RBC Installation Manual
Contents
1. Fig 3 Cradle Setup Clearances Revision D 8 14 03 2011 Final adjustment 10 Using the multiple hole adjustment adjust the wing support arms so that the outer bar is brought up to be in line with the troughing idler rollers Fig 4 Care should be taken to ensure that the outer bar is as close as possible to the roller line If the bar is too high accelerated wear will result If the bar is too low the belt may sag resulting in material spillage Outer Bars adjusted NE JOE Wing Support i e Lightly contacting belt TATTS Revision D Fig 4 Wing Adjustment Repeat the above procedure for all subsequent cradles 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 9 14 03 2011 SECTION 4 COMMISSIONING special commissioning procedures are required for Guardabelt impact cradles Provided the cradles 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 Guardabelt Impact Cradles 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 co2. 5 20 JOTAN ZIW INN 01008087 1108 331 1138V0AVNO AIV1d SAAVL DNIUNLIVJANVW 140438 LNO 031115 39 DOSAUEY AONE LYNAAHHN 013 01 G3IN TIIM 143HS VIVO NOILVIlTddAV L118VQHVND SHANHOD diVHS ANY SYYNE TIY JAOW3H 01001087 TANNVHI LHOdANS ON 9530 ALON 26004 DN 5 804 5 0N LiVd 0341293895 ASIMYSHLO SSTINN SIHLIWITIIW SNOISNAWIG TIY LON AINO SLYVd divdS GYVONVLS NON 55004 14 03 2011 14 D ision Rev 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 inspection 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 D 15 14 03 2011
3. 1 ONY NI GV31 ONIWWOJIN 553 5 3 SITAWISSY 8 ONIGIIS Y3dOYd IWNSNI OL 2 oo JTONY HONOYL GANIVLNIVW 5 SWV38 INOOL NOISNAWIG UWQQE 4 1 9 ose aY 3 5 Q3013M YO 031109 AVW 10 92 E 009 ee 5 ONILMDIS 1138 Suva va Dvdni LIVINOD LSA OL QINOILISOd 10095 SUVA SUVA YILNO H NO LNIWLSAFOV 40 WwWSZ SMOTIV 0130 ITAYA Z 40 1738 5 110534 GINO 40 01 a LLJ 30 JUNIVWIWA 1739 ONY SUVS 1 NIJMLIQ Yad 9 3015 GANIVINIVW 38 LSNW Wuoz 40 JNVUVITI WAWININ 7 8 753104 LNNOW 259001 OLNO LSY 4313W0ANA 05 26 J2V4ANS JVIM 01 Jd MWHN SINIW34IND34 1NI LINS 01 SLIVdWI AAVJH ONY 51138 3QIM 204 G30NDIU INIJJILS JUNLINALS LINS 01 GJHILON 38 NYJ SWV4d ON3 NO NOLLVIIHLINJQI 107 92 5 4 SWV38 NIVW 2000 HLQIM ONY HONOYL SIAYA 7 Id3U MANO HLDN37 WAY 140ddNS 803 593149 2 AISVI 30115 suva 1108 ONINIVLIY ONY WHY 1409905 40 IVAOWIY AILIV IVNOILdO ba ONILYINS 0002553 JIGVIIVAY SUVA 0051 SAINHOD dAVHS SYYNE JAOW3H 0315193945 JSIMSSHLO SSSINN SIJLJIWITIIW NI IXY SNOISNINIG TIY 3125 LON Od 10003 14 03 2011 13 D ision Rev SECTION
4. Engineering Services amp Supplies Pty Ltd 255 1 800 074446 Visit our Web Site www esseng com au GUARDABELT IMPACT CRADLE SAFE WORKING PROCEDURES SWP INSTALLATION MANUAL Pr MARTIN ENGINEERING Revision Description of Change Changed Date A Added Final Checklist AS 28 5 07 B Updated Melbourne Address 8 Removed SA Address SH 3 08 09 Final Checklist Updated Items 4 8 5 Reversed SH 15 04 10 D Updated Drawing F0055 8 20007 KO 14 03 11 Revision D 1 14 03 2011 ENGINEERING SERVICES and SUPPLIES ESS HEAD OFFICE ESS MACKAY ESS PERTH ESS MAITLAND ESS WOLLONGONG ESS MELBOURNE ESS EMERALD ESS GLADSTONE ESS ADELAIDE ESS KALGOORLIE ESS MOUNT ISA Revision D OFFICE DETAILS 11 13 TRADERS WAY PO BOX 121 CURRUMBIN QLD 4223 1 PROGRESS STREET PO BOX 5755 MACKAY MC QLD 4740 19 CLAVERING ROAD BAYSWATER WA 6053 UNIT 2 BARTON COURT 6 JOHNSON STREET MAITLAND NSW 2320 1 20 DOYLE AVENUE PO BOX 343 UNANDERRA NSW 2526 4 314 Governor Road BRAESIDE VIC 3195 11 115 ROBERTS STREET EMERALD QLD 4720 2 34 CHAPPLE STREET PO BOX 1475 GLADSTONE QLD 4680 4 235 HAY STREET PO BOX 10471 KALGOORLIE WA 6430 6 TRADERS WAY PO BOX 1554 MTISA QLD 4825 P 07 5589 2000 F 07 5598 1353 P 07 4952 4600 F 07 4952 4717 P 08 9370 3155 F 08 9272 5130 P 02 4932 3544 F 02 4932 3611 P 02 4272 4422 F 02 4272 4434 P
