hosch tracker roller system - conveyortek ... prior to starting work, the serviceman is to consult...

Installation and Operation Manual

HOSCHTRACKER

ROLLERSYSTEM

TYPE RG2

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This document is subject to technical modifications Installation & Operating Instructions Type RG2 - Page - 02/12

Range of application

UseOne of the most frequent reasons for plant stoppages is belt mistracking, i. e. when the conveyor belt is not properly centered on the conveyor frame. Belt mistracking represents a problem especially on the return side. Belt mistracking may occur permanently or occasionally, for many reasons. In extreme cases, the belt edge can run up against the conveyor frame and this can result in severe damage of the belt and the conveyor frame.The HOSCH Tracker Roller Type RG2 is used on the belt’s return run to ensure the proper tracking of heavy application conveyor belts.

General operating conditionsThe HOSCH Tracker Roller Type RG2 can be used as follows:• for belt widths of 1.200 to 2.400 mm, in standard design• for belt speeds up to 6,5 m/s• for conveyor belts of rubber or PVC with a smooth cover plate and a hardness of 60 to 65° Shore A• for vulcanized belt joints, in standard design.• in a temperature range of max. –20 to +80° C• Tracker roller must be fixed to sufficiently twist-resistant, low-vibration structural components or consoles

Optional operating conditionsThe HOSCH Tracker Roller Type RG2 may only be used with special accessories in the case of the following operating conditions:• Explosive environments: Roller coating in the ATEX execution (anti-electrostatic and self-extinguishing coating,

if the tracker roller is used in explosive environments according to Directive 94/9/EC)• Food Industry: Roller coating in food quality.

NoteThe HOSCH Tracker roller Type RG2 must not be used in other operating conditions without the prior approval by HOSCH.

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DesignThe HOSCH Tracker Roller Type RG2 is a device used on the belt’s return run to ensure proper tracking of the conveyor belt. Characteristic features is the roller bar, tipped against the direction of belt travel. This arrange-ment allows for a swinging movement of the roller depending on the belt position.

FunctionThe Tracker Roller Type RG2 is self-adjusting, since its operation is controlled by the physical laws of friction and balance. It consists of maintenance-free and attendance-free components. Its compact design allows for easy installation on existing conveyors. The system carrier mid-section (4) is equipped with telescopic end-sections (5) that are fixed by means of cutting ring screws (7). The fixing flanges (6) are fastened directly to the conveyor structure. They must be fastened in such a way that the swinging bearing (3) of the roller bar (2) is tipped by 33° in the travel direction of the belt’s return run. The swinging bearing (3) allows for a swinging movement of the roller bar around its center point. The swinging movement is limited by means of swing angle limiters (8). When the belt mistracks, the gravity center of the belt shifts on the tracker roller. Due to the weight dislocation, the roller bar (2) tips downwards and in the belt travel direction at the same time. The special arrangement of the tipping axle of the roller bar (2) against the conveyor belt allows not only for the tipping movement but also for a slant positioning of the roller bar towards the center of the belt. The travel of the conveyor belt over the segmented rollers (1), which are inclined towards the belt travel direction, results in a friction force which steers the belt back towards the center of the conveyor structure.

The intensity of the steering movement depends on the angle size and on the forces exerted on the roller bar. The friction occurring between the belt surface and the segmented rollers also has a considerable influence. The best results are therefore obtained with cleaned, dry belt surfaces (importance of belt scrapers).

1. Coated support roller*

2. Roller bar

3. Swinging bearing

4. System carrier mid-section

5. Telescopic end-sections

6. Fixing flange

7. Cutting ring screw to fix theend-sections

8. Swing angle limiter

(* different qualities available)

Functional Description

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1760 - 23001900 - 24402110 - 26502310 - 2850RG2-2002000

RG2-1801800RG2-1601600RG2-1401400 1645

178519952190

2590 - 3130RG2-2202200 24702730 - 3270RG2-2402400 2610

17001495 - 2035RG2-1201200 1380 1435

18402050225025302670

260 317 46 430

GFEDB min - maxA Cmmmm

ø160ø160

20°

X

X

A

C

B

D F400

230

ø18

280

max. 300max. 300

412

480

525

140

190

E

G


Device layout / Characteristics

Dimension table

Beltwidth

TrackerRoller

Dimensions

Projection- X

Illustration: Position I Illustration: Position II

Arrangement rotatedby 20° - Correspondsto the position under the belt

Direction ofbelt travel


Belt width

NoteBefore installation and commissioning of the tracker roller, the conveyor system and the conveyor belt must bechecked for proper function and condition, e.g. mistracking, belt tension, round running of drums, slope ofreturn idlers, vibrations. In the case of special operating conditions, please contact HOSCH.

