SERIES GRP NYLON POWERTRAK® CHAIN

Installation & Operation Instructions

BEFORE YOU BEGIN installing your GRP PowerTrak Chain and Guide Trays, please read through these Instructions
completely! Refer to the last page for important information about installing your cable and hose conductors. Refer to your
General Arrangement drawing (when supplied) for the overall system layout, mounting dimensions, space requirements, travel
distance, and other application information. Contact the factory if you have any questions or concerns about your PowerTrak
Chain or Guide Trays installation.

INSTALLATION & OPERATION 3.a Lay cables/hoses in the chain compartment, allowing
The PowerTrak carrier system requires a level, rigid support sufficient length at each end for connections. Adjust the
for proper operation. A retaining tray to guide and support the separator(s) as required and reinstall retaining bars as
lower chain section is recommended. Ambient temperature described below. If more convenient, bars may be turned
of +50°F or higher is recommended while working with the around so they open on the opposite side of the chain.
PowerTrak Chain.
3.b Carefully insert hook at one end of the bar into the upper
When trays are required to guide and support the PowerTrak area of the notch in the link side-wall. Swing the bar down
chain for long travel distances: so the clip at the far end of the bar will seat into the notch in
the side of the link. Apply a downward force until the clip
1.a Position and fasten the individual tray sections together “snaps” into place. DO NOT hammer or stomp on the bar as
as shown on the accompanying general arrangement drawing. this could damage the retaining bar!
All tray joints must be butted together tightly and the inside
walls and bottom surfaces must be flush. DO NOT secure the 3.c The top of the link side wall and the retaining bar should
trays to the mounting surface at this time! The trays shall be be flush. Check to make sure the bar is “snapped” securely
supported at five-foot intervals (maximum) throughout the into the link.
entire length of the tray system AND within one foot distance
from all tray joints. 3.d Some PowerTrak chains may utilize a nylon split-bar
insert at every second or third link to carry the cables and
1.b If a general arrangement drawing was not supplied with hoses. In most chains, these are installed before shipment.
the PowerTrak chain, please contact the factory for instruction After removing the retaining bar, simply lift the upper half of
to properly arrange the different tray types to insure proper the split-bar out of the link frame.
installation of the guide trays.
3.e Install the cables and hoses into their proper custom-
2.a If the cables and hoses can be pulled through the machined compartments. Orient the top half of the split-bar to
compartment of the chain, the chain can be placed into the mirror the lower half already set in the link frame. Slide the
guide tray at this time. bar into the link frame so the grooves at each end mate with
the ribs on each side of the link.
2.b Be certain the fixed end mounting brackets are oriented
properly in the cable access tray section and anchor the 3.f Install the retaining bars as described in step-3.b. The
brackets per step 4. split-bar carrier will be captivated all around if properly
installed and cannot be removed or knocked out of the
2.c If the cables and hoses must be placed in the chain surrounding link frame.
compartment with access from the top, then lay the chain on a
clean, flat surface so the snap-fit retaining bars can be accessed 4. Secure the fixed end mounting brackets in the bottom of the
from the top-side of the link. cable access tray. Do NOT fasten to the rigid support beneath
the tray at this time! Locate and drill mounting holes through
2.d Locate clip ends of the retaining bars (largest protrusion at the tray bottom using the brackets as a template. Be certain
one end of the bar). Release the clip from the link using 1/4" the PowerTrak chain is centered between the sides of the tray
wide flat tip screwdriver. Insert the screwdriver beneath the and the chain is directed down the center of the tray system
