Martin Tracker Series User manual

MARTIN®Tracker
Conveyor Belt
Centring System
Installation manual
M3625UK

© Martin Engineering GmbH M3625UK-10/15

© Martin Engineering GmbH 1 M3625UK-10/15
Contents
1 Contents
1 Contents ............................................................................ 1
2 Introduction ...................................................................... 3
2.1 About this Installation Manual ............................................ 3
2.1.1 Scope ............................................................................ 3
2.1.2 Copyright ....................................................................... 3
2.1.3 Disclaimer ...................................................................... 3
2.1.4 Reference to additional documentation ......................... 4
2.1.5 Classification of hazards................................................ 5
2.2 Appropriate Use ................................................................. 6
2.2.1 Use in EX-protection areas ............................................ 6
2.2.2 Operating limits of this product...................................... 7
2.3 Safety in the Workplace ..................................................... 7
2.3.1 Safety instructions, safety in the workplace ................... 7
2.3.2 Obligations of the operator ............................................ 8
2.3.3 Authorised personnel ..................................................... 8
3 Product Description ......................................................... 9
3.1 Design and Function .......................................................... 9
3.2 Models.............................................................................. 10
4 Installation Preparation ................................................. 11
4.1 Prior to Installation ........................................................... 11
4.1.1 Materials and tools required ........................................ 11
4.1.2 Preparatory measures ................................................. 11
5 Installation ...................................................................... 13
5.1 Safety Instructions............................................................ 13
5.2 Installation procedure....................................................... 14
5.2.1 Determining the installation position ............................ 14
5.2.2 Installing the MARTIN®Tracker conveyor
belt centring system (lower unit).................................. 15
5.2.3 Installing the MARTIN®Tracker conveyor
belt centring system (upper unit) ................................. 23
5.3 Trial operation .................................................................. 31
5.4 Installation - Check-list ..................................................... 32
5.5 Attaching the warning label or the warning tag ................ 33
6 Maintenance ................................................................... 34
6.1 Safety instructions............................................................ 34
6.2 Maintenance procedure ................................................... 34
6.3 Regular maintenance ....................................................... 35
7 Troubleshooting ............................................................. 36
7.1 Safety Instructions............................................................ 36
7.2 Troubleshooting ............................................................... 37
8 Storage, De-installation and Disposal .......................... 38
8.1 Storage............................................................................. 38
8.2 De-installation .................................................................. 38
8.3 Disposal ........................................................................... 38
9 Part Numbers .................................................................. 39
9.1 Part number - Description ................................................ 39

© Martin Engineering GmbH 2 M3625UK-10/15
Contents
9.2 MARTIN®Tracker Conveyor Belt Centring System
(upper unit) .......................................................................40
9.3 MARTIN®Tracker Conveyor Belt Centring System
(lower unit) ........................................................................42
10 Declaration of Incorporation ..........................................44

© Martin Engineering GmbH 3 M3625UK-10/15
Introduction
2 Introduction
2.1 About this Installation Manual
Non-compliance with this installation manual can lead to the loss of
any liability claim and/or guarantee.
2.1.1 Scope
This installation manual applies exclusively to the product described
herein and is aimed at those individuals who install this product, put
it into operation and monitor its use.
2.1.2 Copyright
The product described and this installation manual are protected by
copyright. Copying without a license will be legally prosecuted. All
rights to this document are reserved, including the reproduction and/
or distribution in any thinkable way or form. The reprinting of this
document is only allowed with written permission from Martin Engi-
neering.
The technical standard at the time of delivery of the product and
technical documentation is decisive, as long as no other information
is given. We reserve the right to make technical changes without any
announcement. Earlier documents will no longer be valid. Martin En-
gineering General Conditions of Sale and Delivery apply.
2.1.3 Disclaimer
Martin Engineering guarantees the faultless operation of the product
according to the advertising, edited product information, and techni-
cal documentation. Martin Engineering does not accept any liability
for the efficiency and proper operation, if this product is used for any
other purpose, other than as described in the chapter "Appropriate
Use"; or for any damage caused by the use of accessories and/or
spare parts, that were not delivered and/or certified by Martin Engi-
neering.

