TSUBAKI Power Transmission Products Information Site 　Q&A　Top chain

Q1	What are the classifications of top chains?
Q2	What are the classifications and features of plastic top chains and stainless steel top chains?
Q3	How to select the specification (material) of Top chain?
Q4	What is the difference between stainless steel pins and plastic pins?
Q5	How do I select rail material?
Q6	How do I install straight rails?
Q7	Are there any examples of Advanced Low Friction/Wear Resistant (ALF) Series?
Q8	What is the corrosion resistance of the top chain material?

Q9	What are some conveyor designs for top chain and plastic block chain?
Q10	Return way layout for top chain and plastic block chain
Q11	Conveyors using corner discs
Q12	What are some conveyor designs for plastic crescent chain?
Q13	How do I disconnect and assemble plastic top chain and plastic block chain?
Q14	What should I be careful of when using plastic top chain, plastic block chain, and plastic pins?
Q15	Is forward-reverse operation possible with plastic top chain and plastic block chain?
Q16	How to use TTP, TPF, TPS, and TPH for straight running?
Q17	How to use TTUP and TPU for curved side flexing running?

Q18	How do I know when to use plastic modular chain?
Q19	How do I disconnect and assemble plastic modular chain?
Q20	How to install sprockets?
Q21	How about conveyor designs of plastic modular chain?
Q22	Return way layout for plastic modular chain
Q23	Is forward-reverse operation possible with plastic modular chain?
Q24	I need to make a conveyor with a compact transfer area.
Q25	I need to eliminate items remaining when using right-angle conveyors.
Q26	【Plastic modular chain 】The sprockets that can be used with chain with float-preventive Tab.

A1

The top chain consists of three categories of products: plastic top chains made of plastic, stainless steel top chains made of stainless steel, and top chain accessories. For the differences between plastic top chains and stainless steel top chains, please refer to the “Features Chart” and “Summary Comparison of Plastic Top Chains and Stainless Steel Top Chains” below.

【Top chain accessories 】

These are convenient items for peripheral equipment for conveyors, with the optimum combination of various shapes and materials available for each application.

Plastic rail
Set Collar
Chain guide parts
Frame support parts
Product guide parts
Bearing units
Disconnecting and Connecting Tools For Top Chains

are lineuped as conveyor peripheral components.

【Features Chart 】

Features	Plastic top chain	Stainless steel top chain
1	The unique softness of the plastic reduces scratches on the material being conveyed.	High allowable load Note) 1
2	Lightweight and simple structure makes maintenance easy	Can be used in a wide range of temperatures from -20℃ to 400℃ Note) 2
3	Long life is expected due to the use of materials with excellent sliding characteristics	Used as standard corrosion resistant chain Note) 3
4	5 to 7 dB lower noise than stainless steel chain conveyors	---
5	Rust-free and hygienic, allowing food to be directly conveyed	---

Note) 1. Our TT/TP type has approx. 2 times the allowable load.
Note) 2. When made of SUS304.
Note) 3. When all parts are made of SUS304.

【Summary Comparison of Plastic Top Chains and Stainless Steel Top Chains 】

Item	Plastic top chain	Stainless steel top chain
Noise	-5～7dB	As 0
Lightness	1/3	As 1
Coefficient of friction	1/1.5～1/2.5	As 1
Operating temperature	-20°C～80°C (Excluding some )	-20°C～400°C
Allowable load	1/2	As 1

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A2

【Plastic modular chain 】

The brick-like combination of plastic module links with chain structure provides a wide belt-like conveying surface and secure drive by chain and sprocket engagement.

Depending on the application and the shape of the material to be conveyed, you can choose from “closed type,” “open type,” “net type,” etc. In addition, “magnet type,” “rubber type,” and “flight type” suitable for inclined conveyance are also available.

The conveying surface can be as wide as 50 mm, wider than that of plastic top chain or plastic block chain.

[Main purpose(s) ]

Ideal for conveying wide items, many items at once, and heavy items

(Application examples )

Large quantity of containers
Wide items such as packing boxes and sheets
Conveyance of heavy items such as tires

【Plastic top chain 】

The top plate and chain are molded together of plastic and connected by connecting pins.

The lineup also includes a format in which only the top plate is made of plastic and the chain is composed of steel. Other types are available with freely rotating rollers attached to the plate to reduce line pressure during accumulation.

Top plate width can be selected from 42.0 to 304.8 mm according to the material to be conveyed.

[Main purpose(s) ]

Ideal for loading and conveying items one by one on plates

(Application examples )

Container conveyor
Packing box conveyance

【Plastic block chain 】

Simple construction with block-shaped links connected by connecting pins.

Smaller chain pitch (9.525 to 25.4 mm) than plastic top chain allows for a smaller sprocket outer diameter.

The transfer area (dead space) can be made smaller, which allows smooth transfers. Link widths are as small as 13 to 63 mm, allowing installation in small spaces.

[Main purpose(s) ]

Single-strand use : Ideal for conveying small items such as eye drops
Two-strands use : Ideal for conveying pallets and packing boxes

(Application examples )

Conveying small objects
Pallet conveyor
Packing box conveyance

【Stainless steel top chain 】

This top chain uses corrosion-resistant stainless steel for its main components. There are types where the top plate is made integral with the chain, and types where the two are joined together.

Generally, the maximum allowable load is higher than that of plastic top chains.

[Main purpose(s) ]

For conveying heavy objects and long center distances that cannot be handled with plastic.
Furnace or other atmosphere subject to high temperature (In the case of SUS304 ：-20°C～400°C)
Atmosphere subjected to chemicals, etc. (In the case of all parts made of SUS304)

(Application examples )

Heavy object conveyance

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A3

Click on the links below to find out how to select the specification and the applicable table by specification.

How to select specifications and applicable table by specification of Plastic modular chain, Plastic top chain and Plastic block chain.

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A4

With its light weight and easy handling, plastic pins are predominant for plastic modular chains and plastic top chains. The use of plastic pins is recommended when there is exposure to water only (adhering to conveyed items from the previous process) since stainless steel pins have a shorter service life when exposed to water.

