XAManualdeEnsamblaje PDF

XA
ASSEMBLY
MANUAL
XA Assembly Manual
TABLE OF CONTENTS
Introduction ...................................... 2
Document disposition ...................... 2
Installation Site Preparations ......... 3

Assembly planning ........................... 3
Assembly order ................................. 3
Tools
.......................................... 4
General tools ..................................... 4

FlexLink tools ................................... 5
Power tools ....................................... 5
Assembly Instructions .................... 6

Conveyor beam ................................. 6
Cutting beam ............................... 6
Conveyor support ............................. 7
Standard support leg ................... 8
Double support leg ...................... 9
Beam support brace .................... 10
Adjusting Feet ............................. 11
Mounting ground feet ................... 11
Mounting casters .......................... 12
Mounting bullet feet ..................... 12
SS top slide rail support laying

point ............................................. 28
Mounting ss top slide rail
support ..................................... 29
Installing two (2) consecutive ss.
top slide rail supports and top
slide rail ................................... 30
Slide rail attachment on return
area .......................................... 31
Mounting slide rail at wheel
bends ....................................... 32
Fixing slide rail to conveyor
beam ........................................ 33
Drilling slide rail ............................ 33
Slide rail joint ................................ 34
Using plastic screws .................... 35

Chain
............................................. 36
Mounting preparation .................. 36
Joining chain ends ...................... 36
Mounting the chain ...................... 37
Length adjustment of the conveyor
chain ............................................ 39
Guide rail system .............................. 40
Mounting guide rail bracket
types A, B, C, D ........................ 41
Mounting guide rail bracket
type E ........................................ 42
Mounting guide rail ...................... 43
Bending guide rail ....................... 44
Conveyor fixed support bracket ... 13

Conveyor swivel support bracket 15
Installation of conveyor support
bracket on double beam
support ..................................... 16
Joining components to beam ....... 17
Joining two conveyor beams
or components ......................... 18
Bend Assembly ............................ 19
Drive and idler units ......................... 20 Final Preparation ............................. 45
Anchoring feet to the floor ............... 45
Mounting end drive unit ............... 21
Other preparations ........................... 45
Mounting catenary drive unit ....... 23
Start-up and testing......................... 46
Mounting gear reducer and
Safety considerations ...................... 46
support ..................................... 24
Slip adjustment ................................. 47
Mounting idler units ..................... 25
To adjust torque................................ 48
Top Slide rail and Slide Rail
Start-up ............................................. 49
Assembly ........................................... 26
Mounting the raised chain assembly Troubleshooting .............................. 50
bracket ..................................... 27
INTRODUCTION
This manual has been prepared to help selfbuilding end users, with little or no prior
experience, assemble the XA conveyor system.
Each chapter includes detailed instructions
and pictures showing how to assemble the
different components.
All safety, warning & recommendation notices
are identified as follow:
SAFETY
RECOMMENDATION
WARNING
Document disposition
The document contains the following chapters:
Installation site preparations
Tools
Assembly
Final Preparation
Start-up and testing
Troubleshooting
Introduction
XA Assembly Manual
INSTALLATION SITE PREPARATIONS

Assembly planning
Work systematically:
1. Study your assembly drawing.
2. Ensure that the necessary tools are available.
3. Check the parts list. Make sure you have all
the materials and components needed to assemble the conveyor system.
4. Make sure you have enough floor space to
mount the conveyor system.
5. Check to see if the floor at the installation site
is even, so that all feet can be properly level with
the floor.
Assembly order
The following can be used as a checklist during your conveyor assembly work:
Cut beams to appropriate lengths where necessary ........................................................ 6

Cut support leg: Insert round tube inserts and articulated feet (varies) .......................... 8
Attach conveyor support bracket .................................................................................... 13
Connect support leg with conveyor support bracket ...................................................... 13
Install drive end: Connect support leg under drive end ........................................... 21, 24
Install idler end ................................................................................................................. 25
Attach (evenly distributed) raised chain assembly bracket ............................................ 27
Cut and install ss top slide rail support: fix in position with assembly bracket
set screw ........................................................................................................................... 29
Cut and install carry-way ss top slide rail ........................................................................ 30
Cut and install return-way slide rail: Fix with plastic screws ........................................... 31
Loosen the drive unit slip clutch ....................................................................................... 36
Run a short piece of chain through the conveyor to check that there are no
obstructions ..................................................................................................................... 36
Mount chain into the conveyor ......................................................................................... 38
Mount guide rail bracket and other accessories onto the conveyor ................................ 40
Mount railing components to conveyor ............................................................................ 43
Tighten slip clutch to suitable friction ............................................................................... 47
Read final preparations at the end of this manual ........................................................... 45
XA Assembly Manual
Installation site preparations
TOOLS
To assemble an XA conveyor, you will need most of the tools listed on the following pages. Not
all are essential, but they will make your assembly work easier and more efficient.
General tools
1/8 drill bit

