H-Type Enhanced Service Advantage Cartridge HD Primary Belt Cleaner

Transcription

1 H-Type Enhanced Service Advantage Cartridge HD Primary Belt Cleaner Installation, Operation and Maintenance Manual H-Type Dual ESAC HD Primary Belt Cleaner H-Type Single ESAC HD Primary Belt Cleaner

2 H-Type ESAC HD Primary Belt Cleaner Purchase Date: Purchased From: Installation Date: This information will be helpful for any future inquiries or questions about belt cleaner replacement parts, specifications or troubleshooting. ii H-Type ESAC HD Primary Belt Cleaner

3 Table of Contents Section 1 Important Information General Introduction User Benefits Service Option... 2 Section 2 Safety Considerations and Precautions Stationary Conveyors Operating Conveyors... 3 Section 3 Pre-Installation Checks and Options Checklist... 4 Section 4 Installation Instructions H-Type ESAC HD Primary Cleaner with V-Tips a H-Type ESAC HD Primary Cleaner - Chute Mounting b H-Type ESAC HD Primary Cleaner - Open Head Mounting Single Cartridge Installation Dual Cartridge Installation H-Type ESAC HD Primary Cleaner - Compression Spring Tensioner H-Type ESAC HD Primary Cleaner with Bolt-up Tensioner Section 5 Cleaner Pole Location Charts Pole Location Charts Section 6 Pre-Operation Checklist and Testing Pre-Op Checklist Test Run the Conveyor Section 7 Maintenance New Installation Inspection Routine Visual Inspection Routine Physical Inspection Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioner Blade Replacement Instructions - H-Type ESAC HD with Bolt-up Tensioner Maintenance Log Cleaner Maintenance Checklist Section 8 Troubleshooting Section 9 Specs and CAD Drawings Specifications and Guidelines CAD Drawings Section 10 Replacement Parts List Section 11 Other Flexco Conveyor Products

4 Section 1 Important Information 1.1 General Introduction We at Flexco are very pleased that you have selected an H-Type Primary Cleaner with V-Tips for your conveyor system. This manual will help you to understand the operation of this product and assist you in making it work up to its maximum efficiency over its lifetime of service. It is essential for safe and efficient operation that the information and guidelines presented be properly understood and implemented. This manual will provide safety precautions, installation instructions, maintenance procedures and troubleshooting tips. If, however, you have any questions or problems that are not covered, please visit our web site or contact our Customer Service Department: Customer Service: Visit for other Flexco locations and products. Please read this manual thoroughly and pass it on to any others who will be directly responsible for installation, operation and maintenance of this cleaner. While we have tried to make the installation and service tasks as easy and simple as possible, it does however require correct installation and regular inspections and adjustments to maintain top working condition. 1.2 User Benefits Correct installation and regular maintenance will provide the following benefits for your operation: Reduced conveyor downtime Reduced man-hour labour Lower maintenance budget costs Increased service life for the belt cleaner and other conveyor components 1.3 Service Option The H-Type Primary Cleaner with V-Tips is designed to be easily installed and serviced by your onsite personnel. However, if you would prefer complete turn-key factory service, please contact your local Flexco Field Representative. 2 H-Type ESAC HD Primary Belt Cleaner

5 Section 2 Safety Considerations and Precautions Before installing and operating the H-Type Primary Cleaner with V-Tips, it is important to review and understand the following safety information. There are set-up, maintenance and operational activities involving both stationary and operating conveyors. Each case has a safety protocol. 2.1 Stationary Conveyors The following activities are performed on stationary conveyors: Installation Blade replacement Repairs Tension adjustments Cleaning! danger It is imperative that Lockout/Tagout (LOTO) regulations, be followed before undertaking the preceding activities. Failure to use LOTO exposes workers to uncontrolled behavior of the belt cleaner caused by movement of the conveyor belt. Severe injury or death can result. Before working: Lockout/Tagout the conveyor power source Disengage any takeups Clear the conveyor belt or clamp securely in place! WARNING Use Personal Protective Equipment (PPE): Safety eyewear Hardhats Safety footwear Close quarters, springs and heavy components create a worksite that compromises a worker s eyes, feet and skull. PPE must be worn to control the foreseeable hazards associated with conveyor belt cleaners. Serious injuries can be avoided. 2.2 Operating Conveyors There are two routine tasks that must be performed while the conveyor is running: Inspection of the cleaning performance Dynamic troubleshooting!! danger Every belt cleaner is an in-running nip hazard. Never touch or prod an operating cleaner. Cleaner hazards cause instantaneous amputation and entrapment. WARNING Belt cleaners can become projectile hazards. Stay as far from the cleaner as practical and use safety eyewear and headgear. Missiles can inflict serious injury.! WARNING Never adjust anything on an operating cleaner. Unforeseeable belt projections and tears can catch on cleaners and cause violent movements of the cleaner structure. Flailing hardware can cause serious injury or death. 3

6 Section 3 Pre-installation Checks and Options 3.1 Checklist Check that the cleaner size is correct for the belt width Check the belt cleaner carton and make sure all the parts are included Review the Tools Needed list on the top of the installation instructions Check the conveyor site: - Will the cleaner be installed on a chute - Is the install on an open head pulley requiring mounting structure - Are there obstructions that may require cleaner location adjustments 4 H-Type ESAC HD Primary Belt Cleaner

