C O N V E Y I N G

Basic Conveyor Design

& Maintenance
A Superior Industries White Paper
 CONTENTS ABSTRACT
Conveyor maintenance is an important part of the lifespan of any piece of equipment. The harsh operating conditions
Abstract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
experienced by aggregate conveyor systems not only increase the need for proper maintenance but also create a need for
Designing for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
design considerations that facilitate proper maintenance. In many cases, proper design considerations may reduce the cost
Material Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
and time involved with conveyor maintenance. Design considerations are not able to eradicate maintenance altogether
Belt Cleaner Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
however, in order to achieve longevity of the equipment maintenance must be performed correctly and according to the
Impact Absorbing Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
recommended maintenance schedule.
Installing a Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Conveyor Belt Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Loading the Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Weight Weight Surcharge Surcharge
Maximum Maximum DESIGNING FOR MAINTENANCE
Conveying Conveying
Belt Tightening and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Material (LB per (KG per CU. Angle Angle Dry bulk material producers and handlers spend millions
Angle Angle
CU. Foot) Metre) (inches) (mm) of dollars every year maintaining conveyor systems.
Conveyor Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 (inches) (mm)
General Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ashes, Coal Dry -3” 35-40 561-641 25-30 635-762 22 559 Oftentimes, conveyor design does not provide the means
General Conveyor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cement, Portland 90-100 1442-1602 25 635 20 508 for ease of maintenance, and as a result, maintenance may
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cement, Clinker 75-80 1201-1281 20 508 18 457 not be performed correctly, on time, or at all. This eventually
Coal, Anthracite, Sized leads to a greater risk of component failure and a resulting
Troubleshooting Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 .375”- 6”
55 881 12 305 16 406

Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Coal, Bitrum Slack 50 801 22 559 22 559

loss of production.
Coal, Bitrum ROM 50 801 20 508 18 457
Coke, Loose 25-30 400-481 15 381 20 508 Designing a conveyor to be maintenance friendly means
Earth, Common Loam
70-80 1121-1281 15-30 381-762 20 508 providing adequate provisions for necessary service
Dry
from the onset. This means eliminating problems such
Earth, Clay Dry 100-120 1602-1922 10-30 254-762 20 508
as inadequate spacing, inaccessible positions, and other
Earth, Moist 80-100 1281-1602 30 762 22 559
Gravel, Average Blended 90-100 1442-1602 15-20 381-508 18 457 non-repairable configurations. The following sections will
Gravel, Sharp 90-100 1442-1602 15-20 381-508 18 457 illustrate some of the design considerations that may deter
Gravel, Round 90-100 1442-1602 15 381 15 381 or aid in conveyor maintenance.
Iron Ore 135 2162 20 508 22 559
Limestone, Crushed 85-90 1362-1442 25-30 635-762 20 508 MATERIAL CHARACTERISTICS
Phosphate Rock 75-85 1201-1362 25 635 20 508
When designing a conveyor, the type of material to be
Salt, Coarse Dry 40-45 641-721 10 254 20 508
conveyed is the first item to be taken into consideration. The
Salt, Fine Dry 70-80 1121-1281 15 381 22 559
flowability of a material affects the size of the cross section
Sand, Bank Damp 110-120 1762-1922 20-30 508-762 22 559
Sand, Bank Dry 90-110 1442-1762 10-20 254-508 15 381 of load that can be carried on a given belt width. Flowability
Sand, Foundry Shakeout 90 1442 25 635 20 508 is affected by material characteristics such as:
Sand, Silica Dry 90-100 1442-1602 10-20 508 15 381 • Size and shape of the fine particles and lumps
Sand, Saturated 110-130 1762-2082 0-15 0-381 15 381 • Roughness or smoothness of the surface
Shale, Crushed 85-90 1362-1442 25 635 20 508 • Proportion of fines and lumps present
Slag, Furnace Crushed 80-90 1281-1442 12 305 18 457
• Moisture content
Slate, Crushed .5” 80-90 1281-1442 15 381 20 508
• Weight per cubic foot
Soda Ash, Light 25-35 400-561 22 559 20 508
• Abrasiveness
Soda Ash, Heavy 55-65 881-1041 17 432 20 508
Sulfur, Crushed .5” 50-65 801-1041 20 508 20 508 • Temperature
Sulfur, Lumpy 3” 80-85 1281-1362 25 635 20 508 (Table 1) gives the weight per cubic foot, surcharge angle
Wheat 45-48 721-769 8-15 203-381 16 406 (Figure 1), and maximum conveying angle (Figure 2) of
Wood Chips 15-25 240-400 30 762 25 635 some commonly conveyed materials.
[Table 1]

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 BELT WIDTH, SPEED, AND CAPACITY BELT SPEED IN FPM
MATERIAL
For a given speed and material density, the wider the conveyor Belt Width (in) (cm)
belt the more the capacity of the conveyor. A belt must be 18” 24” 30” 36” 42” 48”
Characteristics Example
wide enough so that the combination of fines and lumps do (46cm) (61cm) (76cm) (91cm) (107cm) (122cm)
not push the lumps too close to the edge of the belt. (Table 2) Non-Abrasive Coal, Earth 350 400 450 500 550 600
shows the belt width necessary for a specific lump size, various Lumps at Max Size Recommended Semi-Abrasive Gravel 300 350 400 450 500 550
proportions of lumps and fines, and various surcharge angles. Highly Abrasive Stone, Ore 250 300 350 400 450 500

F1 Non-Abrasive Coal, Earth 400 450 500 550 600 650

Conveyor belt speeds depend upon the material characteristics, the Lumps at Half Size Recommended Semi-Abrasive Gravel 350 400 450 500 550 600
Surcharge angle capacity desired, and belt tensions. Heavy materials with sharp edges
Highly Abrasive Stone, Ore 300 350 400 450 500 550
should be conveyed at moderate speeds. The sharp edges will cause
Granular .125” (3.2mm) to .5” (12.7mm) Sand, Grain, Wood Chips 400 500 600 700 800 900
wear to the belt, particularly if the loading velocity of the material in the
Aerating Powders Cement, Flue Dust 200-300
direction of belt travel is lower than the belt speed.
Conveyors with plow discharge 200

