brelko - oreflow
TRANSCRIPT
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 465 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
Model number information can be found on the Label found on the scraper carton.This information will be helpful for any future inquiries or questions about belt scraper replacement parts, specifications or
troubleshooting.
INSTALLATION, OPERATING & MAINTENANCE MANUAL
Project Name : .
Project Number : .
Order Number : .
: .
Model Number : .
Purchase Date : .
Purchased From : .
Installati on Date : .
: .
BELT TRACKING SYSTEM3 / 5 ROLL TROUGHING FRAMEPATENTED
NEWPRODUCT
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 466 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
Table of Contents1. Disclaimer 467
2. Safety Note 467
3. The following symbols may be used in this manual: 467
4. General Information 467
4.1. Application and Features (Standard System). 468
4.2. Reference Drawing - BTT-006 469
5. Handling 470
5.1. Receiving the goods 470
5.2. Work Safety 470
5.3. Handling 471
5.4. Storage 471
5.5. Preparations for installing Belt Scrapers 471
5.6. Recommended Tools List 471
6. Maintenance 473
6.1. New Installation 473
6.2. Routine Visual Inspection (every 2~4 weeks) 473
6.3. Routine Physical Inspection (every 6~8 weeks) 473
6.4. Parts List and Assembly Instructions (Standard System). 474
6.5. Reference Drawing - BTT-007 475
6.6. Installation Instructions (Standard Mount) 476
6.7. Reference Drawing - BTT-008 477
7. Bearing Replacement Guide - REF. DRW. BTT-007 478
8. Maintenance Log 479
9. Conveyor Belt & Equipment Check List 480
10. Trouble Shooting 483
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 467 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
1. Disclaimer
Brelko conveyor products (Pty) Ltd hereby disclaims any liability for: damage due to contamination of the material; user’s failure to inspect, maintain and take reasonable care of the equipment; injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Brelko’s liability shall be limited to repair or replacement of equipment shown to be defective.
2. Safety Note
Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tag-out procedures as defined by National Standards Institutes, National Standard for Personnel Protection - Lockout/Tag-out of Energy Sources - Minimum Safety Requirements and Occupational Health and Safety.
3. The following symbols may be used in this manual:
DANGER Danger: Immediate hazards that will result in severe personal injury or death.
WARNING Warning: Hazards or unsafe practices that could result in personal injury.
CAUTION Caution: Hazards or unsafe practices that could result in product or property damages.
Important: Important: Instructions that must be followed to ensure proper installation/operation of equipment.
Note: Note: General statements to assist the reader.
4. General Information
Brelko Belt Tracking Systems are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Belt Tracking System is installed a regular maintenance program should be set up. This program will ensure that the Belt Tracking System operates at optimal efficiency and problems can be identified and fixed before the Belt Tracking System stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Belt Tracking Systems operate along the length of the conveyor and are in direct contact with the moving belt. Only visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tag-out procedures.
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 468 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
APPLICATIONS Install the Belt Tracking System on the troughing side of the belt to centralise a misaligned belt, prevent spillage,
decrease downti me, decrease maintenance and extend belt life.
FEATURES Easy installati on. Low maintenance. Vibrati on free rolling acti on. Simple design. Operates in all conditi ons. Manufactured according to S.A.B.S. mounti ng standards. Fully sealed constructi on of bearing housing prevents ingress of material into the bearing unit. Robust constructi on for longer life. Proven polyurethane coated impact rolls, last up to 3 ti mes longer than standard rubber lagged.
BELT TRACKING SYSTEM3 / 5 ROLL TROUGHING FRAMEPATENTED
NEWPRODUCT
REV.
