ESS IPS Belt Cleaner User manual

IPS Belt Cleaner 1 19/11/2021
IPS Belt Cleaner
Installation and Operation 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].au
GLADSTONE
Unit 2/34 Chapple Street
PO Box 1475
Gladstone QLD 4680
[phone]
[email protected].au
KALGOORLIE
Unit 1/ 182 Boulder Rd
Kalgoorlie WA 6430
PO Box 10471
Kalgoorlie WA 6433
[phone]
[email protected]
KARRATHA
26 Midas Road
Malaga WA 6090
[phone]
[email protected].au
MACKAY
1 Progress Street
Paget, QLD 4740
PO Box 5755
Mackay Mail Centre QLD 4741
[phone]
[e-mail]
MAITLAND
Unit 2 Barton Court
6 Johnson Street
Maitland NSW 2320
[phone]
[email protected].au
PERTH
26 Midas Road
Malaga WA 6090
[phone]
[email protected].au
TOWNSVILLE
Unit 4/ 585 Ingham Rd
Mt St John
Townsville QLD 4818
[phone]
[e-mail]
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 IPS Cleaner to be free of defects in both 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 IPS Cleaner, 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
OPERATION OF THE SPRING TENSIONER
SECTION 6
OPERATION OF THE AIR TENSIONER
SECTION 7
RETROFITTING EXISTING CLEANERS
SECTION 8
COMMISSIONING
SECTION 9
ROUTINE MAINTENANCE AND SERVICE
SECTION 10
TROUBLE SHOOTING
SECTION 11
SECTION 12
INSTALLATION DRAWINGS
EXPLODED PARTS DRAWINGS
SECTION 13
FINAL CHECKLIST

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SECTION 1 –SAFETY
The conveyor belt drive and any associated equipment must
be shut down and locked out according to plant safety
procedures before attempting work requiring access to or
opening of the chute or conveyor enclosure. Contact with a
moving conveyor belt and its drive components can result in serious injury or death.
All equipment installed on or around a conveyor belt, including access doors and cut-
outs, must comply with AS 4024.3610:2015 Conveyors –General Requirements.
Ensure that only suitably qualified and trained personnel install and service this
product, and that all site and statutory safety procedures are followed.
The IPS Belt Cleaner is designed to be quickly and easily serviced from outside of the
conveyor enclosure. When correctly installed, there should be no reason to reach into the
chute or enclosure to inspect, adjust or change blades on the cleaner. Where site rules permit,
the cleaner can be safely serviced with the conveyor operating.
Where site rules do not permit servicing on an operating conveyor, ensure that the conveyor
is shut down and locked out before carrying out any service work. The conveyor must be shut
down and locked out during installation of this cleaner.
The following hazards may be present when installing this equipment:
Hazard
Hazard
X
Moving Conveyor - ISOLATE
Other:
Hot Work
Other:
Working at Heights
Other:
Heavy Lift
Other:
Persons Working Overhead
Other:
Persons Working Below
Other:
Electrical & Cabling
Other:
X
Pinch Points
Other:
Trip Hazards
Confined Space Entry
Once hazards have been identified, the installer should undertake and document a
comprehensive Job Hazard Analysis according to site requirements and good safe-working
practice.
The installer must identify all hazards and apply appropriate controls before proceeding with
the installation or servicing of this equipment.

