FLEXICON Flexible Screw Conveyor Models: UTF, UTK, UTR, & UTV Installation and Operation Manual

®

FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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FOREWORD Thank you and congratulations on your purchase of one of the most efficient and reliable flexible screw conveyor systems available. Please refer to the following instructions for installing and operating your FLEXICON® flexible screw conveyor system. If you encounter any problems which prevent safe reliable installation and / or operation of the system, please call the FLEXICON® service department immediately to address any concerns you may have. The flexible screw conveyor system appearance may be slightly different than the details depicted in this manual. Any differences do not affect the function, designed capacity, or operation of the equipment. FLEXICON Corporation has made every effort to ensure the accuracy and validity of this document however errors and omissions may have occurred. If an error or omission is found, please contact FLEXICON Corporation. No part of this publication may be distributed, reproduced or transmitted in any form without the written permission of the FLEXICON Corporation.

Familiarity with Manual and Regulations In order for this machine to be installed, operated, cleaned & maintained safely, all of the provisions of this manual and all other applicable codes and regulations, some of which have been referred to herein, must be strictly adhered to. Codes and regulations enacted to protect personnel from hazard of injury may change from time to time. It is the customer’s responsibility to remain familiar with, and to comply with all codes, and regulations related to this equipment or its use. It is also the customer’s responsibility to teach its employees how to operate the equipment properly, including how to recognize and avoid risks. All personnel who will be involved in installing, operating, cleaning or maintaining the system should be given a copy of this manual to read, and follow.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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TABLE OF CONTENTS TABLE OF FIGURES

4

CONTACTING FLEXICON® Telephone and Fax Numbers Hours of Operation System Identification

5 5 5

INTRODUCTION Safety Terms & Summary Equipment Safety Warnings Applicable FLEXICON® Equipment

6 7 8

INSTALLATION Unpacking the screw conveyor Locating the screw conveyor Material In-feed / Conveyor Discharge Mounting Conveyor Routing and Alignment Conveyor Outer Tube Installation Supporting the Conveyor Overall Spiral Length Measurement Determining Spiral Exposure Length Installing the Spiral Inner Tube Installation (Optional) Low Shear Style Outer Tube (Optional) Anti-Static Tape Installation (Optional) Push-Type Conveyor (Optional)

9 9 9 10-11 13 13 13 14 15 16 16 17 18

OPERATION 19

General Operation

MAINTENANCE 19

Conveyor Clean-out

TROUBLESHOOTING Twisted Break / Jamming Clean Break / No Material Conveying Low Capacity / Noise & Vibration

20 21 22

OPTIONAL EQUIPMENT Packing Gland Seal Mechanical Hopper Agitator Pneumatic Vibrator Capacitive Proximity Level Switch

SPARE PARTS

23 24 26 27 28

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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TABLE OF FIGURES Figure 1: Sample Serial Number Nameplate Figure 2: Typical Screw Conveyor System Figure 3: Discharge Assembly Figure 4: Conveyor Routing Figure 5: Conveyor Alignment Figure 6: Conveyor Bend Radius Chart Figure 7: Charging Adapter Figure 8: Spiral Exposure Length Chart Figure 9: Bev-Con™ Spiral Orientation Figure 10: Spiral Coupling Figure 11: Low Shear Outer Tube Figure 12: Anti-Static Tape Installation Figure 13: Push Type Conveyor Assembly Figure 14: Packing Gland Seal Figure 15: Mechanical Hopper Agitator Figure 16: Vibrator Assembly

5 8 10 11 11 12 14 14 15 15 16 17 18 23 24 26

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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CONTACTING FLEXICON Telephone and Fax Numbers Phone:

1-888-FLEXICON [1-888-353-9426] 610-814-2400

Fax:

610-814-0600

Hours of Operation Monday through Friday 8:00 am to 5:00 pm E.S.T.

System Identification When contacting Flexicon® please refer to the serial number of the material handling system that is associated with the equipment in question. The equipment will have a five-digit serial number nameplate. (See Figure 1)

12345

Figure 1: Sample Serial Number Nameplate

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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INTRODUCTION Safety Terms and Summary This manual provides important information for personnel involved in the installation, operation, and maintenance of this product. Even though you may be familiar with this, or similar equipment, it is highly recommended that you read this manual before installing, operating, or maintaining this particular equipment. Throughout this manual there are steps and procedures that can present hazardous situations. The following words are used to identify the degree or level of hazard seriousness.

!

DANGER

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury, and property damage.

!

WARNING

Warning indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury, and property damage.

CAUTION

Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.

NOTICE

Notice is used to notify people of installation, operation, or maintenance information which is important but not directly hazard-related.

!

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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FLEXICON® Equipment Safety Warnings Locating and installing the FLEXICON® screw conveyor system is a very important step in the correct and efficient use of this equipment. We recommend that you follow these procedures to achieve complete satisfaction.

!

