Product, Installation and Maintenance Manual

Transcription

1 Product, Installation and Maintenance Manual Hi Impact System, Universal Feedboot and Combination Feedboot (Belt Suppport 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 Support Systems 4 6. Recommended Tools List Recommended Tools List Continued Recommended Tools List Continued Recommended Tools List Continued 7 7. Hi Impact, Universal Feedboot and Combination Feedboot Systems 8 8. Hi Impact, Universal Feedboot and Combination Feedboot Systems - Mounting Options 9 9. Hi Impact, Belt Tracking Troughing, Belt Tracking Return - Features and Options Hi Impact - Parts Ordering List Hi Impact - Parts Ordering List Cont Hi Impact - Installation, Repair/Replacement Guide Universal Feedboot- Parts Ordering List Universal Feedboot - Parts Ordering List Cont Universal Feedboot - Installation, Repair/Replacement Guide Combination Feedboot- Parts Ordering List Combination Feedboot - Parts Ordering List Cont Combination Feedboot - Installation Guide Hi-Impact, Universal and Combin ation Feedboot - Trouble Shooting Notes Contacts 20 Product, Installation and Maintenance Manual - Belt Support Systems - Page 1 of 20

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: Service Manager: Craig Abbey Tel: IT Manager: Grant Ritson Tel: 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 Support Systems - Page 2 of 20

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 Support Systems are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Belt Support System is installed a regular maintenance program should be set up. This program will ensure that the Belt Support System operates at optimal efficiency and problems can be identified and fixed before the Belt Support System stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Belt Support 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 Support System, check that it is securely attached to the lifting equipment. Always observe local safety regulations. Product, Installation and Maintenance Manual - Belt Support Systems - Page 3 of 20

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 Support 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 Support Systems can be stored unpacked or in transportation package. It must not be stored on top of one another. Protect the Belt Support Systems by storing them in a cool dry area on a flat surface Preparations for installing Belt Support Systems 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) Product, Installation and Maintenance Manual - Belt Support Systems - Page 4 of 20

6 Tools List QTY DESCRIPTION IMAGE 1 STRAIGHT EDGE (1M MINIMUM) 1 90 SET SQUARE 1 5M TAPE MEASURE 2 ADJUSTABLE SPANNERS 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 Product, Installation and Maintenance Manual - Belt Support Systems - Page 5 of 20

7 Tools List QTY DESCRIPTION IMAGE 1 SOFT FACE HAMMER - 1KG 3M NYLON ROPE 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 Product, Installation and Maintenance Manual - Belt Support Systems - Page 6 of 20

8 Tools List QTY DESCRIPTION IMAGE 1 BELT LIFTER 1 1 TON LEVER HOIST 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 Support Systems - Page 7 of 20

9 Hi Impact System Universal FeedBoot Combination FeedBoot Product, Installation and Maintenance Manual - Belt Support Systems - Page 8 of 20

10 Hi Impact Mounting Transom Universal Feedboot Mounting Transom Combination Feedboot Mounting Transom Product, Installation and Maintenance Manual - Belt Support Systems - Page 9 of 20

11 Hi Impact, Universal Feedboot, Combination Feedboot - Features and Options APPLICATIONS APPLIES TO Hi Impact System Combination Feedboot System Universal Feedboot System DESCRIPTION A load point belt support system designed to offer maximum impact absorbing capabilities. Suitable for all belt conveyors where large particle size and severe impact load conditions occur. A load point belt support system providing flat belt supporting surfaces mounted on an impact absorbing Structure. Suitable for all bulk conveyor systems with medium to severe impact conditions and particles up to 150mm in size. Replaces conventional impact systems in load area. A load point belt support system which elimates conventional conveyor idlers. Suitable for all belt conveyors handling bulk solids with a particle size less than 50mm and low impact conditions. FEATURES APPLIES TO DESCRIPTION Unique torsion arm mountings absorb impact loads and are self dampening. Hi Impact System Combination Feedboot Universal Feedboot Polyurethane impact rolls help to extend belt life. Proven polyurethane coated impact rolls, last up to 3 times longer than standard rubber lagged. Support frame is available in standard 2m length fitted with 5 strings of idler rolls. Support frame is designed to replace existing roller cradles and fixed conveyor stringers. Open construction makes cleaning of spillage and roll replacement very easy. Polyurethane roll arrangement promotes correct belt tracking. Flat belt support surfaces eliminate sag between rolls enabling optimum chute sealing design and operation. Load point spillage and dust escape is controlled and eliminated. Rubber impact cone mountings allow belt deflection under load in centre area whilst maintaining seal at belt edges. Sliding surfaces are lined with low friction, long life UHMW polyethylene sheets. Flat belt support surfaces eliminate sag between idlers enabling optimum chute sealing design and operation. Wing panels can be individually adjusted for optimum conveyor troughing angles from 0 to 60 Accurate belt support allows chutes and seals to be positioned to control and eliminate spillage and dust escape at the load points. Sliding surfaces are lined with low friction, long life UHMW polyethylene sheets. Optional centre panel with polyurethane rolls. Product, Installation and Maintenance Manual - Belt Support Systems - Page 10 of 20

