maintenance manual · 2018. 9. 10. · materials at transfer and load points. this is backed up by...

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Product, Installation and Maintenance Manual

Hi Impact System, Universal Feedboot and Combination Feedboot(Belt Suppport Systems)

OFC is a division of Transmeca s.a. | rue du Rouvroir 11 | 7610 Rumes | Belgium | www.ofc-eu.com | [email protected]



Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Belt Support Systems - Page 1 of 20All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Table of Contents1. Table of Contents �� 1

2. Company Profile �� 2

3. Disclaimer �� 3

3.1. Safety Note �� 3

3.2. The following symbols may be used in this manual: �� 3

4. General Information �� 3

5. Handling �� 3

5.1. Receiving the goods �� 3

5.2. Work Safety �� 3

5.3. Handling �� 4

5.4. Storage �� 4

5.5. Preparations for installing Belt Support Systems�� 4

6. Recommended Tools List �� 4

6.1. Recommended Tools List Continued �� 5



7. Hi Impact, Universal Feedboot and Combination Feedboot Systems �� 8

8. Hi Impact, Universal Feedboot and Combination Feedboot Systems - Mounting Options �� 9

9. Hi Impact, Belt Tracking Troughing , Belt Tracking Return - Features and Options �� 10

10. Hi Impact - Parts Ordering List �� 11

10.1. Hi Impact - Parts Ordering List Cont... �� 12

10.2. Hi Impact - Installation, Repair/Replacement Guide �� 13

11. Universal Feedboot- Parts Ordering List �� 14

11.1. Universal Feedboot - Parts Ordering List Cont... �� 15

11.2. Universal Feedboot - Installation, Repair/Replacement Guide �� 15

12. Combination Feedboot- Parts Ordering List �� 16

12.1. Combination Feedboot - Parts Ordering List Cont... �� 17

12.2. Combination Feedboot - Installation Guide �� 17

13. Hi-Impact, Universal and Combin ation Feedboot - Trouble Shooting �� 18

14. Notes�� 19

15. Contacts �� 20





Head Offi ce: Brelko Conveyor Products (Pty) Ltd.16 Harries street, Reuven Extension 1, Booysens, Johannesburg, South Africa Website: www.brelko.com, e-mail: [email protected], Tel: +27 11 013 4000

Managing Director:Kenny PadayacheeTel: +27 11 013 4000email: [email protected]

General Manager:Jay PillayTel: +27 82 557 5998email: [email protected]

Sales & Marketing Manager: Sharon PadayacheeTel: +27 11 013 4000email: [email protected]

Africa & USA Area ManagerBrent WellerTel: +27 598 4115 email: [email protected]

Technical & CADD Manager: Riaan RyndersTel: +27 82 507 3839email: [email protected]

Service Manager:Craig AbbeyTel: +27 82 407 8581email: [email protected]

IT Manager:Grant RitsonTel: +27 82 337 8162email: [email protected]

Founded in 1987 / Selby, Johannesburg – South Africa.

Brelko design and manufacture conveyor belt cleaning equipment for a trouble-free fl ow of materials at transfer and load points. This is backed up by an installati on and maintenance package.

We have over 30 years experience as a supplier and advisor on spillage control to the bulk materials handling industry and off er proacti ve and ongoing maintenance for preventati ve spillage control and opti mum belt cleaning.

We supply and service our products throughout the world, with branches in the United Kingdom and the United States, our master distributors in Australia, Chile, Europe and Greece, and agents located in Africa and more than 40 countries.

We are accredited with ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007 certi fi cati on and are members of the South African Insti tute of Materials Handling and Conveyor Manufacturers Associati on Limited of South Africa.

The company is accredited with Level 1 B-BBEE status.





3. Disclaimer

Brelko Conveyor Products (Pty) Ltd hereby disclaims any liability for: damage due to contamination of the material; user’s failure to inspect, maintain and take reasonable care of the equipment; injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Brelko’s liability shall be limited to repair or replacement of equipment shown to be defective.

