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Installation and operating manual

CEN-TRAX belt tracker

Type SK and S

www.tbkgroup.com Installation and operating manual CEN-TRAX belt tracker type SK and S

Version: May 2017

Type SK

Type S

www.tbkgroup.com Installation and operating manual CEN-TRAX belt tracker type SK and S

Table of contents:

1 Introduction 01

1.1 Manufacturer, copyright 011.2 Disclaimer 01

2 Safetymeasuresandwarnings 022.1 Legend:(explanationofthesymbols) 022.2 Requiredpersonalprotectiveequipment 022.3 Generalsafetyinstructions 032.4 Specialsafetyinstructions 042.5 Instructionsforuseinexplosiveatmospherezones 052.6 Warninglabelsonproduct 06

3 Productdescription 073.1 Purposeandfunction 073.2 Technicalspecifications 073.3 Operationandfunctionaloverview 083.4 Componentoverview 093.5 Parts list 103.6 Productdimensions&sizetable 113.7 Overviewoftheidlers 11

4 Commissioning 124.1 General 124.2 Transport 124.3 Storage 124.4 Installation/commissioning 124.5 Determinetheinstallationlocation 134.6 Tooloverview 144.7 Openthepackagingandremovetheidlersandidlerbrackets 15

5 Installation 165.1 SettingwidthofCEN-TRAXbelttracker 165.2 Determiningheightofmountingplates 175.3 Positioningmountingplates&markingoncarrierbeams 185.4 Installingsystemcarrier 19 5.5 Determiningtroughangleofconveyorbeltandpositionoftriangleplate 205.6 Installingbracketforconicalidlers 215.7 Installingcentralidler 22 5.8 Installingconicalidlers 23 5.9 Alignmentandadjustment 24 5.10 Test run 25

6 Maintenance 26 6.1 General 26 6.2 Maintenanceinstructionsandintervals 26 6.3 Maintenanceinstructionsforuseinexplosiveatmospherezones 266.4 Repairs/partsreplacement 246.5 Replacingtheidlers 27 7 Malfunctions 298 Environment 309 Warranty 3010 Contact 30

www.tbkgroup.com Installation and operating manual CEN-TRAX belt tracker type SK and S Page 01

1 IntroductionThismanualprovidestheimportantandnecessaryinformationabouttheinstallationandmaintenanceoftheCEN-TRAXbelttrackerstypeSKandS.ThemanualappliestoallCEN-TRAXbelttrackerstypeSKandS.ThestandardtypeSKisshowninthemanual.

Readthemanualcarefullysothatyouarefamiliarwiththeentirecontents.Followtheinstructionsinthe manualcarefully.Alwaysperformthetasksinthecorrectorder.

Keepthisinstallationandoperatingmanualwiththemachinedocumentationforfuturereference,and makesurethemanualisavailabletotheinstallationpersonnelandoperators!Ifthemanualislost,anew copycanberequestedfromTBK spillage control bv.

1.1 Manufacturer, copyright Manufacturer:

TBKspillagecontrolbv Tel.:+31(0)318745740GrootOvereem7 E-mail:[email protected]

1.2 Copyright:Allrightsreserved.Reprinting,reproducingorsupplyingthisinstallationandoperatingmanualtothirdparties,includingstorageanduseonopticalandelectronicdatacarriers,otherthanforusebytheownerfortrainingandoperatingpurposes,areonlypermittedwiththemanufacturer’swrittenpermission.

1.3 Disclaimer:TBKspillagecontrolbvisnotliableforaccidentsordamagesresultingfromfailuretoheedthewarningsorinstruc-tionsprovidedonthebelttrackerandinthismanual,including:• incompetentand/orincorrectuseormaintenance• useforotherpurposesorunderotherconditionsthanthosespecifiedinthismanual• theuseofcomponentsotherthanthosespecified• repairsormodificationsmadewithoutthemanufacturer’sauthorisation.

TBKspillagecontrolbvcannotbeheldliableforindirectdamageresultingfrommalfunctionsordeficienciesofthebelttracker,suchasdowntime,slowdowns,etc.

TBKspillagecontrolbvcannotbeheldliablefordamageorinjuryasaresultoffailuretocarefullycomplywiththeinstructionsinthismanualandlackofpropercareduringtransport,installation,useandmaintenance.Inconnectionwithourpolicyofcontinuousimprovement,certainproductdetailsmaydifferfromwhatisdescribedinthismanual.Forthisreason,theprovidedinstructionsonlyserveasaguidelineforinstallationoftheproductforwhichthismanualwaswritten.Thismanualwaspreparedwithallduecare,butTBKspillagecontrolbvcannotacceptresponsibilityforanyerrorsinthismanualorfortheconsequencesthereof.