7 Section 4 Installation Instructions 4.1 H-Type ESAC HD Primary Cleaner with V-Tips V-TIP SUSPENSION ARM Cartridge removal handle CUSHION POLE Torque Arm Cartridge adapter plate Removable cartridge Lock Plate BEARING BLOCK MOUNTING BRACKET H-Type ESAC HD Primary Cleaner with Compression Spring Tensioner Physically lock out and tag the conveyor at the power source before you begin cleaner installation. Before You Begin: Installation specs and instructions are based on the assumption that the conveyor is in its working position. If the conveyor position will be different, the cleaner should be installed per the final position. Call customer service at if you need help with determining the proper coordinates. Choose instructions for chute mounting or open head mounting. For chute mounting it may be necessary to cut an access hole to allow for installation and inspections. (See dimensions in Step 7 under Chute Mounting.) Follow all safety precautions when using a cutting torch. If welding, protect all fastener threads from weld spatter. Tools Needed Tape Measure 24mm Wrench Ratchet with 24mm Socket Adjustable Wrench Cutting Torch and/or Welder (2) 150mm C-Clamps (for temporary positioning of mounting brackets) 600mm Level Marking Pen Maximum lump size + 200mm Suspension Arm Size CS CM CL CLL Pulley Diameter + Belt and Lagging mm mm mm mm Chute wall Space needed to avoid clogging chute 5

8 Section 4 Installation Instructions 4.1a H-Type ESAC HD Primary Cleaner - Chute Mounting 1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts on pages 16 and 17. The pulley diameter measurement should include lagging and belt. Pulley Diameter mm; X = mm; Y = mm Using the correct X and Y coordinates will position the cleaner at 15 below the horizontal plane on the head pulley. Fig. 1 A B 2a. Measure head pulley shaft. Determine the diameter of the pulley shaft and divide by 2. 2b. Put a level on top of the pulley shaft and draw a horizontal line A. Measure down from Line A half the diameter of the pulley shaft and draw Line B parallel from centre of the pulley shaft (Fig. 1). Fig. 2 3a. Mark X dimension. Subtract the above dimension (Step 2a) from the selected X dimension to establish the modified X dimension. With this new X dimension measure horizontally from the front of the pulley shaft forward on Line B and mark on the chute (Fig. 2). Fig. 2a 3b. Determine Y dimension. From the horizontal X mark, drop a line vertically down to the selected Y dimension and draw an intersecting mark (Fig. 2a). This is the correct position of the centre of the pole. Fig. 2b 4. Locate mounting bracket position (horizontal position). To locate the position of the cleaner mounting bracket, add 70mm to the intersecting mark (Fig. 2b). This mark indicates the pole centre of the mounting bracket. 70mm 6 H-Type ESAC HD Primary Belt Cleaner

9 Section 4 Installation Instructions 4.1a H-Type ESAC HD Primary Cleaner - Chute Mounting (cont.) Fig Cut chute opening. Using the adjusted intersecting mark ( + ) established in Step 4, lay out and cut the required opening 125x150mm on the chute (Fig. 3). If access hole is required, see Step mm 125mm 75mm 75mm Chute Opening + + Adjusted intersecting mark Fig. 4 Mounting Bracket 6. Install the mounting brackets. Centre the mounting bracket on the bottom of the opening. Bolt or weld in position (Fig 4). Repeat process on opposite side Fig Cutting the access hole. Cut access hole, centring the bottom edge on the adjusted intersecting mark ( + ) established in Step 4. Width of hole should be 175mm; height should be 430mm for small arms, 480mm for medium arms, 510mm for large arms or 620mm for extra large arms. Access hole may be oriented within the range shown (Fig. 5), provided bottom edge is still centred as described above. Adjusted Intersecting Mark Fig. 6 Bearing Mount Bolts 8. Install the pole. Remove the two bolts from the bearing mount on the access hole side and remove the bearing mount (Fig 6). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side. Install the removed bearing mount on the pole and reattach to the mounting bracket. Do not tighten; leave finger tight. 7

10 Section 4 Installation Instructions 4.1b H-Type ESAC HD Primary Cleaner - Open Head Mounting Belt Direction 1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts on pages 16 and 17. The pulley diameter measurement should include lagging and belt. Mark "A" Pulley Diameter mm X mm Y mm Mark "B" Fig. 1 Using the correct X and Y coordinates will position the cleaner at 15 below the horizontal plane on the head pulley. Mark "B" 2a. Locate Y location. Determine the diameter of the pulley shaft and divide by 2. 2b. Put a level on top of the pulley shaft and mark A at the structure. Measure down from Mark A half the diameter of the pulley shaft and mark B, locating the shaft centreline (Fig. 1). Y + 70mm Mark Fig. 2 2c. Measure down the given Y dimension plus 70mm and mark (Fig. 2). This mark indicates the top location of support material to be added for installing the cleaner mounting brackets. a Support structure b c+d+e Length of support material needed Fig. 3 a) shaft to structure b) pulley shaft diameter 2 + c) pulley shaft centre line to structure = d) add X measurement from chart + centre of pole from structure = e) add 175mm (half length of mounting bracket) 175mm + length of support material needed = 3. Locate X location. a.) Measure from the back of the pulley shaft to the support structure (Fig. 3). b.) Pulley shaft diameter divided by 2. c.) Add dimensions from a) and b). This dimension is the pulley shaft centreline to the support structure. d.) Add the given X dimension to c). The sum indicates the distance from the centre of the pole to the support structure. e.) Add 175mm (half the length of the mounting bracket). The sum is the total length of support material needed to correctly locate the mounting brackets. 8 H-Type ESAC HD Primary Belt Cleaner