12 Hi Impact - Parts Ordering List 3 1L 2 4 1R ITEM NO. DESCRIPTION 1L 1R SUPPORT BEAM (LEFT HAND) SUPPORT BEAM (RIGHT HAND) 2 2 HOLE LINK 3 BTA UNIT SIZE 5/SIZE 6 (SPECIFY 3 OR 5 ROLL & SERIES) 4 POLYURETHANE IMPACT IDLER ROLL 5 UPRIGHT 6 T-LINK 7 RESTRAINT CHAIN 8 TRANSOM Product, Installation and Maintenance Manual - Belt Support Systems - Page 11 of 20

13 Hi Impact - Parts Ordering List NOTE! Always quote belt width. ITEM No. DESCRIPTION PART No. 1 Support Beam (LH - RH) SPECIFY BELT WIDTH 2 BTA MOUNT - SIZE 5 6-MNT5 BTA MOUNT - SIZE 6 6-MNT6 SPECIFY 3 OR 5 ROLL SYSTEM, AND SERIES 30 OR CONE BUFFER 4-C-BUFFER 4 POLYURETHANE IDLER ROLL SPECIFY 3 OR 5 ROLL SYSTEM, AND SERIES 30 OR 40 SPECIFY BELT WIDTH 5 UPRIGHT SPECIFY 3 OR 5 ROLL SYSTEM SPECIFY BELT WIDTH 6 FLAT LINK ITEMS 6,7,8 & 9 SOLD AS A SET 7 T - LINK 8 CHAIN LINK RESTRAINT CHAIN A (Heavy Duty) 10 TRANSOM SPECIFY BELT WIDTH NOTE! Always quote belt width. ASSEMBLY INSTRUCTIONS 1. Referring to the parts list check that the correct parts and quantities have been supplied for belt width, troughing angle and number of rolls ordered. 2. Attach uprights (5) to transoms (10). 3. Bolt left and right hand support beams (1) to uprights (5). Note: - Left and Right units relative to belt direction. 4. Bolt BTA mounts (2) to support beams (1). Note: - Left and Right units, and belt direction. 5. Assemble polyurethane idler strings by connecting rolls (4) using links (6) and (7). Note: - Use T links (7) on centre rolls. 6. Attach polyurethane idler strings to BTA mounts using the M16 bolts supplied. Securely fasten bolts and nuts. 7. Attach restraining chains (9) using chain links (8) with nyloc nuts. 8. Chain (9) is connected to T links (7) which is bolted to transoms (10). Note: - Belt direction. Product, Installation and Maintenance Manual - Belt Support Systems - Page 12 of 20

14 Before replacing or repairing the Hi Impact: Hi Impact - Installation, Repair/Replacement Guide Request permit to work from an authorised person, who will isolate and lock out the belt. Remove existing idlers and rolls from conveyor structiure in the area where the system is to be installed. 1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for belt width, troughing angle and number of rolls ordered. 2. Remove existing idlers and rolls from conveyor structure in the area where the system is to be installed. 3. If assembled remove polyurethane idler strings, and the support beam (1) with uprights (5). 4. Check direction of belt travel and slide unit under conveyor belt from one side. Note: - For larger sizes lifting equipment may be required. 5. Position unit in impact zone and align centrally to belt. 6. Attach support beam (1) with uprights (5) to transoms (10). 7. Attach polyurethane idler strings to BTA mounts (2) with the M16 bolts supplied. Securely fasten bolts and nuts. 8. Attach retaining chains (9) using chain links (8) with nyloc nuts. 9. Chain (9) connected to T link (7) which is bolted to transoms (10). Note: - Belt direction. 10. Check centre roll height, the belt should just be in contact. If necessary add spacers under the transom ends. Or if the unit needs to be lowered, notch the transom ends and re-weld hold down plates. 11. Securely fasten system to conveyor stringers. 12. Check that polyurethane idler strings do not catch on transoms and that there is freedom of movement of the polyurethane idler strings in a vertical direction. When satisfied that the alignment is correct, bolt down the system to the conveyor stringers 13. Check chute sealing to the conveyor belt, preferably fit BRELKO KEYSKIRT to contain any spillage. Note: - Standard units are for installation in a horizontal position only. For inclines etc... refer to the Brelko Design Dept. Product, Installation and Maintenance Manual - Belt Support Systems - Page 13 of 20