List of toolsThe following tools are required for the installation and maintenance of the tracker roller (minimum requirements):2 pcs. 19 mm ring/open-end spanner;2 pcs. 24 mm ring/open-end spanner; 1 pc. spirit level; 1 pc. fitter's square 160x250;1 pc. one-hand right-angle grinder; 1 pc. welding machine 1 pc. measuring tape 3 m; 1 pc. wire brush; 1 pc. marking pen or chalk 1 pc. hand-brush

Detail - YType

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• Before carrying out installation or maintenance work on HOSCH Tracker Roller, ensure that the conveyor belt has been stopped and “locked-off”. The working area must be secured. Do not begin any work that has not been previously authorised by a responsible works manager and co-ordinated with all the departments involved (such as electrical engineering, safety departments, production department, operation department). Protective clothing, in particular safety boots, gloves, helmet and protective glasses are compulsory.

• An authorised work permit from the relevant manager must be obtained prior to any welding and cutting work. Make sure that appropriate fire extinguishing devices are available.

• When working at height, provide safety devices, for example scaffolds, railings, guard nets, safety belts. The devices must have been installed or inspected by a specialised company and released, as fit for work.

• Prior to starting work, the serviceman is to consult the person in charge of site safety and establish the conveyor environment as well as possible specific security instructions.

• Prior to operating the tracker roller, ensure that the site is completely cleared. All equipment or parts, such as scaffolds, lifting gears, tools etc. should be removed from the area prior to restarting the conveyor belt. Guards etc. that may have been dismantled to ease the installation/maintenance must be refitted.

• HOSCH Tracker Rollers are equipped with rotating components. Risk of trapping and squashing ! The site operator should guard the mountings to prevent accidental contact.

• In case the support rollers jam during operation, the roller coating is likely become very hot. Touching them immediately upon stopping the belt can lead to serious burns.

• In case of improper positioning or alignment of the tracker roller, the belt mistracking may be increased. Installation instructions must be observed.

• The weakened structures of worn components are likely to break. To guarantee the personnel and conveyor

safety, these parts have to be replaced with new ones.

• Tracker rollers are exposed to high dynamic stress. Therefore, all screwed connections are to be checked and secured before each commissioning and upon each maintenance. Security elements (spring washers, counter nuts) should not be re-used. They must be replaced by new parts. In case of mechanical damage e.g. corro-sion, new parts are to be installed.

• Only original, genuine HOSCH parts should be used.

General Danger Notice

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Pos. II

Pos. I

min. 10 m -- max. 50 m

A

A

15 15

275

B*


Installation

1. Determining the installation position

The Tracker Roller is to be installed in or in front of the area showing the biggest mistracking. Make sure that the clearance behind the tracker roller to the next roller is about 5m. Trough-shaped and V-shaped rollers are to be replaced by straight return idlers. The distance to the snub pulley should be about 10m. In case the mistracking extends over a long distance, for example on long conveyor belts, several tracker rollers are to be installed. In this case, the distance between each tracker roller must be 10 to 50m, to avoid the tracker rollers from influenc-ing each other (at least one straight return idler between two tracker rollers).

2. Fixing of the mounting plates

Check if the mounting plates can be fixed on the existing conveyor structure. The maximum distance between the mounting plates is dimension Bmax*, the minimum distance is Bmin* (see Dimension Table). On the belt’s return run, the tracker roller can be installed in 2 different positions (I, II – see dimension table). The difference between both positions is the position of the fixing flanges of the system carrier.Ensure that the mounting plates are easily accessible and that the clearance for tensioning the device is suffi-cient.