#21 drill bit
10-32 imperial tap
Tap handle
7/16 wrench (box, open or socket)
Hex key set (fractional standard)
Cutting Pliers
Hacksaw
Files
Socket wrench
Screwdriver for plastic screw
(slotted or phillips)
Knife (for cutting off plastic screw heads)
Soft-faced hammer
Level
Measuring Tape
Carpenters square
Grooved jaw pliers
Tools
XA Assembly Manual
FlexLink tools
Rivet crimping pliers 4 mm:

part number 3925800
Rivet crimping clamp 4 mm:
part number 3923005
Drill fixture for installation of slide rail
4,2 mm: part number 3920500
Mounting tool for slide rail:

part number XMMR 140
Pin insertion tool for FlexLink chain:
part number XMMJ 6
Power tools
Hand drill
Chop saw or band saw with bimetal blade
XA Assembly Manual
Hand grinder
Tools
ASSEMBLY INSTRUCTIONS
Conveyor beams
The conveyor beam is the base of the system. Every other component will be attached to it, to
build a complete conveyor.
Tools:
Band saw or chop saw
Measuring tape
Carpenters square
Marker
Cutting beams
If you have ordered 8-ft. (2.44m) beams, in
some cases they will need to be cut into
suitable lengths before assembly. Study your
drawing to determine the beam lengths are
required.
Working site
You should use a special area for cutting
beams in order to keep the assembly area
clean.
Conveyor beam
Quality of cut
If burrs are evident, they must be removed
prior to assembly.
Make sure the cut is straight for proper assembly.
SAFETY
Saw requirements
In order to obtain a clean and clear cut, the
use of a horizontal band saw with cooling
system is recommended.
Use a bi-metal high-speed blade
Assembly Instructions
All safety precautions

issued by the cutting saw
manufacturer should be
followed at all times.
XA Assembly Manual
Conveyor support
Support components include the support leg, adjusting feet and support brackets.
Tools:
Measuring tape
Marker
Hacksaw
Hand grinder
File
Soft faced hammer
7/16" box or open wrench
1/2 wrench (box or open)
Support leg
Standard support leg
Double support leg
Beam support brace
Treaded tube insert
Casters
Adjusting feet
Ground base and

vibration pad
Bullet feet
Support bracket
Fixed leg base
XA Assembly Manual
Swivel leg base
Leg base bracket

The beam support leg assembly includes: One (1) beam support and one (1) wedge assembly.
Installation instructions for the wedge assembly are detailed on page 13.
1. Mark and cut the support leg, at the desired

height.
10
Wedge assembly
2. Always cut at the top

end of the leg.
3. Remove all sharp

edges.
XA Assembly Manual
Double support leg

Used to support two (2) parallel beams with one (1) support leg.
The double beam support assembly includes: one (1) double beam support, one (1) joint plate
and two (2) wedge assemblies.
Double support leg
Support joint plate
1. As in the standard support leg, mark

and cut the double support leg at the
desired height.
Always cut at the top end of the leg.
XA Assembly Manual
Wedge assembly
2. Remove all sharp edges.
11
Beam support brace

The beam support brace is used in order to add more rigidity to the standard support, not the
double support leg. It is recommended in portable conveyors, whenever casters are used in the
standard support.
Beam support brace
1. Insert and fix the brace to the conveyor

using a raised chain assembly bracket as a
mounting base. Re-use the assembly
bracket bolts to attach the beam support
brace.
12
2. Connect the beam support

brace to the standard support using the set collar
provided.
XA Assembly Manual
Adjusting feet
Feet are attached to the support leg and come in a number of configurations. Follow the mounting instructions for the type of foot used in your application.
Mounting ground base

Two (2) adjusting feet per support leg are required. Select the desired articulated foot from the
catalogue.
Ground base and

vibration pad
Threaded tube insert
1. Install the inserts for the ground base at

the ends of the support leg.
Tap with the hammer until it is set to the
edge stop on the threaded tube insert.
XA Assembly Manual
2. Screw the ground base onto each threaded

tube insert and set up to desired position.
Then tighten the lock nut.
13
Mounting casters
Two (2) casters per support leg are required. Select the desired casters from the catalogue.
Casters
1. Insert caster at each end of the support leg

with the expansion rubber.
2. Fix the expansion rubber by tightening the

caster adjusting screw with the 7/16
wrench.
Mounting bullet feet

Two (2) bullet feet per support leg are required. Bullet feet do not need inserts.
Bullet feet
1. Install them at each end of the support leg.
Tap with the hammer until set to the edge
stop on the bullet feet.
14
XA Assembly Manual
Conveyor Support Brackets

