ThermoDrive Technical Manual.

Transcription

1 2015 ThermoDrive Technical Manual

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3 3 TABLE OF CONTENTS Section 1: Design Guidelines Typical Components... 7 Belt Support... 8 Framework Sprockets & Related Items Position Limiters Scaper Recoendations Troughed Conveyors Section 2: Product Line ThermoDrive ThermoDrive ThermoDrive Splicing System Belt Material Properties Chemical Resistance Guide Glossary... 48

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5 SECTION 1: DESIGN GUIDELINES 5

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7 Design Guidelines: Typical Components 7 Technical Information and Application The recoendations provided in this document have proven successful for most installations; however, extreme or unique conveyor designs should be reviewed by an Intralox representative. There are two important considerations: Intralox ThermoDrive belting must never be driven with tension (several inches of excess belt accumulation is preferred) Ensure that position limiters are seated correctly in place at the drive section of the conveyor Failure to follow the guidelines presented in this manual could result in improper performance of ThermoDrive belting, voiding the product warranty. ThermoDrive Design Basics DO Ensure that the belt has extra length and hangs loose on the return path Ensure all transitions, guides, and sprockets are at or above the minimum bend radius Limit the drive sprocket engagement to 180 or less Install position limiters in line with each drive sprocket (on flat belting), from about the 4:30 to the 5:30 position relative to the drive sprockets Lock all drive sprockets in position, in line with their corresponding position limiters Lock all support wheels/sprockets on idle shafts Ensure that shafts are squared DON T Pre-tension ThermoDrive belting or make the belt taut. There should be loose belt on the return path. Allow Intralox ThermoDrive belting to bend tighter than the recoended minimum radius Use a snub roller or other device to get more than 180 of wrap TYPICAL COMPONENTS A. Position Limiter B. Drive Sprocket C. Belt Accumulation D. Containment Block E. Intralox ThermoDrive Belt F. Drivebar Platform G. Carryway Support H. Returnway Support I. Support Wheels D I H G H Note: Actual number and type of limiters (A) may vary from what is pictured. Note: Desired location of containment block (D) may vary from what is pictured. A B C D E F fig. 1.1 NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

8 8 Design Guidelines: Belt Support Carryway WEARSTRIP CARRYWAYS There are various methods for supporting Intralox ThermoDrive belting in the load carrying portion. Wearstrip arrangements 1. Straight, parallel rails: These supports consist of strips, either UHMW or 300 Series Stainless Steel. Contact Intralox Technical Support Group for recoendations specific to your application. One rail should be indented 0.5 in (15 ) from each edge. The recoended maximum lateral centerline distance between rails is 6.0 in (152 ). This dimension will vary depending on the density of product and should be verified by an Intralox representative. Note: Special consideration must be given to any intermittent joint in the support rail. At the joint, ensure each end is chamfered to allow for smooth transitions and to avoid catchpoints. Failure to do so will cause interference between the drive bars and the leading edge/trailing edge of the downstream rail, resulting in rough belt operation and possible damage to the belt or rail. Stagger rail joints to further reduce the chance of joint/drive bar interference. An example of joint stagger is shown in Fig Break all sharp corners on the carryway rails. 2. Chevron array: By placing the strips in an overlapping V or chevron array (Fig. 2.1), the underside of the belt is supported across its full width as it moves along the carryway. The angled surfaces can be effective in removing gritty or abrasive material from the underside of the belt. A minimum 0.4 in (10.2 ) gap is recoended between the points of the wearstrip to reduce debris build up. This arrangement is also good for heavily loaded applications. By reducing the spacing between adjacent chevrons, the bearing load on the strips and the belt s unsupported span is decreased. Standard flat wearstrips can be modified to form the chevron array. The recoended maximum lateral center distance between rails is 6.0 in (152 ). Contact Intralox Technical Support Group for recoendations specific to your application. This dimension will vary depending on the density of product and should be verified by an Intralox representative. Belt travel A -Belt travel B -10 to 30 allowable C -Conventional - 2 in (51 ), maximum - 6 in (152 ) For chevron arrangements, ensure that the leading edge of the wearstrip is chamfered to reduce catch points. Failure to do so will cause interference between the drive bars and the leading edge of the downstream rail, resulting in rough belt operation and possible damage to the belt or rail. Break all sharp corners on the carryway rails. In cases where a heavy product is being loaded, a full width Ultra High Molecular Weight Polyethylene (UHMW) plate may be used to help absorb the impact. fig. 2.0 A - Gap for Thermal Expansion B - Joint stagger of the wearstrips fig. 2.1 B C A B NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

