RBC Installation Manual
Contents
1. de M o o Lf Il 1 m o o 5 TOP OF BELT TOP OF BELT B qP MOUNT TURNED s o 5 WARDS i OF BELT q o o TOP OF BELT TYPICAL MOUNT STRINGER ARRANGEMENTS 324 Figure 2 Typical Installation dimensions HD RBC 6 14 03 2011 4 ASSEMBLE THE NECESSARY TOOLS AND SAFETY EQUIPMENT REQUIRED FOR THE JOB SECTION 4 INSTALLATION 4 1 4 2 4 3 NOTES BEFORE PROCEEDING WITH INSTALLATION ENSURE THAT THE CONVEYOR BELT DRIVE IS FULLY ISOLATED AND LOCKED OUT DO NOT ALTER SPECIFIED HDRBC INSTALLATION DIMENSIONS TO AVOID SITE OBSTACLES THE HDRBC WARRANTY WILL BE VOIDED IF NOT INSTALLED TO SPECIFIED DIMENSIONS DIMENSIONAL NOTES AND CHECKLIST The following tolerances may be applied to installation dimensions quoted in this section The dimension from top of belt to centre of support pipes 324 5 mm The dimension between support pipes centres is DIM C 5 mm Tolerance on support pipe squareness to conveyor centreline viewed in plan is maximum 5 mm out of square for each 1000 mm of pipe length Tolerance on support pipe parallelism is maximum 5 mm out of parallel for each 1000 mm of pipe length The centre line of plough should align with the centre line of the conveyor The maximum deviation is 5 mm either side of centre2. Revision E REAR PIPE ENSURE HDRBC IS INSTALLED PARALLEL TO BELT SURFACE Figure 4 8 14 03 2011 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Install rear support pipe and mounts as previously described STOP At this point check that the two support pipes are exactly 324mm from centre of pipe to top of belt Check that the two pipes are exactly Dim C apart from centre to centre Check that the two pipes are square to the belt and parallel to each other If not already done withdraw the pipes though one mount and slide on the urethane tensioning straps one on the front pipe and two on the rear Centralise the HDRBC and pipe supports to the belt and or stringers and align the straps to the holes in the HDRBC frame The holes should easily align without force Insert bolts and bolt the strap ends to the HDRBC frame If the strap holes do not align with the frame holes DO NOT bend or distort the strap to align them Re check pipe installation dimensions to correct the misalignment Distorting the straps may result in vibration and failure of the HDRBC and the straps If after re checking the hole in the straps do not match the holes in the frame immediately contact ESS Attach one end of the safety chain by shackle to the HDRBC frame Loop the other end around the front support pipe and connect to itself with the other shackle allowing approximately 70 80mm of slack for blade wear Tighten
3. Engineering Services amp Supplies Pty Ltd Phone 1 800 074446 Visit our Web Site www esseng com au HEAVY DUTY RETURN BELT CLEANER HDRBC SAFE WORKING PROCEDURES SWP INSTALLATION MANUAL Bee MARTIN ENGINEERING Revision Description of Change Changed By Date A Added Final Checklist AS 28 5 07 B Updated Melbourne Address amp Removed SA Address SH 3 08 09 C Final Checklist Updated Items 4 amp 5 Reversed SH 15 04 10 D Updated manual as per CR2634 SH 12 08 10 E Revised drawing F0147 Rev G 8 F0141 Rev KO 14 03 11 Revision E 1 14 03 201 1 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS 11 13 TRADERS WAY ESS HEAD OFFICE ESS MACKAY ESS PERTH ESS MAITLAND ESS WOLLONGONG ESS MELBOURNE ESS EMERALD ESS GLADSTONE ESS ADELAIDE ESS KALGOORLIE ESS MOUNT ISA Revision E PO BOX 121 CURRUMBIN QLD 4223 1 PROGRESS STREET PO BOX 5755 MACKAY MC QLD 4740 19 CLAVERING ROAD BAYSWATER WA 6053 UNIT 2 BARTON COURT 6 JOHNSON STREET MAITLAND NSW 2320 1 20 DOYLE AVENUE PO BOX 343 UNANDERRA NSW 2526 4 314 Governor Road BRAESIDE VIC 3195 11 115 ROBERTS STREET EMERALD QLD 4720 2 34 CHAPPLE STREET PO BOX 1475 GLADSTONE QLD 4680 4 235 HAY STREET PO BOX 10471 KALGOORLIE WA 6430 6 TRADERS WAY PO BOX 1554 MT ISA QLD 4825 P 07 5589 2000 F 07 5598 1353 P 07 4952 4600 F 07 4952 4717 P 08 9370 3155 F 08 9272 5130 P