15 Universal Feedboot - Parts Ordering List ITEM NO. DESCRIPTION 1 UHMW POLYETHELENE LINER 2 CENTRE PANEL 3 WING PANEL 4 ADJUSTER ARM 5 LEAD-IN ROLL BRACKET C/W WASHER & SCREW SET 6 LEAD-IN & CENTER FRAME ROLLERS 7 TRANSOM 8 ROLLER CENTER FRAME C/W ROLLERS Product, Installation and Maintenance Manual - Belt Support Systems - Page 14 of 20

16 Universal Feedboot - Parts Ordering List NOTE! Always quote belt width. ITEM No. DESCRIPTION PART No. 1 UHMW POLYETHYLENE LINER SPECIFY BELT WIDTH 2 CENTRE PANEL SPECIFY BELT WIDTH 3 WING PANEL SPECIFY BELT WIDTH 4 ADJUSTER ARM HINGE BRACKETS LEAD ROLL BRACKETS 4-L-I-BRK 7 LEAD ROLL SPECIFY BELT WIDTH 8 TRANSOM SPECIFY BELT WIDTH 9 OPTIONAL - ROLLER CENTRE FRAME SPECIFY BELT WIDTH 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 belt width ordered. 2. Attach wing panels (3) to mounting brackets (5) at hinge points and to the transoms (8), only lightly tighten bolts. 3. Fit centre panel (2) so that slots drop over the bolts on the brackets (5); the optional roller centre frame (9) can also be fitted at this time. 4. Check that the wing panels can pivot freely on their hinges. Attach adjustment arms (4) to wing panels and transoms (8). 5. Tighten all bolts and nuts. 6. Fit optional rollers (7) to roller centre section. 7. Fit optional lead-in roll brackets (6) and rolls (7) to wing panels. 8. Proceed with installation as per instructions Universal Feedboot - Installation, Repair/Replacement Guide Before replacing or repairing the Hi Impact: Request permit to work from an authorised person, who will isolate and lock out the belt. Remove existing idlers and rolls from conveyor structiure in the area where the system is to be installed. 1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for the belt width ordered. 2. Remove existing idlers and rolls from conveyor structure in the area where the feedboot is to be installed. Align the feedboot to correspond with the indicated belt direction. 3. With the feedboot wing panels (3) down, slide the feedboot from one side under the conveyor belt. Larger sizes will require the use of mechanical lifting equipment. 4. Ensure that the feedboot is positioned so that the loading area is approximately in the centre. 5. Accurately align the feedboot in the direction of the belt travel. 6. Check that the centre of the feedboot is ± 5-20mm lower than the bottom of the belt line. If not, add spacers under the transom (8) ends to raise the feedboot. If it needs to be lowered, then the ends of the transoms need to be notched and the hold down brackets refitted and welded. 7. Raise the wing panels (3) to the required troughing angle and tighten the support struts. 8. Check that the idlers immediately behind and ahead of the feedboot adequately bend and align to the conveyor belt. If not, then fit the optional lead in rolls (7) and brackets (6) to the ends of the feedboot. 9. When satisfied that the alignment is correct, bolt down the feedboot to the conveyor stringers. 10. Check that the chute skirting is in correct contact with the belt, or preferably fit Brelko Keyskirt to provide a good sealing arrangement. Product, Installation and Maintenance Manual - Belt Support Systems - Page 15 of 20

