MARTIN® Spring and Air Tensioners

We Make Your Bulk Materials Handling

Cleaner, Safer and More Productive

Through Personalized Performance.

Form No. M3263-01/08

© MARTIN ENGINEERING COMPANY 1993, 2008

One Martin Place

Neponset, IL 61345-9766 USA

800-544-2947 or 309-594-2384

FAX: 309-594-2432 www.martin-eng.com

MARTIN

®

Spring and Air

Tensioners

Go to MARTIN ® Spring and Air Tensioners web page

Operator’s Manual

M3263

Important

MARTIN ENGINEERING HEREBY DISCLAIMS ANY LIABILITY FOR: DAMAGE DUE TO

CONTAMINATION OF THE MATERIAL; USER’S FAILURE TO INSPECT, MAINTAIN AND TAKE

REASONABLE CARE OF THE EQUIPMENT; INJURIES OR DAMAGE RESULTING FROM USE OR

APPLICATION OF THIS PRODUCT CONTRARY TO INSTRUCTIONS AND SPECIFICATIONS

CONTAINED HEREIN. MARTIN ENGINEERING’S LIABILITY SHALL BE LIMITED TO REPAIR

OR REPLACEMENT OF EQUIPMENT SHOWN TO BE DEFECTIVE.

Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources -

Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal

Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule.

The following symbols may be used in this manual:

!

DANGER

Danger: Immediate hazards that will result in severe personal injury or death.

!

WARNING

Warning: Hazards or unsafe practices that could result in personal injury.

!

CAUTION

Caution: Hazards or unsafe practices that could result in product or property damages.

IMPORTANT

Important: Instructions that must be followed to ensure proper installation/operation of equipment.

NOTE

Note: General statements to assist the reader.

Table of Contents

Section Page

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installations without chutework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Belt cleaner inspection access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Before Installing Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing mounting plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installing Air Bag Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installing Air Cylinder Tensioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

After Installing Tensioner and Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Martin Engineering M3263-01/11 i

MARTIN

®

Spring and Air Tensioners

Figure

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

List of Figures

Title Page

Pre-Cleaner Mainframe and Tensioner Location . . . . . . . . . . . . . . . . . . . . . . 4

Secondary Cleaner Mainframe and Tensioner Location. . . . . . . . . . . . . . . . . 5

Installing Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installing Air Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Plant Air Kit Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Cylinder Tensioner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Air Cylinder Tensioner Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . 11

Air Cylinder Schematic (dual tensioners). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shock (Ring) Spring Tensioner Assembly, P/N 38180. . . . . . . . . . . . . . . . . . 18

Shock Mount Air Tensioner Assembly, P/N 32745 . . . . . . . . . . . . . . . . . . . . 19

Air Cylinder Tensioner Assembly, P/N 37843 . . . . . . . . . . . . . . . . . . . . . . . . 20

Air Cylinder Tensioner Control Box Assembly, P/N 36489-2 . . . . . . . . . . . . 21

Conveyor Products Warning Label, P/N 23395 . . . . . . . . . . . . . . . . . . . . . . . 22

Air Bag Warning Label, P/N 32255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pinch Point Warning Label, P/N 30528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Air Pressure Label, P/N 30480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Spring Tensioner Label, P/N 32259 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Air Cylinder Pressure Label, P/N 37844 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Table

I

II

III

List of Tables

Title Page

Spring Tensioner Recommended Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Recommended Pressures for Air Bag Tensioners. . . . . . . . . . . . . . . . . . . . . . 9

Recommended Pressures for Air Cylinder Tensioners . . . . . . . . . . . . . . . . . . 13

Martin Engineering M3263-01/11 ii

MARTIN

®


Introduction

General

The MARTIN

®

Spring and Air Tensioners were designed for use with

MARTIN

®

Belt Cleaning Systems. The Spring Tensioner maintains efficient cleaning with a rugged coil spring, while the Air Tensioner is designed to hook directly to your plant’s air supply.

Installations without chutework

These procedures were written for equipment that is being installed on enclosed pulley chutework. If the pulley is not enclosed, the equipment should be installed using the best available field resources and methods to ensure that the critical dimensions are followed for proper installation.

The MARTIN

®

Hanger Mount Assembly, P/N 27382, can be used for installations without chutework.

Belt cleaner inspection access

If the belt cleaner is installed on enclosed pulley chutework, a MARTIN

®

Inspection Door should be installed. MARTIN

®

Inspection Doors are available from Martin Engineering or a representative. See “Part Numbers” for a list of MARTIN

®

Inspection Doors and part numbers.