Stainless steel pins are becoming predominant for plastic block chain. Depending on the product, the allowable load is greater than with plastic pins. Stainless steel pins are recommended when there are impacts on the chain.

with plastic pin

Allowable load roughly equal to stainless steel pins (80% to 100%)
Improvements have been made to the structure of the thick plastic pins and hinges.

Long life: A combination of proprietary Tsubaki materials allows the chain to exhibit outstanding wear resistance between the pin and bushes under dry, soapy water, or wet conditions. The chain works particularly well when using water as the lubricant.

Lightweight: 15% to 25% lighter than stainless steel pin top chains. Easy to handle and effective in reducing noise and required power.

Easy disposal: As the entire chain is made of plastic, it can be disposed of as is.

Conforms to food sanitation regulations: The links and pins are manufactured from materials that are in accordance with Japan's Food Sanitation Act.

Note: Refer to Technical notes, handling of top chain, precaution of plastic pin and disconnection/connection.
2.Operating temperature up to 60℃ is allowed when plastic pin chains are used in wet conditions.

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A5

When installing plastic chains, rails are generally installed as well to guide the chain. Select the material for your rail based on your application and purpose.

General applications

Rails made of ultra-high molecular weight polyethylene (Plastic rail and plastic rails) are often used. Recommended for use in lubricated conditions.
*Be aware that more wear debris will be generated when used in unlubricated conditions.

Suppresses the generation of wear debris

PLF rail or M-rail is recommended. In addition, stainless steel (polished specification) and metal rails (hard Cr plating + buff finish) also reduce the generation of wear powder.

※M-rail is for dry conditions only. Do not use in lubrication or where water may splash on it.

※Wear dust generated on stainless steel and other metal rails will be black in color with metal powder.

Click here for details on the features of each rail

When using in high temperature conditions

Metallic rails are recommended. Use smoothly polished or hard chromium finished + buffed top finished rails.

Use at High Temperature

Recommended wearstrip material is cold-rolled stainless steel.

Secure only one end of wearstrips to allow for thermal expansion. Also, remember to leave a gap between wearstrips to allow for thermal expansion.

(Reference: Coefficient of linear expansion for 304 stainless steel is 1.8 x 10^-5 mm/mm/℃)
Example: Securing stainless steel wearstrips, and leaving space between wearstrips

Standard steel sprockets can be used for ambient temperatures below 150℃. Special sprockets must be used at temperatures higher than 150℃. Contact a Tsubaki representative for details.

Spacing between chains when multiple strands are used is shown below.

Take-up must be done to compensate for slack in the chain caused by thermal expansion. Take-up adjustments should be performed after reaching operating temperature. Lower temperatures only after loosening take-up.

Black wear dust will be generated. Be sure to clean on a regular basis.

Start up slowly (using inverter control) and stop slowly

＜Wearstrip Material Selection Guide ＞
Top Chain Type	Wearstrip Material	No lube		With lube
		Abrasives
		Without	yes	Without	yes
Stainless steel top chain ・Straight running ・Side flexing	Stainless	D	D	B	B
	steel	D	C	B	A
	Plastic rail (P rail ) PLF rail	A	×	A	×
	M plastic rail SJ-CNO	A	×	×	×
Plastic top chain Plastic block chain Plastic modular chain (Mold-to-Width type ) ・Straight running ・Sideflexing	Stainless	B	D	A	A
	steel	A	C	D	D
	P rail	D	×	A	×
	PLF rail	B	×	A	×
	M plastic rail SJ-CNO	A	×	×	×
Plastic modular chain (Wide type ) ・Straight running ・Sideflexing	Stainless	B	D	A	A
	steel	A	C	B	B
	Plastic rail	D	×	A	×
	PLF rail	B	×	A	×
	M plastic rail SJ-CNO	A	×	×	×

A：Especially recommended
B：Recommended
C：Recommended among "Available"
D："Available"
×：Inappropriate

Note)

Stainless steel top chain lambda specifications should be used without lubrication.
For heat-resistant/high-speed (KV) series, rails should be made of stainless steel or steel at room temperature and stainless steel at high temperatures (>50 degree C).
Recommended metallic wearstrip is cold-rolled steel.
The recommended lubricant for steel rails is oil.

	Material, Color	Features
Plastic rail (P rail )	Ultra high molecular weight polyethylene (Color : White or green color )	Most commonly used rail Machined or extruded products For plastic top chain, recommended for use in wet conditions Low water absorption; chemical and impact resistance are also excellent
PLF rail	Low friction and wear resistance Ultra high molecular weight polyethylene (Color : white )	Lower friction and more wear resistant than P plastic rail Machined or extruded products
M plastic rail SJ-CNO	Special polyamide (M rail : Color : Blue color ) (SJ-CNO： Color : Purple color )	Rail for dry conditions only Maintains wear resistance Machined item

Note: Operating temperature range

Plastic rail (P rail ) · PLF rail ：-20～60°C
M rail ·SJ-CNO：-20～80°C

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A6

When plastic rails (plastic rail, PLF rail, M-rail) are used for straight rails, please provide a gap between the rails to allow for expansion due to heat. In addition, the rails should be fixed with screws at one end.

Tongue and groove wearstrips (PR, PH), flat wearstrips

Use a screw to attach only one end of the wearstrip to the frame and leave an appropriate gap at the joint to allow for thermal expansion.

Gap between tongue and groove wearstrips … 3 to 5 mm

Coefficients of linear expansion

Plastic rail (P rail )・(PLF rail )　20×10^-5mm/mm/℃")%>

M plastic rail　9×10^-5mm/mm/℃

Note)

Operating temperature range

Plastic rail (P rail )・PLF rail ：-20～60℃
M plastic rail: -20℃ to 80℃

Do not use in environments where rail components will be exposed to steam.

Mounting long straight wearstrip (extruded wearstrips such as Z, T, L, and flat) when the conveyor length is long

Assuming that these wearstrips are installed in 1-meter units, a gap should be left between wearstrips to prevent chain sag as shown in the illustration below.

