martin brush cleaner with external motor · 2015. 2. 17. · conveyor belts that transport all...

Installation InstructionsM3289UK

MARTIN® Brush Cleanerwith external motor

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I Table of Contents

I Table of Contents ............................................................ iii1 Introduction ...................................................................... 51.1 About these Installation Instructions .................................. 51.1.1 Scope ............................................................................ 51.1.2 Copyright ....................................................................... 51.1.3 Disclaimer ...................................................................... 51.1.4 Reference to Additional Documents .............................. 61.1.5 Classification of Hazards ............................................... 71.2 Intended Use...................................................................... 81.2.1 Conveyor systems with open transfer systems ............. 81.2.2 Use in explosion-proof areas ......................................... 81.2.3 Limitations of the product .............................................. 81.3 Safety ................................................................................. 91.3.1 Safety Instructions, Operational Safety ......................... 91.3.2 Responsibilities of the operating company .................... 91.3.3 Authorised personnel ..................................................... 92 Product Description ....................................................... 112.1 Design and Function ........................................................ 112.2 Type Declaration .............................................................. 123 Preparing for Installation ............................................... 133.1 Prior to Installation ........................................................... 133.1.1 Required Tools and Supplies ...................................... 133.1.2 Preparatory Measures ................................................. 134 Installation ...................................................................... 144.1 Safety Instructions............................................................ 144.2 Installation of the MARTIN® Brush Cleaner..................... 154.2.1 Determine the installation position ............................... 154.2.2 Installation MARTIN® Brush Cleaner ........................... 174.2.3 Electrical connection of the MARTIN® Brush Cleaner . 184.3 Align the MARTIN® Brush Cleaner.................................. 194.3.1 Centre MARTIN® Brush Cleaner shaft under

the conveyor belt. ........................................................ 204.3.2 Align the MARTIN® Brush Cleaner shaft parallel

to the conveyor belt ..................................................... 204.3.3 Align the MARTIN® Brush Cleaner shaft horizontally . 214.3.4 Adjust MARTIN® Brush Cleaner ................................. 214.4 Test run ............................................................................ 234.4.1 Check installation of the MARTIN® Brush Cleaner ...... 234.5 Installation - Checklist ...................................................... 244.6 Placement of warning labels and warning tags................ 255 Maintenance ................................................................... 265.1 Safety Instructions............................................................ 265.2 Weekly Maintenance........................................................ 265.3 Replacement of the cleaning components ....................... 285.3.1 MARTIN® Brush Cleaner Release .............................. 295.3.2 Replacing cleaning components.................................. 30

© Martin Engineering GmbH iii M3289UK-01/13

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6 Troubleshooting ..............................................................32
6.1 Safety Instructions ............................................................ 326.2 Troubleshooting ............................................................... 327 Storage, Removal, Disposal ...........................................347.1 Storage ............................................................................. 347.2 Removal............................................................................ 347.3 Disposal ............................................................................ 348 Part Numbers ..................................................................368.1 MARTIN® Brush Cleaner................................................... 378.1.1 Part Number - Description............................................ 398.2 MARTIN® Inspection doors ............................................... 408.3 Installation instructions...................................................... 408.4 Warning labels / Warning tags.......................................... 408.5 Accessories and Options .................................................. 418.5.1 Inspection doors ...........................................................418.5.2 Cleaning components ..................................................418.6 Specifications.................................................................... 428.6.1 Dimensions ..................................................................428.6.2 Technical Specifications Angle Gearmotor .................. 439 Declaration of Incorporation ..........................................4410 Notes ................................................................................47

© Martin Engineering GmbH iv M3289UK-01/13

Introd

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1 Introduction

1.1 About these Installation Instructions

Failure to observe these installation instructions can void liability andwarranty claims.

1.1.1 Scope

These installation instructions apply only to the product describedhere and is aimed at those people who install and operate it, andmonitor its use.

1.1.2 Copyright

The products described in this installation instructions are protectedby copyright. Reproduction without a license will be prosecuted. Allrights to this document are reserved, including reproduction and/orcopying in any conceivable manner. Reproduction of this documentis only permitted with written permission from Martin Engineering.

The technical standard at the time of delivery of the product and thetechnical documentation applies as long as no other information isprovided. Specifications subject to change without prior notice.Previous documents become invalid. The General Terms andConditions of Martin Engineering apply.

1.1.3 Disclaimer

Martin Engineering guarantees the correct operation of the productaccording to its advertising, published product information andtechnical documentation. Martin Engineering is not responsible forthe efficiency and proper operation if the product is used for apurpose other than those described in the "Intended Use" section,or for damages resulting from the use of accessories and/orreplacement parts that are not delivered and/or certified by MartinEngineering.

Martin Engineering's products are designed for long life. They arestate-of the-art, and have been thoroughly tested before shipment;in addition, Martin Engineering performs product and marketresearch for the continuous development of its products.

When a fault and/or technical problems occur Martin Engineeringoffers expert support. Appropriate measures will be takenimmediately. The warranty terms of Martin Engineering areavailable on request.