11 Section 4 Installation Instructions 4.1b H-Type ESAC HD Primary Cleaner - Open Head Mounting (cont.) Open Head Mounting (cont.) 4. Secure mounting support pieces to the support structure. Weld support pieces to the support structure. 75x75mm angle works well for these support pieces. 5. Prepare the support pieces for the cleaner mounting brackets. Clamp the mounting bracket on the support piece. Mark and drill holes for mounting or weld. Bearing Mount Bolts 6. Install the pole. Remove the two bearing mount bolts from one of the bearing mounts (Fig. 4). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side and allow pole lugs to hang down. Install the removed bearing mount on the pole and reattach to the mounting bracket. NOTE: Do not tighten; leave finger tight. Fig. 4 9

12 Section 4 - Installation Instructions 4.2 Single Cartridge Installation 1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle, then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle, then lock with the set screw. Set screw Handle Lock Plate Knuckle Tighten nut and bolt Knuckle Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the handle in place. Handle removed and stored in pole end Lock Pin 10 H-Type ESAC HD Primary Belt Cleaner

13 Section 4 - Installation Instructions 4.3 Dual Cartridge Installation 1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle, then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle, then lock with the set screw. 4. Repeat for other side. Set screw Handle Lock Plate Knuckle Tighten nut and bolt Knuckle Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the handle in place. 4. Repeat for other side. Handle removed and stored in pole end Lock Pin Fig. 1 Slide Position the pole. Rotate pole upward to bring tips into contact with head pulley (Fig. 1). Centre the tips across the belt. While applying light pressure on the centre tip, shift loosened bearing mount until tips are contacting belt evenly across full width. Lock cleaner into this position by tightening bearing mount bolts. For step-by-step instructions on installing the spring tensioner, refer to page

14 Section 4 Installation Instructions 4.4 H-Type ESAC HD Primary Cleaner - Compression Spring Tensioner 1. Install the compression spring tensioner. Remove the adjusting nuts, bushings and spring from the pivot rod. Insert the pivot arm through the slot in the torque arm. Slide the torque arm onto the pole end (be sure the rotation of the arm is correct to tension the blade). Fig. 1 Mounting Plate Pivot Arm Pole Torque Arm Pivot Shaft Bracket 2. Reassemble the spring assembly. Slide the spring, washer and bushings onto the pivot arm and turn the two adjusting nuts so about 6mm of the pivot arm is exposed above the nuts (Fig. 2). Fig. 2 Adjusting Nuts Bushings Washer Spring Pivot Arm 3. Verify your C dimension to insure the pole is in the correct position. 4. Tension the blades to the belt. Rotate the blades until they contact the belt. While holding the spring bushing flat on the torque arm, rotate the torque arm until the pivot arm is against the end of the slot nearest the pole. Tighten the locking bolts and jam nuts on the torque arm (Fig. 3). NOTE: The torque arm should be up against the mounting plate. Fig. 3 Pivot Arm against slot end nearest the pole Tighten locking bolts and jam nuts 12 H-Type ESAC HD Primary Belt Cleaner

15 Section 4 Installation Instructions 4.4 H-Type ESAC HD Primary Cleaner - Compression Spring Tensioner 5. Set the correct blade tension. Refer to the charts below for the spring length required for the belt width. Lightly pull the pivot arm toward the end of the torque arm slot nearest the pole and turn the adjusting nuts until the required spring length is achieved (Fig. 4). Lock the top adjusting nut. Adjusting Nuts HV/HVP Single SAC Black Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL HV/HVP Single SAC Gold Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL Top of washer to top of torque arm Fig. 4 HV/HVP Dual SAC Gold Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL HV/HVP Dual SAC Silver Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL Test run the cleaner. Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the spring length for proper tensioning. Make adjustments as necessary. 13

16 Section 4 Installation Instructions 4.5 H-Type ESAC HD Primary Cleaner with Bolt-Up Tensioner 1. Install the pole. Remove the two bearing block bolts from one of the bearing blocks (Fig. 1). (If chute mount, remove from the side with access hole.) Slide the pole across the pulley and into the bearing block on other side and allow tips to hang down. Install the removed bearing block on the pole and reattach to the mounting bracket. Do not tighten; leave finger tight. BEARING BLOCK BOLTS Fig Position the pole. Rotate pole upward to bring tips into contact with head pulley (Fig. 2). Centre the tips across the belt. While applying light pressure on the centre tip, shift loosened bearing block until tips are contacting belt evenly across full width. Lock cleaner into this position by tightening bearing mount bolts. Slide Fig Install adjusting arms. a. Screw adjusting bolts into the threaded mounting bracket (about 25mm above the mounting bracket). b. With pole rotated up, so that all tips contact the head pulley, slide the adjusting arm onto pole, tight against bearing block, resting on the adjusting bolt, pointed away from the head pulley (Fig. 8). Tighten both adjusting arm lock bolts and lock nuts (in the order shown in Fig. 3). Repeat on opposite side. ADJUSTING ARM LOCK BOLTS & LOCK NUTS ADJUSTING ARM 25mm Fig Set tip tension. Apply the following tension: V-Tips 1-1/2 turns Lock both adjusting bolt lock nuts (Fig. 4). ADJUSTING BOLT & LOCK NUT Fig H-Type ESAC HD Primary Belt Cleaner

