Installation, Operation and Maintenance...

H-Type® Enhanced Service Advantage Cartridge HD

Primary Belt Cleaner with HXF Blades

Installation, Operation and Maintenance Manual

www.flexco.comwww.flexco.com

H-Type® Dual ESAC with HXF Blades HD Primary Belt Cleaner

H-Type® Single ESAC with HXF Blades HD Primary Belt Cleaner

2 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner

H-Type® with HXF Tips ESAC HD Primary Belt Cleaner

Purchase Date: ______________________________________________________________

Purchased From: ____________________________________________________________

Installation Date: ____________________________________________________________

This information will be helpful for any future inquiries or questions about belt cleaner replacement parts, specifications or troubleshooting.

Project Name Minerá Panama ProjectEquipment Title Conveyor Belt Primary ScrapersProject Number 1824EQR No / Purchase Order 1824-0008 Purchase Date June 29th 2017Specification DAS-0037

Drawing Number Rev. No Conveyor Number Title

K0092 100712-FE-9001 / 712-FE-9002

HXF8 Dual Cartridge Primary Cleaner712-FE-9003 / 712-FE-9004

K0093 100 713-CV-9003 / 713-CV-9004 HXF Single Cartridge Primary CleanerK0094 100 713-CV-9001 / 713-CV-9002 HXF Single Cartridge Primary Cleaner

3

Table of Contents

Section 1 – Important Information ........................................................................................................................4 1.1 General Introduction ................................................................................................................................................ 4 1.2 User Benefits .............................................................................................................................................................. 4 1.3 Service Option ........................................................................................................................................................... 4

Section 2 – Safety Considerations and Precautions ...............................................................................................5 2.1 Stationary Conveyors ................................................................................................................................................ 5 2.2 Operating Conveyors ................................................................................................................................................ 5

Section 3 – Pre-Installation Checks and Options ...................................................................................................6 3.1 Checklist ..................................................................................................................................................................... 6

Section 4 – Installation Instructions.......................................................................................................................7 4.1 H-Type® ESAC HD Primary Cleaner with HXF blades ....................................................................................... 7 4.1a H-Type ESAC HD Primary Cleaner - Chute Mounting .................................................................................... 8 4.1b H-Type ESAC HD Primary Cleaner - Open Head Mounting ........................................................................ 10 4.2 Single Cartridge Installation .................................................................................................................................. 12 4.3 Dual Cartridge Installation .................................................................................................................................... 13 4.4 H-Type ESAC HD Primary Cleaner - Compression Spring Tensioner ........................................................... 14

Section 5 – Cleaner Pole Location Charts ............................................................................................................ 16 5.1 Pole Location Charts ......................................................................................................................................................... 16

Section 6 – Pre-Operation Checklist and Testing................................................................................................. 17 6.1 Pre-Op Checklist ..................................................................................................................................................... 17 6.2 Test Run the Conveyor ............................................................................................................................................ 17

Section 7 – Maintenance ....................................................................................................................................... 18 7.1 New Installation Inspection ................................................................................................................................... 18 7.2 Routine Visual Inspection ...................................................................................................................................... 18 7.3 Routine Physical Inspection ................................................................................................................................... 18 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioner ........................ 19 7.5 Maintenance Log ..................................................................................................................................................... 23 7.6 Cleaner Maintenance Checklist ............................................................................................................................. 24

Section 8 – Troubleshooting ................................................................................................................................. 25

Section 9 – Specs and CAD Drawings................................................................................................................... 26 9.1 Specifications and Guidelines ................................................................................................................................ 26 9.2 CAD Drawings......................................................................................................................................................... 27

Section 10 – Replacement Parts List ..................................................................................................................... 30

Section 11 – Other Flexco Conveyor Products ..................................................................................................... 35


Section 1 – Important Information

1.1 General Introduction

We at Flexco are very pleased that you have selected an H-Type® Primary Cleaner with HXF blades for your conveyor system.

This manual will help you to understand the operation of this product and assist you in making it work up to its maximum efficiency over its lifetime of service.

It is essential for safe and efficient operation that the information and guidelines presented be properly understood and implemented. This manual will provide safety precautions, installation instructions, maintenance procedures and troubleshooting tips.

If, however, you have any questions or problems that are not covered, please visit our web site or contact our Customer Service Department:

Customer Service: 1-800-541-8028

Visit www.flexco.com for other Flexco locations and products.

Please read this manual thoroughly and pass it on to any others who will be directly responsible for installation, operation and maintenance of this cleaner. While we have tried to make the installation and service tasks as easy and simple as possible, it does however require correct installation and regular inspections and adjustments to maintain top working condition.

1.2 User Benefits

Correct installation and regular maintenance will provide the following benefits for your operation: • Reduced conveyor downtime • Reduced man-hour labor • Lower maintenance budget costs • Increased service life for the belt cleaner and other conveyor components

1.3 Service Option

The H-Type Primary Cleaner with HXF blades is designed to be easily installed and serviced by your on-site personnel. However, if you would prefer complete turn-key factory service, please contact your local Flexco Field Representative.

5

Section 2 – Safety Considerations and Precautions

Before installing and operating the H-Type® Primary Cleaner with HXF blades, it is important to review and understand the following safety information.