9 Design Guidelines: Belt Support 9 Wearstrip types and sizes Intralox can provide the following wearstrip material types: UHMW flat wearstrips are available in 0.25 in (6.4 ) thick 1.25 in (31.8 ) wide 10 ft (3 m) lengths. The UHMW wearstrips should be attached with plastic bolts and nuts in slotted holes to allow for expansion and contraction with temperature changes. Contact Customer Service for ordering assistance. Intralox also recoends the use of 300 Series Stainless Steel or UHMW Flat Stock (1 in (25.4 ) wide minimum). Carryway types Intralox recoends the following material types for use as carryway support rails: Smooth surface UHMW Polyethylene free of rough machine marks Smooth surface 300 Series Stainless Steel free of rough weld seams WEARSTRIP DESIGN CONSIDERATIONS Temperature limits UHMW is recoended to 160 F (71 C). Note that belt temperature limits are 140 F (60 C) for Polyurethane and 170 F (77 C) for XT. Thermal expansion and contraction Installation of Intralox flat and angle wearstrips should allow for thermal expansion and contraction. The use of slots when mounting will accoodate changes in dimensions due to thermal expansion. Be cautious to account for gaps between wearstrips when changes in length occur from thermal expansion. For reference, see Figure 2.0 (example) and Figure 2.2 (coefficient of thermal expansion). At operating temperatures of 100 F (38 C) or less, it is sufficient to bevel-cut the opposing ends of strips at an angle of 30 from the horizontal and provide a clearance gap of 0.30 in (7.6 ). At temperatures exceeding 100 F (38 C), the angle of the cut should be 60. The clearance should be determined from thermal expansion calculations. It is recoended that wearstrip joining locations be staggered for smooth belt operation. Δ = L (T 2 -T 1 ) e where: Δ = change in dimension, in () L = total belt length at initial temperature, ft (m) T 2 = operating temperature, F ( C) T 1 = initial temperature, F ( C) e = Coefficient of Thermal Expansion, in/ft/ F (/m/ C) COEFFICIENTS OF THERMAL EXPANSION WEARSTRIP MATERIALS in/ft/ F (/m C) UHMW -100 F to 86 F (-73 to 30 C) 86 F to 160 F (30 C to 71 C) fig (0.14) (0.18) NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

10 10 Design Guidelines: Belt Support Returnway Intralox ThermoDrive belting is installed with ZERO PRE-TENSION. Since a belt installed properly will be loose on the conveyor, belt sag in the returnway should be expected. In order to properly control the shape and location of this sag while ensuring the belt is not pre-tensioned, the belt must have sufficient support in the returnway. Catenary sag, when implemented correctly, is critical because: It indicates zero pre-tension in the belt It accoodates belt storage from changes in length due to load or changes in temperature It enables belt lifting and access for sanitation Possible returnway supports include continuous rails (Fig. 2.3, A), shoes A (Fig. 2.3, B), and rollers (Fig. 2.3 C). On many conveyors, a combination of continuous and intermittent supports is desirable. When using continuous support rails: B fig. 2.3 The lateral center distance between rails should not exceed 12 in (305 ) C The rails on the outer edge should be 2 in (51 ) to in (76 ) from the edge. Further, to accoodate fluctuations in belt length, at least one open span is required in the returnway. This is especially true in longer conveyors (shaft to shaft length over 25 ft [7.6 m]), where at least 1/3 of the returnway should have catenary sections for belt length control where remaining conveyor length uses a returnway of continuous support. B Full-length rail support in the returnway is not recoended A because there is no room to accoodate changes in length (accumulation zone needed). fig. 2.4 When using intermittent supports, they should span the full width of the belt if possible. Roller/shoe spacing down the length (Fig. 2.4, Dim. A) should not exceed 72 in (1829 ). It is important that ThermoDrive belting not be forced to bend to a smaller backbend diameter than the recoended minimum backbend diameter (See Product Line Manual for minimum backbend diameter). Doing so, in any direction, will lead to belt damage, including premature failure of ThermoDrive belting. In general, we recoend 3 ft (0.9 m) spacing of return rollers and one span of 4-6 ft ( m) for accumulation. This accumulation zone needs to be closer to the infeed for inclines and closer to the drive end for horizontal conveyors. In cases where obstacles exist and the accumulation zone needs to be located around the obstacle, be sure to adjust your returnway support to avoid contact with these obstacles. The solution for this situation could be different roller spacing, a short set of rails, or even shoes. As you eliminate dynamic elements (rollers) and replace them with static (rails, shoes), friction will increase in the returnway.. The belt should be installed so that it has an appropriate amount of sag for all unsupported spans (Fig. 2.4, Dim. B): Recoended catenary sag at initial set-up is equal to 1.5 in (38 ) of catenary sag (Fig 2.4 Dim B) per 1 ft (0.305 m) of span (Fig. 2.4 Dim A); this can change depending on conditions such as load, temperatures, etc. Depth of catenary sag will vary as the span of return rollers is adjusted (e.g., max roller span of 6 ft (1.8 m) would require a minimum catenary sag of 9 in (229 ). Depth of sag will vary during belt operation according to belt speed, temperature change, and product load fluctuations. Ensure zero pre-tension in the conveyor. Returnway rollers and shoes coonly have flanged shoulders to assist in containing the belt. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

