Flexco MHCP Documento técnico

MHCP Primary Cleaner

Installation, Operation

and Maintenance Manual

www.ﬂexco.com

MHCP Primary Cleaner

Purchase Date:______________________________________________________________

Purchased From: ____________________________________________________________

Installation Date: ____________________________________________________________

This information will be helpful for any future inquiries or questions about belt cleaner

replacement parts, specifications or troubleshooting.

Table of Contents

Section 1 – Important Information ...........................................................................................................4

1.1 General Introduction ..................................................................................................................................4

1.2 User Benets ................................................................................................................................................4

1.3 Service Option .............................................................................................................................................4

Section 2 – Safety Considerations and Precautions ..................................................................................5

2.1 Stationary Conveyors..................................................................................................................................5

2.2 Operating Conveyors ..................................................................................................................................5

Section 3 – Pre-Installation Checks and Options......................................................................................6

3.1 Checklist .......................................................................................................................................................6

3.2 Cleaner Location Adjustments ..................................................................................................................7

Section 4 – Installation Instructions..........................................................................................................8

Section 5 – Pre-Operation Checklist and Testing....................................................................................12

5.1 Pre-Op Checklist .......................................................................................................................................12

5.2 Test Run the Conveyor .............................................................................................................................12

Section 6 – Maintenance ..........................................................................................................................13

6.1 New Installation Inspection ...........................................................................................................................13

6.2 Routine Visual Inspection........................................................................................................................13

6.3 Routine Physical Inspection.....................................................................................................................13

6.4 Blade Replacement Instructions..............................................................................................................14

6.5 Maintenance Log .......................................................................................................................................16

6.6 Cleaner Maintenance Checklist...............................................................................................................17

Section 7 – Troubleshooting ....................................................................................................................18

Section 8 – Specs and CAD Drawings......................................................................................................19

8.1 Specications and Guidelines.........................................................................................................................19

8.2 CAD Drawings...........................................................................................................................................20

Section 9 – Replacement Parts .................................................................................................................22

9.1 Replacement Parts List..............................................................................................................................22

9.2 Optional Assemblies, Tensioners & Kits.................................................................................................23

Section 10 – Other Flexco Conveyor Products........................................................................................27

4MHCP Primary Cleaner

1.1 General Introduction

Section 1 – Important Information

We at Flexco are very pleased that you have selected a MHCP Primary Cleaner for your conveyor system.

is manual will help you to understand the operation 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.

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: +27-11-608-4180

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 cleaner. While we have tried to make the installation and

service tasks as easy and simple as possible, it does however require correct installation and regular

inspections and adjustments to maintain top working condition.

1.2 User Benets

Correct installation and regular maintenance will provide the following benets for your operation:

• Reduced conveyor downtime

• Reduced man-hour labor

• Lower maintenance budget costs

• Increased service life for the belt cleaner and other conveyor components

1.3 Service Option

e MHCP Primary Cleaner is designed to be easily installed and serviced by your on-site personnel.

However, if you would prefer complete turn-key factory service, please contact your local Flexco Field

Representative.

Section 2 – Safety Considerations and Precautions

Before installing and operating the MHCP Primary Cleaner, it is important to review and understand the following

safety information.

There are set-up, maintenance and operational activities involving both stationary and operating conveyors. Each

case has a safety protocol.

2.1 Stationary Conveyors

The following activities are performed on stationary conveyors:

• Installation • Blade replacement • Repairs

• Tension adjustments • Cleaning

DANGER

WARNING

It is imperative that Lockout/Tagout (LOTO)

regulations, be followed before undertaking the

preceding activities. Failure to use LOTO exposes

workers to uncontrolled behavior of the belt cleaner

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, springs 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 cleaners. Serious injuries

can be avoided.

2.2 Operating Conveyors

There are two routine tasks that must be performed while the conveyor is running:

• Inspection of the cleaning performance

• Dynamic troubleshooting

Every belt cleaner is an in-running nip hazard. Never

touch or prod an operating cleaner. Cleaner hazards

cause instantaneous amputation and entrapment.

Never adjust anything on an operating cleaner.

Unforseeable belt projections and tears can catch on

cleaners and cause violent movements of the cleaner

structure. Flailing hardware can cause serious injury

ordeath.

Belt cleaners can become projectile hazards. Stay as far

from the cleaner as practical and use safety eyewear and

headgear. Missiles can inflict serious injury.

