Flexco Ezp1t series User manual

EZP1T Precleaner

Installation, Operation

and Maintenance Manual

www.ﬂexco.com

EZP1T Precleaner

Serial Number: _____________________________________________________________

Purchase Date:______________________________________________________________

Purchased From: ____________________________________________________________

Installation Date: ____________________________________________________________

Serial number information can be found on the Serial Number Label included in the

Information Packet found in the cleaner carton.

This information will be helpful for any future inquiries or questions about belt cleaner

replacement parts, specifications or troubleshooting.

Table of Contents

Section 1 – Important Information .................................................................................................................. 4

1.1 General Introduction ..........................................................................................................................................4

1.2 User Beneﬁts ........................................................................................................................................................4

1.3 Service Option .....................................................................................................................................................4

Section 2 – Safety Considerations and Precautions ......................................................................................... 5

2.1 Stationary Conveyors..........................................................................................................................................5

2.2 Operating Conveyors ..........................................................................................................................................5

Section 3 – Pre-Installation Checks and Options............................................................................................. 6

3.1 Checklist ...............................................................................................................................................................7

3.2 Cleaner Location Adjustments ..........................................................................................................................7

Section 4 – Installation Instructions................................................................................................................. 8

Section 5 – Pre-Operation Checklist and Testing........................................................................................... 11

5.1 Pre-Op Checklist ...............................................................................................................................................11

5.2 Test Run the Conveyor .....................................................................................................................................11

Section 6 – Maintenance ................................................................................................................................. 12

6.1 New Installation Inspection .............................................................................................................................12

6.2 Routine Visual Inspection ................................................................................................................................12

6.3 Routine Physical Inspection.............................................................................................................................12

6.4 Blade Replacement Instructions......................................................................................................................13

6.5 Maintenance Log ...............................................................................................................................................15

6.6 Cleaner Maintenance Checklist.......................................................................................................................16

Section 7 – Troubleshooting ........................................................................................................................... 17

Section 8 – Specications and CAD Drawings............................................................................................... 18

8.1 EZP1T Precleaner CAD drawing- Belt Width -2".........................................................................................19

8.2 EZP1T Precleaner CAD drawing- Belt Width -8".........................................................................................20

Section 9 – Replacement Parts ........................................................................................................................ 21

Section 10 – Other Flexco Conveyor Products............................................................................................... 23

4EZP1T Precleaner

Section 1 – Important Information

1.1 General Introduction

We at Flexco are very pleased that you have selected an EZP1T Precleaner for your conveyor system.

is manual will help you to understand the operation of this product and assist you in making it work up to

its maximum eﬃciency over its lifetime of service.

It is essential for safe and eﬃcient operation that the information and guidelines presented be properly

understood and implemented. is manual will provide safety precautions, installation instructions,

maintenance procedures and troubleshooting tips.

If, however, you have any questions or problems that are not covered, please contact your ﬁeld representative

or our Customer Service Department:

Customer Service: 91-44-6551-7771

Visit www.exco.com for other Flexco locations and products.

Please read this manual thoroughly and pass it on to any others who will be directly responsible for

installation, operation and maintenance of this cleaner. While we have tried to make the installation and

service tasks as easy and simple as possible, it does however require correct installation and regular

inspections and adjustments to maintain top working condition.

1.2 User Benets

Correct installation and regular maintenance will provide the following beneﬁts for your operation:

• Reduced conveyor downtime

• Reduced man-hour labor

• Lower maintenance budget costs

• Increased service life for the belt cleaner and other conveyor components

1.3 Service Option

The EZP1T Precleaner is designed to be easily installed and serviced by your on-site personnel. However, if

you would prefer complete turn-key factory service, please contact your local Flexco Field Representative.

Section 2 – Safety Considerations and Precautions

Before installing and operating the EZP1T Precleaner, it is important to review and understand the following safety

information.

There are set-up, maintenance and operational activities involving both stationary and operating conveyors. Each

case has a safety protocol.