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SECTION 2 - INTRODUCTION
The IPS Belt Cleaner is a conveyor belt secondary cleaner, and is usually used in conjunction
with a head pulley primary cleaner such as the ESS XHD, DT or TM DOCTOR BLADE
Primary Cleaners.
The IPS is normally mounted such that the cleaning blades contact the belt as it leaves the
head pulley or other accessible position on the return belt. The blades of the IPS, when
tensioned, lay in the direction of belt travel, contacting at a negative angle and presenting no
snag or danger to the belt or splices. (See figure 1.)
Figure 1
The IPS is an upgraded version of the ESS InLine 20-Ten Premium Cleaner & the original
ESS InLine cleaner, which set the standard for cleaning performance combined with safety
and ease of servicing.
Features of the IPS that the user should be aware of include:
Improved slide design and materials to resist wear and prevent jamming under heavy
loading.
Full stainless steel construction.
Tensioner support landing reduced in size to eliminate material accumulation on
mount bracket.
Redesigned Spring Tensioner unit, fully modular and interchangeable with Air
Tensioner.
Improved action and more consistent tensioning from the Spring Tensioner unit.
Air and Spring Tensioned models have identical installation dimensions.
Installation dimensions identical to ESS InLine 20-Ten Premium Cleaner.

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The ESS IPS Cleaner can be supplied or retrofitted with a variety of cleaning blades. These
include:
ABR Tool Steel blades –General purpose blade, suitable for mechanically spliced
belts.
Tungsten Carbide Blades –For very abrasive materials and high speed belts. Also
available in Clip Type for mechanically spliced belts.
Urethane Blades –For damaged belts and special applications.
Reversing Blades –All above options in reversing form for belts that drive in both
directions.
Note: When mounted slightly away from the head pulley or pressure roller, the standard In-
Line blade will handle small amounts of belt reversal or roll-back with no adverse effects.
When fitted with Reversing Blades, the In-Line becomes a fully operational reversing belt
cleaner.

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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 Cleaner(s) 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 cleaner assembly
allow you to plan the installation, reducing installation time.
3. Assemble the Necessary Tools & Safety Equipment Required for the
Installation.
4. Observe the Conveyor While Running and Conveying Material
Observe the belt splice condition
Does the belt run true, or track off to one side?
Is the Head Pulley out-of-round?
Consult ESS if any UNUSUAL conditions are observed in the above. These conditions may
result in recommendation of a different installation position or even a different cleaner.

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SECTION 4 - INSTALLATION
Conveyor must be shut down and locked out before installation is
performed. Contact with a moving conveyor can result in injury or death.
Follow all welding and safety guidelines including Hot Work, Confined
Space, Working at Heights or any other applicable safety procedures.
NOTE 1. For original equipment installation, where cleaner cut-outs and brackets have
been fabricated into the chute during construction, ignore steps 1, 2 and 3.
NOTE 2. Solid backing of the blades is essential to ensure proper operation and efficient
cleaning. Install the cleaner adjacent to the head pulley or a flat pressure roller
to obtain best cleaning results –see figure 2.
NOTE 3. For installation on enclosed head pulley chutework, draw all dimension lines on
chute wall. In applications where head pulley is not enclosed, use the best
available field resources and/or methods to ensure that these critical dimensions
are followed for a proper installation.
Step 1. Locating Cleaner Centreline
On the return side of the belt locate the tangent point at which the belt leaves
the head pulley. Measure a distance 100 mm and scribe a line perpendicular to
the belt at this point. (See figure 2a)
Note: For installation below pressure rollers mark the vertical line 100 mm from
the centreline of the roller. (See figure 2b).
This line represents the centre line of the In-Line Cleaner and the cleaner mount
brackets.
Figure 2a –Installation on horizontal belts

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Figure 2b –Installation on angled belts
Step 2 Mark-Out Chute Cut-outs
Using the previously marked line as the centre line, mark the chute cut-out and bolt
hole locations as shown in figure 3 below. Repeat on both sides of chute, ensuring
that the cut-outs are accurately aligned with each other.
Note: If replacing a 20-Ten series cleaner with the IPS cleaner, mount hole and cut-
out configuration is exactly the same.
Figure 3 –Chute Cut-out for all Models
Verify Cleaner Position before Proceeding
If not already done, disassemble the cleaner mount / tensioner assemblies from the
cleaner mainframe. To do this, simply remove the retaining pin in the operator side
mount, and slide the blade cartridge from the mainframe. Then remove the retaining
pin in the far side mount to remove the mainframe.