2 Safety measures and warnings

2.1 Legend:(explanationofthesymbols)

2.2 Requiredpersonalprotectiveequipment

Alwaysweartheproperpersonalprotectiveequipment(workgloves,safetyglasses,safetyshoes,etc.)when performingthework.

Warning:dangerarea/Particularattentionisrequired,orreadparticularlyattentively.

Donotswitchon/Makesurethebeltconveyorsystemcannotbeswitchedonduringinstallation.

Warning:potentiallyexplosiveatmosphere.

Warning:earthing/Makesurethesystemisproperlyearthed.

Warning:bewareofriskoftrappingofthehands.

Warning:bewareofriskofhandinjury.

Warning:bewareofrotatingpartsandtheriskofbeingpulledintothemachine.

Protectiveclothingrequired

Safetyglovesrequired

Safety shoes required

Safety helmet required

Eyeprotectionrequired

GHearingprotectionrequired


2.3 Generalsafetyinstructions

Important:• PleasereadthesafetywarningsandprecautionsbeforeinstallingtheCEN-TRAXbelttrackers.Followthe

instructionsandguidelinesdescribedinthismanualcarefullyduringinstallation.Neverchangetheorderofthestepstobecompleted.Ifanyaspectoftheinstallationprocessisunclear,pleasecontact

TBKspillagecontrolbv.

• Thisoperatingmanualisintendedforskilledpersonnelwhohavebeentrainedbythemanufactureroritsrepresentative,sincethesepeoplehavethequalifications,experience,additionaltrainingandknow-ledgeofrelevantstandards,legislation,accidentpreventionregulationsandoperatingconditionstoperformtherequiredtaskswhilerecognisingandavoidingpotentialhazards.

• Installation/commissioningmustbeperformedbyskilledpersonnelwhohavebeentrainedbythemanufactureroritsrepresentative(minimumoftwopeople);otherwisethewarrantyisvoid.

• Theinstructionsintheoperatingmanualmustbeobservedwithoutfail.Intheeventofnon-compliancethemanufacturerisnotliableforanyresultingdamagetothemachineorpersonalinjuries. • AsCEN-TRAXbelttrackersaregenerallyintegratedintobeltconveyorsystems,thestipulationsofthe

relevantapplicablemachinerydirectivesmustbecompliedwithbycompaniesusingthesebeltconveyorsystemsandoperatorswhoinstallthetrackingsystems.

• CEN-TRAXBelttrackersystemsofferedbyTBKspillagecontrolbvmayonlybeusedinaccordancewiththeirintendedpurpose:tocorrectconveyorbeltmistrackingatthelocationsprovidedforthatpurposefor the load carrying side

• Checkthedeliveryimmediatelyuponreceipt.IntheeventofdamageoranincompletedeliverywerequestthatyouimmediatelycontactTBKspillagecontrolbv.

• Inordertoensurethesystemfunctionsproperly,inprincipleonlythemanufacturer’sreplacementpartsmaybeused.

• Whenperformingworkofanykind,therelevantregulationsissuedbythelocalauthoritiesandotherrelevantlegislationmustbefollowed.

• TheCEN-TRAXbelttrackers,typeSKandS,meetthehighesttechnicalstandardsatthetimeofdelivery.

• Thesystemsmayonlybeinstalledandoperatedinundamagedcondition,andtheoperatormustcomplywiththerelevantaccident-preventionregulationsinordertoensureoperatingsafety.

• TheremustbeasuitableconveyorconstructiononwhichtomounttheCEN-TRAXbelttracker.Theframemustbeflat,cleananddry.

• Additions,changesandconversionarenotpermitted,astheymayimpairthesafety.

• Ensurethatallthefastenersaretightenedsecurely.Checkthatallfastenersareinthecorrectposition.ATTENTION:theomissionoffastenershasanadverseimpactonthesafetyoftheCEN-TRAXbelttrackersandisthereforestronglydiscouraged!

• Noclaimismadeastothecompletenessofthesesafetyinstructions.Ifyouhaveanyquestionsorprob-lems, contact the manufacturer.


2.4 Specialsafetyinstructions

• Erectabarrieraroundtheinstallationlocationwithbarriertapetokeepunauthorisedpersonsatasafedistance.

• Keeptheworkareacleanandfreeofobstacles.

• Makesurethereisadequateambientlightingduringinstallationandmaintenance.

• Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand-accessoriesbeforestartinganyworkonCEN-TRAXbelttrackers.

• DuringinstallationofCEN-TRAXbelttrackers,compliancewiththeofficialregulations(explosionprotection,fireprotection,etc.)mustbecheckedbeforetheuseofaweldingtorchand/orotherweldingequipment.

• Whenweldingorcutting,componentsthataresensitivetoheat,e.g.theconveyorbelt,mustbecovered.Insomecases,afireprotectionofficermayalsoneedtobepresent.

• Warning:rotatingpartsandriskofbeingpulledintothemachine.Thereisariskofbeingpulledintothemachineandbeingcrushed.Theoperatormusttakeappropriateprecautions(fencing,warningsigns).