Light, powdery materials must also be conveyed at lower speeds to reduce [Table 3] Maximum speeds recommended for standard belt conveyors
dust particles, especially at loading and discharge points on the conveyor.
Fragile materials may degrade at loading and discharge points, as well as
to move with a conveyor. If there is uniform feed to the conveyor, a cross
when moved over idlers. Therefore, these types of materials should also be
section of the material loaded on the belt is used in calculating the
conveyed at lower speeds. (Table 3) recommends maximum belt speeds
capacity of a conveyor. The cross section of material must meet the
for commonly conveyed materials.
following two conditions.
F2
As stated previously, capacity increases with the increase of belt width. It is
First that the material does not extend beyond to the belt edge or the
Conveying angle
important to know the tons per hour (TPH) of material an end user expects
distance recommended by the Conveyor Equipment Manufacturers
Association (CEMA), and secondly that the top of the load does not
26 66 F3 exceed the surcharge angle of loading (Figure 1).
25 64
Fabric ply components
24 61
e BELT SELECTION
23 58 arg
ch The three elements of a conveyor belt are the carcass, top cover, and
22 56 sur
0˚ bottom cover. The carcass of the belt must have the tensile strength to
20 51 ,2
es
18 46 fin withstand the load on the belt, and it must also have the strength to
Lump 0 %
16 41 ,9
Size ps withstand the impact of materials in loading areas. Most carcasses consist
lum arge
(inches) 14 36 ˚ s urch rchar
ge
of multi-ply woven fabrics (Figure 3 & 4). Heavier duty belt carcasses may
10% p s, 2 0
s, 30˚ su
(cm) 12 30 u m fi n e
All l s, 90% 0˚ surchar
ge contain steel cables for reinforcement. The yarns of a belt carcass that run
10 25 lump , 3
10% m p s
8 20 All lu parallel to the conveyor are called warp yarns. These bear the tension of
6 15 the belt. The cross yarns of the belt carcass are called weft yarns and aid in
4 10 impact resistance and fabric stability.
2 5 F4
1 3
0 0 Cut-away of a conveyor belt carcass
18 24 30 36 42 48 54 60 66 72 78 90 96
46 61 76 91 107 122 137 152 168 183 198 229 244
Belt Width (inches) (cm)
[Table 2] Belt width necessary for a given lump size

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ALL-GUM STEEL CORD BELT
FABRIC-REINFORCED STEEL CORD BELT
Steel belt cable
MATERIAL CONVEYED
Non-Abrasive Materials:
Wood chips, grain, loose cement,
or very fine coal.
Mildly Abrasive Materials:
Sand, earth, bituminous coal, and
roack under 3” (76mm)
Abrasive Materials:
Anthricite coal, coke or sinter. Over-
burden or coal up to 10” (254 mm)
Iron and copper ores, or
limestone under 6” (152mm)
Heavy Abrasive Materials:
Iron, copper, zinc, or lead ores, lime-
stone, or slag under 9” (229mm)
Heavy, Sharp Abrasive Materials:
Trap Rock, quartz, glass cullet.
Any hard, heavy, sharp ore over 9”
(229mm)
[Table 4] Belt selection
HEAD PULLEY TAIL PULLEY
12”
18”
18”
24”
30”
[Table 5] Wrap length for head and tail pulleys
There are four types of belt carcasses:
• The multi-ply carcass is usually made up of three or more
plies cemented together by a rubber compound. Strength
and load support depend on the number of layers, which is
usually limited to eight
at the most.
• Reduced-ply belting may be used in place of multi-ply
belting. It consists usually of fewer layers than the multi-ply,
F5 but the layers are made of synthetic fabrics of higher unit
strength.
• A steel-cable belting carcass consists of a single layer of steel
MINIMUM cables embedded in rubber. The all-gum type has only cables
TOP COVER BOTTOM and cable rubber, while the fabric-reinforced type has one or
THICKNESS COVER more layers of fabric above or below the steel cables (Figure F6
THICKNESS
5). This type of carcass is best used for applications where the
1/16” to 1/8” 1/32” tensions required go beyond ply carcasses, and where take-up Performing vulcanized belt splice
(1.6mm to 3mm) (.8mm)
travel is not long enough to compensate for the high elasticity
of ply carcasses.
1/8” to 3/16” 1/16”
(3mm - 4.8mm) (1.6mm) • Solid-woven belts consist of a single ply of solid woven fabric The advantages to vulcanizing belt ends are an improvement in splice
usually covered with a top and bottom cover made of PVC strength, longer belt life, and a lack of interference with belt cleaners, idler
material. This type of carcass aids in abrasion resistance. The rolls, or skirting. The vulcanized splice will eliminate material sifting through
3/16” to 1/4” 1/16”
main purpose of the covers is to protect the carcass from wear the splice as can happen with mechanical fasteners.
(4.8mm - 6.4mm) (1.6mm)
and impact damage. They also provide a friction surface to
aid in the driving of the belt. (Table 4) provides a guide to the The vulcanized splice also has some disadvantages, including initial cost
1/4” to 5/16” 3/32”
required thickness of the top and bottom belt cover. and time required to create the splice. A vulcanized splice takes longer
(6.4mm - 7.9mm) (2.4mm)
than using mechanical fasteners and therefore increases the conveyor
downtime. However, for permanent splicing of a conveyor belt vulcanizing
5/16” to 3/4” 3/16”
(7.9mm - 19mm) (4.8mm) The required length of a belt can be computed by multiplying is the best choice.
the conveyor length by 2 and adding the length needed to wrap F7
around the head and tail pulleys (Table 5). A gravity takeup on a The most important step in using mechanical fasteners to splice a belt is
channel frame conveyor will require an additional 6-feet (1.8m) of Example of mechanical belt splice to recess the top and bottom splice pieces. The top and bottom covers are
belt, while a gravity take-up on a truss frame conveyor will require removed down to the carcass. This does not endanger the belt strength or
an additional 10-feet (3m) of belt. integrity. The recess is needed to keep the fasteners from interfering with
LENGTH OF BELT potential catch points.
REQUIRED
The ends of a conveyor belt must be joined together (spliced)
12” 3’
to create a continuous belt. The two most common ways of Mechanical fasteners (Figure 7) are less expensive than vulcanization and
12” 4’
splicing a belt are vulcanizing and using mechanical fasteners. more easily applied. They are also the preferred method for making repairs
18” 5’
Hot and cold processes are two types of vulcanization. to the belt in the field, such as adding belt length and patching holes or
18” 6’
Using the hot method, the layers of the belt are stripped in tears. Material leakage through mechanical fasteners is inevitable. Over
24” 7’
a stair-step manner and overlapped with glue and rubber. time, this may cause clean up problems and will create the potential for
A heated press is then used to vulcanize the belt, creating damage to other conveyor components.
an endless loop (Figure 6). The cold method laps the
belt’s layers with glue that cures at room temperature.

