AHKG 67025 1 en 1107

Operating Instructions Chain Conveyor
AHKG - 100 / 200
AHKG-67025-1-en-1107
Original Operating instructions
Copyright by BCHA
Table of contents
1 Important information ............................................................................................... 1

1.1 Foreword .................................................................................................................... 1
1.2 Contact....................................................................................................................... 1
1.2.1 Adress .......................................................................................................... 1
1.3 Typographical conventions ........................................................................................ 1
1.3.1 Explanation of the warning instructions........................................................ 1
1.4 Important information ................................................................................................. 2
2 Safety ...................................................................................................................... 3
2.1 Safety of persons ....................................................................................................... 3
2.2 Connecting to the electrical mains .............................................................................3
2.3 Explosion protection .................................................................................................. 3
2.4 Safety concept ........................................................................................................... 4
3 Description .............................................................................................................. 5
3.1 Designated use .......................................................................................................... 5
3.2 Identification ............................................................................................................... 5
3.2.1 Nameplate .................................................................................................... 5
3.2.2 Type code ..................................................................................................... 5
3.3 Design ........................................................................................................................6
3.4 Function ..................................................................................................................... 6
3.4.1 Drive end ...................................................................................................... 6
3.4.2 Outlet on the drive end ................................................................................. 8
3.4.3 Return end .................................................................................................... 9
3.4.4 Conveyor trough ......................................................................................... 10
3.4.5 Intermediate outlets on troughs .................................................................. 11
3.4.6 Trough bends upwards and downwards ....................................................12
3.4.7 Hopper-discharging trough ......................................................................... 12
3.4.8 Conveyor chain .......................................................................................... 13
3.4.9 Chain connection ........................................................................................ 15
3.4.10 Construction of the conveyor chain ............................................................ 15
3.4.11 Outlet flap ................................................................................................... 16
3.4.12 Metering hood for granular products .......................................................... 17
3.4.13 Manual metering box .................................................................................. 17
3.4.14 Sight glasses .............................................................................................. 18
3.5 Noise data ................................................................................................................ 18
3.6 Dimensional sketches .............................................................................................. 19
3.6.1 Trough cross-section .................................................................................. 19
3.7 Machine data ........................................................................................................... 19
3.7.1 Characteristics ............................................................................................ 19
3.7.2 Environmental conditions ........................................................................... 19
3.7.3 Connection values ...................................................................................... 19
3.7.4 Weights....................................................................................................... 20
3.8 Planning information ................................................................................................ 20
BCHA
Chain Conveyor AHKG-67025-1-en1107
Table of contents 3
3.8.1 General information .................................................................................... 20
3.8.2 Fixing the chain conveyor...........................................................................21
3.8.3 Fixing the intake hopper ............................................................................. 22
3.8.4 Fitting inlets ................................................................................................ 23
3.8.5 Compressed air information ....................................................................... 23
3.8.6 Electrical information .................................................................................. 24
3.8.7 Note on control voltage .............................................................................. 26
3.8.8 Screw gear to outlet flap electric ................................................................ 26
3.8.9 Overview of functions ................................................................................. 26
4 Transport ............................................................................................................... 27

4.1 Packaging ................................................................................................................ 27
4.2 Degree of disassembly ............................................................................................ 27
4.3 Transport weights .................................................................................................... 27
4.4 Transport regulations ............................................................................................... 28
4.5 Handling with a crane .............................................................................................. 28
5 Installation ............................................................................................................. 29

5.1 General .................................................................................................................... 29
5.2 Installation ................................................................................................................ 29
5.3 Drive end, return ends and conveyor troughs ......................................................... 29
5.3.1 Sealing against dust and rain ..................................................................... 30
5.4 Installation and tensioning of the conveyor chain .................................................... 30
5.4.1 Installation of the conveyor chain ............................................................... 30
5.4.2 Closing and opening the chain connecting system ....................................31
5.4.3 Tensioning the conveyor chain .................................................................. 32
5.5 Outlet flaps and scraper tabs ................................................................................... 33
5.5.1 On site assembly of outlet flaps ................................................................. 33
5.5.2 On site assembly of scraper tab ................................................................. 33
5.6 Drives ....................................................................................................................... 34
5.6.1 Flat and bevel gear drives .......................................................................... 34
5.6.2 Installation .................................................................................................. 35
5.7 Electrical diagram .................................................................................................... 37
5.8 Electrical components.............................................................................................. 41
5.8.1 Proximity switch capacitive.........................................................................41
5.8.2 Position switch ............................................................................................ 42
5.8.3 Zero-speed detector ................................................................................... 42
5.9 Pneumatic components ........................................................................................... 43
5.9.1 Pneumatic diagram for the solenoid valve (impulse) .................................43
5.9.2 Connection diagram inductive magnetic switch .........................................44
6 Start-up.................................................................................................................. 45
6.1 Checklist for checking the EU conformity ................................................................ 45
6.2 Initial start-up ........................................................................................................... 45
6.3 Inspection before start-up ........................................................................................ 46
6.4 Adjustment ............................................................................................................... 46
6.5 Adjust switching distance of the proximity switches ................................................ 46
7 Operation............................................................................................................... 47
7.1 Controlling ................................................................................................................ 47
7.2 Operation ................................................................................................................. 47
7.3 Procedure in the event of faults (operation via service switch) ............................... 47
8 Maintenance .......................................................................................................... 49
BCHA
Chain Conveyor AHKG-67025-1-en-1107
4 Table of contents
8.1 Maintenance routine ................................................................................................ 49
8.2 Gearbox and drive inspection .................................................................................. 51
8.3 Lubricant table ......................................................................................................... 52
8.4 Maintenance of the flat and bevel gears..................................................................52
8.4.1 Troubleshooting for faults on the gearbox .................................................. 53
8.5 Cleaning ................................................................................................................... 54
8.6 Drive end ................................................................................................................. 54
8.6.1 Installation of new sprocket segments .......................................................54
8.7 Bearings at drive and return end ............................................................................. 56
8.8 Shaft seals at drive and return end ..........................................................................56
8.9 Conveyor trough ...................................................................................................... 56
8.10 Conveyor chain ........................................................................................................ 56
8.11 Disposal ................................................................................................................... 57
9 After-sales service ................................................................................................. 58

9.1 Spare parts .............................................................................................................. 58
BCHA
Table of contents 5
1 Important information
1.1 Foreword
f These operating instructions document the Chain conveyor AHKG.
f The operating instructions have to be handed over to those persons who are
responsible for the operation and the supervision of these devices.
f These operating instructions contain the information required for the user re-
garding installation, operation and maintenance.
f Description of activities that do not require any special knowledge have been
omitted.
f Repair instructions that exceed the normal maintenance work are not provided.
f The machine meets all acknowledged safety regulations. However, improper
use can involve physical danger for the user.
f Highest priority, therefore, has been given to safety.
1.2 Contact
f Address questions to the appropriate branch office or subsidiary of the manu-
facturer.
f Have the Operating instructions at hand.
1.2.1 Adress
Buhler (Changzhou) Machinery CO., LTD.

