Flexco ELEVATE i3 User manual

Cover
FLEXCO ELEVATE™Belt Cleaner i3
Installation, Operation and Maintenance Manual
image source location for MarCom:
https://flexcoonline.sharepoint.com/:f:/s/IoT1.0/EvdUR8HtYw5KtxR_u0mMS0gBypU8I4soIGR2P
MBNg63cqw?e=FkZW5d

For product models 91600, 91601, 91602
Product Registration
Device Number:
Purchase Date:
Purchased From:
Installation Date:
Installation Location, Conveyor #:
The device name is found in the mobile application when Bluetooth® wireless communication
connected to the device.
This information will be helpful for any future inquiries or questions about device replacement
parts, specifications or troubleshooting.
Table of Contents
1. Important information
a. General introduction
b. User benefits
c. Appropriate applications
2. Safety consideration and precautions
3 separate IOMs for each region
Unique country item code
Unique certifications
Australian & global version
English spellings and syntax

a. Stationary or Operating Conveyors
b. Equipment Shipping
c. Battery Storage and Handling
d. Battery Recycling
e. Pole Extenders
3. Pre-installation checks and options
a. Checklist
b. Device Setup
c. Mobile Application Setup
d. Optional Installation Accessories
4. Installation instructions
5. Dashboard setup
6. Maintenance
a. Routine Inspection
b. Battery Replacement
c. Remove a device
d. Remote Device Software Updates
e. Dashboard and Mobile Application Updates
7. Troubleshooting
a. Device LED alerts
b. Device troubleshooting
c. Mobile application troubleshooting
d. Dashboard troubleshooting
8. Specifications
a. Device specifications
b. Digital tools specifications
9. Replacement parts
10. Warranty & Privacy Policy
11. Regulatory Statements
a. United States
b. Europe and Canada
12. Other Flexco Cleaner Replacement Parts
Section 1 –Important Information
1.1 General Introduction
We at Flexco are very pleased that you have selected a FLEXCO ELEVATE™Belt Cleaner i3 device
for your conveyor system.
This manual will help you to understand the installation, operation and maintenance 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. This manual will provide safety precautions, installation
instructions, maintenance procedures and troubleshooting tips. In addition, please follow all
standard, approved safety guidelines when working on your conveyor.

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: USA & Canada 1-800-541-8028, UK 44-1274-600-942, Australia 61-2-8818-
2000
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 device and its tools. While we have tried to
make the installation and service tasks as easy and simple as possible, this product does
however require correct installation and regular inspection and maintenance to maintain top
working condition.
1.2 User Benefits
“i3” stands for “Information, Intelligence & Insights”. Information is collected as the
foundational layer for insights. Then, through analytical, science-driven, intelligent
augmentation of the information, meaningful, action-oriented insights are delivered.
The industry is increasingly becoming insights driven to improve safety measures, increase
productivity and reduce costs. To realize these advantages, Belt Cleaner i3 provides these key
benefits:
oRemotely monitor multiple assets
oView current and historical performance of your assets, systems
oDigital record of asset information and service
oMinimize the number of physical inspections required
oUse insights to predict when and where problems may surface
oProactively schedule maintenance
1.3 Appropriate Applications
Environment and Location Requirements
Description
Requirement
Temperature range
-30°C to +65°C (-20°C to +40°C in explosive
environments)
Cellular coverage
United States: AT&T
Australia: Telstra
Europe & Canada: roaming between in-country
providers
Regulatory, Certifications, Standards, Explosive
Environments
United States: FCC, IP66, RoHS, MSHA (coming
spring 2020)
Australia: RCM, IP66, RoHS, IECEx
Europe & Canada: CE, ISED, IP66, RoHS, ATEX
(coming winter 2019)
Cleaner Requirements
Description
Requirement
Flexco cleaners
Attach only to Flexco branded cleaners
Precleaner
EZP1, MSP, MMP, MHCP, MHP, H-type
Secondary Cleaner
EZS2, Y-type, R/P-type, FMS, MHS, U-type, MDWS
Tensioner
Compatible with all Flexco provided tension
systems