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 IDLER SELECTION Roll Belt Belt PULLEY AND SHAFT SELECTION
All belt conveyor idlers have the same purpose. They provide shape and support for the belting and Class Diameter Width Width Duty The standardization of pulleys lends itself to the ease of choosing the
(in)(mm) (inches) (cm)
minimize the power needed to transport material. Idler spacing affects both the shape and support of correct pulley for a given application. The most commonly used pulley is
the conveyor belt. Idlers placed too far apart will not properly support the belt or enable it to maintain B4 4” (102mm) 18” - 48” 46-122 Light the standard steel pulley. Plain steel drum pulleys are best used in dry clean
the desired profile. B5 5” (127mm) 18” - 48” 46-122 Light environments where traction is not critical, and when no foreign material is
C4 4” (102mm) 18” - 60” 46-152 Medium present on the return belt.
Idlers that are placed too close together will provide the necessary support and profile, but may add C5 5” (127mm) 18” - 60” 46-152 Medium
unnecessary expense to the conveyor. The main influences in idler selection are: C6 6” (152mm) 24” - 60” 61-152 Medium Conveyor pulleys may also be covered with rubber, fabric, or other material.
• Belt weight D5 5” (127mm) 24” - 72” 61-183 Medium This is referred to as lagging. Lagging on a drive pulley provides an increase
• Material weight D6 6” (152mm) 24” - 72” 61-183 Medium in the friction between the belt and the pulley. Lagging is also used to
• Idler load rating E6 6” (152mm) 36” - 96” 91-244 Heavy reduce abrasive wear to the face of the pulley and to create a self-cleaning
• Belt sag E7 7” (178mm) 36” - 96” 91-244 Heavy action on the surface of the pulley. (Figure 9) illustrates a vulcanized
• Idler life F7 7” (178mm) 36” - 96” 91-244 Heavy lagged drum pulley. Typical grooving patterns include herringbone,
• Belt rating chevron, and diamond.
[Table 7] CEMA Coding system
• Belt tension
Plain rubber lagging on drum pulleys is typically used in snub applications
(Table 6) cites suggested idler spacing recommendations under relatively normal operating where traction is not critical. Replaceable lagging is also available. The
conditions when the amount of belt sag is not specifically limited. This table also shows the lagging strips are welded to the face of the pulley, and can easily be
recommended spacing for return idlers. replaced in the field (Figure 11).

Proper idler roll diameter and size of bearing and shaft selection is based on load carried, belt speed, Wing pulleys are typically used in tail pulley applications to reduce the
and operating conditions. To aid in the selection of idlers, various designs have been assigned buildup of material between the belt and pulley. Trapped materials fall
classifications illustrated in (Table 7). through the paddle-like formations of the pulley. Lagged winged pulleys
are used in applications with abrasive material present on the return side
F9 of the belt. It is natural under these conditions for the wing tips to wear
Troughing Idler Spacing prematurely. The rubber lagging will add life to the pulley.
Belt Width Return
(in) (cm) 30 lb/ft. cu. 50 lb/ft. cu. 75 lb/ft. cu. 100 lb/ft. cu. 150 lb/ft. cu. 200 lb/ft. cu. Idlers Vulcanized lagged drum pulley
(481 kg/cu m) (801 kg/cu m) (1201 kg/cu m) (1602 kg/cu m) (2403 kg/cu m) (3204 kg/cu m)
The conventional wing pulley is particularly susceptible to material buildup,
18 (46) 5.5 ft (165cm) 5.0 ft (152cm) 5.0 ft (152cm) 5.0 ft (152cm) 4.5 ft (137cm) 4.5 ft (137cm) 10.0 ft (305cm) wing bending, as well as noise and vibration during operation. Belts and tail
24 (61) 5.0 ft (152cm) 4.5 ft (137cm) 4.5 ft (137cm) 4.0 ft (122cm) 4.0 ft (122cm) 4.0 ft (122cm) 10.0 ft (305cm) pulleys are subject to damage and failures when fugitive material becomes
30 (76) 5.0 ft (152cm) 4.5 ft (137cm) 4.5 ft (137cm) 4.0 ft (122cm) 4.0 ft (122cm) 4.0 ft (122cm) 10.0 ft (305cm) entrapped between the belt and the tail pulley. If the material is not
36 (91) 5.0 ft (152cm) 4.5 ft (137cm) 4.0 ft (122cm) 4.0 ft (122cm) 3.5 ft (107cm) 3.5 ft (107cm) 10.0 ft (305cm) removed, several serious issues can occur:
42 (107) 4.5 ft (137cm) 4.5 ft (137cm) 4.0 ft (122cm) 3.5 ft (107cm) 3.0 ft (91cm) 3.0 ft (91cm) 10.0 ft (305cm) • Degraded material can be carried between the belt and the pulley,
48 (122) 4.5 ft (137cm) 4.0 ft (122cm) 4.0 ft (122cm) 3.5 ft (107cm) 3.0 ft (91cm) 3.0 ft (91cm) 10.0 ft (305cm) causing excess wear and tear on the belt, as well as potential belt
54 (137) 4.5 ft (137cm) 4.0 ft (122cm) 3.5 ft (107cm) 3.5 ft (107cm) 3.0 ft (91cm) 3.0 ft (91cm) 10.0 ft (305cm) slippage and mistracking.
• Large entrapped material with sharp edges can create an uneven belt
60 (152) 4.0 ft (122cm) 4.0 ft (122cm) 3.5 ft (107cm) 3.0 ft (91cm) 3.0 ft (91cm) 3.0 ft (91cm) 10.0 ft (305cm)
surface and can puncture, gouge or rip the belt.
72 (183) 4.0 ft (122cm) 3.5 ft (107cm) 3.5 ft (107cm) 3.0 ft (91cm) 2.5 ft (76cm) 2.5 ft (76cm) 8.0 ft (244cm)
• Also, trapped material can be ejected back onto the return side of the
84 (213) 3.5 ft (107cm) 3.5 ft (107cm) 3.0 ft (91cm) 2.5 ft (76cm) 2.5 ft (76cm) 2.0 ft (61cm) 8.0 ft (244cm)
F11 belt and can become entrapped in the pulley repeatedly until it finally
96 (244) 3.5 ft (107cm) 3.5 ft (107cm) 3.0 ft (91cm) 2.5 ft (76cm) 2.0 ft (61cm) 2.0 ft (61cm) 8.0 ft (244cm)
degrades; or until it damages the pulley face, bends the pulley wings,
[Table 6] Weight of material handled Example of weld on pulley lagging
or causes pulley or belt failure.

