InstallationInstallation

Luff Conveyor Components Luff Conveyor Components

• Structure AlignmentStructure Alignment–ParallelParallel–StraightStraight–SquareSquare–LevelLevel

ParallelParallel

StraightStraight

Frame AlignmentFrame Alignment

LevelLevel

PulleysPulleys

Pulley AlignmentPulley Alignment1.1. + or - 1/32” level & perpendicular to the + or - 1/32” level & perpendicular to the

beltbelt2.2. MisalignmentMisalignment

• Excessive thrust load on bearingsExcessive thrust load on bearings• Accelerated & uneven lagging wearAccelerated & uneven lagging wear• Belt training problemsBelt training problems

InstallationInstallation• Idler alignmentIdler alignment

–Square and in-line to the conveyor Square and in-line to the conveyor centerline and referenced from a centerline and referenced from a terminal pulleyterminal pulley

–Parallel to each otherParallel to each other

Idler AlignmentIdler Alignment

InstallationInstallation• Belt alignmentBelt alignment

–Initially - train the belt emptyInitially - train the belt empty–Then - train the belt under full design Then - train the belt under full design

loadload–Helpful hintsHelpful hints

• Only one person supervise the trainingOnly one person supervise the training

InstallationInstallation• Belt alignmentBelt alignment

–Helpful hints (continued)Helpful hints (continued)• After run-in period, check readings After run-in period, check readings for voltage, amps, or watts for for voltage, amps, or watts for comparisoncomparison–Higher future readings may indicate Higher future readings may indicate

excessive drag from de-training or excessive drag from de-training or frozen idler rollsfrozen idler rolls

InstallationInstallation• Belt alignmentBelt alignment

–Helpful hints (continued)Helpful hints (continued)• Do not over-train. This will Do not over-train. This will increase belt wear and power increase belt wear and power consumptionconsumption

Effect on Idler LifeEffect on Idler Life

Effect on Idler LifeEffect on Idler Life

Effect on Idler LifeEffect on Idler Life

MaintenanceMaintenance• Inspection Plan (continued)Inspection Plan (continued)

–Thoroughly clean grease fittings to Thoroughly clean grease fittings to eliminate the possibility of eliminate the possibility of introducing contamination into introducing contamination into bearingsbearings

MaintenanceMaintenance• Skirtboard adjustmentSkirtboard adjustment

– Skirtboards centralize & shape the load to Skirtboards centralize & shape the load to minimize spillageminimize spillage

– Steel backing plates should be high enough to Steel backing plates should be high enough to avoid risk of contact with the beltavoid risk of contact with the belt

– Typical gap is 1/2” at the tail opening and Typical gap is 1/2” at the tail opening and increases to 1” at the exit of the load zoneincreases to 1” at the exit of the load zone

MaintenanceMaintenance• Belt splicingBelt splicing

–The splice “MUST” be squareThe splice “MUST” be square–The only corrective action for a nonThe only corrective action for a non--

squared splice, is to re-splicesquared splice, is to re-splice

Training Problem ConveyorsTraining Problem Conveyors

MaintenanceMaintenance• TrainingTraining

–Training or self-aligning idlers DO Training or self-aligning idlers DO NOT train a beltNOT train a belt

–Only the center roll of a troughing Only the center roll of a troughing idler effects training. Wing rolls idler effects training. Wing rolls only offer load supportonly offer load support

MaintenanceMaintenance• Training Training (continued)(continued)

–Tilting troughing idlers forward, not Tilting troughing idlers forward, not over 2 degrees, in the direction of over 2 degrees, in the direction of belt travel, produces a self-aligning belt travel, produces a self-aligning effect (caution on reversing belts)effect (caution on reversing belts)

MaintenanceMaintenance• TrainingTraining (continued) (continued)

–ProcedureProcedure• Square and level all troughing idlers, Square and level all troughing idlers, return rolls, tail, head, take-up, snub, and return rolls, tail, head, take-up, snub, and drive pulleysdrive pulleys

• Check counterweights and the sag on the Check counterweights and the sag on the return belt (2” per 10’)return belt (2” per 10’)

MaintenanceMaintenance• TrainingTraining (continued) (continued)

• Check all center rolls on troughing Check all center rolls on troughing idlers & check return rolls for idlers & check return rolls for proper belt contactproper belt contact

• Check troughing frames for tilt Check troughing frames for tilt degree and make correctionsdegree and make corrections

MaintenanceMaintenance• TrainingTraining (continued) (continued)

• Start training adjustments at the head Start training adjustments at the head end and on the return side. Check end and on the return side. Check and adjust all return rolls to the tail and adjust all return rolls to the tail pulley (this assures early centering at pulley (this assures early centering at the loading point on the belt)the loading point on the belt)

MaintenanceMaintenance• TrainingTraining (continued) (continued)

• After the return side is running After the return side is running true, start training the top troughing true, start training the top troughing idlers from the tail to the head idlers from the tail to the head pulley pulley (end of procedure) (end of procedure)

MaintenanceMaintenance• TrainingTraining (continued) (continued)

–Train the belt empty first, then train the Train the belt empty first, then train the belt under full design load belt under full design load • If the belt trains well empty, then later If the belt trains well empty, then later problems will be due usually to off-problems will be due usually to off-center loading or material build-up on center loading or material build-up on rollsrolls

MaintenanceMaintenance• TrainingTraining (continued) (continued)

–Idlers can be “knocked” to train beltIdlers can be “knocked” to train belt• In the direction of belt travel, In the direction of belt travel, knock forward the idler end to knock forward the idler end to which the belt runs (***visualize which the belt runs (***visualize bicycle handle bars***)bicycle handle bars***)

MaintenanceMaintenance• Training Training (continued)(continued)

• Shift idlers in the area preceding the Shift idlers in the area preceding the detraining area of the conveyordetraining area of the conveyor

• 1/4” max adjustment1/4” max adjustment• Caution - knocking may have adverse Caution - knocking may have adverse

effects on reversing beltseffects on reversing belts

MaintenanceMaintenance• TrainingTraining (continued) (continued)

– Training idlers should not be located Training idlers should not be located within 25-50 feet of a head or tail pulley, within 25-50 feet of a head or tail pulley, vertical curves, or abrupt changes in vertical curves, or abrupt changes in directiondirection

– The belt tends to run to the down side of The belt tends to run to the down side of an unlevel pulleyan unlevel pulley

MaintenanceMaintenance• TrainingTraining (continued) (continued)

–V-trough return rolls train very wellV-trough return rolls train very well–The side guide rolls on training idlers The side guide rolls on training idlers

should be mounted inbound of the should be mounted inbound of the belt directionbelt direction