Product, Installation and Maintenance Manual

Transcription

1 Product, Installation and Maintenance Manual Primary & Secondary Scrapers and Belt Ploughs.

2 Table of Contents 1. Table of Contents Table of Contents Continued 2 2. Company Profile 3 3. Disclaimer Safety Note The following symbols may be used in this manual: 4 4. General Information 4 5. Handling Receiving the goods Work Safety Handling Storage Preparations for installing Belt Scrapers and Ploughs 5 6. Recommended Tools List 5 7. Primary Head Pulley Belt Scrapers Secondary Belt Scrapers Belt Ploughs Scrapers & Ploughs Belt Width Range Primary Scrapers Secondary Scrapers Ploughs Scrapers & Ploughs Blade Selection Guide Belt Scraper & Belt Ploughs Mounting Selection Guide Primary Belt Scrapers - Features and Options Primary Belt Scrapers - Parts Ordering List and Assembly Instructions Primary Belt Scrapers - Dimension Table and Installation Guide Primary Belt Scrapers - Parts reference Drawing Secondary Belt Scrapers - Features and Options Secondary Belt Scrapers - Parts Ordering List Assembly Instructions And Reference Dimension Tables Secondary Scrapers Installation Guide Secondary Belt Scrapers - Parts Reference Drawing Secondary Belt Scrapers - Parts Reference Drawing Cont Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 1 of 35

3 11. Belt Ploughs - Features and Options Ploughs - Parts Ordering List Ploughs - Assembly Instructions Ploughs - Installation Guide Ploughs - Parts Reference Drawings Ploughs - Parts Reference Drawings Continued Maintenance For Scrapers Routine Visual Inspection (every 2~4 weeks) Procedure for Replacing/Repairing Primary and Secondary Belt Scrapers Trouble Shooting Primary and Secondary Belt Scrapers Procedure for Replacing/Repairing Belt Ploughs Standard Mount Heavy Duty Mount Trouble Shooting Belt Plough Installation Notes: Contact Details: 35 Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 2 of 35

4 BRELKO Managing Director: Kenny Padayachee Tel: General Manager: Jay Pillay Tel: Sales & Marketing Manager: Sharon Padayachee Tel: Area Manager - Africa & USA: Brent Weller Tel: brentweller@brelko.com 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 including a 24 hour call out service. 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 Level 1 B-BBEE status. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 3 of 35

5 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: 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 scrapers and ploughs are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the scraper is installed a regular maintenance program should be set up. This program will ensure that the scraper operates at optimal efficiency and problems can be identified and fixed before the scraper stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Secondary Scrapers operate 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 when the conveyor is 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 scraper or plough, check that it is securely attached to the lifting equipment. Always observe local safety regulations. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 4 of 35

6 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 scrapers 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 Scrapers can be stored unpacked or in transportation package. Scrapers must not be stored on top of one another, protect the scrapers by storing them in a cool dry area on a flat surface Preparations for installing Belt Scrapers and Ploughs 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) Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 5 of 35

7 Tools List QTY DESCRIPTION IMAGE 1 90 SET SQUARE 1 5M TAPE MEASURE 2 ADJUSTABLE SPANNERS 1 PIPE WRENCH (3" MINIMUM) 1 SOCKET RATCHET SET (6mm - 30mm) 2 RINGSET SPANNERS - M13, 15, 16, 17, 18, 19, 24 1 STANLEY KNIFE 2 M46 SET SPANNERS 2 M65 SET SPANNERS 1 HARD FACE HAMMER 4pd Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 6 of 35

8 Tools List QTY DESCRIPTION IMAGE 1 SOFT FACE HAMMER - 1KG 3M NYLON ROPE 2 "G" CLAMPS - 6" - 8" 1 JIMMY LEVER Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 7 of 35

9 PRIMARY HEAD PULLEY BELT SCRAPERS MODELS : E905, E915, E952, E955 MODEL E905 - PRIMARY BELT SCRAPER WITH TWIST TORSION MOUNT MODEL E915 - PRIMARY BELT SCRAPER WITH TWIST TORSION MOUNT MODEL E952- PRIMARY BELT SCRAPER WITH TWIST TORSION MOUNT MODEL E955 - PRIMARY BELT SCRAPER WITH TWIST TORSION MOUNT Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 8 of 35

10 SECONDARY BELT SCRAPERS MODEL E105, E205, E252, E255, E705 MODEL E105 - SECONDARY BELT SCRAPER WITH TORSION MOUNTINGS MODEL E205 - SECONDARY BELT SCRAPER WITH STANDARD MOUNTINGS MODEL E252 - COMPOSITE HEAVY DUTY SECONDARY BELT SCRAPER WITH PARALLEL TORSION MOUNTINGS MODEL E255 - HEAVY DUTY PREMIUM SECONDARY BELT SCRAPER WITH PARALLEL TORSION MOUNTINGS MODEL E705 - COMPACT SECONDARY BELT SCRAPER WITH STANDARD MOUNTS Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 9 of 35

11 BELT PLOUGHS MODEL E405, E505, E505HD MODEL E405 V PLOUGH MODEL E505 - ANGLE PLOUGH WITH STANDARD MOUNTS MODEL E505 HD - ANGLE PLOUGH WITH HEAVY DUTY MOUNTS Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 10 of 35