end of the clip and gently twist until the bar “snaps” free and during operation.
swings upward. CAUTION: Bend the Clip only enough to
snap free from the side of the Link - too much deflection can 5. Fasten the movable end mounting brackets to the machine
fracture the Clip. tow arm in direct (plumb) alignment with the fixed mounting
brackets.
6. Complete all cable/hose terminations. The cables/hoses All nylons absorb moisture which has proven to enhance
must not be twisted and shall be free of kinks or other certain properties of Series GRP PowerTrak chain. The
irregularities. The basic rule for the maximum allowable moisture content decreases stiffness and increases elongation
cable/hose area utilized within the track compartment for and impact resistance. When handling the chain during
uniform arrangements is 20 percent clearance (minimum installation, length adjustments or part replacement, this
inside dimensions = cable/hose diameter x 1.20). This allows resiliency is important in preventing part fracture or breakage
for dimensional tolerances of the cables/hoses and insures due to abnormally high stresses which don’t occur during
freedom of movement to prevent erratic track operation and normal track operation. This does not imply that nylon Series
premature cable/hose failure. GRP PowerTrak is unbreakable, but it is an extremely tough,
long wearing, lightweight, corrosion resistant, low cost
7. Adjust cable/hose tension to help prevent twisting and method of containing electrical cables and hoses supplying
premature wear. Cable/hose must lay within the loop section power to machinery in motion.
of the track in a relaxed condition–not pulled tight against
the compartment frame–and follow a straight path through Series GRP PowerTrak chain is designed to be simple
the entire length of the track. Secure the cables/hoses at both to use, virtually maintenance free, and strong enough to
ends of the track, near the mounting brackets, to prevent any be self-supporting for shorter travel lengths containing
movement relative to the track. light to moderate payload weights. The resilient nature
of the PowerTrak material will allow deflection of longer
8.a Operate the machine slowly throughout the total travel unsupported track lengths to permit sliding upon itself,
stroke and align the tray system directly beneath the moving finished steel or rollers within a steel tray designed for this
mounting brackets. The brackets must center the chain purpose.
between the sides of the tray system throughout the entire
travel distance to provide smooth and free movement of the Series GRP PowerTrak components require no special tools
PowerTrak chain. Be certain the extreme ends of travel do not for installation or servicing. You will only need a 1/4" wide
exceed the limits of the chain. flat tip screwdriver approximately 6" long. An additional 3/8"
wide flat tip screwdriver is required for the larger chain sizes.
8.b Secure each tray section in at least two places to the
supporting structure or floor. This may be done by welding
or bolting through the bottom of the trays. You must use
flat-headed countersunk screws so the inside surface is flush
1. PART IDENTIFICATION
where the PowerTrak chain rests on the bottom of the trays.
No mounting holes are furnished in the trays, so they must be 1.1 Link Frame – U-shaped body with a wide, ribbed beam
drilled to match your mounting locations. molded integrally with the side plates. Side plates have holes
and slots or holes and pins for joining link frames.
9. No lubrication is required. To clean the PowerTrak chain,
periodically wash-down with water (do not allow to freeze) or 1.2 Link Caps (RH & LH) – For use on 263P and 354P chain
blow dirt and debris away with air pressure. sizes only. Discs with pins and arc-shaped bosses assembled to
sides of track. Model number, RH or LH, and arrow pointing
10. Periodically inspect for cable/hose wear, track wear and to track flexing radius are embossed on the caps. Link caps
breakage. Also check that track mounting brackets and cable/ join all link frames together without pins, bolts, or rivets.
hose terminations are secure. A centrally located 2 or 3 jaw pin holds caps in place for a
secure, reliable track assembly.