Add: Tianmu Lake Industrial Park, Liyang, Jiangsu
Tel: +86-(0)519-87966666
Fax: +86-(0)519-87966000
1.3 Typographical conventions
1.3.1 Explanation of the warning instructions
DANGER
Type and source of danger
Danger will result in death or serious injury.
f Actions for protecting against danger.
BCHA
Chapter 1 Important information 1
WARNING

Danger can result in death or serious injury.
CAUTION

Danger can result in injury.
NOTICE
Danger can result in property damage.
f Actions for protecting against property damage.
1.4 Important information

f Procedures upon receipt
Inspect the equipment visually in accordance with the delivery contract as
soon as it has been received.
f Storage
Equipment that is not installed immediately must be stored protected against
weather and other influences.
f Installation
The assembly and installation of the machine and machine equipment must
only be carried out by observing all installation instructions supplied.
f Design versions
If different designs are described in the documentation provided, only the in-
formation concerning the version supplied will apply. We reserve the right to
make modifications due to technical progress up to the time of delivery.
f Duty of instruction
Commissioning and maintenance must only be done by trained specialists.
Prior to the initial start-up the operating personnel must familiarize themselves
with the documentation provided.
BCHA
2 Chapter 1 Important information
2 Safety
2.1 Safety of persons

f Safety covers must always be installed and locked. Open or removed safety
covers are danger spots for crushing and cutting injuries.
f Always keep safety devices in good working condition. Safety devices must not
be bridged over or rendered inoperable.
f Maintenance work at the conveyor or parts thereof must only take place with
the installation at a standstill. It is absolutely essential that the installation is
switched off without exception and that the switch is locked!
f The Trough chain conveyor AHKG is to be fitted with an all-pole safety switch
and a service switch. It must also be possible to put the Trough chain conveyor
AHKG into operation via the service switch when the monitoring element is ac-
tivated. The service switch must be continually pressed by one person and a
second person has to monitor the Trough chain conveyor AHKG. Both persons
must be in verbal contact with each other.
f If the Trough chain conveyor AHKG has to be put into operation with covers
removed (e.g. floor, lid, outlet flap) two persons are required for safety reasons
to eliminate the fault. Before carrying out any repair work, it must be ensured
that the all-pole safety switch is switched off.
2.2 Connecting to the electrical mains

f Observe the regulations of the local safety authorities.
f The power supply has to be fuse-protected according to the local regulations.
f Check whether the operating voltage and frequency correspond to the specifi-
cations given on the nameplate and in the control cabinet.
f All electrical connections to the control systems must be made according to the
wiring diagram to ensure that the phase conductors are actually switched in the
case of single-phase power supplies.
2.3 Explosion protection
DANGER
Risk of explosion!
If according to the nameplate the machine is approved for use in zones with
potentially explosive atmospheres, it is imperative that hazard instructions
marked with the EX symbol are observed to maintain protection.
BCHA
Chapter 2 Safety 3
2.4 Safety concept
f The Trough chain conveyor AHKG is normally part of an installation and there-
fore integrated into the safety concept of the installation.
f If the Trough chain conveyor AHKG is not used within this safety concept, the
operating organisation must re-define the risk assessment on the hazards in-
volved and take suitable measures.
f The design and construction of the machine comply with the EU directives with
respect to safety and hygiene.
f The CE-marking can be attached and the EU declaration of conformity issued
after start-up and safety inspection.
BCHA
4 Chapter 2 Safety
3 Description
3.1 Designated use

f The Trough chain conveyors of the AHKG series are only designed for
conveying floury, dry fine-grained and coarse-grained products. The AHKG can
be used as a one and two-way conveyors with several inlets and outlets, for
horizontal and also for inclined conveying with an inclination of max. 15°. The
AHKG is also especially suitable for conveying untreated products.
f Any use beyond that described is considered contrary to its designated use.
DANGER
Risk of explosion!
In an area with a potentially explosive atmosphere, only operate the machine
with appropriate approval.
3.2 Identification
3.2.1 Nameplate
NOTICE
Do not remove or cover the nameplate!
3.2.2 Type code
AHKG - 100
AHKG - 200 - T1
AHKG - 200 - T1 - Ex
Explosion-proof machine identifier
Design versions of the conveyor chain (T1, T2, T3)
Capacity size (100 or 200)
(corresponds approx. to conveying capacity for wheat in
t/hr during continuous operation)
Chiffre
BCHA
Chapter 3 Description 5
3.3 Design
The Trough chain conveyor AHKG basically comprises:
Drive end, conveyor trough and return end
f Elements made of materials safe for foodstuffs.
f Bottom plates 5 mm, side plates 4 mm and cover plates 3 mm.
f Precise joints between the troughs.
f Completely enclosed and sealed.
f All moving elements are completely enclosed.
Fig. 3.1
(1) Drive end (5) Conveyor chain
(2) Drive unit (left or right) (6) Outlet
(3) Return end (7) Outlet flap
(4) Conveyor trough
3.4 Function
3.4.1 Drive end
f In the drive end (1), the conveyor chain is driven by the drive sprocket (2). The
drive shaft (3) is made of high-tensile strength steel and the bolted-on, multi-
element sprocket has wear-resistant, hardened tooth flanks.
f The drive shaft runs on flange bearings (4).
f A chain guide (6) allows smooth running of the conveyor chain onto the return
rail.
BCHA
6 Chapter 3 Description
f The drive
e, which can
n be mounted on either side, is ope
erated by me
eans of a
gear-box (7) mounted directly on
n the drive shaft with a shrink disc
c (8) and
torque arrm (9). The material
m flow
w is checked through the
e observation
n window
(10).A sensor (11) sig
gnals any pro
oduct build up
ps which ma
ay occur.
F 3.2
Fig.
(1
1) Drive end
d (7) Drive unit (flat or beve
el gear)
(2
2) Drive spro
ocket (8) Shrink dissc
(3
3) Drive sha
aft (9) Torque arm
a
(4
4) Flange be
earing (10) Inspection window
(5
5) Protection
n cap (11) Sensor for product b
build up
(6
6) Chain guiide top (12) Material derivation (option)
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
3.4.2 O
Outlet on the drive end
F 3.3
Fig.
a) Intermediate flange fo
(a or mounting (c) Ou
utlet for flouryy products
outlets on
n the drive end (d) Ou
utlet flap
(b
b) Outlet forr granular pro
oducts (e) Locking cover
f Outlets have connecttions for grav

vity spouts with
w a diame
eter of 200, 250,
2 300,
350, and square secttion 300, 350
0, 400 mm and fastening
g designs forr sleeves,
screw con
nnections or clamping rin
ngs.
f Either an intermediate
e flange (a), an outlet flap
p (d) or a loccking cover (e
e) can be
fitted to th
he drive end..
f The intermediate flan
nge (a) and the outlet fla
ap (d) can b
be combined
d with an
outlet (b) or (c).
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
3.4.3 Return end
f In the return end (1), the returning conveyor chain is reversed back in the
conveying direction via a bolt-on return sprocket (2).The return shaft (3) is
made of high-tensile strength steel and runs on flange bearings (4).
f A chain guide (6) enables a smooth transfer of the chain onto the sprocket.
f The return roller is mounted outside the housing on two clamping plates which
can be adjusted by means of spindles. These can be used to adjust the chain
sag required for smooth running at the drive end.
f The zero-speed detector (11) stops the conveyor when the return shaft is at a
standstill (e.g. chain breakage).
Fig.3.4
(1) Return end (5) Protection cap
(2) Return sprocket (6) Chain guide top
(3) Return shaft (8) Chain tensioner mechanism
(4) Flange bearing (11) Zero-speed detector
BCHA
3.4.4 C
Conveyor trou
ugh
A conveyor troughs (1) are constructed in leng

All gths of 3000//2400/1800/1200/600
m The conveyor trough
mm. h is complete
ely enclosed and ensuress dust-free operation.
o
T bottom plates
The p (3) are
e fitted with a toothed plate (2) at the joints, which
h ensures
sttep-free tran
nsitions betw
ween the trou
ughs. The tra
ansitions on the bottom plates
p (3)
and covers (4
4) are covere
ed with a cov
vering strip (5
5).
Fig. 3.5, 3.6,, 3.7 Trough

h joints
(1) Conve
eyor trough (4) Cover
(2) Toothe
ed plate (5) Cov
vering strip
(3) Bottom
m (6) Return rail
Fig. 3.8 One-way trough
F 3.9 Two--way drop tro