2.1 Stationary Conveyors

The following activities are performed on stationary conveyors:

• Installation • Blade replacement • Repairs

• Tension adjustments • Cleaning

DANGER

WARNING

It is imperative that OSHA/MSHA Lockout/Tagout

(LOTO) regulations,29 CFR 1910.147, be followed

before undertaking the preceding activities. Failure to

use LOTO exposes workers to uncontrolled behavior

of the belt cleaner caused by movement of the conveyor

belt. Severe injury or death can result.

Before working:

• Lockout/Tagout the conveyor power 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,springs 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 cleaners. Serious injuries

can be avoided.

2.2 Operating Conveyors

There are two routine tasks that must be performed while the conveyor is running:

• Inspection of the cleaning performance

• Dynamic troubleshooting

Every belt cleaner is an in-running nip hazard. Never

touch or prod an operating cleaner. Cleaner hazards

cause instantaneous amputation and entrapment.

Never adjust anything on an operating cleaner.

Unforseeable belt projections and tears can catch on

cleaners and cause violent movements of the cleaner

structure. Flailing hardware can cause serious injury

or death.

Belt cleaners can become projectile hazards.Stay as far

from the cleaner as practical and use safety eyewear and

headgear. Missiles can inflict serious injury.

6EZP1T Precleaner

3.1 Checklist

Section 3 – Pre-installation Checks and Options

• Check that the cleaner size is correct for the beltline width

• Check the belt cleaner carton and make sure all the parts are included

• Review the“Tools Needed” list on the top of the installation instructions

• Check the conveyor site:

· Will the cleaner be installed on a chute

· Is the install on an open head pulley requiring mounting structure

· Are there obstructions that may require cleaner location adjustments

(see 3.2 – Cleaner Location Adjustments)

In certain applications it is necessary to modify the location of the precleaner pole due to permanent obstacles that

obstruct the desired location. Relocating the pole location can be done easily and does not hinder the performance of

the cleaner as long as the“C”dimension is maintained.

NOTE: In the following example we will be lowering the pole location in the“Y”direction, but the same method

could also be applied in the“X”direction.

Conveyor situation:

Pulley Diameter: 12" (300 mm)

X = 6 1/8" (154 mm)

Y = 5 1/2" (138 mm)

C = 8 1/4" (206 mm)

1. Determine the given location dimensions and define the change needed. After laying out the given X &

Y dimensions,determine the distance of the modification required for adequate clearance of the pole and

tensioning system. (In the example we decide to lower the pole 2" (50mm) to clear the support structure).

2. Write down known dimensions. We can now determine two of the three required dimensions which will

allow us to find the third.We know we cannot alter the“C”dimension, so this will remain the same.Also we are

required to lower the unit in the“Y” dimension 2" (50mm), so we add 2" (50mm) to the given“Y” dimension.

X = ?"

Y = 5 1/2 + 2 = 7 1/2" (138 + 50 = 188 mm)

C = 8 1/4" (206 mm)

3. Determine final dimension. On a flat vertical surface,using a level, draw one horizontal line and one vertical line

creating a right triangle (Fig 3a). Measure down from the intersection the determined“Y” dimension and mark

(Fig 3b).With the tape measure starting at the modified“Y”mark,swing the tape across the“X”line and mark

at the“C”dimension where it crosses the“X” line (Fig 3c). Measure from the intersection to the“C” intersection

and this will be your new“X” dimension (Fig. 3d).

X = 3 1/2" (88 mm)

Y = 7 1/2" (188 mm)

C = 8 1/4" (206mm)

3.2 Cleaner Location Adjustments

Section 3 – Pre-installation Checks and Options

Fig. 3a Fig. 3c

Fig. 3b Fig. 3d

Y 7-1/2" (188mm)

mark

This distance is the new

“X” dimension

3 1/2"

(88mm)

C 8-1/4" (206mm))

12"

(300mm)

8EZP1T Precleaner

Section 4 – Installation Instructions

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Installation specs and instructions are based on

the assumption that the conveyor is in its working

position (angle). If the conveyor angle will be

different, the cleaner should be installed per the final

position. Call 91-44-6551-7771 if you need help on

determining the proper coordinates.

