ESS 600-1350 User manual

Upper & Lower Belt Tracker 1 14/06/2021
Upper & Lower Belt Tracker
600-1350 Belt Widths
Installation Operations Manual

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National Office Details
Location
Address
Phone & Email
CURRUMBIN
11 –13 Traders Way
PO Box 121
Currumbin QLD 4223
[phone]
[email protected]
GLADSTONE
Unit 2/34 Chapple Street
PO Box 1475
Gladstone QLD 4680
[phone]
[email protected]
KALGOORLIE
Unit A 255 Dugan St
Kalgoorlie WA 6430
PO Box 10471
Kalgoorlie WA 6433
[phone]
[email protected]
KARRATHA
26 Midas Road
Malaga WA 6090
[phone]
[email protected]
MACKAY
1 Progress Street
Paget, QLD 4740
PO Box 5755
Mackay Mail Centre QLD 4741
[phone]
[email protected]
MAITLAND
Unit 2 Barton Court
6 Johnson Street
Maitland NSW 2320
[phone]
[email protected]
PERTH
26 Midas Road
Malaga WA 6090
[phone]
[email protected]
TOWNSVILLE
Unit 4 / 585 Ingham Rd
Mt St John
Townsville QLD 4818
[phone]
[email protected]
SOUTH AUSTRALIA
38 Montpelier Terrace
Port Elliot SA 5212
0408 948 175
[email protected]
VICTORIA
Unit 4 / 238 Governor Road
Braeside VIC 3195
[phone]
[email protected]
WOLLONGONG
Unit 1 / 20 Doyle Avenue
PO Box 343
Unanderra NSW 2526
[phone]
[email protected]
TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA
VSS TOLL FREE 1800 300 877

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WARRANTY NOTE
ESS WARRANTS the Upper & Lower Belt Tracker 600-1350 Belt Widths to be free of
defects both in materials and workmanship for a period of 12 months from the date of
despatch of the product from the ESS factory. The warranty given by ESS in this regard
will extend only to replacing or repairing product shown to be defective.
The warranty also is subject to the following restrictions:
(a) Installation of the product contrary to the instructions contained in the supplied
manual will void such warranty absolutely;
(b) The warranty will not extend to any liability for injuries incurred and which result from
the use of the product contrary to the instructions in the manual;
(c) Save as prescribed by law, ESS will not be liable for any damage sustained by a
purchaser or a third party by way of consequential loss arising out of defects in the
product.
You are asked to note that ESS offers purchasers a service whereby either:
(a) It will install the product and certify the correctness of such installation, or
(b) Certify the correctness or otherwise of the installation of the product by third parties.
This certification service is designed to ensure that you obtain the full benefit of the ESS
warranty hereby provided. If you would like to take advantage of the installation
certification service provided, please contact ESS regarding the service.
Refer to the Final Checklist at the back of this manual.
Visit the ESS website www.esseng.com.au to register your product warranty.
THE CONTENTS OF THIS MANUAL ARE COPYRIGHT TO:
ESS ENGINEERING SERVICES AND SUPPLIES PTY LTD
ALL RIGHTS RESERVED
Information contained herein is for use in the operation of the Upper & Lower Belt
Tracker 600-1350 Belt Widths, purchased from ESS and cannot be passed on to any
other party without express permission, in writing, from ESS.

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INDEX
SECTION 1
SAFETY
SECTION 2
INTRODUCTION
SECTION 3
PREPARATION FOR INSTALLATION
SECTION 4
INSTALLATION
SECTION 5
COMMISSIONING
SECTION 6
OPERATOR TRAINING
SECTION 7
ROUTINE MAINTENANCE AND SERVICE
SECTION 8
TROUBLE SHOOTING
SECTION 9
INSTALLATION ARRANGEMENT DRAWING
SECTION 10
EXPLODED PARTS DRAWING
SECTION 11
FINAL CHECKLIST

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SECTION 1 - SAFETY
The Belt TRACKER is designed to be quickly and easily serviced by appropriate personnel.
Under no circumstances should servicing or installation of the Belt tracker be carried out whilst the
belt is in operation.
The conveyor must be shut down and locked out before any person enters or reaches into the
conveyor enclosure.
Ensure that only suitably qualified and trained personel install and service this product. Ensure that
all site and statutory safety procedures are followed.