17 Combination Feedboot - Parts Ordering List ITEM NO. DESCRIPTION 1 UHMW POLYETHELENE WING LINER 2 UHMW POLYETHELENE CENTRE LINER 3 WING PANEL 4 IMPACT CONE / BUFFER 5 UPRIGHT 6 ENGINE MOUNT 7 TRANSOM 8 LEAD-IN ROLL BRACKET 9 ROLLERS Product, Installation and Maintenance Manual - Belt Support Systems - Page 16 of 20

18 Combination Feedboot - Parts List ITEM No. DESCRIPTION PART No. 1 UHMW Polyethylene Wing Liner Specify Belt Width 2 UHMW Polyethylene Centre Liner Specify Belt Width 3 Wing Panel Specify Belt Width 4 Cone Buffer 4-C.BUFFER 5 Vertical Support Bracket Specify Belt Width 6 Wing Mount 4-W.MOUNTING 7 Transom Specify Belt Width 8 Lead Roll Bracket 4-L-I-BRK 9 Lead Rollers Specify Belt Width NOTE! Always quote belt width. ASSEMBLY INSTRUCTIONS 1. Referring to the parts list and check that the correct parts and quantities have been supplied for the belt width and troughing angle ordered. 2. Attach required number of rubber cones (4) to the panels (3); see installation instructions. 3. Attach cone buffers (6) to panels. 4. Attach vertical support (5) to mountings (6). Attach panel assemblies to transom (7). 5. Ensure panels and transoms are correctly aligned and tighten all bolts and nuts. 6. Attach optional lead in roll brackets (8) and rolls (9) to wing panels (3). 7. Proceed with installation as per instructions. Combination Feedboot - Installation, Repair/Replacement Guide Before replacing or repairing the Hi Impact: Request permit to work from an authorised person, who will isolate and lock out the belt. Remove existing idlers and rolls from conveyor structiure in the area where the system is to be installed. 1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for the belt width and troughing angled ordered. 2. Remove existing idlers and rolls from conveyor structure in the area where the feedboot is to be installed. 3. Slide the feedboot from one side under the conveyor belt. It may be necessary to remove one half of the feedboot panels. Larger sizes will require the use of mechanical lifting equipment. 4. Ensure that the feedboot is positioned so that the loading area is approximately in the centre. 5. Accurately align the feedboot in the direction of the belt travel. 6. Check that the centre of the feedboot is ±5-20mm lower than the bottom of the belt line. If not, add spacers under the transom ends to raise the feedboot. If it needs to be lowered, then the ends of the transoms (7) need to be notched and the hold down brackets refitted and welded. 7. Check that the idlers immediately behind and ahead of the feedboot adequately bend and align to the conveyor belt. If not, then fit the optional lead in rolls (9) and brackets (8) to the ends of the feedboot. 8. When satisfied that the alignment is correct, bolt down the feedboot to the conveyor stringers. 9. Check that the chute skirting is in correct contact with the belt, or preferably fit Brelko Keyskirt to provide a good sealing arrangement. Product, Installation and Maintenance Manual - Belt Support Systems - Page 17 of 20

19 Hi-Impact, Universal and Combination Feedboot - Trouble Shooting Hi Impact - Trouble Shooting Problem Possible Cause Possible Solution Belt Damage Polyurethane Roll Damage Polyurethane rolls not in full contact with the conveyor belt. Hi-impact System in incorrect position. Broken or loose polyurethane roller retaining chains. Incorrect selection of equipment. Adjust to correct height - refer to installation instructions Reposition Hi-impact System so that the load is evenly distributed across the full length of the Hi-impact System. Repair or replace retaining chains. Consult your Brelko representative or Brelko s Technical Department Universal and Combination Feedboot - Trouble Shooting Problem Possible Cause Possible Solution High UHMW-PE Liner Wear. Uneven UHMW-PE Liner Wear. System or UHMW- PE Liner Damage. UHMW-PE Liner are above idler height or is not parallel to belt travel. Combination Feedboot is not parallel to belt travel or is under impact. Incorrect selection of equipment. Adjust to correct height/position - refer to installation instructions. Inspect loading area and divert impact or reposition Combination Feedboot so that the load is evenly distributed across the full length of the Combination Feedboot. Consult your Brelko representative or Brelko s Technical Department Product, Installation and Maintenance Manual - Belt Support Systems - Page 18 of 20

20 NOTES Product, Installation and Maintenance Manual - Belt Support Systems - Page 19 of 20

21 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 Support Systems - Page 20 of 20