Conveyor-Components-Product-Handbook[1].pdf

COMPONENTS HANDBOOK

Conveyor Idlers, Pulleys, Belt Cleaners and Accessories

Moxie Rolls ®

1

Table of Contents Conveyor Pulleys 01 05 07

Conveyor Pulleys Chevron® Pulleys Core Systems® Designs

Conveyor Idlers 11 15 17 18 19 20 21 23 25 26 27 28

CEMA Rated Idlers Moxie® Rolls 81/91 Series Regreasable Idlers 40 Series Idlers CB504 Idlers Self Aligning Idlers Navigator® Return Trainers Urathon® Return Rolls Rubber Disc Returns Rubber Lagged Returns Beater Bar Returns V-Return Rolls

Belt Scrapers/Cleaners 29 31

Exterra® Primary Belt Cleaner Exterra® SFL Dual Belt Cleaner

Conveyor Accessories 33 34 35 37 39 41 43 45 47 48

Return Roll Guards Guard Panels Conveyor Belt Covers Sealing System Impact Bed Conveyor Take-Ups Superior Belt Scale Superior Auto Greaser Sonicscout™ Material Sensor Contact Us

Core Systems™ Dual Drive

2

Conveyor Pulleys A Complete Line of Pulleys for Every Application

Standard Sizes

(Custom Sizes Available Upon Request)

Diameter: Up to 60” Face Widths: Up to 120” Shafting: Up to 15”

CONVEYOR PULLEYS

Frequently Asked Questions

Features and Benefits

How do I know which class is for me?

Fast Lead Times

There are charts on the next page that help to define applications and match them with specific classes. For an exact match, consider our Core Systems™ Design team. The group of engineers review the specs of your application and design a pulley specific to the job.

What are Superior’s limitations? The specs listed above are considered our standard product line; however that doesn’t mean we cannot go outside of the box for you. If your application specs extend outside our standard listing, contact us to discuss how we can help design and build your big conveyor pulley.

Where can I purchase Superior pulleys? We have teamed up with some of the top distributors in North America to provide you with local sales, service and deliveries. For a listing of our partners, visit superior-ind.com/distributor.

FIG 17.1 DRIVE WEIGHT STRESS TEST

1-2 day turnarounds Expediting services available 10 warehouses stocked with standard products (Fig 17.3) North American distribution network

Comprehensive Product Line

From light, portable applications to high tonnage, extreme jobs CEMA, Mine 1.5, Mine 2.0, Super and Engineered Classes Specialty: Spiral drums and wings, deflection wheels and dead shaft conveyor pulleys

Performance Matched Design

Complete assembly including bearings, couplings, gearing, etc. Engineers apply Finite Element Analysis (FEA) to build per application stress conditions (Fig 17.1)

Quality Craftsmanship

Robotic welding machines for consistent, quality welds Hand welders trained and certified by American Welding Society (AWS)

1

Conveyor Pulleys Pulley Product Line Description

CEMA Duty

Mine Duty 1.5

Mine Duty 2.0

Super Duty

Core SystemsTM Design

Wing Pulleys –

–

–

–

Drum Pulleys

Chevron® Wing Pulley

Design Standards

Load, dimensions and crown defined by ANSI B105.1

Roughly 1.5X service Roughly 2.0X service factor of CEMA factor of CEMA standard standard

Exceeds 2.0X service factor of CEMA standard

Engineered class, FEA Analysis Design, construction based on belt tension, conveyor load, and belt wrap

Conveyor Type

Light duty, portable

Medium duty

Heavy duty

Extra heavy duty

High tonnage

Belt Style

Fabric

Fabric

Fabric

Fabric

Steel cable or fabric

Belt Burden

Not started under load Started under moderate load

Started under full load Started under full load Started under full load

Starts and Stops

Infrequent

Moderate

Frequent

Frequent

Frequent

Load/Feed Characteristics

Uniformly loaded

Uniformly loaded

Non-uniformly loaded



Pulley Product Line Pulley Types

Diameter

Integral Hub Diameter

Face Width

Contact Bar Thickness

CEMA Drum Pulley

4”- 60”

12” and under

12”- 78”

–

CEMA Wing Pulley

6”- 60”

–

12”- 78”

1/4” x 1-1/2” minimum, 3/8” x 1-1/2”, 5/8” x 1-1/2”

Mine Duty 1.5 Drum Pulley

10”- 60”

12” and under

12”- 78”

–

Mine Duty 2.0 Drum Pulley

10”- 60”

12” and under

12”- 102”

–

Mine Duty 2.0 Wing Pulley

8”- 60”

–

12”- 78”

5/8” x 1-1/2” minimum

Super Drum Pulley

10”- 60”

12” and under

12”- 102”

–

Super Wing Pulley

10”- 60”

–

12”- 78”

3/4” x 2” minimum

CEMA Chevron Wing Pulley

10”- 20”

All CEMA

12”- 63”

1” x 1/2” half round bar

Mine Duty Chevron Wing Pulley

12”- 36”

–

12”- 63”

1” round bar

Super Chevron Wing Pulley

12”- 42”

–

20”- 75”

1-1/2” round bar

®

®

®

*NOTE: Other diameters and face widths available upon request. Several hub and bushing types are available with all pulleys.

2

Pulley Product Line

CEMA DRUM PULLEY

MINE DUTY 1.5 DRUM PULLEY

MINE DUTY 2.0 DRUM PULLEY

SUPER DRUM PULLEY

SPIRAL DRUM PULLEY

CEMA WING PULLEY

MINE DUTY 2.0 WING PULLEY

SUPER WING PULLEY

SPIRAL WING PULLEY

DRIVE ASSEMBLIES

CEMA CHEVRON® PULLEY

MINE DUTY CHEVRON® PULLEY

ENGINEERED

SUPER CHEVRON® PULLEY

CORE SYSTEMSTM DESIGNS

CORE SYSTEMSTM DESIGNS

3

Quick Deliveries

FIG 17.3 TEN PULLEY WAREHOUSES STOCKED WITH STANDARD PRODUCTS

Pulley Lagging

4

HERRINGBONE

DIAMOND

SLIDE LAG®

CERAMIC LAGGING OPTIONS

1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-115

SMOOTH

CHEVRON

URETHANE

EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Chevron Pulley ®

V-Shaped Wing Pulley Deflects Fugitive Material

Standard Sizes Classes: CEMA, Mine and Super Duty Diameters: 10” - 42” Face Widths: 12” - 75” Upgrades: Abrasion Resistant (AR) Steel

CHEVRON PULLEY



What are common applications?

Deflects and Sheds Material

Systems where fugitive material is causing wing bending, where uptime is crucial and where noise levels might be a concern.

Is it only a tail pulley? Compared to standard wing pulleys, the Chevron wing is a good alternative for a gravity take-up. It’s a location where you have spillage and where you want to prevent wedged rocks and bent wings.

Traditional Wing: The impact of rocks is directly perpendicular to the wing, causing material to trap easily. Chevron Wing: Rocks hit the wings at a glancing blow, deflecting fugitive material out and away.

Reduces Wing or Fin Bending

Traditional Wing: Over time, trapped fugitive material causes wings to tip or bend. (Fig 16.1) Chevron Wing: Constant deflection prevents entrapment of fugitive material.

How does it compare to spiral wing pulleys?

Longer Lasting Belts

A spiral’s corkscrew shape means they require many spins to auger material from the middle out to the side, versus the material simply deflecting off the plow shaped Chevron wing.

50 Decibels Quieter (Fig 16.2)

What’s the significance of AR steel? Producers requiring high performance in abrasive applications can upgrade to a longer lasting AR model. The wear bars are manufactured with abrasion resistant steel.

Traditional Wing: Trapped material, bent wings and sharp contact bars are three of the most common causes of belt damage. Chevron Wing: Even wearing rounded contact bars and fewer bent wings preserves conveyor belt appearance and performance. Traditional Wing: Apex shape causes belt flapping, much more vibration and 120 db of sustained noise. Chevron Wing: Continuous belt contact significantly reduces beating action, vibration and generates just 70 db of sound.

Traditional Wing Pulley

FIG 16.1 NO MORE BENT WINGS

FIG 16.2 CONSTANT BELT CONTACT

Chevron Wing Pulley

5

Chevron Pulley Chevron Wing Pulley Product Line Specs

Diameter

Face Width

Maximum Wing Height

Wing Thickness

Wear Bar Thickness

CEMA Duty

10”- 20”

20”- 63”

Not defined

3/16” or 1/4”

1” x 1/2” half round bar

Mine Duty

12”- 36”

12”- 63”

Varies with diameter

1/4” - 5/16”

1” round bar*

Super Duty

12”- 42”

20”- 75”

Varies with diameter

3/8”

1-1/2” round bar*

*Upgrade to AR steel model for longer lasting pulleys operating in abrasive conditions.

150 db 125 db 100 db

Standard Wing

75 db 50 db 25 db

Chevron Pulley Radio, Street Noise

Jet Engine, Fireworks

FIG 16.3 REDUCED NOISE POLLUTION

MATERIAL DEFLECTION REDUCES TRAPPED MATERIAL

Producer Perspective Vibrating Office “ I would sit in my office in the scale house and the windows would shake. The vibration is gone now and the only thing we changed were the pulleys!”

