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ARTUR KÜPPER GMBH & CO.

KG
www.kuepper.eu

PLANT 1: ROLLER BEARINGS & TRACK ROLLERS


D-42553 Velbert D-42527 Velbert
Wülfrather Str. 32-52 Postfach 70 02 20
Phone +49 (2053) 497 - 0 bearing@kuepper.eu
Fax +49 (2053) 497 - 20

PLANT 2: IDLERS & CONVEYOR BELT ROLLERS


D-46238 Bottrop D-46209 Bottrop
An der Knippenburg 27 Postfach 10 09 53
Phone +49 (2041) 177 - 0 roller@kuepper.eu
Fax +49 (2041) 177 - 100

Warranty Terms & Conditions /


Instruction Manual
Idlers, idler installations, and idler garlands

EN
AKB-N2006-9 Rev. h
Table of Contents

1. INTAKE CONTROL............................................................................................................................................... 3
2. PRODUCT DESCRIPTION .................................................................................................................................. 3
2.1. SCOPE OF APPLICATION .............................................................................................................................................. 3
2.2. TECHNICAL SPECIFICATION......................................................................................................................................... 3
2.3. IDLER SYSTEMS FOR OPERATION IN EXPLOSIVE AREAS (ATEX) ........................................................................... 4
3. INSTRUCTION MANUAL..................................................................................................................................... 5
3.1. TRANSPORT................................................................................................................................................................... 5
3.2. STORAGE ....................................................................................................................................................................... 5
3.3. ASSEMBLY..................................................................................................................................................................... 6
3.3.1 POTENTIAL EQUALIZATION.................................................................................................................................................... 6
3.3.2 ASSEMBLING IDLERS TO IDLER GARLANDS................................................................................................................................ 6
3.3.3 ASSEMBLY OF FIXED IDLER SUPPORTS ..................................................................................................................................... 7
3.4. MAINTENANCE .............................................................................................................................................................. 7
3.5. REPAIRS......................................................................................................................................................................... 8
4. WARRANTY ........................................................................................................................................................... 8
AKB-N2006-9 Rev.h

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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
1. Intake control
Upon delivery, the goods must be checked for damages in transit and/or damages from
inappropriate intermediate storing.

2. Product description

2.1. Scope of application


The idlers of Artur Küpper GmbH & Co. KG are fit for operation both in bulk material
conveyors and for transporting palettes and containers on roller conveyors. The idlers
can be applied in installations consisting of carrying and return sides, self-aligning impact
devices and frames. Using connecting elements, they can also be assembled to idler
garlands and mounted into support frames.
All idler components have been designed for operation under high applied loads accord-
ing to VDI 2341. Operating locations range from adverse weather conditions open-air to
constant conditions in enclosed spaces. The scope of appropriate environmental tem-
peratures ranges from -35°C to +50°C. The idlers have been conceived for a mainte-
nance-free permanent operation at conveying speeds of up to max. 7.5 m/s, depending
on the idler’s diameter.

2.2. Technical Specification


– Idler tube
The idler tubes are manufactured from steel – blank, zinc-plated, powder-coated or
finished with primer and top coat RAL 5010, depending on customer’s orders. Rub-
berization or PU-coating is also possible. The idlers can in addition be furnished with
support or buffer rings, which are applied to the idler tube.
– Bearings
The precision roller bearings with dust-lid sealings deployed in our idlers have lifetime
lubrication and do not need separate maintenance.
– Axles
The axles used in Küpper idlers are either made of solid or hollow material (with
welded-on axle trunnions).
– Bearing housings
The Bearing housings are available as deep drawn, forged turning work-pieces or
iron-casted. The calibrated/roller-burnished bearing seats with an N7 fit guarantee a
permanent fit of the bearings.
– Sealings
Next to the dust-lid sealings, the bearings are dirt and moisture proof thanks to an in-
ner sealing and a patented QLR sealing group (labyrinth sealing system) with 100 %
grease lubrication. The sealing system is maintenance-free.
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
2.3. Idler systems for operation in explosive areas (ATEX)

This applies to specific designs of idlers belonging to the type series ORP, TRSG and
QLR.
A declaration of conformity is included with suitable products. In order to distinguish them
from non-ATEX products, they are marked with the lettering “Ex” near the stamped pro-
duction date.
Provided they are appropriately installed into the overall system, these products comply
with the requirements of the following protection class:

I M2
II 2GDc IIB T4 120°C -35°C ≤Ta≤ +50°C

Legend:

I M2: Equipment-group I: equipment for use in underground parts of


mines and to those parts of surface installations of such mines,
likely to become endangered by firedamp and/or combustible
dust; equipment group M2.

II 2: Equipment-group II: equipment for other uses than in underground


parts of mines likely to become endangered by explosive atmos-
pheres, equipment group 2.

G: Potentially explosive atmosphere caused by gases, fumes, or fog-


gy atmosphere involved.