12 8. Scrapers & Ploughs Belt Width Range 8.1. Primary Scrapers BELT WIDTH RANGE PRODUCT MOUNT TYPE MODEL E905 TWIST TORSION MODEL E915 TWIST TORSION MODEL E952 TWIST TORSION MODEL E955 TWIST TORSION 8.2. Secondary Scrapers PRODUCT MOUNT TYPE BELT WIDTH RANGE MODEL E105 STANDARD TORSION MODEL E205 STANDARD TORSION MODEL E252 STANDARD PARALLEL TORSION MODEL E255 STANDARD PARALLEL TORSION MODEL E705 STANDARD TORSION 8.3. Ploughs PRODUCT MOUNT TYPE BELT WIDTH RANGE MODEL E405 STANDARD BLADE HEIGHT MODEL E505 STANDARD BLADE HEIGHT MODEL E505HD STANDARD BLADE HEIGHT Scrapers & Ploughs Blade Selection Guide Polyurethane Low abrasion, high impact, low / medium speed. F.R.A.S. (Polyurethane) (FIRE RETARDANT, ANTI STATIC) Low abrasion, high impact, low / medium speed. Chrome Tool Steel Hardened (C10) Corrosive, low abrasion, high impact e.g. clip joints, chemicals, food etc. Tungsten Carbide (TC x 2mm thick) High abrasion e.g. stone, gravel, sand, ore, coal etc. Triplex Tungsten Carbide (T3 x 2mm thick) High abrasion, impact, corrosion e.g. slurry, coke, silica etc. Triplex Tungsten Carbide (T3 x 4mm thick) High abrasion, impact, corrosion / high speed steel cord belts. Boron Carbide (B4C x 4mm thick) High abrasion, low impact, primary & secondary belt scrapers / high speed. MODEL E105, E905, E915, E405, E505, E505HD MODEL E105, E905, E915, E405, E505, E505HD MODEL E205, E705 MODEL E205, E705 MODEL E205, E255, E705, E952 MODEL E255, E952 MODEL E952 Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 11 of 35

13 8.5. Belt Scraper & Belt Ploughs Mounting Selection Guide Primary Scrapers 1 Twist Torsion Mount E905,E915, E952 and E955 Near and Far Sides. Secondary Scrapers 2 Standard Adjustable Mountings Most commonly used, low cost. Manual adjustment for blade wear and correct pressure against the belt. Scraper models: E105-S, E155-S, E205-S, E252-S, E255-S, and E705-S. 3 Torsion Arm Mountings Auto compensating for blade wear, varying belt thickness, ease passage of belt fasteners (clips, suitable for reversing belts, refer to installation guide). Single Arm Scraper models: E105-T, E205-T and E705-T. Parallel Arm Scraper models: E155-T, E252-T, E255-T. Note: T - TWIST TORSION MOUNTS Belt Ploughs Plough Mountings Auto compensating for blade wear, varying belt thickness, ease passage of belt fasteners. E405 V-PLOUGH 4 E505 ANGLE PLOUGH Auto compensating for blade wear, varying belt thickness, ease passage of belt fasteners. E505 ANGLE - PLOUGH Heavy Duty Universal swivel mounting allows the plough to be set to scrape to either side of the belt. The above guidelines are not exhaustive or definitive; please contact us if in any doubt Note: Improper selection, installation & maintenance of scrapers could cause serious injuries, plant and equipment damage. Only use trained & qualified personnel for these functions. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 12 of 35

14 APPLICATIONS APPLIES TO E905, E915, E952,E955 DESCRIPTION As a Head Pulley Scraper, working directly on the head pulley. E905, E915, E955 As a Head Pulley Scraper, when wet and sticky materials are conveyed. E905, E915, E955 Can be installed where there is not enough space for other scrapers. E905, E915 Suitable for all types of conveyor belts and metal fastener systems. E952 E952 Can be used on high speed and steel cord belts. Low impact small particle size materials only. E952, E955 Suitable for all types of conveyor belts with vulcanized joints. E952 E952 FEATURES APPLIES TO E905, E915, E955 E905, E915, E952 Suitable for use in corrosive conditions. Used in conjunction with Brelko Secondary Scrapers. DESCRIPTION Adjustable Brelko torsion twist tensioners allow the scraper to maintain a constant pressure on the belt. They are self adjusting and allow the scraper to deflect away from any obstruction as a significant safety feature. Specially formulated polymeric blades give maximum life, and keep the possibility of damage to belt repairs, splices and metal fasteners to a minimum. E905, E952, E955 Patented V-base blade mounting makes blade changing quick and simple. E905,E915, E952, E955 E905, E915, E952, E955 E952 E952 E952 E952 E955 PRIMARY BELT SCRAPERS - FEATURES AND OPTIONS Multi-blade construction allows individual blades to deflect for minor obstructions and adapt to belt profile. Streamlined scraper construction prevents material build-up on the scraper. Ceramic or Tungsten blade holders with Boron Carbide (BC) and Tungsten Carbide (T3) inserts for long life. Compact torsion twist tensioners for easy adjustment. Low friction and heat generation. Robust construction for longer life. MODELS : E905, E915, E952, E955 Pre-tensioned blades restrict forward movement and reduces belt contact pressure for optimised cleaning, and extends belt life. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 13 of 35

