AGI HI LIFE Original Instructions Manual Download

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8. T

ROUBLESHOOTING

OLLER

- B

ELT

ONVEYORS

OLLER

, M

INI

OLLER

, L

OLLER

& H

IFE

122

P115506 R3

23. Reloading -

cleaning system.

• head pulley slippage

• belt tensions need to be adjusted

• excessive reloading at

the tail section

• loading problems, velocity of the

material is too high, see Section
4.6.

24. Spillage.

• excessive reloading at

the tail section

• loading problems, bi-directional

loaders require a special design -
contact Hi Roller engineering

• loading problems, control gate

not properly installed, see Sec-
tion 4.6.

• loading problems, flow of mate-

rial is not directed down the back-
plate of the loader - see Section
4.6.

• loading problems, flow of mate-

rial is not evenly flowing down the
loader backplate - see Section
4.6.

• loading problems, straight down

flow of material - see Section 4.6.

• plugging tail section

• loading problems, many factors

will cause spillage - see Section
4.6.

25. Splice failures.

• mechanical splice is

wearing out prema-
turely

• belt speed and pulley diameter

specifications must be followed -
contact Hi Roller engineering

• belt tensions are important to

normal splice life - check for
proper belt tensions

• splice protector / wiper cleats

must be installed to reduce wear
on the splice - see “Belt Squaring
& Cutting” on page 42

26. Splice protector /

wiper cleats.

• cleaning system not

working well

• splice protector / wiper cleats

must be installed on all convey-
ors with all types of splices

• splice protector / wiper cleats

must be installed to protect and
clear the return bottom pan

27. Start-up problems.

• belt frozen down

• moisture must be eliminated

• head pulley slippage

• poor head pulley lagging - new

lagging needs to be installed

• belt tensions are too loose

Problem

Effect

Solution

Summary of Contents for HI LIFE

Page 1: ...r property damage Keep manual for future reference BELT CONVEYORS HI ROLLER MINI ROLLER LO ROLLER HI LIFE ASSEMBLY OPERATION MAINTENANCE NORTH AMERICAN VERSION ORIGINAL INSTRUCTIONS A division of AgGrowth Industries 4511 N Northview Ave Sioux Falls SD 57107 Toll free US Canada 800 328 1785 Phone 605 332 3200 Fax 605 332 1107 www hiroller com e mail sales hiroller com ...

Page 2: ...ures required for this product Periodic reviews of this manual with all employees should be standard practice For your convenience we include this sign off sheet so you can record your periodic reviews a Standards include organizations such as the American Society of Agricultural and Biological Engineers American National Standards Institute Canadian Standards Association International Organizatio...

Page 3: ...s and Details 13 3 Conveyor Components 17 3 1 Operator Orientation 17 3 2 Component List 17 3 2 1 Head Sections Discharges 18 3 2 2 Motor Drive Mountings 18 3 2 3 Trunking Sections 19 3 2 4 Covers 20 3 2 5 Inlets Loader 22 3 2 6 V Plow 23 3 2 7 Tail Sections 24 3 2 8 Take Up Sections 24 4 Application Design Considerations 27 4 1 Product Capacity Considerations 27 4 1 1 Aspiration 27 4 2 Clearances...

Page 4: ...on 48 5 4 5 Belt Tension Procedure 48 5 4 6 Normal Idler Wear 51 5 5 Leveling Tail Take Up Section 52 5 6 V Plow Adjustment 52 5 7 Cover Installation 53 5 7 1 Made To Length Covers 53 5 7 2 Cut To Length Covers 54 5 7 3 Cover Hardware 55 5 8 Drive Motor Final Check Before Start Up 56 5 9 Hazard Monitoring Devices 56 5 9 1 Motion Sensor 56 5 9 2 Plug Switch 58 5 9 3 Belt Alignment Monitors 59 5 9 4...

Page 5: ...ller Hi Bulk Models 91 7 2 4 Belt Tracking Misalignments 93 7 2 5 Belt Camber 93 7 2 6 Skew Bow 94 7 3 Idler Replacement Hi Roller Models 94 7 4 Idler Replacement Hi Life Models 99 7 4 1 Bottom Flat Idler 99 7 4 2 Side Troughing Idlers 101 7 5 Liner Bottom Return Pan 103 7 5 1 Fasteners 103 7 5 2 Replacement 104 7 6 Fixed Tripper All Models 106 7 7 Head Drive Pulley Lagging 112 7 7 1 Removing Lagg...

Page 6: ...HI ROLLER BELT CONVEYORS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 6 P115506 R3 ...

Page 7: ...you understand the proper installation procedure We look forward to many years of working with you and encourage anyone who has questions to call us This operator s manual should be regarded as part of the equipment Suppliers of both new and second hand equipment are advised to retain documentary evidence that this manual was provided with the machine Always give your dealer the serial number of y...

Page 8: ...ors in most climates There will a limited number of exposed people and operators as the conveyors will be typically installed in an industrial facility Conveyors are designed and manufactured to be a complete conveyor when properly installed by the customer or his representative Complete Approval Drawings Installation Drawings and Manuals are provided with each conveyor The customer and his repres...

Page 9: ... Accidents can be avoided SIGNAL WORDS Note the use of the signal words DANGER WARNING CAUTION and NOTICE with the safety messages The appropriate signal word for each message has been selected using the definitions below as a guideline DANGER Indicates an imminently hazardous situation that if not avoided will result in serious injury or death WARNING Indicates a hazardous situation that if not a...

Page 10: ...ially and annually with all personnel before allowing them to operate this product Untrained users operators expose themselves and bystanders to possible serious injury or death Use this equipment for its intended purposes only Do not modify the equipment in any way without written permission from the manufacturer Unauthorized modification may impair the function and or safety and could affect the...

