1975 - Trolley Transfer and Cooling Bed Exit Tables

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1,400,000 tpy Rebar Mill with H.S.D. System 58 95 9439
Trolley Transfer and Cooling Bed Exit Tables JOB ITEM 8274.1975
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B - Equipment and Maintenance Manual 00 1
8274.1975 TROLLEY TRANSFER AND COOLING BED EXIT TABLES
B EQUIPMENT
AND MAINTENANCE
MANUAL
ATTENTION:
Please read carefully the instructions before the machine commissioning is executed. It is the
Customers responsibility to study and understand the contents of this manual. Also to pass
the contained information by a training process to the plant operators and maintenance
personnel to result in acceptable and safe working standards with the equipment.
Images and drawing extracts present in this manual are typical of the machine type and
present an indication from which to understand the accompanying descriptions. For the
actual drawings, please refer to the project specific versions.
JIN-8274 Property of SMS MEER S.p.A; copy and disclosure of this document are prohibited 160115
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B - Equipment and Maintenance Manual 00 2
00 Contents
Chapter Title Pages
1.0 Preface 1
2.0 Safety Recommendations 2
3.0 Technical Data and Drawings 4
4.0 Functions 19
5.0 Maintenance and Use Instructions 24
6.0 Trouble-Shooting 2
7.0 Documentation of the Sub-Suppliers 2
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B - Equipment and Maintenance Manual 1.0 1
1.0 Preface
The bars collecting chain conveyor and trolleys transfer tables are installed for the full
length of the cooling bed and directly after the fixed and moving rakes of the cooling bed.
They deliver the configured layers of bars to the cooling bed exit roller table which
functions to convey the layer to the cold shear for cutting to pre-defined customer lengths.
The cold shear is displaced away from the cooling bed location to optimize the handling
logistics of the layers so as not to impede the next layer processing. The exit roller table is
further extended to convey the layers to the entry position of the cold shear - this section
of conveyor is covered in a separate maintenance manual.
The equipments aligned and levelled condition is critical to the correct inter-functionality
of the cooling bed operation and to the smooth operation of the cold shear-line.
The cooled bar layers are collected from the cooling bed and transferred to the shear-line
according to recipe groupings designed to optimize the shearing operations. Specifically,
the bars are geometrically spaced by the functionality of the collecting conveyor,
transferred to and finally conveyed in layers by the roller table to meet the productivity and
quality requirements of the cooling bed and cut-to-length areas.
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2.0 Safety Recommendations

2.1 General
See Plant Manual A
ATTENTION:
Please read carefully the instructions before the machine is commissioned, handed-over and
operated. It is the Customers responsibility to read the following manual and effectively train
and communicate the contained information to all the operational and maintenance
personnel.
2.2 Specific
Attention is drawn to the specific hazards outlined in the text in the specific following
sections: 4.0, 5.0 and 6.0.
ATTENTION:
The bars collecting conveyor, trolley transfer and roller tables are normally automatic in
operation on detection of the bars or layers present on the devices and according to the
software controlling their activation. In any case, the complete equipment is initiated by
PLC automation and since this is not intrinsically a safe system beware that a fault
condition (although rare) has the ability to start the drives or activate the individual
mechanisms at any time.
The boundary area of the equipment is normally totally open to personnel access. In any
case, great care must be exercised when approaching within hand reach of the
equipment and its associated moving devices moving parts whilst they are live due to
the risk of serious injury.
There are many potential trapping hazards within the incorporated mechanisms of the
equipment which are impractical to effectively guard. However, the Operator must ensure
that any supplied guards conform to local or National safety regulations and must risk
assess other such points of perceived danger to identify safe working practices and rules
to control access and to mitigate the dangers when personnel enter areas where the
machines are potentially live.
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ATTENTION CONTD:
The Operator is advised to execute risk assessment methodology in the establishment of

obligatory safe working rules for approaching close to or working directly on the
associated equipment - this should include the provision of fail-safe means of effective
electrical and media isolations of the individual machines comprising the equipment and
issuing an appropriate permit to work whenever access local to the equipment would
otherwise render risk of the operator being struck, trapped or ingested into the moving
parts should the drives and mechanisms be activated.
Be aware that there are no normal, safe walking/access areas on the equipment working
surfaces - access to recover material needs to be risk assessed and controls
implemented e.g. temporary working surfaces, fall restraints etc., to mitigate the
possibility of serious injury due to the risk of trips and falls, falls into pits, falls onto hot
surfaces or sharp edges, ingested into rotating parts, trapped by the moving mechanisms
etc. The Operator should provide temporary means of safe access to the equipment
areas whenever such interventions are required and present a danger.
Be aware of the risk of burns when accessing the equipment which will be very hot during
and immediately after its operation and also when recovering any hot material from the
equipment areas. Be aware of the potential of other personnel who may be working
below the equipment e.g. in the cooling bed pit.
Also be aware that other local and adjacent surfaces/devices such as rakes and cooling
bed equipment are likely to be very hot due to heating conduction and radiation from the
hot bars.
Beware of the risk of burns from and when recovering any hot bar material from the
equipment area.
SMS Meer declines any responsibility towards injuries to people or damages to

things due to the non-compliance of the above mentioned rules and
recommendations and all other safety cautions outlined in specific sections of
this manual.
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3.0 Technical Data and Drawings

3.1 Designation not applicable
3.2 Mechanical
3.3 Electrical
3.4 Hydraulic
3.5 Pneumatic not applicable
3.6 Water not applicable
3.7 Lubrication
3.8 List of Drawings and Drawings
3.9 Table of Production Data not applicable
3.2 Mechanical
Serial no. 8274.1975.01
Year of construction 2015
Type cooling bed exit roller table with
transfer table
Functioning electro-mechanical + hydraulic
Material flow handing
(Handing refers to normal feeding direction) RH
Sections of transfer tables group n. 2
Bars Collecting Conveying Chain Table

Designation bars collecting conveyor
Number of transfer table modules 17
Speed (pitch-pitch) 0,05 m/s at 15 Hz - 0,17 m/s at
50 Hz - 0,25 m/s at 74 Hz
No. gear-motors 1+1
Gear-motor drive 11 Kw i= 1:74,4
Drive system to collecting chain sprockets by line-shafts
No. collecting chains (each section) 5
Total no. collecting chains 85 (5 x 17 modules)
Chains - link pitch 38,1 mm ISO 24-B1
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Transfer chains longitudinal pitch 1200 mm
Trolley Transfer Table

Designation transfer trolley table with lifting
lances
Number of transfer table modules 17
Trolleys translation speed 0,10 m/s at 10 Hz - 0,50 m/s at
50 Hz
Gear-motor drive (each section) 15 Kw i= 1:26,5
No. gear-motors 1+1
Drive to trolleys translation chain sprockets by line-shafts
Trolleys arms longitudinal pitch 1200 mm
Trolleys arms lances working length 1950 mm
Trolley stroke - working translation length 2785 mm
Trolley stroke (lifting) 352 mm
No. Hydraulic cylinders (lifting) 17
Bore/rod dimension/stroke 63/45/S= 285 mm
Working pressure 80 bar
Exit Cooling Bed Roller Table

Designation roller table with apron plates
Roller table speed 0,4 m/s at 9 Hz 2,2 at 52 Hz
Total no. rolls (incl. mag. rolls) 85
No. idling rolls ---
No. magnetic rolls 2
No. rolls driven 85
Rolls drives individual - motor + gearbox
Motor power 2.2 Kw
Gearbox ratio 1 : 8,5
Couplings chain type
Roll diameter 240 mm
Roll barrel working length 1968 (with edges)
2000 mm (rolls without edges)
Rolls longitudinal pitch 1200 mm
3.3 Electrical Electric Manual, chapter E-11.2
Motor List dwg. 2465.E030
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3.4 Hydraulic
Hydraulic central unit Equipment and Maintenance

Manual - 8274.4021
Board machine dwg. 2465.0036 - 2465.0033
Scheme dwg. 2465.N004
3.7 Lubrication Equipment and Maintenance

Manual B - 00, chap. 3.1.2
Type of lubrication
- manual grease KP2K-20, DIN 51502
- splash type gearbox
Chain transfer table gearbox CLP ISO PG VG 220, DIN

51502
- quantity 21,6 l
Trolley transfer table gearbox CLP ISO PG VG 220, DIN

51502
- quantity 15,4l
Roller table gear-motor CLP ISO PG VG 220, DIN

51502
- quantity 0,65 l
Oil type for transmission chains oil suggested: ISO VG 220

Grease type for transport chains grease suggested type high
temperature NLGI grade 1, 2
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3.8 List of Drawings and Drawings
Item Pos. WBS Drawing N Description Pages