References

The following documents are referenced in this manual:

• American National Standards Institute (ANSI) z244.1-1982, American

National Standard for Personnel Protection - Lockout/Tagout of Energy

Sources - Minimum Safety Requirements, American National Standards

Institute Inc., 1430 Broadway, New York, NY 10018.

• Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910,

Control of Hazardous Energy Source (Lockout/Tagout); Final Rule,

Department of Labor, Occupational Safety and Health Administration

(OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street,

Chicago, IL 60604.

• MARTIN

®

Inspection Door Operator’s Manual, P/N M3127.

• MARTIN

®

Chevron Belt Cleaner Operator’s Manual, P/N M3266.

• MARTIN

®

QC

™

#1 Heavy-Duty Belt Cleaners Operator’s Manual,

P/N M3618.

• MARTIN

®

QC

™

#1 Metal-Tipped Belt Cleaners Operator’s Manual:

P/N M3814.

• MARTIN

®

High-Temperature PM Belt Cleaner Operator’s Manual,

P/N M3389.

• HAWG BONE

®

Secondary Belt Cleaner Operator’s Manual, P/N M3619.

Materials required

Only standard hand tools are required to install and service this equipment.

Martin Engineering M3263-01/11 1 MARTIN

®


Safety

All safety rules defined in the above documents and all owner/employer safety rules must be strictly followed when working on the belt cleaner.

!

DANGER

Do not touch or go near the conveyor belt or conveyor accessories when the belt is running. Your body or clothing can get caught and you can be pulled into the conveyor, resulting in severe injury or death.

!

DANGER

Before installing, servicing, or adjusting the belt cleaner, turn off and lock out/tag out all energy sources to the conveyor and conveyor accessories according to ANSI standards. Failure to do so could result in serious injury or death.

!

DANGER

If this equipment will be installed in an enclosed area, test the gas level or dust content before using a cutting torch or welding. Using a torch or welding in an area with gas or dust may cause an explosion resulting in serious injury or death.

!

WARNING

Before using a cutting torch or welding the chute wall, cover the conveyor belt with a fire retardant cover. Failure to do so can allow the belt to catch fire.

!

WARNING

Remove all tools from the installation area and conveyor belt before turning on the conveyor. Failure to do so can cause serious injury to personnel or damage to the belt and conveyor.


®


Before Installing Tensioner

IMPORTANT

The delivery service is responsible for damage occurring in transit. Martin Engineering CANNOT enter claims for damages. Contact your transportation agent for more information.

1. Inspect shipping container for damage. Report damage to delivery service immediately and fill out delivery service’s claim form. Keep any damaged goods subject to examination.

2. Remove Spring or Air Tensioner from shipping container.

3. If anything is missing contact Martin Engineering or a representative.

!

WARNING

Before installing equipment, turn off and lock out/ tag out energy source to conveyor and conveyor accessories.

4. Turn off and lock out/tag out energy source according to ANSI standards

(see “References”).

!

WARNING

If equipment will be installed in an enclosed area, gas level or dust content must be tested before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion.

5. If using a cutting torch or welding, test atmosphere for gas level or dust content. Cover conveyor belt with fire retardant cover.

NOTE

The chute wall that the tensioner will be located on is referred to as the “operator side.” The other side of the chute is referred to as the “far side.” (If installing dual tensioners, side that is most accessible is “operator side.”)

6. Determine which side of chute is easiest to access. Locate the tensioner on the most accessible chute wall.


®


Installing Tensioner

IMPORTANT

Read entire section before beginning work.

To install the tensioner, follow the procedures corresponding to the following steps:

1. Locate center point of belt cleaner mainframe according to appropriate belt cleaner manual (see “References”).

2. Install tensioner mounting plates.

3. Install Spring or Air Tensioner.

Installing mounting plates

NOTE

Tensioner may be bolted or welded to chute wall. Martin

Engineering recommends bolting for ease of maintenance and accessibility.

1. Mark location of holes for belt cleaner mounting plates on chute walls.

Use flange weldment as template. (See Figure 1 for pre-cleaners and

Figure 2 for secondary cleaners.)

X – See belt cleaner operator’s manual.

X

Figure 1. Pre-Cleaner Mainframe and Tensioner Location


®


X – See belt cleaner

operator’s manual.

X

Figure 2. Secondary Cleaner Mainframe and Tensioner Location.

2. Position mounting plate parallel to pulley’s horizontal center line.

3. Bolt or weld mounting plates to chute walls as follows: a. If bolting mounting plates to chute walls, do the following:

(1) Drill or cut one 4-in. (102-mm) hole for mainframe and four

9/16-in. (14-mm) holes for screws in both operator side and far side chute walls. Remove burrs and sharp edges.