Bent Wings “ Our old pulleys had wings folding over or even breaking off, and they were eating away at the bottom side of the belt. Since then, we have installed close to 20 Chevron wing pulleys. Even if we a have little bit of leakage, it spits the rocks out before they bend the wings.”

Plugged Ears

MAINTENANCE SUPERVISOR AT A MINNESOTA QUARRY

“ The noise levels are a night and day difference. We are in the middle of a city, so to have stopped the constant rattling sounds is huge for us.”

Part Number Guide Example: CHVS-4275XT70

6

Style

Type

Diameter

Face Width

Hub Type and Sizes

AR Steel Wear Bars

CHV

C (CEMA), M (Mine Duty), S (Super Duty)

10”- 42”

12”- 75”

XT25 - XT100

AR


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Core Systems Designs ®

Power Transmission Conveyor Components Consulting Services

Standard Sizes


Diameter: Up to 60” Face Widths: Up to 120” Shafting: Up to 15”

CORE SYSTEMS DESIGNS - DUAL HEAD END DRIVE



What is Core Systems Designs?

Single Source Supplier

Simply put, it’s a consulting service to design and supply your power transmission components.

When do I need Core Systems Designs? Anytime you need design expertise advice of your conveyor drive packages. The benefit of the service is, you avoid designing the system or gathering all the parts on your own. It’s one phone call, one point of contact and one warranty. If all you need is a conveyor pulley, then you probably don’t need Core Systems Designs.

Who do I call? We’ve partnered with local distributors to get you the best service and support. To find yours, visit superior-ind.com/ distributor.

Avoid sourcing parts packages from multiple vendors One point of contact One point of purchase

Performance Matched Components

Engineering services align power transmission components to your application Engineers apply Finite Element Analysis (FEA) to build per application stress conditions

Pre-assembled Parts Packages

Eliminates the headaches of onsite assemblies Reduces installation time

Quick Deliveries

Deliveries exceed industry standards Optional 1-2 day turnarounds Expediting services available Stocked power transmission warehouse

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Single Source Supplier

Engineering consultants work directly with you to determine the correct drive package for your application. Motor

Couplings

Variable Frequency Drive

Gear Box

Guards

Shafting

Pulley

Bushings

Shipping Structure

Complete Drive Packages

8

Bearing

BEARINGS

MOTORS

DRIVES

SHAFTING

COUPLINGS

BUSHINGS

GEAR BOX

GUARDING

TAKE-UPS

How it Works

Drive Package Replacement There are two routes, sourcing and assembling the parts on your own or accessing them through one point of purchase.

Contact Superior Distributor We are partnered with some of the best distributors in North America for local sales and support. Find them at superior-ind.com/distributor.

Engineering Consultants Design Package Using the specs of your application, a performance matched package is engineered.

Manufacturing and Assembly Optional 1-2 day turnarounds from phone call to completion if needed.

Package Delivery Guaranteed to work, with the security of a two-year warranty.

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Core Systems Pulley Data Sheet Complete this Form for a Customized Core Systems® Quotation [email protected] • Toll Free – 800-321-1558 • Fax – 320-589-3892 Date __________________________________________________

Submitted By ___________________________________________

Customer ______________________________________________

Contact Name __________________________________________

Plant/Mine/Project _______________________________________

Contact Phone or Email ___________________________________

Application Data:

Altitude (ft) _____________________________________________

Ambient Temp Range (degrees) _____________________________

Operation (days/year) _____________________________________

OperationT/TU (hours/day) ____________________________________ Profile 1 D

Material (type & max lump T/TU size) _____________________________ Profile 1 D

Conveyor Data:

Material Density (lbs/ft3) __________________________________ Profile 1 T/TU D

Conveyor Name/Tag ______________________________________

Material Repose Angle (degrees) ____________________________

Profile 2 D ConveyorT/TU Capacity (TPH) __________________________________

Profile____________________ 2 D Trough Idler Angle, SpacingT/TU & Roll Diameter

Conveyor Length (ft) ______________________________________

Profile 2 T/TU____________________ D Return Idler Angle, Spacing & Roll Diameter

S

S

Profile 1

T/TU

S

D

Conveyor Lift (ft) or Incline (deg) _____________________________ Number of Belt Scrapers/Cleaners ___________________________ T Profile 3 (if not linear, please sketch curve below)

T

D

T B

B B Belt Width (in) __________________________________________

B Profile 3

Length D of Skirtboards (ft) __________________________________

Profile 2

T/TU

D

Profile 3

Number of Belt Plows _____________________________________

D

B B BeltT/TU Speed (FPM) ________________________________________ S TU TU Profile 1 D Height of Material on skirts (in) _____________________________ Motor Horsepower (if known) _______________________________ TU Conveyor Belt Details (if known) _____________________________ T/TU D Profile 4 Profile 1 D T Profile 4 Type of Soft T Start ________________________________________ T D Profile 3 Fabric orD Steel Cord _____________________________________ (Electronic; VFD; Fluid Coupling; or none) ProfileB2

T/TU

D S

B

S Profile 4

B

BT

D

B B S Take-Up Type (manual or automatic) __________________________ Number of Plies & PIW (if known) ____________________________ S B B TU TU TU Covers top x bottom (in x in) ________________________________ Profile 2 T/TU D Total Installed Counterweight (lbs) ___________________________ T Centers Profile D 3 Bearing (in) ______________________________________ Profile 5 T H B B

B B

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T

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D

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T T

T/TU H D

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H/TU D (Reversing) 1-800-321-1558 HD Find local distribution at superior-ind.com/distributor Profile 6 T © 09-2014 Superior Industries CL-117

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Profile 5

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CUSTOMER CARE PLAN

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CEMA Rated Idlers The Broadest Range of Conveyor Idlers on the Market

Standard Sizes Classes: CEMA B, C, D, E, and F Roll Diameter: 4”- 8” Belt Widths: 18”- 120”

CEMA RATED IDLERS



Which CEMA class do I need?

SpinGuard® Seal Technology: (Fig 1.1)

According to CEMA, the main influences in selection are belt weight, material weight, load rating, belt sag, idler life, belt rating and belt tension. It’s a confusing combination of data that we’ve tried to simplify with our Idler Selector Calculator. Find it in the “Quick Links” section at superior-ind.com.

Which roll diameter do I need?

Contact seal prevents foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants Stationary external seal prevents material pinch points

Quick Reaction

Distributors stocked with standard products One to two day turnarounds on custom designs

High Quality Construction

Thick or thicker steel construction compared to other brands Two year complete components warranty Largest, broadest range of all CEMA categories on the market

The rule of thumb considers belt speed. At 400 FPM consider a 4” idler, 500 FPM is 5”, 600 FPM is 6” and so on. It’s also a fact that larger diameter rolls have longer lives due to fewer revolutions and thicker shells.

Economical Retrofit Rolls

Where can I buy Superior Idlers?

No Maintenance Base Frame

We have distribution partners with inventory throughout North America and Central America. For local service and fast deliveries, see our partners at superior-ind.com/distributor.

Slotted shafts fit most competitor frames Hex nut adapter available for hex nut style brackets Angled base sheds material Flared, non-clogging center stands No material pinch points between roll and frame

Idler Specifications Specs

Bearing Size

Diameter

Thickness

Belt Width

CEMA B

17 mm

4”, 5”

11, 9 Ga

18”- 48”

CEMA C

20 mm

4”, 5”, 6”

11, 9, 7 Ga

18”- 60”

CEMA D

25 mm

5”, 6”

9, 7 Ga

24”- 72”

CEMA E

40 mm

6”, 7”

1/4”

36”- 96”

CEMA F

50 mm

7”, 8”

1/2” or 3/4”

42”- 120”

11

SpinGuard Seal Technology 1

1

Flat Surface

Material will not build up across the flat end disc surface

2

Stationary External Seal

Stationary external seal helps prevent material pinch points between the frame and the end of the roller

3 2 3

4

Centrifugal Force Chamber

Centrifugal force creates a self-cleaning flinger effect, keeping water and dirt out

4

Contact Seal

First defense against contaminants is the contact seal, which creates less drag than a rubber seal

5

Triple Labyrinth Seal

Second defense is the triple labyrinth seal which makes contaminants travel a longer distance The labyrinth is also grease filled to keep contaminants away from the ball bearing The durable seal material is more durable and is less susceptible to corrosion

6 5

6

Ball Bearing

Factory sealed metric ball bearing on all CEMA rated idlers

FIG 1.1 SPINGUARD SEAL CUTAWAY

Idler Features 1

Base Plate

Open end stand design gives better access for single or double bolt hole mounting

2 2

No pinch points between roll and frame means no fugitive material jamming

4 6

3

No Pinch Points

3

Locking Mechanism

Integrated locking tab or retainer clip holds roll tight to the frame and offers easy roll change out

