RBC Installation Manual
Contents
1. 53845 5374435 ONREJINDNT 552 HOS TWAD ddY WALIRA 241356 LNOHLUM ALAYA AHLU ANY 01 KMORS UO CALVINO 38 10H LI ULTALA 5319805 ONY 522102 53 40 11434054 JHL SAYWA ONY SI 40551 ONY SHL ay 009 009 0066 0006 0022 0052 0052 0012 056 00 11004 28 z 0 2021 Lou ozo 046 oze sig 0 s99 05 a oe9z oesz oeez oerz 066 060 5291 017 szer osu fooorf wia 0052 002 0022 0002 0081 009 0051 oser 0021 osor 006 HLGIM 1739 JAHGH IET 53 1804405 H106 We J WIG JANVW IVNDA 01 WIC NOILVTIVISNI NAJLLVA 1108 100102 100102 0019 S310H 8LB osl 06 804 IWYS JHL 38 01 WIQ 1 315 NO LINS 01 SONI 0300 5 101 1138 715004 DNIMVUQ 335 284 ALNA QUVONVIS 804 75 17103 ONIMVYC SLYVd 030014 3 77 71148 JHL 1991309 15 02 NI 284 JHL 4333 01 NOILVUBIA 051 72284 20 IYL ONY JSON JHL 01 34055344 QAVMNMOG 15 02 Aldd 5 4 815 1804405 FHL E ALASVS 404 1 3 442 0 34 13315 JAVH 54 15 ANVHLAYNAIOd 77 NOQILVTIVLSNI LV 01 013123 02 38 OL 134 5 l SALON HLM 1138 osl WIG 12 804 AVMY 1N NMOHS SIWV JNIVW 334 2 SHINHOD dAVHS ANY Sana TI2. SECTION 4 INSTALLATION Revision M 7 11 03 2014 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 VOIDED IF NOT INSTALLED TO SPECIFIED DIMENSIONS DIMENSIONAL NOTES AND CHECKLIST The following tolerances may be applied to installation dimensions quoted in this section gt The dimension from top of belt to centre of support pipes is 324 5 mm gt The dimension between support pipes centres is DIM 5 mm gt 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 gt Tolerance on support pipe parallelism is maximum 5 mm out of parallel for each 1000 mm of pipe length gt The centre line of plough should align with the centre line of the conveyor The maximum deviation is 5 mm either side of centre 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 requi
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 hou MARTIN ENGINEERING Installation Operations Manual 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 Final Checklist Updated Items 4 amp 5 Reversed SH 15 04 10 D Updated manual as CR2634 SH 12 08 10 E Revised drawing 0147 Rev G amp FO141 Rev F KO 14 03 11 F Revised dwg F0147 H KO 17 04 12 G Revised dwg F0147 Rev KO 04 06 12 H Revised dwg 0147 rev J removed Mt Isa contact details KO 21 06 12 Revised dwg 0147 Rev K KO 23 8 12 J Updated format of manual KO 20 2 13 K Added paragraph to page 6 KO 30 10 13 L Updated F0147 KO 6 2 14 M Updated office details KO 11 3 14 Revision M 1 11 03 2014 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS Location Address Phone amp Fax CURRUMBIN a Phone 07 5589 2000 Currumbin QLD 4223 Fac 07 9521 0347 esscur esseng com au EMERALD Roberts Street Phone 07 4982 4855 Emerald QLD 4720 Fax 07 4987 5118 esseme esseng com au GLADSTONE ai isba jla Street Phone 07 4972 3759 Gladstone QLD 4680 07 4972 2866 essgla esseng com au KALGOORLIE 2 Phone 08 9021 7991 algoorlie
4. PO Box 10471 Fax 08 9021 7291 Kalgoorlie WA 6433 esskal esseng com au KARRATHA Phone 08 9144 0689 Fax 08 9144 0682 MACKAY 2 Phone 07 4952 4600 PO Box 5755 Fax 07 4952 4717 Mackay Mail Centre QLD 4741 essmac esseng com au MAITLAND ah Court Phone 02 4932 3544 ohnson Street Maitland NSW 2320 Fax 02 4932 3611 essmai esseng com au PERTH i 9 08 9370 3155 ayswater 26 Midas Road Fax 08 9272 5130 Malaga WA 6090 essper esseng com au TOWNSVILLE Unit 6 40 42 Carmel St Phone 07 4755 2776 Garbutt QLD 4814 esstow esseng com au Fax 07 4779 6236 SOUTH AUSTRALIA 5 Cormorant Court Middleton SA 5213 esssa esseng com au Mobile 0408 948 175 VICTORIA Unit 4 314 Governor Road Phone 03 9580 0388 Aaaa 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 M 11 03 2014 WARRANTY NOTE ESS WARRANTS the Heavy Duty Return Belt Cleaner HDRBC 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 als
