Martin DT2S Installation Instructions Manual

MARTIN DT2S Secondary Cleaner

Installation Instructions

M3687UK

1Table of Contents

1 Table of Contents ............................................................. 1

2 Introduction ...................................................................... 3

2.1 About these installation instructions................................... 3

2.1.1 Scope ............................................................................ 3

2.1.2 Copyright ....................................................................... 3

2.1.3 Exclusion of liability ....................................................... 3

2.1.4 Reference to additional documents ............................... 4

2.1.5 Classification of the hazards.......................................... 5

2.2 Intended usage.............................................................. 6

2.2.1 Conveyor systems with open transfer systems ............. 6

2.2.2 Usage in explosion-protected areas .............................. 6

2.2.3 Restrictions on the use of the product........................... 7

2.3 Occupational safety............................................................ 7

2.3.1 Safety information, occupational safety ......................... 7

2.3.2 Duties of the owner-operator......................................... 8

2.3.3 Authorised personnel ..................................................... 8

3 Description of the product .............................................. 9

3.1 Design and function ........................................................... 9

3.2 Type designation ......................................................... 10

4 Preparing for the installation ........................................ 11

4.1 Before the installation....................................................... 11

4.1.1 Required materials and tools ....................................... 11

4.1.2 Preparatory measures ................................................. 11

5 Installation ...................................................................... 13

5.1 Safety information ............................................................ 13

5.2 Installation process...................................................... 14

5.2.1 Determination of the installation position ..................... 15

5.2.2 Conversion of the Bottom Mount spring tensioner

to Top Mount ............................................................... 18

5.2.3 Replacing springs ........................................................ 23

5.2.4 Installing the tensioner................................................. 24

5.2.5 Installing the cleaner.................................................... 25

5.2.6 Securing the cleaner .................................................... 26

5.2.7 Centring the secondary cleaner beneath

the conveyor belt ......................................................... 27

5.2.8 Aligning the secondary cleaner in parallel

to the driving drum axis ............................................... 28

5.2.9 Aligning the secondary cleaner horizontally

to the driving drum axis ............................................... 29

5.2.10 Tightening the cleaner................................................. 30

5.3 Operation with loading................................................. 36

5.4 Placement of warning labels and warning tags ........... 38

6 Maintenance ................................................................... 39

6.1 Safety information ............................................................ 39

6.2 Weekly maintenance........................................................ 39

6.3 Replacing the blades................................................... 42

Table of Contents

7 Troubleshooting ..............................................................49

7.1 Safety information............................................................. 49

7.2 Troubleshooting ................................................................ 49

8 Storage, De-installation, Disposal .................................51

8.1 Packing and transportation ............................................... 51

8.2 Storage ............................................................................. 51

8.3 De-installation ................................................................... 51

8.4 Disposal ............................................................................ 51

9 Part numbers ...................................................................52

9.1 Explanation of part numbers............................................. 52

9.2 Martin

Table of Contents

9.3 Accessories....................................................................... 54

9.4 Warning labels / Warning tags.......................................... 54

9.5 MARTIN

9.6 MARTIN

9.7 MARTIN

9.8 MARTIN

10 Declaration of Incorporation ..........................................64

Inspection Doors.............................................. 54

DT2S Secondary cleaner............................. 55

DT2SC Secondary cleaner cartridge........... 58

DT2S Spring tensioner ................................ 60

DT2S Air tensioner ...................................... 62

2 Introduction

2.1 About these installation instructions

Non-compliance with these installation instructions can result in loss of compensation for damage and/or warranty claims.

2.1.1 Scope

These installation instructions apply solely for the product described herein and are intended for those persons who install this product, commission it and monitor its usage.

2.1.2 Copyright

The products described and these installation instructions are protected by copyright. Any reproduction without a licence will be prosecuted. All rights to the present document are reserved, including its reproduction and/or copying in any conceivable manner. Reprints of this document require the written consent of Martin Engineering.

Introduction

The technical standard at the time of delivery of the product and its technical documentation are decisive as long as no other information is provided. The product and documentation may be subject to technical changes without prior notification. Earlier documents then lose their validity. Martin Engineering's General Terms of Sales and Delivery shall apply.