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Position the mount / tensioner assembly over the marked hole centres, ensuring that
the hole centres are located approximately in the middle of the slots in the mount
bracket. Verify that the mounts fit, and that adequate room is available to tension the
cleaner.
Once mounting position is confirmed, proceed.
Step 3. At the selected mounting positions, cut the cleaner access slots, and drill the
mount holes in each side of the chute. Dress and de-burr the holes and cut-
outs. Repair the paintwork to prevent corrosion.
Step 4. Fit the Operator Side mount bracket to the chute wall. Position the mount so that
the drilled holes in the chute wall are approximately centred in the slots of the
mount. Bolt the mount to the chute wall using 4 x M12 bolts.
Repeat for the Far Side mount bracket.
Step 5. Fit the cleaner Mainframe to the mounts.
Note: The mainframe has a mechanical stop at one end (bolt and nyloc nut).
This is the end that fits to the far side mount. Orientate so mechanical stop is
on the underside of the mainframe.
Fix the mainframe using a securing pin and the mainframe saddle to the far
side mount. Select an appropriate hole where the mainframe sits on the
operator side mount.
Step 6. Slide the Blade Cartridge onto the mainframe from the Operator Side. If not
already done, fit the cleaning blades to the cartridge. If using metal cleaning
blades (ABR or Tungsten Carbide), a Urethane End Blade must be installed at
each end of the blade set. End Blades support the belt and prevent scoring of
the belt by the outer edge of the metal blade.
Step 7. Secure cartridge and mainframe on operator side using a retaining pin in
operator side mount, secure mainframe spacer on far side mount with
fasteners
Note: The mainframe in most cases will have excess length. If required, this
excess can be trimmed from the Far Side end.
Step 8. Centre the blades to the belt by loosening and re-positioning the blade locks.
Fit the blade cartridge retaining pin.
Note: If the cartridge is too long and cannot be installed without hitting the
opposite end structure, contact ESS for instruction.

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Step 9. With the cleaner tensioner in the fully retracted position, the cleaning blades
should be approximately 15-20mm clear of the underside of the belt for Air
Tensioned models and 5-10mm clear for Spring Tensioned models. This
distance should be equal across the width of the belt.
If necessary loosen the bolts and adjust the mounts up or down in the slots to
achieve this clearance. Once all clearances are correct, thoroughly check all
mounting and locking screws to ensure they are tight, and the cleaner is
secured.
Step 10.For the Air Tensioned model only, connect the air tube to the fittings in the Far
Side airbag, on the underside of the mount bracket. See figure 6, section 6.
Pass the tube through the mainframe to the Operator End. Connect the tube to
the Tee air fitting in the Operator Side airbag, adjusting the tube length to suit
by cutting.
Connect the other side of the Tee fitting to the incoming regulated compressed
air supply from the ESS Air Tensioner Control Box. Connect the plant air
supply to the inlet side of the Control Box. Refer to the installation manual for
the ESS Control Box for further set-up instructions.
Installation is now complete, and the cleaner is ready to be adjusted
against the belt.

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SECTION 5 - OPERATION OF THE SPRING TENSIONER
Figure 4 –Mount and Spring Tensioner Arrangement
5.1 Description
The Spring Tensioner on the IPS differs from previous models in the following areas:
The tensioner is not rigidly attached to the slide bracket. The adjusting screw simply
pushes against the base of the spring jacking plate
Spring height indicator removed
Two slide rods are used to control the vertical movement of the slide bracket
The Spring Tensioner consists of a central threaded adjuster screw (jacking bolt), a spring
jacking plate, two compression springs, nut and locknut. The adjusting screw pushes against
the spring jacking plate to adjust the cleaner mainframe and blade assembly against the belt.
The end of the adjusting screw locates in a recess in the centre of the spring jacking plate.
The springs allow storage of force to take up blade wear, and to absorb belt irregularities or
impact from splices.
The amount of force required to be applied is dependent on the belt width, and is gauged by
the amount of spring compression. The reduction in spring length multiplied by the spring rate
will equal the force applied. Because the spring rate and free length are known, the easiest
measure is of the amount of spring compression after adjustment, and this is easily read by
using a ruler on either side of the slide bracket, measuring between the top face of the spring
jacking plate and the underside of the slide bracket.
InLine 20-Ten
Series Mount
InLine 20-Ten
Series Spring
Lock-nut
Adjusting Screw

