untertrum 980 82 bedanl e

8/12/2019 Untertrum 980 82 BedAnl E

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STARCLEAN- Conveyor-Belt CleanersType980/982

with a spindle-type tensioning device

for cleaning of conveyor belts in the road

with tungsten carbide blades for use at

tem eratures from 60 to + 400C

Installation andOperation instructions


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STARCLEAN Conveyor-Belt Cleaner Type 980/982 Operation Instructions

F.E. Schulte StrathausGmbH & Co. KG page 2 of 31

List of Contents

1. Important Safety Information and Safety Notes

1.1 General Safety Information

1.2 General Safety Notes1.3 Special Safety Notes

2. General Description

2.1 Description of Components

2.2 Purpose and Application

2.3 Specifications

3. Commissioning

3.1 General

3.2 Transport

3.3 Installation/ Start-Up

3.3.1 Assembly Steps

3.3.2 Spindle-type tensioning device

4. Maintenance

4.1 General4.2 Maintenance Notes

4.3 Maintenance Checks / Maintenance Intervals / Special Maintenance

4.4 Trouble Shooting

5. Spare Parts List

5.1 Spares with corresponding item numbers

5.2 Sample Spare Parts Order (acc. to ISO 9001:2000)

6. Annex / Technical Drawings

6.1 Technical Drawings

6.2 Spare Parts Lists

7. Declaration of Conformity


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F.E, Schulte Strathaus GmbH & Co. KG Page 3 of 3159457 Werl

1. Important Safety Information and Safety Notes

1.1 General Safety Information

The instructions contained in this operating manual must be observed fully

without any proviso. In the event of contravention, the manufacturer shall notassume any liability whatsoever for any damage caused to man or machine.Since conveyor-belt cleaners are generally installed in belt-conveyorinstallations, the manufacturers of these cleaning systems and the operatorsinstalling them shall comply with the provisions of the Machinery Directive.

Conveyor-belt cleaners made by Schulte Strathaus Co. may only be usedfor their original purpose, i.e. to clean conveyor belts at the planned points.

The conditions under which the conveyor-belt cleaner has to work (e.g.underground) shall be clarified with the operator.

Conveyor-belt cleaning systems of Group I Category M2 shall only be fittedwith one-piece strips and scraper blades made of plastics fit for undergroundhard coal mining. Relative belt speed must not exceed 6 m/s. Surfacetemperature must not exceed 150 C.Operating temperature of scrapers from -20 C to + 40 CLabelling = CE Ex I M2

Group I Category M2 conveyor-belt cleaning systems may only be used withbelt conveyors that can be switched off as soon as an explosive atmosphereforms.

Group II Category 2D conveyor-belt cleaning systems may only be used withdusts whose minimum ignition energy exceeds 3 m J. Relative belt speedmust not exceed 6 m/s. Surface temperature must not exceed 150 C.Operating temperature of scrapers from -20 C to +40 C Labelling = CE Ex II 2D

All conductive parts of the conveyor-belt cleaning systems shall be earthedwith a shunt resistor smaller than 10

6Q.

In all sectors of industry without any special requirements, belt cleanersystems can be used on demand.Operating temperature range from - 20 C to + 70 C for the standard designor from 60C to +400C for the heat-resistant design.

Max. belt speed must not be exceeded and the area of application must beagreed on with the manufacturer.


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To secure the warranty, the cleaners should be installed andcommissioned by the manufacturers expert staff since these persons arequalified due to their training, experience and briefing as well as theirknowledge of all relevant standards, provisions, accident preventionregulations and working conditions to perform the required tasks and toidentify and avoid any potential dangers arising.

As a rule, only the manufacturers spare parts may be used to ensure thewarranted functions.

Any jobs shall be performed in compliance with the relevantregulations of local authorities and with the local legislation.

General Safety Notes

These Safety Notes do not in claim to be exhaustive any way. Forquestions and problems you are requested to contact the manufacturer.

The STARCLEAN Type 980/982 conveyor-belt cleanercorresponds to the latest state of the art as of time of delivery.

It may only be installed and operated in perfect working condition. Thesystem operator shall generally perform the installation conforming tothe relevant rules for the prevention of accidents to meet operating

safety standards.