Conveyor beams can be mounted on to the support leg with two (2) different types of conveyor
beam support brackets. These conveyor beam support brackets can be fixed or swivel, depending on the application.
Conveyor fixed support bracket

Used to support the beam in the horizontal position.
Fixed base
Leg base bracket assembly
1. Attach the wedge (provided with support leg) to the fixed leg base.
2. Join the support leg and the conveyor

fixed leg base. Insert the wedge assembly
into the round tubing leg.
XA Assembly Manual
3. Adjust the wedge screw with the 9/16

wrench.
15
4. Position the leg base bracket assembly

(included with the conveyor fixed support
bracket) on the conveyor beam without
tightening the screw.
5. Slide the support leg from underneath the

leg base bracket.
6. Insert and adjust the four (4) screws with a

7/16 wrench.
16
XA Assembly Manual
Conveyor swivel support bracket
Swivel leg base
Leg base bracket

assembly
1. This conveyor swivel support bracket

provides adjustment up to 30 to the conveyor beam.
For assembly information follow the same
instructions specified on the conveyor fixed
support bracket.
XA Assembly Manual
17
Installation of conveyor support bracket (fixed or swivel) on double beam

support
1. Assemble the fixed or swivel support

bracket to the support joint plate with the
bolt and nut provided.
Follow instructions on page 13 (fixed
conveyor support bracket).
3. Position the two (2) leg base bracket

assemblies.
18
2. As in the conveyor fixed support, connect

both supports to the leg adjusting the
wedge screw with the 5/8" wrench.
4. Slide the support leg from below the

conveyor beam.
Insert and adjust the eight (8) screws with a
7/16" wrench.
XA Assembly Manual
Joining components to beam

Tools:
9/16 wrench
7/16 wrench
Band or chop saw
Measuring tape
3/16 hex key

1/8 drill bit
9/32 drill bit
Hand drill
Connecting saddle
Beam to beam connecting saddle
Bends
Horizontal wheel bends
Vertical plain bends
Up
XA Assembly Manual
Down
19
Joining two conveyor beams or components

To assemble two (2) conveyor beams or any component onto the body of the conveyor you will
required the beam to beam connecting saddle.
Drive units and idler units come with joints included.
1. Connect two (2) conveyor beam ends by

inserting half of the connecting saddle into
one of the conveyor beam. Lightly tighten
the setscrews to maintain the connecting
saddle position.
Slide the other conveyor beam or component until it reaches the correct position.
3. Drill a 1/4 hole in the conveyor beam on

each side of the joint.
20
2. Tighten the screws using the 3/16 hex key.
4. Set and tighten the bolt and nut provided

with the connecting saddle.
XA Assembly Manual
Bend assembly
Select the desired bend from the catalogue.Two (2) connecting saddles per bend are required.
1. Connect a bend to a beam end (or two (2)

bends together) by inserting a connecting
saddle into each end of the bend. Lightly
tighten the set screws to maintain the
connecting saddle position.
Then slide the bend into the beam or the
other bend until it reaches the correct
position.
2. Slightly adjust the three (3) screws of the

connecting saddle on the side of the beam
or the other bend.
Tighten all connecting saddle screws, using
the 3/16" hex key. Avoid tightening two
screws of the same side in sequence.
3. Drill the conveyor beam and the bend

through the 1/4 hole in the joint.
4. Set and tighten the bolt and nut, provided

with the connecting saddle.
XA Assembly Manual
21
Drive and idle units

Next step is to mount drive and idler units to the conveyor beam. All drive and idler units come
with drive/idle joints included.
The mounting kit includes the base plate to attach the beam support below the standard drive
unit. It should be remembered that conveyor chains should always be pulled, not pushed, by the
drive unit.
Tools:
1/8" drill bit
9/32" drill bit
Hand drill
7/16" socket wrench

3/16" hex key
Drive unit
End drive unit
Catenary drive
Gear reducer mounting

kit
Idle unit
22
XA Assembly Manual
Mounting end drive
End drive unit
1. Slide the end drive unit into the conveyor

beam using the drive joint included with the
drive.
2. Tighten the setscrews using the 3/16 hex

key.
3. Drill the conveyor beam through the 1/4

hole at the joint.
4. Set and tighten the bolt and nut.
XA Assembly Manual
23
RECOMMENDATION
When installing a drive
unit, ensure that the slip
clutch is fully released.
The catenary drive units
must always have a
chain slack.Whenever the conveyor chain is
visible on the lower part of the inspection
slot on the side plate, it should be shortened.
24
XA Assembly Manual
Mounting Catenary drive unit
RECOMMENDATION
Catenary drive unit

