Belt Cleaner Handbook

Belt Cleaner Service Manual
BELT CLEANER SERVICE MANUAL

Belt Cleaner Installation & Services Hand Book
Belt Cleaner Installation and Services Hand Book Page 1
Issue #2 Rev. #2 Issued August 2001

Table Of Contents
BELT CLEANER SERVICE GROUP Page 1

BELT CLEANER INSTALLATION & SERVICES HAND BOOK Page 1
TABLE OF CONTENTS Page 2
INTRODUCTION Page 5
1. THE BELT CLEANER SERVICES GROUP Page 5
1.1 THE FOCUS Page 5
1.2 FOCUS ON BELT CLEANING Page 5
1.3 THIS HAND BOOK Page 5
PRODUCT AWARENESS Page 6
2 . FUNCTION OF BELT CLEANERS Page 6
2.1 TERMS USED Page 6
2.2 SOME HISTORY Page 7
2.3 COST BENEFIT ADVANTAGES Page 7
New Sites Page 8
Existing Sites Page 8
3. WHY HAVE BELT CLEANER MAINTENANCE CONTRACTS? Page 8
BELT CLEANER BASICS Page 9
4. FOR THE BEGINNER Page 9
4.1 THE MANUFACTURERS INSTALLATION RECOMMENDATIONS. Page 9
Belle Banne Installation Sketch Page 9
4.2 THE EFFECTS OF BELT MAINTENANCE ON CLEANER PERFORMANCE Page 10
4.3 THE EFFECTS OF CLEANER SELECTION AND INSTALLATION ON BELT PERFORMANCE Page 10
The 15 Offset Page 10
Dimension D Page 11
Dimensions C and B Page 11
4.4 A WORD ABOUT CLEANER POLE DIAMETERS Page 11
4.5 A WORD ABOUT CROWNED PULLEYS Page 11
4.6 STABILISING THE BELT Page 12
4.7 THE SYSTEMS APPROACH Page 12
4.8 WATER AS A CLEANING AID Page 13
The Shear Path Page 13
The Water Control Manifold Page 13
Spray Bar Vs Spraypole Page 14
Spray Shrouds Page 14
4.9 MAINTAINING THE EDGE Page 14
PRIMARY BELT CLEANERS Page 16
5. OVERVIEW Page 16
5.1 COMPETITORS Page 16
Customer Concerns Page 16

5.2 THE H TYPE BELLE BANNE CLEANER Page 16

Spliced Belts Page 17
Clipped or Damaged Belts Page 17
5.3 THE U TYPE AS AN ALTERNATIVE PRIMARY CLEANER Page 18
5.4 H TYPE INSTALLATION PROCEDURE Page 19
5.5 BELLE BANNE X/ Y COORDINATES Page 20
5.6 H TYPE PRE LOAD TENSION TABLE Page 21
5.7 BELLE BANNE H TYPE COMPONENTS Page 21
5.8 H TYPE CLEANER COMPONENT DIMENSIONS Page 21
5.9 H TYPE X&Y COORDINATE CALCULATION Page 22
H Type X & Y Formula Page 22
5.10 CALCULATION SOFTWARE Page 22
BELLE BANNE H TYPE CLEANER ASSEMBLY PROCEDURE Page 23
6. TOOLS & SAFETY EQUIPMENT REQUIRED: Page 23
7. H TYPE ASSEMBLY PROCEDURE Page 23
7.1 POSSIBLE PROBLEMS Page 23
Bent and Corroded Poles Page 24
Cushion Compression Set Page 24
Tungsten Tips Page 24
SECONDARY BELT CLEANERS Page 25
8. OVERVIEW Page 25
8.1 COMPETITORS Page 25
Belle Banne Page 25
Just To Confuse You Page 25
Other Competitors Page 26
Spliced Belts Page 26
Clipped or Damaged Belts Page 26
Reversing Belts Page 26
8.2 SPRAYPOLE P AND P TYPE BELT CLEANERS SPECIFICATION Page 26
8.3 SP AND P TYPE CLEANER INSTALLATION PROCEDURE Page 28
8.4 P TYPE COMPONENT DIMENSIONS Page 29
8.5 U TYPE CLEANER SPECIFICATION Page 30
U Type Dimensions Page 30
8.6 HOW IT WORKS Page 31
U Type Cleaner Installation Procedure Page 31
8.7 R TYPE CLEANER SPECIFICATION Page 32
R Type Cleaner Installation Procedure Page 32
TERTIARY BELT CLEANERS Page 32
9. OVERVIEW Page 32
BELLE BANNE P & SP TYPE CLEANER ASSEMBLY PROCEDURE Page 33
10. TOOLS & SAFETY EQUIPMENT REQUIRED: Page 33

11. SPRAYPOLE, P & R TYPE CLEANER ASSEMBLY PROCEDURE Page 33

11.1 POSSIBLE PROBLEMS Page 34
Bent and Corroded Poles Page 34
Cushion Compression Set Page 34
Tungsten Tips Page 34
RETURN BELT PLOUGHS Page 35
12. OVERVIEW Page 35
12.1 PLOUGH TYPES Page 35
Belle Banne Page 35
12.2 CAUTION Page 35
12.3 INSTALLATION Page 36
ADDED MOISTURE THE ARGUMENT FOR WET BELT CLEANING SYSTEMS Page 37
13. THE ARGUMENT Page 37
13.1 MOISTURE INCREASE JUSTIFICATION FORMULA Page 37
13.2 MOISTURE INCREASE TABLE Page 39
FACTORS THAT INFLUENCE BELT CLEANER EFFICIENCY Page 40
14. INFLUENCING FACTORS Page 40

Introduction
1. The Belt Cleaner Services Group
The Belt Cleaner Service Group has been established to assist the Apex Belting service
network to develop the skills necessary for the maintenance Belt Cleaners and other non
belt conveyor products.
The development of a high level of skills in Belt Cleaner and other mechanical services will
complement the existing rubber service activities, helping us to expand as a total
maintenance contract and service provider.
1.1 The Focus

The Belt Cleaner Services Group is a company training resource to be used by all
Branches. Our aim is to develop and expand all of the Apex maintenance services through
the promotion of comprehensive conveyor maintenance technology.
Our goal is to assist in establishing a reputation for Apex Belting for the provision of
Comprehensive Conveyor Maintenance irrespective of the brand name of the products to
be serviced. This will enable us to compete on a broader scale.
The above training group will provide necessary training so as to realise the potential for
the development of Apex as a complete manufacturing and service provider.
1.2 Focus on Belt Cleaning

Generally, Apex Belting has achieved recognition as a provider of High Quality conveyor
belt and for its capacity to service the belt and associated rubber products such as pulley
lagging.
However, the industry shift towards total out sourcing of conveyor maintenance requires
that our Sales and Maintenance staff are fully conversant with all aspects of the operation
and maintenance of the site conveyor systems.
Belt Cleaning is a significant component of conveyor maintenance and, indeed, total site
maintenance from a cost of operation point of view.
1.3 This Hand Book

Belt Cleaning provides one of the most effective tools available for the reduction in
operating costs of your customers conveyor system.
The purpose of this Hand Book is to provide a point of reference and training for the
inspecting, installing and maintaining of belt cleaning equipment and to lift the awareness
within Apex Belting Sales and Maintenance staff of the importance of this product range
both to us and to our customers.
The objective will be to Sell Clean Belts - Not Belt Cleaners.