(2) Install each mounting plate onto wall with four screws, flat washers, compression washers and nuts (B).

b. If welding mounting plates to chute walls, do the following:

(1) Drill or cut one 4-in. (102-mm) hole for mainframe in both operator side and far side chute walls. Remove burrs and sharp edges.

(2) Position mounting plates over holes and weld onto chute wall.

4. Insert belt cleaner mainframe into mounting plates.


®


D

C

B

A

G

F

B

C

D

K

E

E

H

Installing Spring

Tensioner

J

Figure 3. Installing Spring Tensioner

I

IMPORTANT

If installing pre-cleaner, spring should be pointing in direction of return belt travel. If installing secondary cleaner, spring should be pointing away from direction of return belt.

1. See Figure 3. Install shock rings (C) and nylon bushings (B) over mainframe and into mounting plates (E).

2. Slide paddle arm assembly (I) onto mainframe and rod weldment onto mounting plate pin.

3. Install washer (H) and cotter pin (K).

4. If dual tensioners are required, repeat steps 1 through 3 for far side tensioner.

5. Push blades tight against conveyor belt. Push arm of spring tensioning paddle against spring and tighten three set screws (G).

6. Tension mainframe by adjusting nuts (J) according to Table I or Spring

Tensioner Label. Tighten nuts against each other.

7. Install mounting hub (F) over mainframe on far side using two set screws (A).


®


Table I. Spring Tensioner Recommended Tension

MARTIN ® Spring Tensioners Recommended Tension

Belt width in. (mm)

MARTIN

®

QC

™

#1

Heavy-Duty

HAWG BONE

®

Secondary Cleaner

MARTIN ® QC

™

#1

Metal-Tipped

Spring length † Spring length †

Spring length †

18 (400-500)

24 (500-650)

30 (650-800)

36 (800-1000)

42 (1000-1200)

48 (1200-1400)

54 (1400-1600)

60 (1600-1800)

72 (1800-2000)

84 (2000-2200)

96 (2200-2400)

3.63 (92)

3.50 (90)

3.38 (86)

3.25 (83)

3.13 (79)

3.00 (76)

3.38 (86)*

3.38 (86)*

3.38 (86)

3.25 (83)

3.00 (76)

3.00 (76)

2.88 (73)

2.75 (70)

3.38 (86)*

3.25 (83)*

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)*

3.85 (98)*

3.25 (83)*

3.13 (79)*

3.00 (76)*

3.00 (76)*

3.00 (76)*

2.75 (70)*

3.85 (98)*

3.85 (98)*

3.85 (98)*

*Per tensioner. Dual tensioners required.

800-544-2947 or 309-852-2384 www.martin-eng.com

† Compressed

Place label on chute wall, visible to tensioner user.

Label P/N 32259


®


L

K

A

B

J

E

D

C

C

D

F

G

H

Figure 4. Installing Air Tensioner

Installing Air Bag

Tensioner

1. Install shock rings (C) and nylon bushings (D) over mainframe and into mounting plates (A). Install shock ring spacer (E) into mounting plate on operator side tensioner.

2. Slide tensioning paddle (F) onto operator side mainframe.

3. Install screws and washers (G) through mounting plate and into air bag (H).

4. Install three square head set screws (J) on tensioning paddle but do not tighten.

5. Turn mainframe so blades are 1/16 in. (2 mm) from conveyor belt.

6. Compress air bag and tighten three square head set screws to 75 ft-lb

(102 N-m).

7. If dual tensioners are required, repeat steps 1 through 6 for far side tensioner.

8. Install hub (K) on mainframe on far side of chute and tighten square head set screws (L).


®


A.

B.

Shut-off valve

Air regulator

D

C

To tensioner

C.

D.

Female tee

Hose

B

A

Plant air

Figure 5. Plant Air Kit Detail

9. Connect air supply. See Figure 5.

a. Secure shut-off valve (A), air regulator (B), and female tee (C) to chute wall.

b. Run hose (D) from female tee to air bag, and air lines from plant air supply (50 psi [3.45 bar] minimum) to shut-off valve on assembly.

c. Apply air to air bag according to Table II or Air Pressure Label,

P/N 30480.

Table II. Recommended Pressures for Air Bag Tensioners

Recommended Air Pressure for MARTIN

®

Tensioners

Belt Width in. (mm)

18 (400-500)

24 (500-650)

MARTIN

®

QC

™

#1

Heavy-Duty Pre-Cleaner psi (bar)

30 (650-800) 12 (0.83)

36 (800-1000) 14 (0.97)

42 (1000-1200)

48 (1200-1400)

54 (1400-1600)

60 (1600-1800)

72 (1800-2000)

84 (2000-2200)

6 (0.41)

9 (0.62)

17

20

12*

13*

(1.17)

(1.38)

(0.83)*

(0.90)*

16* (1.10)*

18* (1.24)*

96 (2200-2400) 21* (1.45)*

*Per Tensioner. Dual tensioners required.