*Depending on the belt width (see dimension table)

Projection A

appr. 3 mappr. 3 m

appr. 3 m

appr. 6 m

Direction of belt travel

appr. 6 m

Belt width


appr. 3 m

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PM(I)

PM(I)

PB

PB

PM(II)

D

F

260

300

155

50

G

E


Installation

Starting from point (PB), the center point of the flange of the system carrier PM (I) is to be determined at the frame construction using measures D and E. The measures are always to be marked parallel and vertically to the belt direction (see illustration).Alternatively, position PM (II) can be determined using measures F and G.

Starting from point PM (I), determine the position of the upper edge of the mounting plates. Next weld the mounting plates to the conveyor structure. The position of the mounting plates is to be selected in such a way that it can be fixed to stable, twist-resistant components of the supporting structure such as sectional steel beams. If requested, appropriate intermediate consoles must be provided. The mounting plates are to be installed vertically to the belt. When fixing the mounting plates, make sure that they are positioned in such a way that sufficient space (approx. 50 mm ) is available vertically for tensioning the tracker roller against the belt.

3. Determining the position of the flanges of the system carrier

PB : Contact point of the rollerswith the belt

PM : Center point of the flangeof the system carrier

Position: PM (I) :D : 307 mmE : 253 mm

Alternative position: PM (II):F : 33 mmG : 430 mm

4. Determining the position of the mounting plates

PB : Contact point of the rollerswith the belt

PM : Center point of the flangeof the system carrier



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A

A

max. 300


Installation

Assemble the tracker roller as shown in the above illustration: assemble the roller bar, the swinging bearing and the system carrier mid-section using the supplied screw kit, then tighten the screws. Next assemble the system carrier mid-section and the end-sections considering measure B* (see installation step 2) and tighten the screws.Caution: The end-sections must not jut out of the system carrier mid-section by more than 300 mm.

Get the pre-assembled tracker roller in the right position using mounting devices such as a chain hoist or alifting cylinder. Next fix the tracker roller on the mounting plates using the supplied screw kit. Fasten the screws hand-tight. Observe the direction of belt travel (see Projection A).

5. Pre-assembling the tracker roller

6. Inserting the tracker roller

Projection A

Direction of

belt travel

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PG

PB

ma

x. 5

0

= =

==

=


Installation

Center the tracker roller to the conveyor structure. If necessary, rectify the position of the swinging bearing. Next fix the end-sections with the system carrier mid-section: tighten the cutting ring screws M16 and secure.Get the tracker roller in slight contact with the belt over the whole belt width. Ensure that the system carrier is parallel to the belt surface on both sides of the conveyor structure. Differences in height may be rectified by means of the straining screw.

Spindle up the system carrier evenly on both sides (2) by means of the straining screw. The tensioning course is 20 to 50mm, depending on the load of the belt. Lift heavy belts with large belt width by appr. 20 mm, light belts with small belt width by up to 50 mm.Caution: Once the tracker roller is tensioned, the center point of the tracker roller axle must be positioned at the same height on both sides of the conveyor structure. Check this using a measuring tape or a spirit level.Tighten the screws and secure.

8. Pre-tensioning the tracker roller

Tensioning course : 20 - 50 mm

7. Aligning the tracker roller

PG : Median line of theconveyor structure

Straining screw

Straining screw



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Installation

Check all fixing elements of the tracker roller, re-tighten and secure screws (1). Check function and free motion of all components, especially the roller bar. Check assembly using the installation checklist (2).

Check if the tracker roller reacts to mistracking and if it steers the belt back in the center of the conveyor struc-ture. Check if the belt lies all over the roll bar. If necessary, remove the return idlers on both sides of the tracker roller.If the roller bar remains slanted during a complete belt revolution, the position of the other support idlers must be rectified, in order to obtain a side to side mistracking.

9. Checking the installation

10. Trial run with material

Minimum period of trialrun with material = 0.5 hrs.


Steering direction of the roller

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Maintenance and Service

To maintain its performance, the HOSCH Tracker Roller Type RG2 must be inspected and serviced regularly. The components of the tracker roller as for example the swinging bearing and the support rollers are basically maintenance-free.