There are set-up, maintenance and operational activities involving both stationary and operating conveyors. Each case has a safety protocol.

2.1 Stationary ConveyorsThe following activities are performed on stationary conveyors:

• Installation • Blade replacement • Repairs• Tension adjustments • Cleaning

DANGER

DANGER

WARNING

WARNING

WARNING

!

!

!

!

!

It is imperative that Lockout/Tagout (LOTO) regulations, be followed before undertaking the preceding activities. Failure to use LOTO exposes workers to uncontrolled behavior of the belt cleaner caused by movement of the conveyor belt. Severe injury or death can result.

Before working:• Lockout/Tagout the conveyor power source• Disengage any takeups• Clear the conveyor belt or clamp securely in place

Use Personal Protective Equipment (PPE):• Safety eyewear• Hardhats• Safety footwear

Close quarters, springs and heavy components create a worksite that compromises a worker’s eyes, feet and skull.

PPE must be worn to control the foreseeable hazards associated with conveyor belt cleaners. Serious injuries can be avoided.

2.2 Operating ConveyorsThere are two routine tasks that must be performed while the conveyor is running:

• Inspection of the cleaning performance • Dynamic troubleshooting

Every belt cleaner is an in-running nip hazard. Never touch or prod an operating cleaner. Cleaner hazards cause instantaneous amputation and entrapment.

Never adjust anything on an operating cleaner. Unforeseeable belt projections and tears can catch on cleaners and cause violent movements of the cleaner structure. Flailing hardware can cause serious injury or death.

Belt cleaners can become projectile hazards. Stay as far from the cleaner as practical and use safety eyewear and headgear. Missiles can inflict serious injury.


Section 3 – Pre-installation Checks and Options

3.1 Checklist

• Check that the cleaner size is correct for the belt width

• Check the belt cleaner carton and make sure all the parts are included

• Review the “Tools Needed” list on the top of the installation instructions

• Check the conveyor site:

- Will the cleaner be installed on a chute

- Is the install on an open head pulley requiring mounting structure

- Are there obstructions that may require cleaner location adjustments

7

Section 4 – Installation Instructions

4.1 H-Type® ESAC HD Primary Cleaner with HXF Blades

Before You Begin:• Installation specs and instructions are based on the assumption

that the conveyor is in its working position. If the conveyor position will be different, the cleaner should be installed per the final position. Call customer service at 1-800-541-8028 if you need help with determining the proper coordinates.

• Choose instructions for chute mounting or open head mounting. For chute mounting it may be necessary to cut an access hole to allow for installation and inspections. (See dimensions in Step 7 under Chute Mounting.)

• Follow all safety precautions when using a cutting torch.• If welding, protect all fastener threads from weld spatter. Maximum

lump size + 200mm

Chute wall

Space needed to avoid clogging chute

Suspension Arm Size

Pulley Diameter + Belt and Lagging

SS 250-475mmS 500-775mmM 800-975mmL 1000-1175+-*mm

Tools Needed• Tape Measure• 24mm Wrench• Ratchet with 24mm Socket• Adjustable Wrench• Cutting Torch and/or Welder• (2) 150mm C-Clamps (for temporary positioning of mounting brackets)• 600mm Level • Marking Pen

Physically lock out and tag out the conveyor at the power source before you begin cleaner installation.

H-Type® ESAC with HXF blades HD Primary Cleaner with Compression Spring Tensioner

MOUNTING BRACKET BEARING BLOCK

TORQUE ARM

REMOVABLE CARTRIDGE

LOCK PLATECARTRIDGE REMOVAL HANDLE

BLADE ASSEMBLYHXF BLADE

CUSHION

POLE



4.1a H-Type® ESAC HD Primary Cleaner with HXF Blades - Chute Mounting1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts

on pages 16 and 17. The pulley diameter measurement should include lagging and belt. Pulley Diameter _________mm; X = _________mm; Y = _________mm Using the correct X and Y coordinates will position the cleaner at 15° below the horizontal plane on the head pulley.

Fig. 1

Fig. 2

Fig. 2b 4. Locate mounting bracket position (horizontal position). To locate the position of the cleaner mounting bracket, add 70mm to the intersecting mark (Fig. 2b). This mark indicates the pole center of the mounting bracket.

Fig. 2a

2a. Measure head pulley shaft. Determine the diameter of the pulley shaft and divide by 2.

2b. Put a level on top of the pulley shaft and draw a horizontal line A. Measure down from Line A half the diameter of the pulley shaft and draw Line B parallel from center of the pulley shaft (Fig. 1).

3a. Mark X dimension. Subtract the above dimension (Step 2a) from the selected X dimension to establish the modified X dimension. With this new X dimension measure horizontally from the front of the pulley shaft forward on Line B and mark on the chute (Fig. 2).

3b. Determine Y dimension. From the horizontal X mark, drop a line vertically down to the selected Y dimension and draw an intersecting mark (Fig. 2a). This is the correct position of the center of the pole.

70mm

A

B

9

+ +

+

+ +

+


4.1a H-Type® ESAC HD Primary Cleaner with HXF Blades - Chute Mounting (cont.)

Fig. 3 5. Cut chute opening. Using the adjusted intersecting mark (“+”) established in Step 4, lay out and cut the required opening 125x150mm on the chute (Fig. 3). If access hole is required, see Step 7.

