Flexco Y-type User manual

Y-Type™Heavy-Duty

Secondary Belt Cleaner

Installation, Operation

and Maintenance Manual

www.ﬂexco.com

Y-Type™with Purple

Polyurethane Blade

Y-Type™with White (Food

Grade) Polyurethane Blade

Y-Type™with Tungsten

Carbide Blade

2Y-Type™Standard-Duty Secondary Belt Cleaner

Y-Type™Secondary Belt Cleaner

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 ........................................................................................................................2

1.1 General Introduction ................................................................................................................................................ 2

1.2 User Beneﬁts .............................................................................................................................................................. 2

1.3 Service Option ........................................................................................................................................................... 2

Section 2 – Safety Considerations and Precautions ...............................................................................................3

2.1 Stationary Conveyors................................................................................................................................................ 3

2.2 Operating Conveyors ................................................................................................................................................ 3

Section 3 – Pre-Installation Checks and Options...................................................................................................4

3.1 Checklist ..................................................................................................................................................................... 4

Section 4 – Y-Type™Belt Cleaner Installation Instructions...................................................................................5

Section 5 – Pre-Operation Checklist and Testing...................................................................................................8

5.1 Pre-Op Checklist ....................................................................................................................................................... 8

5.2 Test Run the Conveyor ............................................................................................................................................. 8

Section 6 – Maintenance .........................................................................................................................................9

6.1 New Installation Inspection..................................................................................................................................... 9

6.2 Routine Visual Inspection ........................................................................................................................................ 9

6.3 Routine Physical Inspection..................................................................................................................................... 9

6.4 Blade Replacement Instructions............................................................................................................................ 10

6.5 Maintenance Log ..................................................................................................................................................... 11

6.6 Cleaner Maintenance Checklist............................................................................................................................. 12

Section 7 – Troubleshooting .................................................................................................................................13

Section 8 – Specs and CAD Drawings...................................................................................................................14

8.1 Specs and Guidelines .............................................................................................................................................. 14

8.2 CAD Drawing - Y-Type Heavy-Duty with White or Purple Polyurethane Blades ......................................... 15

8.3 CAD Drawing - Y-Type Heavy-Duty with Tungsten Carbide Blades .............................................................. 16

Section 10 – Other Flexco Conveyor Products..................................................................................................... 17

2Y-Type™Standard-Duty Secondary Belt Cleaner

Section 1 – Important Information

1.1 General Introduction

We at Flexco® are very pleased that you have selected a Y-Type™Secondary Belt Cleaner 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 visit our web site or contact our

Customer Service Department:

Customer Service: 91-44-6551-7771

Visit www.ﬂexco.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

e Y-Type™Secondary Belt Cleaner 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 Y-Type™Secondary Belt Cleaner, 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.

Unforeseeable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.

4Y-Type™Standard-Duty Secondary Belt Cleaner

3.1 Checklist

Section 3 – Pre-installation Checks and Options

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

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

•Review“ToolsNeeded”listonthetopof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

Y-Type™Heavy-Duty Secondary Belt Cleaner

(Polyurethane or Carbide Option)

Section 4 – Installation Instructions

Tools Needed

• 16mm(5/8")Wrench

• 13mm(1/2")Wrench

• 19mm(3/4")Wrench

• TapeMeasure

• Ratchetwith19mm

(3/4")Socket

• (2)152mm(6")

C-Clamps (for

Temp or ar y

Positioning of

Mounting

Brackets)

• CuttingTorch

and/or Welder

• MarkingPen

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

Before You Begin:

• Forchutemountingitmaybenecessarytocutanaccessholeto

allow for installation and inspections. (See dimensions in Step 1.)

• Followallsafetyprecautionswhenusingacuttingtorch.

• Ifwelding,protectallfastenerthreadsfromweldspatter.

• Forcleanerclearancerequirementsseechartatright.

Clearance Requirements for Installation

Vertical Horizontal

Y-Type Polyurethane 248mm (9-3/4") 133mm (5-1/4")

Y-Type Carbide 241mm (9-1/2") 133mm (5-1/4")

150 - 200mm

(6" - 8")

150 - 200mm

(6" - 8")

100mm

(4")

150 - 200mm

(6" - 8")

150 - 200mm

(6" - 8")

Chute wall

Vertical

Horizontal

Pole

Polyurethane Blade Option

Carbide

Blade Option

Blade Angle

Angle Clamp

Push-Up

Tensioning

Position

Optional

Pull-Up

Tensioning

Position

Adjusting Bracket

Adjusting Bolt

Mounting

Bracket

Clamp Block

6Y-Type™Standard-Duty Secondary Belt Cleaner

Section 4 – Installation Instructions (cont.)

Y-Type™Heavy-Duty Secondary Belt Cleaner

1. Install the mounting brackets. Position the mounting bracket to locate the cleaner pole centerline 190mm

(7-1/2")belowthebeltlineforpolyurethanecleanersor170mm(6-3/4")belowthebeltlineforcarbidecleaners.

The pole must be installed so the blades do not touch the belt.Positioning the brackets perpendicular to the belt is

recommended (Fig.1b).

Mounting

Bracket

Adjusting

Bracket

Lock Bolt

Clamp Block

Lock Bolts

Split

Clamp

Block

190mm (7-1/2")

Polyurethane

170mm (6-3/4")

Carbide

Belt Direction

Fig. 1b

90°

2. Choose the tensioner position. The tensioner is shipped

mounted in the push-up position.Depending upon the space

constraints of the installation,the tensioner can be optionally

mounted in a pull-up position.To do this, loosen the threaded

rodlocknut,unscrewthethreadedrodandremoveadjusting

bracketlockbolt.Thenmovetheadjustingbracketand

threaded rod to the top of the clamp blocks (Fig. 2) and tighten

threaded rod lock nut.

