Flexco H-Type Installation, Operation And Maintenance Manual

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H-Type® Precleaner with XF2-Tips

Installation, Operation

and Maintenance Manual

www.ﬂexco.com

H-Type® Precleaner with XF2-Tips

Serial Number: _____________________________________________________________

Purchase Date: ______________________________________________________________

Purchased From: ____________________________________________________________

Installation Date: ____________________________________________________________

Serial number information can be found on the Serial Number Label

included in the Information Packet found in the cleaner carton.

This information will be helpful for any future inquiries or questions

about belt cleaner replacement parts, specifications or troubleshooting.

2 H-Type® Precleaner with XF2-Tips

Table of Contents

Section 1 – Important Information ........................................................................................................................ 2

1.1 General Introduction ................................................................................................................................................ 2

1.2 User Beneﬁts .............................................................................................................................................................. 2

1.3 Service Option ........................................................................................................................................................... 2

Section 2 – Safety Considerations and Precautions ...............................................................................................3

2.1 Stationary Conveyors ................................................................................................................................................ 3

2.2 Operating Conveyors ................................................................................................................................................ 3

Section 3 – Pre-Installation Checks and Options ................................................................................................... 4

3.1 Checklist ..................................................................................................................................................................... 4

3.2 Cleaner Location Adjustments................................................................................................................................. 5

Section 4 – Installation Instructions.......................................................................................................................6

4.1 Installation Instructions ........................................................................................................................................... 6

4.2 Pole Location Charts ................................................................................................................................................. 9

Section 5 – Pre-Operation Checklist and Testing.................................................................................................10

5.1 Pre-Op Checklist ..................................................................................................................................................... 10

5.2 Test Run the Conveyor ............................................................................................................................................ 10

Section 6 – Maintenance .......................................................................................................................................11

6.1 New Installation Inspection ................................................................................................................................... 11

6.2 Routine Visual Inspection ...................................................................................................................................... 11

6.3 Routine Physical Inspection ................................................................................................................................... 11

6.4 Blade Replacement Instructions ............................................................................................................................ 12

6.5 Maintenance Log ..................................................................................................................................................... 14

6.6 Cleaner Maintenance Checklist ............................................................................................................................. 15

Section 7 – Troubleshooting .................................................................................................................................16

Section 8 – Specs and CAD Drawings................................................................................................................... 17

8.1 Speciﬁcations and Guidelines ................................................................................................................................ 17

8.2 CAD Drawings......................................................................................................................................................... 18

Section 9 – Replacement Parts .............................................................................................................................. 22

Section 10 – Other Flexco® Conveyor Products .................................................................................................... 25

Section 1 – Important Information

1.1 General Introduction

We at Flexco® are very pleased that you have selected an H-Type® Precleaner with XF2-Tips for your

conveyor system.

is 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. is 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: 91-44-6551-7771

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 Benets

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

e H-Type® Precleaner with XF2-Tips 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.

2 H-Type® Precleaner with XF2-Tips

Section 2 – Safety Considerations and Precautions

Before installing and operating the H-Type® Precleaner with XF2-Tips, 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 Conveyors

The following activities are performed on stationary conveyors:

• Installation • Blade replacement • Repairs

• Tension adjustments • Cleaning

DANGER

WARNING

It is imperative that OSHA/MSHA Lockout/Tagout (LOTO) regulations, 29 CFR 1910.147, 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

2.2 Operating Conveyors

There are two routine tasks that must be performed while the conveyor is running:

• Inspection of the cleaning performance

• Dynamic troubleshooting

DANGER

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.

WARNING

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

WARNING

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.

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

Section 3 – Pre-installation Checks and Options

3.1 Checklist

• Check that the cleaner size is correct for the beltline 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

4 H-Type® Precleaner with XF2-Tips

Section 3 - Pre-Installation Checks and Options (cont.)

3.2 Cleaner Location Adjustments

In certain applications it is necessary to modify the location of the precleaner pole due to permanent obstacles that

obstruct the desired location. Relocating the pole location can be done easily and does not hinder the performance of the cleaner as long as the “C” dimension is maintained.

NOTE: In the following example we will be lowering the pole location in the “Y” direction, but the same method could also be applied in the “X” direction.

