C 106 Components Handbook Low

CEMA Rated Idlers
The Broadest Range of Conveyor Idlers on the Market
Quick Specs Classes: CEMA B, C, D, E, and F Roll Diameter: 4- 8 u Belt Widths: 18- 120
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CEMA Rated Idlers
Frequently Asked Questions Which CEMA class do I need?

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Features and Benefits

SpinGuard Seal Technology: (Fig 1.1)
Contact seal prevents foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants u Stationary external seal prevents material pinch points
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According to CEMA, the main influences in selection are belt weight, material weight, load rating, belt sag, idler life, belt rating and belt tension. Its a confusing combination of data that weve tried to simplify with our Idler Selector Calculator. Find it in the Quick Links section at superior-ind.com. 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. Its also a fact that larger diameter rolls have longer lives due to fewer revolutions and thicker shells. 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 Reaction
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Distributors stocked with standard products One to two day turnarounds on custom designs
Which roll diameter do I need?

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High Quality Construction

Thick or thicker steel construction compared to other brands Two year complete components warranty u Largest, broadest range of all CEMA categories on the market
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Economical Retrofit Rolls

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Where can I buy Superior Idlers?

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Slotted shafts fit most competitor frames Hex nut adapter available for hex nut style brackets Angled base sheds material Flared, non-clogging center stands No material pinch points between roll and frame
No Maintenance Base Frame

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Idler Specifications
Specs CEMA B CEMA C Bearing Size 17 mm 20 mm 25 mm 40 mm 50 mm Diameter 4, 5 4, 5, 6 5, 6 6, 7 7, 8 Thickness 11, 9 Ga 11, 9, 7 Ga 9, 7 Ga 1/4 1/2 or 3/4 Belt Width 18- 48 18- 60 24- 72 36- 96 42- 120
Digital Literature
Forward to Colleague
CEMA D CEMA E CEMA F
01
SpinGuard Seal Technology

1
Flat Surface
1
2
Material will not build up across the flat end disc surface
Stationary External Seal
3 4
2
3
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
4
Contact Seal
First defense against contaminants is the contact seal, which creates less drag than a rubber seal
5
Triple Labyrinth Seal
Second defense is the triple labyrinth seal which makes contaminants travel a longer distance u The labyrinth is also grease filled to keep contaminants away from the ball bearing u The durable seal material is more durable and is less susceptible to corrosion
6
Producer Perspective
Fig 1.1 SpinGuard Seal Cutaway
Ball Bearing
Factory sealed metric ball bearing on all CEMA rated idlers
Idler Features
1
Base Plate
Open end stand design gives better access for single or double bolt hole mounting 2 3
2
No Pinch Points
4 5 6
3
No pinch points between roll and frame means no fugitive material jamming
Locking Mechanism
Integrated locking tab or retainer clip holds roll tight to the frame and offers easy roll change out
4
Narrow Roll Gap Center Stands

Non-clogging
1
5
No pinch point that leads to belt damage
Base Angle
Sheds material, preventing build-up
02
Fugitive 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 werent 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 Superiors seal in magazines and now Im 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
Part Number Guide

Example: C6-35E-36 1 2 3
CEMA Rating
Roll Diameter
4 - 8
Troughing Angle
20, 35, 45
Idler Type
See Below
Belt Width
18 - 120
B, C, D, E, F
1
CEMA Rating or Series

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Specify either CEMA B, C, D, E, or F Specify either 4, 5, 6, 7 or 8 for the roll size diameter Specify either 20, 35, or 45 for the troughing angle Specify the idler identification letter for the particular idler, you may need from the chart to the right Specify the belt width
Idler Type
E Troughing Idler Equal Length Rolls EI Rubber Cushion Troughing Idler EA Self-Aligner BA Bi-Directional Aligning Idler RET Return Idler FLT Flat Carrier Idler FLTI Flat Carrier Rubber Cushion Idler RETI Return Rubber Cushion Idler RETU Urathon Return RETUSP Spiral Urathon Return Roll RETA Return Self-Aligning Idler Roll RETAI Return Self-Aligning Rubber Cushion Idler RETV V-Return Idler P Picking Idler Length Rolls U Troughing Idler Unequal Length Rolls CM Low-Profile Channel Mount Idler CMI Channel Mount Impact Low Profile Idler SM Low-Profile Standard Mount Idler SMI Standard Mount Impact Low Profile Idler GO Offset Troughing Idler EW Wire Rope Idler VPE Variable Pitch Idler MOX Moxie Roll CB CB504 Series LS Live Shaft LSB Live Shaft Beater
Roll Diameter
u
Troughing Angle
u
Idler Type
u
Belt Width
u
03
Idler Styles
Equal Troughing Moxie Rolls Unequal Troughing CB504 Series Feeder/Picking
Channel Mount Low Profile
Impact
Offset Center Roll
Wire Rope
Variable Pinch
V-Return
Self-Aligner
Self-Aligning Return
Live Shaft Rollers
Beater Bar Return
Flat Carrier Idler
Rubber Cushion Flat Carrier
Return
Rubber Disc Return
Urathon Return Roll
Spiral Urathon Return Roll
Garland
Idler Styles
Products Available in CEMA Rated Idlers

Idler Style Equal Troughing Moxie Rolls
CEMA B x x x x x x x x x x x
CEMA C x x x x x x x x x x x x x x x x x x x x x x
CEMA D x x x x x x x x x x x x x x x x x x x x
CEMA E x x x x x x x x x x x x x x
CEMA F x x x x x x x
Unequal Troughing Feeder/Picking Channel Mount Low Profile Impact Offset Center Roll Wire Rope Variable Pitch V-Return Self-Aligner Self-Aligning Return Live Shaft Return Beater Bar Flat-Carrier Rubber Cushion Flat Carrier Steel Return Rubber Lagged Return Rubber Disc Return Urathon Return Roll
Spiral Urathon Return Roll Garland Return
1-800-321-1558 Find local distribution at superior-ind.com/distributor 2012 Superior Industries CL-101
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04
Moxie Rolls
Energy Efficient Idlers Consume Less Power than Steel
Quick Specs Classes: CEMA C and D Roll Diameters: 5 and 6 u Belt Widths: 18 - 72
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Moxie Rolls
Frequently Asked Questions What are Moxie rolls made from?

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Sheds Sticky Material u Standard Steel: Wet, sticky material tends to cake onto steel cans u Moxie Rolls: The lubricity of Moxie rolls sheds sticky material u Standard Steel: Material bonded to idlers is a chief source of
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Theres a combination of materials that go into the recipe to develop our specially formulated Moxie rolls. 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. 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.
How thick is the idler shell?

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misaligned belts Moxie Rolls: Reduced misalignment and tracking issues Video Proof: http://superior-ind.com/components/idlers/moxie
How is the roller easier on my crews?

