Martin Qc 1 hd mt User manual

MARTIN®QC™ #1 HD MT

primary cleaner

MARTIN®PD QC™ #1 HD MT

primary cleaner with tungsten

carbide inserts

Installation manual

M3814UK

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 Conveyor belt systems with open transfer systems ...... 6

2.2.2 Use in EX-protection areas ............................................ 6

2.2.3 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 Tensioners ......................................................................... 9

3.3 Type explanation.............................................................. 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 tensioner ................................................. 17

5.2.3 Installing the primary cleaner....................................... 18

5.2.4 Centre the mainframe below the conveyor belt........... 20

5.2.5 Aligning the mainframe parallel to the conveyor belt ... 20

5.2.6 Aligning the mainframe horizontally ............................. 21

5.2.7 Install locking sleeve.................................................... 22

5.2.8 Tensioning the primary cleaner blade ......................... 22

5.3 Operation with load.......................................................... 23

5.4 Installation - Check-list..................................................... 24

5.5 Attaching the warning label or the warning tag................ 25

6 Maintenance ................................................................... 26

6.1 Safety Instructions............................................................ 26

6.2 Weekly maintenance........................................................ 26

6.3 Replacing the cleaner blades........................................... 28

7 Troubleshooting ............................................................. 30

7.1 Safety Instructions............................................................ 30

7.2 Troubleshooting ............................................................... 30

Contents

8 Storage, deinstallation, disposal ...................................32

8.1 Packing and transportation............................................... 32

8.2 Storage ............................................................................. 32

8.3 Deinstallation .................................................................... 32

8.4 Disposal............................................................................ 32

9 Part numbers ...................................................................33

9.1 Explanation of part numbers............................................. 33

9.2 Tensioners........................................................................ 35

9.3 Martin®Inspection Doors.................................................. 35

9.4 Installation manuals.......................................................... 36

9.5 Warning labels / Warning trailers...................................... 36

9.6 MARTIN®QC™ #1 HD MT Pre-Cleaner.......................... 37

9.7 MARTIN®PD QC™ #1 HD MT Pre-Cleaner.................... 41

10 Declaration of Incorporation ..........................................44

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 exclusivelyto 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

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

isgiven.Wereservetherighttomaketechnicalchangeswithoutany

announcement. Earlier documents will no longer be valid. Martin En-

gineering General Conditions of Sale and Delivery apply.

2.1.3 Disclaimer

MartinEngineeringguaranteesthefaultlessoperationoftheproduct

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.

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 Engineeringalsoconductsconstantproductandmarket

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 documents are referred to in this installation manual:

• Installation manual for the MARTIN®Inspection Door,

document no. M3127.

• Installation manual for the MARTIN®TWIST™tensioners,

Document no. M3296.

• Installation manual for MARTIN®spring and air tensioner,

Document no. M3263.

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-

• 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.

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.

Introduction

2.2 Appropriate Use

MARTIN®(PD) QC™#1 HD MT primary cleaner with

TC (Tungsten carbide) inserts is used only for cleaning conveyor

belts directly on the head pulley. It can have a maximum belt width

of 2,400 mm or reach a maximum conveying speed up to 5 m/sec..

It cannot be used with conveyor belts having mechanical splices

and/or surface damage.

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 Conveyor belt systems with open transfer systems

Thisinstallationmanualdescribestheinstallationonaconveyorbelt

systemwithanencapsulateddeliverysystem. For the installation on

open delivery systems different MARTIN®installation consoles can

be used.

If installation conditions prove to be difficult, as is the case with im-

passable static components, or using the head drum as the tension

point, Martin Engineering or a representative can help with the posi-

tioning or find customised solutions.

2.2.2 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 cleaner 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.

Introduction

2.2.3 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

namedandpreviouslyspecifiedbyMartinEngineeringisconsidered

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 mustensure 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.

Introduction

2.3.2 Obligations of the operator

The operator of this product must ensure that the personnel entrust-

edwith theinstallation,maintenanceand use ofthisproduct areonly

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-

edthenecessarytraining,holdthe 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 understoodthis

installation manual in full.

Product Description

3 Product Description

3.1 Design and Function

The MARTIN®QC™#1 HD MT primary cleaner or MARTIN®PD

QC™#1 HD MT primary cleaner with tungsten carbide (TC) inserts

enables effective elimination of return material and quick replace-

ment by loosening only one bolt holding the durable primary cleaner

cartridge.Bychoosingthe installationpositionoftheprimarycleaner

at the head pulley and the secondary cleaner just after the head pul-

ley it is ensured that thecleaned off is again fed to the material flow.

The primary and the secondary cleaners can be used individually,

but for optimum cleaning results it is recommended to install a com-

bined system of pre- and primary cleaners.

3.2 Tensioners

The MARTIN®(PD) QC™#1 HD MT primary cleaner and the Martin

Engineering tensioners specifically developed for it give the best re-

sults and conform to the general state-of-the-art technology.

Martin Engineering recommends the following tensioners for the dif-

ferent versions:

MARTIN® QC™#1H primary cleaner with tungsten carbide (TC)

insert

Part no. QC1H-XXMXXXXXXX+E.

•MARTIN

®Twist spring tensioner:

Part no. 31443-I+E.

•MARTIN

®spring tensioning device:

Part no. 38180.

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.

Product Description

MARTIN ®PD QC™#1 pre-wiper blade with carbide insert

Part no. PQC1H-XXMXXXXXXX.

•MARTIN

®Twist spring tensioner:

Part no. 38554.

•MARTIN

®spring tensioning device:

Part no. 38555-1.