6. Install the mounting brackets. Center the mounting bracket on the bottom of the opening. Bolt or weld in position (Fig 4). Repeat process on opposite side.

7. Cutting the access hole. Cut access hole, centering the bottom edge on the adjusted intersecting mark (“+”) established in Step 4. Width of hole should be 175mm; height should be 430mm for small arms, 480mm for medium arms, 510mm for large arms or 620mm for extra large arms. Access hole may be oriented within the range shown (Fig. 5), provided bottom edge is still centered as described above.

8. Install the pole. Remove the two bolts from the bearing mount on the access hole side and remove the bearing mount (Fig 6). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side. Install the removed bearing mount on the pole and reattach to the mounting bracket. Do not tighten; leave finger tight.

150mm

125mm

75mm75mm

Chute Opening

Adjusted intersecting mark

Mounting Bracket

Fig. 4

Fig. 5

Adjusted Intersecting Mark

Bearing Mount Bolts

Fig. 6



4.1b H-Type® ESAC HD Primary Cleaner with HXF Blades - Open Head Mounting

Fig. 2

Fig. 3

a) shaft to structure ________

b) pulley shaft diameter ________ ÷ 2 ________ +

c) pulley shaft center line to structure = ________

d) add X measurement from chart ________ +

center of pole from structure = ________

e) add 175mm (half length of mounting bracket) 175mm +

length of support material needed = ________

3. Locate X location. a.) Measure from the back of the pulley shaft to the support structure (Fig. 3).

b.) Pulley shaft diameter divided by 2.

c.) Add dimensions from a) and b). This dimension is the pulley shaft centerline to the support structure.

d.) Add the given X dimension to c). The sum indicates the distance from the center of the pole to the support structure.

e.) Add 175mm (half the length of the mounting bracket). The sum is the total length of support material needed to correctly locate the mounting brackets.

1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts on pages 16 and 17. The pulley diameter measurement should include lagging and belt. Pulley Diameter________mm X________mm Y________mm Using the correct X and Y coordinates will position the cleaner at 15° below the horizontal plane on the head pulley.

2a. Locate Y location. Determine the diameter of the pulley shaft and divide by 2.

2b. Put a level on top of the pulley shaft and mark A at the structure. Measure down from Mark A half the diameter of the pulley shaft and mark B, locating the shaft centerline (Fig. 1).

2c. Measure down the given Y dimension plus 70mm and mark (Fig. 2). This mark indicates the top location of support material to be added for installing the cleaner mounting brackets.

Fig. 1

Mark "B"

Mark "A"

Belt Direction

Mark

Mark "B"

Y + 70mm

c+d+e

Length of support material needed

Support structure

b

a

11


4.1b H-Type® ESAC HD Primary Cleaner with HXF Blades - Open Head Mounting (cont.)

6. Install the pole. Remove the two bearing mount bolts from one of the bearing mounts (Fig. 4). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side and allow pole lugs to hang down. Install the removed bearing mount on the pole and reattach to the mounting bracket. NOTE: Do not tighten; leave finger tight.

Open Head Mounting (cont.)

Fig. 4

Bearing Mount Bolts

4. Secure mounting support pieces to the support structure. Weld support pieces to the support structure. 75x75mm angle works well for these support pieces.

5. Prepare the support pieces for the cleaner mounting brackets. Clamp the mounting bracket on the support piece. Mark and drill holes for mounting or weld.


Handle

Set screw

Lock Plate

Knuckle

Tighten nut and bolt

Section 4 - Installation Instructions

4.2 Single Cartridge Installation

1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle,

then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the

knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle,

then lock with the set screw.

Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle

into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove

handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and

the handle in place.

Handle removed and stored in pole end

Lock Pin

Knuckle

13

Handle

Set screw

Lock Plate

Knuckle

Tighten nut and bolt

Section 4 - Installation Instructions

4.3 Dual Cartridge Installation


Lock Pin

Knuckle

1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle,

then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the

knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle,

then lock with the set screw. 4. Repeat for other side.

Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle

into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove

handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and

the handle in place. 4. Repeat for other side.

Fig. 1 Position the pole. Rotate pole upward to bring tips into contact with head pulley (Fig. 1). Center the tips across the belt. While applying light pressure on the center tip, shift loosened bearing mount until tips are contacting belt evenly across full width. Lock cleaner into this position by tightening bearing mount bolts.

For step-by-step instructions on installing the spring tensioner, refer to page 14.Slide


1. Install the compression spring tensioner. Remove the adjusting nuts, bushings and spring from the pivot rod. Insert the pivot arm through the slot in the torque arm. Slide the torque arm onto the pole end (be sure the rotation of the arm is correct to tension the blade).

4. Tension the blades to the belt. Rotate the blades until they contact the belt. While holding the spring bushing flat on the torque arm, rotate the torque arm until the pivot arm is against the end of the slot nearest the pole. Tighten the locking bolts and jam nuts on the torque arm (Fig. 3). NOTE: The torque arm should be up against the mounting plate.

3. Verify your “C” dimension to ensure the pole is in the correct position.

2. Reassemble the spring assembly. Slide the spring, washer and bushings onto the pivot arm and turn the two adjusting nuts so about 6mm of the pivot arm is exposed above the nuts (Fig. 2).


