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AGI DC Assembly And Operators Manual

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Drag Conveyors
Assembly and Operator's Manual
This manual applies to:
DC, DCL Models
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: 8210-30002 R0
Revised: October 2022
Original Instructions

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  • Page 1 Drag Conveyors Assembly and Operator’s Manual This manual applies to: DC, DCL Models Read this manual before using product. Failure to Part Number: 8210-30002 R0 follow instructions and safety precautions can Revised: October 2022 result in serious injury, death, or property Original Instructions damage.
  • Page 2 This product has been designed and manufactured to meet general engineering standards. Other local regulations may apply and must be followed by the operator. All personnel must be trained in the correct operational and safety procedures for this product. Use the sign-off sheet below to record initial and periodic reviews of this manual with all personnel.

  • Page 3: Table Of Contents

    DRAG CONVEYORS CONTENTS 1. Introduction ............................5 1.1 Serial Number Location......................5 1.2 Intended Use ..........................5 2. Safety............................... 6 2.1 Safety Alert Symbol and Signal Words..................6 2.2 General Safety Information....................... 6 2.3 Chain Conveyor Safety ......................6 2.4 Torque Arm Safety ........................7 2.5 Rotating Parts Safety.........................
  • Page 4 8.5 Sprockets ..........................50 8.6 Check the Spring Take-up......................51 8.7 Grease Lubrication ........................51 8.8 Replacement Parts ........................51 9. Troubleshooting............................ 52 10. Appendix ............................. 54 10.1 Chain (Drag) Conveyor Customer Selection Sheet ............... 54 11. AGI Warranty ............................57 8210-30002 R0...

  • Page 5: Introduction

    Keep this manual handy for frequent reference and to review with new personnel. A sign-off form is provided on the inside front cover for your convenience. If any information in this manual is not understood or if you need additional information, please contact AGI or your representative for assistance.

  • Page 6: Safety

    2. SAFETY DRAG CONVEYORS 2. Safety 2.1. Safety Alert Symbol and Signal Words This safety alert symbol indicates important safety messages in this manual. When you see this symbol, be alert to the possibility of injury or death, carefully read the message that follows, and inform others.

  • Page 7: Torque Arm Safety

    DRAG CONVEYORS 2. SAFETY 2.4. Torque Arm Safety Bucket Elevator gear reducers may be equipped with backstops and torque arms / swing base. Never remove the torque arm / swing base when the bucket elevator is loaded. Removal of the torque arm / swing base may cause the reducer to suddenly rotate resulting in serious injury or death.

  • Page 8: Ladder Safety

    • If a fall event should occur, immediately call emergency responders. 2.9. Platform Safety • Check the platform working load. Do not overload. Contact AGI before adding any equipment to a platform. • Close platform access door before and after working on the platform.

  • Page 9: Drives And Lockout Safety

    DRAG CONVEYORS 2. SAFETY 2.10. Drives and Lockout Safety Inspect the power source(s) before using and know how to shut down in an emergency. Whenever you service or adjust your equipment, make sure you shut down the power WARNING source and follow lockout and tagout procedures to prevent inadvertent start-up and hazardous energy release.

  • Page 10: Safety Equipment

    2. SAFETY DRAG CONVEYORS 2.12. Safety Equipment The following safety equipment should be kept on site. • Fire Extinguisher • First-Aid Kit Have a properly-stocked first-aid kit Provide a fire extinguisher for use in case available for use should the need arise, of an accident.
  • Page 11 DRAG CONVEYORS 2. SAFETY Figure 1. Safety Decal Locations Applicable for Belt Drive Only Applicable for Direct Drive Only WARNING WARNING ELECTROCUTION HAZARD To prevent serious injury or death: • Only qualified personnel should service electrical components. • Disconnect and lockout power before inspecting or servicing unit.
  • Page 12 2. SAFETY DRAG CONVEYORS Table 1. Safety Decal Details WARNING WARNING WARNING ENTANGLEMENT HAZARD ENTANGLEMENT HAZARD To prevent serious injury or death: • Read and understand the manual before To prevent serious injury or death: To prevent serious injury or death: assembling, operating, or maintaining the •...

