RBC Installation Manual
Contents
1. 03119915 19 NYJ X08 10N1NO2 TWNOILdO 13537 34155184 JYNSNI ANY 3015 401V41dO 3015 4V4 1 04 JNO WOU NOILVIJNI MOTIV HIDN31 WIVUL 01 SDVENIV 3Hl 5 JWVUI 3dld 115440 JHL 015584 3801 33 1 8 33018 51138 0091 035 8313AVIG 1138 SH3NOISN3L NIV 3H3HM l 31104 QV3H S310N 19 31 SMJNMOO 5 SHUNA TIY 3AOW3H 31419395 ISIMHIHLO 5531 S3HIATITI NI SNOISNAWId 31W9S LON 00 03 11 2014 28 Revision L ETA UB mg 21204 Qw MSLSNO 11 064 OSOA fori a z 9 SilVM 313084 30V I8 3 Land Gale OEE BO ld 229110 CO 1101 BBGC 0 MSN SIJJAHAS 9 YD SNOISN3HIU 100 135 53215 131104 OVIH NO DNION3d30 AUVA UNY SLNIWI INI UY TINY NO 03579 3uv SALVA UVJA 38 1 31834 SN liv2OllddV LAMI Ada 3ZIS TV2idAL V 51 57 A3TInd 1510 DL 031414 NMOHS SI 0 19 UDIIVUL 1870 SALON 9 05 30V1A Sawing Tv Ss 9 9500 30V1A 952 1 N a 1 M2. 2 5 1330v88 440 UNVIS 53108 9 0022 0572 0522 0002 008 059 0571 052 oo 006 061 009 057 H1DN310DV 1 0072 0022 0002 008 0091 005 052 002 050 006 054 009 057 101 1738 U3Sfl LON SI 8000 VAI V 5 55 d3AONddY LINIWLUVAIQ 3U3HM S31fHJ 0350 TINI S3NIM ONY 38NLVA3AWAL 803 visa INOIND 53015 NO SUINOISNAL 8 5310 7 9 51138 LN3W3AON IVIXV LN3A3Nd 01 1102 3001 31445 V Q31dn02 SI LNNOW 3015 3QIA 005 01 dN 51139 804 530 18 3NvHL3Un 3HVHJNIVH 1592 32314 JNO JHL 804 SI YINIHILS 304 8 07 50 3 2140253131 008 1138 304 20 is Jdid SNOS IWVAJNIVH 1 MIVUL 3N314H13A10d ONY NOILJ3dSNI ASY3 404 Cows MOTIV SS322V ONY N0I123S GUNNA 78 iL 440 0 15 553 TVNOILdO 4 S W 98 T a 133 INNOW XJOHS 40 9 312 SI YINYIN B JHL NOISN3WIQ 135430 TWidva IHL NIVINIVW TAJTNA AYAH M ET E JHL 40 5 IVINOZIHOH JHL M07139 ss 51 8 0 N334138 dil SLI 3 51 YINYIN N332Vul Land 3HL 40 NOILVTIVISNI WAWILAD 3Hl 1 2 SALON IVNOI L dO 4000 216 2 100112
3. 4 102 201 UV37 WON 512 310N 3434 3201 30v18 30 5 01 4340 3015 135440 oa HiGIM 1138 U3L3WVIQ 1104 SN3NHOO JUVHS SYYNG TV 3AOW3M 031310395 3SIMM3HIO 5531 SIHLIWITIIW NI SNOISN3WIQ 3105 LON OG H19N31 3WV24 86704 03 11 2014 26 Revision L 6603 su avo _ Snolsinzu SONIA SONIA ev Suma JON SIN TIVOS as 031551 514 4 030014 3 56004 IN3N39NVHSV NOLIVTIVISNI YINOISNSL ISIMI 030014 3 Sadvia 2 M3NOISN3L ISIML M3NV31O AMVWRid JIMOVALL LYNG 53184 5 NY 573455 551 140355 MOHLA ALIA ELO ANY OL 00 134 LON 17415 111314 9374905 ONY 538135 553 30 51439089 IHL TVILGOHNO SI 0531 OHY SHL 999920 0081 3OIAM3S JIWOLSND 54114405 29 S3OIAH3S NO MJA NOISN3HIC s 51708 9LW 404 WADNRILS YO 310H20V3H 5 1 3 34 115 81 5310 0096 0066 0016 0062 0012 0092 0572 0052 008 099 005 OSEL H159N31 3WVd4 8217 916 728 2191 02 50895 BIEL 912 790 216 094 70 43A02 30 1 80 TVNOILdO S we 15 530 187
4. ISMMIHLA SALININ NI SNDISN3MIO TIY ASL NYOM 30 18 01 H4OlUd NOILISOd DNILNADW IVNIDIHO NI NADHS 30978 Twas on 03 11 2014 29 Revision L 1 AH 5904 BART SET T ON SIN 9105 05 AH ING SONVEJV TIVISNI TEMONVW 3 5000 VAD H3NOISN3L HLM 1310 DE 03007 310N 3000 8LzLVA2 8 SONIMVAQ 39N383434 DNIMVHQ 4000 ONINOISN3L 5 M J 4 UIMVAL 1300 89 04 TIHONVW 404 8000 8 21 2 7704 LT ALd SDAI 553 TWAQ dAW 38810 ANY 01 NMDHS 80 0340 12 21 24 224112 a IN 1 51146 QW SHRENENG 553 40 ALISON SION UNE SI ISA ONY SHL 999910 0081 ON 35 HIWOLSNI 53 9 5301 35 009z 072 0062 0081 059 005 oser 0021 AWVAH X340 80 108 ose 002 oso 00 07 HLOIM 1138 318VlIVAV SIMBWASSV INIWLUVAJQ SININ ONY 3unlvsidW3l 014 IVINILVW 40 49310 SI YINYIN 394 5 3 NOISN3WIO 135440 1 JHL NIVINIVW A3TInd QV3H 3Hl 40 b IWINOZIMOH 3Hl M0738 Sl 8 0 N33 138 dil 51 5
5. LON 00 3015 Le 5307 18 1592 32318 ANNOW X314 E 310N 33S Y17110 3201 WON 76603 03 11 2014 32 Revision L SECTION 11 EXPLODED PARTS DRAWINGS 5004 a ET excise SIN 31VOS 55 05 eiei 0300 1511 5199 9 d3001dX3 SH3NOISN3L SINNOW 05 660209 03004 SNAL dS A3N ET 13315 SSJINIVLS 73315 OIW 2 pers py or caen p sare Il UJNV3O N3 2VSI LANG d rn Edge pepe tr BO ka 38 10N 11185 LI OLTALd 6214405 ONV 5708925 ONRAJJNIDNA 593 40 11434084 5 ONY 160480 SI NDIS3O ONY OWED SHL 999920 0081 35 53114405 7 530 35 9530 ux H10IM 1138 X ASSY MSJIMJSIXXXO9LSL 05 0 02 u2 HiCIM 1138 X dW31 H ASSY 3 IWV JNIVW illh HE paa d NE Nut XOVMI 109 15 3402 53 77 10 18 z duv 09560800 1438 ONY NOLLJ3dSNI 30818 10 18 30lguv NILSONAL 06609 011 35 404 5 3 015 31 N3HIO 04 8 9 9 YO SAJNOISNIL ISIML 804 8 2 1 SWALI 51342888 4JO GNVIS ONY 54000