3.8.01 8274.1975 2465.0028 Roller table and trolley transfer device at cooling 4
bed exit (only drawing)
3.8.02 8274.1975 2465.0029 RH final module 12 m barrel = 2000 flow from RH to 6
LH
3.8.03 8274.1975 2465.0030 Drive group module 12 m barrel = 2000 flow from 6
RH to LH
3.8.04 8274.1975 2465.0031 Std. module 12 m barrel = 2000 flow from RH to LH 6
3.8.05 8274.1975 2465.0032 Module 6 m barrel = 2000 flow from RH to LH 6
3.8.06 8274.1975 10.121.01 Coupling G.R.G. 63 1
3.8.07 8274.1977 2465.0530 Drive group for transfer exit cooling bed 1
3.8.08 8274.1976 2465.0529 Drive group for trolley exit cooling bed 1
3.8.09 8274.1975 2465.0039 Layer transport roll 240 barrel = 2000 smooth with 1
borders
3.8.10 8274.1975 2465.0040 Layer transport roll 240 barrel = 2000 shaped with 1
borders
3.8.11 8274.1978 2465.0531 Roller drive unit on cooling bed exit roller table 1
3.8.12 8274.1985 2465.0041 Electromagnetic roll 240 barrel = 2000 1
longitudinal polarity
3.8.13 8274.1986 2465.0532 Magnetic roller drive group on cooling bed exit roller 1
table with encoder
3.8.14 8274.1975 2465.0036 Hydraulic plant roller table + trolley transfer device 2
at cooling bed exit
3.8.15 8274.1975 2465.0033 Hydraulic plant on board module barrel = 2000 1
3.8.16 8274.1975 2465.0034 Grease manual plant on board module 12 m 1
3.8.17 8274.1975 2465.0035 Grease manual plant on board module 6 m 1
3.8.18 8274.1975 2465.0037 Limit switches assembly roller table + trolley 3
transfer device at cooling bed exit
3.8.19 8274.1975 2465.0038 Photocells assembly roller table + trolley transfer 1
device at cooling bed exit
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4.0 Functions
4.1 General Functions
4.2 Single Functions
4.1 General Functions
The equipment is positioned at the cooling bed exit and interfaces at one side with the
moving and fixed rake blades of the cooling bed bar translation system and at the
other side with the entry conveyor for the cut-to-length shear. The individual machines
comprising the equipment is a bars collecting, chain conveyor (4.2.2), transfer table
with lances (4.2.3) and an exit conveying roller-table (4.2.4) to permit the feeding of
the bars layer to the shearing line.
The individual machines respectively perform the following functionality:
To collect the deposited bars from the cooling bed moving rakes to form an orderly
layer according to the recipe requirements set in the HMI and in order to fulfill the
productivity and quality throughput at the cut-to-length, shearing line.
To transfer, with minimal disturbance, the collected layer of bars to the exit roller
conveyor to permit the optimum in-feed conditions to the shearing line.
At the same time, the transfer table movement cycle permits the next layer collection of
the bars on the collecting chain so as not to impede productivity due to continuing bars
arrival from the cooling bed rakes.
To convey the layer with minimum disturbance to the entry conveyor of the cut-to-
length shear.
The general functionality of the transfer tables can be described according to the phases
of operation shown below.
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Phase 1
The bar layer is realised on the collecting chain conveyor at the exit of the cooling bed
with successive transfers of each bar from the last notch of cooling bed rakes by an
indexing operation of the collecting chain device.
Phase 2
When the desired bar layer is realised, the trolley transfer table lances are lifted to collect
the full layer previously formed on the chain conveyor. The collecting conveyor is free to
start the formation of the next bar layer.
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Phase 3
If there is no previous layer material in process on the roller table (entry shear side), the
transfer table then translates with the layer on-board the lances to a position above the
roller conveyor (entry side of cold shear). If previous layer material is still being processed
and occupying the roller table, the lifted transfer table lances wait in lifted condition shown
in the Phase 2 shown position in order to free the collecting chain conveyor to commence
the next layer formation.
Phase 4
At the translated position above the roller table, the transfer trolley lances are lowered to
deposit the layer on the conveying rolls. There are slots configured in the roller table
apron-plates to facilitate the lance functionality. The transfer trolley with the fully lowered
lances then translates in reverse direction to the starting position below the collecting
conveyor ready to collect the next formed bar layer.
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4.2 Single Functions
The individual machines comprising the complete Transfer Table device are:
4.2.1 Integrated Support Frame at the Cooling Bed Area
4.2.2 Collecting Chain Conveyor
4.2.3 Trolley Transfer Table with Lances
4.2.4 Conveying Roller Table - Exit Cooling Bed Area
4.2.5 Hydraulic Plant
4.2.6 Lubrication Plant
4.2.7 Limit Switches, Bars and Layers Detection Devices
Specific/Layout Function
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4.2.1 Integrated Support Frame at the Cooling Bed Area

An integrated frame serves to support the collecting chain, the trolley transfer and also the
conveying roller table for the layout area alongside the cooling bed. For the section the
remaining roller conveyor which reaches to the cold shear, the support frame is unique to
the conveying rolls and this area of conveyor in any case is covered in a separate
maintenance manual (Equipment and Maintenance Manual B - 8274.2036 Roller Table
with Crops Ejection System - Entry Side Cold Shear CMC 650)
In both cases the supporting frames are sturdily constructed from welded steel plates and
rolled steel sections and machined where necessary for the interfacing of the critical sub-
components. It is supplied in pre-fabricated modules for delivery logistics reasons and for
ease of installation - refer to the layout drawing for the typical module lengths. The
modules are installed in a series and inter-connected layout for the compete length of the
cooling bed and also to reach the cold shear location. They are mounted to the foundation
on steel packers and grouted after finalisation of assembly and alignment. The aligned
and levelled condition of the support frames is critical to the interfacing with the
downstream and upstream equipment.
For the integrated support of collecting chain, trolley transfer and conveying table the main
component parts are:
Upright, columnar frames assemblies (aligning rollers side)
Upright, columnar frames assemblies (exit roller table side)
Horizontal and bolted connecting members.
The frame serves to support:
The collecting chain conveyor and drive system
The exit conveyor table rolls, drives and apron plates (cooling bed area)
The line-shaft assemblies for the transmission drive to the trolley transfer table
Note - the support and guiding beams for the trolley transfer table are separately mounted
to the foundation - see section 4.2.3.
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4.2.2 Collecting Chain Conveyor

The end-aligned bars arriving from the cooling bed by cyclical translation of the moving
rakes are transferred to the surface of the chains due to the dynamic motion of the last
notch of the cooling bed rakes.
The function of the collecting chain conveyor is to receive each successive bar arriving
from the moving rake cycles and form an orderly, pre-defined, side-by-side layer of bars.
It achieves this by a defined indexing motion of the conveying chains towards the direction
of the exit roller table making space for the next bars to be placed by the rake cycles. The
dimension and speed of the indexing movement is set at the local HMI and is controlled by
encoder device on the drives - it is set according to the presentation requirements of the
bar layer to the shearing line and to optimise the required productivity.
The drive speed of the conveyor is set for faster translation of the chains once the
complete layer is collected and to shift the layer to the collection point for the transfer table
lances. The starting and stopping of the chain both in indexing and fast forward and
reverse movements in controlled by a ramped acceleration and deceleration of the drive in
order to cause as little disturbance to the formed layer as possible.
The collecting chain conveyor for both sections comprises a longitudinal series of
individual conveyors which are mounted in a parallel layout respective the cooling bed
rakes (orthogonal to the centerline of the exit roller conveyor) and driven by a number of
synchronized gear-motor drives. The individual conveyors are supported by the integrated
support frame and are installed for the complete length of the cooling bed. The
longitudinal pitching of the collecting chains is designed to adequately support the bars
without causing excessive droop conditions particularly to the extreme ends of the bar
layer. The support beam members for the individual conveyors are bolted to the integrated
support frame with flange interfaces.
Each conveying chain is formed in an endless loop and its working zone is supported by a
horizontal beam member with integrated support strip for the chain rollers support and
guidance. The bars are supported directly by the chain working surface. The collecting
chain working surface (chain side-plate upper edges) may be flat or ribbed type and is
selected to suit the portfolio of product type to be handled on the conveyor. The selection
is designed to meet the positive conveyance of the bars on the chain during the chain
indexing and fast transfer motion - the bars need to convey without undue slippage or
disturbance.
Two upper sprockets which are fixed to the chain beam serve to guide the chain on the
support strip. The sprocket at the cooling bed side guides the chain towards the driving
line-shaft whilst the sprocket at the roller table end of the support channel acts as
combined guidance and provides the means to tension the installed chain - see section
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5.0. The line-shaft with on-board mounted drive sprockets returns the chain to a further
sprocket mounted above the shaft to the underside of the chain support beam. In the
working zone, the upper surfaces of the chain side-plates directly support the conveyed
bars. All idling type sprockets are installed with pinned connection to the supports and
feature internal anti-friction bearings - the bearings have integral external seals/shields
and are re-lubricated by nipple from the supporting pins. The driving sprockets are split-
clamp type and are fitted to the line-shaft with a keyed connection. All sprockets are
readily replaceable should they become worn or damaged.
Collecting chain drive
The drive for the conveying chains is via a series of longitudinal line-shafts mounted in
flange-type, self-aligning anti-friction bearings and which are supported on brackets on the
integrated support frame. Refer to the layout drawing for the disposition of the positions
where the line-shaft is axially located by inserting of gripping screw from the extended
collar of the flange bearing units - the remaining positions must remain axially free to
permit thermal dilation. For each driven section comprising the complete table, the line-
shafts are connected to and driven by centrally mounted gear-motors with gear-type
couplings in flex-flex configuration - each gear-motor driving to the left and right to
minimize torsional deflections in the shafts. The individual lengths of shaft for each drive
zone are inter-connected with muff couplings to facilitate a synchronous drive to the
conveying chains of each driven section.
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The gear-motors are driven by inverter to facilitate a variable and selectable speed of
operation. The total number and disposition of the gear-motors drives for the complete
collecting chain is dependent on the working length of the collecting chain/cooling bed
system (refer to section 3.0). Where more than a single drive group is configured, one
drive is the nominated master and the other is driven in slave. The gear-motors support
base-plate/s are mounted on foundations at the external sides of the chain transfer
table (cooling bed side) and in line with the transmission shafts.
Refer to the layout drawing for the disposition of the positions where the line-shaft is
axially located by inserting of gripping screw from the extended collar of the flange bearing
units - the remaining positions must remain axially free to permit thermal dilation.
ATTENTION:
The chain conveyor is unguarded and presents the risk of ingestion at e.g. the entry areas of
the chain to the sprockets and at the line-shaft area. Strict procedures to limit and control
access for operational or fault finding reasons when the equipment is potentially live should
be introduced on a risk assessed basis.
Access for maintenance reasons to the conveyor should not be made without effective
electrical isolation of the conveyor drives together with all associated other
machines/mechanisms which, due to their locality, may present a danger. Note section 2.2
re., the risk of burns due to hot surfaces of the equipment.
4.2.3 Trolley Transfer Table with Lances