11 Design Guidelines: Belt Support 11 Returnway with Flights Given that all of the above recoendations for the returnway still apply, the following are recoendations more specific to belts with flights. Continuous rails are recoended for returnway support of Intralox ThermoDrive belts with flights (Fig. 2.5). Flighted belts always need an indent of at least 1.25 in (32 ); returnway support rails should be positioned to support the belt 0.25 in (6.35 ) from the flights (Fig. 2.6, A). It is possible to return on 90-degree flights. Contact Intralox Technical Support Group for recoendations specific to your application. Never return on scooped or 75-degree flights. For flighted belts used in an Incline-to-Packaging application (Z-Conveyor), please refer to the guidelines outlined in the Supplemental Design Guidelines for Incline-to- Packaging Applications. Center Notches When using a center notch in the belt, the following recoendations apply to both the carryway and returnway of the conveyor: Limiters should be used at the drive in the center notch Rails should never contact the edges of the flights or be used for containment/tracking purposes. Maintain in (3.2 ) to 0.25 (6.4 ) clearance between the rail and flight edge. Rails need to be chamfered at the infeed and outfeed to prevent catch points. Break all sharp edges. Belts with center notches may need belt support (e.g., hold downs) at all transitions. Contact TSG for applicationspecific recoendations. Belt Length Fluctuation One of the principal functions of the returnway is to properly accoodate the increase (or decrease) in the length of the belt while operating. Therefore, conveyors should be designed to incorporate a suitable location within the returnway where the temporary length change of the ThermoDrive belt can be accoodated. The natural location of belt accumulation is iediately following the drive sprockets (Fig. 2.7) or at the lowest vertical section of the conveyor. The path the belt takes through the returnway will need to be free of obstructions or catch points (for example: drip pans, structural members, etc) at both the belt minimum and maximum expected lengths. Please contact the Intralox Technical Support Group for recoendations specific to your application. Belts will either elongate or contract in operation because of these factors: Temperature variations Assuming belts are installed at average ambient conditions, normally about 70 F (21 C), any significant temperature change in operation will result in contraction or expansion of the belt. Be sure to consider belt material s full operating cycle (production, sanitation, etc.) when determining the effect of thermal expansion and contraction. The magnitude of the thermal contraction or expansion is dependent upon the belt s material, the difference in temperatures, and the overall length of the belt. A belt which contracts due to cold temperatures may cause overtensioning and excessive shaft loads if surplus belt is not provided. Elongation (strain) under load All belts will elongate if load is applied. It should be noted that under most conveyor conditions, only the carryway length needs to be considered when determining belt elongation. A fig. 2.5 fig. B2.6 fig. 2.7 NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

12 12 Design Guidelines: Belt Support As previously mentioned, changes in belt temperature will change the overall length of ThermoDrive belt based solely upon its Coefficient of Thermal Expansion (CTE). This becomes critical when ThermoDrive belting is made to length at a temperature other than the one at which it will actually run. For instance, a belt will often be cut to length at 70 F (21 C), even for a conveyor intended to run at 20 F (-7 C). In order to size the belt correctly, the Coefficient of Thermal Expansion must be used to calculate the amount the belt will shrink due to the 50 F (28 C) temperature decrease from the time the belt was cut to length to the time that it is running on the conveyor. If this calculation is not done properly, the length of the ThermoDrive belt may be significantly wrong. Examples: Determining the temporary fluctuation in belt length relative to temperature. Imperial Formula: CTE (in / ft / F) x Belt Length (ft) x Temperature change ( F) Metric Formula: CTE ( / m / C) x Belt Length (m) x Temperature change ( C) Coefficient of Thermal Expansion Table Material in/ft/ F /m/ C Polyurethane XT Cold Use Belt Style: ThermoDrive 8050 Polyurethane Belt Length: 200 ft Conveyor Length, Center to Center: 100 ft Temperature Change: 65 F Conveyor Type: Horizontal A to B Formula:.001 x 200 ft x 65 F Calculated length change: 13 in Belt Style: ThermoDrive 8050 Polyurethane Belt Length: 20 m Conveyor Length, Center to Center: 10 m Temperature Change: 36 C Conveyor Type: Horizontal A to B Formula: 0.15 x 20 m x 36 C Calculated length change: 108 D 1 D 2 Section Section X-X X-X fig. 2.8 Consider thermal expansion in the width direction as well. At maximum operating temperatures, the belt edge clearance ( D dimension in fig 2.8 above) needs to be in (3.2 ) on both sides of the belt. USE OF ADJUSTABLE IDLE SHAFTS There are many benefits to having an adjustable idle shaft: The shaft can be moved to make incremental adjustments in belt length and returnway position. For belt installation or repair, the shaft can be moved full forward to provide the shortest path. It may facilitate conveyor cleaning. When using adjustable idle shafts: The take-up is not required for drive-sprocket engagement Meant for fine-tune adjustments to belt path position only Avoid pre-tensioning the belt; belt should stay loose to facilitate cleaning and sanitation Note about belt length: Since ThermoDrive belts do not require return-side tension to operate, it s permissible or even desired to have significant excess belting on the return side of the conveyor. For example, having excess belt in the returnway would allow a sanitation crew to lift the belt from the carryway, giving access to clean the carryway, frame, sprockets, and shafts. In every case, ensure that the belt path is completely free from obstructions such as cross members, bolts, wiring, etc. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