© Martin Engineering GmbH 4 M3625UK-10/15
Introduction
The products from Martin Engineering are designed for a long ser-
vice life. They conform to the respective current state-of-the-art sci-
ence and technology and they have been thoroughly tested prior to
delivery. In addition to continuous advanced development of prod-
ucts, Martin Engineering also conducts constant product and market
analyses.
In the event of faults and/or technical problems Martin Engineering
offers professional support. Appropriate steps will be taken immedi-
ately. Martin Engineering's warranty conditions apply, which can be
sent if required.
2.1.4 Reference to additional documentation
The following standards and directives were applied when compos-
ing this installation manual:
• EU Machinery Directive (2006/42/EC)
• ISO/IEC Guide 37 "Installation instructions for end-
consumer used products“, edition 1995
• DIN 1421 "Structure and numbering in texts", edition 1983-
01
• DIN/EN 12100 "Safety of machinery - Basic concepts,
general principles of design", edition 2013-08
• DIN / ISO 16016 "Technical product documentation -
Protection notices for restricting the use of documents and
products", edition 2007-12
• DIN/EN 60204-1 "Safety of machinery - Electrical
equipment of machines, Part 1, General requirements",
edition 2007-06
• DIN EN 82079-1 Preparation of instructions for use -
Structuring, content and presentation - Part 1: General
principles and detailed requirements.

© Martin Engineering GmbH 5 M3625UK-10/15
Introduction
2.1.5 Classification of hazards
DANGER!
This indicates an imminent danger that leads to serious physical
injuries or death, if not avoided.
WARNING!
This indicates a potentially dangerous situation that could lead to
serious physical injuries or death, if not avoided.
CAUTION!
This indicates a potentially dangerous situation that could lead to
minor physical injuries and/or damage to property, if not avoided.
NOTE
Contains information to the installation or use of the product and
points to situations, that cause neither injuries nor property dam-
age, but is nevertheless important information.

© Martin Engineering GmbH 6 M3625UK-10/15
Introduction
2.2 Appropriate Use
The MARTIN®Tracker conveyor belt centring system is only meant
to be installed in the carrying run and return run of conveyor belts in
order to correct skewed running of the conveyor belt. In the process,
it is differentiated between the upper and lower unit. The upper unit
is placed on the support side of the conveyor belt and the lower unit
on the return side.
The Martin®Tracker conveyor belt centring system can be used un-
der the most diverse conditions of use. There are different models
available for this purpose, which should be used only in the ranges
specified for them. The different models and their applications are
specified in detail in the Chapter 3.2 "Models".
Any other use of this product is deemed to be inappropriate. If you
wish to use the product for any other purpose, please contact Martin
Engineering Customer Service. We will be happy to assist you with
product configuration.
2.2.1 Use in EX-protection areas
Under certain circumstances, this product can also be used in po-
tentially explosive areas. Contact Martin Engineering for more infor-
mation on use in potentially explosive areas.
The use of the product in a device protection category that is higher
than that specified or under operating conditions other than those
specified by Martin Engineering is not permissible or may be done
only if Martin Engineering has granted its approval.

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Introduction
2.2.2 Operating limits of this product
The use of the product mentioned here is allowed only within the
specified specifications. Using it in a higher than specified equip-
ment category or under operating conditions other than those
named and previously specified by Martin Engineering is considered
to be inappropriate use and can only be carried out if approved by
Martin Engineering.
If the product mentioned here is to be used for a different purpose,
then Martin Engineering or a representative can help with the prod-
uct configuration.
2.3 Safety in the Workplace
2.3.1 Safety instructions, safety in the workplace
This installation manual must be read through in full prior to com-
mencing work on the product or the customer's conveyor belt.
The operator must ensure that all installation, inspections, and main-
tenance tasks are carried out exclusively by authorised experts.
All work on conveyor belts and their accessories must always be
carried out only when the system is at a standstill. It is essential that
the procedures described in the relevant installation manual which
explain how to shut down the conveyor system are followed.
Upon completion of work, all safety equipment and protective
guards must be reinstalled and put back into operation.
Prior to commissioning, installation must be completed. Before the
conveyor belt can be put back into operation, the flawless execution
of all steps should be checked and verified. All notes on installation
and commissioning of the product should be observed.