PRODUCT AWARENESS
2. Function of Belt Cleaners
The function of an efficient belt cleaning system is to remove the fugitive material which
remains on the return strand of the belt and to assist in spillage control by returning that
material to the main material flow within the confines of the discharge chute.
The proper selection, installation, commissioning and maintenance of the cleaning system
will ensure that individual cleaners work to their best possible efficiency in reducing site
clean up and maintenance costs while improving the customers profitability and extending
belt life.
By reducing this fugitive material the following benefits are provided to your customer: -
Reduced lost product.
Reduction in dust and other environmentally unacceptable operating practices.
Reduced safety hazard from build up on gantrys, walkways and under conveyors.
Fewer customer resources used in clean up.
Increased life of conveyor belt.
Increased life of associated conveyor components.
Eliminate belt tracking problems that are due to the build up of material on roller and
pulley shells.
Reduction in the corrosion of conveyor structural components from built up materials.
2.1 Terms Used
A Jargon has developed in the belt cleaning business that is used to describe problems
and / or equipment.
Carry Back is used to describe the fugitive material remaining on the return
strand of the belt after the head or discharge pulley.
Primary Cleaner is the belt cleaner which is the first cleaner located in a system
which comprises multiple cleaners.
Secondary Cleaner is the belt cleaner which is the second cleaner located in a
system which comprises multiple cleaners.
Tertiary Cleaner is the belt cleaner which is the third cleaner located in a system
which comprises multiple cleaners.
Belt Stability is the term used to describe the process of removing Flapping or
Dynamics from the return strand of the belt so that consistent and even tip to belt
contact pressure can be maintained for the cleaning process.

2.2 Some History
Over the years, belt cleaners have gained a lot of ground in the recognition of the task that
they perform. Its not all that long ago that things like Piano Wire, Lumps of 4x2 and skirting
rubber bolted to a bit of angle iron were used to clean the belt.
Specifications for belt cleaners have also improved from generic statements such as An
adequate belt cleaner will be provided to things like Performance Guarantees where the
expectation of the cleaning systems performance is stated up front and the selection of
equipment to achieve that performance is critical.
The people who supply belt cleaners too, have come from a position of being recognised
as close relatives of used car salesmen to providing a valuable service to the site.
From the Apex point of view, there is nothing that will destroy a belt faster than a badly
installed or poorly maintained belt cleaner.
Apex is recognised as Australias premier supplier of quality custom belt which is
engineered to suit the requirements of the customer. Apex also has the potential to
engineer the belt cleaning and associated mechanical technologies that will ensure the belt
provided is able to achieve its maximum life.
Perfecting this package is our goal.
2.3 Cost Benefit Advantages
The performance of belt cleaners contributes strongly to the cost effective operation of
conveyor system. The areas that are effected are listed under the heading, Function of
Belt Cleaners earlier in this Hand Book.
As an example, Perth branch recently carried out a cost benefit analysis for one of their
major customers. The results showed clearly that within the first 12 months, the cleaner
system provided an operating cost reduction of $88,000.00 over 5 conveyors. This was
after the purchase cost of the cleaners and their maintenance was taken up.
Capital expenditure and plant maintenance costs are foremost in the mind of every site
operating conveyors. In many cases, the conveyors are not even seen as a component of
the operators core business and are viewed in much the same way as trucks or bulldozers.
That is, minimum maintenance and never at the expense of sacrificing production.
Of necessity, conveyors will require belt cleaners and unless justification can be provided
they will go to the cheapest tenderer. Justification can take several forms. It can be: -
The initial cost of purchase in a competitive tendering situation.
The Cost of ongoing servicing of the cleaners so that the final cost is considered
over the life cycle of the product.
The value of the performance that the product will give over its life cycle. This
includes component life of other elements of the conveyor and the cost of clean up
around the plant.

New Sites
New sites provide an opportunity to justify the purchase of the cleaners and the ongoing
maintenance of them against performance histories of other existing sites.
They also provide the opportunity to design the correct systems into the conveyors when
they are still on the drawing board and have associated chute work designed to
accommodate the cleaners so that future performance and maintenance is significantly
easier to achieve and, accordingly, cheaper.
Once the commitment is made to the brand and the chutes are designed around them, the
tendering process then becomes incidental.
In justify the supply to a new site using history from existing sites, the following will be
relevant.
Existing Sites
More often than not, the records of existing sites for the cost of conveyor maintenance are
far from accurate. Further, the performance of belt cleaners is not known nor is the
potential for cost reductions understood by the customer.
Existing sites provide an opportunity to work with the customer and establish the costs in a
partnership which ultimately leads to a comprehensive cleaner supply and maintenance
arrangement.
As a rule of thumb, the capital cost of a belt cleaning system will usually be recovered
within 10 months of the system going into service and this includes the service costs of the
cleaners for the period. This is based on Belle Banne cleaners - maintenance costs for
other brands can be significantly higher.
3. Why Have Belt Cleaner Maintenance Contracts?
While many sites still have their belt cleaning equipment maintained by their staff, this is
fast becoming the exception rather than the rule. Outsourcing of maintenance is now seen
by many sites as a means to refocus on their core business and to reduce maintenance
costs.
Beyond that, belt cleaner maintenance is now recognised as a specialist field therefore,
where that specialist capacity is demonstrated, the site will chose that supplier over a
simple labour hire company. Ultimately, the company providing the outsourcing services
will be the company that sells the product.
But belt cleaner contracts are frequently a starting point for a much broader contract which
entails the total maintenance of the conveyors - this is where we want to be.

Apex Belting Belt Cleaner Services Group
Belt Cleaner Basics
4. For The Beginner
4.1 The Manufacturers Installation Recommendations.

The manufacturers installation recommendations are fundamental to the successful
selection and installation of belt cleaning equipment. However, the information provided by
the manufacturer is only part of the process.
The following sketch provides the most important basic information for the mechanical
selection and installation of Belle Banne primary and secondary belt cleaners.
Belle Banne Installation Sketch
A The gap between the front of the chute and the pulley must be a minimum of
maximum lump size + 100 mm.
B The cleaner should be positioned a minimum distance of 180 mm from the

back of the chute.
C Angle of inclination (refer chart below).
D P type cleaners should be positioned approximately 200 mm from the

tangential line where the belt and pulley meet. Any position in this 200 mm
area is acceptable but the back position is preferred (as shown).
Material Nominal Angle
Sticky ores, clay and earth 50 to 60 deg.

Run of mine coal (damp) 45 to 55 deg.
Sand (damp) 30 to 40 deg.
Primary crushed rock 35 to 40 deg.

4.2 The Effects of Belt Maintenance on Cleaner Performance
After getting the mechanical selection and installation process of the cleaners right, the
relationship between belt cleaners, splices and repairs then becomes the most important
element for the ongoing efficiency of any belt cleaning system.
This applies to all belt cleaners irrespective of style or brand.
The primary objective is to present a flat and smooth surface to the tips of the belt cleaner.
That surface also needs to be free of any vibrations or Dynamics which cause the belt to
flutter [or flap] over the cleaner tip thus reducing efficiency.
Some of the problems in achieving this objective are: -
Belt wear profiles.
Multiple belt specifications on the one conveyor.
Cover strips.
Belt patches.
Skirt line grooving.
Belt Dynamics [Flapping].
Poor quality pulley lagging
Build up on head and snub pulleys and on adjacent return rollers
All these elements contribute to poor cleaner efficiency and can cause the cleaners to
develop belt problems or compound existing problems.
Belt splices and repairs that are proud of the top cover or sit above the normal height of the
top cover will be picked up by cleaner tips causing inefficient belt cleaning and increasing
the risk of further damage to the belt, the splices and /or repairs.
This is where the skill of the Belt Splicer is also critical to a successful belt cleaner
installation.
If Apex is to be considered as a total service provider, we also have the responsibility of
making sure that the belt cleaners are working before we leave site. It reflects on the
professionalism of us all.
4.3 The Effects of Cleaner Selection and Installation on Belt Performance

Briefly, as a belt manufacturer, Apex should be very concerned about the quality of cleaner
performance and the technology used for its selection and installation. Poor belt cleaner
installations and maintenance destroy belts - its as simple as that.
The two major causes of most damage can be seen in the foregoing Belle Banne
Installation Sketch.
The 15 Offset
Achieving the 15 offset of the tips of the H type primary cleaner is a function of selecting
the correct location for the cleaners pole relative to the size of the suspension arms and the
diameter of the pulley.