2.1.3 Exclusion of liability

Martin Engineering guarantees the flawless function of its product in accordance with its advertising, the published product information and its technical documentation. Martin Engineering shall assume no liability for efficiency and flawless function if the product is used for a purpose other than that described in the “Intended Use” section or for damage resulting from the use of accessories and/or spare parts which were not supplied and/or certified by Martin Engineering.

Introduction

2.1.4 Reference to additional documents

Martin Engineering products are designed for a long service life. They conform to the state of the art in science and technology and were thoroughly inspected before shipment. In addition to this, Martin Engineering constantly performs product and market research for continuous product development.

Martin Engineering offers competent support whenever malfunctions and/or technical problems occur. Suitable actions are taken immediately. The warranty provisions of Martin Engineering apply and can be sent to you as needed.

Reference is made in these installation instructions to the following documents:

• Installation instructions for the MARTIN Publication no. M3127.

The following standards and directives were complied with in the preparation of these installation instructions:

• EU Machinery Directive (2007/42/EC)

• ISO/IEC Guide 37 “Installation instructions for products used by consumers”, 1995 Edition

• DIN 1421 “Arrangement and numbering in texts”, Edition 1983-01

• DIN/EN 12100 “Machine safety - basic definitions, general design guidelines”, Edition 2010-11

• DIN/ISO 16016 “Technical product documentation Protection notices for restricting the use of documents and products“, Edition 2007-12

• DIN/EN 60204-1 “Safety of machines - Electrical Equipment of Machines, Part 1 General requirements”, Edition 2007-07

• DIN EN 82079-1 - Creation of user manuals - Structuring, content and presentation, Part 1 General principles and detailed requirements.

Inspection door,

2.1.5 Classification of the hazards

DANGER

Represents an immediately threatening danger which leads to serious bodily injuries or death if not avoided.

WARNING

Represents a possibly hazardous situation which could lead to serious bodily injuries or death if not avoided.

CAUTION

Represents a possibly hazardous situation which could lead to minor bodily injuries and/or property damage if not avoided.

Introduction

NOTE

Contains comments about the installation and/or the product's usage to point out situations which cause neither personal injury nor property damage but include important information.

2.2 Intended usage

Introduction

2.2.1 Conveyor systems with open transfer systems

MARTIN® DT2S secondary cleaners are used to clean materials clinging to conveyor belts. They can be used on conveyors with a belt width of up to 2400 mm and a belt speed of up to 3.6 m/s. The installation position of the cleaner directly downstream of the head pulley ensures that the cleaned off material is fed back to the material flow.

Every other usage of this product is deemed as misuse. Please contact Martin Engineering customer service if you would like to use this product for a different purpose. We will be happy to assist you with the product configuration.

These installation instructions describe the installation on conveyor systems with encapsulated transfer systems. Various MARTIN installation brackets can be used on open transfer systems.

Martin Engineering or one of its representatives can assist with the position or with special solutions in cases where the installation conditions are complicated such as insurmountable static components or a head pulley as the tensioning station.

2.2.2 Usage in explosion-protected areas

This product can also be used in potentially explosive areas under certain conditions. Contact Martin Engineering for more information on usage in potentially explosive areas.

The cleaner must not be used in a higher equipment protection category or under other operating conditions than those specified by Martin Engineering unless such usage has been approved by Martin Engineering.

2.2.3 Restrictions on the use of the product

The product specified here may only be used within the scope of the specifications referred to above. Usage in a higher equipment protection category or under other operating conditions than those specified by Martin Engineering shall be deemed misuse and is only permitted if approved by Martin Engineering.

Operation of this product is only permitted if all parts are in a flawless state. In case of damage (cracks, rust, etc...) changes or other mechanical modifications, shut down this product immediately.

Martin Engineering or one of its representatives can assist you with the product configuration if you need to use this product for a different purpose.

2.3 Occupational safety

2.3.1 Safety information, occupational safety

These installation instructions must be read through in their entirety before work may be started on the product or on the conveyor system supplied by the customer.

Introduction

The owner-operator must ensure that all installation, inspection and maintenance work is performed solely by trained specialists.

Work on conveyor systems and their accessories must always be performed during shut-down. The procedures described in the applicable installation instructions for shutting down the conveyor system must always be complied with.

All of the safety devices and safeguards must be reattached and/or made operational again immediately following completion of the work.