4.4 H-Type® ESAC HD Primary Cleaner with HXF Blades - Compression Spring Tensioner

Pivot Arm

Torque Arm

Pivot Shaft

Bracket

Mounting Plate

Pole

Fig. 1

Fig. 2 Adjusting Nuts

Washer

BushingsSpring

Pivot Arm

Fig. 3Pivot Arm against slot end nearest the pole

Tighten locking bolts and jam nuts

15

5. Set the correct blade tension. Refer to the charts below for the spring length required for the belt width. Lightly pull the pivot arm toward the end of the torque arm slot nearest the pole and turn the adjusting nuts until the required spring length is achieved (Fig. 4). Lock the top adjusting nut.

Test run the cleaner. Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the spring length for proper tensioning. Make adjustments as necessary.

Tighten locking bolts and jam nuts

Pivot Arm against slot end nearest the pole

Adjusting Nuts

Pivot ArmBushings

SpringWasher

Top of washer to

top of torque arm

Adjusting Nuts

Fig. 4


4.4 H-Type® ESAC HD Primary Cleaner with HXF Blades - Compression Spring Tensioner (con't.)

HXF SAC Black Spring Length Chart(for optimal blade tensioning)

Belt width CSS CS CM CL600 154 151 150 149800 149 146 144 142

1000 144 140 138 1351200 139 135 131 1291400 135 129 125 1221600 130 123 119 -1800 125 118 - -2000 120 - - -2200 - - - -2400 - - - -2600 - - - -2800 - - - -3000 - - - -

HXF SAC Gold Spring Length Chart(for optimal blade tensioning)


1000 154 152 151 1501200 152 150 148 1471400 150 147 145 1441600 147 144 142 1411800 145 142 140 1382000 143 139 137 1352200 141 137 134 1322400 138 134 131 1292600 136 132 128 -2800 134 129 - -3000 132 - - -

HXF SAC Silver Spring Length Chart(for optimal blade tensioning)


1000 162 161 161 1601200 161 160 159 1591400 160 159 158 1571600 159 157 156 1551800 158 156 155 1542000 157 155 153 1522200 155 153 152 1512400 154 152 150 1492600 153 150 149 1472800 152 149 147 1463000 151 148 146 144


Section 5 – Cleaner Pole Location Charts

5.1 Pole Location Charts

15°

Y

CGAP

TO A

RM

X

DIAMETER(OVER BELT)

GAP

TO PO

LE

Cobre Panama Project – Port Conveyors

Conveyor Numbers

Pulley Diameter (mm)

Suspension Arm Size X Coordinate Y Coordinate C Dimension

713-CV-9002 524 S 111 434 448712-FE-9001

624 S 159 447 474712-FE-9002712-FE-9003712-FE-9004713-CV-9001

654 S 171 450 481713-CV-9002713-CV-9003

825 M 248 513 570713-CV-9004

Note: For positioning of the Primary cleaner please refer to the X/Y and C dimension for correct location of the pole.

17

Section 6 – Pre-Operation Checklist and Testing

6.1 Pre-Op Checklist

• Recheck that all fasteners are tightened properly. • Add pole caps. • Apply all supplied labels to the cleaner . • Check the blade location on the belt. • Be sure that all installation materials and tools have been removed from the belt and the conveyor area.

6.2 Test Run the Conveyor • Run the conveyor for at least 15 minutes and inspect the cleaning performance. • Check the tensioner spring for recommended length (proper tensioning). • Make adjustments as necessary.

NOTE: Observing the cleaner when it is running and performing properly will help to detect problems or when adjustments are needed later.


Section 7 – Maintenance

Flexco belt cleaners are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the cleaner is installed a regular maintenance program should be set up. This program will ensure that the cleaner operates at optimal efficiency and problems can be identified and fixed before the cleaner stops working.

All safety procedures for inspection of equipment (stationary or operating) must be observed. The H-Type® Primary Cleaner operates at the discharge end of the conveyor and is in direct contact with the moving belt. Only visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tagout procedures.

7.1 New Installation InspectionAfter the new cleaner has run for a few days a visual inspection should be made to ensure the cleaner is performing properly. Make adjustments as needed.

7.2 Routine Visual Inspection (every 2-4 weeks) A visual inspection of the cleaner and belt can determine:

• If the spring length is the correct length for optimal tensioning. • If the belt looks clean or if there are areas that are dirty. • If the blades are worn out and need to be replaced. • If there is damage to the blades or other cleaner components. • If fugitive material is built up on the cleaner or in the transfer area. • If there is cover damage to the belt. • If there is vibration or bouncing of the cleaner on the belt. • If a snub pulley is used, a check should be made for material buildup on the pulley.

If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for cleaner maintenance.

7.3 Routine Physical Inspection (every 6-8 weeks) When the conveyor is not in operation and properly locked out and tagged out, a physical inspection of the

cleaner to perform the following tasks:

• Clean material buildup off the cleaner.

• Closely inspect the blades, suspension arms and cushions for wear and any damage. Replace if needed.

• Ensure all blades contact the belt .

• Inspect the cleaner pole and cartridge for damage.

• Inspect all fasteners for tightness and wear. Tighten or replace as needed.

• Replace any worn or damaged components.

• Check the tension of the cleaner blades to the belt. Adjust the tension if necessary.

