CONVEYOR DESIGN MANUAL I VERSION 2

Rexnord® MatTop® Chains

Nose-Over Conveyor Design Manual

1500 Series MatTop Chains
7526 Series MatTop Chains
7846 Series MatTop Chains
8500 Series MatTop Chains

REXNORD FLATTOP NORTH AMERICA

Rexnord Industries, LLC
For more than one hundred years, Rexnord® has provided superior power transmission, bearing,
aerospace and specialty components to industries across the globe. We pride ourselves in commitment and dedication
to the customer – from development to manufacturing, from installation to service.

This commitment and dedication are the centerpieces as Rexnord Industries begins our next
century of growth. We are taking on new challenges and opportunities with a fresh look on
the future.

Precision. Power. Performance.TM

It’s more than a new slogan, it’s a promise – the Rexnord promise.

FlatTop Global’s Vision

To be the best in the world at continuously improving customers’ productivity through superior material handling solu-
tions.

Rexnord Industries, LLC Mission

To be a leading marketer and world class manufacturer of precision motion technology products & systems and pro-
vide superior growth and command sustainable competitive advantage.

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800
 CONTENTS

4 Introduction / Safety Considerations

8 NOSE-OVER TRANSFER TYPES

10
1500 SERIES
Components, Mounting & Sprocket Locations

20
7526 SERIES
Components, Mounting & Sprocket Locations

22
7846 SERIES
Components, Mounting & Sprocket Locations

28
8500 SERIES
Components, Mounting & Sprocket Locations

34 DRIVE CONFIGURATIONS
General Recommendations
Bi-Directional Conveyors
Uni-Directional Conveyors

38 carry and return ways

39 high speed applications

40
unstable product transfer applications and
adjustability

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD
Introduction
Typical chain and belt sprockets are approximately 5 to 6 in (127 to 152 mm) in diameter. For end-to-end transfers, long stationary dead
plates are required. Upstream products need to push the containers across the deadplates and can cause tipping or even damage product. In
addition, at the end of a shift or production run, containers must be cleared off manually.

Rexnord® 1500, 7526, 7846 and 8500 series MatTop® chains eliminate these long deadplates. Each of these chains was designed with a small
pitch and both the 1500 and 7846 have a curved bottom contour providing a small transfer length.

• 1500 MatTop Chain has a 0.59 in (14.9 mm) pitch and curved bottom contour

• 7526 MatTop Chain has a a 0.50 in (12.7 mm) pitch and can be used in side-flexing applications

• 7846 MatTop Chain has a 1.00 in (25.4 mm) pitch and curved bottom contour, that can be used in side-flexing
applications

• 8500 MatTop Chain has a 0.75 in (19.1 mm) pitch

As products are becoming less stable, conveyor applications are becoming more demanding. This makes these nose-over chains ideal for
these lighter, less stable containers - especially empty aluminum cans and PET bottles.

1500 MatTop Chain 7526 MatTop Chain 7846 MatTop Chain 8500 MatTop Chain

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

4
INTRODUCTION
To complement the MatTop® chains, Rexnord® offers three nose-over transfer designs to
successfully transfer products from one conveyor to the next:

• Dynamic Nose-over Bar (1500, 7846 and 8500 Series):

The first design is the dynamic nose-over bar which utilizes bearings captured in a bar to
create a rolling surface instead of a sliding surface. The rolling elements help to reduce
wear on the bar, which is especially critical on unstable product transfers. Dynamic Nose-Over Bar

• Static Modular Nose-over Bar (1500 Series):

The second design is a patented stationary nose-over bar that has a modular design to
accommodate all chain widths and eliminate custom fabrication. The wear element is
replaceable, which makes it very cost effective. Conveyors can be designed to allow the
nose-over bar to be replaced without having to disassemble the chain, which reduces
maintenance costs. The smooth surface and curved chain bottom provides increased
surface contact, resulting in decreased wear. The patented nose-over bar was designed Modular Static Nose-Over Bar
specifically for Rexnord 1500 series MatTop chain.

The modular nose-over bar kits are offered in standard and low profile versions. The low
profile version allows the chain to be wrapped 180° around the nose-over bar without
breaking contact, therefore maximizing surface contact and minimizing noise.

• Small Sprocket (1500, 7846 and 8500 Series):

The third design utilizes a small tooth sprocket on a small which are ideal for reducing
friction, noise and vibration.

Small Sprocket

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

5
INTRODUCTION
This manual provides general guidelines for using Rexnord® products in a nose-over conveyor application, including chain dimensions, basic
conveyor design considerations, and installation recommendations. Following the suggestions outlined in this manual will ensure proper
operation of the conveyor to provide the optimal product handling and optimum chain life. This manual contains information that is specific to
the Rexnord 1500, 7526, 7846 and 8500 MatTop® chains and should be used in conjunction with the Rexnord Engineering manual (8rxEM-en)
which can be downloaded from www.rexnord.com website.