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Introduction
2.3.2 Obligations of the operator
The operator of this product must ensure that the personnel entrust-
ed with the installation, maintenance and use of this product are only
those personnel who
• are fully aware of regulations governing safety at work and
accident prevention,
• are instructed in the use of the product and have read and
understood this installation manual in full.
2.3.3 Authorised personnel
Personnel are considered to be authorised when they have complet-
ed the necessary training, hold the technical experience, knowledge
of the relevant standards and directives and are also in a position to
assess any task in order to recognise a critical situation in a timely
fashion and at an early stage.
Operational, Maintenance and Installation Personnel
Personnel are considered to be authorised if they have been in-
structed in the use of the product and have read and understood this
installation manual in full.

© Martin Engineering GmbH 9 M3625UK-10/15
Product Description
3 Product Description
3.1 Design and Function
The MARTIN®Tracker conveyor belt centring system, hereinafter
referred to as tracker, detects skewing in the conveyor belt move-
ment automatically and corrects it permanently. Slight contact of the
conveyor belt against the guide roller enables accurate correction.
The adjustment rod transfer the movements of the guide rollers to
the control rollers and thus enables accurate guidance of the con-
veyor belt.
The upper unit is placed on the support side of the conveyor belt and
the lower unit on the return side.
This installation manual describes the installation of the MARTIN®
Tracker conveyor belt centring system for the models, Mini, Basic,
Heavy-duty and Monster..
NOTE
A product that has not been installed properly or correctly may dis-
rupt the conveyance process and contaminate the bulk material to
be transported.
The operator is therefore responsible for implementing the neces-
sary counter measures.
When using with contaminants Martin Engineering or a represent-
ative can help with the positioning or customized solutions.

© Martin Engineering GmbH 10 M3625UK-10/15
Product Description
3.2 Models
The Martin®Tracker conveyor belt centring system is available in
four models, which can be used as follows:
Mini
• Less load and low stress
• Conveyor belt width: 380 - 560 mm
• Conveyor belt speed max.: 1.5 m/sec.
Basic
• Normal industrial loads and stresses
• Conveyor belt width: 600 - 1340 mm
• Conveyor belt speed max.: 3.5 m/sec.
Heavy-duty
• Thick conveyor belts (> 10 mm) with high conveyor belt
speeds, tonnage and wide conveyor belts.
• Conveyor belt width: 1010 - 1860 mm
• Conveyor belt speed max.: 4.0 m/sec.
Monster
• Worst-case loads and stresses, with very high conveyor
belt speeds, tonnage and very wide conveyor belts.
• Conveyor belt width: 1410 - 2150 mm
• Conveyor belt speed max.: 5.0 m/sec.

© Martin Engineering GmbH 11 M3625UK-10/15
Installation Preparation
4 Installation Preparation
4.1 Prior to Installation
4.1.1 Materials and tools required
In addition to the standard tools, the following special instruments
may be needed for the installation and maintenance of the
product.
• Lifting device with a capacity greater than the weight of the
product to be installed (note the weight on the delivery
note).
4.1.2 Preparatory measures
1. Check the delivery with respect to the following:
• Is the delivery complete? Is the number of pallets/cases/
containers the same as the number on the delivery note?
• Does all the transport packaging appear to be undamaged?
Is there damage which may indicate that the contained
products may be damaged?
NOTE
Pay attention to the following checks and carry them out carefully
and completely.
The freight forwarder is responsible for any transport damage!
For any damage claims, please contact the freight forwarder.

