CONVEYOR CONVERSION MANUAL I VERSION 1
Rexnord® TableTop® and MatTop® Chains
2010-SERIES INTEGRATED SIDERAIL
FLATTOP
Rexnord Industries, LLC
For more than one hundred years, Rexnord has provided superior power transmission, bearing,
aerospace and specialty components to industry across the globe. We pride ourselves in commitment
and dedication to the customer – from development to manufacturing, from installation to service.
This commitment and dedication a the centerpieces as Rexnord Industries begins our next
century of growth. We are taking on new challenges and opportunities with a fresh look on
the future.
SM
Precision. Power. Performance.
FlatTop Global’s Vision
To be the best in the world at continuously improving customers’ productivity through superior material
handling solutions.
Rexnord Industries, LLC Mission
To be a leading marketer and world class manufacturer of precision motion technology products &
systems and provide superior growth and command sustainable competitive advantage.
Contact Rexnord Application Engineering if you need assistance at 262-376-4800
2
CONTENTS
4 SAFETY CONSIDERATIONS
5 1.1 Introduction
Current Systems
6
1.2 Why Change?
10 Rexnord Intergrated SideRail
1.3 New Systems
1.4 Existing Systems
12 Rexnord Intergrated SideRail
1.5 Check list
3
SAFETY CONSIDERATIONS
PRODUCT SAFETY: Products designed and manufactured by Rexnord are capable of being used
in a safe manner; but Rexnord cannot warrant their safety under all circumstances. PURCHASER
MUST INSTALL AND USE THE PRODUCTS IN SAFE AND LAWFUL MANNER IN COMPLIANCE
WITH APPLICABLE HEALTH AND SAFETY REGULATIONS AND LAWS AND GENERAL
STANDARDS OF REASONABLE CARE; AND IF PURCHASER AILS TO DO SO, PURCHASER
SHALL INDEMNIFY REXNORD FROM ANY LOSS, COST OR EXPENSE RESULTING DIRECTLY
OR INDIRECTLY FROM SUCH FAILURE.
SAFETY DEVICES: Products are provided with only safety devices identifi ed herein. IT IS THE
RESPONSIBILITY OF PURCHASER TO FURNISH APPROPRIATE GUARDS FOR MACHINERY
PARTS in compliance with MSHA or OSHA Standards, as well as any other safety devices desired
by Purchaser and/or required by law; and IF PURCHASER FAILS TO DO SO, PURCHASER SHALL
INDEMNIFY REXNORD FROM ANY LOSS, COST OR EXPENSE RESULTING DIRECTLY OR
INDIRECTLY FROM SUCH FAILURE.
General Safety Precautions:
To avoid personal injury, all machinery must be turned off and locked out, prior to chain install-
•
tion, inspection, maintenance and removal.
Always use safety glasses to protect eyes. Wear protective clothing, gloves and safety shoes
•
Support the chain to prevent uncontrolled movement of the chain and parts
•
Maintain tools in proper condition and assure their proper use. Use of chain assembly tools is
•
recommended when applicable.
Do not attempt to connect or disconnect chain unless chain construction is clearly known and
•
understood
Do not reuse any sections of damaged chain because they may have been overloaded and
•
weakened
If any fl ame cutting, welding, etc. is to occur in the conveyor vicinity, take adequate precautions to
insure that no burning of any chain or other components occurs. If adequate protection cannot be provided, remove the chain and other plastic components from the conveyor and store in a safe location.
Thermoplastic and similar materials can burn and give off toxic fumes.
DO NOT INSTALL, OPERATE OR PERFORM MAINTENANCE ON THESE PRODUCTS UNTIL YOU
READ AND UNDERSTAND THE INSTRUCTIONS CONTAINED IN THIS MANUAL.
Contact Rexnord Application Engineering if you need assistance (see paragraph 1.3)
4
4
INTRODUCTION
1.1 INTRODUCTION
Inclined conveyors are one of the areas subject to product loss and diffi cult cleaning. Inclined conveyors are a necessary means of bringing
product to a higher level for processing or packaging. The most used
type of MatTop chain on this kind of conveyor is the 2-inch pitch food
grade execution, like the Rexnord 2010 series.