Conveyor designs from different OEM’s (Original Equipment Manufacturers) vary, and sometimes deviate from our
general guidelines. For example, there are different approaches to transferring product across adjacent nose-over
chains. One method is to step down the product from the infeed chain onto the transfer plate and then step down
again onto the outfeed chain. A second method keeps both the infeed and outfeed chains level to each other with
the nose-over transfer plate orientated slightly lower. Both methods are shown below for reference. The first method
is shown throughout the design manual, however, both methods are acceptable transfer systems.
(0.8 mm)

(0.8 mm)
0.03 in

0.03 in
Outfeed Chain Infeed Chain

Minimum Deadplate Width*

m))

m))
00..0033 iinn
mm

00..0033 iinn
mm
((00..88 m

((00..88 m

Standard Profile Nose-Over Bar Low Profile Nose-Over Bar

(135 - 150° Chain Wrap) (135 - 180° Chain Wrap)

Transfer plate and outfeed chain both step down from the infeed chain
All of the dimensions in the chart are
or based on a gap of 0.06 in (1.5 mm)

Dynamic Nose-Over Bar

m))
m))

00..0033 iinn
mm
00..0033 iinn
mm
(0.8 mm)

(0.8 mm)

(Not Shown)
0.03 in

((00..88 m

0.03 in
((00..88 m

Outfeed Chain Infeed Chain

1500 - 7 Tooth Sprockets (180 Chain Wrap)

Minimum Deadplate Width*

m))

m))
00..0033 iinn
mm

00..0033 iinn
mm
((00..88 m

((00..88 m

Standard Profile Nose-Over Bar Low Profile Nose-Over Bar

(135 - 150° Chain Wrap) (135 - 180° Chain Wrap)

Infeed chain and outfeed chain are level to each other and the transfer plate steps down
All of the dimensions in the chart are
or based on a gap of 0.06 in (1.5 mm)
For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800
Dynamic Nose-Over Bar
m))
m))

00..0033 iinn
mm
00..0033 iinn
mm

(Not Shown)
((00..88 m
((00..88 m

6
1500 - 7 Tooth Sprockets (180 Chain Wrap)
SAFETY CONSIDERATIONS
PRODUCT SAFETY: Products designed and manufactured by Rexnord® are capable of being used in a safe manner;
but Rexnord cannot warrant their safety under all circumstances. PURCHASER MUST INSTALL AND USE THE PROD-
UCTS IN SAFE AND LAWFUL MANNER IN COMPLIANCE WITH APPLICABLE HEALTH AND SAFETY REGULATIONS
AND LAWS AND GENERAL STANDARDS OF REASONABLE CARE; AND IF PURCHASER FAILS TO DO SO, PURCHAS-
ER SHALL INDEMNIFY REXNORD FROM ANY LOSS, COST OR EXPENSE RESULTING DIRECTLY OR
INDIRECTLY FROM SUCH FAILURE.

SAFETY DEVICES: Products are provided with only safety devices identified herein. IT IS THE
RESPONSIBILITY OF PURCHASER TO FURNISH APPROPRIATE GUARDS FOR MACHINERY PARTS in compliance
with MSHA or OSHA Standards, as well as any other safety devices desired by Purchaser and/or required by law; and
IF PURCHASER FAILS TO DO SO, PURCHASER SHALL INDEMNIFY REXNORD FROM ANY LOSS, COST OR EXPENSE
RESULTING DIRECTLY OR INDIRECTLY FROM SUCH FAILURE.

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

7
NOSE-OVER TRANSFER TYPES - End-to-end
There are two types of nose-over transfers: End-to-end transfers or 90° transfers. Both types of transfers typically require a deadplate to span
the gap between the two chains. The deadplate may not be required if the product is large enough to span the gap. The chart below provides
the minimum deadplate width required per chain series.

Outfeed Chain Infeed Chain

Minimum Deadplate Width*

(0.8 mm)

(0.8 mm)
0.03 in

0.03 in

Standard Profile Nose-Over Bar Low Profile Nose-Over Bar

(135 - 150° Chain Wrap) (135 - 180° Chain Wrap)

All of the dimensions in the chart are

or based on a gap of 0.06 in (1.5 mm)

Dynamic Nose-Over Bar

(0.8 mm)
(0.8 mm)

0.03 in
0.03 in

(Not Shown)

1500 - 7 Tooth Sprockets (180 Chain Wrap)

End-to-End Nose-Over Transfer shown with 1500 MatTop® Series

Minimum Deadplate Width per Chain Series

Minimum Deadplate Width
Chain Series
with Nose-Over Bar Sprocket Size with Small Sprocket
1500 0.89 in (22.6 mm) 1.12 in (28.4 mm)
1503 1.03 in (26.2 mm) 7T 1.20 in (30.5 mm)
1505 RubberTop™ 1.08 in (27.4 mm) 1.31 in (33.3 mm)
7526 1.24 in (31.5 mm)
NA NA
7526 PT 1.47 in (37.3 mm)
7846B 1.58 in (40.1 mm)
9T 2.43 in (61.7 mm)
7846 and 7846T 1.38 in (35.0 mm)
8500 1.31 in (33.3 mm) 1.93 in (49.0 mm)
10T
8505 RubberTop™ 1.67 in (42.4 mm) 2.29 in (58.2 mm)

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

8
NOSE-OVER TRANSFER TYPES - 90°

Outfeed Chain

Minimum
Deadplate Width
Infeed Chain

(0.8 mm)
(0.8 mm)

0.03 in
0.03 in

Low Profile Nose-Over Bar

(135 - 180° Chain Wrap)
(0.8 mm)
(0.8 mm)

0.03 in
0.03 in

Standard Profile Nose-Over Bar

(135 - 150° Chain Wrap)

Dynamic Nose-Over Bar

(Not Shown)
(0.8 mm)
(0.8 mm)

0.03 in
0.03 in

1500 - 7 Tooth Sprockets (180° Chain Wrap)

90° Nose-Over Transfer shown with 1500 MatTop® Series

The DynamicTransfer System™ will accomplish a self clearing, 90° transfer without the use of a deadplate.
(Details can be found in the Rexnord­® Engineering Manual 8rxEM-en in the Conveyor Design Recommendations
section for MatTop­® Chains).