Page 11: ...8 A final inspection before start up is extremely important Complete the Final Checklist on page 74 to ensure proper and safe operation of the conveyor 2 4 MAINTENANCE SAFETY 1 Lock out power before performing any maintenance 2 Covers must be clamped in place to keep dust and weather contamination out of the enclosure 3 Drive reducers are shipped dry and must be filled with the proper oil lubrican...

Page 12: ... for each assigned lock and that you are the only one that holds that key After verifying all energy sources are de energized service or installation may be performed Ensure that all personnel are clear before turning on power to equipment For more information on occupational safety practices contact your local health and safety organization 2 5 ELECTRIC MOTOR SAFETY To prevent serious injury or d...

Page 13: ...ll air pockets can be pierced with a pin and smoothed out using the sign backing paper 2 6 2 SAFETY DECAL LOCATIONS AND DETAILS Replicas of the safety decals that are attached to the equipment and their messages are shown in the figure s that follow Safe operation of the equipment requires that you familiarize yourself with the various safety decals and the areas or particular functions that the d...

Page 14: ...AFETY HI ROLLER BELT CONVEYORS 2 6 SAFETY DECALS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 14 P115506 R3 INSTALL ON OR BESIDE GUARD DEPENDING ON AVAILABLE SPACE P115512 P115522 INSTALL NEAR EMERGENCY HANDLE ...

Page 15: ...S 2 SAFETY HI ROLLER MINI ROLLER LO ROLLER HI LIFE 2 6 SAFETY DECALS P115506 R3 15 GENERAL EQUIPMENT LABEL INSTALL ON CONVEYOR SPOUT P115513 INSTALL NEAR CONVEYOR DISCHARGE P115514 INSTALL NEAR CONVEYOR ELECTRIC MOTOR P115515 ...

Page 16: ...2 SAFETY HI ROLLER BELT CONVEYORS 2 6 SAFETY DECALS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 16 P115506 R3 P115528 INSTALL NEAR INLET S P115516 P115524 ...

Page 17: ...s Motor and Drive Mountings Trunking Sections Covers Loaders Inlets V Plow Tail Sections Take Up Sections FITTED WITH CLAMPS FOR A NORTH AMERICAN MARKET FITTED WITH CLAMPS FOR AN INTERNATIONAL MARKET STANDARD ORIENTATION TO DETERMINE RIGHT AND LEFT STAND BY TAIL SECTION AND LOOK TOWARD HEAD SECTION REVERSIBLE CONVEYOR ORIENTATION TO DETERMINE RIGHT AND LEFT STAND AT NON DRIVE SECTION AND LOOK TOWA...

Page 18: ...e 3 1 or snubber head discharge which is bolted to the head section Figure 3 2 Discharges usually have an inspection hatch at the top and a four sided frame for transitions Figure 3 1 Standard Discharge Figure 3 2 Snubber Head Section Discharge 3 2 2 MOTOR DRIVE MOUNTINGS Hi Roller mounts most factory supplied motors and reducers according to manufacturers specifications Figure 3 3 shows a right h...

Page 19: ... coupled drive not shown are not as common 3 2 3 TRUNKING SECTIONS HEAD DRIVE END TRUNKING SECTIONS High leg end channel inspection door location and special flanges Fig ure 3 4 Figure 3 4 TAIL NON DRIVE END TRUNKING SECTIONS High leg end channel inspection door and two equal middle flange chan nels and opposite end of the high leg end channel INTERMEDIATE TRUNKING SECTIONS Each intermediate secti...

Page 20: ...e labeled and numbered starting with 1 on the tail section 3 2 4 COVERS Covers are made to fit over the width of the conveyor and 5 of a section STANDARD 5 COVERS Figure 3 6 Note Covers can be cut to length at the factory if ordered to specific lengths Contact Hi Roller s engineering department INLET LOADER Figure 3 7 shows a hold down clamp with a bend near the inlet ...

Page 21: ...HI ROLLER BELT CONVEYORS 3 CONVEYOR COMPONENTS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 3 2 COMPONENT LIST P115506 R3 21 Figure 3 7 INSPECTION DOORS For trunking head tail and inlet loader Figure 3 8 ...

Page 22: ...ts Flat Top w Matching Flange and Control Gate Important Off center loading is harmful to the belt idlers and shafting and will cause belt alignment problems Custom loaders can be designed for specific overhead clearance considerations Contact Hi Roller s engineering department GATES Gates control the flow of material down the back slope of the inlet when the gate opens Figure 3 10 Figure 3 10 Gat...

Page 23: ...3 23 Figure 3 11 3 2 6 V PLOW The v plow is located just in front of the tail pulley The v plow acts as a dam to hold back large amounts of spilled material that would plug the conveyor and helps direct spilled material to the side of the tail section to be reloaded Figure 3 12 V Plow SHIPPED ATTACHED SHIPPED LOOSE ...

Page 24: ...d they are used to tighten the belt Figure 3 14 Figure 3 14 Tail Take Up Section w Rods and Leveling Rods SPECIAL TAKE UP SECTIONS The take up head section works in the same manner as a sliding box tail The take up rods located on the sides tighten the belt Figure 3 15 Figure 3 15 Head Take Up Sections w Rods and Leveling Rods The sliding plate take up head section uses a sliding plate to mount th...

Page 25: ...HI ROLLER BELT CONVEYORS 3 CONVEYOR COMPONENTS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 3 2 COMPONENT LIST P115506 R3 25 Figure 3 16 Head Take Up Sections w Sliding Bearing Mounts Rods ...

Page 26: ...3 CONVEYOR COMPONENTS HI ROLLER BELT CONVEYORS 3 2 COMPONENT LIST HI ROLLER MINI ROLLER LO ROLLER HI LIFE 26 P115506 R3 ...

Page 27: ...ic meter kg cubic meter etc Abrasive Corrosive Sticky Moist Hot Oily Materials Design considera tions must be reviewed with Hi Roller s engineering department Capacity Inclined conveyors of any type will not convey the same amount of material as a flat horizontal conveyor Hi Roller s engineering department will calculate the capacity of a specific application Belt Speed The minimum for proper relo...

