Flexco RBP1 Technical Document

RBP1 Belt Positioner
Installation, Operation
and Maintenance Manual
www.flexco.com
www.flexco.com

2RBP1 Belt Positioner
RBP1 Belt Positioner
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.
is information will be helpful for any future inquiries or questions
about belt cleaner replacement parts, specications or troubleshooting.

1
Section 1 - Important Information ...................................................................................................2
1.1 General Introduction...........................................................................................................................2
1.2 User Benets .........................................................................................................................................2
1.3 Proper Belt Trainer Selection..............................................................................................................3
Section 2 - Safety Considerations and Precautions ..........................................................................4
2.1 Stationary Conveyors...........................................................................................................................4
2.2 Operating Conveyors...........................................................................................................................4
Section 3 - Pre-Installation Checks and Options..............................................................................5
3.1 Checklist................................................................................................................................................5
3.2 Optional Installation Accessories.......................................................................................................5
Section 4 - Installation Instructions..................................................................................................6
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 Roller Replacement Instructions......................................................................................................10
6.5 Maintenance Log................................................................................................................................11
6.6 Maintenance Checklist ......................................................................................................................12
Section 7 - Troubleshooting ............................................................................................................13
Section 8 - Specs and CAD Drawings..............................................................................................14
8.1 Specs and Guidelines .........................................................................................................................14
8.2 CAD Drawing, RBP1 Small ..............................................................................................................15
8.3 CAD Drawing, RBP1 Medium.........................................................................................................16
8.4 CAD Drawing, RBP1 Large ..............................................................................................................17
8.5 CAD Drawing, RBP1 Extra Large....................................................................................................18
Section 9 - Replacement Parts .........................................................................................................19
9.1 Replacement Parts List ......................................................................................................................19
Section 10 - Other Flexco Conveyor Products ................................................................................21
Table of Contents

2RBP1 Belt Positioner
Section 1 - Important Information
1.1 General Introduction
We at Flexco are very pleased that you have selected a RBP1 Belt Positioner™ for your conveyor system.
is 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 eciency over its lifetime of service.
It is essential for safe and ecient 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. 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: 1-800-541-8028
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 impact bed. 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 Benets
Belt mistracking is a common problem that produces various problems, ranging from belt and structure
damage to product spillage and safety issues. By utilizing the RBP1 Belt Positioner, it is possible to correct a
belt that is mistracking and causing these problems. Multiple units may be required depending on the length
of the mistracking belt.

3
Section 1 - Important Information
1.3 Proper Belt Trainer Selection
Belt Positioner™
PT Max™
Top Side
PT Max™
Return Side
PT Pro™
PTEZ™
PT Smart™
Standard
MODEL APPLICATION RANGE
Belt Positioner™
Return side only, 800 PIW max tension on Small,
Medium and Large; 1200 PIW max tension on
Extra Large. Also works on reversing belts.
PTEZ™Medium-duty belts up to 1600 PIW max tension.
Also works on reversing belts.
PT Smart™
Medium-duty belts up to 1600 PIW max tension.
Belt width + 3" (75mm) idler. Belt thickness 1"
(25mm) maximum.
PT Smart™Underground
Medium-duty belts up to 1600 PIW max tension.
Belt width + 9" (225mm) idler. Belt thickness 1"
(25mm) maximum. Fits underground structure.
PT Pro™
Medium-duty belts 150 PIW min to 1600 PIW max
tension. Belt width 18” - 72” (450 - 1800mm). Also
works on reversing belts.
HD PT Pro™
Heavy-duty belts 300 PIW min to 2400 PIW max
tension. Belt width 48" - 96" (1200 - 2400mm). Also
works on reversing belts.
PT Max™
Heavy-duty belts up to 3000 PIW max
Generally 3/4" to 1" thick (19mm to 25mm)
Belt width 24" - 60" (600 - 1500mm)
HD PT Max™Heavy-duty belts up to 6000 PIW max tension.
Belt width 54" - 84" (1350 - 2100mm)
PT Smart™
Underground
Structure
Conveyor Criteria Belt
Positioner™PTEZ™PT Smart™PT Pro™
Heavy
Duty PT
Pro™
PT Max™
Heavy
Duty PT
Max™
Super
Duty PT
Max™
Top side mistracking No No No No No Yes Yes Yes
Return side mistracking Yes Yes Yes Yes Yes Yes Yes Yes
Reversing Yes Yes No Yes Yes No No No
Belt mistracking to one side Better Better Better Better Better Better Better Better
Belt mistracking to both sides Acceptable Better Best Better Better Best Best Best
Inconsistent tracking problem Good Better Best Better Better Best Best Best
Belt is cupped (heavy) Best ‡ Better ‡ Better Better Better Better Better Better
Belt has edge damage Best Best Good Best Best Good Good Good
Ease of Installation Best Better Good Good Good Good Good Good
Belt has low running tension (150-300 PIW) Good Good Good Good N/A Good N/A N/A
Belt has medium running tension (300-1600 PIW) Better Better Better Better Better Best Best Best
Belt has high running tension (1600+ PIW) N/A N/A N/A N/A Best Better Best Best
Approx. "upstream" effect *∆ 50’ (15 M) 20' (6 M) 20’ (6 M) 20’ (6 M) 20’ (6 M) 50’ (15 M) 50’ (15 M) 50’ (15 M)
Approx. "downstream" effect *∆ 50’ (15 M) 100' – 120'
(30 – 36 M)
120’ – 150’
(36 – 45 M)
100’ – 120’
(30 – 36 M)
100’ – 120’
(30 – 36 M)
150’ – 200’
(45 – 61 M)
150’ – 200’
(45 – 61 M)
150’ – 200’
(45 – 61 M)
‡ Installed on the clean side of the return belt
* Typical results; actual results may vary
∆ Disc idlers have the potential to reduce these numbers