5. 8 59 1100019129 2 815 ONINOISNIL 288 OH 00 002 0012 0561 0041 oost 7 Lo ee 59 055 515547229 adla ANUAS Dea ATES 100 0 0082 0052 0092 0022 0002 0081 009 005 oset 0021 0501 006 5 07005060 288 ALNG H 504017829 S S 31V1d YIHSYM 29 ALNG H 510017679 SW ASSY 058 01 0 2 284 O H SHZ SZ9E0EZO SLX9LW 1108 2894670 JOTAN 9 LON 5 2 9196 20 SIN AIHSVA SEZSSIEZO 55 0 GILNIOd 135 8ZXZIW M3HIS SU9SLEZO INIDd dN SS70E 135 82 91 3825 ZO99SIEZO 92 OSX9LW 3825 5090670 5570 0SX9IW 1108 249670 00 8E 5 1 dZ O H SIW YJHSYM 585704600 5570 8 5 83 5 1502181961820 51021919120 052705920 5 2 0 9 0 20 SY3NYOD dAVHS SYYNB TIV 3AOW34 31310395 3SIMH3HLO SSJINN S3YLIWIMIN NI SNOISN3WIC TIW X340 30 18 325344 HIDNAT 3919 5310 30 18 ON 1 30 18 1138 Twos LON 00 3350 dW3L 32 18 YO W SVAJ NM088 01121484 MOT 3118 NOISVUBV 5 4 3 8 1 14 242 13315 5531 15 55 10d 3115831 HDH QISINVATWD Hn nnn oe 16 M ision Revi SECTION 10 FINAL CHECKLIST Site Number Date Site Equipment No Location Site Contact Completed By Circle Yes or
6. 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 Impress how important it is to maintain and service the cleaners correctly Revision M 13 11 03 2014 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 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 M Shut down and lock out the conveyor Visua
7. No Below Was equipment to ESS Specification Yes No Drawing No Ref Attached Yes No ff No WHY Will this affect performance Yes No If Yes WHY Was this a standard O service LI inspection LI installation Yes No If WHY Was work carried out as per procedure and JSA Yes No No WHY Is equipment fit for commissioning Yes No ff No WHY Was a final inspection carried out while plant was running Yes No ff No WHY Has anything changed from previous service inspection installation Yes No ff Yes WHAT Is equipment performance to Client expectations Yes No ff No WHY ESS Signature Client Signature Revision M 17 11 03 2014
8. Y 3AOWJ Y 0313129395 SSJINN 5 1 SNOISNAWIG TIY A1VOS LON Od 134 5 A WO 11 03 2014 15 Revision M 6 i 900 AL 0 L f 5 04 L16 9 81 31va ee ee TON DNIMVUC 51 41 25 01300 007 2 0005 0082 8 DNIMYYO NOILVTIVISNI 29 0 518 030019 3 NOILVTIVASNI 284 8720921 3 1 09 83 02 30 18 518 4 030014 3 284 22 4 GOW H197 30 18 0501 006 it 4 LL 99 05 JBUGH 12 1738 ALNA Las avon 4 LTAL 5314805 OWY 5014025 ONREJMONI 557 WOKS WAQQA 282345 INDHIA 1610 ANY OL NAOHS 340 as 6578203 did SV 31 7 28 LON TIVES LI 7017414 5318905 ONY 53 DNIJAMONI 553 40 11434054 HA SNIVHIY ONY WILNAOHNOJ SI NOISIO ONY INAVEO SHL 9 0 0081 ON 3214435 2222222 0 2 553 53119905 29 5321 435 ae Bo Ni HLGIM 1738 HLIM 310115805 SHLQIM 1138 08 0 15 11 318 Si 18 4 3HL LVHL JIVDIONI XXX 48 0 SON Ld 11 03 2014 SECTION 9 EXPLODED PARTS DRAWING ON LV d 0114442530 ALD WALI 019101000779 30 18 JSON 13 0 5 28 ALNG H a oesi 5291 ocn szer osu 0004 ulvd Z 1 E79 30778 284 ALNG H 8 59 8 59
9. contact ESS on 1800 074446 within Australia or 61 7 5589 2000 from outside Australia for further advice 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 Secure the system for production Follow plant procedure to secure the conveyor for actual production 42 11 03 2014 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 2 Adhere to all local safety rules Give a Hands instruction with the conveyor system shut down Give a Hands instruction with the conveyor system running All service must be recorded and given to a person of responsibility 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
10. e 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 M 10 11 03 2014 CORRECT INSTALLATION PIPES PARALLEL TO EACH OTHER AND AT 90 TO BELT BELT DIRECTION 2 lt I lt 2 w LU L LU I KI lt L LU o 0 LU 0 01 lt lt a Va Li aA H LLI o oO lt kem 2 D INCORRECT INSTALLATION PIPES NOT PARALLEL TO EACH OTHER AND NOT AT 90 TO BELT Figure 5 11 03 2014 Revision M SECTION 5 COMMISSIONING Step 1 Step 2 Step 3 Revision M Start the belt Observe the action of the HDRBC The HDRBC should ride smoothly the belt with no chatter or vibration If vibration is present repeat the tensioning procedure in Step 10 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
11. lly 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 conveyor to service 14 11 03 2014 SECTION 8 INSTALLATION ARRANGEMENT DRAWING 17109 16 6 SNOISIASRY ON 51 41 25 MIHLL 031 04 1511 1138 INAWJONVEEMV NOLLVTIVISNI YANVITO 139 NUNLIU 284 ALNG