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 Removing material buildup from the pulley or repairing or replacing pulleys
and belts results in significant downtime and maintenance costs.
Within the last decade, a new v-shaped wing pulley (F12) was engineered
to prevent material buildup and belt damage while greatly minimizing
noise and vibration during operation. When compared to the conventional
wing pulley, the v-shaped design delivers numerous time-and -money
F12 saving advantages over that of traditional choices.
Chevron® Pulley reflects fugitive material
Shafting is commonly considered to be a part of the pulley assembly
since the strength and rigidity of the assembly depends on both of these
components. When choosing shaft diameter, it is important to consider
both the shaft diameter required for strength and shaft diameter required
for deflection. Depending on the pulley assembly, either strength or
deflection may be the deciding factor of shaft diameter.
BELT CLEANER SELECTION
Carryback is the fugitive material that sticks to the belt after it passes
over the head pulley and subsequently creates fugitive material piles
along the underside of the conveyor. Fugitive material is a costly problem,
F14
considering that many maintenance hours are spent cleaning these piles.
In order to correct carryback, a belt cleaner is used. This is usually a form of
Standard design primary belt cleaner
a wiper, blade or scraper device mounted near the discharge (head) pulley.
A common type of belt cleaner is the precleaner. This is often referred to
as the primary cleaner and functions by scraping off most of the carryback
leaving only a thin layer of fines on the belt. The pre-cleaner mounted on
the face of the head pulley just below the discharge trajectory. This allows
the material scraped from the belt to fall with the discharge materials.
(Figure 14) shows a typical primary belt cleaner.
RETURN IDLER
Multiple cleaner systems are the preferred method for eliminating
carryback. The multiple systems consist of a pre-cleaner and one or more
PRE-CLEANER
secondary cleaners. In addition to the improvement in belt cleaning,
TERTIARY CLEANER SECONDARY CLEANER multiple belt cleaner systems increase the time interval between scheduled
maintenance. Belt cleaners should be positioned as close to the head end
F15
as possible (Figure 15).
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Secondary cleaners are designed to remove the thin layer of fines left
by the pre-cleaner. It’s best to place the secondary cleaner in contact
with the belt while it is still against the head pulley. This enables the
cleaner to scrape against a firm surface. If you require both primary and
secondary cleaning, but your conveyor is not designed to accommodate
the secondary cleaner, look for technology that combines primary and
secondary blades with one shared mounting pole. (Figure 16)
F16
There are several types of non-traditional belt cleaners available to
Primary and secondary cleaners sharing one pole
eliminate carryback. The brush type can be driven by the pulley motion
or motorized. This type is effective on dry materials, as the bristles of the
brush sweep the belt clean. The disadvantage to brush type cleaners is the
potential for build up on the brush’s bristles.
Pneumatic type belt cleaners send a stream of air across the face of the
pulley to blow off the carryback materials. They are best utilized when
moving dry materials. The disadvantages of the pneumatic cleaners are the
expense of the continual air stream, and the creation of airborne dust as the
carryback is not deposited in the discharge pile.
There are two styles of wash-type cleaners that use water to clean the
belt. The first is a system that sprays a misting of water on the belt in
order to make the scraping process easier. The second type uses a high-
F19 pressure wash to completely remove carryback. Problems occur with these
types of cleaning systems with the removal of the sludge that is created.
V-Plow Return Belt Cleaner
However, in some cases, the water-material mixture can be returned to the
material load. These systems also have the potential for trouble under cold
operating conditions.
Return belt cleaner systems, also known as v-plows, are used to prevent
large objects and tramp iron on top of the return belt from damaging
conveyor components. A low pressure mechanical scraping is used to
remove the material from the belt. (Figure 19)
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 TAKE-UP SELECTION
All conveyors need some form of takeup device in order to ensure proper
belt tension, which prevents material spillage due to belt sag between the
idlers, and to provide enough tension to prevent slippage between the
belt and the drive pulley. They also compensate for belt shrinkage or
stretch, and allow for extra belt length storage for making replacement
splices in the belt.
The required take-up movement length is determined by the type of
mechanism being used to start and stop the conveyor, the frequency of
starts and stops with a loaded belt, stretch characteristics of the belt,
and running tensions.
There are two types of take-up systems, manual and automatic. The
manual systems are preferred when an automatic take-up is impractical.
They are also preferred for use on short, light conveyors where take-ups
are not as critical. The take-ups shown in are most commonly found on belt
conveyors. Window style take-ups are best utilized on conveyors less than
150-feet (45.7m) in length. The travel length of the take-up can be up to
F22 36-inches (914mm).
Gravity take-up tower
Telescoping tube type take-ups can be used on conveyors up to 150-feet
(45.7m) in length where headroom may be a concern. The travel length of
the takeup can be up to 36-inches (914mm). A scissors type vertical gravity
take-up (Figure 22) is also used when headroom is a concern. The travel
length on this takeup can be up to 8-feet (2.4m). Gravity take-ups
(Figure 23) are used on stationary conveyors over 150-feet (45.7m) long
and where vertical headroom is of no concern.
TRANSFER POINTS
A transfer point is any point on the conveyor where material is loaded onto
or unloaded from the conveyor belt. The ideal transfer point would be
designed to load the belt in the center and at a uniform rate. They should
also reduce the impact of the material falling on the belt and maintain a
minimum angle of inclination of the belt at the loading point. The design
of discharge chutes and other loading equipment should take these topics
F23
into consideration. Other factors such as capacity, size, characteristics
Vertical gravity take-up of material handled, speed, and inclination of the belt should also be
considered.
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SKIRTBOARDS
Skirtboards are used to keep transfer material on the belt after
it leaves the loading chute until it reaches belt speed. They
are usually an extension of the loading chute and extend for
some distance along the conveyor.
(Figure 24) The distance between the skirtboard and the
conveyor belt is critical. Skirtboards need to be placed high