Conveyor situation:

Pulley Diameter: 900mm X = 322mm

900mm

Y = 482mm C = 580mm

1. Determine the given location dimensions and define the change needed. After laying out the given X & Y dimensions, determine the distance of the modification required for adequate clearance of the pole and tensioning system. (In the example we decide to lower the pole 50mm to clear the support structure).

2. Write down known dimensions. We can now determine two of the three required dimensions which will allow us to find the third. We know we cannot alter the “C” dimension, so this will remain the same. Also we are required to lower the unit in the “Y” dimension 50mm, so we add 50mm to the given “Y” dimension. X = ?" Y = 482mm + 50mm = 532mm C = 580mm

3. Determine final dimension. On a flat vertical surface, using a level, draw one horizontal line and one vertical line creating a right triangle (Fig 3a). Measure down from the intersection the determined “Y” dimension and mark (Fig 3b). With the tape measure starting at the modified “Y” mark, swing the tape across the “X” line and mark at the “C” dimension where it crosses the “X” line (Fig 3c). Measure from the intersection to the “C” intersection and this will be your new “X” dimension (Fig. 3d). X = 231mm Y = 532mm C = 580mm

This distance is new “X” dimension

(231mm)

Y (532mm)

Fig. 3a Fig. 3b Fig. 3c Fig. 3d

mark

C (580mm)

Section 4 – Installation Instructions

Pole Location Specs

For speciﬁc cleaner specs see charts on page 8

A = Pulley Diameter + Lagging and Belt C = Critical Spec to move location if necessary

Move Dim. C on arc

Offset Bracket

Xf2-Tip

Pole

Pivot Arm

Torque Arm

HXF2 Parts List

Cushion

Tension Spring

Mounting Plate

Pole Lock Collar (Hidden)

Pivot Shaft Bracket

Move Dim. C on arc

½ diameter of pulley shaft

Belt Direction

“B”

“A”

Pole Location Specs

For speciﬁc cleaner specs see charts on page 8

A = Pulley Diameter + Lagging and Belt C = Critical Spec to move location if necessary

Move Dim. C on arc

4.1 H-Type® Precleaner with HXF or HXF2 Tips

Xf2-Tip

Mounting Plate

Pole Lock

Pivot Shaft Bracket

Collar (Hidden)

Torque Arm

Space needed to avoid clogging chute

Belt Direction

Pole

Tension Spring

Pivot Arm

Maximum

lump size

lump size + 8”

(200mm)

+ 200mm (8")

Chute wall

Modiﬁed

Cushion

HXF2 Parts List

Offset Bracket

A = Pulley Diameter + Lagging and Belt C = Critical Spec to move location if necessary

Pole Location Specs

For speciﬁc cleaner specs see charts on page 8

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

½ diameter of pulley shaft

Intersecting mark

“A”

“B”

Fig. 1

Fig. 2

HXF2

Blade Size

SS 250 - 475mm (10" - 19")

S 500 - 775mm (20" - 31")

M 800 - 975mm (32" - 39")

L 1000 - 1175mm (40" - 47")

Pulley Diameter

+ Belt and Lagging

Tools Needed:

• Tape measure

• Level

• Wrenches or Crescent Wrenches: (1) M10 (17mm) (2) M12 (19mm) (1) M16 (24mm)

(2) M24 (36mm)

1. Find X, Y & C measurements. Find the X and Y measurement

specifications for the pulley diameter. See charts on page 8. The pulley diameter measurement should include lagging and belt.

Pulley Diameter ________"; X=________"; Y=________"; C=________".

Using the correct X and Y coordinates will position the cleaner blades at

15° below the horizontal plane on the head pulley.

2. Measure head pulley shaft.

Determine the diameter of the pulley shaft

and divide by 2. ________"

3. Locate horizontal line from center of pulley shaft.

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 the pulley shaft (Fig. 1).

4. Mark X dimension.

Subtract the above dimension (Step 2) 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).

Move Dim. C on arc

Put a level on top of

6 H-Type® Precleaner with XF2-Tips

Section 4 – Installation Instructions

Offset Bracket

Mounting Plate

Chute wall

Offset Bracket

Pulley

Chute wall

Side View

Align the four template notches with location marks

Intersecting

mark

Align the four template notches with location marks

Intersecting

mark

Chute wall

Offset Bracket

Pulley

Chute wall

Side View

Align the four template notches with location marks

Intersecting

mark

4.1 H-Type® Precleaner with HXF or HXF2 Tips (cont.)

Intersecting

Fig. 3

mark

Align the four template notches with location marks

Fig. 4

Pulley

5. Determine Y dimension.

From the X mark, draw a line vertically down to the

selected Y dimension and make a mark (Fig. 3). This is the correct position for the

center of the pole.