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Installation Preparation
2. If the delivery is incomplete or there is any transit damage,
make sure that this is documented and have the freight forward-
er confirm the same. All damaged products should be saved for
inspection.
3. Depending on the scope of the order, the delivery should con-
tain the following parts:
•MARTIN
®Tracker Conveyor Belt Centring System
(upper or lower guide unit)
• Two conveyor belt warning labels, part no. 23395
• Two warning labels for crushing hazard, part no. 30528
•MARTIN
®Tracker conveyor belt centring system, part no.
M3625
4. Missing or damaged parts must be reported to Martin Engineer-
ing or the authorised dealer.

© Martin Engineering GmbH 13 M3625UK-10/15
Installation
5 Installation
5.1 Safety Instructions
NOTE
Read this chapter thoroughly prior to commencing any work!
WARNING! DANGER OF INJURY!
Body parts and/or clothing may get caught and pulled in by rotat-
ing parts or by the moving conveyor belt.
Before any installation or maintenance work is carried out, ensure
that all power sources to the conveyor belt system and its acces-
sories are switched off and secured against inadvertent switching-
on.
Use warning signs!
WARNING! EXPLOSION HAZARD!
In enclosed areas there is an increased risk of explosion when
using a cutting torch or welding equipment!
Before use, check the level of gas and dust in the air.
NOTE
The chute wall on which the spring tensioner shall be installed is
referred to as ‘operator side’. The other chute wall is called the
‘opposite side’.
When installing dual spring tensioners, the most accessible side is
the "operator side".

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Installation
5.2 Installation procedure
5.2.1 Determining the installation position
Lower tracker unit
1. Determine the point from where the conveyor belt runs without
being centred.
2. Install the tracker unit at a distance of three to four times the
conveyor belt width in front of the point determined (for subse-
quent steps of installation, see Chapter 5.2.2).
Upper tracker unit
1. Install the tracker unit behind the loading zone (for subsequent
steps of installation, see Chapter 5.2.3).
or
1. Determine the point from where the conveyor belt runs without
being centred.
2. Install the tracker unit at a distance of three to four times the
conveyor belt width in front of the point determined (for subse-
quent steps of installation, see Chapter 5.2.3).
NOTE
If multiple units are being used, install these at a distance of 20-50
m from one another.
The distance depends on the extent of skewing of the conveyor
belt and must then be determined from case to case.

© Martin Engineering GmbH 15 M3625UK-10/15
Installation
5.2.2 Installing the MARTIN®Tracker conveyor belt centring system
(lower unit)
1. Remove the existing return roller (1, Fig. 1) and keep them
aside. The roller is required for further installation.
2. Install the return roller that has been removed in the supporting
construction of the lower tracker unit (Fig. 1).
3. Centre the roller on the tracker and secure it with 4 screws
(1, Fig. 2).
Fig. 1: Installing the return roller
Fig. 2: Centring and securing the return roller
1
11

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Installation
Fig. 3: Mark the holes in the installation frame
Fig. 4: Holes in the installation frame
90°
1
1

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Installation
4. Mark the holes for the installation frame on the opposite side
(Fig. 3). Ensure that the lower holes (1, Fig. 4) are accessible
for fixing screws from both sides.
5. Drill or cut holes (14 mm dia.) at the points marked earlier in the
stringer.
6. Fix the installation frame with screws (Fig. 5).
Fig. 5: Fix the installation frame with screws

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Installation
7. Position the installation frame on the side turned away (Fig. 6).
Fig. 6: Positioning the installation frame
NOTE
The distance (2, Fig. 6) between the upper edge of the suspension
frame and the lower edge of the conveyor belt (1, Fig. 6) must
match the distance (3, Fig. 6) between the upper edge of the sup-
port frame and the upper peak of the return roller.
12
3
2 = 3
2