conveyor handbook-part 2

4 - 0

4. Belt Carcass Selection

Belt Construction Requirements ……………………………………………………….. 4 - 1

Considerations ….……………………………………………………………………….. 4 - 1

Procedure ………..……………………………………………………………………….. 4 - 2

Table 1A Allowable Working Tensions – Standard constructions…………….. 4 - 3Table 1B Allowable Working Tensions – CoalMaster series………………….. 4 - 4Table 2A Load support table – Standard constructions……………………….. 4 - 5Table 2B Load support table – CoalMaster series……………………………… 4 - 6Table 3 Belt troughability –………………………………………………………. 4 - 7

4 - 1

4. Belt Carcass Selection

BELT CONSTRUCTION REQUIREMENTS.

To select the optimum plied belt carcass, five properties must be considered:

♦ The belt width.

♦ The service conditions under which the belt will operate.

♦ The maximum operating tension (Tmax) – both steady state condition and peak (see table 1).

♦ The minimum number of plies required to support the load (see tables 2).

♦ The maximum number of plies beyond which transverse flexibility is reduced and thetroughing efficiency is affected. This varies with the belt width, trough angle and the idler rollarrangement (see table 3)

CONSIDERATIONS:

Operating conditions

The allowable working tensions shown on Table 1 that follow are applicable for reasonably wellmaintained conveyors operating with moderate impact, infrequent starts and good loading. Peak tension– on starting or braking, should not exceed 140% of the allowable working tension.

For more severe operating conditions, moderate maintenance, short time cycles, frequent DOL or loadedstarts, poor loading or severe impact, hot materials handling etc., reduce the tabled figures by 15%.Tension on starting or braking should not exceed 150% of the resulting rated tension.

For severe service conditions, poor maintenance, very hot materials, chemically aggressiveenvironment, severe impact and short time cycles etc., reduce the tabled figures by 30%. Tension onstarting or braking should not exceed 160% of the resulting rated tension.

Safety factors

The working tensions shown on these tables are based on the application of a safety factor of 6.7:1 onthe strength of the belt at the splice or fastened join. The safety factor is increased for more difficultoperating conditions with further restrictions applying for starting and braking.

Starting and braking tensions

A check should always be made comparing the acceleration or braking tension with the allowable peaktension for the belt, i.e. 140% of rated working tension. If the peak tension exceeds the latter figure, astronger belt can be selected or the choice of control must be changed to reduce peak tension.

4 - 2

Mechanical fasteners

APEX FENNER always recommend hot vulcanised splices for plain weave plied belting. Otherconstructions including the Crows Foot Weave, Double Weave and Solid Woven PVC can besuccessfully operated at close to vulcanised joint tensions for long periods of time whereas plain weaveconstructions generally operate at reduced tensions when fitted with mechanical fasteners

Recommended precautions including frequent inspection and monitoring, any Local Authority restrictionsand greater than normal care should always be observed when using Mechanical Fasteners. Beltcleaners should only be fitted if specifically suited to operation with mechanical fasteners

If a conveyor belt is to be operated for any length of time with mechanical fasteners then the selectedcombination of belt and fastener should be statically tensile tested and a working tension of not morethan 15% of that result. Table 1 lists APEX FENNER recommendations for its common range of belts.

Troughability and load support

This table provides a guide to the maximum width of belt that will support the load when carrying materialwith the bulk density shown.This table provides a guide to the minimum width of belt that will trough satisfactorily at the trough angleshown. The widths shown above are a guide only and experience may dictate the selection of a ply moreor a ply less.

Some factors that may influence the choice are:

♦ Partially filled belt.♦ Idler trough angle♦ Convex or concave curve radius and idler pitch♦ Lump size of material♦ Installed pulley diameters

PROCEDURE:

Consider the possible belt constructions.

1. Calculate working tension needed for the both steady state and peak (accelerating or braking).

Required Working Tension (kN/m) = Tmax (kN) Belt width (m)

Where: Tmax. = Peak or Steady State tension in conveyor (kN).

2. Considering operating conditions and starting and braking tensions and determine suitable beltconstructions from tables 1A and 1B. Working tensions shown in tables 1A and 1B are applicablefor reasonably well-maintained conveyors with moderate impact, infrequent starts and goodloading and are reduced where operating conditions are less favourable - see discussion below

3. Consider special needs and the use of special fabrics such as Crow’s foot or Double weaves.

4. Establish the various practical carcass/ ply number combinations to support the load for theconveyor working conditions under review - (Tables). Load support requirements may dictate thatthe selected belt is operating at a fraction of it’s allowable working tension.

5. Check that the selected construction(s) are acceptable for troughing - (Table 3)

6. Check that the installed pulley diameters are adequate – (refer section 6)

The final selection should be checked with APEX FENNER since cost, availability and servicecriteria can be additional factors for consideration.

4 - 3

Table 1A – ALLOWABLE WORKING TENSION

Standard Constructions(other than CoalMaster series)

RECOMMENDED ALLOWABLE WORKING TENSION

For reasonably well maintained conveyors with moderate impact, infrequent starts and good loading.

Number of plies 2 3 4 5 6

PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6plain weave Spliced 24 kN/m 50 kN/m 72 kN/m 90 kN/m 112 kN/m

Fastened 27 kN/m 40 kN/m 53 kN/m 66 kN/m 79 kN/m


Fastened 34 kN/m 51 kN/m 68 kN/m 85 kN/m 102 kN/m

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave Spliced 37 kN/m 75 kN/m 112 kN/m 150 kN/m 187 kN/m

Fastened See below See below See below See below See below


Fastened See below See below See below See below See below

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5plain weave Spliced 100 kN/m 157 kN/m 192 kN/m

Fastened See below See below See below

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave Spliced 60 kN/m 120 kN/m 168 kN/m 216 kN/m

Fastened See below See below See below See below

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5Spliced 56 kN/m 100 kN/m 140 kN/m 192 kN/mCrow's foot

weave Fastened 56 kN/m 84 kN/m 112 kN/m 140 kN/m

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5Spliced 60 kN/m 120 kN/m 168 kN/m 216 kN/mCrow's foot

weave Fastened 70 kN/m 105 kN/m 140 kN/m 175 kN/m

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5Spliced 150 kN/m 202 kN/m 270 kN/mCrow's foot

weave Fastened See below See below See below

PN 450 PN900 /2 PN1350 /3Spliced 67.5 kN/m 135 kN/mDouble weave

Fastened 90 kN/m 135 kN/m

Not generally recommended for permanent use with mechanical fasteners, but may be used withfasteners either temporarily or permanently under certain conditions.

4 - 4

Table 1B – ALLOWABLE WORKING TENSION

CoalMaster series(For underground coal mining)

RECOMMENDED ALLOWABLE WORKING TENSION

For reasonably well maintained conveyors with moderate impact, infrequent starts and good loading.