15 PRIMARY BELT SCRAPERS - PARTS ORDERING LIST NOTE! Always quote belt width. ITEM No. DESCRIPTION APPLIES TO PRODUCT SIZE SHAFT LENGTH (mm) BELT WIDTH (mm) PART No. A. Carrier Assembly including shaft, V track and end stops. Note: E915 Not Supplied with V-TRACK E905 E915 E955 Size Size Size Size Size Size B. Torsion twist Tensioner and mount assembly including bearing, bushes, mounting brackets and tensioner units (Belt Widths 1500 to 2400 require 2 Twist Tensioner Units) ALL Size 2 N/A Size 3 N/A Size 4 N/A C. Blades - Standard Polyurethane E mm N/A N/A E mm N/A N/A E mm N/A N/A Composite Poly Blade c/w Steel Holder and T3 Tip Ceramic Holder and BC Tip E952 E mm 150mm N/A N/A N/A N/A D. Optional / 3-Piece Shaft Assembly including inner carrier shaft, outer carrier shafts and off-set plates. E905, E955 Size P-(BW) E905, E952, Size P-(BW) E955 E905, E915, Size P-(BW) E952, E955 E905, E915, Size P-(BW) E952, E955 E905, E915, Size P-(BW) E952, E955 E905, E915, E952, E955 Size P-(BW) E. Torsion Holder E mm N/A N/A PRIMARY BELT SCRAPERS - ASSEMBLY INSTRUCTIONS 1. All scrapers will be wrapped and clearly marked with the model number, scraper blade grade and belt width. Note: - Scrapers will be supplied with all nuts and bolts to complete the assembly and installation. 2. Referring to the parts list check that the correct parts and quantities have been supplied for the model and belt width of the scraper ordered. 3. Normally scrapers are supplied with blades (3) and end stops (5) assembled and fixed to the carrier shaft. If this is not the case, assemble as shown using lithium base grease as a lubricant to ease future removal of blades. If necessary, use rubber mallet to tap the blades into the V track. 4. Check that the blades (3) are free to deflect forwards and backwards. If any blades foul those adjacent, slightly slacken the end stop (5) set screws, and tap the torsion holders (4) sideways until the blades (3) clear each other. Tighten end stop (5) set screws. Note: - There should be 0,5mm gap between blades (3) Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 14 of 35

16 1. Proceed with installation as per installation guide. Note : Care should be taken when handling the ceramic components. DIMENSIONS TABLE (mm) Belt Width No. BLADES SIZE RANGE A B C D E F G H J K L M N P Z (3 PIECE) X PRIMARY BELT SCRAPERS - INSTALLATION GUIDE 1. Refer to the Assembly Instructions, Parts List and Parts list drawing to confirm that all the necessary parts have been supplied and that the scraper is correctly assembled. 2. Remove mounting brackets (7) from nearside bearing assembly (9) and farside bearing assembly (8). 3. Referring to the installation data sheet and dimensions given in the dimension table determine the scraper work zone and select the optimum position for the scraper. 4. After establishing the optimum position for the scraper on the head pulley, mark and cut out the near and farside chute openings. The farside opening need only accommodate scraper adjustment. Note 1: - Shield the conveyor belt and head pulley to prevent burning during cutting and welding activities. Note 2: - The mounting brackets (7) may be omitted and the bearing plates bolted directly to the chute sides. Separate chute access doors may then be required for inspection and maintenance access. Please consult a Brelko representative for this installation option. 5. With reference to the installation data sheet select the most convenient location for the mounting brackets (7). Note: - Mounting brackets (7) can be welded or bolted to the chute sides. 6. Tack weld the near and farside mounting brackets (7) to the chute sides or bolt to structure. 7. Remove one or both carrier shaft (1) end caps and install scraper through nearside chute opening. 8. Position carrier (1) centrally with reference to belt edges and head pulley and attach the nearside bearing assembly (9) and farside bearing assembly (8) to the mounting brackets (7). 9. Using nearside bearing assembly (9) and farside bearing assembly (8) as reference determine exact carrier (1) length, mark off; remove carrier (1) and nearside bearing assembly (9) and farside bearing assembly (8). 10. Carefully cut carrier shaft (1) to required length and de-burr shaft ends, reposition carrier shaft (1) centrally with reference to belt edges and head pulley. 11. Fit farside bearing bush (8a) over carrier shaft (1) end, and insert carrier shaft (1) end into farside bearing assembly (8). Tighten bolts and nuts, finger tight only as further adjustment of the scraper will be required. 12. Fit nearside bearing bush (9a) over carrier shaft (1) end, and locate nearside bearing assembly (9) as shown. Tighten bolts and nuts, finger tight only as further adjustment of the scraper will be required. 13. Complete welding of near and farside mounting brackets (7) or ensure all mounting brackets (7) nuts and bolts are firmly fastened. 14. Locate tension unit (6) and insert holding bolt into matching holes between the nearside bearing assembly (9). Tighten holding bolt and nut, finger tight only as further adjustment of the scraper will be required. 15. With reference to the dimension data sheet move scraper into the correct scraping position. Tighten bolts and nuts; do not over tighten nuts and bolts as further adjustment of the scraper might be required. 16. Using a shifting spanner, turn tension unit to bias scraper against head pulley and insert holding bolt. The tensioner only needs to be rotated until the first set of holding bolt holes between nearside bearing assemblies (9) align. 17. Firmly tighten all nuts and bolts. 18. Start the conveyor and check if all blades are in full contact with the belt surface. If further adjustment is required stop the conveyor and adjust the scraper until the next set of holding bolt holes between nearside bearing assemblies (9) align or until optimum cleaning is achieved. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 15 of 35