• Neverplaceyourfingers/handsbetweentheidlersandtheconveyorbeltiftheconveyorbeltisrunningornotlocked-outinaccordancewiththelock-outprocedures.

• Neverrunyourhandsovertheidlersiftheconveyorbeltisrunningornotlocked-outinaccordancewiththelock-outprocedures.

• Makesureyourfingersnevercomeunder/betweenthebeltconstructionandtheCEN-TRAXbelttrack-er.

• ATTENTION:Makesurefingers,feetandlimbsdonotgetcaughtbetweenthecomponentsand/orpivotingparts.Neverplaceyourfingers/handsbetweenthestopandthecentralcarrier.

• Becarefulofthesharpedgesandcornersofthebelttrackingsystem:riskoflaceration.

• MakesuretheearthingoftheCEN-TRAXbelttrackerisproperlyconnected.

• Removalorcoveringofsafetylabelsisnotallowed.

• TheCEN-TRAXbelttrackerisdeliveredinawoodenbox.Thisboxmayweighbetween50and250kgandistop-heavy.Onlymovethisboxwithaforkliftortrolleyswithaliftingdevice.

• Placetheboxascloseaspossibletotheinstallationlocation.Iftheinstallationlocationisdifficultorimpossibletoreachwithaforklift,removetheheavyparts(idlers,brackets)fromtheCEN-TRAXbelttrackerandbringthemtotheinstallationlocationseparately.Alwaysuseliftingassistanceequipmentandliftwiththeassistanceofasecondpersonwhenpossible.

• Heedtheapplicablehealthandsafetystandardsanddirectiveswhencarryingandlifting• thepartsoftheCEN-TRAXbelttracker.Themaximumweighttobeliftedbyeachpersonis23kg.When

exceedingthismaximumliftingweightalwaysuseliftingassistanceequipmentorliftingmachinery.

• Considertheergonomicaspectsduringactivitiessuchaslifting,bendingover,reaching,etc.duringworkontheCEN-TRAXbelttracker.


2.5 Instructionsforuseinexplosiveatmospherezones

• Theusermustspecifytheenvironmentinwhichthebelttrackerwillbeused(e.g.underground,inexplosiveatmospherezones,etc.).

• CEN-TRAXbelttrackerforuseinexplosiveatmospherezonesareequippedwithspecialidlers.Theseidlerscanberecognisedbytheorange-colouredbearinghousings.

• CEN-TRAXbelttrackerthataresuitableforuseinexplosiveatmospherezonesarefittedwiththefollowingtypeplates:

RequirementsandbasicprinciplesforuseinexplosiveatmospherezonesEXIM2andEXII2D

•CEN-TRAXbelttrackersmayonlybeusedincombinationwithelectricallyconductiveconveyorbelts(surfaceresistanceofthetopandbottomofthebelt<3.108Ωat23°Cand50%rel.humidity,aswellasaconductiveresistance<109Ωformulti-layerconveyorbelts).Atbeltspeeds>5m/stheuseofmechanicalfastenersisnotallowed.

•Thebelttrackermustbefittedwithspecialidlersthatareapprovedforuseinexplosiveatmosphere zones.Theseidlerscanberecognisedbytheorange-colouredbearinghousings.•Theidlersmustbereplacedatleastasoftenastheintervalsprescribedinsection6.3.• Max.surfacetemperature+85oC.• Temperaturerange-45o C tot +40oC.• Dustcharacteristics: •ignitiontemperaturemax.128oC •glowtemperaturemax.160oC •ignitionenergy>1mJ.• Max.permittedbeltspeed: •typeSKandSKO3m/s •typeSandSO6m/s.

• Thebeltconveyorsystemmustbeearthed.• Thebelttrackermustbeearthedviathebeltconveyorconstruction.

• Theinstallationmayonlybeputinoperationaftertheuserhasdeterminedthattheinstallation• inwhichthebelttrackerisintegratedmeetsthebasicrequirementsofthedirective.• Use only original replacement parts.


2.6 Warninglabelsonproduct

ThispageincludespicturesofallmajorwarninglabelsontheCEN-TRAXbelttracker.Ifanyoftheselabelsisnolongerclearlyreadable,itmustbereplaced.Removalandcoveringofthelabelsisnotallowed.

Warning:bewareofriskoftrappingofthehands.

Warning:bewareofrotatingpartsandtheriskofbeingpulledintothemachine.


3 Productdescription3.1 Purposeandfunction

TheCEN-TRAXbelttrackerisabelttrackingsystemforcorrectingmistrackingofconveyorbeltsontheloadcarryingsideandisalsosuitableforreversiblebelts.