3.3 Type explanation

Primary cleaner cartridges are available in different materials for the

primary cleaner. The requiredmaterial can be selected to match the

respective material conditions. The selection of different materials

for primary cleaners is listed in chapter 9, "Part numbers".

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

conveyor belt cleaner (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?

• Doesallthetransportpackagingappeartobeundamaged?

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.

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.

For applications involving dirt or impurities, please contact Martin

Engineering or

one of its representatives for advice.

Installation Preparation

2. If the delivery is incomplete or there is any transit damage,

make sure that this isdocumented 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

®QC™#1 HD MT primary cleaner or MARTIN®PD

QC™#1 HD MT primary cleaner with tungsten carbide

inserts,

• any accessories as ordered,

• two warning labels for conveyor belt products, part no.:

23395G.

4. Missing or damaged parts must be reported to Martin Engineer-

ing or the authorised dealer.

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".

Installation

5.2 Installation procedure

5.2.1 Determining the installation position

The position of the mainframe and the tensioner of the MARTIN®

(PD) QC™#1 HD MT primary cleaner must be determined on both

sides of the chute wall. In doing so, the positions are determined

where the mainframe of the MARTIN®(PD) QC™#1 HD MT primary

cleaner passes through the chute wall or where the tensioner is in-

stalled on the chute wall.

The MARTIN®(PD) QC™#1 HD MT primary cleaner is operated in

conjunctionwithatensioner.Thisisde-installedatthefactorybefore

delivery and is reinstalled during the installation along with the pri-

mary cleaner.

The installation of the MARTIN® (PD) QC™#1 HD MT primary clean-

er and the tensioner is described in this manual and the installation

manual of the tensioner.

There follows an overview of the installation steps:

It is possible to have different local conditions at the time of installa-

tion; these require different working steps, which are illustrated be-

low:

Installation on an encapsulated delivery system

• Carry out the instructions according to chapter 5.2.2

onwards.

Installation on an encapsulated delivery system with existing instal-

lation openings and brackets for belt cleaners.

• Carry out the instructions given in chapter 5.2.3 onwards.

Installation on an open delivery system

• Use the local resources to ensure that the dimensions for

the installation are correctly maintained.

No. Installation step Instruction

1 Determining the installation position M3814

2Installing the primary cleaner M3814

3 Installing the tensioner Tensioner

4Installing the scraper Tensioner

Tab. 1: Installation steps

Installation

1. Before starting with the work of installing the conveyor belt sys-

tem, switch off all accessories and secure them against being

switched on again inadvertently.

2. Determine the midpoint position of the mainframe as described

below for the primary cleaner.

3. Mark the vertical and horizontal centre line of the driving drum

to determine the midpoint (1, Fig, 1) of the driving drum. The

vertical line must run at right angles to the conveyor line.

4. Determine or measure the radius (measurement A) of the driv-

ing drum including the thickness of the covering and the con-

veyor belt.

NOTE

The MARTIN® (PD) QC™#1 HD MT primary cleaner is installed

only in the front lower quarter of a head pulley. The specified

installation measurements must be strictly observed.

Fig. 1: Marking the installation radius

NOTE

Martin Engineering recommends the installation of a MARTIN®

inspection door for better access during maintenance and repair.

A + X

Installation

5. Add measurement X from table 2 to measurement A.

6. On the chute wall, mark a circular arc around the midpoint with

the measurement determined in step 5 (1, Fig. 1).

7. Mark a horizontal line below the horizontal centre line of the

headdrum atadistanceofZ(seetable3).Theintersectionwith

the arc marked in step 5 is the midpoint of the mainframe (3,

Fig. 2).

Diameter of the

drum* in mm QC™#1 HD MT PD QC™#1 HD MT

Measurement X in mm

300 to 375 89 102

400 and more 89 89

*incl. Friction material and conveyor belt

Tab. 2: X values for positioning of the mainframe

Fig. 2: Marking the installation height

WARNING! DANGER OF INJURY!

The primary cleaner is heavy and can cause serious injury if it falls

when being lifted or moved.

Only lift the primary cleaner using suitable lifting equipment or with

several persons. Do not stand under suspended loads.

QC™#1 HD MT PD QC™#1 HD MT

Measurement Z in mm min.

216 229

Tab. 3: Installation height Z (See Fig. 2 )

Z min.

(See

390°

90°

Table 3)

Installation

8. Repeat steps 1 to 6 on the opposite side of the chute wall.

5.2.2 Installing the tensioner

Observe the respective instructions on installing the spring tension-

er in the respective installation manual of the spring tensioner used.

(See chapter 2.1.4).

NOTE

This is the best possible installation position recommended by

Martin Engineering for the MARTIN®(PD) QC™#1 HD MT primary

cleaner to achieve optimum cleaning results. Should this not be

possible for structural reasons, the primary cleaner can, in consul-

tation with Martin Engineering, also be installed at an angle of 20°

above or below, but the installation radius must be adhered to in

every case.

Installation

5.2.3 Installing the primary cleaner

1. First remove the primary cleaner cartridge from the mainframe

as described below:

• Open the pin hitch (1, Fig. 3) and pull it out for this purpose.

• Then pull the primary cleaner cartridge (4, Fig. 3) from the

hollow spring dowel sleeve (2, Fig. 3).

2. Remove the two spring bushings of the spring tensioners from

the flange brackets.

Fig. 3: Installing the primary cleaner Figure QC#1H)

NOTE

Observe the following steps when using the spring tensioning

device. Observe the relevant steps in the installation manual of the

tensioner when using the MARTIN®TWIST™tensioner.

21 2

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