Flexco H-Type Primary Cleaner with V-Tips, H-Type HV with PCST Tensioner, H-Type HV with Bolt Tensioner Installation, Operation And Maintenance Manual
H-Type® Primary Cleaner with V-Tips
Installation, Operation
and Maintenance Manual
www.flexco.com
www.flexco.com
HV with Bolt Tensioner
HV with PCST Tensioner
H-Type® Primary Cleaner with V-Tips
Purchase Date: ______________________________________________________________
Purchased From: ____________________________________________________________
Installation Date: ____________________________________________________________
This information will be helpful for any future inquiries or questions
about belt cleaner replacement parts, specifications or troubleshooting.
3
Table of Contents
Section 1 – Important Information ...........................................................................................................4
1.1 General Introduction ..................................................................................................................................4
1.2 User Benets ................................................................................................................................................4
1.3 Service Option .............................................................................................................................................4
Section 2 – Safety Considerations and Precautions ..................................................................................5
2.1 Stationary Conveyors ..................................................................................................................................5
2.2 Operating Conveyors ..................................................................................................................................5
Section 3 – Pre-Installation Checks and Options ......................................................................................6
3.1 Checklist .......................................................................................................................................................6
Section 4 – Installation Instructions..........................................................................................................7
4.1 H-Type® Primary Cleaner with V-Tips ..................................................................................................7
4.2a H-Type® Primary Cleaner with V-Tips - Chute Mounting .................................................................8
4.2b H-Type® Primary Cleaner with V-Tips - Open Head Mounting ......................................................10
4.3 H-Type® Primary Cleaner with V-Tips - Bolt Tensioner ...................................................................11
4.4 H-Type® Primary Cleaner with PCST Tensioner ................................................................................13
4.5 H-Type® Primary Cleaner with PCST Tensione- Bolt Tensiner .......................................................15
Section 5 – Cleaner Pole Location Charts ...............................................................................................17
5.1 Pole Location Charts .................................................................................................................................17
Section 6 – Pre-Operation Checklist and Testing....................................................................................20
6.1 Pre-Op Checklist .......................................................................................................................................20
6.2 Test Run the Conveyor ..............................................................................................................................20
Section 7 – Maintenance ..........................................................................................................................21
7.1 New Installation Inspection .....................................................................................................................21
7.2 Routine Visual Inspection ........................................................................................................................21
7.3 Routine Physical Inspection .....................................................................................................................21
7.4 Blade Replacement Instructions ..............................................................................................................22
7.5 Maintenance Log .......................................................................................................................................24
7.6 Cleaner Maintenance Checklist ...............................................................................................................25
Section 8 – Troubleshooting ....................................................................................................................26
Section 9 – Specs and CAD Drawings......................................................................................................27
9.1 Specications and Guidelines ..................................................................................................................27
9.2 CAD Drawings...........................................................................................................................................28
Section 10 – Replacement Parts List ........................................................................................................31
Section 11 – Other Flexco Conveyor Products ........................................................................................ 35
4 H-Type® Primary Cleaner with V-Tips
Section 1 – Important Information
We at Flexco are very pleased that you have selected an H-Type® Primary Cleaner with V-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 eciency over its lifetime of service.
It is essential for safe and ecient 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: 612-8818-2000
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 Benets
Correct installation and regular maintenance will provide the following benets 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 Primary Cleaner with V-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.
1.1 General Introduction
5
Before installing and operating the H-Type® Primary Cleaner with V-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
Section 2 – Safety Considerations and Precautions
DANGER
DANGER
WARNING
WARNING
WARNING
!
!
!
!
!
It is imperative that Lockout/Tagout (LOTO) regulations, 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
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.
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
Every belt cleaner is an in-running nip hazard. Never
touch or prod an operating cleaner. Cleaner hazards
cause instantaneous amputation and entrapment.
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.
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.
6 H-Type® Primary Cleaner with V-Tips
Section 3 – Pre-installation Checks and Options
• 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
3.1 Checklist
7
4.1 H-Type© Primary Cleaner with V-Tips
Section 4 – Installation Instructions
Before You Begin:
• Installation specs and instructions are based on the assumption
that the conveyor is in its working position (angle). If the
conveyor angle will be different, the cleaner should be installed
per the final position.