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Corrosion Resistant u Standard Steel: In corrosive environments, steel can rust (Fig 2.1) u Moxie Rolls: The specially designed formula is rust resistant u Note: Upgrade to stainless steel shafts and frames Safety u Standard Steel: The more weight, the more power requirements u Moxie Rolls: Low roll resistance cuts horsepower requirements u Standard Steel: Heavy rollers can be ergonomically unhealthy u Moxie Rolls: The lightweight rollers weigh up to 44% less (Fig 2.2) Reduced Noise u Standard Steel: Steel generates a clanking sound when it contacts
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belt fasteners Moxie Rolls: 3x quieter than steel, Moxie rolls provide noise control in residential zones
Moxie Steel
40 Weight (lbs) 30 20 10 C5-36 C6-36 D5-36
44%
21%
44%
23%
Fig 2.1 No More Corroded Idler Rolls Digital Literature

D6-36
Fig 2.2 Weight Comparison
05

1
Flat Surface:
Material will not build up across the flat surface 1 3 4 2

3 2
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
4
Contact Seal:
First defense against contaminants is the contact seal which creates less drag than a rubber seal 6
5
Triple Labyrinth Seal:
Moxie Roll Cutaway
Second defense is the triple labyrinth seal which makes contaminants travel a longer distance u The labyrinth is also grease filled to keep contaminants away from the ball bearing u The glass filled polypropylene seal material is more durable and is less susceptible to corrosion
6
Ball Bearing:
Factory sealed metric ball bearing on all CEMA rated idlers
Pizza Cutter
If we didnt 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 arent 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
Part Number Guide

Example: C5-35E-36MOX
CEMA Rating
C or D
Roll Diameter
5 or 6
Troughing Angle
20, 35, 45
Belt Width
18- 72
Idler Type
MOX
* For return Moxie rolls, substitute roll diameter and troughing angle with RET.
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06
81/91 Series Regreasable Idlers

Regreasable Idlers Stop Invading Water Damage
4 1 3
Quick Specs Classes: CEMA C and D Roll Diameters: 4" - 6 u Belt Widths: 18 - 72
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Fig 3.1 Idler Seal Cutaway
Frequently Asked Questions What are common applications?

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Heavy Duty Rollers
9 gauge on 5 7 gauge on 6 u As thick or thickest steel in the industry
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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 isnt able to do as much damage. 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. As ball bearing technology has improved and the cost of maintenance has increased, ball bearings have significantly replaced tapered roll as the market standard. 5 7 6
How often do you regrease?

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Regreasable Idlers
One side grease relief Grease-filled single point lubrication u Inner grease seal prevents grease from escaping into roll cavity
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Bearing Protection
Delrin triple labyrinth seal External deflector seal keeps material away u Tapered roll bearings
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How do tapered compare to ball bearings?

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Figures 3.1 and 3.2

1 2 3 4
Grease retainer cup 3/4 taper roller bearing Delrin triple labyrinth seal External deflector seal
5 6 7
Hex nut with clip 7 gauge steel center stand Punched hole for safety cable
Part Number Guide

Example: 815-35E-36
Fig 3.2 Idler Frame Digital Literature

Idler Type and Diameter

81 or 91 and 4, 5 or 6
Troughing Angle
20, 35 or 45
Idler Style
Equal Length, Feeder/Picking or Offset Center Roll
Belt Width
18- 72
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07
40 Series Idlers
Replacement Rollers for Track Mounted or Mobile Equipment

Interchange with Powerscreen Rollers
Universal center bracket Replaceable end rollers and die cast stands u 11 gauge steel
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Centered Rolls
Quick Specs Roll Diameter: 4 u Angles: 20, 30, 45, 60 u Belt Width: 24- 54
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Part Number 43-000010 43-000011 43-000012 43-000013 43-000014 43-000015 43-000016 43-000017 43-000018
Powerscreen # Roll Length 07020238 02021138 08010101 06530102 05120115 04220133 09130180 09120129 03220103 8.14 12.00" 14.87" 18.87" 20.87" 25.15" 26.75" 35.07" 35.70"
Shaft Length 9.20 13.06" 15.93" 19.93" 21.87" 26.21" 27.81" 36.13" 36.76"
Metric Size L216 L314 L388 L490 L538 L648 L690 L900 L916

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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. 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.
Outside Rolls
Part Number 43-000019 Powerscreen # Description 8 - 3/4" Outside roller only Degree Fits all degrees
What is the advantage?

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Return Rolls
Part Number 43-000025 43-000026 43-000027 43-000028 43-000029 43-000030 43-000031 Powerscreen # Roll Length 02021145 06530103 05420143 08010102 05120116 03220104 07230107 28.00" 33.50" 33.62" 35.50" 40.00" 53.50" 62.00" Shaft Length 33.00" 38.50" 38.62" 40.50" 45.00" 58.50" 67.00 Metric Size L840 L978 L980 L1025 L1145 L1485 L1700
40 Series Idlers
Center Brackets Return Roll U-Bolts

Part Number 13-03004 13-05005 Shaft Diameter 1 .75 Part Number 43-000021 43-000022 43-000023 43-000024
Powerscreen # Description LH2020608 RH2020609 LH2020606 RH2020607 LH2020604 RH2020605 LH2020610 RH2020611 Center bracket only Center bracket only Center bracket only Center bracket only
Degree 20 30 45 60
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Digital Literature
08
CB504 Idlers
Direct Interchange with MARCO and Cedarapids Idlers
Quick Specs Roll Diameters: 4 and 4-1/2 Stub Pins: 2-1/2 and 3 u Belt Widths: 18- 48
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CB504 Idlers

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Maintenance Friendly in Tight Locations
Channel mount, low profile designs CB504 bearings u Direct interchange with MARCO or Cedarapids idlers u Replacement bearings and pullers
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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. CB504 Idlers are designed to easily replace a bearing and continue to use the can and frame for MARCO or Cedarapids style idlers. Compared to other idlers, CB504 style idlers are designed and manufactured with sealed bearings versus to an external seal design.
What is the idler designed for?

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Adapt to Application
Channel mount design Standard mount low profile design option u Rubber impact design option
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What is special about the bearings?

