Flexco U-Type Secondary Cleaner Installation, Operation And Maintenance Manual
1
www.flexco.com
www.flexco.com
U-Type® Secondary Belt Cleaner
Installation, Operation
and Maintenance Manual
2 U-Type® Secondary Cleaner
Serial Number:
Purchase Date:
Purchased From:
Installation Date:
Serial number information can be found on the Serial Number Label
included in the Information Packet shipped in the cleaner carton.
is information will be helpful for any future inquiries or questions
about belt cleaner replacement parts, specications or troubleshooting.
U-Type Secondary Cleaner
1
Section 1 - Important Information ...................................................................................................2
1.1 General Introduction ...........................................................................................................................2
1.2 User Benets .........................................................................................................................................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 Optional Installation Accessories .......................................................................................................5
3.3 Correct Blade Installation and Tensioning .......................................................................................6
Section 4 - Installation Instructions ..................................................................................................7
Section 5 - Pre-Operation Checklist and Testing ............................................................................12
5.1 Pre-Op Checklist ................................................................................................................................12
5.2 Test Run the Conveyor ......................................................................................................................12
Section 6 - Maintenance...................................................................................................................13
6.1 New Installation Inspection ..............................................................................................................13
6.2 Routine Visual Inspection .................................................................................................................13
6.3 Routine Physical Inspection .............................................................................................................13
6.4 Blade Replacement Instructions .......................................................................................................14
6.5 Maintenance Log ................................................................................................................................16
6.6 Cleaner Maintenance Checklist ........................................................................................................17
Section 7 - Troubleshooting ............................................................................................................18
Section 8 - Specications and CAD Drawing .................................................................................19
8.1 Specs and Guidelines .........................................................................................................................19
8.2 CAD Drawing - Cleaners with UST Tensioners ............................................................................20
8.3 CAD Drawing - Cleaners with J-Bolt Tensioners ..........................................................................21
Section 9 - Replacement Parts .........................................................................................................22
9.1 Replacement Parts and Poles (Mild Steel) ......................................................................................23
9.2 Replacement Parts and Poles (Stainless Steel) ................................................................................24
9.3 Replacement Blades ...........................................................................................................................25
Section 10 - Other Flexco Conveyor Products ................................................................................26
Table of Contents
2 U-Type® Secondary Cleaner
We at Flexco are very pleased that you have selected a U-Type® Secondary Cleaner 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 contact your eld representative or
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 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 U-Type Secondary Cleaner 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.
Section 1 - Important Information
1.1 General Introduction
3
Before installing and operating the U-Type® Secondary Cleaner, it is important to review and understand the following
safety information.
ere are set-up, 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 • Blade replacement • Repairs
• Tension adjustments • Cleaning
DANGER
DANGER
WARNING
WARNING
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
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
ere 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 inict
serious injury.
Section 2 - Safety Considerations and Precautions
4 U-Type® Secondary Cleaner
• 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
(see 3.2 - Optional Installation Accessories)
3.1 Checklist
Section 3 - Pre-Installation Checks and Options
Versatile, adjustable brackets that can be mounted on the conveyor structure so the U-Type cleaner can be quickly
and easily bolted into place. Pole extenders are also available for wide, non-standard conveyor structures.
Optional Installation Accessories
DESCRIPTION
ORDERING
NUMBER
ITEM
CODE
WT.
KGS.
WT.
LBS.
Mounting Bracket Kit EZS2MBK 75666 6.0 13.0
60 mm (2-3/8”) Pole
Extender Kit
RAPEK 77423 8.0 18.0
73 mm (2-7/8”) Pole
Extender Kit
MAPEK 76024 10.0 21.9
75666
Mounting Bracket Kit
(includes 1 le and 1 right bracket)
76024
Pole Extender Kit
(includes 2 pole extenders)
• For cleaner sizes 1800mm (72") and larger
• Provides 750mm (30”) of extended pole length
3.2 Optional Installation Accessories
5
Section 3 - Pre-Installation Checks and Options
3.3 Correct Blade Installation and Tensioning
For optimal cleaning eciency and long wear life, the U-Type® blade must be located and tensioned correctly on
the belt. If the cleaner pole is in the wrong location the performance of the new blade may be adversely aected.