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

9
1500 series - components
Nose-Over Bar Kits

Dynamic nose-over Bar

• Standard material for nose-over bar is UHMWPE
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side-by-side to obtain a variety of
widths; however, they can not be cut to smaller widths 1500 Series Dynamic Nose-over Bar

Standard profile kit

• Kits include 2 clamping plates and 1 nose-over bar (replaceable wear element)
• Standard material for nose-over bar (replaceable wear element) is moly filled
nylon (PA) and base is reinforced nylon
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side-by-side to obtain a variety of widths

Low profile kit

1500 Series Standard Profile Kit
• Kits include 2 clamping plates and 1 nose-over bar (replaceable wear element)
• Standard material for nose-over bar (replaceable wear element) is moly-filled
nylon (PA) and base is reinforced nylon
• Hardware is included
• Multiple modular nose-over bars can be used side by side to obtain a variety of widths

Replaceable wear elements

• Standard material for nose-over bar (replaceable wear element) is moly-filled
nylon (PA) and base is reinforced nylon
• Other widths are available

Dynamic Nose-Over Bar Parts for 1500 MatTop® Chain Series 1500 Series Low Profile Kit
Style Part Number Overall Length Hardware
905-656231 18 in (457 mm) None
Dynamic Nose-Over Bar Kit
905-656241 24 in (609 mm) None
Standard Profile Kit 905-655711 6 in (152 mm) None
905-655721 6 in (152 mm) M6
Low Profile Kit
905-655731 6 in (152 mm) 1/4-20
Replaceable Wear Element* 905-655771 6 in (152 mm) None
1500 Series
* One part number consists of six nose-over bars (each bar is 6.00 in (152.4 mm) long) Replaceable Wear Element

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

10
1500 series - components
N1500-7T Sprocket with Retaining Rings

• Two sprocket halves and two retaining rings are provided per part as shown below
• Small pitch diameter sprocket is ideal for tight end-to-end transfers and low profile conveyors
• Available in two bore styles: Integral key (shown below) and Idler bore (not shown)
• Integral key is cost effective because it eliminates key stock and is easy to assemble – fits standard keyway and does not
require a setscrew
• Bores available to fit standard 3/4 in and 20.0 mm shafting

N1500-7T Sprocket with Two sprocket halves and retaining rings

Integral Key

General Notes

• A polyester pin MUST be used for all nose-over applications – the polyester pin should be specified when ordering.
The only exception is TCF chains which should utilize the standard acetal pin

• Small 0.59 in (14.9 mm) pitch is ideal for handling small, unstable products
• The minimum deadplate widths for 1500 MatTop® Chain series is shown on page 8
• Curved bottom contour for smooth operation over tight nose-over transfers – improved sliding wear life by virtue of full
surface contact between bottom of chain and nose-over bar
• When using TCF chains on UHMWPE nose-over bars, normally the UHMWPE wear element will wear faster than the
chain. UHMWPE wear elements are available on a MTO basis. When using TCF chains on moly-filled nylon nose-over
bars, normally the chain will wear faster than the wear element
• The LBP rollers on 1503 chain extend 0.06 in (1.5 mm) above the chain surface. The RubberTop™ surface on
TCF and HTF1505 chains extend 0.09 in (2.2 mm) above the chain surface. These dimensions must be taken into
account when designing nose-over transfers with LBP and RubberTop™ chains

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

11
1500 series - mounting information
Static Modular Nose-Over Bar - Standard Profile
• Standard nose-over kit should be used for wide conveyors that need more rigid support under nose-over
• Standard profile nose-over kits are not furnished with fasteners
• Nose-over kits should use 5/16-18 or M8 flat head cap screws (not included)

0.72 in 1.50 in Outer Diameter

(18.3 mm) (38.1 mm)

0.75 in See Caution

(19.1 mm) Note below 0.06 in
(1.5 mm)
Minimum Gap

Standard Nose-Over Profile Mounting

See Caution
Note below

135 - 150° Chain Wrap

Standard Nose-Over Profile Mounting

Make sure that the nose-over bar mounting plate does not interfere with the chain.

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

12
1500 series - mounting information
Static Modular Nose-Over Bar - Low Profile
• Low profile nose-over kit is suitable only for narrow conveyor widths and is limited by deflection of the 0.25 in
(8 mm for metric version) thick mounting plate
• Typically the mounting plate extends the width of the conveyor and is mounted to the conveyor side frames
• Low profile nose-over kit can obtain a maximum wrap angle of 180°. This allows the chain to be wrapped completely around
the nose-over bar without breaking contact, maximizing surface contact and minimizing noise

1.50 in
0.72 in 1.50 in Outer Diameter
(38.1 mm)
(18.3 mm) 0.44 in (38.1)
(11.1 mm)

0.75 in 0.25 in
(19.1 mm) (6.4 mm)
0.06 in
(1.5 mm)
Minimum Gap

Imperial Nose-Over Low Profile Mounting

0.72 in 1.50 in Outer Diameter

(18.3 mm) (38.1 mm)

0.32 in
0.75 in
(18.3 mm)
(19.1 mm)

135° - 180° Wrap Angle

Metric Nose-Over Low Profile Mounting

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13
1500 series - mounting information
Dynamic Nose-Over Bar
• Use standard 5/16 in or M8 flat head screws (not included)
• The dynamic nose-over bar is typically used in applications that handle products that are difficult to convey and/or high
speeds

1.50 in
(38.1 mm)
1.50 in Outer Diameter
(38.1 mm)
0.38 in
0.72 in (9.7 mm)
(18.3 mm)

0.75 in
(19.1 mm) See Caution
Note below

0.06 in
(1.5 mm)
Minimum Gap

See Caution
Note below

135 - 150° Chain Wrap

Dynamic Nose-Over Mounting

Make sure that the nose-over bar mounting plate does not interfere with the chain.