© Martin Engineering GmbH 5 M3289UK-01/13

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1.1.4 Reference to Additional Documents
In this manual, reference is made to the following documents:

• MARTIN® Inspection Door M3127

• Operating Instructions for three-phase motor DR71-225,315

• Installation and operation manual for gearbox type seriesR..7, F..7, k.7, S..7, SPIROPLAN® W

The following standards and guidelines were valid at the writing ofthese installation instructions:

• EU Machinery Directive (2006/42/EC)

• ISO/IEC Guide 37 "Instructions for use of products ofconsumer interest", 1995 edition

• DIN 1421 "Outlining and numbering in texts", 1983-01edition

• DIN/EN/ISO 12100 "Safety of machinery - Generalprinciples for design - Risk assessment and risk reduction",2011-03 edition.

• DIN/ISO 16016 "Technical product documentation -Protection notices for restricting the use of documents andproducts", 2007-12 edition

• DIN/EN 60204-1 "Safety of machinery - Electricalequipment of machines - Part 1: General requirements",2007-06 edition

• DIN/EN 1083-1, -2 - Power-driven brush tools - "Part 1:Definitions and Nomenclature" and "Part 2: Safetyrequirements", 1997-07 edition


Introd

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1.1.5 Classification of Hazards

DANGER!Indicates an imminent danger that results in serious bodily injuryor death if not avoided.

WARNING!Indicates a potentially dangerous situation that can result inserious bodily injury or death if not avoided.

CAUTION!Indicates a potentially dangerous situation that can result in bodilyinjury or property damage if not avoided.

NOTICEIncludes notes for installation and use of the product to indicatesituations that cause neither injury nor property damage, but docontain important information.


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1.2 Intended Use
The MARTIN® Brush Cleaner should only be used for cleaningconveyor belts that transport all kinds of bulk materials. TheMARTIN® Brush Cleaner can be used on conveyor belts that do notexceed a width of 2000 mm and a belt speed of 10 m/s. In addition,the MARTIN® Brush Cleaner can be used on reversed conveyorbelts or conveyor belts that are used with an intense reverse motion.

1.2.1 Conveyor systems with open transfer systems

This installation instructions describes the installation at conveyorsystems with encapsulated transfer systems. For installation atopen transfer systems, different MARTIN® Mounting brackets canbe used.

In difficult installation conditions such as insurmountable structuralcomponents or a head pulley tensioning station, Martin Engineeringor a representative can help with special solutions for its positioning.

1.2.2 Use in explosion-proof areas

The MARTIN® Brush Cleaner should not be used in explosiveatmospheres.

1.2.3 Limitations of the product

The use of the product described here is only permitted according tothe specification mentioned above. Use in a class higher than theclass specified or under other operating conditions than thosespecified or named above is considered improper and can only bedone with a release from Martin Engineering.

If the MARTIN® Brush Cleaner is to be used for a non-specifiedpurpose, Martin Engineering or a representative can provideassistance with the product configuration.


Introd

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1.3 Safety

1.3.1 Safety Instructions, Operational Safety

Before starting work on the product or the customer's conveyorsystem, these installation instructions must be read in their entirety.

The operator must ensure that all installation, inspection andmaintenance shall only be performed by authorized personnel.

Work on conveyor systems and their accessories must beperformed at a standstill. The corresponding installation instructionsfor shuttingdown the conveyor system must be strictly adhered to.

Immediately after completion of the work, all safety and protectivedevices must be re-installed and made functional again.

Before operation, the installation process must be carried outcompletely. Before the conveyor system is put back into operation,the proper implementation of all steps must be confirmed. Allinstructions for installation and commissioning of the product mustbe observed.

1.3.2 Responsibilities of the operating company

The operating company of this product must ensure that allpersonnel that installs this product, services and uses it

• know the rules of industrial safety and accident prevention,

• were instructed in the use of this product and have readand understood this installation instructions.

1.3.3 Authorised personnel

Personnel can be regarded as authorised personnel if they haveappropriate training, technical experience and knowledge ofrelevant standards and guidelines, and are also in a position toassess tasks in order to detect critical situations early on.

Operating, maintenance and installation personnel

Personnel is considered to be authorised, which was instructed inthe use of the product and has carefully read and understood theinstallation instructions.


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2 Product Description

2.1 Design and Function

The MARTIN® Brush Cleaner is especially intended for cleaningbaked-on materials from difficult rib belts, such as Chevron orcleated belts. With bristles that are only 96 mm long, the MARTIN®

Brush cleaner can achieve good cleaning results on even the mostdifficult profile conveyors (maximum height of the lugs or projections70 mm), and has gained acceptance over conventional cleaningsystems. The MARTIN® Brush Cleaner is mainly used individuallyas a cleaning system, but can also be used in conjunction with asecondary cleaner.

The MARTIN® Brush Cleaner can be installed below the head pulleyin a centred position to return the bulk material to the materialstream. If the use of this product disrupts the material handlingprocess or the product becomes contaminated, it is the user'sresponsibility to take appropriate countermeasures.