• When maintenance tasks are completed, test run the conveyor to ensure the cleaner is performing properly.

19


7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners

Tools Needed: • Tape measure • Ratchet with 24mm socket • 24mm wrench or adjustable wrench• Wire brush (for cleaning pole) • Small putty knife (for cleaning pole)

1. Remove the tension. Loosen the adjusting nuts on both sides and then turn them out until all cleaner tips leave contact with the belt and the pole rotates into the cartridge extraction position (Fig. 1). This releases the tension of the blade on the belt.

Physically lock out and tag out the conveyor at the power source before you begin cleaner installation.

H-Type® Single ESAC HD with HXF blades Primary Belt Cleaner

2. Different Cartridge Removal Methods. Option A: Handle always on cartridge. 1. Loosen the lock plate set screw and disengage lock

plate from handle. 2. Lift the handle to unlock the knuckle and cartridge,

then pull cartridge out. 3. If using dual cartridge cleaner, repeat for other side.

Lift handle to unlock cartridge

Disengage lock plate

Loosen set screw

Knuckle

Adjusting NutsFig. 1

Pivot Arm



7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners (cont.)

3. Clean off pole. Remove any debris that has built up on the pole.

Option B: Handle stored inside pole. 1. Remove lock pins holding handle and knuckle in place. 2. Slide the handle into the knuckle and twist to lock. 3. Lift the handle to unlock the knuckle and cartridge, then

pull cartridge out. 4. If using dual cartridge cleaner, repeat for other side.

Lift handle to unlock cartridge Insert handle into

knuckle, twist to lock

Lock Pin

Knuckle

4. Remove the worn tips. Remove the nuts on each tip and remove the tips from the suspension arm (Fig. 2). Clean all fugitive material from the pole.

NOTE: If tips are hard to remove use a screwdriver or hammer to loosen them and then remove.

5. Install the new tips. Locate each tip onto each suspension arm, then install the hardware to fasten the tip to the cushion (Fig. 3).

Fig. 3

Removal Nuts

Fig. 2

21



6. Insert the reconditioned or replacement cartridge. Option A: Handle always on cartridge. 1. Slide the cartridge onto the pole and lock down the

knuckle onto the pole. 2. Slide the lock plate onto the pole, over the handle, then

lock with the set screw. 3. If using dual cartridge, repeat for other side.

Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into

the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle

and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the

handle in place. 4. If using dual cartridge, repeat for other side.

Handle

Set screw

Lock Plate

Knuckle


Lock Pin

Knuckle




Top of washerto top of

torque arm

Fig. 44. Reset the correct blade tension. Refer to the chart below for the spring length required for the belt width. Lightly pull the pivot arm toward the end of the torque arm slot nearest the pole and turn the adjusting nuts until the required spring length is achieved (Fig. 4). Tighten jam nut.

Test run the cleaner. Run the conveyor for at least 15 minutes and inspect the cleaning performance. Check the spring length for proper tensioning. Make adjustments as necessary.

HXF SAC Black Spring Length Chart(for optimal blade tensioning)


1000 144 140 138 1351200 139 135 131 1291400 135 129 125 1221600 130 123 119 -1800 125 118 - -2000 120 - - -2200 - - - -2400 - - - -2600 - - - -2800 - - - -3000 - - - -

HXF SAC Gold Spring Length Chart(for optimal blade tensioning)


1000 154 152 151 1501200 152 150 148 1471400 150 147 145 1441600 147 144 142 1411800 145 142 140 1382000 143 139 137 1352200 141 137 134 1322400 138 134 131 1292600 136 132 128 -2800 134 129 - -3000 132 - - -

HXF SAC Silver Spring Length Chart(for optimal blade tensioning)


1000 162 161 161 1601200 161 160 159 1591400 160 159 158 1571600 159 157 156 1551800 158 156 155 1542000 157 155 153 1522200 155 153 152 1512400 154 152 150 1492600 153 150 149 1472800 152 149 147 1463000 151 148 146 144

23


7.5 Maintenance Log

Conveyor Name/No. _________________________

Date: ___________________ Work done by: ___________________ Service Quote #: ___________________

Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________







Activity: __________________________________________________________________________________________________________



7.6 Cleaner Maintenance Checklist

Site: _____________________________ Inspected by: ______________________________ Date: _____________________________

Belt Cleaner: _____________________________________________ Serial Number: _________________________________________

Beltline Information:

Beltline Number: ____________________ Belt Condition: _______________________________________________________________

Belt Width: (18") (24") (30") (36") (42") (48") (54") (60") (72") ¨ 450mm ¨ 600mm ¨ 750mm ¨ 900mm ¨ 1050mm ¨ 1200mm ¨ 1350mm ¨ 1500mm ¨ 1800mm

Head Pulley Diameter (Belt & Lagging):__________ Belt Speed:________ fpm Belt Thickness: __________

Belt Splice:__________ Condition of Splice:_________ Number of Splices:________ ¨ Skived ¨ Unskived

Material conveyed: ________________________________________________________________________________________________

Days per week run:_______________ Hours per day run:_______________

Blade Life:

Date blade installed:___________ Date blade inspected:___________ Estimated blade life:____________

