RBC Installation Manual
Contents
1. c A A8 sood c OED NY 8 00704 wd Hos ISIMHA vg y Noisia Ww SONIMVMO 3ON3N343M oN ONIMVUG SIN 31V2S 99 AB NAVAS fad ds 99 zez 8203 037551 v SluVd Q3001dX3 Avid 1 1806 N3l 0Z i103 JN3N39NYMNMY NOLVTIVISN wag 11 os ux NOISIA3H 8 Z WOO VAD SENOISNJL ONS 536978 M J AWWWIUd LUNG N3l 0Z GHX FAE VAD HINOISNIL S3av1g dWNN3 M 3000 34VS I840 2 SNIL S30Y18 z d8VO M J YIMVAL LYNG NIL OZ OHX YANVIIO AsVAIMHd M3xOvsl LYNG N3l 06 QHX 1 8919915 NY S3JA83S ONRJINIINA SSI NOYA JHD3dS INGHLIM YIHLO ANY OL NADHS YD ED 38 JON TIVHS LI QLTAld 5319915 ONY SAAS ONIYINIONI SSI 40 1430084 IHL 5 ONY TWIINGOHNOJ SI NDIS3O ONY SNIMYUC SIHL 9777 0 0081 3OIAMIS ASAOLSNO avo ssa 5319405 7 S3OIAM3S SNIS3JNISNJ ME V MONNV NO MIA 0092 0ore Sie 0561 0081 0091 HLONIT MINS Moon 0099 0077 000 008 0096 OGvc OOS 012 0561 0081 0081 00 0961 HLONIT 3AVHANIVA 440 ONVIS BL saw 9 Sriz 086L 681 0591 gv 1 0661 5511 066 066 Sze 099 ser occ 33A00 8 sift 68 z 8 8 5 Ela 530008 ON oorz 0512 000 098 0021 0861 cori 0822. Part Number Description Enclosure Material 09000123M Air Ten Compact Control Box 1 Cleaner Plastic 09000124M Air Ten Compact Control Box 2 Cleaners Plastic 09000125M Air Ten Compact Control Box 3Cleaners Plastic 09000126M Air Ten Compact Control Box 4 Cleaners Plastic 09000115M Air Ten Control Box 1 Cleaner Stainless Steel 09000116M Air Ten Control Box 2 Cleaners Stainless Steel 09000117M Air Ten Control Box Cleaners Stainless Steel 09000118M Air Ten Control Box 4 Cleaners Stainless Steel The Air Tensioner Control Boxes are available with optional solenoid valve Once the fittings are connected and secured the air tensioner may be pressurised Pressures are indicated in table 3 On completion pressure check all fittings and connections using soapy water or equivalent to ensure no leaks are present Rectify any leaks found compressed air losses can account for substantial plant running costs Table 3 Air Pressure Settings PRESSURES BELT WIDTH kPa PSI 450 55 8 600 69 10 750 82 12 900 96 14 1050 110 16 1200 124 18 1350 138 20 1500 82 12 1600 96 14 1800 96 14 2000 110 16 2200 124 18 2400 138 20 Revision J 2 Two Tensioners fitted 31 18 03 2014 8 3 OPTIONAL WEAR INDICATOR The XHD 20 Ten Series mount set includes an optional blade wear indicator Correctly set up
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4. socket head screws Attach the open end of the airbag this end has 3 tapped holes to the Pivot Bracket using two only 3 8 UNC socket head screws The Air Tensioner is now assembled and can be fitted to the mount After determining the correct tensioning direction from figure 12 slide the Operating Arm of the tensioner onto the cleaner mainframe until the Pivot Bracket aligns with the two threaded holes in the mount Secure the Pivot Bracket with the two M16 bolts supplied The Operating Arm has an inbuilt Travel Limiter to protect the Air Bag from over extension The Travel Limiter lug locates between the two raised bosses on the Pivot Bracket Depending on tensioning direction the lug will be above or below the Pivot Bracket centre web For cleaners with dual tensioners repeat for the other side For belts with only one tensioner simply fit and secure the locking collar onto the other end of the cleaner allowing 1 to 2mm clearance between collar and mount bush Revision J 29 18 03 2014 7 Do not install or connect air supply fittings at this stage Using a pipe wrench or similar grip and rotate the cleaner mainframe until the blade tips lightly touch the belt surface at the cleaning position With the airbag fully compressed secure the operating arm to the cleaner mainframe using the three locking screws Ensure a clearance of 1 to 2mm between the operating arm and the mount bush to enable free rotation whilst minimising
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6. As the blades wear the indicator will rotate and show the amount of rotation on the scale It is recommended that the operator determine the amount of rotation expected from the blades being used and mark with paint or permanent marker the expected maximum wear life point on the scale It is essential that regular blade inspections are carried out especially as the wear life approaches the expected limit Where the Wear Indicator is used with an Air Tensioner and the Air Tensioner is reset during the blade wear life see section 9 3 do not reset the Wear Indicator It must remain at the original position in order the indicate total travel from the start point Figure 21 Fitting the Wear Indicator Revision J 32 18 03 2014 SECTION 9 CENTRE PIVOT MAINFRAME In some applications the migration of very abrasive fines to the centre of the belt will result in excessive wear rates on the centre blades of the XHD cleaner This will in turn result in the centre blades losing contact with the belt surface The outer unworn blades effectively hold the worn centre blades away from the belt To overcome this ESS developed the Centre Pivot Mainframe This mainframe has a separate portion of the blade track usually 3 blades wide that can be rotated against the belt independently of the rest of the blade set This separate track section has its own air bag tensioner mounted in a protected position under the mainframe The Ce
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9. 03 2014 Lock Bracket Centre Line of XHD Lower Seal Cleaner Mainframe Figure 14 Combi Safe frame installation Step 4 Fit the lower seal into the door frame This urethane piece simply locates in the square cutout in the base of the frame and is held by the recesses in either side of the seal Step 5 Install the XHD mainframe by inserting it through the Combi Safe door opening and passing through the opening door or mount on the far side Fit the mount and tensioner to the Combi Safe bracket and secure the operating arm to the cleaner mainframe Repeat for the far side if required Fit the blades and end stops to the cleaner Step 6 Fit the inner cover to the Combi Safe door by inserting into the guide lugs and sliding down over the cleaner mainframe Recesses in the sides of the cover allow it to be fitted and removed as little as 35mm above the secured position This eliminates the need for excessive headroom above the door The inner cover can be secured to the locking bracket at the top of the door either by a fastener or by a padlock This cover will now comply with the requirements of AS1755 as long as the nearest pinch or nip point is at least 200mm from the door The outer cover will fit to the inner cover to provide a final seal against water and dust The outer cover is also recessed to allow fitting and removal with minimal head room Revision J 22 18 03 2014 Figure 15 Combi Saf
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12. also to dramatically reduce the time taken for a blade change Task duration reductions of the order of 9096 are common with the cost saving directly to the end user However in order to take advantage of this feature the installer must ensure that the service technician is able to use the Keysafe tool to remove the blades This is accomplished very easily and at little or no additional cost and with only a small amount of forethought during installation planning The main requirements for use of the Keysafe are e The tool must be able to be inserted into the Keysafe opening in a relatively straight line e When the blade has been withdrawn to the end of the mainframe track it must be retrievable by the service technician e Aminimum of about 600 mm clear space is required outside of the chute to enable the technician to manoeuvre the tool and slide hammer To facilitate the above the ESS XHD 20 Ten Series mounts have been designed in a cutaway shape to allow alignment of the tool with the Keysafe opening Additionally cleaner accessories such as the XHD Stand off Bracket have also been redesigned with the top cut away also to facilitate access for the tool When combined with an ESS CYA Door the mount and stand off bracket will provide excellent access to use the tool and retrieve the blades Clients are able to custom design similar access and ESS can provide design assistance on tricky applications Material fines entering the
