Flexco RBP1 Installation, Operation And Maintenance Manual

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RBP1 Belt Positioner

Installation, Operation

and Maintenance Manual

www.ﬂexco.com

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RBP1 Belt Positioner

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.

is information will be helpful for any future inquiries or questions

about belt cleaner replacement parts, specications or troubleshooting.

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Table of Contents

Section 1 - Important Information ...................................................................................................2

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

1.2 User Benets .........................................................................................................................................2

1.3 Proper Belt Trainer Selection ..............................................................................................................3

Section 2 - Safety Considerations and Precautions ..........................................................................4

2.1 Stationary Conveyors ...........................................................................................................................4

2.2 Operating Conveyors ...........................................................................................................................4

Section 3 - Pre-Installation Checks and Options ..............................................................................5

3.1 Checklist ................................................................................................................................................5

3.2 Optional Installation Accessories .......................................................................................................5

Section 4 - Installation Instructions ..................................................................................................6

Section 5 - Pre-Operation Checklist and Testing ..............................................................................8

5.1 Pre-Op Checklist ..................................................................................................................................8

5.2 Test Run the Conveyor ........................................................................................................................8

Section 6 - Maintenance.....................................................................................................................9

6.1 New Installation Inspection ................................................................................................................9

6.2 Routine Visual Inspection ...................................................................................................................9

6.3 Routine Physical Inspection ...............................................................................................................9

6.4 Roller Replacement Instructions ......................................................................................................10

6.5 Maintenance Log ................................................................................................................................11

6.6 Maintenance Checklist ......................................................................................................................12

Section 7 - Troubleshooting ............................................................................................................13

Section 8 - Specs and CAD Drawings ..............................................................................................14

8.1 Specs and Guidelines .........................................................................................................................14

8.2 CAD Drawing, RBP1 Small ..............................................................................................................15

8.3 CAD Drawing, RBP1 Medium .........................................................................................................16

8.4 CAD Drawing, RBP1 Large ..............................................................................................................17

8.5 CAD Drawing, RBP1 Extra Large ....................................................................................................18

Section 9 - Replacement Parts .........................................................................................................19

9.1 Replacement Parts List ......................................................................................................................19

Section 10 - Other Flexco Conveyor Products ................................................................................21

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Section 1 - Important Information

1.1 General Introduction

We at Flexco are very pleased that you have selected a RBP1 Belt Positioner™ for your conveyor system.

is manual will help you to understand the installation, operation and maintenance of this product and

assist you in making it work up to its maximum eciency over its lifetime of service.

It is essential for safe and ecient 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. In addition, please follow all standard, approved safety guidelines when working on your conveyor.

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: 1-800-541-8028

Visit www.exco.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 impact bed. While we have tried to make the installation and service tasks as easy and simple as possible, this product does however require correct installation and

regular inspection and maintenance to maintain top working condition.

1.2 User Benets

Belt mistracking is a common problem that produces various problems, ranging from belt and structure

damage to product spillage and safety issues. By utilizing the RBP1 Belt Positioner, it is possible to correct a belt that is mistracking and causing these problems. Multiple units may be required depending on the length of the mistracking belt.

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Section 1 - Important Information

1.3 Proper Belt Trainer Selection

MODEL APPLICATION RANGE

Belt Positioner

™

Return side only, 800 PIW max tension on Small, Medium and Large; 1200 PIW max tension on Extra Large. Also works on reversing belts.

™

PTEZ

PT Smart

™

Medium-duty belts up to 1600 PIW max tension. Also works on reversing belts.

Medium-duty belts up to 1600 PIW max tension. Belt width + 3" (75mm) idler. Belt thickness 1" (25mm) maximum.

PT Smart

™

Underground

Medium-duty belts up to 1600 PIW max tension. Belt width + 9" (225mm) idler. Belt thickness 1" (25mm) maximum. Fits underground structure.