DANGER

Do not allow individuals to stand on, or under any part of the screw conveyor during operation.

!

DANGER

Always perform Lockout / Tagout procedures before performing any repairs, cleaning, and maintenance on this equipment.

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

NOTICE

Before performing any repairs, or maintenance on the screw conveyor, remove all product contained within the system. Do not run the conveyor in reverse with the cleanout cap on. Failure to do so can result in serious injury and equipment damage. Do not allow tools, rags, or clothing to remain in or near the screw conveyor system during operation. Periodically check that all bolted connections are tight, as they might become loose in transit or during operation. Do not mount peripheral equipment to the screw conveyor system. If you wish to alter the equipment, please consult with FLEXICON® before doing so. Do not use the screw conveyor system for materials other than which it was specified for. If you wish to use new materials please consult with FLEXICON® before doing so. Do not allow agglomerating or hygroscopic material to remain in the screw conveyor system for extended periods of time. These materials may tend to set up or become hard making it difficult to discharge from the screw conveyor system.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Applicable FLEXICON® Equipment Equipment

Model Numbers

Reference Diagram

Overview ®

UT Screw Conveyor

FLEXICON screw conveyors consist of a spring steel, or stainless steel flexible screw that is enclosed in a flexible or rigid plastic tube, or a rigid steel tube, and driven by an electric motor normally located at the discharge end of the conveyor. They are designed to convey bulk materials ranging from large pellets to sub-micron powders at a consistent and controllable rate.

UTX-XXXX-XXX-X

MOTOR / GEAR DRIVE ASSEMBLY

MOUNTING BRACKET DISCHARGE BOX

TUBE COUPLING

DISCHARGE TRANSITION ADAPTER

OUTER TUBE SUPPORT BY CUSTOMER

SCREEN (OPTIONAL)

COVER (OPTIONAL)

HOPPER (OPTIONAL)

VIBRATOR (OPTIONAL)

TUBE COUPLING

AGITATOR (OPTIONAL)

CLEANOUT CAP

CHARGING ADAPTER

Figure 2: Typical Screw Conveyor System FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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INSTALLATION A standard screw conveyor system is shipped disassembled and consists of a motor / gear drive, spiral, spiral coupling, outer tube with end couplings, and intermediate support couplings. The discharge end has a transition adapter for connection to flexible or rigid spouting. The pickup in-feed end typically includes a transition charging adapter that is welded to a hopper, however a charging adapter can be custom designed to mate with just about any customer supplied vessel, or transition.

Unpacking the Screw Conveyor Before removing the screw conveyor from the shipping pallet, inspect it for any damage that may have occurred during shipping, and promptly report this to FLEXICON® at the number shown on the contact information page in this manual.

Locating the Screw Conveyor The first step for installing the FLEXICON® flexible screw conveyor is to determine the proper location for either the material in-feed, or conveyor discharge assembly. Conveyor routing and alignment should be done after the first component is located, and before the second component. Please refer to the Conveyor Routing and Alignment section for details. The determination of whether to locate the in-feed or discharge drive assembly first should be made based upon the relative tolerances for deviation from desired location. If the conveyor in-feed location is the most critical due to factors such as limited floor space or mating with an existing piece of equipment then the in-feed should be located first. If the conveyor discharge location is the most critical due to factors such as limited headroom or potential physical equipment interference then the discharge should be located first. If there is no advantage to locating either the in-feed or discharge first then the in-feed should be located first. This is primarily due to the fact that the angle of the discharge assembly can be more readily adjusted during final alignment of the conveyor.

Material In-feed Mounting If the in-feed device is a FLEXICON® floor hopper, the hopper can simply be placed in its location. Consideration should be given as to whether or not the hopper should be lagged to the floor at this point. Delaying the lagging down of the hopper allows for small adjustments during the aligning phase of installation. If the in-feed device is a FLEXICON® charging adapter, the charging adapter can be bolted in place. (See Figure 2)

Conveyor Discharge Assembly Mounting (See Figure 3) The discharge of the conveyor should be rigidly mounted to structural steel. Caution should be taken if the discharge is to be mounted to a structure such as a mezzanine that will also be supporting other pieces of process equipment. Process equipment that produces vibration should not be mounted to the same structure as the conveyor since this type of transmitted vibration can have a negative impact on the operation of the FLEXICON® flexible screw conveyor by compacting static FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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bulk material inside the conveyor thus causing restart overloads. It is also important to note that the conveyor tube is not intended to support the discharge assembly. Main support for the discharge assembly should be derived from the motor mounting bracket. The discharge assembly can be temporarily supported with two in-line opposing side bolts to allow for pivotal adjustment during conveyor alignment. Once installed, the discharge assembly should be mounted at an angle such that the material being conveyed can flow freely from the discharge of the conveyor to the material destination point. Another consideration during discharge assembly mounting is access for maintenance. There should be sufficient clearance around the drive and discharge assembly to allow for service and maintenance. Finally, make certain that the vent plug which is supplied loose is installed in the highest port in the gear reducer housing.