See “Possible Problems” below. For tensioning, please follow these instructions.
Correct Tensioning:
Correct tension is determined and set by blade width. Check the information provided with the tensioner being used
or consult the installation instructions.
Possible Problems:
• Pole location too low - e initial cleaning will be
concentrated in the center of the belt, failing to
clean the outer edges eciently.
• Pole location too high - e intial cleaning will be
concentrated to the outer edges of the belt, failing
to eciently clean the center of the belt.
• Tension too low - Without the optimal tension,
the cleaning eciency is reduced and chatter or
bouncing of the blade can occur.
• Tension too high - Although the cleaning may
appear ecient, accelerated blade wear may
occur; and in some cases less eciency on the
outer edges of the belt, which could result in
increased belt wear.
Correct Pole Location:
When the blade contacts the belt (before tensioning)
there should be blade-to-belt contact across the
entire blade (Fig. 1). If contact is more in the center
with a gap on the outer edges, the pole will need to
be raised until full contact is achieved (Fig. 2). If
contact is more on the outer edges with a gap in the
center, the pole will need to be lowered until full
contact is achieved (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
6 U-Type® Secondary Cleaner
Section 4 - Installation Instructions
4.1 U-Type® Secondary Cleaner
U-Type with J-Bolt Tensioner
Parts List (Stainless Steel only)
J-Bolt Jam Nut
Adjusting Bolt &
Adjusting Bolt
Lock Nut
Mounting Bracket
Tension Spring
J-Bolt
Pole
Adjusting Arm
Stop Collar
Pole Bearing
Retaining Pin
& Spring Clip
Bearing Mount
Mounting Bracket
Set Screw &
Lock Nut
Mounting Bracket
Set Screw &
Lock Nut
Tensioner Adjusting Nut
J-Bolt Mount
Blade Retaining Screw
& Lock Nut
Mounting Bracket
Compression Spring
Pole
Torque Arm
Pole Bearing
Adjusting Bolt &
Adjusting Bolt
Lock Nut
Pivot Shaft Bracket
Slide Plate
Set Screw &
Lock Nut
Tension Adjusting Nut
Blade
Slide Plate
Mounting Bracket
Set Screw &
Lock Nut
Torque Arm
Set Screw
& Lock Nut
U-Type with UST Tensioner
Parts List
Stop Collar
7
Tools Needed:
• Tape measure
• 19mm (3/4") wrench
• Ratchet with 19mm (3/4") socket
• Screwdriver
• (2) 150mm (6") C-clamps (optional for
locating mounting brackets)
• Level (optional for locating belt height)
• Permanent marker
• Cutting torch and/or welder
• Square (for setting blade parallel to belt)
Before You Begin:
• Double-check the blade type needed for your application:
F-Blade - for mechanically spliced belts.
C-Blade - for Flexco Solid Plate mechanically spliced and
vulcanized belts.
V-Blade - for vulcanized belts. Can be used with mechanical
splices (solid bolt fasteners) that are recessed (skived) into the
belt cover (bolts must be ground on plate fasteners).
• For chute mounting it is necessary to cut an access hole. See
access hole dimensions at right.
• Follow all safety precautions when using a cutting torch.
• If welding, protect all fastener threads from weld spatter.
• For cleaner clearance requirements see chart at right.
Cleaner Location Options
Belt Direction
A
C C
U-Type Cleaner
B
Head Pulley
Chute wall
150-200mm
(6-8”)
Min.
150-200mm
(6-8")
Min.
150-200mm
(6-8”)
Min.
100mm (4")
Min.
150-200mm
(
6-8”
)
Min.
(6”)
150
mm
Chute Mounting Access Hole
Dimensions
Belt Width H Dimension
450-1050mm (18" - 42") 200mm (8")
1200-2400mm (48" - 96") 250mm (10")
CLEARANCE
Section 4 - Installation Instructions
4.1 U-Type® Secondary Cleaner
Physically lock out and tag the conveyor at the power source
before you begin cleaner installation.