13. below the pulley centre line and level across the head pulley NOTE Slight inconsistencies in the belt thickness and blade shape accounting for small gaps between blade and belt will quickly be taken up by blade flexure on tensioning For crowned head pulleys ensure that the outside blades on each side are an equal distance from the belt whilst the centre blade is touching Again these gaps will quickly close on tensioning If any questions above have been answered take appropriate action to correct the installation If all questions are answered YES proceed Remove the Installation Gauges and fit the blade locks ensuring that the blades are centred to the belt and pulley Step 6 Fully secure the cleaner mounts brackets and CYA doorframe to the chute wall The CYA doorframe is normally stitch welded to the chute wall but may be drilled and bolted if required Check all blades and locks are centred on the belt surface or pulley face and the locks are secured Step 7 If a CYA Door is used All ESS CYA Doors for belt cleaning applications are now supplied complete with a mesh safety screen to comply with AS1755 2000 Conveyors Safety Requirements The mesh screen will need to be cut away to fit over the cleaner mainframe Do this neatly and accurately from the bottom of the screen to avoid creating sharp edges and to avoid creating non compliant openings in the mesh refer to figure 9 Re fit the scree
14. belt The centre pivot airbag is then set to the same pressure but never more than the main tensioner air bags Refer to Table 3 in the Air tensioner section for recommended pressure settings Revision J 34 18 03 2014 SECTION 10 COMMISSIONING Step 1 Step 2 Step 3 Step 4 Step 5 Step 5 Step 7 Step 8 Revision J Perform Installation Check Double check the items in previous sections safety preparation installation Check that the cleaner is installed to specification all fasteners have been securely tightened and the tensioners adjusted to the correct settings Is the belt empty Make sure there are no foreign objects such as tools or clean up debris left on the belt They may damage the belt cleaners or the conveyor systems Load material on the conveyor If possible test run conveyor with material on the belt This helps to quickly wear in the blades and reduce the initial friction between the belt and the blades The belt may also be moistened with water Start the conveyor Ensure first that all screens and safety barriers are in place Allow only visual access to the cleaner blades ensuring that no person can enter or reach into the conveyor enclosure Follow all safety procedures before starting the conveyor Observe the cleaning action Observe the action of the cleaner Look for blades that are not touching the belt All blade tips should be in contact with the belt and peelin
15. the wear indicator will provide the operator with an instant visual estimate of the wear status of the cleaning blades It is important to note that the wear indicator should not replace or reduce the need for regular inspection of the cleaning blades The Wear Indicator is simply a pointer that rotates with the cleaner mainframe as the blades wear with the amount of rotation indicated on a scale cast into the mount bracket The scale is set out in 5 increments from 0 to 40 Different ESS XHD blades have varying amounts of rotational wearlife and these can vary further with operating conditions For example the Standard CARP and Low Profile blades will have approximately 25 of wearlife whilst the CARP 2 blade can achieve up to 40 in many applications The Wear Indicator is not used with Tungsten Carbide tipped blades which have minimal rotation It is therefore essential that the operator know what type of blade is being used and have some experience of the wearlife achieved on the belt in question Allowing the blades to wear too far can result in blade pull through with mainframe damage common Changing the blades too early will increase blade replacement costs 8 3 1 SETTING THE WEAR INDICATOR Setting the indicator is very simple With a new set of blades installed and tensioned against the belt install the indicator over the end of the cleaner mainframe with the pointer aimed at the 0 mark on the mount Tighten the lockscrews
16. www esseng com au to register your product warranty 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 XHD 20 Ten Series Primary Cleaner purchased from ESS and cannot be passed on to any other party without express permission in writing from ESS Revision J 5 18 03 2014 SECTION 1 SAFETY All equipment installed on or around a conveyor belt must comply with AS 1755 2000 Conveyors Safety requirements Ensure that only suitably qualified and trained personnel install and service this product and that all site and statutory safety procedures are followed The XHD 20 Ten Series Primary Cleaner is designed to be quickly and easily serviced by appropriate personnel however under no circumstances should any personnel attempt installation or service of this equipment whilst the conveyor belt is running The conveyor belt drive and any associated equipment must be shut down and locked out according to plant safety procedures before attempting work requiring access to or opening of the chute or conveyor enclosure Contact with a moving conveyor belt and its drive components can result in serious injury or death The XHD mainframe and blade assembly can be heavy 30 to 130 kg depending on belt width and can require installation in awkward positions Ensure that adequate personnel are available to safel
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20. 3H HO 310N A3Tind QV3H 008 d HION3T 05 009 osy HLOIM 1738 13 0Vvu8 340 QNV1S 035 LON SI 8000 VA V 343HM NV S3lnH2 3S0 DN3 403 130 100102 310H 8L S310H 7 000 8121 2 1VNOILdO 00E VAD 3dld 8NS9 Q031V2lJugv4 5 19893 2015 8018200 UJA0 30V19 3dis HLOIM 1138 H15N31 1 HLDN3T JWV JNIVW SN3NNOO dNVHS ONY 58808 TW 3AOW3N 031312395 3SIMN3HIO 553 SI4LIWITIIW NI SNOISNIWIG 3WOS LON OG 51708 9LW 304 8L S310H 9 310N 33S 3301 L 8 18 03 2014 43 J ision Rev 6104 279 auva 514131925 s NAC INIWJONVEJV NOLLVTIVISNI 4000 SS390V 34VS IBWOD 2 MINOISNAL JYINIO M3NY319 ANVWIHA SIMOVUL LYNG N31 0Z GHX ON ONIMV3SG 977720 0081 ON 3OIAM3S YINOLSNI S3 lddfS X S3OIAM3S 0092 007 05 2 1 11 Qddv 05 00 SNOISIA3 JYNLIVIANVW 03 031551 NOISIAZY SYM 100 102 SONIMVHG 30N33434 51806 030019 3 B3NOISN3L HIV AYWWidd N3 0V3I LYNG NIL 0Z OHX 0V9 3 335 009E 0066 0005 0082 SZ 581 SL GHX 5 4000 4i S301S HLOB dash 38 AVW 58000 34VS I8W0 E
21. 7 4952 4600 aget BOBO 5755 Fax 07 4952 4717 Mackay Mail Centre QLD 4741 essmac esseng com au MAITLAND Eu FT 02 4932 3544 ohnson Stree Maitland NSW 2320 il 02 G essmai esseng com au PERTH n E Phone 08 9370 3155 ayswater Road Fax 08 9272 5130 Malaga WA 6090 essper esseng com au TOWNSVILLE Unit 6 40 42 Carmel St Phone 07 4755 2776 Sault HEN Fax 07 4779 6236 esstow esseng com au SOUTH AUSTRALIA 5 Cormorant Court Mobile 0408 948 175 Middleton SA 5213 esssa esseng com au VICTORIA Unit 4 314 Governor Road Phone 03 9580 0388 Braeside VIC 3195 Fax 03 9587 5199 essvic esseng com au WOLLONGONG Unit 1 20 Doyle Avenue Phone 02 4272 4422 PO Box 343 Unanderra NSW 2526 esswol esseng com au Fax 02 4272 4434 TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA VSS TOLL FREE 1800 300 877 Revision J 18 03 2014 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 SECTION 11 SECTION 12 SECTION 13 SECTION 14 SECTION 15 SECTION 16 Revision J SAFETY INTRODUCTION PREPARATION FOR INSTALLATION KEYSAFE FEATURE TUNGSTEN CARBIDE TIPPED BLADES INSTALLATION COMBI SAFE ACCESS DOOR TENSIONERS CENTRE PIVOT MAINFRAME COMMISSIONING OPERATOR TRAINING ROUTINE MAINTENANCE AND SERVICE TROUBLE SHOOTING INSTALLATION ARRANGEMENT DRAWING EXPLODED PA
