ESS Spraybar DN25 User manual

Spraybar DN25 Installation Manual 1 14/06/2021
Spraybar DN25
(450 - 2000 Belt Widths)
Installation Operations Manual

Spraybar DN25 Installation Manual 2 14/06/2021
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

Spraybar DN25 Installation Manual 3 14/06/2021
WARRANTY NOTE
ESS WARRANTS the Spraybar DN25 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 Spraybar DN25, purchased
from ESS and cannot be passed on to any other party without express permission, in
writing, from ESS.

Spraybar DN25 Installation Manual 4 14/06/2021
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
INSTALLATION ARRANGEMENT DRAWING
SECTION 9
SECTION 10
ESS BELT CLEANER QUICK REFERENCE
FINAL CHECKLIST

Spraybar DN25 Installation Manual 5 14/06/2021
SECTION 1 - SAFETY
The Spraybar 25nb is designed to be quickly and easily serviced by appropriate
personnel.
Under no circumstances should servicing or installation of the Spraybar 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.

Spraybar DN25 Installation Manual 6 14/06/2021
SECTION 2 - INTRODUCTION
The ESS Spraybar is primarily intended as a Conveyor Belt washing Spraybar to be used
in conjunction with a Conveyor Belt Cleaning system. It is normally positioned between the
Primary and Secondary Cleaners, on the lower face of the head pulley.
The ESS Spraybar is designed to remove sticky adhering material from the Conveyor Belt
surface by use of a high velocity, low volume, knife edge spray.
The ESS Spraybar has the added benefits of keeping both the Primary and Secondary
cleaners free of material build-up (when positioned appropriately), as well as assisting in
dust suppression.
The Spraybar is constructed from DN25 Stainless Steel Pipe, with Wash Jet Spray
Nozzles positioned along the centreline of the pipe.

Spraybar DN25 Installation Manual 7 14/06/2021
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 SPRAYBAR AND MOUNTS -Do this in your
workshop or similar free area, rather than at the Conveyor. This will enable you to:
verify all required equipment is present
familiarise yourself with the Spraybar assembly
plan the installation, reducing installation time.
3. ASSEMBLE THE NECESSARY TOOLS & SAFETY EQUIPMENT
REQUIRED FOR THE INSTALLATION

Spraybar DN25 Installation Manual 8 14/06/2021
SECTION 4 - INSTALLATION
DANGER! Conveyor must be shut down and locked out before any
installation or service work is performed.
WARNING! If installation is to be done in an enclosed area, test atmosphere
for gas level or dust content. Follow all welding and safety
guidelines.
NOTE 1 For original equipment installation, where cleaner cutouts and
brackets have been fabricated into the chute during construction,
ignore steps 1 and 2 .
NOTE 2 For installation on enclosed head pulley chutework, draw all
dimension lines on chute wall. In applications where head pulley
is not enclosed, custom designed brackets are necessary to
ensure correct cleaner position.

Spraybar DN25 Installation Manual 9 14/06/2021
Step 1. Locating the Spraybar Centreline
Using the typical installation drawing supplied in this manual, locate the mainframe’s
centreline on both sides of the conveyor. Select the desired impact point for the spray and
measure radially 325mm in the direction of belt flow. The centreline of the Spraybar
cutout is 165mm perpendicular to the belt and 280mm parallel to the belt giving an impact
angle of approximately 30°. If Impacting on the Head Pulley then these measurements
are perpendicular to the tangent of impact (See Fig 1.)
Fig 1.
Verify Mainframe Position before Proceeding
Position the mount assembly over the centreline marks for the Spraybar. Verify that the
mounts fit, If mounts interfere with structural members, it may be necessary to locate the
Spraybar elsewhere along the belt. Once mounting position is confirmed, proceed.
Step 2. At the selected Spraybar mounting position, mark out and cut the Spraybar
and mount fastener holes in each side of the chute. Refer to the installation
drawing at the back of this manual.

Spraybar DN25 Installation Manual 10 14/06/2021
Step 3 Insert the Spraybar through the cutouts making sure that the water inlet is on
the correct side.
Step 4 Place the mounts over each end and bolt to structure. Set the Spraybar in
approximate correct position and lightly tighten up lock screws.
Step 5 If supplied, position the Filter Kit (Fig 2.) in an appropriate position
(remember that the flexible hose is 2m long), and secure using appropriate
fasteners. The figure below shows an ESS Type 2 Filter Kit. If another type
of Filter Assembly is used, ensure that the assembly is mounted correctly in
an appropriate position adjacent to the Spraybar. ESS has a range of Filter
Kits, including the Type 3, which has pressure control, gauge, filter by-pass
and solenoid valve.
Step 6 Connect the site water supply to the inlet side of the Filter Assembly. If no
solenoid valve is present, ensure that the isolating valve is closed until final
connection is completed. If a solenoid valve is included, connect the solenoid
valve so that the valve is opened when the conveyor belt is running, and if
possible, when material is present on the belt.
Step 7 Connect the flexible hose from the Filter Assembly to the Spraybar. The
Spraybar is now ready for commissioning and operation.
Fig 2.

