Trouble Shooting on Conveyor Beltings

8/3/2019 Trouble Shooting on Conveyor Beltings

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SOMI CONVEYOR BELTINGS LTD., Page 1 of 17

SOMI CONVEYOR BELTINGS LTS.,SOMI CONVEYOR BELTINGS LTS.,SOMI CONVEYOR BELTINGS LTS.,SOMI CONVEYOR BELTINGS LTS.,


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Trouble ShootingProblem/Cause For Solutions Refer to Answer

A. Belt runs off tail pulley 39 10 1 19 31

B. Belt runs to one side for long distance or entire length of conveyor. 39 8 5 1

C. Particular section of belt runs to one side at all points on conveyor. 6 7 46

D. Belt runs off at head pulley. 33 10 1 3

E. Conveyor runs to one side at given point on structure. 5 4 1 2 3 44

F. Belt runs true when empty, crooked when loaded. 8 51 52

G. Belt slips. 34 33 31 10 4 30

H. Belt slips on starting. 34 31 33 30

I. Excessive belt stretch. 12 35 32

J. Grooving, gouging or stripping of top cover. 13 4 15 16 53

K. Excessive top cover wear, uniform around belt. 19 20 10 8 36

L. Severe pulley cover wear. 4 9 10 17 1 27

M. Longitudinal grooving or cracking of bottom cover. 4 10 9 33 36

N. Covers harden or crack. 23

O. Cover swells in spots or streaks. 21

P. Belt breaks at or behind fasteners; fasteners pull out. 24 22 48 30 47 49

Q. Vulcanized splice separation. 30 12 17 25

R. Excessive edge wear, broken edges. 8 10 40 7 50

S. Transverse breaks at belt edge. 18 25 26

T. Short breaks in carcass parallel to belt edge, star breaks in carcass. 16 17

U. Ply separation. 29 30 23

V. Carcass fatigue at idler junction.* 25 26 27 28 29 36

W. Cover blisters or sand blisters. 45 21

X. Belt cupping-Old Belt (was OK when new). 21 23


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Conveyor System Problems/Causes andConveyor System Problems/Causes andConveyor System Problems/Causes andConveyor System Problems/Causes and

Their SolutionsTheir SolutionsTheir SolutionsTheir Solutions

1.1.1.1. IdlersorpulleysoutIdlersorpulleysoutIdlersorpulleysoutIdlersorpulleysout----ofsquarewithcenterlineofsquarewithcenterlineofsquarewithcenterlineofsquarewithcenterlinelinel inel inel ineof bel t : readjust id lers inaf fectedof bel t : readjust id lers inaf fectedof bel t : readjust id lers inaf fectedof bel t : readjust id lers inaf fected

area.area.area.area. 2.2.2.2. Conveyorframeorstructurecrooked:straighteninaffectedarea.Conveyorframeorstructurecrooked:straighteninaffectedarea.Conveyorframeorstructurecrooked:straighteninaffectedarea.Conveyorframeorstructurecrooked:straighteninaffectedarea.

3.3.3.3. IdlerIdlerIdlerIdlerstandsnotcenteredonbelt:readjustidlersinaffectedarea.standsnotcenteredonbelt: readjust idlers inaffectedarea.standsnotcenteredonbelt: readjust idlers inaffectedarea.standsnotcenteredonbelt: readjust idlers inaffectedarea.

4.4.4.4. StickingidlersfreeidlersandimprovemaintenanceandlubricationStickingidlersfreeidlersandimprovemaintenanceandlubricationStickingidlersfreeidlersandimprovemaintenanceandlubricationStickingidlersfreeidlersandimprovemaintenanceandlubrication 5.5.5.5. BuilBuilBuilBuildddd----up of materia l on id lers: improve maintenance. Instal lup of materia l on id lers: improve maintenance. Instal lup of materia l on id lers: improve maintenance. Instal lup of materia l on id lers: improve maintenance. Instal l scrapers or otherscrapers or otherscrapers or otherscrapers or other

cleaningdevices.cleaningdevices.cleaningdevices.cleaningdevices.

6.6.6.6. Beltnotjoinedsquarely:removeaffectedspliceandresplice.Beltnotjoinedsquarely:removeaffectedspliceandresplice.Beltnotjoinedsquarely:removeaffectedspliceandresplice.Beltnotjoinedsquarely:removeaffectedspliceandresplice.

7.7.7.7. Bowedbe l t : fo r newbe l t th is condi t ion should d isappeardur ingbreakBowedbe l t : fo r newbe l t th is condi t ion should d isappeardur ingbreakBowedbe l t : fo r newbe l t th is condi t ion should d isappeardur ingbreakBowedbe l t : fo r newbe l t th is condi t ion should d isappeardur ingbreak---- in ; in in ; in in ; in in ; in rare rare rare r ar e instances belt mins tances bel t mins tances bel t minstances be lt mus t be s traightened of rep laced ; check s to rage and ust be s traightened of rep laced; check storage andus t be s traightened of rep laced ; check s to rage and ust be s traightened of rep laced; check storage andhandlingofbeltrolls.handlingofbeltrolls.handlingofbeltrolls.handlingofbeltrolls.

8.8.8.8. OffOffOffOff----center loadingor poor loading:adjustchutetoplaceloadoncenterofbelt; center loadingor poor loading:adjustchutetoplaceloadoncenterofbelt; center loadingor poor loading:adjustchutetoplaceloadoncenterofbelt; center loadingor poor loading:adjustchutetoplaceloadoncenterofbelt;

dischargedischargedischargedischargemateria l in d i rect ionof bel t t ravel at ornearbel t speed.materia l in d i rect ionof bel t t ravel at ornearbel t speed.materia l in d i rect ionof bel t t ravel at ornearbel t speed.materia l in d i rect ionof bel t t ravel at ornearbel t speed.