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

14
1500 Series - mounting information
Dynamic Nose-Over Bar

Hole Spacing Width

(19.1 mm)
0.75 in
0.34 in
(8.6 mm) 3.00 in 1.50 in
Diameter (76.2 mm) (38.1 mm)
Hole Spacing
Length

Overall Length = 18 or 24 in (457 or 609 mm)

Front of Nose-Over Bar

2.62 in

Mounting Hole to
(66.5 mm)

(28.3 mm)
Module Width

1.12 in
(19.1 mm)
0.75 in
Dynamic Nose-Over Mounting

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

15
1500 Series - mounting information
7 Tooth Sprocket
• The 7 tooth sprockets are recommended for nose-over transfers to reduce chain tension and minimize noise
• The minimum deadplate for this type of a transfer is 1.00 in (25.4 mm)
• 180° wrap angle is recommended to ensure proper engagement of chain and sprocket
• A 3/4 in or 20.0 mm diameter shaft is required. The conveyor width will be limited by bending deflection
• Recommend maximum bending deflection of shaft to be 0.06 in (1.5 mm)
• For applications that exceed this deflection, a center support is required (see concept drawings below)
• Use standard ANSI/ASME machine shafting for proper hardness, surface finish and straightness
• Can be used as an idler sprocket or drive sprocket
• Sprocket locations are shown on page 18

(0.8 mm) Transfer Plate

(21.3 mm)

Shaft Drop
(12.7 mm)

0.03 in
0.84 in

0.50 in

(0.8 mm)
Wearstrip

0.03 in
0.59 in
(14.9 mm)

1.69 in
(42.9 mm)
1.75 in
Chain Wrap Diameter
(44.5 mm)

0.06 in
(1.5 mm)
Minimum Gap

1500-7T Sprockets

Concept Drawings of Center Shaft Support (not supplied by Rexnord®)

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

1500-7T Sprockets
16
1500 series - mounting information
General Recommendations (Standard and Low Profile)
It is recommended to extend the nose-over assembly beyond the end of the conveyor frame or otherwise expose the end of the replaceable
wear bar to allow replacement without disassembly of components.

Concept of Nose-over Bar Access for Replaceable Wear Element

Cut Modular Nose-Over Bars (Standard and Low Profile)

• Nose-over bar ends should be positioned in a staggered pattern with the ends of the nose-over clamps
• Clamping plates and wear elements may be cut down the center to create a 3 in (76 mm) module for custom widths
(as shown below)

5 in 5 in 5 in
(127 mm) (127 mm) (127 mm)
(19.1 mm)

(18.8 mm)

Wear Bar Length Wear Bar Length Wear Bar Length

0.75 in

0.74 in

3 in 3 in 3 in 3 in
(76 mm) (76 mm) (76 mm) (76 mm)
(66.5 mm)
2.62 in

Conveyor

15 in
(381 mm)
Chain Width

Example of Cut Modules

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17
1500 series - sprocket location
Sprocket Location and 7T Mounting Information

12.00 in
(304.8 mm)

3.00 in
(76.2 mm)

3.00 in 3.00 in 3.00 in

(76.2 mm) (76.2 mm) (76.2 mm)

See detail below

Sprocket Locations
(0.035 mm +/- 0.05)
0.014 in +/- 0.002

+ 0.002
0.02 in - 0.000
+ 0.051
0.51 mm - 0.000

0.375 in
(9.53 mm)

7T Sprocket Mounting Detail

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

18
notes

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

19
7526 series - components
Nose-Over Bar Dimensional Information (Nose-Over Bar Not Supplied by Rexnord®)
• Rexnord does not supply a nose-over bar; however, the information below provides general dimensional information to match
with the 7526 Series MatTop Chain.

Chain Width
(20.0 mm)
Diameter
0.79 in
(30.0 mm)
Diameter
1.18 in

Chain Width - 2.76 in 0.19 in

0.79 in
(Chain Width - 70.0 mm) (1.0 mm)
(20.0 mm)
Radius

7T Sprocket Mounting Detail

General Notes
• Small 0.59 in (15.0 mm) pitch is ideal for handling small, unstable products
• The minimum deadplate widths for 7526 MatTop® Chain series is shown on page 8
• The nose-over bar must contain two grooves to accomodate the PosiTrack™ Tracking Guides on both edges of the
chain. The chain must be supported on both sides of the PosiTrack Tracking Guides as shown above. These grooves
should not be used to track the chain
• It is recommended to utilize a dynamic nose-over bar whenever possible
• If a static nose-over bar is utilized it is strongly recommended to utilze moly-filled material which provides a higher
PV limit and allows for more optium wear
• See the 7526 MatTop Chain Design Manual (8rx7526dm-en) which can be downloaded from www.rexnord.com
for more details on this chain series

For technical assistance contact Rexnord® Application Engineering if you need assistance at 262-376-4800

20
7526 series - sprocket location
Sprocket Location
• Number of sprockets at drive end: (Chain Width / 85 mm) + 2 for curve applications
• Number of sprockets at idler end: (Chain Width / 85 mm)
• Example: A 340 mm chain requires 6 sprockets at the drive end ((340 mm / 85 mm) + 2 = 6)

W1 W2 W3 Wx

0.50 in 1.34 in 1.34 in Evenly Spaced Sprockets 1.51 in

(12.8 mm) (34 mm) (34 mm) (38.3 mm)

Chain Width
Ro Ri

Sprocket Locations

Ri = Inside Radius
Ro = Outside Radius
Sprockets W1, W2, W3, W4 and Wx are spaced per the drawing. All of the other sprockets are evenly spaced

All sprocket bores are oversized for a sliding fit. To properly track the chain over the head and tail shafts, at least one
sprocket needs to be secured in position on the shaft (i.e. set collars, snap rings, etc.). This is necessary for both
round and square bore sprockets.