enough so that they never come into contact with the belt.
However, the gap between the belt and skirtboards should be
as small as allowable. The closer they are together the easier
it is to maintain a seal between them. The gap between the
bottom edge of the skirtboard and the belt is usually sealed
F24
by a flexible rubber strip attached or clamped to the exterior
Conveyor hopper with integrated skirtboard of the skirtboard.
Commonly, skirtboard length should be 2-3 feet (609mm-
914mm) per 100-feet (30m) per minute of belt travel. The
material should be traveling the same speed as the belt when
it leaves the load area.
IMPACT ABSORBING SYSTEMS
Transfer point structures can rapidly deteriorate due to
loading zone impact from heavy objects or material with
sharp edges. Loading zone impacts also cause wear and
damage to the conveyor belt, weakening the belt carcass. To
aid in the prevention of this damage, transfer points should be
designed to lessen the height of the material drop. There are
also devices made to reduce impact at transfer points. Impact
idlers may be used at the transfer point; these are troughing
idlers that have rubber-cushioned rollers to absorb impact.
F25 Impact beds or cradles can also be positioned under the
conveyor belt to absorb impact at loading areas.
Conveyor with emergency stop cord/switch
EMERGENCY STOP SWITCHES
AND CONVEYOR GUARDING
Emergency stop switches consist of a pull-cable that runs
along the side of the conveyor and is connected to a switch
approximately every 100-feet (30m) of conveyor length
(Figure 25). The emergency stop switch either shuts down
the conveyor system or sounds an alarm if the cord is pulled,
providing an extra safety device for operators and conveyor
maintenance workers.
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Single side return roll guard
Installing flexible guard panels
Threading belt on conveyor
14
Another safety device important in conveyor design is guarding. Machine
guarding provides a safer working environment. Some examples are shown
below. Drive guards are used to cover v-belt drives, rotating shafts, and
jackshafts. Return roll guards (Figure 27) are used to guard return idlers
that are less than 7-feet (2.1m) from the ground or accessible by operators
or maintenance personnel. Side guards (Figure 28) are used on or near
transfer points to prevent access to pinch points and rotating components.
F27
INSTALLING A CONVEYOR BELT
Belts are customarily packaged in crates that can be rolled from place to
place. Crates and rolls are usually marked with an arrow that shows the
direction in which they should be rolled. Most belting is also shipped from
the factory cut to length with additional allowance for squaring ends for
the splice.
When hoisting the belt roll, a bar should be passed through the hole in the
center of the roll. Fasten chain or cable to the ends of the bar for lifting, and
use a spreader bar above the roll to prevent damage to the edge of the belt.
Always store the belt roll suspended on a tube or bar, or resting on the face
width of the belt. Storing the belt roll with weight on one edge may stretch
the belt, making it difficult to square at assembly and train during the initial
F28 operation. Belts should be stored in a dry, cool building. Never drop the belt
or store it on its edges.
Installation of the belt begins with building a suitable stand behind the
conveyor and then aligning the belting roll with the conveyor frame
(Figure 29). If the area behind the conveyor will not permit this method of
threading, the roll of belting can be suspended above the conveyor frame
for threading.
Next, check the position of the side take-up bearings to make sure they are
positioned all the way to the retracted position. This will give you maximum
take-up ability after belt installation. Then check the belt to make sure the
load side (side with the thickest rubber covering) is facing up.
F29
The molded edges on new belts are not always straight and parallel.
Whenever practical, it is recommended to square ends of the belting with
Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267
the centerline. Mark the center point of the belt using a light colored chalk
CENTER POINT
ARC or pencil (Figure 30). Then draw an average centerline using these points
SQUARE LINE ARC INTERSECTION POINT as a guide. Locate two center points on the belt such that arcs will overlay.
(A) Draw the arcs on the belt. Using a steel straight edge, draw the square line
through the two arc intersecting points (A). Measure an equal distance (B)
ARC on both sides of belt from square line to the cut line.
CENTER POINT
B B
Next, position the fastener manufacturer’s template on the belt (or fashion
one yourself given the manufacturer’s recommendation for fastener
spacing) and punch holes in the end of the belt for the fasteners. Always
follow the manufacturer’s recommendations as to the proper size of
CUT LINE F30
fasteners to be used on any belt. Attach a clamping plate onto the end of
the belt to enable an even pull for threading the belt onto the conveyor.
Squaring belt ends
Place the pulling plate on the bottom side of the belt so it will pass more
easily over the troughing idlers. Bolt the clamping plate to the belt through
the fastener holes. The number of bolts should be proportionate to the
amount of pull exerted.
Connect a cable or rope to the clamping plate. A braking system can be
made by using a belt clamp mounted on the conveyor frame to prevent
belt runaway while threading. Slowly pull the belt into position (near the
tail section for easy access) with a block and tackle or similar equipment.
Attach two stretcher clamps roughly 3-feet (914mm) from each end of
the belt. Make sure the stretcher clamp on the squared end of the belt is
parallel with the belt end. Remove the clamping plate and firmly attach the
parallel stretcher clamp to the conveyor frame. Evenly draw the belt ends
together, using a cable-jack or similar means, and pull the unsquared end
of the belt over the top of the squared end until the correct belt tension
is obtained. Maintaining this tension, create a centerline following the
procedure described earlier, and mark a squared line where the belt must
be cut for the splice.
Place a wooden plank under the splice point to facilitate the cutting
and punching of holes in the belt. Cut the belt, position the fastener
manufacturer’s template on the belt end, and punch holes for the fasteners.
The use of belt tape under the belt fasteners is recommended to help
reinforce the splice area. Refer to instructions included with the belt
fasteners for proper installation.
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 FIVE STEPS IN BELT TRAINING
CONVEYOR BELT TRAINING
1 LEVEL ALL FRAMES CROSSWISE Belt training is a process of adjusting idlers and loading conditions in a manner that will correct any
tendency of the belt to run off of center. Never attempt to train the belt by unequal adjustment of
take-ups. The take-ups are only to be used for keeping the tail pulley square with the conveyor frame
and to maintain belt tension.