D: Potentially explosive atmosphere, caused by explosive dust.

c: Type of protection: “constructive safety“ according to EN 13463-5.

IIB: Only for gases, fumes and fogs of gas group IIB.

T4: Suitable for media with a spontaneous combustion temperature


over 135°C according to temperature class T4.

120°C: The maximum surface temperature in operation is 120°C.

-35°C≤ Ta ≤ +50°C: The permissible ambient temperature for operation is -35°C


at minimum and +50°C at maximum.
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
3. Instruction manual

3.1. Transport
The idlers are chiefly delivered in bundles on disposable or wooden flat palettes. Delivery
of pre-assembled garland installations is carried out on specially manufactured disposa-
ble palettes. The idlers are bundled with steel or plastic bands to units appropriate for
transport.
A transport of loose idlers is to be avoided. When using securing belts, the packing units
must be attached in the same direction as the strapping. Palettes must be lifted dead-
centre. Attaching the palette bundles to the strappings or axle trunnions is not permitted.
Sudden impacts and high pressures on the idler axle are to be avoided. The face sides
of the idlers must not be damaged during transport. Transporting of roller frames with
rollers already inserted is only permissible if the rollers are secured against falling our
with suitable means.

3.2. Storage
Inappropriate storing of the idlers before operation can lead to damaging and a short-
ened service life. For example, unfavourable environmental effect, such as solar radia-
tion and strong fluctuations in temperature, can expedite an aging and embrittlement of
rubber and plastic parts.
For these reasons, idlers should be stored in roofed storage areas with a minimum
ground clearance height of 100 mm.
In general, the following instructions must be followed:
– Roofed open-air storing is permissible for a maximum of 12 months after delivery,
provided that there is a minimum ground clearance of 100 mm on fortified ground
and 300 mm on unfortified ground.
– If stored open-air for longer periods of time, the components must be protected from
the elements from all sides. Accumulation of condensate water is to be avoided.
– The storing temperature must correspond to those of operating conditions.

Idlers can be stored in secured stacks. Stacking of pallets is not allowed. The retaining
bands may only be removed/loosened when unloading the idlers from the stacks. The
idlers must be prevented from inadvertent rolling.
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
3.3. Assembly

3.3.1 Potential equalization


All idler systems (idlers, idler garlands and fixed idler supports) must be integrat-
ed into the operational potential equalization of the whole system in order to ex-
clude the danger of static sparking.
This regulation is especially valid for idlers marked for the intended use in poten-
tially explosive atmosphere (ATEX) according to chapter 2.3.!

3.3.2 Assembling idlers to idler garlands


When assembling idlers to idler garlands, standardized roller-chain-connecting links are
used as connecting elements. Screwed connecting elements are also used.
Roller-chain connecting links:
Connecting links are components of roller-chains according to DIN 8187. Securing the
loose lugs is achieved with steel locking bolt of. These may only be used once.
Connecting elements – screwed:
The loose threaded locking bolts are moved through a locking-bolt lug and through the
boreholes of the idler axles or of the suspension elements, respectively. From the oppo-
site side, a second, loose lug is slid on and the connection is secured with self-locking
nuts according to DIN 985.
The jointed idler garlands are hooked into the support frames with hooks, eyehooks,
suspension lugs or special suspensions. The connecting elements do not allow move-
ment in horizontal direction.
The following points must be adhered to in order to decrease the strain on the securing
elements:
– The garlands must be hooked into the frame in such a way that the loose locking-bolt
lugs are positioned in the opposite direction of the belt run.
– When using screwed connecting elements, it must be assured that the nuts are
aligned contrary to the conveying direction.

When designing idlers according to VDI 2341, the additional loads resulting from the
running of the belt must be considered or, respectively, should assuredly be avoided dur-
ing assembly and in operation.
The additional loads may be neglected if the horizontal angular deviation of the belt does
not exceed 1° per individual idler and the descending or ascending setting of the idler
garlands does not exceed 2° with rising or declining conveyance.
The face sides of the idlers must not be damaged during assembly to idler garlands. The
same applies to the installation of idler garlands.
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
3.3.3 Assembly of fixed idler supports
The fixed idler supports are manufactured as welded constructions from hot- or cold-
rolled profiles (U, L profiles, and tubes). The idler supports are screwed onto the belt
frame; the beams must not bend at the joints. The appropriate fastening elements must
be used here.
Idlers are inserted into the holding fixture by the flattened axle ends. If the idlers are to be
additionally secured against derailing, special securing elements are used, which are
subsequently mounted onto the axle ends.
The face sides of the idlers must not be damaged during insertion into the idler installa-
tions.