4. 02 4932 3544 F 02 4932 3611 P 02 4272 4422 F 02 4272 4434 P 03 9580 0388 F 03 9587 5199 P 07 4982 4855 F 07 4987 5118 P 07 4972 3759 F 07 4972 2866 P 08 8262 8955 F 08 8262 4944 P 08 9021 7991 F 08 9021 7291 P 07 4749 4580 F 07 4749 3019 CUSTOMER SERVICE NUMBER 1800 074446 TOLL FREE FROM ANYWHERE IN AUSTRALIA 14 03 2011 WARRANTY NOTE ESS WARRANTS the ESS Product to be free of defects both in materials and workmanship for a period of 12 months from the date of despatch of the product from the ESS factory The warranty given by ESS in this regard will extend only to replacing or repairing product shown to be defective The warranty also is subject to the following restrictions a Installation of the product contrary to the instructions contained in the supplied manual will void such warranty absolutely b warranty will not extend to any liability for injuries incurred and which result from the use of the product contrary to the instructions in the manual c Save as prescribed by law ESS will not be liable for any damage sustained by a purchaser or a third party by way of consequential loss arising out of defects in the product You are asked to note that ESS offers purchasers a service whereby either a t will install the product and certify the correctness of such installation or b Certify the correctness or otherwise of the installation of the product b
5. GHDXXXL IEZI 30y14 ALNG H 2119100017729 ON 19 SHINHOD diVHS Syang TIY 3AOW3M 031312395 JSIMHAHLO SS31Nn S3HLSAFTIA SNOISNAWId 105 LON 04 10 19 JSON T1JAOHS 10 11 41432530 11104 14 03 2011 14 ision Rev FINAL CHECKLIST Site Number Date Site Equipment No Location Site Contact Completed By Circle Yes or No Below Was equipment to ESS Specification Yes No Drawing No Ref Attached Yes No If No WHY Will this affect performance Yes No If Yes WHY Was this a standard O service LI inspection installation Yes No If No WHY Was work carried out as per procedure and JSA Yes No If No WHY Is equipment fit for commissioning Yes No If No WHY Was a final inspection carried out while plant was running Yes No If No WHY Has anything changed from previous service inspection installation Yes No If Yes WHAT Is equipment performance to Client expectations Yes No If No WHY ESS Signature Client Signature Revision E 15 14 03 201 1
6. conveyor system running 4 All service must be recorded and given to a person of responsibility 5 Encourage the person being trained to look for possible problems developing on the system eg excessive or unusual vibrations belt tracking excessively tears or damage to belt seized idlers missing bolts etc A warning to the maintenance department to rectify small problems can save the company a lot of money in repairs and production costs 6 Impress how important it is to maintain and service the cleaners correctly Revision E 11 14 03 2011 SECTION 7 ROUTINE MAINTENANCE AND SERVICE Although the HDRBC requires only minimal maintenance regular inspection and servicing is the key to effective conveyor belt cleaning It is recommended that the cleaner be inspected once per week Actual service intervals will vary considerably from plant to plant CAUTION DO NOT REACH INTO THE