5 4

Narrow Roll Gap

No pinch point that leads to belt damage

1

5

Center Stands Non-clogging

6

Base Angle

Sheds material, preventing build-up

12

Producer Perspective Fugitive Material

“ In the beginning, our plant was stocked by another brand and some of them were lasting just three months! We run a lot of wet sand and they weren’t making the cut. ”

Seal Power

“ With other brands, the problems were directly related to bearing failure. Sand was getting through the seals and into the can. I read about Superior’s seal in magazines and now I’m witnessing it! ”

Competitive Comparison

“ Comparing brand to brand, we get three – sometimes four – times the life with Superior Idlers. They definitely fit the bill! ” PLANT SUPT. AT EASTERN COLORADO AGGREGATES, LA JUNTA, CO

Part Number Guide Example: C6-35E-36

1

2

1

3

4

CEMA Rating

Roll Diameter

Troughing Angle

Idler Type

Belt Width

B, C, D, E, F

4” - 8”

20˚, 35˚, 45˚

See Below

18” - 120”

CEMA Rating or Series

Idler Type

Roll Diameter

E: Troughing Idler Equal Length Rolls EI: Rubber Cushion Troughing Idler EA: Self-Aligner BA: Bi-Directional Aligning Idler RET: Return Idler FLT: Flat Carrier Idler FLTI: Flat Carrier Rubber Cushion Idler RETI: Return Rubber Cushion Idler RETU: Urathon® Return RETUSP: Spiral Urathon® Return Roll RETA: Return Self-Aligning Idler Roll RETAI: Return Self-Aligning Rubber Cushion Idler RETV: V-Return Idler P: Picking Idler Length Rolls U: Troughing Idler Unequal Length Rolls CM: Low-Profile Channel Mount Idler CMI: Channel Mount Impact Low Profile Idler SM: Low-Profile Standard Mount Idler SMI: Standard Mount Impact Low Profile Idler GO: Offset Troughing Idler EW: Wire Rope Idler VPE: Variable Pitch Idler MOX: Moxie® Roll CB: CB504 Series LS: Live Shaft LSB: Live Shaft Beater

Specify either CEMA B, C, D, E, or F

2

Specify either 4, 5, 6, 7 or 8 for the roll size diameter

3

Troughing Angle

Specify either 20, 35, or 45 for the troughing angle

4

Idler Type

Specify the idler identification letter for the particular idler, you may need from the chart to the right

5

5

Belt Width

Specify the belt width

13

Idler Styles EQUAL TROUGHING

MOXIE® ROLLS

UNEQUAL TROUGHING

CB504 SERIES

FEEDER/PICKING

CHANNEL MOUNT LOW PROFILE

IMPACT

OFFSET CENTER ROLL

WIRE ROPE

VARIABLE PINCH

V-RETURN

SELF-ALIGNER

SELF-ALIGNING RETURN

LIVE SHAFT ROLLERS

BEATER BAR RETURN

FLAT CARRIER IDLER

RUBBER CUSHION FLAT CARRIER

RETURN

RUBBER DISC RETURN

URATHON® RETURN ROLL

SPIRAL URATHON RETURN ROLL

GARLAND

Products Available in CEMA Rated Idlers Idler Style

CEMA B

CEMA C

CEMA D

CEMA E

CEMA F

Equal Troughing

x

x

x

x

x

Moxie Rolls

–

x

x

–

–

Unequal Troughing

–

x

x

x

x

Feeder/Picking

–

x

x

x

x

Channel Mount Low Profile

x

x

x

–

–

Impact

x

x

x

x

x

Offset Center Roll

x

x

–

–

–

Wire Rope

–

x

x

–

–

Variable Pitch

–

x

x

x

–

V-Return

–

x

x

x

–

Self-Aligner

x

x

x

x

x

Self-Aligning Return

x

x

x

x

–

Live Shaft Return

–

x

x

–

–

Beater Bar

–

x

x

–

–

Flat-Carrier

x

x

x

x

x

Rubber Cushion Flat Carrier

x

x

x

x

–

Steel Return

x

x

x

x

x

Rubber Lagged Return

–

x

x

–

–

Rubber Disc Return

x

x

x

x

–

®

Urathon Return Roll

x

x

x

x

–

Spiral Urathon® Return Roll

–

x

x

x

–

Garland Return

–

x

–

–

–

®

14


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Moxie Rolls ®

Energy Efficient Idlers Consume Less Power than Steel

Standard Sizes Classes: CEMA C and D Roll Diameters: 5” and 6” Belt Widths: 18” - 72”

MOXIE ROLLS



What are Moxie rolls made from?

Sheds Sticky Material

There’s a combination of materials that go into the recipe to develop our specially formulated Moxie rolls.

How thick is the idler shell? Compared to the rest of the market, we offer the thickest shell. Our 6” diameter rolls are equipped with a 1” thick shell while our 5” rolls are 1/2” thick.

How is the roller easier on my crews? Weighing in at more than 40% lighter than their steel equivalents, Moxie rolls are much lighter on the backs and bones of your maintenance crews. Easier mounting helps prevent back injuries, especially in applications with suspended belts, difficult to access rollers and long conveyors.

Standard Steel: Wet, sticky material tends to cake onto steel cans Moxie Rolls: The lubricity of Moxie rolls sheds sticky material Standard Steel: Material bonded to idlers is a chief source of misaligned belts Moxie Rolls: Reduced misalignment and tracking issues Video Proof: http://superior-ind.com/components/idlers/moxie

Corrosion Resistant

Standard Steel: In corrosive environments, steel can rust (Fig 2.1) Moxie Rolls: The specially designed formula is rust resistant Note: Upgrade to stainless steel shafts and frames

Safety

Standard Steel: The more weight, the more power requirements Moxie Rolls: Low roll resistance cuts horsepower requirements Standard Steel: Heavy rollers can be ergonomically unhealthy Moxie Rolls: The lightweight rollers weigh up to 44% less (Fig 2.2)

Reduced Noise

Standard Steel: Steel generates a “clanking” sound when it contacts belt fasteners Moxie Rolls: 3x quieter than steel, Moxie rolls provide noise control in residential zones

Moxie

Weight (lbs)

40

FIG 2.1 NO MORE CORRODED IDLER ROLLS

30 20

Steel

44%

21%

44%

23%

C5-36

C6-36

D5-36

D6-36

10

FIG 2.2 WEIGHT COMPARISON

15

SpinGuard Seal Technology 1

1

Flat Surface

Material will not build up across the flat end disc surface

2

Stationary External Seal

Stationary external seal helps prevent material pinch points between the frame and the end of the roller

3 2 3

4

Centrifugal Force Chamber

Centrifugal force creates a self-cleaning flinger effect, keeping water and dirt out

4

Contact Seal

First defense against contaminants is the contact seal, which creates less drag than a rubber seal

5

Triple Labyrinth Seal

Second defense is the triple labyrinth seal which makes contaminants travel a longer distance The labyrinth is also grease filled to keep contaminants away from the ball bearing The durable seal material is more durable and is less susceptible to corrosion

6 5

6

Ball Bearing

Factory sealed metric ball bearing on all CEMA rated idlers

MOXIE ROLL CUTAWAY

Producer Perspective Pizza Cutter

“ If we didn’t catch a worn steel roll in time, the sharp points would catch the clips, tear them apart and cause a rip all the way down the belt. That is an expensive problem! ”

Belt Stress

“ Belts aren’t all that easy to come by, so the operation would easily be down a day or more when there was a big tear. That is a problem at our operations with roundthe-clock load-outs. ”

Energy Efficiency

“ The decision to switch to Moxie rolls alone is one of the biggest keys to our current efficiency at the new wash plant. ” PLANT MANGER AT SEVEN POINTS SAND AND GRAVEL, ENIS, TEXAS

Part Number Guide Example: C5-35E-36MOX

CEMA Rating

Roll Diameter

Troughing Angle

Belt Width

Idler Type

C or D

5” or 6”

20˚, 35˚, 45˚

18”- 72”

MOX

* For return Moxie rolls, substitute roll diameter and troughing angle with “RET.”

16


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

81/91 Series Regreasable Idlers Regreasable Idlers Stop Invading Water Damage

4 3 1

2

Standard Sizes Classes: CEMA C and D Roll Diameters: 4” - 6” Belt Widths: 18” - 72”

FIG 3.1 IDLER SEAL CUTAWAY




Heavy Duty Rollers

If you have problems keeping water or slurry out of your idler bearings, regreasable idlers are an alternative. Because you are always purging the bearing with grease, water isn’t able to do as much damage.

9 gauge on 5” 7 gauge on 6” As thick or thickest steel in the industry

Regreasable Idlers

One side grease relief Grease-filled single point lubrication Inner grease seal prevents grease from escaping into roll cavity

How often do you regrease? It is totally dependent on your application and so no one answer is accurate. If you can blame idler failures on water or slurry damage, regrease more often. It could be as often as every day.

Bearing Protection

Delrin triple labyrinth seal External deflector seal keeps material away Tapered roll bearings

Figures 3.1 and 3.2

How do tapered compare to ball bearings? As ball bearing technology has improved and the cost of maintenance has increased, ball bearings have significantly replaced tapered roll as the market standard.

