Product, Installation and Maintenance Manual

Transcription

1 Product, Installation and Maintenance Manual Belt Tracking Troughing & Belt Tracking Return (Belt Tracking Systems)

2 Table of Contents 1. Table of Contents 1 2. Company Profile 2 3. Disclaimer Safety Note The following symbols may be used in this manual: 3 4. General Information 3 5. Handling Receiving the goods Work Safety Handling Storage Preparations for installing Belt Tracking Troughing and Belt Tracking Return Frames 4 6. Recommended Tools List Recommended Tools List Continued Recommended Tools List Continued Recommended Tools List Continued 7 7. Belt Tracking Troughing & Belt Tracking Return Belt Tracking Return & Belt Tracking Troughing - Mounting Selection Guide 9 8. Belt Tracking Return & Belt Tracking Troughing Frame BELT TRACKING RETURN FRAME - BELT WIDTH SABS BELT TRACKING RETURN FRAME -BELT WIDTH PROK BELT TRACKING TROUGHING FRAME - 3 ROLL Belt Tracking Return Frame Belt Tracking Troughing Frame Belt Tracking Return & Belt Tracking Troughing - Parts Ordering List Belt Tracking Return - Parts ordering List and Bearing Replacement Guide Belt Tracking Troughing - Parts ordering List and Bearing Replacement Guide Belt Tracking Return & Belt Tracking Troughing - Installation Guide Belt Tracking Return & Belt Tracking Troughing - Trouble Shooting Notes Contact Details 22 Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 1 of 22

3 Head Office: Brelko Conveyor Products (Pty) Ltd. 16 Harries street, Reuven Extension 1, Booysens, Johannesburg, South Africa Website: Tel: BRELKO Managing Director: Kenny Padayachee Tel: General Manager: Jay Pillay Tel: Sales & Marketing Manager: Sharon Padayachee Tel: Africa & USA Area Manager Brent Weller Tel: Technical & CADD Manager: Riaan Rynders Tel: riaan@brelko.com Service Manager: Craig Abbey Tel: craig@brelko.com IT Manager: Grant Ritson Tel: grant@brelko.com Founded in 1987 / Selby, Johannesburg South Africa. Brelko design and manufacture conveyor belt cleaning equipment for a trouble-free flow of materials at transfer and load points. This is backed up by an installation and maintenance package. We have over 30 years experience as a supplier and advisor on spillage control to the bulk materials handling industry and offer proactive and ongoing maintenance for preventative spillage control and optimum belt cleaning. We supply and service our products throughout the world, with branches in the United Kingdom and the United States, our master distributors in Australia, Chile, Europe and Greece, and agents located in Africa and more than 40 countries. We are accredited with ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007 certification and are members of the South African Institute of Materials Handling and Conveyor Manufacturers Association Limited of South Africa. The company is accredited with Level 1 B-BBEE status. Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 2 of 22

4 3. Disclaimer Brelko Conveyor Products (Pty) Ltd hereby disclaims any liability for: damage due to contamination of the material; user s failure to inspect, maintain and take reasonable care of the equipment; injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Brelko s liability shall be limited to repair or replacement of equipment shown to be defective Safety Note Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tag-out procedures as defined by National Standards Institutes, National Standard for Personnel Protection - Lockout/ Tag-out of Energy Sources - Minimum Safety Requirements and Occupational Health and Safety The following symbols may be used in this manual: DANGER Danger: Immediate hazards that will result in severe personal injury or death. WARNING Warning: Hazards or unsafe practices that could result in personal injury. CAUTION Caution: Hazards or unsafe practices that could result in product or property damages. Important: Instructions that must be followed to ensure proper installation/operation of equipment. Note: General statements to assist the reader. 4. General Information Brelko Belt Tracking Systems are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Belt Tracking System is installed a regular maintenance program should be set up. This program will ensure that the Belt Tracking System operates at optimal efficiency and problems can be identified and fixed before the Belt Tracking System stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Belt Tracking Systems operate along the length of the conveyor and are 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/tag-out procedures. 5. Handling 5.1. Receiving the goods Check that the shipment contains all the products specified in the delivery note. If the goods do not match the delivery note, if the goods show any transportation damage, list it on the freight bill. Describe the damage and the number of wrong or faulty goods, and contact your supplier immediately. Do not use defective parts under any circumstances. Claims must be made within 8 days from the arrival of goods. The factory does not cover expenses caused by exchange of product when installation was not carried out according to factory instructions Work Safety Always use protective gloves and clothing. Always use a lifeline and soft-sole footwear when work will be carried out on raised platforms. Before you move a Belt Tracking System, check that it is securely attached to the lifting equipment. Always observe local safety regulations. Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 3 of 22