Fig. ough with me
etering inletss (drop trough
hs from 1200
0 mm)
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
3.4.5 In
ntermediate outlets
o on tro
oughs
F 3.10 Inte
Fig. ermediate ou
utlets on troug
ghs
(a
a) Intermediate flange fo
or mounting outlets
o on tro
oughs
(b
b) Outlet forr granular pro
oducts
(cc) Outlet for floury produ
ucts
(d
d) Outlet flap
p
f Outlets ha
ave type-dep
pendent connections for gravity spou
uts with a dia
ameter of
200, 250, 300, 350, or square section
s 00, 350, 400 mm and fastening
of 30
designs fo
or sleeves, screw
s connec
ctions or clam
mping rings.
f If outlets (b, c) are mounted
m ctly on the trrough, an intermediate flange
direc f (a)
must be fitted
f to guide
e the chain.
f Outlet flaps (d) can be
b mounted directly on the
t and outlets (b, c) can
trough a
also be mounted
m direcctly on the ou
utlet flap.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
3.4.6 T
Trough bendss upwards an
nd downward
ds
F 3.11,3.12
Fig. 2, 3.13
f The straig
ght conveyorr can be used
d up to a slope of 15°.
f For chan
nges in dire e conveyor, trough ben
ection in the nds can be installed
nwards (2) of 5°, 10° or 15°.
upwards (1) and down 1
f Trough bends
b are to
o be avoided e. Straight conveyors wo
d if possible ork more
efficientlyy.
3.4.7 Hopper-discharging trough

H
f Intermediate hopp
per-dischargin
ng trough
hs (3) with leng
gths of
3000/240
00/1800/1200
0/600 mm can
c be insta en the final hopper-
alled betwee
dischargin
ng trough (1)
( e hopper-disscharging trrough with metering
and the
element (2).
(
f The consstruction is designed
d in such a wayy that the re
eturn end (4
4) can be
mounted directly afterrwards.
f The returning chain iss completely enclosed. The product cconveyed is fed
f to the
lower con
nveyor chain from the side.
f Product removal
r from actly regulatted with the metering
m the hopper can be exa
e (5). Ensure that the two
slide gate o slide gates (5) are adjussted symmettrically.
f The feede
er should ge
enerally be operated
o as close as posssible to 100
0 % layer
height.
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
Fig. 3.14
F 3.15
Fig.
1) Final hopper-discharg
(1 ging trough
(2
2) Hopper-discharging trrough with metering
m elem
ment
(3
3) Intermediate hopper discharging
d trough
t
(4
4) Return en
nd
5) Metering slide gate
(5
(6
6) Fixing scrrew for metering slide gate
3.4.8 C
Conveyor cha
ain
C
Chain / longitudinal chain link
f The convveyor chain consists of drop-forged and case h
hardened lon
ngitudinal
chain linkks to which flights
f are we
elded. The case
c hardening of the lon
ngitudinal
chain linkks gives them
m high tensile
e strength an
nd resistance
e to wear. Th
he shape
and numb
ber of the flig
ghts vary acc
cording to use.
f The chain
n pins are alsso case hard
dened and eq
quipped with an effective
e coupling
system.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
f The convveyor chain is
i designed for long ope
eration and iss subject to stringent
ontrols at the manufacturiing plant.
quality co
T conveyorr chain consiists of the folllowing comp
The ponents:
F 3.16, 3.17
Fig. 7, 3.18
1) Longitudinal chain linkk
(1 (4) Longitudinal
L cchain link witth flight
(2
2) Chain con
nnection, pre
e-assembled (5) Link
L with plasstic scraper
(3
3) Locking ring
F 3.19
Fig. Fig. 3.20 Fig.3.21
T following design versions of the conveyor
The c cha
ain are used:
F 3.22 T1 over
Fig. o 5°15° Fig. 3.23
3 T2 or co
onveying ang
gles up to 5°°
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
F 3.24 T3 for
Fig. f conveying horizontally Fig. 3.2
25 T1 ... T3
3 with plastic
c scraper
for tran
nsfer return w
with closed end
e outlet
and cle
eaning the bo
ottom
3.4.9 C
Chain connecction
f Locking ring-type pinss are used fo

or the chain connection.
c
f The chain
n pin is case
e hardened and
a can with eme stress. If a chain
hstand extre
pin is rem
moved and can
c still be us
sed, a new connecting
c e
element (lock
king ring)
must be used.
u
f The connecting eleme
ent removed is net to be re-used.
nnection system consists
T chain con
The s of:
Fig. 3.26
(1
1) Locking ring-type pin, pre-assemb
bled with a lo
ocking ring
2) Locking ring
(2
3.4.10 C
Construction of the conve
eyor chain
f The chain
n is made up
p of 2,036-m long sections.
ecessary to shorten the
f If it is ne e chain afte
er a long pe
eriod of ope
eration, a
longitudin
nal chain linkk or chain link
k can simply be removed.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
3.4.11 O
Outlet flap
f Flap consstruction in ve
ery compactt, sealed design.
dard drive iss pneumatic (1). Design
f The stand ns with manu
ual (2) or electric (3)
drive are also available. All outlet flaps are fitte
ed with posittion switches
s for open
and close
ed state.
f With flapss closed (4), the bottom of h is absolutely level and open (5),
o the trough
the flap empties comp
pletely withou
ut residue.
f The outle
et flap can be
e fitted at an he bottom off the conveyor trough
ny point on th
and also on
o the drive end.
f For produ
ucts that are
e not free flowing,
f a sttripper cloth can be installed for
efficient emptying.
e W
When the flap
p closes, the
e cloth is lifte
ed up by the
e product
(see section 4.6.2).
F 3.27
Fig.
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
3.4.12 M
Metering hood
d for granula
ar products
Inlet /Hoper
Co
onv. direction
n
F 3.28
Fig.
ering hood (1) can dispen
f The mete nse the incom
ming productt between 36
6 and 95 %
(Z). It is im
mportant for the metering
g plate is mo
ounted as clo
ose as possib
ble to the
inlet.
f The inlet curves (3) prevent the conveyor vanes
v from g
getting caug
ght in the
feeder.
f After succcessful adju
ustment, it is al the slots (4) with
i recommended to sea
sealing co
ompound.
3.4.13 M
Manual meterring box
Inlet /H
Hoper
Conv. direcction
F 3.29
Fig.
f Manual metering
m box for fluidising
g products wh
hich are supp
plied continu
ually.
f The mete
ering box (1)) has basica
ally the same function a
as the meterring hood
under 2.2
2.12.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
f However,, the length of
o the meterin
ng box (3) iss required if fluidising prod
ducts are
to be mettered.
f The mete 5 and 100 % (Y).
ering range iss between 25
f The mete
ering box musst be directly
y mounted on
n the inlet.
f The feede
ers should generally be operated
o as close as possible to 100
0 % layer
height.
3.4.14 S
Sight glassess
gh chain conveyor is fittted as standard with siight glasses on both

f The troug
sides in frront of bottom
m and interm
mediate botto
om outlets forr visual inspe
ection.
f The follow
wing special designs are available ass options:
▷ ht glass with capacitive proximity
Sigh p swittch (product indicator).
▷ Sigh
ht glass for on
o site mountting for checcking addition
nal outlets.
Inlet /Hoperr
Conv. direction
F 3.30
Fig.
(a
a) Standard sight glass on
o both sides
s
(b
b) Sight glasss with capaccitive proxim
mity switch, op
ption
(cc) Sight glasss for on site mounting, option
o for spe
ecial purpose
es
3.5 N
Noise data
f The noise
e levels liste
ed below are
e measured values
v of an
n existing pla
ant. They
may vary according to
o environmen
ntal condition
ns..
Measurin
ng method/va
alues:
f Measuring point 1 m away from
m the greate
est source o
of noise, und
der worst
conditionss (empty con
nveyor):
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
Conveyo
or chain spee
ed v = 0.6 m/s ... Leq
L = 72 dB (A)
L = 75 dB (A)
v = 0.8 m/s ... Leq
3.6 D
Dimensiona
al sketchess
3.6.1 T
Trough cross--section
F 3.31 One
Fig. e-way trough
h Fig, 3.3
32 Two-wayy trough
Mach. model
m A B C D E F
AHKG- 100 3 15 4 33 2 75 3 75 6 10 39
90
AHKG- 200 4 00 5 00 3 60 4 60 78
80 47
75
3.7 M
Machine da
ata
3.7.1 C
Characteristic
cs
f Machine designation:
d Trough cha
ain conveyorr
f Chiffre: AHKG
f Machine model: 100/200
f Chain mo
odel: T1, T2, T3
f Chain spe
eed: with bulk ma
aterial accordiing to Buhler ddesign max.1.2 m/s
3.7.2 E
Environmenta
al conditions
T
Temperature range: -20 ℃ ... +80
+ ℃
3.7.3 C
Connection va
alues
T connectio
The on values are
e customer and
a country-sspecific.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
3.7.4 Weights
f Empty weight: one-way trough or two-way trough, conveyor chain, but

without outlet flap
f Operating weight: empty weight, bulk material with 750 kg/m3, filling level 95%
f Drive with gearmotor: Drive shaft, torque arm, largest possible gearmotor
Weights, one-way trough
Empty weight Operating weight