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Part Number Guide

Example: CB45-35E-36
Idler Type and Diameter

CB and 4 or 4-1/2
Troughing Angle
20 or 35
Idler Style
Equal or Channel Mount
Belt Width
18- 48
CB 504 Parts
Part Number Description 41-542300 30-405044 30-456024 03-01017 32-044081 32-410450 3 Double Pin 4 End Disc 4-1/2 End Disc CB 504 Bearing 1-1/2 Drop Bracket 4-1/2 Drop Bracket Part Number 32-506000 41-541250 41-542250 41-542263 41-541300 Description Channel Mount 2-1/2 Single Pin 2-1/2 Double Pin 2-5/8 Double Pin 3 Single Pin -
Bearing and Pins Digital Literature

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09
Self-Aligning Idlers
Economical Belt Tracking Tool
Quick Specs Classes: CEMA B, C, D, E, and F Roll Diameters: 4 - 7" u Belt Widths: 18 - 96
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Self-Aligning Idlers
Frequently Asked Questions Why might I need a troughing self-aligner?

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Reduce Belt Mis-tracking
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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 belts top side. A carry-side, or troughing self-aligner will track the belt straight at every radial position. 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. Compared to a harder, straighter style guide, the concave shape makes for a softer landing when the side of the belt contacts the guide.
Misaligned belts contact side roller or shoe pad After contact, idler pivots and centers belt Compared to steel, urethane side guide rollers are softer on belting Concave shaped side guide rollers keeps traction on belting
Protect Sides of Belting (Fig 6.1)

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Why choose this style?

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Contact seal prevents foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants u Stationary external seal prevents material pinch points
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Standard
Positive Action Belts
Shoe Activated
Bi-Directional Belts
Why is the belt guide concave shaped?

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Troughing
Troughing
Return
Return
Part Number Guide

Example: B5-35EA-36
Fig 6.1 Softer Landing for Belting Digital Literature

CEMA and Diameter

B, C, D, E or F and 4- 7
Troughing Angle
20, 35 or 45
Aligner Style
Standard (EA) or Shoe Activated (BA)
Belt Width
18- 96
*For return roll self-aligners, substitute RETA for troughing angle and aligner style. 1-800-321-1558 Find local distribution at superior-ind.com/distributor 2012 Superior Industries CL-106
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10
Navigator Return Trainers

Constantly Working to Maintain Proper Belt Tracking
Quick Specs Belt Widths: 24- 72 Lagged Diameter: 7-3/4 or 10-3/4 u Non Lagged Diameter: 7 or 10
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Navigator Return Trainer

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Save the Belt
Works to provide continuous belt alignment Quick reaction time upon installation, reducing the risk of damage u Standard rubber lagging increases friction between belt and roller Video Proof: http://superior-ind.com/components/idlers/aligners/navigator
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The trainer can be used in any application where belt tracking is an issue. Its also recommended for applications where return self-aligners will not fit or are not working. We recommend 25 to 50 feet from the tail or head pulley on the belts 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. 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.
Where should I install?

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Avoids Material Buildup

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

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Can you replace the bearings?

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Largest diameter roll for longer service life Effective in both wet and dry conditions
Be
e for
This Belt was Eating into Brackets and Ripping

Af ter
Fig 3.1 Internal Bearings Digital Literature

Belt Straightened Immediately After Installation
11
Bad 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, its a pretty expensive situation to change out a belt and anyway you look at it, its 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
How it Works
Misaligned Belt Belt Alignment Aligned Belt
Misaligned belt puts pressure on one side of the Navigator return trainer
Misaligned pressure causes the Navigator return trainer to tilt, centering the belt
The Navigator return trainer is constantly guiding and centering the belt
Part Number Guide

Example: NAV-36 or NAV-36LAG
Roller Style
NAV
Belt Width
24- 72
Lagging Options
LAG
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12
Urathon Return Rolls

Prevent Idler Buildup, Shed Sticky Material
Quick Specs Classes: CEMA B, C, D, and E Roll Diameters: 5, 6 and 7" u Belt Widths: 18 - 96
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Urathon Return Rolls

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Sticky Shedder
Eliminate material buildup No maintenance, self-cleaning rolls u Reduce tracking challenges, belt damage and premature failure
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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. Both the standard and spiral versions of this return roll are made from a 87A durometer urethane. Yes, however it involves removing the weld on the retaining ring in order to slip the discs off the shafts.
How hard is the urethane?

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Longer Lasting
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At least 3x the life of rubber discs Reduce maintenance and operating costs Spiral option cleans dirty side of belt (Fig 8.1) Material buildup is the leading cause of belt damage Slotted shaft fits most competitor brackets
Can you replace the discs?

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Belt Cleaning
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Retrofit Rolls
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Rubber Lagged Returns Rubber Disc Return Idlers Urathon Return Roll
60
65
87A
Fig 8.1 Spiral Urathon Return Roll Digital Literature

Durometer is a unit of measurement used to signify the hardness of a material
Durometer Rating
13
Urathon Return Roll

fo Be re Af ter
Sticky Material Clinging to Steel Returns Causes Belt Mis-tracking
Urathon Return Roll Sheds Sticky Material
Balloon 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 didnt 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
Part Number Guide

Example: C5-RETU-36
CEMA Rating
B, C, D, or E
Roll Diameter
5, 6 or 7
Idler Type
RETU or *RETUSP
Belt Width
18- 96
* Spiral option is only available in 6 diameter
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14
Rubber Disc Returns

Cost Effective, Prevents Material Buildup
Quick Specs Classes: CEMA B, C, D, and E Roll Diameters: 4", 5 and 6 u Belt Widths: 18 - 72
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Rubber Disc Return Idler

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Prevent Material Buildup
Sheds material in moist, sticky applications Discs designed with self-cleaning, flat surface u Discs prevents buildup on roll and on return side of belt
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In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns. The answer comes down to simple economics. Compared to the Urathon Return Roll, our Rubber Disc Returns can cost up to 20% less.
Why this style over others?

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Save the Belt

Provides better support for belting Reduces costly belt tracking issues caused by material buildup u Disc spacing prevents belting from getting stuck within outside discs
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Long Lasting Return Rolls

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Synthetic rubber stable in wide temperature range Better wear characteristics than steel rolls
60
65
87A
Durometer Rating
Prevent Material Buildup Digital Literature

Part Number Guide

Example: C5-RETI-36
CEMA Rating
B, C, D, or E
Roll Diameter
4, 5 or 6
Idler Type
RETI
Belt Width
18 - 72
CUSTOMER CARE PLAN
15
Rubber Lagged Return Rolls

Cost Effective, Prevents Material Buildup
Quick Specs Classes: CEMA C, and D Roll Diameters: 4", 5 and 6 u Belt Widths: 18 - 72
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Rubber Lagged Return Rolls

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In sticky applications when material cakes and builds up onto return idler rolls eventually causing belt tracking concerns. You bet! You can choose between 1/4 or 1/2 rubber depending on the ruggedness of your application. Rubber lagged style is targeted for self-aligner frames.
Sheds material in moist, sticky applications Built with hot vulcanized, synthetic rubber Flat style eliminates belt trapping common to disc style returns Reduces costly belt tracking issues caused by material buildup
Does lagging come in different sizes?