Catenary drive units are used in endless
chain (top side chain) conveyor systems with
no return chain.
Catenary drive units can be installed anywhere along the conveyor length.
When installing a catenary drive unit, ensure

that the slip clutch is fully
released.
The bridge area where
the chain goes down
should not be accessible during conveyor
operation.
Catenary drive units must always have a
chain slack.
Whenever the conveyor chain is visible
through the slot in the cover, it should be
shortened.
Attach the catenary drive unit to the conveyor

beam using the beam joint included. Follow
mounting instructions set for the end drive unit
(page 21).
XA Assembly Manual
25
Mounting gear reducer & support
Gear reducer mounting kit
1. Install two (2) side plates (one left and one

right) included in the mounting kit with the
gear reducer. Tapped holes should be offset
to the shaft side.
2. Assemble the beam support leg using the

reducer plate included with the mounting
kit.
3. Place the gear reducer underneath the

4. Install the chain guard.
motor end, do not tighten the screw. Install
reducer sprocket and roller chain. Adjust the
roller chain by sliding the gear reducer on
the mounting slots. Chain slack must be at
least 1/2. Tighten the screw with a 1/2
wrench.
26
XA Assembly Manual
Mounting idler units
RECOMMENDATION
Install a support leg at a
distance no grater that 18"
from the connecting point.
Idler end unit

Idler units are used to guide the conveyor
chain from the return track to the top of the
conveyor. Idler joints are already attached to
the unit.
Follow same mounting instructions set for the
end drive unit (page21).
XA Assembly Manual
27
Top slide rail and slide rail assembly

The top slide rail is attached on top of the conveyor beam to reduce chain friction, otherwise
the chain would be in direct contact with the ss top slide rail support. It is very important that
the top slide rail and slide rail be installed properly, so that the chain can run smoothly and
premature wear is avoided.
Tools:
3/8" socket wrench
7/16" socket wrench
Hand drill
1/8" drill bit
#21 drill bit
10-32 imperial tap
Drill fixture
Cutting pliers
Knife
Soft-faced hammer
Screwdriver
Raised chain assembly bracket
Raised chain assembly

bracket
28
Top slide rail
SS top slide rail

support
Slide rail
XA Assembly Manual
Mounting the raised chain assembly bracket
Raised chain assembly

bracket
SS top slide rail

support
1. Loosen the screws of the raised chain

assembly bracket and place it on the
conveyor beam.
2. Place the raised chain assembly bracket at

even distance, not greater than 16 apart
from each other.
3. Lightly screw the raised chain assembly

bracket to the conveyor beam.
4. Tighten the raised chain assembly brackets

with the 7/16 wrench after all of them are
placed.
XA Assembly Manual
29
SS top slide rail support laying point

Verify the laying point of the ss top slide rail support and measure the distance between the
edges
Drive laying point
Horizontal wheel laying point
Vertical bend laying point
30
XA Assembly Manual
Mounting ss top slide rail support
1. Install the ss top slide rail support on the

raised chain assembly bracket slots.
XA Assembly Manual
2. Tighten screws with a 3/16 hex key.
31
Installing two (2) consecutive ss top slide rail supports and top slide rail
Top slide rail
1. Use the raised chain assembly bracket at

the union of the ss top slide rail support
edges.
Each of the assembly bracket screws must
hold one of the ss top slide rail supports.
2. With the flat face of the top slide rail facing

into conveyor...
3. ... press the top slide rail into ss support,

until it is set in position.
4. Avoid joining the top slide rails on top of

support connection.
32
XA Assembly Manual
Slide rail attachment on return area

Make sure that you mount the slide rail so that it snaps on to the beam. The slide rail is not
symmetrical; the long side should be facing the conveyor.
Slide rail
1. Start at an idler end unit. Separate the top

and bottom flange of the slide rail at the end
of the rail and press it into place.
XA Assembly Manual
2. Use the slide rail mounting tool to press the

slide rail into place. One end of the tool is
used when slide rail is mounted onto only
one side of the beam, and the other end is
used when you mount slide rail onto the
second side.
33
Mounting slide rail at wheel bends
Before wheel bend:
3/8
1. Cut the slide rail end on a 45 angle.
2. The slide rail must be longer than the

conveyor beam itself, and there should be a
3/8 (10 mm) distance between the slide rail
and the wheel of the bend.
Make sure that the end of the slide rail is
not bent up or down.
After wheel bend:
3. Cut the slide rail on a 45 angle with a

short back cut.
The slide rail must be longer than the
conveyor beam itself, and there should be a
3/32 (2 mm) distance between the slide rail
and the wheel of the bend.
34
4. In the outer bend, make sure that the slide

rail is properly pressed to the conveyor
beam profile.
XA Assembly Manual
Fixing slide rail to the conveyor beam