3.1. Safety Note

Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tag-out procedures as defined by National Standards Institutes, National Standard for Personnel Protection - Lockout/Tag-out of Energy Sources - Minimum Safety Requirements and Occupational Health and Safety.

3.2. The following symbols may be used in this manual:

DANGER Danger: Immediate hazards that will result in severe personal injury or death.

WARNING Warning: Hazards or unsafe practices that could result in personal injury.

CAUTION Caution: Hazards or unsafe practices that could result in product or property damages.

Important: Instructions that must be followed to ensure proper installation/operation of equipment.

Note: General statements to assist the reader.

4. General Information

Brelko Belt Support Systems are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Belt Support System is installed a regular maintenance program should be set up. This program will ensure that the Belt Support System operates at optimal efficiency and problems can be identified and fixed before the Belt Support System stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Belt Support Systems operate along the length of the conveyor and are 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/tag-out procedures.

5. Handling

5.1. Receiving the goods

Check that the shipment contains all the products specified in the delivery note. If the goods do not match the delivery note, if the goods show any transportation damage, list it on the freight bill. Describe the damage and the number of wrong or faulty goods, and contact your supplier immediately.

Do not use defective parts under any circumstances. Claims must be made within 8 days from the arrival of goods. The factory does not cover expenses caused by exchange of product when installation was not carried out according to factory instructions.

5.2. Work Safety

Always use protective gloves and clothing. Always use a lifeline and soft-sole footwear when work will be carried out on raised platforms. Before you move a Belt Support System, check that it is securely attached to the lifting equipment. Always observe local safety regulations.





WARNING

Before removing/installing equipment, lock out/tag out energy source to conveyor, and/or conveyor accessories.

Turn off and lock out/tag out energy source according to local standards.

If equipment will be installed in an enclosed area, test gas level or dust content before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion.

5.3. Handling

When Belt Support Systems are unloaded from the transportation vehicle onto customer’s platform, place them on boards spaced max 1m apart at a minimum of 5cm from the ground.

5.4. Storage

Belt Support Systems can be stored unpacked or in transportation package. It must not be stored on top of one another. Protect the Belt Support Systems by storing them in a cool dry area on a flat surface.

5.5. Preparations for installing Belt Support Systems

Before installation, check all measurements and any of the other geometric design

6. Recommended Tools List

Tools List

QTY DESCRIPTION IMAGE

2 EXTENSION CORD (20m MINIMUM)

1 PORT-A-PACK (OXY-ACETYLENE)

1 COMBINATION GAUGE (WITH SPIRIT LEVEL)





Tools List


1 STRAIGHT EDGE (1M MINIMUM)

1 90° SET SQUARE

1 5M TAPE MEASURE

2 ADJUSTABLE SPANNERS

1 SOCKET RATCHET SET (6mm - 30mm)

2 RINGSET SPANNERS - M13, 15, 16, 17, 18, 19, 24, 30

1 STANLEY KNIFE

1 HARD FACE HAMMER – 4pd





Tools List


1 SOFT FACE HAMMER - 1KG

3M NYLON ROPE

2 "G" CLAMPS - 6" - 8"

1 JIMMY LEVER

1 ELECTRIC DRILL

1 SET ELECTRIC DRILL BITS

1 SMALL BLUE TOOL BOX

1 MAGNETIC BASE DRILL

1 LONG NOSE PLIERS

1 PLIERS





Tools List


1 BELT LIFTER

1 1 TON LEVER HOIST

4 1M NYLON SLING

1 HACKSAW

2 SAFETY HARNESS

1 CHALK LINE

1 TORCH LED

1 SET 12, 14, 18 SLUGGER BITS





Hi Impact System

Universal FeedBoot

Combination FeedBoot





Hi ImpactMountingTransom

Universal FeedbootMountingTransom

Combination FeedbootMountingTransom





APPLICATIONSAPPLIES TO DESCRIPTION

Hi Impact System

A load point belt support system designed to offer maximum impact absorbing capabilities.