1.3 Retaining Bar – Removable, ribbed bar located at top

(open end) of the link frame and held in place by a hook at one
MATERIALS AND SERVICING GUIDE
end and a clip at the other end. The bars are factory installed
Track length adjustment and replacement of damaged or worn so the link compartment may be accessed from one side only.
parts can be accomplished by following these instructions When removed, they can be flipped end for end so access is
very carefully. But first, a brief discussion of material and from the other side of the track. This is a unique feature to
components will provide a better understanding. help ease compartment access of an installed track.

All Series GRP PowerTrak components are injection molded 1.4 Separators – Adjustable partitions within the track
of chopped fiberglass filled nylon resin with black colorant. compartment which separate cables/hoses so as to prevent
Nylon (polyamide) is a crystalline plastic exhibiting excellent cable/hose entanglement and act as a support column to
fatigue resistance, low coefficient of friction, good toughness, strengthen load capacity of the retaining bar. Separators
and resistance to a wide range of fuels and chemicals. Glass securely grip the link frame beam and cradle the retaining bar.
fiber reinforced compounds provide greater strength and
stiffness with improved impact strength. Flame retardant nylon
compounds are available with 94V-O classification.
Continued on next page...
2
 links or splice track
ambient temperatur
al fractures. Warm
1.5 Bar Carriers (optional) – For use on 263P and 354P 2.4 Continue forcing the screwdriver blade beneath the link cap until
chain sizes only. Machined nylon bars contain cables/hoses 2. LINK REMO
it snaps free of the inner link side wall. A 90° twist of the screwdriver
on an individual basis. They are custom manufactured per will lift the cap further. Rotate the cap in both directions to be sure it
specific payload requirements and increase cable/hose life by is free. 2.1 If track is
support t
restricting movement within link compartment.
2.5 Position the 3/8" wide screwdriver tip adjacent to the holding from tray
jaws between the link cap and side wall. Twist the screwdriver gently sides of t
1.6 Mounting Brackets – Zinc plated steel brackets are secured using the width of the tip to pry off cap. DO NOT pry off cap by
to both ends of the chain for a strong, reliable assembly. The lifting on screwdriver handle (as a lever) because force applied at
2.2the Identify l
bracket on one end of the chain is bolted to the fixed (non- outer rim could cause cap distortion or breakage. joint stre
moving) support surface. The opposite end is bolted to a arc in the
support arm on the moving machine. Brackets can be pivoted 2.6 Repeat steps 2.3 thru 2.5 for remaining link caps to be removed.
90° for face mounting or inverted. 2.3 Place a 1
2.7 Remove the links as required. edge of e
pushing t
MOUNTING 3. LINK ASSEMBLY (Models 263P & 354P only) shaped b
BRACKET face) and
TIP: Lay PowerTrak links on edge when assembling several links
SNAP-OUT NOT for
RETAINING BARS together and then assemble into track.
jaws at th
screwdriv
3.1 Select the proper radius and RH or LH side link cap by matching
MOUNTING with other link caps in the track. If unsure of RH or LH, position
BRACKET Link Caps, sepa- 2.4 Continue
links so you are looking into the end with the arc-shaped slots and the
rators and Bar
runners are at the bottom. The RH caps go onto the right side, the LH
the link c
Carriers not side wall
shown caps the left side.
the cap fu
LINK 3.2 Position link frames so the round holes at one end match up with to be sure
FRAMES
the arc-shaped slots in the adjacent link and the relative angle formed
2.5the Position
at the runner side is slightly less than 180°. Be sure all links have
runners facing a common direction. the holdi
wall. Tw
3.3 Position the link cap with the center jaws over the center hole of of the tip
the link side wall. Rotate cap until protrusions on the cap are aligned lifting on
with the holes in the inner link side wall. force app
distortion
Use the following procedures to adjust track length, replace
3.4 Gently squeeze link cap and link side walls together with hands
links or splice track sections. Adding or removing links
(apply evenly distributed force) until you hear the jaws snap into2.6 Repeat st
when ambient temperature is lower than +50°F may produce place. Be sure jaws “snap” through both outer and inner link walls. to be rem
material fractures. Warm material in hot tap water if required. A properly installed link cap will be tight against outer link wall and
will rotate with inner link wall. 2.7 Remove
2. LINK REMOVAL (Models 263P & 354P only)
3.5 Repeat steps 3.2 thru 3.4 for all link caps to be installed. 3. LINK ASSEM
2.1 If track is lying within a guide tray, elevate and support TIP: Lay PowerT
track above tray or completely remove from tray to allow eral links together
access to link caps on both sides of track. 4. LINK REMOVAL AND ASSEMBLY (All other models)
4.1 Determine link(s) to be removed and insert blade of 1/4" wide flat
2.2 Identify link joints to be disassembled and relieve joint tip screwdriver between link frame side walls. Gently pry apart until
stress by shimming track to establish a slight arc in the flexing the outer wall pull free from the pin. If links cannot be separated,
direction. carefully repeat operation on the opposite side.