For different applications, different edging materials can beselected. Two different materials (polyester and brass) areavailable, which are specified in more detail in the technical datasheet. Three different edging patterns (full, spiral and straight-lined)are available to choose from.

Only the same material and edging types may be used together. Amixture of different types of materials and edging is not planned for,and each case must be verified separately.

NOTICEA poorly installed product or a product installed in reverse caninterfere with the delivery process or contaminate the conveyedbulk material.The operating company is responsible for taking the necessarycountermeasures.In applications with contamination issues, Martin Engineering or arepresentative can help with the positioning or with specialsolutions.


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2.2 Type Declaration

There are three different brush patterns available as listed below forthe MARTIN® Brush Cleaner. A selection guide for the possibleapplications can be found in the appropriate data sheet.

Fig. 1: Brush patterns

full spiral straight-lined



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3 Preparing for Installation

3.1 Prior to Installation

3.1.1 Required Tools and Supplies

Only standard tools are required for installation and maintenance ofMARTIN® Brush Cleaners.

3.1.2 Preparatory Measures

1. Check the delivery for the following:

• Is the delivery complete? Does the number of deliveredpallets/boxes/containers match the number on the dispatchnote?

• Does all transport packaging appear to be undamaged? Ifany damage is found, does the damage suggest that thecontained products might be damaged?

2. If the shipment is incomplete or damage is visible, document itand have it confirmed by the carrier. All damaged productsmust be stored for later inspection.

3. Depending on the order volume, the delivery should contain thefollowing items:

• MARTIN® Brush Cleaner.

• Installation instructions, as well as warning labels andwarning tags.

4. If parts are missing or damaged, notify Martin Engineering orthe dealer.

NOTICEPerform the described inspections carefully and completely.The freight carrier is liable for transport damages! Please consult the carrier for damage claims.

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4 Installation
4.1 Safety Instructions

NOTICERead this section in its entirety before starting any work.

WARNING! DANGER OF INJURY!Body parts and/or clothing may be pulled in by rotatingcomponents or by the moving conveyor belt.Before servicing the conveyor belt system or its accessories, turnoff the power supply of the conveyor system and secure it againstunauthorised restart. Use warning signs!

WARNING! EXPLOSION HAZARDIncreased risk when using a cutting torch or welding unit inconfined spaces!Before use check gas and dust levels in the air.

NOTICEThe chute wall where the angle gearmotor is installed, ishereinafter referred to as the "operator side". The opposite chutewall is referred to as the "far side".


Installation

4.2 Installation of the MARTIN® Brush Cleaner

4.2.1 Determine the installation position

The position of the shaft and the tensioner of the MARTIN® BrushCleaner must be determined for both sides of the chute wall. Inorder to do that, the positions are determined at which the shaft ofthe MARTIN® Brush Cleaner will be passed through the chute wall,or at which the tensioner will be installed on the chute wall.

The MARTIN® Brush Cleaner is supplied with a tensioner. This isdismantled at the factory and will be installed with the MARTIN®

Brush Cleaner.

The installation of the MARTIN® Brush Cleaner and the tensioner asdescribed in these installation instructions.

An overview of the installation steps follows:

During installation, various possible on-site conditions may requiredifferent steps, which can be outlined as follows:

Installing in an encapsulated transfer system

• Follow instructions in Section 4.2.2.

Installation in an encapsulated transfer system with availablemounting holes and brackets for conveyor belt cleaners.

• Follow instructions in Section 4.2.3.

Installing in an open transfer system

• Use the available materials to stay within the dimensionsfor proper installation.

1. Before commencing the installation of the conveyor belt systemand all its accessories, disconnect the power supply and secureit against unauthorised restart. Ideally, the MARTIN® BrushCleaner should be installed close to a head pulley or counterpressure roller. The distance should not exceed 200 mm.

2. Choose the installation position so that there is sufficient spacefor the installation of the MARTIN® Brush Cleaner. Thisdistance should be at least 350 mm on the outside of the chutewall on the operator side, and at least 100 mm on the far side.

3. Determine the installation position of the tensioner according tothe dimensions in Figure 2 Mark the holes for the tensioner anddrill them into the chute wall. Follow the same procedure on the

No. Installation Step Instruction

1Determine the installation position of the shaft and the tensioner

M3289

2 Installation of the tensioner M3289

3 Installation of the MARTIN® Brush Cleaner M3289

4 Tensioning of the MARTIN® Brush Cleaner M3289

Tab. 1: Installation Steps


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other side. 4. Based on these holes, determine the installation position of the

MARTIN® Brush Cleaner shaft. For the shaft, an elongatedhole (see Figure 2) must be cut in the chute wall. Perform thesame procedure on the far side.

5. Screw the tensioner onto the chute wall.

Fig. 2: Determine the installation position

NOTICEMartin Engineering recommends installing a MARTIN® inspectiondoor for better access for maintenance and repairs.