Drive with
One-way trough one-way trough
gearmotor
[kg per running [kg per running
[kg per piece]
metre] metre]
AHKG - 100 92 153 320
AHKG - 200 102 204 520
Weights, two-way trough
Empty weight Operating weight

Drive with
Two-way trough Two-way trough
gearmotor
[kg per running [kg per running
[kg per piece]
metre] metre]
AHKG - 100 108 230 320
AHKG - 200 120 324 520
Weights, outlet flaps and outlets
Empty weight Empty weight Empty weight

Outlet flap Outlet 35 ° Outlet 55 °
[kg per piece] [kg per piece] [kg per piece]
AHKG - 100 50 30 40
AHKG - 200 55 30 40
3.8 Planning information
3.8.1 General information
f Build conveyor in straight design if possible, avoid trough bends.

f The end outlet on the drive end should be open if possible.
f For conveyors which are regularly started under full load, an electric soft-start
is recommended as a start-up aid.
BCHA
3.8.2 F
Fixing the cha
ain conveyorr
f The drive
e end has fou
ur holes on the
t front D 18
1 mm (M16) for models
s 100 and
200. Thesse are used to nveyor firmly to the base support (1).
t fix the con
Horizonta
al force:
The fixtu
ure of the drive end mus
st be able to
o withstand a horizontal force the
magnitud
de of half the
e chain tensio
on.
f Angle-adjjustable fasttening device
es (2) are available
a for further susp
pension /
support, which can be
b inserted every 300 mm
m for each cover hole
e. These
elements enable unob
bstructed dis
sassembly an
nd assemblyy of cover an
nd bottom
plates.
f R 1 1/4”--pipes are used
u as susp
pension or support
s elem
ments (wall thickness
t
3.25 mm
m) (3), thesse are clos
sed at the end with a plastic cap.
c The
recomme
ended design
n of the supp
ports (4) enssures the necessary stab
bility and,
under no
ormal tempe
erature conditions, flexib
bility of the trough in conveying
c
direction.
f Max. dista
ance betwee
en the supports = 6 m
f With verry heavy drives, an additional
a su
upport (5) for the ge
earbox is
recomme
ended.
f The faste
ening elemen
nt (2) with th
he plastic ca
aps for the p
pipes are pa
art of the
scope of delivery
d of th
he machine.
The susspension and
d support elements
e (1, 3, 4, 5) d
depend on assembly
a
ns and must be procured separately and
condition a finished on site.
Su
uspension
Max. 6m
m
O
O-pt. line Su
upport
Fig
g. 3.33
F 3.34
Fig.
BCHA
Chain Conveyo
or AHKG-670255-1-en-1107
3.8.3 F
Fixing the inta
ake hopper
f So that no foreign ma
atter can gett into the inta
ake hopper, the intake should
s be
fitted with
h a suitable grid.
g
f Manufacturer's recom
mmended des
signs for fixin er-discharging trough.
ng the hoppe
f Alternativve 1: With prre-fabricated
d, concrete-e
encased stee
el frame (ste
eel frame
must fit ho
opper exactly, l).
Fig. 3.35
(1) Framee rifling exacttly to hopper--

disch
harging troug gh
(2) Angle section 80x8 80 mm
(3) Welded-on concrette anchor
(4) Welded-on cap nutt
Fig. 3.36
Altternative 2:
(1)) Concrete-e
encased bolt
or thread
ded rod
(2)) Clamp
F
Fig. 3.37
BCHA
or AHKG-67025-1-en-1107
Chain Conveyo
3.8.4 Fitting inlets
When fitting inlets (1) locally, it is recommended to cut out a corresponding piece of
the cover (2) and fit with the standard covering strips (3) (see Fig. 2.38). This
enables easier access to function controls during operation without having to
dismantle the gravity spout.
Fig. 3.38
3.8.5 Compressed air information
Compressed air quality

f Air connection: D 8/6 mm compressed air hose
f Air pressure: 5 .. 10 bar
f Air quality: Filtered, dust-free, oil-free and water-free according to
regulation 《PNEUROP 6611, quality class 3/3/4》
Outlet flap
Air volume Pressure Pressure
Connection
Size [standard litres (network) (flap)
[mm]
Per stroke mov.] [bar] [bar]
AHKG - 100 3.5 4...6 6 D 8/6
AHKG - 200 3.5 4...6 6 D 8/6
BCHA
3.8.6 Electrical information
Sensor for product build up in the drive end

Designation AHKG -100/ -200 (24 V DC)
Element Proximity switch capacitive

Type KIE 3015-FPKG
Voltage 10...55 V DC
Enclosure IP65
Manufacture IFM
Norm no. UNE-26350-001
Product retention
Function:
Drive shuts down in max. 2 s.
With operation via service switch, interlock is no longer
active.
Zero-speed detector in the return end

Designation AHKG -100/-200 (24 V DC)
Element Zero-speed detector
Type DI 503A
Enclosure IP67
Manufacture IFM
Norm no. UXE-36011-012
Function: Conveyor chain standstill
Drive shuts down in max. 2 s.
With integrated start-up override for 5 s.
With operation via service switch,
interlock is no longer active.
Product indicator
Element Proximity switch capacitive
Type KIE 3015-FPKG

Enclosure IP65
Manufacture IFM
Standard no. UNE-26350-001
BCHA
Outlet flap pneumatic
Magnet coil Magnet coil Solenoid valve
Element
(flap open) (flap closed) (impulse)
Type TM 1502 U TM 1502 U SXE 0573-160-00B
Voltage 24 V DC 24 V DC -
Enclosure IP65 IP65 -
Manufacture IMI Norgren IMI Norgren IMI Norgren
Norm no. UNS-16072-413 UNS-16072-413 UNS-16081-084
Magnetic switch Magnetic switch

Element
(flap open) (flap closed)
Type QM/134/5 QM/134/5
Voltage 10...30 V DC 10...30 V DC
Enclosure IP66 IP66
Manufacture IMI Norgren IMI Norgren
Norm no. UXE-26300-039 UXE-26300-039
Outlet flap manual

Position switch Position switch

Element
Type 3SE3 120-1GW 3SE3 120-1GW

Voltage 5 mA/24 V DC 5 mA/24 V DC
Enclosure IP67 IP67
Manufacture Siemens Siemens
Norm no, UNE-26001-121 UNE-26001-121
Outlet flap electric

Position switch / transmitter for sense of rotation-change of the flap drive.
Designation AHKA-50/-100/-200 (24 V DC)
Position switch Position switch
Element
Type 3SE3 120-1GW 3SE3 120-1GW
Voltage 5 mA/24 V DC 5 mA/24 V DC
Enclosure IP67 IP67
Manufacture Siemens Siemens
Norm no, UNE-26001-121 UNE-26001-121
BCHA
3.8.7 Note on control voltage
f All elements are exclusively designed for a control voltage of 24 V DC.