FEAT
UR
ES &
OPT
ION
S: B
ELT
TRAC
KIN
G T
RO
UG
HIN
G F
RAM
E (3
-RO
LL)
STAN
DARD
MOU
NTIN
G
STAN
DARD
CON
STRU
CTIO
N &
FINI
SHES
FOR
BEL
T W
IDTH
S FR
OM:
BELT
TR
ACKI
NG
TR
OU
GH
ING
FR
AME
03
400 -
2400
DRW
.No
.BT
T-00
6
←BE
LT D
IREC
TIO
N
BELT
DIR
ECTI
ON
IDLE
R R
OLL
S:PO
LYU
RET
HAN
E LA
GG
ED (8
mm
TH
K)
ADJUSTABLE
35°20° /
/ 45°
CO
NVE
YOR
STR
ING
ERs
CO
NVE
YOR
BEL
T
330
SIZE
1_3
R:
SIZE
2_3
R: 4
15SI
ZE 2
_5R
: 430
SIZE
RA
NG
E:- S
IZE
1:
400
- 120
0BW
(3 R
OLL
)- S
IZE
2: 1
050
- 240
0BW
(3 &
5 R
OLL
)
Sz 1
: Ø12
7Sz
2: Ø
152
Sz 1
: SER
IES
25Sz
2: S
ERIE
S 30
15°
* BEA
RIN
G A
NG
LE
(STD SUPPLY)
220
Sz 1: 170 - 270 mmSz 2: 170 - 290 mm
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
© 0
8-20
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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 470 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
5. Handling
5.1. Receiving the goods
Check that the shipment contains all the products specified in the delivery note. If the goods do not match the delivery note, if the goods show any transportation damage, list it on the freight bill. Describe the damage and the number of wrong or faulty goods, and contact your supplier immediately.
Do not use defective parts under any circumstances. Claims must be made within 8 days from the arrival of goods. The factory does not cover expenses caused by exchange of product when installation was not carried out according to factory instructions.
5.2. Work Safety
Always use protective gloves and clothing. Always use a lifeline and soft-sole footwear when work will be carried out on raised platforms. Before you move a scraper or plough, check that it is securely attached to the lifting equipment. Always observe local safety regulations.
WARNINGBefore removing/installing equipment, lock out/tag out energy source to conveyor, and/or conveyor accessories.
Turn off and lock out/tag out energy source according to local standards.
If equipment will be installed in an enclosed area, test gas level or duct content before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion.
If using a cutting torch or welding machine, test atmosphere for gas level or dust content.
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 471 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
5.3. Handling
When scrapers are unloaded from the transportation vehicle onto customer’s platform, place them on boards spaced max 1m apart at a minimum of 5cm from the ground.
5.4. Storage
Scrapers can be stored unpacked or in transportation package. Scrapers must not be stored on top of one another, protect the scrapers by storing them in a cool dry area on a flat surface.
5.5. Preparations for installing Belt Scrapers
Before installation, check all measurements and any of the other geometric design
5.6. Recommended Tools List
BELT TRACKING TROUGHING SYSTEMS
QTY DESCRIPTION
2 EXTENSION CORD (30m MINIMUM)
1 PORT-A-PACK (OXY-ACETYLENE)
1 FLINT LIGHTER
1 ARC WELDER (INVERTER) 200AMP
1 CHIPPING HAMMER
1 ANGLE GRINDER
1 BABY GRINDER
1 5M TAPE MEASURE
1 NOZZLE CLEANER
1 SHIFTING SPANNER
1 PIPE WRENCH 650MM
1 SET SOCKET SET 8MM TO 32MM
1 SOFT FACE HAMMER
2 SAFETY HARNESS
2 G-CLAMPS
1 JIMMY LEVER
1 TORCH (LED)
1 SET SCREW DRIVER SET
1 CHALK LINE
1 SCRIBER
1 CENTRE PUNCH
1 HACK SAW
1 STANLEY KNIFE
1 4PD HAMMER
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 472 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
Recommended Tools List (continued...)
BELT TRACKING TROUGHING SYSTEMS
QTY DESCRIPTION
1 ANGLE FINDER
1 ELECTRIC DRILL
1 SET ELECTRIC DRILL BITS
1 WELDING HELMET
1 FIRE EXTINGUISHER 9KG
1 SET WELDING SPATS
1 WELDING APRON
1 FIRE BLANKET
1 SMALL BLUE TOOL BOX
1 MAGNETIC BASE DRILL
1 SET 12, 14, 18 SLUGGER BITS
2 FLAT RING SPANNER 13”
2 FLAT RING SPANNER 17”
2 FLAT RING SPANNER 19”
2 FLAT RING SPANNER 24”
2 FLAT RING SPANNER 30”
1 LONG NOSE PLIERS
1 PLIERS
1 BELT LIFTER
2 1 TON LEVER HOIST
4 1M NYLON SLING
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 473 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
6. Maintenance
Brelko Belt Tracking Systems are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Belt Tracking System(s) are installed a regular maintenance program should be set up. This program will ensure that the Belt Tracking System operates at optimal efficiency and problems can be identified and fixed before the Belt Tracking System stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tag-out procedures.