Adjusting

Bracket

Lock Bolt

Fig. 2

Push-up

Tensioning

Position

Pull-up

Tensioning

Position

Fig. 1a

Belt Direction Belt Direction

3. Install the pole. Remove the outer half of the clamp block on

one side,and on the opposite side,loosen the two clamp block

bolts. Slide the pole across and into the loosened clamp block,

replace the outer clamp block, center the blades on the belt and

tighten all four clamp block bolts finger tight.

Fig. 3

Section 4 – Installation Instructions (cont.)

Fig. 4

Y-Type™Heavy-Duty Secondary Belt Cleaner

Rotate blades

perpendicular to belt;

No blade-to-belt contact

Clamp

Block Bolts

5. Set the blade tension. Loosen the 4 clamp block lock

bolts (on the back of the mounting brackets) and turn the

topadjustingjamnutoneachsideuntilthebladesmake

light contact across the entire width of the belt. Make an

additional5fullturnsontheadjustingnutstotensionthe

blades.Tightenthebottomadjustingnutsandtheclamp

block bolts (Fig. 5).

4. Secure pole. Center pole/blades on belt and rotate pole

until blades are perpendicular to belt. Tighten clamp block

bolts equally on each tensioner assembly to lock pole in

place (Fig. 4).

Note: make sure there is no tip-to-belt contact while

making this alignment. If contact occurs, lower the pole

by loosening the clamp block lock bolts and raising the top

adjustingjamnut(fig.5).Whentipsareloweredandnot

touching the belt, repeat this step.

Test run the cleaner and inspect the performance. If more cleaning efficiency is desired, the blade tension can be

increasedin1/2turnsontheadjustingnuts(seeStep5).

Clamp Block

Lock Bolts

Adjusting

Nuts

Light tip

contact

Fig. 5

8Y-Type™Standard-Duty Secondary Belt Cleaner

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beltandconveyorarea.

5.2 Test Run the Conveyor

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

  •Ifvibrationoccursormorecleaningefficiencyisdesired,increasebladetensionbymaking1/2turnsonthe

adjustingnuts.

  •Checkadjustingbracketsandtipsforpropertensioning.

  •Makeadjustmentsasnecessary.

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

determinewhenadjustmentsareneeded.

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 the cleaner operates at optimal efficiency and problems can be identified and fixed before the cleaner stops

working.

All safety procedures for inspection of equipment (stationary or operating) must be observed.TheY-Type™

Secondary Belt Cleaner 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:

  •Beltlookscleanorifthereareareasthataredirty.

  •Bladeiswornoutandneedstobereplaced.

  •Thereisdamagetothebladeorothercleanercomponents.

  •Fugitivematerialisbuiltuponcleanerorintransferarea.

  •Thereiscoverdamagetothebelt.

  •Thereisvibrationorbouncingofthecleaneronthebelt.

  •Thereismaterialbuilduponsnubpulley(ifused).

  •Significantsignsofcarrybackexist.

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, perform a physical inspection of

the cleaner through the following tasks:

  •Cleanmaterialbuildupfromcleanerbladeandpole.

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

  •Ensurefullbladetobeltcontact.

  •Inspectcleanerpolefordamage.

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

  •Replaceanywornordamagedcomponents.

  •Checktensionofcleanerbladetobelt.Adjusttensionifnecessaryusingthestepsonpage7.

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

10 Y-Type™Standard-Duty Secondary Belt Cleaner

6.4 Blade Replacement Instructions (Carbide or Polyurethane)

Section 6 – Maintenance (cont.)

Fig. 1a

25mm (1")

Gap

Adjusting

Bracket

Top Adjusting

Bolt Jam Nut

Fig. 1b

Clamp Block

Lock Bolts

25mm (1")

Gap

Top Adjusting

Bolt Jam Nut

Fig. 2

Angle Clamp

Set Screws

and Lock Nuts

Angle

Clamp

Blade Angle

Assembly

1. Release the blade tension and remove worn blade tips.

 a. Loosenandturnthetopadjustingboltjamnuts25mm(1")abovethetopsoftheadjustingbrackets(Fig.1a).

b. Loosen the clamp block lock bolts on both sides and allow the pole to move down and rest on the raised top

adjustingboltjamnuts(Fig.1b).

2. Remove blade angle from pole.

Loosen angle clamp lock nuts and set screws on both sides of cleaner

(Fig. 2). Slide angle clamps off each end of angle and remove blade

angle assembly from pole.

3. Replace the cushions.

Cushions may be removed from the angle by sliding them off each end,

or entire angle with all cushions may be replaced at once.

4. Reinstall blade angle.

Set new cushions and angle back on pole and slide angle clamps back

onto the angle (Fig. 3). Tighten angle clamp set screws and lock nuts on

both sides.Verify blades are centered and perpendicular to belt.

Fig. 3

Angle Clamp

Set Screws

and Lock Nuts

Angle Clamp

Blade Angle

Assembly

5. Set blade tension. Turnthetopadjustingjamnutoneachside

until the blades make light contact across the entire width of

the belt. Makeanadditional5fullturnsontheadjustingnutsto

tensiontheblades.Tightenthebottomadjustingnutsandthe

clamp block bolts (Fig. 5).

Test run cleaner and inspect cleaning performance. If vibration

occurs or more cleaning efficiency is desired, increase blade

tensionbymaking1/2turnsonadjustingnuts..

Clamp

Block

Bolts

Top

Adjusting

Nut

Bottom

Adjusting Nut

Light tip

contact

Fig. 5