6. PRESSURE GAUGE TUBE PASSES THROUGH MAINFRAME SELF RELIEVING PRESSURE 4 REGULATOR FILTER OPTIONAL LOCKABLE ENCLOSURE B riw OPTIONAL SECOND AIRBAG FOR WIDER BELTS PLANT AIR ISOLATION bal I gt pene AT TENSIONER ALL FITTINGS 1 4 BSP OR NPT Revision L 20 03 11 2014 Step 9 Once all fittings are connected and secured the Air Tensioner may be pressurised Pressures are indicated in the following table NOTE Use these inflation pressures as a rough guide only Belt speed material number of cleaners on belt and acceptable blade wear should be taken into account when setting pressures DO NOT EXCEED 275 kPa 40 psi IF YOU HAVE NEED OF ASSISTANCE CONTACT YOUR LOCAL ESS OFFICE BELT PRESSURES o 0 1050 Dual tensioners fitted pressure per tensioner given Generally connected by balance tube O O1 C1 1 Revision L 21 03 11 2014 SECTION 6 COMMISSIONING Step 1 Step 6 Revision L BACK THE CLEANERS AWAY FROM THE BELT Double check the items in previous sections safety preparation installation 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 clog up the conveyor systems PLACE CONVEYED PRODUCT ON THE BELT Place s
7. SH3N3ISVJ M 2 3201 NILOZ 3N INI 555000507 T en sou SUINOISN31 1HDI3MW3LNDOD NOLLINAFNO2 NI IHOMNSINDOD HUM 006 SONJ 0 40253131 91012161 5306 NO SA IBWASSW BANOISNAL 340038 5 M J 8 55 INNOW 20 190001060 5 3 2 98 330 0 15 ABVWlid 150600 060 9 03811038 LNNOW 20HS ON 753109 m 13 vu8 340 0 15 Vl 5831 LSIML 55001060 2 006 SZZ ASSY X000 553229 1532460 0 8 5 3825 135 M 2 8 07 102 3201 is 001060 6 55706 031 0 135 8BZXZIW 3825 562551 20 01 1138 31115805 SHLOIM 1138 QUVONVIS 11 NI 318 SI 18Vd IHL LVHl XXX 18 8 4 13315 8 13315 SSJINIVIS MS 4104 13315 SSJINIVIS 5 dW3L 13315 5531 15 05 dw UW 0 HUM 03114405 St 1490104520 oN d gt INTAY 30 53813 5 3av39 WNIQIW 5784 dil N3ISDNDI 39NVNO 318n00 dil 9 2 N31SONnL P N3349 30185 2 N31S9Nnl 5 SXW 0 99 QUVH H3SIWIXVW 30V89 WNIQAW S3SIWIX VH 30V39 412 ISIWIXVW 30V4D WNIQAW SVA4 3 v45 QUVH SVAJ 30v30 911 5 3 N3349 3018 4 8 4 13315 5531 15 s SN31 M1 804 lIVAV LON
8. 1592 32319 5305 H108 NO 301 50 131104 QV3H 7 SM3NOISN3l 381034 UIGIM 009 51138 INAW3AOH TWIXW LN3A3Bd 01 NVTID 3001 314145 Y 011400 SI INNOW X314 AORN 3015 004 01 51138 N04 S31nHdv3H 03501383 NO 1N3A432Vd3B 30 18 ONY NOLLJ3dSNI ASV3 804 MOTIV 4000 55302V 1694 15 30 18 130VN8 340 QNVIS 553 1 140 WINALVW 40 SI H3NY3T IHL 5 NOISNAWIQ 135440 1VIOVi NIV INIVW A3TMid OVIH IHL 40 3 IVINOZIHOH M0138 SL 8 0 N334138 41 SL SI YINYIN E 310N 335 uixjvul LYNG 40 NOILYTIVLSNI WNWILdO 3HL 1 3v T1102 8201 SALON INNOW X114 312 WON 0350 LON SI 8000 VA V NY 54101 3 3S0 DN3 1130 1n0102 310H2 310H 089 BL S310H 7 L 3015 01 340 3N31AHL3AT0d 030041 3 3015 4 H15N31 MIVUL 3201 3 18 ll o HLGIM 1138 H1DN31 3WVU4 SM3NHOO dAVHS 588 8 TV JAOW3H 03412345 5 SSJINN S3SIJAITIIA NI 34V SNOISNAWIG TIY IS LON OQ Revision L Ady NOILVTIVISNI S30V19 HINOISNAL INNOW X314 2 HINVII 4 9 LYNd 76504 60 1141 31VG 2 444 95 09 2 9NIMVHO SIN 3TVOS OS AH NMWAQ 9
9. If Yes WHY Was this a standard O service LI 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 Signature Revision L 34 03 11 2014
10. stand off bracket and tack weld clamp or bolt the stand off bracket in the desired position Position the orange extrusion so that it is centred on the belt Once centred lightly tighten lock screws on the bottom of the track This will hold the telescoping pipes in place This procedure will need to be repeated at the final step Note Slide the CYA door frame loosely on to the pipe end before the mount to save later mount removal Revision L 9 03 11 2014 Step 5 Check the position of the mainframe Is the centre line of the mainframe positioned 100mm from the belt face Is mainframe level or equal to the pulley shaft Is there at least 152mm clear at one end of the track to remove and replace blades Ensure the far side blade lock is fitted The lock must be sufficiently secure to hold the blades in place Lay the pull strap in the track with the smaller looped end toward the far side blade lock Slide blades on top of pull strap and into track Place operator side blade lock in track and secure to finish blade installation By hand rotate the pipe until the blade tips lightly contact the belt Do the blade tips all touch the belt at the same time Note Slight inconsistencies in 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
11. any other party without express permission in writing from ESS Revision L 3 03 11 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 Revision L SAFETY INTRODUCTION PREPARATION FOR INSTALLATION INSTALLATION OPERATION OF TENSIONERS COMMISSIONING OPERATOR TRAINING ROUTINE MAINTENANCE AND SERVICE TROUBLE SHOOTING INSTALLATION ARRANGEMENT DRAWING EXPLODED PARTS DRAWING FINAL CHECKLIST 4 03 11 2014 SECTION 1 SAFETY The DURT TRACKER 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 L 5 03 11 2014 SECTION 2 INTRODUCTION The Durt Tracker Doctor Blade is a conveyor belt Primary Cleaner It is normally mounted on the face of the conveyor head pulley and is designed to peel off the thick layer of loosely adhering material that often accounts for 8596 9596 of carryback The Durt Tracker Doctor Blade is normally used in conjunction with at least one secondary cleaner suc