6MHCP Primary Cleaner

3.1 Checklist

Section 3 – Pre-Installation Checks and Options

• Check that the cleaner size is correct for the beltline width

• Check the belt cleaner carton and make sure all the parts are included

• Review the “Tools Needed” list on the top of the installation instructions

• Check the conveyor site:

- Will the cleaner be installed on a chute

- Are there obstructions that may require cleaner location adjustments

(see 3.2 – Cleaner Location Adjustments)

- Is the install on an open head pulley requiring mounting structure

(see 3.3 – Optional Installation Accessories)

3.2 Cleaner Location Adjustments

Section 3 – Pre-Installation Checks and Options

In certain applications it is necessary to modify the location of the primary cleaner pole due to permanent

obstacles that obstruct the desired location. Relocating the pole location can be done easily and does not hinder the

performance of the cleaner as long as the “C” dimension is maintained.

NOTE: In the following example we will be lowering the pole location in the “Y” direction, but the same method

could also be applied in the “X” direction.

Conveyor situation:

Pulley Diameter: 900mm

X = 450mm

Y = 359mm

C = 575mm

1. Determine the given location dimensions and define the change needed. After laying out the given X & Y

dimensions, determine the distance of the modification required for adequate clearance of the pole and tensioning

system. (In the example we decide to lower the pole 50mm to clear the support structure).

2. Write down known dimensions. We can now determine two of the three required dimension which will allow us

to find the third. We know we cannot alter the “C” dimension, so this will remain the same. Also we are required to

lower the unit in the “Y” dimension 50mm, so we add 50mm to the given “Y” dimension.

X = ? mm

Y =359+50=409mm

C = 575mm

3. Determine final dimension. On a flat vertical surface,

using a level, draw one horizontal line and one vertical

line creating a right triangle (Fig 3a). Measure down from

the intersection the determined “Y” dimension and mark

(Fig 3b). With the tape measure starting at the modified

“Y” mark, swing the tape across the “X” line and mark at

the “C” dimension where it crosses the “X” line (Fig 3c).

Measure from the intersection to the “C” intersection and

this will be your new “X” dimension (Fig. 3d).

X = 403mm

Y = 409mm

C = 575mm

900 mm

Fig. 3a

Fig. 3c

Fig. 3b

Fig. 3d

Y 409 mm

mark

This distance is the new

“X” dimension

403 mm

C 575 mm

8MHCP Primary Cleaner

Section 4 – Installation Instructions

Physically lock out and tag the conveyor at the power source

before you begin cleaner installation.

1. Find the X, Y & C specifications. Measure the pulley diameter

(including the belt and the lagging) (Fig. 1).

Pulley Diameter _____mm; X=_____mm; Y=_____mm; C=_____mm.

(Adjustments can be made to the X & Y coordinates to move away

from obstacles as long as the C dimension remains constant.)

CAUTION: Components may be heavy. Use safety-approved lifting procedures.

X & Y Chart for Pole Location

Pulley Diameter

(including belt

and lagging) X Y C

500 254 365 445

525 267 365 451

550 279 365 460

575 292 365 467

600 305 365 476

625 318 365 483

650 330 365 492

675 343 365 502

700 356 365 511

725 368 365 518

750 381 365 527

775 394 365 537

800 406 365 546

825 419 365 556

850 432 365 565

875 445 365 575

900 457 365 584

925 470 365 594

950 483 365 606

975 495 365 616

1000 508 365 625

1025 521 365 635

1050 533 365 648

1075 546 365 657

1100 565 365 673

1125 581 365 686

1150 597 365 699

1175 610 365 711

1200 625 365 724

Blades per Cleaner Size

mm 600 750 900 1050 1200 1350 1500 1800

Blades Required 3 4 5 6 7 8 9 11

4.1 MHCP Primary Cleaner

Tools Needed:

• Tape Measure

• Wrenches or Crescent Wrenches: (2)19mm,

(2) 38mm, (1) 24mm, and (1) 16mm

• C-clamps for AWT only

Fig. 1

Pole Location Specs

Pulley Diameter

(incl. belt and

lagging)

AWT Air/Water Tensioner

PST Spring Tensioner

Supershear Blades

Blade Cartridge

Centre Pole

Extender Pole

MHCP Parts List

Chute Wall

Recommended spacing from back chute wall

Maximum

lump size

+ 200mm (8")

5. Install the mounting bases.

Bolt the mounting bases to the

chute with the bolts provided

(Fig. 5).