3 4 1 2

Grease retainer cup 3/4” taper roller bearing Delrin triple labyrinth seal External deflector seal

Hex nut with clip 7 gauge steel center stand 7 Punched hole for safety cable 5 6

Part Number Guide Example: 815-35E-36

5 7

6

Idler Type and Diameter

Troughing Angle

Idler Style

Belt Width

81 or 91 and 4”, 5” or 6”

20˚, 35˚ or 45˚

Equal Length, Feeder/Picking or Offset Center Roll

18”- 72”

FIG 3.2 IDLER FRAME 1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-103

CUSTOMER CARE PLAN

17

40 Series Idlers Replacement Rollers for Track Mounted or Mobile Equipment

Features and Benefits Interchange with Powerscreen Rollers Universal center bracket Replaceable end rollers and die cast stands 11 gauge steel

Centered Rolls Part Number

Powerscreen # Roll Length

Shaft Length

Metric Size

43-000010

07020238

8.14”

9.20”

L216

43-000011

02021138

12.00"

13.06"

L314

43-000012

08010101

14.87"

15.93"

L388

43-000013

06530102

18.87"

19.93"

L490

43-000014

05120115

20.87"

21.87"

L538


43-000015

04220133

25.15"

26.21"

L648


43-000016

09130180

26.75"

27.81"

L690

These rollers are replacement parts common to European-designed track mounted crushers and other small processing equipment. Also, the center stands support all troughing angles.

43-000017

09120129

35.07"

36.13"

L900

43-000018

03220103

35.70"

36.76"

L916

What is the advantage?

Part Number

Powerscreen # Description

Degree

Superior is one of just a few manufacturers who build these parts in the United States, making it easier to access the offshore parts locally. Customers are able to replace separate segments of the idler including the rollers and center stands.

43-000019

8 - 3/4"

Fits all degrees

Part Number

Powerscreen # Roll Length

Shaft Length

Metric Size

43-000025

02021145

28.00"

33.00"

L840

43-000026

06530103

33.50"

38.50"

L978

43-000027

05420143

33.62"

38.62"

L980

43-000028

08010102

35.50"

40.50"

L1025

43-000029

05120116

40.00"

45.00"

L1145

43-000030

03220104

53.50"

58.50"

L1485

43-000031

07230107

62.00"

67.00”

L1700

Standard Sizes Roll Diameter: 4” Angles: 20˚, 30˚, 45˚, 60˚ Belt Width: 24”- 54”

Outside Rolls Outside roller only

Return Rolls

Center Brackets Part Number

Powerscreen # Description

Degree

43-000021

LH2020608 RH2020609

Center bracket only

20º

43-000022

LH2020606 RH2020607

Center bracket only

30º

43-000023

LH2020604 RH2020605

Center bracket only

45º

43-000024

LH2020610 RH2020611

Center bracket only

60º

40 SERIES IDLERS

Return Roll U-Bolts

18

Part Number

Shaft Diameter

13-03004

1”

13-03005

.75”


CUSTOMER CARE PLAN

CB504 Idlers Direct Interchange with MARCO and Cedarapids Idlers

Quick Specs Roll Diameters: 4” and 4-1/2” Stub Pins: 2-1/2” and 3” Belt Widths: 18”- 48”

CB504 IDLERS




Maintenance Friendly in Tight Locations

The simple answer is if this is a product you have used in the past, then we have replacement rollers for you to purchase through our distribution.

What is the idler designed for? CB504 Idlers are designed to easily replace a bearing and continue to use the can and frame for MARCO or Cedarapids style idlers.

What is special about the bearings? Compared to other idlers, CB504 style idlers are designed and manufactured with sealed bearings versus to an external seal design.

Channel mount, low profile designs CB504 bearings Direct interchange with MARCO or Cedarapids idlers Replacement bearings and pullers

Adapt to Application

Channel mount design Standard mount low profile design option Rubber impact design option

Part Number Guide Example: CB45-35E-36

Idler Type and Diameter

Troughing Angle

Idler Style

Belt Width

CB and 4” or 4-1/2”

20˚ or 35˚

Equal or Channel Mount

18”- 48”

CB 504 Parts

BEARING AND PINS 1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-105

Part Number Description

Part Number

Description

41-542300

3” Double Pin

32-506000

Channel Mount

30-405044

4” End Disc

41-541250

2-1/2” Single Pin

30-456024

4-1/2” End Disc

41-542250

2-1/2” Double Pin

03-01017

CB 504 Bearing

41-542263

2-5/8” Double Pin

32-044081

1-1/2” Drop Bracket

41-541300

3” Single Pin

32-410450

4-1/2” Drop Bracket

-

CUSTOMER CARE PLAN

19

Self-Aligning Idlers Economical Belt Tracking Tool

Quick Specs Classes: CEMA B, C, D, E, and F Roll Diameters: 4” - 7” Belt Widths: 18” - 96”

SELF-ALIGNING IDLERS



Why might I need a troughing self-aligner?

Reduce Belt Mis-tracking

There are many factors that cause belt mis-tracking, although some only affect the top side of the belt. Common to radial stackers, off-center loading causes mis-tracking to the belt’s top side. A carry-side, or troughing selfaligner will track the belt straight at every radial position.

Why choose this style? It comes down to simple economics However, there are also distinct performance comparisons. The Navigator return trainer evolved from the self-aligner to solve issues with contact to belt guides.

Misaligned belts contact side roller or shoe pad After contact, idler pivots and centers belt

Protect Sides of Belting (Fig 6.1)

Compared to steel, urethane side guide rollers are softer on belting Concave shaped side guide rollers keeps traction on belting

SpinGuard® Seal Technology

Contact seal prevents foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants Stationary external seal prevents material pinch points

Standard Positive Action Belts

Shoe Activated Bi-Directional Belts

Troughing

Troughing

Return

Return

Why is the belt guide concave shaped? Compared to a harder, straighter style guide, the concave shape makes for a softer landing when the side of the belt contacts the guide.

Part Number Guide Example: B5-35EA-36

FIG 6.1 SOFTER LANDING FOR BELTING

20


CEMA and Diameter

Troughing Angle

Aligner Style

Belt Width

B, C, D, E or F and 4”- 7”

20˚, 35˚ or 45˚

Standard (EA) or Shoe Activated (BA)

18”- 96”

*For return roll self-aligners, substitute “RETA” for troughing angle and aligner style. CUSTOMER CARE PLAN

Navigator Return Trainers ®

Constantly Working to Maintain Proper Belt Tracking

Quick Specs Belt Widths: 24”- 72” Lagged Diameter: 7-3/4” or 10-3/4” Non Lagged Diameter: 7” or 10”

NAVIGATOR RETURN TRAINER




Save the Belt

The trainer can be used in any application where belt tracking is an issue. It’s also recommended for applications where return self-aligners will not fit or are not working.

Where should I install? We recommend 25 to 50 feet from the tail or head pulley on the belt’s bottom or return side and then every 100 feet after that on longer span conveyors. However, if there is a specific spot where there are tracking issues, install the trainer one to two idlers upstream.

Works to provide continuous belt alignment Quick reaction time upon installation, reducing the risk of damage Standard rubber lagging increases friction between belt and roller Video Proof: http://superior-ind.com/components/idlers/aligners/navigator

Avoids Material Buildup

Rubber lagging sheds material Internal, off-the-shelf, flange mount bearings are clear of material buildup (Fig 3.1) No framework, another common spot for material buildup

Extends Service Life

Largest diameter roll for longer service life Effective in both wet and dry conditions

FO BE

If you need to, they are off-the-shelf, flange mount bearings that can be replaced with an extended socket. However, compared to other trainers, the Navigator return trainer is equipped with larger bearings designed to last the life of the product.

RE

Can you replace the bearings?

AF

TE

R

THIS BELT WAS EATING INTO BRACKETS AND RIPPING

FIG 3.1 INTERNAL BEARINGS

BELT STRAIGHTENED IMMEDIATELY AFTER INSTALLATION

21

Producer Perspective Bad Behavior

“ When our belts misalign they cut into return frames and can actually cut right through the conveyor. At the least, the conveyor catches the belt lacing and rips the side of the belt. ”

Pricey Problems

“ At $15 to $20 a foot and three to four maintenance workers, it’s a pretty expensive situation to change out a belt and anyway you look at it, it’s downtime! ”

Advanced Alternative

“ The Navigator return trainer just seems to handle the belt better than those ones with the side guide rollers. They let the belt travel too far before they even start doing anything. ” MAINTENANCE MANAGER AT CAPITOL AGGREGATES, AUSTIN, TEXAS

How It Works Misaligned Belt

Belt Alignment

Aligned Belt

Misaligned belt puts pressure on one side of the Navigator return trainer

Misaligned pressure causes the Navigator return trainer to tilt, centering the belt

The Navigator return trainer is constantly guiding and centering the belt

Part Number Guide Example: NAV-36 or NAV-36LAG

Roller Style

Belt Width

Lagging Options

NAV

24”- 72”

LAG

*Specify if application is for a bidirectional belt.