PT Pro

™

Medium-duty belts 150 PIW min to 1600 PIW max tension. Belt width 18” - 72” (450 - 1800mm). Also works on reversing belts.

HD PT Pro

™

Heavy-duty belts 300 PIW min to 2400 PIW max tension. Belt width 48" - 96" (1200 - 2400mm). Also works on reversing belts.

PT Max

™

Heavy-duty belts up to 3000 PIW max Generally 3/4" to 1" thick (19mm to 25mm) Belt width 24" - 60" (600 - 1500mm)

HD PT Max

™

Heavy-duty belts up to 6000 PIW max tension. Belt width 54" - 84" (1350 - 2100mm)

Belt Positioner

™

PTEZ

PT Smart

™

Standard

PT Smart

™

Underground Structure

™

PT Pro

™

PT Max Top Side

™

PT Max Return Side

Conveyor Criteria

Top side mistracking No No No No No Ye s Yes Yes

Return side mistracking Yes Yes Yes Yes Yes Yes Yes Yes

Reversing Yes Yes No Yes Yes No No No

Belt mistracking to one side Better Better Better Better Better Better Better Better

Belt mistracking to both sides Acceptable Better Best Better Better Best Best Best

Inconsistent tracking problem Good Better Best Better Better Best Best Best

Belt is cupped (heavy) Best ‡ Better ‡ Better Better Better Better Better Better

Belt has edge damage Best Best Good Best Best Good Good Good

Ease of Installation Best Better Good Good Good Good Good Good

Belt has low running tension (150-300 PIW) Good Good Good Good N/A Good N/A N/A

Belt has medium running tension (300-1600 PIW) Better Better Better Better Better Best Best Best

Belt has high running tension (1600+ PIW) N/A N/A N/A N/A Best Better Best Best

Approx. "upstream" effect *∆ 50’ (15 M) 20' (6 M) 20’ (6 M) 20’ (6 M) 20’ (6 M) 50’ (15 M) 50’ (15 M) 50’ (15 M)

Approx. "downstream" effect *∆ 50’ (15 M)

‡ Installed on the clean side of the return belt * Typical results; actual results may vary ∆ Disc idlers have the potential to reduce these numbers

Belt

Positioner

PTEZ™PT Smart™PT Pro

™

100' – 120'

(30 – 36 M)

120’ – 150’

(36 – 45 M)

100’ – 120’

(30 – 36 M)

™

Heavy

Duty PT

™

Pro

100’ – 120’

(30 – 36 M)

PT Max

150’ – 200’

(45 – 61 M)

™

Heavy

Duty PT

™

Max

150’ – 200’

(45 – 61 M)

Super

Duty PT

Max

150’ – 200’

(45 – 61 M)

™

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Section 2 - Safety Considerations and Precautions

Before installing and operating the RBP1 Belt Positioner it is important to review and understand the following safety information.

ere are setup, maintenance and operational activities involving both stationary and operating conveyors. Each case has a safety protocol.

2.1 Stationary Conveyors

e following activities are performed on stationary conveyors:

• Installation • Impact bar replacement • Repairs

• Skirt rubber adjustments • Cleaning

DANGER

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 impact bed 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

WARNING

Use Personal Protective Equipment (PPE):

• Safety eyewear

• Hardhats

• Safety footwear

Close quarters 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 components. Serious injuries can be avoided.

2.2 Operating Conveyors

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

• Inspection of the sealing performance

• Dynamic troubleshooting

DANGER

WARNING

Every belt conveyor is an in-running nip hazard. Never touch or prod an operating impact bed. Conveyor hazards cause instantaneous amputation and entrapment.

WARNING

Conveyor chutes contain projectile hazards. Stay as far from the trainer as practical and use safety eyewear and headgear. Missiles can inict serious injury.

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Never adjust anything on an operating impact bed. Unforseeable materials falling into the chute can cause violent movements of the impact bed structure. Flailing hardware can cause serious injury or death.

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Section 3 - Pre-installation Checks and Options

3.1 Checklist

• Check the model and size of the belt trainer. Is it the right one for your beltline?