Page 28: ...rm moist air must not be allowed to vent through the conveyor because it will cause condensation to form on the inside of the conveyor enclosure as the dew point of the air is reached Condensation or water can freeze inside the conveyor and cause substantial problems Warm hot moist materials will create warm moist air inside the conveyor enclosure and can cause extensive damage through condensatio...

Page 29: ...n Hi Roller s engineering department must complete design calculations to determine the amount of gradual up bend that can be installed on a specific application Sharp up bends Hi Roller Conveyors can be installed with a sharp up bend section This is the highest cost horsepower and maintenance option Hi Roller s engineering department must complete design calculations to deter mine the amount of i...

Page 30: ...avel as the belt with a minimum amount of impact and centered on the belt Note Off center loading is harmful to the belt idlers and shafting An off center load will cause belt alignment problems Please consider control gate orientation control flows from all spouts side loading problems high velocity and turbulent flows straight down flow problems poor loading leading to belt tracking problems bel...

Page 31: ...be installed so that the material flows down the backplate of the loaders as shown in Figure 4 5 and 4 6 3 Control gates must be installed to open from the back tail end of the loader to the front head end so the material flows down the backplate This must be done for proper loading 4 Material speed is very important for proper loading Material flowing too fast will cause the material to splash as...

Page 32: ... ROLLER LO ROLLER HI LIFE 32 P115506 R3 8 For a 45 inlet material must flow down the back slope of the inlet when the gate opens to ensure an even flow that properly acceleration with the speed of the belt Figure 4 5 Figure 4 5 Standard Inlet 45 w Matching Flange Control Gate Figure 4 6 Gate Orientation ...

Page 33: ...ing the first year of operation The belt should be stretched and stabilized before a permanent vulcanized splice is installed because of the limited length of the take up section of the conveyor 4 8 SUPPORTS Supports must be installed at least every 20 of the length of the conveyor Support legs or hangers should always be bolted to the trunking vertical or bottom flanges Supports should never be w...

Page 34: ...4 APPLICATION DESIGN CONSIDERATIONS HI ROLLER BELT CONVEYORS 4 9 GROUNDING HI ROLLER MINI ROLLER LO ROLLER HI LIFE 34 P115506 R3 ...

Page 35: ...g the head end trunking section and tail end trunking section for position of the end channels Bolts hex nuts and lock washers have been included in the hardware package All bolt together points should be caulked with silicone sealant to keep the dust in and weather out 8 Check that you will have adequate clearances around the conveyor Clearances around the head section tail section and trunking a...

Page 36: ...ts can be attached to the bearing mounting vertical plate or the bottom head section bolted connections of the standard head section as shown in Figure 5 1 Figure 5 1 SNUBBER HEAD SECTION Mounting supports can be attached to the bearing mounting vertical plate or the bottom head section bolted connections of the special snubber head section as shown in Figure 5 2 Figure 5 2 ...

Page 37: ...tructure should be attached to the angle vertical flange of the inner box left top picture or the angle bottom flange bolted connections of the inner box of the take up section left bottom picture All conveyors with a belt width larger than 48 or a take up length over 18 must have a sliding support attached to the stub tail for support in the tail and outer box of the take up This sliding support ...

Page 38: ...lp you assemble the trunking in the correct order Figure 5 5 Figure 5 5 3 Caulk and seal all bolt together flanges Figure 5 6 Figure 5 6 4 Check and double check with a laser transit or wire line that trunking is installed straight and level 5 Maintain clearances and install tail end trunking section NOTICE Trunking must be installed straight and level with a tolerance less than 1 8 over the entir...

Page 39: ...alls or flanges All connections must be bolted to the trunking or trunking flanges 5 2 4 TAIL SECTION BACK COVER REMOVAL INSTALLATION 1 The security bolt must be removed by a mechanical technician Then the tail cover clamps Figure 5 7 release the tail cover Figure 5 7 2 The handles on the tail cover should be used to release the tail section The safety chains will stop the tail cover from dropping...

Page 40: ...oint of a belt conveyor is the critical point Here the conveyor belt receives major abrasion and almost all of its impact Ideally material will pass from spout to belt at the same speed and direction of travel as the belt with a minimum amount of impact and centered on the belt Off center loading is harmful to the belt idlers and shafting and will cause belt alignment problems Figure 5 10 Standard...

Page 41: ...d of the skirt If the material is still tumbling as it passes the skirt end the skirts should be lengthened or the speed reduced to match the speed of the belt shows a typical loader inlet as shipped from the factory without skirts installed For skirt installation drawings see Section 9 1 A typical loader inlet as shipped from the factory without skirts installed Fixed skirts are bolted underneath...

Page 42: ...ed to handle the capacity of the discharge flow from the conveyor Figure 5 11 5 4 BELT INSTALLATION 5 4 1 PRE INSTALLATION 1 Clean out interior bottom liner Dirt debris water etc must be removed 2 Bottom liner must be dry 3 Throw down a thin layer of dry grain dust Oil Dri or similar product 4 In order to preserve maximum take up length available a Fully retract telescoping take up box prior to be...

Page 43: ...valent width on the trunking section see Figure 5 13 Bring the belt together over the woodworking surface that will be used for splicing Figure 5 13 3 Find the belt centerline See Figure 5 14 a Measure the belt width at a minimum of five points The first measurement should be near the end of the belt b Measure the belt width in 10 intervals mark them c Each measurement must be divided by two and m...

Page 44: ...belt pick a point on the line at least two times the belt width b Strike an arc across the width of the belt at the belt end from this point A nail may be used as a pivot point with good wire or cord attached to it Use a marker or chalk to mark the arc c A second set of arcs must be struck with the pivot point of the arcs on the centerline with a radius of slightly less than half the belt width d ...

Page 45: ...easure lengthwise 50 or more from each edge of the belt using exactly the same measurement on either side b Draw a diagonal line with a straight edge from the corner of one measurement to the opposite corner of the other measurement Repeat for opposing corners You will have drawn an X on the belt c Ensure that the intersection point of the 2 lines lies on the centerline Figure 5 16 ...