6. Locate offset bracket position. To locate the position of the offset bracket, position

offset bracket template with the large hole notches aligned with the layout lines on the chute wall (Fig. 4). The template can be used with the bracket holes either below or above the Y mark.

7. Cut pole opening. Using template provided, trace and cut the large opening and the

mounting holes.

8. Install offset brackets. Locate the offset brackets in the correct

position on the chute wall and bolt or weld in place (Fig. 5).

Pulley

9. Install the pole. Slide the pole across the pulley and through the

chute openings. Allow the tips to hang down.

Pivot Arm

Offset Bracket

Fig. 5

Fig. 6

Pivot Shaft Bracket

Fig. 7

Chute wall

Torque Arm

Mounting Plate

Pole

Chute wall

Offset Bracket

10. Install mounting plates. On one side, slide mounting plate onto

pole and with the key slot positioned horizontally and toward the pulley, bolt to the offset bracket, center in slots and tighten (Fig. 6). On opposite side repeat the process, but do not tighten.

Side View

11. Position the pole. Rotate the pole upward until the tips touch the belt.

Center the tips across the belt. While applying light pressure on the center

Mounting Plate

tip, shift the loosened mounting plate until tips are contacting the belt evenly across the full width. Lock cleaner into this position by tightening mounting plate bolts.

Offset Bracket

12. Center the cleaner on the belt and lock in place. Center the tips on the

belt and install a pole lock collar on one end of the pole. Slide the collar snugly up to the mounting plate and tighten.

13. Install the QMT 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) and rotate it until the pivot shaft bracket lines up with the desired bolt holes (Fig. 7). Remove bolts, nuts and washers from mounting plate and reinsert through the pivot shaft bracket and mounting plate.

Pivot Arm

Bushings

Spring

Washer

Pivot Arm

Section 4 –

Installation Instructions

4.1 H-Type® Precleaner with HXF or HXF2 Tips (cont.)

Adjusting Nuts

Washer

Fig. 8

Pivot Arm against slot end nearest the pole

Tighten locking bolts and jam nuts

Fig. 9

Bushings

Spring

Pivot Arm

14. Reassemble the spring assembly. Slide the spring, washer and

bushings onto the pivot arm and turn the two adjusting nuts so about 6mm (1/4") of the pivot arm is exposed above the nuts (Fig.8).

15. 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. 9). NOTE: The torque arm should be up against the mounting plate.

Adjusting Nuts

Top of

washer to

top of torque

arm

Fig. 10

HXF2 Spring Length Chart

(for optimal blade tensioning)

Belt

Width Tips

450 2 114 102 145 N/A

600 3 142 138 135 N/A

750 3 142 138 135 N/A

900 4 127 130 5" 109

1050 5 128 120 152 152

1200 5 128 120 152 152

1350 6 120 152 149 149

1500 7 N/A 149 145 145

1800 8 N/A 145 142 142

Purple Spring

SS S M L

Spring Length

Silver Spring

White Spring

16. Set the correct blade tension. Refer to the chart on the pivot shaft bracket (also shown 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. 10). Lock the top adjusting nut.

17. Verify your “C” dimension to insure the pole is in the correct position.

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.

8 H-Type® Precleaner with XF2-Tips

Section 4 –

Installation Instructions

4.2 Pole Location Charts

Extra Small (SS) XF2 Tips for Head Pulley Diameters 250 - 475mm

Diameter

(Over Belt)