PN 150 - 160 PN630 /4 PN800 /5plain weave Spliced 72 kN/m 96 kN/m

Fastened 53 kN/m 66 kN/m

PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6plain weave Spliced 90 kN/m 120 kN/m 150 kN/m

Fastened 68 kN/m 85 kN/m 102 kN/m

PN 250 PN1000 /4 PN1250 /5 PN1500 /6plain weave Spliced 112 kN/m 150 kN/m 187 kN/m

Fastened See below See below See below


Fastened See below See below






weave Fastened 90 kN/m 115 kN/m 140 kN/m


weave Fastened 105 kN/m 140 kN/m 175 kN/m


weave Fastened See below See below See below

PN 450 PN1350 /3Spliced 135 kN/mDouble weave

Fastened 135 kN/m

Not generally recommended for permanent use with mechanical fasteners, but may be usedwith fasteners either temporarily or permanently under certain conditions.

4 - 5

Table 2A - LOAD SUPPORT

Plain Weave Fabrics(with standard thickness skim)

MAXIMUM WIDTH TO SUPPORT THE LOAD

For conventional troughed conveyors


PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6plain weave 800 kg/m3 900 mm 1100 mm 1600 mm 2100 mm 2500 mm

Load 1200 kg/m3 700 mm 1000 mm 1500 mm 1900 mm 2400 mmBulk density: 1800 kg/m3 600 mm 800 mm 1300 mm 1700 mm 2200 mm

2600 kg/m3 - 500 mm 1000 mm 1500 mm 1900 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6plain weave 800 kg/m3 1100 mm 1300 mm 1800 mm 2400 mm -

Load 1200 kg/m3 1000 mm 1200 mm 1700 mm 2300 mm -Bulk density: 1800 kg/m3 800 mm 1000 mm 1500 mm 2100 mm -

2600 kg/m3 500 mm 800 mm 1300 mm 1800 mm 2300 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave 800 kg/m3 1200 mm 1500 mm 2100 mm - mm -

Load 1200 kg/m3 1100 mm 1400 mm 2000 mm - mm -Bulk density: 1800 kg/m3 900 mm 1200 mm 1800 mm 2500 mm -

2600 kg/m3 700 mm 1100 mm 1600 mm 2200 mm -

PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6plain weave 800 kg/m3 1400 mm 1800 mm - mm - -

Load 1200 kg/m3 1300 mm 1600 mm 2500 mm - -Bulk density: 1800 kg/m3 1100 mm 1500 mm 2300 mm - -

2600 kg/m3 800 mm 1200 mm 2100 mm - -

PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5plain weave 800 kg/m3 2000 mm - -

Load 1200 kg/m3 1800 mm - -Bulk density: 1800 kg/m3 1600 mm 2400 mm -

2600 kg/m3 1400 mm 2200 mm -

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave 800 kg/m3 1600 mm 2100 mm 2400 mm -

Load 1200 kg/m3 1500 mm 2000 mm - -Bulk density: 1800 kg/m3 1300 mm 1800 mm - -

2600 kg/m3 1000 mm 1600 mm - -

4 - 6

Table 2B - LOAD SUPPORT

Special Weave Fabrics(with standard thickness skim)

MAXIMUM WIDTH TO SUPPORT THE LOAD

For conventional troughed conveyors


PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5 800 kg/m3 1600 mm 2100 mm - -Crow's foot

weave 1200 kg/m3 1500 mm 2000 mm - -Bulk density: 1800 kg/m3 1300 mm 1800 mm - -

2600 kg/m3 1000 mm 1600 mm 2400 mm -

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5 800 kg/m3 1700 mm 2400 mm - -Crow's foot

weave 1200 kg/m3 1600 mm 2200 mm - -Bulk density: 1800 kg/m3 1400 mm 2000 mm - -

2600 kg/m3 1200 mm 1800 mm - -

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5 800 kg/m3 - - -Crow's foot

weave 1200 kg/m3 - - -Bulk density: 1800 kg/m3 2400 mm - -

2600 kg/m3 2200 mm - -

PN 450 PN900 /2 PN1350 /3Double weave 800 kg/m3 1900 mm -

1200 kg/m3 1800 mm -Bulk density: 1800 kg/m3 1600 mm -

2600 kg/m3 1300 mm -

4 - 7

Table 3 – TROUGHABILITY

Plain Weave Fabrics(with standard thickness skim)

MINIMUM WIDTH TO TROUGH THE BELT(For conventional troughed conveyors)


PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6plain weave 20 to 30º mm 400 mm 450 mm 500 mm 600 mm

30 to 40º mm 450 mm 500 mm 600 mm 750 mmup to 45º 400 mm 500 mm 600 mm 650 mm 800 mm

PN 200 - 220 PN400 /2 PN630 /3 PN800 /4 PN1000 /5 PN1200 /6plain weave 20 to 30º mm 450 mm 500 mm 650 mm 800 mm

30 to 40º 450 mm 500 mm 650 mm 750 mm 900 mmup to 45º 500 mm 650 mm 800 mm 900 mm 1050 mm

PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave 20 to 30º 400 mm 450 mm 650 mm 800 mm 900 mm


PN 300 - 315 PN630 /2 PN900 /3 PN1250 /4 PN1500 /5 PN1800 /6plain weave 20 to 30º 400 mm 600 mm 750 mm 800 mm 1000 mm


PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5plain weave 20 to 30º 600 mm 750 mm 900 mm

30 to 40º 750 mm 900 mm 1050 mmup to 45º 800 mm 1000 mm 1200 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave 20 to 30º 500 mm 650 mm 800 mm 1050 mm

30 to 40º 600 mm 750 mm 900 mm 1200 mmup to 45º 650 mm 900 mm 1050 mm 1400 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /520 to 30º 500 mm 650 mm 750 mm 900 mmCrow's foot

weave 30 to 40º 600 mm 750 mm 900 mm 1050 mmup to 45º 750 mm 900 mm 1050 mm 1350 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /520 to 30º 500 mm 650 mm 800 mm 1050 mmCrow's foot

weave 30 to 40º 650 mm 750 mm 900 mm 1200 mmup to 45º 750 mm 900 mm 1050 mm 1500 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /520 to 30º - - -Crow's foot

weave 30 to 40º - - -up to 45º 2200 mm - -

PN 450 PN900 /2 PN1350 /3Double weave 20 to 30º 1300 mm -

30 to 40º 1800 mm -up to 45º 1900 mm -

5 - 1

5. Cover Gauges and Qualities

Considerations…………………………………………………………………………… 5 - 1

Selection……………….………………………………………………………………….. 5 - 1

Pulley side cover………………………………………………………………………… 5 - 1

Table 1 Top Cover Thickness ………………………………………………… 5 – 2

5 - 2

5. Cover gauges and qualities

CONSIDERATIONS

There are a number of factors that must be taken into account when selecting the belt grade orcover material, such as:

♦ Fire resistance or anti-static properties♦ Resistance to oils or chemicals♦ Temperature of the operating environment or conveyed material♦ Resistance to ageing, weathering and ozone.♦ The type of material being conveyed♦ The lump size and shape of the material being conveyed♦ The mix of lumps and fines in the material♦ The abrasiveness of the material♦ The method of loading the belt♦ The fall height of material to the belt♦ The cycle time of the conveyor for a single revolution of the belt♦ Performance or experience in a similar application♦ For replacement belts – the performance of previous belts on the same installation♦ Availability and cost

SELECTION

Previous experience will always be the best guide to the optimum selection of both the type andthickness of belt cover, however if this information is not available as will be the case for newinstallations, the following steps should be followed.