The beginning of each slide rail section must be attached to the beam, since the chain will
cause the slide rail to be pushed along the direction of the belt travel. Slide rail that moves into a
wheel bend or a drive unit can block the chain movement completely.
To attach the slide rail to the conveyor beam use plastic screws.
Drilling slide rail
1. Drill two (2) holes near the beginning of

each slide rail section. Use the drill fixture to
ensure clean-cut holes and the correct
location of the holes.
Keep a distance of approximately 1-3/16
(30 mm) between screws and drive unit.
This is in case the drive unit has to be
removed after conveyor system assembly.
XA Assembly Manual
2. The holes must be at the leading edge of

the conveyor body, in the direction of travel,
to hold the slide rail in place when the
conveyor is in use. Use a well sharpened
drill-bit.
The arrow indicates running direction.
Use a countersink bit to deburr and countersink the holes. Also make sure that there
are no metal filings left underneath the slide
rail.
35
Slide rail joint
3/8
1. Cut both slide rail ends on a 45 angle.

The beginning of a new slide rail section (in
the direction of travel) must be cut back at
small angle.
2. Do not place two (2) slide rail joints opposite each other. Make sure there is a distance of at least 3/8 (10 mm) between
them to make the chain run smoother. This
does not apply to slide rail that begins at an
idler unit or at a drive unit, where joints are
always parallel.
2-3
3. The arrow indicates travel direction.
4. Drill two (2) holes near each starting edge

of the slide rail. Use the drill fixture to
ensure clean-cut holes and correct location
of the holes.
Observations:
Try to let the slide rail run in as many continuhave an effect on the slide rail composious lengths as possible, except in the following
tion.
situations:
2. Never join slide rail in horizontal or vertical
1. It is recommended to use short slide rails
bends, since forces are higher on the slide
(610 ft. or 2-3 mm) where chemicals may
rail in these sections. Instead, place the
joint before the bend.
36
XA Assembly Manual
Using plastic screws
1. Use a 10-32 tap on the hole.
2. Drive the screws into the holes using a

screwdriver.
3. Cut off the screw heads by using a knife

and a hammer. The cut should be made
away from the joint, in the direction of chain
travel.
4. Make sure the slide rail surface is smooth

and screws do not protrude over the surface
of the slide rail. If the surface is uneven, file
the edges smooth.
Check both top and bottom surface of slide
rail for protruding plastic or metal.
XA Assembly Manual
37
Chain
When all beams have been assembled and the slide rail is in place, it is time to assemble and
mount the chain onto the conveyor system.
Tools:
Jaw pliers
Pin insertion tool for flexible chain
Mounting preparations
1. Before mounting, run a short piece of chain 2. Remove the drive unit transmission cover.
(around 18) through the conveyor to ensure
a smooth running system. If any obstructions
are found, they should be removed and the
checking process repeated.
WARNING
Follow lockout procedure
prior to chain installation.
3. Release the slip clutch so that the drive

shaft is free to turn. (See slip clutch adjustment, on page 47).
With the slip clutch loose, make sure that
the motor is turning in the correct direction.
38
XA Assembly Manual
Joining chain ends

Assemble the chain by inserting the steel pin that comes with each chain link into the opposite
end of another link. Do this by using the FlexLink pin insertion tool.
To take links apart:

1. Line the chain tool up with the pin.
2. Depress the trigger until the pin pops out.
3. Depress lever, pull insertion pin out.
4. Pull chain apart.
1. Insert the plastic pivot with the slot facing

outward.
2. Insert the steel pin halfway, using a pair of

pliers.
3. Align the FlexLink chain tool with the pin.

