RBC Installation Manual
Contents
1. 01 sje gsogopi MIL OD 5720050090 8341102 SON LYWd 31010 LNIWIJVIdIN F a 10 355 43110 0007553 a 67204 SYANYOO dAVHS SYYNG TY SAOWNAY 031312345 ASIMYSHLO SSJINN 5 NI 24V SNOISNSANID TIY AIVOS LON Od SECTION 8 EXPLODED PARTS DRAWING 04 03 11 17 Revision G 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 LI 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 lf No WHY ESS Signature Client Signature Revision G 18 04 03 112. CEDING CLAMP PLATE Any of the above methods is acceptable Again NEVER install a Clamp Plate with only a single Captive Wedge or Cotter A minimum of two Cotters is required for each Clamp Plate 4 9 8 10 NOTE Revision G Grind each plug weld flush with the face of the backing plate if necessary Measure the required length of skirting rubber required and cut this length from the roll supplied See the cutting procedure following in section 4 2 Insert the skirting rubber from one end making sure that the correct edge is downward Secure the rubber by placing the ESS 2000 clamps plates in position over the captive wedges and lightly tapping the wedges to hold the rubber Insert a screwdriver in the Clamp plate slot and push down the rubber until it lightly but uniformly contacts the conveyor belt loosening the nearest wedge if necessary Firmly tap wedges tight and repeat the process for consecutive clamp plates Do not overtighten the rubber against the belt or the wedge Remove the weld blanket and any installation debris from the conveyor Remove danger tags and return conveyor to service following plant procedures IF YOU HAVE ANY PROBLEMS OR ARE UNCLEAR ON ANY INSTALLATION STEP CONTACT ESS ON CUSTOMER SERVICE NUMBER 1800 074 446 11 04 03 11 4 2 Cutting Procedure for ESS 2000 Rubber Skirt Seals Caution e Ensure that the following procedure is carried out in a safe position away from the con
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4. Engineering Services amp Supplies Pty Ltd Phone 1 800 074446 Visit our Web Site www esseng com au ES ESS 2000 SERIES CONVEYOR BELT SKIRTING SYSTEM SAFE WORKING PROCEDURES SWP INSTALLATION MANUAL bee manrin ENGINEERING A Cutting procedure added TTC 26 8 07 B Added Final Checklist AS 128 5007 D Revision G 1 04 03 11 ENGINEERING SERVICES and SUPPLIES ESS WOLLONGONG MAITLAND NSW 2320 1 20 DOYLE AVENUE PO BOX 343 UNANDERRA NSW 2526 PO BOX 1554 ISA QLD 4825 OFFICE DETAILS ESS HEAD OFFICE 11 13 TRADERS WAY P 07 5589 2000 PO BOX 121 F 07 5598 1353 CURRUMBIN QLD 4223 ESS MACKAY 1 PROGRESS STREET P 07 4952 4600 PO BOX 5755 F 07 4952 4717 MACKAY MC QLD 4740 ESS PERTH 19 CLAVERING ROAD P 08 9370 3155 BAYSWATER WA 6053 F 08 9272 5130 ESS MAITLAND UNIT 2 BARTON COURT P 02 4932 3544 6 JOHNSON STREET F 02 4932 3611 P 02 4272 4422 F 02 4272 4434 ESS MELBOURNE 4 314 Governor Road P 03 9580 0388 BRAESIDE VIC 3195 F 03 9587 5199 ESS EMERALD 11 115 ROBERTS STREET P 07 4982 4855 EMERALD QLD 4720 F 07 4987 5118 ESS GLADSTONE 2 34 CHAPPLE STREET P 07 4972 3759 PO BOX 1475 F 07 4972 2866 GLADSTONE QLD 4680 ESS ADELAIDE P 08 8262 8955 F 08 8262 4944 ESS KALGOORLIE 4 235 HAY STREET P 08 9021 7991 PO BOX 10471 F 08 9021 7291 KALGOORLIE WA 6430 ESS MOUNT ISA 6 TRADERS WAY P 07 4749 4580 F 07 4749 3019 CUSTOMER
5. NTENTS 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 ESS 2000 Conveyor Belt Skirting System purchased from ESS and cannot be passed on to any other party without express permission in writing from ESS ESS Despatch Department to complete Client should retain for warranty Purchaser Client Purchase Order Contract No Site Despatch Date Conveyor No s No Supplied Description Part Numbers Comments Revision G 3 04 03 11 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 Revision G SAFETY INTRODUCTION PREPARATION FOR INSTALLATION INSTALLATION COMMISSIONING TROUBLE SHOOTING INSTALLATION ARRANGEMENT DRAWING EXPLODED PARTS DRAWING 04 03 11 SECTION 1 SAFETY The ESS 2000 Conveyor Belt Skirting System is designed to be quickly and easily installed and serviced by appropriate personnel Under no circumstances should servicing or installation of the ESS 2000 Skirt System 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 All equipment equipment access an
