INSTALLATION, OPERATION, MAINTENANCE

AND SPARE PARTS

MANUAL

FOR

APRON FEEDER ORDER NO. : CO/1892 MACHINE NO. : AF: 112-115 CLIENT : M/s TECPRO SYSTEMS LIMITED

A/c RELIANCE ENERGY LTD. MANUFACTURER : ELECON ENGG. CO. LTD VV NAGAR 388 120

I N D E X

CHAPTER NO.

DESCRIPTION

CH-1

INTRODUCTION

CH-II

TECHNICAL DATA SHEET

CH-III

LUBRICATION SCHEDULE

CH-IV

SPARE PARTS LIST

CH-V

ENCLOSURE

(A) - G.A. OF APRON FEEDER

(C) - INSTALLATION MANUAL FOR GEAR BOX (D) - GREASE LUBRICATION SYSTEM (E) - INSTALLATION MANUAL FOR GEAR COUPLING.

CHAPTER I

INTRODUCTION

DESIGN AND CONSTRUCTION FEATURES OF ELECON APRON FEEDERS

* MACHINE DESIGN: Elecon Apron Feeders are of extremely rugged construction and are specifically designed to withstand the shock loading of large lumps being dumped in the hopper above the feeder. These machines can also be employed for drawing material from hoppers and delivering it at controlled rates to succeeding belt conveyors. Apron Feeders have a considerable effect on the efficiency of crushing operations as they ensure that the feed is introduced to the crusher over the full length of the crushing cavity at a steady and controlled rate.

* BEARINGS: Heavy-duty spherical roller type bearings support the head and tail shafts, mounted in pedestals. Those for supporting the head shaft are bolted to the main longitudinal members while those for supporting the tail shaft are mounted in slides, permitting adjustment of the sprocket centers to take up chain slack.

* SPROCKETS:

Segmental, cast steel sprockets are machined and jig drilled to fit their respective mounting hubs, which are keyed to the drive shaft.

* CHAIN AND CARRYING ROLLERS:

Chains of the type used for tractors are fitted, having forged steel links and high-carbon steel pins capable of operating under the most arduous conditions, without the need for lubrication. Steel support rollers fitted with grease lubricated bearing bushes are provided beneath the chains. Mn Cast steel Chains can also be provided upon request.

* APRON PLATES:

Apron feeder pans are designed to suit specific requirements, considering duty factors and type of material. Pans are ribbed for strength and have flanged ends. Sufficient overlap is provided restricting spillage at the moment when passing around the sprocket. Pans can be supplied either in cast manganese steel or pressed mild steel or of welded plate construction, to suit the nature of material to be handled.

Sprockets & Chain Assembly

INTRODUCTION

In general terms Apron Feeder consists of two strands endless chain or other linkage, to which overlapping or interlocking plates of different shapes are attached to form a continuous moving bed for bulk material. They are particularly suited to handling of heavy duty raw materials, such as coal, lignite, coke, ore slag, rock stone, gravel,clinker, etc. They are frequently used as feeders for large crushers breakers, and grinders. They are flexible in arrangement and can be conveniently arranged to follow combined horizontal and inclined conveyor center that can be used depending on the type of chain selected.

The method of direct feed may often essential the free falling of material from appreciable height on to the Apron conveyor. In such circumstances, all components particularly apron chain, apron pan have to be extremely robust construction. DESCRIPTION. The Apron Feeder convey the material tilted by Wagon / Dumper into the feeding hopper upwards into the inlet of the crusher or the any equipment. The weight of filled material and the falling height require a sturdy construction of the apron feeder. The Apron Feeder is driven by an electric motor combined with reduction gearbox and coupling arrangement.

INSTALLATION 1. Check safe arrival of complete material with provided part lists. 2. All the components of equipment are designated with main groups Group for mechanical,

Group for structural, Group for electrical items.

3. Encircled numbers on drawing and part list indicates item to be erected at the site, while num

bers are not encircled items are shop assembled either welded or bolted ready for Erection at

site. The numbers on the parts are assembled in one unit.

