Installation, Operation and Maintenance...
Transcript of Installation, Operation and Maintenance...
H-Type® Enhanced Service Advantage Cartridge HD
Primary Belt Cleaner with HXF Blades
Installation, Operation and Maintenance Manual
www.flexco.comwww.flexco.com
H-Type® Dual ESAC with HXF Blades HD Primary Belt Cleaner
H-Type® Single ESAC with HXF Blades HD Primary Belt Cleaner
2 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
H-Type® with HXF Tips ESAC HD Primary Belt Cleaner
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.
Project Name Minerá Panama ProjectEquipment Title Conveyor Belt Primary ScrapersProject Number 1824EQR No / Purchase Order 1824-0008 Purchase Date June 29th 2017Specification DAS-0037
Drawing Number Rev. No Conveyor Number Title
K0092 100712-FE-9001 / 712-FE-9002
HXF8 Dual Cartridge Primary Cleaner712-FE-9003 / 712-FE-9004
K0093 100 713-CV-9003 / 713-CV-9004 HXF Single Cartridge Primary CleanerK0094 100 713-CV-9001 / 713-CV-9002 HXF Single Cartridge Primary Cleaner
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Table of Contents
Section 1 – Important Information ........................................................................................................................4 1.1 General Introduction ................................................................................................................................................ 4 1.2 User Benefits .............................................................................................................................................................. 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® ESAC HD Primary Cleaner with HXF blades ....................................................................................... 7 4.1a H-Type ESAC HD Primary Cleaner - Chute Mounting .................................................................................... 8 4.1b H-Type ESAC HD Primary Cleaner - Open Head Mounting ........................................................................ 10 4.2 Single Cartridge Installation .................................................................................................................................. 12 4.3 Dual Cartridge Installation .................................................................................................................................... 13 4.4 H-Type ESAC HD Primary Cleaner - Compression Spring Tensioner ........................................................... 14
Section 5 – Cleaner Pole Location Charts ............................................................................................................ 16 5.1 Pole Location Charts ......................................................................................................................................................... 16
Section 6 – Pre-Operation Checklist and Testing................................................................................................. 17 6.1 Pre-Op Checklist ..................................................................................................................................................... 17 6.2 Test Run the Conveyor ............................................................................................................................................ 17
Section 7 – Maintenance ....................................................................................................................................... 18 7.1 New Installation Inspection ................................................................................................................................... 18 7.2 Routine Visual Inspection ...................................................................................................................................... 18 7.3 Routine Physical Inspection ................................................................................................................................... 18 7.4 Blade Replacement Instructions - H-Type ESAC HD with Compression Spring Tensioner ........................ 19 7.5 Maintenance Log ..................................................................................................................................................... 23 7.6 Cleaner Maintenance Checklist ............................................................................................................................. 24
Section 8 – Troubleshooting ................................................................................................................................. 25
Section 9 – Specs and CAD Drawings................................................................................................................... 26 9.1 Specifications and Guidelines ................................................................................................................................ 26 9.2 CAD Drawings......................................................................................................................................................... 27
Section 10 – Replacement Parts List ..................................................................................................................... 30
Section 11 – Other Flexco Conveyor Products ..................................................................................................... 35
4 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 1 – Important Information
1.1 General Introduction
We at Flexco are very pleased that you have selected an H-Type® Primary Cleaner with HXF blades for your conveyor system.
This 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. This 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: 1-800-541-8028
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 Benefits
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
The H-Type Primary Cleaner with HXF blades 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.
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Section 2 – Safety Considerations and Precautions
Before installing and operating the H-Type® Primary Cleaner with HXF blades, 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 ConveyorsThe following activities are performed on stationary conveyors:
• Installation • Blade replacement • Repairs• Tension adjustments • Cleaning
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 ConveyorsThere 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. Unforeseeable 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™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 3 – Pre-installation Checks and Options
3.1 Checklist
• Check that the cleaner size is correct for the belt 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
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Section 4 – Installation Instructions
4.1 H-Type® ESAC HD Primary Cleaner with HXF Blades
Before You Begin:• Installation specs and instructions are based on the assumption
that the conveyor is in its working position. If the conveyor position will be different, the cleaner should be installed per the final position. Call customer service at 1-800-541-8028 if you need help with determining the proper coordinates.
• 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
Suspension Arm Size
Pulley Diameter + Belt and Lagging
SS 250-475mmS 500-775mmM 800-975mmL 1000-1175+-*mm
Tools Needed• Tape Measure• 24mm Wrench• Ratchet with 24mm 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 out the conveyor at the power source before you begin cleaner installation.