12. secure the conveyor for actual production 22 03 11 2014 SECTION 7 OPERATOR TRAINING The decision to purchase ESS cleaning equipment has put within easy reach the reality of a clean plant The last step is the correct training of personnel to maintain and service the equipment or employ ESS on a contract basis to maintain the cleaners so that they remain at optimum efficiency The benefits of efficient cleaners outweigh the cost of maintaining the cleaners many times If you wish to have your cleaning system maintained on a regular contract basis contact ESS f not train your own personnel as follows 1 Adhere to all local safety rules 2 Give a Hands On instruction with the conveyor system shut down 3 Give a Hands instruction with the conveyor system running 4 All service must be recorded and given to a person of responsibility 5 Encourage the person being trained to look for possible problems developing on the system eg belt tracking excessively tears or damage to belt seized idlers missing bolts etc A warning to the maintenance department to rectify small problems can save the company a lot of money in repairs and production costs 6 Impress how important it is to maintain and service the cleaners correctly Revision L 23 03 11 2014 SECTION 8 ROUTINE MAINTENANCE AND SERVICE Regular inspection and servicing is the key to effective conveyor belt cleaning t is recommended that the cleaner
13. tensioner bracket to the Shock Mount using the 4 countersunk head screws Step 2 Attach the airbag bracket to the air tensioner bracket Step 3 Bolt the blank end of the airbag to the operating arm Step 4 Slide the operating arm onto the mainframe with the airbag towards the airbag bracket side of the mount Step 5 Attach the open end of the airbag this end has 3 tapped holes to the airbag bracket Step 6 No air supply fittings should be connected at this point Using a pipe wrench or similar 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 using the locking screws Allow 1 2mm clearance between the operating arm and the Shock Mount to enable free rotation whilst minimising lateral movement Step 7 For cleaners on belts 1600mm or wider repeat the above for the far side For belts 1500mm and less simply fit the lock collar onto the far side of the cleaner again allowing 1 2mm lateral clearance Step 8 The cleaner is now ready for attachment of the air supply system Connect all air fittings using a good quality liquid compound or Seal thread tape System 1 NO PLANT AIR AVAILABLE TUBE PASSES THROUGH MAINFRAME m m PRESSURE GAUGE AIRBAG FOR TANK WIDER BELTS ALL FITTINGS 1 4 BSP OR AIRBAG AT TENSIONER System 2 PLANT AIR AVAILABLE
14. the spring yet Revision L 14 03 11 2014 Step 6 Using a pipe wrench or similar rotate the cleaner until the blade tips are lightly touching the belt With the operating arm fully retracted against the spring lock the operating arm onto the cleaner mainframe by tightening the two lock screws Ensure that the operating arm hub is 1 2mm clear of the mount to allow free rotation without excessive lateral movement of the mainframe Step 7 Whilst still supporting the cleaner with the pipe wrench adjust the nut not locknut against the spring until the spring just begins to compress Release the pipe wrench Step 8 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 Revision L 15 03 11 2014 5 1 2 Installation on Flex Mount Primary Flex Mount with M16 Bolts Qu Es Operating Arm Figure 3 Step 1 Fit the anchor plate to the mount using two of the existing mount bolts There are M16 bolt holes provided for the Primary Flex Mount and M12 bolt holes for the Secondary Flex Mount Ensure that the plate is in the correct orientation for the desired tensioning direction The anchor plate can be installed on the opposite side mount holes for tensioning in the opposite direction The anchor plate and tensioner assembly
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16. 0 95 2 5 600 92 3 75 750 92 3 75 900 89 5 1050 89 5 1200 86 6 25 1350 83 7 5 1500 92 3 75 1600 89 5 1800 89 5 2000 86 6 25 2200 86 6 25 2400 86 6 25 Note Cleaners for belts 1500 and wider have dual tensioners The settings shown are for each tensioner Revision L 03 11 2014 5 2 AIR TENSIONER INTRODUCTION The 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 be assembled to tension in either direction and can be rotated to several positions through 360 to overcome site restrictions Ensure that the tensioner is assembled to operate in the desired direction before mounting onto the mainframe Clockwise Tensioning Anti clockwise Tensioning ASSEMBLY STEPS The Air Tensioner assembly is normally despatched from the factory fully assembled and may only require the installer to slide the assembly onto the mainframe as step 4 and secure the Air Tensioner bracket to the Shock Mount using the 4 countersunk head screws as step 1 Disassembly will only be required if the tensioner is set up to tension in the wrong direction AIR TENSIONER BRACKET END STOP 0 AIR SUPPLY FITTINGS BAG BRACKET boom BAG b OPERATING ARM lt Q 9 Revision L 19 03 11 2014 Fit the air