17 PRIMARY BELT SCRAPERS - PARTS REFERENCE DRAWING H C MODEL E952 BLADE MODEL E905 BLADE MODEL E915 BLADE 250 MODEL E955 BLADE PRIMARY SCRAPER NYLON BLADE OPTIONS PRIMARY SCRAPER POLYURETHANE BLADE OPTIONS POLYURETHANE GRADES STANDARD - 95SH(A) FIRE RETARDANT - 95SH(A) X Z SEE BLADE OPTIONS C - POLYURETHANE BLADES H - NYLON BLADES PRIMARY SCRAPER - SINGLE PIECE CARRIER B 8 / a 9 7 Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 16 of 35

18 SECONDARY BELT SCRAPERS - FEATURES AND OPTIONS APPLICATIONS APPLIES TO E105 E105 E105 E105 E205 E205, E252, E255, E705 E205, E252, E255, E705 E205, E252, E255, E705 E252 E255 E705 E705 DESCRIPTION As a Primary Scraper, when wet and sticky materials are conveyed. May be mounted directly on the head pulley. Can be used individually or in tandem as the secondary scraper. Suitable for all types of conveyor belts and metal fastener systems. Universal choice for all normal cleaning applications. Not suitable for mounting directly onto the head pulley. Use in conjunction with torsion arm mountings to accommodate different belt thicknesses on the same conveyor and excessive belt movement due to pulley eccentricity, thereby ensuring constant pressure with the belt. Selection of correct blade material gives optimum blade life under all operating conditions and conveyed materials. As a Heavy Duty Head Pulley Scraper. Universal choice for heavy duty cleaning applications. Specially suited for wider high speed belts. Specially designed for easy installation on all belts up to 750mm wide. Can be installed where there is not enough space for other scrapers. FEATURES APPLIES TO ALL E105 E105 E252 E205, E255, E705 DESCRIPTION Patented V-Base blade mounting makes blade changing quick and simple. Specially formulated polyurethane blades give maximum life, and keep the possibility of damage to belt repairs, splices and metal fasteners to a minimum. Patented blade design ensures optimum combination of flexibility and stiffness to adapt to belt profile. Specially formulated composite blades give maximum life, and ensure accurate assembly and a clean running scraper. Pre-tensioned blades restrict forward movement and reduces belt contact pressure for optimized cleaning, and extends belt life. E205, E255, E705 Fully sealed construction of torsion holder prevents material build-up or ingress into the spring unit. E205, E255, E705 MOUNTING COMPONENTS APPLIES TO ALL ALL E205, E255, E705 E205, E255, E705 Twin arm design of the torsion holder prevents radial and lateral blade oscillations and only allows longitudinal blade movement thus ensuring uniform and constant blade contact with the belt, irrespective of variations in belt thicknesses and surface conditions. DESCRIPTION All metal components supplied standard as mild steel. NOTE: For corrosive environments components can be supplied galvanized or stainless steel on request. Brelko torsion mountings allow the scraper to maintain a constant pressure on the belt and greatly extend adjustment intervals. Also available is the standard adjustable mounting. Lightweight Nylon material used for the torsion holder ensures ease of handling, corrosion protection and minimum impact on belt surface after deflection. Patented blade torsion holder and blade design incorporating a deflector skirt ensures accurate assembly and a clean running scraper. E205, E255, E705 Robust construction for longer life. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 17 of 35

19 SECONDARY BELT SCRAPERS - PARTS ORDERING LIST NOTE! Always quote belt width. ITEM No. DESCRIPTION APPLIES TO PRODUCT SIZE SHAFT LENGTH (mm) BELT WIDTH (mm) PART No. A. Carrier Assembly including shaft, V track and end stops. ALL Size Size Size Size Size Size C. Blades - Standard Polyurethane E mm N/A N/A Blades - F.R.A.S.O.R. Polyurethane 120mm N/A N/A F Composite Poly Blade c/w Triplex Tungsten blade (4mm) - T3 E mm N/A N/A D. Optional / 3-Piece Shaft Assembly including inner carrier shaft, outer carrier shafts and off-set plates. E. Standard Mount Assembly - including clamp piece, nylon bushes, bolts, nuts and washers. Note: - Spindle to be ordered separately. F. Torsion Mount Assembly - including clamp piece, nylon bushes, bolts, nuts and washers. Note: - Spindle to be ordered separately. ALL Size P-(BW) Size P-(BW) Size P-(BW) Size P-(BW) Size P-(BW) ALL Size 1&2 N/A / Size 3 N/A Size 4 N/A ALL Size 1&2 N/A Size 3 N/A Size 4 N/A G. Spindle Assembly including lock nuts. ALL Size 1 N/A Size 2&3 N/A Size 4 N/A H. Torsion Holder Assembly c/w :- Chrome Tool Steel blade C10 E mm N/A N/A Tungsten Carbide blade (2mm) TC E mm N/A N/A Triplex Tungsten blade (2mm) T3 E mm N/A N/A Triplex Tungsten blade (2mm) T3 E mm N/A N/A Triplex Tungsten blade (4mm) T3 E mm N/A N/A Chrome Tool Steel blade (5mm) C10 E mm N/A N/A Tungsten Carbide blade (2mm) TC E mm N/A N/A Triplex Tungsten blade (2mm) T3 E mm N/A N/A Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 18 of 35

