RBC Installation Manual
Contents
1. SHLQIM 1138 1504 11 03 2014 14 Revision SECTION 10 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 LI installation Yes No ff No WHY Was work carried out as per procedure and JSA Yes No ff 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 H 15 11 03 20142. 5 a SSIEOZ 60 Ud 2201 y NOILYOOJ GVO 553 S3M4dNS 307 35 any EE fh J1VIS NOILdO ONILYINS NI AV1 000553 DNIMOHS aqwvad SX IRR T 1 3140953731 3125 a me vlad avd 1 359084 9 334115 SHY OSXSL ka LNNOW 21402534131 coe Pos 7 7 EES 4 ave Iasvaavno IVNOILAO IVNOILdO ONILYINS NI AVT 0002553 DNILUINS 0002553 NOILIIS A 512 LHOddNS LINS OL S1109 9LW 904 S310H 818 NOILVIITdAV LINS OL 8 1IVL30 SS 030 3 335 4 osL 009 009 0021 097 006 006 009 7 amp 5135 43101 DNILSIXI 34 LYOddNS HLINJI 53 034 ISIMYIHLO 1VNOILdO IL SSJINA 1 3 1 AG 831108 ONILYINS 0002553 ETA SNOILIIYLSIY 3LIS LINS 01 ind 39 DNILSIXI LINS 01 HIDN31 avd SVD SaWVAA X41104 JYLNA SHANHOD 5 11 JAOW34 031319395 ASIMYSHLO 553130 S34LIWITIIW NI SNOISNSWIG 1Y 3125 LON Od 80004 11 03 2014 13 Revision H SECTION 9 EXPLODED PARTS LISTS i Ad 000
3. Engineering Services amp Supplies Pty Ltd Phone 1 800 074446 Visit our Web Site www esseng com au Guardaseal Belt Support System bau 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 Removed Mt isa contact details KO 21 6 12 E Updated format of manual KO 11 9 12 F Updated drawing F0251 KO 5 1 13 G Inserted updated drawing FO251 KO 11 2 14 H Updated office details KO 11 3 14 Revision H 1 11 03 2014 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS Location Address Phone amp Fax CURRUMBIN Way Phone 07 5589 2000 Ox Currumbin QLD 4223 Fac 07 9521 0347 esscur esseng com au EMERALD Pal a f RS Roberts Street Phone 07 4982 4855 Ox Emerald QLD 4720 Fax 07 4987 5118 esseme esseng com au GLADSTONE 0 Street Phone 07 4972 3759 Ox Gladstone QLD 4680 FAX OL S912 2600 essgla esseng com au KALGOORLIE U A Dusan Phone 08 9021 7991 algoorlie 10471 08 9021 7291 Kalgoorlie WA 6433 esskal esseng com au KARRATHA Phone 08 9144 0689 Fax 08 9144 0682 MACKAY 07 4952 4600 PO Box 5755 Fax 07 4952 4717 Mackay Mail Centre QLD 4741
4. essmac esseng com au MAITLAND a Court Phone 02 4932 3544 ohnson Street Maitland NSW 2320 Fax 02 4932 3611 essmai esseng com au PERTH Phone 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 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 51 99 essvic esseng com au WOLLONGONG es Avenue Phone 02 4272 4422 Ox Unanderra NSW 2526 esswol esseng com au TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA VSS TOLL FREE 1800 300 877 Revision H 11 03 2014 WARRANTY NOTE ESS WARRANTS the Guardaseal Belt Support System 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 The warranty will not extend to any liability for injuries incurred and which result from the use of the product contr
5. 2014 Revision Determine the installation position for the Support System s The System s should be installed to cover the entire skirted section of the conveyor belt Having determined the position of the first Support System place the first support frame onto the conveyor stringers in the appropriate position and align with stringers Ensure that the support frame is centred and squared to the stringers and clamp into position Repeat with other support frame Slide the telescoping supports onto the Guardaseal Bar at a distance apart the same as the support frames Slide this assembly onto the support frames until the Guardaseal Bars are under the skirting Adjust the telescoping frames so that the Guaraseal Bar sandwiches the belt firmly between the skirting and the Bar FIG 3 If not already in position install an idler set either side of the Support System ensuring that 25mm clearance will be available at both ends of the Guardaseal Bars FIG 2 Repeat the above procedure for all subsequent Systems IF YOU HAVE ANY PROBLEMS OR ARE UNCLEAR ON ANY INSTALLATION STEP CONTACT ESS ON OUR CUSTOMER SERVICE NUMBER 1800 074446 Remove danger tags and return conveyor to service following plant procedures Support Frame Telescoping Supports Guardaseal Bar Belt FIG 3 8 11 03 2014 SECTION 4 COMMISSIONING No special commissioning procedures are required for Guardaseal Support Systems Provided