The training of a conveyor belt causing it to travel over the center area of troughing idlers, pulleys,
3 SQUARE ALL and return idlers is vitally important to trouble-free operation and low maintenance cost. Unless a
TROUGHING AND belt itself is warped and curved from improper manufacture, use, or storage, it is possible to train it for
A
2 SQUARE THE RETURN IDLERS central running. The following recommendations are basic to belt training procedures:
TAIL PULLEY 1. Level all frames crosswise as gravity will force the belt off-center if one side of the conveyor frame
is lower than the other (Figure 31).
C C 2. Square the tail pulley with the frame. Locate and mark point A at the midpoint of a conveyor cross
Square Edge Troughing Idler
member. Next, measure an arbitrary distance from point A to locate a point X on the edge of the
Square Line
Return Idler conveyor frame. Then measure the same distance from point A to measure a point Y on the other
X Y C C edge of the conveyor frame. Line XY should now be square with the conveyor frame. On the other
side of the square line (line XY), locate a point B at the midpoint of a cross member. Measure the
C C distance of BX and BY to verify that line XY is square. Line BX and BY should be equal. Clamp a
B straightedge to the conveyor frame directly on top of the square line. Any component on the
conveyor can now be squared by measuring from the straight edge equal distance on each side
(Figure 31, distance C).
3. Square all troughing and return idlers with the frame by measuring from the straight edge on
both sides of the conveyor and tighten the attachment bolts.
4. Check the belt splice for squareness. Check the belt run on the return run side of the conveyor, or
5 ADJUST INDIVIDUAL place a large plywood board under the belt on the load side to get accurate measurements.
TROUGHING OR 5. Run the conveyor empty and at reduced speed if possible. If the belt should show a side creep
RETURN IDLERS at only the splice area and this progressed along the conveyor instead of remaining at one point
AS NEEDED on the frame, the splice may not be square and may have to be redone. If necessary, re-splice the
D (For Run-Out at D, Adjust belt. If you don’t have sufficient belt length to resplice after squaring the belt ends, you will have
Preceding Idler E) to add a section of belt. When adding belt sections, remove enough length from the original belt
to allow for a minimum distance of 3-feet (914mm) between belt splices.
E
Once you have determined the splice is square, examine the return run side of the conveyor for side
4 CHECK BELT SPLICE creep first, beginning at the head end and working down to the tail. Make adjustments where side
FOR SQUARENESS creep occurs as follows:

a. The point of maximum side creep (D) requires adjustment of a preceding idler (E) when you are
facing in the direction of belt travel.
b. Loosen the bolts and pivot the idler (E) around its midpoint just as you would turn a steering
F31
wheel to bring an automobile back to the center of its lane. Make these adjustments in small
amounts; tighten the bolts and make a test run after each adjustment to see the effect on side

16 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267 +1 (320) 589-2406 | info@superior-ind.com | www.superior-ind.com 17

creep. Run the belt at least three revolutions for the adjustment to take effect. If the point of
maximum side creep changes, adjust the idler that precedes that new point.
c. When the slow running belt is centered, change to a higher speed (if possible). Load the belt with
material and continue testing until normal operating conditions cause no deviation from central
running.
d. Examine the load run side of the conveyor following the belt travel from tail to head end. Make
the same adjustments where side creep occurs.
LOADING THE BELT
After the conveyor has been thoroughly checked over and all belt training completed, the conveyor
can be loaded. Start with a light load and gradually work up to the load that the conveyor was
designed to handle. When stopping the conveyor, operate until the belt is clear of material, especially
at the end of each working day. During cold weather, material remaining on the belt will freeze to the
belt and may cause damage.
Rubber skirtboards are bolted to the trough to form the load centrally on the belt, to prevent side
spillage, and to prevent material from spilling out the back or bottom of the trough. Larger material
spilling out the back of the trough has potential to catch in the belt or damage the tail pulley.
Skirtboards will require adjustment or replacement as they wear.
Material should be stilled on the belt before it reaches the end of the skirtboards. If the material
particles are still tumbling as they pass the skirtboard ends, belt speed may need to be adjusted, feed
arrangement or rate may need to be adjusted, or the skirtboards may need to be extended in order to
avoid side spillage of material.
BELT TIGHTENING AND REPAIR
Conveyors with manual take-ups are equipped with side adjusting bolts at the tail end to maintain
the necessary belt tension. With a wrench, loosen the take-up side adjusting bolts to move the sliding
bearing assemblies forward. Apply the proper tension to the belt to prevent slippage and excessive
belt sag between troughing idlers, and then re-tighten the take-up side adjusting bolts.
Fasteners can be used to make quick repairs to belt tears or to replace belt sections with new pads of
the same belting. Coat all exposed edges or cuts with rubber cementing compound to prevent any
moisture or foreign material from entering the belt carcass and causing further damage.
CONVEYOR MAINTENANCE SAFETY
Before performing maintenance on a conveyor, it is important to be aware of general safety guidelines
that will help protect operators and maintenance personnel from injury. The first step is to read the
conveyor manufacturer’s operations manual. Manuals have instructions specific to each conveyor
on maintenance schedules, procedures, and requirements. The following section discusses safety
procedures that should be followed before and during conveyor maintenance.
18 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267
GENERAL SAFETY GUIDELINES
Do not allow anyone to operate or perform maintenance on a conveyor until they have read the manufacturer’s operations
manual and are completely familiar with all safety precautions.
• When the belt is moving, the material travels at a speed sufficient to cause injury. Do not start the conveyor until you are
certain no one is exposed to the moving parts or to the material being discharged from the end of the conveyor.
• Never allow anyone to ride on the conveyor.
• Do not leave the conveyor unattended while in operation.
• Do not wear loose hanging clothes, neckties, or jewelry.
• Long hair should be placed under a cap or hat.
• Wear safety glasses, ear protection, respirators, gloves, hard hats, safety shoes, and other protective clothing when
required.
• Requirements for personal protective equipment will vary depending upon conveyor placement and material to be
conveyed.
• Buildup of materials on pulleys or idlers will lead to belt misalignment or damage. When removing such materials, the
conveyor must be stopped and power controls must be locked out or tagged out.
• The conveyor should not be used to handle materials other than those specified as part of its design and manufacture. It
is the operator’s responsibility to be aware of the conveyor system capacities and operate the conveyor accordingly.
• Make sure the operator’s area is clear of any distracting objects. Keep work areas clean and free of grease and oil to avoid
slipping or falling.
• Periodically check all guards, shields, and structural members. Replace or repair anything that could cause a potential
hazard.
• If any safety devices are not functioning properly, do not use the conveyor. Remove it from service until it has been
properly repaired.
• When doing maintenance work on structural parts or repairing any moving parts:
»» Know OSHA requirements.
»» Disconnect and lockout or tagout all power sources.
»» When welding is required, disconnect all power sources and connect ground to point closest to welding area.
»» Block all wheels to prevent the conveyor from moving, and block any extended hydraulic cylinders to prevent them
from moving or retracting.
• Do not replace components or parts with other than factory-recommended service parts. To do so may decrease the
effectiveness of the unit.
• Do not lubricate parts while the conveyor is running.
• Before starting engines within enclosed areas, be certain ventilation is sufficient to avoid buildup of exhaust fumes.
• Relieve any and all pressure before opening, repairing, or removing any air pressure lines, hydraulic lines, valves, fittings,
or seals.
• In the event of a hydraulic line rupture, stay clear of the area until pressure has been relieved.
• Clean up any spilled fluid before performing repairs in the area.
• Safety hazard areas may include but are not limited to:
»» Pinch points at fold hinge areas
»» Pinch points at fold support areas
»» Pinch points where locking pins are used
»» Electrical control panels
»» Moving parts hazards on drives
»» Moving parts hazards where contact with belts and idlers is possible
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 GENERAL CONVEYOR MAINTENANCE TROUBLESHOOTING GUIDE
The following is a troubleshooting guide with suggested solutions to some common conveyor
• Carefully read through all safety instructions in the owner’s manual. problems. Match troubleshooting table (Table 8) to the corresponding number on the
• If applicable, check greaseable idlers to be sure they are filled with grease. Troubleshooting Key.
• Check to be sure the reducer is filled to the proper oil level.
• Check all other fluid levels.
• Check to be sure that skirtboards at loading points are installed and adjusted.
• Check equipment wiring (any and all wiring must be done by a qualified electrician.) PROBLEM SOLUTIONS
• Setting V-Belts Belt runs off at the tail pulley 26 12 11 14 18
»» Loosen and remove the v-belts by adjusting the torque arm reducer or motor mount
Belt runs off at the head pulley 25 12 19 18 13 26
tension bolts.
»» Turn the driven sheave by hand to determine the direction of rotation. Belt runs to one side at particular point 12 11 4 26
»» Run the drive motor or use a phase rotation indicator to determine the drive sheave Belt section runs to one side along full length 21 1 8 26
direction of rotation. Belt runs center when empty, off-center loading 14
»» If both sheaves are not rotating in the same direction, the unit must be rewired by a
Belt slips 23 16 18 11 19 27
qualified electrician.
»» Adjust the torque arm reducer or motor mount tension bolts to set v-belts at proper Belt slips on start-up 23 16 19 7 27
tension. Excessive belt stretch 10 7 18 6 5
»» If the conveyor has multiple motors, steps should be taken to ensure the conveyor load is Belt breaks around fasteners 1 20 10 9 17
shared equally between the motors.
Vulcanized splice separation 10 20 7 17
»» Use amperage meters to measure the current drawn by the motors.
Excessive belt top cover wear 9 22 14 18 5
»» Adjust the tension of the v-belts on the drives until the readings from the motors are
equal. Excessive belt bottom cover wear 18 11 16 17 19
»» Be certain not to over tighten the v-belts. Excessive belt edge wear 14 3 5 18
»» The drives should be checked periodically to see if the motor load is still balanced.
Belt cover swells or soft spots 5 9 7 17
• When a belt scraper is used, be sure that it is properly installed, tensioned, and working.
Belt hardens or cracks 5 20 19 15
• Be certain all guards and safety devices are in place and in working order.
• Visually inspect all hoses, lines, and belts for leaks, wear, and damage. Lengthwise grooving or cracking of top cover 24 11 18 9 27
• Check and remove all tools and any foreign objects from the belt. Belt fabric decay 9 17 7 5
• Grease on the belt should be removed immediately as it will deteriorate the belt. Belt ply separation 10 20 8 5 2
• Make certain no parts of the conveyor power, hydraulics, or moving parts have been locked
Belt cleaning, separation, or damage 20 29 28
out or tagged out. If they have, determine who placed the lockouts, and have them remove
the lockouts or tagouts before starting the conveyor. Belt fasteners pull out 1 30
• Walk completely around the conveyor, making certain no other personnel are under, on top of, Hydraulic cylinders won’t operate 31 32 33 34 35
or next to the conveyor.
• Warn anyone nearby that you are starting up the conveyor. [Table 8] Common conveyor problems
• After starting the conveyor, check all controls and indicators or gauges to be certain they are in
working order.
• Check the operation of safety stop lines and switches, if applicable, after starting the conveyor.
Realign.