20 SECONDARY BELT SCRAPERS - ASSEMBLY INSTRUCTIONS 1. All scrapers will be wrapped and clearly marked with the model number, scraper blade grade and belt width. Note: - Scrapers will be supplied with all nuts and bolts to complete the assembly and installation. 2. Referring to the parts list and installation data sheet check that the correct parts and quantities have been supplied for the model and belt width of scraper ordered. 3. Normally scrapers are supplied with blades (3) and end stops (5) assembled on the carrier shaft (1). If not, assemble as shown using a lithium base grease as a lubricant to ease future removal of blades. If necessary, use a rubber mallet to tap the blades into the V track. Do not over-tighten end stop (5) set screws. 4. Depending on the installation access (see Installation Guide paragraph -1) an optional three piece shaft may be required, then one or both of the carrier shaft end pieces may now be attached. Note: - Three piece carrier shafts are not supplied as standard and must be ordered separately. 5. Check whether the optional offset plates (10) are to be used, and if so; ensure that they are correctly assembled. Ensure that all nuts and bolts are firmly fastened. Note: - Offset plates (10) are not supplied as standard and must be ordered separately. 6. Proceed with the installation as per the installation guide. A B DIMENSION TABLE - 1 STANDARD MOUNT TORSION MOUNT SIZE 1 SIZE 2 SIZE 3 SIZE 4 SIZE 5 SIZE 1 SIZE 2 SIZE 3 SIZE 4 SIZE 5 E E E E E E E E E E C D E M30 M42 M30 M42 F G H J DIMENSION TABLE - 2 SIZE RANGE BELT WIDTH E E NO OF BLADES E E E E E DIM - X E E E DIM - Z Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 19 of 35

21 SECONDARY BELT SCRAPERS - INSTALLATION GUIDE 1. Refer to the Assembly Instructions, Parts List and the Parts List Drawing to confirm that all the necessary parts have been supplied and that the scraper is correctly assembled. Depending on access space, it may be necessary to use an optional 3-piece carrier. Then one or both of the carrier shaft end pieces can be fitted once the scraper is in position. 2. Remove the mount clamp piece (11), and green nylon bushes (12) from standard mount (7) / torsion mounts (8). 3. Check that the lock nuts move freely on the spindles. 4. Remove the standard mount (7) / torsion mount (8) from the spindles (6). 5. Referring to the dimensions given in the table, see the Installation drawing, select the optimum position for the scraper and mark the location of the access apertures. 6. With reference to the Installation drawing, select the most convenient location for the mounting spindles. There are four possible positions but in all cases ensure that the spindles remains at 90 (± 10 ) to the belt surface. If no suitable location can be found to attach the spindle foot to the conveyor structure, the 3 piece shafts may be used as shown in the Parts List Drawing. Note: - Offset plates (10) and 3-piece shafts are not supplied as standard, and must be ordered separately. 7. Fix the spindles (6) firmly in position. Locate standard mount (7) / torsion mount (8) on spindles as shown. 8. Check that carrier shaft end pieces and carrier shaft centrepiece are firmly bolted together (3-piece shaft only). 9. Position carrier shaft underneath the conveyor belt centrally with reference to belt edges and head pulley. 10. Position carrier shaft and attached clamp piece (11) and bushes (12) on standard mount (7) / torsion mount (8) as shown and fit bolts, washers and nuts. Tighten finger tight. For torsion mounts (8) adjust set screws (13) until they just touch the torsion arm. Pre-tension the torsion mount and tighten set screws (13) four full turns. Note: - It may be necessary to adjust the location of the mount on the spindles by means of spindles nuts so that the blades are clear of the belt surface. 11. Lay a straight edge on the top face of the carrier shaft end piece and rotate the assembled carrier shaft until the straight edge is parallel to the belt surface. Note: - This step must be done carefully to ensure that the angle of the blades to the belt is correct. 12. Tighten bolts and nuts. Do not over tighten! 13. By means of spindle nuts adjust the scraper towards the belt surface until all the blades contact the belt surface. 14. Again, adjust the scraper towards the belt. a. For E105 or E252 one further full turn of the spindle nuts. b. For E205, E255 or E705 half a turn of the spindle nuts. 15. The blades should now rest on the belt surface. Note: - For torsion mounts, check that the set screws (13) are not touching the torsion arm. If they are still in contact with the arm continue to adjust the scraper towards the belt in increments of half a turn of the lock nuts until the set screw (13) just clears the torsion arm. 16. For torsion mounts only. Slacken the set screws (13) four full turns and tighten the lock nuts. 17. Check that the complete scraper assembly can move freely up and down on the torsion mounts, and that all blades can move freely. 18. Check that all nuts and bolts are firmly fastened. 19. Check that the spindle lock nuts are firmly tightened. 20. Start the conveyor and check if all blades are moving freely and scraping in full contact with the belt surface. If further adjustment is required, stop the conveyor and adjust the scraper: a. For E105 or E252, one further turn of the spindle nuts towards the belt until all blades are scraping satisfactory. b. For E205, E255 or E705,half a turn of the spindle nuts towards the belt until all blades are scraping satisfactory. Note: - Do not over adjust the scraper. 21. Check that the spindle lock nuts are firmly tightened. 22. To ensure future adjustment of the spindle nuts wrap thread with protective cloth to protect the thread against corrosion, rust and ingress of dust. 23. It may be necessary to install stabilising rollers to keep the belt surface flat and stop belt bounce. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 20 of 35