The trolley transfer with lances has the functionality to collect the prepared bar layers from
the collecting chain and transfer them to the surface of the conveying roller table at the
exit side of the cooling bed. The operation of the associated lifting and translation
movements of the lances is designed to cause a minimum of disturbance to the bar layer.
The machine is divided into two independent sections and is installed for the complete
length of the cooling bed - a series of individual trolley modules which operate in unison
on both the sections constitute the machine. The gear-motor drive systems for the
collecting chain and translation are distributed according to the layout drawing. Depending
on the overall length of the machine, there may be multiple drives configured and which
are series connected to the individual trolley modules.
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The trolley transfer table device is sturdily constructed from rolled steel plates and
sections and includes rolled steel box members to create optimum stiffness conditions in
the design.
The individual features are:
Floor mounted support beams which guide the trolley wheels - the wheels are in free
condition (idling type) and supported within the beam flanges so that they are fully
guided during the translation phase and also contain any vertical reactions. Each beam
guide member serves one side of two adjacent transfer trolleys such that each trolley is
supported in two shared guide beams. They are mounted to the foundation on steel
packers and grouted after finalization of assembly and alignment. The aligned and
leveled condition of the beams is critical to the operation of the equipment.
Transfer trolleys constructed in steel box section each with four support wheels which
are constrained and operate within the guide beam flanges. The wheels are single-
flange type and are fitted with internal anti-friction bearings. The wheel brackets are
bolted to the trolley box-frame construction. The transfer trolleys carry the on-board
mechanism and lances for the layers lifting/lowering functionality.
The lower part of the trolley frames contain the levers and linkage system which supports
and controls the vertical lifting action of the moveable lances - the linkage is hydraulically
actuated. For each trolley module there is a pair of transverse rocker-levers which are
mounted to supporting shafts. The shafts are held in plummer-block bearing housings
which are mounted to short support columns integral to the lower frame fabrication. The
plummer-blocks feature anti-friction bearings which are installed in self-aligning cartridges.
Each supporting shaft has double levers installed which are fitted with a split clamping
block + drive key. For the lifting hydraulic cylinder, a separate driving lever is fitted to the
centre of one of the supporting shafts of a trolley module - it too is fitted with split clamping
block + key drive.
The synchronization of the levers for the frame with trolleys lifting is ensured by the
connection of the shafts levers by a longitudinal pull-rod (transmission tie rod), which
transmits to the lever the movements of the drive lever.
The pull-rod is pin-connected to the levers - each joint carries a spherical, plain bearing
unit.
The hydraulic cylinder which powers the lifting mechanism is installed with split-block
trunnion mounting to the lower frame of the selected trolley. The cylinder rod-eye is pin
connected to the driving lever with self-aligning, plain bearing. As the cylinder rod extends,
the lifting levers are raised and vice versa.
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The lifting levers of each trolley, four in total, support a pin connected frame which carries
the lances which interface directly to interface with the bar layer. Each frame typically
contains five lifting lances - check the specific project solution. The lifting frame is
constructed of beams and plates in the form of a ladder construction. The pinned
connection to each of the driving levers is made via a pair of sealed ball bearings - the
bearings are contained in bored holes in thick drop-plates which are integral to the frame
construction. In the transverse sense and due to the lever length acting through the
horizontal plane the frames are lifted in a shallow arc of movement from the lowered to
lifted condition. In the longitudinal plane, the lifting is purely a vertical movement.
The lances are fitted to the heads of supporting columns to the lifting frame by a bolted
and flanged connection. The column heads are fitted with an integral platform plate and
support bracket from which the horizontal lances are mounted with pinned connection and
supported by a reaction surface. The lances themselves support the bar layer during the
transfer phase. The lance pivot and reaction support design allows the lances to pivot in
only in an upward direction.
Transfer trolley translation drives
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The translation drive is facilitated through longitudinal line-shafts which are mounted in
anti-friction, flange-type bearings to brackets on the integrated support frames. The line-
shaft contains the drive sprockets for the translation. Refer to the layout drawing for the
disposition of the positions where the line-shaft is axially located by inserting of gripping
screw from the extended collar of the flange bearing units - the remaining positions must
remain axially free to permit thermal dilation. The line-shafts are placed to the outside of
the conveying table frame (open side) and are driven by a connected gear-motor.
The transmission chains effecting the translation movement, one to each transfer trolley,
are connected in loop formation between the line-shaft sprocket at one side and an idling
sprocket at the other (inner/cooling bed) side. The chain is connected to each side of the
trolley with tensioning bolts - at one side the tensioner is fitted with a coil-spring to
maintain tension in the chain during the movement reversals. Also see information in
section 5.0. The chain is supported on its lower side by floor-mounted beam with integral
guide strip for the transmission chain rollers. The floor beam also serves to mount the
idling sprocket of the chain loop drive.
The idling type sprockets are installed with pinned connection to the supports and feature
internal anti-friction bearings - the bearings have integral external seals/shields and are
re-lubricated by nipple from the supporting pins. The driving sprockets are split-clamp type
and are fitted to the line-shaft with a keyed connection. All sprockets are readily
replaceable should they become worn or damaged.
For each drive section, the line-shafts are connected to and driven by centrally mounted
gear-motors with gear-type couplings, each gear-motor driving to the left and right to
minimise torsional deflections in the shafts and to facilitate synchronous and continuous
drives to the each of the transfer trolleys. The individual lengths of line-shaft comprising
one drive section are interconnected with muff-type couplings to form a single driving
entity.
The total number and disposition of the inverter driven gear-motors for the trolleys
translation is dependent on the total length of the cooling bed/trolley system (check the
section 3.0). The gear-motors support base-plates are typically mounted directly to the
foundation. The double-sided output shafts of the gear-motors are connected to the line-
shaft with gear-type couplings configured in flex-flex arrangement. The motors are fitted
with integral braking system to lock the drive once the translated positions are attained.
The translation movement is controlled by the inverter-driven motor to give a ramped

speed increase/decrease and with a variable but fixed translation velocity. The speeds of
translation are set in the software - the parameters are set at the HMI and are featured to
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attain the minimum cycle time but also to be sure the bars are not disrupted on the lances
during the translation.
The trolleys have two limit-switch controlled stopping positions - one at the collecting
points of the layer (below the collecting chain conveyor) and the other at the exit roller
table position.
ATTENTION:
The trolley transfer table mechanisms are unguarded and may present risk of ingestion or
trapping at e.g. the entry areas of the chain to the sprockets, at the line-shaft, the lances
lifting mechanisms and due to the translation of the trolleys themselves. Strict procedures to
limit and control access for operational or fault finding reasons when the equipment is
potentially live should be introduced on a risk assessed basis. Access for maintenance
reasons to the trolley transfer devices should not be made without effective electrical
isolation of the associated drives and media supplies. Also consideration must be made to
the associated dangers of other machines/mechanisms which, due to their locality, may
present a significant danger. Note section 2.2 re., the risk of burns due to hot surfaces of the
equipment.
Do not attempt repair or maintenance with the lances in raised condition since loss of
hydraulic fluid from any of the distribution system (e.g. hose removal or burst) or errant
operation of the valve stations may cause the mechanisms to lower unexpectedly and
present a serious striking and trapping danger.
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4.2.4 Conveying Roller Table - Exit Cooling Bed Area
The function of the exit cooling bed roller table is to receive the bar layers from the trolley
transfer device and convey them to the entry roller table of the cut-to-length/shearing line.
It is designed to convey the layer with the minimal disturbance to the bars disposition
respective the conveying rolls surface - this is required to ensure the processing at the
shear is smooth and such that there is a minimum of necessary manual interventions at
the shear entry point. The speed control/automation of the conveying rolls is based on a
ramp acceleration, constant speed and ramp deceleration philosophy to avoid disturbance
of the bars layers whilst optimizing the maximum conveying speed necessary to meet the
productivity.
The roller table is mounted to the integrated support frame (4.2.1) which also serves to
support the trolley transfer and collecting chain systems. The exit roller table consists of
several discreet longitudinal conveying roller sections each supplied by inverter drive - the
automation for the shear feeding line and the conveying rollers of each group is
simultaneously driven. The table is provided with gear-motor driven and shaped flat rolls
which are pitched to adequately support the bar layer and (optionally) electromagnetic
rolls sited in specific and critical locations (check the scope and spec. in section 3.0 - also
the layout for the disposition of any installed electro-magnetic rolls).
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The function of the magnetic rolls is to assist in maintaining the layers formation during the
conveying cycle according to the as-delivered condition made by the transfer table
lances. When the rolls are energized, the magnetic flux from the internal electro-magnets
causes the bars to convey with the minimum of longitudinal or transverse slippage. DC
power is fed via electrical connections to the internal electro-magnets from a slip-rings
system mounted integrally to the roll shafts.
All the rolls are mounted on welded brackets on the integrated support frame. They are
longitudinally pitched according to the portfolio of products and to ensure there is good
support (a minimal droop condition of the bars) during the conveying cycle. The width of
the rolls is designed to meet the throughput conditions dictated by the shear capacity and
working width at the blades. The roll-ends are configured with small flanges to interface
with the shape of the apron plates and to ensure there are no snag-points for the bar-ends
during the conveying operation. The rolls are fabricated from heavy wall steel tubing with
welded end-flanges and stub-shafts - all the critical surfaces are fully machined.
Each of the rolls is separately driven by a gear-motor drive with a chain type coupling o
flexible coupling connection on the low speed shaft. The rolls themselves are supported in
pillow-block type housings fitted with anti-friction bearings, of which the bearing closest to
the gear-motor axially fixes the roll position whilst the opposite bearing is in free condition.
Blocking rings are fitted in the pillow-blocks of the fixed side and omitted in the free side.
The bearings are either configured for manual or automatic re-lubrication from a central
system - check the project scope and specifications.
Between and below the rolls working surface are installed shaped apron plates which are
also mounted on the integrated support frame. Slots/gaps between the steel apron plates
facilitate the access of the lances of the transfer trolleys. The apron plates serve to
provide further containment of the conveyed layer - they also allow for the possibility for
access for an operational intervention. Be aware that the aprons do not constitute a safe
walkway and that access to the apron surface is not provided - such access needs to be in
controlled conditions to avoid accidents.
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ATTENTION:
The exit roller table low speed drives may be unguarded except for the presence of the apron
plates. The apron plates do not present a safe access surface for operational or maintenance
interventions - be aware that there is a risk of falls resulting from the conveyer roll operation
and contact with the conveyed product. Beware of the risk of falls into the inter-space gaps
for the lances operation, trapping by the bars or lances themselves from the lance operation,
falls into pits and trips/falls due to the presence of live, rotating rolls. Strict procedures to limit
and control access for operational or fault finding reasons when the equipment is potentially
live should be introduced on a risk assessed basis. Access for maintenance reasons to the
roller conveyor should not be made without effective electrical isolation of the drives. Also
consideration must be made to the associated dangers of other machines/mechanisms
which, due to their locality, may present a significant danger. Note section 2.2 re., the risk of
burns due to hot surfaces of the equipment.
4.2.5 Hydraulic Plant