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SECTION 2 –INTRODUCTION
The BELT TRACKER Belt Tracking Systems automatically sense and continuously correct belt
tracking. A light touch of the belt against the guide rollers creates precision correction. The
patented tie rod aligner translates the action of the guide roller pivot assembly to the training idler.
The upper guide unit is used on the carry side of the belt, the lower guide unit is used on the
return side.
A steering roller must be supplied by the client. Typically the roller removed from the system will
suffice. For greater efficiency of the BELT TRACKER, ESS recommends the steering roller be
coated with a rubber lagging.
ALTERNATE TRACKING SYSTEMS
For conveying systems that reverse or have substantial roll back the SMART BELT TRACKER is
available.
The HEAVY DUTY BELT TRACKER is available for belt widths from 1500-2000.

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SECTION 3 - PREPARATION FOR INSTALLATION
1. CHECK INSTALLATION DRAWINGS –Ensure that you have the correct drawings and
equipment for your conveyor/s.
2. PRE-ASSEMBLE THE BELT TRACKERS AND MOUNTS –Do this in your workshop or
similar area, rather than at the conveyor. This will enable you to:
(a) Verify all required equipment is present.
(b) Familiarise yourself with the Belt Tracker assembly.
(c) Allow you to plan the installation, reducing installation time.
3. ASSEMBLE THE FOLLOWING TOOLS;
- Wrenches (for M16, M10, M12 Bolts)
- Adjustable Wrenches (300mm) x 2
- Metric/ Imperial Allen Keys
- Measuring Tape and Steel Rule
- Electric Drill & Grinder (if allowable)
- Welding and Cutting Equipment
- G-Cramps
- Square, Level, Straight Edge
- Chalk or Marker
- Lead Lights, Flash Light
- Safety Equipment
- Scaffolding as required

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SECTION 4 –INSTALLATION
Lower Belt Tracker Locate the lower guide unit approximately three times the belt width
before the point where the belt adjustment is needed or before any major pulley. If installing
multiple units, allow 21 to 50m between units depending on the severity of mistracking.
Upper Belt Tracker Locate the upper guide unit beyond the loading point or three times
the belt width before the point where the belt adjustment is needed. If installing multiple units,
allow 21 to 50m between units depending on the severity of mistracking.
Remove existing troughing idler. Set aside for later use.
Step 1.
Refer to the installation drawing F0154 (lower) or F0155 (upper) attached.
Mark out the four hole patterns at 300mm centres on the stringers as shown.
Check before drilling the hole patterns are perpendicular to each other from the left to right
stringers.
If measuring from the tail pulley, first ensure the tail pulley is square with the stringers.
Step 2.
Refer to the exploded parts drawing F0158 (lower) or F0159 (upper) attached.
Install the rear cross section. Mounts should be fastened after the rear cross section is in place.
Step 3.
Fit the cross section/pivot plate into position using the M12 x 210 lg. bolt & nyloc nut.
Tighten the nut & check that the cross section pivots freely.
Step 4.
Adjust both the rear cross section and cross section/pivot plate.
Ensuring that they are both centralised and the cross section/pivot plate is adjusted correctly for
the Idler (client supply), tighten the adjustment screws.
Step 5.
Adjust the rear cross section to engage the training idler to the belt. The idler should be elevated
20-25mm from the standard return idler alignment as shown on the installation drawing.
Step 6.
Install the front cross section.
Mounts should be fastened after the front cross section is in place. Adjust the front cross section,
ensuring the torque arm pivot point is aligned centrally with the cross section/pivot plate pivot
point.
Fit the torque arm using the M12 x 175 lg. bolt & nyloc nut. Tighten the nut and ensure the torque
arm pivots freely.
Step 7.
Fit the guide frame (without guide arms) to the torque arm using the M12 x 135 lg. bolt & nyloc
nut. Tighten the nut and ensure the guide frame pivots freely.
Step 8.
Fit the parallel stay to the guide frame and front cross section using an M12 nyloc nut.
Adjust the parallel stay if required to ensure the guide frame is parallel with the front cross section
and perpendicular with the torque arm when the unit is centralised.

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Step 9.
Rotate the torque arm so the centre pivot of the guide frame is in line with the centre of the belt.
Fit the guide roller arms (including guide rollers) allowing 3-6mm gap between the belt and the
guide rollers. Ensure the guide arms are extended an equal distance from the guide frame and
tighten adjustment screws.
Step 10.
Adjust the guide arms on the upper belt tracker to the belt trough angle.
Adjust the front cross section to allow the belt to contact as close to the middle of the guide roller
as possible. Note that the torque arm must have clearance from the cross section/pivot plate.
Step 11.
Finally the grease nipples on the torque arm, front and rear cross sections should be lubricated
adequately.
Note: Regrease nipples at regular service intervals.