H-Type® ESAC with HXF blades HD Primary Cleaner with Compression Spring Tensioner
MOUNTING BRACKET BEARING BLOCK
TORQUE ARM
REMOVABLE CARTRIDGE
LOCK PLATECARTRIDGE REMOVAL HANDLE
BLADE ASSEMBLYHXF BLADE
CUSHION
POLE
8 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 4 – Installation Instructions
4.1a H-Type® ESAC HD Primary Cleaner with HXF Blades - Chute Mounting1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts
on pages 16 and 17. 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.
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 pole center 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 center of 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 center of the pole.
70mm
A
B
9
+ +
+
+ +
+
Section 4 – Installation Instructions
4.1a H-Type® ESAC HD Primary Cleaner with HXF Blades - Chute Mounting (cont.)
Fig. 3 5. Cut chute opening. Using the adjusted intersecting mark (“+”) established in Step 4, lay out and cut the required opening 125x150mm on the chute (Fig. 3). If access hole is required, see Step 7.
6. Install the mounting brackets. Center 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, centering the bottom edge on the adjusted intersecting mark (“+”) established in Step 4. Width of hole should be 175mm; height should be 430mm for small arms, 480mm for medium arms, 510mm for large arms or 620mm for extra large arms. Access hole may be oriented within the range shown (Fig. 5), provided bottom edge is still centered as described above.
8. Install the pole. Remove the two bolts from the bearing mount on the access hole side and remove the bearing mount (Fig 6). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side. Install the removed bearing mount on the pole and reattach to the mounting bracket. Do not tighten; leave finger tight.
150mm
125mm
75mm75mm
Chute Opening
Adjusted intersecting mark
Mounting Bracket
Fig. 4
Fig. 5
Adjusted Intersecting Mark
Bearing Mount Bolts
Fig. 6
10 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 4 – Installation Instructions
4.1b H-Type® ESAC HD Primary Cleaner with HXF Blades - Open Head Mounting
Fig. 2
Fig. 3
a) shaft to structure ________
b) pulley shaft diameter ________ ÷ 2 ________ +
c) pulley shaft center line to structure = ________
d) add X measurement from chart ________ +
center 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 centerline to the support structure.
d.) Add the given X dimension to c). The sum indicates the distance from the center 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.
1. Find X and Y measurements. Find the X and Y measurement specifications for the pulley diameter. See charts on pages 16 and 17. 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 centerline (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.
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
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Section 4 – Installation Instructions
4.1b H-Type® ESAC HD Primary Cleaner with HXF Blades - Open Head Mounting (cont.)
6. Install the pole. Remove the two bearing mount bolts from one of the bearing mounts (Fig. 4). Remove cartridge from pole. Slide the pole across the pulley and into the bearing mount on other side and allow pole lugs to hang down. Install the removed bearing mount on the pole and reattach to the mounting bracket. NOTE: Do not tighten; leave finger tight.
Open Head Mounting (cont.)
Fig. 4
Bearing Mount Bolts
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.
12 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Handle
Set screw
Lock Plate
Knuckle
Tighten nut and bolt
Section 4 - Installation Instructions
4.2 Single Cartridge Installation
1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle,
then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the
knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle,
then lock with the set screw.
Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle
into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove
handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and
the handle in place.
Handle removed and stored in pole end
Lock Pin
Knuckle
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Handle
Set screw
Lock Plate
Knuckle
Tighten nut and bolt
Section 4 - Installation Instructions
4.3 Dual Cartridge Installation
Handle removed and stored in pole end
Lock Pin
Knuckle
1. Different Cartridge Installation Methods. Option A: Handle always on cartridge. 1. Slide the handle into the already installed knuckle,
then tighten with supplied bolt/nut hardware. 2. Slide the cartridge onto the pole and lock down the
knuckle onto the pole. 3. Slide the lock plate onto the pole, over the handle,
then lock with the set screw. 4. Repeat for other side.
Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle
into the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove
handle and place into open pole end. 3. Using the lock pins provided, lock the knuckle and
the handle in place. 4. Repeat for other side.
Fig. 1 Position the pole. Rotate pole upward to bring tips into contact with head pulley (Fig. 1). Center the tips across the belt. While applying light pressure on the center tip, shift 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 14.Slide
14 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
1. Install the compression 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).
4. 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. 3). NOTE: The torque arm should be up against the mounting plate.
3. Verify your “C” dimension to ensure the pole is in the correct position.
2. Reassemble the spring assembly. Slide the spring, washer and bushings onto the pivot arm and turn the two adjusting nuts so about 6mm of the pivot arm is exposed above the nuts (Fig. 2).