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Save the Belt

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Why this style over others?

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Longer Lasting Return Rolls

60 durometer rubber, similar to car tires (Fig 10.2) Lagging increases thickness of rolls, boosting wear life u Better wear characteristics than steel rolls
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60
65
87A
Fig 10.2 Durometer Rating
Part Number Guide

Example: C5-RET-36LAG.25
Shed Sticky Material Digital Literature

CEMA and Diameter

C or D and 4, 5 or 6
Idler Type
RET
Belt Width
18- 72
Lagging and Thickness

LAG and 1/4 or 1/2
CUSTOMER CARE PLAN
16
Beater Bar Return Rolls

Deflect Sticky Material Off the Belt
Quick Specs Shaft Size: 1-7/16 or 1-15/16 Roll Diameters: 5 and 6 u Belt Widths: 18 - 72
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Beater Bar Return Rolls

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Rods create beating motion to keep belt clean and free of any carryback material u Bars allow gaps for material to escape, eliminating buildup on roll
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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. 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.
Save the Belt

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Where is the install point?

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Reduces costly belt tracking issues caused by material buildup Mounted with live shafts to support conveyor loads
Part Number Guide

Example: LSB-536-107
Idler Style
LSB
Roll Diameter
5 or 6
Belt Width
18- 72
Shaft Size
107 for 1-7/16 or 115 for 1-15/16
Pillow Block Bearing Order Info

Part Number 03-02005 03-02016 Dimensions 1-7/16 1-15/16
Digital Literature
CUSTOMER CARE PLAN
17
V-Return Idlers
Manages Rugged Loads While Aligning Long Overland Belts
Quick Specs Classes: CEMA C, D, and E Roll Diameters: 5, 6, and 7 u Belt Widths: 36 - 96
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V-Return Idlers

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Save the Belt
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Primarily used on long overland conveyors, v-return idlers are used in applications with wide, thick and heavy belting or horizontal curve conveyors. 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.
Help keep the belt aligned Two-roll returns have higher load ratings than single rolls Easy mounting into standard return roll locations Avoid making changes to conveyor structure
What is the load rating?

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Easy Installation
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Contact seal helps prevent foreign material from entering seal cavity Grease-filled triple labyrinth seal shuts out contaminants u Stationary external seal prevents material pinch points
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Part Number Guide

Example: C5-10RETV-36
CEMA and Diameter

Mounting Bracket Digital Literature
Roll Angle
10 or 15
Idler Type
RETV
Belt Width
36- 96
C, D, E and 5- 7
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18
Exterra Primary Belt Cleaner

Jam Packed with More Material Where its Needed Most
Quick Specs Belt Widths: 18 - 72 Blade Widths: 10 - 70 u Durometer: 87A Urethane

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Exterra Primary Belt Cleaner
Frequently Asked Questions Why is belt width minus 8 standard?

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Extended Wear Life
Compared to other comparable primary blades, weve packed ours with 15-40% more urethane (durometer = 87A) u Thicker blade tip means extra material at the critical point of contact
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. Roughly, its 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) There are two options belt width plus 30 or belt width plus 42.
Interchangeable Blade
u
How often should I reset the tension?

u
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 Maintenance

Shipped pre-assembled Blade fits to mounting pole without tools u Simple nut adjustment tightens tensioner u Upgrade to Exterra SFL Primary Belt Cleaner (Fig 14.1)
u u
What is the length of the pole?

u
Se
r Fo
Lif
Digital Literature
One Time Tensioning For the Life of the Blade
Fig 14.1 Exterra SFL Primary Belt Cleaner
19
Part Number Guide

Example: P-4280722
Primary Belt Cleaner

P
Belt Width
18- 72
Belt Width -8 or -2
8 or 2
Pole Length
48- 114
Tensioner Quantity
1 or 2
Complete System Part Numbers

Part Number Belt Width P-1820481 P-1880481 P-2420541 P-2480541 P-3020601 P-3080601 P-3620661 P-3680661 P-4220722 P-4280721 P-4820782 P-4880782 P-5420842 P-5480842 P-6020902 P-6080902 P-6620962 P-6680962 P-7221022 P-7281022 18 18 24 24 30 30 36 36 42 42 48 48 54 54 60 60 66 66 72 72 Blade Length 16 10 22 16 28 22 34 28 40 34 46 40 52 46 58 52 64 58 70 64 Weight 41 38 47 44 53 50 59 56 65 62 75 72 85 82 95 92 105 102 117 112 32-000097 32-000094 13-00975 07-00540 07-00541 07-00542 07-00543 07-00544 07-00545 07-00546 07-00547 07-00549 07-00548 07-00550
Replacement Part Numbers

Part Number Description Assembly Bracket Tensioner Bracket Non-Tensioner Pin Clip Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Dimensions 5/16 x 2-1/2 10 16 22 28 34 40 46 52 58 64 70
Optional Mounting Brackets

u
If the head section of your conveyor is not equipped with proper mounting, consider this Exterra belt cleaner mounting bracket. 22-3/16 4
8 6
25-1/2
4-1/2
Optional Mounting Bracket
EXCLUSIVE PATENT
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TECHNOLOGY
20
Exterra SFL Dual Belt Cleaner

Primary and Secondary Scraper with One Mounting Point
*Patent Pending
Quick Specs Pulley Diameters: 12- 30 Belt Widths: 18- 60 u Secondary: Tungsten Carbide
u u
Exterra SFL Dual Belt Cleaner
Frequently Asked Questions When do I need a secondary cleaner?

u

Hassle-Free, In-Field Installation
One common mounting point Secondary blade shares primary blades mounting pole and tensioner u Maintain existing conveyor structure Installation Instructions: http://superior-ind.com/components/ accessories/cleaners/exterra-sfl-dual
u 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. Because conveyor frames are not usually designed to accommodate secondary cleaners, they arent usually installed. Sharing one mounting pole, this system allows primary and secondary cleaning power without modifying a conveyor structure. 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.
What is special about the design?

u
Set for Life Tensioning

Spring tension is set to match primary blade wear pattern As primary blade wears, spring automatically adjusts to keep proper tension to both blades u Tension is load equalizing as one or both blades wear, dynamically maintaining accurate tension
u u
Will the system fit in my application?

u
Extended Wear Life

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
u
User Friendly Maintenance

Replaceable secondary blade segments adjust to accommodate all splices u Replaceable primary blade u One time tensioning for the life of blade
u
Eliminate Carryback Digital Literature

21
Part Number Guide

Example: SFLD1-428072
SFL Belt Cleaner

SFL
Pulley Diameter
D1, D2
Belt Width
18- 60
Belt Width -8 or -2
8 or 2
Pole Length
48-114
* Diameter of Pulley: D1 = 12-20 D2= 22-30
Complete System Part Numbers