22


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Urathon Return Rolls ®

Prevent Idler Buildup, Shed Sticky Material

Quick Specs Classes: CEMA B, C, D, and E Roll Diameters: 5”, 6” and 7” Belt Widths: 18” - 96”

URATHON RETURN ROLLS




Sticky Shedder

Urathon return rolls are best in applications when wet or sticky material cakes or bonds to steel cans, a problem that can often result in belt mis-tracking.

How hard is the urethane? Both the standard and spiral versions of this return roll are made from a 87A durometer urethane.

Can you replace the discs? Yes, however it involves removing the weld on the retaining ring in order to slip the discs off the shafts.

Eliminate material buildup No maintenance, self-cleaning rolls Reduce tracking challenges, belt damage and premature failure

Longer Lasting

At least 3x the life of rubber discs Reduce maintenance and operating costs

Belt Cleaning

Spiral option cleans dirty side of belt (Fig 8.1) Material buildup is the leading cause of belt damage

Retrofit Rolls

Slotted shaft fits most competitor brackets

Rubber Lagging Returns Rubber Disc Return Idlers Urathon Return Roll 60

65

87A

Durometer is a unit of measurement used to signify the hardness of a material.

FIG 8.1 SPIRAL URATHON RETURN ROLL

DUROMETER RATING

23

Producer Perspective Balloon Effect

“ Clay sticks to steel like a magnet, causing buildup that makes the steel rolls almost double in size. This leads to all kinds of problems! ”

Bloating Steel

“ Some of the steel rolls got so heavy that they stopped rolling. The belt would simply slide across the top of them and potentially end up ripping if you didn’t catch it in time. ”

Zero Buildup

“ These rolls save me time and money and eliminate all the downtime we used to have in change-outs. There is no reason to look any further! ”

PLANT MANAGER; PHOENIX CEMENT COMPANY, SCOTTSDALE, ARIZONA

BE

AF

FO

TE

R

RE

Urathon Return Roll

STICKY MATERIAL CLINGING TO STEEL RETURNS CAUSES BELT MIS-TRACKING

URATHON RETURN ROLL SHEDS STICKY MATERIAL

Part Number Guide Example: C5-RETU-36

CEMA Rating

Roll Diameter

Idler Type

Belt Width

B, C, D, or E

5”, 6” or 7”

RETU or RETUSP*

18”- 96”

* Spiral option is only available in 6” diameter

24


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Rubber Disc Returns Cost Effective, Prevents Material Buildup

Quick Specs Classes: CEMA B, C, D, and E Roll Diameters: 4”, 5” and 6” Belt Widths: 18” - 72”

RUBBER DISC RETURN IDLER




Prevent Material Buildup

In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns.

Why this style over others? The answer comes down to simple economics. Compared to the Urathon® Return Roll, our Rubber Disc Returns can cost up to 20% less.

Sheds material in moist, sticky applications Discs designed with self-cleaning, flat surface Discs prevents buildup on roll and on return side of belt

Save the Belt

Provides better support for belting Reduces costly belt tracking issues caused by material buildup Disc spacing prevents belting from getting stuck within outside discs

Long Lasting Return Rolls

Synthetic rubber stable in wide temperature range Better wear characteristics than steel rolls


65

87A


DUROMETER RATING

Part Number Guide Example: C5-RETI-36

PREVENT MATERIAL BUILDUP 1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-109

CEMA Rating

Roll Diameter

Idler Type

Belt Width

B, C, D, or E

4”, 5” or 6”

RETI

18” - 72” CUSTOMER CARE PLAN

25

Rubber Lagged Return Rolls Cost Effective, Prevents Material Buildup

Quick Specs Classes: CEMA C, and D Roll Diameters: 4”, 5” and 6” Belt Widths: 18” - 72”

RUBBER LAGGED RETURN ROLLS





In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns.

Does lagging come in different sizes? You bet! You can choose between 1/4” or 1/2” rubber depending on the ruggedness of your application.

Why this style over others? Rubber lagged style is targeted for self-aligner frames.

Sheds material in moist, sticky applications Built with hot vulcanized, synthetic rubber

Save the Belt

Flat style eliminates belt trapping common to disc style returns Reduces costly belt tracking issues caused by material buildup

Longer Lasting Return Rolls

60 durometer rubber, similar to car tires (Fig 10.2) Lagging increases thickness of rolls, boosting wear life Better wear characteristics than steel rolls


65

87A


FIG 10.2 DUROMETER RATING

Part Number Guide Example: C5-RET-36LAG.25

SHED STICKY MATERIAL

26


CEMA and Diameter

Idler Type

Belt Width

Lagging and Thickness

C or D and 4”, 5” or 6”

RET

18”- 72”

LAG and 1/4” or 1/2” CUSTOMER CARE PLAN

Beater Bar Return Rolls Deflect Sticky Material Off the Belt

Quick Specs Shaft Size: 1-7/16” or 1-15/16” Roll Diameters: 5” and 6” Belt Widths: 18” - 72”

BEATER BAR RETURN ROLLS





Like the Urathon® return roll and rubber style returns, the beater bar is another tool to defeat sticky material buildup on the return side of your belt. Also, applications with cleated belts where belt cleaners are not an effective cleaning tool.

Rods create beating motion to keep belt clean and free of any carryback material Bars allow gaps for material to escape, eliminating buildup on roll

Save the Belt

Reduces costly belt tracking issues caused by material buildup Mounted with live shafts to support conveyor loads

Where is the install point? Typically, we suggest installing the beater bar in the first return roll location from the head pulley. Here, the cleaning is focused on one roll rather than stressing out all the return rollers.

Pillow Block Bearing Order Info Part Number

Dimensions

03-00016

1-7/16”

03-00115

1-15/16”

Part Number Guide Example: LSB-536-107


Idler Styles

Roll Diameter

Belt Width

Shaft Size

LSB

5” or 6”

18”- 72”

107 for 1-7/16” or 115 for 1-15/16”

CUSTOMER CARE PLAN

27

V-Return Idlers Manages Rugged Loads While Aligning Long Overland Belts

Quick Specs Classes: CEMA C, D, and E Roll Diameters: 5”, 6”, and 7” Belt Widths: 36” - 96”

V-RETURN IDLERS




Save the Belt

Primarily used on long overland conveyors, v-return idlers are used in applications with wide, thick and heavy belting or horizontal curve conveyors.

What is the load rating? There are factors that we need to consider before recommending a load rating (i.e. belt weight, idler spacing, feet-per-minute). However, it is safe to say that v-return idlers have better or stronger load ratings then standard one roll returns.

Help keep the belt aligned Two-roll returns have higher load ratings than single rolls

Easy Installation

Easy mounting into standard return roll locations Avoid making changes to conveyor structure

SpinGuard® Seal Technology

Contact seal helps prevent foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants Stationary external seal prevents material pinch points

Part Number Guide Example: C5-10RETV-36

CEMA and Diameter

Roll Angle

Idler Type

Belt Width

C, D, E and 5”- 7”

10˚ or 15˚

RETV

36”- 96”

MOUNTING BRACKET

28


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Exterra Primary Belt Cleaner ®

Jam Packed with More Material Where it’s Needed Most

Quick Specs Belt Widths: 18” - 72” Blade Widths: 10” - 70” Durometer: 87A Urethane

EXTERRA PRIMARY BELT CLEANER



Why is belt width minus 8” standard?

Extended Wear Life

Easy Installation and Maintenance

Shipped pre-assembled Blade fits to mounting pole without tools Simple nut adjustment tightens tensioner Upgrade to Exterra® SFL Primary Belt Cleaner (Fig 14.1)

E

LIF

There are two options – belt width plus 30” or belt width plus 42”.

Avoid replacing an entire system, retrofit blade to other brand poles Flexo Rockline® EZP1 Martin® Performance Duty QC™ #1 Martin® Pit Viper™ Belt Cleaner Martin® HD Belt Cleaner Argonics Eraser™ and Micro Eraser™ Belt Cleaner Asgco® Skalper® IV and Mini Skalper® Belt Cleaner Arch Saber Primary Belt Cleaner

R

What is the length of the pole?

FO

Roughly, it’s about four to six times throughout the life of the blade. However, we do offer a primary cleaner with a “set for life” tensioning system. If you do not want to waste the time on maintenance, ask to be upgraded to the Exterra SFL Primary Belt Cleaner. (Fig 14.1)

Interchangeable Blade

T

How often should I reset the tension?

Compared to other comparable primary blades, we’ve packed ours with 15-40% more urethane (durometer = 87A) Thicker blade tip means extra material at the critical point of contact

SE

Because material is often handled in the center two-thirds of the belt, wider blades wear faster in the center developing a “smile” wear pattern. The scraper then loses its effectiveness Sized to your belt width minus 8”, the belt cleaner will wear more evenly.