17 Section 4 Installation Instructions 4.5 H-Type ESAC HD Primary Cleaner with Bolt-Up Tensioner (cont.) 5. Check for correct tip tension. Place a Tip Tension Gauge between the tip and the belt on the centre tip (or tips) (Fig. 5). While pulling in a straight motion, read the tension required to break contact between the tip and belt. 12kg is recommended. Also check tension on both outer tips. Make tension adjustments if needed. Fig Check tip alignment with gauge provided. Align the gauge against the head pulley and move down until the gauge contacts the top of the blade. The suspension arm should align with lines marked on gauge (Fig. 6). If the alignment is not correct, loosen both bearing block bolts and slide pole to gain correct alignment. Correct one side at a time. Tighten bolts and repeat Step 5. Fig Test run cleaner and inspect operation. If vibration occurs or more cleaning efficiency is desired, increase tip tension by making a 1/2 turn on each adjustment bolt. 15

18 Section 5 Cleaner Pole Location Charts 5.1 Pole Location Charts 15 GAP TO ARM GAP TO POLE X Y C DIAMETER (OVER BELT) Small (CS) Arms for Pulley OD (Over Belt) of mm Pulley OD Gap Gap X Y C to Arm to Pole Medium (CM) Arms for Pulley OD (Over Belt) of mm Pulley OD Gap Gap X Y C to Arm to Pole Large (CL) Arms for Pulley OD (Over Belt) of mm Pulley OD Gap Gap X Y C to Arm to Pole H-Type ESAC HD Primary Belt Cleaner

19 Section 5 Cleaner Pole Location Charts 5.1 Pole Location Charts (cont.) Extra Large (LL) Arms for Pulley OD (Over Belt) of mm Pulley OD Gap Gap X Y C to Arm to Pole

20 Section 6 Pre-Operation Checklist and Testing 6.1 Pre-Op Checklist Recheck that all fasteners are tightened properly. Add pole caps. Apply all supplied labels to the cleaner. Check the blade location on the belt. Be sure that all installation materials and tools have been removed from the belt and the conveyor area. 6.2 Test Run the Conveyor Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the tensioner spring for recommended length (proper tensioning). Make adjustments as necessary. NOTE: Observing the cleaner when it is running and performing properly will help to detect problems or when adjustments are needed later. 18 H-Type ESAC HD Primary Belt Cleaner

21 Section 7 Maintenance Flexco belt cleaners are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the cleaner is installed a regular maintenance program should be set up. This program will ensure that the cleaner operates at optimal efficiency and problems can be identified and fixed before the cleaner stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. The H-Type Primary Cleaner operates at the discharge end of the conveyor and is in direct contact with the moving belt. Only visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tagout procedures. 7.1 New Installation Inspection After the new cleaner has run for a few days a visual inspection should be made to ensure the cleaner is performing properly. Make adjustments as needed. 7.2 Routine Visual Inspection (every 2-4 weeks) A visual inspection of the cleaner and belt can determine: If the spring length is the correct length for optimal tensioning. If the belt looks clean or if there are areas that are dirty. If the blades are worn out and needs to be replaced. If there is damage to the blades or other cleaner components. If fugitive material is built up on the cleaner or in the transfer area. If there is cover damage to the belt. If there is vibration or bouncing of the cleaner on the belt. If a snub pulley is used, a check should be made for material buildup on the pulley. If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for cleaner maintenance. 7.3 Routine Physical Inspection (every 6-8 weeks) When the conveyor is not in operation and properly locked and tagged out a physical inspection of the cleaner to perform the following tasks: Clean material buildup off the cleaner. Closely inspect the blades, suspension arms and cushions for wear and any damage. Replace if needed. Ensure all blades contact the belt. Inspect the cleaner pole and cartridge for damage. Inspect all fasteners for tightness and wear. Tighten or replace as needed. Replace any worn or damaged components. Check the tension of the cleaner blades to the belt. Adjust the tension if necessary. When maintenance tasks are completed, test run the conveyor to ensure the cleaner is performing properly. 19

22 Section 7 Maintenance 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioners H-Type Single ESAC HD Primary Belt Cleaner Physically lock out and tag the conveyor at the power source before you begin cleaner installation. Tools Needed: Tape measure Ratchet with 24mm socket 24mm wrench or adjustable wrench Wire brush (for cleaning pole) Small putty knife (for cleaning pole) Fig. 1 Adjusting Nuts 1. Remove the tension. Loosen the adjusting nuts on both sides and then turn them out until all cleaner tips leave contact with the belt and the pole rotates into the cartridge extraction position (Fig. 1). This releases the tension of the blade on the belt. Pivot Arm 2. Different Cartridge Removal Methods. Option A: Handle always on cartridge. 1. Loosen the lock plate set screw and disengage lock plate from handle. 2. Lift the handle to unlock the knuckle and cartridge, then pull cartridge out. 3. If using dual cartridge cleaner, repeat for other side. Lift handle to unlock cartridge Loosen set screw Knuckle Disengage lock plate 20 H-Type ESAC HD Primary Belt Cleaner