Belt Width 18 18 24 24 30 30 36 36 42 42 48 48 54 54 60 60 Blade Length 16 10 22 16 28 22 34 28 40 34 46 40 52 46 58 52 Primary Blade Only SFLP-182048 SFLP-188048 SFLP-242054 SFLP-248054 SFLP-302060 SFLP-308060 SFLP-362066 SFLP-368066 SFLP-422072 SFLP-428072 SFLP-482078 SFLP-488078 SFLP-542084 SFLP-548084 SFLP-602090 SFLP-608090 D1 SFL Dual Belt Cleaner Tungsten SFLD1-182048T SFLD1-188048T SFLD1-242054T SFLD1-248054T SFLD1-302060T SFLD1-308060T SFLD1-362066T SFLD1-368066T SFLD1-422072T SFLD1-428072T SFLD1-482078T SFLD1-488078T SFLD1-542084T SFLD1-548084T SFLD1-602090T SFLD1-608090T D2 SFL Dual Belt Cleaner Tungsten SFLD2-302060T SFLD2-308060T SFLD2-362066T SFLD2-368066T SFLD2-422072T SFLD2-428072T SFLD2-482078T SFLD2-488078T SFLD2-542084T SFLD2-548084T SFLD2-602090T SFLD2-608090T
Replacement Part Numbers

Part Number 32-000188 49-000575 13-00975 07-00540 07-00541 07-00542 07-00543 07-00544 07-00545 07-00546 07-00547 07-00549 07-00548 07-00550 Description Bracket Tungsten Exterra Secondary Belt Scraper Blade Pin Clip Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Primary Scraper Blade Dimensions 5/16 x 2-1/2 10 16 22 28 34 40 46 52 58 64 70
EXCLUSIVE PATENT
CUSTOMER CARE PLAN
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TECHNOLOGY
22
Conveyor Pulleys
A Complete Line of Pulleys for Every Application
Standard Sizes
u u
(Custom sizes available on request)
Diameters: Up to 60 Face Widths: Up to 120 u Shafting: Up to 15 Frequently Asked Questions How do I know which class is for me?
u
Conveyor Pulleys

Fast Lead Times
1-2 day turnarounds Expediting services available u 10 warehouses stocked with standard products (Fig 17.3) u North American distribution network
u 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. The specs listed above are considered our standard product line; however that doesnt 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. 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.
Comprehensive Product Line

From light, portable applications to high tonnage, extreme jobs CEMA, Mine 1.5, Mine 2.0, Super and Engineered Classes u Specialty: Spiral drums and wings, deflection wheels and dead shaft conveyor pulleys
u u
What are Superiors limitations?

u
Performance Matched Design

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)
u
Where can I purchase Superior pulleys?

u
Quality Craftsmanship
u u
Robotic welding machines for consistent, quality welds Hand welders trained and certified by American Welding Society (AWS)
Fig 17.1 Drive Weight Stress Test Digital Literature

23
Conveyor Pulleys
Pulley Product Line
Description
Wing Pulleys Drum Pulleys
CEMA Duty
Mine Duty 1.5
Mine Duty 2.0
Super Duty
Core SystemsTM Design
Chevron Wing Pulley
Design Standards
Load, dimensions and crown defined by ANSI B105.1
Roughly 1.5X service Roughly 2.0X service factor of CEMA factor of CEMA standard standard
Exceeds 2.0X service factor of CEMA standard
Engineered class, FEA Analysis Design, construction based on belt tension, conveyor load, and belt wrap High tonnage
Conveyor Type
Light duty, portable
Medium duty
Heavy duty
Extra heavy duty
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
Pulley Product Line

Pulley Types CEMA Drum Pulley CEMA Wing Pulley Mine Duty 1.5 Drum Pulley Mine Duty 2.0 Drum Pulley Mine Duty 2.0 Wing Pulley Super Drum Pulley Super Wing Pulley CEMA Chevron Wing Pulley Mine Duty Chevron Wing Pulley Super Chevron Wing Pulley
Diameter 4- 60 6- 60 10- 60 10- 60 8- 60 10- 60 10- 60 10- 20 12- 36 12- 42
Integral Hub Diameter 12 and under 12 and under 12 and under 12 and under All CEMA
Face Width 12- 78 12- 78 12- 78 12- 102 12- 78 12- 102 12- 78 12- 63 12- 63 20- 75
Contact Bar Thickness 1/4 x 1-1/2 minimum, 3/8 x 1-1/2, 5/8 x 1-1/2 5/8 x 1-1/2 minimum 3/4 x 2 minimum 1 x 1/2 half round bar 1 round bar 1-1/2 round bar
*NOTE: Other diameters and face widths available upon request. Several hub and bushing types are available with all pulleys.
24
Pulley Product Line
CEMA Drum Pulley
Mine Duty 1.5 Drum Pulley
Mine Duty 2.0 Drum Pulley
Super Drum Pulley
Spiral Drum Pulley
CEMA Wing Pulley
Mine Duty 2.0 Wing Pulley
Super Wing Pulley
Spiral Wing Pulley

li mb es
e riv
As
se
CEMA Chevron Wing Pulley
Mine Duty Chevron Wing Pulley

e ine red
En
Super Chevron Wing Pulley
Core SystemsTM Designs
25
Quick Deliveries
Fig 17.3 Ten Pulley Warehouses Stocked with Standard Products
Pulley Lagging
Herringbone
Diamond
Smooth
Chevron
Slide Lag
Ceramic Lagging Options
Urethane
EXCLUSIVE PATENT
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TECHNOLOGY
26
Chevron Wing Pulley

V-Shaped Wing Pulley Deflects Fugitive Material
Quick Specs Classes: CEMA, Mine and Super Duty Diameters: 10" - 42 u Face Widths: 12 - 75
u u
Chevron Wing Pulley

u

Deflects and Sheds Material u Traditional Wing: The impact of rocks is directly perpendicular to
u
Systems where fugitive material is causing wing bending, where uptime is crucial and where noise levels might be a concern. Compared to standard wing pulleys, the Chevron wing is a good alternative for a gravity take-up. Its a location where you have spillage and where you want to prevent wedged rocks and bent wings. A spirals 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.
Is it only a tail pulley?

u
the wing, causing material to trap easily. Chevron Wing: Rocks hit the wings at a glancing blow, deflecting fugitive material out and away.
Reduces Wing or Fin Bending u Traditional Wing: Over time, trapped fugitive material causes wings
u
to tip or bend. (Fig 16.1) Chevron Wing: Constant deflection prevents entrapment of fugitive material.
How does it compare to spiral wing pulleys?