Figure 3: Discharge Assembly

Conveyor Routing (See Figure 4). After either the in-feed or the discharge assembly of the FLEXICON® flexible screw conveyor has been located the next step is to determine the conveyor routing. If FLEXICON® has provided engineered drawings for your system these drawings should be used as a reference in determining the final conveyor routing. The conveyor should be installed straight without a bend whenever possible. A straight installation will potentially provide longer life expectancy for the conveyor outer tube and the flexible screw. However, there are several guidelines that need to be followed when curving the conveyor. The routing of the conveyor through the curve should be designed so the curve is smooth, and as generous as possible. This can be achieved by maximizing the bend radius and minimizing the degree of the curve.

NOTICE

With the exception of the BEV-CON™ model and large diameter conveyors, FLEXICON® flexible screw conveyors can be designed to include a single curve. Multiple curves, or “S” curves should not be present when the conveyor has been installed (See Fig. 4). Multiple bends cause greater resistance within the conveyor and could result in premature spiral failure and/or premature outer tube wear. FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

Incorrect

Correct

Incorrect

Correct

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Incorrect

Correct

Figure 4: Conveyor Routing

Conveyor Alignment (See Figure 5). The conveyor should be properly aligned with the steel conveyor tube fittings where the conveyor outer tube mates with the in-feed, and discharge assembly of the system. It is important that this alignment provides for a smooth linear connection at these points so that a kink or sharp bend is not caused by improper alignment. This smooth alignment of the conveyor tube with the steel conveyor tube fittings is extremely important as misalignment at these points will lead to premature spiral failure. TUBE COUPLING

OUTER TUBE

Incorrect

Correct

Figure 5: Conveyor Alignment Once proper conveyor routing and alignment has been determined the in-feed or discharge component of the conveyor that had not been located previously can be installed. Please refer to the chart on the following page to determine the minimum bend radius that should be used with your FLEXICON® flexible screw conveyor. (See Figure 6)

NOTICE

It should be noted that larger bend radii should be employed in applications that involve highly abrasive materials, heavy materials (in excess of 75 pounds per cubic foot), conveyors that are longer than 30 feet in length and continuous duty applications. FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Conveyor Bend Radius Chart CONVEYOR MODEL

1250

1312 / 1350 1350

1450

1500

1600

1800

DEGREES OF BEND SCREW TYPE 30

45

90

Round

5’

8’

10’

Heavy Duty Round

10’

12’

16’

Versa Flight™

5’

7’

9’

Flat

6’

8’

12’

BEV-CON™ & Heavy Duty BEVCON™

N/A

N/A

N/A

Round

10’

12’

16’

Versa Flight™

8’

10’

12’

Flat

10’

12’

N/A

Heavy Duty Round

20’

20’

N/A

Round

20’

20’

N/A

Heavy Duty Round

25’

25’

N/A

Flat

20’

20’

N/A

Wide Flight Flat

25’

25’

N/A

Heavy Duty Flat

25’

25’

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Round & Heavy Duty Round

N/A

N/A

N/A

Flat & Wide Flight Flat

N/A

N/A

N/A

BEV-CON™

N/A

N/A

N/A

Round

N/A

N/A

N/A

Flat, Wide Flight, & Heavy Duty Flat

N/A

N/A

N/A

BEV-CON™

N/A

N/A

N/A

BEV-CON™ & Heavy Duty BEVCON™ BEV-CON™ & Heavy Duty BEVCON™

Figure 6: Conveyor Bend Radius Chart FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Conveyor Outer Tube Installation

NOTICE

The outer tube for a portable conveyor system will be factory cut to the correct length. The spiral will need to be cut to as per the instructions in this manual.

Cutting the Outer Tube to the correct length Flexicon® flexible screw conveyors are supplied in 5 foot increments and are designed to be cut to fit in the field for ease of installation. As a result it is necessary to cut the conveyor outer tube to the proper length after conveyor routing has been determined. At this point in the installation process both the in-feed and the discharge components of the conveyor should be permanently installed. The conveyor outer tube should first be rigidly connected to the steel conveyor tube fitting at either the in-feed or discharge component by a compression tube coupling. The other end of the conveyor outer tube should be held adjacent and parallel to the other steel conveyor tube fitting. Adjust the routing of the conveyor outer tube to the correct position as described in the Conveyor Routing and Alignment section and mark the end of the conveyor outer tube where it will butt up against the steel conveyor tube fitting. The outer tube can now be cut with a hacksaw or similar means and rigidly connected to the second steel conveyor tube fitting by a compression tube coupling. It may be beneficial to make one or two pre-cuts while aligning the conveyor outer tube before making the final cut in order to make it easier to achieve proper conveyor routing.