6.1. New Installation
After the new Belt Tracking System has run for a few days a visual inspection should be made to ensure the Belt Tracking System is performing properly. Make adjustments as needed.
6.2. Routine Visual Inspection (every 2~4 weeks)
A visual inspection of the Belt Tracking System and belt can determine:
• If the mounts are adjusted at the correct height for optimal roller contact;
• If the rollers are worn and needs to be replaced;
• If there is damage to the bearing or other components; and,
• If fugitive material is built up on the Belt Tracking System.
If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for Belt Tracking Maintenance.
6.3. Routine Physical Inspection (every 6~8 weeks)
When the conveyor is not in operation and properly locked and tagged out perform a physical inspection of the Belt Tracking System performing the following tasks:
• Clean material build-up off of the Belt Tracking System.
• Closely inspect rollers for wear and any damage. Replace if needed.
• Ensure full roller to belt contact;
• Inspect the Belt Tracking System for damage;
• Inspect all fasteners for tightness and wear. Tighten or replace as needed.
• Replace any worn or damaged components i.e. bearings etc.
• Check the pressure of the Belt Tracking System on the belt. Adjust pressure if necessary.
When maintenance tasks are completed, test run the conveyor to ensure the Belt Tracking System is performing properly.
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 474 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
PARTS LIST - REF. DRW. No.: BTT-007
ITEM No. DESCRIPTION SIZE
(mm)
BELTWIDTH(mm)
CODE
A. Transom - Consisting of Spacer, Bolts,
Nuts and Washers
60.3 SQR 400-1200 Specify belt width and height
76.2 SQR 1050-2400
B. Idler Frame - Excluding Bearing Set. 60.3 SQR 400-1200 Specify belt width and height
76.2 SQR 1050-2400
C Bearing set - Consisting of Deep Grooved Ball Bearing, Trust Bearing and Bearing Seal.
DIA 80mm 400-1200 004-145-0001
DIA 110mm 1050-2400 004-145-0002
D Idler Roll (Polyurethane Lagged) Series 25 400-1200 Specify belt width
Series 30 1050-2400
F Hardware Set - Including Bearing Spacer, Top Cap, Idler Roll Retaining Washers and locking Screws
Series 25 400-1200 003-200-0030
Series 30 1050-2400 003-200-0031
NOTE! Always quote belt width.ASSEMBLY INSTRUCTIONS
1. Referring to the parts list, check that the correct parts and quantities have been supplied for the model and belt width of Belt Tracking System ordered.
2. Proceed with installation as per installation guide.
SURVEY and GUIDELINES
SURVEY1. Before installing the Belt Tracking System, carefully inspect the entire length of the conveyor belt. Identify areas of conveyor belt
misalignment. Contributing factors include concave pulleys, where the centre of the pulley has collapsed, and uneven rubber wear on pulleys.
2. Tell-tale marks indicate problem areas where a drifting conveyor belt has come into contact with the structure for instance, damaged drop brackets and structure.
3. Tail, head and take-up pulleys identify areas of greatest damage caused by badly aligned belts.
GUIDELINES1. One correctly installed Belt Tracking System can control misalignment for about 30 metres of belt and need only be installed on areas
where misalignment occurs.2. Always install the Belt Tracking System ahead of the problem area. 3. To obtain maximum belt alignment, use the maximum face length of the Belt Tracking System. This ensures that you obtain the
optimum working life from the Belt Tracking System.4. Insufficient traction between the belt centralising idler frame set and the belt leads to severe rubber wear. Although the Belt Tracking
System will kick in and control the belt, there won’t be enough tension to successfully centre the belt on the Belt Tracking System. This results in chafing of the Belt Tracking System polyurethane lagged rollers. By increasing the tension; the Belt Tracking System will centralise the belt and return to a state of equilibrium.
REV.
PART
S LIS
T: B
ELT
TRAC
KIN
G T
RO
UG
HIN
G F
RAM
E (3
-RO
LL)
BELT
TR
ACKI
NG
TR
OU
GH
ING
FR
AME
03DR
W.