6. SERVICE NUMBER 1800 074446 TOLL FREE FROM ANYWHERE IN AUSTRALIA Revision G 2 04 03 11 WARRANTY NOTE ESS WARRANTS the ESS 2000 Conveyor Belt Skirt Seal 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 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 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 THE CO
7. YINS OL YYTNJIANIdAId JDGIM JAILdYJ NOILISOd l 3903 HJIHM HONOSL 1138 FaNGIIONd ONILNNOW WSLSAS DNILHIS 0002 553 LHIMS LId DANS A WWZL B WVADVIQ 51138 1V7 4 404 aagana Las 51139 QIHDNOJL 3003 3 5 404 7 WW8DVIQ 1 LIAS LId DANS L 1 ILVId HINIT HVIM ee 1 4 IVNOILAQ tga Slob 9 ONIDTM 503 1015 wy L WVADVIQ SYANYOO dAVHS SYYNG TIY JAOW2U HIDN3T 31919 dWV1I WON 009 53419 06 mil 5381437 dWVI 00 MW HIDN31 JLV1d INNOW 0021 031319345 ASIMYSHLO SSJINN SSYSWITIIN NI SNOISNJNIG TIY ATVOS LON Od 04 03 11 16 Revision G MAL Cried MVHQ JONAYS ON DNIMVHQ 67203 SIV CEO havale biel Gw SNOISASU S ON JNIMVHO SIN 31 95 NMVHU asl it 95 09 NDILVWHOJNI 404 03155 ka asa ii ao fas WILLOI 181 1iML1IQ SLMVd Q10014XI WAA MD 05 99 99242013 0300Y ILON 3795 2 22555 SAHHA IDEA ee cetera see lt lt lt 34 10N TNS LI Sarwan ONY 51 40 498048 JIL SAVHE ONY TVLNGOENCD SI KOSH ONY SHL NOLLVQO1 92 553 TES Eo ev 21 11 2 9tttz0 0081 ON JJIAHIS YIWOISN Jala 0L0Z0090 N d TIVL JADU AYVONOIIS ENOILAO XHJNS IHL LNOHLIM YO
8. able IF ANY OF THE ABOVE PROBLEMS EXIST CORRECT BEFORE INSTALLATION OR CONTACT ESS IF PRESENT REMOVE EXISTING SKIRTING SYSTEM AND MOUNTING HARDWARE 3 5 UNUSUAL CONDITIONS CONTACT ESS ON 1800 074 446 before installation if any of the following conditions exist concave or convex curves in chute wall or belt extreme side pressures fast gt 4 6 m sec conveyor belt temperature extremes below 7 or above 65 corrosive atmosphere Revision G 7 04 03 11 SECTION 4 INSTALLATION WARNING BEFORE PROCEEDING WITH INSTALLATION ENSURE THAT THE CONVEYOR BELT DRIVE AND ALL ASSOCIATED EQUIPMENT IS FULLY ISOLATED AND LOCKED OUT CONTACT WITH A MOVING CONVEYOR BELT OR ITS COMPONENTS CAN RESULT IN SERIOUS INJURY OR DEATH 4 1 Installation Procedure Revision G If the steel skirt plates are greater than dimension A Sect 3 4 from the belt surface it may be necessary to extend the plates closer to the belt A 150x10 flat bar welded to the outside of the chute or skirt side walls is an easy way to achieve this as long as sufficient freeboard is available outside the skirt line Take an ESS 2000 Back Plate section and position it such that the bottom edge is uniformly dimension A Sect 3 4 from the belt and one end is at the required Start point of the skirt seal preferably toward the tail end of the conveyor The bottom edge of the ESS 2000 must n
9. aking from under Skirting rubber is not installed uniformly against the belt skirting Revision G 15 04 03 11 SECTION 7 INSTALLATION ARRANGEMENT DRAWING 69104 86 9 52 _ _ 5 0 See SNOISIASY fad GOND Fen ON NIMVYA _SIN 3TVOS OY NAVE w w L asf oyf aasena LIJ DANS Y on ee ET wwa joja _ C zSU INJWJONVJJV NOLLVTIVISNI mw LL od as Q3AQW V WIQ EJ C ee WAISAS 531035 0002553 a PDG LID IT Ald 538915 ONY 511825 WRONG SSI TWAQ dAW HALIM JADIS 1 ALHWA 910 ANY OL NMDHS 40 SS a a d 30 LOW OLTALA 93 4915 ONY SIJJALIS 553 30 11439004 IHL SWAR ONY SI DSJI OHY OMY SHI ay 0 0 0081 ON JJIAHIS JIWOLSNI NOLLW907 avd ssa S3NddNS 9 SJJJAHIS ONINAINIONA i NOLLVW JOJNI SHOW 201 Tu J NOILI3S 553 1IVINOJ INIQd DNIAWVII YVINONIS V OJTIYLSNI a ae 02 5 GE Jg DNILHIDAS 40 NOILISS QINOHS SJINVISWAJAD ON YSONN 5 WWUDVIQ se 7 NI SY NOILISOd 03207 OLNI 3503M JAILdVI 30115 ONY 31 105 F m 9 S3003M INLAY _ Due YJA0 S310H DNILVIDI Z ONILNNOW 3LV1d dW 13 30115 Z E WYYOVIO NI SV 2LV Id HIVA a ag ee ae ONIL