One Time Tensioning For the Life of the Blade

FIG 14.1 EXTERRA SFL PRIMARY BELT CLEANER

29

Part Number Guide Example: P-4280722

Primary Belt Cleaner

Belt Width

Belt Width -8” or -2”

Pole Length

Tensioner Quantity

P

18”- 72”

8 or 2

48”- 114”

1 or 2 Replacement Part Numbers

Complete System Part Numbers Part Number

Belt Width

Blade Length

Weight

Part Number

Description

Dimensions

P-1820481

18”

16”

41

32-000097

Assembly Bracket Tensioner

-

P-1880481

18”

10”

38

32-000094

Bracket Non-Tensioner

-

P-2420541

24”

22”

47

13-00975

Pin Clip

5/16” x 2-1/2”

P-2480541

24”

16”

44

07-00540

Primary Scraper Blade

10”

P-3020601

30”

28”

53

07-00541


16”

P-3080601

30”

22”

50

07-00542


22”

P-3620661

36”

34”

59

07-00543


28”

P-3680661

36”

28”

56

07-00544


34”

P-4220722

42”

40”

65

07-00545


40”

P-4280721

42”

34”

62

07-00546


46”

P-4820782

48”

46”

75

07-00547


52”

P-4880782

48”

40”

72

07-00549


58”

P-5420842

54”

52”

85

07-00548


64”

P-5480842

54”

46”

82

07-00550


70”

P-6020902

60”

58”

95

P-6080902

60”

52”

92

P-6620962

66”

64”

105

P-6680962

66”

58”

102

P-7221022

72”

70”

117

P-7281022

72”

64”

112

Optional Mounting Brackets If the head section of your conveyor is not equipped with proper mounting, consider this Exterra belt cleaner mounting bracket.

22-3/16” 4” 8” 6”

25-1/2”

4-1/2” OPTIONAL MOUNTING BRACKET

30


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Exterra SFL Dual Belt Cleaner ®

Secondary Scraper Mounted in a Primary Position

*Patent Pending

Quick Specs Pulley Diameters: 12”- 30” Belt Widths: 18”- 60” Secondary: AR Steel or Tungsten Carbide

EXTERRA SFL DUAL BELT CLEANER



When do I need a secondary cleaner?

Hassle-Free, In-Field Installation

Whenever the belt is not getting clean enough with a primary scraper is the simplest answer. More specifically, in applications with sticky, aggressive material when cleaning is absolutely necessary.

What is special about the design? Because conveyor frames are not usually designed to accommodate secondary cleaners, they aren’t usually installed. Sharing one mounting pole, this system allows primary and secondary cleaning power without modifying a conveyor structure.

Will the system fit in my application? If you have room for a single primary belt scraper in your application, then you will have plenty of room for this model. However, the unit will not fit near a snub pulley, even if that region is equipped with a primary scraper.

ELIMINATE CARRYBACK

One common mounting point Secondary blade shares primary blade’s mounting pole and tensioner Maintain existing conveyor structure Installation Instructions: Search YouTube for keywords “Exterra SFL Dual Belt Cleaner”

Set for Life Tensioning

Spring tension is set to match primary blade wear pattern As primary blade wears, spring automatically adjusts to keep proper tension to both blades Tension is load equalizing as one or both blades wear, dynamically maintaining accurate tension

Extended Wear Life

The primary blade is packed with 15-40% more urethane than competition (durometer = 87A) High performance AR Steel (STD) or Tungsten Carbide on tip of the secondary blade Segmented secondary blade is designed to withstand conveyor vibration and impact from belt splice

User Friendly Maintenance

Replaceable secondary blade segments adjust to accommodate all splices Replaceable primary blade One time tensioning for the life of blade

31

Exterra SFL Dual Belt Cleaner 1

3 6 2 4

5 1

Primary Blade

Packed with 15-40% more urethane.

2

Mounting Brackets

3

Mounting Pole

Avoid adding to conveyor structure with a single mounting point.

4

Secondary Blade

Choose from AR steel or tungsten carbide.

5

Splice Adjustment (Fig 13.2 - 13.3)

Modify the angle of the secondary blade to accommodate belt splice style.

6

Tension Springs

Set the tension once, during installation, for the life of the blade.

Splice Adjustment A perpendicular angle is best for cleaning when a vulcanized splice is present Belt Travel Unwanted Debris FIG 13.2 VULCANIZED SPLICE

32


A “scraping” angle provides relief for the passing of a mechanical splice Belt Travel Unwanted Debris FIG 13.3 MECHANICAL SPLICE

EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Return Roll Guards Conveyor Pinch Point Protection

Features and Benefits Single Return Roll Guard (Fig 18.1)

Easily mounts to Superior drop brackets Can be modified to fit other brand rollers Works on CEMA B, C, and D series idlers Same guard fits 4”, 5” and 6” rollers and 1-1/2” or 4-1/2” brackets

Dual Return Roll Guard (Fig 18.2)

FIG 18.1 SINGLE RETURN ROLL GUARD

Guards mount into special drop bracket slots Designed to catch roller from dropping Works on CEMA C and D series idlers Same guard fits 5” and 6” rollers and 4-1/2” brackets

ShieldAll™ Roll Guard (Fig 18.3)

UHMW cage prevents material buildup Two pin release system for easy maintenance access Works on CEMA B, C, D, and E series idlers Same guard fits 4”, 5”, 6” and 7” rollers and 1-1/2” or 4-1/2” brackets

Steel Return Guard Basket (Fig 18.4)

Heavy duty steel cage prevents material buildup Works on CEMA B, C, and D series idlers Same guard fits 4”, 5”, and 6” rollers and 4-1/2” brackets

FIG 18.2 DUAL RETURN ROLL GUARD

Part Number Guide Return Roll Guards

FIG 18.3 SHIELDALL ROLL GUARD

BW

Single Guard

Dual Guard

ShieldAll Guard Steel Guard

18”

44-050118

44-118450

44-040118

44-060018

24”

44-050124

44-124450

44-040124

44-060024

30”

44-050130

44-130450

44-040130

44-060030

36”

44-050136

44-136450

44-040136

44-060036

42”

44-050142

44-142450

44-040142

44-060042

48”

44-050148

44-148450

44-040148

44-060048

54”

44-050154

44-154450

44-040154

44-060054

60”

44-050160

44-160450

44-040160

44-060060

72”

44-050172

-

44-040172

44-060072

84”

-

-

44-040184

-

96”

-

-

44-040196

-

FIG 18. 4 STEEL RETURN GUARD BASKET 1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-118

CUSTOMER CARE PLAN

33

Guard Panels Protect Your Crew and Your Pockets

Features and Benefits Flexible Guard Panels (Fig 19.1)

Cuts easily to any size or shape, with shears or cutter UV resistant HDPE Yellow color is easily detectable Shipped with self-tapping screws and washers 3/4” mesh (50’ x 4’ roll) 1/4” mesh (100’ x 4’ roll)

Flexible Guard Panels FIG 19.1 FLEXIBLE GUARD PANELS

Part Number

Description

Lengths

38-000030

Yellow Side Guard Kit - Small 1/4” Mesh

100’ x 4’

38-000032

Yellow Bottom Guard Kit - Large 3/4” Mesh

50’ x 4’

Steel Guard Panels (Fig 19.2)

Attaches with self-tapping screws and washers Can be used on channel or truss frames 10’ x 5’ or 4’ x 5’ panels

Steel Guard Panels FIG 19.2 STEEL GUARD PANELS

EASY TO HANDLE, FLEXIBLE ROLLS

34


Part Number

Description

Lengths

14-00946

Guard, Truss, Mesh, Perf-Metal

10’ x 5’

10-02139

Guard, Truss, Mesh, Perf-Metal

4’ x 5’

SELF-TAPPING SCREWS INCLUDED IN PACKAGE CUSTOMER CARE PLAN

Conveyor Belt Covers Rugged Belt Protection Withstands and Protects the Environment

Standard Sizes


Belt Widths: 24”- 60” Cover Length: 41.88” Standard Covers: Full, 3/4 and 1/2

CONVEYOR COVERS



What are the benefits of corrugated?

Engineered for Strength and Support

When compared to smooth covers, a corrugated design is naturally stronger. On it’s own, each channel (or rib) increases the bending strength of the entire cover. So think of each rib as a little muscle.

Where are the installation supports? Another benefit of a corrugated design is that it allows the cover to be self supporting. That means no additional structure (like supports) is required to hold the cover to the conveyor.

What’s the difference between standard and optional covers?

Rigid, corrugated construction is infinitely stronger than smooth Standard 22 gauge is thickest in the industry Folded edges double thickness and increase strength

Safe to Handle and Easy to Maintain

Folded edges form safe to handle lifting points No installation supports needed to brace covers Installation is not dependent on location of idler frames Mount hinges with self-tapping screws at any point along structure

Fast and Easy Access

Full style hinged on both sides for access at any point Loosen just two nuts for belt access (Fig 23.1) Full style hinges protected with rust free coating

Our standard covers, as defined in the quick specs above and on the back page, are available for immediate deliveries. Meanwhile, our optional covers and accessories are built to order.