305 mm

90 mm

140 mm

178 mm

45 mm

80 mm

R45

Head pulley or counter-pressure roller

Conveyor belt


Installation

4.2.2 Installation MARTIN® Brush Cleaner

1. Slide the shaft of the MARTIN® Brush Cleaner through the twoslots of the chute wall from the inside.

2. Mount the pillow block housing (Fig. 3/3) to both sides of theshaft and secure it with screws (Fig. 3/4) to the tensioner. Donot tighten the screws yet.

3. Put lock washer (Fig. 3/2) on both sides of the shaft, push all the way to the pillow block housing, and secure it withthe locking screws.

WARNING! DANGER OF INJURY!The MARTIN® Brush Cleaner is heavy and can cause seriousinjury due to falling when lifting or moving it.Lift the MARTIN® Brush Cleaner with suitable lifting devices orwith additional personnel. Do not stand under suspended loads.

NOTICECheck the oil level of the angle gearmotor before installation.Follow the instructions in the manufacturer's documentation!

Fig. 3: Installation MARTIN® Brush Cleaner

1 2

3

4

4


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4. Put the angle gearmotor onto the shaft with the mounting platefor the motor torque arm (Fig. 3/1).

5. The mounting plate for the motor torque arm must be installedfrom the bottom of the tensioner. The angle gearmotor mustalways be placed in alignment with the conveyor belt on theshaft.

6. Attach the pillow block housing screws (Fig. 3/4) with nuts onboth sides.

4.2.3 Electrical connection of the MARTIN® Brush Cleaner

The electrical installation must be performed by a qualifiedelectrician. All applicable laws, standards and guidelines for thecompany must be followed. Ground the electrical equipment inaccordance with applicable regulations.

NOTICEMake sure that the feather key lies in the feather key groove of theshaft.

NOTICEThe angle gearmotor can only be mounted on the left side in theconveying direction. It cannot be mounted on the right side.

NOTICEObserve documentation supplied by the manufacturer for theelectrical connection!


Installation

Heed the installation instructions and wiring diagrams thataccompany the MARTIN® Brush Cleaner. The angle gearmotormust be operated so that the cleaning components move against theconveying direction.

4.3 Align the MARTIN® Brush Cleaner

Fig. 4: Direction of rotation of the cleaning components

CAUTION! DAMAGE RISK!Damage to the conveyor belt edge and/or the cleaning components is possible if the conveyor belt is not aligned.Align the MARTIN® Brush Cleaner according to the followinginstructions.

NOTICEThe following descriptions are exemplary and may differdepending on the employed MARTIN® Brush Cleaner.

Conveying direction


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4.3.1 Centre MARTIN® Brush Cleaner shaft under the conveyor belt.

Measure the distances (A) and (B) between the edge of the cleaningcomponents and the conveyor belt edge on both sides.

Move the cleaning components so that distance A is equal todistance B. The conveyor belt must project by about 50 to 100 mmon the right and left. The cleaning components must be centredunder the conveyor belt.

4.3.2 Align the MARTIN® Brush Cleaner shaft parallel to theconveyor belt

Measure the distance between the cleaning components and thehead pulley and/or the counter pressure roller on both sides. Line upthe cleaning components to the conveyor belt. The measured valuesmust be equal on both sides.

Fig. 5: Centre MARTIN® Brush Cleaner shaft (example)

Fig. 6: Align the MARTIN® Brush Cleaner shaft parallel to the head pulley (example)

A = BA B

B

A = BBA

A

A = B


Installation

4.3.3 Align the MARTIN® Brush Cleaner shaft horizontally

Align MARTIN® Brush Cleaner shaft horizontally in relation to thehead pulley, and check that the cleaning components fit evenly onthe conveyor belt.

If all dimensions are correct and the MARTIN® Brush Cleaner isaligned, it can be fastened appropriately. If not, it must be re-installed or repositioned.

4.3.4 Adjust MARTIN® Brush Cleaner

Fig. 7: Align the MARTIN® Brush Cleaner shaft horizontally (example)

WARNING! DANGER OF INJURY!The MARTIN® Brush Cleaner shaft must not extend out furtherthan 10 mm from the chute wall. Otherwise there is a risk of injuryfrom the rotating shaft.The shaft may only be shortened on the far side from the drive andnot on the drive side.

NOTICEFollow these steps carefully to ensure that the MARTIN® BrushCleaner achieves the desired cleaning results.

CAUTION! DAMAGE RISK!Excessive or uneven tension adjustment of the MARTIN® BrushCleaner on the conveyor belt can result in property damage.Only adjust the MARTIN® Brush Cleaner according to theguidelines and pay attention to the tension adjustment on bothsides.

A

B

A = B


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1. Loosen the locking screws (Fig. 8/1). Afterwards, loosen thecounter nut (Fig. 8/4) and the locking nut (Fig. 8/2).

2. On the bottom of the tensioner there is a set screw (Fig. 8/3),which can be used to adjust the height of the MARTIN® BrushCleaner. In order to align the cleaning components with theconveyor belt, the screw must be rotated counter-clockwise.

