“G17 “LAd STIIIW Y3agesny TINV SlTala) BAOASIANODINTRODUCTION The life of a Conveyor Belt depends on a number of factors such as regular maintenance, periodic belt checks, prompt repair of damages and the use of vulcanised spliced joints wherever possible. This booklet details the above subjects exhaustively. The instructions given hercin are simple and straight forward and result from our vast experience. If these instructions are adhered to strictly and followed carefully and closely, it will ensure that the belt runs its true life and result in the lowest cost per tonne transported.STORAGE OF CONVEYOR BELTING Conveyor belt rolls are packed in cylindrical drums which can be rolled from place to place. All drums are marked with an arrow showing the direction in which the drums should be rotated. When rotated ina direction opposite to that of the arrow, the belt rolls tend to loosen. The drums should never be dropped from goods wagons or trucks while unloading. Due to their weight, dropping the drums will damage the packing and perhaps the belts also. They should either be rolled or skid. For hoisting, asquare hole 110 mm X 110 mmis left in the drum centre which is reinforced and a bar should be passed through this. Chains or cables looped around the bar should be provided with a spreader above the drum to avoid damage to the edges. Conveyor belt drums should be periodically examined while in storage to ensure that the packing is not deteriorating. The drums are made from unseasoned Jhelum or Pine wood. If the belting is to be stored for a considerable time, precautions should be taken to ensure that the drums are notattacked by white ants, as these will destroy the packing, Belts are best stored in their drums until they are placed on the conveyors. If the drums are damaged in transit, they should be repaired. If this is not possible, the rolls may be removed from the drums and stored separately. In such a case the belt roll should be so stored that the whole weight of the roll does not fall ona small portion of the belt in the roll as, otherwise, that part of the belt which has to bear the weight of the roll may get distorted and the belt may run crooked when it is subsequently placed on the conveyor. The belt roll should, therefore, be jacked up by placing a bar through the centre of the roll and the bar should be raised up until the belt is clear off the ground. Aconveyor belt drum may weigh upto 10 tonnes dependingupon the size of the roll, and the flooring, therefore, should be strong enough to bear this load. Direct sunlight and heat hasten the ageing of conveyor belts. The drums should, therefore, be stored in as cool a place as possible and covered so that they are not exposed to direct, sunlight: Oil has an injurious effect on the belt covers, which will soften if kept in contact with oil or grease. These materials should not, therefore, comein contact with belts. Water tends to seep intothe belt carcass by capillary action and causes deterioration of the plies overa period of time. The belts should, therefore, be stored dry. When they are despatched from the factory, the open ends of the belts are sealed by a rubber solution to prevent moisture from being absorbed by the carcass. If this solution is removed for any reason, orifthe belts cut and stored subsequently, the raw ends of the belting should be sealed with ‘two coats of conveyor belting solution to prevent ingress of moisture. The shed or store in which the drums are placed should also be well ventilated. Arubber conveyor belt and the packing are inflammable. Reason- able precautions have to be taken to prevent any fire and means should be provided to extinguish a fire should it occur. BELT INSTALLATION The conveyor belt drum should be brought to the point of installation and mounted on a suitable shaft, so that the drum can be rotated to unroll and thread the belt on to the conveyor. “ARM” conveyor belting is rolled at the factory with the carrying side out in the roll. The carrying side is also branded on the belt. When mounting the drum, care should be taken to ensure that the belt leads off the top of the roll if itis being pulled on to the carrying idlers, but off the bottom of the roll if it is being pulled on to the return idlers. If the new belt is being installed to replace the old belt, the best procedure is to use the old belt to pull in the new belt. To do this it necessary to clamp the new belt to the end of the old belt, using approximately half the usual number of the plate fasteners. The conveyor is then started and the new belt pulled in. Simultaneously the old belt may be pulled out with the help of a truck or tractor. When. the new beltis pulled in’completely the end of the old belt can now be unfastened and the new belt tensioned and spliced.If the belt is being installed on a new conveyor, a rope or cable should be attached by means of aclampto the belt end. The clamp can be made from 5.0 mm or 10.0 mm thick plates, 100 mm less than the belt width. The clamp is attached to the belt end with bolts placed at 100 mm intervals about 50 mm back from the belt end. The rope or cables then attached to this clamp by welding an eye to the plate. The rope or cable is used in a manner similar to that used for an old belt to pull on the new. The rope or cable may be attached toa truck, tractor or other means of providing traction. When installing a new belt great care has to be taken to see that, the belt does not rub or catch on sharp comers or rough edges of the steel work. BELTS SPLICED ENDLESS Limitations of metal fasteners Every conveyor belt needs to be joined with mechanical fasteners ‘ora vulcanised splice. A belt joined with mechanical fasteners has the following disadvantages : (a) The strength obtained at the joint