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WARNING AND SAFETY REMINDERS FOR SCREW , DRAG , AND BUCKET ELEVATOR CONVEYORS
APPROVED FOR DISTRIBUTION BY THE SCREW CONVEYOR SECTION OF THE CONVEYOR EQUIPMENT MANUFACTURERS ASSOCIATION (CEMA) It is the responsibility of the contractor, installer, owner and user to install, maintain and operate the conveyor, components and, conveyor assemblies in such a manner as to comply with the Williams-Steiger Occupational Safety and Health Act and with all state and local laws and ordinances and the American National Standards Institute (ANSI) B20.1 Safety Code. In order to avoid an unsafe or hazardous condition, the assemblies or parts must be installed and operated in accordance with the following minimum provisions. 1. Conveyors shall not be operated unless all covers and/or guards for the conveyor and drive unit are in place. If the conveyor is to be opened for inspection cleaning, maintenance or observation, the electric power to the motor driving the conveyor must be LOCKED OUT in such a manner that the conveyor cannot be restarted by anyone; however remote from the area, until conveyor cover or guards and drive guards have been properly replaced. 2. If the conveyor must have an open housing as a condition of its use and application, the entire conveyor is then to be guarded by a railing or fence in accordance with ANSI standard B20.1.(Request current edition and addenda) 3. Feed openings for shovel, front loaders or other manual or mechanical equipment shall be constructed in such a way that the conveyor opening is covered by a grating. If the nature of the material is such that a grating cannot be used, then the exposed section of the conveyor is to be guarded by a railing or fence and there shall be a warning sign posted. 4. Do not attempt any maintenance or repairs of the conveyor until power has been LOCKED OUT. 5. Always operate conveyor in accordance with these instructions and those contained on the caution labels affixed to the equipment. 6. Do not place hands, feet, or any part of your body, in the conveyor. 7. Never walk on conveyor covers, grating or guards. 8. Do not use conveyor for any purpose other than that for which it was intended. 9. Do not poke or prod material into the conveyor with a bar or stick inserted through the openings. 10. Keep area around conveyor drive and control station free of debris and obstacles. 11. Eliminate all sources of stored energy (materials or devices that could cause conveyor components to move without power applied) before opening the conveyor no information regarding plant wiring, plant environment, the interlocking of the screw conveyor with other equipment, extent of plant automation, etc. Other devices should not be used as a substitute for locking out the power prior to removing guards or covers. We caution that use of the secondary devices may cause employees to develop a false sense of security and fail to lock out power before removing covers or guards. This could result in a serious injury should the secondary device fail or malfunction. There are many kinds of electrical devices for interlocking of conveyors and conveyor systems such that if one conveyor in a system or process is stopped other equipment feeding it, or following it can also be automatically stopped. Electrical controls, machinery guards, railings, walkways, arrangement of installation, training of personnel, etc., are necessary ingredients for a safe working place. It is the responsibility of the contractor, installer, owner and user to supplement the materials and services furnished with these necessary items to make the conveyor installation comply with the law and accepted standards. Conveyor inlet and discharge openings are designed to connect to other equipment or machinery so that the flow of material into and out of the conveyor is completely enclosed. One or more warning labels should be visible on conveyor housings, conveyor covers and elevator housings. If the labels attached to the equipment become illegible, please order replacement warning labels from the OEM or CEMA. The Conveyor Equipment Manufacturers Association (CEMA) has produced an audio-visual presentation entitled Safe Operation of Screw Conveyors, Drag Conveyors, and Bucket Elevators. CEMA encourages acquisition and use of this source of safety information to supplement your safety program. SEE OTHER SIDE FOR SAFETY LABELS
12. Do not attempt to clear a jammed conveyor until power has been LOCKED OUT. 13. Do not attempt field modification of conveyor or components. 14. Conveyors are not normally manufactured or designed to handle materials that are hazardous to personnel. These materials which are hazardous include those that are explosive, flammable, toxic or otherwise dangerous to personnel. Conveyors may be designed to handle these materials. Conveyors are not manufactured or designed to comply with local, state or federal codes for unfired pressure vessels. If hazardous materials are to be conveyed or if the conveyor is to be subjected to internal or external pressure, manufacturer should be consulted prior to any modifications. CEMA insists that disconnecting and locking out the power to the motor driving the unit provides the only real protection against injury. Secondary safety devices are available; however, the decision as to their need and the type required must be made by the owner-assembler as we have
NOTICE: This document is provided by CEMA as a service to the industry in the interest of promoting safety. It is advisory only and it is not a substitute for a thorough safety program. Users should consult with qualified engineers and other safety professionals. CEMA makes no representations or warranties, either expressed or implied, and the users of this document assume full responsibility for the safe design and operation of equipment.