5 WARNING Before removing/installing equipment, lock out/tag out energy source to conveyor, and/or conveyor accessories. Turn off and lock out/tag out energy source according to local standards. If equipment will be installed in an enclosed area, test gas level or dust content before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion Handling When Belt Tracking Systems are unloaded from the transportation vehicle onto customer s platform, place them on boards spaced max 1m apart at a minimum of 5cm from the ground Storage Belt Tracking Systems can be stored unpacked or in transportation package. It not be stored on top of one another,. Protect the belt tracker by storing them in a cool dry area on a flat surface Preparations for installing Belt Tracking Troughing and Belt Tracking Return Frames Before installation, check all measurements and any of the other geometric design 6. Recommended Tools List Tools List QTY DESCRIPTION IMAGE 2 EXTENSION CORD (20m MINIMUM) 1 PORT-A-PACK (OXY-ACETYLENE) 1 COMBINATION GAUGE (WITH SPIRIT LEVEL) 1 STRAIGHT EDGE (1M MINIMUM) Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 4 of 22

6 Tools List QTY DESCRIPTION IMAGE 1 90 SET SQUARE 1 5M TAPE MEASURE 2 ADJUSTABLE SPANNERS 1 PIPE WRENCH (6mm) 1 SOCKET RATCHET SET (6mm - 30mm) 2 RINGSET SPANNERS - M13, 15, 16, 17, 18, 19, 24, 30 1 STANLEY KNIFE 1 HARD FACE HAMMER 4pd 1 SOFT FACE HAMMER - 1KG 3M NYLON ROPE Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 5 of 22

7 Tools List QTY DESCRIPTION IMAGE 2 "G" CLAMPS - 6" - 8" 1 JIMMY LEVER 1 ELECTRIC DRILL 1 SET ELECTRIC DRILL BITS 1 SMALL BLUE TOOL BOX 1 MAGNETIC BASE DRILL 1 LONG NOSE PLIERS 1 PLIERS 1 BELT LIFTER 1 1 TON LEVER HOIST Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 6 of 22

8 Tools List QTY DESCRIPTION IMAGE 4 1M NYLON SLING 1 HACKSAW 2 SAFETY HARNESS 1 CHALK LINE 1 TORCH LED 1 SET 12, 14, 18 SLUGGER BITS Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 7 of 22

9 Belt Tracking Troughing Belt Tracking Return Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 8 of 22

10 7.1. Belt Tracking Return & Belt Tracking Troughing - Mounting Selection Guide OPTIONAL 90mm & 1mm DROP HEIGHT Belt Tracking Return Mounting DIMENSION RANGE INCREMENTS OPTIONAL 90mm & 1mm DROP HEIGHT Belt Tracking Troughing Mounting DIMENSION RANGE INCREMENTS Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 9 of 22