Is blade making complete contact with belt? ¨ Yes ¨ No

Blade wear: Left _________ Middle _________ Right _________

Blade condition: ¨ Good ¨ Grooved ¨ Smiled ¨ Not contacting belt ¨ Damaged

Measurement of spring: Required _________ Currently _________

Was Cleaner Adjusted: ¨ Yes ¨ No

Pole Condition: ¨ Good ¨ Bent ¨ Worn

Lagging: ¨ Side Lag ¨ Ceramic ¨ Rubber ¨ Other ¨ None

Condition of lagging: ¨ Good ¨ Bad ¨ Other________________________________________________________

Cleaner's Overall Performance: (Rate the following 1 - 5, 1= very poor - 5 = very good)

Appearance:_ ¨_ Comments: ____________________________________________________________________________________

Location:_ ¨_ Comments: ____________________________________________________________________________________

Maintenance:_ ¨_ Comments: ____________________________________________________________________________________

Performance:_ ¨_ Comments: ____________________________________________________________________________________

Other comments __________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

________________________________________________________________________________________________________________

25

Section 8 – Troubleshooting

Problem Possible Cause Possible Solutions

Poor cleaning performance

Cleaner under-tensioned Adjust to correct tension – see spring length chart

Cleaner over-tensioned Adjust to correct tension – see spring length chart

Cleaner installed in wrong location Verify "C" dimension, relocate to correct dimension

Cleaner blade worn or damaged Replace cleaner blade

Rapid Blade Wear

Tension on cleaner too high/low Adjust to correct tension – see spring length chart

Cleaner not located correctly Check cleaner location for correct dimensions

Blade attack angle incorrect Check cleaner location for correct dimensions

Center wear on blade (smile effect)

Blade wider than material path Replace blade with width to match material path

Tension on cleaner too high/low Adjust to correct tension – see spring length chart

Unusual wear or damage to blade

Mechanical splice damaging blade Repair, skive or replace splice

Belt damaged or ripped Repair or replace belt

Cleaner not correctly located Verify "C" dimension, relocate to correct dimension

Damage to pulley or pulley lagging Repair or replace pulley

Vibration or noise

Cleaner not located correctly Verify "C" dimension, relocate to correct dimension

Blade attack angle incorrect Verify "C" dimension, relocate to correct dimension

Cleaner running on empty belt Use a spray pole when the belt is empty

Cleaner tension too high/low Adjust to correct tension or slight adjust to diminish

Cleaner locking bolts not secure Check and tighten all bolts and nuts

Cleaner not square to head pulley Verify "C" dimension, relocate to correct dimension

Material buildup in chute Clean up buildup on cleaner and in chute

Cleaner being pushed away from pulley

Cleaner tension not set correctly Ensure correct tension/increase tension slightly

Sticky material is overburdening cleaner Increase tension; replace with larger size cleaner

Cleaner not set up correctly Confirm location dimensions are equal on both sides


Section 9 – Specs and CAD Drawings

9.1 Specifications and Guidelines

Overall Pole Length

Maximum Conveyor Span

H-Type® Single ESAC HD Pole Length Specifications*

Cleaner Size

Pole Length

Maximum Conveyor

Spanmm mm mm600 1950 1650800 2250 1950

1000 2400 21001200 2550 22501400 2850 25501600 3150 28501800 3150 2850

Clearance Guidelines for Installation

Suspension Arm Size

Horizontal Clearance Required

Vertical Clearance Required

mm mmCSS 175 410CS 175 470CM 175 520CL 175 550

Specifications:• Maximum Belt Speed ............................ 5M/sec• Temperature Rating ............................... -35°C to 82°C• Usable Blade Wear Length .................... 9mm• Blade Material ......................................... Long Life Tungsten Carbide (for vulcanized belts only)• Available for Belt Widths ...................... 600 to 3000mm

Other sizes available upon request.• CEMA Cleaner Rating .......................... Class 4

VERTICAL

HORIZONTAL

H-Type Dual ESAC HD Pole Length Specifications*

Cleaner Size

Maximum Pole

Length

Maximum Conveyor

Spanmm mm mm1200 3045 27451400 3200 29001600 3350 30501800 3505 32052000 3655 33552200 3960 36602400 3960 36602600 4420 41202800 4570 42703000 4650 4350

27


9.2 CAD Drawing - H-Type® 750 Single ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner

[PO

LE L

ENG

TH]

'B'

[C

HA

NN

EL L

ENG

TH]

'C'

[I/S

MO

UN

T D

ISTA

NC

E] M

IN =

C +

150

[5.

90 in

]M

AX

= B

- 3

00 [

11.8

1 in

]

[TI

P W

IDTH

] 'A

'

.71 18

X =

6.73

171

Y =

17.7

245

0C

=18

.95

481

10

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260

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1213

0

4.

3311

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LLEY

+ B

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799

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17

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CU

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MBE

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'A' (

mm

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NO

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OV

ERA

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LEN

GTH

'B'

(mm

) [in

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CA

RTR

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LEN

GTH

'C' (

mm

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600

[23.

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322

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PRES

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IDE

ASS

EMBL

Y



9.2 CAD Drawing - H-Type® 1000 Single ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner

[PO

LE L

ENG

TH]

'B'

[C

HA

NN

EL L

ENG

TH]

'C'

[I/S

MO

UN

T D

ISTA

NC

E] M

IN =

C +

150

[5.