9.9.9.9. S li ppage on d rive pul ley: iS li ppage on d ri ve pul ley: iS li ppage on d rive pul ley: iS li ppage on d ri ve pul ley: i nc rease t ens ion t hrough screw takencrease tension through screw takencrease tension through screw takencrease tension through screw take---- up or addup or addup or addup or addcounterweight;counterweight;counterweight;counterweight;lagdrivepulley;increasearcofcontact.lagdrivepulley;increasearcofcontact.lagdrivepulley;increasearcofcontact.lagdrivepulley;increasearcofcontact.

10.10.10.10. Material spi l lage and buildMaterial spi l lage and buildMaterial spi l lage and buildMaterial spi l lage and build----up: improve loading and transfer condit ions; instal l up: improve loadingand transfer condit ions; instal l up: improve loading and transfer condit ions; instal l up: improve loadingand transfer condit ions; instal l

cleaningcleaningcleaningcleaningdevices;improvemaintenance.devices;improvemaintenance.devices;improvemaintenance.devices;improvemaintenance.

11.11.11.11. Bo lt heads prot rud ing above lagBolt heads prot ruding above lagBo lt heads prot rud ing above lagBolt heads prot ruding above lagging: t ighten bolt s; replace lagg ing; useging: t ighten bolt s; replace lagging; useging : t ighten bolt s; replace lagg ing; useging: t ighten bolt s; replace lagging; use

vulcanizedvulcanizedvulcanizedvulcanized----onon on onlagging.lagging.lagging.lagging.

12.12.12.12. Tensiontoohigh: increasespeed,sametonnage,samespeed;reducefrict ionTensiontoohigh: increasespeed,sametonnage,samespeed;reducefrict ionTensiontoohigh: increasespeed,sametonnage,samespeed;reducefrict ionTensiontoohigh: increasespeed,sametonnage,samespeed;reducefrict ionwithbetterwithbetterwithbetterwithbettermaintenanceandreplacementofdamagedidlers;decreasetensionmaintenanceandreplacementofdamagedidlers;decreasetensionmaintenanceandreplacementofdamagedidlers;decreasetensionmaintenanceandreplacementofdamagedidlers;decreasetensionb y in creas ing ar c o fb y i nc reas ing ar c of b y in creas ing ar c o fby increasing arc of c ont act or go to contact or go to cont act or go to cont act or go t o lagged pu lley ; r educ e CWT t ola gge d p ul le y; r ed uc e CWT t ol ag ge d p ul le y; r ed uc e CWT t ola gge d p ul le y; r ed uc e CWT t omin imumamount .min imumamount .min imumamount .min imumamount .

13.13.13.13. Sk ir t boards imprope r ly ad justed o r o f w rong ma te r ia l: ad jus t sk ir t board Sk ir t boards imprope r ly adjusted o r o f w rong ma te r ia l: ad jus t sk ir t board Sk ir t boards imprope r ly ad justed o r o f w rong ma te r ia l: ad jus t sk ir t board Sk ir t boards imprope r ly adjusted o r o f w rong ma te r ia l: ad jus t sk ir t board

supports supports supports suppor t s t otototo m inimum m inimum m in imum m in imum 1 " b etween met al a nd b el t w it h g ap i nc re as in g i n 1 " b etween met al a nd b el t w it h g ap i nc re as in g i n 1 " b etween met al a nd b el t w it h g ap i nc re as in g i n 1 " b etween met al a nd b el t w it h g ap i nc re as in g i nd i rect ion o f be l t t rave l ; usesk i r t board rubber (not o ld be l t )d i rect ion o f be l t t rave l ; usesk i r t board rubber (not o ld be l t )d i rect ion o f be l t t rave l ; usesk i r t board rubber (not o ld be l t )d i rect ion o f be l t t rave l ; usesk i r t board rubber (not o ld be l t )

14.14.14.14. LoLoLoLoad jams inchute: redesignchute forproperangleandwidth.adjamsinchute:redesignchuteforproperangleandwidth.adjamsinchute:redesignchuteforproperangleandwidth.ad jams inchute: redesignchuteforproperangleandwidth.

15.15.15.15. Mater ial hanging up in or under chute : improve load ing to reduce sp il lage;Mater ial hanging up in or under chute: improve loading to reduce sp il lage;Mater ial hanging up in or under chute : improve load ing to reduce sp il lage;Mater ial hanging up in or under chute: improve loading to reduce sp il lage;

installbaffles;installbaffles;installbaffles;installbaffles;widenchute.widenchute.widenchute.widenchute.

16.16.16.16. Impact o f mater ia l on be l t ; reduce impact by improv ingchute design; insta l lImpact o f mater ia l on be l t ; reduce impact by improv ingchute design; insta l lImpact o f mater ia l on be l t ; reduce impact by improv ingchute design; insta l lImpact o f mater ia l on be l t ; reduce impact by improv ingchute design; insta l limpactimpactimpactimpact idleidleidleidlers,orimpactbed.rs,orimpactbed.rs,orimpactbed.rs,orimpactbed.


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17.17.17.17. Materia l t rappedbetweenbel t andpul ley: instal l p lowsorscrapersonreturnMateria l t rappedbetweenbel t andpul ley: instal l p lowsorscrapersonreturnMateria l t rappedbetweenbel t andpul ley: instal l p lowsorscrapersonreturnMateria l t rappedbetweenbel t andpul ley: instal l p lowsorscrapersonreturn

runaheadrunaheadrunaheadrunaheadoftailpulley.oftailpulley.oftailpulley.oftailpulley.18.18.18.18. Beltedgesfoldinguponstructure:samecorrectionsasfor1,2,3; instal l l imitBeltedgesfoldinguponstructure:samecorrectionsasfor1,2,3; instal l l imitBeltedgesfoldinguponstructure:samecorrectionsasfor1,2,3; instal l l imitBeltedgesfoldinguponstructure:samecorrectionsasfor1,2,3; instal l l imit

switches;switches;switches;switches;providemoreclearance.providemoreclearance.providemoreclearance.providemoreclearance.

19.19.19.19. Dirty stuck,Dirty stuck,Dirty stuck,Dirty stuck, or misal igned return rolls: remove accumulat ions; install c leaning or misal igned return rolls: remove accumulat ions; install c leaning or misal igned return rolls: remove accumulat ions; install c leaning or misal igned return rolls: remove accumulat ions; install c leaning

devices;devices;devices;devices;useselfuseselfuseselfuseself----cleaningreturnrolls;improvemaintenanceandlubrication.cleaningreturnrolls;improvemaintenanceandlubrication.cleaningreturnrolls;improvemaintenanceandlubrication.cleaningreturnrolls;improvemaintenanceandlubrication.

20.20.20.20. Cover qua li ty t oo l ow : rep lace w it h bel t o f heavier cover gauge o r h ighe rCover qua li ty t oo l ow : rep lace w it h bel t o f heavier cover gauge o r h ighe rCover qua li ty t oo l ow : rep lace w it h bel t o f heavier cover gauge o r h ighe rCover qua li ty t oo l ow : rep lace w it h bel t o f heavier cover gauge o r h ighe rqual i ty rubberorqual i ty rubberorqual i ty rubberorqualityrubberorotherelastomer.otherelastomer.otherelastomer.otherelastomer.

21.21.21.21. Spil led oi l or grease: overSpil led oi l or grease: overSpil led oi l or grease: overSpil led oi l or grease: over----lubrication of idlers: improve housekeeping; reducelubrication of idlers: improve housekeeping; reducelubrication of idlers: improve housekeeping; reducelubrication of idlers: improve housekeeping; reduce

quantityofquantityofquantityofquantityofgreaseused;checkgreaseseals.greaseused;checkgreaseseals.greaseused;checkgreaseseals.greaseused;checkgreaseseals.

22.22.22.22. Wrong type of fastener, fasteners too t ight or too loose: use proper fastenerWrong type of fastener, fasteners too t ight or too loose: use proper fastenerWrong type of fastener, fasteners too t ight or too loose: use proper fastenerWrong type of fastener, fasteners too t ight or too loose: use proper fastenerandspliceandspliceandspliceandsplicetechnique;setupscheduleforregularf technique;setupscheduleforregularf technique;setupscheduleforregularf technique;setupscheduleforregularfastenerinspection.astenerinspection.astenerinspection.astenerinspection.

23.23.23.23. Heatorchemicaldamage:usebeltdesignedforspecificconditioHeatorchemicaldamage:usebeltdesignedforspecificconditioHeatorchemicaldamage:usebeltdesignedforspecificconditioHeatorchemicaldamage:usebeltdesignedforspecificcondition.n.n.n.

24.24.24.24. Fas tene r p la tes t oo long f or pul ley s ize: rep lace w it h sma ll er f as teners: Fas tener p la tes t oo l ong f or pul ley s ize: rep lace w it h sma ll er f asteners: Fas tene r p la tes t oo long f or pul ley s ize: rep lace w it h sma ll er f as teners: Fas tener p la tes t oo l ong f or pul ley s ize: rep lace w it h sma ll er f asteners: increasepulleysize.increasepulleysize.increasepulleysize.increasepulleysize.

25.25.25.25. Severeconvex(hump)verticalcurve:decreaseidlerspacingincurve;Severeconvex(hump)verticalcurve:decreaseidlerspacingincurve;Severeconvex(hump)verticalcurve:decreaseidlerspacingincurve;Severeconvex(hump)verticalcurve:decreaseidlerspacingincurve;increaseincreaseincreaseincrease

curveradius.curveradius.curveradius.curveradius.

26.26.26.26. Excessiveforwardti ltortroughroll:replaceidlers;replacewithheavierbelt.Excessiveforwardti ltortroughroll:replaceidlers;replacewithheavierbelt.Excessiveforwardti ltortroughroll:replaceidlers;replacewithheavierbelt.Excessiveforwardti ltortroughroll:replaceidlers;replacewithheavierbelt.

27.27.27.27. Excessgapbetweenidlerrolls:replacewiththeproperbelt.Excessgapbetweenidlerrolls:replacewiththeproperbelt.Excessgapbetweenidlerrolls:replacewiththeproperbelt.Excessgapbetweenidlerrolls:replacewiththeproperbelt.

28.28.28.28. Insufficienttransversestiffness:replacewiththeproperbelt.Insufficienttransversestiffness:replacewiththeproperbelt.Insufficienttransversestiffness:replacewiththeproperbelt.Insufficienttransversestiffness:replacewiththeproperbelt.

29.29.29.29. PulleystoosmallPulleystoosmallPulleystoosmallPulleystoosmall:uselargerdiameterpulleys.:uselargerdiameterpulleys.:uselargerdiameterpulleys.:uselargerdiameterpulleys.30.30.30.30. Count erwe ig ht t oo l ig ht: a dd c ount erwe ight o r i ncr ea se s cr ew t ak eCount erwe ig ht t oo l ig ht : a dd c ount erwe ight o r in cr ea se s cr ew t ak eCount erwe ig ht t oo l ig ht: a dd c ount erwe ight o r i ncr ea se s cr ew t ak eCount erwe ig ht t oo l ig ht : a dd c ount erwe ight o r in cr ea se s cr ew t ak e----upupupup

tension tovaluetension tovaluetension tovaluetens ion to va luedetermined f romca lcu la t ions.determined f romca lcu la t ions.determined f romca lcu la t ions.determined f romca lcu la t ions.

31.31.31.31. Count erwe ig ht t oo h ea vy : l ig ht en c ou nt erwe ig ht t o v al ue r eq ui re d b yCount erwe ig ht t oo h ea vy : l ig ht en c ou nt erwe ig ht t o v al ue r eq ui re d b yCount erwe ig ht t oo h ea vy : l ig ht en c ou nt erwe ig ht t o v al ue r eq ui re d b yCount erwe ig ht t oo h ea vy : l ig ht en c ou nt erwe ig ht t o v al ue r eq ui re d b yca lcu la t ions.ca lcu la t ions.ca lcu la t ions.ca lcu la t ions .

32.32.32.32. Pul ley lagg ingworn: repPul ley lagg ingworn: repPul ley lagg ingworn: repPul ley lagg ingworn: rep lacepu l ley lagg ing.lacepu l ley lagg ing.lacepu l ley lagg ing.lacepu l ley lagg ing.

33.33.33.33. Insuf fic ient t ract ion between be lt and pu lley: lag dr ive pu lley; increase be lt Insuf fic ient t ract ion between be lt and pu lley: lag dr ive pu lley; increase bel tInsuf fic ient t ract ion between be lt and pu lley: lag dr ive pu lley; increase be lt Insuf fic ient t ract ion between be lt and pu lley: lag dr ive pu lley; increase bel t

wrap;installwrap;installwrap;installwrap;installbeltcleaningdevices.beltcleaningdevices.beltcleaningdevices.beltcleaningdevices.

34.34.34.34. Systemunderbelted:recalculatebelttensionsandselectproperbelt.Systemunderbelted:recalculatebelttensionsandselectproperbelt.Systemunderbelted:recalculatebelttensionsandselectproperbelt.Systemunderbelted:recalculatebelttensionsandselectproperbelt.

35.35.35.35. ExcessiveExcessiveExcessiveExcessive sag between id lers causing load tosag between idlers causing load tosag between idlers causing load to sag between idlers causing load to work and shu ff le on bel t as it work and shu ff le on bel t as i twork and shu ff le on bel t as it work and shu ff le on bel t as i tpassesoverpassesoverpassesoverpassesoveridlers:increasetensionifunnecessarilylow;reduceidlerspacing.idlers:increasetensionifunnecessarilylow;reduceidlerspacing.idlers:increasetensionifunnecessarilylow;reduceidlerspacing.idlers:increasetensionifunnecessarilylow;reduceidlerspacing.

36.36.36.36. BeltrunningoffBeltrunningoffBeltrunningoffBeltrunningoff----centeraroundthetailpulleyandthroughtheloadingarea:installcenteraroundthetailpulleyandthroughtheloadingarea:installcenteraroundthetailpulleyandthroughtheloadingarea:installcenteraroundthetailpulleyandthroughtheloadingarea:install

trainingidlersonthereturnrunpriortotailpulley.trainingidlersonthereturnrunpriortotailpulley.trainingidlersonthereturnrunpriortotailpulley.trainingidlersonthereturnrunpriortotailpulley.37.37.37.37. Belthittingstructure:installtrainingidlersoncarryingandreturnrun.Belthittingstructure:installtrainingidlersoncarryingandreturnrun.Belthittingstructure:installtrainingidlersoncarryingandreturnrun.Belthittingstructure:installtrainingidlersoncarryingandreturnrun.


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38.38.38.38. Improperbeltinstallationcausingapparentexcessivebeltstretch:pullbeltthroughImproperbeltinstallationcausingapparentexcessivebeltstretch:pullbeltthroughImproperbeltinstallationcausingapparentexcessivebeltstretch:pullbeltthroughImproperbeltinstallationcausingapparentexcessivebeltstretch:pullbeltthrough

counterweightwithatensionequaltoatleastemptyrunningtension;runbeltincounterweightwithatensionequaltoatleastemptyrunningtension;runbeltincounterweightwithatensionequaltoatleastemptyrunningtension;runbeltincounterweightwithatensionequaltoatleastemptyrunningtension;runbeltinwithwithwithwithmechanmechanmechanmechanicalicalicalicalfasteners.fasteners.fasteners.fasteners.

39.39.39.39. Structurenotlevel:levelstructureinaffectedarea.Structurenotlevel:levelstructureinaffectedarea.Structurenotlevel:levelstructureinaffectedarea.Structurenotlevel:levelstructureinaffectedarea.40.40.40.40. Covercutsor verysmallcoverpuncturesallowfinestoworkundercoverandcutCovercutsor verysmallcoverpuncturesallowfinestoworkundercoverandcutCovercutsor verysmallcoverpuncturesallowfinestoworkundercoverandcutCovercutsor verysmallcoverpuncturesallowfinestoworkundercoverandcut

cover away from carcass: make spot repair with vulcanizer or self cover away from carcass: make spot repair with vulcanizer or self cover away from carcass: make spot repair with vulcanizer or self cover away from carcass: make spot repair with vulcanizer or self----curing repaircuring repaircuring repaircuring repairmaterial.material.material.material.

41.41.41.41. WornedgeWornedgeWornedgeWornedge:"press"edge.:"press"edge.:"press"edge.:"press"edge.

42.42.42.42. Interferencefrombeltscrapers:adjustbeltscrapers.Interferencefrombeltscrapers:adjustbeltscrapers.Interferencefrombeltscrapers:adjustbeltscrapers.Interferencefrombeltscrapers:adjustbeltscrapers.

43.43.43.43. Tensiontoohighforfasteners:usevulcanizedsplice.Tensiontoohighforfasteners:usevulcanizedsplice.Tensiontoohighforfasteners:usevulcanizedsplice.Tensiontoohighforfasteners:usevulcanizedsplice.

44.44.44.44. Beltcarcasstoolight:selectstrongercarcass.Beltcarcasstoolight:selectstrongercarcass.Beltcarcasstoolight:selectstrongercarcass.Beltcarcasstoolight:selectstrongercarcass.

45.45.45.45. Beltmisalignment:seetrainingrecommendations.Beltmisalignment:seetrainingrecommendations.Beltmisalignment:seetrainingrecommendations.Beltmisalignment:seetrainingrecommendations.

46.46.46.46. VariationsinnatureanforVariationsinnatureanforVariationsinnatureanforVariationsinnatureanformationof load:usenotchedchutetokeeploadpeakmationof load:usenotchedchutetokeeploadpeakmationof load:usenotchedchutetokeeploadpeakmationof load:usenotchedchutetokeeploadpeak

inexactcenterofbelt.inexactcenterofbelt.inexactcenterofbelt.inexactcenterofbelt.

47.47.47.47. Beltnotmakinggoodcontactwithal l idlers:adjustheightsoal l idlerscontactBeltnotmakinggoodcontactwithal l idlers:adjustheightsoal l idlerscontactBeltnotmakinggoodcontactwithal l idlers:adjustheightsoal l idlerscontactBeltnotmakinggoodcontactwithal l idlers:adjustheightsoal l idlerscontactbelt.belt.belt.belt.

48.48.48.48. Sharpedgesofmaterialortrampironcomingincontactwithcover:usej ingleSharpedgesofmaterialortrampironcomingincontactwithcover:usej ingleSharpedgesofmaterialortrampironcomingincontactwithcover:usej ingleSharpedgesofmaterialortrampironcomingincontactwithcover:usej ingle

bars,impabars,impabars,impabars,impactidlers,magneticremovalequipment.ctidlers,magneticremovalequipment.ctidlers,magneticremovalequipment.ctidlers,magneticremovalequipment.

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Below is a general guide to fixing some of the most common problems with

conveyor systems as it pertains to the belt. If you can not successfully overcome

your problem, contact SOMI CONVEYOR BELTINGS LTD. to arrange for a

belting expert to help you with your problem.

1. Excessive top cover wear over entire top surface or in load carrying area.

A. The top cover quality is not adequate for the system/material being conveyed. Upgrade to aheavier top cover. Upgrade to a better cover compound.

B. Off center loading or improper loading of the belt. Make sure load chute places the load inthe center of the belt. Make sure the direction of the material down the chute is in thedirection of the belt travel.

C. Material build-up on the pulley faces of the return idlers, or on the conveyor structure it's self.Clean system, improve material containment, install cleaners, check skirting, install material

plows after the head pulley.

D. Frozen, dirty, or misaligned return idlers. Clean rollers, properly align rollers, install cleaningdevices at head pulley, use self cleaning rollers, improve maintenance (alignment,lubrication, and cleaning).

E. Too much distance in between the idlers causing excessive material movement as the loadtravels up and over the idlers. Decrease the distance between idlers, increase tension if thebelt is under tensioned.

2. Excessive pulley cover wear.

A. Frozen idlers. Replace or repair frozen idlers. Improve maintenance of idlers (lubrication,cleaning, alignment).

B. Insufficient traction between belt and drive pulley. Make sure drive pulley is free of build up.Lag Drive pulley. Increase belt wrap on drive pulley. Increase belt tension if the belt isunder tensioned.

C. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows in front of pulleys.

D. Material is getting trapped between belt and pulleys. Improve containment at load point.

Improve containment along the conveyor. Install plows or scrapers in front of tail pulley.Practice good house keeping.

E. Bolt heads from pulley lagging, or from slider bed material hold down on bare backs, aresticking up and catching the belt. Inspect and replace or tighten as required.

F. A condition of tilted or over tilted troughing idlers exists. Idler frames should be located permanufacturers recommendations, usually at 90 degrees to the belt and conveyor frame.Align idlers per manufacturers recommendations.


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3. Excessive edge wear.

A. The belt is misaligned. Track and train belt.

B. Belt is coming in contact with the conveyor frame and or hardware. Make sure belt is trackingproperly. Make sure there is proper clearance between belt and any hardware. Make sureload is centered on belt. Clear any jammed material. Install training idlers on carry and

return side of belt.

C. Off center loading or improper loading of the belt. Make sure the load chute places the load inthe center of the belt. Make sure the direction of the material down the chute is in thedirection of the belt travel.

D. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows in front of pulley.

E. If the edge wear occurs in the splice area, the splice may have been installed crooked. Re-splice belt.

4. Belt runs off at the head pulley.

A. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows at head pulley.

B. The pulleys and or the idlers are out of square with the belt centerline. Readjust pulleys andor idlers.

C. Pulley lagging is worn or not adequate to produce sufficient traction. Replace with new orcorrect pulley lagging.

D. Idler stands are not centered to the belt. Readjust the stands for proper alignment.

5. Belt runs off at tail pulley.

A. The belt is running off center as it comes around the tail pulley and/or through the load point.Re-track belt, install training idlers on the return prior to the tail pulley.

B. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows in front of pulley.

C. The pulleys and or the idlers are out of square with the belt centerline. readjust pulleys and or

idlers.

D. Frozen, dirty, or misaligned return idlers. Clean rollers, properly align rollers, install cleaningdevices at head pulley, use self cleaning rollers, improve maintenance (alignment,lubrication, and cleaning).

E. Inadequate belt tension is possible, recalculate tension requirements. If necessary increaseweight on gravity take up or increase tension at screw take-up.


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6. Belt runs to one side for a considerable distance, or the entire conveyor.

A. The belt is running off center as it comes around the tail pulley and/or through the load point.Re-track belt, install training idlers on the return prior to the tail pulley.

B. Build up of material on idler rollers. Clean and maintain. Install scrapers, brushes, and othercleaning devices.

C. Off center loading or improper loading of the belt. Make sure load chute places load in thecenter of the belt. Make sure the direction of the material down the chute is in the directionof the belt travel.

D. The pulleys and or the idlers are out of square with the belt centerline. Readjust pulleys andor idlers.

E. Idler stands are not centered to the belt. Readjust the stands for proper alignment.

F. The conveyor frame is not square or the system is not properly supported. Straighten the

frame in the affected area and check to make sure support in that area is correct.

7. Belt slips when conveyor is started.

A. Insufficient traction between belt and drive pulley. Make sure drive pulley is free of build up.Lag Drive pulley. Increase belt wrap on drive pulley. Increase belt tension.

B. Inadequate belt tension is possible, recalculate tension requirements. If necessary increaseweight on gravity take up or increase tension at screw take-up.


D. Counter weight hitting bottom, not enough belt tension. Shorten belt and re-splice

E. One or more of the system pulleys are below the acceptable diameter. Replace pulleys withdiameters acceptable to belt requirements.

F. Conveyor is overpowered. Reduce HP or consider a soft start if applicable.

8. Belt slips while running.

A. Insufficient traction between belt and drive pulley. Make sure drive pulley is free of build up.

Lag Drive pulley. Increase belt wrap on drive pulley. Increase belt tension.

B. Inadequate belt tension. Increase weight on gravity take up. Increase tension at screw take-up.



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D. Frozen idlers. Replace or repair frozen idlers. Improve maintenance of idlers (lubrication,cleaning, alignment).

E. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows and scrapers.

F. One or more of the system pulleys are below the acceptable diameter. Replace pulleys with

diameters acceptable to belt requirements.

9. The covers are hardening and/or cracking.

A. Heat or chemical damage to the belt. Make sure to use the correct belt carcass andcompounds for the application.

B. Compound degradation due to ozone and ultraviolet light during long term storage. Storeinside out of direct sunlight and weather. Utilize spare belts sooner.

C. It is a natural tendency for rubber to get harder as it ages. This is due to the drying out of the

plasticizers in the compound. As belts age, and the rubber dries out, the cover wear will beaccelerated. This is similar to what is commonly referred to as dry rot in tires.

10. The cover/s are swelling and/or getting soft s in certain areas.

The belt is contaminated with spilled oil or grease. Improve house keeping, avoid spilling ofhydrocarbon based lubricants on the belt. Don't over grease bearings. Check grease sealson bearings.

11. A certain section of the belt runs to one side regardless of the location on theconveyor.

If the section is at the splice then the belt splice is crooked. Remove splice and rejoin beltends insuring belt ends are square in accordance with belt/fastener manufacturer.

12. The belt runs to one side only in a certain section or portion of the conveyor.


B. The pulleys and or the idlers are out of square with the belt centerline. readjust pulleys and oridlers.

C. Build up of material on idler rollers. Clean and maintain. Install scrapers, brushes, and othercleaning devices.

D. The conveyor frame is not square or the system is not properly supported. Straighten theframe in the affected area and check to make sure support in that area is correct.

E. The idler stands are not centered to the belt. Readjust the stands for proper alignment.

F. Make sure the conveyor structures is level from side to side. Level structure.


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13. Star breaks in belt carcass, or short breaks in belt carcass parallel to belt edge.

A. Material is getting trapped between belt and pulley. Improve containment at load point.Improve containment along the conveyor. Install plows or scrapers in front of tail pulley.Practice good house keeping.

B. Too great of an impact on the belt at the load point. Install impact idlers or impact bed.

Redesign chute with slow down bars or reduced drop.

C. Upgrade to a carcass with a nylon fill yarn, or an all nylon carcass. (But in the long run fixingthe problem will be cheaper.)

14. Transverse breaks in belt at the edge.

A. Inadequate transition distance from the pulley to the troughing idlers. Increase transitionlength. Rule of thumb, transition is equal to 2.5 times belt width minimum.

B. The belt edges are folding over on the system or folding up on the structure. Re-track belt,

center load point, check the belt as it comes into and through the load point/skirting, check tomake sure the belt isn't coming into contact with the conveyor structure.

15. Vulcanize splice failure.

A. Incorrect belt splice type, or incorrect implementation of the splice procedure. Re-splice beltfollowing manufacturer's recommended splice materials and procedures.

B. One or more of the system pulleys are below the acceptable diameter. Replace pulleys withdiameters acceptable to belt requirements.

C. The operating and/or start up tension is too great for the belt. Decrease the load, increase thespeed utilizing the same drive motor, decrease the angle of incline, increase tension ratingand/or number of plies in the next belt.

D. Material is getting trapped between belt and pulley. Improve containment at load point.Improve containment along the conveyor. Install plows or scrapers in front of tail pulley.Practice good house keeping.

E. Inadequate transition distance from the pulley to the troughing idlers. Increase transitionlength. Rule of thumb, transition is equal to 2.5 times belt width minimum.

16. The belt is curling up on the edges, cupping. The belt was fine when installed but

over time it cupped.

A. Heat or chemical damage to the belt. Make sure to use the correct belt carcass andcompounds for the application. There may be cases where this is the norm in handlingextremely dry products that pull the plasticizers out of the cover compound. In these casesusing a belt with a heavier bottom cover will help off-set the problem. Or, try a belt withbalanced covers which would allow you to turn the belt over several times in the life of thebelt to counteract the problem.


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B. We have seen an incredible amount of belt curling in the last year or better from thecompetitions belt. All I can tell you is that SOMI has never had a warranty claim due to thebelt curling up like a tube.

17. Belt runs fine when it's empty but wont track right when it's loaded.

A. The belt is not making good contact with all of the idlers. Readjust the idlers for proper belt

contact.

B. Off center loading or improper loading of the belt. Make sure load chute places load in thecenter of the belt. Make sure the direction of the material down the chute is in the directionof the belt travel.

C. Variations in the formation and nature of the load at the load point. Use a deflector/notchedchute to keep the load peak as close to the center of the belt as possible.

18. The top cover is grooved, gouged, or the top cover is stripped off.

A. Improper skirt board, improper skirt board adjustment, belt to skirting holding structure. Makesure to use proper skirt board, not old belt! Make sure load point is in proper adjustment, i.e.belt clearance. Adjust skirt board to reduce pressure on the belt top cover.

B. Material is lodging in the chute. Open up the chute, reduce size of lumps in material, restrictfeed rate.

C. Material hanging up at the load point. Either in the chute or under the chute. Increasedistance from belt to chute. Widen the chute. Install baffles to spread the material at theload point.

D. Too great of impact on belt at the load point. Install impact idlers or impact bed. Redesign

chute with deflection (slow down) bars to reduce drop. Upgrade top cover compound.

E. Sharp edges on material, foreign material such as tramp iron in the product. Remove foreignmaterial, i.e.. magnet, improve load point drop, upgrade top cover compound.

F. Improper top cover compound for the application. Check with manufacturer for propercompound.

19. You are experiencing excessive belt stretch.

A. The operating and/or start up tension is too great for the belt. Decrease the load, increase the

speed utilizing the same drive motor, decrease the angle of incline, increase tension ratingand number of plies in the belt. Apply or adjust soft start drive motor controls.

B. The belt is not adequate for the generated tensions. Upgrade to a higher tension belt.

C. The counter weight is too heavy or the screw take-up is over tensioned. Reduce weight incounter weight or reduce tension at screw take-up.

20. Longitudinal grooves or cracks in the bottom cover.


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B. Material build-up on the pulley face or conveyor structure. Clean system, improve materialcontainment, install cleaners, check skirting, install material plows in front of pulley.

C. Insufficient traction between belt and drive pulley. Make sure drive pulley is free of build up.

Lag Drive pulley. Increase belt wrap on drive pulley. Increase belt tension.

D. Pulley lagging is worn. Replace with new or correct pulley lagging.

E. Too much distance in between the idlers causing excessive material movement as the loadtravels up and over the idlers, forcing the belt into the idler junctions. Decrease the distancebetween idlers, increase tension if the belt is under tensioned.

F. Insufficient transverse belt stiffness. Replace belt with one recommended for the weight ofload and belt width. Decrease load.

21. Belt breaks just behind the mechanical fastener, or the mechanical fastener pullsout.

A. The fastener plates used in the mechanical fastener are to long. Replace with a smallerfastener if tensions will permit it, or increase the pulley diameters.

B. Incorrect fastener for the belt/application. Improper fastener installation. Check fastenerapplication specifications, make sure it's the right fastener for the job. Make sure fastener isinstalled per manufacturers instructions.

C. The tension is too great for the fastener. Upgrade to a higher rated fastener if possible.Switch to a vulcanized slice.

D. One or more of the system pulleys are below the acceptable diameter. Replace pulleys withdiameters acceptable to belt requirements.

E. Belt scrapers are not correctly adjusted or installed. Check belt scrapers, readjust or replaceif necessary.

F. The carcass of the belt is too light or of the wrong material. Up grade to a heavier beltcarcass or one that incorporates a nylon fill yarn, or a monofilament fill yarn.

22. Ply separation of the belt.

A. Insufficient ply adhesions in the belt to start with. Check with the manufacturer to make surethe correct belt is being used.

B. Insufficient transverse belt stiffness. Replace belt with one recommended for the weight ofload and belt width. Decrease load.

C. One or more of the system pulleys are below the acceptable diameter. Replace pulleys withdiameters acceptable to belt requirements.


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BELT SELECTION GUIDE

BELT TYPEDESCRIPTION /

GRADESERVICE SPECIFICATION

General Grade M-24Grade N-17

Heavy duty for highlyabrasive material Medium

heavy duty for moderatelyabrasive material

IS 1891 (P ar t i)

IS 1891 (Part-I)

Heat Resistant H.R.-T1H.R. - T 2

Max. operating Temp. 125C Max. operating Temp.

IS 1891 (Part-I I)IS 1891 (Part-I I)

Special HeatResistant

SEHR-72 Max. operating Temp. 200 C "SOM1FLEX"standard

Oil Resistant O.R. Oil & Fat Resistant IS 1891 (Part-Ill)

Friction Top Bare back Light materials IS 1819 (Part-I)

Fire Resistant FR Fire resistance and antistatic CAN/CSA-M-422-M87DIN-

Heavy Duty Rock-2007 Special Developed forSelection lump size 300 x

"SOMIPLEX"standard

Ultra Heavy Duty SAR-36 High Abrasion Resistancetear Strength Heavy Lump

"SOMIFLEX"standard

Should you fail to find the belt suitable for your application from this Cist at standard construction please refer

to us for other types of Belting available from our comprefiensive range, but not listed here.


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CARCASS SELECTION GUIDE

Belt Designation Max.Recommended

WorkingTension

(Vulcanising)

NominalCarcass

Thickness

NominalCarcassWeight

Max. Belt Width (mm) for

satisfactory Load Support

(Material Density in T/m3)

Min. Belt width (mm)for satisfactory

toughing

Type Rat-ing KN/m (mm) (Kg/m2) Upto1.0 Upto1.5 Upto2.5 20 30 45

200/2 20 2.4 2.7 650 500 400 300 300 350250/2 25 2.5 2.8 650 600 450 450 450 500

General 315/3 31 3.3 3.7 .1000 800 650 400 450 500

Duty 400/3 40 3.5 3.9 1050 900 650 500 500 500500/3 50 3.6 4.0 1200 900 800 500 500 500

630/3 63 3.9 4.4 1200 1000 800 500 500 500

400/4 40 4.6 5.2 1200 100 800 500 500 600

Lxtra 500/4 55 4.8 5.4 1200 1050 900 500 500 650

Duty 630/4 70 5.0 5.7 1300 1100 900 500 500 650

200/2 20 2.8 3.1 650 500 400 400 400 450250/2 25 3.1 3.5 650 600 500 400 400 450

Heavy 315/3 31 4.2 4.6 1200 1000 800 500 500 500

Duty 400/3 40 4.4 4.9 1200 1000 800 500 500 600500/3 50 4.5 5.1 1300 1100 900 500 500 600

630/3 63 4.8 5.4 1300 1100 1000 500 500 650

COVER SELECTION GUIDEBELT TYPE DESCRIPTION/

GRADESERVICE SPECIFICATION

General Grade M-24

Grade N-17

Heavy duty for highly abrasive

material Medium heavy duty for

moderately abrasive material

IS 1891 (Parti)

IS 1891 (Part-I)

Heat Resistant H.R.-T1

H.R. -T2

Max. operating Temp. 125C

Max. operating Temp. 150C

IS 1891 (Part-II)IS 1891 (Part-II)

Special Heat

Resistant

SEHR-72 Max. operating Temp. 200u C "SOMIFLEX" standard

Oil Resistant O.R. Oil & Fat Resistant IS 1891 (Part-Ill)

Friction Top Bare back Light materials IS 1819 (Part-I)

Fire Resistant FR Fire resistance and antistatic CAN/CSA-M-422-

M87DIN-22103IS

1891 (Part V)


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Belt Rating / Pulley Diameter SelectionBelt Designation Max.

RecommendedWorkingTension

(Vulcanising)

NominalCarcass

Thickness

NominalCarcassWeight

Max. Belt Width (mm) for

satisfactory Load Support

(Material Density in T/m3)

Min. Belt width (mm) forsatisfactory toughing

TypeRat-ing

KN/m (mm) (Kg/m2) A B C 20 30 45

315/3 31 2.7 3.0 400 315 250 400 450 500400/3 40 3.0 3.1 400 315 250 500 500 500

500/3 55 3.2 3.3 500 400 315 500 500 500

500/4 55 4.0 4.4 500 400 315 500 500 650

630/3 70 3.3 3.6 500 400 315 500 500 500

630/4 70 4.5 4.7 630 500 400 500 500 650

800/4 90 4.7 5.0 630 500 400 500 500 650

800/5 90 5.5 6.0 800 630 500 - - -

1000/4 110 5.5 6.2 800 630 500 500 650 800

1000/5 110 6.0 6.4 800 630 500 - -

GeneralDuty

1250/4 140 5.9 6.7 800 630 500 650 800 900

315/3 31.5 3.2 4.0 400 315 250 500 500 500

400/3 40 39 4.1 400 315 250 500 500 600

500/3 50 4.0 4.3 500 400 315 500 500 650

500/4 55 5.2 5.8 500 400 315 500 500 650

630/3 70 4.3 4.6 500 400 315 500 500 650

630/4 70 5.6 6.1 630 500 400 500 650 800

800/4 90 5.8 6.4 630 500 400 650 800 900

800/5 90 6.4 6.9 800 630 500 - - -

1000/4 110 6.6 6.9 800 630 500 650 800 900

1000/5 110 6.9 7.4 800 630 500 - -

1250/4 140 6.7 7.4 800 630 500 750 900 10001250/5 140 7.4 7.9 1000 800 630 800 1000 1200

1400/4 155 7.5 7.7 1000 800 630 - - -

1600/4 180 7.7 8.1 - . - - - -

1600/5 180 8.1 8.9 1000 800 630 800 1000 1200

Ex

traHeavyDuty

2000/5 220 10.2 9.4 1250 1000 800 - -

For Further Detail Please Contact

Mr. Vimal Bhansali ( Cell : +91 98290-23471)

SOMI CONVEYOR BELTINGS LTS.,4F-15, OLIVER HOUSE, New Power House Road, Jodhpur- 342001

Phone : 0291-2610472, 2637080, Fax : 0291-2432307

E-mail : [email protected] ; [email protected],

Web site : www.somiconveyor.com

Trouble Shooting on Conveyor Beltings

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