No.
BTT-
007
2
D
BA
C
2
3
7
2
4
5
8 10 9
6
3a
1
LEG
END
COM
PONE
NT
I.D.
DESC
RIPT
ION
ATR
ANSO
M A
SSEM
BLY
BID
LER
FRAM
E - E
XCLU
DING
BEA
RING
SET
CBE
ARIN
G SE
T - C
ONSI
STIN
G OF
DEE
P-GR
OOVE
D BA
LL B
EARI
NG, T
HRUS
T BE
ARIN
G &
BEAR
ING
SEAL
DID
LER
ROLL
- PO
LYUR
ETHA
NE L
AGGE
D
FHA
RDW
ARE
SET
- INC
LUDI
NG B
EARI
NG S
PACE
R, T
OP C
AP, I
DLER
ROL
L RE
TAIN
ING
WAS
HERS
& L
OCKI
NG S
CREW
S
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
© 0
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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 476 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
INSTALLATION GUIDE - REF. DRW. No.: BTT-0081. After identifying the problem area on the load-carrying side of the belt, prepare to install the Belt Tracking System ahead of the
problem area, ensuring that it is installed before transitional idlers and after loading chutes.2. Position the Belt Tracking System in place of an existing idler set, before the problem area. For heavy laden belts, install the Belt
Tracking System between two of the existing idler sets, before the problem area. • Note: The Belt Tracking System is direction sensitive and therefore has to be installed correctly. Each Belt Tracking System has
“Belt Direction Labels” on the frame.3. Bolt the Belt Tracking System on to the structure. Before tightening, ensure the Belt Tracking System is perpendicular to the structure.
Once completed, tighten all bolts.• Note: Ensure all the rollers contact the belt.
4. Installation is now complete, start the conveyor belt to test the Belt Tracking System.5. If the problem still persists, knock the existing standard troughing frames perpendicular to the structure before and after the Belt
Tracking System.6. Remove any other tracking devices in front of or behind the Belt Tracking System, as they will reduce or interfere with the
performance of the Belt Tracking System.
CAUTION!!!
This equipment should only be installed, operated & maintained by people competent and fa-miliar with conveyor systems. Improper use or adjustment can result in serious personal injury
or damage to equipment.
IF IN DOUBT ASK!!!
FRO
NT
VIEW
SID
E VI
EW
IDLE
R R
OLL
"PO
LYU
RET
HAN
E-LA
GG
ED"
REV.
INST
ALLA
TION
DET
AIL:
BELT
TR
ACKI
NG
TR
OU
GH
ING
FR
AME
(3-R
OLL
)
BELT
TR
ACKI
NG
TR
OU
GH
ING
FR
AME
03DR
W.
No.
BTT-
008
35°20° /
/ 45°
(A)
B - S
HAF
T SI
ZE
C -
FAC
E LE
NG
TH
D -
GAU
GE
LEN
GTH
S1: Ø 143
S2: Ø 168
(SM
C)
(IDLE
R C
AR)
(TR
NSM
)
BELT
TRA
CKER
- TH
ROU
GHI
NG
FRA
ME
- 3 R
OLL
BELT
WID
TH40
045
050
060
075
090
010
5012
0013
5015
0016
5018
0021
0024
00
SIZE
1
SMC
= “S
TRIN
GER
MOU
NTIN
G CE
NTER
s”
SMC
634
686
736
838
990
1144
1296
1448
A33
0B
Ø 25
C17
019
020
024
029
034
039
045
0D
180
200
210
250
300
350
400
460
TRNS
M60
.3 S
QRID
LR C
AR60
.3 S
QRSI
ZE
SMC
= “S
TRIN
GER
MOU
NTIN
G CE
NTER
s”
2SM
C12
9614
4816
0017
5219
0420
5823
6226
68DH
415(
3R) /
430
(5R)
AØ
30B
390
450
500
560
610
660
765
870
C40
046
051
057
062
067
077
588
0TR
NSM
76.2
SQR
IDLR
CAR
76.2
SQR
←BE
LT D
IREC
TIO
N
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
© 0
8-20
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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 478 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
7. Bearing Replacement Guide - REF. DRW. BTT-007
In order to replace the Bearing housing the following must be followed.