23 Section 7 Maintenance 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioners (cont.) Option B: Handle stored inside pole. 1. Remove lock pins holding handle and knuckle in place. 2. Slide the handle into the knuckle and twist to lock. 3. Lift the handle to unlock the knuckle and cartridge, then pull cartridge out. 4. If using dual cartridge cleaner, repeat for other side. Lift handle to unlock cartridge Insert handle into knuckle, twist to lock Knuckle Lock Pin 3. Clean off pole. Remove any debris that has built up on the pole. 4. Remove the worn tips. Remove the nuts on each tip and remove the tips from the suspension arm (Fig. 2). Clean all fugitive material from the pole. Fig. 2 Removal Nuts NOTE: If tips are hard to remove use a screwdriver or hammer to loosen it and then remove. 5. Install the new tips. Locate each tip onto each suspension arm, then install the hardware to fasten the tip to the cushion (Fig. 3). Fig. 3 21

24 Section 7 Maintenance 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioners (cont.) 6. Insert the reconditioned or replacement cartridge. Option A: Handle always on cartridge. 1. Slide the cartridge onto the pole and lock down the knuckle onto the pole. 2. Slide the lock plate onto the pole, over the handle, then lock with the set screw. 3. If using dual cartridge, repeat for other side. Set screw Handle Knuckle Lock Plate Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the handle in place. 4. If using dual cartridge, repeat for other side. Handle removed and stored in pole end Knuckle Lock Pin 22 H-Type ESAC HD Primary Belt Cleaner

25 Section 7 Maintenance 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioners (cont.) 4. Reset the correct blade tension. Refer to the chart below for the spring length required for the belt width. Lightly pull the pivot arm toward the end of the torque arm slot nearest the pole and turn the adjusting nuts until the required spring length is achieved (Fig. 4). Tighten jam nut. HV/HVP Single SAC Black Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL HV/HVP Single SAC Gold Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL Fig. 4 Top of washer to top of torque arm HV/HVP Dual SAC Gold Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL HV/HVP Dual SAC Silver Spring Length Chart (for optimal blade tensioning) Belt Width CS CM CL CLL Test run the cleaner. Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the spring length for proper tensioning. Make adjustments as necessary. 23

26 Section 7 Maintenance 7.5 Blade Replacement Instructions - H-Type ESAC HD with Bolt-up Tensioner V-Tip Mounting Nuts H-Type Dual ESAC HD Primary Belt Cleaner with bolt-up tensioner Physically lock out and tag the conveyor at the power source before you begin cleaner installation. Tools Needed Tape measure Ratchet with 24mm socket 24mm wrench or adjustable wrench Wire brush (for cleaning pole) Small putty knife (for cleaning pole) Fig. 1 Adjusting Nut 1. Remove the tension. Loosen the adjusting nuts on the mounting bracket assembly to remove tension from the cleaner and rotate into the cartridge extraction position (Fig. 1). This releases the tension of the blades on the belt. 2. Different Cartridge Removal Methods. Option A: Handle always on cartridge. 1. Loosen the lock plate set screw and disengage lock plate from handle. 2. Lift the handle to unlock the knuckle and cartridge, then pull cartridge out. 3. If using dual cartridge cleaner, repeat for other side. Lift handle to unlock cartridge Loosen set screw Knuckle Disengage lock plate 24 H-Type ESAC HD Primary Belt Cleaner

27 Section 7 Maintenance 7.5 Blade Replacement Instructions - H-Type ESAC HD with Bolt-up Tensioner (cont.) Option B: Handle stored inside pole. 1. Remove lock pins holding handle and knuckle in place. 2. Slide the handle into the knuckle and twist to lock. 3. Lift the handle to unlock the knuckle and cartridge, then pull cartridge out. 4. If using dual cartridge cleaner, repeat for other side. Lift handle to unlock cartridge Insert handle into knuckle, twist to lock Knuckle Lock Pin 3. Clean off pole. Remove any debris that has built up on the pole. 2. Remove the worn tips. Remove the nuts on each tip and remove the tips from the suspension arm (Fig. 2). Clean all fugitive material from the pole. Assess any damage to cushions/suspension arms. NOTE: If tips are hard to remove use a screwdriver or hammer to loosen it and then remove. Fig. 2 Removal Nuts 3. Install the new tips. Locate each tip onto each suspension arm then install the hardware to fasten the tip to the suspension arm (Fig. 3). Fig. 3 25

28 Section 7 Maintenance 7.5 Blade Replacement Instructions - H-Type ESAC HD with Bolt-up Tensioner (cont.) 5. Insert the reconditioned or replacement cartridge. Option A: Handle always on cartridge. 1. Slide the cartridge onto the pole and lock down the knuckle onto the pole. 2. Slide the lock plate onto the pole, over the handle, then lock with the set screw. 3. If using dual cartridge, repeat for other side. Set screw Handle Knuckle Lock Plate Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the handle in place. 4. If using dual cartridge, repeat for other side. Handle removed and stored in pole end Knuckle Lock Pin Test run the cleaner. Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the spring length for proper tensioning. Make adjustments as necessary. 26 H-Type ESAC HD Primary Belt Cleaner

29 Section 7 Maintenance 7.6 Maintenance Log Conveyor Name/No. Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: Date: Work done by: Service Quote # Activity: 27