♦ From table 1 – 2 select the most suitable cover types of cover or belt grades for theapplication. In some cases statutory requirements or the operating conditions will limitselections to one or two possibilities.

♦ Calculate the time cycle of the conveyor = (2 x L) S

Where:L = conveyor centres (m)S = belt speed (m/s)

♦ Use table 1 as a guide to select the appropriate thickness of top cover. Considerationshould be given to the applicable properties of the cover in making this selection.

For difficult applications such as belt feeders, or impact belts, heavier covers may be required.

PULLEY SIDE COVER

As a guide, pulley side cover should generally be not less than 1/4 of carry side cover for covers upto 9mm and about 1/3 of carry cover thickness for covers heavier than 9mm. Operating conditionscan dictate that heavier pulley side covers are required.For long centre, long time cycle conveyors, pulley side cover can be up to 1/2 of carry side cover.

5 - 3

TABLE 1BELT COVER THICKNESS

Lightly abrasivematerials

Moderately abrasivematerials

Heavily abrasivematerials

Extremely abrasivematerials

Lump size(mm)

Lump size(mm)

Lump size(mm)

Lump size(mm)

Time cycleseconds

(2 x L)S

Cycle time forcomplete belt

revolution.10 50 125 200 300 10 50 125 200 300 10 50 125 200 300 10 50 125 200 300

15 seconds 1-2 3-5 6-7 8-10 10-12 1-2 4-5 7-10 9-12 11-15 2-4 4-7 7-10 10-15 12-19 3-6 4-10 8-15 10-19 13-23

30 seconds 1-2 3-4 5-6 6-8 8-10 1-2 3-4 5-8 7-10 9-12 2-3 3-6 6-10 8-12 10-15 2-5 4-8 6-12 8-15 10-18

60 seconds 1-2 2-3 4-5 5-6 7-8 1-2 3-4 5-6 6-8 7-10 1-3 3-5 5-8 6-10 8-13 2-4 3-6 5-10 7-13 9-15

120 seconds 1-2 2-3 3-4 5-6 6-7 1-2 2-3 4-6 5-7 6-9 1-2 2-4 4-7 6-9 7-11 2-4 3-6 5-7 6-11 8-13

180 secondsand over 1-2 1-2 3-4 4-5 5-6 1-2 2-3 4-5 5-6 6-8 1-2 2-4 4-6 5-8 6-10 2-3 2-5 4-8 5-10 7-12

Typical materials Wood chips - bituminous coal - grains -round river gravel etc.

Basalt - sand - anthracite coal - crushedgravel etc.

Limestone - ores - phosphate - slag -cement clinker etc. Glass cullet - granite - quartz ores etc.

6 - 0

6. Pulley Diameters

Parallel face pulleys…………………………………………………………………….. 6 - 1

Crown face pulleys……………………………………………………………………… 6 - 2

Pulley face width………………………………………………………………………… 6 - 2

Table 1A Standard constructions– operating at over 60% of allowable working tension ……………… 6 - 3

Table 1B CoalMaster series– operating at over 60% of allowable working tension ……………… 6 - 4

Table 2A Standard constructions– operating at 30 - 60% of allowable working tension ….…………… 6 - 5

Table 2B CoalMaster series– operating at 30 - 60% of allowable working tension …….………… 6 - 6

6 - 1

6. Pulley diameters

The minimum pulley diameter recommended for a particular belt depends upon three factors:

• Carcass Thickness – The wire rope diameter in the case of Steel Cord belts.– The overall thickness of all plies plus the rubber skims between plies in the case of Ply Type belts.– The overall thickness of the thick woven fabric separatingthe top and bottom covers in the case of Solid-woven belts.

• Operating Tension – The relationship of the operating tension of the belt at the particular pulley to the belt’s Allowable Working Tension.

• Carcass modulus – The relationship between elongation of the carcass and the resulting stress.

Whatever the carcass type, Steel Cord, Ply Type or Solid Woven, when the belt is bent around asmall radius, tension stresses are developed in the outer fibres while compression stresses are builtup in the inner fibres. At a given tension, if the radius is too small the elastic limit of the outer fibresmay be exceeded and fracture, and at the same time, the compression of the inner fibres may causesevere crinkling and eventual ply separation.

Since the elastic properties of the rubber or PVC cover material is so much greater than the carcassmaterial, the cover thickness of the belting is not a factor in determining minimum pulley size, andmay be ignored.

The tables of recommended pulley diameters in the APEX FENNER handbook for Ply Type beltingare based on the three classes of pulleys defined in ISO 3684. viz.;

• Type “A” – High tension / tight side pulleys (T1) e.g. head, drive, tripper and shuttle pulleys• Type “B” – Low tension or slack side pulleys (T2) such as tail and take up pulleys• Type “C" – Low tension snub or bend pulleys with wrap angle of less than 30 degrees

Two sets of Pulley Diameter tables follow:

• For belts operating at over 60% of allowable working tensionTable 1 A - for standard belt constructionsTable 1 B – for CoalMaster series belts

• For belts operating at 30 – 60% of allowable working tensionTable 2 A - for standard belt constructionsTable 2 B – for CoalMaster series belts

For belts operating at less than 30% of the allowable working tension, the diameter of Type “A”pulleys can be reduced to the same as Type “B”.

PARALLEL FACE PULLEYS

With just a few special exceptions, all pulleys used with modern high strength, high modulus fabricbelts should be parallel face types. It is absolutely mandatory that all pulleys used in conveyors fittedwith Steel Cord belting be parallel face type. One notable exception to this rule is in the case ofBucket Elevators which, lacking any other means of tracking the belt centrally, may benefit fromCrown Faced Pulleys.

6 - 2

CROWN FACE PULLEYS

A Crown Faced pulley can have the effect of centering the tracking of the belt, but only in the casewhere there is a long unsupported length of belt leading into the pulley, as the belt must be able tobend longitudinally along its centreline to benefit from the crown. High modulus Ply Type belts havevery little ability to bend longitudinally and Steel Cord belts have virtually no ability at all. Solid Wovenbelts are not quite so rigid but still need an unsupported distance of something like 4 to 6 times thebelt width to be able to react.

Apart from not serving much purpose in troughed conveyor systems, Crowned pulleys can seriouslydamage the belt by severely overstressing the carcass in the centre of the belt, particularly in the caseof Steel Cord belts.

The few special cases where Crowned pulleys are useful include, Bucket Elevators, the Take- uppulley in long gravity Take-up arrangements and for some short centre - wide belt, reversingconveyors. In cases like this where there are no supporting idlers to train the belt, some benefit maybe obtained from the installation of Crowned pulleys.

