Installation Luff Conveyor Components

Structure AlignmentStructure Alignment –Parallel –Straight –Square –Level

Parallel

Straight

Frame Alignment

Level

Pulleys

Pulley Alignment 1.+ or - 1/32” level & perpendicular to the belt 2.Misalignment Excessive thrust load on bearingsExcessive thrust load on bearings Accelerated & uneven lagging wearAccelerated & uneven lagging wear Belt training problemsBelt training problems

Installation Idler alignmentIdler alignment –Square and in-line to the conveyor centerline and referenced from a terminal pulley –Parallel to each other

Idler Alignment

Installation Belt alignmentBelt alignment –Initially - train the belt empty –Then - train the belt under full design load –Helpful hints Only one person supervise the trainingOnly one person supervise the training

Installation Belt alignmentBelt alignment –Helpful hints (continued) After run-in period, check readings for voltage, amps, or watts for comparisonAfter run-in period, check readings for voltage, amps, or watts for comparison –Higher future readings may indicate excessive drag from de-training or frozen idler rolls

Installation Belt alignmentBelt alignment –Helpful hints (continued) Do not over-train. This will increase belt wear and power consumptionDo not over-train. This will increase belt wear and power consumption

Effect on Idler Life

Maintenance Inspection Plan (continued)Inspection Plan (continued) –Thoroughly clean grease fittings to eliminate the possibility of introducing contamination into bearings

Maintenance Skirtboard adjustmentSkirtboard adjustment –Skirtboards centralize & shape the load to minimize spillage –Steel backing plates should be high enough to avoid risk of contact with the belt –Typical gap is 1/2” at the tail opening and increases to 1” at the exit of the load zone

Maintenance Belt splicingBelt splicing –The splice “MUST” be square –The only corrective action for a non - squared splice, is to re-splice

Training Problem Conveyors

Maintenance TrainingTraining –Training or self-aligning idlers DO NOT train a belt –Only the center roll of a troughing idler effects training. Wing rolls only offer load support

Maintenance Training (continued)Training (continued) –Tilting troughing idlers forward, not over 2 degrees, in the direction of belt travel, produces a self-aligning effect (caution on reversing belts)

Maintenance Training (continued)Training (continued) –Procedure Square and level all troughing idlers, return rolls, tail, head, take- up, snub, and drive pulleysSquare and level all troughing idlers, return rolls, tail, head, take- up, snub, and drive pulleys Check counterweights and the sag on the return belt (2” per 10’)Check counterweights and the sag on the return belt (2” per 10’)

Maintenance Training (continued)Training (continued) Check all center rolls on troughing idlers & check return rolls for proper belt contactCheck all center rolls on troughing idlers & check return rolls for proper belt contact Check troughing frames for tilt degree and make correctionsCheck troughing frames for tilt degree and make corrections

Maintenance Training (continued)Training (continued) Start training adjustments at the head end and on the return side. Check and adjust all return rolls to the tail pulley (this assures early centering at the loading point on the belt)Start training adjustments at the head end and on the return side. Check and adjust all return rolls to the tail pulley (this assures early centering at the loading point on the belt)

Maintenance Training (continued)Training (continued) After the return side is running true, start training the top troughing idlers from the tail to the head pulley (end of procedure)After the return side is running true, start training the top troughing idlers from the tail to the head pulley (end of procedure)

Maintenance Training (continued)Training (continued) –Train the belt empty first, then train the belt under full design load If the belt trains well empty, then later problems will be due usually to off-center loading or material build-up on rollsIf the belt trains well empty, then later problems will be due usually to off-center loading or material build-up on rolls

Maintenance Training (continued)Training (continued) –Idlers can be “knocked” to train belt In the direction of belt travel, knock forward the idler end to which the belt runs (***visualize bicycle handle bars***)In the direction of belt travel, knock forward the idler end to which the belt runs (***visualize bicycle handle bars***)

Maintenance Training (continued)Training (continued) Shift idlers in the area preceding the detraining area of the conveyorShift idlers in the area preceding the detraining area of the conveyor 1/4” max adjustment1/4” max adjustment Caution - knocking may have adverse effects on reversing beltsCaution - knocking may have adverse effects on reversing belts

Maintenance Training (continued)Training (continued) –Training idlers should not be located within feet of a head or tail pulley, vertical curves, or abrupt changes in direction –The belt tends to run to the down side of an unlevel pulley

Maintenance Training (continued)Training (continued) –V-trough return rolls train very well –The side guide rolls on training idlers should be mounted inbound of the belt direction