7.1. Remove the idler roller retaining washers (1) and the idler rollers (2) from the idler frame (3).
Note: This step must be done carefully to prevent misplacing or losing any components.
7.2. Remove the locking screw (4), top cap (5), idler frame (3) and bearing spacer (6) from the transom (7).
Note: This step must be done carefully to prevent misplacing or losing any components.
7.3. Remove the bearing seal (8), thrust bearing (9) and deep grooved ball bearing (10) from the bearing housing (3a).
7.4. Replace worn and/or damaged bearings and bearing seal with the new components.
7.5. Re-assemble the Belt Tracking System.
7.6. With reference to the installation guide continue with the installation.
DOC No ISSUE No REVISION MARCH PAGEFS 023 02 02 2014 Page 1 of 3
CONVEYOR BELT & EQUIPMENT CHECK LIST
CUSTOMER DETAILSCustomer Name: Contact Number:
Attention: Date of Inspection
Inspected By Brelko Representative
CONVEYOR DIMENSIONSBelt Number: Material Carried: Belt Speed:
Belt Length: Belt Width : Troughing Angle:
Top Cover Condition: Bottom Cover Condition:
Splice: Yes No Clip Joint: Yes No Cover Strip: Yes No
Conveyor Running Yes No Inspection Tags: Yes No
Edge Damage: Yes No
Comments:
HEAD END / HEAD CHUTEChute Condition: Head Pulley Lagging:
Snub Pulley Lagging: Build up:
Belt Movement:
Comments:
IDLER CHECKTrough Idler Condition: Return Idler Condition:Troughing Frame Condition: Return Frame Condition:
Comments:
PRIMARY SCRAPERPosition Correct: Yes No Type of Primary Scraper installed: (Contact of Scraper Blade must be between 10 to 30 degrees, under the pulley horizontal line.)Mounts firmly mounted: Yes No All bolts, nuts tightened: Yes No
Adequate Tensioning: Yes No All Caps, Denso Tape in place: Yes No
Housekeeping:
Chute Material build up:
Blade Wear: Low Medium High Cleaning: Poor Fair Good
Comments:
SECONDARY SCRAPER #1Type / Model of Secondary Scraper Installed:
Positioning Correct:
(Scraper blade must preferably be a minimum 100mm from pulley tangent.)
All Caps, Denso Tape in Place: Yes No Mounts firmly mounted: Yes No
All Bolts & Nuts Tightened: Yes No Adequate tension/adjustment: Yes No
Angle Correct Set: Yes No Carrier Frame cut to size Yes No
Angle of scraper must be 90 degrees to the conveyor belt, dependant on conditions.
Chute / Material build up: Yes No Housekeeping:
Blade wear: Low Medium High Cleaning: Poor Fair Good
Comments:
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
ISO 9001:2008ISO 14001:2004OHSAS 18001:2007
DEKRA
erC cA aRK oE nD
SERVICE EXCELLENCE
30OVER
YEARS
DOC No ISSUE No REVISION MARCH PAGEFS 023 02 02 2014 Page 2 of 3
SECONDARY SCRAPER #2Type / Model of Secondary Scraper Installed:
Positioning Correct:
Scraper blade must preferably be a minimum 100mm from pulley tangent.
All Caps, Denso Tape in Place: Yes No Mounts firmly mounted: Yes No
All Bolts & Nuts Tightened: Yes No Adequate tension/adjustment: Yes No
Angle Correct Set: Yes No Carrier Frame cut to size Yes No
Angle of scraper must be 90 degrees to the conveyor belt, dependant on conditions.