Page 46: ...on the return pan bottom of trunking The splice protectors wiper cleats are extremely important to the proper operation of the Hi Roller Conveyor These cleats protect the splice from prema turely wearing out from sliding on the bottom return liner The cleats also clean the bottom liner as the belt slides back to the tail section Material is cleaned off the bottom and conveyed to the tail section T...

Page 47: ...17 Specifications Table 5 1 Belt Splice Protector Wiper Cleat Spacing Belt Width No Pads ECFT Bolts Dim A Dim B 12 3 6 3 16 3 16 16 4 8 1 4 3 16 18 4 8 3 4 1 2 20 5 10 1 4 3 16 22 5 10 5 8 1 2 24 6 12 1 4 3 16 26 6 12 1 2 1 2 30 7 14 3 8 1 2 36 9 18 1 8 1 4 42 10 20 9 16 3 8 48 12 24 1 8 1 4 54 13 26 3 8 3 8 60 14 28 1 2 1 2 ...

Page 48: ...s the threads in the nuts and rod 3 Lubricate entire rod The washer area must be lubricated with oil 4 Lubricate the nuts and rods of the leveling rods These rods are only used to level the tail section Figure 5 18 5 4 5 BELT TENSION PROCEDURE Important Conveyor belt tension and tracking alignment must be checked weekly more often with seasonal weather changes The belt must be properly tensioned a...

Page 49: ...ch idler under the belt with the inside edges centered over the idler shafts 4 Measure the distance between the nearest edges of the support boards This span should be 5 5 Measure the distance X from the top of the trunking to the unweighted belt 6 Place the third board centered between the support boards 7 Place 200 lb weight on the center board 8 Measure the distance Y from the top of the trunki...

Page 50: ...5 INSTALLATION HI ROLLER BELT CONVEYORS 5 4 BELT INSTALLATION HI ROLLER MINI ROLLER LO ROLLER HI LIFE 50 P115506 R3 Figure 5 19 ...

Page 51: ...ent in the weld area a good rule of thumb is that the paint should not be worn off within 1 of the weld area Figure 5 20 Proper belt tensions can be set using Hi Roller Conveyor s belt tension proce dure Section 5 4 5 Figure 5 20 NOTICE Worn areas too close to the weld area indicate that belt tension is too loose This will dramatically increase the wear on the idler and lead to premature failure ...

Page 52: ...after the conveyor belt has been installed and properly tensioned The v plow is NOT set at the factory It must be adjusted so that the UHMW black plastic blade is 1 4 1 2 above the conveyor belt The v plow may have to be set at an angle to follow the belt line as it rises to the tail pulley After adjustment watch to make sure that the splice protector wiper cleats do not hit the v plow blade when ...

Page 53: ...aders in the proper locations before installing covers 5 7 1 MADE TO LENGTH COVERS See Figure 5 24 5 25 and 5 26 Measure from the centerline of the channel flange to inlet flange as shown in Figure 5 25 This is the measurement that is required by the factory to manufac turer made to length covers All of the covers that are going to be made to length must be measured using the same procedure the lo...

Page 54: ...OLLER MINI ROLLER LO ROLLER HI LIFE 54 P115506 R3 Figure 5 25 Figure 5 26 5 7 2 CUT TO LENGTH COVERS 1 To measure determine the length from the cover channel flange that the cover will fit over as shown Figure 5 24 In the figure the measurement below this length is 24 ...

Page 55: ...4 Weld the two pieces of metal together about every 3 4 with a short stitch weld as well as on the side edges 5 Grind all welds smooth 6 Clean the metal and prime all unpainted areas After the prime has cured finish painting all primed areas 7 After the paint has cured silicone caulk all seams inside and out so that the joints are water tight 8 Install cover and cover clamps Figure 5 27 5 7 3 COVE...

Page 56: ...nitors must be installed correctly to ensure proper operation Hi Roller Conveyors recommends the properly located and installed use of these monitoring devices when specified by the application Monitors must be wired properly into the control circuits so that the conveyor shuts down when a misalignment bearing failure etc is detected 5 9 1 MOTION SENSOR A motion sensor or speed slow down monitor m...

Page 57: ...HI ROLLER BELT CONVEYORS 5 INSTALLATION HI ROLLER MINI ROLLER LO ROLLER HI LIFE 5 9 HAZARD MONITORING DEVICES P115506 R3 57 Figure 5 30 Figure 5 31 ...

Page 58: ...OLLER BELT CONVEYORS 5 9 HAZARD MONITORING DEVICES HI ROLLER MINI ROLLER LO ROLLER HI LIFE 58 P115506 R3 5 9 2 PLUG SWITCH Properly installed and tested plug switches must be included in the design Figure 5 32 Figure 5 33 ...

Page 59: ...r equals the width of the belt Conveyor belt alignment monitors must be wired properly into the control circuits so that the conveyor shuts down when a belt misalignment is detected STANDARD HEAD SECTION Figure 5 34 The head pulley and belt alignment can be monitored with one rub block installed near the top centerline of the head pulley to detect belt and head pul ley misalignment The return belt...

Page 60: ...nd belt alignment can be monitored with one rub block installed near the top centerline of the head pulley to detect a belt and head pulley misalignment The snubber pulley and return belt alignment can be monitored with one rub block installed near the top centerline of the snubber pulley and will detect a return belt misalignment and snubber pulley misalignment Figure 5 35 ...

Page 61: ... 36 The head pulley and belt alignment can be monitored with one rub block installed near the front centerline of the head pulley on the take up slide plate to detect a belt and head pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt and will detect a return belt misalignment Figure 5 36 ...

Page 62: ...ECTION Figure 5 37 The drive pulley alignment can be monitored with one surface mounted sen sor block installed near the front centerline of the drive pulley to detect a drive pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt and will detect a return belt misalignment Figure 5 37 ...