CONVEYOR UNDER ANY CIRCUMSTANCES WHILST THE CONVEYOR IS RUNNING ROUTINE EXTERNAL INSPECTION Step 1 Step 2 Visually inspect the condition of the HDRBC Observe the condition and action of the cleaner with the belt running If vibration or other unusual conditions exist shutdown the conveyor and carry out a Shutdown Service as described below Observe the condition of the blade If necessary and if plant rules allow it hose any material build up from the blade DO NOT REACH INTO THE CONVEYOR WHILST IT IS RUNNING If the blade is excessively
7. measured at the nose and at the tail of the HDRBC frame NOTES ON BELT SUPPORT The HDRBC must be installed on a flat belt to achieve best results and to avoid damage to the unit caused by misalignment of supports The following procedure may be used to achieve a flat belt ESS recommends that a return roller should be installed within 150 mm of the front edge of the cleaner nose before or after A second roller after the HDRBC will only be required if the following factors are present Low belt tension Visible or measurable belt deflection under the weight of the HDRBC Belt edge cupping or curling Belt vibrations that are transferred into the HDRBC Where a belt is in a high tension condition and the unit is installed close to a tail or bend pulley a second support roller is unlikely to be required unless excessive vibration is detected When installing support rollers under a belt in the area of a HDRBC care must be taken not to alter the line of the conveyor belt This may result in the distance from the top of belt to the support pipes being altered If the line of the belt is altered the HDRBC installation dimensions should be re checked and adjusted if necessary Revision E 7 14 03 201 1 4 4 Installation Procedure Step 1 Place the HDRBC without support pipes or tensioning
8. the lockscrews securing the tensioning straps to the support pipes At one end of each support pipe drill a hole large enough for insertion of an appropriate tensioning bar say 225 hole Refer to drawing F0141 in this manual As an alternative a pipe wrench may be used for tensioning If support pipes are over long trim off the appropriate amount remembering to leave enough pipe exposed for tensioning see Step 8 above From outside the conveyor enclosure rotate the front support pipe to just place a slight downward load on the front tensioning strap but without inducing any visible deflection in the strap Tighten the lockscrew s on the support pipe mounts to retain the adjustment and to prevent movement of the pipe Repeat for the rear pipe and straps Installation of the HDRBC is now complete The conveyor can be returned to service and commissioning of the HDRBC can commence Revision E 9 14 03 2011 CORRECT INSTALLATION PIPES PARALLEL TO EACH OTHER AND AT 90 TO BELT BELT DIRECTION 4 INCORRECT INSTALLATION PIPES PARALLEL TO EACH OTHER BUT NOT AT 90 TO BELT I KI lt LLI Zo Or sat 15 lt lt nS En l UO Li 2 un O Cn Zn OTHER AND NOT AT 90 TO BELT Figure 5 14 03 2011 10 Revision E SECTION 5 COMMISSIONING Step 1 Start the belt Observe the action of the HDRBC The HDRBC should ride smoothly on the belt with no chatter or vibr