Face Width W

W/4 W/4W/2

d D

Taper1 in 100

It is fairly common practice to crown a pulley by machining a taper of 1 in 100 from each pulley edgetowards the centre over a distance of 1/4 pulley face. It is more correct to relate the amount of pulleycrown to the pulley diameter, not to its face width. Viz.; d = D - 0.008 x D

PULLEY FACE WIDTH

As all belts tend to wander a bit in operation, the overall face width of the pulleys should exceed thebelt width by the following minimum amounts, if serious edge damage is to be avoided;

• Belts up to 650mm wide …. …. …. …. …. …. …. …. 100mm• Belts 750 to 1400mm wide …. …. …. …. …. …. …. …. 150mm• Belts over 1400mm wide …. …. …. …. …. …. …. …. 200mm

For conveyors built on unstable ground, as in underground coal mines and very long overlandconveyors, the above allowances should be increased by 50mm.

6 - 3

TABLE 1ASTANDARD CONSTRUCTIONS(other than CoalMaster series)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 60% of maximum allowable working tension


PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6plain weave Type “A” 315 mm 400 mm 560 mm 710 mm 800 mm

Type “B” 250 mm 315 mm 450 mm 560 mm 630 mmType “C” 200 mm 250 mm 360 mm 450 mm 500 mm



PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave Type “A” 450 mm 500 mm 710 mm 900 mm 1120 mm




PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5plain weave Type “A” 630 mm 900 mm 1120 mm

Type “B” 500 mm 710 mm 900 mmType “C” 400 mm 560 mm 710 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave Type “A” 560 mm 710 mm 1000 mm 1250 mm

Type “B” 450 mm 560 mm 800 mm 1000 mmType “C” 360 mm 450 mm 630 mm 800 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5Type “A” 560 mm 710 mm 1000 mm 1250 mmType “B” 450 mm 560 mm 800 mm 1000 mm

Crow's footweave

Type “C” 360 mm 450 mm 630 mm 800 mm


Crow's footweave

Type “C” 360 mm 500 mm 630 mm 800 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5Type “A” 900 mm 1250 mm 1600 mmType “B” 710 mm 1000 mm 1250 mm

Crow's footweave

Type “C” 560 mm 800 mm 1000 mm

PN 450 PN900 /2 PN1350 /3Type “A” 630 mm 1000 mmType “B” 500 mm 800 mm

Double weave

Type “C” 400 mm 630 mm

6 - 4

TABLE 1BCOALMASTER SERIES( For underground coal mining)

RECOMMENDED MINIMUM PULLEY DIAMETERS

For belts operating at over 60% of maximum allowable working tension


PN 150 - 160 PN630 /4 PN800 /5plain weave Type “A” 500 mm 710 mm

Type “B” 400 mm 560 mmType “C” 315 mm 450 mm



PN 250 PN1000 /4 PN1250 /5 PN1500 /6plain weave Type “A” 800 mm 1000 mm 1250 mm









Crow's footweave

Type “C” 450 mm 630 mm 800 mm


Crow's footweave

Type “C” 500 mm 630 mm 800 mm


Crow's footweave

Type “C” 560 mm 800 mm 1000 mm

PN 450 PN1350 /3Type “A” 1000 mmType “B” 800 mm

Double weave

Type “C” 630 mm

6 - 5

TABLE 2ASTANDARD CONSTRUCTIONS(other than CoalMaster series)

RECOMMENDED MINIMUM PULLEY DIAMETERSFor belts operating at over 30 to 60% of maximum allowable working tension

(for belts operating at less than 30% of allowable working tension,type “B” diameters can be used for Type “A” pulleys)






PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave Type “A” 360 mm 400 mm 560 mm 710 mm 900 mm






PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave Type “A” 450 mm 560 mm 800 mm 1000 mm

Type “B” 360 mm 450 mm 630 mm 800 mmType “C” 280 mm 360 mm 500 mm 630 mm


Crow's footweave

Type “C” 280 mm 360 mm 500 mm 630 mm


Crow's footweave

Type “C” 280 mm 400 mm 500 mm 630 mm


Crow's footweave

Type “C” 450 mm 630 mm 800 mm

PN 450 PN900 /2 PN1350 /3Type “A” 500 mm 800 mmType “B” 400 mm 630 mm

Double weave

Type “C” 315 mm 500 mm

6 - 6

TABLE 2BCOALMASTER SERIES(For underground coal mining)

RECOMMENDED MINIMUM PULLEY DIAMETERSFor belts operating at over 30 to 60% of maximum allowable working tension

(for belts operating at less than 30% of allowable working tension,type “B” diameters can be used for Type “A” pulleys)






PN 250 PN1000 /4 PN1250 /5 PN1500 /6plain weave Type “A” 630 mm 800 mm 1000 mm









Crow's footweave

Type “C” 360 mm 500 mm 630 mm


Crow's footweave

Type “C” 400 mm 500 mm 630 mm


Crow's footweave

Type “C” 450 mm 630 mm 800 mm

PN 450 PN1350 /3Type “A” 800 mmType “B” 630 mm

Double weave

Type “C” 500 mm

7. Design Considerations

Multiple Slope and Vertical Curve Conveyors …………………………………….. 7 - 1

Terminal Troughing Idler Arrangements ……………………………………………. 7 - 4

Transitions …………………………………………………………………..…………... 7 - 4

Take – Up Arrangements ………………………………………………………………. 7 - 5

Table 1 Average Elastic Modulus ‘E’ ……………………………….… 7 - 3Table 2 Transition Distances for Head Pulleys ……………………… 7 - 4Table 3 Transition Distances for Tail End Loading Points ………..… 7 - 5Table 4 Gravity Take – Up Travel ………………………………..…… 7 - 6

8 - 0

8. General Data

Belt Mass and thickness………………………..………………………………,,,,,,,,,,, 8 - 1

Shipping dimensions and roll sizes…………………………….………………...… 8 - 1

Length of belt on a roll…………………………………………………………...…… 8 - 2

Belt transport guidelines……………………………………………………….…… 8 - 3

Table 1 Belt carcass mass and thickness– standard constructions……………………………………………… 8 - 4

Table 2 Belt carcass mass and thickness– CoalMaster series…………………………………………………… 8 - 5

Table 3 Belt carcass and cover mass factors……………………………….. 8 – 6

8 - 1

8. General Data

BELT MASS AND THICKNESS

On the following pages are three tables:

Table 1Belt Carcass Mass and Thickness for Standard Belt Constructions(other than CoalMaster belting for underground coal mining)

Table 2Belt Carcass Mass and Thickness for CoalMaster Belting(for underground coal mining)

Table 3Carcass Mass Factor and Cover Mass Factor

To calculate Belt Mass

• Look up Belt Carcass Mass (kg/m2) from either table 1 - Standard Belt Constructions or table 2 -CoalMaster Belting as applicable.

• To obtain the actual Belt Carcass Mass, multiply this by the Belt Carcass Mass factor from table3.

• To obtain the mass of the belt covers, add together the top and bottom cover thickness andmultiply this by the Belt Cover Mass factor, also from table 3.

• Add together the mass of the Belt Carcass and Covers for the belt mass per square metre(kg/m2) and multiply by the belt width (in metres) for the belt mass per metre run (kg/m).

To obtain belt thickness

• Look up Belt Carcass Thickness (mm) from either table 1 - Standard Belt Constructions or table2 - CoalMaster Belting as applicable.

• Add to this the thickness of both the top and bottom covers.