30 Section 7 Maintenance 7.7 Cleaner Maintenance Checklist Site: Inspected by: Date: Belt Cleaner: Serial Number: Beltline Information: Beltline Number: Belt Condition: Belt Width: 18" 24" 30" 36" 42" 48" 54" 60" 72" (450mm) (600mm) (750mm) (900mm) (1050mm) (1200mm) (1350mm) (1500mm) (1800mm) Head Pulley Diameter (Belt & Lagging): Belt Speed: fpm Belt Thickness: Belt Splice Condition of Splice Number of splices Skived Unskived Material conveyed Days per week run Hours per day run Blade Life: Date blade installed: Date blade inspected: Estimated blade life: Is blade making complete contact with belt? Yes No Blade wear: LEFT MIDDLE RIGHT Blade condition: Good Grooved Smiled Not contacting belt Damaged Measurement of spring: Required Currently Was Cleaner Adjusted: Yes No Pole Condition: Good Bent Worn Lagging: Slide lag Ceramic Rubber Other None Condition of lagging: Good Bad Other Cleaner's Overall Performance: ( Rate the following 1-5, 1 = very poor - 5 = very good ) Appearance: Location: Maintenance: Comments: Comments: Comments: Performance: Comments: Other Comments: 28 H-Type ESAC HD Primary Belt Cleaner

31 Section 8 Troubleshooting Problem Possible Cause Possible Solutions Poor cleaning performance Rapid Blade Wear Centre wear on blade (smile effect) Unusual wear or damage to blade Vibration or noise Cleaner being pushed away from pulley Cleaner under-tensioned Cleaner over-tensioned Cleaner installed in wrong location Cleaner blade worn or damaged Tension on cleaner too high/low Cleaner not located correctly Blade attack angle incorrect Blade wider than material path Tension on cleaner too high/low Mechanical splice damaging blade Belt damaged or ripped Cleaner not correctly located Damage to pulley or pulley lagging Cleaner not located correctly Blade attack angle incorrect Cleaner running on empty belt Cleaner tension too high/low Cleaner locking bolts not secure Cleaner not square to head pulley Material buildup in chute Cleaner tension not set correctly Sticky material is overburdening cleaner Cleaner not set up correctly Adjust to correct tension see spring length chart Adjust to correct tension see spring length chart Verify "C" dimension, relocate to correct dimension Replace cleaner blade Adjust to correct tension see spring length chart Check cleaner location for correct dimensions Check cleaner location for correct dimensions Replace blade with width to match material path Adjust to correct tension see spring length chart Repair, skive or replace splice Repair or replace belt Verify "C" dimension, relocate to correct dimension Repair or replace pulley Verify "C" dimension, relocate to correct dimension Verify "C" dimension, relocate to correct dimension Use a spray pole when the belt is empty Adjust to correct tension or slight adjust to diminish Check and tighten all bolts and nuts Verify "C" dimension, relocate to correct dimension Clean up build-up on cleaner and in chute Ensure correct tension/increase tension slightly Increase tension; replace with larger size cleaner Confirm location dimensions are equal on both sides 29

32 Section 9 Specs and CAD Drawings 9.1 Specifications and Guidelines H-Type Single ESAC HD Pole Length Specifications* Cleaner Size Pole Length Maximum Conveyor Span mm mm mm H-Type Dual ESAC HD Pole Length Specifications* Cleaner Size Maximum Pole Length Maximum Conveyor Span mm mm mm Overall Pole Length Maximum Conveyor Span Clearance Guidelines for Installation Suspension Arm Size Horizontal Clearance Required mm Vertical Clearance Required mm CS CM CL CLL VERTICAL HORIZONTAL Specifications: Maximum Belt Speed... 5M/sec Temperature Rating C to 82 C Usable Blade Wear Length... 9mm Blade Material... Long Life Tungsten Carbide (for vulcanized belts only) Available for Belt Widths to 3000mm.... Other sizes available upon request. 30 H-Type ESAC HD Primary Belt Cleaner

33 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Single ESAC HD Primary Belt Cleaner with Spring Tensioner TIP WIDTH (mm) COMPLETE CLEANER ITEM ITEM CODE CODE M/S S/S CS CM CL CS CM CL CS CM CL CS CM ARM SIZE WEIGHT (kg) CL CS CM CL CM CL CLL CM CL CLL X Y C [TIP WIDTH] 'A' [CHANNEL LENGTH] 'C' [I/S MOUNT DISTANCE] MIN = C MAX = B [POLE LENGTH] 'B' CS ARM FOR CM ARM FOR CL ARM FOR FOR INSTALLATION COORDINATES X Y AND C SEE FLEXCO H SAC IOM MANUAL CLL ARM FOR

34 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Dual ESAC HD Primary Belt Cleaner with Spring Tensioner TIP WIDTH (mm) COMPLETE CLEANER ARM SIZE CM CL CLL ITEM CODE M/S ITEM CODE S/S WEIGHT (kg) CS CM CL CLL CS CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL [TIP WIDTH] 'A' [CENTRE POLE LENGTH] 'C' [I/S MOUNT DISTANCE] MIN = 'C' MAX = 'B' [MAX POLE LENGTH] 'B' 73 CS ARM FOR CM ARM FOR CL ARM CLL ARM FOR FOR CL ARM X 15 Y C FOR INSTALLATION COORDINATES X Y AND C SEE FLEXCO H SAC IOM MANUAL 32 H-Type ESAC HD Primary Belt Cleaner