Exposed moving parts can cause severe injury LOCK OUT POWER before removing guard
CHR930001
Walking or standing on conveyor covers or gratings can cause severe injury STAY OFF
CHS991026
CVS930010
CVS930012
Exposed conveyors and moving parts can cause severe injury LOCK OUT POWER before removing cover or servicing
Exposed buckets and moving parts can cause severe injury LOCK OUT POWER before removing cover or servicing
WARNING
Exposed screw and moving parts can cause severe injury LOCK OUT POWER before removing cover or servicing
CHR930011
CVS930011
Exposed screw and moving parts can cause severe injury LOCK OUT POWER before removing cover or servicing
This catalog is a partial representation of the different styles, designs and options of ORTHMAN belt conveyors and the accessories that accompany them. ORTHMAN will design and manufacture complete systems using either standard or special parts to meet the customers exact needs. ORTHMANS experience in handling products such as sand, gravel, grain, coffee, minerals, etc. will insure a properly sized conveyor for handling any bulk material. We specialize in heavy duty construction as a standard to reduce maintenance and extend the life of all equipment. ORTHMAN puts a very strong emphasis on application engineering. Studied attention to detail during this phase eliminates costly installation and operation errors. Meeting our clients performance expectations with quality machinery is our number one goal.
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DESIGN CONSIDERATIONS:
Belt Widths: Belt Speeds: 18, 24, 30, 36, 48 18 B. W. 400 FPM max. 24 B. W. 500 FPM max. 30 B. W. 600 FPM max. 36 B. W. 650 FPM max. 48 B. W. 700 FPM max. CEMA B, CEMA C, flat steel, 20 degree troughing, 35 degree troughing, impact and training Carrying: 5 0 Return: 10 0 Standard drives include: 1750 rpm, TEFC, NEMA B motor with a 1.15 S.F. Class II shaft mounted gear reducer V type sheaves and belts Motor Mount Belt Guard Integral Backstop (if required)
BASIC DESIGN
STEP 1: Compile the Basic Design Information Required Length of Conveyor: Measured in feet from center to center of pulleys, parallel to belt line. Inclination of conveyor: Measured in degrees off the horizontal, consult the CEMA Belt Conveyor Manual or ORTHMAN CONVEYING Engineering Department to determine the maximum angle at which the particular material may be conveyed. Maximum and Minimum Material Density: Measured in pounds per cubic foot (PCF), the maximum density is used for power calculations while the minimum density is used in the conveyor calculations. Peak Capacity: Measured in tons per hour (TPH), the capacity used should be the peak capacity at which the conveyor is expected to perform, not a lesser average capacity.
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STEP 2: Determine Belt Width Using Table 1 (pg. 3), determine the conveyor belt width required in inches.
TABLE 1 Capacity in Tons per Hour at 100 FPM Belt Speed Weight of Material, Pounds per cu. ft (PCF) 50 27 50 81 117 75 41 75 122 176 100 54 100 162 235 Maximum Lump Size Inches Sized 3 4 7 8 Unsized 5 8 10 12 Maximum Recommended Belt Speed, FPM* 50% Max. Size Lumps 400 500 600 650 100% Max. Size Lumps 300 400 450 500
18 24 30 36
*Certain materials should not be handled at maximum belt speeds. Consult the CEMA Belt conveyor manual or Orthman Engineering Department.