3.2 Technicalspecifications

Beltwidth 650to1800mm(from1800mmonrequest)Belt speed typeSKmax.3m/sec.

typeSmax.6m/sec.Conveyorbelttype smoothrubberorPVCfabricbelt*

Therequirementslistedinsection2.5applyforuseinanATEXzonedenvironment

Beltjoint vulcanisedormechanicalAmbienttemperature -45°Cto+40°CDirectionofbelttravel suitableforoneandtwodirectionsoftravelIdler lining wear-resistantrubber,ATEX-approvedrubber,polyurethane


3.3 Operationandfunctionaloverview

CEN-TRAXbelttrackers,typeSKandS,consistofasystemcarrierrigidlymountedonthebeltconstructionandatrackingcrossbeamfittedwithacentralidlerandtwoconicalidlers.Theidlersarelinedwithdiamondprofiledrubberorpolyurethane.Thetrackingcrossbeamisconnectedtothesystemcarrierviaacentralswivelbearingarrangement.Theangleoftheconicalidlerscanbesteplesslyadjustedtomatchthetroughangleofthebelt.

Operation:

Whentheconveyorbeltbeginsmistracking,thespeedofthetwoconicalidlerschanges.Theconicalidleronthesidetowardswhichthebeltismovingturnsfaster,andtheconicalidlerontheoppositesidebeginstoslowdown.Thisdifferenceinspeedandfrictioncausesthetrackingcrossbeamtorotateonitsaxis,outofalignmentwiththecentre-lineofthebelt.Thesteeringforcegeneratedbythismisalignmentguidesthebeltbacktothecentre.Thegreaterthemisalignmentofthebelt,thegreatertheguidingforceexertedbytheCEN-TRAXbelttracker.

Functionaloverview

Conical idler

Central idler

Angle adjustment 0 - 45°

Stop

(max 5° rotation to stop)

Swivel bearing

Height adjustment(for idler tension on belt)

Height adjustmentWidth adjustment

Lateral adjustment

Idler bracket

System carrier

Tracking crossbeam

Clamping plate


3.4 Component overview

20

23

22 23

21

6141312

16*

18 19*

11

23 1

46768

9

5

3

10

15

176

24*

25* 6* 7*

26*

TYPES(*thesepartsarespecifictoTYPES)

TYPESK&S(*16and*19,thesepartsarespecifictoTYPESK)


3.5 Parts list

REF.NO. QUANTITY DESCRIPTION(TYPESK&S)1 2 MountingplateLandR2 2 ISO4017-M16x2003 4 DIN125-A174 2 ISO4032-M165 2 Endpiece6 30 DIN125-A137 8 ISO4017-M12x208 12 ISO4017-M12x259 4 Clamping plate10 1 Type plate11 1 Central carrier12 1 Swivelbearing,complete13 8 DIN125-A10,514 4 ISO4017-M10x2515 4 ISO4032-M1016 1 Bracketforcentralidler(TYPESK)*17 4 ISO4017-M12x3018 2 Screwplate(triangle)M1219 6 ISO4017-M12x35(TYPESK)*20 1 BracketforconicalidlerL21 1 BracketforconicalidlerR22 1 Central idler23 2 Conical idler

REF.NO. QUANTITY DESCRIPTION(TYPES)6 38 DIN125-A13(TYPES)*7 16 ISO4017-M12x20(TYPES)*24 1 ConnectingplateS(TYPES)*25 1 Bracketforcentralidler(TYPES)*26 6 ISO4017-M12x40(TYPES)*

(*thesepartsarespecifictoTYPESKandS)


3.6 Productdimensions&sizetable

Type Belt width

A min. A max. B C min. C max. D Weightkg

E F

SK650-P(-A/-PU) 650 900 1160 289 104 256 242 63 150 200SK800-P(-A/-PU) 800 1050 1316 289 104 256 307 70 150 200SK1000-P(-A/-PU) 1000 1250 1516 289 104 256 372 80 150 200S1200-P(-A/-PU) 1200 1475 1960 428 152 316 449 156 180 230S1400-P(-A/-PU) 1400 1660 2150 428 152 316 514 166 180 230S1600-P(-A/-PU) 1600 1870 2360 428 152 316 584 178 180 230S1800-P(-A/-PU) 1800 2070 2560 428 152 316 654 188 180 230

3.7 Overviewoftheidlers

Belt width Type Central idler

Dimension Weightkg

Conical idler

Dimension Weightkg

650 mm SK650-P(-A/-PU) MR65 Ø80x242 3,4 CR65 Ø83/104x242 3,8800mm SK800-P(-A/-PU) MR80 Ø80x307 3,7 CR80 Ø83/110x307 4,7