f In the case of a control voltage of 120/230 V 50 Hz the power supply UXE-
80204-006 can be used to maintain 24 V DC.
3.8.8 Screw gear to outlet flap electric
Designation AHKG-100/-200
kW 0,12 0,12
r/min 50 Hz 6,9 -
r/min 60 Hz - 8,3
Type Gearmotor GM Gearmotor GM
Structure size SCAZ 63 AF71/8B-7 SCAZ 63 AF71/8B-7
Construction type H01 H01
Enclosure IP55 IP55
Norm no. UXM-17016-271 UXM-17016-272
Manufacture Flender Flender
Designation AHKG-100/-200
kW 0,12 0,12
r/min 50 Hz 5.5 -
r/min 60 Hz - 8,3
Type Gearmotor GM Gearmotor GM
Structure size SK1 S1 63/H10-IEC/3D SK1 S1 63/H10-IEC/3D
Construction type H01 H01
Enclosure IP55 IP55
Norm no. UXM-17243-271 UXM-17243-272
Manufacture Nord Nord
3.8.9 Overview of functions
Designation See chapter
Compressed air information 2.8.5, p. 2-20

Sensor for product backup 2.8.6, p. 2-21
Zero-speed detector 2.8.6, p. 2-21
Product indicator 2.8.6, p. 2-21
Limit switch outlet flap pneumatic 2.8.6, p. 2-22
Limit switch outlet flap manually activated 2.8.6, p. 2-22
Limit switch outlet flap electric 2.8.6, p. 2-22
BCHA
4 Transport
f Transport may only be carried out by persons familiar with and specially
trained for this task.
f Freezing represents a bursting hazard for motors, gearboxes, pressure lines
and fixtures.
f Observe prescribed transport position of components. Transport in other
positions is prohibited. The machine has to be taken apart.
f Lifting gear must be checked for required design and permissible load.
f Provide appropriate securing devices according to type and duration of
transport.
f Components must be protected against large temperature fluctuations during
transport, as otherwise condensation is formed under the packaging. Avoid
knocking the components.
4.1 Packaging
The Trough chain conveyor AHKG is packed in crates and dispatched in individual
parts or as pre-assembled subassemblies.
4.2 Degree of disassembly

f The degree of disassembly of the components generally depends on the
transport conditions, local conditions and the lifting gear available. However,
the technically permitted degree of disassembly of the components must be
observed. Transport in other positions or unauthorised disassembly are
prohibited.
f It should be endeavoured to transport the components as complete as possible.
f However, if certain components are to be delivered disassembled, the order-
related degree of disassembly is to be agreed with B0hler AG, Uzwil,
Switzerland.
4.3 Transport weights

The weights in the shipping documents are to be observed
((for approximate recommended values, see section 3. 7.4 《Weights》).
BCHA
Chapter 4 Transport 27
4.4 Transport regulations
f A crane can be used for unloading and transporting.
f To be able to lift the components safely with the crane, ropes appropriate to
the load are to be used.
f Select the rope length so that the components hang as horizontally as possible
on the crane.
DANGER
Never walk under suspended loads.
CAUTION
Check the lifting gear for required design and permissible load.
4.5 Handling with a crane

To lift the conveyor with ropes, use spacer (1) to avoid pressure on the conveyor
trough.
Fig. 4.1
BCHA
28 Chapter 4 Transport
5 Installation
5.1 General
f Before installation, check drive end, return ends and conveyor troughs for
deformation. In particular, check the trough flanges and the running surfaces
for the conveyor chain at the joints. Any alignment work must be carried out
before assembly.
f Sealing: use of sealing material between connection points is not
recommended, as the accuracy of the connection decreases and plates are
bent.
f For the trough joints, the gaps on the floor and on the cover are sealed with
adhesive tape or plastic sealant before the covering strip is fitted.
f For the flange connection, only a little grease is recommended for protection
against dust. After complete assembly, leaky points are to be treated with
plastic sealant.
f When installing outside, it is important that the joints on the covers are sealed
well so that no rain water can enter. For this, plastic sealants or closed-pore
sealing strips are suitable.
f Customer's cut-outs for inlet/outlet nozzles must be made according to the
factory drawing (see section 3.8.4).
5.2 Installation
Before installation, the individual elements are to be identified according to the
assembly plan and provided for installation in the exact prescribed order.
DANGER
Inlets and outlets must be arranged in such a way that it is not possible to reach
into the product area or danger area.
5.3 Drive end, return ends and conveyor troughs

f As first element, the drive station must be fixed firmly onto the support provided
for this purpose. The entire trough chain conveyor must be precisely aligned.
f The conveyor troughs and the return ends can be fixed at maximum distances
of 6 m from the drive station.
f For suspension, support and fixing of the chain conveyor and of the inlet
hoppers, see planning information (see section 2).
BCHA
Chapter 5 Installation 29
f A last che
eck of the op
pen conveyor troughs is essential
e beffore the drive
e chain is
mounted and the cove
ers are close
ed in order to
o check align
ned joints and
d remove
solid obje
ects.
NOTICE
Trough jointss, transitionss:
olting together, all trough
f When bo h joints must be adjusted such that they are
absolute
ely flush in th
he product arrea (no dama
age to the bu
ulk material).
f For this purpose, use
e a tensioned steel wire or
o measure w
with theodoliite.
CAUT
TION
If assembly is not perform

med exactly,, the bottom and side wa
alls at the con
nnection
points 《A》, are subjecct to excessiv
ve wear (see
e Fig. 4. I).
f The interiior clearance

e dimension of the trough
hs must be u
uniform along the en-
tire length
h.
5.3.1 S
Sealing again
nst dust and rain
P
Place sealing strips underr the covers and cover plates of the e
ends and trou
ughs.
5.4 In
nstallation and tensio
oning of the
e conveyor chain
5.4.1 In
nstallation off the conveyo
or chain
Return end
d Drive
e end
F 5.1
Fig.
1. Switch offf master switch and secure.
2. Remove covers (1 an
nd 2) of the drive
d end and
d return end..
3. Loosen clamping
c scrrews (4). Using the spind
dles (5) movve the return sprocket
fully in th
he direction of
o the drive end.
e
4. hain through the opening
Pull the conveyor ch g (3) into the
e conveyor such
s that
the direcction arrow on chain lin
nks matchess the conveyyor direction
n. Ropes,
winches or gripping hoists
h are suitable for pullling in the ch
hain.
NOTICE
In circumsta
ance the drive
e to pull in th
he chain.
5. Shorten the conveyo

or chain by re
emoving chain links such
h that it is the
e shortest
length that can be joined using a chain pin.
BCHA
Chain Conveyoor AHKG-67025-1-en-1107
30 Chapter 5 Insstallation
5.4.2 C
Closing and opening
o the chain
c connec
cting system
Chain conn
nection syste
em
Ma
ax. 0.5mm
F 5.4
Fig.
f Slide the locking ring (1) axially onto
o the lockking ring-type
e pin (2) untiil it slides
into the groove, then push from th
he opposite side
s of the re
ecess (gap) firmly
f into
the groovve.
f Fit the pin
ncers (3) at the ers can also be used)
t points prrovided (water pump plie
and presss the locking ring (1) toge
ether so that the gap is a maximum of
o 0.5 mm
when the locking ring (1) is installe
ed.
f Check to be sure thatt the locking ring (1) sits properly and is pressed
d an even
circle. If not,
n replace with
w a new lo
ocking ring (1
1).
CAUT
TION
The locking ring (1) can be used only once. Whenever it is removed, it must
m be
replaced with a new one
e.
f If a lockin
ng ring (1) must
m be repla
aced, open itt at the slit w
with a chisel and lift it
out of the
e groove on the pin.
BCHA
Chain Conveyo
or AHKG-67025 5-1-en-1107
5.4.3 T
Tensioning th
he conveyor chain
c
Fig. 5.5 Retturn end
2-3 cm ch
hain sag
F 5.6 Drive
Fig. e end
1. Tension the conveyo
or chain using spindles (5
5) until the cchain sag in the drive
end is 2--3 cm. The end link sha n be exactly perpendicular to the
aft must then
conveyorr chain running direction (dimension X the same
e on both sid
des of the
return en
nd).
2. Tighten clamping
c scrrews (4).
3. Fit coverrs (1,2 and 3)).
CAUT
TION
Check the chain

c sag periodically after the run-in
n of the convveyor chain and
a dur-
ing operation
n and readju
ust if necessa
ary.
BCHA
5.5 O
Outlet flapss and scrap
per tabs
5.5.1 O site assem