6. Install the blade cartridge.

Place the blade cartridge onto

the centre pole. Adjust the

extender poles until the holes

align with the holes in

the centre pole and lock the cartridge into place with the two bolts,

washers and nuts (Fig. 6). NOTE: Be sure at least 150mm of the extender

pole extends out of the mounting base on each side for tensioner

installation. Adjust the extender poles in the centre pole if more or less

length is needed.

Section 4 – Installation Instructions

2. Lay out the dimensions on the chute wall. Measure out the X dimension

horizontally from the centre of the pulley shaft and mark. (NOTE: It may be

easier to put a level on top of the pulley shaft, draw a horizontal line and then

measure down half the diameter of the shaft and make a line from the front of

the shaft. Now subtract half the pulley shaft diameter from the X coordinate

and measure on the line and make a mark.) Then measure down vertically the

Y dimension and mark. This is the correct position for the centre of the cleaner

pole (Fig. 2). Lay out and mark the same dimensions on the other side.

3. Mark and cut the mounting base holes. Using the

mounting base template provided in the instruction packet,

position the large pole hole of the template on the chute with

the hole notches aligned with the layout lines. Trace the pole

hole and mounting holes (Fig. 3). Each base can be mounted

in any position 360° around the pole as long as the pole’s

centre point does not change. Cut the holes on both sides of

the chute.

4. Assemble the extender poles to the centre pole. Insert the

extender poles through the chute holes and into the centre

pole and make sure the locating bolt holes align with the

centre pole holes (holes are offset to the lower half). Position

the centre pole with the welded nuts and locking bolts on

one side facing down and on the adjoining side facing away

from the head pulley (Fig. 4). Leave the locking bolts loose.

4. 1 MHCP Primary Cleaner (cont.)

mark

Center large template hole notches on pole center mark,

rotate to desired angle and trace holes

Template for

PST mounting baseTemplate for

AWT/NT mounting base

Blade

Cartridge

6" of pole end

must extend

outside the

mounting base

on each side

Align holes

and install

bolts, washers

and nuts

Extender

Pole

Mounting Plate

(Pst Shown)

Chute wall

(cut away)

Chute wall

(cut away)

Center Pole

Extender Pole

Must be facing

away from

head pulley

Locating bolt

holes

Locking

Bolts

Must align with

extender pole

holes

Must be

facing down

Fig. 2

mark

Center large template hole notches on pole center mark,

rotate to desired angle and trace holes

Template for

PST mounting baseTemplate for

AWT/NT mounting base

Blade

Cartridge

6" of pole end

must extend

outside the

mounting base

on each side

Align holes

and install

bolts, washers

and nuts

Extender

Pole

Mounting Plate

(Pst Shown)

Chute wall

(cut away)

Chute wall

(cut away)

Center Pole

Extender Pole

Must be facing

away from

head pulley

Locating bolt

holes

Locking

Bolts

Must align with

extender pole

holes

Must be

facing down

Fig. 3

mark

Center large template hole notches on pole center mark,

rotate to desired angle and trace holes

Template for

PST mounting baseTemplate for

AWT/NT mounting base

Blade

Cartridge

6" of pole end

must extend

outside the

mounting base

on each side

Align holes

and install

bolts, washers

and nuts

Extender

Pole

Mounting Plate

(Pst Shown)

Chute wall

(cut away)

Chute wall

(cut away)

Center Pole

Extender Pole

Must be facing

away from

head pulley

Locating bolt

holes

Locking

Bolts

Must align with

extender pole

holes

Must be

facing down

Fig. 4

mark

Center large template hole notches on pole center mark,

rotate to desired angle and trace holes

Template for

PST mounting baseTemplate for

AWT/NT mounting base

Blade

Cartridge

6" of pole end

must extend

outside the

mounting base

on each side

Align holes

and install

bolts, washers

and nuts

Extender

Pole

Mounting Plate

(Pst Shown)

Chute wall

(cut away)

Chute wall

(cut away)

Center Pole

Extender Pole

Must be facing

away from

head pulley

Locating bolt

holes

Locking

Bolts

Must align with

extender pole

holes

Must be

facing down

Fig. 5

Fig. 6 Blade

Cartridge

150 mm of pole

end must extend

outside the

mounting base

on each side

Align holes

and install

bolts, washers

and nuts

10 MHCP Primary Cleaner

Section 4 – Installation Instructions

7. Centre the blades on the belt.

Slide the pole until the blades

are centreed or cover the belt’s

material path (Fig. 7). NOTE:

Standard blade coverage is

belt width minus 150mm. If

less blade coverage is required,

single blades can be removed

from the blade cartridge.