is only about 50% of the strength of the belt. (b) Where hot materials are conveyed, metal fasteners absorb the heat and transmitit to the belt plies causing carcass deterioration. (Most metal fasteners cause leakage of fine mat joint. through the (@) Metal fasteners require frequent inspection, as fastener fatlure can be a cause of severe belt damage. (e) Where the material carried is wet, water will seep into the joint and cause the fabric reinforcement to rot. Advantages of vulcanised splice Wherever practicable, a vulcanised splice is recommended for joining conveyor belting. A vulcanised splice will (a) Last longer than any type of fastener. (b) Develop nearly the strength of the belt itself. (© Not tear out suddenly, but give ample war to be made. \gin time for repairs (d) Maintain the continuous surface of the belt on both sides, forming a smooth endless band. (e) Travel smoothly over idlers and terminal pulleys, reducing idler and pulley wear, (f) Bend around pulleys without injury to the belt. (® Permit magnetic separators, belt cleaners and scrapers to work to maximum efficiency. (h) Seal the ends of the belt against damage from moisture and fine material, thereby increasing belt life (Reduce noise. ()_Economise on maintenance and cleaning by preventing 5 through fastener gap. lage Limitations of vulcanised splice A vulcanised splice is not recommended where {a) Frequent extensions or retractions of conveyor length are made, as in under-ground coal mining, quarrying, ete. (b) Inadequate take-up has been provided, as this would require removal of pieces of belt frequently to restore belt tension. (©) Thebeltis being used continuously and itis not possible to stop it long enough to allow a splice to be made.Equipment, materials and tools required for splicing belts The following equipment, materials and tools are required for spl belts endless on site -— ing 1. Portable electric vulcanising press. A Harvey Forest belt vulea- niser, Model G or Jis frequently used for this purpose. Model Gis suitable for belts upto 1200 mm widths and Model J issuitable for belts upto 1500 mm widths. 2. Two moulding irons of sufficient length, approximately 25 mm wide and of a thickness of 0.5 mm to 1.0 mm less than the thickness of the belt to be spliced. 3. Two carpenter-joining-clamps to apply pressure onthe moulding, irons placed along the edges of belt. 4, Achain block or pull lift and tackle for tensioning the belt. 5. Two angle irons or wooden clamps for lashing the belt. 6. Wooden planks approximately 2 m long to build up a platform slightly wider than the belt and about 1 m longer than the splice. This is to give a firm working area under the belt to allow efficient working while making the splice. 7. Heat re ig leather glovés to handle the vulcaniser. 8. A set of spanners to tighten the vulcaniser. 9. Straight edge or ruler and steel tape about 2 m. long. 10. Right angle steel square with at least 1.5 m long side. 11. Rubber cutting knife. 12. Ply cutting knife. 13. Screw driver at least 400 mm long, 14, Vee knife. 15. Wire brush. 16. Pincers. 17. Rubber cutting scissors. 18. Hand roller. 19. 20. 21. 22. 23. 24, 25. 26. 27. 28. 29. . Cover compound. This compoun: Serrated edge wheel. Pricker or sharp pointed aw. Soft hair brush. Paint brushes 50 mm wide. Emery cloth No. 2. Approximately 6 sheets, 300 mm square are required per splice. Naphtha pads. These can be made up by stitching together 4 to 6 layers of cloth approximately 75 mm to 100 mm square. About 2 pads are required per splice. Grease proof paper. Small strips of grease proof paper are placed on the channels of the splice before curing to prevent the rubber from adhering to the press platens. If grease proof paper is not available, Holland glazed cloth or tracing cloth may be used. Solvent naphtha. This is used for cleaning, It can generally be obtained from petroleum companies, who sell it as Solvent Oil S.B.P., 55°/115°C. If solvent naphtha is not available, non-leaded petrol may be used. An average splice requires approximately 2 litres of naphtha or petrol Conveyor belting solution. Normally three coats of this solution are applied by brush to replace the frictioning on the fabric plies. ‘An average splice may require upto 5 litres of this solution. Insulation compound. This compound is applied over the conveyor belting solution to skim coat ot top the plies. An average splice may require upto 1 kg of this compound. used to build up the face and back cover channels and any thickness of cover can be built up by using several layers of the compound. An average splice may require approximately 0.5 kg of.this compound.RANGE OF SPLICING ACCESSORIES 1. Conveyor belting solution ‘This solution is applied by brush over the fabric plies or carcass, after cleaning, in order to replace the frictioning which is removed during the splicing or repairing of conveyor belts. The solution is available in five litre containers. 5 litres can cover approximately 4.5 sq. mt. per coat. Three coats of this solution have to be applied and an average splice requires upto 5 litres conveyor belting solution. It has a shelf life of 9 months. 2, Insulation compound This compound is applied over the conveyor belting solution in order to skim coat the plies and increase their adhesion. The compound is required for belt splicing only and not for belt repair. Itis packed in 1.5 kg tins containing approximately 20 mts of compound, 150 mm wide and 0.35 mm or 0.6 mm thick, interleaved in alkathene. 0.35 mm thick insulation is recommended for use with Fabrics 28, 32, 36, and 42 (CN 40, 45, 50 and 60). 0.6 mm thick insulation is recommended for use with Fabric 48 (CN 75 and 100). An average splice requires upto 1 kg insulation compound. It has a shelf life of 6 months. 