Suitable for all belt conveyors where large particle size and severe impact load conditions occur.

CombinationFeedboot

System

A load point belt support system providing flat belt supporting surfaces mounted on an impact absorbing Structure.

Suitable for all bulk conveyor systems with medium to severe impact conditions and particles up to 150mm in size.

Universal Feedboot

System

Replaces conventional impact systems in load area.

A load point belt support system which elimates conventional conveyor idlers.

Suitable for all belt conveyors handling bulk solids with a particle size less than 50mm and low impact conditions.

FEATURESAPPLIES TO DESCRIPTION

Hi Impact System

Unique torsion arm mountings absorb impact loads and are self dampening.

Polyurethane impact rolls help to extend belt life.

Proven polyurethane coated impact rolls, last up to 3 times longer than standard rubber lagged.

Support frame is available in standard 2m length fitted with 5 strings of idler rolls.

Support frame is designed to replace existing roller cradles and fixed conveyor stringers.

Open construction makes cleaning of spillage and roll replacement very easy.

Polyurethane roll arrangement promotes correct belt tracking.

Combination Feedboot

Flat belt support surfaces eliminate sag between rolls enabling optimum chute sealing design and operation.

Load point spillage and dust escape is controlled and eliminated.

Rubber impact cone mountings allow belt deflection under load in centre area whilst maintaining seal at belt edges.

Sliding surfaces are lined with low friction, long life UHMW polyethylene sheets.

UniversalFeedboot

Flat belt support surfaces eliminate sag between idlers enabling optimum chute sealing design and operation.

Wing panels can be individually adjusted for optimum conveyor troughing angles from 0° to 60°

Accurate belt support allows chutes and seals to be positioned to control and eliminate spillage and dust escape at the load points.

Sliding surfaces are lined with low friction, long life UHMW polyethylene sheets.

Optional centre panel with polyurethane rolls.

Hi Impact, Universal Feedboot, Combination Feedboot - Features and Options





3

1R

1L

2

4

7

6

5

8

ITEM NO. DESCRIPTION

1L SUPPORT BEAM (LEFT HAND)

1R SUPPORT BEAM (RIGHT HAND)

2 2 HOLE LINK

3 BTA UNIT SIZE 5/SIZE 6 (SPECIFY 3 OR 5 ROLL & SERIES)

4 POLYURETHANE IMPACT IDLER ROLL

5 UPRIGHT

6 T-LINK

7 RESTRAINT CHAIN

8 TRANSOM

Hi Impact - Parts Ordering List





Hi Impact - Parts Ordering ListNOTE! Always quote belt width.

ITEMNo. DESCRIPTION PART No.

1 Support Beam (LH - RH) SPECIFY BELT WIDTH

2BTA MOUNT - SIZE 5BTA MOUNT - SIZE 6SPECIFY 3 OR 5 ROLL SYSTEM, AND SERIES 30 OR 40.

6-MNT56-MNT6

3 CONE BUFFER 4-C-BUFFER

4 POLYURETHANE IDLER ROLLSPECIFY 3 OR 5 ROLL SYSTEM, AND SERIES 30 OR 40 SPECIFY BELT WIDTH

5 UPRIGHTSPECIFY 3 OR 5 ROLL SYSTEM SPECIFY BELT WIDTH

6 FLAT LINK ITEMS 6,7,8 & 9 SOLD AS A SET

7 “T” - LINK 6-2.46-2.4.1 (Heavy Duty)8 CHAIN LINK 6-2.1

9 RESTRAINT CHAIN 6-2.1 A

10 TRANSOM SPECIFY BELT WIDTH

NOTE! Always quote belt width.ASSEMBLY INSTRUCTIONS

1. Referring to the parts list check that the correct parts and quantities have been supplied for belt width, troughing angle and number of rolls ordered.

2. Attach uprights (5) to transoms (10). 3. Bolt left and right hand support beams (1) to uprights (5).

• Note: - Left and Right units relative to belt direction.4. Bolt BTA mounts (2) to support beams (1).