22. AN 3 7 8000 YA SNIL DNlidS S30V18 Z AUVI M UHDVUL LYNG Nil 07 HX 17104 JINVID ANVWINd SINIVUL LYNG NIL 0Z GHX os NOISIA 3S 1V13N35 0 4000 335 1840 2 SNIL DNRidS SIQVIE 7 dNV ANVHRid YINVAL LUNG NIL 02 5104 QLTALd 5119405 NV SIIAYIS DNI JINIDNI 553 KOR TVAQAdAY DHD3AS INOHIIM ALAYA H3HLO ANY 01 NMOHS 30 031 6000 36 LON TIVHS 11 QLTAId 5318905 NV 5 35 DNIJJINIDNI SSI 30 41414084 3H SNIVW3Y NV TWILNAQIJNO SI NDISAQ NV DNIMV30 SIHL 977740 0081 ON 3210035 YIWOLSNI 09 553 530005 29 5301835 9NIN33NION3 4 Inn Ee ON livd JON 990 AI0 NOIIdIH2S30 ON 4 2250602060 6 1 SS 1330Vv38 100 SN3L 05 NALOZ GHX l 20 SS ASSY N31 DNIHdS LNW 3112 QHX 02951920 SSO 135 Orx9LN M389S Z 2259002060 SS N31 65 LNW N310Z GHX 581961920 Z 55905 ONINdS 91W 43HSVM e 22520020601 SS N11 9NIsdS IVO 13S LNW N310Z GHX 2250602060 6 503805 M 2 SS AINO WY 4340 SNIL NdS NALOZ QHX Z 0 SS ASSY YJNOISNIL DNI3dS NILIZ GHX SIL9SIEZO INIOd dnd SSYOS 13S BZX9LW MINDS 7 22519902060 SS 00 5 NIL 65 3102 OHX 0Z060 JNIJ4S YANOISNAL 465 9 OHX 92573202060 SS THAMS SN3L 805 N3LOZ OHX S 20599902060 99906 1 SS dv NV 300 SNIL 65 102 GHX 9 562951920 55909 13S SZXZIN M389S 9 571961920 570 ONIdS Z
23. Engineering Services amp Supplies Pty Ltd Phone 1 800 074446 Visit our Web Site www esseng com au XHD Primary Belt Cleaner With 20 Ten Series Mounts MARTIN ENGINEERING Installation Operations Manual Revision J 1 18 03 2014 REVISIONS TABLE Revision Description of Change Changed By Date A First Issue TT 18 3 11 B Added dwg F0458 KO 7 6 12 Removed Mt Isa s contact detail added dwg F0459 KO 21 06 12 D Update format of manual KO 11 9 12 E Updated drawings F0418 amp F0422 KO 17 9 12 F Revised drawing F0414 KO 21 9 12 G Added Combi Safe TC Blade Centre Pivot TT 12 12 12 H Updated format of manual KO 31 1 13 Updated drawings F0419 0421 2 KO 01 10 13 J Update office details KO 18 3 14 Revision J 2 18 03 2014 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS Location Address Phone amp Fax CURRUMBIN oh Ded Way Phone 07 5589 2000 OX Currumbin QLD 4223 FER ooo esscur esseng com au EMERALD oe Roberts Street Phone 07 4982 4855 OX Emerald QLD 4720 Fax 07 4987 5118 esseme esseng com au GLADSTONE Street Phone 07 4972 3759 OX Gladstone QLD 4680 Fo 00 09 2800 essgla esseng com au KALGOORLIE 08 9021 7991 algoorlie 10474 Fax 08 9021 7291 Kalgoorlie WA 6433 esskal esseng com au KARRATHA Phone 08 9144 0689 Fax 08 9144 0682 MACKAY dir 21s Phone 0
24. IN N3HSVM 9 989502060 Oreta 55 88 LAN ONINOISN3L SN3L 805 NILOZ GHX 4 599600060 iseia I SS 19 51 319 SN3L NILOZ QHX 8 9900 1 SS dldd 8 dnd 8 22515002060 996 JOLVOIONI JVIM SNIL NILOZ QHX 6 900 B 56705 O3INIOd 13S 8ZXZIW M3 X S 6 1 1 1 1 2258002060 4 22 a LON SI ATAW3SSY INNOW JHL LON dAVHS ONY SYYNE 1Y J3AOW3S 031312395 3SIMHIHLO 553 S3S13ATTIIA NI 38V SNOISNIWIQ TIv 3TWOS LON OG CC103 18 03 2014 47 J ision Rev Revision J i v i z x 4 8 2 WI 8 x 48 18 03 2014 SECTION 16 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 L inspection LI 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 Si
25. ISOd NOILVTIVISNI Ag G3NINN3L30 ino 102 40 3 SLN3W93S 30V18 Z 13 32319 INO 135330 1ViQva d ari QV3H B 318VlIVAV S3dAl 3078 0 Ne lins OL SONI WIL AT8W3SSY 4000 I8WO 2 SN3L ONINdS 8 S30V18 Z div M NAL 0Z GHX 02000967 YIGWNN Livd 000 55322 34VS I8WO GHX V NO SM3IA 3A VNB3LTV Q3TIVISNI 43A0 HS3W 318V5207 HLIM Q3AOW3H S43A0 000 34VS I8WO OHX 000 34VS I8WO QHX TIVM 3LNHD 01 031108 3WVU4 Hood 33VS IgW02 GHX ANNOW SS 07 310N 33S uv TIOD 4201 WON L 34VS IgW0 3015 yolvaado L 310N 33S SH3NNOO dNVHS SYNE TW 031310395 3SIMN3HIO SSFINN S3MI3ATTIIA NI 33V SNOISN3WIQ TW 3301 30V18 HLOIM 1138 H19N31 3AV3JNIVW 39S LON OQ 18 03 2014 41 J ision Rev
26. Keysafe slot can be problematic but a couple of measures are available to overcome this For relatively easy to move materials such as coal simply hosing water into the slot will clear it sufficiently The Keysafe tool has been recently redesigned to allow use of the slide hammer in the reverse direction This means that the spade tip can be hammered in to the slot through the fines ESS is currently working on alternative designs and measures to allow use of the Keysafe feature with even the most difficult materials so clients are advised to prepare for use of the feature even if it is not usable at this time The reduction in hazards and task duration will pay for the minimal preparation at the very first service Revision J 11 18 03 2014 SECTION 5 USE OF TUNGSTEN CARBIDE TIPPED BLADES ESS has for many years promoted urethane as the preferred material for primary cleaner blades This is due to the combined qualities of wear resistance good cleaning performance and above all safe application to the belt surface at an attack angle However ESS also recognises that there are some applications where urethane is not the best material due usually to a specific property of the material being handled on the conveyor For example some extremely sharp and abrasive materials may score the urethane surface and lead to excessive wear Materials such as Bauxite can catch under the leading edge of urethane blades and cause erratic wear and materia
27. L iNawisnrav YINVID 804 MOTIV OL ino 119 3LNHI 0962 OLOZ 010 0691 100 LN 000 Sv 3WVS 3HL 38 01 LNO 102 30 0072 0022 0002 99603 DNIMVUQ 335 318V lVAV 1001 NOILIVULXI 30V18 34VSA3 1 318VlIVAV JYV 531184355 Q3AOUddV LNIWLYVd3d S3NIN ONY 30N1VA3AW3L HDIH 53015 H108 NO SHANOISNIL u30IM wwoos 8 LN3W3AOW IVIXV 1N3A3Bd 01 5201 31dNIS V HLIM 031910 SI LNNOW 3015 30IM 056 01 dn 51139 3 MOT IVIXJLYW 40 38V31 SI 33NV31 3HL 38NSN3 NOISNIWIQ 135330 Widva 31 NIVINIVW A3TInd JHL JO b 0 02 1 M0739 SL 3 0 N33 138 dll SLI SI YINYIN OHX JHL 40 15 1 W WILdO 3HL SALON 5 38 NV X08 0 1 0 0 W3NOISN31 3 3 1 341 01 75 3LVUVAIS V 6031 8 3HL H9noBHl 0355 SI 3801 V 38155384 3 3805 ONY INIOd NOILVIJNI MOTIV 01 SOVBXIV 3HL SNIO 3WVA4 Jdid JHL HONOYHL Q3SSvd 38N1 INVIVA 83aiM ONY 51738 00st 0345 adv SWH3NOISN31 HIV TVNG 383HM S310N dn13S 0 305 ino LN 310H2 3 S310H BD A3110d OVIH AJ 5 S S 0 S W NI 318VTIVAV ATBH3SSV 3HVMJNIVH NOILISOd NOILVTIVISNI A8 031V2 48V4 151909 Q3NIWA3130 100 1 40 315NV N Pisis DA AaTINd OVH 2 Lins OL SONI Wil A18W3SSV 8000 3dVS I8402 GHX 135440 Widv
28. NFRAMES The Centre Pivot Mainframe has an additional air line connection over standard air tensioned cleaners The extra air line is to supply air to the centre pivot airbag The air line extends from the centre pivot air bag into the mainframe and out through the operator end of the mainframe This air line is connected to a separate outlet from the control box and has a separate regulator to allow the pressure to the centre pivot to be independently adjusted Revision J 33 18 03 2014 AIR LINE TO CENTRE PIVOT OPERATOR SIDE OPERATOR SIDE FAR SIDE MOUNT AND TENSIONER NOT SHOWN FOR CLARITY PASS TUBE THROUGH MAINFRAME FOR DUAL TENSIONER CLEANERS Figure 22 Centre Pivot mainframe Air Connections The Centre Pivot airbag connection will also have a separate pressure regulator that must be set to the appropriate pressure This means that the blade set is being adjusted against the belt by three airbags instead of two but the centre airbag may also act against the main airbags if it is over pressurised Care must be taken to set the pressures correctly Because the Centre Pivot Mainframe is usually operating under arduous conditions with heavy material loading the air pressure to the outer airbags is unchanged from the recommendations in the air tensioner section even though it is actually tensioning fewer blades against the