13 Design Guidelines: Belt Support 13 Catenary sag A belt hanging under the influence of gravity between two supports will assume the shape of a curve called a catenary. The specific dimensions of this curve will depend upon the distance between supports, the length of hanging belt, and the belt s weight. In most cases, the actual shape of catenary curve is not important, but the conveyor designer is interested in the excess belt stored in the returnway section. The excess belt in each section, X, is found from: X = (2.66 S²) / D where: X = excess belt, in () S = sag, in () D = distance between supports, in () Determining where length changes will be accoodated can be controlled by creating a larger span where the sag is preferred. When using continuous rail supports in the returnway, length changes may be accoodated by creating an open span in the rails. Regardless of returnway belt support method, typically, one 6 ft (1.8 m) longitudinal span will be sufficient to control where the belt length accumulates (Fig. 2.9, Dim. A). After thermal elongation and belt strain effects have been considered and a range of belt lengths has been calculated, it is important to design the returnway to be able to accoodate the belt at both the shortest and longest predicted lengths. It is quite possible that multiple catenary sag sections may be required to properly store belt, though remember that sag will not distribute evenly it generally will collect in the longest sections and where belt tension is lowest. In most applications, this change in belt length will be relatively insignificant and will thus require nothing more than a designated location for accumulation (as needed). For long, heavily loaded conveyors (above 100 ft (30.5 m) and 50% Allowable Belt Pull - ABP) that utilize continuous support rails in the returnway, Intralox Technical Support Group should be consulted to ensure that sufficient space has been designed for belt length accumulation. For example, a horizontal conveyor 30 ft (9.1 m) long and 30 in (762 ) wide, with a product load of 200 lbs (90.7 kg) will only accumulate in (3.2 ) of temporary belt length. However, a horizontal conveyor 100 ft (30.5 m) long and 30 in (762 ) wide, carrying 4000 lbs (1814 kg) will accumulate 9 in (228.6 ) of temporary belt length. A fig. 2.9 NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

14 14 Design Guidelines: Belt Support CONTAINMENT Containment of ThermoDrive belting is accomplished along the belt edges. The drive bars on the bottom surface of ThermoDrive belting extend to the edge of the belt, allowing for the lateral rigidity required to effectively contain the belt. Conveyor side rails, frames, containment blocks, or flanged rollers (Fig. 2.10) can be utilized to contain the belt. Recoended clearance between the belt guide and the edge of the belt is a minimum of in (3.2 ) per side (refer to page 12 for Coefficient of Thermal Expansion calculations). It is recoended that the containment blocks have a minimum 0.25 in (6 ) chamfer and 0.03 in (0.8 ) transition radius to avoid damage to the belt edge (Fig. 2.11). The flange height of a return roller should be.75 in (19 ). (Fig 2.10) See page 40 for Intralox s stocked flanged rollers. Chamfer both sides of containment block-leading and trailing ends (Fig 2.11). Minimum length of containment block should be 6 in (150 ). When containment blocks are used, spacing should fall into the range of 6-8 ft ( m). Applications where side loading is present need longer containment blocks. Full-length containment rails are preferred at areas where side loading or diverting product occur. All hardware should be countersunk below the level of the belt. Material recoended is UHMW; contact Intralox Technical Support Group for other alternatives. Drive shafts should be square with conveyor frame (best practice). NOTE: To avoid mistracking, the use of perpendicular surface to belt edge (not angled/tapered) is recoended..75 in (19 ).25 (6 in ) (6 ) minimum chamfer.031 (.8 in ) (.8 ) minimum radius fig fig NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

15 Design Guidelines: Framework 15 ThermoDrive belting has been designed as an optimal hygienic solution to greatly reduce the time and effort required to clean the belt. In order to fully realize the benefits of this hygienic solution, the conveyor should be designed to allow for a loosely fitted ThermoDrive belt. The loose fit will allow the belt to be simply lifted and cleaned in place or, depending upon the conveyor design, easily removed from the conveyor so that the conveyor may be easily cleaned. The framework configuration should allow for appropriate sanitation and maintenance as required in the specific application. Further, if the conveyor design requires ThermoDrive belting to be delivered open-ended, an access window of no less than 24 in (610 ) can be included to accoodate a ThermoDrive splicer. If the conveyor is designed to accept an endless belt, then a splicer and splicer window is not required. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