Page 63: ...n drive pulley alignment can be monitored with one surface mounted sensor block installed near the front centerline of the non drive pulley to detect a non drive pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt in the special section for mounting the sensor and will detect a return belt misalignment Figure 5 38 ...

Page 64: ...39 The non drive pulley alignment can be monitored with one surface mounted sensor block installed near the front centerline of the non drive pulley to detect a non drive pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt in the existing trunking section and will detect a return belt misalignment Figure 5 39 ...

Page 65: ...0 The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt in the space allowed in the take up section and will detect a return belt misalignment Figure 5 40 ...

Page 66: ...gure 5 41 The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt in the existing trunking section and will detect a return belt misalignment Figure 5 41 ...

Page 67: ...gure 5 42 The tail pulley alignment can be monitored with one surface mounted sensor block installed near the top centerline of the tail pulley to detect a tail pulley misalignment The return belt alignment can be monitored with one rub block installed on the bottom return belt in the trunking section and will detect a return belt mis alignment Figure 5 42 ...

Page 68: ... pulley EXISTING The tripper top and bottom pulleys can be monitored similar to the mounting in Figure 5 43 However the mounting locations must be reviewed by Hi Roller Conveyors Each existing tripper section will have to be reviewed and specifications will be required for each type Please contact Hi Roller Conveyors Figure 5 43 5 9 4 BELT PULLEY ALIGNMENT MONITORS TYPICAL RUB BLOCKS There are man...

Page 69: ...ed to properly set the width between the rub blocks All applications require different shim arrangements to properly locate the rub blocks The number of shims will vary depending on the mounting and appli cation Please contact Hi Roller Conveyors to confirm the proper location and mounting of these devices Figure 5 45 Brass Rub Block Mounting w Inner Shims BRASS WITH MOUNTING BOLTS BRASS WITH WIRI...

Page 70: ...HI ROLLER BELT CONVEYORS 5 9 HAZARD MONITORING DEVICES HI ROLLER MINI ROLLER LO ROLLER HI LIFE 70 P115506 R3 Figure 5 46 Brass Rub Block Mounting w Outer Shims STANDARD HEAD SECTIONS SNUBBER HEAD SECTIONS Figure 5 47 ...

Page 71: ...D TRUNKING SECTIONS Figure 5 48 STANDARD TAIL SECTIONS Figure 5 49 TYPICAL SURFACE MOUNT SENSORS Figure 5 50 shows a typical wiring harness with a temperature sensor molded in the end of the washer type end These surface mounted sensors can be used to monitor pulley alignment The customer must specify the supplier of these devices ...

Page 72: ...2 P115506 R3 Figure 5 50 Figure 5 51 and 5 52 show the mounting of a surface mounted sensor on the side of a tail and head section of a Hi Roller Conveyor Please note that the proper location is very important All applications require different arrangements to properly monitor the pulley Figure 5 51 Figure 5 52 ...

Page 73: ...ing monitors that can be used to monitor the head snubber tripper and tail bearings The customer must specify the supplier of these devices Several photos of the bearings that are typically monitored follow Figure 5 54 Various Monitors TYPICAL INSTALLATION OF A BEARING MONITOR TEMP PROBE BEARING MONITOR TAIL PULLEY BEARINGS HEAD PULLEY BEARINGS SNUBBER PULLEY BEARING TRIPPER PULLEY BEARINGS ...

Page 74: ...l and intermediate trunking section installed in numerical order Sections rechecked to ensure a 1 8 tolerance for the full length of the conveyor Sections installed level not as critical as straightness of trunking Properly installed clearances on bottom to remove conveyor bottoms for servicing Properly installed clearances on both sides to remove service idlers and bearings Supports installed at ...

Page 75: ...ient aspiration to maintain slight negative pressure in conveyor enclosure Hot moist aspiration insulation for slight neg pressure to prevent condensation Motor Drive Motor drive couplings etc securely locked in place and properly aligned Proper belt chain couplings cooling fan and other required guards properly installed Drive lubrication oil properly filled Bearings properly lubricated Monitors ...

Page 76: ...rate with 75 load checking visually 11 Operate with full load checking visually 5 12 FINAL INSPECTION DURING OPERATION 1 Remove covers for visual checks with personnel ready to shut down immediately if there is a problem 2 The conveyor should be inspected from the head section to the tail section to be sure everything is operating properly 3 Make sure to inspect belt tracking loading discharging c...

Page 77: ...by mail or fax to Hi Roller Conveyors Conveyor Owner Company ___________________________________ Contact __________________________________________________ Address __________________________________________________ City _____________________________________________________ Zip Postal Code ____________________________________________ PHONE _________________________FAX ___________________ ...

Page 78: ...5 INSTALLATION HI ROLLER BELT CONVEYORS 5 12 FINAL INSPECTION DURING OPERATION HI ROLLER MINI ROLLER LO ROLLER HI LIFE 78 P115506 R3 ...

Page 79: ...hen feed small material load into conveyor checking visually 3 For initial startup remove covers for visual checks 4 Have personnel ready to shut down immediately in case there is a problem Important When starting conveyor for the first time be prepared for an emergency shutdown in case of excessive vibration or noise WARNING Before continuing ensure you have read and understand the relevant infor...

Page 80: ...a complete inspection of conveyor following the checklist at the beginning of this section 12 Keep operation of empty conveyor to a minimum as this results in excessive wear 13 Once conveyor is broken in the checklist should be a part of a monthly routine before operating 6 3 2 OPERATING WITH A FULL LOAD 1 Monitor the conveyor during operation for abnormal noises or vibrations 2 Shut off all power...

Page 81: ... on the belt ing It increases belt wear Do not flood feed 6 3 5 PLUGGING 1 If the conveyor becomes plugged stop conveyor motor and lockout tagout motor 2 Shut inlet feed gates or stop other equipment feeding inlet to stop flow to plugged conveyor and determine the source of the plug 3 Check tail section first by removing cover or opening inspection doors and clean out 4 Check head discharge and cl...