22 SECONDARY BELT SCRAPERS - PARTS REFERENCE DRAWING MODEL E205 BLADE MODEL E255 BLADE C MODEL E105 BLADE MODEL E252 BLADE MODEL E705 BLADE SECONDARY SCRAPER NYLON BLADE OPTIONS H SECONDARY SCRAPER POLYURETHANE BLADE OPTIONS POLYURETHANE GRADES STANDARD - 95SH(A) FIRE RETARDANT - 95SH(A) SEE BLADE OPTIONS C - POLYURETHANE BLADES H - NYLON BLADES Z 3 X 5 A 1 SECONDARY SCRAPER - SINGLE PIECE CARRIER B MOUNTING OPTIONS: MOUNT DIRECTLY ONTO CONVEYOR STRINGER or CHUTE SIDE PLATE (SUPPORT CLEATS NOT SUPPLIED AS STANDARD) A G C 6 D J E E F H F Ø20 G STANDARD MOUNT TORSION MOUNT 7 8 DOUBLE ARM TORSION MOUNT Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 21 of 35

23 PARTS REFERENCE DRAWING (continued...) OPTIONAL 3 PIECE CARRIER D 10 OPTIONAL OFFSET PLATE 100mm MIN 100mm MIN 100mm MIN SPINDLE POSITION "A" SPINDLE POSITION "B" SPINDLE POSITION "C" 100mm MIN SPINDLE POSITION "D" NOTE: FOR INCLINED BELTS SPINDLE CAN BE MOUNTED IN POSITION A or C, BUT MUST REMAIN AT 80 TO 100 BELT SURFACE. (MAX BELT DECLINE ANGLE 15 ) Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 22 of 35

24 BELT PLOUGHS - FEATURES AND OPTIONS MODEL E405, E505, E505HD APPLICATIONS APPLIES TO E405 E505 E505HD DESCRIPTION Designed to be installed in the trailing configuration on the inner surface return. Alternative to the E405 where material can only be discharged on one side. For use on reversible belts. For heavier duty applications.. FEATURES APPLIES TO DESCRIPTION ALL Unique track mounted scraping blade facilitates very easy and quick blade change. ALL Specially formulated PU blades ensure maximum blade life and minimum belt wear. ALL Can be mounted on the top, bottom or inside of the stringers. E405 Unique hinged assembly results in compact packaging for easy transport and installation. E405 Parallel tri-link mounting allows the plough to move freely thus maintaining constant contact with the belt E405 Interlocking blades ensure no blade distortion at leading edge. E505 For use on reversible belts E505 Parallel dual-link mounting allows the plough to move freely thus maintaining constant contact with the belt. E505 Unique bolted assembly results in compact packaging for easy transport and installation. E505 Universal swivel mounting allows the plough to be set to scraper to either side of the belt. MOUNTING COMPONENTS APPLIES TO DESCRIPTION ALL All metal components supplied standard in mild steel. NOTE: For corrosive environments components can be supplied galvanized or stainless steel on request. ALL Universal Mounting Options. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 23 of 35

25 PLOUGHS - PARTS ORDERING LIST NOTE! Always quote belt width. ITEM No. DESCRIPTION APPLIES TO PRODUCT SIZE BELT WIDTH (mm) PART No. A. V Arm Assembly including Polyurethane blades E405 Size (Specify Belt Width) Size (Specify Belt Width) Size (Specify Belt Width) B. Front Cross Brace E405 Size (Please Specify Belt Width) Size (Please Specify Belt Width) Size (Please Specify Belt Width) C. Rear Cross Brace E405 Size (Please Specify Belt Width) Size ( (Please Specify Belt Width) Size (Please Specify Belt Width) D. Centre Cross Brace E405 Size (Please Specify Belt Width) E. Stringer Mount Bracket E405 Size 1, 2 & F. Link Arm ALL Size 1, 2 & G. Safety Chain Assembly - 1mtr- E405 Size 1, 2 & H Side Blades (L & R) E mm (Specify Belt Width) 150mm (Specify Belt Width) I Standard Carrier Assembly E505 E505HD Size 1 Size 2 Size (Please Specify Belt Width) (Please Specify Belt Width) (Please Specify Belt Width) J Standard Stringer Mount Assembly, including Link Arms, Mounting Plates and Swivel Brackets. E K Optional Heavy Duty Mount Assembly, including Spindles assembly, Spindle Bracket & Mounting Plates. E505 E505HD Size 2& Size L Poly Blades E505 E505HD 100mm (Specify Belt Width) 150mm (Specify Belt Width) M Optional Heavy Duty Deflector Plate E505HD (Please Specify Belt Width) N Optional Spindle Assembly including Lock Nuts. E505 E505HD Size 2& Size Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 24 of 35