3. Cover compound This compound is required to replace cover rubber and is used to build up the face and back cover channels in splices and for replacing damaged covers. It is packed in 1.5 kg tins containing approximately 5 mts. of compound, 150 mm wide and 1.6 mm thick, interleaved in alkathene. Any thickness of cover rubber can be built up by using several layers of the compound. An average splice requires upto0.5 kg cover compound. It has a shelf life of 6 months. 4, Splicing and repair tool kit This kit comprises 15 tools consisting of a serrated edge wheel, rubber cutting knife, ply cutting knife, rimming knife, general purpose knife, flexible steel tape, wire brush, soft brush, solution brushes, screw driver, hand roller, cobbler’s pincers, rubber pricker and rubber cutting scissors. 5. Repair spot vulcaniser This spot vulcaniser has been designed for use with the splicing and repair tool kit for permanently repairing surface damage on any part of a conveyor belt without removing the belt from the installation. It-can, in one operation, vulcanise a repair upto 200 mm X 140 mm. The vulcaniser measures 220 mm X 150 mm X 90 mm and weighs 5.75 kg, It is heated by two 350 watt. 230 volt elements and the temperature is accurately controlled by a bimetal thermostat which has been factory adjusted to operate the vulcaniser at the correct temperature. Asimple clamping press to exert the necessary pressure, while vulcanising the repair, is supplied in two sizes for belts upto 900, mm width and 1200 mm width, respectively. The press is so designed that it permits the vulcaniser to be positioned on any part of the belt and applies the necessary pressure on the area under repair. SPLICING INSTRUCTIONS The following process applies to chevron splices only : Preliminary preparations 1. Selecta suitable location on the conveyor run to make the splice. This location should preferably be horizontal and protected from sun and rain. 2. Check that the take-up is in its minimum position. 3. Install the belt and bring the two ends to the location selected for splicing. Ascertain that the belt to be joined is of the correct length ie, belt length plus the splice length. Ensure that the belt is the right way up. All ARM belts are branded on the carrying side. If the belt is already in operation, stop the belt with the joint at this location.Preparation of the belt for sp! 1 2 Remove about six idlers at this location. Fit clamps to the belt beyond the area to be spliced, leaving the ends free with sufficient spare length to enable them tobe fitted together and cured. Where the belt is already in operation, the metal fasteners should be cut out and removed after the clamps have been fitted to the belt. Tension the belt by anchoring one clamp to the conveyor structure and pull the other clamp with a pull lift or chain block. Anchor the belt in this position by lashing the other clamp to the idlers or to the conveyor structure. Connect the vulcaniser and adjust the thermostat to a tempera~ ture of 140°C. This will be reached in approximately 1.50 hours. If the thermostat is not functioning, control the temperature by switching off when the temperature reaches 143°C and switch- ing on again when the temperature drops to 140°C. is Cut the belt ends square: Usinga stee! tape, mark on carrying side of the belt end, two points half way across the belt width, one at the end of the belt and the other about 3 metres into the belt from the end. Join these two points with a wax crayon. This line is the centre line of the belt. See Fig. 1 <— Approx. 3m— FIG. 1. Drawing the central line. ‘Measure the splice length L plus 25 mm along the centre line of the belt from the end and draw a reference line AB with tailor’s L square, across the belt at right angles :o the belt centre line. See Fig. 2 FIG. 2.: Drawing the reference line ‘The splice length L may be obtained from the formula :— L= Weta x st Where L= Splice length, mm W= Width of belt, mm Number of plies and S = 150 mm for Fabric 28 & Fabric 32 (CN 40 & CN 45) 200 mm for Fabric 36 (CN 50) 250 mm for Fabric 42 (CN 60) 300 mm for Fabric 48 (CN 75) 350 mm for Fabric CN 100 In the case of Fabric 48 (CN 75 & CN 100) if the working tension of the belt is between 75% and 100% of its maximum rated working tension, step lengths of 350 mm and 400 mm respec- tively should be used. Similarly for Nylon Belts. All measurements for marking out the ply steps are taken from the reference line AB. This eliminates the possibility of an accumulating error arising when ply steps are measured from the previous cut.5 ‘Make one mark at a distance of half the width of the belt from the reference line. Join this point to the ends of reference line AB to form a 45° chevron. Draw a second chevron parallel to the first ‘one but 25 mm further back into the belt. Cut through-the belt cover along these lines with the rubber cutting knife, taking care that the ply beneath is not damaged. Remove the strip of rubber cover between these two lines, using the cobbler’ pincers. The channel thus formed is part of the filling channel and leaves the outer ply of the belt exposed. A part of the reference line will be removed by this operation and this should be redrawn on the exposed fabric to the edge of the belt. Using the ply cutting knife, cut through this first exposed ply along the first V-cut line. Prise up the cut ply and rubber cover right across the belt towards the belt end, using the large blunt screw driver. Take care not to damage the ply beneath and just lift sufficient fabric to provide a grip for the cobbler’s pincers.9. Cut the prised ply into narrow longitudinal strips in the area between the first V-cut and the belt end with the general purpose knife. 