35 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Single ESAC HD Primary Belt Cleaner with Bolt-up Tensioner TIP WIDTH (mm) COMPLETE CLEANER ARM SIZE ITEM CODE M/S ITEM CODE S/S WEIGHT (kg) CS CM CL CS CM CL CS CM CL CS CM CL CS CM CL CM CL CLL CM CL CLL [TIP WIDTH] 'A' [CHANNEL LENGTH] 'C' [I/S MOUNT DISTANCE] MIN = C MAX = B [POLE LENGTH] 'B' CS ARM FOR CM ARM FOR CL ARM FOR X Y C FOR INSTALLATION COORDINATES X Y AND C SEE FLEXCO H SAC IOM MANUAL CLL ARM FOR

36 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Dual ESAC HD Primary Belt Cleaner with Bolt-up Tensioner TIP WIDTH (mm) COMPLETE CLEANER ARM SIZE CS CM CL CLL CS CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM ITEM CODE M/S ITEM CODE S/S WEIGHT (kg) CL CLL [TIP WIDTH] 'A' [CENTRE POLE LENGTH] 'C' [I/S MOUNT DISTANCE] MIN = 'C' MAX = 'B' [MAX POLE LENGTH] 'B' 73 CM ARM CLL ARM FOR CS ARM FOR FOR CL FOR X 15 Y C FOR INSTALLATION COORDINATES X Y AND C SEE FLEXCO H SAC IOM MANUAL 34 H-Type ESAC HD Primary Belt Cleaner

37 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Single ESAC HD Cartridge Kit COMPLETE KIT TIP WIDTH ARM SIZE MILD STEEL STAINLESS STEEL ITEM CODE ITEM CODE WEIGHT CS CM CL CS CM CL CS CM CL CS CM CL CS CM CL CM CL CLL CM CL CLL NO. DESCRIPTION TIP WIDTH ORDER NUMBER ITEM CODE 1 2 SAC SINGLE CARTRIDGE REPLACEMENT KIT H CARTRIDGE ADAPTER PLATE DESCRIPTION 600 CART-24/600-S/S CART-36/900-S/S CART-42/1050-S/S CART-48/1200-S/S CART-60/1500-S/S CART-72/1800-S/S H-SAC-AP-600-S/S H-SAC-AP-800-S/S H-SAC-AP-1000-S/S H-SAC-AP-1200-S/S H-SAC-AP-1400-S/S H-SAC-AP-1600-S/S H-SAC-AP-1800-S/S MILD STEEL ORDER NO MILD STEEL ITEM CODE STAINLESS STEEL ORDER NO STAINLESS STEEL ITEM CODE 3 H TYPE HD CUSHION HSHD HSHD-S/S CS HSA8CS HSA8CS-S/S CM HSA8CM HSA8CM-S/S SUSPENSION ARM CL HSA8CL HSA8CL-S/S CLL HSA8CLL HSA8CLL-S/S HV CLEANER TIPS HSA HVT8-S/S SAC REMOVAL KNUCKLE SACRKN SACRKN SAC REMOVAL HANDLE AND PIN SACRH SACRH-S/S SAC HANDLE LOCK PLATE SACRHL SACRHL-S/S TIP WIDTH 35

38 Section 9 Specs and CAD Drawings 9.2 CAD Drawing - H-Type Dual ESAC HD Cartridge Kit TIP WIDTH COMPLETE KIT ARM SIZE MILD STEEL STAINLESS WEIGHT ITEM STEEL ITEM (kg) CODE CODE CS CM CL CLL CS CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL CM CL CLL NO DESCRIPTION TIP ORDER NUMBER ITEM CODE WIDTH 1200 CART2-60/1500-S/S CART2-66/1650-S/S CART2-72/1800-S/S SAC DUAL 1800 CART2-78/1950-S/S CARTRIDGE REPLACEMENT KIT 2000 CART2-84/2100-S/S CART2-96/2400-S/S CART2-114/2850-S/S CART2-120/3000-S/S CART2-126/3150-S/S ITEM 2 CARTRIDGE ADAPTER PLATE TIP LEFT HAND WIDTH H CARTRIDGE ADAPTER PLATE **REQUIRE 1 EA LEFT HAND AND RIGHT HAND ITEM 3 CARTRIDGE ADAPTER PLATE RIGHT HAND ORDER NUMBER ITEM CODE ORDER NUMBER ITEM CODE 1200 H-SAC-AP-600-S/S H-SAC-AP-600-S/S H-SAC-AP-800-S/S H-SAC-AP-600-S/S H-SAC-AP-800-S/S H-SAC-AP-800-S/S H-SAC-AP-1000-S/S H-SAC-AP-800-S/S H-SAC-AP-1000-S/S H-SAC-AP-1000-S/S H-SAC-AP-1200-S/S H-SAC-AP-1000-S/S H-SAC-AP-1200-S/S H-SAC-AP-1200-S/S H-SAC-AP-1400-S/S H-SAC-AP-1200-S/S H-SAC-AP-1400-S/S H-SAC-AP-1400-S/S H-SAC-AP-1600-S/S H-SAC-AP-1400-S/S DESCRIPTION MILD STEEL ORDER NO MILD STEEL ITEM CODE STAINLESS STEEL ORDER NO TIP WIDTH STAINLESS STEEL ITEM CODE 4 H TYPE HD CUSHION HSHD HSHD-S/S CS HSA8CS HSA8CS-S/S CM HSA8CM HSA8CM-S/S SUSPENSION ARM CL HSA8CL HSA8CL-S/S CLL HSA8CLL HSA8CLL-S/S HV CLEANER TIPS HSA HVT8-S/S SAC REMOVAL KNUCKLE SACRKN SACRKN SAC REMOVAL HANDLE AND SACRH SACRH-S/S PIN 9 SAC HANDLE LOCK PLATE SACRHL SACRHL-S/S H-Type ESAC HD Primary Belt Cleaner