If this is not done correctly, the H type tips will Chatter on the belt and cause significant
top cover damage.
Dimension D
Belle Banne P type cleaners are not designed to work where the belt is still in contact with
the pulley.
In cases where the P cleaner must be installed in this position, the concentricity of the
pulley and the quality of the lagging is critical otherwise cleaner cushion failure will occur.
Similarly, in these circumstances, no secondary cleaner should be installed if the pulley is
crowned. This will result in the top cover of the belt being worn away at the peak of the
crown.
Dimensions C and B
These two dimensions are closely aligned in that they are the principle cause of chute
blockage and belt wear.
The result of these two dimensions being incorrect is that material will Bridge between the
pole of the cleaner and the chute rear wall which will build up and lift the belt off the tips of
the cleaner.
When this occurs, it causes high belt cover wear and zero belt cleaning.
4.4 A Word About Cleaner Pole Diameters

Belt cleaners operates in an area where damage to the cleaner is most likely to occur.
Damage to this cleaner WILL result in damage to the belt. The diameter of the pole or
additional bracing of the pole will help reduce the potential for damage and has the added
advantage of removing any vibration from the cleaner which may lead to Chattering of the
tips on the belt cover resulting in significant belt cover damage.
Most manufacturers have factored these considerations into their design and the belt width
will dictate the diameter of the pole. With an increase in width, the diameter of the pole will
increase however you should be mindful of the cleaners pole diameter in any selection
process.
4.5 A Word About Crowned Pulleys

Crowned pulleys have been widely used in the past.
The Primary Cleaner, particularly the H type, is not designed to accommodate any
crowning in the pulley and will damage the belt unless it is set up to accommodate the
profile of the crown.
Because of the rigid steel and tungsten components of this cleaner, shims will be required
at the connection of the suspension arm to the mounting cushion.
Shimming should be installed between the metal plate of the cushion and the suspension
arm and can be achieved using washers.
Care must be exercised in shimming H type cleaners. It is strongly recommended that this
work be undertaken on site with the pulley in question used as a template for the profiling of
the belt cleaner.

4.6 Stabilising the Belt

Consider a conveyor where the belt cleaning system is to be located at the head end which
is also the drive of the system. Typically, this conveyor will have a snub pulley to give the
belt a 210 degree angle of wrap over the drive pulley.
The belt, as it leaves the drive pulley is in the T2 tension zone and after the snub pulley,
about three metres away, is the first flat return roller.
The belt in this zone is under low tension.
The any minor run out on the snub pulley and first return idler roller will generate dynamics
in the belt. Frequently, because of the cycle time, the dynamics cant be seen or the belt
edge instead of appearing as sharp, looks fuzzy or damaged.
This is a major cause of the failure in performance of the secondary and tertiary cleaners
because these dynamics cause the belt to be away from the tips of the belt cleaner for up to
50% of the time.
In reviewing the vertical adjustment capability of a SP or P type Belle Banne cleaner, it is
only 3mm between off the belt and being correctly tensioned to the belt. If there is 3mm
movement in the belt dynamics, it must be eliminated by using stabilisation rollers.
These are a set of rollers which are installed on the return strand between the trough and
return belt to provide a downward pressure to the return strand. These should be located
immediately behind or, if space is available, in front of the belt cleaners.
They should never be installed directly over the belt cleaners for adjustment purposes.
4.7 The Systems Approach

Belt cleaners work most efficiently as a system. The make up of each system will vary from
job to job and depending on the clients belt cleaning requirements, chute design, material
types, tonnages, belt speeds, the presence of mechanical fasteners and the quality of the
belt top cover.
There may be a number of different types of belt cleaners used in a system.
Generally they will consist of a Primary Cleaner, a Secondary Cleaner and for High
Performance Belt Cleaning, a 3rd cleaner will be installed in the Tertiary position. In
extreme cases of high carry back a fourth cleaner can be used to lower carry back levels.
The reason that a systems approach is best is entirely related to performance and belt life.
For instance, overloading a single belt cleaner will result in a higher rate of maintenance
and a rapid reduction in belt cover life whereas a multiple cleaner system that employs
water will reduce belt cover wear, cleaner component wear and contribute substantially to
dust suppression.

4.8 Water As A Cleaning Aid
There have been all sorts of rash promises made by all sorts of belt cleaner manufacturers
about how great their cleaner is, and how cheap it is.
The simple facts are that not many of these brands are prepared to go up against a
properly installed and maintained Belle Banne system where a Spraypole cleaner is
involved because its performance has been quantified time after time in field trials.
The use of water as a cleaning assistant will: -
Reduce the level of carry back on a given system by up to 75% when compared to dry
system.
The lubrication effect of the water will provide up to 15% better belt cover wear life
than for a comparable dry system.
The lubrication of the cleaners and belt means that the loading on the cleaner
components is less than for a dry system thus providing longer component life.
The Shear Path

A popular misconception is that the water applied to the belt is spraying the carry back off
the conveyor before it reaches the cleaner tips. Not True.
The water is used to create a shear path for the blades of the cleaners by placing the carry
back material into suspension. This then allows the blades of the cleaner to run ON the belt
NOT on the carry back material.
On short centred belts, this can be used to good effect by spraying the belt at the tail before
the material is loaded.
The volume of moisture in the product being conveyed has little or no effect on the
performance of the cleaners. Consider your cars windscreen wipers trying to get mud off
without the washers.
The spray of water onto the belt is also very practical for lifting the edge of small flat
particles which would otherwise slide past the cleaner blades.
The Water Control Manifold

The volume of water used is an important consideration.
Many people think that the more water used, the better the performance will be. Again, Not
True.
The ideal method of application of water is through an Apex Water Control Manifold which
provides water to the Spraypole or Spray Bar at a constant pressure or 50 Psi.
The volume of water used is relative to the width of the belt, the number of sprays and the
spray nozzle size used.
Calculation formulas of water volumes and the effect it has on the percentage moisture
increase to product are discussed later in this Hand Book.
The Water Control Manifold provides the water at the correct pressure when it is needed
and shuts it off when its not.

Spray Bar Vs Spraypole

The debate rages. Which is the best?
By placing a Spray Bar in front of a standard P or U or R cleaner provides the same
effect as having the sprays mounted into the pole of the cleaner.
The Spray Bar provides the following advantages over the Spraypole: -
The sprays are less like to be blocked because they are out of the flow of material
being removed by the cleaner.
The Spray Bar can be easily removed for servicing without having to disturb the
cleaners set up.
The Spray Bar is lighter and easier to handle.
Existing dry cleaning systems can be converted to wet systems at minimal cost.
The Spray Bar can be installed at the tail of short centred conveyors.
The Spray Bar can also be used for dust suppression away from belt cleaning altogether.
Spray Shrouds
The development of the Spray Shroud has come about as the result of frequent blockages
to the sprays of the Belle Banne Spraypole cleaner. The position of the sprays on the
cleaner pole cause the material removed by the cleaner to wash over the sprays when in
operation.
The Shroud is fitted to the spray nozzle and an extension is fitted to move the spray forward
of the cleaner pole and away from the wash. This significantly reduces the incidence of
blockage.
4.9 Maintaining The Edge
For years, the debate has raged over the relative merits of polyurethane tips Vs Tool Steel
Tips Vs Tungsten Carbide Tips.
All of these materials when new are effective at cleaning the belt but within as little time as
a week, substantial variations occur in performance.
The reason is that the material of the tip will dictate the wear rate and the softer the
material, the faster the cleaning edge is removed.
For a belt cleaner tip to be consistently effective over a long period of time, it has been
identified that it must maintain an edge of not more than 3mm. That is, the thickness of the
blade actually contacting the belt.
As the thickness of that material is increased, then the performance of the cleaner will
deteriorate accordingly. If you've used a blade shaver, youll know what I mean.
Conversely, a thinner material will clean better but last less time. The 3mm thick Belle
Banne Tungsten Carbide tip segment is the ideal balance between performance and life
under most circumstances.
Polyurethane blades will initially work reasonably well. In the moulding process, a clean and
sharp edge is provided. However, this wears away very quickly.