Page 82: ...6 OPERATION HI ROLLER BELT CONVEYORS 6 3 OPERATING PROCEDURE HI ROLLER MINI ROLLER LO ROLLER HI LIFE 82 P115506 R3 ...

Page 83: ... manufacturer prior to initial start up Important Bearings must be properly lubricated and checked weekly to ensure proper operation Hi Roller Conveyors are installed in many different types of applications A lubri cation schedule must be developed for each application WARNING Before continuing ensure you have read and understand the relevant information in the safety section Safety information is...

Page 84: ...mary rule of tracking a conveyor belt is simple the belt moves toward the end of the roll it contacts first The conveyor structure must be straight relative to centerline and level side to side All pulleys snub rollers carrying idlers and return idlers must be square with the frame perpendicular to belt centerline and parallel to each other Check by measuring diagonals they should be equal Belt te...

Page 85: ...king effect of the roll is virtually non existent However such a roll can induce camber see page 93 into the belt as it leaves the roll Trunking must be installed straight and level The tolerance must be less than 1 8 over the entire length of the conveyor The complete conveyor trunking must be checked for straightness and squareness completed during installation with a laser or wire The conveyor ...

Page 86: ...a shim pack Belt tracking can be adjusted by changing shims See Figure 7 2 If the belt is tracking in the direction of A the end of the pulley should be moved in the direction of C by removing a shim If the belt tracks to B side the pulley end should be moved in the direction of D by removing a shim Opposite end and opposite direction adjustments can be made if required Shims can be removed from o...

Page 87: ...flat part of the idler and the load must be centered on the belt All of these must check out before attempting to train the belt with the idlers 1 Hi Roller and Mini Roller idler adjustments are completed by loosening the two bearing retainer bolts This should be done on the bearing that is easiest to work on These bolts hold the bearings in place and are located on both sides of the conveyor as s...

Page 88: ... position See Figure 7 4 Remember the belt will move toward the end of the idler that the belt first contacts Note Right or Left is determined by standing at the tail section and looking toward the head section of the conveyor Figure 7 4 5 Test run the conveyor both empty and properly loaded Continue the training process until the desired training is achieved 6 If adjusting the bearings on one sid...

Page 89: ... in Figure 7 6 b Side troughing 45 idlers These set screws are on the outside of the trunking holding the stationary shaft of each idler There is a keeper bolt on the end of the stationary shaft as shown Figure 7 5 Figure 7 5 HEAD TAIL PULLEYS Belt tracking is adjusted at the head and tail pulley by changing the position of the pulleys See Head Tail Pulleys on page 86 IDLERS Idlers may be adjusted...

Page 90: ...close to the opposite side move the bearing toward the tail section Figure 7 6 4 If the belt is tracking to the right in the conveyor the end of the flat idler should be shifted in A position If the belt is tracking to the left the end of the flat idler should be shifted in B position See Figure 7 7 Remember the belt will move toward the end of the idler that the belt first contacts Note Right or ...

Page 91: ...leys on page 86 IDLERS Idlers may be adjusted only if attempts to train the belt with the head and tail pulleys have failed The conveyor must be square level in line belt splice must be square belt must be running on the flat part of the idler and the load must be centered on the belt All of these must check out before attempting the train the belt with the idlers 1 Lo Roller and Hi Bulk idler adj...

Page 92: ...fted in B position See Figure 7 10 Remember the belt will move toward the end of the idler that the belt first contacts Note Right or Left is determined by standing at the tail section and looking toward the head section of the conveyor Figure 7 10 4 Test run the conveyor both empty and properly loaded Continue the training process until the desired training is achieved 5 If adjusting the bearings...

Page 93: ...enter Inspect the area where the belt runs out of alignment for cuts burns or other localized damage The defective section of belt must be replaced BELT TRACKING EMPTY 1 The belt may not be contacting the center flat area of the idlers This can be caused by a stiff belt This must be corrected review belt specifications with Hi Roller engineering department 2 The above points 2 6 also apply to an e...

Page 94: ...ue to the torn fill yarn Usually this type of camber will be less than 1 2 of 1 and can be easily pulled out when the belt is properly tensioned and tracked Camber is typically instilled into a belt during improper storage Currently there is no accepted camber standard in the US market For a maximum acceptable camber relative to a given conveyor belt construction please contact your belt manufactu...

Page 95: ...rmine if there will be adequate slack in the belt to allow it to be held above the conveyor by retracting the inner box take up section Mark and measure the position of the inner box of the take up section Figure 7 12 6 The belt splice may have to be removed by drilling out the bolts and removing the splice The complete splice plates bolts and nuts should be replaced if the splice appears partiall...

Page 96: ... Figure 7 13 are for Models 25 54 of the larger Hi Roller idlers Models 18 and 22 require a height opening of 1 8 12 Loosen jam nut on set bolts on each side of the idler See Figure 7 14 Figure 7 14 13 Mark the location of the idler bearings on the sidewall of the trunking so that the new idler bearings can be installed in the same location 14 Loosen and remove bolts holding idler bearings in plac...

Page 97: ...type of pulling device may be required to help pull this assembly Use by removing the keeper bolt and large washer in the end of the stub shaft and then inserting the slide hammer in the end threads of the stub shaft b A long rod may have to be used to drive out the idler bearing and stub shaft assembly from the opposite side if there is not adequate clearance to use a slide hammer or another type...

Page 98: ...24 Spin the idler to make sure it is centered and secure 25 Retighten the set bolts 26 Tighten the jam nuts on the set bolts 27 Spin the idler to make sure it is centered and secure 28 Lubricate the bearings if they have not been filled with grease It is very important to not over grease these small bearings It only requires a small amount of grease to fill this type of bearing Check the bearing m...