On mbly of outlett flaps
1. Fix outlet flap.
2. C
Cut hole in
n bottom
plate for outle
et flap.
F 5.8
Fig.
3. Weld alig
gnment plate
es (1) into the three cut-o
outs (2) provvided for this
s purpose
and drill fixing
f holes (3).
(
4. Replace cut plastic ra anganese rails.
ails left/right of the outlet flap with ma
5.5.2 O site assem

On mbly of scrap
per tab
F 5.9
Fig.
5 mm (1) with distances X and Y in cconveying dirrection of
f Drill holess with D 10.5
the lower product line.
BCHA
Chain Conveyo
or AHKG-67025 5-1-en-1107
f Mount scraper tab. Fiix screws (2)) according to
t Fig. 4.10 so that the cloth
c is in
the middle
e of the troug
gh and turns
s absolutely freely.
f
F 5.10
Fig.
Machine
e model AH KG - 100 A
AHKG - 200
0
X 220 220
Y 272 357
NOTICE
The scraperr tab must no
ot be used in reverse mod
de.
5.6 D
Drives
F drives de
For elivered disasssembled, as
ssembly musst be carried
d out according to the
m
manufacturer
r's instruction
ns.
5.6.1 F and beve

Flat el gear drivess
P
Preparation
f The information on th
he nameplate of the drivve must corrrespond to th
he mains
supply.
osive must be thorough
f Anti-corro hly removed from outpu
ut shafts an
nd flange
surfaces (use comme
ercially available solven
nt). Do not le
et solvent come
c into
contact with
w the sealin
ng lips of the
e shaft sealing rings (mate
erial damage
e)!
BCHA
f Before operation, the
e screw plu
ug must be replaced w
with the ventt plug or
ventilating
g valve supp crew plug iss marked witth a plastic plug and
plied! The sc
can be pa
ainted over.
f Only use the prescribe
ed materials for assemblly.
5.6.2 In
nstallation
A
Assembly is carried
c out ass follows:
1. Check drive shaft fo
or deformatio ntations. If prresent, they must be
ons or inden
carefully evened out.
2. Determin
ne position of
o drive sha g to factory drawing an
aft according nd mount
torque arm
a in correcct position on
o gearbox flange.
f Checck that the tightening
t
screws are
a tightened fully.
3. Carefullyy degrease hollow shaft bore
b hole and
d drive shaft (Fig. 4.1 la)..
4. Push gea
arbox onto shaft
s and alig
gn, observing
g plane para
allel outer rin
ngs of the
shrink dissc (2) (Fig. 4.1
4 lb).
F 5.11a
Fig. Fig. 5.11b
5. Insert torrque arm (4)) in fastening
g plate. Whe
en tightening the fastenin
ng plates,
move the
e plates (3) with
w a mandrrel inserted in
n the hole (5) such that th
he torque
arm (4) iss free of playy (Fig. 12)
F 5.12
Fig.
6. Tighten tension scrrews (M...) by several turns one after the otther (not
crosswise). Tightenin
ng torques (M
Ma = .... Nm
m) (Fig. 4.13)).
BCHA
Chain Conveyo
or AHKG-67025 5-1-en-1107
F 5.13
Fig.
B olts M6 M8 M
M10 M12 M14 M1 6 M20
T ightening to
orques
M a [Nm] 2
12 29 58 100 160 24 0 470
（ tensile stre
ength class 10.9）
CAUT
TION
The protectio
on hood musst then be mounted again
n.
NOTICE
Do not twist torque supp
port (4) when mounting!
Drive side 《right》
Drive side 《left》
F 5.14 View
Fig. w from the to
op
( Drive uniit
(1) (3) Fas
stening plate
e
(2
2) Shrink dissc (4) Torrque arm
BCHA
5.7 Electrical diagram
The electrical connection must be made according to the following electrical
diagram:
Fig. 5.15
BCHA
Fig. 5.16
BCHA
38 Chapter 5 Installation
Fig. 5.17
Fig. 5.18
BCHA
Fig. 5.19
BCHA
5.8 Electrical components
5.8.1 Proximity switch capacitive
f Nominal switching 15 mm
distance Sn:
f Actual switching 3...15 mm
distance Sr:
f Connection: Terminals max. 2.5 mm2
f Display: LED
f Sensitivity: Adjustable with built-in potentiometer
f Function: With bridge in terminal connection room =
normally open contact
Without bridge (bridge severed) =
normally closed contact1
f Enclosure: IP65
Fig. 5.20
f Design Three-wire direct voltage

f Operating voltage: 10...55 V DC incl. residual ripple
f Power consumption: < 5 mA at 24 V DC
f Load: max. 250 mA
f Output: pnp, sustained short-circuit-proof,
programmable function
BCHA
5.8.2 Position switch
Fig. 5.21
f The switch can be operated from the left or right. The switching direction can
be set to switching left or right.
5.8.3 Zero-speed detector
f Connection: Cable socket according to DIN 34650

f Display: LED yellow = sensor attenuated,
LED green = output conn. through
f Operating voltage: 10...36 V DC
f Current: < 3 mA at 24 V DC
Consumption:
f Output: pnp, short-circuit proof, clocked
f Load: max. 250 mA
f Enclosure: IP67
Fig. 5.22
f The distance between the switch lug (2) on the end of the shaft and the
proximity switch (1) is to be adjusted on assembly and must be 5...8 mm.
f The proximity switch must not touch the switch lug (2).
f Set switch-point to operating speed by means of 《Move reference》.
BCHA
F 5.23
Fig.
5.9 P
Pneumatic componen
nts
5.9.1 P
Pneumatic dia
agram for the
e solenoid va
alve (impulse
e)
Air supply
F 5.24
Fig.
M
Magnet coil 12
2 and 14
Voltage Power
P consumption
Pick-up
P Opera
ation
24
4 V DC
2,1W 2,1W
Protection typ
pe: IP65 (when connecte
ed)
In
nsulation classs: F
BCHA
Chain Conveyo
or AHKG-67025 5-1-en-1107
5.9.2 Connection diagram inductive magnetic switch
The feedback of the flap and gate position is made via the end position of the
pneumatic cylinder.
Fig. 5.25
f Operating voltage: 10...30 VDC
f Overvoltage resistance: 55 V / 1.3 ms
f Display: LED red
f Power consumption: < 15 mA
f Load: max. 200 mA
f Breaking capacity: max. 6 W
f Protection type: IP66
f Cable length: 5m
BCHA
6 Start-up
Only have the machine started up initially, the test run performed and adjustments
made by appropriately trained and authorised personnel.
6.1 Checklist for checking the EU conformity