16 16 Design Guidelines: Sprockets & Related Items Shafts Shafts should be fastened to the conveyor frame level and square with the belt s path. Further adjustment is not required. In most cases, the standard 1.5 in (40 ) square shaft is sufficient to minimize deflection. All drive sprockets and support wheels should be fixed/locked on the shaft with retainer rings, heavy duty locking collars, or self-set retainer rings. When utilizing retainer rings, shaft corners require grooves. MACHINED TO CUSTOMER SPECIFICATIONS After the stock is cut to length, the raw shaft is precision straightened. The bearing journals are turned, followed by the cutting of retainer ring grooves, keyways and chamfers*. The final step is a thorough, quality control inspection before shipping. Contact Customer service for a form to fill in specifying shaft dimensions. *If the shaft is to operate under high belt loads, retainer ring grooves are not recoended. Self-set or split heavy-duty retainer type rings are recoended in these cases. Contact the Technical Support Group for retainer ring recoendations. E DIMENSIONS REQUIRED: A - LENGTH, overall B - LENGTH, bearing-end journal C - LENGTH, square section D - LENGTH, drive-end journal and keyway dimensions Square Size B C A (REF) E - DIAMETER, bearing journal F - DIAMETER, drive-end journal G - LENGTH, of keyway SHAFTS AVAILABLE FROM INTRALOX USA a SHAFT TOLERANCES IN INCHES Aluminum (6061-T6 Carbon Steel (C1018) 5/8 in. N/A in in in. N/A in. b N/A D G fig Shaft dimensions Stainless Steel (303/304) (304 CR) F Stainless Steel (316) N/A N/A Square Size SHAFTS AVAILABLE FROM INTRALOX EUROPE a SHAFT TOLERANCES IN INCHES Carbon Steel (KG-37) a. Consult Intralox for shafts longer than 3 m. Stainless Steel (303/304) SHAFT DIMENSIONS AND TOLERANCES Shaft Retainer Ring Groove and Chamfer Dimensions Size Groove Diam. Width Chamfer a 5/8 in ± in / in ± in. 1 in ± in / in ± in. 1.5 in ± in / in ± in. 2.5 in ± in / in ± in. 3.5 in ± in / in ± in ± / ± ± / ± ± / ± ± / ± ± / ± 0.25 Note: some instances, the retainer ring grooves will be offset from the shaft center. See Retaining sprockets (page 362 of 2014 Engineering Manual) a. Shaft chamfers must be added for molded S8050 and S8026 sprockets to fit. TOLERANCES (Unless otherwise specified) OVERALL LENGTH < 48 in. ± in. (< 1200 ± 0.8 ) < 48 in. ± in. (< 1200 ± 1.2 ) JOURNAL DIAM IN./ in. (Øh7 vlgs. NEN-ISO 286-2) KEYWAY WIDTHS in./ in. (+ 0.05/ ) SURFACE FINISHES JOURNAL 63 microinches (1.6 micrometers) OTHER MACHINED 125 microinches (3.25 micrometers) SURFACES Unless otherwise specified USA keyways are for parallel square keys (ANSI , R1973). Metric keyways are for flat, inlaid keys with round ends (DIN 6885-A). a. Consult Intralox for shafts longer than 12 ft. b. 3.5 in. carbon steel shafts can be nickel plated for corrosion resistance. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

17 Design Guidelines: Sprockets & Related Items 17 Frame Dimensions Certain dimensions are required on all conveyors using Intralox ThermoDrive belting. These dimensions vary depending on the ThermoDrive belting series and sprocket size, and are defined below (Table 4.1 and Table 4.2). B Dimension A: The vertical distance between the center line of the sprocket shaft and the top of the carryway. Dimension B: The horizontal distance between the center line of the sprocket shaft and the beginning of the carryway. A C Dimension C: The vertical distance between the top of the carryway and the top of the returnway. fig. 4.1 Table 4.1: Intralox ThermoDrive 8050 Sprocket Description A B C Pitch Diameter Outer Diameter No. Minimum Minimum in in Teeth in in in Table 4.2: Intralox ThermoDrive 8026 Sprocket Description A B C Pitch Diameter Outer Diameter No. Minimum Minimum in in Teeth in in in NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

18 18 Design Guidelines: Sprockets & Related Items Drive Sprockets It is important to install drive sprockets at the outside edges of ThermoDrive belting (Fig 4.2). Although it is not necessary that sprockets have freedom to move laterally, a limited amount of movement is allowable. Lateral movement of the sprockets on the outside edge of the belt should be limited to +/ in (3 ). All other sprockets may laterally move +/-0.25 in (6.4 ). The centerline of the sprocket should have a 1 in (25 ) indent from the belt edge. To achieve published belt pull capability, the maximum center distance for sprockets is 3 in (76 ). fig. 4.2 The belt must not haock between drive sprockets during operation. Additional sprockets are required if the haock depth is greater than 0.25 in (6 ). Idle Shaft (non-driving) Considerations Conveyor Entry (Infeed) of End Drives: Spacing of segmented discs = 6 in (152 ) maximum center line spacing when using 1 in (25 ) wide discs. Infeed belt wrap should have an arc of contact of at least 120 degrees to avoid vibration. Conveyor Exit (Outfeed) of Center Drives: Solid roller recoended to prevent haocking between sprockets. 3 in (76 ) disc spacing (center to center) is recoended when using 1 in (25 ) wide discs. Idle Shaft Belt Wrap Intralox ThermoDrive belting is designed to function on a range of roller diameters. However, minimum recoended roller diameters are achieved only by using Intralox designed rollers. Preferred roller materials are UHMW Polyethylene. ThermoDrive belts are installed without pre-tension, and therefore may not accurately conform to certain idle end roller diameters. As a general rule, increasing the roller diameter and/or using a thinner belt will enhance the belt s ability to conform to the roller diameter. However, when smaller diameter rollers are necessary, creating belt drag in the returnway area iediately before idle-end rollers will aid the belt in accurately conforming to these smaller roller diameters. To create belt drag, it is recoended that returnway rails, etc., be placed iediately before idle end rollers (Fig. 4.3). A fig. 4.3 Intralox recoends solid idle rollers for center-drive arrangements. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