  • Page 13: Features

    DRAG CONVEYORS 3. FEATURES 3. Features Read this section to familiarize yourself with the basic component names and functions of the conveyor. Figure 2. Main Components Description Description Item Item Cover Head Section Tail Section Chain with UHMW Paddle (not shown) Inlet Return Rails or Idlers (see Figure...
  • Page 14 3. FEATURES DRAG CONVEYORS Description Description Item Item Bend Section Divider Plate Intermediate Trough Section with Divider Plate Figure 3. Types of Chain Return IDLERS RAILS Figure 4. Types of Conveyor Chain ROLLER CHAIN PINTLE CHAIN WELDED CHAIN 8210-30002 R0...
  • Page 15 DRAG CONVEYORS 3. FEATURES Figure 5. Types of Inlet STANDARD INLET BYPASS INLET METERING INLET Figure 6. Head Section Figure 7. Tail Section Description Description Item Item Motor Tail Sprocket Gearbox Screw Take Up Drive Sprocket Inspection Hatch (optional) Torque Arm Drive Shaft 8210-30002 R0...
  • Page 16 3. FEATURES DRAG CONVEYORS Figure 8. Intermediate Gate (Optional) INTERMEDIATE INLINE GATE INTERMEDIATE FLUSH GATE 8210-30002 R0...

  • Page 17: Site Preparation

    DRAG CONVEYORS 4. SITE PREPARATION 4. Site Preparation A Professional Engineer must follow this section for proper site design. Serious injury or equipment failure can result from a lack of proper site design. 4.1. Site Layout Check the following when developing the site layout where a conveyor is installed: •...
  • Page 18 4. SITE PREPARATION DRAG CONVEYORS SUPPORT SUPPORT Do not weld supports to the conveyor. SUPPORT Note Indicates support location 8210-30002 R0...

  • Page 19: Inlet Applications

    DRAG CONVEYORS 4. SITE PREPARATION 4.4. Inlet Applications Consider the method of feeding the conveyor, type of product conveyed, trough capacity and chain speed when selecting an inlet. Below are examples of inlet configurations. Figure 9. Standard Inlet for Metered Feed Conveyor Figure 10.

  • Page 20: Location Of Spouting And Dust Control

    • Emergency stop switches that are readily accessible. • Signal devices to warn personnel of imminent start up, especially if started from a remote location. Conveyors are commonly equipped with devices listed below, and these may be required by local fire codes. AGI recommends these safety devices.
  • Page 21 DRAG CONVEYORS 4. SITE PREPARATION Interlocking Devices There are various types of electrical devices for interlocking of conveyor with other equipment. An interlock shall be used on a conveyor that is connected to downstream or upstream equipment. If downstream equipment is plugged, or has its power disconnected, the equipment feeding it should immediately have its power disconnected as well.

  • Page 22: Pre-Assembly

    Safety section, in addition to the safety information in the section(s) below. 5.1. Approval Drawing An approval drawing from AGI is provided with the conveyor. Use the approval drawing when assembling/ installing as it contains specific information about component placement and locations.

  • Page 23: Product Storage

    DRAG CONVEYORS 5. PRE-ASSEMBLY 6. Report missing or damaged parts to AGI or your representative. Report immediately to receive proper credit and so missing parts can be shipped quickly. Take pictures of shipments after unloading if there are any damaged parts.
  • Page 24 5. PRE-ASSEMBLY DRAG CONVEYORS Figure 13. Checking Trough Squareness TROUGH SECTION IS SQUARE IF A=B 8210-30002 R0...

  • Page 25: Assembly

    DRAG CONVEYORS 6. ASSEMBLY 6. Assembly Before continuing, ensure you have completely read and understood this manual’s Safety section, in addition to the safety information in the section(s) below. 6.1. Assembly Safety • Do not take chances with safety. The components can be large, heavy, and hard to handle. Always use the proper tools, rated lifting equipment, and lifting points for the job.
  • Page 26 6. ASSEMBLY DRAG CONVEYORS Figure 14. Proper Lifting of Conveyor Components 8210-30002 R0...

  • Page 27: Connecting The Head, Tail, And Trough Sections

    1. Place head, troughs and tail in proper sequence as shown in the supplied approval drawing. Note Intermediate troughs are supplied in 10’ long assembled sections. Figure 15. DC Chain Conveyor — Example Figure 16. DCL Chain Conveyor — Example 2. Level the head section. Add support to the head and drive (see Section 6.5 –...
  • Page 28 6. ASSEMBLY DRAG CONVEYORS Figure 17. Aligning the Divider and Bottom Plates 5. Bolt the trough flanges. 6. For models having return rails, align the top surfaces and connect using splice plates. Figure 18. Installing Splice Plates 8210-30002 R0...
  • Page 29 DRAG CONVEYORS 6. ASSEMBLY 7. Add structural support, see Section 4.3 – Supporting Structures on page 8. As the conveyor is assembled, check the alignment of the trough surfaces in both horizontal and vertical directions using a string/chalk line and a level. Proper alignment will minimize wear on flights and other potential damage to the conveyor.
  • Page 30 6. ASSEMBLY DRAG CONVEYORS Figure 20. Checking Horizontal Alignment DEVIATION FROM THE REFERENCE LINE (STRING) MUST BE LESS THAN 1/8" PER 100' OF CONVEYOR STRING 9. Once alignment and level is confirmed, tighten the flange bolts to proper torque rating. See Section 6.11 –...