u
Longer Lasting Belts u Traditional Wing: Trapped material, bent wings and sharp contact
u
bars are three of the most common causes of belt damage. 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
u
vibration and 120 db of sustained noise. Chevron Wing: Continuous belt contact significantly reduces beating action, vibration and generates just 70 db of sound.
Traditional Wing Pulley
Chevron Wing Pulley
Fig 16.1 No More Bent Wings Digital Literature

Fig 16.2 Constant Belt Contact
27
Chevron Wing Pulley

Chevron Wing Pulley Product Line
Specs CEMA Duty Mine Duty Super Duty Diameter 10- 20 12- 36 12- 42 Face Width 20- 63 12- 63 20- 75 Maximum Wing Height Not defined Varies with diameter Varies with diameter Wing Thickness 3/16 or 1/4 1/4 - 5/16 3/8 Wear Bar Thickness 1 x 1/2 half round bar 1 round bar 1-1/2 round bar
150 db 125 db 100 db 75 db 50 db 25 db
Standard Wing Chevron Wing Pulley

Radio, Street Noise Jet Engine, Fireworks
Fig 16.3 Reduced Noise Pollution
Material Deflection Reduces Trapped Material
Vibrating 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
Part Number Guide

Example: CHVS-4275XT70
Style
CHV
Type
C (CEMA), M (Mine Duty), S (Super Duty)
Diameter
10- 42
Face Width
12-75
Hub Type and Sizes

XT25 - XT100
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28
Power Transmission Conveyor Components Consulting Services
Standard Sizes
u u
(Custom sizes available on request)
Diameters: Up to 60 Face Widths: Up to 120 u Shafting: Up to 15 Frequently Asked Questions What is Core Systems Designs?
u
Core Systems Designs - Dual Head End Drive

Single Source Supplier
Avoid sourcing parts packages from multiple vendors One point of contact u One point of purchase
u u
Simply put, its a consulting service to design and supply your power transmission components. 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. Its one phone call, one point of contact and one warranty. If all you need is a conveyor pulley, then you probably dont need Core Systems Designs. Weve partnered with local distributors to get you the best service and support. To find yours, visit superior-ind.com/distributor.
When do I need Core Systems Designs?

u
Performance Matched Components

Engineering services align power transmission components to your application u Engineers apply Finite Element Analysis (FEA) to build per application stress conditions
u
Pre-assembled Parts Packages

u u
Eliminates the headaches of onsite assemblies Reduces installation time
Who do I call?
u
Quick Deliveries
Deliveries exceed industry standards Optional 1-2 day turnarounds u Expediting services available u Stocked power transmission warehouse
u u
Digital Literature
29
Single Source Supplier

u
Engineering consultants work directly with you to determine the correct drive package for your application. Motor Couplings Gear Box Shafting Pulley Bearing
Variable Frequency Drive
Guards
Bushings
Shipping Structure
Complete Drive Packages
Bearings
Motors
Drives
Shafting
Couplings
Bushings
Gear Box
Guarding
Take-ups
30
How it Works
Drive Package Replacement

u
There are two routes, sourcing and assembling the parts on your own or accessing them through one point of purchase.
Contact Superior Distributor

u
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 Package

u
Using the specs of your application, a performance matched package is engineered.
Manufacturing and Assembly

u
Optional 1-2 day turnarounds from phone call to completion if needed.
Package Delivery
u
Guaranteed to work, with the security of a two-year warranty.
31
Core SystemsTM Pulley Data Sheet

Complete this Form for a Customized Core Systems Quotation coresystems@superior-ind.com Toll Free 800-321-1558 Fax 320-589-3892 Date ________________________________________________ Customer _____________________________________________ Plant/Mine/Project ______________________________________ Application Data:
Profile 1 Ambient T/TU Temp Range (degrees) ____________________________ D Profile 1 T/TU Altitude (ft) _____________________________________ D Profile 1 T/TU D Operation (days/year) ____________________________ T/TU DMaterial Profile 2 D S
Submitted By __________________________________ Contact Name __________________________________ Contact Phone or Email ___________________________
Operation (hours/day) ___________________________________ Conveyor Data:Profile 2 T/TU

D S Conveyor Name/Tag _____________________________________ Profile 1 Conveyor Capacity (TPH) _________________________________ T/TU T D Profile 3 Conveyor Length (ft) _____________________________________ Profile 2 T/TU (if not linear, please sketch curve below) TU S Profile 1 T/TU D Belt Width (in) __________________________________________ B (deg) ____________________________ Conveyor Lift (ft) or Incline B
SProfile 2 Material (type & max lump size) T/TU ____________________ D
Density (lbs/ft3) __________________________

T B Profile 3 B D
D Profile 3 Material Repose Angle T (degrees) ____________________ B Trough Idler Angle, Spacing & Roll Diameter _____________ D TU _____________ Return Idler Angle, Spacing & Roll Diameter B TU
Belt Speed Profile 4 T (FPM) _______________________________________ D
Number of Belt Scrapers/Cleaners ____________________

Profile 1 T/TU D Number of Belt Plows _____________________________ D Profile 4 T Profile 4 D
T Profile 3 S B Motor Horsepower B (if known) ______________________________ Profile 2 T/TU B D B S Type of Soft Start _______________________________________ TU (Electronic; VFD; Fluid Coupling; or none) TU
Length of Skirtboards (ft) __________________________ S B B

T/TU Profile 2 TU D
BT
TU Height of Material on skirts (In) ______________________

HTB
Take-Up Type (manual or automatic) ________________________ Profile 5 T H

Profile 4 T/TU T Total Installed Counterweight (lbs) ___________________________ B D B B B T Profile 3 D
HTB
S Conveyor Belt Details T (if known) Profile _____________________ 5 H S 1 D ______________________________ Profile 5 D Profile Fabric or Steel Cord BT HTB D B T ____________________ B S D Profile 3 B Number of Plies & PIW (if known) S B B Covers top x bottom (in x in) ________________________ TU Profile 2 D
HTB
H D
Bearing Centers (in) ______________________________________

TU TU T/TU Profile 1 TU D T/TU
Conveyor Profile Circle one. Profile 4 (See types T D 1 10 below). Profile 5 T

T/TU H D T T/TU T T B B Profile 1 TU TU S Profile 6 T/TU D H Profile 2 S H TU Profile 3 T/TU H B B T TU TU Htrip H Profile 4 B T TU D Profile 5 B D D S Profile 7 T B B
HTB TU
S H D Profile 3 B
trip
TU TU T Htrip D Profile 6 Profile 4 Profile 6 D S B TU B D TU T D S Htrip TU T BT D Profile 7 B H Profile 5 Dp 7 HTB Profile Ds B Dp B B B S B trip TU TU Profile 8 Profile 6 H/TU Profile 10 TU (Reversing) B
trip
H H
B D
B T
T D
TU T
D Profile 5 T Profile 2 D HTB S B D Profile 7 B S Dp B Ds B D Profile 3 TU B TU B T

trip
B B
D Profile T 6
TU B Profile 8 H Profile 4 B TU T Dp Profile 5 Profile 9H DsB H D T