29. RTS DRAWING FINAL CHECKLIST 4 18 03 2014 WARRANTY NOTE ESS WARRANTS the XHD 20 Ten Series Primary Cleaner 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 The 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 It will install the product and certify the correctness of such installation or b Certify the correctness or otherwise of the installation of the product by third parties This certification service is designed to ensure that you obtain the full benefit of the ESS warranty hereby provided If you would like to take advantage of the installation certification service provided please contact ESS Refer to the Final Checklist at the back of this manual Visit the ESS website
30. Release the mainframe For dual tensioner cleaners repeat for the other side Turn on the air supply and adjust the pressure as described in section 6 Remove locks or tags and return the belt to service Observe the cleaner in operation then replace the access door cover 38 18 03 2014 SECTION 13 TROUBLE SHOOTING Problem Mounts won t fit in desired location CAUSE SOLUTION Structural members in the way Relocate the cleaner elsewhere on the offset radial Consult ESS if unsure Modify structural members only as a last resort and only with plant engineer approval Obstructions prevent mounting to chute wall Provide gussets or spacers to secure mounts away from obstructions e Problem Blades fold under at Start up CAUSE SOLUTION Incorrect mainframe offset Relocate mounts so that the shaft is the correct radial distance from the belt face on the head pulley see section 5 Excessive tension Relax blade tension to recommended settings in section 6 Belt running dry Always put material on belt for start up or a little water if material is unavailable Poor belt or splice condition Repair belt dress splices to smooth contour New belt with sticky surface Fit low friction blades contact ESS for assistance e Problem Poor blade life CAUSE SOLUTION Excessive tension Relax blade tension to recommended settings
31. VI 33NV3TD 6 U OVAL 13900 N31 07 HX 503 0319000 5986 S338 JIL 006 34 5 18 0 SNIL HIV 510719 Z d8V M ANVWINd 1 LUNG NIL 0Z HX 25104 UJNV3D ANVWhid 1 LUNG NIL 0Z OHX oe DUT ALd 5219405 ONY SIJIAQJS SSI TWAQQdAW 7140145 LNOHIIM ALAYA YIHLO ANY OL NMOHS 30 031 and 03140 Q 38 10N TIVHS LI OLTAld 5319915 ONY S3MA33S DNIIJNON 553 30 51834084 IHL SNIVWAW NV TVIIN303N0 SI NDISIO ONY ONIMVYO SHI ay ONV ISN3IRD 9rrr 0 0081 ON 3OIANH3S JIWOLSNI avo 553 53119915 2 S30IAN3S 9NIJ33NION3 553 an EE oN 1dVd ON 6 NOILdINOS3Q LOJW3LI oN 4 NOlLdlH2S3Q 22515102060 68 Ss Lpovsg SNIL N3LOZ aux gt L 22560102060 SS ASSY NIL 8 LNW NILOZ Qux S0E9 0 Z0 F 5570 08X9LW 1108 z 21 22590102060 SS N31 3 13S LNW 3102 GHX 581961820 z SS 0 05 9LW 4IHSVM z 22510102060 SS NIL TVAQ 13S LNW 3102 GHX 569291820 2 dv 205 7 X INN 8 E MINIS Z 22580102060 S4unow ou SS ASSY 4INOISNIL NILOZ GHX 2205102060 0 SS WHY 1 8360 SNIL 3102 GHX z 1951620 1NIOd dn 55706 115 8ZX9LW MINIS 7 S69Z91 Z0 B 205 X INN 8 MINIS 2 EZ 5108100060 015 591 4V34000D Dveuv 1 22515002060 MELA SS uolvolaN SNIL N3102 GHX S6ZSSLEZO 5 SS 0 GILNIOd 135 8ZXZLW MINIS Z QLE199EZ0 2 Lid d
32. Y3A0 000 3dVS I840 QHX dnl3S 0b 100 102 052 9 135 0 3015 avd 571130 804 553 LIVLNOD 3T8VTIVAV SHLON3T 15 55603 335 318V lIVAV 1001 NOILIVYLX3 30V 18 33053 318v llIVAV 3uv SIMBWISSV O3AONddV LN3IWLYVd30 S3NIW 3YNLVY3dW3L HDIH S30IS H108 NO SY3NOISN3L 8 005 330IM 1N3N3A0N LN3A30d Ol 5201 a7dwis V 031d00 SI 1 5 avd JHL 3QIW WWQSEL OL dn 51738 404 MOTH 1 30 4V37 SI 93NV37D 3HL 3YNSN3 ONY NOISN3WIG 135330 TVIQVH 3HL NIVLNIVW A3110d QV3H 3HL 30 gt 2 1 3HL M0138 5 2 0 N33M138 dll SLI HLIM SI A VWi d OHX JHL 40 NOILVTIVISNI WAWILdO 3Hl l S3LON 100 ino 31nH2 A3TInd QV3H S310H 8l G7 NOIID3S JIBVIIVAW 53641 30978 83HLO NOILISOd NOILVTIVLSNI A8 QINIW43130 100 102 30 319NV Lins OL SONI 1 IN SIN3WD3S 30078 2 JAW INVHLIWA 32319 INO A3Tlnd OVIH MIGWASSV 8000 34VS I8WO QHX 3dld 8NS 031 9 TIVM 310H2 01 031108 3WVd4 X000 34VS I840 HX ANNOW SS H19N31 ADVEL 310 335 4201 38V31 WON L 5201 8 2 3015 1 0 135340 12V1NO2 30NVU SIHL 40 3015110 SA3TInd QV3H 303 3LON Sth EY 310N 33S 135330 17139 SNIGN ON 7 4 QV3H
33. a 310N 33S SS3 LIVLNO 39NVM SIHL 40 30ISLNO SAITINd QV3H 304 310N om en sa ses sm 135440 wav NO SM3IA 3AILVNS3I TV 000 4 553 34VS I8N0J Q311V1SNI 4 31 83A02 Q3TIVISNI AINO 3 02 83100 3 HS3W HLIM HS3W 318V5201 HLIM ood 34VS Ig40 GHX 3000 34VS I8g40 GHX S43A0 HLIM Hood 8 0 5 33 QHX TIVM 310H2 01 031109 3WVi Hood 34VS 18WO GHX Jdid 8NS9 3WVHHNIVW 031 2 310N 33S 4307 WON L 3301 308 3015 dvd s 83 0 30V18 Hiaim 1138 1138 DNIQ DNI H15N31 3AVtJNIVW SH3NHOO dHVHS ONY SYYNG Tv 3AOW3N 031310395 3SIMN3HIO SS31Nn S3HI3WITIIN NI 34v SNOISN3AIQ TW 731V9S LON 0 18 03 2014 44 J ision Rev SECTION 15 EXPLODED PARTS DRAWINGS s900 SIN JIY S 99 mam 3 as 59 28200203 031551 ux 3000 5553007 3375 1600 8 03007 8 W3ll 7201 30719 A18N3SSV S1HVd 03001dX3 SONIMVMO 008 335 1980 SNIL UV WNO ERMONYH S30VJ8 Z AAWI HAXJVALL LANA N3l 02 HX U3iv dn 151 Wall 0 4000 345 1840 SNL INIYAS TWAQ S30V T8 2 40 A D AMVWlid ADDVAL 1400 NAL QZ HX GHX 1 02 LYNG 1 AYVWIdd 006 HYS I8HOJ SNIL 9 5 53078 N3dO
34. ad chutes high speeds or handling abrasive materials It is normally mounted on the face of the conveyor belt head pulley The cleaner blades face against the direction of belt travel and are designed to peel off the thick layer of loosely adhering material that often accounts for up to 8096 of carryback The XHD 20 Ten Series Primary Cleaner is normally used in conjunction with at least one secondary cleaner such as the Inline Premium Secondary Cleaner and often with a water spraying system The blades are of cast urethane in a range of grades shapes and sizes for various applications plus a tungsten carbide tipped version for very abrasive materials The blades slide into a steel track on the mainframe for ease of replacement One side of the track is removable for very tight or difficult applications Figure 1 XHD with Green Low Profile Blades on a Sugar Mill 28808556 Belt Revision J 7 18 03 2014 The Keysafe system has been developed to further assist blade replacement Refer to the details of this in section 4 of this manual Important Points to Remember Concerning the XHD 20 Ten Series Primary Cleaner are 1 The cleaner is directional it will only clean the belt travelling in the design direction However the cleaner will not be damaged or affected by belt direction reversal 2 Using urethane blades the cleaner is suitable for use on crowned head pulleys and damaged or grooved belts The urethane blades q
35. ad pulleys outside of this range Revision J 18 03 2014 TC Tipped 2011 Blade Blade P N 36500055 P N 36500080 Superseded Current Verify Mainframe Position Before Proceeding Position the selected mount and tensioner assembly over the centre line marks for the mainframe Verify that the mounts fit and that adequate room is available to tension the cleaner If used position the CYA Door frame and Stand off Bracket to ensure they fit If mounts brackets or doorframe interfere with structural members it may be necessary to locate the cleaner elsewhere on the offset radius or rotate the mount bracket door assembly to any angle to suit see figure 6 If the tensioner only interferes remember that the tensioner can be flipped to a reverse assembly on the mount bracket or fitted to the other side of the conveyor for belt widths less than 1500 Ensure that the tensioner set up is rotating the cleaner in the correct direction The mounts now have slotted holes to allow some in situ adjustment of mount position Figure 8 Mount Position Options Step 2 At the selected mainframe mounting positions cut a hole in each side of the chute as shown in figure 7 If a CYA Door is to be installed use the cutout shown below on the operator side and on the far side if dual doors are required All XHD blades are now supplied with the Keysafe feature Refer the Section 4 for more details Plan your cutouts and brackets t
