Flexco DRX3000 Installation, Operation And Maintenance Manual Download Page 21

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Section 6 - Maintenance

6.6 Impact Bed Maintenance Checklist

Site:

_______________________________

Inspected by

: ________________________________

Date:

_____________________________

DRX Impact Bed:

__________________________________________

Serial Number: _____________________________________________

Beltline Information:

Beltline Number: ____________________ Belt Condition: ___________________________________________________________________

Belt

42"

48"

54"

60"

72"

84"

96"

Width: (1050mm) (1200mm) (1350mm) (1500mm) (1800mm) (2100mm) (2400mm)

Transition Distance (back of bed to center of tail pulley): ____________ Belt Speed: ____________ Belt Thickness: ____________

Distance to Leading Idler: ________________ Distance to Trailing Idler: ________________

Vertical Distance between top of nearest idler and top surface of center impact bars: _______________

Impact Bar Life:

Date bars installed: _____________ Date bars inspected: ____________ Estimated bar life:_____________

Bar Condition: ____________________ inches of top cover remaining:____________

Impact Bed Frame Condition:

Good

Bent

Rusted

Overall Impact Bed Performance:

(Rate the following 1 - 5, 1= very poor - 5 = very good)

Appearance:

Comments: ____________________________________________________________________________________

Location:

Comments: ____________________________________________________________________________________

Maintenance:

Comments: ____________________________________________________________________________________

Performance:

Comments: ____________________________________________________________________________________

Other comments:

______________________________________________________________________________________________________

____________________________________________________________________________________________________________________

Summary of Contents for DRX3000

Page 1: ...www flexco com www flexco com DRX3000 Installation Operation and Maintenance Manual ...

Page 2: ...ed From _____________________________________________________________ Installation Date _____________________________________________________________ Serial number information can be found on the Serial Number Label included in the Information Packet shipped with the impact bed This information will be helpful for any future inquiries or questions about replacement parts specifications or troubles...

Page 3: ...tional Installation Accessories 10 Section 4 Installation Instructions 11 Section 5 Pre Operation Checklist and Testing 15 5 1 Pre Op Checklist 15 5 2 Test Run the Conveyor 15 Section 6 Maintenance 16 6 1 New Installation Inspection 16 6 2 Routine Visual Inspection 16 6 3 Routine Physical Inspection 16 6 4 Impact Bar Replacement Instructions 17 6 5 Maintenance Log 20 6 6 Impact Bed Maintenance Che...

Page 4: ...s possible it does however require correct installation and regular inspections and adjustments to maintain top working condition 1 2 User Benefits The transfer point is integrally important to the successful operation of a belt conveyor system The material transferred from one conveyor or other source to another conveyor must be done without damaging the conveyor s key component the belt A correc...

Page 5: ...set 3 Roller Diameter and CEMA Rating Rollers are typically 5 or 6 and rated CEMA C D or E 4 Bed Length Typically 4 or 5 Special lengths available upon request 5 Drop Height and Lump Size Weight This is the critical information required a Drop Height The measurement from where the material leaves the feeding conveyor to where it makes contact with the receiving conveyor b Lump Size and Weight The ...

Page 6: ...nce Some general guidelines 1 The impact bed s primary use is for dust suppression with no sizeable amount of impact for loads not exceeding 1500 lb ft of impact energy choose the 1 25mm top cover It will offer twice the service life with no measurable performance degradation 2 For applications with 1500 lb ft or more of impact force the 1 2 13mm top cover is strongly recommended It will provide 5...

Page 7: ...t Width F Length of Load Zone G Material H Drop Height I Maximum Lump Size Length Width Height J Tons per Hour K Belt Speed W Maximum Lump Weight Idler Length 1 Idler Length 2 Idler Length 3 Drop Height h See below for bed recommendation selection Largest Material Lump Weight w Lump Weight w Drop Height h x Total lb ft kg m Up to 200 lb ft 25 kg m DRX 200 200 to 750 lb ft 25 to 100 kg m DRX 750 75...