Slowly depress the trigger until the pin
seats.
4. Check that the chain is flexible in the joint,

and that the pin does not stick out or extended the other side.
XA Assembly Manual
39
Mounting the chain

Make sure that the slip clutch is released allowing the drive shaft to turn freely. (See previous
section.)
1. Insert the chain into the underside of the

drive unit. Make sure the chain will be
moving in the correct direction, as indicated
by the arrow located at the side of all chain
links.
2. Join 16.4 ft (5-meter) lengths of chain when

necessary.
Tension the chain and remove links if
necessary, so that the chain will exhibit
some slack at the drive unit.
Length adjustment, see page 39.
Assemble the chain ends. (See page 37)
WARNING
prior to chain installation.
40
XA Assembly Manual
Length adjustment of the conveyor chain

End drive units and catenary drive units
Adjustment of the conveyor chain is done at

the drive end of the conveyor.
The transmission guard cover must be removed from the drive unit and the slip clutch
disengaged or transmission chain removed.
The conveyor chain should now be free to
travel within the conveyor beam profile.
WARNING
prior to chain installation,
service or maintenance.
For long conveyors with heavy loads the chain

should be pre-tensioned within the conveyor
system, because the chain tends to stretch at
long runs. Clamp across the conveyor chain to
trap the chain on to the beam profile. The
clamp should be placed over the edges of the
drive unit to reduce the risk of damage to the
profile. The chain should be tensioned enough
so that under maximum load conditions there
is a catenary sag under the drive.
Short conveyors do not need to have the chain
tensioned, because it does not stretch too
much in short runs. Leave enough chain for
proper catenary sag under the drive.
Remove all slack links from the conveyor chain
using the pin insertion tool.
Rejoin the conveyor chain using a new steel
pin and plastic pivot.
Remove the chain clamp and reset the slip
clutch.
Replace the transmission guard cover. The
conveyor is now ready for operation.
XA Assembly Manual
41
Guide rail system

Guide rails are used to guide products being conveyed, and also to prevent them from falling off
the conveyor. Guide rails are supported by guide rail brackets attached to the sides of the
conveyor beam. Follow the mounting instructions for the type of bracket used in your application.
Brackets should be placed approximately 24to 36 apart (or every two raised chain assembly
bracket) depending on type of product and if accumulation occurs or not. If brackets are spaced
at greater distances than 36, there is a possibility that guide rails will become deformed if there
is product back-up.
Tools:
7/16" socket wrench
1/2" open wrench
Hack saw
Bracket type A
Hex key set

Guide rail bending machine
File
Bracket type B
Bracket type C
Bracket type D
Bracket type E
Wide flat SS guide

rails
42
Round SS guide
rail
Guide rail sleeve union
XA Assembly Manual
Mounting guide rail brackets type A, B, C, D
Bracket type A
Bracket type B
Autos.tif
Bracket type C
1. Remove the hex screw on the raised chain

assembly bracket. You will use the same
hex screw to install the guide rail bracket.
Bracket type D
2. Use the hex screw to join the top part of the

guide rail bracket support.
XA Assembly Manual
3. Assemble the rest of the components. Do

not tighten the guide rail clamp system until
the guides are installed.
43
Mounting guide rail bracket type E
Bracket type E
1. Remove the hex screw on the stand up

assembly bracket. You will usea the same
hex screw to install the guide rail bracket.
2. Use the hex screw to fix the guide rail

bracket support.
3. Assemblea the rest of the components and

press the star knob.
4. Do not tighten the guide rail clamp system

until the guides are installed.
44
XA Assembly Manual
Mounting guide rail
Wide flat SS guide

rails
Round SS guide
rail
Guide rail sleeve union
1. Install the guide rail in the bracket by

pressing the guide into the guide rail clamp
system until it fits in the desire position.
2. Rotate the adjusting rod with the 1/2 open

wrench to press the guide rail on the clamp.
3. Use the guide rail union to attach two (2)

consecutive guide rails.
4. To prevent products from being scratched

or damaged verify that the guide rail unions
are even.
XA Assembly Manual
45
Bending guide rail

If the construction of your conveyor system requires customized guide rail bends, you can use a
guide rail bending machine to bend them according to your own requirements:
To calculate the length of guide rail to be

bent, use the following formula:
L=2r x Desired angle () / 360
r = radius, L = length of bend, = 3.1416
If multiple bends with the same radius are to
be made, note the final position of the movable wheel indicator scale to ensure correct
radius of subsequent rails.
It is possible to bend angles up to 180.
Minimum radius is 4.
2. Place the rail horizontally between the

movable wheel and the fixed wheels.
When bending guide rail, you should start
bending at the center of the required radius.
46
1. Mark the length of the rail to be bent.