Gap between long straight wearstrips … 10 mm per meter

Mounting long straight wearstrip (extruded wearstrips such as Z, T, L, and flat) when the conveyor length is short

If both ends of the wearstrip are secured using small flathead screws, the wearstrip will warp (become rippled) due to the difference in coefficient of thermal expansion between the wearstrip and metal frame. Attach only one end of the wearstrip using a small flathead screw.

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A7

There are many examples, but we will introduce some typical examples.

Application	Conditions	Measures (Model No.)
Milk carton conveying line (Before Caser ) ※500 ml and 1 liter packs	Short distance to the final process (caser) and accumulates throughout the line. Completely no slider (no water is allowed to protect the paper pack)	Conventional low-friction plastic chains from various companies have caused rattling and tipping of conveyed objects, but TTUP826-ALF prevents this problem. ※The TTUP type is used for the 500 ml and 1 liter paper carton lines.
Canned beer conveyor line (Entrance of corrugated cardboard caser ) 1500 cpm line (line producing 1500 cans of beer per minute)	Intermittent accumulate (completely dry conditions for dry conveying from before the caser).	Replace the RSP60 standard model (white) with the RSP60-ALF to reduce line pressure.
500ml PET bottle conveyor line (Conveyor before shrink machine )	The PET bottle line used to be dominated by 1.5-liter and 2.0-liter bottles, but nowadays, many bottles have smaller capacities, such as 500 ml. (Due to the shift from canned to PET ) Therefore, the line must be sped up in order to maintain production volume. (Simply put, 500 ml requires 4 times the speed of 2.0 liters )	TPH830P-ALF and TTUP826-ALF enable high-speed response with slider reduction (MAX 120m/min) Free-flow type chains were used for 1.5-liter and 2.0-liter bottles to reduce line pressure. However, 500 ml bottles will tip over on free-flowing items.
2-liter PET bottle conveying line (Sorting section )	Sorting 2L rectangular PET bottles in three strands (rear end of line sorting)	Low-friction plastic chains of various companies caused bottle misalignment and rattling during sorting, but the TPH830P and TTP826P type ALF series has solved this problem.
Cup container conveyor line (Accumulate conveyor )	Fully accumulate Completely no-slider (upper guide to prevent containers from rattling by pressing down from above)	TSUBAKI Belltop BTC6-3048-ALF is used in the section using resin belts made overseas. Prevents container rattling with ultra-low friction and slipperiness

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A8

When selecting a chain, check from the table below that its material is adequate. This corrosion resistance can also be used to check the rail material used with the top chain.

Note that the results in this table are based on a 20°C atmosphere and do not represent the degree of guarantee. Comprehensively consider the temperature/usage conditions, etc. in actual use. The table below lists the materials (specifications) of the top plate and chain components individually, so please check them in combination.

Reagents without a concentration indication are saturated or 100% solution. Note that conditions will change when solutions are mixed together.

[Corrosion resistance to various liquids ]

Material ^{Note) 2}		Liquid name
Material ^{Note) 2}		Acetone	Oil (plant/mineral)	Alcohol (ethyl)	Ammonia water (28%)	Whiskey	Sodium chloride	Hydrochloric acid (2%)	Seawater	Hydrogen peroxide (3%)	Sodium hydroxide (caustic soda) (25%)	Gasoline	Formic acid (50%)	Formic aldehyde	Milk and butter	Citrate	Chromic acid (5%)	Acetic acid (10%)	Carbon tetrachloride	Sodium hypochlorite (sodium)(5%)	Nitric acid (5%)	Vinegar	Potassium hydroxide	Drinking water/Coffee	Soapsuds	Lactic acid	Paraffin	Beer	Fruit juice	Benzene	Water	Vegetable juice	Iodine	Sulfuric acid (5%)	Phosphoric acid (10%)	Wine	Xylene	Ozone	Peracetic acid
steel		×	○	○	△	○	×	×	×	×	×	○	×	○	○	×	×	×	△	×	×	×	△	○	△	×	○	○	×	○	×	△	×	×	×	○	○	×	×
Stainless	18-8	○	○	○	○	○	○	×	△	○	○	○	○	○	○	○	○	○	○	×	○	△	○	○	○	○	○	○	○	○	○	○	×	×	△	○	○	○	○
	18Cr	○	○	○	○	○	○	×	×	△	○	○	○	○	○	○	△	○	○	×	△	×	○	○	○	△	○	○	△	○	○	○	×	×	△	○	○	△	○
	Martensitic	○	○	○	○	○	○	×	×	△	○	○	×	○	○	△	○	×	△	×	△	×	○	○	○	×	○	○	△	○	○	○	×	×	×	○	○	△	○
	AS Series	○	○	○	○	○	○	×	×	△	○	○	○	-	○	○	△	○	○	×	△	×	○	○	○	△	○	○	△	○	○	○	-	×	△	○	○	-	-
Plastic pin (Special engineering plastic )		○	○	○	△	○	○	×	△	×	×	○	△	-	○	×	×	×	○	△	○	○	×	○	○	△	○	○	○	○	○	○	-	×	△	○	-	×	○
Polypropylene (HTW included )		○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	×	-	△	○	○	○	-	○	○	○	○	○	○	△	○	○	-	○	○	○	△	×	○
Standard Series Polyacetal (Including rubber type ) ^{Note) 3}		○	○	○	○	○	○	×	△	×	○	○	×	○	○	×	×	×	○	×	×	△	○	○	○	○	○	○	○	○	○	○	×	×	×	○	△	×	△
LF series Polyacetal (Including rubber type ) ^{Note) 4}		○	○	○	○	○	○	×	△	×	×	○	×	○	○	×	×	×	△	×	×	△	○	○	○	○	○	○	○	○	○	○	×	×	×	○	△	×	×
Heat resistant/High speed series (KV180) ^{Note) 5}		○	○	○	○	○	○	×	△	○	○	○	-	-	○	○	△	○	○	×	○	△	○	○	○	○	○	○	○	○	○	○	×	×	△	○	-	△	○
Heat resistant/High speed series (KV250) ^{Note) 5}		○	○	○	○	○	○	×	△	○	○	○	△	-	○	○	×	○	○	×	○	△	○	○	○	○	○	○	○	○	○	○	×	×	△	○	○	○	○
Polyamide, Reinforced Polyamide (Including slit pin )		○	○	○	○	○	○	×	△	×	△	○	×	○	○	△	×	×	○	×	×	×	×	○	○	△	○	○	○	○	○	○	×	×	×	○	-	×	×
Chemical Resistant (Y) (DIY included ) ^{Note) 6}		×	○	○	○	○	○	×	△	○	○	○	○	○	○	○	○	○	○	×	○	△	○	○	○	○	○	○	○	○	○	○	×	×	△	○	○	○	○
Super chemical resistance (SY)		×	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○
Ultra high molecular weight polyethylene (Including LTW and UPE )		○	○	○	○	○	○	○	○	○	○	△	○	○	○	○	○	○	△	○	△	○	○	○	○	○	○	○	○	△	○	○	△	○	○	○	△	×	○
Heat/Radiation/Vacuum resistant series (PK150)		○	○	○	○	○	○	○	○	○	○	○	△	-	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	○	△	○	○	○	○	○	○
Polycarbonates ^{Note) 9･10}		×	×	×	-	×	-	×	-	×	×	×	×	-	×	×	×	×	×	×	×	○	×	△	△	×	-	○	△	×	○	△	-	×	×	-	×	-	-