  • Page 31: Installing The Head Drive

    DRAG CONVEYORS 6. ASSEMBLY 6.4. Installing the Head Drive Note For units that require field-installation, refer to the steps below. Check the following items before installing the head drive. • Side panel corners are welded. • All cover, side and bottom flanges are installed flush. •...
  • Page 32 6. ASSEMBLY DRAG CONVEYORS FIXING ELEMENT HEAD SHAFT DRIVE 3. Assemble the two-piece drive mount bracket to the head section bolts, lock washers, and nuts. Hand tighten bolts. TWO PIECE DRIVE MOUNT BRACKET TO HEAD HOUSING TO DRIVE 4. Insert the drive and head shaft through the drive mount bracket head. 5.
  • Page 33 DRAG CONVEYORS 6. ASSEMBLY 6. Align and square the head shaft to the head section. Note Shaft must be 90° to the head section sides. 7. Adjust drive mount bracket, if required. Once square, tighten and torque the drive mount bracket bolts. 8.

  • Page 34: Installing The Head Drive Support

    6. ASSEMBLY DRAG CONVEYORS 6.5. Installing the Head Drive Support 1. Install support post under the gearbox to provide stability during operation. 2. Install two shock absorbers (not supplied) between the gearbox and support post. SHOCK ABSORBER SHOCK ABSORBER SUPPORT POST BASE PLATE SUPPORT POST 6.6.
  • Page 35 DRAG CONVEYORS 6. ASSEMBLY Figure 22. Chain Travel Direction ROLLER CHAIN DISCHARGE PINTLE CHAIN WELDED CHAIN 8210-30002 R0...
  • Page 36 6. ASSEMBLY DRAG CONVEYORS Figure 23. Chain with Bolted Return Cups Figure 24. Chain with Welded Return Cups 3. Connect the chain sections with a pin or connecting link. (See Figure 25 Figure 26.) Figure 25. An Example of Connecting Two Chain Sections 8210-30002 R0...

  • Page 37: Installing Trough Covers

    DRAG CONVEYORS 6. ASSEMBLY Figure 26. Types of Chain Connector ROLLER CHAIN CHAIN CONNECTOR FULL LINK CHAIN CONNECTOR OFFSET LINK PINTLE CHAIN CHAIN CONNECTOR WELDED CHAIN CHAIN CONNECTING PIN Note Some connecting pins can only be inserted one way. For proper installation, make sure the head of the pin is flush to the chain.

  • Page 38: Installing Slack Chain Sensor

    6. ASSEMBLY DRAG CONVEYORS 6.8. Installing Slack Chain Sensor To complete the assembly of the slack chain sensor system on the En Masse Chain Conveyor, you will need to install the parts shipped loose after attaching the head to the trough. The main components are already assembled into the conveyor head but the external components need to be attached and adjusted.
  • Page 39 DRAG CONVEYORS 6. ASSEMBLY 1. Install the swing arm, with flange facing inward towards the conveyor, onto the shaft. Leave the swing arm locking collar bolts loose at this point. Note The swing arm and shaft are keyed to ensure proper alignment. SWING ARM 2.
  • Page 40 6. ASSEMBLY DRAG CONVEYORS 3. Assemble the Honeywell limit switch and then attach it to the switch bracket. 4. Position the swing arm on the shaft so that the cam roller of the switch lines up with the center of the switch landing on the end of the swing arm.
  • Page 41 DRAG CONVEYORS 6. ASSEMBLY Figure 29. Ideal Clearance Between the Roller and Chain b. Slide the weights back and forth on the swing arm. To avoid false trips and make the system less sensitive, slide the weights towards the limit switch. Tighten the bolt going through the weights once adjusted.
  • Page 42 6. ASSEMBLY DRAG CONVEYORS 9. Install the upper stop bracket, with existing flange bolt. This bracket is for safety and it prevents the swing arm from rotating past the Honeywell limit switch. 10. After the system is set properly, install the guards. a.

  • Page 43: Tensioning The Conveyor Chain

    DRAG CONVEYORS 6. ASSEMBLY 6.9. Tensioning the Conveyor Chain Lock out all power before making adjustments to conveyor components. 1. Re-energize the equipment and bump test the motor 3 times. Check that the rotation is correct (see Figure 30). This will ensure to remove all remaining chain slack in the top chain behind the head sprocket. Figure 30.

  • Page 44: Torque Requirements

    6. ASSEMBLY DRAG CONVEYORS 6.11. Torque Requirements Torque Wrench Torque the following components with an appropriate torque wrench. Apply factor to the maximum torque value shown in Table 3 Table Factor Pillow Block Bearings to Pedestal Flange Bearings to Plate Gear Drive to Torque Mount Plate 100% Motor to Gear Drive Motor Flange...