Polyurethane blades are generally designed as large blocks of material. The reason is to
provide a perception of a reasonable wear life expectation. In reality, when the sharp edge
wears off a radius develops and allows material to Roll through between the blade and the
belt.
This rolling action of the material then scrubs both the belt and the blade resulting in higher
wear rates. No amount of over tensioning of the cleaner will improve its performance and
only wears the belt out faster.

Primary Belt Cleaners
5 Overview
The function of the Primary Cleaner is to Scalp the

belt of the course carry back materials which would
otherwise overload the secondary and tertiary
cleaners.
In terms of volume, the primary cleaner is responsible
for the removal of up to 75% of the total carry back and
is an essential part of the system. It has the added
advantage of placing the carry back directly into the
flow of material.
However, the course materials generally do not cause a problem of carry back. This is
normally a function of the fine and sticky particles that are in the mix of material.
The fine and sticky particles are removed by the secondary and tertiary cleaners.
5.1 Competitors
The Primary Cleaner market is dominated by two suppliers, Belle Banne and ESS.
Each brand is available in a number of configurations depending on belt splice type, type of
material and chute design.
Customer Concerns
In recent times a growing concern has developed over the use of primary cleaners. To a
large extent, this has came about as a result of two issues: -
1. Poor chute designs where large lumps get wedged over the cleaner causing
subsequent belt damage.
2. Poor belt repair, splice and belt cleaner maintenance resulting in continuing or
exaggerating belt damage.
In neither case is it the fault of the belt cleaner. But these issues need to be kept in mind
when selecting a primary cleaner for an application.
The following comments are based on the selection, installation and maintenance of the
Belle Banne range of Primary Cleaners.
5.2 The H Type Belle Banne Cleaner

The Belle Banne H Type is used as a primary cleaner or scalping cleaner to remove most
of the residue from the belt surface prior to final cleaning by secondary cleaners.
The H Type is responsible for the removal of approximately 75% of the carry back material
and is usually located at the head or discharge pulley.
For spliced conveyors, this cleaner is set up with tungsten tips and screw tensioned end
assemblies. (High efficiency - Low maintenance). For belts with mechanical fasteners or
damaged top covers, cleaners should be set up with Poly tips; soft mounts to help absorb

clip impact and spring tensioned end assemblies to ensure constant tip to belt pressure.
(Reduced efficiency-increased maintenance).
The H Type cleaner is specified by first checking the pulley dimension then identifying the
cleaner coordinates and finally checking that these details are not obstructed by structure or
gearbox drives.
When installed correctly, the tips of the cleaner will contact the belt at 15 degrees
underneath the horizontal centre line of the pulley. Irrespective of the angle of incline of the
conveyor.
The design of the H Type allows for installation on reversing conveyors, shuttle heads,
trippers or any situation where multi-directional belts are encountered.
Spliced Belts
In most cases the Primary cleaner will be a Belle Banne H Type or equivalent other
proprietary brand, installed on the head pulley. In some applications, an H Type will not be
suitable either due to chute design, belt condition or at the clients request.
For spliced belts with good to reasonable top cover condition (i.e.; any repairs, splices or
patches are recessed level with the top cover) and head pulley lagging that is in good
condition and running concentrically, the H Type will be set up with Tungsten Carbide tips
and screw tensioned end assemblies.
The tungsten tip is a very long wearing component and where conditions are favourable 1-2
years tip wear life can be expected.
Clipped or Damaged Belts

For conveyor belts using mechanical fasteners or that have a damaged top cover and
repairs that are proud of the top cover surface, the cleaner should be set up with Poly Arms,
spring tensioned end assemblies and soft mounted pivot bearings.
This cleaner configuration will absorb the impact from clips and patches and allow the
cleaner to maintain a constant tip to belt pressure providing good cleaning levels.
However, this set up will require a higher frequency of service. The inspection frequency of
these cleaners must also be much higher because the Poly tips will wear more quickly than
Tungsten and with the added impact of mechanical fasteners which tend to hammer the
cleaners.
The carry back levels will also be higher using the Poly tips.

5.3 The U Type as an Alternative Primary Cleaner

A Belle Banne U Type Cleaner is the most efficient single cleaner available and is
sometimes installed in the primary position due to conditions which prohibit the use of a H
type.
The U type can be set up under the head pulley out of harms way with a secondary SP,
P or U Type cleaner following as per the following sketch.

5.4 `H Type Installation procedure
Risk Hazard Assessments must be top priority when client requirements are considered
and accessed for installations. The supply of suitable power, plant air and water must be
available for ease of installation.
1. Check that the correct cleaner has been selected and supplied to suit the belt width
and pulley diameter size for specifying suspension arm size. Chute widths also need
to be checked to make sure the pole length is correct or if the standard pole length
needs to be altered.
2. Mark or scribe a vertical line down from the centre line of the head pulley.
3. Determine the centre of the pole by selecting the X and Y dimensions as shown on the
Installation diagram corresponding to the pulley diameter taking into account the belt
thickness and head pulley lagging thickness. For odd sized pulleys see Coordinate
Formula attached.
4. Having established the centre of the pole (NOTE: this will position the cleaner at 15
Degrees below the horizontal centre line of the pulley) select the cut dimensions from
the table and cut opening as shown on installation diagram.
5. Mark and cut reverse side opening and remove any sharp edges to avoid injury.
6. Re-establish X and Y dimensions to determine the centre of the mounting bracket and
weld or bolt in position to the chute on the horizontal plane.
7. Pass the cleaner through cut out window ready for mounting. A long pole that can be
slide inside the cleaner pole to secure it from falling and a securing rope are
recommended for addition to installation tools to reduce the risk of the cleaner falling
into the chute at this stage of installation.
8. Mount as per cleaner installation diagram or to other specific installation instruction.
9. Bring tips into contact with the belt and lock adjuster arm in the horizontal position;
ensure tips are horizontal and square to the belt surface.
10. Pre tension cleaner to a loading 7-8 KGs per 200mm tip width by using the adjuster
bolt. (See table below)
11. Check loading with spring scale and test run to ensure correct operation.

5.5 Belle Banne X/ Y Coordinates
As noted earlier, the Belle Banne H type cleaner is

designed to function as a scalping scraper removing 75%
of course fines and carryback materials.
This cleaner should only be used with flat faced pulleys.
However, the cleaner can be set up to handle crowned
pulleys and the Services group or Belle Banne Aust
should be consulted.
H type cleaners will also function on reversing
conveyors, shuttle heads, trippers or any other situation
where the belt will be functioning multi-directionally.
ARM PULLEY Pole Diameter Pole Diameter Pole Diameter

SIZE DIAMETER 48.6mm 60.5mm 76.5mm
X Y X Y X Y
SS 250 41 298 36 303 31 308
300 65 305 60 310 55 315
350 89 311 84 316 79 321
400 113 318 109 323 103 328
450 137 324 133 329 127 334
499 161 331 157 336 151 341
S 500 138 384 135 390 129 396

600 186 397 183 403 177 409
700 234 410 231 416 225 421
799 282 423 279 429 273 434
M 800 268 470 264 474 258 480

900 317 483 312 487 306 493
999 365 496 360 500 355 506
L 1000 340 520 336 525 330 529

1100 388 533 384 538 378 542
1199 437 546 432 551 427 555
LL 1200 427 658 423 663 418 669

1300 475 671 472 676 466 682
1400 523 684 520 689 514 695
1500 572 697 568 702 562 708
1600 620 710 616 715 611 721
1700 668 723 665 728 659 734