Pole Diameter
2-7/8” (73mm) or 2-3/8” (60mm) with adapter
< 3-1/2”(90mm) of pole outside of the tensioner
Requires pole extender for short poles
User Requirements
Description
Requirement
Smartphone or tablet use
Android or iOS with Bluetooth® wireless
communication
Browser
Any (optimized for Google Chrome)
Language
English (US)
Section 2 –Safety consideration and precautions
2.1 Stationary or Operating Conveyors
Before installing and operating BRAND NAME, it is important to review and understand the
following safety information. Setup, maintenance and operational activities for the BRAND
NAME device can be performed on operating or stationary conveyors. Please reference the
appropriate cleaner manual before performing any work on the cleaner.
Five tasks that can be performed while the conveyor is running [or stationary]:
oInstallation
oDe-installation
oPowering device on/off
oEstablish Bluetooth® wireless communication connection for service documentation
oDiagnostic status check
Battery replacement can NOT be performed on an operating conveyor. De-install the entire
device from the cleaner pole before replacing the battery.
DANGER
Every belt conveyor is an in-running nip hazard. Conveyor hazards cause instantaneous
amputation and entrapment.
WARNING
Conveyors contain moving hazards. Stay as far from the conveyor as practical and use Personal
Protective Equipment (PPE):
oSafety eyewear
oHardhats
oSafety footwear
Handle screws and tools with care as these items may become projectiles if coming into contact
with moving conveyor components.
2.2 Equipment Shipping
Shipping of devices and spare batteries must be performed by an authorized shipper. Flexco and
its manufacturing partners are authorized to ship devices and batteries.
To become an authorized shipper, please reference your region’s compliance requirements to
pursue appropriate training. This training resource provides additional information:
https://dgtraining.com/program-catalog/lithium-batteries-training/
It is advised to have devices and spare batteries shipped to a location where they may be
ground transported as needed to their final destination to avoid transit overhead.
2.3 Battery Storage and Handling

Battery packs may be replaced by the customer
This product contains a 3.6V, non-rechargeable, lithium metal thionyl chloride (Li/SOCl2) cell
battery. The battery cells are hermetically sealed units which are not hazardous when used as
recommended in this operating manual.
Recommended storage is in a room temperature (+25⁰C, +/-5⁰C), dry (relative humidity below
80%) and ventilated area that is subject to little temperature change for optimal life. Do not
place the battery near heating equipment. Do not expose the battery to direct sunlight or store
in high humidity environments for long periods. Do not store batteries where any liquids may
spill onto the batteries or packaging.
Keep replacement batteries in original packaging until ready to use.
Do not puncture, crush or immerse the battery in any liquids.
Batteries should be activated in a device within two years after receiving when properly stored.
If devices are stored for an extended period of time (over 3 months) with batteries installed,
then disconnect the battery plug from the jack to prevent a potential short circuit.
Storing batteries for longer than two years in ideal storage conditions may result in loss of
operable life once installed.
Additional safety information can be found here (reference battery cell TL-5930 by Tadiran):
http://www.tadiranbat.com/assets/tadiran-batteries-msds(1).pdf
WARNING
Do not replace battery when an explosive atmosphere is present.
Do not leave an expended/discharged battery in a device for more than one year.
Never attempt to disassemble, machine or otherwise alter the battery as personal injury or
environmental harm may result.
Do not attempt to recharge the battery as this causes a risk of fire or explosion.
2.4 Battery Recycling
Do not crush or incinerate batteries as this may cause cells to rupture and increase the risk of
fire.
Battery recycling and disposal guidelines constantly evolve and regulations change from country
to country. Battery recycling should be done in authorized facilities through licensed waste
management organizations. Please consult with your country’s environmental or recycling
services governing body for more information and recycling locations.
Any used batteries may be returned to a Flexco facility.
The following regions may wish to consider these sources to identify a recycling location:
oUS and Canadian customers: Retriev Technologies https://www.retrievtech.com
oEU and UK customers: European Recycling Platform https://erp-recycling.org
oAustralia customers: BusinessRecycling https://businessrecycling.com.au
Batteries do not contain mercury, lead, manganese or cadmium.
2.5 Pole Extenders
2-3/8” (60mm) and 2-7/8” (73mm) pole extenders (item code #91596 and #91595, respectively)
are NOT intended to be a replacement for pole extender kits (item code #77423 and #76024).
#91596 and #91595 pole extenders are only available for use with the digital cleaner devices.
Cleaner devices may be attached to #77423 and #76024 pole extender kits, and an additional
#91596 or #91595 pole extender may be affixed to a pole extender kit.