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18. 21 7291 Kalgoorlie WA 6433 esskal esseng com au KARRATHA 336 Wickerson Way Phone 08 9144 0689 Bulgarra Karratha WA 6714 Fax 08 9144 0682 esskar esseng com au MACKAY jis jaq pi Phone 07 4952 4600 aget 5755 Fax 07 4952 4717 Mackay Mail Centre QLD 4741 essmac esseng com au MAITLAND 5 Court Phone 02 4932 3544 ohnson Street Maitland NSW 2320 Fax 02 4932 3611 essmai gesseng com au PERTH l 9 owen 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 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 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 L 03 11 2014 WARRANTY NOTE ESS WARRANTS the Durt Tracker Doctor Blade 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 pro
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20. 99920 0081 3210035 53 5 29 S3OIMH3S 13811014 NDISN3HIO W30NIIS 31nHJ0Y3H 5 1 uva 11 as 0066 oore oosz 0012 0092 0592 0062 008 059 0051 oses 0000 HIONJI 3v 96 7281 219 0251896 896 9121 790 216 091 809 957 AB 5904 00 _ nn 05 05 031551 v L e 2 006 5 v S3QV 1H ON 009 057 H15N31 AYAL EM 0542 09522 0002 00 Z 0022 0002 0081 057 0521 001 006 051 0051 OSEL 002 050 006 051 009 057 HLOIM 1138 03114405 38 NYJ 10ULNO IVNOILAO Z 38155184 34015 3 ONY LNIOd NOLLV INI MOTIV 01 SDV8uIV SNIO 3Wv34 Jdid 3Hl 1 0355 deni JINVIVS HIQIM ONY 51738 0051 Q3sn SWINDISNIL NIV ON 80f SONIMVYMO 30N343434 ONIN avo 553 pe NOLLV2OT 1N3NO 03451 10 SI 4000 VAD V 31nH2 3S0 DN3 404 TIVLAQ 100113 310H 089 8 28 5310 7 V NO IVNOILdO 1392 98 340 0 15 51108 9LW 04 810 S310H e 4 SALON OVEUIV 13315 SSJINIVIS 40 ONY WNINIWN TY NI
21. EGG ENGINEERING SERVICES amp SUPPLIES PTY LTD Ph 1800 074 446 www esseng com au Durt Tracker Doctor Blade Primary Cleaner Installation Operations Manual Revision Description of Change Changed By Date A Added Final Checklist AS 28 5 07 B General Review and Update Added Warranty Registration TT AS 02 11 07 C Updated Melbourne Address amp Removed SA Address SH 3 08 09 D Drawings updated CW 02 10 09 E Final Checklist Updated Items 4 8 5 Reversed SH 15 04 10 F Tensioner information Updated KOR 25 5 11 Updated Drawings KOR 17 04 12 H Removed Mts contact details KO 12 6 12 Updated format of manual KO 5 2 13 J Updated office details KO 10 3 14 K Updated ESS amp Martin Logo amp Karratha contact details KO 4 6 14 L Updated drawing F0035 amp inserted F0495 KO 3 11 14 Revision L 1 03 11 2014 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS Location Address Phone amp Fax 5 2 iE s Way Phone 07 5589 2000 OX Currumbin QLD 4223 Fac 07 3921 0947 esscur esseng com au EMERALD Ent 2 Roberts Street Phone 07 4982 4855 OX Emerald QLD 4720 Fax 07 4987 5118 esseme esseng com au GLADSTONE iig Street Phone 07 4972 3759 OX Gladstone QLD 4680 07 4972 2866 essgla esseng com au KALGOORLIE KG A M NET Phone 08 9021 7991 algoorlie PO Box 10471 Fax 08 90
22. NOISNAL 9 5 INNOW X3 M 2 i E YANVIIO JIMOVAL LYNG id 511945 ONY 53335 ONREJNDNI 551 TVAU ddY WALIRA THOS ALAYA 5810 ANY OL MADNS 80 1340 38 LON TIVHS 01144 510845 MY 5214035 OMHEENDNI 553 30 11434084 SHIRE ONY SI ONY MAYAI SHL OD at 989920 0081 5 1502 ava ssa 51 5 S4DIAH4S sisti NOISN3HIC H1DN31 TVNOILdO 5 NO 5 1 3 344115 NO ind ind ne 0096 0088 0016 0062 0012 009 0572 0052 0081 059 005 OSEL 002 HIDON31 IJWVA4 8212 9161 728 2191 02510891 8961 912 5901 216 091 809 955 Yoe u3A02 80 6 9 5 7 S30V 187ON 001210872 0822 0002 008 099 057 0521 006 05 009 057 H15N31 2VHL 0072 00 0002 0081 009 00SL OSEL OO L OSOL 006 0S7 009 057 1138 lt gt 13315 SSJINIVIS 31 2148 3 ONY a WNINIANTY CIGNYLXI JTAVMWAW 0519 SjDVML 79 d VNOILdO STAVIIVAY SIAWISSY 03408449 5 3000 216 32 LNAWLUVJJQ SINIW 5 135440 Iova 3AVSJNIVH 3Hl 304 03811013 o onf sn S3qv18 INVHLIW 51 5 008 51738 803
23. OW3H 031312345 ISIMHIHLO SSJINN SIHLIWITIIN NI 34V SNOISN3MIQ TIY 31IV2S LON OQ IVNOILdO X000 216443 100102 VAI 556 576 03 11 2014 27 Revision L 5204 71004 677 11 31VQ L E ib SIN TTWOS NAVHO3H NOLIVTIVISNI aalvadn 1511 1138 15 31 ONY INNOW 20HS ONIJdAS 1 LYNG 511945 NY STATS 553 K3LIRIA 1 155 SEO ANY OL NAOS 80 Q imi iin el mme o m IN 30 TIVHS OLTALd 53189415 ONY 5214135 553 30 513084 381 SMYRCE ONY SI 80531 ONY 1 SHL 9 0091 ON JJIAHIS JIWOLSNI 2 093 553 53114405 P SJJIAYIS ONRIJ3NION3 nang EE NOISN3HIG 4 19 11 0350 38 HOLVINDIU ovauly 40 N3ONBILS YO ALNHJOWAH 5 1 33N34411S 319 115 v NAHL LNVId NOISN31X3 HIQVHHIS 1N3A3Bd 01 0056 0066 0015 0062 0092 0572 0052 008 059 005 OSEL 0021 10 31 3NV H 30NVD 18155184 ONIGNTINI 4015 TWIINVHIAW 10511896 9901 246 091 809 957 voe 1 4 9