5.6 H Type Pre Load Tension Table
LOAD M12 BOLT M16 BOLT

7-8 kgs/200mm 3 Turns 2.5 Turns
5.7 Belle Banne H Type Components
COMPONENT DESCRIPTION
Standard Units: Blasted, primed and Green Powder
Frame Coated paint finish. Stainless Steel and Galvanized
finish is also available
Tips HS Tungsten Tip

PA200 Poly Arm
HS Standard Cushion
Cushions
HS High Speed Cushion
5.8 H Type Cleaner Component Dimensions
BELT
B N A D E F G L
WIDTH
450 400 2 42.7 300 20 49 L50x6 950
600 600 3 42.7 300 20 49 L50x6 1,100
750 600 3 42.7 300 20 49 L50x6 1,250
900 800 4 42.7 300 20 49 L50x6 1,400
1,000 1,000 5 48.6 300 20 49 L50x6 1,500
1,050 1,000 5 48.6 300 20 49 L50x6 1,600
1,200 1,200 6 48.6 300 20 49 L50x6 1,800
1,400 1,400 7 60.5 350 23 59 L65x6 2,000
1,500 1,400 7 60.5 350 23 59 L65x6 2,100
1,600 1,600 8 60.5 350 23 59 L65x6 2,200
1,800 1,800 9 76.3 350 23 67 L65x6 2,500
2,000 2,000 10 76.3 350 23 67 L65x6 2,900
2,200 2,200 11 76.3 350 23 67 L65x6 3,100

5.9 H Type X&Y Coordinate Calculation
Please find following the formula for calculating the X & Y coordinates for the positioning of
H Type belt cleaners.
H Type X & Y Formula
R = Radius of Pulley-including lagging and belt

A = Constant from table for set suspension arm size
C = Constant from table for set suspension arm size
A & C Constant Table

SUSPENSION ARM A C
SS 23 278
S 32 336
M 34 385
L 51.5 414
LL 32 525
X = (0.966 x Radius) - (0.966 x A) - (0.259 x C) + 14.5

Y = (0.259 x Radius) + (0.966 x C) - (0.259 x A) + 3.88
Example 1
900 mm belt for H type c/w 60 mm pole and S size suspension arms.
800 mm diameter pulley, 15 mm belt thickness and 12 mm lagging thickness.
Radius 400 mm + 15 mm + 12 mm = 427 mm Radius
X = (O.966 x 427 mm) - (0.966 x 32 mm) - (0.259 x 336 mm) + 14.5mm = 306 mm
Y = (0.259 x 427 mm) + (0.966 x 336 mm) - (0.259 x 32 mm) + 3.88mm = 430 mm
Example 2
1200mm belt for H type c/w 60 mm pole and M size suspension arms.
1000 mm diameter pulley, 12 mm belt thickness and 10 mm lagging thickness.
Radius 500 mm + 12 mm + 10 mm = 522 mm Radius
X = (O.966 x 522 mm) - (0.966 x 34 mm) - (0.259 x 385 mm) + 14.5mm = 386 mm
Y = (0.259 x 522 mm) + (0.966 x 385 mm) - (0.259 x 34 mm) + 3.88mm = 502 mm
5.9 Calculation Software

Software to calculate the correct X and Y coordinates is available on request from the Belt
Cleaner Services Group.

Belle Banne H Type Cleaner Assembly Procedure

6. Tools & Safety Equipment Required:
You will need :-

1 x 13mm, 17mm & 19mm open ended/ring spanners and/or ratchet set.
1 x Straight Edge
1 x Hammer
1 set of Vee Blocks, Jimmy bar or large screwdriver.
[to be used to position cleaner on bench for alignment purposes].
Shim pieces. [Metal Strapping is ideal]
Safety Glasses
Safe Working Procedure
7. H Type Assembly Procedure
1. Ensure that correct Tips, Suspension Arms, Mounting Cushions and Polyshields
have been issued from stores.
2. Ensure that the pole of the cleaner is supported by Vee Blocks or alternatively, a bar
is placed through the hole in the pole of the cleaner to prevent it from rotating during
cleaner assembly.
3. Assemble Mounting Cushions to the Cleaner Pole and turn the Cushion Nuts until
they are finger tight.
4. If Polyshields are to be used, fold and compress the Polyshields so that the holes
are aligned then place the lower two holes of the Polyshield over the threaded studs
of the Suspension Arms. Assemble the Suspension Arms to cushions and fold the
Polyshield over so that the remaining holes are fitted over the threaded studs of the
Suspension Arms. Secure finger tight using the nuts and washers supplied.
5. Assemble Tips to the top of the Suspension Arms, again finger tight.
6. Using a straight edge, check to see the amount of misalignment of the cleaner tips.
7. Ensure that the tips of the cleaner are level and that there is clearance of 0.05mm
between the tip ends so that clashing does not occur as this will lead to damage of
the tips in operation.
8. Commence tensioning the fastenings of the cleaner. This is best commenced with
the nuts of the Suspension Arms at the Mounting Cushion and will cause some
alignment movement at the cleaner Tips.
Note that at this point, it is advisable to place the Shim Pieces between the metal
face of the Mounting Cushion and the flange of the cleaner Pole. This should be
done where particular misalignment is identified during the tensioning process.
9. Continue with the tensioning process until all fasteners are secure and the cleaner is
aligned and square to the cleaner Pole.

7.1 Possible Problems

The accuracy of the alignment of the cleaner Tips is very important. Misaligned tips will
result in belt damage and vibration from the cleaner.
Bent and Corroded Poles

When overhauling a H type cleaner, it is important to take the condition of the pole into
consideration. Always ensure that the pole of the cleaner is straight and that corrosion has
not caused the Cushion plates to bolt up to the pole in an uneven way.
If the cleaner pole is corroded or bent - replace it.
Cushion Compression Set

In operation, the Mounting Cushions of Belle Banne cleaners are subjected to a consistent
load. This load will eventually take its toll on the rubber of the Mounting Cushions and the
angle of the metal plates will be permanently altered.
When overhauling H Type cleaners, pay particular attention when combining old Mounting
Cushions with new Cushions on the same pole. Variations in alignment will occur at the tips
and cause assembly problems.
Tungsten Tips
Tungsten is a particularly brittle material which does not handle impact well at all.
Impact can come from many sources. The most prominent is from the clash of tips where
insufficient clearance has been provided when the cleaner is assembled.
Always ensure that when overhauling a cleaner, the tips are free from tungsten damage as
a result of impact. In all cases, this damage will cause sharp edges which will damage the
belt.

Secondary Belt Cleaners
8. Overview
The function of the Secondary Cleaner is to remove fine and sticky materials from the belt
after the Primary cleaner has removed the course carry back.
In terms of volume removed, the Secondary cleaner does not appear to be as effective as
the Primary cleaner. However, this is not the true case when looking at the mess around a
conveyor or the build up on return rollers.
In fact, it is the fine and stick material that is responsible for the mess as it is particularly
hard to remove. In many cases, it is necessary to apply water to the belt in front of the
Secondary cleaner to achieve the required end result.
8.1 Competitors
There is a wide variety styles and a large range of brands available in the Secondary belt
cleaner market.
Belle Banne
The Belle Banne Secondary Cleaner range is as follows: -
'P' Type & 'SP' Type - Used with Water 'U' Type
Just to Confuse You

A Typical Dry set up would have a Belle Banne P or U
Type installed in the secondary position set up within the
confines of the head chute so that fines removed will be
redirected with the main material flow.
A Wet set up would see either a SP Type cleaner, a P
type cleaner with a separate spray bar or a U type
cleaner again with a separate spray bar installed in the
secondary position.
'R' Type