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SECTION 5 - COMMISSIONING
Step 1.
Manually move the guide rollers from side to side to check the system function.
Ensure all bolts have been tightened adequately.
Step 2. Is the belt empty?
Make sure there are no tools left on the belt
They may clog up conveyor systems.
Step 3. Start the conveyor.
Follow the established safety rules.
Step 4. Observe the action of the Belt Tracker.
Check the Belt Tracker action to ensure it is functioning correctly. Allow at least 10 revolutions of
the belt.
If adjustment is required, turn off and lock out/tag out the energy source to the conveyor and
conveyor accessories.
Check and tighten all fasteners after running the belt.
Step 5. Demonstrate the system to the Operating Supervisors and Crew.
Call the Supervisors responsible for the maintenance and operation to the site. Make a
short run of the system. Show the operator how to adjust the system.
Step 6. Secure the system for production.
Follow plant procedure to secure the conveyor for production.

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SECTION 6 - OPERATOR TRAINING
The last step is the correct training of personnel to maintain and service the equipment or employ
ESS on a contract basis to service and maintain ESS equipment keeping it in its optimum working
condition.
If using your own personell to maintain the equipment, train them as follows;
1. Adhere to all local safety rules.
2. Give a “hands on” instruction with your conveyor system shut down.
3. Give a “hands on” instruction with your conveyor system running.
4. All services must be recorded and given to a person of responsibility.
5. Encourage the person being trained to look out for possible problems developing on the
system.
eg. Belt tracking excessively, tears or damage to the belt, excessive carry back, seized idlers,
missing bolts etc. A warning to the Maintenance Department to rectify small problems
can save the company a lot of money in repairs and production costs.
6. Impress how important it is to maintain and service ESS equipment correctly.

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SECTION 7 - ROUTINE MAINTENANCE AND SERVICE
Regular inspections and servicing is the key to an efficient conveyor system. It is recommended
that the Belt tracker be inspected once per week. Actual intervals will vary considerably from plant
to plant.
Inspection
Inspect the condition of the Belt Tracker. Check the pivot points and guide rollers for free
movement.
If maintenance is required
Step 1 Shut down and lock out the conveyor.
Step 2 Grease the service nipples on the torque arm and the front and rear cross frames.
If required replace guide rollers.
Step 3 Remove locks or tags and restart belt. Observe Belt Tracker action. Clean up work
area.

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SECTION 8 –TROUBLE SHOOTING
PROBLEM –Mounts don’t fit in desired location
CAUSE
SOLUTION
Belt is too far below the stringers
Use alternative mounts available from ESS
Belt returns between the stringers
The belt will need to be deflected into position
along the length the Belt tracker will be
mounted.
PROBLEM –Groove worn into the guide roller
CAUSE
SOLUTION
Guide roller bearing may be seizing
Replace guide rollers
Torque arm, Front or Reat pivot
points may be seizing
Check pivot points and replace bushing and
grease if required
PROBLEM –Belt is not Tracking correctly
CAUSE
SOLUTION
Belt Tracker may not be adjusted
correctly
Adjust Belt tracker as mentioned in Installation
There may be multiple points of
misalignment in the structure
Multiple Belt Trackers may be required

Revision C 14 10/02/2010
SECTION 9 –INSTALLATION DRAWINGS

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SECTION 10 –EXPLODED PARTS DRAWINGS

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SECTION 11 FINAL CHECKLIST
Site: ____________________________ Number: _____________________ Date: ___________________
Site Equipment No./Location: __________________________ Site Contact: __________________________
Completed By: ______________________________________
(
(C Ci ir rc cl le e Y Ye es s o or r N No o B Be el lo ow w) )
1. Was equipment to ESS Specification? _______________________________Yes/No
Drawing No. Ref: ________________________________________ Attached? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
Will this affect performance? Yes/No
If Yes, WHY _______________________________________________________________________________
_________________________________________________________________________________________
2. Was this a standard service inspection installation? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
3. Was work carried out as per procedure and JSA? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
4. Is equipment fit for commissioning? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
5. Was a final inspection carried out while plant was running? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
6. Has anything changed from previous service / inspection / installation? Yes/No
If Yes, WHAT______________________________________________________________________________
_________________________________________________________________________________________
7. Is equipment performance to Client expectations? Yes/No
If No, WHY________________________________________________________________________________
_________________________________________________________________________________________
ESS Signature: _____________________________ Client Signature:_____________________________