Belt conveyor

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INSTRUCTION MANUAL . BELT CONVEYOR RT 70030286-1.0
  Mounting, Operation and MaintenanceThe text refers to the following instructions etc.:
  Storage of rubber belt 15951 Repair of rubber belt 19991 Assembly of rubber belt 5721
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  Contents:Page:
  General ................................................................................................... 4 Drive Station (04) ................................................................................... 5 Drive Pulley (01) .................................................................................... 7 Scraper For Pulley (101) ......................................................................... 8 Mounting Of Conveyor Pulleys (17) ....................................................... 10 Idlers (30) ............................................................................................... 12 Shock-Absorbing Idlers (67) ................................................................... 16 Self-Cleaning Idlers (68) ........................................................................ 17 Conveyor Frame (36) .............................................................................. 18 Filling Hopper With Guide Plates (26) .................................................... 19 Side Guides, Closed (23) ........................................................................ 20 Cover Over Netting For Rubber Belt Conveyor (100) .............................. 21 Covering of Belt Return Part (70) ........................................................... 27 Emergency Stop (103) ............................................................................ 28 Speed Monitor (69) ................................................................................. 29 Skew-Running Switch (72) .................................................................... 30 Baffle Plate (28) ..................................................................................... 31 Plough Deflector (20) ............................................................................. 33 Mounting Of Conveyor Pulleys (17) ....................................................... 35 Mounting Of Conveyor Frame (22) ......................................................... 37 Adjustment Of Belt Conveyor (21) ......................................................... 41 Operation (74) ........................................................................................ 44
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  3 Appendices: This instruction manual contains no appendices.
  4 70030286-1.0Note!
  The present instruction manual is concerned with the situations which, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during the erection, operation and maintenance of the machine cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action.General
  The instruction manual contains a description of the belt conveyor features and also deals with the installation, operation and maintenance of latter.
  The relevant data for the belt conveyor is given in specifications, parts list, order drawing and layout drawing.
  The belt incorporates a number of features, which are described in greater detail in separate instruction manuals.
  5 70030286-1.0Drive Station (04)
  The belt conveyor is driven by a drive station which consists of a drive pulley (A) directly coupled to a motor through a reduction gear unit.
  The pulley is provided with a scraper (B), which keeps the outer belt side clean.
  Maintenance. Weekly: Remove material cakings and/or dirt from the pulley.
  Monthly: Clean the drive station and its surroundings. Check the pulley for mechanical faults. Look, listen and check for irregularities of any kind. Check the fastening of bearing housings and the temperature in
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  Twice a year: Charge bearings with lubricating grease BG-U. Maintenance of reduction gear unit, see separate instruction manual.
  7 70030286-1.0Drive Pulley (01)
  The drive pulley is provided with a vulcanised rubber lining in order to increase the friction between belt and pulley and to prevent material cakings.
  During erection, a check must always be run to ensure that the joint of rubber lining is correctly orientated relative to the rotational direction indicated on the sketch.
  Maintenance. Monthly: Check the condition of the rubber lining. Replace if required.
  8 70030286-1.0Scraper For Pulley (101)
  The pulley is provided with 2 scrapers. A front scraper A and a secondary scraper B. The scrapers serve to clean the outside of the conveyor belt of any sticking residues of material.
  Technical specifications for scrapers: See separate instruction manual.
  Mounting: The secondary scraper must be mounted first.
  Slide the scraper member into the matching holes in the side plates of the drive station. Position the member so that it rests at the bottom of the holes and subsequently insert the actual scraper
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  The scraper may either be inserted through the hole at front scraper A or through the upper rear plate E. The fittings for the member may now be mounted in the matching side plate holes. Now adjust the scraper in compliance with separate instruction manual.
  Having completed adjustment, mount cover plates C and D for covering the holes in the side plates.
  Mount the front scraper A on the side plate flange, and adjust in compliance with separate instruction manual.
  Having completed adjustment, mount the side plate F of the scraper.
  10 70030286-1.0Mounting Of Conveyor Pulleys (17)
  Drive station and tail station to be mounted in accordance with the dimensions and data contained on drawings and parts lists forwarded on separate basis.
  The conveyor pulleys must be mounted so that they are absolutely horizontal and parallel. The axes of pulleys must be absolutely square with the centreline of the belt.
  1. Determine the centreline of the belt conveyor.
  2. Stretch a piece of piano wire (A) at a distance of
  approximately 1 metre above the conveyor frame and vertically to the centreline.
  Mount the pulley (C) on the frame.
  3.
  4. Find the centre of a generatrix on the surface of the pulley and mark off that point.
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6. Turn the pulley through 180˚ and check that the point remains at the same vertical plane.
  
