1. Purpose and application range
This practical guide is intended for technical personnel who perform maintenance and repair of conveyor lines in industrial plants. The guide covers traction adjustment, connection checks, belt tension measurement, and roller replacement. These procedures are carried out during planned technical maintenance, repairs, or when improper operation of the conveyor is detected.
2. Safety
Use of personal protective equipment: When performing work on conveyor belts, it is mandatory to use work gloves, goggles, and open protective devices against tools and grinding. When working with welding or cutting tools, use special protective equipment.Lockout and Disconnection of Energy: Before starting any work on the conveyor, perform lockout and disconnection of energy, set up warning signs and open the ventilation if necessary. Risks from Electrical and Mechanical Load: Ensure compliance with electrical safety rules. Before work, check that the conveyor drive motors are disconnected and use electrical switches to disconnect the energy.
3. Required Tools and Materials
| Tool | Specification | Quantity |
|---|---|---|
| Torque wrench with range 10–100 Nm | Metric nuts, open screw | 1 |
| Multimeter | Range 0–500 V, 0–20 A, 0–500 Ω | 1 |
| Laser for Parallelism Measurement | Range 1–10 m | 1 |
| Tape Supports | Metallic, with open ends | 2 |
| Tape Rewinder | For cutting and joining the tape | 1 |
| Roller stands | Metallic, with open ends | 2 |
| Special Clips | For fixing the belt during setup | 2 |
4. Maintenance Check
| Item | Check | Acceptance/Rejection Criteria | Notes |
|---|---|---|---|
| Electric drive | Check motor drive disconnection | The electric drive must be switched off | Use the tester for checking |
| Suspension system | Check if the boundary opening is open | The separation must be set | Use the "Do Not Connect" sign |
| Tension of belt | Check for tightness | The tension should be within the range of 10–30 N | Use torque wrench |
| Rollers | Check for deviations | Rollers must be installed correctly | Use the ruler |
| Connection | Check whether there is a break | Connections must be continuous | Use a microscope |
5. Step-by-step procedure
Tension Measurement of Belt
Use a torque wrench to measure the belt tension. Apply tension within the range of 10–30 N. Open the belt by 20 cm and measure the tension in the suspension zone.
Error: incorrect measurement within the tension range may cause cracking or breakage.
Traction Setup
Use a laser to measure the parallelism of the rollers. Set the rollers to 0.5 mm within the range of 1 to 10 m. Use a microscope for inspection.
Error: incorrect parallelism setting causes malfunction.
Connection Check
Use a microscope to inspect the connections. Check for cracks or breaks. Use a wire stripper for cutting and connecting.
Error: connections since lead to failure.
Roller Replacement
Use roller stands and clips for fixing. Measure the distance between rollers and install new rollers. Use a torque nut for fixing.
Error: Incorrect roller installation causes cracks.
Tape Selection
Use the cutter for cutting and joining the tape. Measure the length and install the new tape. Use the microscope for inspection.
Error: incorrect belt connection causes breakage.
Tool Selection
Use a torque wrench to fix the rollers. Measure the distance between the rollers and install new rollers. Use a microscope for inspection.
Error: Incorrect roller installation causes cracks.
Measurement and Adjustment
Use a microscope to inspect the connections. Use a wire stripper to cut and connect. Measure the distance between the rollers and install new rollers.
Error: Incorrect roller installation causes cracking.
Measurement and Adjustment
Use a microscope to inspect the connections. Use a wire stripper to cut and connect. Measure the distance between the rollers and install new rollers.
Error: incorrect roller installation causes cracking.
6. After-sales inspection
| Test | Expected result | Actual Result | Pass/Fail |
|---|---|---|---|
| Tension of belt | 10–30 N | Measure | Pass/Fail |
| Roller Parallelism | 0.5 mm | Measure | Pass/Fail |
| Connection | Continuous | Check | Pass/Fail |
| Rollers | Correctly installed | Check | Pass/Fail |
| Tape | Continuous | Check | Pass/Fail |
7. Problem Detection and Correction
| Symptom | Possible cause | Correction |
|---|---|---|
| Since the belt is running | Incorrect tension or connection | Measure the tension and restore the connection |
| Roller approach | Incorrect parallelism | Set rollers |
| Since the rollers | Incorrect installation | Replace bearings |
| Incorrect opening | Incorrect configuration | Restore opening |
| Since the connections | Incorrect installation | Restore connection |
8. Recommended Maintenance Schedule
| Task | Frequency | Estimated duration | Skill Level |
|---|---|---|---|
| Tension Measurement | Monthly | 15 minutes | Average |
| Traction Setup | Monthly | 30 minutes | Average |
| Check connections | Monthly | 15 minutes | Average |
| Roller Replacement | Annual | 45 minutes | High |
| Tape Selection | Annual | 30 minutes | High |
9. Special Parts
| Part description | Typical Specification | Category UNITEC-D |
|---|---|---|
| Conveyor belt | 250 mm, 1200 mm | 2001 |
| Rollers | 250 mm, 1200 mm | 2002 |
| Mounting | Metal, 250 mm | 2003 |
| Breaker | For cutting and joining | 2004 |
| Clips | For fixing | 2005 |
Для отримання деталей, перейдіть на e-каталог UNITEC-D.
10. References
This manual complies with the standards:
- DSTU 2816:2012 – General requirements for industrial conveyors
- EN 1150:2015 – Technical requirements for conveyors
- ISO 10228:2014 – Belt Tension Range
- CE – Conformity Certification
- UkrSEPRO – Compliance Certification in Ukraine
Additional documents:
- Technical documentation of the manufacturer
- Warranty Conditions
- Quality Certificates
