Martin Xhd qc 1 User manual

MARTIN®QC™ #1

Heavy-duty pre cleaner

Installation manual

M3618UK

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 ........... 19

5.2.5 Aligning the mainframe parallel to the conveyor belt ... 19

5.2.6 Aligning the mainframe horizontally ............................. 20

5.2.7 Tensioning the primary cleaner blade ......................... 20

5.3 Operation with loading ..................................................... 21

5.4 Installation - Check-list ..................................................... 22

5.5 Attaching the warning label or the warning tag ................ 23

6 Maintenance ................................................................... 24

6.1 Safety Instructions............................................................ 24

6.2 Weekly maintenance........................................................ 24

6.3 Replacing the cleaner blades........................................... 26

7 Troubleshooting ............................................................. 28

7.1 Safety instructions............................................................ 28

7.2 Troubleshooting ............................................................... 28

8 Storage, De-installation and Disposal .......................... 30

8.1 Storage............................................................................. 30

Contents

8.2 De-installation ................................................................... 30

8.3 Disposal ............................................................................ 30

9 Part Numbers ..................................................................31

9.1 Part number - Description................................................. 31

9.2 Tensioner.......................................................................... 32

9.3 MARTIN®Inspection Doors .............................................. 32

9.4 Installation manual............................................................ 32

9.5 Accessories....................................................................... 33

9.6 Warning label / Warning tag.............................................. 33

9.7 MARTIN®QC™#1 heavy-duty primary cleaner................ 34

10 Declaration of Incorporation ..........................................36

Introduction

1 Introduction

1.1 About this Installation Manual

Non-compliance with this installation manual can lead to the loss of

any liability claim and/or guarantee.

1.1.1 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.

1.1.2 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

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.

1.1.3 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.

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.

1.1.4 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

1.1.5 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

1.2 Appropriate Use

The MARTIN®QC™#1 heavy-duty primary cleaner is only used for

cleaning the conveyor belts. It can be used on conveyor belts with a

width of up to 3,000 mm and a belt speed of up to 5 m/s. The primary

cleaner can only be used directly on the head drum.

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.

1.2.1 Conveyor belt systems with open transfer systems

This installation manual describes the installation on a conveyor belt

system with an encapsulated delivery system. 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.

1.2.2 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

1.2.3 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

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.

1.3 Safety in the Workplace

1.3.1 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.

Introduction

1.3.2 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.

1.3.3 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.

Product Description

2 Product Description

2.1 Design and Function

The MARTIN®QC™#1 heavy-duty conveyor belt scraper is de-

signed for extremely heavy-duty applications; it can be used on con-

veyor belts with a width of up to 3000 mm and a belt speed of up to

5 m/s. The cleaner blade is replaced by pulling out one single pin

hitch with the help of a clip lock. Placing the installation position of

the primary cleaner at the head drum and the primary cleaner (e.g.

QC™#2) just after the head drum ensures that scraped-off material

is again added to the material flow.

The pre-cleaner and the primary cleaner can be used individually,

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

bined system of pre- and primary cleaners..

2.2 Tensioners

The MARTIN®QC™#1 heavy-duty pre-cleaner and the Martin Engi-

neering spring tensioners specifically developed for it give excellent

results and conform to the general state of technology.

Martin Engineering recommends the following spring tensioners for

the MARTIN®QC™#1 heavy-duty pre-cleaner:

•MARTIN

®TWIST™spring tensioner:

Part number 31443-I+E.

•MARTIN

®TWIST™spring tensioner with L-bracket: Part

number 31443-IL+E.

•MARTIN

®spring tensioning device:

Part number 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

2.3 Type explanation

Cleaner blades for the MARTIN®QC™#1 heavy-duty primary clean-

er are available in different materials. The required material can be

selected to match the respective material conditions. The selection

of different materials for blades is listed in the chapter on "Part num-

bers".

Installation Preparation

3 Installation Preparation

3.1 Prior to Installation

3.1.1 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).

3.1.2 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.

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 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

®QC™#1 heavy-duty primary cleaner,

• 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

4 Installation

4.1 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

4.2 Installation procedure

4.2.1 Determining the installation position

Determining the position of the mainframe and the tensioner of the

MARTIN®QC™#1 heavy-duty primary cleaner must be done on

both sides of the chute wall. In doing so, the positions are deter-

mined where the mainframe of the MARTIN®QC™#1 heavy-duty

primary cleaner passes through the chute wall or where the tension-

er is installed on the chute wall.

The MARTIN®QC™#1 heavy-duty pre-cleaner is operated along

with a spring tensioner. This is de-installed at the factory before de-

livery and is reinstalled during the installation along with the primary

cleaner.

The installation of the MARTIN®QC™#1 heavy-duty primary cleaner

and the tensioner is described in this manual and in 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 Positioning the mainframe of the

primary cleaner

M3618

2Installing the primary cleaner M3618

3 Installing the tensioner M3296 or M3263

4Installing the primary cleaner M3618

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®QC™#1 heavy-duty pre-cleaner is only installed in

the front lower quarter of a head drum. 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 improved maintenance and repair access.

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

head drum at a distance of 216 mm. The intersection with the

arc marked in step 5 is the midpoint of the mainframe (3, Fig. 2).

Diameter of the drum* in mm Measurement X in

400 102

>=400 89

*incl. Friction material and conveyor belt

Tab. 2: X values for the 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.

90°

min.

216

Installation

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

4.2.2 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®QC™#1 heavy-duty pre-

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

4.2.3 Installing the primary cleaner

1. First remove the cleaner blade from the mainframe as de-

scribed below:

• To do this, open the pin hitch (2, Fig. 3) with the clip lock

and pull it out.

• Then pull the cleaner blade (4, Fig. 3) from the hollow

spring dowel sleeve (1, Fig. 3).

2. Follow the relevant instructions of the respective tensioner

used to install the mainframe.

3. Place the cleaner blade on the mainframe once it has been in-

stalled in the tensioner. Make sure that the cleaner blade is po-

sitioned in such a way that the tip of the cleaner blade points

towards the conveyor belt.

4. Then slide one end of the cleaner blade into the hollow spring

dowel sleeve until it sits tight and place the cleaner blade on the

mainframe.

5. Secure the cleaner blade with the pin hitch using the clip lock.

Fig. 3: Installing the primary cleaner

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