Note)

○: Totally resistant, △: Partially resistant (depending on operating conditions, ×: Not resistant, -: No data
Please check two things: the chain base material and the pin material.
Applicable to: Standard, Low-friction/Wear-resistant (CB), Advanced-low-friction/Wear-resistant (ALF), Low-friction (WR), Electroconductive (E), Ultraviolet-resistant (UVR), and Food conveying (PFS) series.
Applicable to: Low friction/Wear resistant (LFW, LFG, LFB) , Low friction (NLF), Low friction/Wear resistant (HG), Antibacterial/Mold resistant (MWS) series.
Applicable to: Heat resistant/High speed (KV) series also consider corrosion resistance of stainless steel pin type.
Chemical-resistant (Y) series also takes into account the corrosion resistance of stainless steel pin types.
Do not use the heat-resistant/High-speed (KV150), High-speed (HS), Impact-resistant (DIA), Metal detectable (MPD), and Middle-friction (MF) series under conditions where they will be subjected to liquids such as detergents or chemicals. If you have any requests or questions, please contact us.
For corrosion resistance of Metal detectable (MPW) series, please contact us.
Do not wash the chain except with water.
Do not clean the chain with detergents, organic solvents, acids or alkalis. Do not use the product in areas where it will come in contact with such chemicals.
Chemical cracks may occur and the chain may break.

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A9

Generally, for plastic chain, the wearstrip should support the chain on the carry way, and the chain should be slack on the return way. Chain slack below the drive sprocket is especially important. Ensure there is 50 - 100mm of slack for 500 - 900mm spans (in drive operations). Tooth jumping (skipping) may occur with other slack values.

The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below. See Question No.8 for the layout of the return way of the chain.

Chain slack

Return rollers should be spaced at intervals of 500 to 900 mm to support the return way of the chain. The amount of slack in the chain between return rollers should be 50 to 100 mm. This slack prevents tooth jumping (skipping). Tooth jumping may occur when the amount of slack in these intervals falls outside of this range.

Engagement angle

The engagement angle between the drive sprocket and the chain must be greater than 150°.

Wearstrip ends

A distance equivalent to the pitch spacing of the chain must be established between the end of the wearstrip and the respective shaft centers on both the drive and driven ends. Also, the tail end of the return wearstrip on the driven side must be rounded or chamfered (sloped) to prevent catching or snagging of the chain on the wearstrip.

Height of carry-way wearstrip

Refer to Technical notes, conveyor design, rail mounting on drive/driven side.

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A10

As the most common layout, we recommend supporting your chain with return rollers. Supporting with return roller enables to you to set an applicable chain slack and absorb elongation. When using chains with float-preventive tabs, you can also support the chain through the sliding action of the tabs. However, consider using a system (such as a tensioner) to absorb chain elongation.
Other options include using a guide rails and wearstrips, using glide shoes, using guide rails only, no support on return way, etc. Be aware that not supporting the return way may cause vibration and prevent smooth operation.

The return-way layout will vary according to the type of chain, the type of goods being conveyed, the flow system and route topology, but in general, layouts will be similar to those illustrated below.

[Click to enlarge ]	Supported by return rollers This is the most common and recommended layout. Angle of chain wrap on the drive sprocket must be at least 150°. Make sure the return rollers rotate freely. If they do not rotate freely, localized sliding will occur, possibly generating wear dust or causing the top plate to wear unevenly.High-rotation return rollers or return rollers with integrated bearings are recommended for the return rollers. For chain speeds greater than 50 m/min, dimension C must be less than 300 mm. A: 50 to 100 mm (during operation) B: 500 to 900 mm C: 400 to 600 mm D: Less than half the outer diameter of sprocket May vary depending on chain type and conveying conditions. To be used only as a basic guide. ※Refer to the technical notes in the catalog for details.
[Click to enlarge ]	Supported by wearstrip fitted with float-preventive tabs Using a wearstrip to support chains fitted with float-preventive tabs eliminates sliding on the top plate surface. This is particularly applicable in situations where damage (such as scratching) to the top plate’s upper surface must be avoided during conveying. Angle of chain wrap on the drive sprocket must be at least 150°. A: 50 to 100 mm (during operation) B: 500 to 900 mm May vary depending on chain type and conveying conditions. To be used only as a basic guide. ※Refer to the technical notes in the catalog for details.
[Click to enlarge ]	Supported by serpentine-style wearstrip Supporting the top plates only in localized areas may result in uneven wear. Install the rail in an “8”-shaped or wavelike layout so that the top chain plates are fully supported at all points. The construction should be such that extraneous matter, dirt, etc., falls through easily. Angle of chain wrap on the drive sprocket must be at least 150°. A: 50 to 100 mm (during operation) B: 500 to 900 mm May vary depending on chain type and conveying conditions. To be used only as a basic guide. ※Refer to the technical notes in the catalog for details.
[Click to enlarge ]	Supported by sliding shoes Suitable for relatively slow-speed conveying conditions (less than 50 m/min). Generally used for accumulation chain (TTPDH-LBP) or roller tables (ST/RT). Angle of chain wrap on the drive sprocket must be at least 150°. A: 50 to 100 mm (during operation) B: 500 to 900 mm C: 400 to 600 mm May vary depending on chain type and conveying conditions. To be used only as a basic guide. ※Refer to the technical notes in the catalog for details.
[Click to enlarge ]	Using guide rails only Although this is an economical option for layouts, it has a disadvantage in that the upper surface of the top plates is susceptible to damage from sliding. Suitable for chains with relatively large back-flex radius. Angle of chain wrap on the drive sprocket must be at least 150°. The radius of curvature (R) on both ends of the guide rails must be greater than the back-flex radius of the chain. ※Refer to the technical notes in the catalog for details. A: 50 to 100 mm (during operation) B: 500 to 900 mm May vary depending on chain type and conveying conditions. To be used only as a basic guide.
[Click to enlarge ]	No support This conveyor layout is normally not recommended because the tension of the return way from the weight of the chain causes chain vibration and prevents smooth operation. If this method is navoidable in the case of short conveyor lengths (less than 1.5 m), provide a take-up mechanism on the driven side or splice the chain in case the chain elongates. The wrap angle on the drive sprocket must be at least 150°. The amount of chain slack A should be approximately 10% of the conveyor length B.