Page 8: ...wer 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 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 components Serious injuries can be avoided 2 2 Operati...

Page 9: ...mation Packet in the shipment Review the Tools Needed section on the front of the installation instructions Prepare the conveyor site Lift the belt in the transfer zone Use a lifting hoist or Flexco s Belt Lifters Remove the old impact bed or impact idlers Inspect the conveyor structure for damage or misalignment Make adjustments as necessary Troughing idlers should be installed directly before an...

Page 10: ...lers Impact Bed Size Cema C or D 5 125mm IDLERS Cema C or D 6 150mm IDLERS DRX200 24 36 600 900mm Shim idler up 1 2 13mm No Kits Required DRX200 42 72 1050 1800mm No Kits Required Use 1 SHIM KITL Shim up 1 2 13mm DRX750 24 36 600 900mm Shim idler up 1 2 13mm No Kits Required DRX750 42 72 1050 1800mm No Kits Required Use 1 SHIM KITM Shim up 1 2 13mm DRX1500 24 36 600 900mm Shim idler up 1 2 13mm No...

Page 11: ...ctions 4 1 DRX Impact Bed Physically lock out and tag the conveyor at the power source before you begin cleaner installation DRX 3000 Dynamic Impact Bed Caution Components may be heavy Use safety approved lifting procedures Fig 1a BELT DIRECTION Tools Needed 2 15 16 19mm wrenches or crescent wrenches Measuring Tape 4 C clamps Slider Bars Impact Bars Impact Energy Absorber Crossbrace Suspension Rai...

Page 12: ... Slide center assembly back onto mounting plates and reinstall bolts 5 Compress suspension rails Compress suspension rails with four C clamps to give an additional 2 5 63mm of clearance for assembly Fig 5 Fig 4b Fig 4a Fig 4c A D C B Tack weld impact energy absorber mounting plates to structure Suspension rail Crossbraces Crossbrace angle Move frame assembly off mounting plates Weld mounting plate...

Page 13: ...e inner mounting holes of the crossbeam Fig 8a Reinsert the two mounting bolts and the center retaining bolt in each wing bracket Fig 8b Tighten to 100 ft lb NOTE Confirm all of the bar mounting tabs on the wings are pointing towards the tail pulley Fig 8a Fig 8b Tabs must face tail pulley Center Retaining Bolt Wing Plate Mounting Bolts Wing Plate Wing Plate Crossbeam B E L T D I R E C T I O N 9 I...

Page 14: ...ad zone Fig 13 11 Install stationary arms Place stationary arms onto structure aligning holes in bases with center holes of impact energy absorbers Fig 11a Chamfer on stationary bars must face tail pulley Align ends of stationary impact bars flush with center bars Fig 11b Clamp in place and tack weld stationary arms to structure on both sides Align centers with center holes of impact energy absorb...

Page 15: ...erly sealing the transfer point Adjust skirt rubber as needed Recheck that all fasteners are tight Check that empty belt is 1 2 13mm above the impact bars Apply all supplied labels Be sure that all installation materials and tools have been removed from the belt and conveyor area 5 1 Pre Op Checklist 5 2 Test Run the Conveyor ...

Page 16: ...ure the bed is performing properly Make adjustments as needed 6 2 Routine Visual Inspection every 2 4 weeks A visual inspection of the impact bed can determine If the skirt rubber is adequately keeping the chute area sealed If the impact bars are worn out and need to be replaced If there are excessive materials building up around the impact bed If there is damage to the impact bed belt or other co...

Page 17: ...utty knife for cleaning bed and structure Come along 4 C clamps Impact Bar and Fastener Detail Section 6 Maintenance Physically lock out and tag the conveyor at the power source before you begin cleaner installation 2 Remove stationary bars Remove bolts at bases of stationary arms and lift assembly out of the way Fig 2 DRX 3000 Dynamic Impact Bed Flat washers lock washers and Nylock nuts Slider Ba...