FIG 23.1 FULL STYLE LOCK HINGE

35

Conveyor Covers 1

2

1

Cover

2

Lock Hinge

3

Bracket

4

Screw

5

Nut

3 4

5

HINGES FOR FULL STYLE COVERS

COVERS ARE NOT DEPENDENT ON LOCATION OF IDLER FRAMES

Cover Styles Style

Application

Full*

100% coverage of belt.

3/4*

Open access on one side of belt.

1/2

Open access on both sides of belt.

*Standard covers are available for immediate delivery. Other styles are built to order.

Cover Materials Material

Application

Galvanized*

Approved resistance in nearly every environment.

Lacquered Steel

Colored to blend in with surroundings or branding.

HPS 200

Fiber reinforced polyester, colored covers for highly corrosive environments.

Stainless Steel

Highly corrosive environments.

Aluminum

Lightest weight material for easy manipulation.

Fiberglass

Avoid contamination in the food industries.

*Galvanized covers are available for immediate delivery. Other materials are built to order.

36


CUSTOMER CARE PLAN

Sealing System Prevent Material Spillage in Load Zones

Quick Specs Cartridges: 5” or 10” Bars: 48” or 60” Belt Widths: 24”- 72”

SEALING SYSTEM




Stop Material Spillage

Do you have spillage in load zones of your systems? If yes, then you have the application.

How does it work? While normal idler rolls create spacing between the conveyor belt and hopper skirting, the sealing cartridges or bars are designed to close that gap, making for a tight seal.

System or cartridges maintain a tight seal between belt and hopper skirting Eliminates belt sagging between idler rolls in conveyor load zone Material spillage is the #1 cause of conveyor maintenance

Quick, Low Cost Installation

Retrofit cartridges fit to existing, installed idler frames Single cartridge (5”), double cartridge (10”) or sealing bar options Easy to handle and install (Fig 19.1)

Is it an impact bed? While in some cases they look the same, no, this is not an impact bed. The sealing system is designed to handle finer material which can leak out in load zones.

5” CARTRIDGE

10” CARTRIDGE

FIG 19.1 EASY INSTALLATION

48” SEALING BAR

37

BE

AF

FO

TE

R

RE

Eliminate Spillage

SKIRTING WITH IDLER ROLLS; GAPS BETWEEN SKIRTING AND ROLLS

SKIRTING WITH SEALING SYSTEM; KEEP EXISTING IDLER FRAME

Common Applications

MATERIAL SPILLAGE

IDLER ROLL WEAR

MIXED IDLER STYLES

HIGH CAPACITY OF FINE MATERIAL

LOAD ZONE IDLER GAPS

LOAD ZONE SPILLAGE

Part Number Guides Full Sealing System Steel Roll Center Roll

Impact Cushion Center Roll

Roll Diameter

Double Cartridge

Slide Bars

Double Cartridge

Slide Bars

C-5”

C5S-20E-(24-72)-410

C5S-20E-(24-72)-448

C5S-20EI-(24-72)-410

C5S-20EI-(24-72)-448

C-6”

C6S-20E-(24-72)-410

C6S-20E-(24-72)-448

C6S-20EI-(24-72)-410

C6S-20EI-(24-72)-448

D-5”

D5S-20E-(24-72)-410

D5S-20E-(24-72)-448

D5S-20EI-(24-72)-410

D5S-20EI-(24-72)-448

D-6”

D6S-20E-(24-72)-410

D6S-20E-(24-72)-448

D6S-20EI-(24-72)-410

D6S-20EI-(24-72)-448

Replacement Cartridges Double Cartridges

38

Seal Bar

5”

6”

48”

60”

D5S-(24-72)-2

D6S-(24-72)-2

38-000026

38-000027


CUSTOMER CARE PLAN

Impact Beds Protect Conveyor Belts from the Beating of Large Material Lumps

Quick Specs Lengths: 4’ or 5’ Diameter: 5” or 6” Existing Roller Belt Widths: 24”- 72”

IMPACT BEDS



What are the characteristics of the bars?

Save the Belt

The impact bars are made from a top layer of 1/2” UHMW and a bottom layer of 2-1/2” SBR rubber.

Do you offer different classes? You bet! Any application that exceeds the specs of our entry level impact bed will graduate to an engineered class.

How do I know which class I need? Unfortunately, there is no simple answer or equation. We need specific application data (i.e. material size, tons per hour, drop height, etc.) and our engineering team can calculate the style and size needed for your job.

Energy absorbing impact bars protect belting from falling material Bars made of low-friction UHMW and high impact SBR rubber

Rugged Construction

Rigid, structurally sound frame for extra support Custom engineered style available on request (Fig 20.1)

Perfect Fit

Wings adjust to 20˚, 35˚ and 45˚ Available in 4’ or 5’ lengths

18” IMPACT BEDS

FIG 20.1 SPECIALTY IMPACT TRANSITION BED

MEDIUM DUTY IMPACT BEDS

39

Common Applications

HIGH CAPACITY APPLICATIONS

LARGE MATERIAL LUMPS

SHARP, DAMAGING MATERIAL

EXTENDED DISCHARGE HEIGHT

Part Number Guide Example: I-C5355-361

40

Impact Bed and CEMA Class

Existing Roll Diameter

Wing Angle

Bar Length

Belt Width

I and C

5” or 6”

20˚, 35˚, 45˚

4’ or 5’

24”- 72”


Duty Standard = 1 or Medium = 2

CUSTOMER CARE PLAN

Take-Ups Accurately Maintain Belt Tension to Prevent Slippage

Quick Specs Style: Pillow Block, Wide Slot, Top Angle Mounting Positions: Side or Top Size Range: 1/2”- 9” Bearing Diameter

TAKE-UPS



What size do I need?

High Quality Construction

The common “rule of thumb” is to choose a travel size that is 2% of your center to center belt length.

What is distinct about Superior’s design? The ACME screw has nonbinding characteristics resulting in less seizing and longer life. ACME screws are standard on all of our take-ups.

ACME rod is standard ACME thread design provides quick movement and reliability in corrosive conditions Durable Powder Coat finish

Stocked for Quick Deliveries

Carried by your local Superior distributor Quick lead times from factory

What is significant about screw protection? The screw is the heartbeat of the takeup. Once damaged or bent, you lose the effectiveness of the component. Telescoping tube take-ups are the only style manufactured with a completely enclosed screw, although each model has some protection to block material.

FIG 20.1 SPECIALTY IMPACT TRANSITION BED

CENTER PULL

TOP ANGLE

HEAVY DUTY

TELESCOPING TUBE

LIGHT DUTY

WIDE SLOT

41

Take-Up Selection Guide Scenario One: Style

Bearing Style

Pillow Block

Conveyor Style

Truss Frame

Wide Slot

Top Angle

Channel/I-Beam Frame

Truss/Channel Frame

Take-Up Style

TUTT

TULD

TUHD

TUCP

TUWS

TUTA

Mount Position

Side

Top

Top

Top

Side

Top

Scenario Two: Bearing Size

0.0”

TUTT

1/2”

TULD

1/2”

1.0”

TUHD

2.0”

3.0”

4.0”

5.0”

6.0”

7.0”

8.0”

6” 3-7/16” 1-7/16”

TUWS

9”

1/2”

TUCP

9.0”

3” 1-3/8”

TUTA

5”

1-3/4”

3-15/16”

Scenario Three: Bearing Type

Bearing Type Take-Up Style

SealMaster

Browning

Link-Belt

Rexnord

Dodge

SKF

TUTT

NP, MP

VPS, SPB1000, PBE

PB22400, EPB22400, C35

ZA, ZEP

SC, SCM, S2000, Type E, Imperial

–

TULD (Roller)

NP, MP

VPS, SPB1000

PB22400, C35

ZA

SCM, S2000, Imperial

–

TUHD (Roller)

USRB

VPS, SPB1000, PBE, SAF22500

PB22400, EPB22400, PLB

ZA, ZAF, ZEP

S2000, Type E, USAF, TAF, Imperial

SAF

TUWS (Ball)

MST

VTWS

–

WSTU-SC, WSTU-SCM

–

TUCP (Roller)

–

TUE-920, ST-1000

–

Type E (WSTU-E), S-2000 (WSTU-S2)

–

TUTA

–

–

ETPB-22400

Type E (TPE), Type G (SC), Type GM (SCM), S-2000

–

Part Number Guide

42

ZT-2000, ZT-5000

*Not all configurations are possible, see catalog for available parts

Take-Up Style

Frame Size

Travel Distance

TUTT, TUWS, TULD TUTA, TUHD, TUCP

100-1004

1.5”- 60”


EXCLUSIVE PATENT

PATENTED TECHNOLOGY

CUSTOMER CARE PLAN

Superior Belt Scale Evaluate Inventory, Production Goals and Rail Car or Truck Loading

Quick Specs Belt Widths: 18” - 72” Accuracy: +/- 1% or +/- 0.5% TPH: Up to 3000, dependant on belt speed and idler spacing

HD CONVEYOR BELT SCALE



What are the package options?

Precision Accuracy

Depending on your needs, you can purchase each of the following separately or together as a total package: WB or HD belt scale, PM1500 or PM2000 integrator and the speed sensor.