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A11

For chains with a small sideflex radius (minimum sideflex radius (under R190)), install a corner disc when manufacturing a conveyor with a small sideflex radius. A corner disc should be installed at the center of the sideflex radius for the conveying surface and return way sides.

Curved Section Using Corner Disc on TPUSR Chain

Explanation of symbols

R: Sideflex radius of chain (mm)
R1: Outer radius of corner disc (mm)
R2: Inside radius of wearstrip for outside of chain (mm)
R3: Inner circumference of conveyor frame used to secure outside wearstrip (mm)

As shown in the figure below, for chains supported by return rollers, rollers must be installed to guide the straight portion of the return-way chain at the point where the chain enters and exits the corner.

Note: Use in a dry environment is recommended.

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A12

Plastic crescent chain is designed for use in horizontal conveyors. For TORP types with rollers, guide the chain with a sprocket or wearstrip at the corners. For TORP types without rollers, use sprockets at the corners. For horizontal conveyance, a take-up mechanism must be installed to absorb elongation resulting from temperature changes or wear elongation of the conveyor. Without one, tooth jumping (skipping) can occur.

Wearstrip layout

Layout will vary depending on the installation space, but the following examples can be used for reference.

Wearstrip layout example 1 … Using TOSP1143 and corner sprocket

[Click to enlarge ]

Wearstrip layout example 2 … Using TORP1143 and corner sprocket

[Click to enlarge ]

Wearstrip layout example 3 … Using TORP1143 and curved wearstrip

[Click to enlarge ]

Precautions on conveyor layout

A take-up mechanism must be installed to absorb elongation resulting from temperature changes or wear elongation of the conveyor. See example below for reference.

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A13

Connecting pins differ by type. Disassemble, cut, or connect with a punch and hammer suited to the shape of the connecting pins. Only plastic crescent chain has a unique structure. See below for further information.

When D-pins are used (except TPUN555)

The chain can be disconnected at any link and the pin can be removed from either the left or the right.

When knurled pins are used

To disconnect, place a punch on the end of the connecting pin on the side that is not knurled and lightly tap it with a hammer to remove it. To reconnect, place a punch on the end of the connecting pin on the knurled side and lightly tap it with a hammer to insert it.(For TTPDH and TTPDH-LBP only, the knurled side is inserted from the same side even for reconnecting.)

For TN, TNU, TRU, TP-1873T

The pin for the connecting link is loosely fitted on the appropriate side of the outer plate. When disconnecting the chain at links other than the connecting link, remove a pair of pins parallel to one another by means of a chain vice. Once a chain is disconnected at links other than the connecting link, the link cannot be reused.

When D-pins are used (except TPUN555)

Pin insertion direction is from one direction only. Place a punch on the opposite end of the pin from the insertion direction, and tap it lightly with a hammer to remove it.

For Plastic Crescent Top Chain

1.Remove the snap cotter pin from the connecting pin, and carefully pull the offset link up and off.

2.Turn the offset link 90 degrees.

3.Remove the main link and the connecting pin from the previous link.

Note: When disconnecting, be sure not to pull the connecting pin out of the main link.

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A14

Once removed, pins should not be reused to prevent a reduced push out force and other problems with pins falling out. The disassembling pin is colored orange so as to distinguish it from base-chain pins (colored white). Use the disassembling pin included with chain when cutting. Avoid use in wet environments where temperatures exceed 60℃. Pin may break.

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A15

The direction of plastic top chains and plastic block chains is set. Forward-reverse operation is not recommended. If considering forward-reverse operation, consider using plastic modular chains.

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A16

See the table below for the difference in use between TTP and TPF, TPS, and TPH for straight running.

Model	TTP type	TPF	TPS type	TPH type
Appearance
Features	Global standard shape	Higher allowable load than TTP type	Higher allowable load than TTP type The same sprockets as TTUP and TPU types can be used.	Can be directly replaced by TPS type conveyor Comb-toothed plates are used to minimize the gap between the front and rear links. Numerous holes placed in the plate
Application examples	Can be used for various applications such as cans and PET bottles	Conditions under which more working tension loads are applied	Conditions where greater tension load is applied, such as when the machine center distance is long or during high-speed conveyance	Conveying unstable containers such as PET bottles and dessert cups. Effective in removing excess lubricant and water left on the top surface of the plate
Note	TTP type sprockets can be used with stainless steel top chain TT type (TT type sprockets cannot be used with TTP type)	Same thickness (3.2mm) as stainless steel top chain TT and TTU types, allowing “replacement from TT type” and “common use with TT and TTU types”.	Integrated hinge structure increases bearing area and achieves high allowable load. The same sprockets can be used as the basic 3 dimensions are the same as those of TTUP and TPU types. The above features have made our products popular among major set manufacturers and beverage factories.	Same basic 3 dimensions as TPS type, so the same sprockets can be used. (However, the hinge part is a multi-hinge structure ) The TPS type conveyor can be replaced as is.