10. Strip off cover and ply beneath with the cobbler’s pincers towards the belt end. 11 With the general purpose knife, cut the edge rubber of the belt along the exposed ply, flush with the ply step. Check that the length of the step is correct: 13. Prise up the cut ply across the belt towards the belt end as before, and tear off in strips towards the belt end. 12. On the newly exposed ply, draw the second chevron and, using the ply cutting knife, cut through the ply along this line. 14, Repeat V-cut marking, ply cutting and stripping until all the plies have been stepped down. With the general purpose knife, cut the edge rubber on the belt sides flush with the ply steps.15, 16. V7. Cut the last ply and the cover beneath right along through the final V-cut and remove the cut portion. Check that all the steps are cut to the required length. Reverse the belt and cut through the rubber only, ata distance of 25 mm along the belt away from the final V-cut line. Remove this rubber strip. 18. 19. 20. 716 3 Maring of py to. Work on the other end of the belt but on the reverse side, repeating steps 1 to 17, but with the chevron angle marked in the opposite direction. ‘The chanel on the pulley side of the belt goes over the drive pulley fist fotowed by the channel on the face ofthe el The pont the chevron wil Be towards the head ply Using coarse emery cloth and wire brush, clean the surface of the ply steps of excess friction or topping compound. Buff all rubber surfaces that are to be bonded and also rubber covers for at least 25 mm from the chevron. Brush whole splice area free of loose fluff and buffings with the soft brush and ascertain that the fabric is clean and dry. If any doubt exists as to the dryness of the exposed fabric, lay the stepped ends over the heated platen of the press until they are quite dry.21. Apply three coats of conveyor belting solution to the ply stepsat each end of the belt and allow to dry thoroughly. Each coat must dry thoroughly for at least 15 minutes before the next coat is applied. to 22. Lay one layer of the insulation compound over the exposed plies (except the channel) which are stepped down from face side ‘only. Roll down into position with 50 mm dia, roller. Avoid all creases, overlaps and trapped air. 23, Finish by edge-wheeling the insulation compound. Lay a strip of cover compound 6.0 mm wide along the whole length of the splice at either edge of the belt. Roll down and edge-wheel.es 24, 25. Clean the surface with naphtha. Fit both ends of the splice together, ensuring that the belt edges are in a straight line. ‘Match the middle steps with the edges square and carefully butt them. Then progressively fit the other steps into position. Both end steps are 25 mm longer than required. The final joints are edge-wheeled and trimmed with the trimming knife, giving a close butt joint on each side FIG. 4.3 Method of stepping plies W 26. Firmly roll down the whole joint. 27. Halve the filling channel on the back of the belt. The half next to the final butt joint on the leading end of the splice should now be buffed and given two coats of conveyor belting solution ; the whole channel is then covered with one layer of insulation compound to bring it up to the same guage as the rest of the splice. 28. Roll down the whole of the splice area with the hand roller. 29. Lay layers of the cover compound into the filling channel at each endof the splice, building up the coverto the required thickness Prick the rubber after laying each layer. Edge-wheel the joints and trim off any excess rubber. Roll down and prick to eliminate air bubbles. 30. Cover both channels with grease proof paper, Holland glazed cloth or tracing cloth. 31. Mark off each charge and allow for 25 mm overlap between the charges. Vulcanising the splice 32. Place the curing press in position. Position the splice in the press. Care should be taken to see that the channel is vulcanised in one cure if possible. On very wide belts the press may have to be installed at an angle in order to accomplish this. 33. Place moulding irons, which should be 0.5 mm to 1.0 mm less i thickness than the thickness of the belt, along each edge of the belt and press them up against the belt just sufficiently to make contact with the belt by means of the joiner’s clamps. 34. Tighten the joiner's clamps. 35. Carefully tighten the press so as to ensure even pressure. All nuts should first be made hand-tight and then tightened in pairs across the press.36. The following curing table should be used for each charge:— Size of Temperature Time moulding iron in mm *c minutes Upto 13 140 35 131016 140 40 16 t019, 140 50 1910.2 140 65 37. Open the press and position the next charge for curing, with 25mm overlap from the previous one. Cure as for first charge. Repeat for further charges: 38, Examine the cured splice for any defects and trim the edges. 39. After the splice has been cured, ré belt after one hour. stall the idlers and release the Nore: 1G) “Conveyor belt compounds have 4 short shel de of 6 to 9 months. Therefore, before ‘commencing wok ensure that they arin ood condita, (6) aconveyo belt does not have enough spare lenath forthe overlap, an entra piece of belt or Tetinhas to beincorprated, which quires two spss, (0 Waletin isincorporate, the minimum ditance between the two slices should be 3m, (21 Whenever compounds ae applied tothe belt, eshen the surface notin contact with the backing material with naphtha or ptt but dry thoroughly before applying a asembling fr ‘icing. (©) Ply sipping willbe acitated it the lyst withthe goneral purpote knile int 50 mm wide ip. Actual splice length for 3Ply 4 Ply Fabric Fabrics Belt Width “70/3236 =O mm CN4O/45 50 6D 75100 300 40 580 350 a 400 500 600 700 450 55 65725 ws — 500 590660750 50 600 600 700800 900 — 650 os 725859251025, 700 650750 8509501050 750 3 7S WSS O75 800 700 800 900 1000 1100 ‘900 750 850950 10501150, ‘1000 800 900 1000 1100 1200 1200 900 1000 1100 1200 1300 400 00011001200 13001400 1500 105011501250 13501450 2various sizes of belts (in millimetres) 37 oR Thy oh fabric rable Fabre abe Wid) “aay a aaa waa wa ae ‘mm chars 30 dS 100 CNMOMS «30 «a.