Where should I install the scale? If possible, it’s best to install on the first half of the conveyor from the tail pulley. Installation should be at least 20 feet from your load zone and 40 feet from any curve up or down. The owner’s manual is packed with more specific details to help get it right.

What if I already have a speed sensor? There is good news! In most cases, both the PM1500 and PM2000 are designed to recognize third party sensors. However, the SS-150 comes standard with the package.

SPEED SENSOR

+/- 1% accuracy or +/- 0.5% accuracy 2 independent load cells for greater accuracy NOTE: You can achieve (+/- ¼%) accuracy when using 2 HD scales in conjunction with one PM2000 monitor. (Dual idler option)

Ease of Troubleshooting

Avoid replacing entire system if one cell is damaged Independent load cell read-outs allows you to easily see which load cell is malfunctioning

Fast and Easy Installation

Easy clamping method secures scale package to conveyor frame Superior quality idler with 0.015” TIR tolerance and custom frame

Powerful Integration

PM2000 Limitless integration into existing in-plant controls PM2000 Control the speed of the belt PM1500 & PM2000 Save up to 8 totals PM1500 & PM2000 Built-in inclinometer for use on variable incline conveyors

43

Belt Scales

Wide Belt Scale +/- 1% accuracy Up to 1,000 TPH 24" - 36" belt width is primary use 42” up to 750 TPH Two independent load cells wired in parallel for easy troubleshooting

Independent weigh bridge brackets

Heavy Duty Belt Scale +/- 0.5% accuracy Up to 3,000 TPH and beyond Two independent load cells wired in parallel for easy troubleshooting

Continuous weigh bridge for increased accuracy and structural integrity

Powder Coated

accommodate multiple belt widths

Powder Coated

Integrators

PM1500 Functions with either WB or HD belt scales Store up to eight resettable totals Diagnostics screen shows load cell readings independently Easy to operate touch screen menu Output for PLC integration 10-30VDC and 115VAC power

PM2000 All the functionality of the PM1500 Control the speed of the conveyor belt when used with a VFD Blend/rate controller uses one output for rate control or two outputs for blending product

Customized and limitless in-plant controls 10-30VDC and 115VAC power Wireless options available

Speed Sensor SS-150 Speed Sensor Easily mounts to a conveyor frame Adjusts to 24” - 36” belt width Use existing speed sensor if applicable

44


CUSTOMER CARE PLAN

Superior Auto Greaser Temperature Compensating Electrochemical Lubrication System

Quick Specs Operating Temp: -4°F to 140°F Discharge Period: 1, 2, 3... to 12 months Dimensions: Approx. 2.5” x 5.5”

SUPERIOR AUTO GREASER



What is the typical application?

Accurate Lubrication Solution

Superior’s Auto Greaser is especially suited to single-point lubrication of rolling element bearings, seals and chains located in areas with considerable temperature variations or where intrinsic safety is a requirement.

Is the unit reusable? It sure is! All of the components are available for order separately, including the lubricator cartridge, cap and dust cover.

Does the lubricator adjust to temperature?

Provides accurate lubricant delivery across a broad range of settings in extreme temperature environments Simple to set, install and maintain with a highly intuitive operating menu

Extends Equipment Service Life

Lubricates equipment while it is running to provide optimal lubricant exchange Delivers gradual purge of fresh grease to labyrinth and taconite seals to prevent the ingress of contaminants

Safer Compared to Manual Greasing

Reduces work load by automating an otherwise manual process Continues to lubricate without the need for shutdown and isolation

A temperature sensor regularly measures the ambient temperature and the control unit calculates the required gas generation based on this data.

Auto Greaser Control Unit Gas generating cell

Re-usable control unit

Display (discharge period + function)

LC unit with integrated battery

Lubricant

Push button programming

Built-in robust support flange with 1/4” NPT outside thread Oil-filled units come with an integrated oil retaining valve and can be recognized by a red plug.

PUSH BUTTON CONTROL

DUST AND WATER PROOF

45

Auto Greasers in Application

Part Number Guide Replacement Parts Part Number

Description

03-03003

Lube Cart. Kit, Cap, Dust Cover

03-03002

Lubricator Cartridge, Dust Cover

03-03001

Cap, Auto Lubricator

08-02768

Black Pipe Nipple

08-02569

Black Tee-Pipe

08-10025

Adaptor

A B

B

A

C

C

top view

46

C

bottom view


OPTIONAL FITTINGS CAN BE USED TO INSTALL MULTIPLE CARTRIDGES. 45˚ Elbow and 90˚ Tee available. CUSTOMER CARE PLAN

Sonicscout Material Sensor ™

Accurately Monitor Material on a Conveyor Belt

Quick Specs Belt Widths: 24” - 72” SONICSCOUT MATERIAL SENSOR



How does it work?

Maintain Material Flow

As material passes, the sensor detects it on the belt. When there is no material on the belt, the sensor sends a signal (i.e. alarm, shutdown, etc.) so action can be taken.

Can you adjust the distance? Yes, the sensor itself has 2” of thread adjustment up or down.

What are the power requirements? 24VDC electric power.

Detects material on conveyor belt Feeds data to machine’s automation program

Heavy Duty Sensor

Unaffected by winds up to 30 MPH Unaffected by external noise Tolerates dusty environments Tolerates temperatures down to -14° F

Easy Installation

Adjust to custom belt widths (Fig 22.1) Attaches to all brands of idler frames

Replacement Parts Adjustable Mount

Part Number

Description

11-00966

Switch

11-01122

Cord

32-000071

Mount 24-48

32-000072

Mount 54-72

Flow Switch Part Number

Belt Width

18-10002

24-48

18-10003

54-72

FIG 22.1 ADJUSTABLE MOUNT PER BELT WIDTH 1-800-321-1558 Find local distribution at superior-ind.com/distributor © 09-2014 Superior Industries CL-123

CUSTOMER CARE PLAN

47

Contact Us Superior Industries, Inc.

Vermont

New Hampshire Massachusetts

Morris

New York Rhode Island Connecticut New Jersey Delaware Maryland Virginia

Prescott Valley

Norcross

Headquarters

Fesco Systems Division

Southwest Division

315 East State Highway 28 Morris, Minnesota 56267

3985 Steve Reynolds Blvd, Building F Norcross, Georgia 30093

9880 East Superior Lane Prescott Valley, Arizona 86314

P: 800-321-1558 P: 320-589-2406 F: 320-585-5644 E: [email protected]

P: 770-825-0955 F: 770-825-0083 E: [email protected]

P: 928-759-8908 E: [email protected]

Customer Service 24 Hours a Day Monday - Saturday P: 800-321-1558 C: 320-267-6639

Connect With Us! Facebook Twitter Youtube Flicker RSS

48

Solution’s Guide Solution’s Guide Problem

Solution

Page

Back and muscle soreness from heavy idlers

Moxie Rolls

15-16

®

Belt slippage

Conveyor Take-ups

41-42

Belt tracking

Navigator® Return Trainer

21-22

Bent pulley wings

Chevron Wing Pulley

05-06

Buying drive components from multiple sources

Core Systems Designs

07-10

Carryback material piling up under belt

Exterra SFL Dual Belt Cleaner

31-32

Extra material sticking to belt

Exterra Primary Belt Cleaner

29-30

Guides of return trainer damaging belt

Self-Aligning Idlers

20

Load zone material spillage

Sealing System

37-38

No material on conveyor belt

Sonicsout Material Sensor

47

Material sticking to return idlers

Urathon Return Roll

23-24

®

®

® ®

TM

®

Material sticking to troughing idlers

Moxie Rolls

15-16

Material trapping between pulley wings

Chevron® Wing Pulley

05-06

MSHA fines

Conveyor Guarding

33-34

Power transmission components not working together

Core Systems Designs

07-10

Ripped or torn belt edging

Navigator Return Trainer

21-22

®

TM

®

Short idler bearing life

®

SpinGuard Seal Technology

11-14

Short return idler life

Urathon® Return Roll

23-24

Exterra® SFL Dual Belt Cleaner

49

Components Handbook Conveyor Pulleys

Belt Scrapers/Cleaners

Conveyor Pulleys Chevron® Pulleys Core Systems® Designs

Exterra® Primary Belt Cleaner Exterra® SFL Dual Belt Cleaner

Conveyor Idlers CEMA Rated Idlers Moxie® Rolls 81/91 Series Regreasable Idlers 40 Series Idlers CB504 Idlers Self Aligning Idlers Navigator® Return Trainers Urathon® Return Rolls Rubber Disc Returns Rubber Lagged Returns Beater Bar Returns V-Return Rolls

Spiral Urathon® Return Rolls

1-800-321-1558 superior-ind.com © 09-2014 Superior Industries, Inc.

50

Conveyor Accessories Return Roll Guards Guard Panels Conveyor Belt Covers Sealing System Impact Bed Conveyor Take-Ups Superior Belt Scale Superior Auto Greaser Sonicscout™ Material Sensor

Conveyor-Components-Product-Handbook[1].pdf

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