SHIPPING DIMENSIONS AND ROLL SIZES

Roll diameter

Roll diameter for belts can be determined from figure 1 below. The diameters shown are for a beltwrapped on a 600mm-diameter centre. For belts supplied on enclosed drums, an additional 0.15mshould be added for clearance and slats where fitted.

Alternatively the diameter can be calculated from the following formula: ______________ ____

D = √ d2 + (0.001273 x L x G)

Where D = Overall diameter (m)d = core diameter (m)L = Belt length (m)G = Belt thickness (mm)

8 - 2

Belt thickness (mm)

0.5

1

1.5

2

2.5

3

3.5

4

50 100

150

200

250

300

350

400

450

500

550

600

Belt length (m)

Rol

l dia

met

er (m

)

Shipping dimensions

Add 50mm to belt width for clearance on belts supplied on cores.For belts supplied on enclosed drums:

- Add 300mm to belt width- Add 150mm to belt diameter

Figure 1. Belt roll diameter

LENGTH OF BELT ON A ROLL

The length of belt on a roll may be determined using the following formula:

L = (d + (D – d) / 2) x π) x N

Where D = outside diameter of the roll (m)d = diameter of the roll centre (m)N = the number of wraps of the beltπ = 3.1416

5

7.5

10

12.5

15

202530

8 - 3

BELT TRANSPORT GUIDELINES

Road freight

Trailer type Maximum roll diameter Load weight

Tray 2.75m 20 – 22 tonne

Drop-deck 3.20m 20 tonne

Low loader 3.8m * 1 roll

* may vary with loader height and state regulations

Sea freight

Container type Maximum roll diameter Load weight

2o ft. or 40 ft. * 2.29m 18.3 tonne

Heavy duty 2.29m 21.3 tonne

*Container internal dimensions (nominal):20ft – 2.29m high x 2.35m wide x 5.93m long40ft – 2.29m high x 2.35m wide x 12.0m long

8 - 4

TABLE 1STANDARD CONSTRUCTIONS(other than CoalMaster series)

BELT CARCASS MASS AND THICKNESS


PN 150 - 160 PN315 /2 PN500 /3 PN630 /4 PN750 /5 PN900 /6plain weave Mass 3.7 kg/m2 4.4 kg/m2 5.8 kg/m2 7.3 kg/m2 8.8 kg/m2

Thickness 2.7 mm 3.3 mm 4.6 mm 5.9 mm 7.1 mm



PN 250 PN500 /2 PN750 /3 PN1000 /4 PN1250 /5 PN1500 /6plain weave Mass 4.4 kg/m2 5.8 kg/m2 7.7 kg/m2 9.6 kg/m2 11.5 kg/m2




PN 320 - 350 PN1000 /3 PN1400 /4 PN1600 /5plain weave Mass 7.2 kg/m2 9.7 kg/m2 12.1 kg/m2

Thickness 5.6 mm 7.7 mm 9.8 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5plain weave Mass 6.0 kg/m2 7.7 kg/m2 10.4 kg/m2 13.9 kg/m2

Thickness 4.7 mm 6.1 mm 8.4 mm 11.3 mm

PN 315 - 375 PN750 /2 PN1000 /3 PN1250 /4 PN1600 /5Mass 6.0 kg/m2 7.7 kg/m2 10.3 kg/m2 13.0 kg/m2Crow's foot

weave Thickness 4.7 mm 6.1 mm 8.4 mm 10.7 mm

PN 360 - 400 PN800 /2 PN1200 /3 PN1500 /4 PN1800 /5Mass 6.4 kg/m2 8.3 kg/m2 11.1 kg/m2 14.0 kg/m2Crow's foot

weave Thickness 5.0 mm 6.7 mm 9.1 mm 11.6 mm

PN 450 - 500 PN1500 /3 PN1800 /4 PN2250 /5Mass 9.5 kg/m2 12.7 kg/m2 15.9 kg/m2Crow's foot

weave Thickness 7.7 mm 10.5 mm 13.3 mm

PN 450 PN900 /2 PN1350 /3Mass 7.0 kg/m2 11.0 kg/m2Double weave

Thickness 5.5 mm 9.0 mm

8 - 5

TABLE 2COALMASTER SERIES(For underground coal mining)

BELT CARCASS MASS AND THICKNESS

Add 1.4 kg/m2 for each millimetre of cover


PN 150 - 160 PN630 /4 PN800 /5plain weave Mass 7.8 kg/m2 9.6 kg/m2


PN 200 - 220 PN800 /4 PN1000 /5 PN1200 /6plain weave Mass 9.5 kg/m2 11.9 kg/m2 14.2 kg/m2


PN 250 PN1000 /4 PN1250 /5 PN1500 /6plain weave Mass 11.1 kg/m2 13.9 kg/m2 16.6 kg/m2














PN 450 PN1350 /3Mass 14.1 kg/m2Double weave

Thickness 9.0 mm

8 - 6

TABLE 3BELT CARCASS ANDCOVER MASS FACTORS

Belt Cover Grade CarcassMass Factor

CoverMass Factor

Mining, Quarrying and General Service beltsGrade M - 1.11Grade N - 1.11Grade A - 1.11Super M - 1.10Grade MA - 1.10XCG - 1.14QuarryMaster - 1.11

Heat resistant gradesCRHR - 1.15EPT-GP - 1.05EPT-Super - 1.05HRNR - 1.10Hi-Temp Nitrile 1.05 1.16

Oil and Chemical Resistant gradesNitrile 1.05 1.16ORS Neoprene 1.2 1.40PVC Nitrile 1.05 1.19SOR - 1.14K, SOR - 1.24EPT-GP - 1.05

Fire Resistant and Anti-static beltsGrade S,D & grade S Use table 2

CoalMaster 1.40

Grade D,E,F & grade E,F 1.2 1.40

Grade K,D 1.2 1.40

Grade K,L & grade K 1.1 1.28

Grade K, SOR - 1.24

Grade E - 1.11

9 - 0

9. Solid Woven Belting

Belt construction…………………………………………………………………………. 9 - 1

Belt and cover thickness……………………………………………………………….. 9 - 2

Operating temperature range………………………………………………………….. 9 - 2

Operating factor of safety………………………………………………………………. 9 - 2

Safety………………………………………………………………………………………. 9 - 2

Table 1 Belt Designations…………………………….. ….……..…………….… 11 – 2

9 - 1

9. Solid Woven belting

BELT CONSTRUCTION

Fenaplast conveyor belting consists of three main components: -

♦ Textile Solid Woven Carcass♦ PVC Impregnation♦ Cover Material

THE TEXTILE CARCASS

The solid-woven carcass is generally woven with nylon or polyester load bearing warp fibres andnylon or nylon/cotton weft. Synthetic binder yarns follow a complex pattern to give the carcass itssolid-woven properties. Various combinations of synthetic, and natural fibres are chosen, togetherwith the fabric design to meet the requirements of impact resistance, belt elongation, flexibility fortroughing and small diameter pulleys, load support and fastener retention. The patented FenaplastPVC impregnation method also renders the carcass impervious to attach from moisture, dirt,chemicals, bacteria, and oils. Cotton pile warp yarns may be included for improved impactresistance and special edge reinforcement can be included where these are particular problems.The Fenaplast carcass design facility enables users to choose the properties of a custom-built belt.