«7S~— 00 CNMOras «50g 7S 100 OMS «50a 100 wee ee ee ee eee et Oe wo ee ee ee eee ee ee @e fe es tee eee eee mw OM - — HH ee Se ee em em met wm ee ee ee ee Oe ew ee 650 $00 0 SS ro 9s sm 750 950 S030 St ws wo 7S WS 1S rs — 150 Hoo 16S tm 00 1000 1200 1400 16 — «1200450. 700 1980 2200 0 HO 1000 1100 1300 1500 1700. 190012501500 1750 2000 2250 1400 1700 2000 2300 — 1580 00 1200 1200 400 1600 1000 200013501600 1680 7100 2350 1500 1800 2100 2400 2700 1650 2000 2380 Zuo 1400 1300 15001700 1910 2100 145017001950 2200 2450 1600 1900 200 2500 2000 1750. 2100 2450 2800 2150 1500 13501550 17501950 2150 1500. 17502000 2250 2500 150 1950 2250 2550 2850 100 150 2500 2850 3200 NOTE : The above applies for equivalent Nylon Bolting also.Precautions to be taken while splicing 1 Great care must be taken in the use ofa ply cutting knife as,on the lighter weight fabrics, if itis pressed down too much, the next ply will be cut or “nicked”. Careful inspection, by bending the belt along the cut, is necessary. If the next ply is cut, then the belt must be stepped down again to get away from the cut. If a cut is not noticed or is left, the splice may fail prematurely. Operators making splices must keep in practice by handling the knife on scrap pieces of conveyor belting. The buffing operation to remove surplus rubber from the steps is a severe action, especially ifan electrical buffing machine is used instead of emergy cloth. Great care has to be taken to see that the fabric ply is not damaged in the process as this will reduce the strength of the ply considerably. The amount of buffing required can only be judged by experience. Blisters are sometimes formed while curing the splice. These may occur because sufficient time was not allowed for the vulcanising solution or naphtha to dry, or because of foreign matter, or due to moisture in the belt carcass. All blisters must be cut open and the area carefully examined to determine the cause of the blister. Any evidence of what caused the blister must be removed either by pricking off or buffing carefully. The area must be wiped clean with naphtha and two coats of conveyor belting solution applied, allowing each coat to dry thoroughly. If only the cover is blistered, this part of the cover must be removed and replaced with a patch of the required thickness. The patch must be covered with grease-proof paper and cured with appropriate moulding irons for at least 40 minutes at 140°C using the curing table given on page 11 If the blister is in the carcass, this area must be cut open longitudinally and dried thoroughly. It must then be roughened up with emery cloth, wiped clean and dried. Two coats of conveyor belting solution must then be applied, allowing each coat to dry thoroughly. The opening must then be closed and the belt cured with moulding irons, using curing times and tempe- ratures given on page 11 4, Sometimes the edges of the belt along the splice become porous if the moulding irons are not fitted tightly or if the pressure is insufficient while curing, In such cases the area of porosity must be removed, replaced with new compound and treated as for cover repairs. In case the channel is found to be porous after vulcanisation due to insufficient curing pressure, the channel rubber must be removed, replaced with new compound and treated as for cover repairs. BELT REPAIRS When conveyor belts are damaged in service the exposed fabric will deteriorate if leit unattended to. To obtain maximum belt life, damaged covers should be repaired immediately. The following instructions will help to make on-the-spot conveyor belt cover repairs :-— Cut around outside the area to be repaired the rubber cutting knife to remove all dirt and loose cover, making the cut bevelled from the carcass of the belt towards the sound portion of the cover rubber. Care should be taken not to cut outer ply of carcass. The cut should preferably be circular or oval in shape. Care should be taken to ensure that when two cuts meet at a point, they do not cross and form a split in the cover. Using pincers remove the defective portion of cover tubber. This must be done without loosening the cover rubber outside the area to be stripped. When relatively large areas are to be removed, divide the strips by longitudinal knife cuts and remove the strips one at a time. Clean the exposed surface of grease and dirt by swabbing it with solvent naphtha. Then roughen the exposed canvas surface and bevel cut edges with No. 2 emergy cloth or a wire brush. 4, The carcass must be free from moisture. If in doubt, place the exposed surface of the belt under the spot vulcaniser for half hour. Cool and apply two coats of conveyorbelting solution. Each coat must dry separately for at least 15 minutes.5, Cuta patch of cover compound to the correct shape, bevelling, the edges and painting the underside with one coat of conveyor belting solution. 6. When solution on carcass and patch is dry, fit solutioned surface of patch to belt and roll down well with hand roller! 7, Build up the coverto the required thickness, edge-wheeling each layer and pricking it. Trim off any excess at the joints with hand knife and prick patch thoroughly. 8. Cure in press to specified time as shown below:— Cover repaits upto and including 6.0 mm thick... Cover repairs over 6.0 mm thick... 