1. Locate the correct pole position. Measure and determine Dimension

A (see instructions above). Find Dimension A on the Pole Location

Chart at right and determine Dimensions X,Y and C. Measure out

horizontally from the center of the pulley shaft Dim X and mark. From

that mark, draw a long vertical line down,then measure and mark Dim

Y. This indicates the location of the center of the cleaner pole. Measure

and mark both sides. NOTE: If the location is obstructed,use Dim. C

and move on an arc from the center of the pulley shaft to find an open

position.Dim. C must remain constant to correctly locate the pole (see

drawing above). NOTE: For open head installs, first add mounting

support materials to the structure.

2. Mark and cut the mounting plate

holes. Using the mounting plate

template provided in the instruction

packet, position the large pole

access hole on the chute, aligning

the hole notches with the layout

lines. Position the keyway toward

the pulley. Trace the pole cutout and

mounting holes (Fig. 1). Cut the

holes on both sides of the chute.

NOTE: Hole cutouts are slotted for later adjustment if needed.

Mounting

Plate

Torsion

Mounting

Plate

Torsion

Spring

Pole

Conshear™

Blade

Torsion Cap

Blade Pin

EZP1T Parts List

Pole Lock

Collar

(hidden)

Fig. 1

Keyway toward

pulley

Aligning Notches

Tools Needed:

• 1/4" (6mm) allen wrench

• 15/16" (23mm) wrench

for standard tensioner

• 1 1/8" (29mm) wrench

for heavy duty tensioner

• 3/4" (19mm) wrench or

crescent wrench

• 1/2" (13) wrench or

crescent wrench

• cutting torch

• grinder

Pole Location Specs

A = Pulley Diameter + Lagging and Belt

C = Critical Spec to move location if necessary

Pole Location Chart

A X Y C

mm in. mm in. mm in. mm in.

250 10" 74 3" 230 9" 242 9 1/2"

275 11" 92 3 3/4" 230 9" 248 9 3/4"

300 12" 108 4 3/8" 230 9" 254 10"

325 13" 131 5 3/8" 230 9" 265 10 1/2"

350 14" 146 5 7/8" 230 9" 273 10 3/4"

375 15" 166 6 3/4" 230 9" 284 11 1/4"

400 16" 179 7 1/8" 230 9" 291 11 1/2"

425 17" 195 7 7/8" 230 9" 301 12"

450 18" 207 8 1/4" 230 9" 309 12 1/4"

475 19" 223 9" 230 9" 320 12 3/4"

500 20" 235 9 3/8" 230 9" 329 13"

525 21" 249 10" 230 9" 339 13 1/2"

550 22" 266 10 3/4" 230 9" 352 14"

575 23" 283 11 3/8" 230 9" 365 14 1/2"

600 24" 299 12" 230 9" 377 15"

625 25" 314 12 5/8" 230 9" 390 15 1/2"

650 26" 330 13 1/4" 230 9" 402 16"

675 27" 346 13 7/8" 230 9" 415 16 1/2"

700 28" 360 14 3/8" 230 9" 427 17"

725 29" 374 15" 230 9" 439 17 1/2"

775 30" 389 15 5/8" 230 9" 452 18"

775 31" 403 16 1/8" 230 9" 464 18 1/2"

825 32" 417 16 3/4" 230 9" 477 19"

825 33" 432 17 1/4" 230 9" 489 19 1/2"

850 34" 446 17 7/8" 230 9" 501 20"

875 35" 460 18 3/8" 230 9" 514 20 1/2"

900 36" 474 19" 230 9" 526 21"

Section 4 – Installation Instructions (cont.)

3. Install the mounting plates. Bolt flat mounting plate (with

keyhole) to the side opposite where the tensioner will be

mounted. Keyhole should face the pulley (Fig. 2). Install torsion

mounting plate (with circular weldment) to the tensioner side.

Center plates on the slotted holes and tighten bolts.

4. Install the pole. Remove both blade pins and blade from the

pole (Fig. 3a) and insert the pole in through the mounting

plates (starting with keyhole plate) (Fig. 3b).

5. Center pole to the belt (Fig. 4a). Mark pole 3/4" (75mm)

outside torsion mounting plate (Fig. 4b).Feed pole further

through torsion mounting plate so pole can be cut on the mark

(slide pole away from UHMW bearing at least 6" before cutting

to prevent melting.) After cut is made, grind end of pole clean

from rough edges (Fig. 4c).