Section 4 – Installation Instructions
4.4 H-Type® ESAC HD Primary Cleaner with HXF Blades - Compression Spring Tensioner
Pivot Arm
Torque Arm
Pivot Shaft
Bracket
Mounting Plate
Pole
Fig. 1
Fig. 2 Adjusting Nuts
Washer
BushingsSpring
Pivot Arm
Fig. 3Pivot Arm against slot end nearest the pole
Tighten locking bolts and jam nuts
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5. Set the correct blade tension. Refer to the charts 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. 4). Lock the top adjusting nut.
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.
Tighten locking bolts and jam nuts
Pivot Arm against slot end nearest the pole
Adjusting Nuts
Pivot ArmBushings
SpringWasher
Top of washer to
top of torque arm
Adjusting Nuts
Fig. 4
Section 4 – Installation Instructions
4.4 H-Type® ESAC HD Primary Cleaner with HXF Blades - Compression Spring Tensioner (con't.)
HXF SAC Black Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 154 151 150 149800 149 146 144 142
1000 144 140 138 1351200 139 135 131 1291400 135 129 125 1221600 130 123 119 -1800 125 118 - -2000 120 - - -2200 - - - -2400 - - - -2600 - - - -2800 - - - -3000 - - - -
HXF SAC Gold Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 158 157 157 156800 156 155 154 153
1000 154 152 151 1501200 152 150 148 1471400 150 147 145 1441600 147 144 142 1411800 145 142 140 1382000 143 139 137 1352200 141 137 134 1322400 138 134 131 1292600 136 132 128 -2800 134 129 - -3000 132 - - -
HXF SAC Silver Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 165 164 164 163800 164 163 162 162
1000 162 161 161 1601200 161 160 159 1591400 160 159 158 1571600 159 157 156 1551800 158 156 155 1542000 157 155 153 1522200 155 153 152 1512400 154 152 150 1492600 153 150 149 1472800 152 149 147 1463000 151 148 146 144
16 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 5 – Cleaner Pole Location Charts
5.1 Pole Location Charts
15°
Y
CGAP
TO A
RM
X
DIAMETER(OVER BELT)
GAP
TO PO
LE
Cobre Panama Project – Port Conveyors
Conveyor Numbers
Pulley Diameter (mm)
Suspension Arm Size X Coordinate Y Coordinate C Dimension
713-CV-9002 524 S 111 434 448712-FE-9001
624 S 159 447 474712-FE-9002712-FE-9003712-FE-9004713-CV-9001
654 S 171 450 481713-CV-9002713-CV-9003
825 M 248 513 570713-CV-9004
Note: For positioning of the Primary cleaner please refer to the X/Y and C dimension for correct location of the pole.
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Section 6 – Pre-Operation Checklist and Testing
6.1 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.
6.2 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.
18 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 7 – 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® Primary Cleaner 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.
7.1 New Installation InspectionAfter 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.
7.2 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 blades are worn out and need to be replaced. • If there is damage to the blades 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.
7.3 Routine Physical Inspection (every 6-8 weeks) When the conveyor is not in operation and properly locked out and tagged out, a physical inspection of the
cleaner to perform the following tasks:
• Clean material buildup off the cleaner.
• Closely inspect the blades, suspension arms and cushions for wear and any damage. Replace if needed.
• Ensure all blades contact the belt .
• Inspect the cleaner pole and cartridge 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 blades to the belt. Adjust the tension if necessary.
• When maintenance tasks are completed, test run the conveyor to ensure the cleaner is performing properly.
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Section 7 – Maintenance
7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners
Tools Needed: • Tape measure • Ratchet with 24mm socket • 24mm wrench or adjustable wrench• 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 all cleaner tips leave contact with the belt and the pole rotates into the cartridge extraction position (Fig. 1). This releases the tension of the blade on the belt.
Physically lock out and tag out the conveyor at the power source before you begin cleaner installation.
H-Type® Single ESAC HD with HXF blades Primary Belt Cleaner
2. Different Cartridge Removal Methods. Option A: Handle always on cartridge. 1. Loosen the lock plate set screw and disengage lock
plate from handle. 2. Lift the handle to unlock the knuckle and cartridge,
then pull cartridge out. 3. If using dual cartridge cleaner, repeat for other side.
Lift handle to unlock cartridge
Disengage lock plate
Loosen set screw
Knuckle
Adjusting NutsFig. 1
Pivot Arm
20 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 7 – Maintenance
7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners (cont.)