Leave approximately 8 straight section at
each end.
3. Operate the crank to run the rail back and

forth while lowering the upper wheel step by
step until the desired radius and angle is
achieved.
XA Assembly Manual
FINAL PREPARATIONS
Anchor feet to the floor

After the assembling of all components it may
be necessary to anchor the conveyor support
feet to the floor.
Use a type of fastener that is right for the kind
of floor where the conveyor is installed.
Instability of the conveyor during operation
may result in a dangerous operating environment or damage the conveyor components.
Other preparations
Adjust the height of the conveyor if necessary.
Make sure that the installation is stable and
that all screws have been properly tightened.
Use a plummet and/or water level to make
sure that the construction is not askew.
Make sure that all electrical equipment is
properly connected.
Make sure that the conveyor is running in
the correct direction before starting the
conveyor! Never run the conveyor with
tightened slip clutch until you have ensured
that the running direction is correct.
XA Assembly Manual
Tighten the slip clutch to a suitable friction.

(Slip clutch adjustment, see page ?)
Make sure that the transmission cover is
attached to the drive unit.
Remember that conveyor chains should
always be pulled, not pushed, by the drive
unit.
Final Preparations
47
START-UP AND TESTING

Safety considerations
To eliminate the risk of accidents, it is important to be aware of certain areas of the conveyor where special caution is required during
installation, operation and maintenance. Some
areas present a higher danger to personal
safety, and because of this various kinds of
safety devices need to be installed.
All pinch and shear points as well as other
exposed moving parts that present a hazard to
employees at their workstations or their
passageways must be safeguarded.
Cleated conveyor chains are more susceptible
of creating pinch and shear points than plain
chain.
When two (2) or more pieces of equipment
are interfaced, special attention must be given
to the interfaced area to ensure proper safeguarding.
For overhead equipment, guards must be
provided if products may fall off the equipment
for some reason.
The same applies to all incline, decline and
vertical conveyors.
SAFETY
It must be difficult to
bypass or inactivate
safeguards during
operation!
Safety devices should be
designed to minimize discomfort or difficulties for operators.
Safeguarding can be achieved by:

Location: locate the hazardous area out of
reach of the personnel involved.
Guards: mechanical barriers preventing entry
into the hazardous area or protecting against
falling goods.
Control devices: machine controls preventing
or interrupting hazardous conditions.
Warnings: instructions, warning labels, or
sound or light signals, alerting on hazardous
conditions.
Warnings shall be used when other means of
safeguarding will impair the function of the
installation.
48
Start-up and Testing
XA Assembly Manual
Slip clutch adjustment

Introduction
The slip clutch on the drive unit is a safety
device which allows the chain to stop if the
load becomes excessive. It has two (2) purposes:
Prevent damage to conveyor.
Prevent damage to the products on the
conveyor.
Where a slip clutch is fitted, it must be adjusted so that it does not slip whenever the
drive unit is started under full load. The installation is carried out as follows:
WARNING
If you try to adjust the slip
clutch when there is still
load on the conveyor, the
accumulated tension in
the chain can cause
severe injuries when you release the clutch.
The slip clutch is not a personal safety
device. It is primarily intended to protect the
equipment.
Preparations for adjustment

Stop the conveyor.
Ensure that the conveyor cannot be started
accidentally. For example: unplug the
electric power plug.
Lock the electrical feeder.
Remove any load on the conveyor.
Slip clutch should not be adjusted

until:
Motor direction is confirmed.
Conveyor is fully assembled.
XA Assembly Manual
49
To adjust torque
Preparation of adjustment:
Stop the conveyor.
Ensure that the conveyor cannot be started accidentaly. For example: unplug the electric
power plug.
Lock the electrical feeder.
Remove any load on the conveyor.
1. Remove drive end cover.

Insure that the adjusting nut is in a fingertight position.
Match mark the adjusting nut with the hub.
2. Advance the adjusting nut the number of

turns that correspond to the desired break
away torque as shown in the chart below.
After breakaway torque is set, bend the tabs
of the lockwasher over the hex flats of the
adjusting nut.
MODEL
APPROXIMATE BREAK-AWAY
TORQUE
350
2 spring
60 Lb/Ft110 Lb/Ft150 Lb/
Ft 190 Lb/Ft
Turns 1/2
1 1/2
1 3/4
WARNING