9. worn or blade to belt contact is not even shutdown the conveyor and carry out a Shutdown Service as described below SHUTDOWN INSPECTION SERVICE Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Revision E Shut down and lock out the conveyor Visually inspect the blade Check the condition of the urethane torsion straps looking for cracks cuts or any damage Check that all fasteners are secure If the blade is not excessively worn and straps and fasteners are in good condition check the tension of the cleaner and if necessary re tension as described in Section 4 Step 10 Service completed If the blade or torsion straps are excessively worn or damaged proceed Release the lockscrews on the HDRBC mounts to release tensioning pressure on the HDRBC Remove the bolts securing the tensioning straps to the HDRBC mainframe Remove the HDRBC frame and blade assembly from the conveyor enclosure and place in accessible area Alternatively if it is easier to access the HDRBC in situ place appropriate packing under the RBC frame to allow removal and replacement of the HDRBC blade Clean and inspect the HDRBC blade and replace if necessary Inspect closely the tensioning straps and replace if damaged See section 4 for description of HDRBC assembly Re install all parts ensuring that all fasteners are adequately secured Re tension the HDRBC as described in Section 4 Remove locks and return the conveyo
10. LIS Figure 1 Typical installation positions and use of HD RBC Revision E 5 14 03 2011 SECTION 3 PREPARATION FOR INSTALLATION T ASCERTAIN INSTALLATION POSITION As previously noted the ESS HDRBC is intended to be installed on the inside return conveyor belt just before the tail pulley gravity take up or similar The position selected for installation should have a flat taut belt see notes in Section 4 and good access for installation and maintenance Suitable support structure for attachment of the HDRBC mounts is also required 2 OBSERVE BELT CONDITIONS Does the belt reverse or roll back on stopping If so do not use this HDRBC An ESS Diagonal Plough is used on reversing belts Is the belt flat and taut or does it sag or cup Does the belt bounce or vibrate The HDRBC will operate best on a flat vibration free belt Achieve these conditions by appropriate use of flat rollers SEE NOTES IN SECTION 4 If a flat stable belt cannot be achieved contact ESS before proceeding with the installation 3 TRIAL ASSEMBLE HDRBC Revision E Familiarise yourself with the parts and operation of the HDRBC Plan the installation Measure and pre manufacture any mounting brackets that may be required Note Dimensions shown here are for the HDRBC
11. MOT 3018 NOISVUBV 51 3NVHI3UD 72 031 14 JNIZ 13115 5531 15 5 5 4104 315 31 HBIH QISINVATVD 55 AQTIV 50 1114 SH3N3ISV3 L S310N XHINS AVMV LNI NMOHS oosz oosz 00 2 0012 1006 001 sest sv 686 osu 000 83A0 30V78 ENSI 859 859859 JENS9 859 JENS9 8 59 8159 325 344 009 0098 0006 00 2 005210052 0012 056 nost HIDNAT 3did sno 196 1962 eror 248 oez 259 oss 47 oss svv HLDNAT 30 18 0052 0052 0022 0002 008 0051 005 oser 0041 0501 006 HLGIM 1738 092705920 2 X SATOH 30V 18 ON 315 14 8 59 0114 IWVYINIVW 9LW LAN S 2 8196LEZ0 DNIHdS 9LW H3HSVM 5884702620 211961 20 559708 8 9 UIHSVM 5 1 dZ O H 9LW AIHSVM 28191 20 15120 9 0 20 SOLSEOEZO SS70 OSX9LW 1108 Z079SLEZO 42 05X9IW M332S 102000060 M38255301 1 04 INOI 2 1 LXMS8 7 S6ZSSLEZO SS40 QILNIOd 13S MINIS 08X9LW 1108 5 9229 5 9129 2100017429 5701017629 3132VHS 8 Al3dVS 289 ALNG H 15101017829 31 1 HIHSVM ALNG H 15105005060 SUINILSVA 3 INDnOM AING H 3dld LHOddNS LMGZH A1nQ H dVULS DNINOISN3I ALNG H