4.2 To assemble, match male and female ends of adjacent links and
2.3 Place a 1/4" screwdriver into the recess at the edge of each push together for a snap-fit.
link disc. Gently pry the cap off by pushing the screwdriver tip
between the kidney shaped bosses (visible as indentations on NOTE: Some PowerTrak chains are available as riveted assemblies.
disc face) and the central holding jaws. NOTE: DO NOT force Long sections are shipped in shorter lengths with additional pop-
the blade directly toward the holding jaws at the center of the rivets and washers for splicing joints. For additional information
cap. An impact from the screwdriver may fracture the jaws. contact Gleason Reel.

3
 Cable and Hose Guidelines
Special attention must be given when installing cable or hose into PowerTrak chain. Below are a few considerations:

MOVING END MACHINE MOVEMENT

CURVE RADIUS
Minimum cable/hose bend radius POWERTRAK
must be less than chain bend radius. CHAIN
FIXED END

Figure 1

CABLE/HOSE SELECTION
1. Select cable or hose with minimum bend radius (MBR) less 3. Arrange cables/hoses in the compart-
than bend radius of the chain. Follow cable or hose manufacturer’s ment so as to allow adequate movement.
specifications and guidelines. See Figure 1. The largest cable or hose in the chain should
have 20% clearance of the inside height and
2. Select cable that is rated “continuous flex”. Cables built for the total of all cables/hoses should have 20%
robotics are designed to flex millions of times, but some only flex on clearance of the inside width (Fig. 7).
one axis. Consult your supplier for complete
cable specifications. Figure 7
4.
3. Be sure cable and hoses are suitable for use in anticipated oper- Figure 8 Cables/hoses should be
ating environment. This is especially important in outdoor applica- installed along the centerline
tions where sub-zero temperatures cause some cable or hose material of the carriers (Fig. 8). This
to stiffen or even break. eliminates undue cable/hose
wear caused by excessive contact
INSTALLATION on the inner or outer radius of
the chain. Be sure cables/hoses
1. The cables/hoses must not have twists, bends or kinks at the are not under tension or installed
time of installation. Unspool (do not uncoil) cable or hose from with too much slack.
shipping reel several hours in advance of installation. Hang cables
and hoses for 24 hours or, at the 5. Allow extra space in the
minimum, lay out in straight compartment for high pressure hoses. Depending on type of con-
line to allow kinks and curves to struction, some hoses will increase in length under pressure while
straighten out. See Figure 2. others will shrink. Check hose manufacturer to ascertain how much
shrinkage or lengthening will occur.
Figure 2
2. Arrange cables and hoses in
the chain so that load is evenly 6. Clamp all cables/
CABLE
distributed across width with largest and/ hoses firmly at CLAMPS
or heaviest cables/hoses located to the outer both ends of the
sides of the chain (Fig. 3). Use separators chain (Fig. 9). To
between different sizes of cables and hoses to avoid damage to the
Figure 3 maintain proper spacing and to reduce cable/ inner structure of the
hose jacket wear (Fig. 4). Do not place large cables/hoses, clamp
cable or hoses in same compartment with over a wide area Figure 9
small ones (Figs. 5 & 6). of the outer jacket.
Always leave slack
Figure 4 between clamps and
termination points to
avoid stress on cables/hoses.

7. Test run PowerTrak chain at slow speed to make sure there is

no pinching and that no kinks have developed in hoses or cables.
Figure 5 Figure 6 Perform test with hoses at operating pressure. Re-adjust cable/hose
length if required.

Gleason Reel Corp.

600 S. Clark St.
Mayville, WI 53050
Phone 920-387-4120 • FAX 920-387-4189
© COPYRIGHT GLEASON REEL CORP. [Link] Bulletin 046823.b