Chute / Material build up: Yes No Housekeeping:
Blade wear: Low Medium High Cleaning: Poor Fair Good
Comments:
TAKE UP PULLEYS / COUNTERWEIGHT / PLOUGHType / Model of Plough Installed:
Are Flat Return Idlers Installed: (In front) Yes No (Behind) Yes No
Any excessive belt movement: Yes No Adequate space for material to fall off of conveyor belt Yes No
Is the Plough firmly mounted: Yes No Is the Safety Chain firmly mounted and correctly adjusted: Yes No
Is the Plough Free moving: Yes No Is the entire Blade / Nose Piece in contact with the conveyor belt: Yes No
Housekeeping:
Comments:
CONVEYOR BELT TRACKING / ALIGNMENTIs the Belt Tracking centre: Yes No Are there any Tracking Systems installed: Troughing Return
Is there any visible damage to structure caused by poor belt tracking: Yes No
Conveyor belt length: Are the tracking systems correctly positioned: Yes No
Are the tracking systems firmly mounted: Yes No Are all bolts & nuts tightened: Yes No
Are all Idlers in contact with the Belt - Adequate Tension on the system: Yes No Housekeeping:
Comments:
LOADING / TRANSFER CHUTEChute Condition: Poor Fair Good Material loading in centre of conveyor belt:
Dead Boxes: Yes No Deflector Plates: Yes No Drop Heights:
Tail Pulley Condition Good Fair Poor
Comments:
KEYSKIRTING®
Size of Keyskirt®: 1 2 3 4 Length of Keyskirt® Installed :
Positioning of Keyskirt® : Other Product used as Skirting Yes No State
Mounting Arrangement Std. Offset Other
All bolts & nuts securely fastened: Yes No Housekeeping:
Comments:
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
ISO 9001:2008ISO 14001:2004OHSAS 18001:2007
DEKRA
erC cA aRK oE nD
SERVICE EXCELLENCE
30OVER
YEARS
DOC No ISSUE No REVISION MARCH PAGEFS 023 02 02 2014 Page 3 of 3
FEEDBOOTSType of Feedboot installed: Universal Combination Is the system correctly positioned: Yes No
(System to be positioned centrally to the load area.)
Drop Height: Is the system securely mounted: Yes No
All Bolts & Nuts tightened: Yes No Condition of Idlers: Poor Fair Good
Lead in and lead out Idlers in place: Yes No Condition of UHMW Liners: Low Medium High
Housekeeping:
Comments:
HI - IMPACT SYSTEMType of Hi - Impact system installed :
Is the system correctly positioned: Yes No Drop heights:
System to be positioned centrally to the load area.
Is the system securely mounted: Yes No All bolts & nuts tightened: Yes No
Are all Idlers in contact with the belt: Yes No Idler condition: Poor Fair Good
BTA Condition: Poor Fair Good Are chains / D shackles in place & securely fastened: Yes No
All Hardware in Good Condition: Yes No Housekeeping:
Comments:
AIR CANNONS
Size of Air Cannon Installed:
5ltr Quantity 10ltr Quantity
25ltr Quantity 50ltr Quantity
100ltr Quantity 200ltr Quantity
Is the Air Cannon securely fastened onto the structure: Yes No Is an Air Lance installed: Yes No
Size of the Air Lance: Are the Air Cannons correctly positioned: Yes No
Power supply: Air supply:
Operating system: Single timer PLC Manual push button Sequential
All Bolts & Nuts securely tightened: Yes No All components in good order: Yes No
Distance between Air Cannon & Solenoid Valve: Any Air Leaks in the Pipe Work: No
Is a Water Trap Installed: Yes No Is a Lubricator installed: Yes No
Distance from Air Cannon: Distance from Air Cannon:
Are the safety / warning signs in place and visible: Yes No Housekeeping:
Comments:
TAIL PULLEY / PLOUGHType / Model of Plough Installed:
Are Flat Return Idlers installed: (In front) Yes No (Behind) Yes No
Any excessive belt movement: Yes No Adequate space for material to fall off of conveyor belt: Yes No
Is the Plough firmly mounted: Yes No Is the Safety Chain firmly mounted and correctly adjusted: Yes No
Is the Plough free moving: Yes No Is the entire Blade / Nose Piece in contact with the conveyor belt: Yes No
Housekeeping:
Comments:
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
ISO 9001:2008ISO 14001:2004OHSAS 18001:2007
DEKRA
erC cA aRK oE nD
SERVICE EXCELLENCE
30OVER
YEARS
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016BELT TRACKING TROUGHING SYSTEMS - Page 483 to 483
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
10. Trouble Shooting
Problem Possible Cause Possible Solution
Poor Tracking
Tracker belt contact pressure too low. Increase belt contact pressure, refer to installation instructions.
Tracker belt contact pressure too high. Decrease belt contact pressure.
Tracker installed in wrong direction. Verify directional labels - refer to installation drawing.