STEP 3: Determine Operating Speed Using Table 2 (below), determine the conveyor operating speed in feet per minute (FPM)
TABLE 2 Material Density PCF BELT WIDTH, INCHES 18 24 30 36 18 24 30 36 18 24 30 36 Capacity, Tons per Hour (TPH) Belt Speed, Feet per minute (FPM) 300 350 400 450 500 81 95 108 150 175 200 225 250 243 284 324 365 405 353 411 470 529 588 122 142 162 225 263 300 338 375 365 425 486 547 608 529 617 705 793 881 162 189 216 300 350 400 450 500 486 567 648 729 810 705 822 940 1057 1175
50
75
100
200 54 100 162 235 81 150 243 353 108 200 324 470
250 68 125 203 294 101 188 304 441 135 250 405 587
550
600
650
446 646
486 705
764
668 969
729 1058
1146
891 1292
972 1410
1527
STEP 4: Calculate the Horsepower Required Using Table 3, determine the horsepower required to drive the empty conveyor per each 100 FPM of belt speed, HPo. then, HPe= (Belt Speed/100) X HPo.
TABLE 3 BELT WIDTH, INCHES
Horsepower to drive empty conveyor for each 100 FPM of belt speed Conveyor centers, feet
1000 1.70 2.20 3.00 3.80
50 100 150 200 300 400 500 600 700 800 900 18 0.20 0.37 0.45 0.52 0.67 0.82 1.00 1.20 1.40 1.50 1.60 24 0.30 0.47 0.57 0.66 0.88 1.10 1.20 1.40 1.60 1.80 2.00 30 0.40 0.60 0.75 0.90 1.20 1.40 1.70 2.00 2.30 2.60 2.80 36 0.65 0.80 0.95 1.10 1.50 1.80 2.10 2.40 2.70 3.00 3.40 Using Table 4 (pg.4) determine the horsepower required to convey the material horizontally, HPm.
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50
0.3 0.6 0.9 1.2 1.8 2.4 3.0 3.6 4.2 4.8 5.5 6.1 6.7 7.3
100
0.4 0.8 1.1 1.5 2.3 3.0 3.8 4.5 5.3 6.1 6.8 7.6 8.3 9.1
TABLE 4 Horsepower to convey material horizontally* Conveyor Centers, feet 150 200 300 400 500 600 700 800
0.5 0.9 1.4 1.8 2.7 3.6 4.5 5.5 6.4 7.3 8.2 9.1 10.0 10.9 0.6 1.1 1.6 2.1 3.2 4.2 5.3 6.4 7.4 8.5 9.5 10.6 11.7 12.7 0.7 1.4 2.0 2.7 4.1 5.5 6.8 8.2 9.5 10.9 12.3 13.6 15.0 16.4 0.8 1.7 2.5 3.3 5.0 6.7 8.3 10.0 11.7 13.3 15.0 16.7 18.3 20.0 1.0 2.0 3.0 3.9 5.9 7.9 9.8 11.8 13.8 15.8 17.7 19.7 22.0 24.0 1.1 2.3 3.4 4.5 6.8 9.1 11.4 3.6 15.9 18.2 20.0 23.0 25.0 27.0 1.3 2.6 3.9 5.2 7.7 10.3 12.9 15.5 18.0 21.0 23.0 25.0 27.0 31.0 1.4 2.9 4.3 5.8 8.6 11.5 14.4 17.3 20.0 23.0 26.0 29.0 32.0 35.0
900
1.6 3.2 4.8 6.4 9.6 12.7 15.9 18.7 22.0 25.5 28.5 32.0 35.0 38.5
1000
1.7 3.5 5.2 7.0 10.5 13.9 17.4 21.0 24.0 28.0 31.0 35.0 38.0
50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200
Using Table 5, determine the horsepower required to elevate the material, HPj.