Section 3 –Pre-Installation Checks and Options
3.1 Checklist
Necessary tools: T40 and T20 6-lobe (Torx) drive bits or wrench, Android or iOS smartphone or
tablet with Bluetooth® wireless communication, installed BRAND NAME mobile application
Necessary preparation data: site name, conveyor names, belt speed, material being conveyed,
tonnage, splice type (mechanical or vulcanized) and number of splices
If possible, discard packaging before going to the installation location (peripheral packaging on
site is a safety hazard)
Ensure that the correct device model was received—regions are specified by the following part
numbers on the back panel label:
Part numbers assigned to the region of installation
oUnited States: 91600
oAustralia: 91602
oEurope & Canada: 91601
Check the device for damage and missing parts
Prepare the device for installation:
oLoosen the screws so the top cap is loosely connected to the body
oRemove the cellophane wrap over the keypad
Identify and note where the devices will be installed
Prepare the conveyor site:
oAdjust the spring, bolt or air tensioner to its recommended tension level
oClean the end of the pole to remove dirt and debris
3.2 Device Setup
Before going to the installation site, power on each device to ensure it connects to the local
cellular provider (you must be in the same country as the installation site)
Power on each device and wait for the Connectivity LED to display solid green
In the event that the Connectivity LED turns red, then turn off/on the device for a second
attempt, after which refer to section 7.
Power off the device when finished
3.3 Mobile Application Setup
The mobile application setup process will be initiated and managed by Flexco. Flexco will
request email addresses for authorized application users, and each mobile application user will
receive a unique download link with setup instructions.
The mobile application is only available via unique link emailed to the authorized users.
Downloads are not available through the Apple App or Google Play stores.
The mobile application requires Android or iOS operating system and Bluetooth® wireless
communication capability.
3.4 Optional Installation Accessories

If the application uses a 2-3/8” (60mm) diameter pole, then an adapter will be required for
installation. The adapter will slide onto the 2-3/8” (60mm) pole to increase the outside diameter
to 2-7/8” (73mm). The adapter is a compression fitting that clamps to the pole as the device
tightens around the adapter.
If the application uses a pole that has been shortened or cut off allowing less than 3-1/2”
(90mm) of exposed pole, then an extender will be required during installation. Clean the burrs
off the inside diameter of the pole if necessary. The extender draws a wedge outward against
the inside diameter of the pole as the set screw is turned. The extender may require assembly.
Customers that have applications using Wi-Fi® must contact their service partner or Flexco
customer service for setup procedures.
Section 4 –Installation Instructions –BRAND NAME

image source location for MarCom:
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3cqw?e=FkZW5d
1. Rubber boot on top cap protects screws
2. Rubber covers on the back panel protects screws and power switch
3. Back panel: Power switch
4. Back panel: regulatory information label
5. Keypad: Bluetooth® wireless communication connectivity button
6. Keypad: Information button
ADVISORY: Devices should not be stored in extreme temperatures prior to installation. Prolonged
exposure to extreme temperature may shorten the battery life. Please reference section 2.3 for proper
storage requirements.
Before You Begin:
oPlan on a 5- to 10-minute installation per device if all cleaner profile information is
known and the cleaner is easily accessible
oEnsure that the cleaner will not jolt or twist suddenly which may cause injury (it may be
advantageous to back the cleaner away from an operating belt to minimize vibration
and decrease the chance of a sudden movement)
Tools Needed:
oDevice/s (it is advised to bring an extra device with you in case an issue arises)
oT40 and T20 6-lobe (Torx) driver
oAndroid or iOS smartphone or tablet with Bluetooth® wireless communication
oBRAND NAME mobile application
oOptional tools depending on application and availability of information for the cleaner
profile:
Brush or rag to clean the pole
Hammer (fitting the pole extender)
½” (13mm) socket wrench (fitting the pole extender)
Headlamp
Tape measure