24. Sv33 8v3 13115 SSJINIV LS 13315 SSJINIV LS s ISN31 M1 403 TIVAW LON 5 4 8 3 13315 018 4 13315 OW 3I31dH0 SU3NV3D Tena Qqaivid ONZ 2 DILVLS IINV INVOUV LIU 38i 593 13315 5531 15 58 m 5 nn 40 9 5 559 1 00 73315 5531 15 38In034 NOISN3AIO s M39NhHIS MO BAR 1 oosc ooee ooie ooez 00 2 _ 0092 0572 0022 008 069 005 062 1 0021 ONT JAW 1712 696 1 2281 989 1 186 rect 620 2101 666 622 129 697 16 3077 att 092 706 43A02 30718 80 05 0S4 821219 6 928 12 91 025 8961 89611912 19901 216 0 ti e 111 oe f 618 9 c SXwiB ON SION XHINS 0022 0672 0622 0002 0081 91 052 0011 00 EJ 152 0072 002 2 0002 0081 009 0061 05 1 0021 0601 006 009 1738 SM3NNOO dHVHS SYYNA Tiv 3AOW3M 031310395 ISIMHIHLO 5531 S3HI3AITIIW NI SNOISN3AIGQ 17 31405 10N OQ SE003 03 11 2014 33 L ision Rev SECTION 12 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
25. be 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 ROUTINE INSPECTION TENSION Step 1 Inspect the condition of the cleaner Open the inspection door if fitted and observe the condition and action of the blades and cleaner Step 2 If necessary and if plant rules allow it hose any material build up from the blades or mainframe DO NOT REACH INTO THE CHUTE WHILST CONVEYOR IS RUNNING Step 3 If necessary re tension the cleaner refer to Section 5 IF BLADE SERVICING IS REQUIRED Step 1 Shut down and lock out the conveyor Step 2 Release the tension and back the blades away from the belt Sharply rap the blades against the belt to dislodge any build up Visually inspect the blades If blades are clean and not excessively worn re tension the cleaner If material build up is still present or blades are excessively worn proceed Step 3 Remove the operator side blade lock and slide the blade assemblies from the track Note blades may require a slight rap with a hammer to loosen before sliding Step 4 Clean and inspect the blades if blades are worn past the wear line on the back of the blade replace with new or refurbished blades Step 5 Re install blades into mainframe track followed by blade lock Re tension the cleaner as previously descri
26. bed Step 6 Remove locks or tags and restart belt Observe cleaner action and blade effectiveness Replace CYA door cover if fitted Clean up work area Revision L 24 03 11 2014 SECTION 9 TROUBLE SHOOTING PROBLEM Blades fold through on start up CAUSE SOLUTION Incorrect angle of attack Relocate mounts so that the shaft is 100mm radial installation dimensions from the belt face on the head pulle Excessive tension Relax blade tension to maximum tension recommended in installation instructions Belt running dry Always place material on the belt for start up or a little water if material is unavailable Poor belt condition Repair belt dress spices to smooth contour PROBLEM Mainframe bent CAUSE SOLUTION Mainframe undersized Stiffened mainframe required Contact ESS for assistance Excessive tension Relax blade tension to maximum tension recommended in installation instructions Blades folded through mainframe and belt week A small amount of deflection is considered normal Contact ESS if excessive deflection occurs PROBLEM Higher blade wear rate than estimated CAUSE SOLUTION Cleaner over tensioned Tension cleaner enough to clean the belt only Incorrect blade material Contact ESS for re appraisal PROBLEM Insufficient cleaning too much carryback CAUSE SOLUTION Cleaner under tensioned Build up on blade Rap blades against belt Increase service frequenc Cleaner overloaded Add additiona
27. can also be turned upwards to suit site restrictions Step 2 Slide the operating arm onto the cleaner mainframe again ensuring that it is in the correct orientation for the desired tensioning direction Step 3 Insert the threaded end of the adjusting rod through the operating arm slot with the clevis end toward the anchor plate Step 4 Fit the adjusting rod clevis onto the pivot plate pin and secure with clip provided Step 5 Fit spring nut and locknut to the threaded end of the adjusting rod Only run the adjusting nut a few turns onto the adjusting rod Do not try to adjust or compress the spring yet Revision L 16 03 11 2014 Step 6 Using a pipe wrench or similar rotate the cleaner until the blade tips are lightly touching the belt With the operating arm fully retracted against the spring lock the operating arm onto the cleaner mainframe by tightening the two lock screws Ensure that the operating arm hub is 1 2mm clear of the mount to allow free rotation without excessive lateral movement of the mainframe Step 7 Whilst still supporting the cleaner with the pipe wrench adjust the nut not locknut against the spring until the spring just begins to compress Release the pipe wrench Step 8 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 int
