Installation Instructions for Conveyor Belt Arrestor (PATENT 95/6363)
A Product of GRUISFONTEIN ENGINEERING C.C.

A. GENERAL

Refer to the component description drawing of the CONVEYOR BELT ARRESTOR. It is assembled and tested prior to delivery to ensure that all components fit properly and that it functions correctly. All beams are marked for your convenience, to ensure that they are all installed in the right place. They are marked with numbers at each end. Care must be taken to ensure that the CONVEYOR BELT ARRESTOR is installed correctly i.e. the support beams (7a and 7b) must be facing in the run-away direction in order for them to carry the load and for the ARRESTOR to operate properly. Normal L & R positions would be that when standing in front of the conveyor belt's arrestor looking in normal running direction of the belt.

B. INSTALLATION INSTRUCTIONS

When a component is named it's corresponding number on the component description drawing will follow it, for example CLAMPING BEAM (14).

Please note that the belt should be locked out of operation while installing the CONVEYOR BELT ARRESTOR. All bolts must be properly tightened, especially all bolts in the CLAMPING BEAM (13).

The following bolts, nuts and washers is supplied with the machine:

20 x 95 mm high tensile steel 12 off - for beam 13 onto beam 3.

20 x 75mm high tensile steel 28 off - for beam 14a onto beam 1 and beam 14a onto beam 13. Also for beam 16 onto beam 3.

10 x 4Omm mild steel 18 off - for drive end / non drive end brackets onto beam 1 and bearings onto brackets as well as directional switch onto bracket, bearings onto brackets and valve on beam 1.

8 x 3Omm mild steel 4 off - for gearbox onto bracket.

20 x 75mm mild steel 44 off - for all other brackets.

Use flat washers on round 2Omm holes and square washers on slots.

  1. Determine where the CONVEYOR BELT ARRESTOR is to be installed. It is recommended that this should be at about one third of the total length of the belt down from the head pulley. But this is totally up to the customer.

  2. Position UPRIGHT BEAMS (1), (3) and SUPPORT BEAMS (14b) into position. Beams marked (1) have a right and left. Install beam (1R) on the right hand side of the normal running direction. A total of 6 beams. The UPRIGHT BEAMS (1 + 3) must be at a 90 angle with the belt and SUPPORT BEAMS parallel with the BELT. The distance of thess beams to the stringer must be the same at both sides, in other words the belt must be in the middle between Beams (3) and in the middle of Beams (1). SUPPORT BEAMS (3) must be at the runaway direction of the belt and SUPPORT BEAMS (1) at the normal running direction. Normally the stringers must be cut and after installation of the machine, be secured onto beams (1) and (3 or 7).

  3. Fit CROSS BEAM (15a) into BEAMS (3). Fit CROSS BEAM (15b) with CLEVES facing inwards, onto UPRIGHT BEAMS (1).

  4. Slide the SPACER BUSH over the SHAFT BEAM (5) and push the SHAFT in the BUSH of BEAM (16) that is already fitted. The CLEVES of beam (5) must face the normal running direction of the belt towards BEAM (1).

  5. Slide the other SPACER BUSH over the other side of shaft. Fit the BUSH of BEAM (16) over the SHAFT and then secure BEAM (16) onto BEAM (3).

  6. Install the AIR CYLINDER with the SHAFT towards the belt. Make sure that both pins are fitted with the circlips provided. The back side of the CYLINDER is now fitted onto CROSS BEAM (15b) and SHAFT onto ARRESTING ARM (5).

  7. Fit SUPPORT BEAMS (7a and 7b) onto BEAMS (3) - two on each beam.

  8. Fit clamping beam (13) with the cover plate facing upwards onto beams(3). Fit beams (14a) in between upright beam (1) and CLAMPING BEAM (13).

  9. Secure the CONVEYOR BELT ARRESTOR onto the footwall by using High tensile HAS Anchor Rods with nut and washer, 3Omm diameter x 70Omm long. (These can be obtained from Hilti Fastening Technology, Customer Services; Telephone (011-887 3500.) These should be grouted into the footwall at least 70Omm deep.