11 APPLICATIONS APPLIES TO Belt Tracking 3 / 5 roll Troughing Frame Belt Tracking Return Frame BELT TRACKING AND TROUGHING SYSTEMS - FEATURES AND OPTIONS BELT TRACKING TROUGHING, BELT TRACKING RETURN DESCRIPTION Install the Belt Tracking system on the troughing side of the belt to centralise a misaligned belt, prevent spillage, decrease downtime, decrease maintenance and extend belt life. Install the Belt Tracking system on the return side of the belt to centralise a misaligned belt, prevent belt edge damage, prevent structural damage, decrease downtime, decrease maintenance and extend belt life. FEATURES APPLIES TO DESCRIPTION Easy Installation Belt Tracking Troughing System 3 / 5 roll and Belt Tracking Return Frame Low Maintenance Vibration free rolling action Simple Design Operates in all conditions Manufactured according to S.A.B.S mounting standards Fully sealed construction of bearing housing prevents ingress of material into the bearing unit. Robust construction for longer life Proven Polyurethane coated impact rolls, lasts up to 3 times longer than standard rubber lagged. NOTE! Always quote belt width. ASSEMBLY INSTRUCTIONS 1. Referring to the parts list, check that the correct parts and quantities have been supplied for the model and belt width of Belt Tracking System ordered. 2. Proceed with installation as per installation guide. SURVEY 1. Before installing the Belt Tracking System, carefully inspect the entire length of the conveyor belt. Identify areas of conveyor belt misalignment. Contributing factors include concave pulleys, where the centre of the pulley has collapsed, and uneven rubber wear on pulleys. 2. Tell-tale marks indicate problem areas where a drifting conveyor belt has come into contact with the structure for instance, damaged drop brackets and structure. 3. Tail, head and take-up pulleys identify areas of greatest damage caused by badly aligned belts. GUIDELINES 1. One correctly installed Belt Tracking System can control misalignment for about 30 metres of belt and need only be installed on areas where misalignment occurs. 2. Always install the Belt Tracking System ahead of the problem area. 3. To obtain maximum belt alignment, use the maximum face length of the Belt Tracking System. This ensures that you obtain the optimum working life from the Belt Tracking System. 4. Insufficient traction between the belt centralising idler frame set and the belt leads to severe polyurethane wear. Although the Belt Tracking System will kick in and control the belt, there won t be enough tension to successfully centre the belt on the Belt Tracking System. This results in chafing of the Belt Tracking System polyurethane lagged rollers. By increasing the tension, the Belt Tracking System will centralise the belt and return to a state of equilibrium. Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 10 of 22

12 8. Belt Tracking Return & Belt Tracking Troughing Frame 8.1. BELT TRACKING RETURN FRAME - BELT WIDTH SABS BELT WIDTH SIZE 1 OW SMC DH * UP TO 1mm A Ø 20 (SHAFT SIZE) B OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT C TRANSOM IDLER CAR 60.3 SQR 60.3 SQR SIZE 2 OW SMC DH * UP TO 1mm A Ø 30 (SHAFT SIZE) B OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT C TRANSOM IDLER CAR 76.2 SQR 76.2 SQR SIZE 3 OW SMC DH * UP TO 1mm A OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT Ø 40 (SHAFT SIZE) B C TRANSOM IDLER CAR 76.2 SQR 76.2 SQR Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 11 of 22

13 8.2. BELT TRACKING RETURN FRAME -BELT WIDTH PROK BELT WIDTH SIZE 1 OW SMC DH * UP TO 1mm A Ø 25 (SHAFT SIZE) B OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT C TRANSOM 60.3 SQR IDLER CAR 60.3 SQR SIZE 2 OW SMC DH * UP TO 1mm A Ø 30 (SHAFT SIZE) B OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT C TRANSOM IDLER CAR 76.2 SQR 76.2 SQR SIZE 3 OW SMC DH A OW = OVERALL WIDTH SMC = STRINGER MOUNTING CENTRES DH = DROP HEIGHT * UP TO 1mm Ø 40 (SHAFT SIZE) B C TRANSOM IDLER CAR 76.2 SQR 76.2 SQR Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 12 of 22

14 8.3. BELT TRACKING TROUGHING FRAME - 3 ROLL BELT WIDTH SIZE 1 SMC DH 330 A Ø 25 B SMC = STRINGER MOUNTING CENTRES C TRANSOM IDLER CAR 60.3 SQR 60.3 SQR SIZE 2 SMC DH 415 (3R) / 430 (5R) A Ø 30 SMC = STRINGER MOUNTING CENTRES B C TRANSOM IDLER CAR 76.2 SQR 76.2 SQR Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 13 of 22

15 8.4. Belt Tracking Return Frame FRONT VIEW (Overall Width) (OW) DROP HEIGHT 5 TOP VIEW STRINGER MOUNT CENTRES (SMC) STANDARD ARRANGEMENT SIZE -SIZE 1: BW -SIZE 2: BW -SIZE 3: BW* * ON REQUEST ONLY 100 BELT DIRECTION IDLER ROLL BRELKO POLYURETHANE - COATED A = SHAFT SIZE SIZE 1 = Ø 143 / S25 SIZE 2 = Ø 143 / S30 SIZE 3 = Ø 168 / S40 B = FACE LENGTH C = GAUGE LENGTH Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 14 of 22