The following points must be checked before starting up the machine:
1. The operating organisation is informed that the operating instructions must
always be accessible for personnel and that the operating organisation is
responsible for the instruction of the personnel.
2. Assembly and installation have been carried out according to the operating
instructions.
3. If there is an overflow relief gate, it is secured with a positive action limit switch.
The drive shuts down as soon as the switch is activated.
4. The chain cover is mounted and the chain is not accessible by hand.
5. With accessible product inlets, an Emergency Stop button is installed and the
conveyor shuts down immediately when this Emergency Stop button is
actuated.
The danger area must also be secured according to the assembly diagram.
6. An all-pole isolating service switch is fitted and the operating or maintenance
personnel is in possession of a lock.
7. A warning sign UNN-52002 is fitted in a clearly visible place on the drive
station of the machine.
8. The machine cannot be put into operation when the service switch is set to
《0》.
9. The warning sign is fitted on all inspection covers.
10. Earthing has been performed correctly.
6.2 Initial start-up
CAUTION
It is prohibited to disable safety devices in order to continue using the machine

despite a fault.
BCHA
Chapter 6 Start-up 45
6.3 Inspection before start-up
The inspection before start-up is carried out by specialist Buhler personnel.
1. Check whether deformations are present.
2. Check conveyor chain tension and correct if necessary.
3. Check oil level on gearbox (see lubrication schedule section 7.2).
6.4 Adjustment
1. With the conveyor chain is running, check whether the chain is running in the
middle of the conveyor trough and return rail.
2. Ensure that the conveyor chain does not rub against protruding corners or
teeth.
3. Adjust safety and monitoring elements.
6.5 Adjust switching distance of the proximity switches

Adjust triggering switching distance of the proximity switches with potentiometer on
corresponding proximity switch in installed position.
BCHA
46 Chapter 6 Start-up
7 Operation
7.1 Controlling
► The AHKG is operated interlinked with other conveyors. Control is central.
There are no control elements fitted to the AHKG.
► Operation is restricted to checking for correct running and monitoring the
product feed and product removal. No product build up is allowed to occur
which might prevent correct function of the AHKG.
► If a product build up is detected, ensure immediate remedy in order to prevent
machine damage.
► If a plant has to be shut down with an emergency stop, the AHKG should be
emptied as soon as possible by operating it for a short time.
7.2 Operation
► The conveying properties of almost all products are altered by humidity
(product and also air humidity), temperature, granulation, etc.
► For this reason, take precautions so that these changes remain within limits
during conveying.
► Before being shut down, the AHKG should be emptied whenever possible.
► Product which remains in the trough can become consolidated as a result of
vibrations from nearby machines and plants or from railway lines and streets.
► Start-up the plant again is thus prevented or only possible under difficult
conditions.
► First remove consolidated, hardened or encrusted product manually before
putting the AHKG in operation again.
7.3 Procedure in the event of faults (operation via service switch)

► Maintenance work on the conveyor or parts thereof must only take place with
the installation at a standstill. It is absolutely essential that the installation is
switched off without exception and that the switch is locked!
► The AHKG is to be fitted with an all-pole safety switch and a service switch. It
must also be possible to put the AHKG into operation via the service switch
when the monitoring element is activated. The service switch must be
continually pressed by one person and a second person has to monitor the
Trough chain conveyor AHKG. Both persons must be in verbal contact with
each other.
BCHA
Chapter 7 Operation 47
► If the AHKG has to be put into operation with covers removed (e.g., bottom, lid,
outlet flap), two persons are required for safety reasons to eliminate the fault.
Before carrying out any repair work, it must be ensured that the all-pole safety
switch is switched off.
DANGER
f The trough chain conveyor may only be put into operation when all protec-
tive covers or openings are closed.
f Exception: operation via service switch
BCHA
48 Chapter 7 Operation
8 Maintenance
The maintenance of the machine is only allowed to be performed by appropriately

trained and authorised personnel.
DANGER
f For all inspection work which requires the machine to be shut down for
safety reasons, always switch off the control mains switch and remove the
key and switch off and lock all master switches.
f Also disconnect external power supplies (e.g. from plant control)!
NOTICE
Always remove dust, dirt or product deposits. Cleanliness on the trough chain
conveyor and observation of the maintenance intervals increase the reliability
and smooth running of the machine.
8.1 Maintenance routine

► Good maintenance increases reliability and helps to prevent accidents.
► All plant parts should be inspected regularly, if only visually and acoustically.
This aids early detection of any faults and causes of failures. It also enables
procurement of spare parts in time and helps to reduce the number and length
of downtimes. Consequential damage can also be largely avoided.
► The following maintenance routine is intended to help you to detect at an early
stage any faults which may occur, and to eliminate these without
consequential damage:
Plant part Measure Comment Interval
Sprocket in Sprocket in drive end must be every 3 months

drive end centred and secured.
Drive shaft must be mounted every 3 months
perpendicular to the AHKG running
direction.
If the tooth flanks are worn away every 3 months
more than 3 mm or if the conveyor
chain does not run off of these
properly, replace the sprocket or in
the case of mult-element sprockets,
the sprocket segments.
Drive and return Bearing screwed together and monthly
end lubricated properly.
BCHA
Chapter 8 Maintenance 49
Check bearing for impermissible monthly

knocking noises.
Bearing normal temperature. monthly
Bearing seals in order, i.e. no loss monthly
of lubricant.
For pillow blocks, remove old annually
grease from the bearing, clean and
refill with fresh grease.
Sprocket cleaner Play to sprocket base circle 0,5 ... 3 every 3 months
in mm
drive end Must brush against the sides of the every 3 months
sprocket segments.
Replace worn-out sprocket every 3 months
cleaners,
Return sprocket in Set perpendicular to conveying Section 4 every 3 months
return end direction.
Centred and secured correctly. every 3 months
Replace chain guide if extremely every 3 months
worn.
Conveyor trough: A certain amount of wear is every 3 months
- Bottom/side walls permissible if operation can be
- Return rail guaranteed until the next inspection.
Conveyor chain A certain amount of wear is every 3 months
permissible if safe, uninterrupted
operation can be guaranteed until
the next inspection.
All cross-bars straight and all chain every 3 months
connections closed properly.
Motor, gearbox, Check lubricant; monthly
fluid clutch
Replace lubricant; See manufacturer's information
No leaks as at shaft seals and monthly
gearbox flange and no loss of
lubricant;
No impermissible noises; normal monthly
gearbox temperatures;
Clean dust deposits from electric monthly
motor.
Gearboxes Check oil temperature daily
Check for any changes in gearbox daily
sound
Check oil level monthly
Check gearbox for leaks monthly
First oil change after start-up after approx. 10000
hours
at the latest after 3
years
BCHA
50 Chapter 8 Maintenance
Subsequent oil changes every3 years or

10000 hours
Re-grease roller bearings annually or
every4000
hours
Clean vent plug every 3 months
Clean drive according to
degree of
soiling
Check fastening bolts for tightness at least once a
year
Conduct complete inspection of at least once a
drive year
AHKG general Conveyor trough free throughout, after each service

no foreign bodies or tools in
conveyor trough
All covers closed, sealed and after each service
secured
All inspection openings closed and after each service
secured
Electrical control Functional inspection of electrical annually (if not
control, incl. emergency stop and otherwise
check of feedback signal to control prescribed by law)
centre Check adjustment of motor
protection General check of all
electrical connections and threaded
fittings as well as isolation check
8.2 Gearbox and drive inspection

Gearboxes Check fastening bolts for tightness at least once a year
Conduct complete inspection of drive at least once a year
BCHA
8.3 Lubricant table
The oil viscosity given on the rating plate of the gearbox (ISO VG class)
determines the oil to be used. The stated viscosity class applies to the
contractually agreed operating conditions..
8.4 Maintenance of the flat and bevel gears

Only change oil when gearbox is at operating temperature, as excessive viscosity
due to cold oil makes correct draining difficult.
DANGER
f The surface of the gearbox must be warm to the touch only.
f Danger of burns due to hot oil.
1. Place container under oil drain plug.