12. N0dNI3H NIVHD 1331S JAVH SdVMIS INVHLI0NA10d NOILVTIVLSNI LV 01 03133 02 38 OL 134 5 1 SALON osl HLOIM 1138 Q ALAY 1 404 AVMV NMOHS S3WVBSNIVM 333 2 WIQ WO 14 03 2011 13 E ision Rev SECTION 9 EXPLODED PARTS DRAWING 5204 11104 269 8 Aiva Livo ddv SNOISIAdH m SONIMVHO 30N3H333H ON ONIMYNO 518 31 05 SLIVd Q3Q01dX3 AB NAWSO 11 98 as 25303 daddy 5411 0 107679 11 as wal 00958409 SYM 01017829 19 9 avs wr 11 500 S310N 3 N3NV310 1139 NUNLIH ANG AAVSH MMT ost se S ES 0300 0501 006 DNIMVUQ NOLLVTIVISNI 2840H S1uvd 030014 3 283 0 00 SY3HS M 11 29 as CULT Ald 511445 SIDANS 553 WALLA 14135 ALAYA 5810 ANY OL MAOHS XO 11 33 1340 He 11 99 Ou LOW TWHS U ULTALd 531485 ONY 5435 ONREG IDNI 551 30 118384 SAYWA ONY TYLLINGUHNC SI 83530 OHY SHL z 999940 0081 ON 3OIAM3S HIWOLSNI 314405 9 S3OIANIS WI NI HLOIM 1138 XXX 310111158 15 SHLQIM 1138 QUVONVIS TIY NI 318VIIVAV SI L Yd 3HL IVHI 31 210 XXX A8 Q3MOTIOd S ON LYYd S310N ON luvd 183330 dWAL B ODv18 UD W Svid 1 NMOS NOLS
13. ation vibration is present repeat the tensioning procedure in Step10 of Section 4 but slightly increase the contact pressure Do not over tension the HDRBC it will not increase cleaner efficiency but will increase blade wear If vibration is present after moderate tensioning contact ESS on 1800 074446 within Australia or 61 7 5598 1077 from outside Australia for further advice Step 3 Demonstrate the system to the operating supervisors and crew Call the supervisors responsible for maintenance and operation to the site Make a short run of the system Show the operator how to adjust and operate the system Step 4 Secure the system for production Follow plant procedure to secure the conveyor for actual production SECTION 6 OPERATOR TRAINING The decision to purchase ESS Belt Cleaning equipment is the first step toward achieving a clean plant The next step is the correct installation of the equipment as outlined in this manual The final step is to maintain and service the equipment to guarantee ongoing performance ESS strongly recommends that operators are correctly trained to maintain ESS equipment or that ESS is commissioned to maintain the equipment on a scheduled basis The benefits of efficient cleaners outweigh the cost of maintaining the cleaners many times 1 Adhere to all local safety rules 2 Give a Hands On instruction with the conveyor system shut down 3 Give a Hands instruction with the
14. elt is in operation The conveyor must be shut down and locked out before any person enters or reaches into the conveyor enclosure Ensure that only suitably qualified and trained personnel install and service this product Ensure that all site and statutory safety procedures are followed SECTION 2 INTRODUCTION The ESS HEAVY DUTY RETURN BELT CLEANER HDRBO is a return belt cleaner designed to remove fugitive material from the inner side of the return strand of a conveyor belt The HDRBC is normally located before the tail pulley gravity take up mid drive unit or any other position where fugitive material can become trapped between the belt and pulley causing damage or wear to the belt pulley or pulley lagging The ESS HDRBC features a urethane blade for long life and efficient cleaning and can also be supplied in Mines Department approved FRAS urethane for underground coal and similar applications The main feature however of the ESS HDRBC is the unique urethane torsion strap suspension This suspension arrangement allows pre tensioning of the HDRBC onto the belt by simply rotating the support pipes The HDRBC is held lightly against the belt surface and floats with the belt movement eliminating the chatter commonly associated with gravity type Vee Ploughs NOTE The ESS HDRBC is directional and is not suitable for reversing belts lt gt TYPICAL H DRBC LOCATIONS DO NOI USE ON REVERSING BE