Supporting the Conveyor Outer Tube Proper conveyor support must be provided so that the conveyor does not deviate from the intended routing once it is loaded with the weight of the conveyor spiral and the material that is being conveyed. Outer tube supports should be located so that the conveyor has no more than 10 feet of unsupported length at any point. FLEXICON® supplies a number of support couplings to meet this requirement. However, it is important to note that the installer of the system may need to provide additional supports and support couplings in order to maintain correct conveyor routing. Supports can be constructed from various rigid materials such as angle or threaded rod. Non-rigid supports such as cable can also be used provided that the use of non-rigid conveyor supports does not allow significant oscillation of the conveyor outer tube during normal operation. If the conveyor outer tube sways back and forth while operating fully loaded with material additional support points will be required. Rubber vibration isolation liners should be employed at support points to avoid premature outer tube wear. Additionally, it is important that the support methods used do not compress the outer tube into an oval as this could result in premature conveyor failure.

Overall Spiral Length Measurement To determine the overall length of the spiral measure from the point where the spiral will terminate on the spiral coupling (making sure there is sufficient spiral to connect to the spiral coupling using the Ubolt and clamp bar) down along the outer tube to the predetermined point where the spiral will terminate in the charging adapter. Cutting the spiral can be done by any normal means of cutting a steel bar. An abrasive cut-off wheel, powered band saw or hack saw are commonly used. After cutting the spiral, be sure to remove all sharp edges and burrs with a grinder or hand file. FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Determining Spiral Exposure Length The first step for the installation of a FLEXICON® spiral is to determine the spiral "exposure” which is defined as the length of the spiral inside the charging adapter (See figure 6). The exposure length is measured from the front inside wall of the charging adapter (nearest to the outer tube) to the tail end of the spiral. This length varies depending on the material being conveyed and the particular model FLEXICON® conveyor. There are two major categories of material classification which are free flowing and non-free flowing. Granular sugar and table salt are good examples of free flowing materials while flour, pancake mix and other fine powders are examples of non-free flowing materials. (See Figure 7 & 8) to determine the correct spiral exposure for your particular application.

INNER TUBE (NOT ALL UNITS) SPIRAL SPIRAL EXPOSURE OUTER TUBE

OUTER TUBE COUPLING

CHARGING ADAPTER CLEANOUT CAP

Figure 7: Charging Adapter

Spiral Exposure Length Chart Note: Spiral exposure varies for conveyor models 1600 & 1800 based on hopper model. Your system Bill of Materials lists the hopper model(s). Conveyor / Hopper Model Free Flowing Material Non-Free Flowing Material 1250 / ( D / T / I ) Hopper 6” – 8” 8” – 11” 1312 / ( D / T / I ) Hopper 6” – 8” 8” – 11” 1350 / ( D / T / I ) Hopper 6” – 8” 8” – 11” 1450 / ( D / T / I ) Hopper 6” – 8” 8” – 11” 1500 / ( D / T / I ) Hopper 6” – 8” 8” – 11” 1600 / ( D ) Hopper 14” – 16” 16” – 18” 1600 / ( T ) Hopper 12” – 14” 14” – 16” 1600 / ( I ) Hopper 12” – 14” 14” – 16” 1800 / ( D ) Hopper 14” – 16” 16” – 18” 1800 / ( T ) Hopper 12” – 14” 14” – 16” 1800 / ( I ) Hopper 12” – 14” 14” – 16” Figure 8: Spiral Exposure Length Chart FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Installing the Spiral (See Figure 9) If you are installing a BEV-CON™ spiral make sure the outer tube is straight and that the full flat side of the spiral faces the discharge end of the conveyor. The BEV-CON™ spiral is the only spiral that is direction sensitive with a "top" & "bottom" end.

NOTICE

MATERIAL FLOW

CONVEYOR IN FEED END

CONVEYOR DISCHARGE END

FULL FLAT SIDE BEVELED EDGE

BEVELED EDGE

Figure 9: Bevcon™ Spiral Orientation

NOTICE

Do not bend the spiral to a point where it loses its resilience and permanently kinks. This will cause extremely rough operation and premature spiral failure.

With most 4 ½” diameter (and smaller) conveyor models the spiral can be inserted through the cleanout port located at the bottom of the charging adapter. Insufficient clearance under the system or spiral size may require removal of the in-feed component to allow the installation of the spiral. In these cases, uncouple the bottom of the conveyor's outer tube keeping the tube coupling on the conveyor outer tube and move the outer tube laterally away from the nosepiece on the hopper charging adapter. The spiral should then be inserted through the bottom of the outer tube. Next, position the outer tube and in-feed component so that the tail end of the spiral can be placed into the nosepiece. At this point the in-feed component may need to be moved to allow spiral insertion. Once the spiral has been inserted in the nosepiece reinstall the in-feed component and replace the outer tube coupling. SPIRAL ENDS HERE U-BOLT COUPLING SPIRAL

CLAMP BAR

NUTS INNER TUBE (NOT ALL UNITS)

INNER TUBE ENDS HERE

Figure 10: Spiral Coupling FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Once the spiral is installed in the outer tube it is necessary to connect it to the spiral coupling at the top of the conveyor. (See Figure 10) To gain access to the spiral coupling, remove the cover plate on the discharge box. Next, pull the spiral up onto the spiral coupling and connect it using the U-bolt and clamp bar. Make sure that there are three contact points between the spiral, U-bolt and clamp bar assembly.