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

21
7846 - Components
Dynamic Nose-Over Bar Kits

• Standard material for nose-over bar is UHMWPE

• For use with 7846 and 7846T MatTop chains (and also 8500)
• The optimum nose-over bar diameters are as follows:
7846B = 1-5/8 in (40 mm) diameter (Not supplied by Rexnord)
7846 and 7846T = 1-1/8 in (30 mm) diameter (Supplied by Rexnord)
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side-by-side to obtain a variety of widths; however, they cannot be cut to
smaller widths

Dynamic Nose-Over Bar

Style Part Number Overall Length Hardware
905-656481 6 in (152 mm) None
905-656501 12 in (304 mm) None
Dynamic Nose-Over Bar Kit 905-655511 15 in (381 mm) None
905-655521 18 in (457 mm) None
905-655541 24 in (609 mm) None

7846 and 7846T Series Dynamic Nose-over Bar

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

22
7846 - components
KU7846-9T Sprocket

• Bores available to fit standard 3/4 to 1-7/16 in and 19.0 to 350.0 mm shafting

KU7846-9T Sprocket

General Notes
• A polyester pin MUST be used for all nose-over applications – the polyester pin is a standard offering for the 7846 MatTop
Chain Series

• Small 1.00 in (25.4 mm) pitch is ideal for handling small, unstable products
• The minimum deadplate widths for 7846 MatTop® Chain series is shown on page 8
• See the 7846 MatTop Chain Design Manual (8rx7846dm-en) for more details on this chain series

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

23
7846 series - mounting information
Dynamic Nose-Over Bar
• The optimum nose-over bar diameters are as follows:
7846B = 1-5/8 in (40 mm) diameter (Not supplied by Rexnord)
7846 and 7846T = 1-1/8 in (30 mm) diameter (Supplied by Rexnord)
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side by side to obtain a variety of widths; however, they can not be cut to
smaller widths
• The dynamic nose-over bar is typically used in applications that handle difficult-to-convey products and/or high speeds

0.25 in
(6.35 mm)

(0.8 mm)
1.58 in

0.03 in
(0.8 mm)

(40.1 mm)
0.03 in
(34.3 mm)
1.35 in

(43.2 mm)
1.70 in

See Caution
Notes below

0.06 in 2.97 in Outer Diameter

(1.5 mm) (75.4 mm)
2.54 in Minimum Gap
(64.5 mm)

Dynamic Nose-Over Mounting (7846B)

1.38 in
(0.8 mm)
(0.8 mm)

0.03 in
(29.2 mm)

0.53 in
0.03 in

(35.0 mm)
1.15 in

(13.5 mm)
(33.3 mm)

See Caution
1.31 in

Notes below

0.06 in 2.48 in Outer Diameter

2.33 in (1.5 mm) (63.0 mm)
(59.2 mm) Minimum Gap

Dynamic Nose-Over Mounting (7846 or 7846T)

Make sure that the nose-over bar mounting plate does not interfere with the chain.
The chain should be wrapped around the nose-over 135 - 150°.

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

24
7846 series - mounting information
Dynamic Nose-Over Bar

Hole Spacing Width

0.34 in
(8.6 mm) 3.00 in 1.50 in

(38.1 mm)
1.50 in
Diameter (76.2 mm) (38.1 mm)
Hole Spacing
Length

Front of Nose-Over Bar

Mounting Hole to
Overall Length = 6, 12, 15, 18 or 24 in

(42.0 mm)
(152, 304, 381, 457 or 609 mm)

1.05 in
(133.2 mm)

Thickness
Module
1.31 in
3.79 in
(96.2 mm)
Module Width

Dynamic Nose-Over Drawing

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

25
7846 series - mounting information
9 Tooth Sprocket
• The 9 tooth sprockets are recommended for nose-over transfers to reduce chain tension and minimize noise
• 180° wrap angle is recommended to ensure proper engagement of chain and sprocket
• A 3/4 to 1-7/16 in and 19.0 to 35.0 mm diameter shaft is required. The conveyor width will be limited by bending
deflection. Recommend maximum bending deflection of shaft to be 0.06 in (1.5 mm). For applications that exceed this
deflection, a center support is required (see page 16 for concept drawing)
• Use standard ANSI/ASME machine shafting for proper hardness, surface finish and straightness
• Can be used as an idler sprocket and as a drive sprocket
• Sprocket locations are shown on page 27

2.43 in 1.00 in

(0.8 mm)
(0.8 mm)

0.03 in
(61.7 mm)
0.03 in

(25.4 mm)
(43.4 mm)

(30.7 mm)
1.71 in

1.21 in

0.06 in
(1.5 mm)
Minimum Gap 3.42 in Outer Diameter
3.48 in (86.9 mm)
(88.4 mm)

7846-9T Sprockets

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

26
7846 series - sprocket location
Sprocket Location
• The 7846 MatTop Chain design requires 1 sprocket per 3.35 in (85 mm) chain width as shown below

1.95 in 3.35 in 3.35 in 3.35 in

(49.5 mm) (85.0 mm) (85.0 mm) (85.0 mm)

Sprocket Locations

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

27
8500 series - COMPONENTS
Dynamic Nose-Over Bar Kits

• Standard material for nose-over bar is UHMWPE

• For use with all 8500 MatTop chains (and also 7846 and 7846T)
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side-by-side to obtain a variety of widths; however, they cannot be cut to
smaller widths