55 minutes, 40 minutes. The temperature will fall as soon as the spot vulcaniseris applied over the repair. The curing time should start only after the vulcaniser again reaches the curing temperature. TRAINING THE BELT A belt has to be trained to run straight and centrally alone the conveyor by adjusting idlers, pulleys and loading conditions in such a way as to correct any tendency for the belt to run crooked. If every portion of the belt climbs or rides off centre at the same place or places, along the conveyor run, it is almost certain that the cause lies in structural defects or misalignment in idiers and pulleys. If, however, one or more portions of the belt persistently run off centre at every point on the convevor, the belt or the jointis the cause of the difficulty. ‘Sometimes a small maldistribution of tension will tend to make a belt behave in this manner, but the trouble will usually disappear onits own accord as the belt gets run in. ‘These are the basic rules for finding out why a belt does not run straight. A combination of the two basic reasons sometimes produces cases that do not appear clear cut as to the cause. In such cases the belt must be observed for a number of belt revolutions when the running pattern will become clear and the cause discovered. The terminal, snub, bend and take-up pulleys should be checked and setlevel and at 90° to the belt centre line. They must not be moved for purposes of belt training, Initially, all troughing and return idlers should also be similarly aligned. Care should be taken before correc tive action is needed to check that all the idlers and pulleys are clean and are free to rotate. Provided that the belt is sufficiently flexible transversely to conform to the troughed contours of the idlers and thus receive the benefit of the guiding action of the rolls, the belt should be trained to run straight in the empty condition. Once this has been accomplished satisfactorily, it will continue to run straight when loaded so long as the load is applied centrally and in the direction of belt travel. The recommended procedure for training the beltis to commence on the return run of the conveyor to ensure that the belt runs centrally as it approaches the tail pulley by adjusting the return idlers. This will ensure that when the belt is run under load, the load itself will help to keep the carrying run in good alignment. If the tail pulley alsoacts asa take-up pulley, a check should be made to ensure that itis set with its axis at 90° to the conveyor run and that itis level. Horizontal gravity take-up mounted on carriages are often offenders n this respect and it is, therefore, necessary to ensure that in such cases the take-up pulley remains in correct alignment throughout its travel. Belt training should proceed from this point right round the conveyor in the direction of belt travel until the starting point is reached. Most modem sets of troughing and return idlers are mounted in a manner which permits the idler axis to be adjusted afew degrees on either side of the correct centre line which is initially set at 90" to the conveyor centre line. This adjustment is usually provided by mounting the idlers on the structure by means of bolts, the holes for which are slotted. If these bolts are slackened off, the whole assembly can be slewed round to guide the belt. When an idler assembly is “trimmed” in this manner the belt will be guided towards that side of the idler which it meets first. Excessive adjustment of this nature will result in increased belt cover wear due to the wiping action between the belt and idler and for this reason it is preferable to make slight adjust ments in several sets of idlers than to makea large adjustment in one. 6The belt should be started intermittently for short periods and its, behaviour studied under no load. Correction should first be made by trimming the idlers at those places where the belt misalignment is likely to cause damage. Very small adjustments should be made at a time and between each adjustment the belt should be run for a few complete revolutions to allow it to settle down to the new conditions. Idler trimming should be carried out three or four sets behind the points where the belt rides out of line. When the danger points have been taken care of, belt training should be started from the tail pulley right round the conveyor in the direction of belt travel until the starting point is reached. Due to the progressive adjustments made upto the starting point, itis often necessary to make further adjustments as the initial settings may not now be sufficient. These adjustments, mainly of a minor character, should be made following the direction of belt travel as before. Ifidlers have been over-trimmed these same idlers should be trimmed back until the belt is running true. It is not advisable to compensate this by adjusting other sets of idlers to steer the belt back into line. In order to avoid this possibility, the idlers should be marked ateach correction. When all corrections have been made and the belt is running satisfactorily, the correct position of the idlers should be permanently marked, so that they may be replaced correctly if ever they are removed for maintenance. In those cases where the beit is too stiff transversely, it will behave very erratically and it will then be necessary to train the belt under load. Before doing so, the return run should be trained as before to run centrally on the tail drum, so that a centralised load will assist subsequent training operations. It is sometimes necessary to leave different sections of the belt loaded overnight in turn to permit the belt to conform better to the troughed idlers. Care, however, should be taken to ensure that the belt is aligned correctly, and that the load is disposed centrally when this practice is followed. Ifa belthas been trained to run correctly when empty but runs off centre when loaded, it is obvious that the fault lies in the method of loading. Off centre loading or loading from the side i.e., not in the direction of belt travel, are the usual causes. The remedy here is to correct the method of loading. 