Belt speed reader
Conveyor Site Preparation:
oIdentify where the device will be installed
The device requires 3-1/2” (90mm) of clearance on the pole
Placement outside OR inside the tensioner on the pole is acceptable, but it is
advised to add a pole extender to the pole before placing the device inside a
tensioner
If using a pole extender, then use care that it does not cause an undue tripping
or safety hazard on a catwalk
Placement inside a chute wall is NOT acceptable due to increased risk of
damage to the device and inaccessibility for maintenance
Place the device where it can be serviced
On precleaners, make sure you attach the device so it has enough room to turn
as the blade wears and the pole rotates
On secondary cleaners, make sure you attach the device so it has enough
vertical space to travel as the tips wear
oDownload the BRAND NAME mobile application
1. Prepare the pole (optional). If using a pole extender, then push/hammer the extender into the pole
and turn the draw bolt to 80 in-lbs (9.0 Nm). If using a pole adapter, then slide the adapter over the
pole.
2. Affix the device.
a. Depending on the location of the device on the pole, slide the device onto the pole or
remove the top cap completely and reattach around the pole so the keypad faces forward.
Do not affix the device so the keypad faces the conveyor as this will inhibit your ability to
use the Bluetooth® wireless communication button, information button and LEDs for
routine maintenance.

Caption: Device mounted facing forward on the pole
Caption: Device mounted facing forward inside the
tensioner
b. If using a pole adapter (replacement part 91597) or pole extender (replacement part 91595
or 91596), then affix the device so the body clamps only to the adapter or extender. The
device body cannot sit half on a pole extender and half on the cleaner pole.
c. Using a T40 6-lobe (Torx) driver, tighten one screw on opposite sides of the top cap, and
then tighten the remaining screws. Do not exceed 72 in-lbs (8.1 Nm) torque.

d. Maintain an equal gap between the device body and the top on each side of the pole.
Caption: equal space between device body and top
cap on either side of the pole
e. Place the rubber boot over the screw heads when finished.
f. Replace the rubber pole end cap.
3. Connect to the device. Power on the device. Wait for the Connectivity LED to turn green.
a. While standing next to the device, press the left Bluetooth® wireless communication button.
The LED light will blink yellow as the device prepares to connect to the mobile
application.
b. When the LED begins to blink blue, then the device is ready to connect. The device will be in
a ‘prepared to connect’ state for 1 minute after which point you will need to press the
button again. Do not press the Bluetooth® wireless communication button on more than
one device at a time before you are ready to connect it to the mobile application. Enabling
the wireless communication on multiple devices at the same time may cause interference in
the mobile application.
c. To ensure uninterrupted connectivity between the mobile application and the device, turn
off and on Bluetooth® wireless communication on your smartphone or tablet before
connecting to a new device.
d. Open the BRAND NAME mobile application and tap the “Connect to Device” button on the
home screen. Caption: variations between Android, iOS and tablet visuals
will exist

e. All available devices within range (approximately 10 meters) will appear on the screen.
Connect to the appropriate device.
i. The application will automatically find the device as long as the LED light on the
device is blinking blue.
ii. The device name is predefined by the manufacturer. This name is only used to
identify the device for Bluetooth® wireless communication connection. The device
will be renamed in the online dashboard once conveyor information is entered
through the mobile application.
iii. The initial name of the device in the mobile application will have the same last 5
digits as the serial number printed in the battery compartment of the device.
iv. Because you will not know the serial number of each device, this is why it is
recommended to press the Bluetooth® wireless communication button on one
device at a time.
f. Once the device is paired, the device’s Bluetooth® wireless communication LED will change
to solid blue, and you will receive a connection confirmation.