H/TU
trip
trip
T/TU Htrip D Ds H H
T/
T TU T T/TU
TU 6 Profile
trip Htrip
T/TU B D S D
HTB
H D S Profile 10 T D D D T H
(Reversing)
D T H
H/TU
B Profile 10 4 D Profile(Reversing) trip D H/TU Profile 8 D S B B T Dp
B B
Htrip
T/TU If from trip T profile differs Bhere: Profile 7 one shown, please H sketch TU B T T B Profile B5 B TU TU B Ds D
trip
Profile 8
B trip TU
TU
S Profile 10
trip
HTB
D TU D S TU
Htrip 6 Profile TU
trip
Profile 9 Profile 7 B B
(Reversing)
B Dp
Profile S9
B T
B TU
Profile 6 T T
D H Profile 9
B Ds TU
D T/TU S B
D ProfileB 7 B Dp TU Htrip S Ds D H
TU T/TU B
Htrip
CUSTOMER CARE PLAN
trip
1-800-321-1558 Profile 10 H/TU D Find local (Reversing) distribution at superior-ind.com/distributor HD 2012 Superior Industries CL-117 Profile 6 T
Profile 8
trip
B B H Dp T/TU B TU trip
trip
T
H/TU
32
D
TU
Profile 7
Profile 8
(Reversing) trip
Profile B 10
Htrip D
Return Roll Guards

Conveyor Pinch Point Protection

Single Return Roll Guard (Fig 18.1)
Easily mounts to Superior drop brackets Can be modified to fit other brand rollers u Works on CEMA B, C, and D series idlers u Same guard fits 4, 5 and 6 rollers and 1-1/2 or 4-1/2 brackets
u u
Fig 18.1 Single Return Roll Guard
Dual Return Roll Guard (Fig 18.2)

Guards mount into special drop bracket slots Designed to catch roller from dropping u Works on CEMA C and D series idlers u Same guard fits 5 and 6 rollers and 4-1/2 brackets
u u
ShieldAllTM Roll Guard (Fig 18.3)

u u u u
UHMW cage prevents material buildup Two pin release system for easy maintenance access Works on CEMA B, C, D, and E series idlers Same guard fits 4, 5, 6 and 7 rollers and 1-1/2 or 4-1/2 brackets
Fig 18.2 Dual Return Roll Guard
Steel Return Guard Basket (Fig 18.4)

u u u
Heavy duty steel cage prevents material buildup Works on CEMA B, C, and D series idlers Same guard fits 4, 5, and 6 rollers and 4-1/2 brackets
Part Number Guides

Return Roll Guards
BW Single Guard 44-050118 44-050124 44-050130 44-050136 44-050142 44-050148 44-050154 44-050160 44-050172 Dual Guard 44-118450 44-124450 44-130450 44-136450 44-142450 44-148450 44-154450 44-160450 ShieldAll Guard Steel Guard 44-040118 44-040124 44-040130 44-040136 44-040142 44-040148 44-040154 44-040160 44-040172 44-040184 44-040196 44-060018 44-060024 44-060030 44-060036 44-060042 44-060048 44-060054 44-060060 44-060072 -
Fig 18.3 ShieldAll Roll Guard
18 24 30 36 42 48 54 60 72
Fig 18. 4 Steel Return Guard Basket Digital Literature

84 96
CUSTOMER CARE PLAN
33
Guard Panels
Protect Your Crew and Your Pockets

Flexible Guard Panels (Fig 19.1)
Cuts easily to any size or shape, with shears or cutter UV resistant HDPE u Yellow color is easily detectable u Shipped with self-tapping screws and washers u 3/4 mesh (50 x 4 roll) u 1/4 mesh (100 x 4 roll)
u u
Fig 19.1 Flexible Guard Panels

Part Number 38-000030 38-000032
Flexible Guard Panels

Description Yellow Side Guard Kit - Small 1/4 Mesh Yellow Bottom Guard Kit - Large 3/4 Mesh Lengths 100 x 4 50 x 4
Steel Guard Panels (Fig 19.2)

Attaches with self-tapping screws and washers Can be used on channel or truss frames u 10 x 5 or 4 x 5 panels
u u
Fig 19.2 Steel Guard Panels

Part Number 14-00946 10-02139
Steel Guard Panels

Description Guard, Truss, Mesh, Perf-Metal Guard, Truss, Mesh, Perf-Metal Lengths 10 x 5 4 x 5
Easy to Handle, Flexible Rolls Digital Literature

Self-Tapping Screws Included in Package

CUSTOMER CARE PLAN
34
Conveyor Belt Covers

Rugged Belt Protection Withstands and Protects the Environment
Quick Specs
(See back for custom options)
Belt Widths: 24- 60 Cover Length: 41.88 u Standard Covers: Full, 3/4 and 1/2
u u
Frequently Asked Questions What are the benefits of corrugated?

u

Stronger than Smooth Covers
Rigid, corrugated construction is infinitely stronger than smooth Standard 22 gauge is thickest in the industry u Folded edges double thickness and increase strength
u u
When compared to smooth covers, a corrugated design is naturally stronger. On its own, each channel (or rib) increases the bending strength of the entire cover. So think of each rib as a little muscle. Another benefit of a corrugated design is that it allows the cover to be self supporting. That means no additional structure (like supports) is required to hold the cover to the conveyor.
Where are the installation supports?

u
Easy, Uncomplicated Installation

No installation supports needed to brace covers Installation is not dependent on location of idler frames u Mount hinges with self-tapping screws at any point along structure
u u
Safe to Handle and Easy to Maintain

Folded edges form safe to handle lifting points Hinged on both sides for access at any point u Loosen just two nuts for belt access (Fig 23.1) u Hinges protected with rust free coating
u u
Whats the difference between standard and optional covers?