3. Clean off pole. Remove any debris that has built up on the pole.
Option B: Handle stored inside pole. 1. Remove lock pins holding handle and knuckle in place. 2. Slide the handle into the knuckle and twist to lock. 3. Lift the handle to unlock the knuckle and cartridge, then
pull cartridge out. 4. If using dual cartridge cleaner, repeat for other side.
Lift handle to unlock cartridge Insert handle into
knuckle, twist to lock
Lock Pin
Knuckle
4. 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 them and then remove.
5. Install the new tips. Locate each tip onto each suspension arm, then install the hardware to fasten the tip to the cushion (Fig. 3).
Fig. 3
Removal Nuts
Fig. 2
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Section 7 – Maintenance
7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners (cont.)
6. Insert the reconditioned or replacement cartridge. Option A: Handle always on cartridge. 1. Slide the cartridge onto the pole and lock down the
knuckle onto the pole. 2. Slide the lock plate onto the pole, over the handle, then
lock with the set screw. 3. If using dual cartridge, repeat for other side.
Option B: Handle stored inside pole. 1. Set the cartridge onto the pole, then slide the handle into
the already installed knuckle. 2. Lock down the knuckle onto the pole, then remove handle
and place into open pole end. 3. Using the lock pins provided, lock the knuckle and the
handle in place. 4. If using dual cartridge, repeat for other side.
Handle
Set screw
Lock Plate
Knuckle
Handle removed and stored in pole end
Lock Pin
Knuckle
22 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 7 – Maintenance
7.4 Blade Replacement Instructions - H-Type® ESAC HD with HXF Blades with Compression Spring Tensioners (cont.)
Top of washerto top of
torque arm
Fig. 44. Reset the correct blade tension. Refer to the chart 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. 4). Tighten jam nut.
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.
HXF SAC Black Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 154 151 150 149800 149 146 144 142
1000 144 140 138 1351200 139 135 131 1291400 135 129 125 1221600 130 123 119 -1800 125 118 - -2000 120 - - -2200 - - - -2400 - - - -2600 - - - -2800 - - - -3000 - - - -
HXF SAC Gold Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 158 157 157 156800 156 155 154 153
1000 154 152 151 1501200 152 150 148 1471400 150 147 145 1441600 147 144 142 1411800 145 142 140 1382000 143 139 137 1352200 141 137 134 1322400 138 134 131 1292600 136 132 128 -2800 134 129 - -3000 132 - - -
HXF SAC Silver Spring Length Chart(for optimal blade tensioning)
Belt width CSS CS CM CL600 165 164 164 163800 164 163 162 162
1000 162 161 161 1601200 161 160 159 1591400 160 159 158 1571600 159 157 156 1551800 158 156 155 1542000 157 155 153 1522200 155 153 152 1512400 154 152 150 1492600 153 150 149 1472800 152 149 147 1463000 151 148 146 144
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Section 7 – Maintenance
7.5 Maintenance Log
Conveyor Name/No. _________________________
Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________Date: ___________________ Work done by: ___________________ Service Quote #: ___________________
Activity: __________________________________________________________________________________________________________
24 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 7 – Maintenance
7.6 Cleaner Maintenance Checklist
Site: _____________________________ Inspected by: ______________________________ Date: _____________________________
Belt Cleaner: _____________________________________________ Serial Number: _________________________________________
Beltline Information:
Beltline Number: ____________________ Belt Condition: _______________________________________________________________
Belt Width: (18") (24") (30") (36") (42") (48") (54") (60") (72") ¨ 450mm ¨ 600mm ¨ 750mm ¨ 900mm ¨ 1050mm ¨ 1200mm ¨ 1350mm ¨ 1500mm ¨ 1800mm
Head Pulley Diameter (Belt & Lagging):__________ Belt Speed:________ fpm Belt Thickness: __________
Belt Splice:__________ Condition of Splice:_________ Number of Splices:________ ¨ Skived ¨ Unskived
Material conveyed: ________________________________________________________________________________________________
Days per week run:_______________ Hours per day run:_______________
Blade Life:
Date blade installed:___________ Date blade inspected:___________ Estimated blade life:____________
Is blade making complete contact with belt? ¨ Yes ¨ No
Blade wear: Left _________ Middle _________ Right _________
Blade condition: ¨ Good ¨ Grooved ¨ Smiled ¨ Not contacting belt ¨ Damaged
Measurement of spring: Required _________ Currently _________
Was Cleaner Adjusted: ¨ Yes ¨ No
Pole Condition: ¨ Good ¨ Bent ¨ Worn
Lagging: ¨ Side Lag ¨ Ceramic ¨ Rubber ¨ Other ¨ None