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5.2 Adjustment Procedure
Loosen the locking nut situated under the mount bracket. Repeat for both sides.
Turn the adjusting screw (equally on both sides) until the cleaner blades are just touching
the belt. You might need to further release the locking nut during adjustment.
Ensure that the blade position is equal across the belt –that is, the blades are just
touching across the belt width.
Continue turning the adjusting screw equally on both sides until the spring compression
setting is measured to be equal to what is indicated in the table below. Measure the
spring compressed length using a rule or measuring tape.
Tighten the locking nuts against the mount bracket.
Start the conveyor and observe the cleaning action of the blades. Ensure that the blades
ride smoothly on the belt with no vibration.
ESS offers stronger springs for wider belts or heavy duty applications. These springs are
supplied with cleaners for belts 2600 or wider. The tensioner adjustment will differ when
these springs are used. Contact ESS Engineering Department for more information.
Table A. Recommended Spring Settings
Belt Width
Standard Springs
HD Springs
450
8.5 (51.5)
600
10 (50)
750
12 (48)
900
15 (45)
1050
16.5 (43.5)
1200
18.5 (41.5)
13 (47)
1350
21.5 (38.5)
15 (45)
1500
23 (37)
16.5 (43.5)
1600
24.5 (35.5)
17.5 (42.5)
1800
20 (40)
2000 and over
22.5 (37.5)
Note: Figures show spring compression indicator reading and (spring compressed
length).

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5.3 Maintenance Procedure
To access the blade cartridge for maintenance, first de-adjust the cleaner by reversing the
above procedure. Loosen the locking nuts, and turn the adjusting screws to release the blades
from the belt.
Alternate sides every 2 turns (or use an assistant) to ensure that the cleaner is backed off the
belt evenly.
When fully retracted, simply remove the retaining pin securing the blade cartridge to the
operator end of the mainframe. Grasp the handle and pull the blade cartridge off the
mainframe and away from the mount bracket. Completely remove the blade cartridge from
the mainframe, and place it in a suitable position for maintenance work to be carried out.
Refer to the Routine Maintenance Section 8.
Re-assembly is the reverse of the above procedure. Re-adjust the cleaner as described in
Section 5.2.

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SECTION 6 –OPERATION OF THE AIR TENSIONER
6.1 Description
Figure 5 –Air Tensioner and Mount Arrangement
The Air Tensioner utilises an inflatable air bag on each cleaner mount to provide the force to
adjust the blades against the belt. Cleaner adjustments and correct force are automatically
applied by controlling the air supply pressure. See figure 6 below.
Figure 6 –Air Supply Connections
InLine IPS
Mount
Air Bag
Air Supply
Fittings
ESS Control Box
(Range of Models Available)
Connection to
far Side Air Bag
Compressed Air
Supply
Air Line to
Cleaner
Tee Connection on
Operator side
Air Line Passes
Through Mainframe