prior to chain installation,
service or maintenance.
3. Reinstall chain cover.
50
XA Assembly Manual
Start-up
Lubrication
The conveyor chain is lubrication-free. However, for some specific applications where the
operating environment is particularly hostile,
regular lubrication of the slide rail/conveyor
chain will result in a lower coefficient of friction, longer life and reduced running costs.
Use a silicone-based lubricant (LDSS 450 or
an equivalent lubricant).
Wear
The degree of wear on a conveyor depends on
a number of factors, such as:
Running time
Load, contact pressure
Speed
Product accumulation
Sharp or rough products
Chemicals
Foreign particles, e.g. chips, grinding particles, broken glass, sand, sugar
Temperature
Plain bends
Try to minimize the running time for the
conveyor by stopping it when there is no
transport.
Multiple horizontal wheel bends and vertical
plain bends in a conveyor will often result in
increased wear. One reason is that the friction
accumulation is greater in plain bends. Also,
the contact surface between chain and slide
rail is small and the chain pull is acting towards the slide rail in the bends.
XA Assembly Manual
Run-in period
Two or three days are usually enough as a
run-in period.
During this time, the conveyor should be
cleaned a couple of times to remove dust:
Remove the chain and clean it with warm
water (50C), use soap if necessary.
Clean the conveyor beam itself
Re-install the chain.
After run-in, wear will be minimal, unless
particles from the product or process reach
the conveyor continuously.
Chain elongation
During the run-in period, regular checks
should be made to the elongation of the
conveyor chain. This is especially important if
the conveyor is transporting high loads or if it
is of long overall length.
Regular inspections of the chain elongation
are important.
The chain should be shortened after a run-in
time of 40 hours. Further inspections should
be made at 200, 500 and then at 1000 hour
intervals.
51
TROUBLESHOOTING
Symptom
Cause
Corrective Action
Jerky
Running
Damaged or badly fitted slide rail Inspect and replace as necessary

Check and adjust slip clutch
Wrongly adjusted slip clutch
Check/replace transmission chain, chain
Worn transmission parts
drive sprocket
Conveyor chain is too tight/loose Tension conveyor chain correctly
Clean conveyor chain/slide rail. Lubricate
Dirty conveyor
with silicone based lubricant
Drive unit is Wrongly adjusted slip clutch
running,
conveyor
Check and adjust slip clutch
Friction disc in slip clutch are
chain is not warm or contaminated
Check and replace if necessary
running
Damaged or badly fitted slide rail Check the free running of the conveyor
chain
Check and fit
Transmission products are not
fitted
Motor
Overload conveyor
overheating
on drive unit
Gearbox leaking oil
Dirty conveyor
Noise
Damage due to ingress of particles, swarf, etc.
52
If Fault
Remains
31
47
Consult a
XA System
Distributor
39
47
31
Remove products from conveyor and test

run
Check actual conveyor load against recommended loading
Check output shaft seal and area around
motor/gearbox interface
Clean the conveyor chain with warm water
(50)
Check/replace drive unit

Worm or damaged bearings in
drive unit
Damaged or badly fitted slide rail Check the free running of the conveyor
chain, especially in slide rail joint
Lower speed
Excessive conveyor speed
Incorrect conveyor chain tension Lengthen/shorten conveyor chain
Abnormal
Overload conveyor
wear of
plastic parts
See
Page
21
30
39
Remove products from conveyor and test

run
Check the free running of the conveyor
chain
Clean the system
Remove source of contamination
Troubleshooting
XA Assembly Manual

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XA

Installation Site Preparations ......... 3

General tools ..................................... 4

Assembly Instructions .................... 6

SS top slide rail support laying

Using plastic screws .................... 35

Conveyor fixed support bracket ... 13

INSTALLATION SITE PREPARATIONS

Cut beams to appropriate lengths where necessary ........................................................ 6

Installation site preparations

1/8 drill bit

Rivet crimping pliers 4 mm:

Mounting tool for slide rail:

All safety precautions

Standard support leg

Double support leg

Beam support brace

Treaded tube insert

Ground base and

Fixed leg base

Swivel leg base

Leg base bracket

Standard support leg

Standard support leg

1. Mark and cut the support leg, at the desired

2. Always cut at the top

3. Remove all sharp

Double support leg

Double support leg

Support joint plate

1. As in the standard support leg, mark

2. Remove all sharp edges.

Beam support brace

Beam support brace

1. Insert and fix the brace to the conveyor

2. Connect the beam support

Mounting ground base

Ground base and

Threaded tube insert

1. Install the inserts for the ground base at

2. Screw the ground base onto each threaded

1. Insert caster at each end of the support leg

2. Fix the expansion rubber by tightening the

Mounting bullet feet

Conveyor Support Brackets

Conveyor fixed support bracket

Leg base bracket assembly

2. Join the support leg and the conveyor

3. Adjust the wedge screw with the 9/16

4. Position the leg base bracket assembly

5. Slide the support leg from underneath the

6. Insert and adjust the four (4) screws with a

Conveyor swivel support bracket

Swivel leg base

Leg base bracket

1. This conveyor swivel support bracket

Installation of conveyor support bracket (fixed or swivel) on double beam

1. Assemble the fixed or swivel support

3. Position the two (2) leg base bracket

2. As in the conveyor fixed support, connect

4. Slide the support leg from below the

Joining components to beam

3/16 hex key