• Check the RBP1 Belt Positioner to be sure all the parts are included in the shipment.

• Find the Information Packet in the shipment.

• Review the “Tools Needed” section on the front of the installation instructions.

• Prepare the conveyor site:

- Identify the point(s) of mistracking, expecting 50' (15M) of downstream and upstream inuence.

- Position the unit in the center of the mistracking.

- Optimal location: No closer than 3' (.9M) and no further than 6' (1.8M) from a return roller.

- Remove old tracking devices.

3.2 Optional Installation Accessories

Optional tools can make the installation of the RBP1 Belt Positioner easier and faster.

Flex-Lifter™ Conveyor Belt Lifter

Ordering

Description

Medium Flex-Lifter 36" - 60" (900 - 1500 mm) FL-M 76469 Large Flex-Lifter 48" - 72" (1200 - 1800 mm) FL-L 76470 XL Flex-Lifter 72" - 96" (1800 - 2400 mm) FL-XL 76983

Number

Flex-Lier™ Conveyor Belt Lier

e Flexco Flex-Lier makes the job of liing the conveyor belt easy and safe. Using two Flex-Liers, the belt can be quickly lied out of the way to install the PT Smart™. e Flex-Lier has the highest safe li rating available at 4000 lbs. (1810 kg) for Medium and Large, 6000 lbs. (2750 kg) for XL. And it’s versatile. It can also be used to li topside or return side belt for splicing, roller replacement or other maintenance jobs. Available in three sizes: Medium for belt widths 36" - 60" (900 - 1500mm), Large for belt widths 48" 72" (1200 - 1800mm), and XL for belt widths 72" - 96" (1800 - 2400mm).

Item

Code

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Section 4 - Installation Instructions

4.1 RBP1 Belt Positioner

Frame Adjustment Bolts, (2) Nuts & Lock Washers

Set Screws & Jam Nuts

Rollers (Rubber-Lagged or Steel)

Inner Tubes

Frame

RBP1 Parts List

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Tools Needed:

- Tape measure

- (2) 5/8" (16 mm) wrench or crescent wrench

- (2) 1/2" (13 mm) wrench or crescent wrench

Mounting Bolts, Lock Washers & Nuts

Mounting Bracket

Roller Retainer

Tail

Pulley

Locating the Positioner

• Look at the belt on the return side and identify where the belt is mistracking.

• Locate the Positioner in the center of the problem area.

• Generally, if the belt is correctly positioned at the tail pulley (A) so the belt is center loaded, it will run straight on the top side.

• Another problem area may be at the counter-weight pulley (B and C).

Fig. 1

Fig. 2

Shipping position

Move down

Remove for later use

1. Reposition mounting brackets (Fig. 1). Remove the mounting brackets from the inner shipping position, move them down toward the rollers, and remount them on the outside of the frames. Remove the mounting bolts, lock washers and nuts from the brackets and set them aside for Step 4.

2. Determine Positioner location on the belt (in the

selected location). Measure an equal distance from a

common point on both sides of the structure and mark both sides at the measured points (Fig. 2). e unit must be square to the conveyor.

NOTE: e Positioner should be centered between

two standard return rollers. For general applications-standard belts up to 72" (1800mm): position the unit no closer than 3' (.9M) to a return roller and no farther than 6' (1.8M).

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Section 4 - Installation Instructions

4.1 RBP1 Belt Positioner

Fig. 3

SET SCREWS (2 on opposite side)

Fig. 4

Not enough adjustment range in slot

FRAME

MOUNTING BRACKET (standard)

Center Mark

FRAME

Structure

MOUNTING BRACKET (upside-down)

Increased range of slot adjustment

3. Adjust unit for conveyor width.

a. Measure the structure’s inside width from side to side. b. Loosen the four jam nuts and set screws on the frames

and slide the unit apart to the same dimension as the inside structure width measurement minus 1/2" (13mm) to ensure

an easy t. Retighten set screws and jam nuts (Fig. 3). NOTE: e inner tubes between the two frames should be kept centered to ensure both sides have maximum support. Center marks on the inner tubes make it easy to see that the tubes are centered.