1000 mm SK1000-P(-A/-PU) MR100 Ø80x372 4 CR100 Ø83/116x372 5,41200 mm S1200-P(-A/-PU) MR120 Ø 124 x 441 11,4 CR120 Ø155/196x449 18,91400 mm S1400-P(-A/-PU) MR 140 Ø 124 x 506 12,7 CR140 Ø155/201x514 20,41600 mm S1600-P(-A/-PU) MR160 Ø124x576 14,2 CR160 Ø155/207x584 21,81800mm S1800-P(-A/-PU) MR180 Ø 124 x 646 15,7 CR180 Ø155/202x654 22,5

P=idlerslinedwithwear-resistantrubberA=idlerslinedwithATEX-approvedrubberPU=idlerslinedwithpolyurethanecoating

FE

14 50

Cm

in

D

A

0-45°

D

Cm

ax B


4 Commissioning

4.1 General

Installationand,inparticular,commissioning,mayonlybeperformedbyauthorised,skilledpersonnel thathavebeentrainedbythemanufactureroritsrepresentative.Thelocallyapplicablesafetyregulations mustbeobserved.Intheeventofnon-compliancethemanufacturerisnotliableforanyresultingdamage tothemachine,personalinjuriesoranyconsequentialdamage.

4.2 Transport

• TheCEN-TRAXbelttrackerissuppliedpre-assembledandispackedinawoodenbox.Thiscratemayweighbetween50and250kgandistop-heavy.Onlymovethisboxwithaforkliftortrolleyswithaliftingdevice.• Placetheboxascloseaspossibletotheinstallationlocation.Iftheinstallationisdifficultorimpossibletoreach

withaforklift,opentheboxandremovetheheavyparts(idlers,brackets)fromtheCEN-TRAXbelttracker.Bringthepartstotheinstallationlocationseparately.Alwaysuseliftingassistanceequipment(e.g.trolley,wheelbarrow)andliftwiththeassistanceofasecondpersonwhenpossible.• Heedtheapplicablehealthandsafetystandardsanddirectiveswhencarryingandliftingthepartsofthebelt

trackersystem.Themaximumweighttobeliftedbyeachpersonis23kg.Whenexceedingthismaximumliftingweightalwaysuseliftingassistanceequipmentorliftingmachinery.

• Considertheergonomicaspectsduringactivitiessuchaslifting,bendingover,reaching,etc.duringworkontheCEN-TRAXbelttracker.

Itisessentialthatpartsarenotdamagedorsubjectedtoexternalforcesduringtransport.Damagedparts maynotbeinstalled–riskofinjury!

4.3 Storage

• Thestorageareamustbedry.• TheCEN-TRAXbelttrackermaynotbeinstalledorstoredinanareawhereitwillbeexposedtomoistureand

water.• AfteranextendedperiodofstoragetheCEN-TRAXbelttrackermustbeinspectedbyskilledpersonnel.

4.4 Installation/commissioning

Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand-accessories beforestartinganyworkonCEN-TRAXbelttrackers.

Ifchangesaremadetotheproduct,inparticularduringtheinstallation,removal,replacementofparts,installationofnewpartsorchangestoinstalledpartsthatarenotauthorisedbythemanufacturer,thewarrantyisvoidforanyresultingdeficiencies.


4.5 Determinetheinstallationlocation

4.5.1 General

Therearemanyfactorsthatcancausemistrackingoftheuppersection.Theseinclude:• incorrectly or inadequately aligned drums and idler sets• unevenlyworndrums• skewedbeltconnection• skewedbeltconstruction• weatherinfluences,suchascrosswind• off-centreloadingoftheconveyorbelt• mistrackingofthereturnstrand,asaresultofwhichtheconveyorbeltisalreadyoff-centreatthetailendbeneaththeloadingpoint.

Mistrackingcausedbyoff-centreloadingandmistrackinginthereturnstrandaregenerallythethemostcommoncausesofmistrackingintheloadcarryingside.Inspectthebeltconveyorsystemduringoperationbeforehandtodeterminethecauseofmistrackingandthelocationwhereitbegins.

4.5.2Installationinstructions • Never placeaCEN-TRAXbelttrackerdirectlybeneaththeloadingpoint.• InstalltheCEN-TRAXbelttrackeratthelocationofatroughidlerset.• Thedistancebetweenthetwotroughidlersetsshouldbe1to2metres.• Makesurethatthefreespacebetweenthebottomofthebeltontheloadcarryingsideandthetopofthebelt

onthereturnstrandisatleast300mm(typeSK)or450mm(typeS).• Ingeneral,placetheCEN-TRAXbelttrackerjustbeforethespotwherethemistrackingbegins.OneCEN-TRAXbelttrackercorrectsthebeltoveralengthofapprox.50metres.Forconveyorbeltsthatareloadedoff-centreand/oratmultipleloadingpointsthisdistanceisoftenshorter.