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A17

See the table below for the use of TTUP and TPU for side flexing running conveyance.

Model	TTUP type	TPU type With float-preventive tabs	Note
Appearance			1. Ascending conveyors The TPU type has an float-preventive attachment that makes it possible to prevent the chain from floating up in areas where it is prone to floating up. 2. 3D conveyors (e.g., can manufacturers) Float-preventive attachments are effective for layouts such as "ascending/descending" plus "side flex." Can be used in complex layouts for fixing attachments with rails. 3. Can be used in complex layouts for fixing attachments with rails. In the case of food products, the most important point to keep in mind is that the top surface of the plate should not slide against anything other than the product being conveyed. With the TPU type, the return chain's float-preventive attachment is supported by the guide rail, reducing friction with anything other than the conveyed item on the top surface of the plate.
Features	Most popular chain series designed for use in sideflexing conveyors. Simple structure and easy cleaning The same sprockets as the TPS and TPU types can be used, allowing for common parts.	Side flex chain with float-preventive attachment (tab). Prevents lifting at corners and on ascending and descending conveyors, as well as scratches on the top surface of the plate on the return side. The same sprockets as the TPS and TTUP models can be used, allowing for common parts.
Application examples	For corners with a minimum side flex radius of R600 or greater, basically one corner with one conveyor length	With float-preventive attachment (tab), it corresponds to minimum side flex radius R500. It is also more stable than the TTUP type at high speeds and in dry conditions. Also, when there are S-curves and multiple corners in one conveyor length, the TTUP type is effective because of the possibility of chain float-prevention.

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A18

We recommend WT1500 series, BTN5, BT6, BTC4-M, and TOD type chains with small chain pitches for reducing the size of your conveyor transfer areas. For general applications, we recommend BT8, WT2250, WT2706, WT3835 and WT300 chains. For higher applied loads and conveying heavy objects, we recommend WT2500 and BTH16 series chains. For eliminating gaps in connecting areas, we recommend WT1907, 3827, 5707 series chains. Try magnet-embedded BTM8H and BTM8H-M chains for inclined conveyance of metal trays and parts (to prevent slipping). We recommend BTC8S for conveying cardboard boxes. For inclined conveyance, we also recommend WT2250 series with attached flights and rubber pads.

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A19

The structure of each chain series differs. See below for further information.

■Structure and Disconnecting/Reconnecting of the BTN5, BT6, and BT8 Series

Structure of both ends of chain

A snap attachment is inserted in the link from the underside of the link at each end of the chain to prevent the pin from coming out (snap fit).

[Click to enlarge ]

Procedure for disconnecting and reconnecting

1) Insert a small flathead screwdriver into the gap (about 1mm) between the link hole and the snap attachment to detach the snap attachment.

[Click to enlarge ]

2) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.

[Click to enlarge ]

3) When connecting the links of a chain, bring both ends of the chain together and insert the pin in the hole from one side. Finally, insert the snap attachment from the underside of the chain. Make certain that the snap attachment does not protrude from the bottom of the link.

■Disconnecting the WT1500/3000 Series

1) Insert a small flathead screwdriver or similar tool between the chain and the plug-clip on the side of the chain.

[Click to enlarge ]

2) Using the screwdriver as a lever, pry out and remove the plug-clip from the base chain. Work carefully so that the plug-clip does not pop out and fly off.

[Click to enlarge ]

3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.

[Click to enlarge ]

■Reconnecting the WT1500/3000 Series

1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.

[Click to enlarge ]

2) Then re-insert the plug-clip to cover the insertion area. At this point, check the orientation of the plug-clip (make sure that the protrusion is going into the pin hole), and seat the plug-clip by pushing in until you hear it click into place.

[Click to enlarge ]

3) Check that the plug-clip is properly installed.

[Click to enlarge ]

Note: When reconnecting chain links, be sure to use the pins provided or special pins.

■Disconnecting the WT2500 Series and BTM8H Series

1) Insert a small flathead screwdriver or similar tool into the hole in the plug on the side of the chain.

[Click to enlarge ]

2) Push the screwdriver in the direction of the arrow to slide the plug to the side.

[Click to enlarge ]

3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.

[Click to enlarge ]

Note: The shape for BTM8-M is different.

■Reconnecting the WT2500 Series and BTM8H Series

1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.

[Click to enlarge ]

2) Slide the plug to the side to cover the insertion area.

[Click to enlarge ]

Note: The shape for BTM8-M is different.

Note: When reconnecting chain links, be sure to use the pins provided or special pins.

■Disconnecting the WT3800 Series

1) Insert a small flathead screwdriver or similar tool between the chain and the plug-clip on the side of the chain.

[Click to enlarge ]

2) Push the screwdriver in the direction of the arrow to slide the plug to the side.

[Click to enlarge ]

3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.

[Click to enlarge ]

■Reconnecting the WT3800 Series

1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.

[Click to enlarge ]

2) Slide the plug to the side to cover the insertion area.

[Click to enlarge ]

Note: When reconnecting chain links, be sure to use the pins provided or special pins.

■Disconnecting and Reconnecting BTC-4M and BTO8-M

1) Disconnecting

・Place a punch (2.5mm dia. or smaller) on the outer edge of the D-pin on the D-hole side of the link and lightly knock the punch with a hammer to remove the pin.

・Or, the pin can be removed using a small flathead screwdriver from the stopper side.

[Click to enlarge ]

2) Connecting

・Use the exclusively prepared D-pin (colored orange).

・Make certain that the D-pin is facing the correct direction and insert it into the chain link.

・Push by a finger or lightly knock by a hammer the stopper of the D-pin.

3) Reconnecting

・Do not cut the chain where a connecting D-pin (colored orange) is already inserted.