Condition of lagging: ¨ Good ¨ Bad ¨ Other________________________________________________________
Cleaner's Overall Performance: (Rate the following 1 - 5, 1= very poor - 5 = very good)
Appearance:_ ¨_ Comments: ____________________________________________________________________________________
Location:_ ¨_ Comments: ____________________________________________________________________________________
Maintenance:_ ¨_ Comments: ____________________________________________________________________________________
Performance:_ ¨_ Comments: ____________________________________________________________________________________
Other comments __________________________________________________________________________________________________
________________________________________________________________________________________________________________
________________________________________________________________________________________________________________
________________________________________________________________________________________________________________
________________________________________________________________________________________________________________
________________________________________________________________________________________________________________
25
Section 8 – Troubleshooting
Problem Possible Cause Possible Solutions
Poor cleaning performance
Cleaner under-tensioned Adjust to correct tension – see spring length chart
Cleaner over-tensioned Adjust to correct tension – see spring length chart
Cleaner installed in wrong location Verify "C" dimension, relocate to correct dimension
Cleaner blade worn or damaged Replace cleaner blade
Rapid Blade Wear
Tension on cleaner too high/low Adjust to correct tension – see spring length chart
Cleaner not located correctly Check cleaner location for correct dimensions
Blade attack angle incorrect Check cleaner location for correct dimensions
Center wear on blade (smile effect)
Blade wider than material path Replace blade with width to match material path
Tension on cleaner too high/low Adjust to correct tension – see spring length chart
Unusual wear or damage to blade
Mechanical splice damaging blade Repair, skive or replace splice
Belt damaged or ripped Repair or replace belt
Cleaner not correctly located Verify "C" dimension, relocate to correct dimension
Damage to pulley or pulley lagging Repair or replace pulley
Vibration or noise
Cleaner not located correctly Verify "C" dimension, relocate to correct dimension
Blade attack angle incorrect Verify "C" dimension, relocate to correct dimension
Cleaner running on empty belt Use a spray pole when the belt is empty
Cleaner tension too high/low Adjust to correct tension or slight adjust to diminish
Cleaner locking bolts not secure Check and tighten all bolts and nuts
Cleaner not square to head pulley Verify "C" dimension, relocate to correct dimension
Material buildup in chute Clean up buildup on cleaner and in chute
Cleaner being pushed away from pulley
Cleaner tension not set correctly Ensure correct tension/increase tension slightly
Sticky material is overburdening cleaner Increase tension; replace with larger size cleaner
Cleaner not set up correctly Confirm location dimensions are equal on both sides
26 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 9 – Specs and CAD Drawings
9.1 Specifications and Guidelines
Overall Pole Length
Maximum Conveyor Span
H-Type® Single ESAC HD Pole Length Specifications*
Cleaner Size
Pole Length
Maximum Conveyor
Spanmm mm mm600 1950 1650800 2250 1950
1000 2400 21001200 2550 22501400 2850 25501600 3150 28501800 3150 2850
Clearance Guidelines for Installation
Suspension Arm Size
Horizontal Clearance Required
Vertical Clearance Required
mm mmCSS 175 410CS 175 470CM 175 520CL 175 550
Specifications:• Maximum Belt Speed ............................ 5M/sec• Temperature Rating ............................... -35°C to 82°C• Usable Blade Wear Length .................... 9mm• Blade Material ......................................... Long Life Tungsten Carbide (for vulcanized belts only)• Available for Belt Widths ...................... 600 to 3000mm
Other sizes available upon request.• CEMA Cleaner Rating .......................... Class 4
VERTICAL
HORIZONTAL
H-Type Dual ESAC HD Pole Length Specifications*
Cleaner Size
Maximum Pole
Length
Maximum Conveyor
Spanmm mm mm1200 3045 27451400 3200 29001600 3350 30501800 3505 32052000 3655 33552200 3960 36602400 3960 36602600 4420 41202800 4570 42703000 4650 4350
27
Section 9 – Specs and CAD Drawings
9.2 CAD Drawing - H-Type® 750 Single ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner
[PO
LE L
ENG
TH]
'B'
[C
HA
NN
EL L
ENG
TH]
'C'
[I/S
MO
UN
T D
ISTA
NC
E] M
IN =
C +
150
[5.
90 in
]M
AX
= B
- 3
00 [
11.8
1 in
]
[TI
P W
IDTH
] 'A
'
.71 18
X =
6.73
171
Y =
17.7
245
0C
=18
.95
481
10
.24
260
5.
1213
0
4.