Mistrackingcausedbyoff-centreloading(loadingpointdirectlyafterthetaildrum):PlaceaCEN-TRAX-belttrackertypeSKO-SO(seethecorrespondingmanualformoreinformation)inthereturnstrand5-10metresbeforethetaildrum.Thisensuresthatthebeltisascentredaspossiblewhenitarrivesbeneaththeloadingpoint.ThenplaceaCEN-TRAXbelttrackertypeSK-Sapprox.1-2metresaftertheendoftheskirtboard.DetermineduringthetestrunwhetherandatwhatdistanceafollowingCEN-TRAXbelttrackertypeSK-Sshouldbeplaced.Asaruleofthumbthisis25-50metres,butthisdependsonthedegreeofloadingandthebeltspeed.

Mistrackingcausedbyoff-centreloading(loadingpoint>5metresafterthetaildrumorconveyorswithmultipleloadingpoints):PlaceaCEN-TRAX-belttrackertypeSK-Sapprox.2metresbeforeeachloadingpoint(thisensuresthatthebeltisascentredaspossiblewhenitarrivesbeneaththeloadingpoint).ThenplaceaCEN-TRAXbelttrackertypeSK-Sapprox.1-2metresaftertheendoftheskirtboard.DetermineduringthetestrunwhetherandatwhatdistanceafollowingCEN-TRAXbelttrackertypeSK-Sshouldbeplaced.Asaruleofthumbthisis25-50metres,butthisdependsonthedegreeofloadingandthebeltspeed.

Centre the conveyor belt on the head drum:InstalltheCEN-TRAXbelttrackerSK-Sapprox.5metresbeforetheheaddrum.

approx. 1 - 2 m approx. 5 m

300 mm (type SK)450 mm (type S)

Loading point 1 Loading point 2

Tail drum

Head drum

= CEN-TRAX belt tracker

5 - 10 m

approx. 1 - 2 m approx. 1 - 2 m


4.6 Tool overview

Ø14 M12 / 16 S19 / 24


4.7 Openthepackagingandremovetheidlersandidlerbrackets

1. Openthetransportboxandremovethepackagingmaterials.TheCEN-TRAXbelttrackerispre-assembled inthebox.

Attention!IntheassembledstatetheCEN-TRAXbelttrackermaybetop-heavy.Thereforealways removetheidlersandidlerbracketsfirst.Alwayslifttheindividualpartswithassistancefromasecondpersonanduseliftingassistanceequipmentwheneverpossible.Todothis,followthesesteps:

2. removethecentralidlerfromthebracket3. removetheconicalidlersfromthebrackets 4. removetheconicalidlerbrackets5. liftthesystemcarrieroutoftheboxandplacethesystemcarrieronthefloorbesidethebeltconstruction, whereitwillbeinstalled.

S19


5 Installation

5.1 SettingwidthofCEN-TRAXbelttracker

1. DeterminetheexactinstallationlocationoftheCEN-TRAXbelttracker(seesection4.5).2. MeasuredistanceXbetweenthetwocarrierbeamsofthebeltconstruction.3. RemovetheM12x25bolts(8)andwashers(6)fromthecentralcarrier.4. SlidethetwoendpiecesinthecentralcarrieruntilthecorrectdistanceXisreached.Makesuretheend piecesareslidintothecentralcarrierexactlythesamedistanceandthattheswivelbearingisinthemiddle.5. FittheM12x25bolts(8)andwashers(6)intheslottedholesofthecentralcarrierandthefourclamping plates that are on the inside of the end pieces.6. TightentheM12x25bolts(8)securely.

X

X

X

= =

X

S19


5.2 Determiningheightofmountingplates 1. MeasuredistanceXfrombottomofconveyorbelttotopofbeltconstruction.2. CalculatedimensionY(TypeSK:Y=X-215,TYPES:Y=X-340).3. RemovetheM16x200tensioningbolts(2),washers(3)andM16nuts(4).4. RemovetheM12x20bolts(7)andwashers(6)fromthemountingplates.5. PositionthemountingplatesatheightY.6. FitthemountingplatesontheendpieceswiththeM12x20bolts(7)andwashers(6).7. FittheM16x200tensioningbolts(2),washers(3)andM16nuts(4).

Attention!Tightentheboltshand-tightinitially,becausethebelttrackermuststillbepre-tensioned.

215 / 340 mm

S19 / S24

YX


5.3 Positioningmountingplates&markingoncarrierbeams 1. Placethesystemcarrierofthebelttrackeronthetwocarrierbeamsofthebeltconstruction. Makesureyourfingersnevercomeunder/betweenthebeltconstructionandtheCEN-TRAXbelttracker.

2. Makesurethemountingplatesarelevelandperfectlyperpendiculartothecarrierbeams.3. Useapentomarkthepositionsofthemountingholesonthetopsideofcarrierbeams,withdistanceE betweenthem,inthecentreoftheslottedholesofthemountingplates. Makesurethemountingholesareatleast30mmfromthetopedgeofthecarrierbeams.