• Note: - Left and Right units, and belt direction.5. Assemble polyurethane idler strings by connecting rolls (4) using links (6) and (7).

• Note: - Use “T” links (7) on centre rolls.6. Attach polyurethane idler strings to BTA mounts using the M16 bolts supplied. Securely fasten bolts and nuts.7. Attach restraining chains (9) using chain links (8) with nyloc nuts.8. Chain (9) is connected to “T” links (7) which is bolted to transoms (10).

• Note: - Belt direction.





10.2. Hi Impact - Installation, Repair/Replacement GuideBefore replacing or repairing the Hi Impact:

Request permit to work from an authorised person, who will isolate and lock out the belt. Remove existing idlers and rolls from conveyor structiure in the area where the system is to be installed.

1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for belt width, troughing angle and number of rolls ordered.

2. Remove existing idlers and rolls from conveyor structure in the area where the system is to be installed.3. If assembled remove polyurethane idler strings, and the support beam (1) with uprights (5).4. Check direction of belt travel and slide unit under conveyor belt from one side.

• Note: - For larger sizes lifting equipment may be required.5. Position unit in impact zone and align centrally to belt.6. Attach support beam (1) with uprights (5) to transoms (10).7. Attach polyurethane idler strings to BTA mounts (2) with the M16 bolts supplied. Securely fasten bolts and nuts.8. Attach retaining chains (9) using chain links (8) with nyloc nuts.9. Chain (9) connected to “T” link (7) which is bolted to transoms (10).

• Note: - Belt direction.10. Check centre roll height, the belt should just be in contact. If necessary add spacers under the transom ends. Or if the unit needs to

be lowered, notch the transom ends and re-weld hold down plates.11. Securely fasten system to conveyor stringers.12. Check that polyurethane idler strings do not catch on transoms and that there is freedom of movement of the polyurethane idler

strings in a vertical direction.

When satisfied that the alignment is correct, bolt down the system to the conveyor stringers13. Check chute sealing to the conveyor belt, preferably fit BRELKO KEYSKIRT to contain any spillage.

Note: - Standard units are for installation in a horizontal position only.

For inclines etc... refer to the Brelko Design Dept.






1 UHMW POLYETHELENE LINER

2 CENTRE PANEL

3 WING PANEL

4 ADJUSTER ARM

5 LEAD-IN ROLL BRACKET C/W WASHER & SCREW SET

6 LEAD-IN & CENTER FRAME ROLLERS

7 TRANSOM

8 ROLLER CENTER FRAME C/W ROLLERS

Universal Feedboot - Parts Ordering List

86

1

3

5

2

4

7





Universal Feedboot - Parts Ordering ListNOTE! Always quote belt width.

ITEMNo. DESCRIPTION PART No.

1 UHMW POLYETHYLENE LINER SPECIFY BELT WIDTH

2 CENTRE PANEL SPECIFY BELT WIDTH

3 WING PANEL SPECIFY BELT WIDTH

4 ADJUSTER ARM 4-1.10

5 HINGE BRACKETS 4-1.11

6 LEAD ROLL BRACKETS 4-L-I-BRK

7 LEAD ROLL SPECIFY BELT WIDTH

8 TRANSOM SPECIFY BELT WIDTH

9 OPTIONAL - ROLLER CENTRE FRAME SPECIFY BELT WIDTH


1. Referring to the parts list check that the correct parts and quantities have been supplied for the belt width ordered.2. Attach wing panels (3) to mounting brackets (5) at hinge points and to the transoms (8), only lightly tighten bolts.3. Fit centre panel (2) so that slots drop over the bolts on the brackets (5); the optional roller centre frame (9) can also be fitted at this

time.4. Check that the wing panels can pivot freely on their hinges. Attach adjustment arms (4) to wing panels and transoms (8). 5. Tighten all bolts and nuts. 6. Fit optional rollers (7) to roller centre section. 7. Fit optional lead-in roll brackets (6) and rolls (7) to wing panels. 8. Proceed with installation as per instructions

Before replacing or repairing the Hi Impact:


1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for the belt width ordered. 2. Remove existing idlers and rolls from conveyor structure in the area where the feedboot is to be installed. Align the feedboot to

correspond with the indicated belt direction.3. With the feedboot wing panels (3) down, slide the feedboot from one side under the conveyor belt. Larger sizes will require the use

of mechanical lifting equipment.4. Ensure that the feedboot is positioned so that the loading area is approximately in the centre. 5. Accurately align the feedboot in the direction of the belt travel.6. Check that the centre of the feedboot is ± 5-20mm lower than the bottom of the belt line. If not, add spacers under the transom (8)

ends to raise the feedboot. If it needs to be lowered, then the ends of the transoms need to be notched and the hold down brackets refitted and welded.

7. Raise the wing panels (3) to the required troughing angle and tighten the support struts.8. Check that the idlers immediately behind and ahead of the feedboot adequately bend and align to the conveyor belt. If not, then fit

the optional lead in rolls (7) and brackets (6) to the ends of the feedboot.9. When satisfied that the alignment is correct, bolt down the feedboot to the conveyor stringers.10. Check that the chute skirting is in correct contact with the belt, or preferably fit Brelko Keyskirt to provide a good sealing

arrangement.

11.2. Universal Feedboot - Installation, Repair/Replacement Guide






1 UHMW POLYETHELENE WING LINER

2 UHMW POLYETHELENE CENTRE LINER

3 WING PANEL

4 IMPACT CONE / BUFFER

5 UPRIGHT

6 ENGINE MOUNT

7 TRANSOM

8 LEAD-IN ROLL BRACKET

9 ROLLERS

Combination Feedboot - Parts Ordering List

1

2

3

4

8

6

5

7





Combination Feedboot - Parts List

ITEM No. DESCRIPTION PART No.

1 UHMW Polyethylene Wing Liner Specify Belt Width2 UHMW Polyethylene Centre Liner Specify Belt Width3 Wing Panel Specify Belt Width4 Cone Buffer 4-C.BUFFER5 Vertical Support Bracket Specify Belt Width6 Wing Mount 4-W.MOUNTING7 Transom Specify Belt Width8 Lead Roll Bracket 4-L-I-BRK9 Lead Rollers Specify Belt Width


1. Referring to the parts list and check that the correct parts and quantities have been supplied for the belt width and troughing angle ordered.

2. Attach required number of rubber cones (4) to the panels (3); see installation instructions.3. Attach cone buffers (6) to panels.4. Attach vertical support (5) to mountings (6). Attach panel assemblies to transom (7).5. Ensure panels and transoms are correctly aligned and tighten all bolts and nuts.6. Attach optional lead in roll brackets (8) and rolls (9) to wing panels (3). 7. Proceed with installation as per instructions.

Before replacing or repairing the Hi Impact:


1. If not assembled refer to assembly instructions and check that all necessary parts have been supplied for the belt width and troughing angled ordered.

2. Remove existing idlers and rolls from conveyor structure in the area where the feedboot is to be installed.3. Slide the feedboot from one side under the conveyor belt. It may be necessary to remove one half of the feedboot panels. Larger

sizes will require the use of mechanical lifting equipment.4. Ensure that the feedboot is positioned so that the loading area is approximately in the centre. 5. Accurately align the feedboot in the direction of the belt travel. 6. Check that the centre of the feedboot is ±5-20mm lower than the bottom of the belt line. If not, add spacers under the transom ends

to raise the feedboot. If it needs to be lowered, then the ends of the transoms (7) need to be notched and the hold down brackets refitted and welded.

7. Check that the idlers immediately behind and ahead of the feedboot adequately bend and align to the conveyor belt. If not, then fit the optional lead in rolls (9) and brackets (8) to the ends of the feedboot.

8. When satisfied that the alignment is correct, bolt down the feedboot to the conveyor stringers.9. Check that the chute skirting is in correct contact with the belt, or preferably fit Brelko Keyskirt to provide a good sealing

arrangement.

