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INSTALLATION, OPERATION, MAINTENANCE

AND SPARE PARTS



MANUAL


FOR




APRON FEEDER



ORDER NO. : CO/1892


MACHINE NO. : AF: 112-115


CLIENT : M/s TECPRO SYSTEMS LIMITED
A/c RELIANCE ENERGY LTD.


MANUFACTURER : ELECON ENGG. CO. LTD
VV NAGAR 388 120













I N D E X





CHAPTER
NO.
DESCRIPTION

CH-1

INTRODUCTION

CH-II

TECHNICAL DATA SHEET

CH-III

LUBRICATION SCHEDULE

CH-IV

SPARE PARTS LIST

CH-V

ENCLOSURE


(A) - G.A. OF APRON FEEDER
(C) - INSTALLATION MANUAL FOR GEAR BOX

(D) - GREASE LUBRICATION SYSTEM

(E) - INSTALLATION MANUAL FOR GEAR COUPLING.













CHAPTER I


INTRODUCTION



DESIGN AND CONSTRUCTION FEATURES
OF ELECON APRON FEEDERS

* MACHINE DESIGN:

Elecon Apron Feeders are of extremely rugged construction and are specifically designed
to withstand the shock loading of large lumps being dumped in the hopper above the
feeder. These machines can also be employed for drawing material from hoppers and
delivering it at controlled rates to succeeding belt conveyors. Apron Feeders have a
considerable effect on the efficiency of crushing operations as they ensure that the feed is
introduced to the crusher over the full length of the crushing cavity at a steady and
controlled rate.

* BEARINGS:

Heavy-duty spherical roller type bearings support the head and tail shafts, mounted in
pedestals. Those for supporting the head shaft are bolted to the main longitudinal members
while those for supporting the tail shaft are mounted in slides, permitting adjustment of the
sprocket centers to take up chain slack.
* SPROCKETS:

Segmental, cast steel sprockets are machined and jig drilled to fit their respective
mounting hubs, which are keyed to the drive shaft.

* CHAIN AND CARRYING ROLLERS:

Chains of the type used for tractors are fitted, having forged steel links and high-carbon
steel pins capable of operating under the most arduous conditions, without the need for
lubrication. Steel support rollers fitted with grease lubricated bearing bushes are provided
beneath the chains. Mn Cast steel Chains can also be provided upon request.
* APRON PLATES:
Apron feeder pans are designed to suit specific requirements, considering duty factors and
type of material. Pans are ribbed for strength and have flanged ends. Sufficient overlap is
provided restricting spillage at the moment when passing around the sprocket. Pans can be
supplied either in cast manganese steel or pressed mild steel or of welded plate construction,
to suit the nature of material to be handled.
Sprockets & Chain
Assembly


INTRODUCTION



In general terms Apron Feeder consists of two strands endless chain or
other linkage, to which overlapping or interlocking plates of different shapes are
attached to form a continuous moving bed for bulk material. They are particularly
suited to handling of heavy duty raw materials, such as coal, lignite, coke, ore slag,
rock stone, gravel,clinker, etc. They are frequently used as feeders for large crushers
breakers, and grinders. They are flexible in arrangement and can be conveniently
arranged to follow combined horizontal and inclined conveyor center that can be used
depending on the type of chain selected.

The method of direct feed may often essential the free falling of material from
appreciable height on to the Apron conveyor. In such circumstances, all components
particularly apron chain, apron pan have to be extremely robust construction.

DESCRIPTION.


The Apron Feeder convey the material tilted by Wagon / Dumper into the feeding hopper upwards
into the inlet of the crusher or the any equipment.

The weight of filled material and the falling height require a sturdy construction of the apron feeder.

The Apron Feeder is driven by an electric motor combined with reduction gearbox and coupling
arrangement.

















INSTALLATION


1. Check safe arrival of complete material with provided part lists.

2. All the components of equipment are designated with main groups Group for mechanical,
Group for structural, Group for electrical items.

3. Encircled numbers on drawing and part list indicates item to be erected at the site, while num
bers are not encircled items are shop assembled either welded or bolted ready for Erection at
site. The numbers on the parts are assembled in one unit.