Dynamic Nose-Over Bar

Style Part Number Overall Length Hardware
905-656481 6 in (152 mm) None
905-656501 12 in (304 mm) None
Dynamic Nose-Over Bar Kit 905-655511 15 in (381 mm) None
905-655521 18 in (457 mm) None
905-655541 24 in (609 mm) None

Dynamic Nose-over Bar

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

28
8500 series - components
KU8500-10T Sprocket

• Bores available to fit standard 3/4 to 1 in and 25.0 mm shafting

KU8500-10T Sprocket

General Notes
• A polyester pin MUST be used for all nose-over applications – the polyester pin is a standard offering for most materials. If
it is not a standard offering it should be specified when ordering. The only exception is TCF chains which should utilize the
standard polypropylene pin

• Small 0.75 in (19.1 mm) pitch is ideal for handling small, unstable products
• The minimum deadplate widths for 8500 MatTop® Chain series is shown on page 8

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

29
8500 series - mounting information
Dynamic Nose-Over Bar
• The optimum nose-over bar diameters are as follows:
8500 = 1.125 in (30 mm) diameter
• Uses standard 5/16 in or M8 flat head screws (not included)
• Multiple modular nose-over bars can be used side-by-side to obtain a variety of widths; however, they can not be cut to
smaller widths
• The dynamic nose-over bar is typically used in applications that handle difficult to convey products and/or high speeds
Make sure that the mounting plate does not interfere with the chain
1.31 in
(33.3 mm)

(0.8 mm)
(0.8 mm)

0.03 in
0.03 in
(25.4 mm)

0.53 in Transfer Plate

1.00 in

(13.5 mm)

See Caution
(33.3 mm)

Note below
1.31 in

0.06 in
(1.5 mm) 2.00 in Outer Diameter
2.09 in Minimum Gap (50.8 mm)
(53.1 mm)
Dynamic Nose-Over Mounting (8500)

Transfer Plate
0.53 in
1.67 in
(13.5 mm)
(0.8 mm)

(42.4 mm)
0.03 in
(27.9 mm)

(0.8 mm)
1.10 in

0.03 in

See Caution
(33.3 mm)

Note below
1.31 in

0.06 in
(1.5 mm) 2.07 in Outer Diameter
Minimum Gap (52.6 mm)
2.13 in
(54.1 mm)

Dynamic Nose-Over Mounting (8500 RubberTop™)

Make sure that the nose-over bar mounting plate does not interfere with the chain.
The chain should be wrapped around the nose-over 135 - 150°.

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

30
8500 series - mounting information
Dynamic Nose-Over Bar

Hole Spacing Width

0.34 in
(8.6 mm) 3.00 in 1.50 in

(38.1 mm)
1.50 in
Diameter (76.2 mm) (38.1 mm)
Hole Spacing
Length

Front of Nose-Over Bar

Mounting Hole to
Overall Length = 6, 12, 15, 18 or 24 in

(42.0 mm)
(152, 304, 381, 457 or 609 mm)

1.05 in
(133.2 mm)

Thickness
Module
1.31 in
3.79 in
(96.2 mm)
Module Width

Dynamic Nose-Over Drawing

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

31
8500 series - mounting information
10 Tooth Sprocket
• The 10 tooth sprockets are recommended for nose-over transfers to reduce chain tension and minimize noise
• 180° wrap angle is recommended to ensure proper engagement of chain and sprocket
• A 3/4 to 1 in or 25.0 mm diameter shaft is required. The conveyor width will be limited by bending deflection.
Recommend maximum bending deflection of shaft to be 0.06 in (1.5 mm). For applications that exceed this deflection, a
center support is required (see page 16 for concept drawing)
• Use standard ANSI/ASME machine shafting for proper hardness, surface finish and straightness
• Can be used as an idler sprocket or as a drive sprocket
• Sprocket locations are shown on page 33
1.93 in
(49.0 mm)
(0.8 mm)

0.76 in
0.03 in

(0.8 mm)
0.03 in
(19.3 mm)
(35.6 mm)
1.40 in

(26.7 mm)
1.05 in

2.07 in Outer Diameter

0.06 in (52.6 mm)
(1.5 mm)
2.85 in Minimum Gap
(72.4 mm)
8500-10T Sprockets (8500)

2.29 in
(58.2 mm)
0.76 in
(0.8 mm)

(0.8 mm)
0.03 in

(19.3 mm)
0.03 in

Wearstrip
(38.1 mm)
1.50 in

(26.7 mm)
1.05 in

2.79 in Outer Diameter

(70.9 mm)
2.95 in
(74.9 mm)
0.06 in Minimum Gap
(1.5 mm)

8500-10T Sprockets (8500 RubberTop™)

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

32
8500 series - sprocket locations
Sprocket Location

18.00 in
(457.2 mm)

3 Sprockets:
0-25% Capacity
3.00 in 6.00 in 6.00 in 3.00 in
(76.2 mm) (152.4 mm) (152.4 mm) (76.2 mm)

6 Sprockets:
25-75% Capacity
1.66 in 3.00 in 3.00 in 2.66 in 3.00 in 3.00 in 1.66 in
(42.2 mm) (76.2 mm) (76.2 mm) (67.6 mm) (76.2 mm) (76.2 mm) (42.2 mm)

9 Sprockets:
75-100% Capacity
1.00 in 2.00 in 2.00 in 2.00 in 2.00 in 2.00 in 2.00 in 2.00 in 2.00 in 1.00 in
(25.4 mm) (50.8 mm) (50.8 mm) (50.8 mm) (50.8 mm) (50.8 mm) (50.8 mm) (50.8 mm) (50.8 mm) (25.4 mm)

Sprocket Locations

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

33
drive configurations
General Recommendations for Nose-Over Configurations
There are many different drive configurations that can be used for nose-over conveyors. The catenary or take-up arrangements will vary based
on drive configurations. The following pages give a few examples that can be used for either uni-directional or bi-directional conveyors.