Combination Feedboot - Installation, Repair/Replacement Guide





Hi-Impact, Universal and Combination Feedboot - Trouble Shooting

Problem Possible Cause Possible Solution

Belt Damage Polyurethane rolls not in full contact with the conveyor belt. Adjust to correct height - refer to installation instructions

Polyurethane Roll Damage

Hi-impact System in incorrect position. Reposition Hi-impact System so that the load is evenly distributed across the full length of the Hi-impact System.

Broken or loose polyurethane roller retaining chains. Repair or replace retaining chains.

Incorrect selection of equipment. Consult your Brelko representative or Brelko’s Technical Department

Hi Impact - Trouble Shooting

Universal and Combination Feedboot - Trouble Shooting

Problem Possible Cause Possible Solution

High UHMW-PE Liner Wear.

UHMW-PE Liner are above idler height or is not parallel to belt travel. Adjust to correct height/position - refer to installation instructions.

Uneven UHMW-PE Liner Wear.

Combination Feedboot is not parallel to belt travel or is under impact.

Inspect loading area and divert impact or reposition Combination Feedboot so that the load is evenly distributed across the full length of the Combination Feedboot.

System or UHMW-PE Liner Damage. Incorrect selection of equipment. Consult your Brelko representative or Brelko’s Technical Department





NOTES





Head Offi ceSouth AfricaBrelko Conveyor Products (Pty) Ltd16 Harries Street, Reuven Extension 1, Booysens, Johannesburg, South AfricaWebsite: www.brelko.com, E-Mail: [email protected], Tel: +27 11 013 4000

BranchesUnited States of AmericaBrelko Conveyor Products Inc.Telephone:+1 303 544 0817, Telefax: +1 303 544 0818Mobile: +1 720 771 4035, E-mail: [email protected]

United KingdomSimm Conveyor Services LTDTelephone: +44 170 981 8511, Telefax: +44 170 981 2557, E-Mail: [email protected]

Agents: AfricaBotswanaEtubaMobile: +267 297 2305, E-Mail: [email protected]

DRCMickem Consulti ngTelephone: +243 812 666 404, E-Mail: mickemconsulti [email protected]

GhanaAlshtechTelephone: +233 30 330 4231, Mobile: +233 26 283 3604, E-Mail: [email protected]

NamibiaSepp ThalmaierTelephone: Windhoek +264 61 225 808, Oranjemund: +264 63 233 111 Telefax: +264 63 232 015, E-Mail: [email protected]

ZambiaConveyor Engineering & EquipmentMobile: +260 96 811 1646, +260 97 729 6288, E-Mail: [email protected]

ZimbabweHilmaxTelephone: +263 77 213 4610/1/2/3, Telefax: +263 4 620 670, E-Mail: [email protected]

Master Distributors: Internati onalAustraliaOrefl owTelephone: +61 8 9472 0800, Telefax: +61 8 9472 0811, E-Mail: sales@orefl ow.com.au

ChileMantexTelephone: +56 2 212 9475, Telefax: +56 2 212 8260, E-Mail: [email protected]

EuropeOFC - Opti m’ For ConveyorsTelephone: +32 69 64 74 38, Telefax: +32 69 64 74 41, E-Mail: [email protected]

GreeceSolergon Ltd.Telephone: +30 210 86 75 229, E-Mail: [email protected]

Malaysia & IndonesiaMax Classics (M) SDN. BHD.Telephone: +60 35 635 6212, Telefax: +60 35 636 1190, E-Mail: [email protected]

MexicoConstrumacTelephone: +52 55 53 281 700, E-Mail: [email protected]

Portugal & SpainMasanés ServindustriaWeb: www.masanes.com

Saudi ArabiaSynergies TechTelephone: +971 4 4275069, Telefax: +971 4 4324256, E-Mail: [email protected]

United KingdomMillenium Conveyor Services LTDTelephone: +44 191 456 5700, Telefax: +44 191 456 3300


maintenance manual · 2018. 9. 10. · materials at transfer and load points. this is backed up by...

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