90 in

]M

AX

= B

- 3

00 [

11.8

1 in

]

[TI

P W

IDTH

] 'A

'

X =

9.76

248

C =

22.4

357

0

5.

1213

0

PULL

EY +

BEL

T =

33

.94

862

18

Y =

20.1

951

3

4.

3311

0

10

.24

260

4

5

2

3

1

18

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73

M A

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FOR

80

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9

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11.0

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TOU

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N

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MBE

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COD

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TYP

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TIP

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TH

'A' (

mm

) [in

]

NO

. TI

PS

OV

ERA

LL

LEN

GTH

'B'

(mm

) [in

]

CA

RTR

IDG

E C

HA

NN

EL

LEN

GTH

'C' (

mm

) [in

]

1000

[3

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PRES

SIO

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PRIN

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IDE

ASS

EMBL

Y

29


9.2 CAD Drawing - H-Type® 2000 Dual ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner

MA

X P

OLE

LEN

GTH

'B'

TIP

WID

TH 'A

'

CEN

TER

PO

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ENG

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[I/S

MO

UN

T D

ISTA

NC

E] M

IN 2

300

[90.

55]

MA

X 2

950

[116

.14]

A A

X =

6.26

159

Y =

17

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447

C =

18

.65

474

4.

2410

8

4.

1410

5

4.

7312

0

1.

15 29

.71 18

PULL

EY +

BEL

T =

26

.46

672

5

4

2

3

1

6

13

.78

350

12

.31

313

2.

95 75

10

.24

260

16

.93

430

CU

TOU

T

16

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429

2.88 73

SEC

TIO

N A

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FOR

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9

ITEM

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DES

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LESS

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EL

1

H T

YPE

2SA

C

CEN

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TIP

WID

TH

'A' (

mm

) [in

]

NO

. TI

PS

MA

X P

OLE

LE

NG

TH 'B

' (m

m)

[in]

CEN

TER

PO

LE

LEN

GTH

'C'

(mm

) [in

]

ORD

ER N

UM

BER

ITEM

CO

DE

2000

[7

8.74

]10

3655

[1

43.9

0]22

86 [

90.0

0]H

2CP-

2000

-S/S

6280

5

2EX

TEN

DER

PO

LE K

ITM

HP-

EP-S

/S77

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RTR

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6C

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PRES

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PRIN

G S

IDE

ASS

EMBL

Y


Section 10 – Replacement Parts List

H-Type® Single ESAC HD Primary Belt Cleaner

REPLACEMENT PARTS

REF DESCRIPTION

MILD STEEL STAINLESS STEELORDERING NUMBER

ITEM CODE

WT. KG.

ORDERING NUMBER

ITEM CODE

WT. KG.

1 H-Type® Single ESAC Center Pole

HCP-600 62751 30.5 HCP-600-S/S 62757 31.4HCP-800 62752 35.6 HCP-800-S/S 62758 36.7HCP-1000 62753 38.1 HCP-1000-S/S 62759 39.3HCP-1200 62754 40.7 HCP-1200-S/S 62760 42HCP-1400 62755 45.9 HCP-1400-S/S 62761 47.3HCP-1800 62756 51.0 HCP-1800-S/S 62762 52.6

2 HD Cushion HSHD 73483 2.0 HSHD-S/S 76467 2.0

3 HXF Blades

HXF8SS 74307 3.4HXF8S 74689 3.8HXF8M 74690 4.1HXF8L 74691 4.5

4

Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B 62749 17.8 H73CSK-B-S/S 62750 18.3

Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G 62743 17.8 H73CSK-G-S/S 62744 18.3

Silver 6" Compression Spring Side Assembly (above 2400) H73CSK-G 62745 18.0 H73CSK-G-S/S 62746 18.4

REF DESCRIPTIONTIP

WIDTHORDERING NUMBER

ITEM CODE

WT. KG.

5 H-Type Cartridge Adapter Plate

600 H-SAC-AP-600 62452 3.5800 H-SAC-AP-800 62453 4.8

1000 H-SAC-AP-1000 62454 6.01200 H-SAC-AP-1200 62455 7.31400 H-SAC-AP-1400 62456 8.51600 H-SAC-AP-1600 62457 9.81800 H-SAC-AP-1800 62458 11.0

6 ESAC HD Single Cartidge Replacement

600 CART-24/600-S/S 78576 4.5800 CART-36/900-S/S 78578 6.7

1000 CART-42/1050-S/S 78579 7.81200 CART2-48/1200-S/S 78580 8.91400 CART-60/1500-S/S 78582 11.31600 CART-72/1800-S/S 78583 13.51800

1

2

3

4

5

6

31

Section 10 – Replacement Parts List

H-Type® Dual ESAC HD Primary Belt Cleaner

REPLACEMENT PARTS

REF DESCRIPTION

MILD STEEL STAINLESS STEELORDERING NUMBER

ITEM CODE

WT. KGS.

ORDERING NUMBER

ITEM CODE

WT. KGS.

