INSTRUCTION MANUAL
.
! " " # $
BELT CONVEYOR RT
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Mounting, Operation and Maintenance
The text refers to the following instructions etc.:
Storage of rubber belt Repair of rubber belt Assembly of rubber belt FLS lubricants, lubrication key
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Scraper For Pulley (101) ... 8
Mounting Of Conveyor Pulleys (17) ... 10
Idlers (30) ... 12
Shock-Absorbing Idlers (67) ... 16
Self-Cleaning Idlers (68) ... 17
Conveyor Frame (36) ... 18
Filling Hopper With Guide Plates (26) ... 19
Side Guides, Closed (23) ... 20
Cover Over Netting For Rubber Belt Conveyor (100) ... 21
Covering of Belt Return Part (70) ... 27
Emergency Stop (103) ... 28
Speed Monitor (69) ... 29
Skew-Running Switch (72) ... 30
Baffle Plate (28) ... 31
Plough Deflector (20) ... 33
Mounting Of Conveyor Pulleys (17) ... 35
Mounting Of Conveyor Frame (22) ... 37
Adjustment Of Belt Conveyor (21) ... 41
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Editor: Translator: Pages:
Approbator: MGN code:
3
Appendices:
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Note!
The present instruction manual is concerned with the situations which, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during the erection, operation and maintenance of the machine cannot be provided.
Consequently, if a situation should arise, the occurrence of conveyor features and also deals with the installation, operation and maintenance of latter.
The relevant data for the belt conveyor is given in specifications, parts list, order drawing and layout drawing.
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Drive Station (04)
The belt conveyor is driven by a drive station which consists of a drive pulley (A) directly coupled to a motor through a reduction gear unit.
The pulley is provided with a scraper (B), which keeps the outer belt side clean.
Maintenance.
Weekly:
Remove material cakings and/or dirt from the pulley.
Monthly:
Clean the drive station and its surroundings.
Check the pulley for mechanical faults. Look, listen and check for irregularities of any kind.
Check the fastening of bearing housings and the temperature in pulley bearings, use a contact thermometer.
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Twice a year:
Charge bearings with lubricating grease BG-U.
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Drive Pulley (01)
The drive pulley is provided with a vulcanised rubber lining in order to increase the friction between belt and pulley and to prevent material cakings.
During erection, a check must always be run to ensure that the joint of rubber lining is correctly orientated relative to the rotational direction indicated on the sketch.
Maintenance.
Monthly:
Check the condition of the rubber lining.
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Scraper For Pulley (101)
The pulley is provided with 2 scrapers. A front scraper A and a secondary scraper B. The scrapers serve to clean the outside of the conveyor belt of any sticking residues of material.
Technical specifications for scrapers: See separate instruction manual.
Mounting:
The secondary scraper must be mounted first.
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The scraper may either be inserted through the hole at front scraper A or through the upper rear plate E. The fittings for the member may now be mounted in the matching side plate holes. Now adjust the scraper in compliance with separate instruction manual.
Having completed adjustment, mount cover plates C and D for covering the holes in the side plates.
Mount the front scraper A on the side plate flange, and adjust in compliance with separate instruction manual.
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Mounting Of Conveyor Pulleys (17)
Drive station and tail station to be mounted in accordance with the dimensions and data contained on drawings and parts lists forwarded on separate basis.
The conveyor pulleys must be mounted so that they are absolutely horizontal and parallel. The axes of pulleys must be absolutely square with the centreline of the belt.
1. Determine the centreline of the belt conveyor.
2. Stretch a piece of piano wire (A) at a distance of approximately 1 metre above the conveyor frame and vertically to the centreline.
3. Mount the pulley (C) on the frame.
4. Find the centre of a generatrix on the surface of the pulley and mark off that point.
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6. Turn the pulley through 180˚ and check that the point remains at the same vertical plane.
7. Attach the base feet of pulley to the frame, with shims inserted for alignment so that the pulley is in horizontal position.
