Installation, Maintenance and Operation of En-Masse Conveyor

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The en-masse conveyor’s installation includes basic laying requirements, specific specifications for its head, trough, chain, tail and electrical equipment, as well as post-installation commissioning. It also covers operational precautions and regular daily and weekly maintenance to ensure safe, stable and efficient operation.

I. Installation Requirements of En-Masse Conveyor

1. Basic Laying Requirements

  1. The type and conveying capacity of the conveyor must match the working face conditions. When multiple conveyors are used on the same working face, their conveying capacities shall be roughly equivalent.
  2. The roadway for conveyor installation shall comply with specification requirements, and a pedestrian passage of at least 0.7 meters shall be reserved beside the head section.
  3. When two conveyors are connected in a straight line, the head of the rear conveyor shall be 0.3 meters higher than the tail of the front one, with a front-rear stagger distance of 0.5 meters.

2. Specific Installation Specifications

(1) Conveyor Head

The laying quality of the head frame is critical for stable operation of the conveyor. The bottom beam shall be firmly laid and fully padded without shaking.

Before chain installation, the main shaft of the head mounted on the head frame shall rotate flexibly. For coupling-connected parts, the two shafts shall be concentric without deflection. After installing the head, laying the trough and connecting the scraper chain, fix the head with support props to prevent vibration and displacement during operation.

 

(2) Conveyor Trough

Lay the troughs with aligned joints to avoid protrusions that may cause scraper chain jamming during operation. The joint interface of troughs shall be flat without warping; lap connections shall be firm and fully padded, with connecting pins properly inserted.

 

(3) Scraper Chain

Install the scraper chain with correct scraper orientation. Weld seams on circular links must face upward, and no chain twisting is allowed. After chain tensioning, slight slack of the scraper chain under the head sprocket is acceptable as long as no chain accumulation occurs, indicating proper chain tightness.

 

(4) Conveyor Tail

The tail shaft installed on the tail frame shall rotate smoothly without jamming. Apply appropriate lubricating oil before installation.

 

(5) Electrical Equipment

Cables shall be properly hung. Explosion-proof starters and motors shall be installed in dry locations.

3. Commissioning After Installation

Before putting the conveyor into formal operation, conduct a strict inspection of all components for safety and production efficiency, with the following requirements:

  1. Check all fasteners for looseness and ensure sufficient lubricant in all lubrication systems.
  2. Thoroughly verify the lap joint quality of all conveyor troughs.
  3. Confirm proper water level of the coupling and oil level of the reducer.
  4. Start the motor to inspect the scraper chain for twisting, deviation and firm connection.
  5. Check whether the signal system meets operational standards.
  6. Perform no-load test run and complete chain tensioning.

II. Operation and Maintenance of En-Masse conveyor

1. Operational Precautions & Requirements

  1. Monitor the tightness of the scraper chain during initial operation; tension the chain timely once looseness is found.
  2. Keep the conveyor straight and adjust immediately if any misalignment occurs.
  3. The conveyor shall be arranged with proper bending; sharp bends are prohibited.
  4. The conveyor is allowed a vertical inclination variation of 3° to 5°. Adjust promptly if the bending angle exceeds the limit.
  5. Ensure complete scraper plates and proper chain tightness at all times.
  6. Protect the transmission parts, cables and switches of the conveyor during blasting operations.
  7. Pay close attention to coupling vibration. Regularly clean up floating coal and debris on motors and reducers to ensure good heat dissipation.

2. Operating Safety Guidelines

  1. Send a signal before startup; adopt intermittent starting first, then formal startup after a few seconds.
  2. Forced startup is forbidden. If startup fails, identify and eliminate the fault before restarting.
  3. Follow the sequence of from outside to inside, from bottom to top for sequential startup.
  4. Stop feeding coal onto the conveyor when it is shut down to avoid heavy-load startup.
  5. Clear all residual coal inside the conveyor after stopping coal feeding.
  6. Prolonged no-load operation without material conveying is prohibited.
  7. Follow the Four Frequents principle during operation: frequent inspection, timely repair, regular oiling and routine cleaning.

3. Regular Maintenance of En-Masse conveyor

Implement planned, targeted and periodic maintenance and inspection for the conveyor.

Daily Inspection

  1. Check the reducer for abnormal noise, vibration and normal oil level.
  2. Inspect the reducer for oil leakage and the coupling for water seepage.
  3. Verify proper tightness of the scraper chain, and check completeness of scraper plates and fastening bolts.
  4. Examine the troughs for wear, deformation and connection reliability.
  5. Check the coal baffle for deformation and damage.

 

Weekly Inspection

  1. Inspect the integrity and damage condition of the head frame and tail frame.
  2. Tighten connecting bolts of reducers and couplings.
  3. Check the meshing condition of sprockets.
  4. Measure motor insulation performance; inspect switch contacts and explosion-proof surfaces.
  5. Examine the wear of chain press devices to ensure reliable operation.
  6. Check the wear of rubber sleeves on coupling wheels.

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