All Fenaplast belts have a solid woven carcass where all layers of yarn are mechanicallyinterlocked during the weaving process and bound together by a self binding warp yarninterweave, thus making subsequent delamination impossible. High tenacity continuous filamentsynthetic yarns are used for the warp fie length direction), such yarns also provide most of thenecessary strength in the weft (transverse/width) direction.

PVC IMPREGNATION

After weaving the roll of carcass is vacuum impregnated with PVC plastisol containing a carefulblend of polymer, plasticisers, stabilisers, fire retardants, and special additives, with specialattention being given to viscosity control in order to ensure full impregnation of the wovenstructure.

Whilst the textile elements fix many of the belts properties such as tensile strength and elongationin service, the properties of the plastisol are equally important, and it's formulation will influence notonly the fire performance properties but also operational factors such as troughability and theability to hold fasteners.

COVER MATERIAL

PVC coversPVC covers to meet numerous fire resistance specifications or for other properties such asresistance to oils, chemicals, fertiliser etc., are generally available up to 3mm thick per side. Theycan also be compounded to give improved abrasion resistance or coefficients of friction.

9 - 2

COVER MATERIAL …continued

Rubber coversRubber covers to a specified safety standard may be applied on one or both sides of a PVCimpregnation parent belt up to a maximum of 6mm + 2mm, dependent on belt width, tensile andconstruction. SR wear-resistant nitrile rubber covers are also available, single or double sided, upto 6mm + 2mm maximum, dependent on belt construction.

BELT AND COVER THICKNESS

When considering cover thickness the user should be aware of the thick, high textile content ofFenaplast and the special solid-woven carcass properties. Consequently thinner covers maygenerally be chosen than normal with rubber, plied belting; the Fenaplast carcass being moresubstantial and providing the necessary load support and impact resistance.

OPERATING TEMPERATURE RANGE

Above 90°C PVC softens and the belt properties change, therefore Fenaplast is not recommendedfor conveying materials above this temperature. Standard Fenaplast can be used in cold climatesat minus 15°C and special cover compounds are available for operation down to minus 40°C. Coldweather details should be supplied to ensure a belt with suitable coefficient and flexibilitycharacteristics is supplied.

OPERATING FACTOR OF SAFETY

With good quality mechanical fasteners or vulcanised joints a factor of safety of 8:1 may beacceptable.

SAFETY

Fenaplast is used extensively in underground coal mines and as such it exhibits excellent FireResistant, Anti-Static properties.

In Australia it is manufactured to AS 1332 and is tested to AS1334.It meets or exceeds all of the requirements of AS 4606-2000.

9 - 3

TABLE 1BELT DESIGNATIONS

Nominal beltthickness

Nominal beltweight

Minimum recommended pulleydiameters

High tension Low tension

BeltDesignation

Minimumwarp

strength

kN/m

Minimumweft

strength

kN/m mm kg/m2 mm mm2240 400 160 4.8 6.2 250 2252800 500 245 7.7 10.5 315 2503300 580 24 8.0 10.7 355 3153500 630 263 8.1 11.0 400 3154000 700 263 8.4 11.0 400 3554500 800 315 8.5 11.0 500 3555000 875 320 8.7 11.3 500 3556000 1 050 350 8.9 11.4 630 4006500 1140 350 9.0 11.5 630 4007000 1250 350 9.3 11.8 750 4508000 1400 350 9.8 12.7 750 4509000 1600 450 11.0 14.2 800 600

10000 1750 450 12.0 14.6 800 60012000 2100 450 14.0 16.2 1000 75015000 2625 450 15.3 17.4 1250 80018000 3150 450 17.6 21.4 1500 1000

BELT DESIGNATION: Belts can be produced to various tensile specifications, using either polyamide orpolyester base warp yarn. Some markets still prefer to specify belt types based on tensile strengthexpressed in Ibs/in width (the Fenaplast Belt Designation uses this terminology), whilst others opt for thepreferred ISO types expressed in kN/m.

BELT WEIGHTS: The above table shows some typical figures for minimum warp and weft strengths, beltthickness and weight for a selection of belt types, based on In- PVC covers. For thicker covers, add 1.3kg/m2/mm for PVC covers and 1.4 kg/m2/mm for rubber covers. The nominal figures quoted for thicknessand weight are based on specific belt constructions and PVC covers of l mm. Alternative belt constructionsmay vary these figures which are only for indicative purposes and establishing shipping capacities.

ALTERNATIVE CONSTRUCTIONS: Many alternative constructions are available which give values higherthan those in the table. This is particularly relevant to weft strength, where special yarns designs may berecommended for improved properties such fastener holding, load support, weft stability etc. The use of suchspecial yarns may increase the belt weight and thickness which may be critical for shipping purposes orunderground transportation. An APEX FENNER engineer should always be consulted where this informationis likely to be critical.

PULLEY DIAMETERS: The drum diameters are the minimum recommended without complete applicationdetails. With information regarding wrap configurations, tensions, belt speeds, jointing methods, etc., it maybe possible to accept smaller drums.

10 - 0

10. Trouble Shooting

General Maintenance .…………………..…………………………………..… 10 – 1

Loading point considerations……………………………………………….. 10 - 2

Random events ………………………………………………………………… 10 - 4

Troubleshooting ………………….………………………………………………….… 10 - 5

10 - 1

10. Trouble shooting

GENERAL MAINTENANCE

Conveyor belting represents a very significant portion of the overall plant cost and as such warrantsregular inspection and maintenance to protect this investment.

Broadly speaking, apart from normal wear, rubber conveyor belting fails through chemical attack ormechanical damage in one form or another.

♦ Chemicals such as all greases, oils, solvents and animal fats should be removed as soon asdetected from belts not designed to handle these materials. Susceptible belts including all naturalrubber belts should be washed down with water and detergent immediately after contamination.

♦ Ozone is a common cause of premature failure in natural rubber and many synthetic and rubberbelts, particularly when operating near the sea, enclosed near electrical machinery or in a saltyenvironment. APEX FENNER belts are supplied with high levels of ozone resistance, and thislevel of protection can be increased by special request at the time of ordering for extremeconditions.

♦ Mechanical damage is best prevented by clean design and erection, (no jagged edges) goodpath clearance, generous belt paths, frequent checking and prompt remedying of all faults.

♦ Belt cleaners perform a very important role in the protection of the belt. Properly sited and fittedthey protect the belt from damage through:

♦ Trapping of material between return belt flight and pulley.♦ Belt wander through running off as material forms a crown on the pulley.♦ Damage to pulley face through belt edge slapping and grinding at the pulley face

edges.♦ Spill from the return side building up under the belt to damage both belt and return

idlers.♦ Belt cleaners must be selected carefully and deserve frequent attention.

♦ Idlers - All noisy idler should be looked at immediately. All jammed or broken idlers should beremoved immediately. Hot idlers should be hosed down and remain under supervision whilst theconveyor is stopping and down to ambient temperature. It must be removed immediately theconveyor is stopped. A jammed idler causes increased friction resulting in excess cover wear,higher power consumption and may create sufficient heat to start a fire when the belt stops.