Inner Tube Installation (Option)

NOTICE

It is important not to cut the inner tube too short. Material conveyance could then cause severe compression of the inner tube inside the conveyor resulting in system failure.

Not all FLEXICON® flexible screw conveyor systems utilize an inner tube. If your system has an inner tube it should be cut shorter than the spiral length by the length that the spiral extends onto the spiral coupling to compensate for the length of the spiral that is attached to the spiral coupling at the top of the conveyor. Simply slide the inner tube up the inside diameter of the spiral until it contacts the spiral coupling (See Figure 10). When the top of the inner tube is in contact with the spiral coupling the end of the inner tube should be even with the end of the spiral. No additional means are required to hold the inner tube in place.

Low Shear Style Outer Tube (Option) The low shear style outer tube is designed to eliminate the “step” (ledge) between the charging adapter nosepiece, and the outer tube. Flexicon® will precut the outer tube to provide a stub piece that is inserted into the full length of the flanged nosepiece until it comes to rest against the charging adapter front plate. An o-ring is slid over the stub and seated against the nosepiece flange. A beveled flange plate is provided to compress, and seal the oring around the stub. The conveyor outer tube is then butted against the stub, and clamped in place with a compression coupling & gasket. NOSE PIECE

OUTER TUBE INSERTED TO THIS POINT

O-RING SEAL

Figure 11: Low Shear Outer Tube FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Anti Static Tape Installation (Option) Anti static tape is to be installed along the exterior surface of the polyethylene, and / or polypropylene outer tube in order to provide a “path” for static buildup to travel and dissipate. Prior to installing the outer tube, install anti static tape as follows: (See Figure 12) 1) Begin wrapping the tape around the circumference of one end of the tube making certain that there is at least one complete layer as close to the end of the tube as possible. Make sure that the tape does not extend past the edge of the tube which could potentially come in contact with the interior surface. 2) Continue wrapping in an overlap fashion towards the opposite end of the tube for approximately 6 inches. It is not necessary to overlap the entire tube with tape. 3) After the initial end is complete begin wrapping a single layer spaced about 6 inches apart along the length of the tube to within approximately 6 inches of the opposite end of the tube. Overlap the tape for the remaining portion of the tube in the same fashion as the beginning. Proceed with installing the outer tube.

!

WARNING

The grounding strap inside the outer tube coupling must make contact with the anti-static tape on the outer tube, and also the conveyor nosepiece on the charging adapter in order to complete the path for static to travel across the tube coupling.

6” 6” 6”

6”

DRIVE ASSEMBLY NOSE PIECE

TUBE COUPLING

CHARGING ADAPTER

TUBE COUPLING

GROUNDING STRAP (INTERIOR OF COUPLING)

NOSE PIECE ANTI-STATIC TAPE GROUNDING STRAP (INTERIOR OF COUPLING)

Figure 12: Anti-Static Tape Installation FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Push Type Screw Conveyor (Option) Push type flexible screw conveyors feature a drive that is mounted to the material in-feed charging adapter as opposed to the discharge end (See Fig. 13). Since the conveyor spiral is welded to the spiral coupling, exposure is not adjustable, and the spiral is cut from the discharge end rather than the in-feed side. There is no u-bolt / clamp bar assembly. Two set screws are utilized to fasten the spiral coupling to the drive shaft. Once the conveyor outer tube has been installed and cut to length, the spiral should be cut so that the tail end of the spiral is within 1” of the conveyor discharge. Push type flexible screw conveyors do not have a clean-out cap to remove material. If the push type conveyor includes the optional bottom access cover, the bulk of the residual material in the conveyor is removed similar to a standard conveyor, except that the bottom access cover is removed rather than the clean-out cap. The conveyor should be operated in forward to evacuate the residual material. To remove the spiral from the conveyor, first remove the upper drive standoff cover to access the spiral coupling setscrews and then loosen both setscrews on the spiral coupling. At the discharge end, loosen the outer tube compression coupling on the discharge adapter and remove it from the tube. Carefully slide the spiral and spiral coupling out of discharge end of the outer tube. To install the spiral, follow the above steps in reverse order. GEAR REDUCER SPIRAL COUPLING SET SCREW SPIRAL WELDED TO COUPLING

PACKING GLAND SEAL STANDOFF MOTOR MOUNTING BRACKET

SPIRAL CUT TO WITHIN 1 INCH OF DISCHARGE

MOTOR INTERLOCK SWITCH (4) QUICK RELEASE CLAMPS

UPPER STANDOFF MOTOR MOUNTING BRACKET

ACCESS COVER

OUTER TUBE COUPLINGS

LOWER STANDOFF MOTOR MOUNTING BRACKET

DISCHARGE TRANSITION ADAPTER

Figure 13: Push Type Conveyor Assembly FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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OPERATION NOTICE

A vent plug is provided with each gear reducer. Failure to install the vent plug in the gear reducer can result in premature wear of the gear reducer seals.

