Temporarily re-
move the slack chain assembly, and drill the four
7/16” diameter holes.
Before attaching slack chain assembly to the
conveyor, apply sealant to bottom surfaces of
slack chain assembly.
Fasten slack chain assembly to conveyor with 3/8”
hardware. See illustration below regarding direc-
tion of slack chain assembly on the conveyor.
After installation, check that the clearance be-
tween the UHMW paddle in the slack chain
assembly and the UHMW flights on the chain is
approximately 1/2” to 3/4”. Adjust if necessary.
Options
Top Mount Slack Chain
with NEMA 4 limit switch Top Mount Slack Chain
with NEMA 9 limit switch

20
Series 2 Chain Conveyors
Optional Carry-over Bars
Carry-Over Bars - Reversing Conveyor
For applications where the enmasse conveyor may
run in a reversing direction, carry-over bars should
be installed in the head assembly. These bars will
ensure a smooth transition of the chain and flights
from the head discharge into the conveyor box.
The carry-over bar package consists of four (4)
carry-over bars, four (4) clips, and two (2) shims
plus the hardware necessary to attach these com-
ponents within the head assembly.
Pre-assemble the two pairs of carry-over bars
and clips using the 3/8” bolts and nuts. Be sure to
center the clips to the vertical slots on each end
of the carry-over bars.
Next, place the pre-assembled pairs of carry-over
bars in the head discharge as shown below. It is
imperative that these carry-over bars be spaced
so that they pick up the UHMW flights as shown
below.
After the two pairs of carry-over bars have been
positioned, mark the locations for the eight (8)
9/16” diameter holes and drill. Attach with the
1/2” hardware provided.
After installation, check that the top edge of the
carry-over bars does not extend above the top sur-
face of the bottom plate.