g. Tap the “Return to Home” button, and the mobile application will now give you the option
to enter cleaner profile information or disconnect from the device.
4. Enter conveyor and cleaner information.
a. In the mobile application, tap the “Conveyor Information” button.
b. Type in or select from the dropdown fields your responses to each question.
c. Tap the “Save” button at the bottom of the screen once all information is entered.
d. Use the table below as a reference sheet to collect and write in all conveyor and cleaner
information.
DESCRIPTION
SELECTION OPTION
RESPONSE
Customer Name
Text response
Site/Location Name
Text response
Plant Name
Text response
Conveyor Name
Text response
Belt Speed
0 fpm
201-400 fpm
401-600 fpm
601-800 fpm
801-1000 fpm
1001-1200 fpm
1201-1400 fpm
1401-1600 fpm

1601-1800 fpm
1801-2000 fpm
>2000 fpm
Material Conveyed
Coal
Sand & Gravel
Iron Ore
Limestone
Cement
Clinker
Copper
Silver
Nickel
Platinum
Asphalt
Granite
Wood
Sugar
Metal/Recycling
Glass
Tonnage
0 tons/hour
0-100 tons/hour
101-200 tons/hour
201-300 tons/hour
301-400 tons/hour
401-500 tons/hour
501-600 tons/hour
601-700 tons/hour
701-800 tons/hour
801-900 tons/hour
901-1000 tons/hour
1001-2000 tons/hour
2001-3000 tons/hour
3001-4000 tons/hour
4001-5000 tons/hour
5001-6000 tons/hour
6001-7000 tons/hour
7001-8000 tons/hour
8001-9000 tons/hour
9001-10,000 tons/hour
>10,000 tons/hour
Material Frequency
Continuous
Intermittent
Splice Type
Vulcanized
MBF
Both
Splice Number
1

2
3
4
5
6
7
8
9
10
Material Path
-2 in
0 in
4 in
6 in
8 in
10 in
12 in
14 in
Cleaner Position
Precleaner 1
Precleaner 2
Secondary 1
Secondary 2
Secondary 3
Secondary 4
Basic Cleaner Type*
CBS
EZP1
*cleaner type determined by
the cushions used
EZS2
FMS
H-type
MDWS
MHCP
MHP
MHS
MMP
MSP
P-type
R-type
U-type
Y-type
Blade Material
Polyurethane
Carbide
Blade Type
Food/Chem Resistant Urethane
(White)
High Temp Urethane (Yellow)
Standard Urethane (Purple)
Ultra High Temp Urethane (Red)

ATEX/FRAS Urethane (Blue)
Drywipe Urethane (Black)
C-tip
V-tip
V-tip Protected Carbide
Belt Width
12 in / 300 mm
16 in / 400 mm
18 in / 450 mm
20 in / 500 mm
24 in / 600 mm
26 in / 650 mm
30 in / 750 mm
32 in / 800 mm
36 in / 900 mm
38 in / 950 mm
40 in / 1000 mm
42 in / 1050 mm
46 in / 1150 mm
48 in / 1200 mm
54 in / 1350 mm
56 in / 1400 mm
Blade Coverage
8 in / 200 mm
10 in / 250 mm
12 in / 300 mm
14 in / 350 mm
16 in / 400 mm
18 in / 450 mm
20 in / 500 mm
22 in / 550 mm
24 in / 600 mm
26 in / 650 mm
28 in / 700 mm
30 in / 750 mm
32 in / 800 mm
34 in / 850 mm
36 in / 900 mm
38 in / 950 mm
Cleaner Tension Type
Cradle/Bolt
Spring (Compression)
Spring (J-bolt)
Air
Pole Style or Type
1 piece
3 piece
Cartridge
Curved