3311
0
PUU
LLEY
+ B
ELT
=
27.0
968
8
4
5
2
3
1
17
.12
435
73
S
AR
MFO
R
500-
799
13
.78
350
2.95 75
14
.94
380
17
.32
440
11
.02
280
CU
TOU
T
ITEM
N
O.
DES
CRIP
TIO
NST
AIN
LESS
STE
EL
ORD
ER
NU
MBE
RIT
EM
COD
E
1H
TYP
E SA
C
POLE
TIP
WID
TH
'A' (
mm
) [in
]
NO
. TI
PS
OV
ERA
LL
LEN
GTH
'B'
(mm
) [in
]
CA
RTR
IDG
E C
HA
NN
EL
LEN
GTH
'C' (
mm
) [in
]
600
[23.
92]
322
86 [
90.0
0]71
1 [2
8.00
]H
CP-
600-
S/S
6275
7
2R
EPLA
CEM
ENT
CA
RTR
IDG
ES A
ND
CA
RTR
IDG
E KI
TS A
VA
ILA
BLE
3H
D C
USH
ION
HSH
D-S
/S76
467
4H
XF8
PO
LY B
LAD
ES
HX
F8S
7468
9
5C
OM
PRES
SIO
N S
PRIN
G S
IDE
ASS
EMBL
Y
28 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 9 – Specs and CAD Drawings
9.2 CAD Drawing - H-Type® 1000 Single ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner
[PO
LE L
ENG
TH]
'B'
[C
HA
NN
EL L
ENG
TH]
'C'
[I/S
MO
UN
T D
ISTA
NC
E] M
IN =
C +
150
[5.
90 in
]M
AX
= B
- 3
00 [
11.8
1 in
]
[TI
P W
IDTH
] 'A
'
X =
9.76
248
C =
22.4
357
0
5.
1213
0
PULL
EY +
BEL
T =
33
.94
862
18
Y =
20.1
951
3
4.
3311
0
10
.24
260
4
5
2
3
1
18
.78
477
73
M A
RM
FOR
80
0-99
9
13
.78
350
2.95 75
14
.94
380
18
.90
480
11.0
228
0
CU
TOU
T
ITEM
N
O.
DES
CRIP
TIO
NST
AIN
LESS
STE
EL
ORD
ER
NU
MBE
RIT
EM
COD
E
1H
TYP
E SA
C
POLE
TIP
WID
TH
'A' (
mm
) [in
]
NO
. TI
PS
OV
ERA
LL
LEN
GTH
'B'
(mm
) [in
]
CA
RTR
IDG
E C
HA
NN
EL
LEN
GTH
'C' (
mm
) [in
]
1000
[3
9.37
]5
2438
[95
.98]
1169
[46
.02]
HC
P-10
00-S
/S62
759
2R
EPLA
CEM
ENT
CA
RTR
IDG
ES A
ND
CA
RTR
IDG
E KI
TS A
VA
ILA
BLE
3H
D C
USH
ION
HSH
D-S
/S76
467
4H
XF8
PO
LY B
LAD
EM
HX
F8M
7469
0
5C
OM
PRES
SIO
N S
PRIN
G S
IDE
ASS
EMBL
Y
29
Section 9 – Specs and CAD Drawings
9.2 CAD Drawing - H-Type® 2000 Dual ESAC HD with HXF Blades Primary Belt Cleaner with Spring Tensioner
MA
X P
OLE
LEN
GTH
'B'
TIP
WID
TH 'A
'
CEN
TER
PO
LE L
ENG
TH 'C
'
[I/S
MO
UN
T D
ISTA
NC
E] M
IN 2
300
[90.
55]
MA
X 2
950
[116
.14]
A A
X =
6.26
159
Y =
17
.60
447
C =
18
.65
474
4.
2410
8
4.
1410
5
4.
7312
0
1.
15 29
.71 18
PULL
EY +
BEL
T =
26
.46
672
5
4
2
3
1
6
13
.78
350
12
.31
313
2.
95 75
10
.24
260
16
.93
430
CU
TOU
T
16
.88
429
2.88 73
SEC
TIO
N A
-A
S A
RM
FOR
50
0-79
9
ITEM
N
O.