19 Design Guidelines: Position Limiters 19 Position Limiters Position limiters are necessary to ensure proper, continuous engagement between Intralox ThermoDrive belting and drive sprockets without the use of pre-tension. The ideal position limiter is a shoe that spans an arc length larger than one belt pitch (Fig 5.1). Other objects, such as rollers and scrapers have proven successful as position limiters. Contact Intralox Technical Support Group for further assistance. All position limiters must be mounted where they can support the seated belt directly at the drive sprockets. A small gap of in (0.127 ) to 0.05 in (1.27 ) should be maintained between the seated belt and the position limiter (See dimension A on Fig 5.1). If the position limiter is too far from the belt it may cause engagement issues. Stainless Steel feeler gauges are recoended to verify this dimension. A fig. 5.1 The position limiter does not exert pressure through the belt and on to the sprocket. The limiters need to be rigidly mounted to resist any tendency the belt may have to lift off of the sprockets _LIMITER-GAP-DETAIL_1 Limiters that pinch the belt against the drive sprocket may cause intermittent drive disruption and create noisy EZ Clean belt/drive operation. Limiters should be installed laterally across the width of the belt (Fig 5.2) and remain in-line with the drive sprockets (Fig 5.3). If a flighted belt is used, position limiters should be placed in plane with the outside drive sprockets (Fig. 5.4). In order to ensure that the flights do not impact these limiters, the lateral movement of the belt should be sufficiently contained with in (3.2 ) to 0.25 in (6.4 ) clearance required.. Excessive Lateral Movement Improper Vertical Alignment Improper Vertical Alignment Correct Alignment and Spacing fig. 5.3 fig _ENDDRIVE-SPROCKETPOSITIONS_1 fig ENDDRIVE-SPROCKETPOSITIONS_2 NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

20 20 Design Guidelines: Position Limiters END DRIVE For typical pull in unidirectional applications, the position limiters should be installed approximately at the 5:30 position 1 when the belt is running in the clockwise direction (Fig. 5.5). This provides 165 of belt wrap around the drive pulley, which is ideal in most applications. In applications where the position limiter cannot be placed in this location, it should be placed somewhere between 120 and 180. It is important to ensure that no device causes the belt to wrap around the sprocket more than 180. CENTER DRIVE All center drive configurations must use a drive sprocket with no fewer than ten teeth (6.5 in [165 ] pitch diameter). Retrofitting a Center Drive to Work with Intralox ThermoDrive Belting Although most traditional center drive configurations can be easily retrofitted to work with ThermoDrive belting, the use of ThermoDrive belting provides the designer with the opportunity to use simpler configurations. To better understand the benefits of these new configurations, the typical retrofit options will be addressed first. As with the end drive, in any center drive scenario, it is important to ensure that no device causes the belt to wrap around the sprocket more than 180 nor exceed the minimum backbend radius (see the Intralox ThermoDrive Product Line Guide for the minimum backbend radius for each belt). The following should be done only when retrofitting an existing center drive conveyor of conventional design. If the conveyor is unidirectional, one position limiter must be placed over the last engaged drive bar, just before it leaves the sprocket in its direction of travel, bypassing the existing load-bearing roller. If the conveyor is bidirectional, there must be two position limiters used, one for each direction, bypassing both of the existing load-bearing rollers. If these modifications are not practical, the Intralox Technical Support Group should be contacted. fig Bidirectional - Preferred Design 5:30 7:30 6 4: fig Time references refer to the position of the hour hand of a clock. The clock is oriented such that the direction of product travel is tangent to the clock at the 12:00 position with the belt moving primarily in the clockwise direction. NOTE: ThermoDrive belting is not to be tensioned. Consult with the Intralox Technical Support Group for conveyor design and belt specification assistance prior to ordering. This service is available at no additional charge to ensure you receive the best performance from this conveyance solution and receive the Intralox Performance Guarantee.

21 Design Guidelines: Position Limiters 21 Drive Layout for a New Center Drive Conveyor When a new conveyor is being designed to use ThermoDrive belting, there are two basic configurations recoended. Neither of these configurations rely on achieving 180 of belt wrap, but rather use approximately 70 of belt wrap and use of position limiters. This reduction in belt wrap eliminates the need for the robust load-bearing rollers of the conventional configuration and allows the designer to configure a more compact drive system. For a bidirectional drive, two position limiters should be installed at the approximate 4:30 and 7:30 positions (Fig. 5.7). It is critical that all position limiters for bidirectional center drives are not smaller than the minimum backbend diameter rated for the particular ThermoDrive belt being used. For a unidirectional drive, two belt position limiters should be installed. One position limiter at the natural infeed and another at the discharge location on the sprocket, approximately located at the 6:00 and 8:30 positions, respectively (Fig. 5.8). In all cases, a minimum of three drive bars must be seated on the sprocket after the position limiters have been installed. NOTE: Intralox recoends dynamic rollers be a minimum diameter of 4 in (102 ) for Polyurethane belts and 6.5 in (165 ) for XT belts. 8: fig :30 4: : fig. 5.8 Center Drive (Bidirectional) fig. 5.9 All center drive configurations must use a drive sprocket with no fewer than ten teeth (6.5 in [165 ] pitch diameter). If interested in making a flighted belt conveyor with a center drive, contact Intralox Technical Support Group.