250 51 302 305 60

275 64 305 311 57

300 73 308 318 54

325 86 311 324 51

350 98 314 330 48

375 111 318 337 44

400 124 321 343 41

425 137 324 352 38

450 149 327 359 38

475 159 330 368 35

500 171 333 378 35

525 184 337 384 32

550 197 340 394 32

575 210 343 403 29

600 222 349 413 29

625 235 352 422 29

Recommended range for tip size Optional extended range

X Y C Gap

Small (S) XF2 Tips for Head Pulley Diameters 350 to 925mm

Diameter

(Over Belt) X Y C Gap

350 70 371 378 79

375 83 375 381 73

400 95 378 387 70

425 108 381 394 67

450 117 384 400 64

475 130 387 410 57

500 143 391 416 54

525 156 394 422 54

550 168 397 432 51

575 181 400 438 48

600 194 403 448 44

625 203 406 454 44

650 216 410 464 41

675 229 413 473 38

700 241 416 483 38

725 254 419 489 35

750 267 422 498 35

775 279 425 508 32

800 292 429 518 32

825 302 432 527 29

850 314 435 537 29

875 327 438 546 25

900 340 441 559 25

925 352 445 568 25

Medium (M) XF2 Tips for Head Pulley Diameters 650 to 1125mm

Diameter

(Over Belt) X Y C Gap

650 206 451 495 64

675 219 454 505 60

700 232 457 511 57

725 244 460 521 57

750 254 464 530 54

775 267 467 540 51

800 279 470 549 51

825 292 473 556 48

850 305 476 565 44

875 318 479 575 44

900 330 483 584 41

925 343 486 594 41

950 352 492 603 38

975 365 495 616 38

1000 378 498 625 35

1025 391 502 635 35

1050 403 505 645 35

1075 416 508 654 32

1100 429 511 667 32

1125 438 514 676 32

Large (L) XF2 Tips for Head Pulley Diameters 850 to 1325mm

Diameter

(Over Belt)

850 298 511 591 60

875 311 514 600 57

900 324 518 610 54

925 337 521 619 54

950 349 524 629 51

975 362 527 638 51

1000 375 530 648 48

1025 384 533 657 44

1050 397 537 667 44

1075 410 540 679 41

1100 422 543 689 41

1125 435 546 699 41

1150 448 549 708 38

1175 460 552 718 38

1200 473 556 730 35

1225 483 559 740 35

1250 495 562 749 35

1275 508 565 762 32

1300 521 568 772 32

1325 533 575 781 32

X Y C Gap

Section 5 – Pre-Operation Checklist and Testing

5.1 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

5.2 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.

10 H-Type® Precleaner with XF2-Tips

Section 6 – 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® Precleaner 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.

6.1 New Installation Inspection

After 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.

6.2 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 blade is worn out and needs to be replaced.

• If there is damage to the blade 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.

6.3 Routine Physical Inspection (every 6-8 weeks)

When the conveyor is not in operation and properly locked and tagged out a physical inspection of the cleaner to perform the following tasks:

• Clean material buildup off of the cleaner blade and pole.

• Closely inspect the blade for wear and any damage. Replace if needed.

• Check both blade pins for proper installation and condition. Replace if needed.

• Ensure full blade to belt contact.

• Inspect the cleaner pole 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 blade to the belt. Adjust the tension if necessary using the chart on the cleaner or the one on Page 7.

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

Section 6 – Maintenance

6.4 Blade Replacement Instructions

XF2 Tip

Removal Nuts

H-Type® Precleaner with XF2-Tips

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Tools Needed:

• Tape measure

• (1) M10 (17mm) wrench or crescent wrench

• (2) M24 (36mm) wrenches or crescent wrenches

• 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 they are flush with the ends of the pivot arms (Fig. 1). This releases the tension of the blade on the belt.

XF2 Replacement Tip

Pivot Arm

Adjusting Nuts

Fig. 1

2. 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 it and then remove.

12 H-Type® Precleaner with XF2-Tips

Removal Nuts

Fig. 2

Section 6 – Maintenance

6.4 Blade Replacement Instructions (cont.)

3. Install the new tips. Locate each tip onto each

suspension arm, then install the hardware to fasten the tip to the cushion (Fig. 3).

4. Reset the correct blade tension. Refer to the chart 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.

NOTE: The chart is also on the cleaner’s pivot shaft for future reference for retensioning maintenance.

Fig. 3

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.

Top of

washer

to top of

torque arm

HXF2 Spring Length Chart

(for optimal blade tensioning)

Belt

Width Tips

450 2 114 102 145 N/A

600 3 142 138 135 N/A

750 3 142 138 135 N/A

900 4 127 130 5" 109

1050 5 128 120 152 152

1200 5 128 120 152 152

1350 6 120 152 149 149

1500 7 N/A 149 145 145

1800 8 N/A 145 142 142

Purple Spring

SS S M L

Spring Length

Silver Spring

White Spring