• The function of the catenary is to allow a place for excess chain to accumulate
• Rexnord MatTop® chains should never be run tight
• The catenary sag should always be measured when running
• If the catenary sag is excessive or increases due to wear, it should be adjusted by removing links to obtain the proper sag
• Take-ups are typically not recommended. However, if a take-up must be used, a pneumatic type is preferred
• The catenary sag should be located as close to the drive as possible
• The minimum size roller should be 2 in (50 mm) diameter; however, a larger roller is always recommended to decrease joint
wear and extend the life of the chain
• The lead-in shoe from the catenary sag to the return bed is recommended to have a 6 in (150 mm) radius to ensure the
chain does not over-backflex. It is always recommended to minimize back-flexing as this decreases joint wear and extends
chain life (i.e. utilize lead in shoes with a generous radius). See the table below for the minimum back-flex radius for each
chain series.
• The recommended wrap angle on nose-over bars is 135 - 180°
• Chain elongation is a concern with nose-over conveyor designs and a polyester pin MUST be used. The only exception is the TCF
chains which should utilize the standard pin material

The catenary sag area must be free of all obstructions, such as frame cross-members, supports and drive components
that can damage chain or inhibit proper catenary sag.

Minimum Back-flex Radius per Chain Series

Chain Series Minimum Back-flex Radius
1500 1.00 in (25.4 mm)
7526 0.59 in (15.0 mm)
7846 2.00 in (50.8 mm)
8500 0.75 in (19.1 mm)

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

34
drive configurations
General Recommendations for Bi-Directional Conveyor

(76 mm to 127 mm)

Travel

Vertical Sag
3 in to 5 in
Nose-Over Bar
Diameter
0.75 in
(19.1 mm) Horizontal Span
Not to Scale
5 ft to 6 ft
(1.5 m to 1.8 m)

Head Shaft
(Drive Sprockets) Travel

Drive Configuration for Bi-Directional Conveyor (Drawing is shown with 1500 MatTop® Chain Series)

Height Roller Diam-

(H) eter (RD)

Roller Spac-
ing (RS)
Horizontal Span
(HS)
L

Bottom Drive Location (Drawing is shown with 1500 MatTop® Chain Series)

The horizontal span of the catenary in a bi-directional, bottom drive conveyor is very critical. The horizontal span must be larger than
the length of chain wrapped around the sprocket (L-dimension). If the horizontal span is not larger than
the L-dimension, the catenary will form at the drive location and cause chain-sprocket engagement issues.
The following formulas provide general guidelines for designing bi-directional, bottom drive conveyors.

• RD = 2 x back-flex radius (minimum)

• PD = Pitch Diameter
• CP = Chain Pitch
• H (minimum) = (PD + RD)/2 + CP
• L = 2 x H + (PD x 3.14)/2
• HS = 1.5 x L (5 to 6 ft (1.5 to 1.8 m))
• RS = HS / 2

Make sure that all the units are the same when completing calculations

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

35
drive configurations
General Recommendations for Uni-Directional Conveyor

Horizontal Span
Reference Not to Scale

(76 mm to 127 mm)

18 in 5 ft to 6 ft

Vertical Sag
(457 mm)

3 in to 5 in
(1.5 m to 1.8 m)
Travel

Roller Moves to
Adjust Tension
See Note
Nose-Over Bar
Diameter
0.75 in
(19.1 mm) Trav
el

Head Shaft
(Drive Sprockets)

Concept A: Drive Configuration for Uni-Directional Conveyor (Drawing is shown with 1500 MatTop® Chain Series)

Note: The vertical catenary sag must be maintained by adjusting the roller to ensure sag does not interfere with chain
leaving the drive sprocket

(76 mm to 127 mm)

(76 mm to 127 mm)

Travel Travel

Vertical Sag

Vertical Sag
3 in to 5 in

Nose-Over Bar
Nose-Over Bar 3 in to 5 in
DiameterDiameter
0.75 in 0.75 in
(19.1 mm) Horizontal Span Span
Horizontal
(19.1 mm) Not to Scale
Not to Scale
5 ft to 6 ft5 ft to 6 ft
(1.5 m to(1.5
1.8 mm)to 1.8 m)

Head Shaft
Head Shaft
(Drive Sprockets)
(Drive Sprockets) Travel Travel

Concept B: Drive Configuration for Uni-Directional Conveyor (Drawing is shown with 1500 MatTop® Chain Series)

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

36
DRIVE CONFIGURATIONS
General Recommendations for Uni-Directional Conveyor

Concept C: Drive Configuration for Uni-Directional Conveyor (Drawing is shown with 7846 MatTop® Chain Series)

The chain wrap around the sprocket must be between 150 - 180° wrap to ensure proper chain-sprocket engagement.