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 TROUBLESHOOTING KEY
1. Improper or incorrectly installed belt fasteners.
2. Belt running speed may be too fast. Contact the
manufacturer about using a different drive sheave to
change the running speed.
3. Belt may be strained on one side. A new belt should
straighten out after two to three hours running. Belt
section may require replacement.
4. Conveyor frame may not be level. Position the conveyor
in a level
work area.
5. Damage to belt by abrasives, chemicals, heat, oil, etc. Be
certain belt was designed for use with specific materials
being conveyed. If abrasive materials work into cuts
and between plies, make spot repairs.
6. Dual pulley drives may not be running at the same
speed. This is likely only if friction wheel drive tires were
replaced. Contact the manufacturer for replacement
tires.
7. Drive may be underbelted. If you are not handling
material for which the conveyor was manufactured,
installation of another grade of belt may be required.
Contact the manufacturer.
8. Belt edge may be worn or broken. Remove worn
section and splice in
a new one.
9. Excessive impact of material on belt or fasteners.
Modify feed to reduce impact. Contact the
manufacturer about installing impact idlers, where
possible, to absorb impact.
10. Excessive belt tension. Reduce load being conveyed or
adjust conveyor take-up side adjusting bolts to reduce
tension.Frozen idlers. Free idlers
and lubricate according to manufacturer’s instructions.
Replace
idlers if necessary.
11. Idlers or pulleys out-of-square with center line of
conveyor. Realign.
12. Idlers improperly placed. Contact the manufacturer
about relocating idlers or inserting additional idlers
spaced to support the belt.
22 Superior Industries, Inc. | 315 E State Highway 28, Morris MN 56267
TROUBLESHOOTING KEY
13. Off-center loading. Material feed should be in direction 31. Check oil pressure. If gauge indicates low pressure,
of belt travel and at belt speed, centered on the belt. contact the manufacturer about relief valve adjustments.
14. Improper belt storage and handling. 32. Check for hydraulic line leakage. Relieve line pressure
15. Insufficient traction between belt and pulley. Lag the before tightening or replacing fittings or hoses.
drive pulley, using grooved lagging in wet conditions. 33. Check to be certain you are using recommended oil,
Contact the manufacturer about increasing wrap with particularly when running in hot or cold weather
the addition of snub pulleys. conditions.
16. Material between belt and pulley. Remove accumulation 34. Check dual overcenter valve. Contact the manufacturer
and improve maintenance. Adjust the skirtboards. for instructions on replacement or repair.
17. Material build up. Remove accumulation and install
cleaning devices, scrapers, or return belt covering.
18. Pulley lagging may be worn-replace if necessary.
Use grooved lagging for wet conditions. Repair any
protruding loose bolts.
19. Pulleys are too small. Contact the manufacturer about
using larger diameter pulleys.
20. Belt splices may not be square. Check and replace
if necessary.
21. Material loading speed too high or too low. Adjust feed
rate or change belt speed. Contact the manufacturer to
determine if a different drive sheave size may be used to
change belt speed.
22. Insufficient belt tension. Use take-up side adjusting bolts
to increase belt tension.
23. Skirtboards improperly placed. Adjust skirtboards so that
they do not rub against the belt.
24. Idlers leading to head pulley may be out of alignment.
Realign.
25. Return rollers may be out of alignment. Inspect and
realign at right angles to the center of the belt.
26. Material may be wedged between skirtboards and belt.
27. Material conveyed may be breaking the bond. Contact
the manufacturer.
28. Improper belt tracking, with cleating hitting the
conveyor frame.
29. Splice area may be striking obstructions, including the
conveyor frame.
30. Check power to hydraulic pump, and pump rotation.
Have a electrician rewire if necessary.
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 CONCLUSION
The beginning of a good maintenance program for a conveyor starts
with the engineering of the equipment. Choosing the correct conveyor
components for the given conveying application can reduce or eliminate
many maintenance issues. Components such as belt scrapers, impact beds,
and skirtboards can further reduce maintenance issues and lengthen the
time between maintenance tasks.

Since all maintenance issues can not be resolved through design, a well-
run maintenance program is essential to the safety of the operators and
maintenance personnel. Each operator or maintenance personnel should
be trained in safety procedures and proper maintenance procedures
before working on equipment. Personnel should be trained as to what
maintenance tasks need to be performed and when they must be done.

Once a conveyor has left the manufacturer, it is the owner’s and operator’s
responsibility to provide consistent and complete maintenance in order to
ensure a long life for the equipment.

SPWP1009ENPR-02

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