Tracker stoppers not correctly adjusted. Adjust accordingly - refer to installation instructions.
Belt not in contact with all idlers Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions.
Wear on Rollers / Roller failure
Belt not in contact with all idlers Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions.
Belt contact pressure too high/low. Adjust to correct pressure, refer to installation instructions.
No Frame Movement
Material build-up and ingress of material on frame or components. Clean and remove.
Bearing failure. Repair or replace - refer installation instructions
Belt contact pressure too high/low. Adjust Tracker to ensure all idlers are in full contact with the belt - refer to installation instructions.
Check Tracker and Belt troughing angle match Replace Tracker with belt troughing angle.
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016LEGAL - Page 596 to 597
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
DISCLAIMER - CatalogueThe information provided in these documents is advisory only. These recommendations are provided by BRELKO® in the interest of promoting safety in the work place. These recommendations are general in nature and are not intended as a substitute for a thorough safety program. Users should seek the advice, supervision or consultation of qualified engineers or other safety professionals. Any use of this document, the information contained herein, or any other BRELKO® publication may only be made with the agreement and understanding that the user and the user’s company assume full responsibility for the design, safety, specifications, suitability and adequacy of the system component, or mechanical or electrical device designed or manufactured using this information. The user and the user’s company understand and agree that BRELKO®, its member companies, its officers, agents and employees shall not be liable in any manner under any theory of liability for the user or user’s reliance on these recommendations. The users and the user’s company agree to release, hold harmless and indemnify BRELKO®, its member companies, successors, assigns, officers, agents and employees from any and all claims of liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this information. BRELKO® and its member companies, successors, assigns, officers, agents and employees make no representations or warranties whatsoever, either express or implied, about the information contained in this document, including, but not limited to, representations or warranties that the information and recommendations contained herein conform to any federal, state or local laws, regulations, guidelines or ordinances.
DISCLAIMER - Digital Media CatalogueThe materials on the digital media are provided “as is” and without warranties of any kind either express or implied. To the fullest extent permissible pursuant to applicable law, we disclaim all warranties, express or implied, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. We do not warrant that the functions contained in the materials on any BRELKO® digital media will be uninterrupted or error-free, that defects will be corrected, or that any BRELKO® digital are free of viruses or other harmful components. We do not warrant or make any representations regarding the use or the results of the use of the materials on any BRELKO® digital media in terms of their correctness, accuracy, reliability, or otherwise. You assume the entire cost of all necessary servicing, repair, or correction. Applicable law may not allow the exclusion of implied warranties.
PRODUCT, PARTS LIST and INSTALLATION INSTRUCTION, DIGITAL MEDIA CATALOGUE TERMS OF USE.Although care has been taken to ensure, to the best of our knowledge, that all data and information contained on this digital media is accurate to the extent that it relates to either matters of fact or accepted practice or matters of opinion at the time of publication, Brelko® Conveyor Products assumes no responsibility for any errors in or misinterpretations of such data and/or information, or loss or damage arising from or related to its use.
TRADEMARKS.All registered trademarks, trademarks and/or service marks mentioned or implied on these compact discs are copyright by their respective owners. It shall not be construed that any products sold or manufactured by Brelko® Conveyor Products are the original product of the O.E.M.
RESTRICTIONS ON USE OF MATERIALS.All materials contained on these digital media are the copyrighted property of Brelko®. All trademarks, service marks, and trade names are proprietary to Brelko® Conveyor Products. No material from these compact discs be may copied, reproduced, republished, posted, transmitted, or distributed in any way, without prior written consent of Brelko®. For purposes of these terms, the use of any such material on any other digital media or computer environment is prohibited. All trademarks, service marks, trade names and trade dress are proprietary to Brelko®. In the event you copy any software, files, images, images incorporated into or generated by the software, data or data produced by the software (collectively known as, the “Software”) from these compact discs, are licensed to you by us (or third party licensors) for your personal use only.