HAWG BONE

7 (0.48)

11 (0.76)

14 (0.97)

18 (1.24)

21 (1.45)

24 (1.65)

14* (0.97)*

16* (1.10)*

19* (1.31)*

23* (1.59)*

26* (1.79)*

®

Secondary Cleaner psi (bar)



Label P/N 30480


®


B

A

E

J

K

D

Installing

Air Cylinder

Tensioner

Assembly

C

H

Figure 6. Air Cylinder Tensioner Installation

F

G

1. Slide force arm weldment (C) onto operator side mainframe end weldment (D). Tighten set screws (A) to fasten onto mainframe end weldment.

2. Slide force arm weldment tight against shock bushing (B) to retract end weldment. Tighten square head set screws on telescoping mainframe weldment.

3. Remove cotter pin (F) and clevis pin (G) from force arm.

4. Place air cylinder (H) on force arm and fasten with clevis pin (G) and cotter pin (F).

5. Place mount bracket (E) on air cylinder and fasten with clevis pin (K) and cotter pin (J).


®


3.50

(89)

5.00

(127)

J

K

E

M

H

L

90°

13.13 (333)

1.00 (25) min.

3.00 (76) max.

C

Figure 7. Air Cylinder Tensioner Mounting Dimensions

6. Make sure the distance between the mainframe vertical center line and the force arm clevis pin vertical center line is between 1 and 3 in. (25 and

76 mm) as shown in Figure 7.

7. Push force arm (C) toward air cylinder (H) until sewn rod boot (L) retracts and the distance between the clevis pins on the cylinder measures

13-1/8 in. (333 mm).

8. Mark location of cylinder mount bracket (E) holes on chute wall.

9. Remove clevis pin (K) and cotter pin (J). Remove mount bracket.

NOTE

For easier maintenance, Martin Engineering recommends bolting rather than welding mount bracket to chute wall.

10. Bolt or weld cylinder mount bracket to chute wall as follows: a. If bolting mount bracket to chute wall, do the following:

(1) Drill or cut four 9/16-in. holes in operator side chute wall.

Remove burrs and sharp edges.

(2) Install mount bracket on chute wall with four hex head cap screws, flat washers, compression washers, and hex nuts (M).

b. If welding mount bracket to chute wall, do the following:

(1) Position mount bracket on chute wall so that four mounting holes line up with four holes marked on chute wall.

(2) Weld mount bracket onto chute wall. Skip weld around entire mount bracket surface contacting chute wall.

11. Install air cylinder onto mount bracket and fasten with clevis pin and cotter pin.


®


B

A C

D

E

1 4

3 2

F

G

A.

B.

C.

D.

1/2-in. NPTL air line

Filtered plant air

(100 psi [7 bar] min.)

Lockout valve

Check valve

E.

F.

Pressure regulator

3-way valve

G.

Air cylinders

Ports 1 - 4

Figure 8. Air Cylinder Schematic (dual tensioners)

!

CAUTION

Do not use nitrogen in Air Tensioner. Nitrogen can dry out rubber seals and damage tensioner. Use only filtered air.

12. Install air line to Air Tensioner as shown in Figure 8.

IMPORTANT

If dual Air Tensioners are used, make sure you install air line into same port location on far side cylinder as on operator side cylinder.

a. Install air line from port 1 on 3-way valve into one of two ports on air cylinder (G). If dual Air Tensioners are used, run air line through mainframe to far side air cylinder.

b. Install air line from port 2 on 3-way valve into unused port on air cylinder. If dual Air Tensioners are used, run air line through mainframe to far side air cylinder.

!

CAUTION

Do not apply pressures greater than those recommended in

Table III. Higher pressures can damage conveyor belt or cleaner, and blades will wear faster.

13. Apply air pressure to Air Tensioner(s) as recommended in Table III or Air

Cylinder Tensioner Label, P/N 37844.


®


Table III. Recommended Pressures for Air Cylinder Tensioner


®

Air Cylinder Tensioner

Belt MARTIN ® QC™ #1 Heavy-Duty HAWG BONE ® Heavy-Duty in. (mm) psi (bar) psi (bar)

18 (400-500) 8 (0.55) 9 (0.62)

24 (500-650)

30 (650-800)

36 (800-1000)

42 (1000-1200)

48 (1200-1400)

12 (0.83)

16 (1.10)

20 (1.37)

24 (1.65)

28 (1.93)

13 (0.89)

18 (1.24)

22 (1.51)

27 (1.86)

31 (2.14)

54 (1400-1600)*

60 (1600-1800)*

72 (1800-2000)*

84 (2000-2200)*

96 (2200-2400)*

16 (1.10)*

18 (1.24)*

22 (1.51)*

26 (1.79)*

30 (2.06)*

* Dual tensioners required. Pressure per side.