DES
CRIP
TIO
NST
AIN
LESS
STE
EL
1
H T
YPE
2SA
C
CEN
TER
PO
LE
TIP
WID
TH
'A' (
mm
) [in
]
NO
. TI
PS
MA
X P
OLE
LE
NG
TH 'B
' (m
m)
[in]
CEN
TER
PO
LE
LEN
GTH
'C'
(mm
) [in
]
ORD
ER N
UM
BER
ITEM
CO
DE
2000
[7
8.74
]10
3655
[1
43.9
0]22
86 [
90.0
0]H
2CP-
2000
-S/S
6280
5
2EX
TEN
DER
PO
LE K
ITM
HP-
EP-S
/S77
599
3R
EPLA
CEM
ENT
CA
RTR
IDG
ES A
ND
CA
RTR
IDG
E KI
TS A
VA
ILA
BLE
4H
D C
USH
ION
HSH
D-S
/S76
467
5H
XF8
PO
LY B
LAD
E
SH
XF8
S74
689
MH
XF8
M74
690
LH
XF8
L74
691
6C
OM
PRES
SIO
N S
PRIN
G S
IDE
ASS
EMBL
Y
30 H-Type™ with HXF Blades ESAC HD Primary Belt Cleaner
Section 10 – Replacement Parts List
H-Type® Single ESAC HD Primary Belt Cleaner
REPLACEMENT PARTS
REF DESCRIPTION
MILD STEEL STAINLESS STEELORDERING NUMBER
ITEM CODE
WT. KG.
ORDERING NUMBER
ITEM CODE
WT. KG.
1 H-Type® Single ESAC Center Pole
HCP-600 62751 30.5 HCP-600-S/S 62757 31.4HCP-800 62752 35.6 HCP-800-S/S 62758 36.7HCP-1000 62753 38.1 HCP-1000-S/S 62759 39.3HCP-1200 62754 40.7 HCP-1200-S/S 62760 42HCP-1400 62755 45.9 HCP-1400-S/S 62761 47.3HCP-1800 62756 51.0 HCP-1800-S/S 62762 52.6
2 HD Cushion HSHD 73483 2.0 HSHD-S/S 76467 2.0
3 HXF Blades
HXF8SS 74307 3.4HXF8S 74689 3.8HXF8M 74690 4.1HXF8L 74691 4.5
4
Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B 62749 17.8 H73CSK-B-S/S 62750 18.3
Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G 62743 17.8 H73CSK-G-S/S 62744 18.3
Silver 6" Compression Spring Side Assembly (above 2400) H73CSK-G 62745 18.0 H73CSK-G-S/S 62746 18.4
REF DESCRIPTIONTIP
WIDTHORDERING NUMBER
ITEM CODE
WT. KG.
5 H-Type Cartridge Adapter Plate
600 H-SAC-AP-600 62452 3.5800 H-SAC-AP-800 62453 4.8
1000 H-SAC-AP-1000 62454 6.01200 H-SAC-AP-1200 62455 7.31400 H-SAC-AP-1400 62456 8.51600 H-SAC-AP-1600 62457 9.81800 H-SAC-AP-1800 62458 11.0
6 ESAC HD Single Cartidge Replacement
600 CART-24/600-S/S 78576 4.5800 CART-36/900-S/S 78578 6.7
1000 CART-42/1050-S/S 78579 7.81200 CART2-48/1200-S/S 78580 8.91400 CART-60/1500-S/S 78582 11.31600 CART-72/1800-S/S 78583 13.51800
1
2
3
4
5
6
31
Section 10 – Replacement Parts List
H-Type® Dual ESAC HD Primary Belt Cleaner
REPLACEMENT PARTS
REF DESCRIPTION
MILD STEEL STAINLESS STEELORDERING NUMBER
ITEM CODE
WT. KGS.
ORDERING NUMBER
ITEM CODE
WT. KGS.
1 H-Type® Dual ESAC Center Pole
H2CP-1200 62763 39.7 H2CP-1200-S/S 62801 39.7 H2CP-1400 62764 42.6 H2CP-1400-S/S 62802 42.6 H2CP-1600 62765 45.7 H2CP-1600-S/S 62803 45.7 H2CP-1800 62766 48.6 H2CP-1800-S/S 62804 48.6 H2CP-2000 62767 51.6 H2CP-2000-S/S 62805 51.6 H2CP-2400 62768 57.6 H2CP-2400-S/S 62806 57.6H2CP-2600 62769 71.0 H2CP-2600-S/S 62807 71.0H2CP-2800 62770 74.3 H2CP-2800-S/S 62808 74.3H2CP-3000 62771 77.8 H2CP-3000-S/S 62809 77.8
2 Extender Pole MHP-EP 76392 24.5 MHP-EP-S/S 77599 24.53 HD Cushion HSHD 73483 2.0 HSHD-S/S 76467 2.0
4 HXF Blades
HXF8SS 74307 3.4HXF8S 74689 3.8HXF8M 74690 4.1HXF8L 74691 4.5
5
Black Compression Spring Side Assembly (to 1600 belt width max) H73CSK-B 62749 17.8 H73CSK-B-S/S 62750 18.3
Gold Compression Spring Side Assembly (to 2400 belt width max) H73CSK-G 62743 17.8 H73CSK-G-S/S 62744 18.3
Silver 6" Compression Spring Side Assembly (above 2400) H73CSK-G 62745 18.0 H73CSK-G-S/S 62746 18.4
REF DESCRIPTIONTIP
WIDTH
ITEM 8 / LEFT HAND ITEM 9 / RIGHT HANDORDERING NUMBER
ITEM CODE
WT. KGS.