Page 18: ...the chamfered end facing the tail pulley Fig 6 Line up the bolts and tighten the bars to the cross stringers Fig 5 Remove nut install support on new impact bar Impact bar support 6 4 Impact Bar Replacement Instructions cont 3 Inspect bars Check to see which bars are worn or damaged and need to be replaced Fig 4 Fig 6 Flat washers lock washers and Nylock nuts Chamfers must face tail pulley Position...

Page 19: ...s performing properly Make adjustments as necessary 8 Replace stationary bar s Replace bar s on stationary arm assembly if needed and reinstall arms into mounting bases Insert and tighten bolts Fig 8 Section 6 Maintenance 6 4 Impact Bar Replacement Instructions cont Bolts Stationary Arm Assy Fig 8 ...

Page 20: ...________________________ ______________________ Date _____________ ______ Work done by ____________________ Service Quote ____________________ Activity ________________________________________________________________________________________ ______________________ Date _____________ ______ Work done by ____________________ Service Quote ____________________ Activity ________________________________...

Page 21: ..._____________________________ Maintenance Comments _____________________________________________________________________________________ Performance Comments _____________________________________________________________________________________ Other comments _______________________________________________________________________________________________________ _____________________________________...

Page 22: ...lers Material buildup under bed Clean up buildup adjust skirting Skirt rubber pushing too hard on belt Adjust skirt rubber Bars deforming Larger material than specified is flowing through transition under specified bed Replace with a heavier duty version of impact bed or add additional bar supports Bar damage Mechanical splice damaging UHMW top covers Repair skive or replace splice For more inform...

Page 23: ...3000 Belt Width in 42 48 54 60 72 84 96 Belt Width mm 1050 1200 1350 1500 1800 2100 2400 SLIDER BARS DRX3000 2 2 4 4 4 4 4 IMPACT BARS DRX3000 8 8 8 9 12 12 16 Troughing Angles 20 and 35 Bed Specs per lump size and drop height needs Per Conveyor Equipment Manufacturers Association CEMA guidelines Bed Length 5 1 5M Bed Rating 1500 to 3000 lb ft DRX3000 200 to 400 kg m Impact Energy Calculation Lump...

Page 24: ... 273mm 1 09 27 7mm 64 25 1632 0mm 54 1350mm 63 1600 2mm 10 75 273mm 1 09 27 7mm 70 25 1784 4mm 60 1500mm 69 1752 6mm 10 75 273mm 1 09 27 7mm 76 25 1936 8mm 72 1800mm 81 2057 4mm 11 5 292 1mm 1 15 29 1mm 90 25 2292 4mm 84 2100mm 93 2362 2mm 11 75 298 5mm 1 15 29 1mm 102 25 2597 2mm 96 2400mm 105 2667 0mm 11 75 298 5mm 1 15 29 1mm 114 25 2902 0mm 32 813mm 58 4 1483mm 58 4 1483mm 27 7 703mm Dim B Dim...

Page 25: ... IBS DH5 76934 21 0 4 Sliding Support Arm Bolt Kit incl 4 1 1 2 bolts 2 2 bolts 6 lock washers 6 Nylock nuts ISABK 76935 2 0 5 Impact Energy Absorber 42 60 1050 1500mm IEA 42 60 76937 42 0 6 Impact Energy Absorber 72 96 1800 2400mm IEA 72 96 76938 66 0 Lead time 1 working day Impact Bed Handy Wrench A ratcheting wrench with 2 common socket sizes 3 4 15 16 19mm 24mm for installation and maintenance...

Page 26: ......

Page 27: ...de MHS HD 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 seize or freeze 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 Ma...

Page 28: ...mers worldwide through superior service and innovation 1995 Oak Industrial Dr NE Grand Rapids MI 49505 U S A Telephone 616 459 3196 Fax 616 459 4976 E mail info flexco com Visit www flexco com for other Flexco locations and products 2018 Flexible Steel Lacing Company 01 02 19 For reorder X2509 ...

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