Inspected
Yes/No (timestamped upon
selection)
Tensioned
Yes/No (timestamped upon
selection)
Blade Replaced
Yes/No (timestamped upon
selection)
Manually Disengaged
Yes/No (timestamped upon
selection)
Remaining Blade Life
Yes/No (timestamped upon
selection)
5. Disconnect mobile application. Once all information is entered and saved, disconnect the
mobile application from the device by tapping the “Disconnect Device” button on the home
screen and turn off/on Bluetooth® wireless communication on your smartphone or tablet. Wait
at least 30 seconds before restarting the cleaner device to allow the cleaner profile information
to save in the cloud.
Section 5 –Dashboard Setup
The dashboard account creation process will be initiated and managed by Flexco. Flexco will
request email addresses for authorized dashboard users, and each user will receive a unique
invitation email with account setup instructions.
Each authorized user will be required to accept the terms of use and privacy policy when logging
into the dashboard for the first time. Please review the Privacy Policy in section 10.2.
View the online dashboard on any internet enabled device using any browser. The
recommended browser is Google Chrome for optimal performance.
Section 6 –Maintenance
All installation safety procedures (section 2.1) must be observed for inspection of equipment.
6.1 Routine Inspection

A visual inspection of the cleaner can indicate underlying issues with the device. Reference the
appropriate cleaner maintenance manual to correct all operating abnormalities.
Inspect the devices for cracks, missing screws or deformities as these situations can impact the
collection of data or short circuit the entire device.
Press the right information button on the keypad. The Connectivity LED will light green if it is
connected to cellular service; the Wrench icon will light green if the conveyor information has
been entered; and the battery LED will indicate approximate remaining battery life.
Connect to the device via Bluetooth® wireless communication and view the same battery life
and cellular connectivity information on the mobile application. Note in the application that you
performed an inspection.
Mobile application may take 2-3 minutes to populate previously entered cleaner profile
information in the mobile application depending on cellular service strength. If the Wrench LED
is green, then the device has cleaner profile information.
Use the dashboard to remotely monitor the status of the device and the cleaner.
6.2 Battery Replacement
Batteries must be routinely replaced to power the device. Battery life is highly dependent on the
temperature and can range between 3 months to 12 months with Flexco recommended configuration.

Leave the replacement battery in its original packaging until ready to use. Please reference the battery
storage guidelines (section 2.3). Only use replacement batteries supplied by Flexco. Keep batteries in
original packaging until ready to replace.
Remove the device. Completely remove the device from the cleaner to change the battery. DO
NOT attempt to open the back panel of the device while the device is attached to the cleaner.
Use a T40 6-lobe (Torx) driver on the top cap screws.
Power down the device. Power down the device using the power switch behind the center
rubber shield on the back of the device.
Prepare your workspace. Changing the battery requires opening the device body and therefore
exposing the device to dust, water and more. Minimize the exposure of electronic components
to potentially harmful agents as much as possible. While the internal device components have a
second protection barrier, it is still advised to shield the internal housing. Suggestion: return the
device to a vehicle or shop before opening the back panel. Suggestion: swap one device for a
spare device to avoid battery changes in the field (follow section 4 to pair the new device to the
cleaner).
Open the back panel. Clean the device to remove excess dirt and debris. On the back panel,
remove the four screws using a T20 6-lobe (Torx) driver.
Remove the battery. Unclip the battery connector. Remove the battery pack. Please reference
the battery recycling guidelines (section 2.4).

Replace the battery. Unpackage the spare battery. Clip the lead into the appropriate terminal.
Wait. Once the battery is plugged in, wait at least 30 seconds before powering on the device.
Failure to wait may result in a false, low-battery warning.
Power on the device. Before closing the device, turn the power on to ensure the device is
functioning as expected. The battery LED will display 4 green bars.
Replace the back panel. Place the battery pack in the housing. Position the back panel on the
body so the edges are flush. Tighten the back panel screws and cover the screw heads with the
rubber covers.
Replace the device. Place the device back on the cleaner.
Inspect the application. Adjust cleaner tension and inspect the application as needed. Connect
to the device via Bluetooth® wireless communication and make a note in the mobile application
that an inspection was made. If the entire device was replaced, then the new cleaner profile
information entered will act as a cleaner inspection.
6.3 Remove a Device