Packaging

At your packaging facilities, the best conveyor solutions should make the most use of moving trays, boxes, crates and available floor space.

Retail & E-Commerce

From order fulfillment to shipping, large products to tiny products, Span Tech conveyors can be custom designed to fit your e-commerce needs.

Food Production

Span Tech designs food conveyor systems that effectively do it all: accumulate, merge, divide, incline, vertically convey, deposit, reject and reclaim.

Beverage Production

With easy sanitation and cleaning, our conveyors can handle beverage products and compounds of all dimensions.

Manufacturing

Span Tech manufactures easy to integrate, modular custom conveyor solutions that can easily be modified or redesigned for all product changes.

Pharmaceutical

Pharmaceutical production requires especially sterile conveyor environments designed for accessibility, reliability, and flexibility to prevent the dangers of cross-contamination across multiple products.

Cosmetics

Span Tech offers a range of solutions that are also highly adaptable, meaning they can easily accommodate the assembly and distribution of even the most delicate cosmetic materials and personal care items.
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Troubleshooting Diagnostic Chart

The Troubleshooting Diagnostic Chart is designed to help you quickly diagnose common conveyor system problems. Below, you’ll find a list of common symptoms, their potential causes, and recommended corrective actions.

Diagnostic Chart Overview

How to Use This Chart:

  1. Find the Symptom: Identify the problem you’re experiencing.
  2. Check the Probable Causes: Review the possible reasons the issue is happening.
  3. Follow the Corrective Actions: Use the suggested steps to resolve the issue and prevent it from recurring.

Quick Links:

  • Chain Issues
  • Sprocket Problems
  • Motor and Electrical Issues
  • Wearstrip and Contamination Issues
  • Alignment Problems

Troubleshooting Chart: Problems and Solutions

Symptom Probable Causes Corrective Actions
Chain jumping sprockets Misaligned sprockets, improper sprocket/chain engagement, too much slack in the chain Realign sprockets, adjust chain slack, check sprocket teeth for wear
Excessive chain slack Elongated chain, improper installation of chain Remove extra links from the chain or replace worn chain
High friction or overheating Contaminated chain/wearstrips, worn or damaged wearstrips Clean chain and wearstrips, replace worn wearstrips, check lubrication levels
Chain derailment Broken or bent chain links, improperly installed wearstrips, foreign object interference Replace broken links, realign wearstrips, remove foreign objects
Motor strain or high current draw Excessive chain tension, improper sprocket engagement, blocked components Adjust chain slack, inspect sprockets, clear any blockages or foreign objects
Loud scraping or grinding noises Worn wearstrips, foreign object interference, chain misalignment Replace wearstrips, remove obstructions, realign the chain
Chain doesn’t move smoothly Chain slack issues, chain elongation, worn sprockets Adjust chain slack, replace elongated chains, inspect and replace sprockets if necessary
Sprocket teeth worn down Misaligned chain/sprockets, over-tensioned chain, lack of lubrication Re-align sprockets, adjust chain tension, ensure proper lubrication
Conveyor stopping intermittently Overloaded system, motor overheating, excessive chain slack Reduce load, check motor for overheating, adjust chain slack

Detailed Problem Categories

Let’s break down some of the most frequent issues in more detail, providing a deeper dive into symptoms and solutions.

1. Chain Issues

Problem: Chain Jumping Sprockets

Symptoms: The chain frequently comes off or jumps sprocket teeth.
Possible Causes:

  • Sprockets are misaligned or not engaging with the chain correctly.
  • Excessive slack in the chain.

Fixes:

  • Realign Sprockets: Use an alignment tool to ensure sprockets are aligned with the chain.
  • Adjust Chain Slack: Add or remove links to get the proper amount of slack.
Problem: Chain Derailment

Symptoms: Chain falls off the conveyor track.
Possible Causes:

  • Wearstrips are damaged or misaligned.
  • Foreign objects are interfering with the chain’s path.

Fixes:

  • Replace Wearstrips: Ensure they are properly seated and free from overlaps.
  • Remove Debris: Clear any objects that may have fallen into the chain’s path.

2. Sprocket Problems

Problem: Sprocket Teeth Worn Down

Symptoms: Sprocket teeth are visibly worn, causing the chain to slip or jump.
Possible Causes:

  • Chain is too tight, causing excessive wear on the sprockets.
  • Chain and sprockets are misaligned, causing uneven wear.