28. dd 3330 V1 LYNG JHL 40 NOILVTIVISNI WAWILdO 03 14405 38 1081 02 TVNOILdO 38055384 IYNSNI UNV 1 04 NOILV 13NI MOTIV 01 SOV NIV JHL 5 3WV24 Jdid JHL 0355 4 SI 3801 32NV V8 430IM ONY 51138 0091 0350 583 015 31 IWNQ 383HM 56703 avon ava exwosev DO TAH 3 NOS NOLIVTIVISNI 530018 9 1 30V4 90 3 SNIL ONS INNON 00 LYN Shy S310N KA z 1 135445 S310N DV8 Wavy SNOISIA3 Q3nssi WV 52 50 01 VTOZ OT OE BMP SOPO VOOVOHSONIMVSG NOLIVTIVISN VU3N3OVSSN INEAN E SONIMVHQ 30N343434 Mx 9607 Juv 9607 jNV ON 80 NOILVOO7 GVO 553 NO MIIA Dv8slv 30 NOISN31X3 3A0O 1N3A3Ud 01 4015 TWIINVHI3W 005 056 0021 51108 914 804 13 2V88 340 0 15 140 8 28 S310H 7 m 2 03511 LON SI X000 VA V aw ONY 53183 Q3S0 DN3 38 404 11041 5 4000 5503 51108 91W X04 2 810 S310H 1352 8 310H 08 8L S310H 7 TWNOILdO 340 0 15 WNOILdO 9 Jdid 8 07 SONI 2190253131 IWVUJNIVW 13315 MIVUL 4 431104 OVIH 522 S S 091 on S W 59 HI5N31 30V 18
29. duct 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 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 Durt Tracker Doctor Blade Primary Cleaner purchased from ESS and cannot be passed on to
30. er over the mainframe pipe and push into place on the door frame Anchor the loose end of the cover lanyard Revision L 11 03 11 2014 SECTION 5 OPERATION OF THE TENSIONERS ESS Durt Tracker Doctor Blade Cleaners are mounted to the conveyor structure via Shock Mounts or Flex Mounts The Shock Mount has a set of four threaded holes as shown in Figure 1 and Figure 2 The Flex Mount is a steel mount plate with a urethane insert as shown in Figure 3 Mild Steel Shock Mount Stainless Steel Shock Mount FIG 1 FIG 2 2 S 2 2 Flex Mount FIG 3 Revision L 12 03 11 2014 5 1 SPRING TENSIONER INTRODUCTION The 40 NB Spring Tensioner is a simple robust and reliable blade tensioning unit The Spring Tensioner can be assembled to tension in either the clockwise or anti clockwise direction and has multiple mounting positions for each direction Clockwise Anti Clockwise Tensioning Tensioning Figure 1 The Spring Tensioner is available in two variations Part number 09010309 is a Spring Tensioner Assembly suitable for attachment to a Primary Cleaner Shock Mount This is often used as a retrofit to replace either a superseded ESS Pin Tensioner or an ESS Air Tensioner Part number 09010310 is a Spring Tensioner Assembly suitable for attachment to a Primary Flex Mount see Figure 1 This is the most common mount and tensioner combination for a n
31. ew cleaner and is also used to replace the superseded ESS Counterweight Tensioner Adding an S as a suffix to the above part numbers denotes a stainless steel model Both types are available as a set with the mounts included Where a complete cleaner is ordered it would normally be supplied with the Flex Mounts as the lower cost option Revision L 13 03 11 2014 5 1 1 Installation on Shock or TA Mount Shock Mount Operating Arm Adjusting Rod Figure 2 Step 1 Fit the anchor plate to the mount using the four countersunk head screws Ensure that the plate is in the correct orientation for the desired tensioning direction The anchor plate can be flipped over for the opposite direction but the anchor pin must be removed and installed on the other side The anchor plate and the tensioner assembly can also be rotated to four different angles through 360 to suit site restrictions Step 2 Slide the operating arm onto the cleaner mainframe again ensuring that it is in the correct orientation for the desired tensioning direction Step 3 Insert the threaded end of the adjusting rod through the operating arm slot with the clevis end toward the anchor plate Step 4 Fit the adjusting rod clevis onto the pivot plate pin and secure with clip provided Step 5 Fit spring nut and locknut to the threaded end of the adjusting rod Only run the adjusting nut a few turns onto the adjusting rod Do not try to adjust or compress
32. h as the Inline Premium Secondary Cleaner and often with a water spray system The blade material is one piece cast urethane These segmented blades can be easily removed by sliding on and off the mainframe track Important points to remember concerning the Durt Tracker Doctor Blade are Tis The cleaner is directional it will only clean a belt travelling in the design direction however the cleaner will not be damaged or affected by belt direction reversal The cleaner is suitable for use on crowned head pulleys and damaged or grooved belts The urethane blades quickly conform to the belt profile 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 For belts greater than 1500mm wide a tensioner is required on both sides to ensure equal pressure across the cleaning face For belts greater than 1800mm wide or for certain heavy duty applications a mainframe stiffener is required Revision L 6 03 11 2014 SECTION 3 PREPARATION FOR INSTALLATION 1 CHECK INSTALLATION DRAWINGS Ensure that you have the correct drawings and equipment for your 5 2 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 verify all required equipment is present familiarise yourself with the cleaner assembly allow you to plan the installation reducing