Hydraulic plant is associated with the transfer trolley lances lifting/lowering operations.
The central system serving the valve block which controls these devices is located in the
supports of the machine - check the project layout for its location and scope of supply
responsibility.
Transfer Tables - Lances Operation

For response and equal distribution reasons, the valve-block controlling the lances
raising/lowering functions are installed on-board the translating trolleys adjacent to the
cylinder positions - check the project layout for the trolley table for exact location detail.
Each cylinders which actuates a group of lances on adjacent trolley pairs is mounted on-
board the translating trolleys and is served from a separate directional control valve
(DCV). The presence of the layer itself and the adjustments to the speed control devices
ensures the necessary amount of synchronised movement of the lances lifting and
lowering functionality. The controlling valves are mounted on a manifold block and in a
stack form and each comprising:
A check valve is fitted to the incoming P line to the DCV. The check valve prevents
creep conditions from the cylinders when the central system may be pressure-
unloaded.
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Directional control valve (DCV) - two-position type with solenoid-operation. The valve
once selected by electrical signal the spool stays shifted due to the detent function of
the valve.
Flow controls - meter-out type and installed on the A and B line and which allow
independent control of the raising and lowering speed of the lances.
Each valve-block is supplied with an isolation valve on the P line and a spring-biased
check valve on the T line. Refer to the project layout drawing for the quantity and
disposition of the benches.
The supply to the DCVs for each cylinder operation groups is fed from trolley mounted P
and T header pipes - there are flexible connection hoses in the headers to permit thermal
dilation. The two headers are mounted to the translating frame in clamps and provide for
an off-take each DCV position - the headers are generously dimensioned to ensure low
pressure drop conditions throughout the working length Final connection connections to
the cylinders from the DCV stacks are made with flexible hoses to permit cylinder
articulation.
The P and T headers are serviced from floor-mounted cable-tracks - the tracks contain
flexible hoses and also the supply and signal cable from low-voltage electrical devices on-
board the translating trolleys. Depending the total length of the trolley system one or more
cable tracks may be configured - check the project layout.
ATTENTION:
Do not attempt invasive trouble shooting or maintenance activity to the valve stations or any
part of the fluid distribution system without full and effective isolation of the associated central
hydraulic unit - this includes the blow-down of any oil storage accumulators located at a
central system. Beware of the risk of stored hydraulic pressure in the distribution system -
especially if the lances are not in fully lowered condition. The presence of stored pressure
should be checked and, as necessary, safely vented before invasive maintenance is
undertaken.
4.2.6 Lubrication Plant

The functionality of the lubrication systems is to ensure that the rotating parts operate
efficiently and with minimal frictional contact, also to ensure the equipment has a long
service-life. The re-lubrication systems to the described equipment of the transfer table,
collecting conveyor and exit roller tables equipment are normally by manual means.
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The gear-motor drives of the conveying rolls, the trolley transfer and collecting chain are
lubricated by splash system resulting from the quantity of oil contained in the gear-
housings and applied during first-fill and subsequent lubrication renewals or
replenishment. Note: the gear-motors are not pre-filled at delivery and must be filled at
site according to the OEM information considering there mounting/driving orientated
positions.
Any remaining points are either installed with sealed for life bearings or are re-lubricated
manually and periodically according to the lubrication instructions data and details - refer
to section 5.0.
4.2.7 Limit Switches, Bars and Layers Detection Devices

Limit switches are installed to detect:
Bar transfer conditions off the last rake notches - a rocker detection device is located at
the deposition point of bars at the chain collecting conveyor. A mounted proximity limit
detects the raised or lowered positions of the rocker which detects the material present
or conversely not present.
Trolley lances raised and lowered conditions. Adjustable, mounted proximity switches
detect the fully raised or fully lowered condition of each section/module for the lances
operation - for each position they are operated from a flag device which is mounted to
the supporting shafts of the rocker-levers for lances actuation.
Trolley translation in collecting position and at the roller table - adjustable, lever-
operated limit switches are statically mounted to the rail supports for trolley translation -
flags mounted on-board the trolley trigger the limits operation.
Additionally, layers present detection (photo-optic type) are installed:
In the exit roller table area to detect the layers presence or layers head entry/tail
leaving positions - such devices are linked to the conveying automation cycle and also
protect the lances and trolleys movements when there are bars layers are blocking the
free motion. The devices are mounted in separate supports to the foundation and view
the presence of bar through configured slots in the roller table apron plates. Great care
must be taken in alignment and maintenance of the photo-optic devices to ensure
correct functioning of the automated cycles.
Check the electrical maintenance manual and functional system device for the locations
and further description of the function of these devices.
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ATTENTION:
Be aware of the risk of causing accidental signals to the sensor devices since such signals
can cause unwanted initiation of the equipment and also present associated dangers. The
accuracy and sensitivity of the devices adjustment is critical to correct functioning of both
automated and manual cycles - the maintenance requirements must not be overlooked.
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5.0 Maintenance and Use Instructions

Refer also to Plant Manual A - Instructions for Erection, No-Load Tests and Commissioning
Manual D
5.1 Receiving
5.2 Storage
5.3 Installation
5.4 Handling
5.5 Assembly/Disassembly
5.6 Commissioning
5.7 Every-day Adjustments
5.8 Maintenance (General - Lubrication Instructions)
5.9 Special Checking/Adjustment Procedures
5.10 Special Safety Points and Instructions
5.11 Shutdown and Storage
5.1 Receiving
Check that there are no obvious damages to the equipment due to packaging or
transportation - report any defects immediately on receipt with photographic evidence of
any damage. Check that the temporary protective plugs applied to any media connections
on the machines and supplied media distribution pipes are intact and that there is no
penetration contamination of water or dirt. Check that any loose parts are delivered with
the main equipment.
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5.2 Storage
Store the collecting chain, trolley transfer table, and roller table equipment including all
associated supports and associated ancillary equipment on flat level surfaces preferably
in the correct working axis and suitable supported on packs to avoid bending or twisting
deformations.
The equipment, excepting any un-machined structural parts should be stored in dry
conditions, preferably indoors or covered adequately with suitable protection sheets to
eliminate water ingress. Do not store in standing water conditions or where the
atmosphere is very humid. Inspect any equipment stored outside at regular intervals to be
sure it is not deteriorating or that temporary coverings are intact and functional. In any
case sensitive equipment such as the motors, couplings, cylinders, valve bench
components, bearings, machined items such as shafts must be stored in dry,
workshop/warehouse conditions - never in an open environment.
Ensure the stability of any pre-assembled sections of equipment etc., is assured and that
the equipment cannot accidentally fall and be damaged. Ensure that any installed motors
are protected against mechanical damage both in storage and subsequent handling -
remove and refit the motors later after the main equipment in installed to the structure or
foundations if necessary.
5.3 Installation
Before the Installation