  10. Fit to NON DRIVE END BRACKET onto BEAM (1) on the walkway side of the belt and fit 3Omm PILLOW BLOCK.

  11. Fit DRIVE END BRACKET at the other side onto BEAM (1).

  12. Fit the MONITOR ROLLER into the BEARING that is installed. Fit the other BEARING and secure onto bracket.

  13. Fit the COUPLING onto the SHAFT of the MONITOR ROLLER (8).

  14. Fit the REDUCTION GEARBOX with SHAFT and COUPLING to link with MONITOR ROLLER.

  15. Fit the FRICTION SWITCH with SHAFT and SPRAG CLUTCH into REDUCTION GEARBOX. Make sure everything is properly aligned.

  16. Turn the MONITOR ROLLER in the normal running direction of the belt. The SHAFT in the FRICTION SWITCH must be stationary. Turn the MONITOR ROLLER in the running direction. The SHAFT in the FRICTION SWITCH must now turn. Adjust the height of the MONITOR ROLLER by moving the two brackets up or down. The ROLLER must be at contact with the belt at all times without excessive pressure on the belt.

  17. Fit SOLENOID VALVE onto beam (1). Connect air hoses between solenoid valve and air cylinder according to diagram. Diagram is supplied with each solenoid valve. Hoses from valve to CYLINDER is provided.

  18. See the ELECTRICAL CONNECTION DRAWING. Connect power supply to SOLENOID VALVE (6) and FRICTION SWITCH (11).

  19. AIR SUPPLY: A minimum air pressure of 4 bar is required for operation with a maximum of 15 bar. Connect the air supply from the main air line to the inlet port off the solenoid valve. In this line a water trap and a on / off valve must be installed (to be supplied by mine or contractor) All this must be able to withstand a pressure of 20 bar and have a minimum inner diameter of 2Omm. The inlet port of the solenoid valve is 2Omm UNC thread. The air cylinder (4) keeps the arresting arm in the up position when the solenoid valve (6) is de-energised.

  20. Connect the LIMIT SWITCH (12) to the CONVEYOR BELT SAFETY CIRCUIT to ensure that the belt drive is tripped when the ARRESTING ARM (5) starts to the conveyor to move down. (Optional)

  21. Ensure that all bolts are tightened and the CONVEYOR BELT ARRESTOR is securely fixed to the footwall.

C. ADJUSTING AND SETTINGS

  1. Let the CLAMPING BEAM (13) about 20-25mm below the belt by moving it up or down in the slots provided. Tighten bolts and nuts and lock adjusting bolts.

  2. Adjust the ARRESTING ARM (5) that when lowered, the gap between the ARRESTING ARM (5) and the CLAMPING BEAM is half (1/2) the thickness of the belt. For example, if the belt is 2Omm thick, the gap between the arm 5 and beam 13 must be 1Omm.

  3. Tighten all bolts and nuts on the machine.

D. TESTING

  1. Before testing make sure no persons are near arresting arm (5).

  2. Turn the MONITOR ROLLER in the running direction. The CYLINDER must be retracted thus lifting the ARRESTING ARM (5).

  3. Turn the ROLLER in the runaway direction. As soon as the FRICTION SWITCH (11) has made contact, the SOLENOID VALVE (6) should energise and the air supply should extend the air cylinder. The ARRESTING ARM (5) will lower and clamp the belt down. Measure again the gap as described in C3 above.

  4. Make sure the ARRESTING ARM is clear of any tools and persons. To retract the CYLINDER open the DIRECTIONAL SWITCH ASSEMBLY. Manually move the DIRECTIONAL SWITCH to other side. This will cause the ARRESTING ARM to lift. Close the DIRECTIONAL SWITCH. BEWARE OF ELECTRICAL SHOCK.

  5. Contact Gruisfontein Engineering at tel no: 018 - 6321777 to arrange a date for commissioning. If you have any problems, do not hesitate to contact us.