18 (1.24)*

20 (1.37)*

25 (1.72)*

29 (2.00)*

33 (2.28)*

Label P/N 37844

www.martin-eng.com

800-544-2947 or 309-852-2384


®


After Installing Tensioner and Belt Cleaner

Martin Engineering M3263-01/11

1. Thoroughly wipe chute wall clean above tensioner.

2. Place Conveyor Products Warning Label (P/N 23395) on outside chute wall visible to belt cleaner operator.

!

WARNING

Failure to remove tools from installation area and conveyor belt before turning on energy source can cause serious injury to personnel and damage to belt.

!

DANGER

Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death.

3. Turn on conveyor belt for 1 hour, then turn off.

!

DANGER

Before installing, servicing, or adjusting the belt cleaner/ tensioner, turn off and lock out/tag out all energy sources to the conveyor and conveyor accessories according to ANSI standards. Failure to do so could result in serious injury or death.

4. Make sure all fasteners are tight. Tighten if necessary.

5. Make sure cleaner is not changing belt line. If it is, install belt support ahead of blade-to-belt contact point (Secondary Cleaner).

6. Inspect belt cleaner for the following:

• Wear. (A small amount of “break-in” wear may be found. This will stop once blades wear to conveyor belt contour.)

• Material buildup. (No material between blades and return side of conveyor belt should be found.)

7. If wear, material buildup, or some other problem exists, see

“Troubleshooting.”

14 MARTIN

®


Weekly Maintenance

!

WARNING

Lock out/tag out all energy sources before beginning any work on conveyor or conveyor accessories.

1. Turn off and lock out/tag out energy source according to ANSI standards

(see “References”).

2. For Spring Tensioners, do the following:

IMPORTANT

If blades are not cleaning effectively or approximately half of blade life has been used, tension will decrease and must be re-applied.

a. If blades are worn or are not cleaning effectively, release any remaining tension and re-tension according to Table I. b. Spray threaded rod with rust-inhibiting lubricant.

c. Check spring for buildup under cover. Clean if necessary.

3. For Air Tensioners, do the following: a. Check air gauge and ensure tension against conveyor belt is correct

(see Table II or Table III).

b. Check air bag and fittings for leaks. Replace as follows:

(1) Shut off air to tensioner.

(2) Release pressure on bag by opening relief valve.

(3) Disconnect hose from bag.

(4) Remove four hex head cap screws and washers from each side of leaking bag. Discard leaking bag.

(5) Install new bag with four hex head cap screws and washers.

(6) Reconnect hose and close relief valve.

(7) Turn on air pressure and reset tension according to Table II.


®


Troubleshooting

Symptom

Insufficient cleaning and carryback.

Corrective Action

• Tension of cleaner on belt is set too low or too high. Increase or decrease tensioner setting.

• Blades are worn. Check blades and replace if necessary.

Noise or vibration.

High blade wear rate.

Tension is not sufficient or is set too high. Correct tension as necessary. If this does not correct problem, blade urethane may not match application. Contact Martin Engineering or representative.

Tension of cleaner on belt is set too high. Reduce tensioner setting.

Unusual wear or damage to blades.

Check belt splice(s) and repair as necessary.

Bent or broken mainframe or support frame due to blade slipping through.

Corrosion or chemical degradation.

If blades are worn to or past the wear line, replace blades. If blades are not worn, check mainframe location.

Blade urethane may not match application. Contact Martin

Engineering or representative.

NOTE

Conveyor equipment such as conveyor belt cleaners are subject to a wide variety of bulk materials characteristics and often have to perform under extreme operating or environmental conditions. It is not possible to predict all circumstances that may require troubleshooting. Contact Martin

Engineering or a representative if you are experiencing problems other than those listed in the

“Troubleshooting” chart above. Do not return the equipment to operation until the problem has been identified and corrected.

Installation checklist

If after taking the corrective actions suggested under “Troubleshooting” you are still experiencing problems, check for the following:

Installation Checklist

✓ Pre-Cleaner mainframe is proper distance from belt surface on both ends of mainframe.

✓ Pre-Cleaner blade tip is at or below horizontal center line of pulley and does not lie in path of material flow.

✓ Secondary Cleaner blade tip is 1 in. (25 mm) past vertical center line of pulley.

✓ Secondary Cleaner is not changing belt line.