The integrated support structure is supplied as loose pieces for site installation, alignment
and levelling directly to the foundation.
The layer collecting conveyor sections are normally supplied partially pre-assembled - the
chains are installed when the alignments are completed and the line-shafts are installed.
The line-shafts and trolleys themselves are fully pre-assembled wherever possible.
The trolley transfer units with on-board lances mechanisms are installed to the rails once
the rails are aligned and levelled. The line-shafts for the trolley translation are normally
supplied fully pre-assembled - the line-shafts are installed to the structure and aligned to
the trolleys.
The hydraulic header distribution pipes for the lances operation is normally supplied pre-
fabricated and internally cleaned and are installed to the trolleys. The valve stations are
supplied fully pre-assembled and are mounted directly to the trolleys for the connections
to the cylinders. The cable tracks and supports are supplied as loose pieces - the flexible
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hoses need to be installed to the cable tracks and the cable tracks installed to the
supports on the foundation.
The individual conveying rollers for the exit conveyor are supplied fully pre-assembled
with bearings - the gear-motors are supplied as loose pieces to avoid shipping damages -
it may be necessary to install the chain couplings to the rolls and gear-motors. The apron-
plates are supplied as loose parts.
The remaining parts are supplied as loose or packaged items. In any case, check the
assembly drawings and assemble any and all loose parts strictly according to the drawing
layout/general assembly and interconnection details.
Before attempting the equipment installation, it is necessary to become fully familiar with
the requirement of the installation accuracy so far as critical alignments and leveling is
concerned - it is recommended that a detail discussion is taken with an SMS specialist
before planning or undertaking the work.
A network of interlinked and extremely accurate setting-out datum points for alignments
and levelling is required to avoid e.g. dimensional accumulation errors.
Check that all the foundations and bolt-hole provisions comply with the engineered
requirements including the drawings of the complete cooling bed exit area.
The foundation preparation must be complete and the concrete fully cured to receive the
base-plates/supports/structural elements. Check that the correct elevations and critical
alignments for all the components can be achieved on the foundation. A check to any
installation and assembly drawings must be made.
All the described cooling bed exit equipment needs to be established and connected
according to drawings datums to ensure the correct inter-functional requirements and
also with the downstream (shear-line entry area) and upstream (cooling bed rakes)
equipment.
Immediately prior to installation of the equipment the base-plates any protective coatings
and any protections media on machined interfaces is to be removed and a check made
that all areas are suitably clean to receive the critical pieces. Also check that there are no
foreign particles adhered to the undersides of the equipment to be secured to the base-
plates during the storage/transport phase.
The undersides of the base-plates/supports must be free of oil/grease to ensure a correct

fixation to the concrete and grout. The base-plates/supports must be adequately
supported on steel packs and the bolts to the foundation fully tensioned.
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Checks during Installation

Check that the support structure, wheel guides aligned positions and critical levels have
been set correctly. Check that the line-shafts are aligned before the interconnecting
couplings of the shafts is made. Check that the critical alignment and levels of the
collecting conveyor, trolley transfer device and exit roller table have been made correctly.
Check that the accurate alignment and level of the raised position of the trolley lances is
made before connection and finalization of the transmission installation.
Check that its forward and backwards positions are set according to the detailed
dimensional requirements.
Finally, that welded stop-blocks and location clamp blocks are applied strictly to the
designated feet positions to permit the thermal expansion functionality and prevent any
unwanted movements and future lost alignment conditions. Check that any other
designated welded stop-blocks on the associated pre-assembled equipment of the
equipment have been installed and welded according to the drawing indications.
Check the collecting conveyor, trolley transfer table and exit roller table including sub-
components have been mounted correctly and that everything corresponds to the
assembly drawings. It is necessary to install the loose components of the hydraulic
system, any pneumatic plant on-board and the pipes/connections to any central system or
valve bench location (if configured) according to the single-line diagrams and the
assembly drawings.
Make sure that any safety and heat protections have been installed and function correctly.
Refer to special notes 1 below for the base-plates support criticality. It is recommended
that the grouting is not applied to any of the individual sections of equipment base-plates
until all critical positions and alignments are verified.
Check that all the fluid media piped systems are fully flushed and certified clean before
connection to the T.O.P.s.
Check that any speed regulation devices have been installed in the correct direction for
functionality.
Check that the first-fill lubricants are installed to all the defined positions according to
specification for the lubricant and fill volumes.
Special note 1. The base-plates need to be established on multiple steel packs/shims to
avoid twisting distortions when the foundation bolts are correctly tensioned.
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The equipment cannot be operated until all the necessary grouting (including curing of the
grout) of base-plates is completed to a high standard.
Checks after Installation

Check that all piping installed is suitably clean and that there are no external leaks.
After installation and also after one month from machines operation, check that all
connecting bolts, including the foundation bolts, are still correctly tensioned. Check the
welded clamp and location blocks are all intact and as-installed. Check that the
connections bolts of the interconnecting couplings of the line-shaft are as-installed and
tensioned correctly. Check that the lances operation cylinders are secure and that the
hydraulic distribution pipe clamps are still tight.
5.4 Handling
The handling of the collecting conveyor, trolley transfer and exit roller table equipment is
normally only that required for off-loading, storage and installation. Use any provided
attachment points and soft slings wherever there is the risk that surfaces may be
damaged or too much pressure will be exerted to vulnerable parts. Do not sling off the
shafts, any castings components or other critical moveable parts.
Whenever the assistance of the overhead crane is to be utilised, it is strongly

recommended not to lift directly with slings from the crane hook since it is impossible to
control the applied force - use e.g. a 1/2 tonne or appropriately rated secondary chain-
block device attached to the crane hook to make a controlled movement of the device.
ATTENTION:
Refer to the drawings information or revert to SMS if there is any doubt about the attachment
points on any of the equipment for correct slinging and handling. Employ the normal good
and safe practices when slinging - in any case, slinging should only be undertaken by trained
operatives and with full information about the mass of the equipment to be slung and also its
centre of gravity/stability.
Check if the moving parts of the pre-assemble equipment are temporarily blocked for
shipment - remove such blocks in a careful way so as to prevent accidents from devices
moving suddenly and without warning.
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Be aware of trapping points when handling the equipment into confined positions during its
installation. Unless the handled device has special provisions, check that all attachments
points are fully engaged at all times during lifting/lowering operations.
Refer to the sub-suppliers information for the correct handling points of the cylinders and
motors/gear-motors. Any eye-bolts should be inspected before every use and also to check
that they are fully engaged to the threaded holes and without any threads damages. Shock
loads must not be applied due to the risk of internally damaging the motors - the feet/flanges
may be of cast iron.
When handling sub-component parts e.g. during invasive maintenance - check the weight of
parts are handle-able or use a lifting device.
5.5 Assembly/Disassembly
Equipment and Maintenance Manual B - 00, chap. 3.2.1
5.5.1 General
Follow the drawings for the installation and assemblies of the interconnections of the any
pre-assembled sections and the assembly of the loose parts.
Assembly and disassembly will only be required in the event of abnormal maintenance
situation resulting from equipment failure or wear after prolonged operation. The
Manufacturers drawings and tolerances should be consulted before any work is
contemplated and any parts substituted should be of O.E.M. source and quality.
Consult the assembly drawings and SMS expertise, as necessary, for invasive
maintenance or major repair work where the methods of disassembly or the degree of
repair needed to restore functionality are not clear.
Assembly and disassembly of the cylinders, motors, gearboxes and valve bench
components and their associated parts are specialist procedures and should only be
entrusted to the O.E.M. or a repairing specialist.
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ATTENTION:
Disassembly and re-assembly are irregular activities and should not be undertaken
without the necessary skills and training due to the risk of damaging the machines and
the risk of injuries.
5.6 Commissioning
ATTENTION:
Be aware that this must be strictly controlled and supervised to avoid danger to
personnel not involved in this process. Special barrier systems and warning notices are
likely to be required and precise and definitive communication must be made to all who
work in the area. The commissioning area is very large - barrier systems and
communications to personnel not involved in the commissioning process are especially
important.
Attention: refer to the critical safety points contained in section 2.0 before accessing the
equipment and related equipment areas for commissioning and start-up. Be aware of the
inter-related equipment (entry and exit areas) commissioning status and whether this is
live and potentially operable - take such steps as are necessary to mitigate the risks of
injury from the intentional or accidental operation of this equipment.
SMS Meer S.p.A. declines any responsibility towards injuries to persons or damages to
equipment due to the non-compliance of the above mentioned rules and
recommendations.
If any abnormalities occur, the equipment should be immediately stopped for