Retrofits, modifications or re-builds are generally prohibited and requireprior consultation with the manufacturer in each individual case.


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1.3 Special Safety Notes

Prior to executing any type of work on the STARCLEAN conveyor-beltcleaner Type 980/982, power supply to the belt conveyor must be

disconnected and secured against unauthorised connection.

Upon installation of a STARCLEAN conveyor-belt cleaner Type 980/982,make sure the welding torch and/or other welding equipment to be usedconform to the relevant regulatory provisions (explosion protection, FLPetc.).

During welding and cutting jobs any components sensitive to heat such asthe conveyor belt, for instance, must be covered.

2. General Description

2.1 Description of Components

The STARCLEAN conveyor-belt cleaner Type 980/982 (Pages 6 and 7) consists of the

following components:

1. Scraper strip composed of:

1.1 Blade base with insertion pockets (figures 1.1.1, 1.1.2)

Figure 1.1.1

Standard

blade base,

Type 0

Figure 1.1.2

Tubular blade

base, type 2


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Figure 2


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Figure 3


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1.2 Scraper blades, type 50 / 55 / 56 long1.3 Scraper blades, type 50 / 55 / 56 short

Figure 4 a / scraper blades type 55Figure 4 b / scraper blades type 56Figure 4 c / scraper blades type 50


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Type 55 scraper blades (1.3, Figure 4 a) consist of an insertion footing in springsteel with an integral spatula plate, to which a revolving spatula Type 55 (1.3.1and 1.4.1) is fastened in a short and long version. In this design the spatulas areequipped with tungsten carbide support with a soldered-in tungsten carbide part.The spatulas are made of corrosion-resistant material. The Type 55 scraperblades must not be used with mechanical joints.Operating temperature from 60C to + 400C.

Type 56 scraper blades (1.3 Figure 4 b) consist of an insertion footing inpolyurethane and a revolving spatula Type 56 (1.3.1 or 1.4.1) in a short or longversion. This model features spatulas equipped with a tungsten carbide support towhich a tungsten carbide part is glued or soldered. The spatulas are made ofcorrosion-resistant material. The scraper blades Type 56 must not be used withmechanical joints.Operating temperature from 20C to +70C

Type 50 scraper blades (1.3, Figure 4 c) consist of an insertion footing inpolyurethane and a revolving spatula Type 50 (1.3.1 or 1.4.1) in a short or longversion. This model features spatulas equipped with a tungsten carbide support towhich a tungsten carbide part is glued or soldered. The spatulas are made ofcorrosion-resistant material. Type 50 scraper blades can be used with mechanicaljoints.Operating temperature from 20C to +70C.

2. Spindle-type tensioning device, type 980 (2x), consisting of:

2.1 hold-down device, type 9802.2 strip receiver2.2.1 locking screws with locknut for blade base or lengthening

lever2.3 clamping nut and locknut2.4 locknut2.5 spindle2.6 adjusting lever


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2.2 Purpose and Application

STARCLEAN conveyor belt cleaners 980/982 are used to clean conveyor beltresidues off the surface of the conveyor belt behind the discharge pulley.

The scraper blades of the cleaner models consist of a polyurethane footing and amoveable tungsten carbide spatula integrated into the footing. The scraper blades ofthe types 50 and 56 are not suitable for reversible belt installations.

The polyurethane footings for use in underground mining, for example, are madefrom an approved material. The footings for general industrial use possess no furtherspecial characteristics.

The tungsten carbide spatulas of the types 50, 55 and 56 are designed differently. Theyconsist of a stainless steel girder with an integrated tungsten carbide insert.


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2.3 Specifications

The cleaner width and number of scraper blades depend on the width of the framestructure or the belt width. Generally, the assignment according to the correspondingbelt widths used in the blade base with a separation of 100 mm applies. The bladewidth at the footing of the blade is 100 mm. The scraper spatulas are 120 mm wide andare placed in varying distances, i.e. 220 mm and 240 mm from the blade footing.Because of this, the scraper spatulas overlap at the cleaning location.The segments Type 55 are designed for belt speeds of 3.5 m/s.