4RBP1 Belt Positioner
Section 2 - Safety Considerations and Precautions
Before installing and operating the RBP1 Belt Positioner it is important to review and understand the following safety
information.
ere are setup, maintenance and operational activities involving both stationary and operating conveyors. Each case
has a safety protocol.
2.1 Stationary Conveyors
e following activities are performed on stationary conveyors:
• Installation • Impact bar replacement • Repairs
• Skirt rubber adjustments • Cleaning
DANGER
DANGER
WARNING
WARNING
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 impact
bed 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 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
components. Serious injuries can be avoided.
2.2 Operating Conveyors
ere are two routine tasks that must be performed while the conveyor is running:
• Inspection of the sealing performance
• Dynamic troubleshooting
Every belt conveyor is an in-running nip hazard.
Never touch or prod an operating impact bed.
Conveyor hazards cause instantaneous amputation
and entrapment.
Never adjust anything on an operating impact
bed. Unforseeable materials falling into the chute
can cause violent movements of the impact bed
structure. Flailing hardware can cause serious
injury or death.
Conveyor chutes contain projectile hazards. Stay as far
from the trainer as practical and use safety eyewear and
headgear. Missiles can inict serious injury.

5
3.1 Checklist
•Check the model and size of the belt trainer. Is it the right one for your beltline?
• Check the RBP1 Belt Positioner to be sure all the parts are included in the shipment.
• Find the Information Packet in the shipment.
• Review the “Tools Needed” section on the front of the installation instructions.
• Prepare the conveyor site:
- Identify the point(s) of mistracking, expecting 50' (15M) of downstream and upstream inuence.
- Position the unit in the center of the mistracking.
- Optimal location: No closer than 3' (.9M) and no further than 6' (1.8M) from a return roller.
- Remove old tracking devices.
Section 3 - Pre-installation Checks and Options
3.2 Optional Installation Accessories
Flex-Lier™ Conveyor Belt Lier
e Flexco Flex-Lier makes the job of liing the
conveyor belt easy and safe. Using two Flex-Liers,
the belt can be quickly lied out of the way to install
the PT Smart™. e Flex-Lier has the highest safe li
rating available at 4000 lbs. (1810 kg) for Medium and
Large, 6000 lbs. (2750 kg) for XL. And it’s versatile.
It can also be used to li topside or return side belt
for splicing, roller replacement or other maintenance
jobs. Available in three sizes: Medium for belt widths
36" - 60" (900 - 1500mm), Large for belt widths 48" -
72" (1200 - 1800mm), and XL for belt widths 72" - 96"
(1800 - 2400mm).
Flex-Lifter™ Conveyor Belt Lifter
Description
Ordering
Number
Item
Code
Medium Flex-Lifter 36" - 60" (900 - 1500 mm) FL-M 76469
Large Flex-Lifter 48" - 72" (1200 - 1800 mm) FL-L 76470
XL Flex-Lifter 72" - 96" (1800 - 2400 mm) FL-XL 76983
Optional tools can make the installation of the RBP1 Belt Positioner easier and faster.