6. IWVHH FYLNAD 2 SJI0H 0 M dWOJ Wasvaevnoj z Z079E0EZ0 ZILILLEZO ZBLILLEZO 2 5 TZ SW AZ SW OSX9LW MIAS 06 9 1108 X3H IW LAN 8 JOTAN 9LW LAN ZI Raed Led Bell ahd Bl al 29196120 21196120 28196120 a Z S W a Z S W SIN AIHSVAJ 82 OL QZH 9LW z L S6ZSSLEZO 2986 70 Z0 ss JTZ SW DNI dS 9LW AHSVMJ 8 SS40E GALNIOd 135 BZXZLW MINIS 8 EL 2 1 9 X MSO Z 1 1108 7 Z4HLEZLEZO JTZ SH JOTAN MS8 Z L LAN 9 Sb 22102620 JTZ SW SNOIHVA VIO aZ X 5 OL 809 706920 WI NI HLONST AYA JHL HLIM ON d NI OOS 0021 7006 009 SHIDNIT QUVONVLS 7 IWO SUVA S W D 6 WILI WI NI 039 5 HLQIM 1139 XXX ILNLILSANS SHLOIM 1138 QAVINVIS TIY SI LY d 3HL IVHL 3LVJIONI XXX G3M07 a 5 ats 131512395 ASIMYSHLO SSJINN SINLWITIIN SNOISNIWIG TIY 3705 LON 0212209 0 031 1 INIZ 2 13315 SSJINIVLS S S 5 SNILLI 7 SUJNALSVA MILVLS LINY LNVQUVL30 3814 SVUA 4 13315 SSJINIVISI SS 5 TwAINID SALON XI44NS 43101 Z SHUOSXSL LINS OL DNId JWVAJNIVWI Ob 0072 002 0002 008 009 095 004 0501 006 OSL 009 05
7. TAR SSS Ss A ACO Ea EAS heie KAS SNOISIAZA SONIMVEO SONA Ma ON ONIMVUQI SINTITWOS AaTAVO IL as NOILVNOUANI 401 031551 V INIHJONVUV NOILVTIVISNI Tvasvouyno 80004 as 11 as 25 0351 Z WV LIG SLYVd 03001dX3 ave as as aay 61474203 153 034 SV Jlvddn 2 LYOddNsS 1138 5 9 5 CIT Ald 5208905 ONY 511435 DNREINDHG SSI TWAQ dAW 141345 INOHIA ANY 01 WOKS XO LON TWHS 531805 ONY 521435 553 30 1344 SAYWA ONY TVLUGUHNQJ SI NISXI ONY OMAWHO SHL ay 9bbyZO 0081 ON 30044345 YIWOLSND 553 1 4 TIWIHILVN 192530 ALO 53 5 SJJIAH1S ONINSSNIONA IN3MD 9 094 AVD S W a XxXS80S7 00 XXXEBOST 002 X78 054 006 057 009 1 4 HLON T 2137980 SIMEWISSV 1WOddNS 1138 59 51 8 4 45 9 40 NIHM ON 43000 TWNIDINO JLOND 35V3Id SNOILVIITAAV 404 QANDISIQ SIYA JIV1d SIMVL ONIUNLIVANNYW 200438 100 03174 01 G33N THM 143HSVLVQ 431QI ONY WED4 VIVO NOILYJNddY TWIS 1738V04VND ALON SYSNYOO dY VHS ANY SHNNA TIY 3AOW3U 5000109 01001097 JZ SW 3SYg LHOdANS 2140253131 5000E097 AKALZOSA Z049SLEZO ATID S W 3d MWHN d Z 725 41101 ON
8. the Systems are installed as per the drawing and instructions then operational attention should not be required A note on safety No additional safety hazards are present with Guardaseal Support Systems other than normal conveyor belt dangers In particular Beware of moving conveyor belts Beware of pinch points Do not attempt to install maintain or disassemble any part of a conveyor belt without first isolating and tagging the conveyor drive Revision H 9 11 03 2014 SECTION 5 OPERATOR TRAINING Servicing There are no operator serviceable or adjustable functions on an ESS Guardaseal Support System No in service procedures need to be followed other than normal conveyor belt operating procedures Safety As mentioned in Section 4 no additional safety hazards exist with an ESS Guardaseal Support System other than normal conveyor belt dangers Do not attempt to perform any job on or around a moving conveyor belt isolate and tag the belt first Problems The operator during routine conveyor inspections should be alert to the following problem indicators Smoke or burning rubber smell the belt should be stopped immediately and the problem located It is far more likely to be a seized impact idler or a skirting problem but could possibly indicate an Support System fault Leakage of material from skirts at load zone this should be notified to the appropria
9. ODED PARTS DRAWING SECTION 10 FINAL CHECKLIST Revision H 4 11 03 2014 SECTION 1 SAFETY The GUARDASEAL 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 personel install and service this product Ensure that all site and statutory safety procedures are followed Revision H 5 11 03 2014 SECTION 2 INTRODUCTION The ESS Guardaseal Belt Support System consists of a telescoping steel frame fitted with low friction UHMW Polyethylene bars that are designed to be easily removed without the necessity of pulling out the support frame from the conveyor The System is fabricated to conform exactly to the troughed belt profile FIG 1 E fai A Support Frame B Telescoping Supports ji KN C Guardaseal Bar ed jos D Roller By Others e E Skirt TIN 7 ESS Guardaseal Belt Support System holds conveyor belts in a stable sag free position to allow effective sealing By minimising belt vibration and sag the Guardaseal Belt Support System reduces escaping material and risk of damage to the belt and conveyor accessories Guardaseal bars provi