✓ Blades are centered on belt.


®


Part Numbers

This section provides product names and corresponding part numbers for the

Spring and Air Tensioners and related equipment. Please reference part numbers when ordering parts.

IMPORTANT

Use only MARTIN

®

replacement springs or Spring Tensioner will not work.

Spring Tensioner

Assemblies

Belts 18 to 48 in. (400 to 1400 mm) wide:

Shock (Ring) Mount Spring Tensioner Assembly: P/N 38180


Dual Shock (Ring) Mount Spring Tensioner Assembly: P/N 38180-2

Air Bag Tensioner

Assemblies


Shock Mount Air Tensioner Assembly: P/N 32745.


Dual Shock Mount Air Tensioner Assembly: P/N 32745-2R.

Air Cylinder

Tensioner

Assemblies

Single Air Tensioner Assembly: P/N 37843-1

Dual Air Cylinder Tensioner Assembly: 37843-2

Air Tensioner Control Box Assembly: P/N 36489-2

Optional mounts

Flange Mount Bracket: P/N 30537. Use to mount Spring or Air Tensioner on chute wall with MARTIN

®

Inspection Door.

Hanger Mount Assembly: P/N 27382. Use to mount Spring or Air Tensioner on stringer instead of on chute wall.

Operator’s manuals

MARTIN

®

Inspection Door Operator’s Manual: P/N M3127.

MARTIN

®

Chevron Belt Cleaner Operator’s Manual: P/N M3266.

MARTIN

®

QC

™

#1 Heavy-Duty Belt Cleaners Operator’s Manual:

P/N M3618.

MARTIN

®

QC

™

#1 Metal-Tipped Belt Cleaners Operator’s Manual:

P/N M3814.

MARTIN

®

High-Temperature PM Belt Cleaner Operator’s Manual:

P/N M3389.

HAWG BONE

®

Secondary Belt Cleaner Operator’s Manual:

P/N M3619.

Miscellaneous


Plant Air Kit with Gauge for Single Air Tensioner: P/N 31772-AS.

Plant Air Kit with Gauges for Single Primary and Secondary Air

Tensioners: P/N 31772-A.

17 MARTIN

®


13

3

12

2

14

7

1

11

6

10

8

9

5

4

Item Description Part No.

Qty

P/N 38180*

Qty

P/N 38180-2*

9

9

10

11

12

13

14

Fig. 13

7

8

5

6

3

4

1

2

Fig. 15

Fig. 17

NS

Spring Tensioner Mount Plate Weldment

Shock Ring

Nylon Bushing

Spring Tensioner Paddle Arm

Rod Weldment with SS Rod

Washer Flat 1 ZP

Hairpin Cotter .18 Dia x 3.56 ZP

Washer Flat 3/4 Wide ZP

Spring Medium Duty Green

Spring Medium-Heavy Duty Blue

Nut Hex 3/4-6 ACME ZP

Flange Plate Weldment

Mounting Hub

Screw SHS 1/2-13NC x 1 SS

Mounting Hardware Kit

Label Conveyor Products Warning

Label Pinch Point Warning

Label Spring Tensioner

Operator’s Manual

38179

32501

33335

30588-ST

38176

32315

35171

20164

32244-M

32244-MH

38170

32496

16845

22763-03

34498

23395

30528

32259

M3263

1

2

1

5

2

2

1

1

1

1

1

1

2

1

1

2

1

1

2

Figure 9. Shock (Ring) Spring Tensioner Assembly, P/N 38180

*Part number 38180 is a single spring tensioner assembly for belts 48 in. and below. Part number 38180-2 is a dual spring tensioner assembly for belts 54 in. and above.

—

6

1

2

2

2

4

—

2

2

1

2

4

2

2

2

2

2

2

NS = Not Shown


®


1

2

3

4

5

6

7

8

9

10

12

13

14

15

11

Item


Description

19

Part No.

Qty

P/N 32745*

Qty

P/N 32745-2R*

7

8

5

6

3

4

1

2

Air Paddle

Screw SHS 1/2 -13 NC x 1

Shock Ring Spacer

Nylon Bushing

Shock Ring

Screw HHC 1/2 -13 NC x 2.00 ZP

Washer Flat 9/16 ZP

Washer Compression 1/2 ZP

9

10

11

12

Nut Hex 1/2 -13 ZP

Far Side Flange Plate Weldment

Tensioner Locking Collar

Tensioner Flange Plate Weldment

13

14

Screw HHC 3/8 -16 x 1-1/4 GR 5 ZP

Washer Flat 3/8 ZP

15 Air Actuator/Isolator 1/4 NPT

Fig. 13 Label Conveyor Products Warning

Fig. 14 Label Air Bag Warning

Fig. 15 Label Pinch Point Warning

Fig. 16 Label Air Pressure

NS Operator’s Manual

1

1

4

4

1

1

8

1

1

1

1

1

8

8

2

8

1

2

1

5

11771

32496

16845

32521

12215

18007

30587

23395

30588

22763-03

33346

33335

32501

14196

17328

11750

32255

30528

30480

M3263

Figure 10. Shock Mount Air Tensioner Assembly, P/N 32745

*Part number 32745 is a single air tensioner assembly for belts 48 in. and below. Part number 32745-2R is a dual air tensioner assembly for belts 54 in. and above.