CAUTION: A roller bar which can not move free may restrict the steering function of the tracker roller, or even increase the mistracking.

First inspection:Directly after the first full working day of a tracker roller, a visual inspection should be carried out. In this inspec-tion, especially the steering efficiency, the free movement of the roller bar and the contact of the belt all over the roller bar, in different operating conditions, should be checked.

Follow-up inspections: The intervals for follow-up inspections are variable and mainly depend on the operating conditions of the tracker roller. Generally, the inspections should be carried out at intervals of 2 to 4 weeks. If necessary, the inspection intervals must be shorter. The follow-up inspections include the same steps as the first inspection. Additionally, the degree of wear of the rollers must be assessed and the rollers must be replaced if necessary.

Maintenance:Depending on the operating conditions, the tracker roller must undergo a regular service inspection. A maximum of 8 to 12 operating weeks is a very general value for the time between two service inspections. Depending on the type of installation and the material conveyed, this value may differ greatly, however. Please coordinate the service intervals with HOSCH. The following work is to be carried out:

• Cleaning of all components• Functional check and especially the free movement of all components• Assessment and, if necessary, repair of anti-corrosion coat of all components• Assessment of the degree of wear of all components, especially of the roller coating• Replacement of worn-out or damaged parts by original parts• Installation and re-adjustment of the tracker roller according to the installation & operating instructions.

HOSCH ServiceThe required inspection and service intervals can be coordinated with HOSCH's Service Department if requested. HOSCH service staff is available world-wide to carry out the work. Additionally, HOSCH offers its customers training seminars on the selection, installation, inspection and service of its belt conveyor cleaning systems.

HOSCH in the United Kingdom

The HOSCH Group

HOSCH Equipment (India) PVT Ltd.Calcutta, Indiae-mail: [email protected]

HOSCH Italia S.R.L.Pontecagnano, Italye-mail: [email protected]

HOSCH Techniki Transportowe Polska Sp. z o.o.Wrocław, Polande-mail: [email protected]

HOSCH Fördertechnik (SA) (Pty) Ltd.Johannesburg, South Africae-mail: [email protected]

HOSCH Iberia S.R.L.U.Barcelona, Spaine-mail: [email protected]

HOSCH COMPANYPittsburgh, USAe-mail: [email protected]

HOSCH International Pty Ltd.Perth, Australiae-mail: [email protected]

HOSCH do Brasil Ltda.Belo Horizonte, Brazile-mail: [email protected]

HOSCH France S.A.R.L.Réau, Francee-mail: [email protected]

HOSCH Schweiz GmbHRotkreuz, Switzerlande-mail: [email protected]

HOSCH (G.B.) Ltd.97, Sadler Forster Way, Thornaby, Teesside, TS17 9JYTel: 01642 751 100, Fax 01642 751 448e-mail: [email protected], web: www.hosch.co.uk

HOSCH Hellas Monoprosopi E.P.E.Thessaloniki, Greecee-mail: [email protected]

HOSCH-Fördertechnik GmbHRecklinghausen, Germanye-mail: [email protected]

HOSCH Austria GmbHTechelsberg am Wörther See, Austriae-mail: [email protected]

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©2010 HOSCH-Fördertechnik GmbH

No part of this publication may be reproduced, transmitted, transcribed, stored in any retrieval system or translated into any human or computer language by any means or in any form, without the prior written permission of HOSCH-Fördertechnik GmbH. Contravention of the owner's copyright may also reduce the ability of HOSCH-Fördertechnik GmbH to provide effective support for its equipment.

HOSCH-Fördertechnik GmbH reserves the right to make changes without notice to both this document and to its products described within this document. Nothing in this publication represents any contractual or other commitment on the part of HOSCH-Fördertechnik GmbH and should not be taken as such. All possible care has been taken in the preparation of this publication.

However, if you find any errors or would like to make suggestions for improvement then write to HOSCH-Fördertechnik GmbH.


hosch tracker roller system - conveyortek ... prior to starting work, the serviceman is to consult...

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