12. o 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 6 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 6 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 regarding the service Refer to the Final Checklist at the back of this manual Visit the ESS website 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 Heavy Duty Return Belt Cleaner HDRBC purchased from ESS and cannot be passed on to any other party without express permission in
13. on 4 and good access for installation and maintenance Suitable support structure for attachment of the HDRBC mounts is also required 2 OBSERVE BELT CONDITIONS gt 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 gt Is the belt flat and taut or does it sag or cup gt Does the belt bounce or vibrate gt 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 gt If a flat stable belt cannot be achieved contact ESS before proceeding with the installation 3 TRIAL ASSEMBLE HDRBC 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 rf i a Ri 4 a OF BELT OF BELT H MOUNT TURNED o 5 J g OF BELT 324 TOP OF BELT TYPICAL MOUNT STRINGER ARRANGEMENTS Figure 2 Typical Installation dimensions HD RBC 4 ASSEMBLE THE NECESSARY TOOLS AND SAFETY EQUIPMENT REQUIRED FOR THE JOB
14. ong 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 HDRBG 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 TYPICAL HDRBC LOCATIONS OO NOT USE ON REVERSING BELTS Figure 1 Typical installation positions and use of HD RBC Location of the Return Belt Cleaner should be carefully considered so that the material removed from the belt does not create a hazard as it falls or where it accumulates Also the consideration should be given to having the ability to observe the cleaner during operation The cleaner should be installed so that it is positioned between return rollers and not on top of a return roller Revision M 6 11 03 2014 SECTION 3 PREPARATION FOR INSTALLATION 1 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 Secti
15. pes 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 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 0141 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 th
16. red 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 Vv V 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 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 M 8 11 03 2014 4 4 Installation Procedure Step 1 Place the HDRBC without support pipes or tensioning 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 fig 3 Step 2 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 ma
17. writing from ESS Revision M 3 11 03 2014 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 Revision M SAFETY INTRODUCTION PREPARATION FOR INSTALLATION INSTALLATION COMMISSIONING OPERATOR TRAINING ROUTINE MAINTENANCE AND SERVICE INSTALLATION ARRANGEMENT DRAWING EXPLODED PARTS DRAWING FINAL CHECKLIST 4 11 03 2014 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 belt 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 Revision M 5 11 03 2014 SECTION 2 INTRODUCTION The ESS HEAVY DUTY RETURN BELT CLEANER HDRBC 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 l
18. y 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 0 0 FRON REAR PIPE jA HI A PIPE HEIGH TOP OF 457 R _ HEIGHT 124 150 PIPE SUPPORT 18 HOLES MOUNT HOLE B 100 CUTOUT DETAILS a Figure 3 Relationship to Belt Position Step 4 Measure back from the above point a distance equal to dimension C from above table 1 and parallel to the belt i e 324mm from belt surface This point represents the centre line of the rear support pipe and mounts ENSURE HDRBC IS INSTALLED e ee PARALLEL TO BELT SURFACE Figure 4 Installation Dimensions Revision M 9 11 03 2014 Table 1 Dimension Belt Width 900 1050 1200 1350 1500 1600 1800 2000 2200 2400 2500 Dim C Pipe Centres 277 352 427 502 577 627 727 827 927 1027 1077 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 pi
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