26 PLOUGH - ASSEMBLY INSTRUCTIONS - STANDARD ASSEMBLY 1. Referring to the parts list check that the correct parts and quantities have been supplied for the model and belt width plough ordered. 2. Normally ploughs are supplied with blades (6) assembled in the channel track (1). If not, slide the blade (6) into the slotted carrier (1) and lock in a central position with set screws supplied. 3. Fit the HDPE washer (2), along with the swivel mounts (3) to the the carrier shaft (1). 4. Assemble the links (5) to the two side mounting frames (4). 5. Decide on the side (L or R) the plough must scrape to and swivel the blade/carrier assembly accordingly. 6. Fit the mountings (4) and links (5) to the swivel mounts (3). PLOUGH - ASSEMBLY INSTRUCTIONS - HEAVY DUTY ASSEMBLY 1. Referring to the parts list check that the correct parts and quantities have been supplied for the model and belt width plough ordered. 2. Normally ploughs are supplied with blade/s (6) assembled in the channel track (1). If not, slide the blade (6) into the slotted carrier (1) and lock in a central position. 3. Normally ploughs are supplied with the spindle brackets (8) and the heavy duty deflector plate (10) assembled on the carrier assembly (1). If not, fit the spindle brackets (8) and heavy duty deflector plate (10) onto the carrier assembly (1), and firmly tighten all nuts and bolts. Note: If welding the deflector plate (10) to the carrier assembly (1), remove the blade/s to avoid the polyurethane from melting. Note: Shield the conveyor belt during welding and cutting activities. 4. Decide on the side (L or R) the plough must scrape to and swivel the blade/carrier assembly accordingly. Note: Care should be taken to ensure that spindle brackets (8) point in the correct direction. With reference to drawing number E B 5. Fit the mounting plates (9) to the stringers and locate the spindles (11) into the spindle brackets (8). DIMENSION TABLE (mm) - E405 Belt Width STD MNT CNTR SIZE RANGE 1 / 2 3 A B C D (BLADE HEIGHT) DIMENSION TABLE (mm) - E505 Belt Width SIZE RANGE A B C D DIMENSION TABLE (mm) - E505 HEAVY DUTY Belt Width SIZE RANGE A B C Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 25 of 35

27 INSTALLATION GUIDE E405 / E505 / E505 HD The plough is intended for removing loose material on the inside of the return side of the conveyor belt ahead of take-ups, drives and tail pulleys. 1. Refer to the assembly instructions and parts list to confirm that all the necessary parts have been supplied and that the plough is correctly assembled. Note: The plough mountings can be reversed giving three possible mounting positions on the conveyor stringers, to suit different return belt positions relative to the stringers. 2. If the return belt is not parallel to the stringers the nose or tail of the plough can be lowered by adjusting the front cross brace (3c) and stringer mounting brackets (6). (Up to 10 from parallel can be accommodated). Note: It may be necessary to install flat return idlers. 3. Select the most suitable positions for the plough which should be with the connecting links near horizontal. Mark out and make the mounting holes - (to suit M12 bolts). 4. If mounting on the inside of the stringer is required the use of tapered washers may be required. 5. Fix the front cross brace (3c) and stringer mounting brackets (6) firmly in position. 6. Ensure that the plough is securely linked to its frame and that it is free to move up and down to follow the belt movement. 7. Make an attachment point on the conveyor frame above and ahead of the plough. Attach the chain (7) to the conveyor frame and allow only sufficient slack in the chain to accommodate wear of the plough blades, and to prevent the plough frame from touching the belt. 8. Check that the plough is central on the belt and free to move up and down and that all bolts, nuts, links and shackles are securely fastened. 9. Start the conveyor and check for even contact of the blades with the belt and that the plough is moving freely with the belt. 10. The conveyor belt should be flat at the plough position. Note: If necessary, install flat return rollers ahead and behind the plough. 11. The plough is intended for removing loose material on the inside of the return side of the conveyor belt ahead of take-ups, drives and tail pulleys. Use instead of an E405 V-Plough when discharge can only be accepted to one side of the belt. 12. Refer to the assembly instructions and parts list to confirm that all the necessary parts have been supplied and that the plough is correctly assembled. Note: - The plough can be altered to discharge to the left or right hand side of the belt. 13. The return belt at the plough position must be flat and supported ahead and behind the plough. Note: - It may be necessary to install flat return idlers. 14. Select the most suitable position for the plough. The link arms (5) should be near horizontal. 15. Mark out the mounting holes for the two mountings (4). Note: - The mountings may be fitted on top, inside or below the conveyor stringers to accommodate the position of the return belt and the conveyor decking, bracing etc. 16. Fix the mounting frame (4) firmly in position. If mounting on the inside of the stringer web is required the use of tapered washers may be required. 17. Ensure that the plough is securely linked to its mounting brackets (4) and that the carrier & blade assembly (1) is central. 18. Ensure that a minimum overlap of 15mm on both sides of the belt is maintained and to clear the stringers during vertical movement. It may be necessary to trim the ends of the carrier & blade assembly (1). 19. Securely lock the swivel mounts (3) to the carrier assembly (1). 20. Check for free up and down movement with the belt of the plough and for good contact with the belt. 21. Ensure safety chains (7) are firmly fixed to the mounting brackets (9) and carrier assembly (1), there should be enough slack to accommodate blade wear and to prevent the carrier touching the belt. 22. To ensure future adjustment of the spindle nuts wrap thread with protective cloth, to protect the thread against corrosion, rust and ingress of dust. 23. It may be necessary to install stabilising rollers to keep the belt surface flat and stop belt bounce. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 26 of 35