6. Reinstall blade. Reinstall blade with both blade pins.Center

the blade on the belt. Rotate the blade up to the belt and check

to insure that the blade is square to the pulley face (Fig. 5a). If

not,loosen a mounting plate on one side and adjust the plate

forward or backward to square the blade to the pulley, and

retighten the bolts (Fig.5b).

7. Install the tensioner. Slide torsion spring assembly into cut

end of pole until fully engaged with the pole (Fig. 6a). Hold

blade against pulley and rotate indicator mark until it is vertical.

Tighten set screws with 1/4" (6mm) allen wrench (Fig.6b).

Fig. 2

Adjust plate forward or

backward in slots as needed

to square blade to pulley

Tighten set screws

with allen wrench

Fig. 3a

Keyhole

Mounting Plate

Torsion

Mounting Plate

Fig. 3b

Fig. 5a

Fig. 5b

Fig. 4a

Fig. 4b Fig. 4c

Mark pole 3/4" (75mm) from torsion

mounting plate; then slide pole

at least 6" (150mm) from UHMW

bearing before cutting

Grind end of pole to

remove rough edges

Center pole to belt

Fig. 6a

Fig. 6b

10 EZP1T Precleaner

Section 4 – Installation Instructions (cont.)

9. Set the blade tension. While

holding the blade to the belt,

place cap over spring. Use

wrench on center hex shaft to

apply tension to spring at desired

angle (see chart).While holding

tension with wrench,tighten the

two set screws (Fig. 8).

8. Lock pole with collar. Ensure pole is flush (no space) on tensioner side.

Install and tighten pole lock collar on non-tensioned side (Fig. 7).

10. Confirm correct pole location. After the cleaner is installed, slide the Pole Location Gauge (provided in the

instruction packet) between the cleaner pole and the pulley, until it stops at a step (Fig. 9a). Read the flat area

where the pole is resting (Fig. 9b.) This diameter should be equal to Dim A used in Step 1.

NOTE: If the diameter reading on the Pole Location Gauge does not read the same as in Step 1, check the“C”

dimension and correct accordingly.

Test run the cleaner and inspect the performance. If vibration occurs or more cleaning efficiency is desired,make

the necessary tensioning adjustments.

Fig. 7

Fig. 8

Pole Lock

Collar

Tighten Set

Screws

Torsion

Spring Cap

Fig. 7a Fig. 7b

HEAD PULLEY

POLE LOCATION

GAUGE

CLEANER

POLE

DIM “A” = 16"

Slide gauge between

pole and head pulley

Twist Tensioner Chart

Blade Width Standard Heavy Duty

in. mm in. mm in. mm

10" 250 8 8 6 6

16" 400 13 13 9 9

22" 550 18 18 12 12

28" 700 23 23 16 16

34" 850 27 27 19 19

40" 1000 32 32 23 23

46" 1150 37 37 26 26

52" 1300 N/A N/A 29 29

58" 1450 N/A N/A 33 33

64" 1600 N/A N/A 36 36

70” 1750 N/A N/A 40 40

Section 5 – Pre-Operation Checklist and Testing

5.1 Pre-Op Checklist

• Recheck that all fasteners are tightened properly

• Add pole caps

• Apply all supplied labels to the cleaner

• Check the blade location on the belt

• Be sure that all installation materials and tools have been removed from the belt and the conveyor area

5.2 Test Run the Conveyor

• Run the conveyor for at least 15 minutes and inspect the cleaning performance

• Check the tensioner spring for recommended length (proper tensioning)

• Make adjustments as necessary

NOTE: Observing the cleaner when it is running and performing properly will help to detect problems or

when adjustments are needed later.

12 EZP1T Precleaner

Section 6 – Maintenance

Flexco belt cleaners are designed to operate with minimum maintenance. However, to maintain superior performance

some service is required.When the cleaner is installed a regular maintenance program should be set up. This program

will ensure that the cleaner operates at optimal efficiency and problems can be identified and fixed before the cleaner

stops working.ww

All safety procedures for inspection of equipment (stationary or operating) must be observed.The EZP1T Precleaner

operates at the discharge end of the conveyor and is in direct contact with the moving belt. Only visual observations

can be made while the belt is running.Service tasks can be done only with the conveyor stopped and by observing the

correct lockout/tagout procedures.