8. All bearings must be opened and checked for alignment, backlash, distance rings is placed correctly and that the locking ring is secured. Backlash should be in according with the bearing suppliers specifications. In the same time the conservation grease can be removed and the supplied grease can be applied.
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Idlers (30)
The carrying part and return part of the belt are supported by idlers between the drive station and tail station.
The ordinary plain idlers consist of a cylindrical tube (D) with a through-going stationary shaft (E), roller end-caps (A), ball bearings (C) and labyrinth seals (B).
For plane belts identical idlers are used on the carrying and return part of the belt. Normally, one single idler is placed on each support. The shaft end is shaped as indicated in the Figure below.
30.1
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On the carrying part of troughed belts each support consists of 2 or 3 idlers, placed on a joint supporting iron.
For the return part each support consists of one single idler.
For belt widths of 400, 500 and 650 mm, idler units with two idlers are normally used, forming an angle of 25˚ to the horizontal plane.
For belt widths of 800, 1000, 1200, 1400 and 1600 mm idler units with 3 idlers are used. The two outer idlers form an angle to the horizontal, called trough angle.
30.3
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Idler units on the carrying part of the belt are so designed, that the side idlers have a slight forward inclination, approx. 1 , in the transport direction of the belt.
This is done to ensure on-centre belt training on idlers.
Shock-absorbing idlers and idler units at the tail end do not have
a slight forward inclination.
NOTE !
During erection it must be ensured that the supporting irons are correctly orientated so that the inclination occurs in the direction of transport.
An orientation sketch is inserted in the parts list.
On the carrying part of the belt each support consists of one or several centre idlers, dependent on the belt width.
The idlers may be either plain or shock-absorbing idlers. Inclined idlers are always plain.
The idlers on the belt return part may comprise one single idler, or it may be made up of several plain or self-cleaning idlers.
30.5
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Maintenance Monthly:
Walk along the entire length of the conveyor. Take a close look at various idlers and check that they rotate and, that they centre on the shafts without giving off any abnormal sounds.
Replacement of idlers is required in instances where abnormal sounds from bearings are ascertained.
In case an idler has got stuck, the surface of the latter must be carefully examined, and the idler must be replaced if there are any signs of cutting caused by the friction between belt and idler.
The ball bearings are supplied with full grease charge and do not require refilling.
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Shock-Absorbing Idlers (67)
Shock-absorbing idlers are placed under the loading point to protect the belt against shock impacts caused by falling material.
The idlers have a grooved rubber lining (A), which provides the shock-absorbing effect.
Maintenance
Monthly:
Walk along the entire length of conveyor. Take a close look at the idlers and check, that they rotate without giving off any abnormal sounds, and that they centre on the shafts.
Replace idlers, where abnormal sounds from bearings are ascertained.
Check that the rubber lining on idlers is intact.
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Self-Cleaning Idlers (68)
Self-cleaning idlers are provided with rubber discs (A). They are only used for the belt return part, and they are well-suited for applications where sticky materials are handled as the rubber discs prevent material build-ups on the idlers.
Maintenance
Monthly:
Walk along the entire length of conveyor. Take a close look at the idlers and check that they rotate without giving off any abnormal sounds, and that they centre on the shafts.
Replace idlers if abnormal sounds from bearings are ascertained.
Check that the rubber lining on idlers is intact.
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Conveyor Frame (36)
The conveyor frame is a sectional iron structure. The members and legs of the frame are assembled by means of round bar clamps.
The frame is made with cross bracings, as indicated on the order drawing.
The legs are either made with a fixed baseplate for attachment to concrete foundation, or without any baseplate for direct welding to the embedded steel plate on the support.
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Filling Hopper With Guide Plates (26)
The material is charged to the belt through a filling hopper.
The hopper (A) is equipped with adjustable guide plates (B) and rubber seal strips (C).
The guide plates are adjusted so that the material flow is conducted to the centre of the belt.