36. belt face The offset can be checked using ESS XHD Installation Gauges refer instruction and figure 8 following Is the mainframe level or equal to the pulley shaft Is there at least 165mm clear at one end of the track to remove and replace blades Use of the XHD Installation Gauge The XHD Installation Gauge is a urethane gauge that can be fitted to the cleaner track ina similar way to the blades The curved surface of the gauge forms a radius of 120mm from the centre line of the cleaner mainframe If the curved edge of the gauge just touches the belt the mainframe offset is 120mm For larger offsets measure the gap between the gauge and the belt and for smaller offsets measure the distance the gauge overhangs the edge of the belt See figure below 4 GAUGE 10mm CLEAR OF BELT GAUGE OVERHANGS GAUGE BELT EDGE BY 10mm TOUCHING BELT NIN N 5 N NS NA A LA NW 9 RO WY Pus ae Y NEN a oe kl E Deme x ls Sta As NUCNS See DS eV Ne EM Figure 10 Use of Installation Gauges Revision J 17 18 03 2014 Slide the blades onto the track and fit an Installation Gauge to each end leaving the blade locks off at this time Check the offset as described above Rotate the mainframe until the blade tips lightly contact the belt Do the blade tips all touch the belt at the same time 1mm Do the tips contact the belt at the desired position 0 to 15
37. d additional support and instruction at regular future intervals to ensure that all information has been understood and retained Encourage the trainee to look for and report other problems developing on the conveyor system such as excessive belt tracking belt damage seized idlers missing bolts and the like 36 18 03 2014 SECTION 12 ROUTINE MAINTENANCE AND SERVICE Regular inspection and servicing is the key to effective conveyor belt cleaning t is recommended that the cleaner be visually inspected once per week Actual service intervals will vary considerably from plant to plant CAUTION Do not reach inside the conveyor chute under any circumstances whilst the conveyor is running 12 1 ROUTINE INSPECTION PROCEDURE Step 1 Step 2 Inspect the condition of the cleaner Open the inspection door if safety compliant and observe the condition and action of the blades and cleaner If the blades are excessively worn or damaged schedule a blade changeout at the next available opportunity Refer to the blade change procedure following If necessary and if plant rules allow it hose any material build up from the blades or mainframe do this through the safety mesh screen DO NOT REACH INTO THE CHUTE WHILST CONVEYOR IS RUNNING Step 3 Step 4 Check the tensioner settings and adjust if necessary DO NOT OVER TENSION refer to the tensioner settings in Section 6 for the required belt width For Air Tensioned c
38. e frame with and without inner cover 7 2 Maintenance Procedures and Advantages 7 2 1 Visual Inspection The Combi Safe door allows inspection access by simply lifting and removing the outer cover plate At this stage the inner mesh cover prevents contact with moving parts inside the chute but will allow the service technician to visually inspect the belt cleaner or any other object within the line of sight Caution To proceed beyond this level of access the conveyor belt must be shut down and locked out Ensure that all safety procedures are followed before accessing the area inside the conveyor enclosure 7 2 2 Maintenance Access Remove the lock or fastener from the top of the inner cover and lift the cover off the door frame The XHD cleaner blades are now able to be removed through the opening in the frame If using genuine ESS blades with Keysafe feature the blades may be removed safely one at a time and with little effort The Combi Safe door has been designed specifically to allow use of the Keysafe tool with no interferences Revision J 23 18 03 2014 If the XHD cleaner has been fitted with an ESS XHD Mandarel the complete cleaner be withdrawn through the Combi Safe door Remove the tensioner and mount assembly from the Combi Safe door by first removing the four bolts Loosen the lockscrews securing the tensioner to the mainframe and slide the mount and tensioner assembly from the mainframe Caution When the lockscrews ar
39. e loosened the cleaner mainframe may spin Keep fingers clear of any pinch points Caution When withdrawing the tensioner take care that the individual parts of the tensioner are supported The parts may relax fall when coming clear and could cause impact injury Lift the end of the cleaner mainframe and remove the lower seal This will allow the mainframe to rest on the Combi Safe frame at any time during withdrawal Do not forget to re fit the lower seal when re installing the cleaner Refer to the XHD Mandrel manual for more information On completion of maintenance re fit the inner mesh cover and secure with the designated locking system Set the tensioner s to the required setting and check the blade contact with the belt Fit the outer cover and remove locks or tags so that the conveyor can be returned to service Revision J 24 18 03 2014 SECTION 8 TENSIONERS The XHD 20 Ten Series mounts differ from previous models in that the tensioner does not attach to the mounting bolts Instead the pivot bracket of either tensioner type attaches to separate tapped holes in the mount hub This allows easy interchanging of tensioners without disturbing the mount installation and also allows inclusion of slotted holes in the mount for minor positional adjustment 8 1 SPRING TENSIONER The XHD 20 Ten Series Spring Tensioner is a simple robust and reliable tensioning unit It can be assembled to tension in either the clockwise or an
40. emove the Adjusting Nut and Spring from the Adjusting Rod and insert the threaded end of the Adjusting Rod through the small end of the Swivel in the Operating Arm from the Pivot Bracket side Fit the Adjusting Rod Clevis and Clevis Pin to the Pivot Bracket and secure with clip provided 6 Fit the Spring and Adjusting Nut 3 or 4 turns only to the threaded end of the Adjusting Rod Do not try to adjust or compress the spring yet 7 Using a pipe wrench or similar rotate the cleaner until the blade tips are lightly touching the belt With the Operating Arm fully rotated against the Spring lock the Operating Arm onto the cleaner mainframe by tightening the three lock screws Ensure that the Operating Arm hub is 1 to 2mm clear of the mount bush to allow free rotation without excessive lateral movement of the mainframe 8 Adjust the Nut against the Spring until the Spring just begins to compress ensuring that the Spring has located on the raised shoulders on the Adjusting Nut and the Swivel Revision J 26 18 03 2014 9 For belts 1500mm and wider tensioners are fitted to both sides Repeat above procedure for other side For cleaners with one tensioner only fit the Locking Collar onto the far end of the cleaner mainframe again locking it into position 1 2mm clear of the mount 10 Tension the cleaner by rotating the Adjusting Nut until the Spring is compressed to the length shown in table 2 following For dual tensioner cleaners repeat both
41. ey diameter Determine the contact point for the blade tips This should be between 0 15 below the horizontal centre line of the head pulley Very slow belts may require the cleaner to be installed lower to clear the material flow Measure radially the offset dimension Z from the face of the belt Through this point draw an arc using the pulley s centre line as the centre point From the tip contact point measure a distance H and mark the intersection on the offset arc This will represent the centre point of the cleaner mainframe Repeat for both sides E RIAL IRAJECIORY Wolfe deg AD MGE Figure 6 XHD Installation Position Revision J 14 18 03 2014 ad TC Tipped Blade P N 36500001 Superseded 340 OS D 09 TC Tipped Open Face Z IA W tii Y Y CARP 2 Blade Standard Blade CARP Blade Low Profile Blade P N 36300095 P N 36013095 P N 36200095 P N 36013295 Figure 7 Blade Identification Information and Dimension H value Head Pulley Diameter 450 600 750 900 1050 1200 B CARP 2 145 135 125 120 110 100 L A Standard 145 135 125 120 110 100 D E CARP 135 125 115 110 100 95 T Low Profile 135 125 115 110 100 95 TC Tipped TC 210 180 155 135 120 110 E Open Face and TC 2011 Blades Table 1 Cleaner Mainframe Offset Z for Different Head Pulley Diameters Contact ESS for he