16 8.5. Belt Tracking Troughing Frame TOP VIEW BELT DIRECTION FRONT VIEW 20 / 35 / 45 TRANSOM SIDE VIEW IDLER CARRIER ASSEMBLY SIZE 1 Ø127 SERIES 25 SIZE 2 Ø152 SERIES 30 BELT DIRECTION Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 15 of 22

17 BELT TRACKING RETURN & TROUGHING FRAME - PARTS ORDERING LIST REF. APPLIES TO DESCRIPTION SIZE (mm) BELT WIDTH (mm) CODE 60.3 SQR / 0008 A BTR / BTT Transom - Consisting of Spacer, Bolts, Nuts and Washers 76.2 SQR / SQR / SQR / 0017 B BTR / BTT Idler Frame - Excluding Bearing Set SQR / 0005 / 0006 / SQR / 0012 / 0013 / SQR XXXX (Specify Belt Width) 76.2 SQR XXXX (Specify Belt Width) DIA 80mm C BTR / BTT Bearing set - Consisting of Deep Grooved Ball Bearing, Thrust Bearing and Bearing Seal. DIA 110mm DIA 80mm DIA 110mm Series Specify belt width Idler Roller (Polyurethane) Series Specify belt width D BTR / BTT Series Specify belt width - On request only Idler Roller (Polyurethane Lagged) Series Specify belt width Series Specify belt width - On request only E BTR Mounting Bracket (LH & RH) including Bolts, Nuts, and Washers. Size Size Size F BTR / BTT Hardware kit consisting of Idler Roll Retaining washers complete with Locking Screws & Bottom Cap retaining Screw. Hardware Set - Including Bearing Spacer, Top Cap, Idler Roll Retaining Washers and locking Screws Series Series 30 & Series Series (3 ROLL) (5 ROLL) G BTR / BTT Spacer & Bottom Cap Set Series Series H BTR / BTT Polyurethane Stoppers ALL ALL Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 16 of 22

18 BELT TRACKING RETURN - PARTS ORDERING LIST AND BEARING REPLACEMENT GUIDE 2 D 1 (F) H 7 B BELT DIRECTION LABEL 3 E 6 (G) A 8 9 7a E BELT DIRECTION LABEL 10 C 5 (G) 8 4 (F) DETAIL E COMPONENT ID A B C D E F G H TRANSOM ASSEMBLY IDLER FRAME ASSEMBLY DESCRIPTION BEARING SET - CONSISTING OF DEEP-GROOVED BALL BEARING,THRUST BEARING & BEARING SEALS IDLER ROLL - POLYURETHANE MOULDED COVER MOUNTING BRACKETS - INCLUDING BOLTS, NUTS & WASHERS HARDWARE KIT - CONSISTING OF IDLER ROLLER RETAINING WASHERS COMPLETE WITH LOCKING SCREWS & BOTTOM CAP RETAINING SCREW. SPACER & BOTTOM CAP SET POLYURETHANE STOPPERS Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 17 of 22

19 BELT TRACKING TROUGHING - PARTS ORDERING LIST AND BEARING REPLACEMENT GUIDE C 6 9 D 2 2 B 1 3a 7 2 A COMPONENT ID A B C D TRANSOM ASSEMBLY IDLER FRAME ASSEMBLY DESCRIPTION BEARING SET - CONSISTING OF DEEP-GROOVED BALL BEARING,THRUST BEARING & BEARING SEALS IDLER ROLL - POLYURETHANE MOULDED COVER Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 18 of 22