The guide plates are adjusted through the nuts (D) on the adjusting screws (E).
During erection the seal strips must be adjusted so that the rubber belt and strips are spaced 0.5 mm apart.
Maintenance.
Monthly:
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Side Guides, Closed (23)
Closed side guides are mounted on the belt as shown on the sketch.
The side guides (A) are bolted to the supporting irons (D) and the plates are closed at the top with cover plate (B).
The side guides are equipped with rubber seal strips (C) along the edge of the belt.
During erection, the seal strips must be adjusted so that the rubber belt and strips are spaced approximately 0.5 mm apart.
Maintenance.
Monthly:
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Cover Over Netting For Rubber Belt Conveyor
(100)
The cover netting is divided as follows:
Cover netting for drive station.
Cover netting for tail station.
Cover netting belt conveyor between drive and tail station. Cover netting for bottom idlers.
Cover netting for take-up station (vertical loop take-up).
NOTE!
Cover nettings only to be mounted when the belt conveyor has been finish-mounted an trial-run with material for a couple of days so as to make sure that the belt conveyor operates correctly.
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1) Cover netting for drive station
The cover netting for the drive station consists of different sections. As shown in the sketch below, the drive station cover netting consists of:
Side netting (C), which is mounted by means of fittings (A) and
fittings (B).
Guarding for scraper (D).
Cover (E) for drive shaft, between pulley and bearing housing.
Cover (F) for drive shaft, between bearing housing and gear unit/coupling.
Fittings (G) serve to fasten cover (F).
Mounting:
Fittings (A) and (B) are welded to the drive station frame when mounting.
Mount cover (C).
Mount cover for scraper (D) by means of the existing bolts.
Mount cover (E) for drive shaft by means of the bolts for the bearing housing.
Fasten fittings (G) by means of the bolts for the bearing housing.
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2) Cover netting for tail station.
The cover netting of the tail station consists of a side cover (H), top cover (I), end cover (J) and side hatch (K).
Mounting:
Side hatch (K) is bolted with the same bolt which assembles the tail station frame and legs.
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3) Cover netting for belt conveyor between drive and
tail station.
The cover netting consists of side cover (L), top cover (M) and side hatch (N).
Mounting:
Side hatch (N) is fastened to the belt conveyor frame with round U-bolts (X) (see sketch).
At belt conveyor roundings/curves special side members (N) are used enabling turning/adjustment. This facilitates adaptation of the cover netting.
Mount side cover (L) and top cover (M).
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4) Cover netting for bottom idlers.
Cover (O) is mounted by means of fittings (P) which are fastened on channel iron (U) (see sketch below).
Mounting:
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5) Cover netting for take-up station (vertical
loop
take-up)
Mounting:
Mount cover (Q) by means of fittings (R).
Fittings (R) are bolted with the same bolt which assembles the take-up station frame and legs.
Mount cover (Q).
NOTE
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Covering of Belt Return Part (70)
At either end of the conveyor belt return part a cover plate is built in over a length of approx. 5 metres.
This serves to prevent material from the load carrying part, or tramp material, from dropping onto the return part of the belt, involving the risk of becoming jammed between the belt and the pulleys.
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Emergency Stop (103)
The emergency stop consiosts of a steel wire (A) which is stretched out along the belt conveyor and connected to the arm of an electric switch (B) at certain intervals. Thus the conveyor may be stopped by pulling the wire in an emergency situation.
The steel wire rests in eye-bolts (C) which are mounted in compliance with the dimensions specified in the parts list drawing.
Mount the switch as illustrated on the parts list drawing.
Maintenance
Monthly
Check that wire, springs and fittings are in order and undamaged. Replace, if necessary.
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Speed Monitor (69)
The speed monitor consists of a proximity switch (A) which supplies a number of pulses by means of a perforated disc, the latter being placed on a belt pulley (B), which is driven by the rubber belt.