3.4. Maintenance
Idlers, idler garlands and fixed idler supports are maintenance-free.
The roller bearings of the idlers have lifetime lubrication and are 100% proof against dirt
and moisture thanks to the patented QLR-sealing assembly group.
Nevertheless, a regular inspection of the idlers and idler garlands is absolutely neces-
sary, for example in the form of section patrols or visual checks in regular timed intervals
(weekly).
Inspection the roller bearings should be carried out by a heat check at the axle stubs us-
ing suitable measuring instruments (e.g. infrared). It should be noted here that during
normal operation, the temperature on the axle ends can be up to 35°C higher than that
of the surrounding area.
CAUTION!
Manual procedures on rotating idlers are prohibited.
RISK OF SERIOUS INJURY!
Accumulations of the conveyed materials in the operating area of the idlers are to be
avoided and should be removed regularly if they occur.
When cleaning the idlers with jets of water, special care must be taken to avoid any hard
jet from hitting the face sides of the idlers in order to prevent the intrusion of moisture.
Defective idlers or garlands are to be replaced immediately; otherwise, subsequent
damages to the belt or to neighbouring components cannot be excluded.

A replacement is imperative if any of the following damages occur:


– Bearing failure, which is announced by heightened operating noises or unusually
high temperatures when touching the bearing
– Failure of the locking ring, which can be recognized by an obvious dislocation of the
idler tube
– Clearly visible wear-out of the casing tube
– Wear and tear of the support rings
AKB-N2006-9 Rev.h

– Defective connecting element

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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
3.5. Repairs
Repairing idlers is not recommended.
It is explicitly stated here that repairing idlers will automatically render the declaration of
their conformity according to 94/9/EG (ATEX) null and void. The products in question
must no longer be used in potentially explosive areas.
The same applies to welding repair works on idler installations.

4. Warranty
Within the scope of the 24 months’ warranty (12 months in case of impact rollers),
Company Artur Küpper shall assume liability providing the defects are already present
upon transfer of peril. Amendments to these warranty terms and conditions require
the confirmation Company Artur Küpper in writing.
In order to be valid, this warranty requires proper installation and storage according to
our storage instructions. Wear and tear as well as wear and tear parts and consuma-
bles (e. g. support rings, rubber lining etc.) shall be excluded from this warranty. Also
excluded shall be claims for consequential damages as well as claims based on the
tolerable rate of failure for rollers of 1% annually.
This warranty by Company Artur Küpper shall cover the deliverable items exclusively.
Any and all consequential damages shall be excluded.
The warranty period begins with the date of delivery “FCA Bottrop” (Incoterms 2010).
The delivered idlers may be used solely and exclusively in those belt conveyors and
areas (carry side / return side / impact area) for which they have been designed.
Any non-intended use of the idlers renders this warranty null and void.
Company Artur Küpper or its contractual partners, respectively, have the right to inspect
the site of operation of the damaged idlers as well as to perform a detailed examination
of the failed idlers. For this, Company Artur Küpper will be granted an adequate time
frame.
Moreover, the end customer will grant Company Artur Küpper and its contractual part-
ners the right to inspect the belt conveyor system into which Küpper idlers are installed,
at regular intervals on one week’s notice.
During the warranty period, Company Artur Küpper or its contractual partners, respec-
tively, will remedy a justified warranty claim by repairing or exchanging the defective
idlers as they see fit.
On principle, a warranty claim is only recognized if the idlers have been installed in com-
pliance with the installation instructions and the belt conveyor is professionally operated.

Any warranty claims are excluded in the following cases:


– Improper or inappropriate usage
– Non-observance of the included instruction manual AKB-N-2006-9
AKB-N2006-9 Rev.h

– Use of the idlers for any other than the intended use
– Normal wear and tear damage
– Damages caused by belt misalignment
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper
– Damages caused by misalignment of the belt conveyors
– An inclined position of the idlers > 2°
– Damages caused by faulty belt tension
– Damages caused by insufficient cleaning and maintenance of the belt conveyor
– Use of force such as shock, hit or fall
– Changes or interventions to the idlers by the customer
– Unauthorized attempted repairs
– Return delivery without transport locks
– Accessories that are not part of the idler’s basic configuration
– Improper storage of the idlers
Idlers must be stored in a roofed storage area protected from direct atmospheric in-
fluence. The minimum clearance height is 100 mm providing the installation sur-
face is solid; otherwise the minimum clearance must be 300 mm. Rust-proofing is
designed for a protection period of 12 months.
– Idle-time corrosion
After installation of the idlers, the belt conveyor must be put into operation as soon as
possible, no later than 14 days after installation. Failure to do so will result in the dan-
ger of contact corrosion inside the bearing, between balls and ball track.
After commissioning of the belt conveyor, idle times of more than 14 days are to be
avoided.
– Electrical continuity
Internal to the belt conveyor, any electrical continuity running through the roller bear-
ings must be prevented by all means.

Any warranty claim must be stated by the customer, in writing, within 3 (three) days after
the damage has occurred. The claim must include the order number, job number, deliv-
ery date etc.
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Persönlich haftende Gesellschaft: Rolf Küpper Beteiligungsges. mbH, Velbert HRB 17345 • Geschäftsführende Gesellschafterin: Susan Küpper