・Connecting D-pin

1) Use the exclusively prepared D-pin to connect the chain links.

2) The connecting D-pin is colored orange so as to distinguish it from base-chain pins (colored white).

3) One connecting D-pin is provided per chain.

■Structure and Disconnecting/Reconnecting of the WT2250 and BTC8S Series

Structure of both ends of chain

A snap attachment is inserted in the link from the underside of the link at each end of the chain to prevent the pin from coming out (snap fit).

[Click to enlarge ]

Procedure for disconnecting and reconnecting

1) Insert a small flathead screwdriver into the gap (about 1mm) between the link hole and the snap attachment to detach the snap attachment.

[Click to enlarge ]

2) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.

[Click to enlarge ]

3) When connecting the links of a chain, bring both ends of the chain together and insert the pin in the hole from one side. Finally, insert the snap attachment from the underside of the chain. Make certain that the snap attachment does not protrude from the bottom of the link.

[Click to enlarge ]

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A20

For wide plastic modular chains, be aware that the number of sprockets and installing positions will differ depending on chain width and tension rate. A sprocket's square or hexagonal bore will be finished larger that the corresponding shaft to handle expansion and contraction with changes in temperature and move freely laterally.

Determine Sprocket Locations

The diagrams below show the location and distance between prockets (pitch) for each type of chain. Find the percentage of maximum allowable load (maximum allowable load per 1 meter of chain width) that the tension per 1 meter of chain width F’ derived by means of formula (2) represents. Note that the locations and pitch may change depending on chain tension rate F1.

Formula of chain tension rate F1 (%)

F’…Tension applied per 1 meter of chain width derived by formula (2) [kN (kgf)]
A …Maximum allowable load per 1 meter of chain width with given temperature [kN (kgf)]

Wide type

1. BTN5, BTN5-A	2. WT1505-K, WT1505G-K, WT1506-K
[Click to enlarge ] Note: A sprocket with 24 teeth cannot be used with BTN5-A (with tab guide attachments). A sprocket with 32 teeth should be used.	[Click to enlarge ]
3. WT1505GTO-K	4. WT2505-K, WT2506-K, BTM8H
[Click to enlarge ]	[Click to enlarge ]
5. WT3005-K/WT3005G-K	6. WT3086-K/WT3086G-K
[Click to enlarge ]	[Click to enlarge ]
7. BT6, BTC8, BTC8-A ・Sprocket locations when chain tension rate (F1) is 50% or less	8. BT6, BTC8 ・Sprocket locations when chain tension rate (F 1) greater than 50%.
[Click to enlarge ]	[Click to enlarge ]
9. BTC8-A ・Sprocket locations when chain tension rate (F 1) greater than 50%.	10. WT3816K
[Click to enlarge ]	[Click to enlarge ]
11. WT2250FT, FG	12. BTC8S
[Click to enlarge ]	[Click to enlarge ]

Mold-to-Width type

1. BTC4-500-M	2. BTO8-830-M	3. BTC8H-M/BTM8H-M	4. WT1505G-M300
[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]
5. WT1505GTO-M300	6. WT1505GTO-M600	7. WT1505TOD-M450L	8. WT2505-M325/G-M325
[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]
9. WT2505-M450/G-M450	10. WT2505TOD-M450R	11. WT2505TOD-M750R	12. WT3005G-M300
[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]
13. WT3005G-M450	14. WT3086G-M85	15. WT1515G-M50
[Click to enlarge ]	[Click to enlarge ]	[Click to enlarge ]

Handling Sprockets

In general, square shafts are recommended for the drive and driven shafts used with plastic modular chain, except for special cases. Because changes in temperature will cause the chain to expand and contract, sprockets must be mounted so that they are free to move laterally in the across-the-width direction. However, to prevent meandering (snaking) of the chain, one (or two) sprocket(s) should be locked in position in the center of both the drive and driven shafts using setscrews or set-collars and hexagonal socket head cap screws. When installing the sprockets on the square shaft, the inscribed markings or identification marks should be used to orient the sprockets so that they all face the same direction and to keep the position of the teeth aligned.

■Phase Matching of Sprockets

Install the sprockets on the shaft in such a manner that the direction and the position of all the inscribed markings or identification marks on the sprockets are aligned.

[Click to enlarge ]

■Chain Expansion/Contraction

Plastic modular chain is made of polymer resin, and will expand and contract with changes in temperature. A rough estimate for linear chain expansion is 15×10^-5 (/℃) using 20℃ as the reference temperature. The expansion per nominal width (⊿W) is found using the following formula:

⊿W = chain nominal width × (operating ambient temperature-20) ×15×10^-5

(Example) For K60 chain (1,524mm wide) used in an environment where the temperature rises from 20℃ to 60℃:

⊿W=1524× (60-20) ×15×10^-5 =9.1mm

■Locking Sprockets

The sprockets and the shaft are loosely fitted in order to absorb differences in thermal expansion between the chain and the conveyor and also installation errors of the chain and the sprockets. However, a setscrew, a hexagonal socket head cap screw, or a set-collar should be mounted on each side of a sprocket installed around the center with about 0.5mm (1.6mm for WT) clearance with the sprocket in order to prevent winding motion in the chain.

[Click to enlarge ]

Note: Fix the sprocket to be installed between the tab guide attachments when using a chain equipped with tab guide attachments.

■Chain Installation

Wind the chain onto the sprockets installed at the given intervals (refer to the “Chain Selection” section).

If the sprockets are installed at the wrong interval, the chain may run over the sprocket and break. Make certain of the center distance between the sprockets.

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A21

Generally, for plastic chain, the wearstrip should support the chain on the carry way, and the chain should be slack on the return way. Chain slack below the drive sprocket is especially important. Ensure there is 50 - 100mm of slack for 500 - 900mm spans (in drive operations). Tooth jumping (skipping) may occur with other slack values. Also, wearstrip installation on the conveying surface side will differ depending on the width of the chain, the presence of tab guide attachments, and Mold-to-Width chains.

Wearstrip layout

The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below.

Note: The wearstrip of the drive sprocket section and the end of the frame should be chamfered to prevent interference.