The installation must be completed before the system is started up. The flawless execution of all operating steps must be tested before the conveyor system can be started up again. Please observe all information on the installation and start-up of the product.

2.3.2 Duties of the owner-operator

Introduction

2.3.3 Authorised personnel

This product's owner-operator must ensure that this product is installed, serviced and used solely by those persons who

• know the rules regarding occupational safety and accident prevention,

• were trained on using this product and have read and understood these installation instructions.

Personnel are considered authorised when they have suitable training and technical experience, can demonstrate knowledge of the applicable standards and directives, and are able to evaluate tasks in order to recognise critical situations at an early stage.

Operating, maintenance and installation personnel

Personnel are considered authorised when they have been trained on using the product and have read and understood these operating instructions in their entirety.

3 Description of the product

3.1 Design and function

The Martin® DT2S secondary cleaner is primarily installed in a cleaner system consisting of pre-cleaners and secondary cleaners, but can also be used as a single cleaner.

The cleaner is installed directly behind a head pulley or tension pulley. Its slide-on blade holder enables quick and easy maintenance.

When the blades are properly selected, it can also be used on reversing conveyor belts or conveyor belts with a high return flow rate - also refer to the type description.

The cleaner can also be used in connection with mechanical joints if they are in good condition and optimally installed.

Although pre-cleaners and secondary cleaners can each be used individually, the installation of a system consisting of pre-cleaners and secondary cleaners is recommended for an optimal cleaning result.

Description of the product

NOTE

An unfavourably or improperly installed product can disrupt the conveyor process or contaminate the bulk material to be transported. The owner-operator is responsible for taking the required countermeasures. In the case of applications with contaminants, Martin Engineering or one of its representatives can assist with the positioning or with special solutions.

3.2 Type designation

The Martin® DT2S secondary cleaners can be equipped with various blade types:

• Reversing blades with tungsten carbide inserts Also available completely of urethane or stainless steel for reversing operation or conveyor belts with a high return flow rate.

The Martin different types of tensioners:

Description of the product

DT2S secondary cleaners can be equipped with two

• Spring tensioner Can be used for most applications

• Air tensioner For applications in heavily polluted areas or where air is generally available. An additional advantage is that the cleaner can be tensioned and slackened automatically.

4 Preparing for the installation

4.1 Before the installation

4.1.1 Required materials and tools

Along with the standard tools, the following special equipment may be needed for the installation and maintenance of your product.

• Lifting device with a capacity greater than the weight of the

product (see delivery note for weight data).

4.1.2 Preparatory measures

NOTE

Perform the inspections described - carefully and completely. The shipping company is liable for any transport damage! Please contact the shipper with any damage claims.

Preparing for the installation

1. Inspect the delivery for the following conditions:

• Is the delivery complete? Does the number of pallets/

crates/containers delivered match the number on the delivery note?

• Do all of the transport packages appear to be undamaged?

Does damage to the packaging indicate possible damage to the product contained inside?

2. Always record any incompleteness or transport damage discovered in the delivery and have it confirmed by the shipper. All damaged products must be kept for inspection.

3. The delivery should include the following parts, depending on the scope of the order:

•MARTIN blades).

• Two Conveyor Products Warning Labels, Part No. 23395

• Two Crushing Hazard Warning Labels Part No. 30528

4. Report any missing or damaged parts to Martin Engineering or one of its authorised dealers.

DT2S secondary cleaner (mainframe, tensioner,

Preparing for the installation

5 Installation

5.1 Safety information

WARNING RISK OF INJURY!

Body parts and/or clothing may get caught and pulled in by rotating parts or by the moving conveyor belt.

Before any installation or maintenance work is carried out, ensure that all power sources to the conveyor belt system and its accessories are switched off and secured against unauthorised reactivation. Use warning s igns!

WARNING DANGER OF EXPLOSION!

Increased risk when using a cutting torch or welding device in closed spaces!

Check the gas and dust content of the air before usage.

Installation

WARNING RISK OF INJURY!

The secondary cleaner is heavy and can cause serious injuries if it is dropped during lifting or moving.

Always use a suitable lifting device or engage the help of several persons when lifting the secondary cleaner. Do not stand under hanging loads.

NOTE

The item numbers in the pictures correspond to the numbering in the parts list in Section 9.