investigation/corrective action and the appointed SMS Meer Engineer informed.
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The sequence for commissioning and start-up is:
- Verification of all installation completion with full tension to all the bolts and critical
alignments checked and approved by SMS Meer.
- The maximum number of guards or safety barriers is attached in the work area to avoid
Danger to other personnel.
- A check that all the I/O of the PLC is correct at the application points of the valve
benches.
- Full commissioning of the fluids media systems including final connections and
verifications of supplies to the valve bench. This includes the setting and checking the
specified pressures and flows.
- All manual lubrications to be undertaken before any commissioning activity. Refer to the
lubrication section in 5.0 to identify all manual points etc.
- Set the supply pressure on any air pressure regulator and fill any supplied lubricator with
oil.
- Motors - check for the correct and common direction of rotation of the output shafts.
- Operate the cylinders movements in manual mode using firstly the manual override on
the DCV and then the local desk controls.
- Set the operation of the speed control for any hydraulic cylinders piston-rod retraction
and extension actuators according to the specified speeds in the schematic drawings or
the experience of the SMS commissioning engineer.
Before proceeding with hot start-up:
- Check the full functionality of the operation from the remote pulpits via the mill
automation system.
- Check that the actual peripheral speed of the exit conveyor rolls and the speed of the
collecting chain conveyor and trolley translation conform to that of the automation
settings considering the input of the speed input data etc.
- Check by simulation that any HMD/photo-optic devices are working within the required
sensitivity ranges.
- Check that the proximity sensors for the stopping controls/parking positions are set
correctly.
5.7 Every day Adjustments
There are no every-day physical adjustments necessary. The setting of the chain speeds
indexing dimensional value, trolleys speed, roller table sections speeds and any
associated timers are set within the HMI according to product types and operational
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experience gained during the commissioning of each product type within the portfolio of all
the mill products.
Adjustments are necessary from time to time on the chain tensioning devices of the
collecting chain conveyors and the trolley transfer transmission. The adjustments are
made when the chains have observable slackness condition and according to experience
of the maintenance/operator personnel. High chain tensions are not necessary and are to
be avoided since they induce higher loads to the sprocket bearings and wear conditions in
the sprockets and chain support devices. Conversely, slack chain conditions will
precipitate snagging, chain breakages and snatch conditions when the drive to the chains
is initiated and reverses (mainly for the case of the trolley transmission chains).
5.7.1 Collecting Chain Tensioning
Photo-shot - Typical chain tensioner
The tensioning sprocket (at the roller table side) is held in an extendable support arm
guided by key blocks on-board the chain support member. Two bolts clamp the support
arm to the chain support member to make the sprocket arm rigid once the adjustment is
made. A provided jacking screw reacts to the face of a block on the support arm to push
the support arm in the key block guides. Clockwise rotation of the jacking screw causes
the support arm to extend and apply greater tension to the chain - counter-clockwise
rotation permits the support arm to retract and reduce the tension to a slack condition (e.g.
when the need to replace the chain or work on the sprocket replacements is required).
Adjustment steps are:
Slacken the clamp bolts but only by enough to allow the support arm to reasonably
freely slide in the key block guides.
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Loosen the locking nut on the jacking screw to allow the jacking screw to be turned in
the required direction.
Turn the jacking screw head clockwise or anti-clockwise so that it reacts to the support
arm block. The arm will extend or retract accordingly. When slackening the chain and
after the initial tension release stops pushing back the support arm, it may be
necessary to apply an external pushing force to cause further retraction of the arm.
When the desired position of the support arm is reached, tighten the locking nut of the
jacking screw - note that the jacking screw must stay in contact with the block of the
support arm to help resist backwards sliding of the support arm under the forces
reacting from the drive of the chain.
Tighten fully the two clamping bolts of the tensioning sprocket support arm.
5.7.2 Trolley Drive Chains Tensioning
Fig. - Typical tensioner of trolley translation transmission
The two ends of the chain are anchored to the frame of the trolley. The side closest to the
cooling bed is terminated with a special threaded attachment to the last chain link. The
device is fitted with a coil-spring in front of the securing nuts to partially absorb the shock
forces when the chain drive is initiated - it also helps to maintain a constant tension in the
chain e.g. from the applied adjustment of the opposite tensioning device and during
reversals of the driving direction.
The second end of the chain is also terminated with a special threaded attachment to the
last chain link - this passes through the box construction of the trolley to form the means
of applying the tension to the chain from the adjustment nuts. It is normally not necessary
to make adjustments at the spring-side of the chain anchorage - all re-tensioning
adjustments would normally be made at the second device once the initial synchronisation
of all driving chains has been set during the installation. Clockwise rotation of the main
nuts (free end of the screw thread) will cause the tension in the chain to increase and
vice-versa - the locknut closest to the chain link must be released to allow the tensioner to
operate.
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Adjustment steps are:
Slacken the lock-nut closest to the chain to allow the tensioner to move in the box.
Slacken the locknut of the double nut assembly.
Turn the main nut in the required direction to tension or slacken the chain.
When the degree of tension or slackness is created, tighten both locking nuts to make
rigid the screw thread device passing through the box section.
Check that the spring loaded device is still applying tension to the opposite end of the
chain and the spring is in a working condition e.g. not coil-bound and not free.
5.8 Maintenance
5.8.1 General
5.8.2 Lubrication Instructions
5.8.1 General
A preventative approach to maintenance will secure a good operational result and limit
expensive failures.
Where possible and appropriate predictive techniques can also give optimum results e.g.
vibration analysis, thermo-graphic imaging, wear particle analysis in lubrication and fluids
systems etc. The user is strongly advised to research the availability of such techniques
and employ them as appropriate to this equipment.
Wherever possible it is important to establish a quantitative way to establish and record

machine condition - this avoids subjective opinion of condition and allows a proper basis
for trending condition. If this is not possible, it is useful to contain the task of undertaking
machine inspections to a minimum number of fully trained staff.
Establishing data base of records of machine condition is essential as is consulting the

data base to highlight a worsening trend and predicting when a necessary intervention of
adjustment, component exchange etc., is to be planned.
Establishing check sheets for each adopted maintenance routine is essential - in the
design of the check sheet there should be enough prompts of exactly what to check and
record in order to take out any subjectivity - also there should, wherever possible, be
limiting values/conditions stated on the sheets such that immediate action can be taken if
there is a critical non-conformity.
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Maintenance should only be carried out by fully trained personnel who are familiar with the
specific equipment.
Critical alarms - it is recommended that critical alarms resulting from field-mounted

transducers are tested by simulation method wherever possible and according to periodic
routines
It is recommended that the maintenance is carried out in a routine manner according to
specific timetable or taking account of equivalent machine operating time. The
recommended frequencies should be adjusted according to local conditions.
The following is to be regarded as a minimum requirement for preventative maintenance
practice.
For the terms relating to the operating conditions and frequency, please refer to
Equipment and Maintenance Manual B - 00, chapter 3.1.1. The following is a minimum list
of routine planned maintenance which must be considered.
Trolley transfer, Conveying roller-table and Collecting-chain Conveyor
Operating
Equipment Inspection/Test Condition
Frequency
Entire machines Cleaning FE S2

Foundation bolts/grouting Tension FE 6M
Grout condition/cracks FE 6M
Machine/mechanisms Movements synchronisation FE/FU S4/T
general Locknuts tension FE S4
Bolts/screws in-place and tensioned FE S4
Limit switches security/settings FE S2
Hydraulic valve-benches FE S2
condition/leakages
Hydraulic distribution pipes FE S2
security/leakages
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Operating
Frequency
Trolley transfer machine Wheels condition/wear FE S4

Wheels bearings radial clearances FE 3M
Rails/running surfaces condition/wear FE 3M
Wheels clearances to rails FE S4
Lances fixation security/condition FE S4
Lances pivot pins security/clearance FE S4
Levers, linkages, pivots/pins - fixation FE S4
security/bushes -bearings clearances
Transmission chain condition/tension FE S4
Sprockets wear/condition FE 3M
Chain guide strips condition FE 3M
Idling sprockets bearings radial FE 3M
clearance
Sprockets security/split clamp bolts FE S4
tension
Line-shafts bearing radial clearances FE 3M
Line-shafts muff couplings bolt FE S4
tension/keys condition
Gear-couplings - security/condition FE S4
Gear couplings - open inspect and re- FE A
pack with grease
Cable-tracks condition/security FE S4
Lifting linkage fixation security FE S4
Lifting linkage bearings clearances FE 3M
Turn-buckles locknuts tension FE S4
Trolley transfer - hydraulic Security of fixings/correct functioning FU/FE S4
cylinders General condition/leakages FU/FE S4
Hoses condition/leakages FE S2
Rod-eye security/bearing radial FE 3M
clearance
Overhaul the cylinders FE 2Y
Gear-motors - trolley Security of fixation/bolts fastenings FE S4
translation drives Abnormal noises/correct functioning FU/FE T/S4
Lubricant leakages FE S4
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Operating
Frequency
Collecting chain conveyor Correct function FU T

Chain tension/condition FE S4
Chain supports condition/wear FE 3M
Sprockets security/condition/wear FE S4
Idling sprockets bearings radial FE 3M
clearance
Sprockets security/split clamp bolts FE S4
tension
Line-shafts bearing radial clearances FE 3M
Line-shafts muff couplings bolt FE S4
tension/keys condition
Gear-couplings - security/condition FE S4
Gear couplings - open inspect and re- FE A
pack with grease
Chain guide strips condition FE 3M
Gear-motors - collecting Security of fixation/bolts fastenings FE S4
Chain drives Abnormal noises/correct functioning FU/FE T/S4
Conveying rolls Rolls drives functioning FU/FE T/S2
Bearings fixation security FE S4
Bearing radial clearance FE 3M
Aprons security/wear FE 3M
Couplings - open/inspect/re-pack with FE A
grease
Rolls surface wear/damage FE 3M
Gear-motors - conveying Security of fixation/bolts fastenings FE S4
roll drives Abnormal noises/correct functioning FU/FE T/S4
Electromagnetic rolls Functioning/surface condition/wear FU/FE S2
Slip-rings/brushes condition/wear FE S4
Photo-cells Functioning FU T
Cleaning/alignment check FE S
Limit switches Security FE S
Adjustment sensitivity FE S
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5.8.2 Lubrication Instructions
For the terms used for the Type of Lubrication, Lubrication Interval, Quantity of Lubricant
and Type of Lubricant, refer to Equipment and Maintenance Manual B - 00, chapter 3.1.2.
All the values indicated in the lubrication schedule are estimates and can vary according
to the work experience.
N of points
Type of Lubrication Quantity of Type of
N Assembly N Part Item Item to be
lubrication interval lubricant lubricant
lubricated
01 2465.0029 14A transport chain 24B1 - 10 IN S12 240
n208 pitch
02 14E transmission chain 2 IN S12 300
ISO 24B1 - n299 pitch
03 25A hydraulic cylinder/ 2 IN S12 10 3
spherical joint
04 16A support - FYJ 80 16 IN S12 20 3
05 16B support - SYJ 90 8 IN S12 20 3
06 107 pin/bearing 15A 30 IN S12 20 3
07 132 pin/bearing 15A 2 IN S12 20 3
09 2465.0030 14A transport chain 24B1 - 10x2 IN S12 240
n208 pitch
10 14E transmission chain 2x IN S12 300
11 25A hydraulic cylinder/ 2x2 IN S12 10 3
spherical joint
12 16A support - FYJ 80 16x2 IN S12 20 3
13 16B support - SYJ 90 8x2 IN S12 20 3
14 107 pin/bearing 15A 30x2 IN S12 20 3
16 2465.0031 14A transport chain 24B1 - 10x5 IN S12 240
n208 pitch
17 14E transmission chain 32x5 IN S12 300
18 25A hydraulic cylinder/ 2x5 IN S12 10 3
spherical joint
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N of points
Type of Lubrication Quantity of Type of
N Assembly N Part Item Item to be
lubrication interval lubricant lubricant
lubricated
19 16A support - FYJ 80 16x5 IN S12 20 3
20 16B support - SYJ 90 8x5 IN S12 20 3
23 2465.0032 14A transport chain 24B1 - 5 IN S12 240
n208 pitch
24 14E transmission chain 1 IN S12 300
25 25A hydraulic cylinder/ 1 IN S12 10 3
spherical joint
26 16A support - FYJ 80 8 IN S12 20 3
27 16B support - SYJ 90 4 IN S12 20 3
28 107 pin/bearing 15A 15 IN S12 20 3
29 132 pin/bearing 15A 1 IN S12 20 3
30 2465.0039 16A support - SNL513 42 IN S12 20 3
31 2465.0040 16A support - SNL513 42 IN S12 20 3
32 2465.0041 16A support - SNL513 1 IN S12 20 3
33 2465.0531 10A gearmotor 84 F Refer to catalogue
34 12A chain coupling 84 IN Refer to catalogue
36 12A chain coupling 1 IN Refer to catalogue
38 12A gear coupling 2x4 IN Refer to catalogue
40 12A gear coupling 2x4 IN Refer to catalogue
= grease suggested type high temperature NLGI grade 1, 2

Transmission chain lubrication oil suggested type: ISO VG 220
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5.9 Special Checking/Adjustment Procedures
5.9.1 General - Radial/Axial Clearance in Bearings and Pivot Bushes

These checks relate to bearings of the:
Collecting chain line-shafts and sprockets

Linkages for the lifting/lowering mechanism
Transfer trolley line-shafts and sprockets for the translation drives
Conveying rolls
Cylinder rod-eyes
Use levers and a clock-gauge to detect and record the radial and axial play in the
bearings and bushes - do not apply more force than that is necessary to detect the actual
clearance condition.
5.9.2 Conveying Rolls - Bearings Replacement/Drive Alignments

Non-magnetic rollers
Fig. - Typical conveying roller assembly
Check that any intended replacement bearing meets the quality and specification
including internal clearance requirements compared the OEM supply. Take care to
note from the assembly drawing which bearing position is nominated to be the axially
fixed unit - one bearing position is in axially free condition to permit thermal dilation of
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the shaft during working conditions. The new bearing should be hand-packed with
grease during the assembly process. Seals should be inspected and renewed
according to condition.
Remove the apron plate by disconnection at the bolted interface to the conveyor
frame.
Disconnect the drive coupling or the transmission chain at the gear-motor as

applicable.
Disconnect the centralised grease supply pipes (where provided).
Remove the roll assembly to the work-bench by disconnection at the fixing bolts of
the plummer-block bearing housings. Clean all external surfaces in a wash-tank en-
route.
Remove the driven coupling/sprocket using a suitable hydraulic puller device - if

heat is additionally applied, check the condition for damage and provide a
replacement at re-assembly. Note the location of any removed coupling spacers.
Support the plummer housings and remove the bolts which fix the caps. Place the
removed housings to the wash-tank for cleaning residual grease. Remove and
inspect the outermost shaft sealing rings.
Wipe away the excess grease around the bearings, remove and note the position
of the locating rings which control the axial fixation in the located bearing housing.
Mark or measure the bearings position so that the new bearing can be replaced in
the same position.
Bend back the locking tab and slacken the locking nut at the tapered sleeve release
the grip of the sleeve using a soft drift tool.
Slide off the bearing unit from the shaft.
Recover and inspect the shaft sealing rings of the plummer housings.
If the bearings have failed be sure to carefully measure and check that the shaft journal
remains in tolerance condition - also check the plummer housings are not scored or are
over-dimension.
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Clean the shaft areas ready for re-assembly and fit the new bearings with the locking
nut of the tapered sleeve left loose - position the bearing according to the measured
position before the old one was removed.
Tighten the locking nut to cause the taper sleeve to grip the shaft - do not over-tension
it so as to remove the internal clearance of the bearing - a guide-line is to leave around
0.05 mm residual gap at the rollers.
Pre-pack by hand the bearing rotating elements with grease before re-assembling the
plummer housings to the bearings. Re-fit the locating rings to the correct housing and
install any loose sealing rings to the plummer housings in this process.
Refit the drive coupling/sprocket and any spacers which may be provided. A bearing
induction heater is used to heat the coupling/sprocket for installation to the shaft.
Refit the roll sub-assembly to the support. Once on the support and with the fixing bolts
of the plummer housings fitted, check that the bearing within the free-side plummer
housing is approx. centrally located in width the bore of the housing. To make this
check, remove the housing cap and visualize this condition - as necessary, adjust the
fitted position of the plummer housing to the support.
Reconnect the centralised grease supply pipes and cycle the system to ensure there
are no leakages. Check for free rotation of the roll before checking the alignment
condition and reconnecting the drive according to OEM information or the below
guidelines.
Refit any guards, heat-shield and aprons devices before returning the unit to service.
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Magnetic rollers
Fig. - Section view of the magnetic roller - direct drive
Follow the guidelines as for the non-magnetic conveying roller except for the following
differences:
At the side where the slip-rings are installed, the cabling connections must be
disconnected and the slip-ring hub assembly withdrawn from the shaft. Ensure that
an experienced Electrical Technician makes such work including the re-assembly
of this essential part.
If the shaft are equipped with shoulders to define the bearings stops ignore the
references to the fitting of the bearings to the shaft by taper-locking sleeves and the
respective need for the correct axially positioning the replacement bearings to the
shaft. The two bearings are shrink-fitted to the roller stub-shafts at each side - they
are positioned against steps/abutments of the shaft to positively provide their
location.
Follow the assembly drawing respective recovery of the various tubular spacers
during the disassembly and their re-fitting.
Check the radial clearance in the re-fitted bearings before mounting to the
plummer-blocks.
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5.9.3 Chain Drives of Collecting Chain and Trolley Translation
Chain Stretch/Sprocket and Guide-strip Wear Conditions

Unless the chain or sprockets have an extreme amount of wear it is not easy to detect the
condition - chains which jump or do not appear to be smooth on the sprocket teeth during
working conditions give an indication of wear problems. Compare the pieces with new
equipment to determine a visual wear condition - the length of the chain can be measured
when stretched taut across e.g. 50 link pitches and the dimension compared to the
theoretical multiple of link pitch X No. pitches.
For the collecting chain, the chain rollers support the layers via the guiding strips surface
and barreling conditions of the rollers or wear to the normally flat surface of the
support/guides-strips will cause misaligned running conditions of the chain. When the
rollers become barrel-shaped or the guide-strips are worn they must be replaced
respectively - the chain tension must be completely slackened in order to assess the wear
condition to the guide strips. The guide-strips are intermittently welded to the support
beams - to replace them, remove the welds and dress flat the support surface before
careful aligning of the new pieces and welding again.
Idling Sprockets Bearings Replacement

The idling sprockets must be removed by releasing them from the pinned connection - the
chain must also be released or split at a joining link to allow removal of the sprocket to the
workshop.
Where the sprockets are installed to pins which are integrally welded into the supports,
they are retained by spring-clip - release the clip and draw the sprocket from the pin
surface. Where the sprockets are installed to thro pins - drive out the pins are recover the
sprocket.
It is important to measure the pin diameters in the area where the bearings seat to be sure
that they are not under-tolerance - replace them as necessary.
The bearings are pushed into the sprockets to abut internal spring-rings - take care when
driving the bearings out of the sprocket bores not to damage the rings - replace them if
they are damaged in any way. After measuring the sprocket bores to be sure they are not
worn or damaged, press the new bearings to meet the abutment at the spring-rings - do
not use excessive force to damage the bearing or the rings. Where the new bearings may
feature a single outer seal or shield, pre-pack the bearings with grease by hand before
assembling them into the sprockets. The bearing should be pressed-in using the outer
track, never the inner track to interface with the press-tooling.
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Drive Sprockets Bearings Replacement

The drive sprockets are split-type and held to the shaft with the clamping bolts and drive
key. Remove the bolts and examine the shaft surface and key for wear or damage -
replace as necessary. When replacing with new split sprockets, the securing bolts which
provide the clamped connection to the shaft must be tensioned evenly to avoid pitching
errors in the sprocket teeth at the split-line - check that the split-line gaps are exactly even
at each side before applying fully tensioning torque to the bolts.
5.9.4 Cylinder Replacement - Lances Lifting Mechanism