Other Competitors
Hosch
ESS
Dyna
Prok
Spliced Belts
The Belle Banne SP, P, R and U Types fitted with Tungsten Carbide tips should be
used for spliced belts in good condition.
Clipped or Damaged Belts
The Belle Banne P and U Type fitted with Polyurethane tips should be installed on
damaged belts. Where belts are fitted with mechanical fasteners, SP and P type cleaners
fitted with R type tungsten carbide tips have proven effective but care should be taken
where clips are not recessed or bad clip installation practices are observed.
The use of P types with R tips is usually found in underground coal mines.
Reversing Belts
In the Belle Banne range, only the H and R types can be used.
The use of the SP, P or U types will result in damage to the cleaner and ultimately
damage to the belt.
8.2 Spraypole P and P Type Belt Cleaners Specification

The efficiency of any belt cleaner depends on the correct installation of the equipment and
the maintenance carried out after installation. Where the end user demands high
performance carry back levels, it is necessary to install both SP and P cleaners in the
secondary location.
The major difference between the SP Type and P Type cleaners is that the SP uses
water sprays. The SPs cleaner pole has been redesigned to include facilities for the
handling and application of water to improve belt cleaning.
Both the SP and P Type cleaners can be mounted in any position from the tangential line
of where the belt leaves the pulley.
The SP cleaner utilises water as an aid in belt cleaning. An example of this would be to
think of your car windscreen wipers. Switching the wipers on without water will create a
messy screen; spray water onto the screen and the difference soon becomes visible.
What the water achieves is to put the residual fines into a water suspension which allows
these fines to be cleaned off the belt easily whilst acting as a lubricant to help reduce tip
wear. Three styles of tips are available to handle spliced, clipped and damaged belts. The
Tungsten P type for spliced belts, Tungsten R type for Underground spliced belts that are
subject to change pending breakdown situations and clipped belts and polytuff urethane for
soft compound belts (Cable Belts) clipped belt and belts with damaged top covers.
The most important element to maintain with this type of cleaner is the constant supply of
water to the cleaner when the belt is running. When set up correctly a Water Control Unit
set up on the SP cleaner will supply and regulate this flow of water. This will help reduce
the incidence of spray nozzles becoming blocked reducing cleaner efficiency.

COMPONENT DESCRIPTION
FRAME Standard Units: blasted, primed
Green Lacquer paint finish
Galvanized Finish
Stainless Steel
TIPS PS 150 Tungsten Tip
RS150 Tungsten Tip
PS 150 Polytuff Tip
CUSHIONS PS Cushion

8.3 SP and P Type Cleaner Installation Procedure
Check that the correct cleaner has been selected and supplied to suit the belt width. Chute
widths also need to be checked to make sure the pole length is correct or if the standard
pole length needs to be altered.
1. Mark or scribe a vertical line down from the centre line of the head pulley.
2. Measure a distance of 265 from the tangential point where the belt leaves the pulley.
3. Cut a hole in the chute wall 200 x 120mm using the 265mm measure from the belt
tangent as reference.
4. Repeat procedure on reverse side of chute removing any sharp edges around opening.
5. Tack weld brackets to chute and bring the cleaner tips into contact with the belt ensuring
the approach angle of 70 degrees is maintained. This will determine correct position for
the cleaner.
6. Refit the clamp bolts and finger tighten all adjusting bolts.
7. The cleaner tips should be adjusted by using the adjustment bolts to lift the cleaner until
the centre tips touch the belt. Recheck the approach angle at this point.
8. Pre load tension is applied to the rubber cushions by rotating adjuster bolt so that the tip
is lifted a further 3mm approximately ( Refer to chart below)
9. Tighten the clamp bolts, lock nuts and check all other securing fasteners.
10. Test run the conveyor to ensure the correct operation of the cleaner, the Spray Jets and
Spray Shrouds [where fitted]. The Spray Fan should be checked to ensure that the
Shroud does not impede its action.

NOTE:
If lines of carry back are noted to be passing the cleaner, a further adjustment may be
required.
DISTANCE LOAD M 12 BOLT M 16 BOLT
3 mm Lift 5Kg/150 mm 1.7 mm 1.5 turns
4 mm Lift 6Kg/150 mm 2.3 mm 2.0 turns
5 mm Lift 8Kg/150 mm 2.9 mm Turns
8.4 P Type Component Dimensions
Belt Width Tip Width Tip Total Frame A B C D E F

(W) Count Length (L) Approx. Approx. Dia.
(N)
600 (24) 600 (24) 4 1100 (44) 160 150 48.6 350 65 90
750 (30) 750 (30) 5 1250 (49) 160 150 48.6 350 65 90
800 (32) 750 (30) 5 1300 (51) 160 150 48.6 350 65 90
900 (36) 900 (36) 6 1400 (55) 160 150 60.5 350 75 100
1000 (40) 900 (36) 6 1500 (59) 160 150 60.5 350 75 100
1050 (42) 1050 (42) 7 1600 (63) 160 150 60.5 350 75 100
1200 (48) 1200 (48) 8 1800 (71) 165 155 76.3 400 140 120
1400 (55) 1350 (53) 9 2000 (79) 165 155 76.3 400 140 120
1500 (60) 1500 (60) 10 2200 (87) 165 155 76.3 400 140 120
1600 (64) 1500 (60) 10 2300 (90) 165 155 76.3 400 140 120
1800 (72) 1800 (72) 12 2500 (98) 170 160 76.3 400 140 120
2000 (80) 1950 (77) 13 2700 (106) 170 160 76.3 dual 400 140 120
2200 (88) 2100 (83) 14 3000 (118) 170 160 76.3 dual 400 140 120

8.5 U Type Cleaner Specification

High efficiency and low maintenance make this cleaner very attractive to applications were
an H type is not suitable and a U type can be fitted as a primary cleaner. As a single
cleaner set up the U type represents the best efficiency and value if budget is limited. It
can be used on spliced and clipped belts and utilises spring tensioned end assemblies
ensuring regular adjustments to cleaner are not required.
U Type Dimensions
Model Belt: B Frame:L C D E F G H Weight
35U 350 1,050 130 48.6 38 134 237 175 25Kg
45U 450 1,150 27Kg
50U 500 1,200 28Kg
60U 600 1,300 30Kg
75U 750 1,550 32Kg
90U 900 1,700 36Kg
100U 1,000 1,800 38Kg
105U 1,050 1,850 41Kg
120U 1,200 2,100 160 60.5 240 343 185 47Kg
140U 1,400 2,300 50Kg
150U 1,500 2,400 55Kg
160U 1,600 2,500 246 349 60Kg
180U 1,800 2,700 76.3 46 357 67Kg
200U 2,000 3,100 70Kg
220U 2,200 3,300 73Kg

8.6 How it Works
The scraping portion consists of a single blade with an arched shape. A shaft is attached to
the scraping portion, which is lifted upwards using a lever on the shaft, thus rotating the
blade so that the maximum pressure is given at the centre of the cartridge. This pressure
reduces gradually toward the end of the scraping blade, which are the points of the lowest
contact.
The U Types design enables the cleaner to accommodate the wear patterns which form in
the centre of older belts as a result of poor loading practice. The advantage of the U Type
is in its ability to accept a larger amount of wear in the belt cover.
For this reason when using the U as a Primary Cleaner, a distance of 300-400mm
separation must be observed as the U Type will profile the belt to its shape and not allow
the straight line SP or P Type cleaner tips to sit evenly across the belt. Pressure rollers
must also be used where belt stability is an issue for optimum cleaning efficiency.
U Type Cleaner Installation Procedure