33. ing at the back of this manual If a CYA door is to be installed use the door frame as a template to mark the door cut out on the operator side Proceed to cut the door hole but ensure that the marked centre lines of the cleaner are not totally removed you will need these to position the mainframe If a stand off bracket is to be bolted over a CYA door the mounting holes also have to be Cut Step 3 The Durt Tracker Mainframe is a combination of extruded polyethylene steel tubing and telescoping mounting pipes The telescoping mounting pipes allow precise length adjustment each side removing the need for site trimming Remove the blades if they have been mounted on the mainframe Do this by loosening the blade lock screw from the end to be the operator side Remove blade lock and blades by sliding them out of the track end using the pull strap Insert the mainframe without the blades through the inspection window Pass one end of the mainframe telescoping pipe through the mount hole on the far side then the other through the operator side mount Step 4 Loosen the lock screws on the bottom of the track and either extend or retract the telescoping pipe ends as required Slide the operator and far side mounts on to the telescoping pipes then tack weld clamp or loosely bolt the mounts to the chute walls If stand off bracket is to be used over a CYA door and the cutout has been made fit the operator side mount to the appropriate
34. installation time 3 ASSEMBLE THE NECESSARY TOOLS amp SAFETY EQUIPMENT REQUIRED FOR THE INSTALLATION 4 OBSERVE THE CONVEYOR WHILE RUNNING AND CONVEYING MATERIAL Observe the material trajectory Observe the belt direction does it reverse or roll back Observe the belt splice condition Does the belt run true or track off to one side Is 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 L 7 03 11 2014 SECTION 4 INSTALLATION DANGER WARNING NOTE 1 NOTE 2 Step 1 Conveyor must be shut down and locked out before any installation or service work is performed If installation is to be done in an enclosed area test atmosphere for gas level or dust content Follow all welding and safety guidelines For original equipment installation where cleaner cutouts and brackets have been fabricated into the chute during construction ignore steps 1 and 2 For installation on enclosed head pulley chutework draw all dimension lines on chute wall In applications where head pulley is not enclosed custom designed brackets are necessary to ensure correct cleaner position Locating Mainframe s Centreline Using the typical installation drawing supplied in this manual locate the mainframe s centreline
35. l secondary cleaner Secondary cleaner not functioning Service the secondary cleaner correctly Revision L 25 03 11 2014 SECTION 10 INSTALLATION ARRANGEMENT DRAWING 999910 0081 JJIAHIS M3WOISQO 53114405 29 530835 133 5 VIVO 31334403 1 1 1 1 1 1 1 0066 0066 0016 0062 0012 0092 0572 0062 008 oso 0012 061 008 059 005 05 056 002 050 006 051 009 057 o __ 3018 we 6 9 5 7 2 _ saovieo 0012 0672 0522 0002 008 oss 0521 006 051 009 057 HLONAT 0072 0022 0002 008 009 005 056 0021 050 006 05 009 057 1138 318VilVAV 5311803557 03 0844 IN3WLYVd30 53 ONY 38 1 434431 753015 H108 NO 583 015 31 JWIND3U 8301 009 51138 INIW3AQW 1VIXV 1 3 384 OL 8 710 3201 31dWIS 03141002 SI INNOW 3015 005 01 dn 51138 804 IWVUSNIVW 3Hl 404 03811038 51 43N34JILS V N30IM ONY 0081 51138 404 S310H QV3H 035012 3 NO 1N3W32V 7438 30V18 ONY NOI123dSNI ASV3 404 MOTIV 4000 55322 8 21 2 ONY 13 2V38 340 0 15 553 IWNOILdO 30 UV3 SI INVIT 38nSN3 ONY NOISN3WIG 135440 WIGVY NIVLNIVW A3TInd QV3H JHL 30 1 02140 0138 S 0 N33 M138 dil SLI SI YINYIN AYWWI