Refer to the formulas on page 35 to properly locate the bottom drive (note refers to Concept A, B and C)

General Recommendations for Uni-Directional Conveyor with No Catenary

Reference
18 in
(457 mm)

Travel

Roller Moves to
Nose-Over Bar
Diameter
Adjust Tension
0.75 in See Note
(19.1 mm) Trave
l

Head Shaft
(Drive Sprockets)

Drive Configuration for Uni-Directional Conveyor (Drawing is shown with 1500 MatTop® Chain Series)

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

37
carry and return ways
General Recommendations
• UHMWPE wearstrips are recommended

• If required for improved performance, nylon wearstrips may be used in the corners (applies only to 7526 and 7846)

• All sharp edges of wearstrips, including corner tracks, should be chamfered to ensure smooth chain movement.
Recommended contact surface finish of wearstrips is 32 to 125 µ-in Ra (0.8 to 3.2 µ-m Ra) for best wear performance

• Inside edges of straight and corner sections should contain a lead-in or chamfer for a smooth transition

• If center wearstrips are required due to product loading stagger them to distribute chain wear

• Offset rail, serpentine and chevron patterns are recommended to maximize chain life because they provide uniform wear
across the full width of the chain (Details of wearstrip patterns can be found in the Rexnord® Engineering Manual 8rxEM-en
in the Carry and Return Way section for MatTop® chains)

• The wearstrips under each chain on horizontal conveyors must be level and even with each other

• The MatTop® Chains can be edge guided via solid edge-guides, guide blocks spaced every 2 ft (0.6 m) or L-shaped outside
wearstrips. It is critical to allow proper clearance between edge of chain and conveyor frame for thermal expansion (refer to
engineering manual for details)

• Return rollers should have a minimum of 2 in (50.8 mm) diameter and spaced no more than 18 in (450 mm) apart.
However, a larger diameter is recommended to decrease joint wear

• To provide proper catenary sag, the first roller spacing after the drive should be 1.5 times the spacing between all of the
other rollers as shown below. The return chain can be edge-guided by the use of thin collars or flanges at the outer edges of
the rollers

DIRECTION Head Shaft

OF TRAVEL (Drive Sprockets)

B B
(1 ft - 2 ft) (1 ft - 2 ft) AA
B - 0.6 m)
(0.3 m (0.3 mB- 0.6 m) (1.5
(1.5 x xB)B)

Use Last Roller or

Guide Shoe to Guide
Chain onto Corner Track
or Wearstrips

Roller Return Configuration

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

38
high speed applications
General Recommendations
The following table gives general guidelines when selecting a nose-over transfer style depending on the speed of the
application. These are general recommendations and are based on the assumption that the chain tension is within capacity

Recommended Nose-Over Type

Speed Chain Material
FPM MPM HP™ / PS™ TCF HT / HTF / KHT

Moly filled nylon UHMWPE* Moly filled nylon*

less than 150 less than 45
Small sprocket Small sprocket Small sprocket

Moly filled nylon Dynamic Dynamic

150 to 300 45 to 90
Small sprocket Small sprocket Small sprocket

Dynamic** Dynamic** Dynamic**

over 300 over 90
Small sprocket*** Small sprocket*** Small sprocket***

* The HTF/TCF1505 and HTF8505 chains’ maximum speed is 150 FPM (45 MPM) based on a maximum load of 80 lbs/ft
(119 kg/m). When using TCF1505 chains on UHMWPE nose-over bars, normally the UHMWPE wear element will wear faster
than the chain. UHMWPE wear elements are available on a MTO (made-to-order) basis. When using TCF1505 chains on
moly filled nylon nose-over bars, normally the chain will wear faster than the wear element

**The dynamic nose-over bar option can be utilized for any speed if the chain is within capacity for the specific application

*** Consult Application Engineering for high speed applications in which a small sprocket may be an option (or utilize the
Calculation Program to determine if the bore size limitations are appropriate for the specific loading)

• For obtaining optimum chain life it is recommended that customer should specify chains with polyester pins for all nose-over
applications. It is especially critical for high speed applications. The only exception is TCF chains which should utilize the
standard pin material
• The maximum wrap angle is recommended for high speed applications to obtain as much surface contact as possible,
avoiding PV-type failures
• Noise, vibration and excessive wear are more prevalent on high speed conveyors. For applications in which these issues are
critical it is recommended to use a small sprocket

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

39
unstable product transfr applications and adjustibility
General Recommendations for Unstable Products
• Normal component wear may cause instability issues or product tippage problems for products that are difficult to convey.
It is recommended to use the dynamic nose-over bar option for these applications

• Contact Application Engineering to discuss options or to perform a product handling test

General Recommendations for Adjustability

• All components will wear with time. Adjustments to the nose-over bar and/or transfer plate may be required to maintain
smooth product transfer throughout the life of the conveyor

• Due to the wear on the components, it is recommended to design an adjustable deadplate between head and tail ends

• Rexnord recommends a minimum deadplate adjustability between head and tail nose-over bar to be 0.13 in (3.2 mm) in
both the horizontal and vertical plane with a +/- 10° rotation

• To further assure smooth transfers due to wear it is recommended to design adjustment capabilities into the nose-over bar
support structure

• Since the static nose-over bar (1500 series only) is considered the replaceable wear element it is recommended to design an
opening or access area in the conveyor frame to assure that the nose-over bar can easily be replaced (see page 17). This
allows the nose-over bar to be replaced without having to disassemble the chain, which reduces maintenance

For technical assistance contact Rexnord® Application Engineering at 262-376-4800

40
Notes

For pricing and delivery assistance contact Rexnord® Customer Care at 866-REXNORD

41
World Class Customer Service
For more than 100 years, the dedicated people of Rexnord
have delivered excellence in quality and service to our
customers around the globe. Rexnord is a trusted name when
it comes to providing skillfully engineered products that
improve productivity and efficiency for industrial applications worldwide.
We are committed to exceeding customer
expectations in every area of our business: product design,
application engineering, operations, and customer service.

Because of our customer focus, we are able to thoroughly

understand the needs of your business and have the resources available
to work closely with you to reduce maintenance
costs, eliminate redundant inventories and prevent equipment down
time.

Rexnord represents the most comprehensive portfolio of power trans-

mission and conveying components in the world with the brands you
know and trust.

Rexnord, TableTop, and MatTop are registered trademarks of Rexnord Industries, LLC. All rights reserved.

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