Spraybar DN25 Installation Manual 11 14/06/2021
SECTION 5 - COMMISSIONING
Step 1. TURN WATER SUPPLY ON
Double check the items in previous sections - safety - preparation -
installation.
Step 2. TURN ON SUPPLY TO THE SPRAYBAR
If a solenoid valve is used, have electrical personnel override the controls to
open the valve for testing and commissioning, with the conveyor locked out.
Check all joints for leaks. (If there are any leaks, isolate the water supply,
dismantle the appropriate joint and reseal with appropriate thread sealing
tapeor compound).
Step 3. CHECK SPRAY IMPACT POINT
If the spray impact point is not at the intended position, loosen off the lock
screws and rotate the Spraybar as required.
Once correct spray impact point is achieved, tighten the lock screws.
Check the water spray pattern adjacent patterns are overlapping. If adjacent
spray patterns are colliding, use a spanner to rotate the nozzles slightly to
prevent, until the patterns just clear.
Step 4. START THE CONVEYOR
Follow the established safety rules.
Step 5. OBSERVE THE CLEANING ACTION
If installed as part of a total cleaning system with ESS Primary and
Secondary cleaners then observe the cleaning action of the entire system.
Place some product on the belt and look to see that all cleaners are
operating properly.
Step 6. DEMONSTRATE THE SYSTEM TO THE OPERATING SUPERVISORS
AND CREW
Call the supervisors responsible for maintenance and operation of the site.
Make a short run of the system, putting material on the belt. Show the
operator how to adjust and operate the system.
Step 7. SECURE THE SYSTEM FOR PRODUCTION
Follow plant procedure to secure the conveyor for actual production.

Spraybar DN25 Installation Manual 12 14/06/2021
SECTION 6 - OPERATOR TRAINING
The decision to purchase ESS cleaning equipment has put within easy reach the reality of
a clean plant. The last step is the correct training of personnel to maintain and service the
equipment or employ ESS on a contract basis to maintain the cleaners so that they
remain at optimum efficiency.
The benefits of efficient cleaners outweigh the cost of maintaining the cleaners many
times.
If you wish to have your cleaning system maintained on a regular contract basis, contact
ESS. If not, train your own personnel as follows:
1. Adhere to all local safety rules.
2. Give a “Hands On” instruction with the conveyor system shut down.
3. Give a “Hands On” instruction with the conveyor system running.
4. All service must be recorded and given to a person of responsibility.
5. Encourage the person being trained to look for possible problems developing on
the system, eg. belt tracking excessively, tears or damage to belt, 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 the cleaners correctly.

Spraybar DN25 Installation Manual 13 14/06/2021
SECTION 7 - ROUTINE MAINTENANCE AND SERVICE
Regular inspection and servicing is the key to effective conveyor belt cleaning. It is
recommended that the Spraybar be inspected once per week. Actual service intervals will
vary considerably from plant to plant.
CAUTION! DO NOT REACH INSIDE THE CONVEYOR CHUTE UNDER ANY
CIRCUMSTANCES WHILST THE CONVEYOR IS RUNNING.
ROUTINE INSPECTION
Step 1. Inspect the condition of the Spraybar. Open the inspection door (if fitted) and
observe the condition and action of the cleaning system.
Step 2. If necessary (and if plant rules allow it), hose any material build-up from the
Spraybar - DO NOT REACH INTO THE CHUTE WHILST CONVEYOR IS
RUNNING.
Step 3. If necessary, rotate the Spraybar - refer to Section 5.
IF SPRAY PATTERN APPEARS WEAK OR INCOMPLETE
Step 1. Isolate the Spraybar water by closing isolating valve (‘C’ in Fig 2)
Step 2. Remove filter basket and visually inspect for any material buildup on filter.
By opening valve ‘D’ you can wash the filter basket clean.
Step 3. If pressure is still low then undo plug from far end of the Spraybar and flush the
Spraybar out.
Step 4. If pressure is still low then remove the entire Spraybar from the structure by
loosening lockscrews on mount then remove and clean the nozzles.

Spraybar DN25 Installation Manual 14 14/06/2021
SECTION 8 –INSTALLATION ARRANGEMENT DRAWING

Spraybar DN25 Installation Manual 15 14/06/2021
SECTION 9 –ESS BELT CLEANER QUICK REFERENCE

Spraybar DN25 Installation Manual 16 14/06/2021
SECTION 10 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: ____________________________