39 Section 10 Replacement Parts List H-Type Single ESAC HD Primary Belt Cleaner REPLACEMENT PARTS Mild Steel Stainless Steel REF DESCRIPTION ORDERING NUMBER ITEM CODE WT. KG. ORDERING NUMBER ITEM CODE WT. KG. HCP HCP-600-S/S HCP HCP-800-S/S H-Type HCP HCP-1000-S/S Single ESAC Centre Pole HCP HCP-1200-S/S HCP HCP-1400-S/S HCP HCP-1800-S/S HD Cushion HSHD HSHD-S/S HSA8CS HSA8CS-S/S Suspension Arm HSA8CM HSA8CM-S/S HSA8CL HSA8CL-S/S HSA8CLL HSA8CLL-S/S HV Tips HSA HVT8-S/S HVPT Tips HVPT-S/S Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B H73CSK-B-S/S Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G H73CSK-G-S/S Bolt Tension Side Assembly H73BTK H73BTK-S/S REF DESCRIPTION Tip Width ORDERING NUMBER ITEM CODE WT. KG. 600 H-SAC-AP H-SAC-AP H-SAC-AP H-Type Cartridge Adapter Plate 1200 H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP CART-24/600-S/S CART-36/900-S/S CART-42/1050-S/S ESAC HD Single Cartidge Replacement 1200 CART2-48/1200-S/S CART-60/1500-S/S CART-72/1800-S/S

40 Section 10 Replacement Parts List H-Type Dual ESAC HD Primary Belt Cleaner REPLACEMENT PARTS Mild Steel Stainless Steel REF DESCRIPTION ORDERING NUMBER ITEM CODE WT. KGS. ORDERING NUMBER ITEM CODE WT. KGS. H2CP H2CP-1200-S/S H2CP H2CP-1400-S/S H2CP H2CP-1600-S/S H-Type H2CP H2CP-1800-S/S H2CP H2CP-2000-S/S Dual ESAC Centre Pole H2CP H2CP-2400-S/S H2CP H2CP-2600-S/S H2CP H2CP-2800-S/S H2CP H2CP-3000-S/S Extender Pole MHP-EP MHP-EP-S/S HD Cushion HSHD HSHD-S/S HSA8CS HSA8CS-S/S Suspension Arm HSA8CM HSA8CM-S/S HSA8CL HSA8CL-S/S HSA8CLL HSA8CLL-S/S HV Tips HSA HVT8-S/S HVPT Tips HVPT-S/S Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B H73CSK-B-S/S Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G H73CSK-G-S/S Silver 6" Compression Spring Side Assembly (above 2400) H73CSK-G H73CSK-G-S/S Bolt Tension Side Assembly H73BTK H73BTK-S/S Item 8 / Left Hand Item 9 / Right Hand REF DESCRIPTION Tip Width ORDERING NUMBER ITEM CODE WT. KGS. ORDERING NUMBER ITEM CODE WT. KGS H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP & 9 H-Type Cartridge Adapter Plate 2000 H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP H-SAC-AP Tip ORDERING ITEM WT. REF DESCRIPTION Width NUMBER CODE KGS CART2-60/1500-S/S CART2-66/11650-S/S CART2-72/1800-S/S CART2-78/1950-S/S CART2-84/2100-S/S ESAC HD Dual Cartidge Replacement 2200 CART2-96/2400-S/S CART2-114/2850-S/S CART2-120/3000-S/S CART2-126/3150-S/S H-Type ESAC HD Primary Belt Cleaner 8 1 9

41 Section 11 Other Flexco Conveyor Products Flexco provides many conveyor products that help your conveyors to run more efficiently and safely. These components solve typical conveyor problems and improve productivity. Here is a quick overview on just a few of them: Rockline EZP1 Primary Cleaner Flexco Slider and Impact Beds Patented ConShear blade renews its cleaning edge as it wears Visual Tension Check for optimal blade tensioning and simple retensioning Quick and easy one-pin blade replacement Material Path Option for optimal cleaning and reduced maintenance MHS SAC Secondary Cleaner Adjusting troughing angles for easy installation and adjustability Long-wearing UHMW for sealing the load zone Offered in both Light & Medium duty designs to affordably fit your application PT Max Belt Trainer Long-wearing tungsten carbide blades for superior cleaning efficiency Patented PowerFlex cushions, the proven design found on our industry-leading MHS Secondary Cleaner Service Advantage Cartridge can be easily removed and replaced, even in the dirtiest conditions Works with Flexco mechanical belt splices Flexco Specialty Belt Cleaners Patented pivot & tilt design for superior training action Dual sensor rollers on each side to minimise belt damage Pivot point guaranteed not to freeze or seize up Available for topside and return side belts Belt Plough Limited space cleaners for tight conveyor applications High Temp cleaners for severe, high-heat applications A rubber fingered cleaner for chevron and raised-rib belts Multiple cleaner styles in stainless steel for corrosive applications A belt cleaner for the tail pulley Exclusive blade design quickly spirals debris off the belt Economical and easy to service Available in vee or diagonal models 39