NS = Not Shown

2

2

8

8

8

—

—

2

2

1

2

2

8

8

2

8

2

2

2

6

MARTIN

®


4

1

3

13

2

12

11

5

6

9

8

10

7

Item

9

10

11

12

13

Fig. 13

NS

Fig. 18

NS

NS

7

8

5

6

3

4

1

2

Description Part No.

Flange Plate Weldment

Shock Ring

Nylon Bushing

Mount Weldment Rear Cylinder

Force Arm Weldment

Air Cylinder

Cylinder Rod Clevis with Pin

Rod Boot

32496

32501

33335

37840

37842

37835

37836

37837

Hose Clamp

Hose Clamp

Locking Collar

Screw SHS 1/2-13NC x 1 SS

20339-06

20339-03

16845

22763-03

Mounting Hardware Kit

Label Conveyor Products Warning

34845

23395

Label MARTIN Products 32238

Label Tensioner Recommended Air Pressure 37844

Label Air Pressure Warning

Operator’s Manual

37845

M3263

Figure 11. Air Cylinder Tensioner Assembly, P/N 37843*

*Part number 37843-S is a single air cylinder tensioner assembly.

*Part number 37843-D is a dual air cylinder tensioner assembly.

NS = Not Shown

Qty

P/N 37843-S*

2

1

1

2

1

1

1

4

1

1

1

1

1

1

2

1

2

2

Qty

P/N 37843-D*

2

2

1

2

2

2

—

4

1

1

2

2

2

2

2

2

2

2


®


1

3

9

11

4,5

14

16

2

12

10

13

15

6,7,8

Item

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

NS

NS

NS

NS

NS

NS

NS

NS

Description

Enclosure

Pressure Gauge

Screw PHP #8 x 5/8 SS

Washer Lock 1/2 ZP

Female Bulkhead 1/4 NPT

Flat Washer 5/16 Narrow ZP

Screw HHC 5/16-18NC x 1 ZP

Nut Hex Elastic Lock 5/16-18NC SS

Pressure Regulator

Male Swivel Elbow 1/4 NPT

Male Microlock Connector 1/4 NPT

Male Elbow 1/4 NPT

Union Y Male Connector 1/4

Nipple 1/4 NPT x 1-1/2

Ball Valve 1/4 NPT

Street Elbow 1/4 NPT

Label Air Pressure

Label MARTIN Products

Plastic Tie Cable

Plastic Tie Mount

Inlet Label

Outlet Label

Polyurethane Tubing 1/4

Operator’s Manual

Part No.

37189

37248

37187

37192

37188

37190

32284

37191

30897-06

37195

36372

30228

37186

17083

32583

33054

30480

32238-01

30916

30918

37253-A

37253-B

100791

M3263

Qty

2

1

1

1

1

1

2

2

4

4

3

8

6

3

1

2

1

2

5 ft

1

2

1

1

1

Figure 12. Air Tensioner Control Box Assembly, P/N 36489-2

NS = Not Shown


®


!

!

ADVERTENCIA

WARNING

Lock out and/or tag out all energy sources to conveyor system and loading system before performing any work on conveyor or conveyor accessories. Failure to do so could result in severe injury or death.

Cierre y/o rotule todas las fuentes de energía al sistema transportador y al sistema de carga antes de realizar cualquier trabajo en el transportador o sus accesorios. El no hacerlo puede resultar en heridas serias o muerte.

Label P/N 23395

Figure 13. Conveyor Products

Warning Label, P/N 23395

!

!

!

ADVERTENCIA

WARNING

!

!

ADVERTENCIA

WARNING

Do not apply over 100 psi (6.9 bar) to tensioning components. Air bag can explode and cause severe injury.

No infle el cojin a más de 6.9 bar

(100 psi). Los cojines pueden explotar y causar daños severos.

Label P/N 32255

Figure 14. Air Bag Warning Label, P/N 32255

Pinch point!

¡Usted se puede pellizcar!