20 BELT TRACKING RETURN & TROUGHING FRAME - INSTALLATION GUIDE Note: - The Belt Tracking System is direction sensitive and therefore has to be installed correctly. Each Belt Tracking System has Belt Direction Labels on the frame. 1. Bolt the Belt Tracking System onto the structure. Before tightening, ensure the Belt Tracking System is perpendicular to the structure. Once completed, tighten all bolts. Note: - Ensure all the rollers contact the belt. Note: - Adjust the gap between the roller frame polyurethane stoppers (x) and transom (A) to +-5mm. 2. Installation is now complete, start the conveyor belt to test the Belt Tracking System. Note: - If the desired steering is not achieved increase or decrease the gap between the roller frame polyurethane stoppers tansom (x) until the desired result is achieved. 3. If the problem still persists, knock the existing standard troughing frames perpendicular to the structure before and after the Belt Tracking System. 4. Remove any other tracking devices in front of or behind the Belt Tracking System, as they will reduce or interfere with the performance of the Belt Tracking System. CAUTION!!! This equipment should only be installed, operated & maintained by people competent and familiar with conveyor systems. Improper use or adjustment can result in serious personal injury or damage to equipment. IF IN DOUBT ASK!!! BELT TRACKING RETURN & TROUGHING FRAME - Bearing Replacement Guide In order to replace the Bearing housing the following must be followed. Remove the idler roller retaining washers (1) and the idler rollers (2) from the idler frame (3). Note: This step must be done carefully to prevent misplacing or losing any components. Remove the locking screw (4), top cap (5), idler frame (3) and bearing spacer (6) from the transom (7). Note: This step must be done carefully to prevent misplacing or losing any components. Remove the bearing seal (8), thrust bearing (9) and deep grooved ball bearing (10) from the bearing housing (3a). Replace worn and/or damaged bearings and bearing seal with the new components. Re-assemble the Belt Tracking System. Refering to the installation guide continue with the installation. Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 19 of 22

21 Belt Tracking Return & Belt Tracking Troughing - Trouble Shooting Problem Possible Cause Possible Solution Tracker/belt contact pressure too low. Increase belt contact pressure, refer to installation instructions. Tracker/belt contact pressure too high. Decrease belt contact pressure. Poor Tracking Tracker installed in wrong direction. Verify directional labels - refer to installation drawing. Wear on Rollers / Roller failure No Frame Movement Tracker stoppers not correctly adjusted. Belt not in contact with all idlers Belt not in contact with all idlers Belt contact pressure too high/low. Material build-up and ingress of material on frame or components. Bearing failure. Belt contact pressure too high/low. Check Tracker and Belt troughing angle match Adjust accordingly - refer to installation instructions. Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions. Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions. Adjust to correct pressure, refer to installation instructions. Clean and remove. Repair or replace - refer to installation instructions Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions. Replace Tracker with belt troughing angle. Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 20 of 22

22 NOTES: Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 21 of 22

23 Head Office South Africa Brelko Conveyor Products (Pty) Ltd 16 Harries Street, Reuven Extension 1, Booysens, Johannesburg, South Africa Website: Tel: Branches United States of America Brelko Conveyor Products Inc. Telephone: , Telefax: Mobile: , United Kingdom Simm Conveyor Services LTD Telephone: , Telefax: , Agents: Africa Botswana Etuba Mobile: , DRC Mickem Consulting Telephone: , Ghana Alshtech Telephone: , Mobile: , Namibia Sepp Thalmaier Telephone: Windhoek , Oranjemund: Telefax: , Zambia Conveyor Engineering & Equipment Mobile: , , Zimbabwe Hilmax Telephone: /1/2/3, Telefax: , info@hilmax.co.zw Master Distributors: International Australia O r e fl o w Telephone: , Telefax: , sales@oreflow.com.au Chile Mantex Telephone: , Telefax: , proyectos@mantex.cl Europe OFC - Optim For Conveyors Telephone: , Telefax: , info@ofc-eu.com Greece Solergon Ltd. Telephone: , solergon@otenet.gr Malaysia & Indonesia Max Classics (M) SDN. BHD. Telephone: , Telefax: , maxclassics@gmail.com Mexico Construmac Telephone: , atencionaclientes@construmac.com Portugal & Spain Masanés Servindustria Web: Saudi Arabia Synergies Tech Telephone: , Telefax: , shadab@synergies-group.com United Kingdom Millenium Conveyor Services LTD Telephone: , Telefax: Product, Installation and Maintenance Manual - Belt Tracking Systems - Page 22 of 22