7. Attach the base feet of pulley to the frame, with shims inserted for alignment so that the pulley is in horizontal position.
  
8. All bearings must be opened and checked for alignment,
  backlash, distance rings is placed correctly and that the locking ring is secured. Backlash should be in according with the bearing suppliers specifications. In the same time the conservation grease can be removed and the supplied grease can be applied.
  12 70030286-1.0Idlers (30)
  The carrying part and return part of the belt are supported by idlers between the drive station and tail station.
  The ordinary plain idlers consist of a cylindrical tube (D) with a through-going stationary shaft (E), roller end-caps (A), ball bearings (C) and labyrinth seals (B).
  30.1 For plane belts identical idlers are used on the carrying and return part of the belt. Normally, one single idler is placed on each support. The shaft end is shaped as indicated in the Figure below.
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  On the carrying part of troughed belts each support consists of 2 or 3 idlers, placed on a joint supporting iron.
  For the return part each support consists of one single idler. For belt widths of 400, 500 and 650 mm, idler units with two idlers are normally used, forming an angle of 25˚ to the horizontal plane.
  30.3 For belt widths of 800, 1000, 1200, 1400 and 1600 mm idler units with 3 idlers are used. The two outer idlers form an angle to the horizontal, called trough angle.
  30.4
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  Idler units on the carrying part of the belt are so designed, that the side idlers have a slight forward inclination, approx. 1 , in the transport direction of the belt. This is done to ensure on-centre belt training on idlers.
  Shock-absorbing idlers and idler units at the tail end do not have a slight forward inclination.
  NOTE !
  During erection it must be ensured that the supporting irons are correctly orientated so that the inclination occurs in the direction of transport. An orientation sketch is inserted in the parts list. On the carrying part of the belt each support consists of one or several centre idlers, dependent on the belt width.
  The idlers may be either plain or shock-absorbing idlers. Inclined idlers are always plain.
  30.5 The idlers on the belt return part may comprise one single idler, or it may be made up of several plain or self-cleaning idlers.
  30.6
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  Maintenance Monthly: Walk along the entire length of the conveyor. Take a close look at various idlers and check that they rotate and, that they centre on the shafts without giving off any abnormal sounds.
  Replacement of idlers is required in instances where abnormal sounds from bearings are ascertained.
  In case an idler has got stuck, the surface of the latter must be carefully examined, and the idler must be replaced if there are any signs of cutting caused by the friction between belt and idler.
  The ball bearings are supplied with full grease charge and do not require refilling.
  The labyrinth seals are supplied charged with lubricating grease of grade CHEVRON POLYUREN EP GREASE L + 170˚C. Do not change the lubricating grease.
  16 70030286-1.0Shock-Absorbing Idlers (67)
  Shock-absorbing idlers are placed under the loading point to protect the belt against shock impacts caused by falling material.
  The idlers have a grooved rubber lining (A), which provides the shock-absorbing effect.
  Maintenance Monthly: Walk along the entire length of conveyor. Take a close look at the idlers and check, that they rotate without giving off any abnormal sounds, and that they centre on the shafts. Replace idlers, where abnormal sounds from bearings are ascertained.
  Check that the rubber lining on idlers is intact. Replace the idler in case a bearing or rubber lining is defective.
  17 70030286-1.0Self-Cleaning Idlers (68)
  Self-cleaning idlers are provided with rubber discs (A). They are only used for the belt return part, and they are well-suited for applications where sticky materials are handled as the rubber discs prevent material build-ups on the idlers.
  Maintenance Monthly: Walk along the entire length of conveyor. Take a close look at the idlers and check that they rotate without giving off any abnormal sounds, and that they centre on the shafts. Replace idlers if abnormal sounds from bearings are ascertained. Check that the rubber lining on idlers is intact. Replace the idler in case a bearing or rubber lining is defective.
  18 70030286-1.0Conveyor Frame (36)
  The conveyor frame is a sectional iron structure. The members and legs

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