3. Follow the same procedure on the far side. 4. When the cleaning components are in the correct position,

tighten the locking nut (Fig. 8/4), the counter nut (fig. 8/2) andthe locking screws (Fig. 8/1).

NOTICEAfter installation, the MARTIN® Brush Cleaner must be alignedwith the conveyor belt. The cleaning components should not pressagainst the conveyor belt more than 3-4 mm.

NOTICEIn order to avoid tilting, both tensioners should be tightenedsimultaneously.

Fig. 8: Tensioning of the cleaning components

1

2

3

4

1 - Locking screws

2 - Locking nut

3 - Set screw

4 - Counter nut


Installation

4.4 Test run

4.4.1 Check installation of the MARTIN® Brush Cleaner

1. Remove all tools and fire protection covers from installationareas and from the conveyor belt.

2. Perform a one-hour test run of the conveyor belt system. 3. After the trial run, power off the conveyor belt system and

secure it against unauthorised restart. 4. Check that all fasteners are tight. Tighten loose connections. 5. Check the MARTIN® Brush Cleaner for the following:

• Wear: Slight wear during start-up is normal. Once thecleaning components have adapted to the contour of theconveyor belt this wear will stop.

• Bulk material accumulation: No bulk material mayaccumulate between the cleaning components and thereturn side.

NOTICERead this section in its entirety before starting any work on theMARTIN® Brush Cleaner or the customer's conveyor system.

CAUTION! FLYING PARTS!Lost tools or installation parts can fall off the moving conveyor belt,causing minor injuries and property damage.After installation, remove tools from the installation site and fromthe conveyor belt before turning on the power supply.

WARNING! DANGER OF INJURY!Body parts and/or clothing may be pulled in by rotatingcomponents or by the moving conveyor belt.Before servicing the conveyor belt system or its accessories, turnoff the power supply of the conveyor system and secure it againstunauthorised restart.Use warning signs!

CAUTION! DAMAGE RISK!Never run the MARTIN® Brush Cleaner longer than 15 minutes onan unloaded conveyor belt. There is risk of damage to theMARTIN® Brush Cleaner and/or the conveyor belt due tooverheating.Only operate the MARTIN® Brush Cleaner on a running, fullyloaded conveyor belt.


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6. In the case of excessive wear, bulk material accumulations orother problems, please refer to the instructions in section 4.5.,page 24 and section 6.2., page 33.

4.5 Installation - Checklist

If the MARTIN® Brush Cleaner does not work as expected after thetest run, the following table "Installation - Checklist" can assist youin resolving any problems. If problems persist, refer to Chapter 6"Troubleshooting":

Installation - Checklist

The MARTIN® Brush Cleaner is installed on both sides according to the dimensions in section 4.2.1. page 14 ff.

The distance from the centre of the MARTIN® Brush Cleaner shaft to the reverse side of the conveyor belt must be 125 mm on both sides.

The MARTIN® Brush Cleaner must be set so that the cleaning components press against the conveyor belt by about 3-4 mm.

The MARTIN® Brush Cleaner is centred on the conveyor belt.

Tab. 2: Installation - Checklist


Installation

4.6 Placement of warning labels and warning tags

Fig. 9: Placement of warning labels

Lock out and / or tag out all energy sources to

Vor Beginn von Arbeiten an Förderanlagen

Part no. 23395G

conveyor system and loading system before performing any work on conveyor or conveyoraccessories. Failure to do so could result insevere injury or death.

und deren Zubehör, alle Energiequellenzum Förder- und Ladesystem ausschalten und gegen unbefugtes Einschalten sichern.

DANGERWARNING!

!


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5 Maintenance

5.2 Weekly Maintenance

1. Remove bulk material deposits from the cleaning componentsand the MARTIN® Brush Cleaner shaft.

2. Check that all fasteners are tight. Tighten loose connections. 3. Check tension adjustment of the MARTIN® Brush Cleaner. If

necessary, readjust the MARTIN® Brush Cleaner inaccordance with the instructions in this installation instructions(section 4.3.4., Page 20).

NOTICEMaintenance inspections must be conducted at least once perweek. Depending on operating conditions, shorter maintenanceintervals may be required.

NOTICERead this section in its entirety before starting any work.

WARNING! DANGER OF INJURY!Body parts and/or clothing may be pulled in by rotatingcomponents or by the moving conveyor belt.Before servicing the conveyor belt system or its accessories, turnoff the power supply and secure it against unauthorised restart.Use warning signs!

NOTICECheck and readjust tension adjustment for wear and tear at leastonce per week. The cleaning components must always haveenough contact with the conveyer belt.


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4. Check cleaning components for wear and/or damage.

5. If the cleaning components have a smaller outer diameter than90mm, these need to be replaced according to the instructionsin section 4.2. on page 29.

6. Clean all warning labels. Replace illegible warning labelsimmediately. Warning labels are available from MartinEngineering or a dealer.

7. Remove all tools from the work area.

NOTICEIf there are any signs of malfunction, take the appropriate parts ofthe conveyor system out of service. Contact Martin Engineering ora representative for assistance. Do NOT put the conveyor beltsystem into operation until the cause of the problem has beendetected and eliminated.