6RBP1 Belt Positioner
Section 4 - Installation Instructions
Physically lock out and tag the conveyor at the power source
before you begin cleaner installation.
Locating the Positioner
ABC
• Look at the belt on the return side and identify where the belt is mistracking.
• Locate the Positioner in the center of the problem area.
• Generally, if the belt is correctly positioned at the tail pulley (A) so the belt is
center loaded, it will run straight on the top side.
• Another problem area may be at the counter-weight pulley (B and C).
Tail
Pulley
RBP1 Parts List
Rollers
(Rubber-Lagged or Steel)
Set Screws
& Jam Nuts
Mounting Bolts,
Lock Washers
& Nuts
Mounting
Bracket
Inner
Tubes
Frame Adjustment Bolts,
(2) Nuts & Lock Washers
Roller
Retainer
Frame
1. Reposition mounting brackets (Fig. 1). Remove the
mounting brackets from the inner shipping position,
move them down toward the rollers, and remount them
on the outside of the frames. Remove the mounting
bolts, lock washers and nuts from the brackets and set
them aside for Step 4.
Move down
Remove for
later use
Shipping position
Fig. 1
Fig. 2 2. Determine Positioner location on the belt (in the
selected location). Measure an equal distance from a
common point on both sides of the structure and mark
both sides at the measured points (Fig. 2). e unit must
be square to the conveyor.
NOTE: e Positioner should be centered between
two standard return rollers. For general applications--
standard belts up to 72" (1800mm): position the unit no
closer than 3' (.9M) to a return roller and no farther than
6' (1.8M).
4.1 RBP1 Belt Positioner
Tools Needed:
- Tape measure
- (2) 5/8" (16 mm) wrench or crescent wrench
- (2) 1/2" (13 mm) wrench or crescent wrench

7
Section 4 - Installation Instructions
3. Adjust unit for conveyor width.
a. Measure the structure’s inside width from side to side.
b. Loosen the four jam nuts and set screws on the frames
and slide the unit apart to the same dimension as the inside
structure width measurement minus 1/2" (13mm) to ensure
an easy t. Retighten set screws and jam nuts (Fig. 3).
NOTE: e inner tubes between the two frames should be
kept centered to ensure both sides have maximum support.
Center marks on the inner tubes make it easy to see that
the tubes are centered.
4. Mount unit on the conveyor.
Align the unit with the location marks on the structure.
NOTE: Check the slot adjustment range of the frame and
the mounting bracket (Fig. 4). If there is not 4" to 6" of slot
visible, turn the mounting brackets upside down for more slot
adjustment. Clamp or hold the unit in place, drill mounting
bolt holes on each side and secure with mounting bolts, lock
washers and nuts, or weld in place.
5. Adjust Positioner to the belt.
Loosen the two frame adjustment bolts on the side the belt is
running o and apply pressures as follows (Fig. 5):
a. Push down on unit until roller contacts 6" to 8" (150 to
200mm) of the belt. e roller on the other side should be set
to contact the belt 4" (100mm) or less. Tighten all nuts.
b. Allow the conveyor to run a minimum of ve revolutions
and evaluate the results.
IMPORTANT: If more correction is needed, increase the
roller-to-belt contact pressure on the side running o; if
necessary, decrease contact pressure on the opposite side.
Fig. 3
Fig. 5 FRAME ADJUSTMENT
BOLTS
(on inside of bracket)
Loosen for Adjustment
MAINTENANCE
e rollers on the Positioner are sealed for life.
Center Mark
SET SCREWS
(2 on opposite side)
Fig. 4
Not enough adjustment
range in slot
Increased range of
slot adjustment
MOUNTING
BRACKET
(upside-down)
MOUNTING
BRACKET
(standard)
FRAME
FRAME
Structure
4.1 RBP1 Belt Positioner

8RBP1 Belt Positioner
Section 5 - Pre-Operation Checklist and Testing
• Run the conveyor for at least 15 minutes and conrm the belt is tracking properly.
• If belt is still mistracking too far to one side, increase the roller-to-belt contact pressure on the side
running o; if necessary, decrease contact pressure on the opposite side.
• Recheck that all fasteners are tight
• Apply all supplied labels
• Be sure that all installation materials and tools have been removed from the belt and conveyor area
5.1 Pre-Op Checklist
5.2 Test Run the Conveyor