Install the blade in the pole:
a. Loosen both locknuts on the blade retaining bolts.Turn blade
retaining bolts out 8 turns (Fig. a).
b. Loosen (but do not remove) all plate retaining bolts (Fig. b).
c. Install the new blade as shown in Fig. b. e ap on the blade
should face away from bladeholder screws.
d. Center the blade in the holder.
e. Tighten all plate retaining screws.
f. Tighten blade retaining screws 8 turns and tighten the blade
retaining screw locknuts.
Blade
retaining
bolt
Plate
retaining
bolts
Center blade
in holder
Blade holder
Flap facing away
from bladeholder
bolts
Locknut
Fig. a
Fig. b
Cleaner Clearance Requirements
U Cleaner Size Clearance
mm in.
mm in.
450 18" 155 6
600 24" 180 7
750 30" 205 8
900 36" 205 8
1050 42" 235 9 1/4
1200 48" 270 10 1/2
1350 54" 275 10 3/4
1500 60" 275 10 3/4
1800 72" 275 10 3/4
2100 84" 275 10 3/4
2400 96” 275 10 3/4
8 U-Type® Secondary Cleaner
3U. Install the cleaner pole into the slider plates.
a. Set pole ends into slider plate on both sides (Fig. 3Ua).
b. Slide pole bearings onto both ends of the pole with ange facing away from the belt (Fig. 3Ub).
c. Slide stop collar onto both ends of the pole (Fig. 3Ub). Do not tighten at this time.
d. Slide torque arms onto both ends of pole and attach both pivot sha brackets to slider plates (Fig. 3Ub).
Blade and torque arm must face either in the direction of belt travel (Fig. 3Uc), or if clearance is an issue,
switch to rotated tensioner conguration and assemble as shown (Fig. 3Ud).
e. Move slider plate to bottom of bracket to allow blade to rotate up into position in the next steps.
Fig. 3Ua
Repeat at
other end
Repeat at
other end
Slider Plate
Pole
Pole Bearing
(flange facing out)
Pole
- OR -
Fig. 3Ub
Slider Plate
Torque
Arm
Stop
Collar
Pivot Shaft
Bracket
Belt Direction Belt Direction
Blade and torque arm
must face in the direction
of belt travel
If clearance is an issue
switch to rotated tensioner
configuration and assemble
as shown.
Section 4 - Installation Instructions
4.1 U-Type® Secondary Cleaner
Fig. 3UdFig. 3Uc
Fig. 2Ua
2U. Install mounting brackets.
a. Using a level, lightly raise return side belt (take out cupping or sagging on edges) to nd belt's true parallel path to
the structure; and mark reference point #1 on structure. Measure down 75mm (3”) from reference point #1 and
mark reference point #2 (Fig. 2Ua). Make sure brackets are the same distance away from head pulley or a reference
point on both sides of the structure. If there is no structure to mount to, install mounting bracket kit rst.
b. Position mounting brackets so centerline marks on brackets are in line with reference points #2 on the structure
(Fig. 2Ub).
c. Clamp or weld into position.
Return
Side Belt
Belt Direction
Mounting
Bracket
Ref.
Point #1
Level
Return
Side Belt
Structure
Right
Side
Left
Side
#1
#2
Ref.
Point #2
Ref.
Point #2
Fig. 2Ub
Centerline on
Bracket
Bracket flush
to structure or
mounting kit
Slider Plate
3" (75mm)
UST Tensioner Instructions
1. Choose conveyor location where cleaner will be installed.
e U-Type may be positioned at any spot from where belt leaves head pulley on down the conveyor line (see
positions A to B). If a chute area is too small due to a snub pulley, it may be necessary to mount cleaner behind
chute (see position C). In chute applications a minimum of 150-200mm (6”-8”) is required between cleaner and
chute wall to prevent clogging of material.
NOTE: For U-Type cleaners using UST Tensioners, proceed to Steps 2U - 7U.
For U-Types using J-Bolt Tensioners, skip ahead to Steps 2J - 8J on Page 10.
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