1. Secure cartridge centrally in frame
2. Fix mounting brackets. Weld brackets to the selected location on either side of the
conveyor.
3. Fix the bearing mount at a position approximately 20mm below the centre line of the
mounting bracket.
4. Sit the shaft of the cleaner into the bearing mounts and fit the securing pins.
5. Fit the nylon bushes to the shaft of the cleaner with the small flange facing outwards.
6. Slide the stops onto the cleaner shaft on either end.
7. Insert a rod through the cleaner using the hole at each end to rotate the cleaner until
the blade cartridge is parallel with the belt.
8. Lock the stops onto the shaft so that the cleaner remains parallel to the belt.
9. Height adjustment to be made using adjuster bolts to raise or lower the cleaner until
both leading edges and the centre of the cleaner are in contact with the belt.
10. Fit adjusting arms to the cleaner shaft.
11. Loose assemble the adjusting spring and stainless steel hook bolt to the adjusting
arms and determine the position of the bracket.
12. Ensure that the holes in the bracket and the adjusting arm are vertically aligned and
weld the bracket to the conveyor structure.
13. Secure the hook bolts to the brackets and connect the adjusting springs and arms.
14. Tension the adjusting springs such that the weight of the cleaner is supported.
15. Apply tension to the cleaner by adjusting the hook bolts so that the blade of the
cleaner is in contact with the full width of the belt and a nominal 0.5 mm is present
between the coils of the springs.
16. Test run belt to ensure correct operation of the cleaner.
8.7 R Type Cleaner Specification

The R Type cleaner is used on reversing belts where it is not possible to fit an H Type
cleaner. In some instances, R Types are also used as a secondary cleaner behind an H
Type for two-way travel installations. This type of cleaner is a special purpose unit, which is
usually used, in the above applications.
This cleaner is suitable for mobile trippers and shuttle installations. Tips are at 90 degrees
to the belt and screw tensioned end assemblies, similar to SP and P types are used for
adjustment.
The design of the R Type cleaner incorporates the use of a rubber cushion similar to the
P and SP Type cleaners. The tungsten tips are mounted at 90 degrees to the conveyor
belt, with the cleaner installed in a vertical position, creating the same approach angle of
tips to belt, regardless of the direction of travel.
R Type Cleaner Installation Procedure

The same techniques for the installation of P and SP Type cleaners should be used here.
Tertiary Belt Cleaners

9 Overview
The same cleaners that are used in the Secondary position are used in the Tertiary
position. However, it need not be the same cleaner type as is used in the Secondary
position.
The Tertiary cleaner should also be installed within the chute confines to direct the material
flow back to the main product stream.

Belle Banne P & SP Type Cleaner Assembly Procedure

10 Tools & Safety Equipment Required:
You will need :-

1 x 13mm, 17mm & 19mm open ended/ring spanners and/or ratchet set.
1 x Straight Edge
1 x Hammer
1 set of Vee Blocks, Jimmy bar or large screwdriver.
[to be used to position cleaner on bench for alignment purposes].
Shim pieces. [Metal Strapping is ideal]
Safety Glasses
Safe Working Procedure
11 Spraypole, P & R Type Cleaner Assembly Procedure
1. Ensure that correct Tips, Mounting Cushions and Polyshields have been issued from
stores.
2. Ensure that the pole of the cleaner is supported by Vee Blocks or alternatively, a bar is
placed through the hole in the pole of the cleaner to prevent it from rotating during
cleaner assembly.
3. Assemble Mounting Cushions to the Cleaner Pole and turn the Cushion Nuts until they
are finger tight.
4. If Polyshields are to be used, fold and compress the Polyshields so that the holes are
aligned then place the lower two holes of the Polyshield over the threaded studs of
the cleaner Tips. Assemble the Tips to the cushions and fold the Polyshield over so
that the remaining holes are fitted over the threaded studs of the Tips. Secure finger
tight using the nuts and washers supplied.
5. Use straight edge to check alignment of tips.
6. Ensure that the tips of the cleaner are level and that there is clearance of 0.05mm
between the tip ends so that clashing does not occur as this will lead to damage of the
tips in operation.
7. Commence tensioning the fastenings of the cleaner. This is best commenced with the
nuts of cleaner Tips followed by the Mounting Cushion and will cause some alignment
movement at the cleaner Tips.
Note that at this point, it is advisable to place the Shim Pieces between the metal face
of the Mounting Cushion and the flange of the cleaner Pole. This should be done
where particular misalignment is identified during the tensioning process.
8. Continue with the tensioning process until all fasteners are secure and the cleaner is
aligned and square to the cleaner Pole.

11.4 Possible Problems
The accuracy of the alignment of the cleaner Tips is very important. Misaligned tips will
result in belt damage and vibration from the cleaner.
Bent and Corroded Poles

When overhauling a H type cleaner, it is important to take the condition of the pole into
consideration. Always ensure that the pole of the cleaner is straight and that corrosion has
not caused the Cushion plates to bolt up to the pole in an uneven way.
If the cleaner pole is corroded or bent - replace it.
Cushion Compression Set

In operation, the Mounting Cushions of Belle Banne cleaners are subjected to a consistent
load. This load will eventually take its toll on the rubber of the Mounting Cushions and the
angle of the metal plates will be permanently altered.
When overhauling H Type cleaners, pay particular attention when combining old Mounting
Cushions with new Cushions on the same pole. Variations in alignment will occur at the tips
and cause assembly problems.
Tungsten Tips
Tungsten is a particularly brittle material which does not handle impact well at all.
Impact can come from many sources. The most prominent is from the clash of tips where
insufficient clearance has been provided when the cleaner is assembled.
Always ensure that when overhauling a cleaner, the tips are free from tungsten damage as
a result of impact. In all cases, this damage will cause sharp edges which will damage the
belt.

Return Belt Ploughs

12 Overview
The ploughs are designed to clean the inside of a conveyor belt on its return trip and to
remove any large lumps that can potentially damage the belt or tail pulley lagging if allowed
to travel through this area.
12.4 Plough Types

There is a wide variety styles and a large range of brands available in the market. Normally,
Ploughs are supplied by belt cleaner manufacturers.
Belle Banne
The Belle Banne Plough range is as follows: -
Vee Plough Bi Directional Plough Single Side Discharge
12.5 Caution
To avoid belt damage, Belle Ploughs have been designed to be fitted in a trailing position.
Fine-tuning of the plough is possible through the use of the adjustment turnbuckle fitted to
the nose of the plough.
The Belle Banne Vee and BI Directional Ploughs are designed to be self-actuating, so that
when wear occurs they automatically adjust themselves to the belt. The ploughs are used
to prevent the carriage of material on the return strand, which can cause damage to the
pulley lagging and belt.
The Ploughs are set up on the return side of the belt at tail and take up pulleys.

12.6 Installation
It is important that the Belle Plough be correctly positioned, ideally on a flat surface as close
as practicable to the tail end or take up area of the conveyor. The apex of the plough should
be located 150 mm behind a flat return roller to achieve optimum cleaning performance.
1. Loosely assemble plough connecting linkage arms to the plough body.

2. Place the plough on the belt and ensure there is enough clearance. Position the
mounting brackets in either a vertical or horizontal position, ensuring that the centre
line of the pole is between 190-350 mm above the return side of the belt.
3. Mark and drill the holes to correspond with the mounting brackets and attach with M12
bolts.
4. Centralise the Belle Plough in the correct position to the belt, located by locking shaft
collars into position.
5. Adjust the turnbuckle so that the plough sits evenly across the belt.
6. Test run belt to ensure the correct operation of the unit.