6 In those cases where the belt is sufficiently flexible transversely to trough satisfactorily yet the belt behaviours erratic. a check should be made toascertain that the idlers have been installed correctly and that the idler tilt is in fact in a forward direction. BELT FASTENERS Metal fasteners may have to be used sometimes on belts, and the following information will then be useful. Several types of conveyor belt fasteners are available which are capable of giving satisfactory service provided that they are fitted exactly as recommended by the manufacturers. The most important instruction that should always be followed is to cut both ends of the belt forming the joint absolutely square to the belt centre line. Owing to the fact that the edges of even a new belt may not always be perfectly straight, itis unwise to apply a square to the belt edge. in the case of old belts with worn edges, this procedure in any case, is impossible. Therefore, in all cases, a centre line should be established ‘extending 3 mm back into the belt. The square should be set to this centre line to give a square cut. The belt ends should be sealed by applying two coats of conveyor belt solution. We recommend either of the following types of fasteners for conveyor belts: 1. The Wire Hook Type (e.g. Hayden Nios, Mastabar, P-14, Comet, etc). ‘A special machine is required to apply this fastener, which consists of sections of hooks which are driven into the belt from both faces and made to interlock over a steel pin to form a hinge between the ends of the belt. This type of joint is quiet-running and flexible transversely. The latest development overcomes the main objection of this design, that there is a gap at the joint which allows spillage. This development consists of plastic or synthetic rubber seal strip which is incorporated in the fastening to make a dust tightjoint. The wire hook joint causes the least amount of damage to the belt carcass while fitting as the hooks in the main find their way through the interstices of the belt plies.Wire hook fasteners are available in galvanised steel for normal conveying work and in stainless steel whete conditions are wet, abrasive or corrosive. No. 10 hooks are recommended for belts 9.5 to 12.5 mm thick and No. 15 hooks for belts 12.5 to 16 mm thick. Nos. 6 and 7 size hooks are for belts less than 9.5 mm thick. 2. The Bolted Plate Type (e.g. Plategrip, G.D. Hawk, Astar etc). This type of fastener has been successfully used for many years on heavy duty conveyor belts. Care should be taken to select the correct size in relation to belt thickness and drum diameter. Plategrip fasteners are available in six sizes of plates as follows — Plate No. % % 2% Belt thickness Centre distance Minimum pulley of bolt holes diameter mm mm mm 65 to 11.0 25.5 300 8.0 to 12.5 30.0 350 95 to 14.0 40.0 450 125 0 19.0 55.0 750 175 to 25.5 65.0 1050 22.0 to 38.0 75.0 1225 The plates are available in malleable cast iron or mone! metal. Special templates and tools are required to enable correct fastener spacing to be achieved. They take rather longer to fit than wire hook fasteners and are usually used only on permanent conveyors. 7WORN COVERS (a) Face cover CONVEYOR BELT FAILURES AND SERVICE PROBLEMS Causes, diagnosis and remedies Cause Diagnosis Remedy 1. Cover under-specified. 2. Unsuitable loading. 3. Speed too high. 4. Skirtboards badly set 5. Handling wet sharp material through a tripper in absence of belt cleaning facilities. ischarge chute choking. 7. Insufficient clearance between tail pulley and floor, or excess spillage at this point. Cover wears out uniformly while carcass undamaged and reliable condi- (A) Material accumulates at loading point and increases abrasion— usually with inclined belts. (B) Wear confined to narrow central section of the belt suggests load being concentrated on the centre of the belt by means of too narrow a chute or loading. skirtboards too close together. (A) Cover worn in centre — only a thin’ load carried. (8) On inclined belts, if speed is too high for loading arrangement, material will slide or roll back Wear and scoringat the sides of the face Material sticks to belt and abrades or punctures the face cover when doubling back through the tipper pulleys, Scoring of face cover and cover rubber torn off belt Spilled material accumulates under tail pulley and sets up abrasion, Specify thicker face cover to protect carcass for full belt life. Improve loading conditions. Redesign chute so that material is led on to the belt. Load should be led on to the belt uniformly across its effective width Redesign drive at a reduced speed. Reduce belt speed. Reduce angle of inclination, Avoid loading large lumps without smaller material accompanying them, Adjust skirtboards. Equipment should be installed to clean belt surface before it wraps the second tripper pulley. Design discharge chute with minimum possibility of choking. Also check that choking is not caused by frequent sto- pages. Inctease clearance between tail pulley and floor, fit decking to avoid spillage reaching such a vulnerable point, or prevent spillage.