Belt Width Length of Number of

Scraper Strip Scraper Blades

[mm] [mm] Number

400 320 3

500 420 4

650 520 5

800 720 7

1000 920 9

1200 1120 11

1400 1320 13

1600 1520 15

1800 1720 17

2000 1920 19

2200 2120 21

2400 2320 23

Table 1: Specifications


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3. Start-Up

3.1 General

Installation and start-up, in particular, must only be performed by theappropriate, specially trained, skilled staff in compliance with the relevantregulations in force. In case of contravention, the manufacturer shall assumeno responsibility whatsoever for any damage caused to man or machine orfor any consequential loss.

3.2 Transport

Belt cleaners are generally delivered as 3 (4) assemblies:

a) Spindle-type tensioning device, type 980 2 x

b) Blade base including scraper bladesc) [Additional fastening elements, if ordered]d) Lengthening lever, if ordered

During transport, any damage and the impact of externalforces must be avoided at all costs.


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3.3 Installation/ Start-Up

For installation always ensure that the conveyor system is disconnected

from the power supply and cannot be started up by third parties.Should the product be modified and any parts be built in, dismantled or replaced or newcomponents be fitted or any built-in parts be modified without the manufacturers priorapproval the warranty for any defects occurring subsequently shall extinguish.

3.3.1 Assembly Steps according to Zg.-No. PAS 820.19-4A, ZAS-980.02-4A,ZAS-980.03-4A

Selection of installation location e.g. according to drawing No. PAS

820.19-4A (Figure 4) Note! Observe the distance to the lower rim of theconveyor belt. In the basic model of STARCLEAN 980/982, the spindle-type tensioning device must be installed such that the upper plate of thehold-down device, item 2.1 is mounted no more than 30 mm above or 10mm below the lower rim of the conveyor belt. This is illustrated in figurePAS-820.19-4A. Should the described installation not be possible becauseof the construction of the conveyor system, lengthening levers, item 2.6 ),must be used. The levers are then each screwed on to the strip receivers,item 2.2 (pages 6,7). With this solution, the spindle-type tensioning devicemay be mounted approximately 250 mm above or below the conveyorbelt. In this case, the blade strip is installed into the lengthening lever, pos.

2.6.1.

Installation of the spindle-type tensioning device, type 980,according to installation drawing PAS-820.19-4A Figure 4.

Alignment of the spindle-type tensioning device type 980.

Note! The threaded spindled should be aligned in a 90 angle to theconveyor belt.

Installation including alignment of the scraper strip (fig. 2 and 4).

Insert blade base item 1.1 with scraper blades into the strip receiveritem 2.2 or 2.6 without screwing down the blade base. The scraperblades with the spatulas hang downward. Using the nuts, items2.2 2.3 and 2.4, adjust the blade bases item 1.1 at the threadedspindle to the desired distance (Lk) to the conveyor belt (according table2). The blade strip mustbe installed parallel to the conveyor belt. Thescraper blades with the spatulas still hang freely downward.

11.

2.

3.


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Figure 5

Bild

5


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4. Use the blade strip at the conveyor belt as follows. Turn the bladebase, item 1.1, with the scraper blades until all or at least the longscraper blades rest against the conveyor belt evenly. Now screwtight the blade base on both sides using the spindle-type tensioningdevice with the 2 screws, item 2.2.1, provided for each side. Thereare several drilled holes in the strip receiver intended for the screws.Using the 2 screws per side, firmly attach the blade strip!Several drilled holes are provided for this purpose in theadjusting levers, item 2.6. The levers of the scraper bladesmust point in running direction of the belt! The scraper bladesare not yet pre-tensioned (fig. 5)!

5. Re-tighten all screwed joints.

6. Pre-tension the scraper blades according to table 3.For the pre-tensioning, use the nuts (2.3) at the spindle-typetensioning devices that press the blade strip - according to table 3 -up and against the conveyor belt (Zg. Nr. PAS-820.19-4A). The pre-tension must be adjusted to the selected distance of the blade baseLx.After reaching the calculated pre-tension, the belt cleaner base ofthe scraper blades should:

- be in a 90 angle to the conveyor belt for type 55+56- be in an angle < 90 to the belt for type 50

(dragging effect).Monitoring of counter pressure is of advantageous beneficial toensure quiet cleaning operation.