22 22 Design Guidelines: Scraper Scraper Recoendations for ThermoDrive When scraping ThermoDrive belting, it is important to design and mount your scraper in the proper position to maximize performance as both a scraper and a position limiter. Scrapers may require adjustments over time as this component can wear with use. In the figure below, there are 5 key dimensions to note when locating a scraper on your conveyor: a, b, X, Y, and Z. 165 X β Z α Y Figure 1 Locating a scraper to maximize performance with ThermoDrive Belting a = Face Angle = 45 The face angle, a, is the angle at which to prepare the face of the scraper in relation to the scraper itself. b = Mounting Angle = 45 The mounting angle, b, is measured from the center line of the conveyor. This is the best angle to minimize product accumulation and still provide good beam deflection. X = (Outer diameter of the sprocket/2) + (cover thickness of the belt) The scraper will act as a limiter as well as a scraper when placed at 165 degrees from top dead center (reference the centerline of the shaft). This dimension will vary with sprocket size and belt cover thickness. To be effective, scrapers must contact the surface of the belt, so place the scraper up against the belt to where it is just touching the surface, but not pinching the belt. Pinching the belt can cause surface damage to the belting, accelerated wear on the scraper, and can compromise belt to sprocket engagement in extreme cases. Y = Face width Minimizing the face width, Y, will help prevent product accumulation on the scraper. Minimizing scraper deflection is more important than minimizing face width. Contact Intralox Technical Support Group (TSG) for additional support. Z = Scraper Thickness Scraper thickness is determined through deflection calculations and will vary based upon the width of the belt, the load on the conveyor, and the design of the scraper. The scraper needs to do two things: scrape and maintain belt to sprocket engagement. Contact Intralox TSG for additional support. Deflection Considerations: When designing a scraper for a given conveyor, the design of the scraper must be of sufficient stiffness to minimize deflection away from the belt to inches or less at the center. If the scraper is allowed to deflect:

23 Design Guidelines: Scraper 23 Product yield will not be maximized. It will be less effective as a scraper and could allow product to hang up between the belt surface and the scraper (product jams). It will be less effective as a limiter and, in extreme cases, will allow the belt to jump on the sprockets. Scraper Material: For the majority of applications, a solid UHMW or Acetron scraper will perform well to scrape the surface of the belt if the above guidelines are followed. For inherently sticky products (e.g. icing, raw dough, ground meat, etc.), a softer tip scraper can be used to create a wiper effect on the belt. For these applications a urethane material in the durometer range of Shore A is recoended. The material should be suitable for FDA/EU Direct Food Contact. Urethanes are inherently flexible and will need to be secured to a stiffer element across the width of the conveyor to perform well. Scraper Materials Scraper Material Compatibility ThermoDrive Belt Materials PUR XT CU UHMW Acetron Urethane X = Recoend = No Data X = Not Recoended Considerations for Sanitation Make sure the materials used to construct the scraper are compatible with coon cleaning chemicals. The fewer the parts in the construction of your scraper, the better. Make sure any junctions are not collection points or niches for bacteria growth. If junctions exist, design the unit so it can be easily taken apart and cleaned as necessary. If possible, do not use threaded components in the construction of your scraper mount. Best Practices when using a scraper with ThermoDrive belting Under high loads, ThermoDrive belting will deflect away from the scraper between drive sprockets, so minimizing the space between sprockets (maximizing the number of sprockets) will enhance the performance of a scraper. Using a full width sprocket or drum motor is ideal for both performance and sanitation. The surface texture of the scraper can affect the release of product from the scraper. In general, the smoother the surface, the more product will want to stick to the scraper (adhesion). Make sure to design with sanitation in mind. When using ThermoLace, the width of your scraper should be reduced to avoid catching the edges of the ThermoLace and account for belt clearance allowed in the conveyor system. The width of the scraper should be the width of the belt (BW) minus one inch, centered to leave a half inch indent on both sides of the scraper. a. Scraper Width = BW - 1 in (25.4 ) Application Environments Every application is different. Scraper performance can be effected by (and not limited to): Temperature variations Product conveyed Scraper Deflection

24 24 Design Guidelines: Troughed Conveyors Unlike tensioned flat belting or rigid modular belting, ThermoDrive belts can be easily troughed for product control without sacrificing the benefits of zero-tension, sprocket-driven operation. There are several possible configurations, including: continuous, two-section, or three-section. Contact an Intralox representative for assistance with troughing configurations. Troughing conveyors should be designed using the principles and guidelines discussed in this manual while also incorporating the guidelines listed below. Use UHMW Containment Guides for lateral belt containment (see page 8 for specific guidelines) Carryway should transition from trough to flat for a distance of 1.5x belt width (when a full depth trough is required) before engaging with the sprockets/rollers. This transition length is required to minimize strain on the outer edges of the belt and significantly reduce belt drag. Lt= Transition Length