{NOTICE: Third party licensors may have further rules and/or restrictions regarding their software and/or products. Please see and follow all third party licensors information} we do not transfer the title to any Software to you in any way. You own the medium on which the Software is recorded, but we (or third party licensors) retain full and complete title to the You may not redistribute, sell, de-compile, reverse engineer, disassemble, or otherwise reduce the Software to a human-readable form (into any language, natural or computer) or by any other form or means without prior written consent from Brelko®. Any code, text, photo, graphic, audio and/or video material contained on these Brelko® digital media shall not be published, broadcast, rewritten for broadcast or publication or redistributed directly or indirectly in any medium. Neither these materials nor any portion thereof may be stored in a computer except for personal and non-commercial use without prior consent, in writing, from Brelko®. Brelko® will not be held liable for any delays, inaccuracies, errors or omissions there from or in the transmission or delivery of all or any part thereof or for any damages arising from any of the foregoing.
P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com
BRELKOCONVEYOR PRODUCTS ®
Version 7.0 – © 08/2016LEGAL - Page 597 to 597
All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.
SUBMISSIONSWe are pleased to hear from our distributors/customers and welcome your comments regarding our products and services. Unfortunately, however, our long-standing company policy does not allow us to accept or consider creative ideas, suggestions, or materials other than those that we have specifically requested. We hope you will understand that it is the intent of this policy to avoid the possibility of future misunderstandings when projects developed by our professional staff might seem to others to be similar to their own projects. Please do not send us any unsolicited original materials such as CAD drawings, ideas, equipment layouts or specifications. While we do value your feedback on our services and products, we request that you be specific in your comments on those services and products, and not submit any ideas, suggestions, or materials (unless specifically requested by Brelko®). If, at our request, you send certain specific submissions (i.e., email, attachments) or, despite reading our above warning you send us suggestions, ideas, notes, drawings, concepts, or other information (collectively, the “Submissions”), the Submissions shall be deemed, and shall remain, the property of Brelko® unless noted otherwise. None of the Submissions shall be subject to any obligation of confidence on our part and we shall not be liable for any use or disclosure of any Submissions. Without limitation of the foregoing, we shall exclusively own all now known or hereafter existing rights to the Submissions of every kind and nature and shall be entitled to unrestricted use of the Submissions for any purpose whatsoever, commercial or otherwise, without compensation to the provider of the Submissions.
TERMINATIONThese terms are effective until terminated by either party. You may terminate these terms at any time by discontinuing use of these compact discs and destroying all materials obtained from and all related documentation and all copies and installations thereof, whether made under the terms of these terms or otherwise.
!!!WARNING!!!
General Safety ProceduresBelt conveyors and their transfer points can be dangerous. By their very nature, they feature many “pinch” points and speeding objects. They apply large amounts of mechanical energy to what is basically a loaded rubber band. Operations and maintenance personnel must always be aware of the power of a conveyor, and they must maintain a healthy respect for its potential to injure or kill an untrained or unwary individual.
General Safety GuidelinesThere are certain safety procedures that should be observed regardless of the design of the conveyor or the circumstances of operation.
They include:
1. Lock out/tag out all energy sources to conveyor belt, conveyor accessories, and associated process equipment before beginning any work-whether it is construction, installation, maintenance, or inspection in the area. Use a lock with one key for each piece of equipment. Only the person doing the work should hold the key to the lock.
2. Employees should be properly trained on the material handling System (including emergency warning signals and emergency stop controls) before they are allowed to work in the area or attempt to install any Brelko® equipment or system.
3. Employees and visitors should learn and observe all applicable company, local, state, and federal safety rules. It is recommended that a formal testing program covering the safety rules be conducted annually.
4. The recommended operating speed and capacity for the conveyor and chute should not be exceeded. If assistance for product selection is required, please contact your Brelko® representative.
5. All tools and work materials should be removed from the belt and chute before restarting a conveyor. A safety “walk around” is recommended prior to conveyor operation, making sure that all nuts and bolts are tightened on all Brelko® equipment or systems installed. Also ensuring that all other items adjusted during installation are tightened, safety guards replaced etc...
6. All emergency controls should be close to the system, easy to access, and free of debris and obstructions.7. A hard hat, safety glasses, and steel-toe shoes should be worn when in the area of the conveyor. Loose or bulky clothing should not
be allowed.8. Never poke, prod, or reach into a material handling system while it is in operation, to clean or remove foreign objects from the
Brelko® equipment or systems installed.The above guidelines are not intended to replace the safety guidelines of the industrial area, and must be used in conjunction with the industrial area’s safety regulations and those supplied by the manufactures of the specific systems.