The function of the speed monitor is to ensure that the belt is pulled along by the drive pulley.
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Skew-Running Switch (72)
The skew-running switches are mounted in pairs on both sides of the conveyor belt.
The function of the skew-running switches is to emit a signal in case belt skew-running on idlers is ascertained.
The skew-running switch (D) is equipped with an idler (A), and the latter is activated by the rubber belt in the event of off-centre belt training on the idlers (B).
NOTE !
The holes (E), in the supporting irons of the idlers, for the bracket of the skew-running switch is marked out and drilled during erection on site.
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Baffle Plate (28)
A baffle plate (B) fitted with a wear plate (A) is mounted in the discharge casing. The surface of wear plate is shaped and made from a material, which is suitable for the materials handled on the belt conveyor.
The baffle plate can be adjusted by means of two screws (C) so that the material from the belt can be controlled in the chute.
In connection with the adjusting screws, thre is a built-in pressure spring to ensure that the baffle plate will yield subject to severe impact forces.
Maintenance.
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Plough Deflector (20)
A plough deflector is fitted at the take-up pulley or tail pulley, the function of the latter is to prevent material lumps etc. from getting jammed between the conveyor pulley and the inner side of the belt.
The plough deflector follows the offset rates of the pulley, when the belt is tensioned. The plough deflector must be fitted in the immediate proximity of the conveyor pulley (A).
The plough deflector consists of a steel frame (D) covered by a plate.
The suspension of the frame is such that it can turn on the bolts (E), which are bedded in connection with the conveyor pulley bracket, with an offset rate identical to that of the latter.
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Maintenance.
Monthly: Check the rubber strip for wear. Strip to be replaced when worn to 5 mm off the wear edge, in order to prevent the steel frame from colliding with the rubber belt.
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Mounting Of Conveyor Pulleys (17)
Drive station and tail station to be mounted in accordance with the dimensions and data contained on drawings and parts lists forwarded on separate basis.
The conveyor pulleys must be mounted so that they are absolutely horizontal and parallel. The axes of pulleys must be absolutely square with the centreline of the belt.
1. Determine the centreline of the belt conveyor.
2. Stretch a piece of piano wire (A) at a distance of approximately 1 metre above the conveyor frame and vertically to the centreline.
3. Mount the pulley (C) on the frame.
4. Find the centre of a generatrix on the surface of the pulley and mark off that point.
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6. Turn the pulley through 180˚ and check that the point remains at the same vertical plane.
7. Attach the base feet of pulley to the frame, with shims inserted for alignment so that the pulley is in horizontal position.
8. All bearings must be opened and checked for alignment, backlash, distance rings is placed correctly and that the locking ring is secured. Backlash should be in according with the bearing suppliers specifications. In the same time the conservation grease can be removed and the supplied grease can be applied.
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Mounting Of Conveyor Frame (22)
Information regarding mounting procedure
The actual order drawing, layout drawing as well as parts list provide the information required for the mounting operation.
Check that the frame legs and frame members supplied are intact and that no damage has occured during transit.
1. Stretch out a piece of piano wire (A) across the centre points of the two conveyor pulleys (B), see Figures.
Determine the actual height (H) on the frame legs closest to the drive station and the tail station on the basis of data given on drawings. The height is determined by using the line of tangent as basis point.
NOTE !
Attention is drawn to the fact that the upper edge of idlers (C) for troughed belts with belt widths 800 mm may be lowered to point under the line of tangent, see Fig. 22.1.
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For plane and troughed belts with a belt width 650 mm, the upper edge of the idler lies in the line of tangent, see Fig. 22.2.
2. Adapt the height of a few frame legs and mount them on both sides of the conveyor, together with the frame members by means of round iron clamps and bolts.
Align the framework so, that the centreline is made to lie exactly in the centreline of the belt conveyor. Use the stretched piano wire to check this.
NOTE !
For long belt conveyors a theodolite should be used instead of the piano wire.