25 Design Guidelines: Troughed Conveyors 25 Option 1: No Troughing Groove A B R C Minimum belt width: 24 in (610 ) Minimum radius: 20 in (508 ) D Rail spacing: 3-6 in ( ) centers Maximum containment block spacing: 6-8 ft ( m) Minimum transition length: equal to 1.5 times belt width (1.5 x belt width) B A C Standard troughing notch Option 2: One Troughing Groove Minimum belt width: 10 in (254 ) Standard groove width: 1.75 in (44.5 ) Base belt thickness at groove: 2 Maximum angle from horizontal: 30 Maximum containment block spacing: 6-8 ft ( m) Minimum transition length: equal to 1.5 times belt width (1.5 x belt width) Option 3: Two Troughing Grooves B C Standard groove width: 1.75 in (44.5 ) A Base belt thickness at groove: 2 Minimum groove center distance: 10 in (254 ) Minimum section length: 4 in (102 ) 2 Std. Maximum angle from horizontal: 60 Standard troughing notch Maximum containment block spacing: 6-8 ft ( m) Minimum transition length: equal to 1.5 times belt width (1.5 x belt width)

26 26 SECTION 2: PRODUCT LINE

27 ThermoDrive in. Pitch Overall Thickness Minimum Width 1 25 Maximum Width a Open Area (seamless surface) 0% Product Notes Flat Top (7 ) Always check with Customer Service for precise belt width measurement and stock status before designing a conveyor or ordering a belt Available in blue or white All Flat Top belting has an engineered matte surface finish that is optimized for efficient product release and cleanability S8050E Flat Top in Polyurethane is available in widths up to 42 (1067 ) Belt withstands typical sanitation temperatures Zero pre-tension required when using patented limiter system. Positive drive system. Minimum backbend diameter is 4 (102 ) Minimum sprocket diameter is 4.0 (102 ) 6 tooth Splicing methods - ThermoDrive Splicing System, Thermolace and Endless belts available 0.118" (3 ) 1.96" NOM. (50 ) 0.276" (7 ) a Contact Customer Service for more information regarding belt widths over 42 (1067 ). Belt Data Belt Material BS Belt Strength a Temperature Range (continuous) W lb/ft kg/m F C lb/ft² Belt Weight kg/ m² FDA (USA) USDA Meat & Poultry NSF Agency Acceptability 3A Dairy c CFIA d A e J f Z g EU MC h Polyurethane to 140 b -7 to 60 b a. With sprockets spaced on 3 (76 ) centers. b. For continuous use over 100 F (38 C) contact Customer Service for actual belt strengths. c. 8050E in White is currently undergoing 3A Dairy testing. Contact Customer Service for updated information. d. Canadian Food Inspection Agency e. Australian Quarantine Inspection Service f. Japan Ministry of Health, Labour, and Welfare g. MAF-New Zealand Ministry of Agriculture and Forestry. MAF acceptance requires the use of a clean-in-place system. h. European Migration Certificate providing approval for food contact according to EU Directive 2002/72/EC and all its amendments to date.

28 28 ThermoDrive 8050 in. Pitch Overall Thickness Minimum Width 1 25 Maximum Width a Open Area (seamless surface) 0% Product Notes Flat Top Cold Use (7 ) Always check with Customer Service for precise belt width measurement and stock status before designing a conveyor or ordering a belt All Flat Top belting has an engineered matte surface finish that is optimized for efficient product release and cleanability S8050E Flat Top in Cold Use is available in widths up to 42 (1067 ) Belt withstands typical sanitation temperatures Cold Use material is only available in 8050E Blue Zero pre-tension required when using patented limiter system. Positive drive system. Minimum backbend diameter varies with temperature Above 20F (-6.7C), minimum backbend diameter = 4in (102 ) 0F (-17.8C) to 20F (-6.7C) = 5in (127 ) -30F (-34.4C) to 0F (-17.8C) = 6 in (152 ) Splicing methods - ThermoDrive Splicing System and Endless belts available 0.118" (3 ) 1.96" NOM. (50 ) 0.276" (7 ) Belt Data Belt Material BS Belt Strength a Temperature Range (continuous) W lb/ft kg/m F C lb/ft² Belt Weight kg/ m² FDA (USA) USDA Meat & Poultry NSF Agency Acceptability 3A Dairy c CFIA d A e J f Z g EU MC h Cold Use to to a. With sprockets spaced on 3 (76 ) centers. b. For continuous use over 100 F (38 C) contact Customer Service for actual belt strengths. c. 8050E in White is currently undergoing 3A Dairy testing. Contact Customer Service for updated information. d. Canadian Food Inspection Agency e. Australian Quarantine Inspection Service f. Japan Ministry of Health, Labour, and Welfare g. MAF-New Zealand Ministry of Agriculture and Forestry. MAF acceptance requires the use of a clean-in-place system. h. European Migration Certificate providing approval for food contact according to EU Directive 2002/72/EC and all its amendments to date. Note: Belt strength increases with decreasing temperature. Refer to page 44 of this manual.