♦ Pulleys - Material trapped between a pulley and the belt may cause belt wander and if hard lumpsare present may rupture the belt. Plough cleaners should be fitted wherever a spill onto the returnbelt is carried onto a pulley. This is crucial at high tension pulleys but can lead to tracking andloading problems after the tail pulley.

♦ Take-up may be automatic or manual. The Automatic Take-up is the most desirable as properlymaintained, it is able to maintain the correct tension in the belt under all normal operatingconditions including starting, running, stopping and changes in belt length caused by changes inambient and operating temperature .

If for any reason the Automatic Take-up travel becomes restricted or jammed, belt slippage at thedrive may occur, this will cause extreme damage to the belt.

10 - 2

The Manual Take-Up has the advantages of compactness and low cost, however it is unable tomaintain optimum tension through the normal operating conditions including starting, running,stopping and changes in belt length caused by changes in ambient and operating temperature.

♦ Be aware of abnormal or changed noises emanating from the conveyor as these, if leftunattended, could lead to a fire, gearbox or pulley / coupling failure to name just two items. Thefollowing plant items should be frequently listened to and looked at. Analyse the problem andtake maintenance precautions.

LOADING POINT CONSIDERATIONS:

Chutes, loading boots and skirts - These items are frequent trouble spots when fitted too closely tothe belt. They can cause rapid localised cover wear and in extreme cases, slit the belt.

Conversely when installed with too much clearance, material is allowed to spill over, often falling ontothe return belt and building up on the tail pulley causing tracking problems in the loading boot furtherexacerbating the problem. If the spilled material is hard, the belt may also be punctured.

Also to be considered is wedging between a chute wall and the belt. In the mildest occurrence, thiswill accelerate the cover wear, in more severe occurrences the belt carcass is permanently damaged.

Most wear and tear on the belt takes place at the loading point. The manner of loading may influencethe life expectancy of the belt and the components of the loading boot. Loading points should bearranged with particular care and the following points should be observed:

♦ The material being conveyed should be fed onto the belt at belt speed in the running direction ofthe belt.

♦ The height of the drop from the feeding point onto the belt should be as small as possible.

♦ Impact idlers should be installed at the loading points.

The following sketches show some loading point arrangements.

Loading Point Arrangements

10 - 3

10 - 4

RANDOM EVENTS AND CAUSES OF BELT DAMAGE

TRAMP IRON

Most rips, some continuing the entire length of the belt, are caused by tramp iron becoming wedgedinto the belt at loading chutes. If this hazard is prevalent, the installation of a mechanical or magneticdetector to stop the belt may be justified. Dangerous material can be magnetically extracted or somereliable rip detection/protection device may be warranted.

Work practices and vigilance among all employees and contractors can also reduce this problem.

MINOR REPAIRS

Unless repaired, minor tears quickly become major repairs or catastrophic failure. Early detection andprompt attention is the best long-term strategy.

10 - 5

TROUBLESHOOTING

The following tables list problems sometimes encountered and suggests possible solutions.The causes are in the left-hand column and the corrections in the right hand column.

Conveyor belt problems – causes and corrections

1. Conveyor running to one side at a given point on structure:

A) One or more idlers immediatelypreceding trouble point not square (atright angles) to longitudinal axis of belt.

A.1) Utilising slots in idler stand, foot rotate entire idlerassemblies in same direction as for the steeringwheel of an automobile, to steer belt back tocentre.

B) Conveyor frame or structure crooked. B.1) Stretch string along to determine extent andmake correction.

C) One or more idler stands not centredunder belt.

C.1) Same as B.1 above.

D) Sticking idlers. D.1) Improve maintenance and lubrication.

E) When the run-off begins on a terminalpulley, it follows that terminal pulley isout of alignment. Note that a conveyorbelt shifts to the low or short side.

E.1) Re-align pulley.

F) Build-up of material on idlers andpulleys.

F.1) Improve maintenance.F.2) Install scrapers or other cleaning device.

G) Structure not level and belt tends toshift to low side.

G.1) Level structure.

2. Particular section of conveyor belt runs to one side at all points on a conveyor

A) Belt not joined squarely. A.1) Cut ends square and re fasten.

B) Bowed belt. B.1) Avoid bad storage conditions such as telescopedrolls or one edge close to damp ground or wall.

B.2) With a new belt, this condition should disappearas soon as the belt has operated under full loadand tension, and becomes "broken in".

B.3) Use self-aligning idlers, particularly on return runapproaching tail pulley to obtain central loading.

B.4) In rare instances belt must be replaced.

10 - 6

3. Conveyor belt runs to one side for long distance along bed

A) Load being placed on belt off-centre. A.1) Adjust chute and loading conditions so as toplace load in centre of belt.

C) See 1.E See 1.E

C) See 1.G See 1.G

4. Belt is erratic (follows no pattern of performance)

A) Belt too stiff to train. A.1) Use self-aligning idlers.A.2) Tilt troughing idlers forward, but not more that 2

degrees.A.3) Use more troughable belt.

5. Severe wear on pulley side of conveyor belt

A.) Slippage on drive pulley. A.1) Increase the tension through screw take-up ormore counterweight.

A.2) Lag drive pulley.A.3) Increase the arc of contact on the drive pulley

with a snub pulley.

B) Spillage of material which is groundbetween belt and pulley or whichbuilds up at loading point until belt isdragging.

B.1) Improve loading conditions with a chute.B.2) If belt is overloaded, increase belt speed or

decrease feed onto belt.B.3) install decking between top and return runs.B.4) Install ploughs or scrapers in front of tail pulley on

return runB.5 Prevent leakage of abrasive fines at fasteners by

changing to plate fasteners or vulcanised splice.

C) Sticking idlers C.1) Improve maintenance and lubrication.

D) Bolt head protruding above pulleylagging.

D.1) Tighten bolts.D.2) Replace worn lagging.D.3) Use vulcanised-on lagging.

E) Excessive tilt to troughing idlers. E.1) Adjust to not more that 2 degrees from lineperpendicular to belt.

10 - 7

6. Excessive stretch in conveyor

A) Tension too high. A.1) Increase speed, keeping tonnage same.A.2) Reduce tonnage at same speed.A.3) Reduce friction with better maintenance and

replacing of worn out and frozen idlers.A.4) Decrease tension by improving drive with

lagging, increase arc contact and counterweighttake-up.

A.5) Replace with heavier belt.Above is based on the assumption thatadequate take-up is available.

7. Belt shrinks

A) Belt absorbing moisture. A.1) Put in extra piece, installing with take-up halfway down.

8. Lengthwise gouging or stripping of top cover

A) Skirt board seals too stiff and pressedagainst belt.

A.1) Use more pliable seals.A.2) Adjust to relieve pressure on belt.

B) Excessive space between belt and skirtseals.

B.1) Adjust seals to minimum clearance.

C) Metal sides of chute or skirts too closeto belt and gap not increasing indirection of travel.

C.1) Adjust to at least 50mm gap between metaland belt and have gap increasing in directionof travel so as to prevent material jamming atthis point.

8. Lengthwise gouging or stripping of top cover (Cont.)

D) Belt spanks down under impact atloading point, allowing material to betrapped under skirts.