10. d installation service procedures must comply with AS1755 Conveyors Safety Requirements ESS strongly recommends that a thorough Job Safety Analysis should be undertaken prior to commencement of the installation to identify and manage hazards SECTION 2 INTRODUCTION ESS 2000 Series is a conveyor belt skirting and sealing system comprising a rubber or urethane seal and a weld on clamp assembly ESS 2000 Series attaches to the outside of the conveyor belt load skirts to provide an effective seal and prevent material loss and dust emissions Each ESS 2000 Skirting assembly comprises a 1200mm long backplate with four captive wedge or cotter assemblies and two 590mm long clamp plates The backplate may be site cut to 600mm long and used with a single clamp plate This enables skirt lengths of any multiple of 600mm to be accommodated using standard components For skirt lengths that are not a multiple of 600mm refer to Section 4 1 for installation details The rubber seal is secured in place by the clamp plates which are in turn held by two captive wedges or Cotters This system allows ease of adjustment or replacement of the rubber seal Never install a Clamp Plate that is secured by only one captive wedge Cotter Severe belt damage may result Refer to Section 4 1 for installation details Revision G 5 04 03 11 SECTION 3 PREPARATION FOR INSTALLATION 3 1 CHECK INSTALLATION DRAWINGS Ensure that you have the correct drawi
11. e cut is completed Release the end of the rubber from the vice and install as described in the ESS 2000 manual Store the left over rubber in a suitable place in line with good house keeping practice Revision G 14 04 03 11 SECTION 5 COMMISSIONING A note on safety No additional safety hazards are present with ESS 2000 Skirting other than normal conveyor belt dangers In particular Beware of moving conveyor belts Beware of pinch points gt not attempt to install maintain or disassemble any part of a conveyor belt without first isolating and tagging the conveyor drive 1 Following site safety and start up procedures start conveyor belt and run under normal conditions for 10 minutes Observe ESS 2000 Skirting and look for material leakage WARNING BEFORE PROCEEDING WITH COMMISSIONING ENSURE THAT THE CONVEYOR BELT DRIVE IS FULLY ISOLATED AND LOCKED OUT 2 Lockout tagout all power to conveyor belt and conveyor accessories 3 Adjust skirting rubber by following step 7 in Section 4 1 4 Remove danger tags and return conveyor to service following plant procedures 5 Start conveyor and run under normal conditions SECTION 6 TROUBLESHOOTING a PROBLEM SOLUTION Conveyor belt won t run after Skirting Rubber is installed too tightly against conveyor installation belt Excessive Skirting Rubber Skirting Rubber is installed too tightly against conveyor wear belt l Product le
12. evision G 9 04 03 11 e For lengths of 380 600mm the Backplate can be trimmed equally from both ends so that the two captive wedges cotters remain in the centre Fit the Backplate as described above Similarly trim the Clamp Plate to the same length minus 5mm each end for clearance ORIGINAL 590 CLAMP LENGTH REQUIRE Dt EENGIH 7 COM FERS e For smaller lengths the Backplate may be trimmed as described above plus cut and joined in the middle to reduce the centres of the captive wedges cotters The two cotters may be reduced to 150mm centres minimum Weld the Backplate sections back together and dress smooth with a grinder The Clamp Plate will also be cut and re joined in a similar manner again allowing 5mm clearance at the ends ORIGINAL 590 CLAMP LENGTH BACKING amp CLAMP PLATES TRIMMED BOTH ENDS 7 COTTER BACKING AND CLAMP PLATES CUT AND JOINED AT CENTRE Revision G 10 04 03 11 e Finally a Three Cotter Clamp Plate may be constructed The Backplate can be cut to a single cotter and installed as per standard units The Clamp Plate is then cut to match the Backplate and welded to the adjacent Clamp Plate to form a longer Clamp Plate with three cotters Ensure that the fabricated longer Clamp Plate has its holes at the same centres as the Cotters in the Backplate EXTRA LONG CLAMP PLATE WITH 3 COTTERS 590 ORIGINAL CLAMP LENGTH SHORT CLOSING LENGTH CUTTERS WELD SHORTENED CLAMP PLATE TO PRE