Added Moisture The Argument For Wet Belt Cleaning Systems
13 The Argument
With the use a Spraypole belt cleaners [or spray bars], the increase in moisture content can
sometimes cause problems for the end user, e.g. coal mines feeding power stations may
have their product refused due to the high water content.
The standard spray nozzles used in the SP cleaner are spaced at 300 mm intervals and
deliver 3.2 liters per minute per spray. The Spray Pattern of the SP cleaner is designed to
create a shear path which enables the tips of the cleaner to contact the belt surface rather
than skid over the particles.
13.4 Moisture Increase Justification Formula

Following is a formula used to calculate the increase in moisture content when using a Belle
Banne SP belt cleaner or Spray Bar [with P or U system].
Conveyor Throughput Tons per hour
Nominal Moisture Content of product % ( Wet Basis)
Belt Speed m/s
Belt Width mm
Step 1
Calculate moisture contained in product being conveyed.
Moisture in product = Conveyor Throughput * Moisture Content
100
= *
100
= ... Tonnes per hour

Step 2
Calculate moisture added to product due to SP Cleaner or Spraybar.
Number of Nozzles = #
Nozzle Capacity at 350kPa = litres/minute
= Tons per hour
Nozzle Capacity
(Tonnes per hour) = Nozzle Capacity * 60 minutes * Tonnes
( litres/minute) hour 1000 lt.
= 0.06 * Nozzle Capacity
(Litres / minute)
= 0.06 *
( / )
= Tonnes per hour (Water)
Moisture Added by = Number * Nozzles Capacity
Sprays of Nozzles * (tonnes per hour)

= Tons/hour
Step 3
Calculate total moisture in Product
Total Moisture = Moisture in product + Moisture Added by SP cleaner or Spraybar
= +
= Tonnes per Hour
Step 4
Calculate new moisture in Product
New Moisture Content % = Total Moisture * 100
Con Throughput + Water added by SP 1
= * 100
+ 1
= %
Step 5
Calculate increase in moisture content.
Increase Moisture = New Moisture (%) - Nominal Moisture (%)
= %

13.2 Moisture Increase Table

NOMINAL MOISTURE CONTENT OF PRODUCT = 8%( Wet Basis)
Orifice Designation = 0.08mm
Belt Nozzle 500 1000 1500 2000 2500 3000 4000 5000 6000 7000 8000
Width No.
600 2 .0739 .0370 .0246
750 3 .1108 .0544 .0369 .0277 .0222
800 3 .1108 .0544 .0369 .0277 .0222 .0185
900 3 .1108 .0554 .0369 .0277 .0222 .0185 .0139
1000 3 .1108 .0554 .0369 .0277 .0222 .0185 .0139 .0111
1050 4 .1477 .0739 .0492 .0369 .0295 .0246 .0185 .0185 .0123
1200 4 .1477 .0739 .0492 .0369 .0295 .0246 .0185 .0185 .0123 .0106
1400 5 .1845 .0923 .0615 .0461 .0369 .0308 .0231 .0185 .0154 .0132 .0115
1500 5 .1846 .0923 .0615 .0461 .0369 .0308 .0231 .0185 .0154 .0132 .0115
1600 5 .1845 .0923 .0615 .0461 .0369 .0308 .0231 .0185 .0154 .0132 .0115
1800 6 .2214 .1107 .0738 .0554 .0443 .0369 .0277 .0221 .0185 .0158 .0138
2000 7 .2582 .1291 .0861 .0646 .0516 .0430 .0323 .0258 .0215 .0184 .0161
2200 7 .2582 .1291 .0861 .0646 .0516 .0430 .0323 .0258 .0215 .0184 .0161

Factors That Influence Belt Cleaner Efficiency

14 Influencing Factors
The efficiency of any Belt Cleaning System will be affected by a number of factors and they
are listed below:
Correct Specification of Belt Cleaners
The Use of Water & Its Proper Regulation
Belt Specification, Condition & Type of Join
Correct Installation
Belt Stabilisation
Belt Tension
Regular Inspection & Maintenance Programmes
The correct specification of the Belt Cleaning System is essential when planning any belt
cleaning application. The required parameters for the level of carry back required will
decide the type and number of cleaners required to achieve these goals.
The use of water as an aid in belt cleaning will improve expected dry carry back levels by
40-50%. Proper regulation is an issue as excess moisture content in coal may cause
problems for the end user e.g. Coal fired power stations refusing coal supplied due to a too
high moisture percentage in the coal.
The Belt Spec and condition will determine the level of effectiveness the cleaning system
will be able to achieve. Also the type of join will dictate the style of tip and end assembly
arrangement to be used.
Proper Installation instructions should be followed to ensure the correct operation of any
new cleaner installation. After any service or new installation, the conveyor should be test
run to check correct operation and ensure the cleaners do not vibrate and are adjusted to
the correct tension. This is a priority and must be carried out immediately after installation
or at the earliest opportunity a Service Technician must inspect to check the efficiency and
security of the mounting brackets and tensioning systems.
Pressure rollers must be used where required to hold the belt flat and allow the cleaner tips
to remain in constant contact at all times. This will eliminate belt flap that will set up a
vibration frequency causing cleaner inefficiency.
A plan of regular inspection and maintenance will ensure the cleaners work to their
optimum level and any required maintenance will be observed and carried out
preventatively rather than unplanned and in response to a breakdown situation.

Belt Cleaner Handbook

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Belt Cleaner Handbook

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Belt Cleaner Service Manual

BELT CLEANER SERVICE MANUAL

Belt Cleaner Installation and Services Hand Book Page 1

Issue #2 Rev. #2 Issued August 2001

BELT CLEANER SERVICE GROUP Page 1

Belt Cleaner Installation and Services Hand Book Page 2

Issue #2 Rev. #2 Issued August 2001

5.2 THE H TYPE BELLE BANNE CLEANER Page 16

Belt Cleaner Installation and Services Hand Book Page 3

Issue #2 Rev. #2 Issued August 2001

11. SPRAYPOLE, P & R TYPE CLEANER ASSEMBLY PROCEDURE Page 33

Belt Cleaner Installation and Services Hand Book Page 4

Issue #2 Rev. #2 Issued August 2001

1.1 The Focus

1.2 Focus on Belt Cleaning

1.3 This Hand Book

Belt Cleaner Installation and Services Hand Book Page 5

Issue #2 Rev. #2 Issued August 2001

2.1 Terms Used

Belt Cleaner Installation and Services Hand Book Page 6

Issue #2 Rev. #2 Issued August 2001

2.2 Some History

2.3 Cost Benefit Advantages

Belt Cleaner Installation and Services Hand Book Page 7

Issue #2 Rev. #2 Issued August 2001

3. Why Have Belt Cleaner Maintenance Contracts?

Belt Cleaner Installation and Services Hand Book Page 8

Issue #2 Rev. #2 Issued August 2001

4.1 The Manufacturers Installation Recommendations.

B The cleaner should be positioned a minimum distance of 180 mm from the

C Angle of inclination (refer chart below).

D P type cleaners should be positioned approximately 200 mm from the

Material Nominal Angle

Sticky ores, clay and earth 50 to 60 deg.

Belt Cleaner Installation and Services Hand Book Page 9

4.2 The Effects of Belt Maintenance on Cleaner Performance

4.3 The Effects of Cleaner Selection and Installation on Belt Performance

Belt Cleaner Installation and Services Hand Book Page 10

4.4 A Word About Cleaner Pole Diameters

4.5 A Word About Crowned Pulleys

Belt Cleaner Installation and Services Hand Book Page 11

4.6 Stabilising the Belt

4.7 The Systems Approach

Belt Cleaner Installation and Services Hand Book Page 12

4.8 Water As A Cleaning Aid

The Shear Path

The Water Control Manifold

Belt Cleaner Installation and Services Hand Book Page 13

Spray Bar Vs Spraypole

4.9 Maintaining The Edge

Belt Cleaner Installation and Services Hand Book Page 14

Belt Cleaner Installation and Services Hand Book Page 15

The function of the Primary Cleaner is to Scalp the

5.2 The H Type Belle Banne Cleaner

Belt Cleaner Installation and Services Hand Book Page 16

Clipped or Damaged Belts

Belt Cleaner Installation and Services Hand Book Page 17

5.3 The U Type as an Alternative Primary Cleaner

Belt Cleaner Installation and Services Hand Book Page 18

5.4 `H Type Installation procedure

Belt Cleaner Installation and Services Hand Book Page 19

5.5 Belle Banne X/ Y Coordinates

As noted earlier, the Belle Banne H type cleaner is