5. 03 9580 0388 F 03 9587 5199 07 4982 4855 F 07 4987 5118 P 07 4972 3759 F 07 4972 2866 P 08 8262 8955 F 08 8262 4944 P 08 9021 7991 F 08 9021 7291 07 4749 4580 07 4749 3019 CUSTOMER SERVICE NUMBER 1800 074446 TOLL FREE FROM ANYWHERE IN AUSTRALIA 14 03 2011 WARRANTY NOTE ESS WARRANTS the ESS Product 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 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 o
6. 8 56 0 95 220 135 0SX9IW 3475 L 52009087 D70544 30115 INIM 17139 0 02009087 0105 055 30115 DNIM 1 7139 0 51009087 97055 05 20115 1 139 01009084 D10Se lt 30115 DNIM 1 9 91052087 DNOT 005 105208 00 01052087 DNOT 002 60052084 006 G30 TNOW 80052087 DNOT 009 5 0100 087 7 52002087 Suva LINS ONIM 1738 9 02002087 Suva 4 LINS ONIM 17139 0 51001087 Suva LINS ONIM 1739 0 0100108 Sava LINS DNIM 1739 0 0z001087 910577 WAY 1904915 LTadvoX ND 51001081 0105 lt WAY LUOAANS 1739 0 XxxOS184 DNOT 005 3578 1130 0 KXXO NB 00ZL 3578 XXXOELY DNOT 006 3578 L1IAVGUVND XXXOZ197 DNOT 009 asya 1 L ON Livd 953 WILI Q3UNSVIW HLOIM 1738 HLIM XXX JLNLILSANS SHLOIM 1138 QAVONVLS T1 NI 51 JHL 3LYJANI 48 G3M07104 5 9 194 SALON ON 1899 19315 SSJINIVLSI 55 WALI GUYONVLS SV G3SINVAT D SLNANOdWO 53 JuVdS ONINSCYO NIHM ON 43090 TVNIDINO JLOND ISVJIdA SLiVd 5 NAHM NOILYWHOSNI ALIS 3WWN SNOILVII lddvV TIVAGIAIQNI 404 03391530 53704
7. Ensure that only suitably qualified and trained personel install and service this product Ensure that all site and statutory safety procedures are followed SECTION 2 INTRODUCTION The ESS Guardabelt Impact Cradle consists of an adjustable steel frame fitted with impact absorbing rubber bars that are designed to be easily removed without the necessity of pulling out the cradle frame from the conveyor The bars have a low friction UHMW Polyethylene top wear surface The cradle is fabricated to conform exactly to the troughed belt profile The ESS Guardabelt Impact Cradle is designed to replace conventional impact idlers in the load zone of a conveyor Under heavy impact loading the Guardabelt bars will easily outlast standard impact idlers absorb shock loads and increase belt life by reducing material piercing In addition to these benefits the Guardabelt impact bars are able to hold the belt flat under the skirting thereby virtually eliminating material spillage To achieve these results however the ESS Guardabelt Impact Cradle must be installed in the correct manner Clearances and adjustments which are specified later are essential Revision D 5 14 03 2011 to the performance of the cradle The cradles have been designed and manufactured to simply bolt into place on the conveyor stringers and achieve these clearances from a set of dimensions supplied by the client The clearances should however be checked at installation to ensure t
8. Siezed idler Overadjusted or damaged skirting Worn out impact bar rubber not adjusted or failed Impact cradle wings not adjusted up to belt Replace idler Replace or adjust skirting rubber Disassemble impact cradle and replace bars If bar life is short or wear is uneven contact ESS Adjust or replace skirting Adjust the cradle wings 14 03 2011 Cradle Disassembly Procedure The disassembly of an ESS Guardabelt Impact Cradle is a simple process 1 Remove the slide locks from the outer wing bars two per side 2 Remove the securing bolt and nuts holding the wing assembly to the base two per side 3 Slide the entire wing assembly out from the belt about 50mm 4 Slide the individual wing bars from the wing assemblies Note the bar positions by numbering with a marking pen or chalk 5 Slide the wing frame assemblies from the base four per side 6 Repeat for the other side 7 Slide the centre bars of the base again noting the positions 8 Inspect the bars for wear or damage If severe or unusual wear is noted contact ESS on 1800 074446 for advice Cradle Re assembly Revision D Re assemble the cradle in reverse order of disassembly paying attention to the following If new bars are being fitted or if existing bar wear is negligible refit the bars in any order If wear spots are evident on certain bars rotate or rearrange bars on re assem