13. ngs and equipment for your conveyor s 3 2 ASSEMBLE THE NECESSARY TOOLS amp SAFETY EQUIPMENT REQUIRED FOR THE INSTALLATION 3 3 OBSERVE THE CONVEYOR WHILE RUNNING AND CONVEYING MATERIAL Determine loading point Note direction of conveyor belt travel Observe conveyor belt tracking Conveyor belt must track centrally Observe idlers e Ensure conveyor belt does not raise from idlers e Ensure idlers are spaced correctly so conveyor belt does not sag lf conveyor belt does sag under material loading additional idlers or ESS GUARDABELT Impact Cradle or GUARDASEAL Belt Support Systems should be installed Observe Material on conveyor belt Material should be loaded on centre of belt 3 4 INSPECT WEAR LINERS AND CHUTE WALL Revision G Ensure wear liners and chute wall are in good condition no cracks holes slits or grooves Ensure wear liners and chute wall are straight along bottom edge or material will build up between wear liner and the skirting system For Snug Fit Rubber Skirt ensure dimension A from conveyor belt to the bottom of the existing steel work is obtainable See table below and drawing FO169 at rear 6 04 03 11 SNUG FIT SKIRT RUBBER BELT DIM A WHICH EDGE DOWN THROUGH ANGLE 2 2 10 For Square Edge Skirting Rubber ensure 8 12mm from convevor belt to the bottom of the existing steel work is obtain
14. ot protrude below the bottom edge of the skirt plate or chute wall see step 1 above Weld the backplate to the skirt chute wall using a 3mm x 25 long fillet weld at the top above each captive wedge and plug weld in each lower slot Use an appropriate welding blanket to protect the belt surface Repeat step 2 for the full skirt length simply butting consecutive Backing Plates against each other maintaining dimension A from the belt For skirt lengths that are multiples of 600mm and the final or closing length required is 600mm simply cut the backing plate in half 2 x 600mm sections and fit the half length of Backplate with one full Clamp Plate For closing lengths greater than 600mm but less than 1200mm cut a Backing Plate to 600mm and install as described above Use the following procedures to complete the installation 8 04 03 11 NEVER INSTALL A CLAMP PLATE WITH ONLY ONE CAPTIVE WEDGE OR COTTER SEVERE BELT DAMAGE MAY RESULT CLOSING LENGTH SINGLE Potential Belt Damage Point For closing lengths less than 600mm the following procedures may be utilised There are four options for a smaller Clamp Plate length e For lengths of 500 600mm the Backplate may be trimmed to the required length at one end only Cut the end furthest from the previous Backplate Fit the Backplate as previously described Cut the Clamp plate at the same end ORIGINAL 590 CLAMP LENGTH REQUIRED LENGTH 2 COMERS R
15. veyor belt This procedure is to be undertaken in conjunction with the Safe Working Practices outlined in this Installation Manual e Any installation of equipment and any equipment installed must comply with AS 1755 2000 Conveyors Safety requirements The following steps are recommended for the safe cutting of ESS Snug Fit and Square Edge rubber skirt seals Step 1 Measure and mark the required length of ESS 2000 skirt rubber for the job being undertaken A white paint marker is recommended and the mark should be perpendicular to the length of the rubber Step 2 Place the rubber in a vice or firmly clamp it to a suitable piece of structure Position the cut mark so that it is free and accessible for a cut to be made and that the rubber is free on one side of the mark Step 3 Have an assistant grip the free end of the rubber to prevent excessive movement and to open the cut as it progresses Using a hacksaw with a fresh blade slowly begin to cut the rubber from the top of the mark A knife or sharp blade is not recommended due to the hazards involved Ensure that appropriate PPE is worn including eye protection and suitable gloves Revision G 12 04 03 11 Step 4 The assistant should hold the cut open by firmly holding the rubber and turning it slightly downward Do not apply excessive load this could result in a fall when the final cut releases the rubber Revision G 13 04 03 11 Step 5 Continue as above until th
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