Rexnord is introducing a new type of side rail, the Integrated SideRail.
This is a side rail that retains product, travels with the chain and is an
integral part of the chain design. However, this system is very different
from current two piece assembled or one piece molded side guard executions.
This manual describes the easy steps for converting your current system to the new effi ciency improving Rexnord 2010 Integrated SideRail
5 5
CURRENT SYSTEMS
1.2 WHY CHANGE?
In processing lines currently several system are being used in combination with 2inch pitch food grade Modular belting/MatTop chains:
1. Flighted chains with static side guides
2. Flighted chains with conventional sidegaurds (Loose ele
ments to the chain)
3. Fligthed chains in combination with Integrated (or Molded-In)
side-gaurds
Although the functionality of all these systems should be the same; bringing product
to a higher or lower level on an inclined or declined conveyor, in the fi eld they have
their own specifi c issues causing down time and product loss.
Static guides
Conveyors with static guides trap the product
between the moving plastic modular belt/chain
and stationary PE or stainless steel side walls
that are mounted to the conveyor. This results
in several disadvantages:
• More expensive conveyor construction because of the additional material
needed to create the static guides and mounting supports.
• Installation and adjustment of the guides is time consuming and can be fairly
complicated.
o The guides need to be mounted, but also carefully adjusted in relation
to the position of the pusher attachment. If the guides are too far away
from the pusher attachment excessive amounts of product can escape
downwards in between the guide and the pusher.
o If the guides are too high in relation to the belt surface product can es
cape out the side of the conveyor. However, if the static guides are to
close to the chain or to the pusher, they can jam the chain or wear out
6
the chain surface.
CURRENT SYSTEMS
• Cleaning of the inclined conveyor is often not easy because of their
height. The chain rotates and passes the lowest point in the conveyor
and therefore can be cleaned. However, the static guides at the top of
the conveyor cannot be reached easily. This is an issue as there are
parts of the conveyor that actively touch the product. If the guides can
be opened up or removed for enhanced cleaning, they have to be ac
curately re-positioned prior to start-up, which again is time consuming
and needs to be done accurately.
The advantage of static guards is that they can be custom made to a desired height
to create the required capacity of the conveyor. In practice this means they can be
used to accompany up to a 6-inch high pusher attachment that are typically used on
plastic modular belt/chain, optimizing conveyor capacities.
Conventional two piece side guards
Two piece side guards are the conventional
system; they exist as loose parts that are connected with the chain using the chain connection pin. Although this system eliminates the
installation and cost issues of static guides
there are still some disadvantages:
• Due to their connection with the chain, a pin-hinge construction, sideguards
are not very stable and the top of the sideguards can move to the left and the
right rather easily. This makes the conveyor design for chains with convention
al side guards more complicated. Every construction element that could
cause the side guards to jam during operation should be addressed thus re
quiring more chain clearance through out the system.
• As a standard the conventional side guards often are not positioned directly
against the pusher. This is done to avoid jamming between the sideguards
and the pusher when for-fl exing around a sprocket and fl exing back when
entering the conveyor return. If an opening between the pusher and side
guard is allowed, product is not properly retained.
• Conventional side guards have a clear orientation in relation to the direction
of chain travel. This is because they are located in an angled overlapped posi
tion. If they are set to retain the product in an optimum way, they are more
sensitive to jamming in the conveyor frame. If they are set not to jam (oppo
site overlap), product can get caught in between them.
7
CURRENT SYSTEMS
• The conventional sideguards are available up to 4-inch high and therefore
can not be combined with 6-inch tall pusher fl ight, limiting the capacity of the
inclined conveyor.
• However, because the sideguards located in an angled overlapped position
they cannot be properly reached for cleaning and large surface areas remain
unexposed. Residual coatings like spices or fl avourings can be very diffi cult
to clean when caught in the side guard area.