Fixes:

  • Adjust Chain Tension: Ensure proper slack to reduce strain on the sprockets.
  • Check Sprocket Alignment: Realign sprockets to ensure smooth engagement with the chain.
Problem: Improper Sprocket/Chain Engagement

Symptoms: Chain doesn’t fully engage with the sprockets, causing slippage.
Possible Causes:

  • Sprockets are misaligned or the teeth are worn down.

Fixes:

  • Realign or Replace Sprockets: If sprockets are worn, replace them. Ensure proper alignment to prevent future issues.

3. Motor and Electrical Issues

Problem: High Motor Current Draw

Symptoms: The motor is pulling more current than normal, causing strain or overheating.
Possible Causes:

  • Excessive chain tension or friction due to contaminated wearstrips.
  • Blocked components such as foreign objects stuck in the conveyor path.

Fixes:

  • Reduce Chain Tension: Adjust chain slack to reduce strain on the motor.
  • Clear Blockages: Inspect the entire system for foreign objects or blockages that may be causing resistance.
Problem: Conveyor Stops Intermittently

Symptoms: Conveyor runs but frequently stops unexpectedly.
Possible Causes:

  • Overloaded system or motor overheating.
  • Chain slack causing excessive strain on the motor.

Fixes:

  • Reduce Load: Ensure the load on the conveyor is within specified limits.
  • Check Motor Temperature: If the motor is overheating, allow it to cool and investigate the cause (overload, lack of lubrication, etc.).

4. Wearstrip and Contamination Issues

Problem: High Friction or Overheating

Symptoms: Conveyor is hot to the touch or producing unusual noise due to friction.
Possible Causes:

  • Contaminated chain or wearstrips with debris like dirt, dust, or product residue.
  • Worn or damaged wearstrips.

Fixes:

  • Clean the Conveyor: Use rubbing alcohol or water to clean the chain and wearstrips.
  • Replace Wearstrips: If they are worn or warped, replace them immediately.
Problem: Wearstrips Damaged or Misaligned

Symptoms: Chain binds, derails, or grinds against the side of the conveyor.
Possible Causes:

  • Wearstrips are not seated properly or have been damaged due to wear.

Fixes:

  • Realign Wearstrips: Check that wearstrips are seated correctly and meet without overlapping.
  • Replace Damaged Strips: Install new wearstrips if the old ones are worn down or warped.

5. Alignment Problems

Problem: Misaligned Conveyor Bed Sections

Symptoms: Conveyor sections are misaligned, causing the chain to bind or derail.
Possible Causes:

  • Side frames or bed sections are not aligned correctly.

Fixes:

  • Realign Conveyor Bed Sections: Ensure that all sections of the conveyor bed are properly aligned. Use an alignment tool if necessary.
  • Inspect Side Frames: Make sure side frames are straight and free from warping.
Problem: Bound or Locked Idler Shaft

Symptoms: Idler shaft is not rotating freely, causing increased torque and motor strain.
Possible Causes:

  • Outer sprockets are rubbing against the side plates or there’s a bearing failure.

Fixes:

  • Loosen Sprockets: Place a shim between the side plates and the sprockets to reduce friction.
  • Check Bearings: Inspect and replace any damaged bearings to ensure the idler shaft rotates freely.

Additional Troubleshooting Tips

Preventing Chain Elongation:

  • Chains naturally elongate over time due to wear. Measure the chain’s elongation percentage regularly and replace it if elongation exceeds 4% for MonoSpan and MultiSpan chains or 2% for MaxiSpan chains.

Chemical Contamination:

  • Certain chemicals can cause conveyor components, like plastic parts, to become brittle and fail. Always check the Chemical Compatibility Chart and avoid exposing the system to harsh chemicals.

 

Need Expert Help?

Still having trouble diagnosing an issue? Contact our support team for further assistance or to schedule a service visit. We can also help you order replacement parts to get your system up and running as soon as possible.

Contact Information

Our dedicated team of technicians is available to assist with any troubleshooting, assembly, or maintenance questions.

Customer Support Team

Ordering Replacement Parts

Need a replacement part for your conveyor system? We make it easy to order what you need to keep your system running smoothly.

How to Order Parts:

  1. Identify the Part: Use the conveyor’s Bill of Materials, Span Tech’s Owner’s Manual or The Service & Parts Manual to locate the part number. Common replacement parts include wearstrips, chain links, sprockets, and safety labels.
  2. Submit a Request: Contact our parts department with the part number and a description of the issue to ensure the correct part is ordered.
  3. Shipping and Delivery: Most parts are available for immediate shipping. Expect delivery within 3–5 business days.

     

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