1 H-Type® Dual ESAC Center Pole

H2CP-1200 62763 39.7 H2CP-1200-S/S 62801 39.7 H2CP-1400 62764 42.6 H2CP-1400-S/S 62802 42.6 H2CP-1600 62765 45.7 H2CP-1600-S/S 62803 45.7 H2CP-1800 62766 48.6 H2CP-1800-S/S 62804 48.6 H2CP-2000 62767 51.6 H2CP-2000-S/S 62805 51.6 H2CP-2400 62768 57.6 H2CP-2400-S/S 62806 57.6H2CP-2600 62769 71.0 H2CP-2600-S/S 62807 71.0H2CP-2800 62770 74.3 H2CP-2800-S/S 62808 74.3H2CP-3000 62771 77.8 H2CP-3000-S/S 62809 77.8

2 Extender Pole MHP-EP 76392 24.5 MHP-EP-S/S 77599 24.53 HD Cushion HSHD 73483 2.0 HSHD-S/S 76467 2.0

4 HXF Blades

HXF8SS 74307 3.4HXF8S 74689 3.8HXF8M 74690 4.1HXF8L 74691 4.5

5

Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B 62749 17.8 H73CSK-B-S/S 62750 18.3

Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G 62743 17.8 H73CSK-G-S/S 62744 18.3

Silver 6" Compression Spring Side Assembly (above 2400) H73CSK-G 62745 18.0 H73CSK-G-S/S 62746 18.4

REF DESCRIPTIONTIP

WIDTH

ITEM 8 / LEFT HAND ITEM 9 / RIGHT HANDORDERING NUMBER

ITEM CODE

WT. KGS.

ORDERING NUMBER

ITEM CODE

WT. KGS.

8 & 7 H-Type Cartridge Adapter Plate

1200 H-SAC-AP-600 62452 3.5 H-SAC-AP-600 62452 3.51400 H-SAC-AP-800 62453 4.8 H-SAC-AP-600 62452 3.51600 H-SAC-AP-800 62453 4.8 H-SAC-AP-800 62453 4.81800 H-SAC-AP-1000 62454 6.0 H-SAC-AP-800 62453 4.82000 H-SAC-AP-1000 62454 6.0 H-SAC-AP-1000 62454 6.02200 H-SAC-AP-1200 62455 7.3 H-SAC-AP-1000 62454 6.02400 H-SAC-AP-1200 62455 7.3 H-SAC-AP-1200 62455 7.32600 H-SAC-AP-1400 62456 8.5 H-SAC-AP-1200 62455 7.32800 H-SAC-AP-1400 62456 8.5 H-SAC-AP-1400 62456 8.53000 H-SAC-AP-1600 62457 9.8 H-SAC-AP-1400 62456 8.5

REF DESCRIPTION

TIP WIDTH

ORDERING NUMBER

ITEM CODE

WT. KGS.

8 ESAC HD Dual Cartidge Replacement

1200 CART2-60/1500-S/S 78584 11.21400 CART2-66/11650-S/S 78634 12.31600 CART2-72/1800-S/S 78585 13.41800 CART2-78/1950-S/S 78635 14.52000 CART2-84/2100-S/S 78586 15.62200

CART2-96/2400-S/S 78587 17.824002600 CART2-114/2850-S/S 78639 23.72800 CART2-120/3000-S/S 78588 22.63000 CART2-126/3150-S/S 78640 23.7

3

4

5

67

821

35

Section 11 – Other Flexco® Conveyor Products

Flexco® provides many conveyor products that help your conveyors to run more efficiently and safely. These components solve typical conveyor problems and improve productivity. Here is a quick overview on just a few of them:

• Patented ConShear™ blade renews its cleaning edge as it wears

• Visual Tension Check™ for optimal blade tensioning and simple retensioning

• Quick and easy one-pin blade replacement Material Path Option™ for optimal cleaning and reduced maintenance

MHS SAC Secondary Cleaner

• Patented “pivot & tilt” design for superior training action• Dual sensor rollers on each side to minimize belt damage• Pivot point guaranteed not to freeze or seize up• Available for topside and return side belts

• A belt cleaner for the tail pulley• Exclusive blade design quickly spirals debris off the belt• Economical and easy to service• Available in vee or diagonal models

PT Max™ Belt Trainer

Flexco® Slider and Impact Beds

Belt Plough

• Long-wearing tungsten carbide blades for superior cleaning efficiency

• Patented PowerFlex™ cushions, the proven design found on our industry-leading MHS Secondary Cleaner

• Service Advantage Cartridge can be easily removed and replaced, even in the dirtiest conditions

• Works with Flexco mechanical belt splices

• “Limited space” cleaners for tight conveyor applications• High Temp cleaners for severe, high-heat applications• A rubber fingered cleaner for chevron and raised-rib belts• Multiple cleaner styles in stainless steel for corrosive applications

Rockline® EZP1 Primary Cleaner

Flexco Specialty Belt Cleaners

• Adjusting troughing angles for easy installation and adjustability• Long-wearing UHMW for sealing the load zone• Offered in both Light & Medium duty designs to affordably fit

your application

The Flexco Vision

To become the leader in maximising belt conveyor productivity for our customers worldwide

through superior service and innovation.

2525 Wisconsin Avenue • Downers Grove, IL 60515-4200 • USA Tel: (630) 971-0150 • Fax: (630) 971-1180 • E-mail: [email protected]

Visit www.flexco.com for other Flexco locations and products.

©2017 Flexible Steel Lacing Company. 08/15/17. For reorder: X4706

Installation, Operation and Maintenance...

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