E

30 mm 30 mm

E

= =

E

90°90°

TOP VIEW

FRONT VIEW

SKS

E150180


5.4 Installing system carrier 1. Checkthedistancefromthebottomofthebelttothetopoftheframe(215/340mm).2. Slide the system carrier aside.

Makesureyourfingersnevercomeunder/betweenthebeltconstructionandtheCEN-TRAXbelttracker.

3. Drill4holes(Ø14mm)andremoveanyburrs.4. AttachthemountingplatestothecarrierbeamswithM12bolts,nutsandwashers.

E

2x Ø14 mm

30 mm

E

Ø14

2x Ø14 mm

M12 S19


5.5 Determiningtroughangleofconveyorbeltandpositionoftriangleplate 1. Determinethetroughangleoftheconveyorbelt.2. Positionthetriangleclampingplateonthecorrectholepatternoftheconicalidlerbracketthatcorresponds to the trough angle.

0°- 45°

0°- 45° ?

45°

10°

15°

0°

10°- 45°

0°- 15°


5.6 Installingbracketforconicalidlers 1. Placetheconicalidlerbracketsonthearc-shapedguidesofthecentralidlerbracket.2. Positionthetriangleclampingplatesonthecentralidlerbracketonthecorrectholepatternoftheconical idlerbrackets.3. Fitthetriangleclampingplatesandconicalidlerbracketsonthecentralidlerbracketwiththesuppliedbolts andwashers. Attention!Tightentheboltshand-tightinitiallysothetroughanglecanbesetpreciselylater.

S19


5.7 Installingcentralidler Fitthecentralidlerinthecentralidlerbracket.


5.8 Installing conical idlers Placethetwoconicalidlersintheconicalidlerbrackets.

Attention!Theconicalidlersmustbeinstalledwiththelargediametertowardsthemiddleofthebelt.


5.9 Alignmentandpre-tensioning AligntheCEN-TRAXbelttrackersoitisparallelwiththebelt.

1. RaisetheentiresystemusingtheM16x200tensioningbolts(2)untilthecentralidlertouchesthebelt.2. Rotatebothbracketsfortheconicalidlersuntiltheidlersjustcontactthebelt.Thenrotatethemanother2° (e.g.troughangle=30°,settingoftheconicalidlers32°).

Attention!Theanglemustbeequalonbothsides!

3. Tightentheboltsoftheidlerbrackets.4. Tensiontheentiresystem10-20mmusingtheM16x200tensioningbolts(2).Theruleofthumbfor determiningthecorrectpre-tensionisthattheidlerscannolongerbeturnedbyhand.5. Makesurethetrackingsystemcanturnfreelyaroundtheswivelbearingshaft.6. TightentheM12x20bolts(7).

1°- 2°

10 / 20 mm

1°- 2°

S19 / S24

M16x200 (2)

M12x20 (7)


5.10 Testrun

Makesurealltoolsandotherpartsonandaroundtheconveyorbelthavebeenremovedbeforethe powerisswitchedonagain.Ifthisisnotdone,thereisasignificantriskofdamagetothemachineand injurytopeople.

Donottouchthemovingbelt,andstayatasafedistance.Thereisariskofbeingpulledintothemachine andbeingcrushed.

Thetestruntakesatleast30minutes.Thebeltmaynotbeloadedduringthetestrun. CheckwhethertheCEN-TRAXbelttrackerrespondstomistrackingandguidesthebelttowardsthemiddle position.Ifnecessary,increasethepre-tensionofthesystem.

Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand-accessories beforestartinganyworkonCEN-TRAXbelttrackers

Repeattestrunandobservetheguidingeffectagain.

Thenrepeatwithloadedbelt.

Re-installanysafetyprovisionsthatwereremoved!


6 Maintenance

6.1 General

TheoptimaloperationandlonglifeoftheCEN-TRAXbelttrackerareonlyguaranteedifthedeviceismaintainedinaccordancewiththeapplicablemaintenanceinstructions.

6.2 Maintenanceinstructionsandintervals

Attention!

Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand-accessories beforestartinganyworkonCEN-TRAXbelttrackers.Alltheinstructionsregardingaccidentpreventionmustbeheeded.

AlthoughtheCEN-TRAXbelttrackerrequiresverylittlemaintenance,thefollowingpointsmustbecheckedregularly:

1. Weekly Aretheidlersfreefromdirtdeposits?Cleanifnecessary,alsobelowtheidlers. Isthewearoftheidlerssuchthatfurtheruseisstillpossible? Iftheidlersareworn,theymustbereplacedtopreventdamagetothebelt! Isthepre-tensioncorrect?Adjustifnecessary. Checkthetroughangle Legibilityofthewarningstickers

2. Everytwelveweeks Arealltheboltsproperlytightened?Tightenifnecessary. Canthetrackingsystempivotfreelyaroundtheswivelbearingshaft?