TABLE 5
Tons Per Hour (TPH) 50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200
20
1.0 2.0 3.0 4.0 6.1 8.1 10.1 12.1 14.1 16.2 18.2 20.0 22.0 24.0
30
1.5 3.0 4.5 6.1 9.1 12.1 15.2 18.2 21.0 24.0 27.0 30.0 33.0 36.0
40
2.0 4.0 6.1 8.1 12.1 16.2 20.0 24.0 28.0 32.0 36.0 40.0
50
2.5 5.1 7.6 10.1 15.2 20.0 25.0 30.0 35.0 40.0
60
3.0 6.1 9.1 12.1 18.2 24.0 30.0 36.0
70
3.5 7.1 10.6 14.2 21.2 28.0 35.0
80
4.0 8.1 12.1 16.2 24.0 32.0 40.0
90
4.6 9.1 13.7 18.1 27.0 36.0
100
5.1 10.1 15.2 20.0 30.0 40.0
HPreq=HPe+HPm+HPj.
STEP 5: Determine the Motor Horsepower Motor HPmin = HPreq/Drive Efficiency Motor HP = next standard Motor HP greater than Motor HPmin STEP 6: Identify the Conveyor Layout Identify the conveyor layout. See following sections to determine channel or truss construction, gravity or screw take-up, sideboards, covers, etc. STEP 7: Complete the Request for Quotation form included in this catalog. Page 4
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Custom chute extensions or flange connections may be specified by the customer. Standard discharge angle is 60 degrees, but customer may specify required discharge angle. Please note that some materials require a steeper discharge angle than others to prevent material from sticking to inside of chute. Consult ORTHMAN CONVEYOR SYSTEMS to determine the optimum angle for the material to be conveyed. Page 7
Notes: 1. Weight values are frame-weights only; tail pulley guard weight is not included. 2. Pulley and shaft diameters will change with excessive loads and/or capacities.
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GRAVITY TAKE-UP
This illustration shows a standard gravity takeup. Depending on the specific conveyor requirements, design changes may be made to accommodate them. The standard gravity takeup includes two drum bend pulleys with plain lagging and one wing-type take-up pulley. The bearings are ball or roller type pillow blocks. The frame is fabricated carbon steel that is designed to either weld or bolt to the conveyor structure, depending on customer requirements. There is also a counterweight box, not shown for clarity. A take-up guard may be required for certain conveyors. Gravity take-ups have a travel of 18, 24 and 30 depending on conveyor length. Longer travel lengths may be designed if required. The chart shows values for standard gravity take-ups. Pulley diameters, shaft diameters and weights may change if there are excessive loads and/or capacities.
GRAVITY TAKE-UP SPECIFICATION STANDARD Belt Width, in 18 18 18 18 24 24 24 24 30 30 30 36 36 36 36 Pulley Diameter, in 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 Shaft Diameter, in 1 15/16 2 7/16 2 15/16 3 7/16 1 15/16 2 7/16 2 15/16 3 7/16 2 7/16 2 15/16 3 7/16 2 7/16 2 15/16 3 7/16 3 15/16 Weight, lbs 285 365 395 440 325 380 455 515 410 515 605 500 550 690 740
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CONVEYOR ACCESSORIES
BELT CLEANERS ORTHMAN has several different styles of industrial and food grade belt cleaners. The most standard design is a spring-loaded belt cleaner with either a rubber or UHMW scraper blade. This type cleaner is the most often used and will provide adequate cleaning in most applications. Motor driven brush type cleaners are also available for applications where the scraper type cleaner does not remove enough material. Please consult the Engineering Staff at ORTHMAN to determine what type of belt cleaner best suits your application. The chart below shows the most standard belt cleaners available: SCRAPER-TYPE BELT CLEANERS, STANDARD Belt Width, In 18 24 30 36 18 24 30 36 Blade Material Standard Rubber Standard Rubber Standard Rubber Standard Rubber UHMW UHMW UHMW UHMW Weight, lbs 25 30 35 40 25 30 35 40
These inlets provide a guide for incoming flow for covered conveyors. The flange may be the ORTHMAN standard or specified by the customer to attach to already existing chuting. The inlet chute itself is made of 14 ga. steel metal, standard. The chute is designed to be welded to a standard ORTHMANS curved cover. This same type of cover may be adapted for a box-type cover. UHMW or abrasion-resistant lining may be added if required. For applications where conveyors must be dust-proof, a gasket will be supplied with the flange.