Page 99: ...e without splitting the belt 7 4 1 BOTTOM FLAT IDLER 1 Follow all safety precautions that apply to the installation 2 Remove necessary covers Secure covers during the replacement process 3 Loosen jam nut on set bolts on each side of the idler See Figure 7 18 Figure 7 18 4 Mark the location of the idler bearings on the sidewall of the trunking so that the new idler bearings can be installed in the ...

Page 100: ...e may be required to help pull this assembly Use by removing the keeper bolt and large washer in the end of the stub shaft and then inserting the slide hammer in the end threads of the stub shaft Figure 7 19 6 Remove the bottom flat idler through the top of the conveyor See Figure 7 20 A piece of wood or steel bar may have to be used to push the belt to the side to allow the idler to be removed ou...

Page 101: ...vers making sure they are secured properly 7 4 2 SIDE TROUGHING IDLERS Figure 7 21 Idler replacement on all Hi Life Models can typically be done without splitting the belt Hi Life side troughing idler assemblies are sealed for life and must be replaced as a unit The complete assembly can easily be removed through the top of the trunking with the cover removed See Figure 7 22 1 Follow all safety pr...

Page 102: ...mpletely so the side idler assembly can be pushed in through the mount collar 7 The side troughing idler assembly must be pushed in completely through the dust seals into the conveyor trunking 8 The side troughing idler assembly can be rotated and removed straight through the open top of the conveyor trunking Figure 7 22 9 The complete assembly can easily be installed through the top of the convey...

Page 103: ...y a pattern of pop rivets prior to 1998 The pattern of pop rivets varies by model width and other factors See Figure 7 23 Figure 7 23 Truss Head Bolts Locknuts Floating Liner 1998 to 2002 The bottom return pan liner was held in place with a truss head bolt fender washer and locknut nylon The fasteners were specially installed to allow the liner to float The bottom metal pan was slotted to allow th...

Page 104: ... Figure 7 25 7 5 2 REPLACEMENT To replace and reinstall the bottom return pan Pop Rivets Fixed Liner prior to 1998 First remove all old pop rivets The new UHMW liner must be installed with new pop rivets in newly drilled holes in the metal bottom Truss Head Bolts Locknuts Floating Liner 1998 to 2002 First remove all old bolts washers and nuts It is recommended that they be replaced with new fasten...

Page 105: ...gure 7 28 Liner replacement requires that all of the bolts washers and nuts first be removed and discarded Remove the worn out liner Clean and treat any bare metal areas as required Install the new liner in its proper place so that the holes line up with the holes and slotted holes in the bottom return pan Install all new bolts washers and locknuts The locknuts should be tight ened and then backed...

Page 106: ...been checked during installation with a laser or wire The conveyor must meet a 1 8 tolerance A level must be placed exactly 90 from the centerline to ensure conveyor is not twisted b The tripper trunking sections must be installed in the correct order The trunking sections leading into the tripper section are higher than the normal sections The idler height continues to rise in each section so the...

Page 107: ...strung over the top of the idlers and top pulley of the tripper b strung back over the top of the bottom pulley of the tripper c around the bottom pulley of the tripper and back toward the head of the conveyor over the top of the idlers d over the top of the head pulley and the return belt slides back on the bottom of the trunking e under the belt plow just ahead of the tail pulley f and under and...

Page 108: ... Figure 7 31 Figure 7 32 3 The tripper valve must be adjusted properly for proper operation in the pass through and discharge positions Clearances must be checked and adjusted to eliminate leakage in each position at the top pulley and side discharge spouts See Figure 7 33 7 34 7 35 and 7 36 Figure 7 33 Tripper Valve Down ...

Page 109: ...OLLER MINI ROLLER LO ROLLER HI LIFE 7 6 FIXED TRIPPER ALL MODELS P115506 R3 109 Figure 7 34 Tripper Valve Up Figure 7 35 Discharge Spout Note Discharge spout has removable sides for ease of relining internal wear points and a top inspection door ...

Page 110: ...AINTENANCE HI ROLLER BELT CONVEYORS 7 6 FIXED TRIPPER ALL MODELS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 110 P115506 R3 Figure 7 36 4 Electric or manual actuators must be properly adjusted See Figure 7 37 ...

Page 111: ... without spillage when the valve is in the pass through position They are shipped loose and wired to the bottom of the of the tripper section see Figure 7 38 Figure 7 38 7 The back flow baffle must be properly installed and adjusted to prevent material from flowing backwards into the bottom pulley during start up and shutdown with full loads NOTICE In case of actuator malfunction use emergency han...

Page 112: ...re on the opposite side of the conveyor 11 If the belt will not train after all of these procedures thoroughly check that the trunking tripper head and tail sections are square level and straight and that the belt splice is square the belt is running on the flat part of the idler and that the load is centered If nothing helps contact Hi Roller Conveyors 12 If the belt trains significantly differen...

Page 113: ...g on the lagging plate with a come a long or similar device In some cases due to corrosion and rust the retainers will have to be driven out with a large punch or chisel type tool 1 diameter or a simi larly sized square bar that will bend them up as they are driven out of the retainers see Figure 7 41 Figure 7 40 Figure 7 41 3 Clean the head pulley and retainers Figure 7 42 Clean all dirt rust etc...

Page 114: ...115506 R3 Figure 7 42 7 7 2 INSTALLATION OF NEW LAGGING PLATES 1 Install new lagging plates In some cases the metal edge will have to be ground smooth so that the metal plate can be eas ily installed in the retainers Drive new lagging plates in the retainers with a hammer and wooden block to protect the metal edge ...

Page 115: ...e Use a hammer or punch 3 Install new retainer bolts and locknuts Drill new 1 4 pilot holes and drill to 3 8 hole for a 3 8 retainer bolt OR drill a new hole offset from the old hole Drill out the rubber 7 8 or 1 hole saw or equivalent piloted on the bolt hole on the lag ging plate a wood chisel could also be used for this Clean out rubber from the hole cut with the hole saw for the bolt head see ...