Mount a few of the upper idler units.
Always remember that the supporting irons must incline in the
direction of conveyance, see sketch in parts list. However, this does NOT apply for reversible belts.
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3. Align the framework in the horizontal and vertical plane by means of a straightedge and a spirit level.
4. Fix the frame legs by welding/bolting to the embedded foundation plates/concrete foundations (G) in floor.
5. Adapt the remaining frame legs to the same height as the frame members, including the expansion pieces.
Mount the parts and fix the legs to floor by welding/bolting.
Fit cross bracings.
6. Fit all idlers for the belt return part.
7. Conveyors with endless belts.
Remove the upper idlers. Retract the idlers with shafts and ball bearings from their bearing housings, the latter must remain fitted in correct positions.
Position the rubber belt.
Mount the two conveyor pulleys with shafts and ball bearings in the bearing housings.
Mount the idlers for the carrying part of belt.
8. Conveyors with open belt.
Fit the remaining idler units on the carrying part of the belt.
Position the belt and vulcanize the latter, see separate instruction manual for vulcanizing.
9. Mount the supporting irons for the self-adjusting idlers of the return part on the brackets.
Attach the brackets to the vertical legs of the conveyor frame, but
do not mount the idler rollers.
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11. Mount the scraper for drive pulley and adjust the latter so that it exerts a light pressure on the drive pulley.
12. Mount the plough deflector.
13. Mount the baffle plate in the discharge casing. Adjustments should not be carried out until the conveyor has been test-run loaded with materials.
14. Mount the filling hopper in accordance with dimensional indications on layout and order drawings.
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Adjustment Of Belt Conveyor (21)
After the framework has been aligned and attached to the foundation, with the rubber belt correctly positioned and all idler units fitted and with the drive station connected to the mains, the conveyor must be test-run and adjusted.
1. Self-adjusting idlers must not be fitted.
2. Start the belt and let it run without material load.
3. Conveyor pulleys.
A visual check must be made to ensure that the rubber belt tracking on the conveyor pulleys is absolutely straight. If this is not the case, the conveyor pulley must be aligned in accordance with the directions given below.
4. In case of off-centre belt running in direction "a", the conveyor pulley must be aligned in direction "b".
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5. Idlers.
Next, check whether the belt running is off-centre on one or several idlers.
If so, these idlers are not square with the centre- line of the belt.
Walk back a few metres in direction of travel from the point where off-centre belt running was ascertained.
6. If the belt is off-centre in direction "a", the idler unit must be aligned in direction "b".
An arrow indicates the belt's direction of travel.
Quite often, the idler unit fitted a few metres ahead of trouble point, in the direction of travel, is responsible for the off-centre belt running at a given point.
70030286-1.0 43 vulcanisation must be renewed. See separate instruction manual dealing with this subject.
8. Materials are charged, when the belt training is correct, when running unloaded.
In case off-centre belt running is subsequently ascertained, this is explained by the fact that the material is not supplied to the centre of the belt.
Corrective action must be taken at the point of loading, either by adjusting the guide plates or by adjusting the baffle plate in the discharge casing of the preceding belt conveyor.
9. NOTE ! In the event of off-centre belt running on idler
rollers, remedial action can NOT be taken by adjusting the drive pulley or the tail pulley. Nor by increasing the counterweight load.
Vertical idlers must never be used to retain the belt in position since this would damage the belt edges.
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Operation (74)
1. Start-up
Always make sure prior to start-up, that no foreign objects are deposited on the carrying and return part of the belt.
Start the machines handling the onward conveyance of the materials discharged from the belt.
Start the belt conveyor.
Start the material feed.
2. Shutdown
Interrupt the material feed.
Stop the conveyor belt as soon as the latter has been run empty of material.
3. Emergency shutdown
In the event of belt stoppage caused by power failure or by activation of the emergency trip wire, the motor has been designed so that the conveyor can be restarted with material deposited on the belt.