DRIP PANS
Essential for conveyors running in areas where delicate machinery or people may be underneath the conveyors, the fabricated drip pans are designed to keep any material on the carrying and return runs from falling below the conveyors. The drip pans are made of 14 ga. carbon steel and are joined together with bolted splice sections. For totally enclosed conveyors, gaskets will be provided to ensure the drip pans are dust-proof.
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This picture shows a conveyor installation by ORTHMAN already in the field. The walkways, handrails, platforms, ladders and/or steps are tailored to the individual customers application. Please note that a safety stop switch is recommended on conveyors where workers will be near a running conveyor. Some welding and/or assembly may be required in the field for installation of walkways and handrails. ORTHMAN will supply any installation instructions that are needed.
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SCREW CONVEYORS
Industrial and food grade screw conveyors are available for conveying a variety of different materials. ORTHMAN offers a wide range of standard screw conveyors and options shown in our Screw Conveyor catalog. This catalog is also available through contacting the Sales Department at our home office or through your local sales representative. ORTHMAN provides a full line of screw conveyors and related components from water-jacketed heat-transferring models to multiple-screw live bottom type feeder units.
GATES
ORTHMAN offers gates of virtually any configuration. Electric-actuated, air-operated, and manual Y flop gates, flat slide gates, as well as made-to-order gates of the customers design are available. Our general catalog shows many types of gates already in use in the field. A wide range of materials is available for fabrication of the gates including steel, stainless steel, and aluminum. Gates lined with abrasion resistant steel or UHMW are available to suit customer requirements.
DRAG CONVEYORS
Drag conveyors are typically a chain-driven series of solid or perforated flights. This type of conveyor is used for material retrieval where there is little overhead room, such as under a casting line. They are also used for material retrieval in an oil or water pit after a wash procedure. These conveyors are designed per customer requirements and are tailored to fit customer needs. Because these conveyors are usually installed in areas where maintainance access is usually difficult, they are built ruggedly. As with all ORTHMAN products, these conveyors are built with the highest level of quality to avoid frequent maintainance.
CUSTOM FABRICATION
From support steel structures to custom conveyors and mass flow hoppers, ORTHMANS fabrication, welding and machine departments are able to supply just about any type of fabricated steel structure, designed to suit customer requirements. Page 14
*Bents designed for 40 wind sheer and 90 DL & LL (per col.) GENERAL DIMENSIONS FOR CONVEYORS 12 THROUGH 42 IN WIDTH
BENT HEIGHT A 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
CONVEYOR WIDTHS 18 AND 24 B C WT/LBS 4 3 4 8 5 1 5 6 5 11 6 3 6 8 7 1 7 6 7 11 8 3 8 8 9 1 9 6 9 11 10 4 10 5 11 1 11 6 11 11 12 4 12 8 13 1 13 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 159 190 281 324 459 516 634 671 723 774 858 1177 1232 1225 1384 1656 1759 1998 2064 2507 2593 2677 3722 3844 BENT HT A 4 6 8 10 12 14 16 18 20 22 24 26 CONVEYOR WIDTHS 30, 36 AND 42 B C WT/LBS 5 3 5 8 6 1 6 6 6 11 7 3 7 8 8 1 8 6 8 11 9 3 9 8 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 178 219 312 351 486 543 863 7-5 775 798 870 1222 BENT HT A 28 30 32 34 36 38 40 42 44 46 48 50 CONVEYOR WIDTHS 30, 36 AND 42 B C WT/LBS 10 1 10 6 10 11 11 4 11 8 12 1 12 6 12 11 13 4 13 8 14 1 14 8 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 1282 1354 1435 1732 1806 2053 2129 2618 2673 2781 3783 3907
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MATERIAL HANDLED
Material Type: Minimum Density, PCF: Maximum Density, PCF: Maximum Lump Size, in.: % Lumps at Max. Size: Capacity Required, TPH:
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