[Click to enlarge ]

Chain slack

Table 1 shows the spacing L between return rollers supporting the chain on the return way below the drive sprocket. The amount of slack in the chain between return rollers should be 50 to 100 mm. This slack prevents chain teeth jumping. There is a possibility of chain teeth jumping if the amount of slack is outside this range.

Return Roller Spacing L (Units: mm)
Chain Type	Chain tension rate (F1)
Chain Type	50% or less	More than 50%
BT6, BT8	500～700	800～1000
WT2250, BTC8S	600～900
WT1500, 2500, 3000, 3800	450～500

Note)

1.Refer to the technical notes in the catalog for Mold-to-Width chains.

2.For pasteurizers and other special conveyors, contact a Tsubaki representative.

3.Refer to the catalog technical notebook for installation of the nose bars at both ends.

Engagement angle

The engagement angle of the chain on the drive sprocket should be at least 180°. If the angle is small, teeth jumping may occur.

Wearstrip ends

A distance C equivalent to the pitch spacing of the chain should be provided between the sprocket and the end of the wearstrip. In addition, the end of the driven-side wearstrip should be rounded or chamfered to prevent the chain from snagging or catching on the wearstrip.

Location of Sprockets and Wearstrips

See illustration below.

[Click to enlarge ]

Example of Wearstrip Installation (at Ambient Temperature)

Wide Types (without Tab Guide Attachments)

Wearstrips should be located at equal intervals alternating with sprockets. Wearstrip spacing A is 76 mm for BTN; 76.2 mm for BT6, BT8, WT1500, WT3005, and BTC8S; 76.2 mm for WT2500 (wearstrip width of 25 mm); 85 mm for WT3086 and WT2250; and 100 mm for WT3816 (wearstrip width of 30 mm).

[Click to enlarge ]

Wide Types (with Tab Guide Attachments)

(Chains with tab guide attachments: BTN5-A, WT1505GK, WT1505GTOK, WT3005GK, and WT3086GK)

Tab guide attachments (to prevent meandering) should be installed so as not to interfere with the wearstrip.

[Click to enlarge ]

A Dimensions
Chain	A(mm)	Chain	A(mm)
WT1505G	44	BTC8-A	44
WT1505GTO	47	WT3005G	44
BTN5-A	44	WT3086G	44

Mold-to-Width Types (with Tab Guide Attachments)

Refer to the table below for guide clearance for chains with guides.Leave a clearance of around 1 mm between chains when used in multi-strand conveyors.

Chain	A(mm)
WT1505GM	44
WT1505GTOM	47
WT1505TOD	53
WT1515GM	31
WT2505GM	45
WT2505TOD	45
WT3005GM	44
WT3086GM	44
BTO8-M	44
BTC8H-M	44
BTM8H-M	44

[Click to enlarge ]

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A22

As the most common layout, we recommend supporting your chain with return rollers. Supporting with return roller enables to you to set an applicable chain slack and absorb elongation. When using chains with flights, you need to ensure that the flights and rollers do not interfere with one another. Other options include using a wearstrip.

Conveyor Layout

There are two methods of supporting the return way: the return roller system, and the wearstrip system. Examples are shown below.

Precautions:

1.Pay particular attention to the ends when connecting conveyors using TOD chain.

2.The infeed section of the return wearstrip should be made with a large radius of at least R40.

3.Cut the chain so that the catenary section will have an appropriate amount of slack to compensate for expansion and contraction caused by temperature changes. A tensioner or similar device should be used to adjust the chain take-up.

Supported by return rollers

Conveyor side view

Refer to the technical notes for L dimensions.
[Click to enlarge ]

Conveyor plan view

[Click to enlarge ]

The center distance of the rollers (in the direction of the conveyor width) should be adjusted according to the width of the chain to be used.

Supported by serpentine-style wearstrip

Conveyor side view

Refer to the technical notes for L dimensions.
[Click to enlarge ]

Flight Chain Return Way

The return way of a chain with attached flights or rubber carriers should be set up as shown below so that the flights do not interfere with rollers.

[Click to enlarge ]

Note: For wide chain, rollers should be positioned at 765-mm intervals.

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A23

Plastic modular chains are suitable for forward-reverse operation. See below for examples.

[Click to enlarge ]

Because a load 1.5 times the operating tension acts on the idler roller section in forward/reverse bottom drive, for wide machine width conveyors (greater than 1 m), either select a shaft that has adequate rigidity, or support the shaft using three-point mounting.

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A24

Using a nose bar can help you reduce the size of your transfer areas. See further information on BTC4-M chains, which can also provide the same function.

Layout of Abutting Nose Bars

The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below.

[Click to enlarge ]

Note: 1. Indicated dimensions are just for information, so finely adjust them depending on transfer conditions of the conveyed goods.

Note: 2. Even slight jerking due to the unstable shape of conveyed goods may cause trouble. Contact a Tsubaki representative when such goods have to be conveyed or chain jerking must be avoided.

[Click to enlarge ]

The use of WT1500 series or BTN5 chain allows layouts in which two conveyors connect head-to-tail. The width of the dead-plate used in the space where the two conveyors abut can be as small as 20 mm.

Note)

1.The dead-plate gap (marked with ※ in illustration above) will need to be adjusted depending on the objects being conveyed.

2.Applicable chains are the WT1500 series and BTN5 only. It should be noted that WT1505G cannot be adapted to this kind of layout.

Layout of Abutting BTC4-M Chains

For straight transfer with 10T sprockets

[Click to enlarge ]

For straight transfer with 18-mm-dia. shafts

[Click to enlarge ]

Note: The height level of the dead-plate should be finely adjusted according to transfer conditions of the conveyed goods.

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A25

We recommend using a TOD or GTO type chain that has an integrated transfer area. See below for layout and other information.

Layout of Right-Angle Transfers

A combination with WT1505GTO enables right-angle transfer of goods without using a dead-plate.

[Click to enlarge ]

Dimensions for mounting the chains are given below.

Insertion Conveyor (WT1505TOD/WT1500)

[Click to enlarge ]