Please note that when using the belt cleaning system equipped withType 55 scraper blades used for elevated temperatures, you alwayshave to check whether the conveyor belts are designed for suchoperating temperatures.You should also take into consideration that the surface of the

conveyor belt at 200 C is softer than that of belts for generalindustrial applications and therefore the pre-tension of the belt

cleaner must not be set too high.

7. The scraper blades are now pre-tensioned (fig. 6).

After pre-tensioning, it is imperative that you control whether the blade stripis installed parallel to the conveyor belt!

Afterwards fixthe clamping nuts, item 2.3, with the additional nuts, item2.4.

8. Perform a test run, monitor the functions and adjust the setting of the pre-tension level


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Table 2

Distance between Blade baseAxis and Belt Surface (*) in Slack

State (Lk)

Pre-Tensioning Valuesfor Pre-Tensioning of

the Pre-set Blade Strip(*)

Pre-Setting for Areas of Application (mm) Pre-TensioningCharacteristics

STAR-CLEAN

980

STARCLEAN

982

(mm) (mm)

Hexagon

Bladebase

Tubular

BladeBase

Very strong setting Very strong pre-tension

For undamagedconveyor belts andgreasy materialscontaining plenty ofwater and sludge

50 to70

For very wet, sludgy andvery greasy materials andundamaged conveyorbelts.

150 165

Required pre-tension> 50 mm

Strong setting 30 to50

Strong pre-tension125 140

For undamagedconveyor belts andgreasy materials.


For wet and sludgymaterials and conveyorbelts in a good state.

110 125 Belt-saving setting 20 to30

Light to medium pre-tension


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For undamagedconveyor belts andgreasy materials


For slighty sticky undslighty moist material

Very belt-savingsetting

> 10mm

Light pre-tensioning85 100

For conveyor beltsdamaged in severalplaces and belts withmechanical joints


For slightly stickymaterials, e.g. powderymedia

Immediate values are admissible Impor-tant

A combination of the pre-setting and pre-tensioningvalue produces optimumresults depending on thearea of application.Sometimes it may be

necessary to ascertainoptimum values duringactual operation. Formechanical joints the valuemust be established as afunction of the hook typeand its fastening.

(*)

The blade base must always beparallel to the conveyorbeltsurface

(*) Intermediate and highervalues may also be used ifneed be. The blade basemust always be parallel to

the conveyor belt surface.

By adjusting the distance between the blade base axis and the conveyor beltsurface, the angle of the tungsten carbide spatulas is determined, which in turndetermines the scraping effect and the operation of the spatulas (table 2.3).After re-tensioning the blade strip, the contact pressure of the spatulas againstthe conveyor belt is created and the scraping performance is set (table 3). Thepre-tension depends on the conveyed materials, the condition of the conveyorbelt and the design of the belt joints


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Figure 6


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7. Note! Secure all openings and draw-in points between the scraperblades and the conveyor belt against tempering and accidental draw-inaccording to the applicable rules for prevention of accidents.

8. Note! Installation into existing belt-conveyor systems must beperformed in compliance with the Machinery Directive for Belt-ConveyorSystems.

After completion of installation: Commissioning

1) Switch on belt conveyor and check specifications and the scrapingbehaviour.

2) If necessary, reset pre-tension, i.e. increase or decrease pre-tensionconforming to the rules for prevention of accidents.The pre-tension values in the "Specifications" Table are approximate.

Depending on the belt soiling, pre-tension may be increased or decreased.When faced with specific cleaning problems, users are requested to contactthe manufacturer.In case of extremely severe soiling, it is recommended to use an additionalpre-scraper.

3.3.2 Spindle-type tensioning device

Operation principle of the Spindle-type tensioning deviceType 980

Figure 7STARCLEAN 980/982


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Figure 7: Designs of the spindle-type tensioning devices, type 980

The spindle-type tensioning device type 980, item 2, is designed toguide the blade base, item 1.1, with the scraper blades along theconveyor belt.The hold-down devices, item 2.1, are screwed onto the belt structure,and the blade strips are either inserted into the strip receiver, item 2.2,or screwed onto the lengthening lever, item 2.6.