• Choose instructions for chute mounting or open head
mounting. For chute mounting it may be necessary to cut
an access hole to allow for installation and inspections.
(See dimensions in Step 7 under Chute Mounting.)
• Follow all safety precautions when using a cutting torch.
• If welding, protect all fastener threads from weld spatter.
Maximum
lump size +
200mm
Chute wall
Space needed to avoid clogging chute
V-Tip Size Pulley Diameter + Belt and Lagging
SS up to 499mm
S 500-799mm
M 800-999mm
L 1000-1199mm
LL 1200-1700mm
Tools Needed
• Tape Measure
• 19mm Wrench
• Ratchet With 19mm Socket
• Adjustable Wrench
• Cutting Torch and/or Welder
• (2) 150mm C-Clamps (For Temporary
Positioning of Mounting Brackets)
• 600mm Level
• Marking Pen
Physically lock out and tag the conveyor at the power source
before you begin cleaner installation.
V-TIP
CUSHION
BEARING BLOCK
POLE
MOUNTING BRACKET
SUSPENSION
ARM
ADJUSTING ARM
ADJUSTING BOLT
8 H-Type® Primary Cleaner with V-Tips
4.2a H-Type© Primary Cleaner with V-Tips
Section 4 – Installation Instructions
1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts
on pages 14, 15 and 16. The pulley diameter measurement should include lagging and belt.
Pulley Diameter _________mm; X = _________mm; Y = _________mm
Using the correct X and Y coordinates will position the cleaner at 15° below the horizontal plane on the head
pu lley.
Fig. 1
Fig. 2
Fig. 2b
4. Locate mounting bracket position (horizontal position). To locate the
position of the cleaner mounting bracket, add 70mm to the intersecting
mark (Fig. 2b). This mark indicates the top centre of the mounting bracket.
Fig. 2a
2a. Measure head pulley shaft. Determine the diameter of the pulley shaft
and divide by 2.
2b. Put a level on top of 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).
3a. Mark X dimension. Subtract the above dimension (Step 2a) 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).
3b. Determine Y dimension. From the horizontal X mark, drop a line
vertically down to the selected Y dimension and draw an intersecting mark
(Fig. 2a). This is the correct position of the centre of the pole.
Chute Mounting
70mm
9
+ +
+
4.2a H-Type© Primary Cleaner with V-Tips
Section 4 – Installation Instructions
Fig. 3
5. Cut chute opening. Using the adjusted intersecting mark (“+”) established in
Step 4, layout and cut the required opening 125x150mm on the chute (Fig. 3).
If access hole is required, see Step 7.
6. Install the mounting brackets. Centre the mounting bracket on the bottom of
the opening. Bolt or weld in position (Fig 4). Repeat process on opposite side.
7. Cutting the access hole. Cut access hole, centreing the bottom edge on the
adjusted intersecting mark (“+”) established in Step 4. Width of hole should be
175mm; height should be 325mm for extra small arms, 375mm for small arms,
420mm for medium arms, 450mm for large arms or 555mm for extra large
arms. Access hole may be oriented within the range shown (Fig. 5), provided
bottom edge is still centreed as described above.
Slide
Fig. 7
9. Position the pole. Rotate pole upward to bring tips into contact with head
pulley (Fig. 7). Centre the tips across the belt. While applying light pressure
on the centre tip, shi loosened bearing mount until tips are contacting belt
evenly across full width. Lock cleaner into this position by tightening
bearing mount bolts.
For step-by-step instructions on installing the spring tensioner, refer to page 13.
Bearing Mount Bolts
8. Install the pole. Remove the two bearing mount bolts from one of the
bearing mounts (Fig. 6). (If chute mount, remove from the side with access
hole.) Slide the pole across the pulley and into the bearing mount on other
side and allow tips to hang down. Install the removed bearing mount on
the pole and reattach to the mounting bracket. Do not tighten; leave nger
tight.