10. ary 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 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 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 Guardaseal Belt Support System purchased from ESS and cannot be passed on to any other party without express permission in writing from ESS Revision H 3 11 03 2014 INDEX SECTION 1 SAFETY SECTION 2 INTRODUCTION SECTION 3 INSTALLATION SECTION 4 COMMISSIONING SECTION 5 OPERATOR TRAINING SECTION 6 ROUTINE MAINTENANCE AND SERVICE SECTION 7 TROUBLE SHOOTING SECTION 8 INSTALLATION ARRANGEMENT DRAWING SECTION 9 EXPL
11. de a low friction self lubricating surface for conveyor belts to skim over without heat builldup or undue wear on the belt surface or bars The ESS Guardaseal Belt Support System is not intended to absorb impact Revision H 6 11 03 2014 SECTION 3 INSTALLATION Installation Procedure 1 4 NOTE Determine approximate installation position for each Support System on the conveyor and place the appropriate Systems adjacent to the installation area Before commencing installation or any work around the conveyor belt ensure that the belt is isolated and tagged The ESS Guardaseal Belt Support System is intended to be installed between idler troughing assemblies Multiple Support Systems will have an idler trough assembly between each successive System Ensure that the idler assemblies are either already installed or available at the installation site If the idlers are already installed check that sufficient clearance is available between successive sets of rollers to fit a Support System Standard Systems are 1200mm long and require 25mm clearance at each end between System bar and roller FIG 2 If required the Guardaseal Bars can be easily cut to suit on site Assemble the necessary tools and safety equipment required for the job BEFORE PROCEEDING WITH INSTALLATION ENSURE THAT THE CONVEYOR BELT DRIVE IS FULLY ISOLATED AND LOCKED OUT Revision H 7 11 03
12. r or replace System Disassembly Procedure The disassembly of an ESS Guardaseal Support System is a simple process 1 Loosen the lock screws on the telescoping supports 2 Slide the assembly from the support frame 3 Loosen the lock screws on the bars 4 Slide the Bars from the supports 5 Inspect the bars for wear or damage 6 Rotate the bars if necessary or replace them 7 Repeat for the other side System Re assembly Re assemble the System in reverse order of disassembly Revision H 12 11 03 2014 SECTION 8 INSTALLATION ARRANGEMENT DRAWING 5 d 80004 Roget NG B JA LVQ dav IQMHO SNOISIN34 ON JNIMVUQ 8 211 31 05 TTH Oaivadn DNIMVUJ y 15204 JON DIQ 1994 JIDJAQ SHOd 3 403 6 TS 031 09 DNILNNOW 8 ug eae aav sine 9 W3ISAS 190ddNS 1138 S W 9 WISVQUWNJ ut ZOS OLTALA 53119905 ONY 53214835 DNI JINIDNA 553 WOYS IWAOYddY NIL LIUM 45 LNOHLIM ALUYd Y3H1O ANY 01 NMOHS 20 on T 0 6 LL as oy 318 1 HIDNIT 4 38 LON TIVHS LI QITALd 531915 ONY SIDIA 3S INIYJINIONI 553 30 41834044 JHL ONY 1 SI NDIS30 ONY D NOIL dO DNILUDIS 0002554
13. te maintenance personnel for attention at the earliest plant stoppage It may mean that skirting requires attention and or that the Support System wings require adjustment or are worn Revision H 10 11 03 2014 SECTION 6 ROUTINE MAINTENANCE AND SERVICE Safety Before attempting any maintenance on or around a conveyor belt ensure that the belt drive is isolated and tagged General The ESS Guardaseal Support System requires virtually no maintenance to operate under extreme conditions for thousands of hours However to achieve the best bar life and avoid the need for unscheduled bar change outs the following maintenance practices should be adopted Routine Maintenance The Systems should be inspected for bar wear after one month of operation and again after three months Subsequent inspection frequency can be determined after the wear rate is assessed at these initial inspections Revision H 11 11 03 2014 SECTION 7 TROUBLE SHOOTING If the routine maintenance and scheduled bar change outs are performed as per Routine Maintenance non routine maintenance should be virtually non existent However the following situations are possible Smoke or burning rubber 1 Seized idler Replace idler smell Over adjusted or damaged Replace or adjust skirting skirting rubber Material spillage under skirts 1 Skirting rubber not Adjust or replace skirting adjusted or failed Guardaseal Bars are worn Adjust or turn Bars ove
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