28 PLOUGHS - PARTS REFERENCE DRAWINGS E405 ASSEMBLY 6 Blade wear level B A C D 6 1 Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 27 of 35

29 PLOUGHS - PARTS REFERENCE DRAWING (continued...) E505 STD MOUNT ASSEMBLY E505 HD MOUNT ASSEMBLY E505 STANDARD / HD BLADE ASSEMBLY 8 Blade wear level E505 HEAVY DUTY PLATE ASSEMBLY B A D 10 3 C Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 28 of 35

30 11.6. Maintenance For Scrapers Brelko belt scrapers are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the scraper is installed a regular maintenance program should be set up. This program will ensure that the scraper operates at optimal efficiency and problems can be identified and fixed before the scraper stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. The Scraper 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/tag-out procedures. New Installation After the new scraper has run for a few days a visual inspection should be made to ensure the scraper is performing properly. Make adjustments as needed Routine Visual Inspection (every 2~4 weeks) A visual inspection of the scraper and belt can determine: If the mounts are adjusted at the correct pressure for optimal cleaning If the belt looks clean or if there are areas that are dirty If the blade is worn out and needs to be replaced If there is damage to the blade or other scraper components If fugitive material is built up on the scraper or in the transfer area If there is cover damage to the belt If there is vibration or bouncing of the scraper on the belt If a snub pulley is used, a check should be made for material build-up on the pulley If any of the above conditions exist, a decision should be made on when the conveyor can be stopped for scraper maintenance. 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 scraper to perform the following tasks: Clean material build-up off the scraper blade and shaft. Closely inspect the blade for wear and any damage. Replace if needed. Check blade for proper installation and condition. Replace if needed. Ensure full blade to belt contact. Inspect the scraper carrier for damage. Inspect all fasteners for tightness and wear. Tighten or replace as needed. Replace any worn or damaged components. Check the pressure of the scraper blade on the belt. Adjust the pressure if necessary, refer to scraper model installation guide. When maintenance tasks are completed, test run the conveyor to ensure the scraper is performing properly. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 29 of 35

31 12. Procedure for Replacing/Repairing Primary and Secondary Belt Scrapers Repair/replace Belt Scraper components when general maintenance tasks are performed, scraper damage due to accelerated blade wear, scraper damage due to blocked chutes, clip joints/emergency belt repairs etc Request permit to work from an authorised person, who will isolate and lock out the belt Open access door, if provided, and clear loose items about the spindle before commencing with work Loosen the locknuts and then lower/raise the scrapers, as necessary If replacing scrapers, insert balance pipe which must be longer than the carrier shaft into the one end of the shaft Loosen the shaft and turn it 180 degrees, that is, scraper tips pointing downward Remove one spindle on the intended exit end Slide out the scraper assembly from the intended exit end of the pipe Service the scraper on the platform Blade replacement: Refer to Brelko installation instructions for belt scraper model in use. Brelko nylon torsion holders have been designed to break out of the torsion holder support v-track to protect the scraper, scraper mounting components, conveyor belt and conveyor belt equipment against damage due to emergency clip joints, loose/damaged splicing, belt protrusions, chute blockages etc. If torsion holders damaged occur follow the steps below to replace individual or all of the torsion holders: a. Remove and clean the damaged scraper to assess the amount of damage to the scraper, the scraper torsion holders and scraper components. b. If the scraper has been working for more than 4 weeks and/or there has been significant blade wear remove and replace all the torsion holders and blades and replace with new kits, this will eliminate belt damage due to uneven scraper torsion holder and blades. c. If the scraper has been working for 1~2 weeks replace only damaged torsion holders and blades, however assess the damage and ensure the remaining torsion holders will not cause any damage to the conveyor belt Scraper Adjustment: Refer to Brelko installation instructions for belt scraper model in use. a. Reposition using the balance pipe. b. Obtain sanction for test, or permission to adjust for performance evaluation. c. Tighten all nuts and ensure that belt cleaning or scraper performance is acceptable. d. Clear up any loose items which resulted from your work. Primary, Secondary and Ploughs - Product, Installation and Maintenance Manual - Page 30 of 35