  • Page 45: Operation

    DRAG CONVEYORS 7. OPERATION 7. Operation Before continuing, ensure you have completely read and understood this manual’s Safety section, in addition to the safety information in the section(s) below. 7.1. Operation Safety • Do not operate the equipment in manual mode. In manual mode, all safety devices are not activated.

  • Page 46: Emergency Shutdown

    Section 9. – Troubleshooting on page 52 or contact AGI if any problems are encountered. 4. Check that the chain is properly aligned and running in the center of the head and boot shafts. To correct a misaligned chain, refer to Section 8.

  • Page 47: Restarting A Plugged Conveyor

    If the conveyor is plugged (shut down inadvertently, for an emergency, or other reason), lock out power and remove all material from the interior. Do not remove the torque arm or backstop (for DC Models only) when the conveyor is plugged.

  • Page 48: Maintenance

    • Shut down and lock out power before maintaining equipment. • After maintenance is complete, replace all guards, service doors, and/or covers. • Use only genuine AGI replacement parts or equivalent. Use of unauthorized parts will void warranty. If in doubt, contact AGI or your local dealer.

  • Page 49: Measure Chain Elongation

    DRAG CONVEYORS 8. MAINTENANCE 8. Check the chain tension: Tension the chain as required to prevent slippage on the head and tail sprockets, refer to Section 6.9 – Tensioning the Conveyor Chain on page Section 8.3 – Measure Chain Elongation on page 49 Section 8.4 –...

  • Page 50: Sprockets

    Figure 31 (C), not only do the sprockets need to be replaced, but further examination of the individual chain components is required. AGI sprockets are split for easy removal. Replacement 1.

  • Page 51: Check The Spring Take-Up

    If it is required to take up assembly apart, make sure that both springs are decompressed before taking everything a part. To reassemble the spring take-up, refer to DC26 DC Tail Spring Take-up Maintenance Instructions (provided separately). 8.7. Grease Lubrication Dodge IP, ISAF, and ISN bearings are pre-packed with NLGI-2 Lithium Complex Grease.

  • Page 52: Troubleshooting

    Cause Problem Solution Premature Trough Worn flights Replace flights Failure Excessive chain speed Reduce speed. Consult AGI to determine proper chain speed. Accelerated Flight Excessive heat Change flight material. UHMW is limited Wear to 80°C Excessive chain speed Reduce speed. Consult AGI to determine proper chain speed.
  • Page 53 Change outboard bearing Lubricate properly Insufficient/Excessive lubrication Section 8.7 – Grease Lubrication on page 51 Amp demand too excessive Contact AGI for assistance. Motor/Heaters for motor, incorrect motor size Overload Check material characteristics Check capacity Regulate feed Drastic Capacity Loss...

  • Page 54: Appendix

    10. APPENDIX DRAG CONVEYORS 10. Appendix 10.1. Chain (Drag) Conveyor Customer Selection Sheet __________________________________________________________________________________________________ Standard Design Mild Steel Construction Right Angle Helical Bevel Gearbox UHMW Drag Paddle, Mild Steel Chain and Paddle Attachment AGMA Class II Gearbox Bolted Covers, Flanged and Cross Broke NEMA C-Face Motor __________________________________________________________________________________________________ Customer Requirements - Tag#...
  • Page 55 DRAG CONVEYORS 10. APPENDIX Inlet Selection Plug Fed - Metering Inlet Plug Fed - Bypass Inlet Meter Fed - STD Inlet QTY: QTY: QTY: SIZE: SIZE: SIZE: Width x Length θ: Liner: ________ / ________ Material / Thickness ____________________________________________________________________________________________________________ Options Intermediate Inline Gate Intermediate Flush Gate Support Stands...
  • Page 56 10. APPENDIX DRAG CONVEYORS Options (Continued) Tail Screw Take-Up Slack Chain Sensor 8210-30002 R0...

  • Page 57: Agi Warranty

    10. APPENDIX 11. AGI Warranty 1. AGI warrants that equipment is free of defects in material and workmanship for a period of one year from the date of delivery, or as noted in the contract. 2. AGI will replace or repair damaged or substandard components, as it deems appropriate. Customer is responsible for all freight and labour costs for the replacement of warranty parts.
  • Page 58 AGI is a leading provider of equipment solutions for agriculture bulk commodities including seed, fertilizer, grain, and feed systems with a growing platform in providing equipment and solutions for food processing facilities. AGI has manufacturing facilities in Canada, the United States, the United Kingdom, Brazil, South Africa, India and Italy and distributes its products globally.

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