Before introducing any material into the FLEXICON® flexible screw conveyor, the conveyor spiral must be checked for correct rotation. Correct spiral rotation is counter-clockwise when viewed from the in-feed end looking towards the conveyor discharge. All fasteners should be checked and tightened if necessary. In order for a FLEXICON® flexible screw conveyor to operate correctly it must be fully charged with material and have a sufficient head load of material at the in-feed point. When starting a FLEXICON® flexible screw conveyor that has no material in the conveyor tube the system will be louder and exhibit more vibration than during normal operation. As the system becomes charged with material the noise level and vibration should lessen. During normal operation the conveyor should run relatively smoothly without excessive vibration. Additionally, the smooth rotation of the conveyor spiral should be heard at even regular intervals and should not chug or vary in frequency. It should be noted that some types of materials such as those with hard, large and irregularly shaped particles will run more roughly than others. If you suspect that your system is operating in an improper manner contact your local representative or the FLEXICON® service department.

MAINTENANCE Conveyor Clean-out Clean-out of the conveyor system is accomplished via the clean-out cap located at the bottom of the charging adapter. Once the clean-out cap has been removed the bulk of the residual product in the conveyor can be evacuated by reversing the direction of rotation of the conveyor spiral. It is important to note that the conveyor should never be run in reverse if the clean-out cap has not been removed or if there is still a significant head load of material above the in-feed of the conveyor. Either of these two conditions can cause conveyor spiral failure. Any additional cleaning that is required should be performed based upon existing inhouse cleaning protocols. Cleaning methods such as water, air or solvents can be employed to flush the conveyor without disassembling the conveyor. If additional cleaning is required the conveyor outer tube and spiral can be removed from the system and thoroughly cleaned. It is extremely important to allow the conveyor’s components to completely dry before reintroducing any material to the flexible screw conveyor in order to avoid solidification of material thereby negatively affecting material flow properties.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Screw Conveyor Gear Reducer All standard gear reducers are filled with synthetic lubricant to operate within a temperature range of 30 to 100 degrees F. The lubricant should be changed every 6 months or 2500 operating hours with the manufacturers recommended lubricant.

Screw Conveyor Packing Gland Seal Packing gland seal adjustment can be achieved by sequentially tightening the mounting bolts one quarter turn at a time until desired compression is achieved.

NOTICE

Adjustment of the mounting bolts will alter the compression of the Teflon packing around the spiral coupling shaft. Caution should be taken not to over tighten the retaining ring bolts. This may result in a mechanical bind of the spiral coupling shaft.

TROUBLESHOOTING The following section will help in the identification and resolution of the most likely problems to be encountered with a FLEXICON® flexible screw conveyor. Contact the FLEXICON® service department for further assistance to optimize the performance of your conveyor system. The following charts each address a specific problem. Conveyor Spiral Failure Load Type (Twisted Break) Diagnostic Action or Symptom Potential Cause(s) Load failure occurred immediately upon -Agglomeration / hardening of material restart of fully charged conveyor tube inside conveyor tube due to moisture -Compaction of material inside conveyor tube due to vibration from outside source -Foreign object present in conveyor -Conveyor operated in reverse Load failure occurred as material level -Material bulk density too high began to rise up the conveyor but had not -Material particle size too great yet reached the discharge -Spiral exposure too long -Material compressed in tube causing binding of the spiral Load failure occurred while conveyor is in -Material bulk density too high operation under full load -Material particle size too great -Spiral exposure too long -Material compressed in tube causing binding of the spiral -Material back-up in conveyor discharge

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Conveyor Spiral Failure Fatigue Type (Clean Break) Diagnostic Action or Symptom Potential Cause(s) Fatigue break occurred at the top of the -Misalignment between conveyor tube and steel conveyor near the drive coupling conveyor discharge end fitting -Conveyor running empty or starved, indicated by excessive vibration and noise during normal operation -Consistent chugging / conveyor spiral not rotating smoothly Fatigue break occurred in the conveyor -Conveyor running empty or starved, indicated by tube excessive vibration and noise during normal operation -Bend radius too tight, or “S” bend present in system Fatigue break occurred at the bottom of -Misalignment between conveyor tube and steel the conveyor near the junction of the lower conveyor tube fitting end of the outer tube and the steel -Conveyor running empty or starved, indicated by conveyor tube fitting excessive vibration and noise during normal operation -Extreme build-up of material under the tail of the conveyor spiral Low Conveyor Capacity Diagnostic Action or Symptom Potential Cause(s) Examine material flow in the in-feed -Insufficient material flow promotion at in-take of hopper conveyor Verify proper conveyor spiral exposure -Conveyor spiral exposure too short Check variable speed controller settings -Improper speed setting on variable speed controller Verify proper mechanical connection of the -Spiral coupling not properly connected to gear conveyor spiral to the drive unit reducer -Conveyor spiral not properly connected to spiral coupling Conveyor Jams or Motor Trips Diagnostic Action or Symptom Potential Cause(s) Review all potential causes for load type -Potential causes for load type spiral failures in the spiral failures in the preceding chart preceding chart Check electrical parameters -Thermal overloads set improperly -Incorrect fuses -Improper supply voltage -Three phase motor wired for improper voltage