4. The floor on which Apron Feeder is to be installed should be properly leveled and foundation

for the footing should be correctly marked. All levels should tally with general arrangement drawing of the equipment furnished by ELECON.

5. Take care in selection for components with proper erection marking. 6. Check the Apron Feeder structure is perfectly straight and correct by leveled. 7. Check the head end and tail end sprockets are all correctly mounted, such that they are

leveled, and with their axis perpendicular to the center line of the pan. 8. Ensure that all parts of the conveyor is greased / oiled where necessary. 9. Check along the length of the conveyor and ensure that there are no item left, lying about

which may obstruct and cause damage to moving equipment. 10. Please check whether pans are bolted to each other properly or not. 11. Check drive machinery for alignment on assembly and before starting the conveyor, check the

motor installation resistance.

OPERATING INSTRUCTIONS

1. After conforming no load operation, feed the material on the pan uniformly and carefully. 2. Quantity of material feed should be controlled. If material is fed in excess, the motor of the Apron Feeder drive will be overloaded in addition the material on the pan apart to spi ll. 3. When Apron Feeder is to be stopped, it is preferable that there is no material left on the pan. 4. Check that the feed on to the Apron Feeder is central and that the pan at the feed point is Is running centrally and straight. If not, establish the cause of the non-central feed and rectify as necessary. 5. Inspect the condition of the pan of apron feeder regularly and arrange for the earliest possible repair of any damage which may have occurred as this can make a worth while extension to the useful life of the pan. 6. Check regularly that all rollers and driven sprockets are rotating freely. If not, rectify or rep lace as necessary to avoid unnecessary wear, inspect all rollers regularly and arrange for any damage ones to be replaced at the earliest opportunity. 7. Grease or oil all bearings and moving parts requiring lubrication at regular intervals. Beari ngs should be stripped, cleaned and repacked with grease at the intervals as recommend ded by ELECON. It is important to bear in mind of that the bearing should not be over over greased as this can cause over heating and consequent damage. 8. In the case of gear boxes, check the oil level indicator everyday or two, replenish if necess ary or drain if it is out dated and refill with clean oil as recommended by ELECON. 9. Inspect the driving gear regularly following the manufacturers, maintenance instruction for the various parts involved. Ensure that any brakes involved are correctly adjusted to avoid snatching when running or slipping when at rest and that linings are renewed immediately as it is becomes necessary. 10. If possible, keep regular record of motor AMP, as this will give an indications of any overload ing which occurs and may be of assistance in tracing faults in this system

11. In the interest of different operation and in obtaining the maximum life from equipment, it is important that operating condition should be kept as clean as possible. Any spillage, which occurs, should be cleaned up on floors or in any other location to the point where it is obstructing to running equipment. Chutes should be inspected at regular intervalsand any build up of material, which is accumulation should be removed in order to minimize the likelihood of eventual chute blockage. 12. It is important to ensure that any item of plant require repair or replacement it should be dealt with as soon as possible to avoid the possibility of chain reaction or damage. Also if the course of inspection any abnormality in operation should be seen for which there is no obvious reason this should be and expert advice sought

PREVENTIVE MAINTENANCE INSTRUCTION

G E N E R A L The reliable operation and life of machine is strongly influenced by the standard of maintenance of the electrical and mechanical equipment It is imperative that regular checks are carried out in respect to lubrication,operating efficiency and wear to replace damage or won parts.

The painting should be subjected to routine checks and where necessary to be touched up in an efficient manner. The frequency of such checks and associate maintenance work depends upon length of operation and the possible wear on the machine parts Contamination caused by spillage or other accumulations of dirt should be constantly cleaned up. This also applies to the cleaning up of machinery as well as for steel structure, protection device. Rotating machine parts must only be cleaned when they are at standstill whereby the respective safety and accident prevention regulation must be observed. Damage to load bearing steel structure, loose rivets, bolts or screws as also the peeling of paint which point to over stressing respectively, to forceful deformation must be reported immediately to the supervising personnel.

LUBRICATION SCHEDULE

SPARE PARTS LIST