Molded one piece side guards
Current molded one piece side guards are being offered. These systems address
the issue of the instability of conventional side guards and the accurate positioning
need of static side guides as well. However, in their current design there are two
major disadvantages:
• The maximum height of the current molded one piece side guards design is
limited to 4-inchs. This restricts the optimum conveyor capacity when utilized
in combination with 6-inch straight or curved pusher fl ights.
• The design of the current molded one piece side guard is rectangular with
out an overlap between the blade elements from pitch to pitch. This allows
the side guards to open up in two important positions and cause (signifi cant)
product loss:
o When the chain reaches the crest of the incline and begins to for-fl ex to
the horizontal section or downwards.
o When product is unloaded from the conveyor at the position of the drive
sprockets.
8
REXNORD INTEGRATED SIDERAIL
Integrated Side Rail (ISR)
Based on feedback from the market Rexnord
has designed the new Integrated SideRail to
address the defi ciencies of most conventional
systems. The system consists of 2 integrated
staggered blades per end module that interact
together when the chain operates; this system
provides the following advantages and features:
• The blades overlap in such a way that allows the Integrated SideRail to al
ways stay fully closed through out the chain cycle. This includes when fl exing
over a sprocket and through all angled transitions. The orientation of the Inte
grated SideRail blades is such that the product is always guided to the inside
of the chain when travelling up the incline. These features result in minimizing
product loss and increasing throughput.
• Due to rigid design of the Integrated SideRail, the system is very stable and
can work in accurately designed conveyors. This also minimizes any gap
between the pusher fl ight and the side rail system as they can be positioned
virtually against each other. This reduces product loss, damage and elimi-
nates adjustment issues associated with other side rail systems.
• The Integrated SideRail can be used with a back-fl ex radius as small as 12-
inch [305mm], meeting the industry standard for existing and new conveyors.
• The side indent is a fi xed 2-inch [50,8mm] from the edge of the chain to the
outboard side of the blade. This allows for an optimum chain support through
out the return way. Also this side indent maximizes upgrade possibilities in
existing conveyors [see paragraph 1.4].
• The Integrated SideRail remains overlapped through out the incline and when
for-fl exing around the sprocket. The minimum sprocket diameter for this is
6.5-inch [165mm, 10 teeth]. This optimizes the unloading of the conveyor with-
out any product loss.
• Integrated SideRail maximizes the conveyor capacity due to the availability of
a 4-inch [101,6mm] (ISR4) and 6-inch [152,6mm] (ISR6) high execution. This
makes it possible to combine the system with any straight or curved pusher
attachments when utilized with the 2-inch pitch 2010-series MatTop® chain.
9
REXNORD INTEGRATED SIDERAIL
• This system is designed for easy cleaning. At the tail shaft the blades open up
in a way that all areas and surfaces can be reached and cleaned easily. The
base of the system is ported to allow the removal of possible fi ne product resi-
due such as seasoning or fl avouring.
1.3 NEW SYSTEMS
Obviously the Rexnord 2010 ISR system can be used on new equipment as well.
In this case you will experience the easy and simple conveyor design needed for
the 2010 ISR. Details about new conveyor design can be found in our engineering
manual, section inclined conveyors. If you need this information and do not have it
yet please contact our Application Engineering department at AE.Europe@Rexnord.
com (for Europe, Africa, Asia and South America) or AE@Rexnord.com (for Mexico,
United States and Canada) depending on your location.
1.4 EXISTING SYSTEMS
In the case of existing systems the conversion to the Rexnord 2010 Integrated SideRail is possible with minimal modifi cations. The most common retrofi t situations are
described below.
Static Guides
Conveyors with static guides typically
use a 2-inch side indent (distance from
the side of the chain to the side of the
pusher attachment). The static guides
need to be removed and the ISR chain
4/5
1
can be installed. In the return way the
Integrated SideRail can be implement-
1/5 IN
[5,1 MM]
IN
[45.7 MM]
ed system because it falls within the
outer most dimensions of the current
pusher attachments. If desired the stat-
2,0 IN
[50,8 MM]
ic guides could be left on the conveyor,
however this would greatly reduce the
overall cleanability. If the side indent is
smaller then 2-inch the Rexnord 2010
Integrated SideRail can still be used.
Only if the current side indent is larger
than 2-inch more conveyor modifi ca-
tions are required.
10
REXNORD INTEGRATED SIDERAIL
Conventional side guards
In case of conventional sideguards, the
current chain can simply be exchanged
for a 2010 ISR chain. Due to the slightly
larger side indent of the 2010 ISR (2-inch
instead of 1 1/3 or 1 2/3 –inch), the ISR
chain will always be within the current
chains parameters, both in the carry and
return way.
Molded one piece side guards
The side indent of molded one piece side
guards is the same as the up mentioned
conventional side guard indent. Therefore
the change to 2010 ISR is just as easy.
1
[33,8 MM]
2/3
1
[41,8 MM]
2,0 IN
[50,8 MM]
1/3
IN
IN
2010 Integrated SideRail (ISR)
The integrated siderail normally fi ts the
current conveyor design. Besides the minor changes described above, the following points should be noticed:
• The guides (static or roller) that
hold down the current chain can be
2,0 IN
[50,8 MM]
used for the ISR chain as well. In
case of a change from conven
tional side guards, these guides
can be set somewhat further to
wards the chain (1/3-inch maxi-
2/3
2
IN
[67,8 MM]
mum).
• Some attention needs to be paid to the chain tension. The chain should not be
tight but it is recommended to limited the amount of chain sag in the return
part.
• If the current chain is not a Rexnord 2010-series chain, the drive sprockets
need to be changed. If sprockets are being used on the idler shaft, these need
to be replaced as well. Discs (or other systems not interacting with the chain
hinges), normally can be re-used.
11
REXNORD ISR CHECKLIST
• At the loading position of the conveyor the positioning of the infeed chute
needs to be reviewed. Due to the slightly different position of 2010 ISR it must
be made sure that product is loaded inside the Integrated SideRail system
and not on top.
Besides the up mentioned recommendations, as with any renewal or conversion of
conveyor Modular belt/chain the carry way and return way should be inspected on
their general condition.
1.5 CHECKLIST
To determine if your conveyor can be changed to Rexnord Integrated SideRail the
following checklist should be completed:
Item Description Yes/No
1Defi ne the current chain specifi cation, is this a 2-inch pitch chain?
2 Is the horizontal – incline backfl ex radius 12 inch [305mm] or larger (see fi g 1)?
3 Is the conveyor top radius 3½ inch [90mm] or large (see FIG 2)?
4 Are the drive sprockets 10 teeth or more?
5 Are the idler sprockets or disks larger than 6 ½ inch [165mm] diameter?
6 Is the current side indent 2 inch [50,8mm] or smaller?
7 Is the smallest chain backfl ex radius in the return part 12 inch [305mm] or larger?
Figure 1. Back-Flex min. 12 inch [305mm] Figure 2. Conveyor Top Radius min. 3½ inch [90mm]
If all answers are YES, the conversion is truly simple. If one of the answers is NO,
some slight conveyor modifi cations are required before Rexnord 2010 ISR can be
installed. If you have some doubt or if one of more items above are answered with
“NO” please contact our application engineers (see contact details in paragraph 1.3).
Contact Rexnord Application Engineering if you need assistance.
12
NOTES
13
World Class Customer Service
For more than 100 years, the dedicated people of Rexnord
have delivered excellence in quality and service to our
customers around the globe. Rexnord is a trusted name when
it comes to providing skillfully engineered products that
improve productivity and e ciency for industrial applications
worldwide. We are committed to exceeding customer
expectations in every area of our business: product design,
application engineering, operations, and customer service.
Because of our customer focus, we are able to thoroughly
understand the needs of your business and have the resources avail-
able to work closely with you to reduce maintenance
costs, eliminate redundant inventories and prevent equipment
down time.
Rexnord represents the most comprehensive portfolio of power
transmission and conveying components in the world with the
brands you know and trust.
********* are registered trademarks, and $$$$$$ are trademarks of Rexnord Industries, LLC. All rights reserved.
WORLDWIDE CUSTOMER SERVICE
AUSTRALIA
Rexnord Australia Pty. Ltd.
Picton, New South Wales
Phone: 61-2-4677-3811
Fax: 61-2-4677-3812
BRAZIL
Rexnord Correntes Ltda.
Sao Leopoldo - RS
Phone: 55-51-579-8022
Fax: 55-51-579-8029
CANADA
Rexnord Canada Ltd.
Scarborough, Ontario
Phone: 1-416-297-6868
Fax: 1-416-297-6873
CHINA
Rexnord China
Shanghai
Phone: 86-21-62701942
Fax: 86-21-62701943
FLATTOP EUROPE
Rexnord FlatTop Europe b.v.
‘s-Gravenzande, The Netherlands
Phone: 31-174-445-111
Fax: 31-174-445-222
After Hours/Emergency Phone:
31-174-445-112
Rexnord Marbett®, S.r.l
Correggio (RE), Italy
Phone: 39-0522-639333
Fax: 39-0522-637778
RMCC Deutschland Kette GmbH
Aßlar-Werdorf, Germany
Phone: 49-6443-83140
Fax: 49-6443-831420
Rexnord FlatTop France
Orly Cedex
Phone: 33-1-4173-4220
Fax: 33-1-4173-4229
MEXICO
Rexnord S.A. de C.V
Queretaro, Qro.
Phone: 52-442-218-5000
Fax: 52-442-218-1090
UNITED STATES
Customer Service
Phone: 1-866-REXNORD
(1-866-739-6673)
Fax: 1-614-675-1898
E-mail: rexnordcs(state)@rexnord.com
Example: rexnordcsohio@rexnord.com
Rexnord FlatTop North America
Grafton, Wisconsin
Phone: 1-262-376-4700
Fax: 1-262-376-4720
Rexnord International - Power Transmisson
Milwaukee, Wisconsin
Phone: 1-414-643-2366
Fax: 1-414-643-3222
international2@rexnord.com
ALL COUNTRIES NOT LISTED
Rexnord FlatTop Europe b.v.
‘s-Gravenzande, The Netherlands
Phone: 31-174-445-111
Fax: 31-174-445-222
After Hours/Emergency Phone:
31-174-445-112
Rexnord FlatTop Europe b.v. attopeurope@rexnord.com www.rexnord attop.com
Rexnord FlatTop North America 1272 Dakota Drive Grafton, WI www.rexnord.com
©2007 Rexnord Industries, LLC
stock number month/year Delzer Litho Printed in USA
Rexnord® TableTop® and MatTop® Chains
Rexnord® 2010 Series MatTop® Integrated Side Rails
OPTIMIZE PRODUCTIVITY
Rexnord®’s new Integrated Side Rail ( ISR) system for
2 inch pitch 2010 Series MatTop
reduces product loss and damage on incline and
decline conveyors for snack foods, fruits and vegetables,
confectionary, poultry, and other food processing
applications .
Integrally molded into the 2010 chain, the Integrated
Side Rail is positioned fl ush with 2010 Pushers, fully
enclosing conveyed product on inclines and declines,
even in diffi cult “over-the-top” positions. This uniquely
designed Rexnord
100% product retention on incline-decline conveyors ,
and eliminates product loss and damage from trapped
or dropped product.
®
Integrated Side Rail system ensures
®
chain drastically
The maximum-height 6 inch ISR model increases
conveyor capacity and can be used with high-capacity
6 inch straight and curved Pushers. For more compact
construction, choose the standard 4 inch ISR model.
Rexnord
conveyor construction and signifi cantly improves
cleanability. Hard-to-clean static guides that trap
product are eliminated, so overall conveyor system
cleaning is improved.
Use Rexnord
Integrated Side Rail system on new or existing conveyors
to minimize product loss and save substantially on
production costs.
®
’s new Integrated Side Rail system simplifi es
®
’s new high-capacity, easy-release 2010
FOOD INDUSTRY
Features & Benefi ts
•
Fully enclosed moving Integrated Side Rails increases
productivity by eliminating product loss on incline
conveyors.
•
Replacing static conveyor guides with Rexnord
Integrated Side Rails eliminates product damage,
increases conveyor hygiene, simplifi es conveyor
construction, and reduced conveyor maintenance.
•
4 and 6 inch high-capacity models ensure fully closed
systems when 10-teeth or larger sprockets are used.
•
2010 Integrated Side Rail has a 2
2
/
inch fi xed indent to
3
the pusher, and 12 inch min. backfl ex radius for both
4 inch high and 6 inch high models.
•
Robust ,stable side rail system eliminates chain
damage and jamming issues found with conventional
sideguards.
•
Robust hinge and pin design of Rexnord 2010 Series
MatTop chain increases reliability.
Easy retrofi t design for existing incline conveyors with
•
static guides or conventional side-guard systems.
Available in white and blue materials with Microban
•
®
antibacterial product protection. Though not a
replacement for good hygiene practices, Microban
ensures improved hygiene, especially in between
cleaning operations. Microban is safe, durable
and effective.
Indent to Pusher
2.67 in
(67.8 mm)
Side Indent
2.00 in
(50.8 mm)
Chain Height
0.63 in
(16.0 mm)
Minimum Backfl ex radius
12.00 in
(304.8 mm)
Chain Pitch
2.00 in
(50.8 mm)
4.00 in
Rail Height
(101.6 mm)
6.00 in
Rail Height
(152.4 mm)
Microban is a registered trademark of Microban Products Company.
Rexnord, TableTop and MatTop are registered trademarks of Rexnord Industries, LLC. All rights reserved.
WORLDWIDE CUSTOMER SERVICE
AUSTRALIA
Rexnord Australia Pty. Ltd.
Picton, New South Wales
Phone: 61-2-4677-3811
Fax: 61-2-4677-3812
BRAZIL
Rexnord Correntes Ltda.
Sao Leopoldo - RS
Phone: 55-51-579-8022
Fax: 55-51-579-8029
CANADA
Rexnord Canada Ltd.
Scarborough, Ontario
Phone: 1-416-297-6868
Fax: 1-416-297-6873
CHINA
Rexnord China
Shanghai
Phone: 86-21-62701942
Fax: 86-21-62701943
Rexnord FlatTop Europe b.v. fl attopeurope@rexnord.com www.rexnordfl attop.com
Rexnord FlatTop North America 1272 Dakota Drive Grafton, WI www.rexnord.com
©2007 Rexnord Industries, LLC
FLATTOP EUROPE
Rexnord FlatTop Europe b.v.
‘s-Gravenzande, The Netherlands
Phone: 31-174-445-111
Fax: 31-174-445-222
After Hours/Emergency Phone:
31-174-445-112
Rexnord Marbett®, S.r.l
Correggio (RE), Italy
Phone: 39-0522-639333
Fax: 39-0522-637778
RMCC Deutschland Kette GmbH
Aßlar-Werdorf, Germany
Phone: 49-6443-83140
Fax: 49-6443-831420
Rexnord FlatTop France
Orly Cedex
Phone: 33-1-4173-4220
Fax: 33-1-4173-4229
MEXICO
Rexnord S.A. de C.V
Queretaro, Qro.
Phone: 52-442-218-5000
Fax: 52-442-218-1090
UNITED STATES
Customer Service
Phone: 1-866-REXNORD
(1-866-739-6673)
Fax: 1-614-675-1898
E-mail: rexnordcs(state)@rexnord.com
Example: rexnordcsohio@rexnord.com
Rexnord FlatTop North America
Grafton, Wisconsin
Phone: 1-262-376-4700
Fax: 1-262-376-4720
Rexnord International - Power Transmisson
Milwaukee, Wisconsin
Phone: 1-414-643-2366
Fax: 1-414-643-3222
international2@rexnord.com
ALL COUNTRIES NOT LISTED
Rexnord FlatTop Europe b.v.
‘s-Gravenzande, The Netherlands
Phone: 31-174-445-111
Fax: 31-174-445-222
After Hours/Emergency Phone:
31-174-445-112
8rxISRSss-en 09/08 Delzer Litho Printed in USA
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