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Note: Conveyor must be fully charged and have an appropriate head load / supply of material in order to accurately assess conveyor capacity. Conveyor Runs, But No Material Is Conveyed Diagnostic Action or Symptom Potential Cause(s) Verify proper conveyor spiral rotation -Conveyor operating in reverse direction Examine material flow in the in-feed -Poor flowing material bridging causing no hopper material to flow by gravity into the conveyor Material conveys partially up the conveyor -Aeratable material fluidizing inside conveyor then stops -Not enough material fed into system to fully fill the conveyor tube Verify proper conveyor spiral exposure Motor turns but the conveyor spiral does not

-Conveyor spiral exposure too short -Spiral coupling not properly connected to gear reducer -Conveyor spiral not properly connected to spiral coupling

Excessive Noise or Vibration During Operation Diagnostic Action or Symptom Potential Cause(s) Conveyor not running with even rotations -Large material particle size binding the but rather is surging unevenly conveyor -Conveyor spiral permanently kinked -Long conveyor running too slow -Tail end of spiral catching on centering rod (if applicable) or other obstruction in conveyor infeed -Foreign object caught in conveyor -Highly compactable material being conveyed Material conveyance rate low during -Material aerating inside conveyor operation -Material feed to conveyor is low causing a starved or partially empty state inside the conveyor -Material feed to conveyor has stopped with no provisions to automatically deactivate conveyor -Conveyor spiral not joined properly to spiral coupling, allowing spiral to slip Material being fed to the conveyor -Lumps of material causing improper operation contains some lumps or agglomerations Verify proper conveyor bend radius -Conveyor bend radius too tight Confirm proper conveyor installation -Improper support of conveyor tube or methods discharge assembly

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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PACKING GLAND SEAL (Option) A packing gland seal is available to seal the entry point between the gear drive shaft and the discharge box (See Figure 14). Two rows of Teflon packing are used to maintain this seal as the shaft rotates. Adjustment to the packing gland seal can be performed by sequentially tightening the retaining ring bolts one quarter turn at a time until desired compression is achieved. DRIVE MOUNTING BRACKET PACKING GLAND COMPRESSION PLATE

DISCHARGE BOX GEAR DRIVE

TEFLON PACKING RETAINING RING RETAINING RING BOLTS

FIGURE 14: PACKING GLAND SEAL

NOTICE

Adjustment of the mounting bolts will alter the compression of the Teflon packing around the rotating shaft. Caution should be taken not to over tighten the retaining ring bolts which can result in a mechanical bind of the shaft.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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MECHANICAL HOPPER AGITATOR (Option) A mechanical hopper agitator assembly is comprised of a motor, right angle gear reducer, packing gland seal, and a two-piece agitator shaft with paddles (See Figure 15). In order to prevent access to the agitator paddles during operation an interlock switch, or hold down lugs will be factory installed on the hopper prior to shipment.

!

CAUTION

In order to avoid potential compaction of material, the agitator should only operate when the material contained in the hopper is intended to flow. Agitating a static volume of material can hinder subsequent discharge of material and/or cause damage to downstream equipment. The agitator should only operate when the conveyor or other downstream device is also operating.

ROTATION

Figure 15: Mechanical Hopper Agitator

Agitator Motor The agitator motor should be wired to the control panel such that it starts when the conveyor or other downstream device turns on and stops when the conveyor or other downstream device turns on / off. Verify that the motor is configured properly for available line voltage. FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Agitator Gear Reducer All standard agitator gear reducers are filled with synthetic lubricant to operate within a temperature range of 30 to 100 degrees F. The lubricant should be changed every 6 months or 2500 operating hours with any high quality AGMA 7 rated lubricant.

Agitator Packing Gland Seal Packing gland seal adjustment can be performed by sequentially tightening the mounting bolts one quarter turn at a time until desired compression is achieved.

NOTICE

Adjustment of the mounting bolts will alter the compression of the Teflon packing around the rotating agitator shaft. Caution should be taken not to over tighten the retaining ring bolts. This may result in a mechanical bind of the agitator shaft.

Agitator Rotation Inspection Inspection can be performed with or without product in the hopper since the agitator shaft protrudes through the back of the right angle reducer. The agitator shaft should be rotating clockwise when looking at it from the back of the gear reducer. (See Figure 14).