(b) Back cover (0) Edges cur COVER COVER BREAK UP Surface cracking or decomposition. |. Material trapped between skirt- boards and belt. |. Belt speed too low. Idlers affected by dirt in bearings or neglected lubrication. Spillage on to back cover on return . Sand thrown between drive pulley and belt. |. Joint not square. . Belt too stiff for adequate troughing. Loading directly over an idler roller. Skirtboards too long or badly set, Speed too high for proper pick-up of lumps. Broken or seized idler rolls. Damage may result from causes given under WORN COVERS 1,5, 6, 7, 8, etc. Cuts and indentations on pulley side Exposure to sunlight. ‘Wear and cutting at sides. Jamming at loading point, Idlers do not rotate freely and when seized cause abrasive wear on back Material falls from carrying side on the retum pulley side, and causes abrasion of belt in contact with pulley. ‘Sometimes carried out on conveyors in ‘wet weather to prevent slip. Belt runs to one side and fouls support, ete. Back cover at sides will be worn, or belt ‘edges damaged. The belt does not bed down properly and make full contact with the centre of the idlers, and runs to ‘one side or the other. Large lumps of material falling on to the belt over an idler roller which i rigid will ‘cause cover cuts, and carcass fractures. Cutting or scoring at the sides of the belt. Large lumps tend to run back and, if having sharp edges, will cause scoring or cutting, Abrasion or cutting of the back cover following a longitudinal pattern. ‘As for WORN COVERS. Bolt head in pulley protruding above lagging which may be worn. Surface cracking—small cracks in all directions. which extend when helt is 9 Adjust loading and/or skirtboards. Reduce rate of loading or increase belt speed. Lubricate regularly and keep clean. Provide decking to protect return run from spillage. Design and layout of conveyor should enable it to operate efficiently under all reasonable and foreseeable conditions. Remove and rejoin after cutting ends square. Equip the installation with belt more flexible laterally. Avoid idlers at loading point. Adjust skirtboard setting or, if practi- cable, increase belt speed so that load will be more central and will not jam between belt and skirt-boards Redesign drive at reduced speed. Repair or replace unserviceable idles As for WORN COVERS. Remove or tighten bolt. Replace lagging, Protect belt from direct sunlight.Cover softening, ete BELT CARCASS DAMAGE OR DETERIORATION PLY OR COVER SEPARATION 2, Oil or grease on belt. 3. “Short” in magnetic pulley. 4, Carrying hot materials on a standard conveyor belt. 5. Idler spacing unsuitable, givingriseto belt distortion, 1. Impact of large lumps due to unsui- table loading arrangements. 2. Face rubber cover of inadequate thickness. 3. Material rapped between pulley and belt. 4, Mildew—a result of water pene- tration into carcass. 5. Tension too great. 1. Pulley diameter too small—either head, tail, snub or tripper pulleys. 2. Oil contamination. flexed, If contamination is patchy, source will probably be from lubrication system. If general, suspect material being carried, eg, green bricks or tiles ina brick- making factory. Evidence of oil conta- mination will be obvious signs of swell- ing of the cover rubber, which will also be soft and even sticky if contamination hhas been extensive. Belt will also pro- bably run crooked especially if on one side. Belt will be distorted and may not lie flat on idlers. A short in a magnetic pulley will cause heating up of pulley and hence the belt, especially if indoors and away from draughts, etc. Burns in cover or a general cover break- down, atc. Often carcass is exposed and even burned through in places. Longitudinal splits or cracks are pro- ably due to idlers spaced too far apart, siving rise to excessive lateral flexing. Fractures on pulley size-short and usually parallel to belt edge. Numerous cover and carcass fractures. Belt may eventually tear across. Carcass fractures. This may cause belt to tear along its length. Carcass duck dark in colour and exhi- biting no strength in patches. Lateral breaks in carcass at right angles to direction of travel. Joint troubles with fasteners pulling out or belt breaking at fasteners. Separation or “blisters” where there Is no evidence of carcass rot or signs of abuse other than pulley sizes. Rubber in vicinity of separation soft and swollen. 20 Avoid contact with oil and grease, which are injurious to rubber. Correct the electrical fault, (abnormal ‘moisture in atmosphere may be cause of short, etc.). Avoid conveying materials at high tem- peratures unless the belt has been spe- cially designed to suit them. ‘Adjust idler spacing according to reco- mmended practice. Improve loading arrangements. Install “Grizzly” to reduce impact. Reduce maximum lump size or fit hea vier belt, or increase cover thickness. Install scraper on return run to clean belt just before pulley. Avoid source of moisture or fit belt with thicker cover rubber. Reduce tension or install belt with 1er permissible operating tension. Increase pulley size, or if conditions permit, instal lighter belt. Remove source of contamination.‘Too many reverse bends. |. Idler spacing too great. . Edge wear/damage. - Under-belting, -. Cover cuts and penetration of fines. General separation actoss full width of bolt. Belt oo heavy for pulley diameters, Separation near centre of belt, longitu: dinally. Separation at edge and evidence of edge wearas a result of rubbingonsome obstruction, a guide idler, etc. Carcass not sufficiently rigid — excess flexing causing separation—often starts at joint, Blisters at point of cover cuts. Examina- tion of separation will reveal penetra tion of fines and small stones working their way between the face cover and the carcass. 2t Redesign drive and belt. Reduce idler spacing. Conect any misalignment present, or remove obstruction Install heavier belt. Repair cuts which penetrate to carcass.ANIL RUBBER MILLS PRIVATE LIMITED REGISTERED OFFICE: WORKS/ SALES OFFICE: 0.837, NewFriends Colony, PlotNo.30, Sector.6 New Delhi 110085 Faridabad 121 006 Tel:26319479 Tol: 4065637, 38, 39, Fax 91-11-26897381 Fax: 91-129-4065636 ‘91-128-4061637 E-m armak@nda.vsni.net in ‘armakindia@aitelbroadband in Web: vow arilrubber.com