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6.2 Adjustment Procedure
Adjusting the Air Tensioned In-Line cleaner is simply a matter of supplying air at the
appropriate pressure to the tensioner air bags. Refer to the table below for recommended air
pressures.
If using an ESS Air Tensioner Control Box, connect the plant air line to the lockable ball valve
on the outside of the enclosure, and check that all air connections are in place as per section
4, step 8 of this manual, figure 6 above and the ESS Control Box manual. Turn on the air
supply and open the lockable ball valve. Open the individual isolation valve for this cleaner in
the ESS Control Box to pressurise the tensioner. The cleaner will automatically raise, and the
blades will contact the belt.
Adjust the pressure to the required level via the regulator unit inside the Control Unit. The
regulator is self-relieving, so the pressure will stabilise, but it is advisable to wait a short while
after each adjustment to allow excess pressure to bleed.
Once the correct pressure has been achieved, lock the regulator adjustor, and replace the lid
on the enclosure.
Table B. Recommended Air Pressure
PRESSURES
BELT WIDTH
kPa
PSI
450
34
5
600
41
6
750
55
8
900
62
9
1050
76
11
1200
83
12
1350
97
14
1500
103
15
1600
110
16
1800
124
18
2000
138
20
2200
138
20
2400
138
20

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6.3 Maintenance Procedure
To access the blade cartridge for maintenance, first de-adjust the cleaner by shutting off the
air supply at the individual isolation valve for the cleaner in the Air Tensioner Control Box.
The cleaner will automatically retract from the belt. When fully retracted, close or re-fit the
Control Box lid. This will prevent re-pressurising of the Air tensioners during maintenance.
Next remove the retaining pin securing the blade cartridge to the operator end of the
mainframe. Grasp the handle and pull the blade cartridge off the mainframe and away from
the mount bracket. Completely remove the blade cartridge from the mainframe, and place it
in a suitable position for maintenance work to be carried out.
Refer to the Routine Maintenance Section 8.
Re-assembly is the reverse of the above procedure. Once the blade cartridge has been re-
fitted and secured, open the isolation valve in the Control Box to pressurise and automatically
adjust the cleaner to the belt. Check that the air pressure is to specification and adjust if
necessary.

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SECTION 7 –RETROFITTING EXISTING CLEANERS
7.1 20-Ten Mainframe to IPS Brackets
20Ten Mainframe
IPS Mandrel Mainframe
20Ten Tensioners
Superseded product
offering that will be
found on-site
existing 20Ten slide
brackets will require
machining
IPS Tensioners
Direct swap. Mainframe
retrofit kit required (P/N
09030079S)
New product offering
20-Ten style mainframes can be retrofitted to the New ESS Inline IPS Mount Brackets.
The optional ESS IPS Retrofit Kit can be utilised to install the mounts to an existing 20-Ten
mainframe. Utilizing this kit will allow the customer to have the newest IPS Brackets without
the expense of purchasing a complete new cleaner.
Figure 7 –IPS Retrofit Kit for existing 20Ten installations
7.2 IPS Mainframe to 20-Ten Brackets
The IPS Mainframe can be retrofitted to 20-Ten slide brackets using the ESS 20-TEN
SLIDE BRACKET –TO SUIT IPS KIT. Utilizing this kit will allow the customer to have the
easy sliding IPS Mainframe if new mounts are not required.

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SECTION 8 - COMMISSIONING
STEP 1 Ensure that the cleaners are correctly adjusted against the belt as described in
the previous sections.
STEP 2 Ensure that all foreign materials, tools and rubbish have been removed from the
belt and the immediate area.
STEP 3 Start the conveyor, following all appropriate safety start-up procedures.
STEP 4 Observe the action of the cleaner blades. Ensure that there is no vibration in
the blades or mainframe. Ensure that all blades are contacting the belt evenly.
Ensure that there is no marking of the belt surface from the cleaner blades.
Refer to the Trouble Shooting section or contact ESS if any problems are
observed.
STEP 5 If possible, observe the operation of the cleaner once the belt is loaded.
Observe the cleaning action of the blades. Is the belt clean after the cleaner? If
not, check the cleaner adjustment again, referring to the appropriate tensioner
section. If problems persist, contact ESS.
STEP 6 Shut down the conveyor. Correct any problems observed. Re-test if necessary.
The cleaner is now ready for production.