CAUTION! DAMAGE RISK!Cleaning components must not be worn below the height of thelocking screws on the shaft, or must have at least an outerdiameter of 90 mm, otherwise serious property damage mayresult.Inspect cleaning components regularly and replace them in atimely manner!

CAUTION! FLYING PARTS!Lost tools or installation parts can fall off the moving conveyor belt,causing minor injuries and property damage.After installation, first remove tools from the installation site andfrom the conveyor belt before turning on the power supply.

NOTICEAt least once per month check the angle gearmotor oil level,change the oil, and check for leakage, etc. Follow themaintenance intervals in the supplied manufacturer'sdocumentation!

NOTICETest the bearings of the angle gearmotor at least once per weekfor lubrication, damage, mileage, etc.. Observe the instructions inthe manufacturer's documentation!


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8. Start conveyor belt system.
9. Monitor MARTIN® Brush Cleaners and check cleaningperformance.

5.3 Replacement of the cleaning components

1. Release the tensioner according to the instructions in thisinstallation instructions (see section 5.3.1., page 30).

WARNING! DANGER OF INJURY!Body parts and/or clothing may be pulled in by rotatingcomponents or by the moving conveyor belt.Do not touch or reach into the conveyor belt system and itsaccessories during operation.

CAUTION! DAMAGE RISK!Never run the MARTIN® Brush Cleaner longer than 15 minutes onan unloaded conveyor belt. There is risk of damage to theMARTIN® Brush Cleaner and/or the conveyor belt due tooverheating.Operate MARTIN® Brush Cleaners exclusively on a movingconveyor belt.

WARNING! DANGER OF INJURY!Body parts and/or clothing may be pulled in by rotatingcomponents or by the moving conveyor belt.Before installation or maintenance work, turn off the power supplyto the conveyor belt system and its accessories, and secure itagainst unauthorised restart. Use warning signs!


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5.3.1 MARTIN® Brush Cleaner Release

For maintenance and removal, the MARTIN® Brush Cleaner mustbe released.

The following steps are necessary:

1. Loosen the locking screw (Fig. 10/1). Afterwards, loosen the counter nut (Fig. 10/2) and the locking nut (Fig. 10/4).

2. On the bottom of the tensioner there is a set screw (Fig. 10/3), which can be used to adjust the height of the MARTIN® Brush Cleaner. To release the MARTIN® Brush Cleaner, turn the set screw clockwise. Set the MARTIN® Brush Cleaner so that the cleaning components no longer touch the conveyor belt.

3. Follow the same procedure on the other side. 4. The MARTIN® Brush Cleaner is now released. 5. To realign the cleaning components refer to Chapter 4.3.4.

page 20.

Fig. 10: Releasing the cleaning components

4

1

2

3

1 - Locking screws

4 - Locking nut3 - Set screw2 - Counter nut


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5.3.2 Replacing cleaning components
1. Remove the electric power cable from the angle gearmotor.Then remove the angle gearmotor (Fig. 11/2) from the shaft ofthe MARTIN® Brush Cleaner and place it on a flat stablesurface. Make sure that the electrical connection cables are notcaught and are not exposed to any mechanical stress.

2. Pull the locking washer (Fig. 11/3) off of the shaft on both sides. 3. Loosen the screws on both sides of the pillow block housing

(Fig. 11/1) and pull them off the shaft. 4. From the inside, pull the MARTIN® Brush Cleaner shaft out of

the elongated hole on the far side. Then from the elongated sloton the operator side.

CAUTION! DANGER OF INJURY!When disassembling, the angle gearmotor can swing out.Secure the angle gearmotor when disassembling.

Fig. 11: Removal of the MARTIN® Brush Cleaner

1

2 3

1


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5. Release the screws on the lock washer (Fig. 12/1) and theadjustment ring for the Zick-Zack system (Fig. 12/2), then pull itoff the shaft.

6. Worn cleaning components (Fig. 13/1) can now be replaced.Only replace cleaning components (material and stocking type)with the same ones.

7. Install the MARTIN® BrushCleaner in reverse order.

Fig. 12: Removal of cleaning components

Fig. 13: Replacement of the cleaning components

1 2

1


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6 Troubleshooting

6.2 Troubleshooting

If an excessive amount of wear on the cleaning components and/oran unsatisfactory cleaning performance is observed, check thefollowing points:

NOTICEMARTIN® Brush Cleaners are exposed to very different bulkmaterials and are often used in extreme working andenvironmental conditions. Therefore, problems other than thoselisted below can occur.In such cases, Martin Engineering or a representative can helpwith positioning or special solutions. Only put the conveyor systemback into operation if the fault has been detected and eliminated.

Symptom Cause Corrective Action

Excessive wear on cleaning components, noise or vibration.

The MARTIN® Brush Cleaner is too tightly fitted.

Reduce the tension on the tensioner (see section 4.2.5).

Insufficient cleaning action.