42. fe and easy blade replacement This feature is now included in all current XHD blades What is Keysafe The Keysafe feature is simply a hole through the blade that changes from a round bore to a slot halfway through This allows an extraction tool with a spade tip to be inserted through the slot into the round bore The tool is then rotated 90 and withdrawn The spade tip engages on the shoulder of the slot to pull the blade out of the track The advantages of this system are many e Only one blade is withdrawn at a time e Works from either side of the belt e Noconfined space entry required e No heavy lifts e Hole is low on centre line of blade for best application of effort e Optional slide hammer available for tight blades e Tool is adjustable in length for wide belts or tight spaces The Keysafe feature is included in the blades at no cost to clients The extraction tool is available for purchase from any ESS representative P N 36900005 Keysafe Blade Extraction Tool P N 36900020 Keysafe Tool Slide Hammer m 4 be Keysafe tool inserted into Keysafe slot Older XHD Mount modified for Keysafe tool insertion Good access for blade retrieval Revision J 10 18 03 2014 4 1 TAKING ADVANTAGE OF THE KEYSAFE FEATURE The Keysafe feature is provided free of charge to purchasers of genuine ESS blades and has the potential to not only eliminate many of the safety hazards associated with belt cleaner blades changes but
43. g material from the belt Run for several belt rotations to appraise the action and effect of the splices on the belt cleaner Check the Tensioner Setting Refer to previous section 6 Operation of Tensioner After running check and reset if necessary the cleaner tensioner setting Initial running and bedding in can loosen parts and reduce the tensioner loading Do not over tension excessive pressure unnecessarily reduces the life of the blade without any increase in the cleaner effectiveness Train Operators and Maintenance Personnel Ensure that operators and service personnel are aware and familiar with the cleaning system Ensure that they are aware of all safety hazards that exist around conveyor belts and that all safety procedures are followed Thoroughly train service personnel in inspection and maintenance of the cleaning system Contact ESS for assistance if required Return the system to production Follow all plant procedures to return the conveyor system to operational status 35 18 03 2014 SECTION 11 OPERATOR TRAINING The decision to purchase the XHD 20 Ten Series Primary Belt Cleaner is a major step toward the realisation of a clean plant The next step is to train personnel to maintain and service the equipment or employ ESS to maintain the belt cleaning equipment so that it continues to operate at optimum efficiency The benefits of efficient cleaners outweigh the cost of maintaining the cleaners many t
44. gnature Revision J 49 18 03 2014
45. imes over lf you wish to have your cleaning system maintained for you contact ESS If not train your own personnel as follows 1 10 Revision J Ensure that personnel working around conveyors are thoroughly trained to recognise existing and potential hazards involved and that a Job Safety Analysis is conducted to identify and control those hazards Ensure personnel are trained in correct equipment isolation and lock out procedures Ensure that personnel have all required safety equipment and are thoroughly trained in the use of that equipment Ensure that all appropriate permits are in place and that personnel involved are qualified to undertake the required work Provide the trainee with a copy of this manual and ensure that they read and understand the contents Provide the trainee with all relevant conveyor data such as belt speed width and material handled and ensure that they understand the required belt cleaner settings and adjustments that pertain to the conveyor Instruct the trainee to look for problems existing or developing in the belt cleaning system such as increasing carryback irregular or excessive blade wear blade vibration and the like Encourage them to safely observe and try to determine the cause of the problem Ensure that the trainee is given hands on instruction in maintenance procedures during down time in the company of an experienced service technician Ensure that the trainee is provide
46. in section 6 Improper blade application Consult ESS Revision J 39 18 03 2014 SECTION 14 INSTALLATION ARRANGEMENT DRAWINGS S4704 L M2 Q ddv 0S GMHO ON oNimvsa 5 IN3W3ONVAUV NOLLVTIVISNI 000 SS300V 3445 1802 SNIL ONIJJS SONIA Z dWVO M 2 M3NV3T JIMOVUL LYNG 1 06 GHX 977720 0081 ON 3OIAM3S YIWOLSNI 5319905 S3OIAM3S 0092 0072 05 2 1 00 gt 0096 0066 0006 0082 0572 0062 0012 056 008 SAZ 086 5181 059 OZEL 556 066 066 8 EL a or 8 L 9 5 0002 0521 002 0082 0512 0581 0851 00 006 os 8 00 z 0022 0002 0051 05 050 006 052 Q3Nin038 31 53015 108 Q3Sf 38 AVW 58000 33VS I8W02 INIWLSNFOV Y3NV31 303 MOTIV 1 100 10 000 SV IWYS 38 01 100 102 30 SKSSNIMVEC NOLLY 5200 5 d i DMP 0 00003 v NOISIA38 1V33N39 gt 0 83NV37 Q300V Wid 017 SYM ino 105 NOILV901 0V9 553 1 E e 000 34VS IgW0 GHX 100 102 31NHI 7001 1 3Q0V18 33VSA33 SSE03 0Z0009EZ 43BWNN 55 000 6 1 34VS I8W02 HX V NO SM3IA JAILVN23311V 15 Y3A0 HS3W 318V5201 HLIM 8000 3dVS Ig40 OHX Q3T1V1SNI 31V1d 83 02 83100 HS3W HLIM 000 34VS I8WO GHX Q3AOW3Y S
47. l by pass In these cases the use of Tungsten Carbide tipped blades can provide a solution ESS offers Tungsten Carbide tipped blades for the XHD primary cleaner and these blades are designed to slide directly into the XHD blade track In 2011 the ESS XHD Tungsten Carbide tipped blade was redesigned for better track fit inclusion of the Keysafe feature and to share a replaceable tip with other ESS cleaner models The new blade has exactly the same installation dimensions as previous versions but cannot be mixed on the same cleaner The new blade arrangement uses single blade units where previous versions required a joiner to form 2 or 3 blade assemblies Replacement Tip Cast Stainless Steel P N 36500008sc Figure 4 2011 Model Tungsten Tipped XHD Blade part number 36500080 Revision J 12 18 03 2014 Original TC Blade Assembly P N 36500001 Superseded Replacement Tip P N 36500010 36500012 Several Types Available Open Faced TC Blade Assembly P N 36500055 Superseded Figure 5 previous Tungsten Tipped XHD Blade models used a joiner to form 2 or 3 blade assemblies and had a flat replaceable tip same for both types Important The most important thing to be aware of when using Tungsten Carbide tipped blades is that the tip must be perpendicular to the belt at the contact point To achieve this the offset dimension which determines the cleaner mainframe position in relation to the head pulley m