2. Remove oil level check plug, ventilation plug/valve and oil drain plug.
3. Drain oil completely.
4. Screw in oil drain plug.
5. Pour in new oil via ventilation bore hole.
Check amount at oil level check plug.
6. Screw in oil level check plug.
7. Screw in ventilation plug/valve.
BCHA
8.4.1 Troubleshooting for faults on the gearbox
Fault Cause Remedy
Unusual, even running a) Rolling/grinding noise: 1. Check oil

noises bearing damage 2. Call customer service
b) Knocking noise:
irregularity in gearing
Unusual, uneven running Foreign bodies in oil 1. Check oil
noises 2. Shut down drive, call
customer service
Oil leaking a) Seal defective If a) call customer service
- from motor flange b) Gearbox not be bled If b) bleed gearbox
- from motor shaft sealing
ring
- from gearbox flange
- from drive-side shaft
sealing ring
Oil leaking from vent plug a) Too much oil a) Correct the oil quantity
b) Vent plug fitted incorrectly b) Fit vent plug correctly
c) Frequent cold start (oil c) Replace vent plug with
foams) and/or high oil level valve
Increased temperature at Oil level in gearbox housing Check oil level at room
bearing points too low temperature, top up oil if
necessary
Increased temperature at Oil is too old Check when last oil change
bearing points was carried out, change oil
if necessary
(see maintenance routine)
Bearing defect Contact customer service;
inspect bearing, replace if
necessary
Increased operating Oil level in gearbox Check oil level at room
temperature housing too high temperature, correct oil
level if necessary
Oil is too old Check when last oil change
was carried out, change oil
if necessary
(see maintenance routine)
Oil is very dirty Change oil
BCHA
Fault Cause Remedy
Ventilation cover on the Clean ventilation cover and

motor and/on drive very surface of drive
dirty
Back stop does not run Contact customer service;
freely free back stop, replace if
necessary
Altered gearbox noises Damage to gearing Contact customer service;
check geared components,
replace damaged
components if necessary
Bearing play increased Contact customer service;
adjust bearing play
Bearing defect Contact customer service;
replace defective bearing
External load on drive or Adjust load to rated
output too specifications
high
8.5 Cleaning
Clean the inside only when the machine is at a standstill.
8.6 Drive end
8.6.1 Installation of new sprocket segments
If the sprocket segments are worn away more than 3 mm and/or the chain no
longer runs properly in the teeth or falls out of it, replace the sprocket segments.
To do this, proceed as follows:
► Always change sprocket segments in pairs.
► Clean anti-corrosive and paint from the new sprocket segments.
► Mount the separation points of both sprocket segments over each other.
► Oil the screws lightly and insert them alternately, i.e. one bolt head left, then
right; then tighten slightly.
► Use a square to check whether the tooth flanks of both sprocket segments are
aligned. The maximum permissible misalignment is less than 0.5 mm.
► Screw the aligned sprocket segments together firmly and tighten with a torque
wrench as follows (bolt quality b8.8):
BCHA
Fig. 8.1
Bolt Tightening torque [Nm]
M16 195
► After a number of service hours, check the screws for proper position and
tightening torque and correct if necessary.
► Use a torque wrench if at all possible. If there is none available, a normal
spanner with an extension pipe can be used.
Required pipe length L = MA / F
L = pipe length (m)
MA = tightening torque (Nm)
F = tightening force (N)
10 N = approx. 1 kp
► Apply the tightening force onto the extension pipe without jerking.
BCHA
8.7 Bearings at drive and return end
► The bearings for the drive and return end are adequately greased in the
factory.
► After approx. 8000 service hours, remove the covers of the flanged bearing
housing, wash out the bearing with petroleum and after it has dried completely,
refill it 2/3 full with fresh grease and reassemble. The bearing does not need to
be removed from the shaft for this purpose.
► Greases in accordance with Grease Directive UAB-18020, Code T (see also
UZM-20127 《Pillow block - Removal, installation, maintenance》).
8.8 Shaft seals at drive and return end

► At the drive and return end, seals are fitted to seal the rotating shafts in order
to prevent conveyed material particles from escaping.
► Dismantle defective shaft seals (conveyed material particles escape) and
replace.
8.9 Conveyor trough

► Check the conveyor trough periodically and service worn parts or replace
them with new parts in good time. Install new bottom and return rails so that
no protruding edges are produced (chamfer if necessary).
► Seal covers, bottoms, etc. that have been removed according to requirements
and screw together.
8.10 Conveyor chain

► After commissioning and during operation of the conveyor, check the tension
of the conveyor chain periodically and re-tension if necessary. This helps the
machine-run more efficiently and reduces the wear on the chain wheel, bottom
and return rails.
► At the same time, check the conveyor chain and replace defective chain links
and worn chain pins with new parts.
► Longitudinal chain links should not be straightened when cold or warm or
annealed as this can cause cracks to occur.
► Bent cross-bars (Fig. 7.2) can be straightened by heating approx. 2 cm from
the weld.
► For this purpose, fix or clamp the longitudinal chain link and heat the cross rib
without heating the longitudinal link (hardness loss).
► Straighten without jerking or hammering.
► In case of doubt, it is better to install a new chain link rather than risk fatigue
fractures with cracked chain links.
BCHA
Fig. 8.2
8.11 Disposal
► The trough chain conveyor and its component parts is to be disposed of
according to local laws.
► When the machine is put out of service permanently, the following is to be
observed in the interests of environmental protection and recycling:
▷ Drain off liquids (gear oil) into special containers and pass on to
processing companies.
▷ Separate plastic parts and pass on for recycling.
▷ Provide metal parts for shredding or scrapping, pre-sorted according to
type of metal.
BCHA
9 After-sales service
9.1 Spare parts

When ordering spare parts please use the spare parts catalog and the related
illustrations.
NOTICE
The information on the machine identification plate is to be used to identify the
machine when making any inquiries at Bühler AG.
BCHA
58 Chapter 9 After-sales service

AHKG 67025 1 en 1107

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Operating Instructions Chain Conveyor

AHKG - 100 / 200

1 Important information ............................................................................................... 1

4 Transport ............................................................................................................... 27

5 Installation ............................................................................................................. 29

8 Maintenance .......................................................................................................... 49

9 After-sales service ................................................................................................. 58

Buhler (Changzhou) Machinery CO., LTD.

1.3 Typographical conventions

1.3.1 Explanation of the warning instructions

Type and source of danger

Type and source of danger

1.4 Important information

2.1 Safety of persons

2.2 Connecting to the electrical mains

2.3 Explosion protection

3.1 Designated use

3.2.2 Type code

3.4.1 Drive end

f Outlets have connecttions for grav

A conveyor troughs (1) are constructed in leng

Fig. 3.5, 3.6,, 3.7 Trough

Fig. 3.8 One-way trough

F 3.9 Two--way drop tro

3.4.7 Hopper-discharging trough

f Locking ring-type pinss are used fo

gh chain conveyor is fittted as standard with siight glasses on both

f Empty weight: one-way trough or two-way trough, conveyor chain, but

Weights, one-way trough

Empty weight Operating weight

AHKG - 100 92 153 320

AHKG - 200 102 204 520

Weights, two-way trough

Empty weight Operating weight

AHKG - 100 108 230 320

AHKG - 200 120 324 520

Weights, outlet flaps and outlets

Empty weight Empty weight Empty weight

3.8 Planning information

3.8.1 General information

f Build conveyor in straight design if possible, avoid trough bends.

(1) Framee rifling exacttly to hopper--

3.8.5 Compressed air information

Compressed air quality

Sensor for product build up in the drive end

Element Proximity switch capacitive

Zero-speed detector in the return end

Type KIE 3015-FPKG

Magnetic switch Magnetic switch

Outlet flap manual

Position switch Position switch

Type 3SE3 120-1GW 3SE3 120-1GW

Outlet flap electric

f All elements are exclusively designed for a control voltage of 24 V DC.

3.8.8 Screw gear to outlet flap electric

3.8.9 Overview of functions

Designation See chapter

Compressed air information 2.8.5, p. 2-20

4.2 Degree of disassembly

4.3 Transport weights

Never walk under suspended loads.

4.5 Handling with a crane

5.3 Drive end, return ends and conveyor troughs