The MARTIN® Brush Cleaner is too loosely fitted.

Increase the tension on the tensioner. The bristles of the cleaning components need to be bent approx. 3-4 mm on the conveyor belt.

High temperature applications (overheating).

The MARTIN® Brush Cleaner can be used in temperatures ranging from 0° C to +100° C.

Cleaning components do not rotate.

Cleaning components are not attached on the shaft, check attachments (Zick-Zack system).

Cleaning performance is not sufficient due to high contamination levels.

Install an additional pre-cleaner.

Tab. 3: Troubleshooting


Trou

blesh

ooting

Unusual noises or cleaning results.

Maintenance intervals are not met.

The angle gearmotor must be serviced every 10,000 work hours in accordance with the accompanying documentation.

Wrong rotational direction of the angle gearmotor.

The angle gearmotor must rotate against the direction of the conveyor belt.

Shocks, vibrations from the conveyor. Motor out of balance, excessive contamination of the cleaning components.

MARTIN® Brush Cleaner installed too far from the head pulley or return idler. Align shaft to gear box. Improper cleaning components used.

Excessive accumulation of material.

The MARTIN® Brush Cleaner is too loosely fitted.

Reduce tension of the cleaning components on the conveyor belt.

Cleaning components have excessive material residues.

Install a different type of cleaning components.

Uneven wear of the cleaning components.

Cleaning components are not evenly arranged under the conveyor belt.

Align the MARTIN® Brush Cleaner with the belt.

Cleaning components are not centrally aligned with the belt load. Cleaning width is too small.

Check alignment, installation. Adjust cleaning width.

Motor is warm, does not rotate.

Shaft touching structure, tension too high, MARTIN® Brush Cleaner not correctly aligned. Fibres on the brush or in the bearings, bristles full of bulk material.

Check alignment and installation, correct it; incorrect brush attachment.

Symptom Cause Corrective Action

Tab. 3: Troubleshooting


Sto

rage

, Rem

oval

, Dis

pos

al
7 Storage, Removal, Disposal
7.1 Storage

For best results, MARTIN® Engineering recommends storing theMARTIN® Brush Cleaner and cleaning components in a dry place,at room temperature, and protected from sunlight.

Optimum storage conditions are between +0°C and +30°C and at60% relative humidity.

7.2 Removal

Perform the removal in the reverse order of the installation (seeSection 4.2.2., Page 16).

7.3 Disposal

Assemblies and/or individual parts of the MARTIN® Brush Cleanerfrom Martin Engineering must be disposed of properly as follows.

• Complete assemblies must be disassembled and thematerials disposed of by material type.

When disposing of parts, observe all national and internationalrecycling laws.


Storage, R

emoval, D

isposal


Par

t N

um

ber

s
8 Part Numbers
In this chapter the MARTIN® Brush Cleaner products andaccessories, with their corresponding part numbers, are described.

When ordering, always include the part number.


Part N

um

bers

8.1 MARTIN® Brush Cleaner

Fig. 14: MARTIN® Brush Cleaner 41580

Item Quantity Description Part no.

1 2 Shaft for MARTIN® Brush Cleaner s.T.5

2 1 Pillow block housing with housing unit 41584-035-A

3 s. T.5 Cleaning components 41586-XXXX

4 2 Fixing collar Zick-Zack system 41587-035

5 2 Bearing mounting console 41589-A

6 2 Tensioner 41591

7 1 Mounting plate for motor torque arm 41592-A

8 2 Lock washer for shaft 41593-035-A

9 1 Spiroplan angle gearmotor 41582-XXX-XX

10 1 Feather key DIN 6885-A 6x6x70mm 41588-A-06-06-70

11 4 Flat washer M6 DIN 125 galvanized steel 41088-06AZP

12 4 Compression washer M6 DIN 127 galvanized steel 41090-06AZP

13 4 Hexagon head screw M6x20, DIN 933, galvanized steel 41081-06020BZP88

Tab. 4: Parts List - MARTIN® Brush Cleaner

2 1 8 4 3

5

79

6

13

11 12

10


Par

t N

um

ber

s

AssemblyPart Number

QuantityItem 5

Part no.Item 2

41580-18 3 41581-18XXX

41580-24 5 41581-24XXX

41580-30 6 41581-30XXX

41580-36 7 41581-36XXX

41580-42 9 41581-42XXX

41580-48 10 41581-48XXX

41580-54 12 41581-54XXX

41580-60 13 41581-60XXX

41580-66 15 41581-66XXX

41580-72 16 41581-72XXX

41580-78 18 41581-78XXX

Tab. 5: Part numbers and quantities - MARTIN® Brush Cleaner


Part N

um

bers

8.1.1 Part Number - Description

Frequency in Hertz:5 = 50 Hz6 = 60 Hz

Voltage in Volt:11 = 110V AC (option)23 = 230V AC40 = 400V AC46 = 460V AC

Material keyshaft:MS = 1.0037 (mild steel, galvanized)A2 = 1.4031 (stainless steel)

Cleaning width in inches

Bristle material:PB = Polyester (PBT)BR = Brass (option)

Brush pattern: F = full seat S = spiral L = linear

Belt width in inch

41580 - XXXXXXXXXXXX - 00

41581 - XXXX

Shaft material MS = 1.0037 (mild steel, galvanized) A2 = 1.4031 (stainless steel)

Band width in inches

Part Number

41582 - XXX

Frequency in Hertz 5 = 50 Hz 6 = 60 Hz

Voltage in volts 11 = 110V AC 23 = 230V AC 40 = 400V AC 46 = 460V AC

Part Number


Par

t N

um

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s

8.2 MARTIN® Inspection doors

With standard rubber door, up to 68° C:

• 229 x 305 mm: Part no. CYAR-0912M.