150mm
125mm
Chute Mounting (cont.)
75mm
75mm
+ +
+
Chute
Opening
Adjusted
intersecting
mark
Mounting
Bracket
Fig. 4
Fig. 5
Adjusted Intersecting Mark
Fig. 6
10 H-Type® Primary Cleaner with V-Tips
4.2b H-Type© Primary Cleaner with V-Tips
Section 4 – Installation Instructions
Fig. 2
Fig. 3
a) shaft to structure ________
b) pulley shaft diameter ________ ÷ 2 ________
+
c) pulley shaft centre line to structure = ________
d) add X measurement from chart ________
+
centre of pole from structure = ________
e) add 175mm (half length of
mounting bracket) 175mm
+
length of support material needed = ________
3. Locate X location.
a.) Measure from the back of the pulley shaft to the support structure (Fig. 3).
b.) Pulley shaft diameter divided by 2.
c.) Add dimensions from a) and b). This dimension is the pulley shaft centreline to the support structure.
d.) Add the given X dimension to c). The sum indicates the distance from the centre of the pole to the support
structure.
e.) Add 175mm (half the length of the mounting bracket). The sum is the total length of support material needed
to correctly locate the mounting brackets.
4. Secure mounting support pieces to the support structure. Weld support pieces to the support structure.
75x75mm angle works well for these support pieces.
5. Prepare the support pieces for the cleaner mounting brackets. Clamp the mounting bracket on the support
piece. Mark and drill holes for mounting or weld.
1. Find X and Y measurements. Find the X and Y measurement
specifications for the pulley diameter. See charts on pages 12 and 13.
The pulley diameter measurement should include lagging and belt.
Pulley Diameter________mm X________mm Y________mm
Using the correct X and Y coordinates will position the cleaner at 15°
below the horizontal plane on the head pulley.
2a. Locate Y location. Determine the diameter of the pulley shaft and
divide by 2.
2b. Put a level on top of the pulley shaft and mark A at the structure.
Measure down from Mark A half the diameter of the pulley shaft and
mark B, locating the shaft centreline (Fig. 1).
2c. Measure down the given Y dimension plus 70mm and mark (Fig. 2).
This mark indicates the top location of support material to be added for
installing the cleaner mounting brackets.
Open Head Mounting
Fig. 1
Mark "B"
Mark "A"
Belt Direction
Mark
Mark "B"
Y + 70mm
c+d+e
Length of
support
material
needed
Support structure
b
a
11
4.2b H-Type© Primary Cleaner with V-Tips
Section 4 – Installation Instructions
7. Position the pole. Rotate pole upward to bring tips into contact with
head pulley (Fig. 7). Centre the tips across the belt. While applying
light pressure on the centre tip, shift loosened bearing mount until
tips are contacting belt evenly across full width. Lock cleaner into
this position by tightening bearing mount bolts.
6. Install the pole. Remove the two bearing mount bolts from one of
the bearing mounts (Fig. 6). (If chute mount, remove from the side
with access hole.) Slide the pole across the pulley and into the bearing
mount on other side and allow tips to hang down. Install the removed
bearing mount on the pole and reattach to the mounting bracket.
NOTE: Do not tighten; leave finger tight.
Fig. 7
4.3 H-Type© Primary Cleaner with V-Tips - Bolt Tensioner
Open Head Mounting (cont.)
Bearing
Mount Bolts
Fig. 6
Slide
1. Install the pole. Remove the two bearing block bolts from
one of the bearing blocks (Fig. 1). (If chute mount, remove
from the side with access hole.) Slide the pole across the
pulley and into the bearing block on other side and allow tips
to hang down. Install the removed bearing block on the pole
and reattach to the mounting bracket. Do not tighten; leave
nger tight.
2. Position the pole. Rotate pole upward to bring tips into
contact with head pulley (Fig. 2). Centre the tips across
the belt. While applying light pressure on the centre tip,
shi loosened bearing block until tips are contacting belt
evenly across full width. Lock cleaner into this position by
tightening bearing mount bolts.
Fig. 2
Fig. 1
BEARING
BLOCK
BOLTS
Slide
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