4. The floor on which Apron Feeder is to be installed should be properly leveled and foundation
for the footing should be correctly marked. All levels should tally with general arrangement
drawing of the equipment furnished by ELECON.

5. Take care in selection for components with proper erection marking.

6. Check the Apron Feeder structure is perfectly straight and correct by leveled.

7. Check the head end and tail end sprockets are all correctly mounted, such that they are
leveled, and with their axis perpendicular to the center line of the pan.

8. Ensure that all parts of the conveyor is greased / oiled where necessary.

9. Check along the length of the conveyor and ensure that there are no item left, lying about
which may obstruct and cause damage to moving equipment.

10. Please check whether pans are bolted to each other properly or not.

11. Check drive machinery for alignment on assembly and before starting the conveyor, check the
motor installation resistance.

















OPERATING INSTRUCTIONS


1. After conforming no load operation, feed the material on the pan uniformly and carefully.

2. Quantity of material feed should be controlled. If material is fed in excess, the motor of
the Apron Feeder drive will be overloaded in addition the material on the pan apart to spi
ll.

3. When Apron Feeder is to be stopped, it is preferable that there is no material left on the
pan.

4. Check that the feed on to the Apron Feeder is central and that the pan at the feed point is
Is running centrally and straight. If not, establish the cause of the non-central feed and
rectify as necessary.

5. Inspect the condition of the pan of apron feeder regularly and arrange for the earliest
possible repair of any damage which may have occurred as this can make a worth while
extension to the useful life of the pan.

6. Check regularly that all rollers and driven sprockets are rotating freely. If not, rectify or rep
lace as necessary to avoid unnecessary wear, inspect all rollers regularly and arrange for
any damage ones to be replaced at the earliest opportunity.

7. Grease or oil all bearings and moving parts requiring lubrication at regular intervals. Beari
ngs should be stripped, cleaned and repacked with grease at the intervals as recommend
ded by ELECON. It is important to bear in mind of that the bearing should not be over
over greased as this can cause over heating and consequent damage.

8. In the case of gear boxes, check the oil level indicator everyday or two, replenish if necess
ary or drain if it is out dated and refill with clean oil as recommended by ELECON.

9. Inspect the driving gear regularly following the manufacturers, maintenance instruction for
the various parts involved. Ensure that any brakes involved are correctly adjusted to avoid
snatching when running or slipping when at rest and that linings are renewed immediately
as it is becomes necessary.


10. If possible, keep regular record of motor AMP, as this will give an indications of any overload
ing which occurs and may be of assistance in tracing faults in this system











11. In the interest of different operation and in obtaining the maximum life from equipment, it
is important that operating condition should be kept as clean as possible. Any spillage,
which occurs, should be cleaned up on floors or in any other location to the point where
it is obstructing to running equipment. Chutes should be inspected at regular intervalsand
any build up of material, which is accumulation should be removed in order to minimize
the likelihood of eventual chute blockage.

12. It is important to ensure that any item of plant require repair or replacement it should be dealt
with as soon as possible to avoid the possibility of chain reaction or damage. Also if the course
of inspection any abnormality in operation should be seen for which there is no obvious reason
this should be and expert advice sought


































PREVENTIVE MAINTENANCE INSTRUCTION
G E N E R A L


The reliable operation and life of machine is strongly influenced by the standard of maintenance of
the electrical and mechanical equipment

It is imperative that regular checks are carried out in respect to lubrication,operating efficiency and
wear to replace damage or won parts.

The painting should be subjected to routine checks and where necessary to be touched up in an
efficient manner.

The frequency of such checks and associate maintenance work depends upon length of operation
and the possible wear on the machine parts

Contamination caused by spillage or other accumulations of dirt should be constantly cleaned up.
This also applies to the cleaning up of machinery as well as for steel structure, protection device.

Rotating machine parts must only be cleaned when they are at standstill whereby the respective
safety and accident prevention regulation must be observed.

Damage to load bearing steel structure, loose rivets, bolts or screws as also the peeling of paint
which point to over stressing respectively, to forceful deformation must be reported immediately to
the supervising personnel.



































LUBRICATION SCHEDULE















SPARE PARTS LIST