9. and tagged General The ESS Guardabelt Impact Cradle 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 cradles should be disassembled Cradle Disassembly Procedure page 13 and 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 The UHMW Polyethylene top cover of the bar is 8mm thick The bars should be scheduled for change out when the top cover thickness reaches 2mm TIP During inspection higher wear areas may be identified on some bars or sections of bars This is caused by uneven belt loading in the transfer point Longer overall bar life may be achieved by noting the position of the bars at disassembly and rotating the bars to a differeant position on re assembly much like rotating the tyres on a car Non Routine Maintenance 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 SYMPTOM POSSIBLE CAUSE REMEDY Smoke or burning rubber smell Material spillage under skirts Revision D Skirting
10. 8 EXPLODED PARTS DRAWING BELS6LEZO 5106 21561 20 SM IZLSILEZO 5 0 59220 3 55004 97770 0081 59784076 5104035 551 WOR 4 ALUNA 20305 ANY OL 80 id CdD Q 38 JON TIVHS JU ALTA LA 5379905 SIRAS 553 30 1954044 HL SHY 51 NOSSO ONY DNAV U SHL z FINAIS YIWOLSND 53 29 SJJJAH4S ZIW JHSVM ZIW YIHSYM ZLW LIN 135 0EXZIW MIAS SONIMVAQ JONIAHAHAN TON a 2 i mamma lt 1 37 95 ISM SRIVd 03001dX3 5478 LOVdWI NO LSVO HLM ATGWASSY LOVHAI LAVQHVNJ H oH _______ 3sva 14 05 aa 0351 03543 SDNIMV Q Jay X31104 17I8VQUVNI 5194 03001 3 103 NO M I 92 LIVdWI 17I8VQUVND SLUVd 03001 3 9 005 31022 19409 1738VQUVAD 5194 Q3001dX1 6E004 AUL 1 3 NOLLVQOT DVO 553 1139 E 3SV8 3IQVAI NO JBWAN 1 1035 553 13119915 ILYA 83080 TVNIDIHO HOAJANOI 61 96LEZO _9IW HIHSVM 5 16 9 96 20 IW 5 OL 5 9 20 S LJEDEZO X3H O9X9IW 1108
11. bly to maximise total bar life 12 14 03 2011 SECTION 7 INSTALLATION ARRANGEMENT DRAWING Mu 10003 L 9 ____ SOHO 9 kwa 20 e S SONIMVUQ JONSNAISY ONIMVAQ _ 37 05 _ m i 59 05 JIVOdN 17 93139 1907 519 9 9003 een A WYANS9D NOLLVTIVISNI e __________ FIGVYO 138 4 9 34 LI ULTALd 5314905 ONY SIJJALIS ONRGINDA 553 30 1839099 IHL SHVH ONY SI ONY OMA SHL 9 0 0081 ON 32435 YINOISND 9 553 SIMddAS 29 SHOIANSS en DV1d SIIVL DNIYNLIYANNYW 340438 110 037114 01 TIM 133HS VIVG NOLLVIIIdAV 17139 0 8 o 0002 WALSAS 1 40 SLHANA IZIWIXVH oos TTS Viva 01 SWALSAS PNILWS 0002553 40 ISN IHL SONIWWOJJY 553 L IT EL E g 0 Z NOILVII lady SOVNS 40 5221145 TVIINVHIIW ida 40 123443 OL TIAVUL 1138 40 238 os 58 1108 L II8VQUVNAD ASNIVDV 32V4 ISNW 5 1738VONVND 40 3903 0343dVL 9 01 OSEL 2 WILSAS LVdWI 1138 01 0021 340439 WWsz QINOLLISOd 39 5310 e LVaWI INNOW IVUL 1
12. btain 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 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 Guardabelt Impact Cradle 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 D 3 14 03 2011 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 Revision D SAFETY INTRODUCTION INSTALLATION COMMISSIONING OPERATOR TRAINING ROUTINE MAINTENANCE AND SERVICE INSTALLATION ARRANGEMENT DRAWING EXPLODED PARTS DRAWING 14 03 2011 SECTION 1 SAFETY The Guardabelt Impact Cradle 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
13. f 1400mm and 1500mm are also available 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 6 14 03 2011 Load Chute i 4 25min 1200 Impact Cradle N 5 Rott i i LESS II A tN Troughing Idler Set Troughing Idler Set Additional Cradles Fig 1 Guardabelt Impact Cradle Layout 5 Determine the installation position for the impact cradle s The impact cradle s should be installed to cover the entire direct load area of the conveyor belt For a short load zone this may mean one cradle and for longer load zones multiple cradles may be used Having determined the position of the first impact cradle disassemble one cradle for installation This involves removal of the wing locks two per side and sliding off the wing bars from both sides After this is done the four wing support assemblies can be slid from either side of the cradle The centre bars can then be slid from the cradle base Insert the cradle base onto the conveyor stringers in the appropriate position and align with stringers Ensure that the base is centred and squared to the stringers and clamp into position NOTE If