By turning the clamping nut, item 2.3, the blade strip at the spindle, item2.5, is pressed vertically against the conveyor belt. Once the required pre-tension is achieved, the position is fixed with locknut, item 2.4.

This allows for easier access to the surface of the conveyor belt withouthaving to make modifications to the belt system.

The lengthening lever should be used if the standard tensioning devicecannot be mounted according to specifications.

a) Release pre-tensioned spindle-type tensioning deviceFirst loosen the locknut, item 2.4, on both sides and then screw downwards

the clamping nuts (2.3) as required.


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4. Maintenance

4.1 General

Optimum cleaning results and a long service life can only be achieved if thecleaner is maintained according to the relevant maintenance guidelines.

4.2 Maintenance Notes (according to figure 7)

Although the cleaner is low-maintenance, the following should be considered:

1) Clean any residues off the scraper blades if necessary.

2) Check whether pre-tension corresponds to specs re-tension ifnecessary. Then repeat steps 3, 3.1, 4, 5 and 6 .

3) Are all screws tight? Tighten them all if necessary.

4) Do all scraper blades sit close to the belt according to specification?

5) Does the blade wear allow further use?If the scraper blade spatula bases are worn, they must be replaced asdescribed below:

- Loosen the locknuts, item 2.4, on both sides of the spindle-typetensioning device. After that, screw the clamping nuts, item 2.3.downwards.

- Loosen the fastening screws (2.2.1) of the blade base.

- Unhinge the blade strip from the guide.

- While applying pressure to the snap-in footing of the scraper blade,pull the scraper blades out of the blade base.

- Check whether the scraper blade footings are still flexible andundamaged.

- If the scraper blade footings are in good order, only exchange the hardmetal spatulas, items 1.4.1 and 1.3.1.

- If the scraper blade footings are not in good order, install thecomplete scraper blades, type 50 or 56, items 1.4 and 1.3figure 2, and pre-tension the blade strip again.

- Important:The spatulas must be able to rotateinside the blade footing at alltimes. Always grease newly installed spatulas.


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Figure 8: Spatula base of scraper blade type 50

Figure 9: Spatula base of scraper blade type 55 and 56

! Once the blades are worn, we recommend that you always re-equip the entire blade strip!

- Are the scraper blades free from any damage?- Are the cleaning results good?- Check the mobility of the hard metal spatulas.


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4.3 Maintenance Checks / Maintenance Intervals / Special Maintenance

Weekly Every 2 weeks -

Every 3 weeks -

3-shift operation2-shift operation

1-shift operation

In winter, belt-cleaning systems must be maintained with special care (and atshorter intervals than specified).

We recommend that you release the tension of the scraper strip each time you de-commission the belt conveyor and remove any residues from the blade strip. This ensuresthat the scraper blades will not freeze and thus remain flexible.Furthermore, this precautionary measure prevents the conveyor belt from being damaged byfrozen material when the conveyor system is re-commissioned.

Allow us to point out once again that where damage to the conveyor belt is caused byfrozen material to be conveyed or water, such damage cannot be attributed to the blades ofthe belt-cleaning system.

For this reason the system manufacturer shall assume no responsibility for such

cases.

In winter, we recommend that you switch on the conveyor first and only pre-tensionthe de-commissioned cleaner later.

A similar approach must be taken for such materials as gypsum and clay. After de-commissioning the conveyor, these materials tend to solidify to such an extent that thesurface of the hardened materials may attack the belt and cause damage to the systemafter re-commissioning the conveyor installation.

For conveyor belts operated with mechanical joints it is recommended that scraper systems

be checked daily.

This check-up serves to prevent damaged mechanical joints fromdamaging the belt-cleaning system.

We would like to draw your attention to the fact that mechanical joints can impact theservice life of the scraper blades in the system and induce premature wear. It musttherefore be ensured that the mechanical joints are countersunk in the cover of the belt onthe carrying side.


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4.4 Trouble Shooting

Should malfunctions occur in the scraping system, make sure to observe thefollowing notes:

Causes:

"Poor cleaning results"

Action:

Blades not properly pre-tensioned (too tight or tooloose).