6.1 New Installation Inspection

After the new cleaner has run for a few days a visual inspection should be made to ensure the cleaner is

performing properly. Make adjustments as needed.

6.2 Routine Visual Inspection (every 2-4 weeks)

A visual inspection of the cleaner and belt can determine:

• If the spring length is the correct length for optimal tensioning.

• If the belt looks clean or if there are areas that are dirty.

• If the blade is worn out and needs to be replaced.

• If there is damage to the blade or other cleaner components.

• If fugitive material is built up on the cleaner or in the transfer area.

• If there is cover damage to the belt.

• If there is vibration or bouncing of the cleaner on the belt.

• If a snub pulley is used, a check should be made for material buildup on the pulley.

If any of the above conditions exist, a determination should be made on when the conveyor can be stopped for

cleaner maintenance.

6.3 Routine Physical Inspection (every 6-8 weeks)

When the conveyor is not in operation and properly locked and tagged out a physical inspection of the cleaner

to perform the following tasks:

• Clean material buildup off of the cleaner blade and pole.

• Closely inspect the blade for wear and any damage.Replace if needed.

• Check both blade pins for proper installation and condition.Replace if needed.

• Ensure full blade to belt contact.

• Inspect the cleaner pole for damage.

• Inspect all fasteners for tightness and wear. Tighten or replace as needed.

• Replace any worn or damaged components.

• Check the tension of the cleaner blade to the belt.Adjust the tension if necessary using the chart on the

cleaner or the one on page 10.

• When maintenance tasks are completed, test run the conveyor to ensure the cleaner is performing properly.

Tools Needed:

• 15/16" (23mm) wrench for standard

tensioner

• 1 1/8" (29mm) wrench for heavy duty

tensioner

• 3/4" (19mm) wrench or crescent wrench

• 1/2" (13mm) wrench or crescent wrench

• Wire brush (for cleaning pole)

• Small putty knife (for cleaning pole)

Section 6 – Maintenance (cont.)

6.4 Blade Replacement Instructions

EZP1T Precleaner ConShear™ Replacement Blade

Blade Pin

1. Remove the tension. WARNING: Apply torque to center hex shaft

prior to release of set screws (Fig. 1). Failure to do so will result in

immediate tension release and can damage the mechanism.

2. Remove the worn blade. Remove one blade pin and remove the blade

from the pole (Fig.2). Clean all fugitive material from the pole.

NOTE: If blade is hard to remove use a screwdriver or hammer to

loosen it and then remove.

Fig. 2

Blade Pin

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Fig. 1

B. Loosen

Set Screws

A. Apply Torque to

center hex shaft

14 EZP1T Precleaner

6.4 Blade Replacement Instructions

Section 6 – Maintenance (cont.)

3. Install the new blade. Slide the new blade onto the pole, locking

it into the far blade pin,then reinstall the removed blade pin,

washer and clip (Fig.3).

Test run the cleaner. Run the conveyor for at least 15 minutes and

inspect the cleaning performance.Make adjustments as necessary.

Fig. 3

Slide blade

into far side

blade pin

Seat other end

of blade on

pole plate and

reinstall pin

4. Reset the correct blade tension. While holding the blade to the

belt, use wrench on center hex shaft to apply tension to spring

at desired angle (see chart).While holding tension with wrench,

tighten the two set screws (Fig. 4).

Fig. 4 Tighten Set

Screws

Twist Tensioner Chart

Blade Width Standard Heavy Duty

in. mm in. mm in. mm

10" 250 8 8 6 6

16" 400 13 13 9 9

22" 550 18 18 12 12

28" 700 23 23 16 16

34" 850 27 27 19 19

40" 1000 32 32 23 23

46" 1150 37 37 26 26

52" 1300 N/A N/A 29 29

58" 1450 N/A N/A 33 33

64" 1600 N/A N/A 36 36

70” 1750 N/A N/A 40 40