Agitator Interlock Switch

!

DANGER

The interlock switch must be wired to disable the agitator motor and the conveyor motor if the cover, screen or grate is removed. Failure to do so can result in serious injury if access to the agitator paddles is allowed during operation. The interlock switch should be tested for proper function on a daily basis.

There are two basic types of interlock switches installed by FLEXICON®. A ‘Pin Plunger’ type switch is mounted vertically on a hopper sidewall and interfaces with the bottom of a solid hopper cover. A ‘Roller Plunger’ type switch is mounted on a hopper sidewall with the plunger protruding into the hopper and interfaces with a vertical tab on a screen or grate.

Agitator / Hopper Screen Hold Down Lugs If an Interlock switch is not included FLEXICON® will install hold down lugs for the hopper screen which must be mechanically removed in order to access the agitator paddles.

!

DANGER

Power to the agitator MUST be disconnected prior to removing these lugs. Failure to do so can result in serious injury if access to the agitator paddles is allowed during operation.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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PNEUMATIC TURBINE VIBRATOR (Option) The pneumatic turbine vibrator assembly is supplied with a solenoid valve, filter / regulator and gauge. (See Figure 16) It is recommended to install a manual shut off valve just prior to the inlet port of the regulator. Regulator settings will vary depending upon material flow characteristics, normally 60-80 PSI. Optimum setting can be determined by field trial. Pneumatic turbine vibrators are self-lubricating and require no lubrication.

NOTICE

HOPPER WALL

Vibrating a static volume of material can hinder subsequent discharge of material and/or cause damage to downstream equipment. In order to avoid potential compaction of material or damage to the hopper or vessel the vibrator should ONLY operate when material is contained in the hopper or vessel, and is intended to flow. The vibrator should only operate when the conveyor or other downstream device is also operating.

VIBRATOR MOUNTING PAD

PNEUMATIC TURBINE VIBRATOR

FLEXIBLE TUBING GENERAL PURPOSE SOLENOID

FILTER, REGULATOR AND GAUGE

AIR INLET PORT MUST POINT DOWN

WIRING TO CONTROL PANEL

SUPPLY LINES AND FITTINGS BY CUSTOMER

Figure 16: Vibrator Assembly Install vibrator securely on the mounting pad utilizing nuts and lock washers provided. Install the regulator in a convenient location and provide a constant supply of clean dry air. Mount the solenoid in a convenient location and connect the inlet port to the regulator output port. Connect the solenoid output port to the vibrator inlet port. The solenoid should be wired so that it starts and stops the vibrator automatically with the conveyor or other downstream device. FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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Standard Capacitive Type Proximity Level Switch (Option) A standard capacitive type proximity level switch can be utilized in a variety of locations and for a variety of reasons within a FLEXICON® material handling system. It is generally used to detect the presence of a bulk solid material. The signal transmitted by the level switch is used to automate equipment operation, or to alert an operator to a specific condition. Level switches are supplied loose and are to be inserted in a 30 mm half coupling by threading it into place until it protrudes approximately ¾” into the hopper or other process vessel. The level switch should be wired to a control panel to allow the system to operate as intended.

Normally Open / Normally Closed Sensing A standard level switch is sent in a normally open state but can be set to operate in a normally closed state. When set to operate in a normally open state an output signal will not be provided when there is no material present at the switch location, and will provide an output signal when material passes above (covers) the level switch. Conversely, a level switch set to normally closed will provide an output signal when there is no bulk solid material present at the switch location, and will not provide output when material level passes above the level switch.

NOTICE

To change a standard capacitive level switch to a normally closed state please reference the manufacturer’s documentation for further instructions.

Level Switch Sensitivity Adjustment A standard capacitive level switch features a red LED to indicate a positive output, and a potentiometer for sensitivity adjustment. It is essential that the sensitivity of the switch be properly adjusted as per the following instruction for a normally open condition. 1. Once the switch has been mounted in the application set up the worst case conditions that would cause a false “ON” signal. For example, the worst case condition may be a dusting of product coating the switch even after the material level has dropped below the switch. Turn the potentiometer clockwise until the LED is on then turn the potentiometer counterclockwise until the LED just turns off. 2. Cover the switch with bulk solid material. The LED should turn on. Turn the potentiometer counterclockwise and count the number of turns until the LED turns off. 3. Turn the potentiometer clockwise half the number of turns counted in step 2. The switch is now ready for use.

FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

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FLEXICON Flexible Screw Conveyor Installation and Operation Manual

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SPARE PARTS See the Contacting FLEXICON® page of this manual for the telephone number and the information required to identify your material handling system and its components.

Revised 09-29-10 FLEXICON CORPORATION 2400 Emrick Boulevard ■ Bethlehem, PA 18020-8006 USA Tel: 1-888-FLEXICON ■ Tel: 1-610-814-2400 ■ Fax: 1-610-814-0600 ■ www.flexicon.com ®

Copyright 2003 Flexicon