15. r to service 12 14 03 2011 SECTION 8 INSTALLATION ARRANGEMENT DRAWING 104 l wam ON SNIA VS SIN 31V2S M3HL l IN3A39NVHNV NOLLVTIVISNI JINVJID 1138 NYNLIJY 984 ALNG AAV3H S 61 0 60 Ud 4405 S 0022 0092 0054 2 982 290 ud MSN qo JJIAHIS 00106600000 a wio joeszjoeszjoeezjoeizjoesi 060 5291 0291 526 osu ooo wa 0052 00721002210002 0081 009 005 oser 0021 osor 006 1138 2 WIO JNNVW SNOISIASRY c UU 2 e Q31VQdN 1511 1138 0501 8 006 17 004 DNIMVAQ 335 28H ALNG QUVONVIS 404 S as wi LL 39 as NOLLV901 9 553 DNT Al34VS ALV1d 705 002 J WIG IVNDA 01 WIQ NOIL V TIV ISNI 5310 8 SAINYO dAVHS Syna TIY 3AOW3M A5 CE osl 4109002092 Q3SIA3H S3dld 14044105 108 304 IWYS JHL 38 01 WIQ 1109 100112 100102 009 1117 7031312395 3SIMM3HIO SSJINN SAHLIWITIIW NI SNOISN3MWIO TIY 1v9S LON OQ 3115 NO LINS 01 SONI 17104 DNIMVAQ SLUVd 030014 34 7 1138 3HL LIVLNOD INVISNOJ NI 388 diay 01 NOILVABIA OSIV A3HL 7288 FHL dO IYL 350 3Hl 01 34155384 Q4uVMNMOQU LNVISNOD Aldd SavalS LHOddNS 3Hl E 134 5 LIN3W32
16. straps on the belt at the selected position Ensure that the HDRBC frame rear cross member is 90 to the centre line of the belt see fig3 Step2 Measure 124mm forward from the nose of the HDRBC and 324mm perpendicular upwards from the belt surface see fig 1 Mark this point on the stringer or conveyor structure on each side of the belt ensuring that the line between the points is at 90 square to the belt These points represent the centre lines of the front support pipe and front mount sets Step 3 Install the front support pipe and mounts at the above point Installation may involve cutting holes or attaching brackets to conveyor structure see typical mount arrangements in previous section and cut out details below Seek site Engineer s approval before modifying conveyor structure PIPE CENTRES DIM C 0 0 0 0 U U eL E FRON 0 REAR PIPE 2 AN 4 A PIPE HEIGH l TE TG HEIGHT 124 150 PIPE SUPPORT 018 HOLES MOUNT HOLE 2 100 CUTOUT DETAILS Figure 3 Table 1 Belt Width 900 1050 1200 1350 1500 1600 1800 2000 2200 2400 2500 Pipe Centres 277 352 427 502 577 627 727 827 927 1027 1077 Dim C Step 4 Measure back from the above point a distance equal to dimension C from above table and parallel to the belt i e 324mm from belt surface This point represents the centre line of the rear support pipe and mounts PIPE CENTRES pp gt gt gt pud l FRONT l PIPE d i HEIGHT
17. y third parties This certification service is designed to ensure that you obtain the full benefit of the ESS warranty hereby provided you would like to take advantage of the installation certification service provided please contact ESS regarding the service THE CONTENTS OF THIS MANUAL ARE COPYRIGHT TO ESS ENGINEERING SERVICES AND SUPPLIES PTY LTD ALL RIGHTS RESERVED Information contained herein is for use in the operation of the HEAVY DUTY RETURN BELT CLEANER purchased from ESS and cannot be passed on to any other party without express permission in writing from ESS ESS Despatch Department to complete Client should retain for warranty Purchaser Client Purchase Order Contract No Site Despatch Date Conveyor No s No Supplied Description Part Numbers Comments Revision E 3 14 03 2011 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 Revision E SAFETY INTRODUCTION PREPARATION FOR INSTALLATION INSTALLATION COMMISSIONING OPERATOR TRAINING ROUTINE MAINTENANCE AND SERVICE INSTALLATION ARRANGEMENT DRAWING EXPLODED PARTS DRAWING 14 03 2011 SECTION 1 SAFETY The HEAVY DUTY RETURN BELT CLEANER is designed to be quickly and easily serviced by appropriate personnel Under no circumstances should servicing or installation of the cleaner be carried out whilst the b
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