NOTE

The chute wall on which the inline reversing tensioner is to be installed is designated as the "operator side". The other chute wall is referred to as the "far side". When dual inline reversing tensioners are installed, the easiest side to access is the "operator side".

5.2 Installation process

An overview of the installation steps follows:

No. Installation step Instructions

Installation

1 Positioning the mainframe of the

cleaner 2 Installing the cleaner M3687 3 Installing the tensioner M3687 4 Tightening the cleaner M3687

Tab. 1: Installation steps

Various on-site conditions requiring different work steps are possible for the installation. These are presented as follows:

Installation on an encapsulated transfer system

• Follow the instructions given in Section 5.2.2.

Installation on an encapsulated transfer system with pre-existing installation openings and air line brackets for belt cleaners.

• Follow the instructions given in Section 5.2.3. Installation on an open transfer system Use the equipment provided at the site to comply with the

dimensions for correct installation.

M3687

5.2.1 Determination of the installation position

Installation

Fig. 1

NOTE

The installation dimension recommended by Martin Engineering, the cleaner must not be installed further than 51 mm from the head pulley as otherwise a counter-pressure roller is required.

Item Description

1 Centre point of the driving drum 2 Perpendicular on the lower conveyor belt level 3 Exit point of the conveyor belt from the driving drum 4 Position of the belt cleaner's blade tip 5 Running direction of the conveyor belt 6 Installation opening 7 Installation holes in the tensioner 8 Lower conveyor belt level

Tab. 2: Determination and creation of the installation position

Installation

Spring tensioner

Bottom Mount

Fig. 2

NOTE

Martin Engineering recommends installing a MARTIN® inspection door for the purpose of better accessibility for maintenance and repairs.

1. Sketch the lower conveyor belt level (8, Fig. 1) on the operator side of the chute wall.

2. Determine the centre point (1, Fig.1) of the driving drum.

3. Drop a perpendicular (2, Fig. 1) from the centre point to the lower conveyor belt level.

4. Mark a point (4, Fig. 1) at a distance of 51 mm from the exit point (3, Fig. 1) in the running direction of the conveyor belt (5, Fig. 1). This point is the later position of the blade tip.

5. Starting from the point marked in step 4, sketch the cut-out for the installation opening (6, Fig. 1) on the chute wall using the dimensions from Fig. 2.

NOTE

The dimensions differ, depending on the tensioner or tensioner variant used (Fig. 2). The tensioner equipment bracket can be used as a template.

6. Use the dimensions from Fig. 2 to mark the installation holes (7, Fig. 1) on the chute wall.

7. Create the cut-out for the installation opening at the points marked in Step 5.

8. Drill the holes for the installation (Ø14 mm).

9. Repeat steps 1 to 8 on the far side.

Installation

5.2.2 Conversion of the Bottom Mount spring tensioner to Top Mount

Installation

5.2.2.1 Operator side and far side

NOTE

The spring tensioner is delivered in the Bottom Mount variant as standard. Proceed as follows if spatial restrictions require a conversion from Bottom Mount to Top Mount:

Fig. 3

1. Loosen the locknut SW32 (9, Fig. 3 left) clockwise and screw it up to the hex nuts.

2. Unscrew the threaded rod (10, Fig. 3 right) with the locknut (9, Fig. 3 right) clockwise.

Fig. 4

3. Slide the bracket all the way to the top.

4. Turn all of the locknuts and the adjusting nut counter-clockwise and remove them from the threaded rod.

Fig. 5

5. Pull the threaded bolt (Fig. 5 left) downwards and remove it.

6. Remove the hammerlock cotter pins from the bolts (Fig. 5 left).

7. Remove the force spring with its washers and bolts (Fig. 5, right).

Installation

NOTE

Please note during conversion that the threaded rod can only be screwed in from one side. The thread of the threaded rod is blocked on one side.

Fig. 6

8. Screw the hex nut (9) (Fig. 6 left) counter-clockwise onto the threaded rod.

9. Screw the second hex nut (9) (Fig. 6 centre left) counterclockwise up to the first hex nut on the threaded rod.

10. Slide the tension spring with its washers and bolts (Fig. 6 centre right) up to the hex nuts on the threaded rod.

11. Screw the counter hex nut (9) (Fig. 6 right) counter-clockwise, as in the picture, onto the threaded rod.

+ 46 hidden pages

Martin DT2S Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual