C 106 Components Handbook

Moxie® Rolls

Table of Contents

010507080910111315161718

Conveyor IdlersCEMA Rated IdlersMoxie® Rolls81/91 Series Regreasable Idlers40 Series IdlersCB504 IdlersSelf Aligning IdlersNavigator® Return TrainersUrathon® Return RollsRubber Disc ReturnsRubber Lagged ReturnsBeater Bar ReturnsV-Return Rolls

Belt Scrapers/CleanersExterra® Primary Belt CleanerExterra® SFL Dual Belt Cleaner

Conveyor PulleysConveyor PulleysChevron® Wing PulleysCore SystemsTM Designs

Conveyor AccessoriesReturn Roll GuardsGuard Panels Sealing SystemImpact BedConveyor Take-UpsBelt ScaleSonicscoutTM Material SensorSentinelTM Belt Speed SensorSuperior Auto Greaser

Digital LiteratureForward to Colleague

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232729

3334 35 3739 41434446

Core SystemsTM Dual Drive

01

SpinGuard® Seal Technology: (Fig 1.1)u Contact seal prevents foreign material from entering seal cavityu Grease-filled triple labyrinth seal shuts out contaminantsu Stationary external seal prevents material pinch points

Quick Reactionu Distributors stocked with standard productsu One to two day turnarounds on custom designs

High Quality Constructionu Thick or thicker steel construction compared to other brandsu Two year complete components warrantyu Largest, broadest range of all CEMA categories on the market

Economical Retrofit Rollsu Slotted shafts fit most competitor framesu Hex nut adapter available for hex nut style brackets

No Maintenance Base Frameu Angled base sheds materialu Flared, non-clogging center standsu No material pinch points between roll and frame


CEMA Rated Idlers

Frequently Asked Questions

Which CEMA class do I need?u According to CEMA, the main influences in selection are belt weight, material weight, load rating, belt sag, idler life, belt rating and belt tension. It’s a confusing combination of data that we’ve tried to simplify with our Idler Selector Calculator. Find it in the “Quick Links” section at superior-ind.com.

Which roll diameter do I need?u The rule of thumb considers belt speed. At 400 FPM consider a 4” idler, 500 FPM is 5”, 600 FPM is 6” and so on. It’s also a fact that larger diameter rolls have longer lives due to fewer revolutions and thicker shells.

Where can I buy Superior Idlers?u We have distribution partners with inventory throughout North America and Central America. For local service and fast deliveries, see our partners at superior-ind.com/distributor.

Quick Specs

u Classes: CEMA B, C, D, E, and Fu Roll Diameter: 4”- 8”u Belt Widths: 18”- 120”

Features and Benefits

Idler SpecificationsSpecs Bearing Size Diameter Thickness Belt Width

CEMA B 17 mm 4”, 5” 11, 9 Ga 18”- 48”

CEMA C 20 mm 4”, 5”, 6” 11, 9, 7 Ga 18”- 60”

CEMA D 25 mm 5”, 6” 9, 7 Ga 24”- 72”

CEMA E 40 mm 6”, 7” 1/4” 36”- 96”

CEMA F 50 mm 7”, 8” 1/2” or 3/4” 42”- 120”

CEMA Rated IdlersThe Broadest Range of Conveyor Idlers on the Market

02

2

3

1

4

65

SpinGuard Seal Technology

Idler Features

2

3

1

4

6

5

Flat SurfaceMaterial will not build up across the flat end disc surface

Stationary External Seal Stationary external seal helps prevent material pinch points between the frame and the end of the roller

Centrifugal Force ChamberCentrifugal force creates a self-cleaning flinger effect, keeping water and dirt out

Contact SealFirst defense against contaminants is the contact seal, which creates less drag than a rubber seal

Triple Labyrinth SealSecond defense is the triple labyrinth seal which makes contaminants travel a longer distanceu The labyrinth is also grease filled to keep contaminants away from the ball bearingu The durable seal material is more durable and is less susceptible to corrosion

Ball BearingFactory sealed metric ball bearing on all CEMA rated idlers

2

3

1

4

6

5

Base PlateOpen end stand design gives better access for single or double bolt hole mounting

No Pinch Points No pinch points between roll and frame means no fugitivematerial jamming

Locking MechanismIntegrated locking tab or retainer clip holds roll tight to the frame and offers easy roll change out

Narrow Roll GapNo pinch point that leads to belt damage

Center StandsNon-clogging

Base AngleSheds material, preventing build-up

Producer PerspectiveFig 1.1 SpinGuard Seal Cutaway

23

1

4

6 5

03

CEMA Rating or Seriesu Specify either CEMA B, C, D, E, or F

Roll Diameteru Specify either 4, 5, 6, 7 or 8 for the roll size diameter

Troughing Angleu Specify either 20, 35, or 45 for the troughing angle

Idler Typeu Specify the idler identification letter for the particular idler, you may need from the chart to the right

Belt Widthu Specify the belt width

B, C, D, E, F 4” - 8” 20˚, 35˚, 45˚ 18” - 120”See Below

Producer PerspectiveFugitive Material“ In the beginning, our plant was stocked by another brand and some of them were lasting just three months! We run a lot of wet sand and they weren’t making the cut. ”

Seal Power“ With other brands, the problems were directly related to bearing failure. Sand was getting through the seals and into the can. I read about Superior’s seal in magazines and now I’m witnessing it! ”

Competitive Comparison“ Comparing brand to brand, we get three – sometimes four – times the life with Superior Idlers. They definitely fit the bill! ”

Plant Superintendent at Eastern Colorado Aggregates, La Junta, CO

E Troughing Idler Equal Length RollsEI Rubber Cushion Troughing IdlerEA Self-AlignerBA Bi-Directional Aligning IdlerRET Return IdlerFLT Flat Carrier IdlerFLTI Flat Carrier Rubber Cushion IdlerRETI Return Rubber Cushion IdlerRETU Urathon® ReturnRETUSP Spiral Urathon® Return RollRETA Return Self-Aligning Idler RollRETAI Return Self-Aligning Rubber Cushion IdlerRETV V-Return IdlerP Picking Idler Length RollsU Troughing Idler Unequal Length RollsCM Low-Profile Channel Mount IdlerCMI Channel Mount Impact Low Profile IdlerSM Low-Profile Standard Mount IdlerSMI Standard Mount Impact Low Profile IdlerGO Offset Troughing IdlerEW Wire Rope IdlerVPE Variable Pitch IdlerMOX Moxie® RollCB CB504 SeriesLS Live ShaftLSB Live Shaft Beater

BeltWidth

IdlerType

RollDiameter

CEMARating

TroughingAngle

Idler Type2

3

1

4

5

Part Number GuideExample: C6-35E-36

2 31 4 5

04

Idler Styles

1-800-321-1558Find local distribution at superior-ind.com/distributor© 2012 Superior Industries CL-101

CUSTOMER CARE PLANEXCLUSIVE PATENT

PATENTED TECHNOLOGY

Idler Styles

Equal Troughing Moxie® Rolls

Wire Rope

CB504 Series Feeder/Picking

Channel Mount Low Profile Impact Offset Center Roll Variable Pinch

V-Return Self-Aligner

Unequal Troughing

Self-Aligning Return Beater Bar ReturnLive Shaft Rollers

Rubber Cushion Flat Carrier Return Rubber Disc Return Urathon® Return Roll

Spiral Urathon Return Roll Garland

Flat Carrier Idler

Products Available in CEMA Rated IdlersIdler Style CEMA B CEMA C CEMA D CEMA E CEMA F

Equal Troughing x x x x x

Moxie® Rolls – x x – –

Unequal Troughing – x x x x

Feeder/Picking – x x x x

Channel Mount Low Profile x x x – –

Impact x x x x x

Offset Center Roll x x – – –

Wire Rope – x x – –

Variable Pitch – x x x –

V-Return – x x x –

Self-Aligner x x x x x

Self-Aligning Return x x x x –

Live Shaft Return – x x – –

Beater Bar – x x – –

Flat-Carrier x x x x x

Rubber Cushion Flat Carrier x x x x –

Steel Return x x x x x

Rubber Lagged Return – x x – –

Rubber Disc Return x x x x –

Urathon® Return Roll x x x x –

Spiral Urathon® Return Roll – x x x –

Garland Return – x – – –

05

Moxie® RollsEnergy Efficient Idlers Consume Less Power than Steel


Moxie Rolls


What are Moxie rolls made from?u There’s a combination of materials that go into the recipe to develop our specially formulated Moxie rolls.

How thick is the idler shell?u Compared to the rest of the market, we offer the thickest shell. Our 6” diameter rolls are equipped with a 1” thick shell while our 5” rolls are 1/2” thick.

How is the roller easier on my crews?u Weighing in at more than 40% lighter than their steel equivalents, Moxie rolls are much lighter on the backs and bones of your maintenance crews. Easier mounting helps prevent back injuries, especially in applications with suspended belts, difficult to access rollers and long conveyors.

Quick Specs

u Classes: CEMA C and Du Roll Diameters: 5” and 6”u Belt Widths: 18” - 72”


Fig 2.1 No More Corroded Idler Rolls

40

30

20

10

44% 21% 44% 23%

C5-36 C6-36 D5-36 D6-36

We

igh

t (l

bs)

Moxie

Steel

Fig 2.2 Weight Comparison

Sheds Sticky Materialu Standard Steel: Wet, sticky material tends to cake onto steel cansu Moxie Rolls: The lubricity of Moxie rolls sheds sticky materialu Standard Steel: Material bonded to idlers is a chief source of misaligned beltsu Moxie Rolls: Reduced misalignment and tracking issues Video Proof: http://superior-ind.com/components/idlers/moxie

Corrosion Resistantu Standard Steel: In corrosive environments, steel can rust (Fig 2.1)u Moxie Rolls: The specially designed formula is rust resistantu Note: Upgrade to stainless steel shafts and frames

Safetyu Standard Steel: The more weight, the more power requirementsu Moxie Rolls: Low roll resistance cuts horsepower requirementsu Standard Steel: Heavy rollers can be ergonomically unhealthyu Moxie Rolls: The lightweight rollers weigh up to 44% less (Fig 2.2)

Reduced Noiseu Standard Steel: Steel generates a “clanking” sound when it contacts belt fastenersu Moxie Rolls: 3x quieter than steel, Moxie rolls provide noise control in residential zones

06



PATENTED TECHNOLOGY

SpinGuard® Seal Technology

Producer PerspectiveMoxie Roll Cutaway

23

1

4

6 5

2

3

1

4

6

5

Flat Surface: Material will not build up across the flat surface

Recessed/Stationary External Seal: Stationary external seal helps prevent material pinch points between the frame and the end of the roller

Centrifugal Force Chamber:Centrifugal force creates a self-cleaning flinger effect, keeping water and dirt out

Contact Seal:First defense against contaminants is the contact seal which creates less drag than a rubber seal

Triple Labyrinth Seal:Second defense is the triple labyrinth seal which makes contaminants travel a longer distanceu The labyrinth is also grease filled to keep contaminants away from the ball bearingu The glass filled polypropylene seal material is more durable and is less susceptible to corrosion

Ball Bearing:Factory sealed metric ball bearing on all CEMA rated idlers

C or D 5” or 6” 20˚, 35˚, 45˚ MOX18”- 72”

Producer PerspectivePizza Cutter“ If we didn’t catch a worn steel roll in time, the sharp points would catch the clips, tear them apart and cause a rip all the way down the belt. That is an expensive problem! ”

Belt Stress“ Belts aren’t all that easy to come by, so the operation would easily be down a day or more when there was a big tear. That is a problem at our operations with round-the-clock load-outs. ”

Energy Efficiency“ The decision to switch to Moxie rolls alone is one of the biggest keys to our current efficiency at the new wash plant. ”

Plant Manger at Seven Points Sand and Gravel, Enis, Texas

IdlerType

BeltWidth

RollDiameter

CEMARating

TroughingAngle

Part Number GuideExample: C5-35E-36MOX

* For return Moxie rolls, substitute roll diameter and troughing angle with “RET.”

07

81/91 Series Regreasable IdlersRegreasable Idlers Stop Invading Water Damage


CUSTOMER CARE PLAN

Heavy Duty Rollersu 9 gauge on 5”u 7 gauge on 6”u As thick or thickest steel in the industry

Regreasable Idlersu One side grease reliefu Grease-filled single point lubricationu Inner grease seal prevents grease from escaping into roll cavity

Bearing Protectionu Delrin triple labyrinth sealu External deflector seal keeps material awayu Tapered roll bearings


Fig 3.1 Idler Seal Cutaway


Quick Specs

u Classes: CEMA C and Du Roll Diameters: 4" - 6”u Belt Widths: 18” - 72”

2

31


What are common applications?u If you have problems keeping water or slurry out of your idler bearings, regreasable idlers are an alternative. Because you are always purging the bearing with grease, water isn’t able to do as much damage.

How often do you regrease?u It is totally dependent on your application and so no one answer is accurate. If you can blame idler failures on water or slurry damage, regrease more often. It could be as often as every day.

How do tapered compare to ball bearings?u As ball bearing technology has improved and the cost of maintenance has increased, ball bearings have significantly replaced tapered roll as the market standard.

Figures 3.1 and 3.2

Fig 3.2 Idler Frame

6

5

7

2

3

1

4

Grease retainer cup

3/4” taper roller bearing

Delrin triple labyrinth seal

External deflector seal

6

5

7

4

81 or 91 and

4”, 5” or 6”

20˚, 35˚ or 45˚ Equal Length,Feeder/Picking or Offset Center Roll

18”- 72”

Idler Typeand

Diameter

Troughing Angle

IdlerStyle

BeltWidth

Hex nut with clip

7 gauge steel center stand

Punched hole for safety cable

Part Number GuideExample: 815-35E-36

08

Interchange with Powerscreen Rollersu Universal center bracketu Replaceable end rollers and die cast standsu 11 gauge steel



What are common applications?u These rollers are replacement parts common to European-designed track mounted crushers and other small processing equipment. Also, the center stands support all troughing angles.

What is the advantage?u Superior is one of just a few manufacturers who build these parts in the United States, making it easier to access the offshore parts locally. Customers are able to replace separate segments of the idler including the rollers and center stands.


Quick Specs

u Roll Diameter: 4”u Angles: 20˚, 30˚, 45˚, 60˚u Belt Width: 24”- 54”

40 Series IdlersReplacement Rollers for Track Mounted or Mobile Equipment

40 Series Idlers

Return RollsPart Number Powerscreen # Roll Length Shaft Length Metric Size

43-000025 02021145 28.00" 33.00" L840

43-000026 06530103 33.50" 38.50" L978

43-000027 05420143 33.62" 38.62" L980

43-000028 08010102 35.50" 40.50" L1025

43-000029 05120116 40.00" 45.00" L1145

43-000030 03220104 53.50" 58.50" L1485

43-000031 07230107 62.00" 67.00” L1700

Outside RollsPart Number Powerscreen # Description Degree

43-000019 8 - 3/4" Outside roller only Fits all degrees

Centered RollsPart Number Powerscreen # Roll Length Shaft Length Metric Size

43-000010 07020238 8.14” 9.20” L216

43-000011 02021138 12.00" 13.06" L314

43-000012 08010101 14.87" 15.93" L388

43-000013 06530102 18.87" 19.93" L490

43-000014 05120115 20.87" 21.87" L538

43-000015 04220133 25.15" 26.21" L648

43-000016 09130180 26.75" 27.81" L690

43-000017 09120129 35.07" 36.13" L900

43-000018 03220103 35.70" 36.76" L916

Return Roll U-BoltsPart Number Shaft Diameter

13-03004 1”

13-05005 .75”


CUSTOMER CARE PLAN

Center BracketsPart Number Powerscreen # Description Degree

43-000021 LH2020608RH2020609

Center bracket only 20º

43-000022 LH2020606RH2020607


43-000023 LH2020604RH2020605


43-000024 LH2020610RH2020611


09

CB504 IdlersDirect Interchange with MARCO and Cedarapids Idlers


CUSTOMER CARE PLAN

Maintenance Friendly in Tight Locationsu Channel mount, low profile designsu CB504 bearingsu Direct interchange with MARCO or Cedarapids idlersu Replacement bearings and pullers

Adapt to Applicationu Channel mount designu Standard mount low profile design optionu Rubber impact design option


CB504 Idlers


What are common applications?u The simple answer is if this is a product you have used in the past, then we have replacement rollers for you to purchase through our distribution.

What is the idler designed for?u CB504 Idlers are designed to easily replace a bearing and continue to use the can and frame for MARCO or Cedarapids style idlers.

What is special about the bearings?u Compared to other idlers, CB504 style idlers are designed and manufactured with sealed bearings versus to an external seal design.


Quick Specs

u Roll Diameters: 4” and 4-1/2”u Stub Pins: 2-1/2” and 3”u Belt Widths: 18”- 48”

Bearing and Pins

CB and 4” or 4-1/2”

20˚ or 35˚ Equal or Channel Mount

18”- 48”

Idler Typeand

Diameter

TroughingAngle

IdlerStyle

BeltWidth

Part Number GuideExample: CB45-35E-36

CB 504 PartsPart Number Description Part Number Description

41-542300 3” Double Pin 32-506000 Channel Mount

30-405044 4” End Disc 41-541250 2-1/2” Single Pin

30-456024 4-1/2” End Disc 41-542250 2-1/2” Double Pin

03-01017 CB 504 Bearing 41-542263 2-5/8” Double Pin

32-044081 1-1/2” Drop Bracket 41-541300 3” Single Pin

32-410450 4-1/2” Drop Bracket - -

10

Reduce Belt Mis-trackingu Misaligned belts contact side roller or shoe padu After contact, idler pivots and centers belt

Protect Sides of Belting (Fig 6.1)u Compared to steel, urethane side guide rollers are softer on beltingu Concave shaped side guide rollers keeps traction on belting

SpinGuard® Seal Technologyu Contact seal prevents foreign material from entering seal cavityu Grease-filled triple labyrinth seal shuts out contaminantsu Stationary external seal prevents material pinch points


Self-Aligning Idlers


Why might I need a troughing self-aligner?u There are many factors that cause belt mis-tracking, although some only affect the top side of the belt. Common to radial stackers, off-center loading causes mis-tracking to the belt’s top side. A carry-side, or troughing self-aligner will track the belt straight at every radial position.

Why choose this style?u It comes down to simple economics. However, there are also distinct performance comparisons. The Navigator return trainer evolved from the self-aligner to solve issues with contact to belt guides.

Why is the belt guide concave shaped?u Compared to a harder, straighter style guide, the concave shape makes for a softer landing when the side of the belt contacts the guide.


Fig 6.1 Softer Landing for Belting

Quick Specs

u Classes: CEMA B, C, D, E, and Fu Roll Diameters: 4” - 7"u Belt Widths: 18” - 96”

Self-Aligning IdlersEconomical Belt Tracking Tool


CUSTOMER CARE PLAN

Standard

Troughing Troughing

Return Return

Shoe ActivatedPositive Action Belts Bi-Directional Belts

B, C, D, E or Fand 4”- 7”

20˚, 35˚ or 45˚ Standard (EA) or Shoe Activated (BA)

18”- 96”

CEMAand

Diameter

TroughingAngle

AlignerStyle

BeltWidth

*For return roll self-aligners, substitute “RETA” for troughing angle and aligner style.

Part Number GuideExample: B5-35EA-36

11

Navigator® Return TrainersConstantly Working to Maintain Proper Belt Tracking

Save the Beltu Works to provide continuous belt alignmentu Quick reaction time upon installation, reducing the risk of damageu Standard rubber lagging increases friction between belt and roller Video Proof: http://superior-ind.com/components/idlers/aligners/navigator

Avoids Material Buildupu Rubber lagging sheds materialu Internal, off-the-shelf, flange mount bearings are clear of material buildup (Fig 3.1)u No framework, another common spot for material buildup

Extends Service Lifeu Largest diameter roll for longer service lifeu Effective in both wet and dry conditions


Navigator Return Trainer


What are common applications?u The trainer can be used in any application where belt tracking is an issue. It’s also recommended for applications where return self-aligners will not fit or are not working.

Where should I install?u We recommend 25 to 50 feet from the tail or head pulley on the belt’s bottom or return side and then every 100 feet after that on longer span conveyors. However, if there is a specific spot where there are tracking issues, install the trainer one to two idlers upstream.

Can you replace the bearings?u If you need to, they are off-the-shelf, flange mount bearings that can be replaced with an extended socket. However, compared to other trainers, the Navigator return trainer is equipped with larger bearings designed to last the life of the product.


Fig 3.1 Internal Bearings

Quick Specs

u Belt Widths: 24”- 72”u Lagged Diameter: 7-3/4” or 10-3/4”u Non Lagged Diameter: 7” or 10”

Before

This Belt was Eating into Brackets and Ripping

After

Belt Straightened Immediately After Installation

12

How it Works

Producer PerspectiveBad Behavior“ When our belts misalign they cut into return frames and can actually cut right through the conveyor. At the least, the conveyor catches the belt lacing and rips the side of the belt. ”

Pricey Problems“ At $15 to $20 a foot and three to four maintenance workers, it’s a pretty expensive situation to change out a belt and anyway you look at it, it’s downtime! ”

Advanced Alternative“ The Navigator return trainer just seems to handle the belt better than those ones with the side guide rollers. They let the belt travel too far before they even start doing anything. ”

Maintenance Manager at Capitol Aggregates, Austin, Texas



PATENTED TECHNOLOGY

Misaligned Belt

Misaligned belt puts pressure on one side of the Navigator returntrainer

The Navigator return trainer is constantly guiding and centering the belt

Misaligned pressure causes the Navigator return trainer to tilt, centering the belt

Belt Alignment Aligned Belt

Part Number Guide

NAV 24”- 72” LAG

BeltWidth

RollerStyle

LaggingOptions

Example: NAV-36 or NAV-36LAG

13

Urathon® Return RollsPrevent Idler Buildup, Shed Sticky Material

Sticky Shedderu Eliminate material buildupu No maintenance, self-cleaning rollsu Reduce tracking challenges, belt damage and premature failure

Longer Lastingu At least 3x the life of rubber discsu Reduce maintenance and operating costs

Belt Cleaningu Spiral option cleans dirty side of belt (Fig 8.1)u Material buildup is the leading cause of belt damage

Retrofit Rollsu Slotted shaft fits most competitor brackets


Urathon Return Rolls


What are common applications?u Urathon return rolls are best in applications when wet or sticky material cakes or bonds to steel cans, a problem that can often result in belt mis-tracking.

How hard is the urethane?u Both the standard and spiral versions of this return roll are made from a 87A durometer urethane.

Can you replace the discs?u Yes, however it involves removing the weld on the retaining ring in order to slip the discs off the shafts.


Fig 8.1 Spiral Urathon Return Roll

Quick Specs

u Classes: CEMA B, C, D, and Eu Roll Diameters: 5”, 6” and 7"u Belt Widths: 18” - 96”

60 65 87A

Rubber Lagged Returns

Rubber Disc Return Idlers

Urathon® Return Roll

Durometer is a unit of measurement used to signify the hardness of a material

Durometer Rating

14


Producer PerspectiveBalloon Effect“ Clay sticks to steel like a magnet, causing buildup that makes the steel rolls almost double in size. This leads to all kinds of problems! ”

Bloating Steel“ Some of the steel rolls got so heavy that they stopped rolling. The belt would simply slide across the top of them and potentially end up ripping if you didn’t catch it in time. ”

Zero Buildup“ These rolls save me time and money and eliminate all the downtime we used to have in change-outs. There is no reason to look any further! ”

Plant Manager at Phoenix Cement Company, Scottsdale, Arizona

Before

Sticky Material Clinging to Steel Returns Causes Belt Mis-tracking

After

Urathon Return Roll Sheds Sticky Material

Part Number Guide



PATENTED TECHNOLOGY

B, C, D, or E 5”, 6” or 7” RETU or *RETUSP 18”- 96”

BeltWidth

RollDiameter

CEMARating

IdlerType

Example: C5-RETU-36

* Spiral option is only available in 6” diameter

15

Prevent Material Buildupu Sheds material in moist, sticky applicationsu Discs designed with self-cleaning, flat surfaceu Discs prevents buildup on roll and on return side of belt

Save the Beltu Provides better support for beltingu Reduces costly belt tracking issues caused by material buildupu Disc spacing prevents belting from getting stuck within outside discs

Long Lasting Return Rollsu Synthetic rubber stable in wide temperature rangeu Better wear characteristics than steel rolls


Rubber Disc Return Idler


What are common applications?u In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns.

Why this style over others?u The answer comes down to simple economics. Compared to the Urathon® Return Roll, our Rubber Disc Returns can cost up to 20% less.


Quick Specs

u Classes: CEMA B, C, D, and Eu Roll Diameters: 4", 5” and 6”u Belt Widths: 18” - 72”


CUSTOMER CARE PLAN

Rubber Disc ReturnsCost Effective, Prevents Material Buildup

Prevent Material Buildup

60 65 87A





Durometer Rating

B, C, D, or E 4”, 5” or 6” RETI 18” - 72”

CEMARating

RollDiameter

IdlerType

BeltWidth

Part Number GuideExample: C5-RETI-36

16

Rubber Lagged Return RollsCost Effective, Prevents Material Buildup


CUSTOMER CARE PLAN

Prevent Material Buildupu Sheds material in moist, sticky applicationsu Built with hot vulcanized, synthetic rubber

Save the Beltu Flat style eliminates belt trapping common to disc style returnsu Reduces costly belt tracking issues caused by material buildup

Longer Lasting Return Rollsu 60 durometer rubber, similar to car tires (Fig 10.2)u Lagging increases thickness of rolls, boosting wear lifeu Better wear characteristics than steel rolls


Rubber Lagged Return Rolls


What are common applications?u In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns.

Does lagging come in different sizes?u You bet! You can choose between 1/4” or 1/2” rubber depending on the ruggedness of your application.

Why this style over others?u Rubber lagged style is targeted for self-aligner frames.


Quick Specs

u Classes: CEMA C, and Du Roll Diameters: 4", 5” and 6”u Belt Widths: 18” - 72”

Shed Sticky Material

60 65 87A





Fig 10.2 Durometer Rating

C or D and4”, 5” or 6”

RET 18”- 72” LAG and1/4” or 1/2”

CEMAand

Diameter

IdlerType

BeltWidth

Laggingand

Thickness

Part Number GuideExample: C5-RET-36LAG.25

17

Prevent Material Buildupu Rods create beating motion to keep belt clean and free of any carryback materialu Bars allow gaps for material to escape, eliminating buildup on roll

Save the Beltu Reduces costly belt tracking issues caused by material buildupu Mounted with live shafts to support conveyor loads


Beater Bar Return Rolls


What are common applications?u Like the Urathon® return roll and rubber style returns, the beater bar is another tool to defeat sticky material buildup on the return side of your belt. Also, applications with cleated belts where belt cleaners are not an effective cleaning tool.

Where is the install point?u Typically, we suggest installing the beater bar in the first return roll location from the head pulley. Here, the cleaning is focused on one roll rather than stressing out all the return rollers.


Quick Specs

u Shaft Size: 1-7/16” or 1-15/16”u Roll Diameters: 5” and 6”u Belt Widths: 18” - 72”

Beater Bar Return RollsDeflect Sticky Material Off the Belt


CUSTOMER CARE PLAN

LSB 5” or 6” 18”- 72” 107 for 1-7/16”or

115 for 1-15/16”

IdlerStyle

RollDiameter

BeltWidth

ShaftSize

Part Number GuideExample: LSB-536-107

Pillow Block Bearing Order InfoPart Number Dimensions

03-02005 1-7/16”

03-02016 1-15/16”

18

V-Return IdlersManages Rugged Loads While Aligning Long Overland Belts

Save the Beltu Help keep the belt alignedu Two-roll returns have higher load ratings than single rolls

Easy Installationu Easy mounting into standard return roll locationsu Avoid making changes to conveyor structure

SpinGuard® Seal Technologyu Contact seal helps prevent foreign material from entering seal cavityu Grease-filled triple labyrinth seal shuts out contaminantsu Stationary external seal prevents material pinch points


V-Return Idlers


What are common applications?u Primarily used on long overland conveyors, v-return idlers are used in applications with wide, thick and heavy belting or horizontal curve conveyors.

What is the load rating?u There are factors that we need to consider before recommending a load rating (i.e. belt weight, idler spacing, feet-per-minute). However, it is safe to say that v-return idlers have better or stronger load ratings then standard one roll returns.


Quick Specs

u Classes: CEMA C, D, and Eu Roll Diameters: 5”, 6”, and 7”u Belt Widths: 36” - 96”

Mounting Bracket


C, D, Eand

5”- 7”

10˚ or 15˚ RETV 36”- 96”

CEMAand

Diameter

RollAngle

IdlerType

BeltWidth


PATENTED TECHNOLOGY

Part Number GuideExample: C5-10RETV-36

19

Exterra® Primary Belt CleanerJam Packed with More Material Where it’s Needed Most

Extended Wear Lifeu Compared to other comparable primary blades, we’ve packed ours with 15-40% more urethane (durometer = 87A)u Thicker blade tip means extra material at the critical point of contact

Interchangeable Bladeu Avoid replacing an entire system, retrofit blade to other brand poles u Flexo Rockline® EZP1 u Martin® Performance Duty QC™ #1 u Martin® Pit Viper™ Belt Cleaner u American Eagle Standard Duty

Easy Installation and Maintenanceu Shipped pre-assembledu Blade fits to mounting pole without toolsu Simple nut adjustment tightens tensioneru Upgrade to Exterra® SFL Primary Belt Cleaner (Fig 14.1)


Exterra Primary Belt Cleaner


Why is belt width minus 8” standard?u Because material is often handled in the center two-thirds of the belt, wider blades wear faster in the center developing a “smile” wear pattern. The scraper then loses its effectiveness. Sized to your belt width minus 8”, the belt cleaner will wear more evenly.

How often should I reset the tension?u Roughly, it’s about four to six times throughout the life of the blade. However, we do offer a primary cleaner with a “set for life” tensioning system. If you do not want to waste the time on maintenance, ask to be upgraded to the Exterra SFL Primary Belt Cleaner. (Fig 14.1)

What is the length of the pole?u There are two options – belt width plus 30” or belt width plus 42”.

Quick Specs

u Belt Widths: 18” - 72”u Blade Widths: 10” - 70”u Durometer: 87A Urethane


Set Fo

r Life

Fig 14.1 Exterra SFL Primary Belt Cleaner

One Time Tensioning For the Life of the Blade

20



PATENTED TECHNOLOGY

Optional Mounting Brackets

Optional Mounting Bracket

u If the head section of your conveyor is not equipped with proper mounting, consider this Exterra belt cleaner mounting bracket.

22-3/16”

25-1/2”4-1/2”

4”

6”8”

Complete System Part NumbersPart Number Belt Width Blade Length Weight

P-1820481 18” 16” 41

P-1880481 18” 10” 38

P-2420541 24” 22” 47

P-2480541 24” 16” 44

P-3020601 30” 28” 53

P-3080601 30” 22” 50

P-3620661 36” 34” 59

P-3680661 36” 28” 56

P-4220722 42” 40” 65

P-4280721 42” 34” 62

P-4820782 48” 46” 75

P-4880782 48” 40” 72

P-5420842 54” 52” 85

P-5480842 54” 46” 82

P-6020902 60” 58” 95

P-6080902 60” 52” 92

P-6620962 66” 64” 105

P-6680962 66” 58” 102

P-7221022 72” 70” 117

P-7281022 72” 64” 112

P 18”- 72” 8 or 2 48”- 114”

PrimaryBelt

Cleaner

BeltWidth

Belt Width

-8” or -2”

PoleLength

Part Number GuideExample: P-4280722

1 or 2

TensionerQuantity

Replacement Part NumbersPart Number Description Dimensions

32-000097 Assembly Bracket Tensioner -

32-000094 Bracket Non-Tensioner -

13-00975 Pin Clip 5/16” x 2-1/2”

07-00540 Primary Scraper Blade 10”











21

Exterra® SFL Dual Belt CleanerPrimary and Secondary Scraper with One Mounting Point

Hassle-Free, In-Field Installationu One common mounting pointu Secondary blade shares primary blade’s mounting pole and tensioneru Maintain existing conveyor structure Installation Instructions: http://superior-ind.com/components/ accessories/cleaners/exterra-sfl-dual

Set for Life Tensioning u Spring tension is set to match primary blade wear patternu As primary blade wears, spring automatically adjusts to keep proper tension to both bladesu Tension is load equalizing as one or both blades wear, dynamically maintaining accurate tension

Extended Wear Lifeu The primary blade is packed with 15-40% more urethane than competition (durometer = 87A)u High performance AR Steel (STD) or Tungsten Carbide on tip of the secondary blade. u Segmented secondary blade is designed to withstand conveyor vibration and impact from belt splice

User Friendly Maintenanceu Replaceable secondary blade segments adjust to accommodate all splicesu Replaceable primary bladeu One time tensioning for the life of blade


Exterra SFL Dual Belt Cleaner


When do I need a secondary cleaner?u Whenever the belt is not getting clean enough with a primary scraper is the simplest answer. More specifically, in applications with sticky, aggressive material when cleaning is absolutely necessary.

What is special about the design?u Because conveyor frames are not usually designed to accommodate secondary cleaners, they aren’t usually installed. Sharing one mounting pole, this system allows primary and secondary cleaning power without modifying a conveyor structure.

Will the system fit in my application?u If you have room for a single primary belt scraper in your application, then you will have plenty of room for this model. However, the unit will not fit near a snub pulley, even if that region is equipped with a primary scraper.

Quick Specs

u Pulley Diameters: 12”- 30”u Belt Widths: 18”- 60”u Secondary: Tungsten Carbide


Eliminate Carryback

*Patent Pending

22



PATENTED TECHNOLOGY

18”- 60” 8 or 2 48”-114”

BeltWidth

BeltWidth

-8” or -2”

PoleLength

Replacement Part NumbersPart Number Description Dimensions

32-000188 Bracket -

49-000575 Tungsten Exterra Secondary Belt Scraper Blade -

13-00975 Pin Clip 5/16” x 2-1/2”












SFL D1, D2

SFL Belt Cleaner

PulleyDiameter

Part Number GuideExample: SFLD1-428072

* Diameter of Pulley: D1 = 12”-20” D2= 22”-30”

Complete System Part Numbers

Belt Width Blade Length Primary Blade OnlyD1 SFL Dual Belt Cleaner D2 SFL Dual Belt Cleaner

Tungsten Tungsten

18” 16” SFLP-182048 SFLD1-182048T -

18” 10” SFLP-188048 SFLD1-188048T -

24” 22” SFLP-242054 SFLD1-242054T -

24” 16” SFLP-248054 SFLD1-248054T -

30” 28” SFLP-302060 SFLD1-302060T SFLD2-302060T

30” 22” SFLP-308060 SFLD1-308060T SFLD2-308060T

36” 34” SFLP-362066 SFLD1-362066T SFLD2-362066T

36” 28” SFLP-368066 SFLD1-368066T SFLD2-368066T

42” 40” SFLP-422072 SFLD1-422072T SFLD2-422072T

42” 34” SFLP-428072 SFLD1-428072T SFLD2-428072T

48” 46” SFLP-482078 SFLD1-482078T SFLD2-482078T

48” 40” SFLP-488078 SFLD1-488078T SFLD2-488078T

54” 52” SFLP-542084 SFLD1-542084T SFLD2-542084T

54” 46” SFLP-548084 SFLD1-548084T SFLD2-548084T

60” 58” SFLP-602090 SFLD1-602090T SFLD2-602090T

60” 52” SFLP-608090 SFLD1-608090T SFLD2-608090T

23

Conveyor PulleysA Complete Line of Pulleys for Every Application

Fast Lead Times u 1-2 day turnaroundsu Expediting services availableu 10 warehouses stocked with standard products (Fig 17.3)u North American distribution network

Comprehensive Product Line u From light, portable applications to high tonnage, extreme jobsu CEMA, Mine 1.5, Mine 2.0, Super and Engineered Classesu Specialty: Spiral drums and wings, deflection wheels and dead shaft conveyor pulleys

Performance Matched Design u Complete assembly by Superior including bearings, couplings, gearing, etc.u Engineers apply Finite Element Analysis (FEA) to build per application stress conditions (Fig 17.1)

Quality Craftsmanship u Robotic welding machines for consistent, quality weldsu Hand welders trained and certified by American Welding Society (AWS)


Conveyor Pulleys


How do I know which class is for me?u There are charts on the next page that help to define applications and match them with specific classes. For an exact match, consider our Core SystemsTM Design team. The group of engineers review the specs of your application and design a pulley specific to the job.

What are Superior’s limitations?u The specs listed above are considered our standard product line; however that doesn’t mean we cannot go outside of the box for you. If your application specs extend outside our standard listing, contact us to discuss how we can help design and build your big conveyor pulley.

Where can I purchase Superior pulleys?u We have teamed up with some of the top distributors in North America to provide you with local sales, service and deliveries. For a listing of our partners, visit superior-ind.com/distributor.

Standard Sizes (Custom sizes available on request)

u Diameters: Up to 60”u Face Widths: Up to 120”u Shafting: Up to 15”


Fig 17.1 Drive Weight Stress Test

24

Pulley Product LineDescription CEMA Duty Mine Duty 1.5 Mine Duty 2.0 Super Duty Core SystemsTM

Design

Wing Pulleys– –

Drum Pulleys

Chevron® Wing Pulley– –

Design Standards Load, dimensions and crown defined by ANSI B105.1

Roughly 1.5X service factor of CEMA standard

Roughly 2.0X service factor of CEMA standard

Exceeds 2.0X service factor of CEMA standard

Engineered class, FEA Analysis Design, construction based on belt tension, conveyor load, and belt wrap

Conveyor Type Light duty, portable Medium duty Heavy duty Extra heavy duty High tonnage

Belt Style Fabric Fabric Fabric Fabric Steel cable or fabric

Belt Burden Not started under load Started under moderate load

Started under full load Started under full load Started under full load

Starts and Stops Infrequent Moderate Frequent Frequent Frequent

Load/Feed Characteristics

Uniformly loaded Uniformly loaded Non-uniformly loaded Non-uniformly loaded Non-uniformly loaded

Pulley Product LinePulley Types Diameter Integral Hub Diameter Face Width Contact Bar Thickness

CEMA Drum Pulley 4”- 60” 12” and under 12”- 78” –

CEMA Wing Pulley 6”- 60” – 12”- 78” 1/4” x 1-1/2” minimum, 3/8” x 1-1/2”, 5/8” x 1-1/2”

Mine Duty 1.5 Drum Pulley 10”- 60” 12” and under 12”- 78” –

Mine Duty 2.0 Drum Pulley 10”- 60” 12” and under 12”- 102” –

Mine Duty 2.0 Wing Pulley 8”- 60” – 12”- 78” 5/8” x 1-1/2” minimum

Super Drum Pulley 10”- 60” 12” and under 12”- 102” –

Super Wing Pulley 10”- 60” – 12”- 78” 3/4” x 2” minimum

CEMA Chevron® Wing Pulley 10”- 20” All CEMA 12”- 63” 1” x 1/2” half round bar

Mine Duty Chevron® Wing Pulley 12”- 36” – 12”- 63” 1” round bar

Super Chevron® Wing Pulley 12”- 42” – 20”- 75” 1-1/2” round bar

*NOTE: Other diameters and face widths available upon request. Several hub and bushing types are available with all pulleys.

Conveyor Pulleys

25

Drive A

ssemblies

Pulley Product Line

CEMA Drum Pulley

Super Drum Pulley

Mine Duty 2.0 Wing Pulley

CEMA Chevron® Wing Pulley

Super Chevron® Wing Pulley

Mine Duty 2.0 Drum Pulley

CEMA Wing Pulley

Spiral Wing Pulley

Core SystemsTM Designs

Mine Duty 1.5 Drum Pulley

Spiral Drum Pulley

Super Wing Pulley

Mine Duty Chevron® Wing Pulley

Engineered

Core SystemsTM Designs

26



PATENTED TECHNOLOGY

Quick Deliveries

Pulley Lagging

ChevronDiamond SmoothHerringbone

Slide Lag® Ceramic Lagging Options Urethane

Fig 17.3 Ten Pulley Warehouses Stocked with Standard Products

27

Chevron® Wing PulleyV-Shaped Wing Pulley Deflects Fugitive Material

Deflects and Sheds Materialu Traditional Wing: The impact of rocks is directly perpendicular to the wing, causing material to trap easily.u Chevron Wing: Rocks hit the wings at a glancing blow, deflecting fugitive material out and away.

Reduces Wing or Fin Bendingu Traditional Wing: Over time, trapped fugitive material causes wings to tip or bend. (Fig 16.1)u Chevron Wing: Constant deflection prevents entrapment of fugitive material.

Longer Lasting Beltsu Traditional Wing: Trapped material, bent wings and sharp contact bars are three of the most common causes of belt damage.u Chevron Wing: Even wearing rounded contact bars and fewer bent wings preserves conveyor belt appearance and performance.

50 Decibels Quieter (Fig 16.2)u Traditional Wing: Apex shape causes belt flapping, much more vibration and 120 db of sustained noise.u Chevron Wing: Continuous belt contact significantly reduces beating action, vibration and generates just 70 db of sound.


Chevron Wing Pulley


What are common applications?u Systems where fugitive material is causing wing bending, where uptime is crucial and where noise levels might be a concern.

Is it only a tail pulley?u Compared to standard wing pulleys, the Chevron wing is a good alternative for a gravity take-up. It’s a location where you have spillage and where you want to prevent wedged rocks and bent wings.

How does it compare to spiral wing pulleys?u A spiral’s corkscrew shape means they require many spins to auger material from the middle out to the side, versus the material simply deflecting off the plow shaped Chevron wing.


Fig 16.1 No More Bent Wings

Fig 16.2 Constant Belt Contact

Traditional Wing Pulley Chevron Wing Pulley

Quick Specs

u Classes: CEMA, Mine and Super Dutyu Diameters: 10" - 42”u Face Widths: 12” - 75”

28

Chevron® Wing PulleyChevron Wing Pulley Product Line

Specs Diameter Face Width Maximum Wing Height Wing Thickness Wear Bar Thickness

CEMA Duty 10”- 20” 20”- 63” Not defined 3/16” or 1/4” 1” x 1/2” half round bar

Mine Duty 12”- 36” 12”- 63” Varies with diameter 1/4” - 5/16” 1” round bar

Super Duty 12”- 42” 20”- 75” Varies with diameter 3/8” 1-1/2” round bar

150 db

125 db

100 db

75 db

50 db

25 db

ChevronWing Pulley

Standard Wing

Radio, Street Noise Jet Engine, Fireworks

Fig 16.3 Reduced Noise Pollution Material Deflection Reduces Trapped Material



PATENTED TECHNOLOGY

Producer PerspectiveVibrating Office“ I would sit in my office in the scale house and the windows would shake. The vibration is gone now and the only thing we changed were the pulleys!”

Bent Wings“ Our old pulleys had wings folding over or even breaking off, and they were eating away at the bottom side of the belt. Since then, we have installed close to 20 Chevron wing pulleys. Even if we a have little bit of leakage, it spits the rocks out before they bend the wings.”

Plugged Ears“ The noise levels are a night and day difference. We are in the middle of a city, so to have stopped the constant rattling sounds is huge for us.”

Maintenance Supervisor at a Minnesota Quarry

CHV C (CEMA), M (Mine Duty),S (Super Duty)

10”- 42” XT25 - XT10012”-75”

Hub Typeand Sizes

Face WidthTypeStyle Diameter

Part Number GuideExample: CHVS-4275XT70

29

Core SystemsTM DesignsPower Transmission Conveyor Components Consulting Services

Single Source Supplieru Avoid sourcing parts packages from multiple vendorsu One point of contactu One point of purchase

Performance Matched Components u Engineering services align power transmission components to your applicationu Engineers apply Finite Element Analysis (FEA) to build per application stress conditions

Pre-assembled Parts Packages u Eliminates the headaches of onsite assembliesu Reduces installation time

Quick Deliveries u Deliveries exceed industry standardsu Optional 1-2 day turnaroundsu Expediting services availableu Stocked power transmission warehouse


Core Systems Designs - Dual Head End Drive


What is Core Systems Designs?u Simply put, it’s a consulting service to design and supply your power transmission components.

When do I need Core Systems Designs?u Anytime you need design expertise advice of your conveyor drive packages. The benefit of the service is, you avoid designing the system or gathering all the parts on your own. It’s one phone call, one point of contact and one warranty. If all you need is a conveyor pulley, then you probably don’t need Core Systems Designs.

Who do I call?u We’ve partnered with local distributors to get you the best service and support. To find yours, visit superior-ind.com/distributor.

Standard Sizes (Custom sizes available on request)

u Diameters: Up to 60”u Face Widths: Up to 120”u Shafting: Up to 15”


30

Single Source Supplieru Engineering consultants work directly with you to determine the correct drive package for your application.

Complete Drive Packages

Bearings Motors Drives

Shafting Couplings Bushings

Gear Box Guarding Take-ups

Motor BearingCouplings Gear Box Shafting Pulley

Variable Frequency Drive Guards Bushings Shipping Structure

31

How it Works

Drive Package Replacementu There are two routes, sourcing and assembling the parts on your own or accessing them through one point of purchase.

Contact Superior Distributoru We are partnered with some of the best distributors in North America for local sales and support. Find them at superior-ind.com/distributor.

Engineering Consultants Design Packageu Using the specs of your application, a performance matched package is engineered.

Manufacturing and Assemblyu Optional 1-2 day turnarounds from phone call to completion if needed.

Package Deliveryu Guaranteed to work, with the security of a two-year warranty.

32

Core SystemsTM Pulley Data Sheet


CUSTOMER CARE PLAN

Complete this Form for a Customized Core Systems™ [email protected] • Toll Free – 800-321-1558 • Fax – 320-589-3892

Date ________________________________________________

Customer _____________________________________________

Plant/Mine/Project ______________________________________

Application Data:

Ambient Temp Range (degrees) ____________________________

Operation (hours/day) ___________________________________

Conveyor Data:

Conveyor Name/Tag _____________________________________

Conveyor Capacity (TPH) _________________________________

Conveyor Length (ft) _____________________________________

Conveyor Lift (ft) or Incline (deg) ____________________________(if not linear, please sketch curve below)

Belt Width (in) __________________________________________

Belt Speed (FPM) _______________________________________

Motor Horsepower (if known) ______________________________

Type of Soft Start _______________________________________(Electronic; VFD; Fluid Coupling; or none)

Take-Up Type (manual or automatic) ________________________

Total Installed Counterweight (lbs) ___________________________

Bearing Centers (in) ______________________________________

Conveyor Profile (See types 1 – 10 below). Circle one.

If profile differs from one shown, please sketch here:

Submitted By __________________________________

Contact Name __________________________________

Contact Phone or Email ___________________________

Altitude (ft) _____________________________________

Operation (days/year) ____________________________

Material (type & max lump size) ____________________

Material Density (lbs/ft3) __________________________

Material Repose Angle (degrees) ____________________

Trough Idler Angle, Spacing & Roll Diameter _____________

Return Idler Angle, Spacing & Roll Diameter _____________

Number of Belt Scrapers/Cleaners ____________________

Number of Belt Plows _____________________________

Length of Skirtboards (ft) __________________________

Height of Material on skirts (In) ______________________

Conveyor Belt Details (if known) _____________________

Fabric or Steel Cord ______________________________

Number of Plies & PIW (if known) ____________________

Covers top x bottom (in x in) ________________________

Profile 9

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33

Return Roll GuardsConveyor Pinch Point Protection


Single Return Roll Guard (Fig 18.1)u Easily mounts to Superior drop bracketsu Can be modified to fit other brand rollersu Works on CEMA B, C, and D series idlersu Same guard fits 4”, 5” and 6” rollers and 1-1/2” or 4-1/2” brackets

Dual Return Roll Guard (Fig 18.2)u Guards mount into special drop bracket slotsu Designed to catch roller from droppingu Works on CEMA C and D series idlersu Same guard fits 5” and 6” rollers and 4-1/2” brackets

ShieldAllTM Roll Guard (Fig 18.3)u UHMW cage prevents material buildupu Two pin release system for easy maintenance accessu Works on CEMA B, C, D, and E series idlersu Same guard fits 4”, 5”, 6” and 7” rollers and 1-1/2” or 4-1/2” brackets


Part Number Guides


CUSTOMER CARE PLAN

Return Roll GuardsBW Single Guard Dual Guard ShieldAll Guard Steel Guard

18” 44-050118 44-118450 44-040118 44-060018

24” 44-050124 44-124450 44-040124 44-060024

30” 44-050130 44-130450 44-040130 44-060030

36” 44-050136 44-136450 44-040136 44-060036

42” 44-050142 44-142450 44-040142 44-060042

48” 44-050148 44-148450 44-040148 44-060048

54” 44-050154 44-154450 44-040154 44-060054

60” 44-050160 44-160450 44-040160 44-060060

72” 44-050172 - 44-040172 44-060072

84” - - 44-040184 -

96” - - 44-040196 -

Steel Return Guard Basket (Fig 18.4)u Heavy duty steel cage prevents material buildupu Works on CEMA B, C, and D series idlersu Same guard fits 4”, 5”, and 6” rollers and 4-1/2” brackets

Fig 18.1 Single Return Roll Guard

Fig 18.2 Dual Return Roll Guard

Fig 18.3 ShieldAll Roll Guard

Fig 18. 4 Steel Return Guard Basket

34

Guard PanelsProtect Your Crew and Your Pockets




CUSTOMER CARE PLAN

Fig 19.1 Flexible Guard Panels

Fig 19.2 Steel Guard Panels

Flexible Guard Panels (Fig 19.1)u Cuts easily to any size or shape, with shears or cutteru UV resistant HDPEu Yellow color is easily detectableu Shipped with self-tapping screws and washersu 3/4” mesh (50’ x 4’ roll) u 1/4” mesh (100’ x 4’ roll)

Steel Guard Panels (Fig 19.2)u Attaches with self-tapping screws and washersu Can be used on channel or truss framesu 10’ x 5’ or 4’ x 5’ panels

Easy to Handle, Flexible Rolls

Self-Tapping Screws Included in Package

Flexible Guard PanelsPart Number Description Lengths

38-000030 Yellow Side Guard Kit - Small 1/4” Mesh 100’ x 4’

38-000032 Yellow Bottom Guard Kit - Large 3/4” Mesh 50’ x 4’

Steel Guard PanelsPart Number Description Lengths

14-00946 Guard, Truss, Mesh, Perf-Metal 10’ x 5’

10-02139 Guard, Truss, Mesh, Perf-Metal 4’ x 5’

35

Sealing SystemPrevent Material Spillage in Load Zones

Stop Material Spillage u System or cartridges maintain a tight seal between belt and hopper skirtingu Eliminates belt sagging between idler rolls in conveyor load zoneu Material spillage is the #1 cause of conveyor maintenance

Quick, Low Cost Installation u Retrofit cartridges fit to existing, installed idler framesu Single cartridge (5”), double cartridge (10”) or sealing bar optionsu Easy to handle and install (Fig 19.1)


Sealing System


What are common applications?u Do you have spillage in load zones of your systems? If yes, then you have the application.

How does it work?u While normal idler rolls create spacing between the conveyor belt and hopper skirting, the sealing cartridges or bars are designed to close that gap, making for a tight seal.

Is it an impact bed?u While in some cases they look the same, no, this is not an impact bed. The sealing system is designed to handle finer material which can leak out in load zones.

Quick Specs

u Cartridges: 5” or 10”u Bars: 48” or 60”u Belt Widths: 24”- 72”


Fig 19.1 Easy Installation 10” Cartridge5” Cartridge

Sealing Bar

SuperiorChoice

36


CUSTOMER CARE PLAN

Eliminate Spillage

Before

Skirting with Idler Rolls

After

Skirting with Sealing System - Keep Existing Idler Frame

Gaps between skirting and rolls Sealing System holds belt flat to the skirting

Part Number GuidesFull Sealing System

RollDiameter

Steel Roll Center Roll Impact Cushion Center Roll

Double Cartridge Slide Bars Double Cartridge Slide Bars

C-5” C5S-20E-(24-72)-410 C5S-20E-(24-72)-448 C5S-20EI-(24-72)-410 C5S-20EI-(24-72)-448

C-6” C6S-20E-(24-72)-410 C6S-20E-(24-72)-448 C6S-20EI-(24-72)-410 C6S-20EI-(24-72)-448

D-5” D5S-20E-(24-72)-410 D5S-20E-(24-72)-448 D5S-20EI-(24-72)-410 D5S-20EI-(24-72)-448

D-6” D6S-20E-(24-72)-410 D6S-20E-(24-72)-448 D6S-20EI-(24-72)-410 D6S-20EI-(24-72)-448

Replacement CartridgesDouble Cartridges Seal Bar

5” 6” 48” 60”

D5S-(24-72)-2 D6S-(24-72)-2 38-000026 38-000027

Common Applications

Material Spillage Idler Roll Wear Mixed Idler Styles

High Capacity of Fine Material Load Zone Idler Gaps Load Zone Spillage

37

Impact BedsProtect Conveyor Belts from the Beating of Large Material Lumps

Save the Belt u Energy absorbing impact bars protect belting from falling materialu Bars made of low-friction UHMW and high impact SBR rubber

Rugged Construction u Rigid, structurally sound frame for extra supportu Custom engineered style available on request (Fig 20.1)

Perfect Fit u Wings adjust to 20˚, 35˚ and 45˚u Available in 4’ or 5’ lengths


Impact Beds


What are the characteristics of the bars?u The impact bars are made from a top layer of 1/2” UHMW and a bottom layer of 2-1/2” SBR rubber.

Do you offer different classes?u You bet! Any application that exceeds the specs of our entry level impact bed will graduate to an engineered class.

How do I know which class I need?u Unfortunately, there is no simple answer or equation. We need specific application data (i.e. material size, tons per hour, drop height, etc.) and our engineering team can calculate the style and size needed for your job.

Quick Specs

u Lengths: 4’ or 5’u Diameter: 5” or 6”u Belt Widths: 24”- 72”


Fig 20.1 Specialty Impact Transition Bed

Medium Duty Impact Beds

18” Impact Beds

38

Common Applications


CUSTOMER CARE PLAN

5” or 6” 20˚, 35˚, 45˚ 24”- 72”4’ or 5’

BeltWidth

BarLength

ExistingRoll

Diameter

WingAngle

Part Number GuideExample: I-C5355-361

I and C

Impact Bedand

CEMA Class

High Capacity Applications

Sharp, Damaging Material

Large Material Lumps

Extended Discharge Height

Standard = 1or

Medium = 2

Duty

39

Take-UpsAccurately Maintain Belt Tension to Prevent Slippage

High Quality Constructionu ACME rod is standardu ACME thread design provides quick movement and reliability in corrosive conditionsu Durable Powder Coat finish

Stocked for Quick Deliveriesu Carried by your local Superior distributor (superior-ind.com/distributor)u Quick lead times from factory


Take-Ups


What size do I need?u The common “rule of thumb” is to choose a travel size that is 2% of your center to center belt length.

What is distinct about Superior’s design?u The ACME screw has nonbinding characteristics resulting in less seizing and longer life. ACME screws are standard on all of our take-ups.

What is significant about screw protection?u The screw is the heartbeat of the take-up. Once damaged or bent, you lose the effectiveness of the component. Telescoping tube take-ups are the only style manufactured with a completely enclosed screw, although each model has some protection to block material.


Quick Specs

u Style: Pillow Block, Wide Slot, Top Angleu Mounting Positions: Side or Topu Size Range: 1/2”- 9” Bearing Diameter

Take-Up Styles

Center Pull

Heavy Duty

Light Duty

Telescoping Tube

Top Angle

Wide Slot

40

Side Top Top Top Side Top

Take-Up Selection Guide



PATENTED TECHNOLOGY

1 Scenario One: Style

Bearing Style

Conveyor Style

Take-Up Style

Pillow Block

Channel/I-Beam Frame Truss/Channel Frame

TUTT TULD TUHD TUCP TUWS TUTA

Truss Frame

Wide Slot Top Angle

TUTT

2 Scenario Two: Bearing Size

TULD

TUHD

TUWS

TUCP

TUTA

1.0” 2.0” 3.0” 4.0” 5.0” 6.0” 7.0” 8.0” 9.0”0.0”

1/2” 6”

1/2” 3-7/16”

1-7/16” 9”

1/2” 3”

1-3/8” 5”

1-3/4” 3-15/16”

3 Scenario Three: Bearing Type

Bearing TypeTake-Up Style SealMaster Browning Link-Belt Rexnord Dodge SKF

TUTT NP, MP VPS, SPB1000, PBE PB22400, EPB22400, C35

ZA, ZEP SC, SCM, S2000, Type E, Imperial

–

TULD (Roller) NP, MP VPS, SPB1000 PB22400, C35 ZA SCM, S2000, Imperial –

TUHD (Roller) USRB VPS, SPB1000, PBE, SAF22500

PB22400, EPB22400, PLB

ZA, ZAF, ZEP S2000, Type E, USAF, TAF, Imperial

SAF

TUWS (Ball) MST VTWS – WSTU-SC, WSTU-SCM

–

TUCP (Roller) – TUE-920, ST-1000 – ZT-2000, ZT-5000 Type E (WSTU-E), S-2000 (WSTU-S2)

–

TUTA – – ETPB-22400 Type E (TPE), Type G (SC), Type GM (SCM), S-2000

–

Mount Position

Part Number Guide

TUTT, TUWS, TULDTUTA, TUHD, TUCP

100-1004 1.5”- 60”

FrameSize

Take-UpStyle

TravelDistance

Example: TUTT-350-12

*Not all configurations are possible, see catalog for availavbe parts

41

Superior Belt ScaleEvaluate Inventory, Production Goals and Rail Car or Truck Loading


HD Conveyor Belt Scale


What are the package options?u Depending on your needs, you can purchase each of the following separately or together as a total package: WB or HD belt scale, PM1500 or PM2000 integrator and the speed sensor.

Where should I install the scale?u If possible, it’s best to install on the first half of the conveyor from the tail pulley. Installation should be at least 20 feet from your load zone and 40 feet from any curve up or down. The owner’s manual is packed with more specific details to help get it right.

What if I already have a speed sensor?u There is good news! In most cases, both the PM1500 and PM2000 are designed to recognize third party sensors. However, the SS-150 comes standard with the package.

Quick Specsu Belt Widths: 18” - 72”u Accuracy: +/- 1% or +/- 0.5%u TPH: Up to 3000* *(dependant on belt speed and idler spacing)


Speed Sensor

Precision Accuracyu +/- 1% accuracy or +/- 0.5% accuracyu 2 independent load cells for greater accuracyu NOTE: You can achieve (+/- ¼%) accuracy when using 2 HD scales in conjunction with one PM2000 monitor. (Dual idler option)

Ease of Troubleshootingu Avoid replacing entire system if one cell is damagedu Independent load cell read-outs allows you to easily see which load cell is malfunctioning

Fast and Easy Installationu Easy clamping method secures scale package to conveyor frameu Superior quality idler with 0.015” TIR tolerance and custom frame

Powerful Integrationu PM2000 Limitless integration into existing in-plant controlsu PM2000 Control the speed of the beltu PM1500 & PM2000 Save up to 8 totalsu PM1500 & PM2000 Built-in inclinometer for use on variable incline conveyors

42

Integrators


Wide Belt Scaleu +/- 1% accuracyu Up to 1,000 TPHu 24" - 36" belt width is primary useu 42” up to 750 TPHu Two independent load cells wired in parallel for easy troubleshootingu Independent weigh bridge brackets accommodate multiple belt widthsu Powder Coated

PM1500u Functions with either WB or HD belt scalesu Store up to eight resettable totalsu Diagnostics screen shows load cell readings independentlyu Easy to operate touch screen menuu Output for PLC integrationu 10-30VDC and 115VAC power

SS-150 Speed Sensoru Easily mounts to a conveyor frameu Adjusts to 24” - 36” belt widthu Use existing speed sensor if applicable

Heavy Duty Belt Scaleu +/- 0.5% accuracyu Up to 3,000 TPH and beyondu Two independent load cells wired in parallel for easy troubleshootingu Continuous weigh bridge for increased accuracy and structural integrityu Powder Coated

PM2000u All the functionality of the PM1500u Control the speed of the conveyor belt when used with a VFDu Blend/rate controller uses one output for rate control or two outputs for blending productu Customized and limitless in-plant controlsu 10-30VDC and 115VAC poweru Wireless options available

Speed Sensors

Belt Scales

43

SonicscoutTM Material SensorAccurately Monitor Material on a Conveyor Belt

Maintain Material Flowu Detects material on conveyor beltu Feeds data to machine’s automation program

Heavy Duty Sensoru Unaffected by winds up to 30 MPHu Unaffected by external noiseu Tolerates dusty environmentsu Tolerates temperatures down to -14° F

Easy Installationu Adjust to custom belt widths (Fig 22.1)u Attaches to all brands of idler frames

Sonicscout Material Sensor


How does it work?u As material passes, the sensor detects it on the belt. When there is no material on the belt, the sensor sends a signal (i.e. alarm, shutdown, etc.) so action can be taken.

Can you adjust the distance?u Yes, the sensor itself has 2” of thread adjustment up or down.

What are the power requirements?u 24VDC electric power.

Quick Specs

u Belt Widths: 24”- 72”


Fig 22.1 Adjustable Mount per Belt Width



CUSTOMER CARE PLAN

Adjustable Mount

Flow SwitchPart Number Belt Width

18-10002 24-48

18-10003 54-72

Replacement PartsPart Number Description

11-00966 Switch

11-01122 Cord

32-000071 Mount 24-48

32-000072 Mount 54-72

44

SentinelTM Belt Speed SensorAccurately Monitor Conveyor Belt Speed

Monitor Belt Movementu Indicates if belt has stopped movingu Indicates if belt has slippedu Indicates how fast a belt is moving

Safety Shutoffu Prevent damage to drive componentsu Stops the motor in the event of belt problems

Easy Installationu Mounts to standard return roll bracketsu 4-1/2” drop bracket

Minimal Replacement Costsu Replacement parts sold separately

Sentinel Belt Speed Sensor


How does it work?u The sensor is designed to count return roll idler rotations, feeding the data back to a conveyor’s automation program. Operators set the speed (FPM) that indicates a problem and can be alerted via an audible alarm, a light or a cutoff switch.

What is the install point?u The distance between the proximity sensor face and the bolt head lugs on the idler should be 5/16”.

Quick Specs

u Belt Speed: Up to 1,000 FPM




CUSTOMER CARE PLAN


D5-RET-36SEN Sentinel

11-01299 Switch, Proximity, 24V, 12MM, QD, P&F

11-01122 Power-Cord, Utrasonic 30MM, Pepperal

32-00402 Drop Bracket

18-10006 Sentinel Multi-System Kit without Controller

* Part Numbers will be CEMA D, but may be used in B & C applications as well

Sentinel Belt Speed Sensor KitsKit Part Number Part Numbers Description

18-10000 32-00401 Drop Bracket for Sentinel

11-01122 Sensor Cord

11-01299 Switch, Proximity, 24V, 12MM, QD, P&F

11-01114 PLC, Monitor, Sentinel Speed Sensor

13-00850 BLT Carriage 20-1/4 x 3/4

13-10016 Flanged Nut 20-1/4

13-10086 Self-Drilling Hex Screw 12 x 3/4

11-01114 11-00702 Logo Smart Relay

11-00343 24 Volt Relay

11-00965 120 Volt Relay

11-01161 Power Supply 24 VDC

18-10001 Includes Everything in 18-10000 except 11-01114 Monitor

45

Superior Auto GreaserTemperature Compensating Electrochemical Lubrication System

Accurate Lubrication Solutionu Provides accurate lubricant delivery across a broad range of settings in extreme temperature environmentsu Simple to set, install and maintain with a highly intuitive operating menu

Extends Equipment Service Lifeu Lubricates equipment while it is running to provide optimal lubricant exchangeu Delivers gradual purge of fresh grease to labyrinth and taconite seals to prevent the ingress of contaminants

Safer Compared to Manual Greasingu Reduces work load by automating an otherwise manual processu Continues to lubricate without the need for shutdown and isolation


Superior Auto Greaser


Quick Specs

u Operating Temp: -4°F to 140°Fu Discharge Period: 1, 2, 3... to 12 monthsu Dimensions: Approx. 2.5” x 5.5”


What is the typical application?u Superior’s Auto Greaser is especially suited to single-point lubrication of rolling element bearings, seals and chains located in areas with considerable temperature variations or where intrinsic safety is a requirement.

Is the unit reusable?u It sure is! All of the components are available for order separately, including the lubricator cartridge, battery cap and dust cover.

Does the lubricator adjust to temperature?u A temperature sensor regularly measures the ambient temperature and the control unit calculates the required gas generation based on this data.

Push Button Control

Display(discharge period + function)

Push buttonprogramming

Re-usablecontrolunit

Dust and Water Proof

Gas generating cell

Lubricant

Auto Greaser Control Unit

LC unit with integrated battery

Built-in robustsupport flange with1/4” BSP M outside thread

Oil-filled units come with an integrated oil retaining valve and can be recognized by a red plug.

46


CUSTOMER CARE PLAN


03-03003 Lube Cart. Kit, Cap, Dust Cover

03-03002 Lubricator Cartridge, Dust Cover

03-03001 Cap, Auto Lubricator

08-02768 Black Pipe Nipple

08-02569 Black Tee-Pipe

08-03314 Brass Pipe, BSH Hex-Reducer

Part Number Guide

Auto Greasers in Application

Optional fittings can be used to install multiple cartridges.

u 45˚ Elbow and 90˚ Tee available.

A

AB

BC

C

Solution’s Guide

Exterra® SFL Dual Belt Cleaner

Solution’s GuideProblem Solution Page

Back and muscle soreness from heavy idlers Moxie® Rolls 05-06

Belt slippage Conveyor Take-ups 39-40

Belt tracking Navigator® Return Trainer 11-12

Bent pulley wings Chevron® Wing Pulley 27-28

Buying drive components from multiple sources Core SystemsTM Designs 29-32

Carryback material piling up under belt Exterra® SFL Dual Belt Cleaner 21-22

Conveyor belt stops or slips SentinelTM Belt Speed Sensor 44

Extra material sticking to belt Exterra® Primary Belt Cleaner 19-20

Guides of return trainer damaging belt Self-Aligning Idlers 10

Load zone material spillage Sealing System 35-36

No material on conveyor belt SonicsoutTM Material Sensor 43

Material sticking to return idlers Urathon® Return Roll 13-14

Material sticking to troughing idlers Moxie® Rolls 05-06

Material trapping between pulley wings Chevron® Wing Pulley 27-28

MSHA fines Conveyor Guarding 33-34

Power transmission components not working together Core SystemsTM Designs 29-32

Ripped or torn belt edging Navigator® Return Trainer 11-12

Short idler bearing life SpinGuard® Seal Technology 01-04

Short return idler life Urathon® Return Roll 13-14

1-800-321-1558superior-ind.com© 11-2012 Superior Industries, LLC. C-106

Components HandbookConveyor IdlersCEMA Rated IdlersMoxie® Rolls81/91 Series Regreasable Idlers40 Series IdlersCB504 IdlersSelf Aligning IdlersNavigator® Return TrainersUrathon® Return RollsRubber Disc ReturnsRubber Lagged ReturnsBeater Bar ReturnsV-Return Rolls

Belt Scrapers/CleanersExterra® Primary Belt CleanerExterra® SFL Dual Belt Cleaner

Conveyor PulleysConveyor PulleysChevron® Wing PulleysCore SystemsTM Designs

Conveyor AccessoriesReturn Roll GuardsGuard Panels Sealing SystemImpact BedConveyor Take-UpsBelt ScaleSonicscoutTM Material SensorSentinelTM Belt Speed SensorSuperior Auto Greaser

Spiral Urathon® Return Rolls

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C 106 Components Handbook

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