• 305 x 356 mm: Part no. CYAR-1214M.

• 305 x 457 mm: Part no. CYAR-1218M.

• 457 x 610 mm: Part no. CYAR-1824M.

• 610 x 610 mm: Part no. CYAR-2424M.

8.3 Installation instructions

• MARTIN® Inspection doors Form no. M3127.

8.4 Warning labels / Warning tags

• Conveyor Products Warning Label: Part no. 23395.

41586 - XX - XX - X

Edging type F = Full S = spiral L = straight-lined

Type of material PB = Polyester (PBT) BR = brass

Edging diameter in mm

Part number


Part N

um

bers

8.5 Accessories and Options

8.5.1 Inspection doors

When installing the MARTIN® Brush Cleaner in an encapsulatedtransfer system, an additional MARTIN® Inspection door should beinstalled to provide better access for inspection and maintenance.These can be obtained from Martin Engineering or a dealer.

8.5.2 Cleaning components

The cleaning components for the MARTIN® Brush Cleaners areavailable with various materials and edging materials. Select thematerial type and edging type based on the operating conditions(bulk materials, temperature, etc.). Further specifications can befound in the corresponding data sheet of the MARTIN® BrushCleaner L3863.


Par

t N

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s
8.6 Specifications
8.6.1 Dimensions

Fig. 15: MARTIN® Brush Cleaner - Dimensions

Assembly Part Number

Belt width (mm)

A(mm)

B(mm)

C(mm)

D(mm)

41580-18 500 300 1000 1170 1382

41580-24 650 500 1150 1320 1532

41580-30 800 600 1300 1470 1682

41580-36 950 700 1450 1620 1832

41580-42 1100 900 1600 1770 1982

41580-48 1200 1000 1750 1920 2132

41580-54 1400 1200 1900 2070 2282

41580-60 1500 1300 2050 2220 2432

41580-66 1650 1500 2200 2370 2582

41580-72 1800 1600 2350 2520 2732

41580-78 2000 1800 2400 2670 2882

Tab. 6: MARTIN® Brush Cleaner - Dimensions

A

B

C

D

303 mm 83 mm


Part N

um

bers

8.6.2 Technical Specifications Angle Gearmotor

• Operating voltage 110V-460V at 50/60 Hz 4-pole (specialvoltages available on request).

• Performance 0.55 KW

• Current consumption: 1.55 A at 400V/50Hz

• Protection type: IP55

• Protection class: ISO-F

• Rotational speed: 135 min.-1 50 Hz

• Peripheral speed: 0.4 m/s @ 50 Hz

• Operating temperatures: -20° C to +60° C


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9 Declaration of Incorporation
The EC Declaration of Incorporation of Partly Completed Machineryfor the MARTIN® Brush Cleaner is included below.


Declaration

of Incorp

oration

EC - Declaration of Incorporation according to the Machinery Directive (2006/42/EC)

Annex II B for the Incorporation of Partly Completed Machinery

We Martin Engineering

In der Rehbach 14 Tel.: +49 (0)6123-97820

D-65396 Walluf Fax: +49 (0)6123-75533

hereby declare that the product mentioned below

Product description:

Conveyor belt cleaner

of the make/type:

MARTIN® Brush Cleaner

with the serial number:

not required

corresponds to the following directive:

EC - Machinery Directive 2006/42/EC

DIN EN 618 - equipment and systems for bulk materials

DIN EN 1083-1, -2 - Power-driven brush tools

In particular, the following harmonized standards have been applied:

DIN EN ISO 12100 Safety of machinery

Notified Body:

not required

The product installation instructions and technical documentation in the original version accompany the named product.

The commissioning of this product is prohibited until it is determined that the facility where it will be assembled meets the provisions of the EC Directive as amended by 98/37/EC and 2006/42/EC.

Date: 01/21/2010

Manufacturer's signature: Managing Director, Michael Hengl


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Notes

10 Notes

Form no. M3289UK-01/13 ©MARTIN ENGINEERING 2011

Subject to change without prior noticeQuality Managment System Certified by DNV - ISO 9001

Problem Solved™

MARTIN ENGINEERING GMBH

In der Rehbach 14

65396 Walluf, Germany

Phone 0049 (0)6123 97820

Fax 0049 (0)6123 75533

E-Mail: [email protected]

www.martin-eng.de