Page 116: ...8 9 5 mm bolt from the outside of the lagging plate so that the locknut is installed on the inside of the pulley Locknut is installed on the inside of the pulley and properly tightened 4 Install head pulley if removed 5 Re splice the belt if necessary 6 Tighten the belt to proper specifications 7 Install all guards inspection doors etc 8 Replace all removed attachments discharges spouts etc ...

Page 117: ...r section of the conveyor belt runs to one side at all points of the conveyor belt not joined square square ends and re splice properly 8 Bowed belt adjust tension or replace 9 Conveyor belt runs to one side for long distance bed load being placed on belt off center adjust chute and loading conditions 10 Conveyor frame or structure crooked straighten 11 Belt is erratic does not follow a pattern be...

Page 118: ...e failures 4 Belt damage head pulley slippage damaged the belt motion sensor must be installed on the tail pulley or a non drive pulley to detect a belt slow down motion sensor must be opera tional to shut down the conveyor immediately 5 Belt failures belt is failing prema turely belt tensions are important to normal belt life check for proper tensions hot and oily materials will attack the belt c...

Page 119: ...he first few months of operation 8 Build up of material material builds up underneath the return bottom belt splice protector wiper cleats must be installed see Splice Protector Wiper Cleats on page 46 splice protector wiper cleats must be installed even vulcan ized splices see Splice Protec tor Wiper Cleats on page 46 9 Capacity rated capacity cannot be reached due to head pulley slippage belt te...

Page 120: ...ity cannot be reached check size of the spouting to be sure it is adequately sized for the capacity of the conveyor check the spouting angle to be sure it is not too flat an angle and will not flow at the conveyor capacity 12 Freeze down belt is frozen down moisture and water must be elim inated from the inside of the con veyor 13 Head Pulley Slippage start up problem belt frozen down under the re...

Page 121: ... belt at full capacity 17 Moisture moisture is forming inside the conveyor moisture and water must be elim inated from the inside of the con veyor 18 Moisture build up moisture forms on the inside of the enclosure moisture must be eliminated 19 Moisture sensor conveyor doesn t shut down when the belt slips on the head pul ley the motion sensor must be tested by physically simulating a tail pul ley...

Page 122: ...aight down flow of material see Section 4 6 plugging tail section loading problems many factors will cause spillage see Section 4 6 25 Splice failures mechanical splice is wearing out prema turely belt speed and pulley diameter specifications must be followed contact Hi Roller engineering belt tensions are important to normal splice life check for proper belt tensions splice protector wiper cleats...

Page 123: ...de see Sec tion 4 6 belt misalignment loading problems bi directional loaders require a special design contact Hi Roller engineering loading problems control gate not proper installed see Section 4 6 loading problems flow of mate rial is not directed down the back plate of the loader see Section 4 6 loading problems flow of mate rial is not evenly flowing down the loader back place see Section 4 6...

Page 124: ...8 TROUBLESHOOTING HI ROLLER BELT CONVEYORS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 124 P115506 R3 ...

Page 125: ...T CONVEYORS 9 APPENDIX HI ROLLER MINI ROLLER LO ROLLER HI LIFE 9 1 SKIRT INSTALLATION DRAWINGS P115506 R3 125 9 Appendix 9 1 SKIRT INSTALLATION DRAWINGS Figure 9 1 Fixed Skirt Installation Type IV Inlet Model 18 54 ...

Page 126: ...9 APPENDIX HI ROLLER BELT CONVEYORS 9 1 SKIRT INSTALLATION DRAWINGS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 126 P115506 R3 Figure 9 2 Swing Skirt Installation Type IV Inlet Model 18 ...

Page 127: ...HI ROLLER BELT CONVEYORS 9 APPENDIX HI ROLLER MINI ROLLER LO ROLLER HI LIFE 9 1 SKIRT INSTALLATION DRAWINGS P115506 R3 127 Figure 9 3 Swing Skirt Installation Type IV Inlet Model 22 ...

Page 128: ...9 APPENDIX HI ROLLER BELT CONVEYORS 9 1 SKIRT INSTALLATION DRAWINGS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 128 P115506 R3 Figure 9 4 Swing Skirt Installation Type IV Inlet Model 26 54 ...

Page 129: ...y discloses in writing to HI ROLLER the method and details of the proposed installation and the intended use of the product or equipment and HI ROLLER approves in writing of such method and details HI ROLLER makes no warranties when damage results from the failure to follow instruction decals on certain components of the HI ROLLER system The purchaser or user of any HI ROLLER equipment shall be re...

Page 130: ...rights or delegate any performance owed under this agreement without the express written consent of HI ROLLER management CLAIM NOTICE OF DEFECTS In the event the purchaser claims that a HI ROLLER product is defective HI ROLLER shall be given an equal opportunity for inspection or upon request shall be furnished a sample of such product Any claim must be made within thirty 30 days after receiving t...

Page 131: ...kota Southern Division SEVERABILITY If for any reason any one or more of the provisions contained in this offer are held to be invalid illegal or unenforceable in any respect such invalidity illegality and unenforceability shall not affect any other provision hereof and this offer shall be construed as if such invalid illegal or unenforceable provision had never been contained herein ATTORNEYS FEE...

Page 132: ...HI ROLLER BELT CONVEYORS HI ROLLER MINI ROLLER LO ROLLER HI LIFE 132 P115506 R3 ...

Page 133: ...n of Conformity complies with the Applicable European Direc tives and relevant sections of the Applicable International Standards The signature on this document authorizes the distinctive European mark to be applied to the equipment described A Technical Construction File is available for inspection by designated bodies Applicable Directives Applicable Standards Certification Method Machinery Dire...

Page 134: ...g Growth International Inc Group 4511 N Northview Ave Sioux Falls SD 57107 Toll free US Canada 800 328 1785 Phone 605 332 3200 Fax 605 332 1107 www hiroller com e mail sales hiroller com Ag Growth International 2014 ...

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AGI HI LIFE, Original Instructions Manual

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