48. lateral movement For dual tensioners repeat for the other side 8 The cleaner is now ready for the attachment of the air supply system 8 2 2 AIR SUPPLY CONNECTION The XHD 20 Ten Series Air Tensioner Assembly is supplied with a 74 BSP 6mm push fit tube connector This fitting is simply screwed into the air bag and the 6mm air supply tube pushed into the fitting For cleaners with dual tensioners additional fittings are supplied to allow the air supply to be connected to both air bags via a tee The 6mm tube is passed through the cleaner mainframe to provide air to the far side airbag Connect all air fittings using a good quality liquid compound or gas seal thread tape 8 2 3 AIR SUPPLY CONTROLS ESS recommends the use of an ESS Air Tensioner Control Box to deliver the correct air pressure to the tensioner s A number of models are available Refer to the ESS Air Tensioner Control Box manual for further installation and operation details Air Tensioner Control Box Compact Control Unit for Dual Cleaners shown 6mm Nylon Tube OPERATOR SIDE FAR SIDE Push fit Connector i N Tee and Nipple with two Push fit PASS TUBE THROUGH MAINFRAME FOR DUAL TENSIONER CLEANERS Connectotrs Figure 20 Air Supply Arrangement Revision J 30 18 03 2014 Control boxes available include
49. leaners only Carefully inspect the air tensioner to determine the position of the safety stop lug If the lug is close to the raised hub of the pivot bracket but the blades still have substantial wear life the air tensioner will need to be reset This job will require the conveyor to be shut down and should be programmed for the next available opportunity Refer to the procedure following in 9 3 12 2 BLADE SERVICE PROCEDURE Step 1 Step 2 Step 3 Revision J Shut down and lock out the conveyor Never try to replace the Blades on an XHD Primary Cleaner with the conveyor running Severe injury or death can result from contact with a moving conveyor belt Release the tension and back blades away from the belt For the Spring Tensioner release the adjusting nut For the Air Tensioner close the isolation valve for the cleaner in the air control box Remove the safety screen to access the cleaner then release and remove the operator side blade lock 37 18 03 2014 Step 4 Step 5 Step 6 Step 7 Step 8 Step 8 12 3 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Revision J Slide the blade assemblies off the cleaner mainframe utilising the Keysafe feature where possible see section 4 Clean and inspect the blades if worn excessively or otherwise damaged replace with new blades Always replace blades as a full set Re install new blades onto cleaner followed by lock Re ten
50. n to the frame using the fasteners supplied If a Combi Safe Door is used refer to section 7 of this manual Revision J 18 18 03 2014 rn Figure 11 Fitting the Safety Mesh Screen Measure the position of the mainframe in relation to the CYA doorframe Mark this position on the CYA Door rubber cover and cut a neat hole approximately 75mm diameter in the cover Cut a straight line from this hole to the nearest edge of the rubber cover Install the rubber cover over the mainframe pipe and push into place on the doorframe Anchor the loose end of the cover lanyard Step 8 Install tensioners see section 8 Revision J 19 18 03 2014 SECTION 7 COMBI SAFE ACCESS DOOR ESS recently introduced the Combi Safe Access Door for the XHD Primary Belt Cleaner This access opening is designed to provide excellent inspection and maintenance access whilst being fully compliant with the guidelines of AS1755 Conveyors Safety Requirements The Combi Safe door comprises an outer frame with an integrated cleaner mount bracket a lower cleaner seal an inner mesh cover and seal that is lockable in place and a further steel outer cover The frame of the Combi Safe door bolts to the chute wall The cutout and bolt hole pattern are shown below Bolting of the frame allows adjustment of the XHD cleaner position by loosening the bolts and moving the frame and cleaner as a unit By doing this the Combi Safe cover and lower seal never need to be m
51. ntre Pivot Mainframe is available for air tensioned cleaners only In the rest position or without any air applied the centre blades will align with all other blades in the blade set When air pressure is applied to the centre tensioner the centre blades will pivot forward against the belt to take up excessive wear On release of air pressure a spring retractor will return the blades to the base position The set up of the Centre Pivot Mainframe is exactly the same as described previously for the standard air tensioned XHD cleaner Room must be available to insert the mainframe with centre tensioner into the chute but otherwise cleaner installation is unchanged To further compensate for centre wear ESS offers an enlarged one piece blade called the Mega Blade This blade is available in Standard and Carp 2 blade shapes The Mega blade has increased volume in the blade tip to reduce wear rates plus reinforcing ribs to resist deflection under load The Mega blade is equivalent to 3 blades wide about 490mm and is designed to fit as a single unit into the Centre Pivot mainframe The installation position of the mainframe when using Mega blades is the same as that for the original blade type The Mega blade is usually combined with an equal number of standard sized blades either side to make up a complete blade set for the required belt width Refer to the drawing at the back of this manual 9 1 AIR CONNECTIONS AND SETTINGS FOR CENTRE PIVOT MAI
52. o allow access to the cleaner blades with the Keysafe tool This will greatly assist in achieving simple and hazard free blade replacement in future services 220 18 l x ot ki gt 4 E 300 1 CUTOUT AND HOLES FOR FAR SIDE AND WHERE al CYA DOOR IS NOT USED CUTOUT AND HOLES WHERE CYA DOOR AND STAND OFF BRACKET ARE USED Figure 9 Cut out Details See also section 7 for Combi Safe Door details 450 150 Revision J 16 18 03 2014 Step 3 Remove the blades from the mainframe by first loosening and removing the blade locks Insert the bare cleaner mainframe through the cutouts in the chute wall Caution Remember the XHD is a large and heavy cleaner Use hoisting equipment or ensure adequate personnel are available to safely lift the cleaner into position Step 4 Slide the tensioner side and far side mounts onto the pipe ends of the mainframe and clamp or loosely bolt the mounts to the chute walls with the mainframe in the pre selected position If a CYA Door is to be used and the cutout has been made fit the tensioner side mount to the appropriate stand off bracket and clamp or bolt the stand off bracket in the desired position Note Slide CYA doorframe loosely onto the pipe end before the stand off bracket and mount to save later removal Step 5 Check the mainframe position Doesthe centre line of the mainframe lie the correct offset distance from the
53. odified or damaged and a good seal is maintained Figure 12 Combi Safe Access Door and XHD Cleaner Revision J 20 18 03 2014 7 1 Installation of Combi Safe Doors Step 1 As previously described in this manual determine the centre line of the cleaner mainframe Using this centre line as the start point mark out the cleaner cutout and bolt holes as shown below Check the marking out again and then cut drill the cutout and holes Dress the edges of the cutout to remove burrs and slag and apply protective coating as required 350 250 215 HOLES 518 410 l ur LB Si i r A Lomo Figure 13 Combi Safe cutout and hole details Step 2 If dual Combi Safe doors are required repeat step 1 for the opposite side of the chute If not use the far side mount cutout and holes as described previously in this manual Step 3 Fit the Combi Safe door frame in place and secure with M16 bolts at the 6 holes A small folded steel bracket is supplied with the door This is fitted via the slotted hole under either of the top bolts This Lock Bracket will provide a locking point for the inner door mesh cover Centralise the door in the slotted holes This should locate the XHD mainframe in the position previously determined in this manual Secure the bolts Fit the far side Combi Safe or XHD Mount to the cutout on the opposite side of the chute Revision J 21 18