6.3 Maintenanceinstructionsforuseinexplosiveatmospherezones

Attention!

Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand-accessories beforestartinganyworkonCEN-TRAXbelttrackers.Alltheinstructionsregardingaccidentprevention mustbeheeded.

ReplacingtheidlersTheidlersofthebelttrackermustbepreventivelyreplacedeverythreeyearsorafter26,000hoursofoperation,orsooneriftheliningoftheidlersisworn-out.Theidlershaveanin-vulcanisedorangeindicatorlayer.Oncethisbe-comesvisibletheidlermustbereplaced.

Checkingtheearthing:ITheearthingoftheCEN-TRAXbelttrackerandtheearthingofthebeltconveyorsystemitselfmustbecheckedeverythreemonths.Theleakageresistanceshouldhaveavalueof<106Ω.

6.4 Repairs/partsreplacement

Onlyoriginalpartsfromthemanufacturermaybeusedforreplacement.DeviationfromtheaforementionedinstructionsmayhaveconsequencesforthesafetyoftheCEN-TRAXbelttracker.Themanufactureracceptsnoliabilityforthis.


6.5 Replacingtheidlers

1. Switchoffpowerandlockout/tagouttheenergysourcetothebeltconveyorinstallationand -accessoriesbeforestartinganyworkonCEN-TRAXbelttrackers. 2. Useachainorstraptolifttheconveyorbeltatthelocationoftheidlerssotheidlerscanberemoved fromthebrackets(alternatively,thetensioningboltscanbeloosenedtolowerthesystem). 3. Removethewornconicalidlersfromthebrackets. 4. Removetheworncentralidlerfromthebracket.

6. Fitthenewidlersinthebrackets.

Attention!Theconicalidlersmustbeinstalledwiththelargediametertowardsthemiddleofthe belt.

7. Lowertheconveyorbeltbackontotheidlers.Removethechain/strap.8. Makesurealltoolsandotherpartsonandaroundtheconveyorbelthavebeenremovedbeforethepoweris switchedonagain.9. Switchthepowerbackon.



7 Malfunctions

7.1 Troubleshootingtable

Problem Possiblecause PossiblesolutionBelttrackercorrectsalignmenttoolittleornotatall

Toolittlepre-tensionConicalidlersareinstalledbackwards

Belttrackernotinstalledinthemiddleofthebeltconstruction

Belttrackerisnotlevel

Belttrackerinstalledinwronglocation

Troughanglenotadjustedcorrectlyononeorbothsides

Increasepre-tensionTurn conical idlers around

Centrethebelttracker

Levelit

Selectdifferentlocation

Checktroughangleandcorrectbyadjustingconicalidlerbrackets

Belttrackernotprovidingmaximumcorrectionwhileconveyorbeltmistrackingisatitsworst

Toolittlepre-tension

Troughanglenotadjustedcorrectlyononeorbothsides

Increasepre-tension

Checktroughangleandcorrectbyadjustingconicalidlerbrackets

Measureslistedabove donotcorrectsituation adequately or at all:Shiftthebelttrackerseveralcentimetresoff-centre,towardsthedirectioninwhichthebeltmustbemoved

Idlers do not turn Idlersareworn

Belttrackerverydirty

Replace idlers

CleanBelttrackerIdlerswearouttoofast Conveyorbeltdirty

Pre-tensiontoohigh

Idlercoatinginadequatelywear-resistantfortheapplication*

Installbeltscraper

Reducepre-tension(then checkwhetheradequatetrackingcorrectionisstillachieved)

Iftheapplicationallows(ATEXenvironment),replaceidlerswithtypethathasPUcoating

Trackingcrossbeamnolongerrotates

Swivelbearingdefective Replaceswivelbearing

*IdlerswithrubberliningtypeA(ATEX)arelesswear-resistantthanidlerswitharubberliningtypeP.

IntheeventofamalfunctionalwayscontactTBKspillagecontrolbv.


8 Environment

8.1 Disposal of material

Removethepackagingmaterialsfromtheproductinaccordancewithlocallawsandregulations.Thecoatedidlersmaynotbedisposedofwithhouseholdwaste.Contactthelocalwasteprocessororthemanufac-turer.Beforethecentralswivelbearingisdisposedof,theoilpresentintheswivelbearingmustberemovedanddis-posedofinaccordancewithapplicableregulations.Thentheswivelbearingandalltheotherpartscanbedisposedofviaametalwasteprocessor.

9 WarrantyForthedurationandthetermsandconditionsofwarrantywerecommendthatyoucontactTBKspillagecontrolbv.WealsoreferyoutoourGeneralConditionsofSaleandDelivery,whichareavailableonrequest.

10 Contact

TBK spillage control bv GrootOvereem7 3927GHRenswoude

Tel.:+31(0)318745740E-mail:[email protected]

installation and operating manual - centrax · installation and operating manual cen-trax belt...

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