Label P/N 30528

Figure 15. Pinch Point Warning

Label, P/N 30528


®



®

Tensioners

Belt Width in. (mm)

MARTIN ® QC

™

#1

Heavy-Duty Pre-Cleaner psi (bar)

18 (400-500)

24 (500-650) 9 (0.62)

30 (650-800) 12 (0.83)

36 (800-1000)

42 (1000-1200)

48 (1200-1400)

54 (1400-1600)

60 (1600-1800)

72 (1800-2000)

84 (2000-2200)

96 (2200-2400)

6 (0.41)

14

17

20

(0.97)

(1.17)

(1.38)

12* (0.83)*

13* (0.90)*

16* (1.10)*

18* (1.24)*

21* (1.45)*

*Per Tensioner. Dual tensioners required.

HAWG BONE

7 (0.48)

11 (0.76)

14 (0.97)

18 (1.24)

21 (1.45)

24 (1.65)

14* (0.97)*

16* (1.10)*

19* (1.31)*

23* (1.59)*

26* (1.79)*

®

Secondary Cleaner psi (bar)



Label P/N 30480

Figure 16. Air Bag Pressure Label, P/N 30480

18 (400-500)

24 (500-650)

30 (650-800)

36 (800-1000)

42 (1000-1200)

48 (1200-1400)

54 (1400-1600)

60 (1600-1800)

72 (1800-2000)

84 (2000-2200)

96 (2200-2400)

MARTIN

®

Spring Tensioners Recommended Tension

Belt width in. (mm)

MARTIN ® QC

™

#1

Heavy-Duty

HAWG BONE

®

Secondary Cleaner

Spring length † Spring length †

MARTIN

®

QC

™

#1

Metal-Tipped

Spring length †

3.63 (92)

3.50 (90)

3.38 (86)

3.25 (83)

3.13 (79)

3.00 (76)

3.38 (86)*

3.38 (86)*

3.25 (83)*

3.13 (79)*

3.00 (76)*

3.38 (86)

3.25 (83)

3.00 (76)

3.00 (76)

2.88 (73)

2.75 (70)

3.38 (86)*

3.25 (83)*

3.00 (76)*

3.00 (76)*

2.75 (70)*

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)

3.85 (98)*

3.85 (98)*

3.85 (98)*

3.85 (98)*

3.85 (98)*

*Per tensioner. Dual tensioners required.


† Compressed


Label P/N 32259

Figure 17. Spring Tensioner Label, P/N 32259


®



®

Air Cylinder Tensioner

Belt MARTIN

®

QC™ #1 Heavy-Duty HAWG BONE

®

Heavy-Duty in. (mm) psi (bar) psi (bar)

18 (400-500) 8 (0.55) 9 (0.62)

24 (500-650)

30 (650-800)

36 (800-1000)

42 (1000-1200)

48 (1200-1400)

12 (0.83)

16 (1.10)

20 (1.37)

24 (1.65)

28 (1.93)

13 (0.89)

18 (1.24)

22 (1.51)

27 (1.86)

31 (2.14)

54 (1400-1600)*

60 (1600-1800)*

72 (1800-2000)*

84 (2000-2200)*

96 (2200-2400)*

16 (1.10)*

18 (1.24)*

22 (1.51)*

26 (1.79)*

30 (2.06)*

* Dual tensioners required. Pressure per side.

18 (1.24)*

20 (1.37)*

25 (1.72)*

29 (2.00)*

33 (2.28)*

Label P/N 37844

www.martin-eng.com

800-544-2947 or 309-852-2384

Figure 18. Air Cylinder Pressure Label, P/N 37844


®


Any product, process, or technology described here may be the subject of intellectual property rights reserved by

Martin Engineering Company. Trademarks or service marks designated with the ® symbol are registered with the U.S.

Patent and Trademark Office and may be proprietary in one or more countries or regions. Other trademarks and service marks belonging to Martin Engineering Company in the United States and/or other countries or regions may be designated with the “TM” and “SM” symbols. Brands, trademarks, and names of other parties, who may or may not be affiliated with, connected to, or endorsed by Martin Engineering Company, are identified wherever possible.

Additional information regarding Martin Engineering Company’s intellectual property can be obtained at

www.martin-eng.com/trademarks.

We Make Your Bulk Materials Handling

Cleaner, Safer and More Productive

Through Personalized Performance.

Form No. M3263-01/11

© 1993, 2011 MARTIN ENGINEERING COMPANY. All rights reserved.

One Martin Place

Neponset, IL 61345-9766 USA

800-544-2947 or 309-852-2384

FAX: 800-814-1553 www.martin-eng.com

MARTIN

®

Spring and Air

Tensioners

Operator’s Manual

M3263

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