54. sides 8 1 2 SPRING TENSIONER SETTINGS Table 2 Spring Compression Settings Blades Spring Length Turns 6800 r SE gt SE 4 J __ 90 5 762 18 100 6 S JS E A200 ee o SPE RES CT 1600 16 415 2 DUAL TENSIONERS REQUIRED ADJUSTMENT PER TENSIONER Revision J 27 18 03 2014 8 2 AIR TENSIONER The XHD 20 Ten Series Air Tensioner is a robust tensioner capable of delivering very precise blade to belt contact force whilst allowing the cleaner to respond and absorb belt or pulley irregularities The Air Tensioner can also be assembled to tension in either direction and has two mounting positions for each direction Figure 18 Air Tensioner Options Revision J 28 18 03 2014 8 2 1 AIR TENSIONER ASSEMBLY NOTE The Air Tensioner assembly is normally dispatched from the factory fully assembled and may only require the installer to slide the assembly onto the mainframe and secure the Pivot Bracket to the mount as per step 4 below Mount Bracket Pivot Bracket Travel Limiter Lug Blade Wear indicator Optional Figure 19 Air Tensioner Components Fit the cleaner and mounts as previously described checking that position and offset are correct Attach the blank end of the airbag to the Operating Arm using two only 3 8
55. sion cleaner onto the belt as previously described in the Tensioners section 6 Remove all tools or debris from belt Replace all access screens and guards Remove locks or tags and restart belt Observe cleaner action and blade effectiveness Replace CYA Door rubber cover if installed Clean up work area RE SETTING THE AIR TENSIONER This procedure is used when the Air Tensioner travel limiting lug is in contact or close to contacting the Pivot Bracket hub but substantial wear life remains in the blades Shut down and lock out the conveyor There is no need to enter the chute to perform this task but the technician will be required to release the lockscrews to the mainframe and may be exposed to a twisting hazard if the blades are impacted by a moving belt or material load Release the air pressure by closing the isolating valve in the control box Release the lockscrews securing the Operating Arm to the mainframe but do not release the blade wear indicator if fitted Caution For single tensioner cleaners the mainframe may rotate sharply keep fingers clear On dual tensioner cleaners the opposite side tensioner will hold the mainframe in place An assistant may be required for this step Using a pipe wrench or similar rotate the mainframe until the blades touch the belt and hold in that position Fully compress the air bag and secure the lockscrews in the Operating Arm onto the mainframe while the air bag is compressed
56. ti clockwise direction and has two mounting positions for each direction see figure 10 The four basic mounting positions for the mount and Spring Tensioner assembly are as follows Remember that the mounts can also be rotated to other angles Lock Screws We ae opposite side to Ka T 47 Pivot Bracket b o C CO O N B Il CI C2 C lt gt Figure 16 Spring Tensioner Options Revision J 25 18 03 2014 8 1 1 SPRING TENSIONER ASSEMBLY Mount Bracket Operating i Arm 7 Adjusting Nut Blade wear Indicator Optional Adjusting Rod Figure 17 Spring Tensioner Components 1 Fit the cleaner mounts as previously described checking that position and offset are correct 2 Determine the tensioning direction required from the figure 10 preceeding 3 Using 2 x M16 bolts supplied fit the Pivot Bracket to the mount in the determined position and orientation and tighten securely 4 Fit the Operating Arm onto the end of the cleaner mainframe with the Swivel inwards leaving the hub of the Operating Arm 1 or 2 mm clear of the mount bush Ensure that the three lockscrews are installed in the top threaded hole and the two threaded holes furthest from the Pivot Bracket 5 R
57. uickly conform to the belt profile 3 For slow moving belts the cleaner should be positioned lower on the head pulley to ensure the blades are clear of the main material flow 4 For belts greater than 1500mm wide a tensioner is required on both sides to ensure equal cleaning pressure across the cleaning face Figure 2 XHD with Orange Carp 2 Blades Revision J 8 18 03 2014 SECTION 3 PREPARATION FOR INSTALLATION 1 Check Installation Drawings Ensure that you have the correct drawings and equipment for your conveyor s Pre assemble the Cleaner s and Mounts Do this in your workshop or similar free area rather than at the Conveyor This will enable you to e verify all required equipment is present e familiarise yourself with the cleaner assembly e allow you to plan the installation reducing installation time Assemble the Necessary Tools amp Safety Equipment Required for the Installation Observe the Conveyor While Running and Conveying Material e Observe the belt splice condition e Does the belt run true or track off to one side gt ls the Head Pulley out of round Consult ESS if any UNUSUAL conditions are observed in the above These conditions may result in recommendation of a different installation position or even a different cleaner Revision J 9 18 03 2014 SECTION 4 KEYSAFE FEATURE ESS has incorporated the patented Keysafe blade removal feature in the XHD Primary Cleaner to facilitate sa
58. ust be adjusted Refer to the table 1 and figure 5 in section 6 of this manual This table will give the required offset dimension for a range of head pulley diameters Refer also to drawings at the back of this manual for parts details for Tungsten Tipped blades Note The XHD TC blade is taller than the standard urethane blades This means that at some angles it does not withdraw through the CYA or Combi Safe doors This will be overcome by ensuring that there is sufficient distance between the end of the blade track and the chute wall to allow the blade to disengage from the track for removal Revision J 13 18 03 2014 SECTION 6 INSTALLATION This section details the procedure for installing the XHD cleaner mainframe and mounts Danger Conveyor must be shut down and locked out before any installation or service work is performed Caution If installation is to be done in an enclosed area ensure that all Confined Space permits are in place and procedures followed If welding or cutting are required ensure that Hot Work permits are in place and procedures followed Protect the belt surface from weld spatter with appropriate shield Step 1 Locate the Centre line of the XHD Primary Cleaner Mainframe Using the sketches following determine the blade type supplied or to be used on this application The blade type sketch shows the vertical dimension H and the radial offset Z can be read from table 1 for the blade type and head pull
59. y lift the cleaner during installation or use appropriate lifting gear The XHD Cleaner may be inspected or the tension adjusted with the belt running as long as suitable visual access is available but the service person should never reach into or enter the conveyor enclosure No other service work is able to be carried out with the conveyor running Shut down and lock out the conveyor for any work requiring any part of the body to enter the conveyor enclosure or be exposed to moving components The following are some of the hazards that may be present when installing this equipment Hazard Hazard X Moving Conveyor ISOLATE Other Hot Work Other Working at Heights Other Heavy Lift Other Persons Working Overhead Other Persons Working Below Other Electrical amp Cabling Other Pinch Points Other Trip Hazards Once hazards have been identified the installer should undertake and document a comprehensive Job Hazard Analysis according to site requirements and good safe working practice The installer must identify all hazards and apply appropriate controls before proceeding with the installation or servicing of this equipment Revision J 6 18 03 2014 SECTION 2 INTRODUCTION The XHD 20 Ten Series Primary Cleaner is a conveyor belt primary cleaner It is a cleaner of massive and robust construction and was designed for use on conveyor belts having large head pulleys wide he
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