ORDERING NUMBER
ITEM CODE
WT. KGS.
8 & 7 H-Type Cartridge Adapter Plate
1200 H-SAC-AP-600 62452 3.5 H-SAC-AP-600 62452 3.51400 H-SAC-AP-800 62453 4.8 H-SAC-AP-600 62452 3.51600 H-SAC-AP-800 62453 4.8 H-SAC-AP-800 62453 4.81800 H-SAC-AP-1000 62454 6.0 H-SAC-AP-800 62453 4.82000 H-SAC-AP-1000 62454 6.0 H-SAC-AP-1000 62454 6.02200 H-SAC-AP-1200 62455 7.3 H-SAC-AP-1000 62454 6.02400 H-SAC-AP-1200 62455 7.3 H-SAC-AP-1200 62455 7.32600 H-SAC-AP-1400 62456 8.5 H-SAC-AP-1200 62455 7.32800 H-SAC-AP-1400 62456 8.5 H-SAC-AP-1400 62456 8.53000 H-SAC-AP-1600 62457 9.8 H-SAC-AP-1400 62456 8.5
REF DESCRIPTION
TIP WIDTH
ORDERING NUMBER
ITEM CODE
WT. KGS.
8 ESAC HD Dual Cartidge Replacement
1200 CART2-60/1500-S/S 78584 11.21400 CART2-66/11650-S/S 78634 12.31600 CART2-72/1800-S/S 78585 13.41800 CART2-78/1950-S/S 78635 14.52000 CART2-84/2100-S/S 78586 15.62200
CART2-96/2400-S/S 78587 17.824002600 CART2-114/2850-S/S 78639 23.72800 CART2-120/3000-S/S 78588 22.63000 CART2-126/3150-S/S 78640 23.7
3
4
5
67
821
35
Section 11 – Other Flexco® Conveyor Products
Flexco® provides many conveyor products that help your conveyors to run more efficiently and safely. These components solve typical conveyor problems and improve productivity. Here is a quick overview on just a few of them:
• Patented ConShear™ blade renews its cleaning edge as it wears
• Visual Tension Check™ for optimal blade tensioning and simple retensioning
• Quick and easy one-pin blade replacement Material Path Option™ for optimal cleaning and reduced maintenance
MHS SAC Secondary Cleaner
• Patented “pivot & tilt” design for superior training action• Dual sensor rollers on each side to minimize belt damage• Pivot point guaranteed not to freeze or seize up• Available for topside and return side belts
• A belt cleaner for the tail pulley• Exclusive blade design quickly spirals debris off the belt• Economical and easy to service• Available in vee or diagonal models
PT Max™ Belt Trainer
Flexco® Slider and Impact Beds
Belt Plough
• Long-wearing tungsten carbide blades for superior cleaning efficiency
• Patented PowerFlex™ cushions, the proven design found on our industry-leading MHS Secondary Cleaner
• Service Advantage Cartridge can be easily removed and replaced, even in the dirtiest conditions
• Works with Flexco mechanical belt splices
• “Limited space” cleaners for tight conveyor applications• High Temp cleaners for severe, high-heat applications• A rubber fingered cleaner for chevron and raised-rib belts• Multiple cleaner styles in stainless steel for corrosive applications
Rockline® EZP1 Primary Cleaner
Flexco Specialty Belt Cleaners
• Adjusting troughing angles for easy installation and adjustability• Long-wearing UHMW for sealing the load zone• Offered in both Light & Medium duty designs to affordably fit
your application
The Flexco Vision
To become the leader in maximising belt conveyor productivity for our customers worldwide
through superior service and innovation.
2525 Wisconsin Avenue • Downers Grove, IL 60515-4200 • USA Tel: (630) 971-0150 • Fax: (630) 971-1180 • E-mail: [email protected]
Visit www.flexco.com for other Flexco locations and products.
©2017 Flexible Steel Lacing Company. 08/15/17. For reorder: X4706