PHOSPHATE AND E-COAT

CONVEYORS
LESSONS LEARNED AND
MAINTENANCE TIPS

CONCERN # 1: Poor Lighting

Normally 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 of

Close up view of drive with lights of

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 Access

Typically 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 Wear
Typically 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
Jams
Typically 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 intended
Switch Arms turned such that the
drive would never shutdown on overtorque
Repeated 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 resets

5:29PM: Initial VFD Fault
5:31PM: Second VFD Fault
5:33PM: Inline Drive # 2 Torque
Overload Fault
5:40PM: Take Up Extended Fault

SUMMARY
Install 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.

SUMMARY
Keep 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.

SUMMARY
If 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.