The blades do not have to be

centred in the cartridge. They

should be centred on the belt’s

material path.

8. Lock the extender poles in the centre pole. Tighten the two locking bolts and jam nuts on each end of the centre

pole (Fig. 8).

Install the tensioning system. For the PST Spring Tensioner go to step 9S. For the AWT Air/Water or PAT

Tensioner proceed to step 9A.

9S. Install the torque pivot rod. Remove the

adjusting nuts and springs from the rods.

The pivot rod base can be installed in any of

the four mounting plate holes. Determine

the rotation desired. Insert the pivot rod

mounting bolt through the chute wall and

the mounting plate and into the pivot rod

base and tighten (Fig. 9S).

10S. Slide the torque arm onto the pole end. Again ensuring the

correct pulling rotation, put the torque arm onto the pole end

and rotate it around until the torque pivot rod slides through

the slot (Fig. 10S).

11S. Reassemble the spring assembly. Slide the spring, washer and

bushings onto the pivot rod and turn the two adjusting nuts

so about 6mm of the rod is exposed above the nuts (Fig. 11S).

Complete steps 9S through 11S on the other side.

12S. Tension the blades to the belt. Rotate the blades until they contact the

belt. While holding the spring bushing flat on the torque arm, rotate the

torque arm until the pivot rod is against the end of the slot nearest the

pole. Tighten the locking bolts and jam nuts on the torque arm (Fig. 12S).

NOTE: The torque arm should be up against the mounting base.

Primary Cleaner Spring

Tensioner (PST)

4.1 MHCP Primary Cleaner (cont.)

Fig. 7 Fig. 8

Slide pole to center

blades or cover

belt’s material path

Remove

blade stop

to slide

blade(s)

off if

necessary

Tighten locking bolts and

jam nuts (both ends)

Slide pole to center

blades or cover

belt’s material path

Remove blade

stop to slide

blade(s) off if

necessary

Tighten locking bolts and

jam nuts (both ends)

Pivot Rod

Bushings

Adjusting

Nuts

Washer

Torque

Arm

Torque

Pivot Rod

Pivot Rod Base

Torque Pivot

Rod

Chute

Wall

(cut

away)

Pivot Rod

Mounting Bolt

Pivot rod against slot

end nearest the pole

Tighten

locking bolts

and

jam

nuts

Fig. 9S

Slide pole to center

blades or cover

belt’s material path

Remove blade

stop to slide

blade(s) off if

necessary

Tighten locking bolts and

jam nuts (both ends)

Pivot Rod

Bushings

Adjusting

Nuts

Washer

Torque

Arm

Torque

Pivot Rod

Pivot Rod Base

Torque Pivot

Rod

Chute

Wall

(cut

away)

Pivot Rod

Mounting Bolt

Pivot rod against slot

end nearest the pole

Tighten

locking bolts

and

jam

nuts

Fig. 10S

Slide pole to center

blades or cover

belt’s material path

Remove blade

stop to slide

blade(s) off if

necessary

Tighten locking bolts and

jam nuts (both ends)

Pivot Rod

Bushings

Adjusting

Nuts

Washer

Torque

Arm

Torque

Pivot Rod

Pivot Rod Base

Torque Pivot

Rod

Chute

Wall

(cut

away)

Pivot Rod

Mounting Bolt

Pivot rod against slot

end nearest the pole

Tighten

locking bolts

and

jam

nuts

Fig. 11S

Slide pole to center

blades or cover

belt’s material path

Remove blade

stop to slide

blade(s) off if

necessary

Tighten locking bolts and

jam nuts (both ends)

Pivot Rod

Bushings

Adjusting

Nuts

Washer

Torque

Arm

Torque

Pivot Rod

Pivot Rod Base

Torque Pivot

Rod

Chute

Wall

(cut

away)

Pivot Rod

Mounting Bolt

Pivot rod against slot

end nearest the pole

Tighten

locking bolts

and

jam

nuts

Fig. 12S

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