14. hat no fabrication error or design errors have resulted in incorrect installation position of the cradle SECTION 3 INSTALLATION Handling and Storage Instructions The ESS Guardabelt Impact Cradle is a sturdy and robust assembly is unlikely to be damaged during normal transport and handling procedures Each Impact Cradle assembly is despatched individually and is suitable for forklift handling Average weight depending on belt width is of the order of 300 500kg per assembly The units are suitable for outdoor storage on site Installation Procedure 1 4 NOTE Revision D Determine approximate installation position for each impact cradle on the conveyor and place the appropriate cradles adjacent to the installation area by use of a forklift crane etc Before commencing installation or any work around the conveyor belt ensure that the belt is isolated and tagged The ESS Impact Cradle is intended to be installed between impact idler troughing assemblies Multiple impact cradles will have an impact idler trough assembly between each successive cradle Ensure that impact idler assemblies are either already installed or available at the installation site the idlers are already installed check that sufficient clearance is available between successive sets of rollers to fit an impact cradle Standard impact cradles are 1200mm long and require 25mm clearance at each end between cradle bar and roller Non standard cradles o
15. nveyor belt without first isolating and tagging the conveyor drive SECTION 5 OPERATOR TRAINING Servicing Recommended dismantle amp Hose down and reassemble every 6 months There are no operator serviceable or adjustable functions on an ESS Guardabelt Impact Cradle 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 Guardabelt Impact Cradle 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 siezed impact idler or a skirting problem but could possibly indicate an impact cradle fault Leakage of material from skirts at load zone this should be notified to the appropriate maintenance personnel for attention at the earliest plant stoppage It may mean that skirting requires attention and or that the impact cradle wings require adjustment Revision D 10 14 03 2011 SECTION 6 ROUTINE MAINTENANCE AND SERVICE Safety Before attempting any maintenance on or around a conveyor belt ensure that the belt drive is isolated
16. the conveyor belt is not already in place the cradle can be lifted complete into position and installed without disassembly This would require crane or fork handling 6 Slide the centre bars onto the base frame and centre them on the base 7 not already in position install an impact idler set either side of the impact cradle base ensuring that 25mm clearance will be available at both ends of the centre impact bars Fig 1 Revision D 7 14 03 2011 8 Using a string line or straight edge ensure that the top of the centre bars is approximately 20mm below the top of the centre rollers of the impact idler frame Fig 2 If this dimension is not approximately 20mm packing of either the impact cradle base or the impact idler frames may be necessary to achieve this 20mm clearance Once this clearance is achieved drill bolt holes in the stringers at appropriate position and bolt the cradle base in place Alternatively weld in place NOTE Accelerated bar wear will result from insufficient clearance Belt damage may result from an excessive clearance due to lack of belt support String Line or Straight Edge Lead in __ Belt Direction Fig 2 Cradle Positioning 9 Re assemble the cradle in reverse order of disassembly The wing bars that is the troughing bars should also be approximately 20mm away from the troughing idler line Fig 3 20mm Clearance 20mm Clearance
Download Pdf Manuals
Related Search