4. Mount unit on the conveyor.

Align the unit with the location marks on the structure. NOTE: Check the slot adjustment range of the frame and

the mounting bracket (Fig. 4). If there is not 4" to 6" of slot visible, turn the mounting brackets upside down for more slot adjustment. Clamp or hold the unit in place, drill mounting bolt holes on each side and secure with mounting bolts, lock washers and nuts, or weld in place.

Fig. 5

FRAME ADJUSTMENT BOLTS (on inside of bracket) Loosen for Adjustment

5. Adjust Positioner to the belt.

Loosen the two frame adjustment bolts on the side the belt is

running o and apply pressures as follows (Fig. 5):

a. Push down on unit until roller contacts 6" to 8" (150 to

200mm) of the belt. e roller on the other side should be set to contact the belt 4" (100mm) or less. Tighten all nuts.

b. Allow the conveyor to run a minimum of ve revolutions

and evaluate the results.

IMPORTANT: If more correction is needed, increase the

roller-to-belt contact pressure on the side running o; if necessary, decrease contact pressure on the opposite side.

MAINTENANCE

e rollers on the Positioner are sealed for life.

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Section 5 - Pre-Operation Checklist and Testing

5.1 Pre-Op Checklist

• Recheck that all fasteners are tight

• Apply all supplied labels

• Be sure that all installation materials and tools have been removed from the belt and conveyor area

5.2 Test Run the Conveyor

• Run the conveyor for at least 15 minutes and conrm the belt is tracking properly.

• If belt is still mistracking too far to one side, increase the roller-to-belt contact pressure on the side running o; if necessary, decrease contact pressure on the opposite side.

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Section 6 - Maintenance

Flexco belt trainers are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the trainer is installed a regular maintenance program should be set up. is program will ensure that the trainer operates at optimal eciency, and problems can be identied and xed before any damage is done to the belt, the trainer, other conveyor components, or structure.

All safety procedures for inspection of equipment (stationary or operating) must be observed. e RBP1 Belt Positioner 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

Aer the RBP1 Belt Positioner has run for 15 minutes a visual inspection should be made to ensure the trainer is performing properly. Make adjustments as needed.

6.2 Routine Visual Inspection (every 2-4 weeks)

A visual inspection of the RBP1 Belt Positioner can determine:

• If the belt is tracking as required

• If the main frame is free of material and rolling properly

• If there is damage to the main frame or other components

• If the rollers are turning freely and without damage If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for trainer 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 trainer to perform the following tasks:

• Clean material buildup o the trainer and components.

• Closely inspect main roller for free movement and wear. Replace if needed.

• Closely inspect complete unit for damage.

• Inspect all fasteners for tightness and wear. Tighten or replace if needed.

• When maintenance tasks are completed, test run the conveyor to ensure the trainer is

performing properly.

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Section 6 - Maintenance

6.4 Roller Replacement Instructions

Roller Retainer (hidden)

Roller Retainers

Fig. 1

Roller Retainer

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Tools Needed:

- Tape measure

- 5/16" (8 mm) wrench or crescent wrench

CAUTION: Components may be heavy. Use safety-approved liing procedures.

1. Remove tension from belt. Use a Flex-Lier or other appropriate liing equipment to li the belt

approx. 3" (75mm) o the trainer.

2. Remove roller by unbolting (4) Roller Retainers (Fig. 1).

3. Install new roller and re-bolt Roller Retainers (Fig. 1). Conrm roller turns smoothly.

4. Lower the belt. Ensure belt completely contacts rollers. Lower brackets if there is not good contact.

Tighten all bolts.

5. Refer to pre-op checklist (page 8) before running the conveyor. If belt is still mistracking, refer to Section 5.2 on page 8.

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