The lifting frame for the lances must be temporarily and evenly supported with blocks
before the cylinder can be removed - it is unsafe to proceed without execution of this task
since the weight of the upper frame with lances is acting through the cylinder axis. The
cylinder removal and replacement is quite simple - it is released from the trunnion mounts
and the rod-eye pinned connection.
Note: The rod-eye is adjustable on the cylinder rod - take care to replicate the dimension
from the trunnion centres to the rod-eye centre whenever the cylinder is exchanged and
the rod-eye is swapped to the new cylinder.
ATTENTION:
Disassembly and re-assembly are irregular activities and should not be undertaken
without the necessary skills and training due to the risk of damaging the machines and
the risk of injuries.
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5.10 Special Safety Points and Instructions
Plant Manual A, chapter 2.0
ATTENTION:
Be aware that unless the equipment is properly maintained in accordance with suppliers
minimum recommendations, then failure conditions may precipitate danger to operational
and maintenance staff. Persons undertaking maintenance must be fully trained, assessed
and approved to be competent in the specific tasks. Be aware that the on-board piped
system may contain stored energy. Make any disconnections with care. Be aware that if any
seal are from Viton material; special handling precautions are needed if the seals are burnt
or charred, check the specific recommendations for this material. The user is recommended
to evaluate all media supplies to the equipment under the requirements of COSHH
regulations or equivalent (if applicable) and to train and execute any recommended control
measures. A risk assessed method to undertake the work should always be taken. This
should include the regular tasks and the irregular and maybe unforeseen tasks which may
present themselves. Persons undertaking operational duties must be fully trained, assessed
and approved to be competent in the specific tasks so as not to present unacceptable risks
to themselves or others. Attention is drawn to the nature of the use of the equipment; the
main apparent risks are:
Danger of becoming trapped or struck by moving parts.
Risks from burns or being struck by the red-hot bars during the rolling operations.
Risk of sudden and unexpected movements of the equipment in automatic PLC driven
controls (fault conditions). The user is specifically recommended to adopt strict controls of:
Equipment electrical isolation and permit/certificate procedures.
Stored energy systems which supply the equipment - isolations and permit procedures.
Tasks which may be permitted to be undertaken without general electrical isolation of the
machine and control of stored energy devices.
Be aware of the parts of the machines which are to be handled without lifting aids. Ensure
that operators or maintenance staff are not exposed due to lack of knowledge or training to
lifting operations which may be instantly or longer term injurious.
SMS Meer declines any responsibility towards injuries to people or damages to

things due to the non-compliance of the above mentioned rules and
recommendations.
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5.11 Shutdown and Storage
It is recommended to purge the old grease residues from all of the manual application
points and refill with fresh grease. See special note in 5.8.
Re-lubricate all points according to the lubrications instruction list.
Apply protective grease to any adjustable threaded parts (as applicable) if the shutdown is
to be longer than 1 month.
Clean all the areas of the equipment from free scales and water entrapment points to
prevent severe corrosion occurring - re-paint/apply a protective barrier where paint
removal has left surfaces open to oxidation effects.
Shut-off the air/hydraulic supplies.
Move the collecting chain conveyor, trolley transfer devices and operate the conveyor rolls
by re-energizing the equipment to prevent seizures or Brinelling effects to the bearings.
It is recommended to re-energize the machine and operate in manual mode and in

controlled conditions each 1 month of stoppage if this is possible.
Refer to SMS Meer for recommendations if periods of shutdown in excess of 6

months are envisaged.
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6.0 Trouble-shooting
ATTENTION:
Be aware that fault/trouble-shooting can result in exceptional hazards. A risk assessed method
to undertake the work should always be taken. Persons undertaking fault finding must be fully
trained, assessed and approved to be competent in the specific tasks so as not to present
unacceptable risks to either themselves or other Workers.
Trolley Transfer, Conveying Roller-table and Collecting-chain Conveyor
Defect Possible Causes Solutions

Rolls/chains/trolley Lack of electric power to motor Check the electric board
translation stops/will not Drive trips Check for free operation
start Limits faults/positions over-run Reset limits positions/replace
limit switches
Defective electric motor Repair or replace the motor
Drive couplings broken Repair/replace
Drive keys broken Repair/replace
Gearboxes broken Repair/replace/lack of
lubrication
Transmission chains/sprockets Repair/replace
broken
Software problem Investigate/resolve
Permissive signals missing Investigate/resolve
Cabling faults Investigate/repair
External influence Investigate/remove source
Bearings seized Replace/lack of lubrication
Noises or vibrations from Gear-motor fault Repair/replace
collecting chains, trolley Anchoring or fixing screws are Tighten the bolts
translation or rolls drives loose
Bearings condition - wheels, Check the radial clearances
line-shaft and sprockets Check the lubrication
Check the alignment
Chains/sprockets/guide strips Repair/replace
worn or damaged
Couplings loose or damaged Tighten/replace
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Defect Possible Causes Solutions

Insufficient chain tension Apply correct tension
Extern. influence/obstruction Remove the obstruction source
Lances lifting does not Not initiating/permissive signal Check automation/sequence
operate missing
Software fault Repair/correct
Valve benches fault Investigate/correct
Central system not available Initiate system
Central system fault Correct fault
Severe hyd. oil leakage Repair leaks
Cylinders fault Repair/replace
Linkages broken Replace
Bearings seized Replace/lack of lubrication
External influence Remove source
Lances lifting too slow/too Settings of the valve bench Correct the adjustments
fast adjustments
Faulty valve bench components Replace components
Partial seizure of bearings Investigate/replace
Conveying rolls/collecting Inverter faults Investigate/repair
chains not operating at HMI settings faults Correct the settings
correct speed Software fault Investigate and correct
Magnetic rolls not working Not initiating Check software/sequence
Power supply/cable faults Investigate/repair
Slip-ring/brushes faults Repair
Internal faults Replace roll
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7.0 Documentation of the Sub-Suppliers for the

Erection, the Commissioning and the
Maintenance
* Refer to Components Manual C - 2.0.
Drawing N Item Supplier Description Catalogue N*

2465.0029 14A CHAIN N.A.
14E CHAIN N.A.
25A HYDRAULIC CYLINDER N.A.
2465.0030 14A CHAIN N.A.
14E CHAIN N.A.
2465.0031 14A CHAIN N.A.
14E CHAIN N.A.
2465.0032 14A CHAIN N.A.
14E CHAIN N.A.
2465.0530 10A SIEMENS GEARMOTOR C-2.1.20
12A COUPLING N.A.
12A COUPLING N.A.
12A COUPLING N.A.
2465.0041 30A GI-DA ELECTROMAGNET C-2.2.14
12A COUPLING N.A.
2465.0037 30A TELEMECANIQUE LIMIT SWITCH C-2.2.03
30B HT ITALIA PROXIMITY SWITCH C-2.2.01
2465.0038 30A DIELL EMITTER C-2.2.06
30B DIELL RECEIVER C-2.2.04
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N.A. Sub-suppliers documentation to be defined; for information please contact Mr. Arindam
Chodhury of SMS Meer India at the following number: +91/124/4352234

1975 - Trolley Transfer and Cooling Bed Exit Tables

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1,400,000 tpy Rebar Mill with H.S.D. System 58 95 9439

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8274.1975 TROLLEY TRANSFER AND COOLING BED EXIT TABLES

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2.0 Safety Recommendations

See Plant Manual A

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The Operator is advised to execute risk assessment methodology in the establishment of

SMS Meer declines any responsibility towards injuries to people or damages to

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3.0 Technical Data and Drawings

3.5 Pneumatic not applicable

3.6 Water not applicable

3.8 List of Drawings and Drawings

3.9 Table of Production Data not applicable

Bars Collecting Conveying Chain Table

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Transfer chains longitudinal pitch 1200 mm

Trolley Transfer Table

Exit Cooling Bed Roller Table

3.3 Electrical Electric Manual, chapter E-11.2

Motor List dwg. 2465.E030

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Hydraulic central unit Equipment and Maintenance

3.7 Lubrication Equipment and Maintenance

Chain transfer table gearbox CLP ISO PG VG 220, DIN

Trolley transfer table gearbox CLP ISO PG VG 220, DIN

Roller table gear-motor CLP ISO PG VG 220, DIN

Oil type for transmission chains oil suggested: ISO VG 220

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3.8 List of Drawings and Drawings

Item Pos. WBS Drawing N Description Pages

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4.1 General Functions

4.2 Single Functions

4.1 General Functions

The individual machines respectively perform the following functionality:

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4.2 Single Functions

4.2.1 Integrated Support Frame at the Cooling Bed Area

4.2.2 Collecting Chain Conveyor

4.2.3 Trolley Transfer Table with Lances

4.2.4 Conveying Roller Table - Exit Cooling Bed Area

4.2.5 Hydraulic Plant

4.2.6 Lubrication Plant

4.2.7 Limit Switches, Bars and Layers Detection Devices

CHAPTER SHEET REV.

4.2.1 Integrated Support Frame at the Cooling Bed Area

Upright, columnar frames assemblies (aligning rollers side)

Upright, columnar frames assemblies (exit roller table side)

Horizontal and bolted connecting members.

The frame serves to support:

The collecting chain conveyor and drive system

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4.2.2 Collecting Chain Conveyor

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Collecting chain drive