Blades do not sit snugly to thebelt.

Re-tension, release or checkspindle-type tensioning device.

Check that installation conforms tooperation instructions.

Blades defective or worn. Replace blades or spatulas.

Blades or blade strip soiled.

Blade base not parallel withbelt surface.

Not all blades sit uniformly atthe conveyor belt.

Clean blades, spatulas and blade

strip.

Check whether installed in compliancewith instructions, check proper fit ofmounting bases, check properfastening of blade base.

Release blade strip, clean scraperblades or spatulas. Re-tension theblade strip according to specs.


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5. Spare Parts List STARCLEAN 980/982 (acc. to drawing ZAS-980.02-4Aand drawing ZAS-980.03-4A)

5.1. Spares with corresponding item numbers

1. Blade base

1.1 Blade base type 0 from SW 36

1.2 Blade base type 2 from tube D = 60.3 mm

1.3 Scraper blade long1.3.1 Spare scraper blades, type 50, 55 or 56 long

1.4 Scraper blade short1.4.1 Spare scraper blades, type 50, 55 or 56 short

2. Spindle-type tensioning device, type 980 complete one side

2.6 Lengthening lever

5.2. Sample Spare Parts Order (acc. to ISO 9001:2000)

Original order XYZ dated.......... STARCLEAN 90-980.56n.09spare part no. 1.4.1 x 5spare part no. 1.3.1 x 4


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ARCLEAN Conveyor-Belt Cleaner Type 980/982 Operation Instructions

, Schulte Strathaus GmbH & Co. KG Page 27 of 31457 Werl

7. Annex

7.1. Technical Drawings


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ARCLEAN Conveyor-Belt Cleaner Type 980/982 Operation Instructions

. Schulte Strathaus


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Tubular blade base

A (mm) B (mm) Lr (mm) L (mm) X Blade base

pockets

Belt

width (mm)

310 370 900 1380 7 800

310 370 1100 1580 9 1000

310 370 1300 1780 11 1200

310 370 1500 1980 13 1400

335 395 1700 2230 15 1600

335 395 1900 2430 17 1800

335 395 2100 2630 19 2000

400 450 2300 2950 21 2200

400 450 2500 3150 23 2400


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F E Schulte Strathaus GmbH & Co KG Page 31 of 31

7. Declaration of Conformity

KonformittserklrungDeclaration of Conformity

im Sinne der Richtlinie 94/9/EG, Anhang VIII (ATEX) Kategorie I M2 und II 2Daccording to EC Directive 94/9/EG, Appendix VIII (ATEX) Category I M2 und II 2D

Frdergurt Reinigungssysteme Typ STARCLEANConveyor-Belt Cleaning System Type STARCLEAN

F.E. Schulte Strathaus erklrt in alleiniger Verantwortung, dass die Frdergurt-GmbH & Co. KG Reinigungssysteme Typ STARCLEAN der Baureihen

240, 620, 622, 624, 627, 628, 630, 720, 722, 724, 820, 822940, 942, 950, 952, 960, 962, 970, 972, 980 und 982auf die sich diese Erklrung bezieht mit der Richtlinie94/9/EG (ATEX)bereinstimmen

declares n sole responsibility that the Coneyor-Belt-CleaningSystems Type STARCLEAN of our productline

240, 620, 622, 624, 627, 628, 630, 720, 722, 724, 820, 822940, 942, 950, 952, 960, 962, 970, 972, 980 und 982that are subject to this declaration are meeting the requirementsset forth in Directive 94/9/EC (ATEX)

Angewandte Norm: EN 13463-1 von 4.2004Applicable standard: EN 13463-1 dated 4.2004

F. E. Schulte Strathaus GmbH & Co. KG hinterlegt die gem 94/9/EG, Anhang VIII (ATEX)geforderten Unterlagen bei benannter Stelle:F. E. Schulte Strathaus GmbH & Co. KG will archive the documents required according to

94/9/EC (ATEX), Appendix VIII at the following location:

EXAM GmbH, Bochum, EU-Code 0158

Werl, den 16. April 2004

F.E. Schulte Strathaus GmbH & Co. KG Geschftsfhrung

untertrum 980 82 bedanl e

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