D.1) Install cushion or pneumatic idlers to hold beltup against skirts.

E) Material hanging under back panel. E.1) Improve loading to prevent spillage or installbaffle.

F) Jamming of material in chute. F.1) Widen chute.

10 - 8

9. Short breaks in carcass parallel to belt edge and star breaks in carcass

A) Impact of lumps failing on belt. A.1) Reduce impact.A.2) Use cushion idlers.

B) Material trapped between belt andpulley.

B.1) Install plows or scrapers on return run ahead oftail pulley.

10. Transverse breaks at belt edges

A) Belt edges folding up on structure dueto wander or pressing too hard againstside guide idlers.

A.1) See troubles (1), (2), (3) and (4).A.2) Install limit switches to stop belt in cases of

extreme shifting.

B) Mildew. B.1) Replace with APEX FENNER belt.

C) Final idler before head pulley locatedtoo close or too high in respect to headpulley.

C.1) Adjust idler position in accordance with normaldesign practice.

11. Cover blisters or sand blisters

A) Cover cuts or very small coverpunctures allow fine particles of "sand"to work under cover and cut coveraway from carcass.

A.1) Make spot repair with vulcaniser or "cold"patches.

A.2) In severe and repeating cases refer all details toAPEX FENNER for analysis.

12. Belt rises up off troughing idlers, bowing towards load

A) Oil contamination in material. A.1) Remove source of oil, if possible.A.2) To eke out the life of present belt, cut longitudinal

grooves in cover with tyre grooving tool to relievetransverse pressure exerted by swelling rubber.

A.3) For proper selection of replacement belt, send insample of oil to determine best oil resistingcompounds.

10 - 9

13. Cover swells in spots, or lines of swelling on pulley side coincident with junction ortroughing idler rolls.

A) Spilled oil or grease. A.1) Better housekeeping.

B) Over-lubrication of top run idlers. B.1) Reduce quantity of lubricant used.

14. Excessive top cover wear, uniform around belt

A) Dirty return rolls. A.1) Install cleaning devices.A.2) Wash belt.A.3) Use rubber disc return idlers.

B) Cover quality too low. B.1) Replace with better belt.

C) Pile up of spilled material at tail pulley. C.1) Improve housekeeping and loading.

D) Slide loading, or poor loading, i.e.speed of delivery of material too slow.

D.1) Redesign chute to make load feed onto belt insame direction as belt runs and at approximatelysame speed as belt.

E) Excessive sag between idlers causingload to work and shuffle on belt as itpasses over idlers.

E.1) Increase tension where it is unnecessarily low.E.2) Reduce idler spacing.E.3) Replace with belt of heavier carcass.

15. Fasteners pulling out

A) Mildew. A.1) Replace with APEX FENNER belt.

B) Wrong type of fastener or fastenersnot tight.

B.1) Re fasten belt and set up schedule for frequentfastener inspection. Re-tighten new fastenersafter a few hours run.

C) Tension too high. C.1) Check tension in belt and if too high, see item (6)for corrections.

C.2) Use vulcanised splice.

D) Heat. D.1) Use heavier top covers.D.2) Consult APEX FENNER.

10 - 10

6. Transverse breaks in belt immediately behind fasteners

A) Fastener plates too long for pulleysizes.

A.1) Change to smaller, shorter fasteners.A.2) Increase pulley size.

B) Mildew. B.1) Replace with APEX FENNER belt.

17. Lengthwise rips partially or entirely through belt

A) See trouble (8)

B) Belt running off and snagging onstructure.

B.1) See trouble (1), (2), (3) and (4)

C) Puncture by tramp iron at chute. C.1) Use metal detector.

18. Crescent breaks in carcass, or mushy spots where carcass rotted under cover

A) Mildew. A.1) Replace with APEX FENNER belt.

19. Lengthwise rupture of carcass with top cover and possible parts of pulley cover unbroken

A) Belt running off against structure andfolding back on itself as it passesaround terminal pulley.

A.1) See troubles (1), (2), (3) and (4)A.2) Install limit switches.

20. Hardening and cracking of covers with eventual hardening of carcass and loss of duckstrength

A) Heat. A.1) Consult APEX FENNER for thorough analysisof conditions for application of correct heatresisting belt.

APEX FENNER CONVEYOR BELTING Australasia

Victoria – Head office and factoryAddressP.O BoxTelephoneFax

268 Geelong Road, West Footscray Victoria 30124006, West Footscray, Victoria 301203 9680 450003 9689 9191

New South WalesAddressP.O BoxTelephoneFax

81 Milperra Road, Revesby, NSW 22124756, Milperra, NSW 189102 9773 041102 9772 1808

AddressP.O BoxTelephoneFax

11 Aruma Pl Cardiff 2285612 Cardiff 228502 4956 937702 4956 9293


31 Eddie Rd Minchinbury 2770

02 9832 075502 9832 2400


13 Doyle Av Unanderra 2526361 Unanderra 252602 4272 926602 4272 9223


Unit 7/40 Main St Wallerawang 284574 Wallerawang 284502 6355 766102 6355 7659


19 Piercefield Rd Mt Thorley 23302006 Singleton 233002 6574 662202 6574 6652


Corner Mitchell Ave & Government Road, Weston 232593, Cessnock NSW 232502 4937 319902 4937 2579


59 Railway Avenue, Gunnedah NSW 2380743, Gunnedah NSW 238002 6742 571102 6742 2969


Unit 1, 3 Fox Street, Narellan NSW 2567

02 4647 162402 4627 1705


Unit 2, 1 O’Connor Street, Lithgow NSW 2790

02 6351 487502 6351 3098

QUEENSLANDAddressP.O BoxTelephoneFax

Young St Gladstone, Qld 46801307 Gladstone, Qld 468007 4972 215507 4972 2664


Lot 8 Nightingale Ave Capella.1688 Emerald Qld 4720. All postage to this address07 4982 457707 4982 4401


3 David Muir St Slade Point 474048 Mackay Qld 474007 4955 187707 4955 2353 (Admin)07 4955 4445 (Sales)


Ron Searl Dr Mt Bassett 474048 Mackay Qld 474007 4955 256007 4955 2433


614 Ingham Rd Garbutt Qld 48147541 Garbutt Qld 481407 4774 823807 4774 8239

AddressP O BoxTelephoneFax

Lot 64 John Vella Drive, Central Park Ind. Estate, Mackay Qld 47405597, Mackay Qld 474007 4952 207707 4952 2744


Unit 1/12-14 Hasell St, Cairns Qld 48715991 Cairns Mail Centre 487107 4035 641107 4035 6433


241B George St Rockhampton, Qld 4700

07 4922 898407 4922 8949


26 Ryan Rd Mt Isa 48252247 Mt Isa 482507 4743 6622 / 4743 3215 (2nd line)07 4743 8622

SOUTH AUSTRALIAAddressP.O BoxTelephoneFax

151 William St Beverley, South Aust. 5009131 Welland SA 500708 8268 425508 8347 1087

WESTERN AUSTRALIAAddressP.O BoxTelephoneFax

11 Kitson Pl Maddington, West Australia 6109PO Box 121 Maddington 698908 9452 838908 9452 8361

conveyor handbook-part 2

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