36. o position 1 2mm clear of the mount Revision L 17 03 11 2014 5 1 3 Spring Tensioner Adjustment Procedure Note The Spring Tensioner is mounted externally to the conveyor chute and as such is normally able to be adjusted with the conveyor in service Under no circumstances should any person reach into or enter a conveyor enclosure while the belt is running For any conveyor belt cleaner service maintenance or adjustment that requires entry to the conveyor enclosure by any part of the body first ensure that the conveyor is shut down and locked out to site safety procedures Warning Contact with moving conveyor components can result in severe injury or death To adjust the Spring Tensioner Loosen the locknut away from the adjusting nut on the adjusting rod Turn the adjusting nut until the cleaner blades are pressed against the belt and the spring begins to compress Continue until the spring is compressed to the height shown in the following table 1 Ensure that the correct height is used for the appropriate belt cleaner and belt width If in doubt contact ESS Once the correct spring compression is achieved run the locknut up against the adjusting nut and use two wrenches to tighten the nuts together Forcleaners with dual tensioners repeat this procedure on the opposite side Table 1 Primary Cleaners Belt Width Spring Length No of Turns 45
37. ome material on the belt before starting up system This helps to quickly Wear in the blades and reduce the initial friction between the belt and the blades Handfuls of conveyed material spaced along the belt will do The belt may also be moistened with water START THE CONVEYOR Follow the established safety rules ADJUST DURT TRACKER DOCTOR BLADE CLEANER EVENLY ONTO THE BELT Refer to Section 5 Operation of the Tensioners Adjust the cleaner so that all of the blades are touching the belt with even pressure DO NOT OVER ADJUST Each blade should be in contact and flexing back and forth with the irregularities of the belt surface The Doctor Blade is designed to lightly ride on the surface of the belt and remove a large percentage of the carryback Excessive pressure unnecessarily reduces the life of the blades without any increase in cleaner efficiency OBSERVE THE CLEANING ACTION Using a light observe the belt and the action of the cleaner Place material on the belt Look for blades that are not touching the belt Run for 5 minutes to get a good idea of the action and the effect of the splices on the belt cleaner 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 putting material on the belt Show the operator how to adjust and operate the system SECURE THE SYSTEM FOR PRODUCTION Follow plant procedure to
38. on both sides of the conveyor Measure radially 100mm from the face of the belt From this point draw an arc using the pulley s centreline as the centre point The centreline of the mainframe can be located anywhere along the radius as long as the blades do not lie in the material s trajectory The optimum position is for the blade tips to be between 0 and 15 below the horizontal centreline NOTE Material trajectory is defined as the path of the material being discharged from the belt VERTIC p e A MATERIAL TRAJECTORY s PIS Se m HORIZONTAL Revision L 8 03 11 2014 Verify Mainframe Position before Proceeding Position the selected tensioner mount assembly over the centreline marks for the mainframe Verify that the mounts fit and that adequate room is available to tension the cleaner used position the CYA door frame to ensure it fits If mounts or door frame interfere with structural members it may be necessary to locate the cleaner elsewhere on the 100mm offset radius If the tensioner only interferes remember that the tensioner can be rotated to several different mounting positions by removal of the four countersunk screws Once mounting position is confirmed proceed Step 2 At the selected mainframe mounting positions mark out and cut the mainframe and mount fastener holes if required in each side of the chute Refer to the installation draw
39. 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 proceed Step 6 Fully weld or bolt the cleaner mounts brackets and CYA door frame to the chute wall If not already done fit the tensioner assembly ies to the mount s Centre the blades on the belt All ESS cleaners are designed to clean an area narrower than the actual belt width This is to allow for a small amount of lateral movement of the belt and to protect the edge of the belt from possible damage Loosen the lock screws on the bottom of the track and adjust the telescoping pipe ends to the required length Firmly tighten the lock screws Lateral movement of the mainframe is prevented by the tensioner s locking hubs or a lock collar on the far side mount when only a single tensioner is used i e on belt widths less than 1600mm Lock these items in position allowing about 1 2mm of end float in the cleaner mainframe Revision L 10 03 11 2014 Step 7 WHERE A CYA DOOR IS FITTED Measure the position of the mainframe in relation to the CYA door frame Mark this position on the CYA door rubber cover and cut a neat hole approximately 50mm diameter in the cover Cut a straight line from this hole to the nearest edge of the rubber cover Install the rubber cov
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