u
Our standard covers, as defined in the quick specs above and on the back page, are available for immediate deliveries. Meanwhile, our optional covers and accessories are built to order.
Fig 23.1 Lock Hinge www.superior-ind.com

superiorindustries @superiorind
35

Cover Nut Lock Hinge Bracket Screw
Part Names
Covers Are Not Dependent on Location of Idler Frames
Cover Styles
Style Full* 3/4* 1/2 Application 100% coverage of belt. Open access on one side of belt. Open access on both sides of belt.
*Standard covers are available for immediate delivery. Other styles are built to order.
Cover Materials
Material Galvanized* Lacquered Steel HPS 200 Stainless Steel Aluminum Fiberglass Application Approved resistance in nearly every environment. Colored to blend in with surroundings or branding. Fiber reinforced polyester, colored covers for highly corrosive environments. Highly corrosive environments. Lightest weight material for easy manipulation. Avoid contamination in the food industries.
*Galvanized covers are available for immediate delivery. Other materials are built to order.
CUSTOMER CARE PLAN
36
Sealing System
Prevent Material Spillage in Load Zones
Quick Specs Cartridges: 5 or 10 Bars: 48 or 60 u Belt Widths: 24- 72

u u
Sealing System

u

Stop Material Spillage
System or cartridges maintain a tight seal between belt and hopper skirting u Eliminates belt sagging between idler rolls in conveyor load zone u Material spillage is the #1 cause of conveyor maintenance
u
Do you have spillage in load zones of your systems? If yes, then you have the application. 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. 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.
How does it work?

u
Quick, Low Cost Installation

u u
Is it an impact bed?
u
Retrofit cartridges fit to existing, installed idler frames Single cartridge (5), double cartridge (10) or sealing bar options u Easy to handle and install (Fig 19.1)
Superior Choice
Fig 19.1 Easy Installation Digital Literature

5 Cartridge
10 Cartridge
Sealing Bar
37
Eliminate Spillage
Be e for
Gaps between skirting and rolls
Af
ter
Sealing System holds belt flat to the skirting
Skirting with Idler Rolls
Skirting with Sealing System - Keep Existing Idler Frame
Common Applications
Material Spillage
Idler Roll Wear
Mixed Idler Styles
High Capacity of Fine Material
Load Zone Idler Gaps
Load Zone Spillage
Part Number Guides

Full Sealing System
Roll Diameter C-5 C-6 D-5 D-6 Steel Roll Center Roll Double Cartridge C5S-20E-(24-72)-410 C6S-20E-(24-72)-410 D5S-20E-(24-72)-410 D6S-20E-(24-72)-410 Slide Bars C5S-20E-(24-72)-448 C6S-20E-(24-72)-448 D5S-20E-(24-72)-448 D6S-20E-(24-72)-448 Impact Cushion Center Roll Double Cartridge C5S-20EI-(24-72)-410 C6S-20EI-(24-72)-410 D5S-20EI-(24-72)-410 D6S-20EI-(24-72)-410 Slide Bars C5S-20EI-(24-72)-448 C6S-20EI-(24-72)-448 D5S-20EI-(24-72)-448 D6S-20EI-(24-72)-448
Replacement Cartridges
Double Cartridges 5 D5S-(24-72)-2 6 D6S-(24-72)-2 48 38-000026 Seal Bar 60 38-000027
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Impact Beds
Protect Conveyor Belts from the Beating of Large Material Lumps
Quick Specs Lengths: 4 or 5 Diameter: 5 or 6 u Belt Widths: 24- 72

u u
Impact Beds
Frequently Asked Questions What are the characteristics of the bars?

u

Save the Belt
u u
The impact bars are made from a top layer of 1/2 UHMW and a bottom layer of 2-1/2 SBR rubber. You bet! Any application that exceeds the specs of our entry level impact bed will graduate to an engineered class. 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.
Energy absorbing impact bars protect belting from falling material Bars made of low-friction UHMW and high impact SBR rubber Rigid, structurally sound frame for extra support Custom engineered style available on request (Fig 20.1) Wings adjust to 20, 35 and 45 Available in 4 or 5 lengths
Do you offer different classes?

u
Rugged Construction
u u
How do I know which class I need?

u
Perfect Fit
u u
18 Impact Beds
Fig 20.1 Specialty Impact Transition Bed Digital Literature

Medium Duty Impact Beds
39
Common Applications
High Capacity Applications
Large Material Lumps
Sharp, Damaging Material
Extended Discharge Height
Part Number Guide

Example: I-C5355-361
Impact Bed and CEMA Class

I and C
Existing Roll Diameter

5 or 6
Wing Angle
20, 35, 45
Bar Length
4 or 5
Belt Width
24- 72
Duty
Standard = 1 or Medium = 2
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Take-Ups
Accurately Maintain Belt Tension to Prevent Slippage
Quick Specs Style: Pillow Block, Wide Slot, Top Angle Mounting Positions: Side or Top u Size Range: 1/2- 9 Bearing Diameter
u u
Take-Ups
Frequently Asked Questions What size do I need?

u

High Quality Construction
ACME rod is standard ACME thread design provides quick movement and reliability in corrosive conditions u Durable Powder Coat finish
u u
The common rule of thumb is to choose a travel size that is 2% of your center to center belt length. The ACME screw has nonbinding characteristics resulting in less seizing and longer life. ACME screws are standard on all of our take-ups. 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.
What is distinct about Superiors design?

u
Stocked for Quick Deliveries

Carried by your local Superior distributor (superior-ind.com/distributor) u Quick lead times from factory
u
What is significant about screw protection?

u
Center Pull
Telescoping Tube
Heavy Duty Wide Slot Light Duty
Digital Literature
Top Angle
Take-Up Styles
41
Take-Up Selection Guide

1
Scenario One: Style
Bearing Style Conveyor Style Take-Up Style Mount Position

2
Pillow Block Truss Frame Channel/I-Beam Frame TUTT Side 0.0 TULD Top 1.0 TUHD Top 2.0
Wide Slot
Top Angle Truss/Channel Frame
TUCP Top 3.0 4.0

3-7/16
TUWS Side 5.0 6.0

6
TUTA Top 7.0 8.0 9.0
Scenario Two: Bearing Size
TUTT TULD TUHD TUWS TUCP TUTA

3
1/2 1/2
1-7/16 1/2 3
1-3/8 1-3/4 3-15/16
Scenario Three: Bearing Type
Bearing Type
Take-Up Style TUTT TULD (Roller) TUHD (Roller) TUWS (Ball) TUCP (Roller) TUTA SealMaster NP, MP NP, MP USRB MST Browning VPS, SPB1000, PBE VPS, SPB1000 Link-Belt Rexnord Dodge SC, SCM, S2000, Type E, Imperial SCM, S2000, Imperial S2000, Type E, USAF, TAF, Imperial WSTU-SC, WSTU-SCM ZT-2000, ZT-5000 Type E (WSTU-E), S-2000 (WSTU-S2) Type E (TPE), Type G (SC), Type GM (SCM), S-2000 SKF SAF PB22400, EPB22400, ZA, ZEP C35 PB22400, C35 ZA
VPS, SPB1000, PBE, PB22400, EPB22400, ZA, ZAF, ZEP SAF22500 PLB VTWS TUE-920, ST-1000 ETPB-22400
Part Number Guide

Example: TUTT-350-12
Take-Up Style
TUTT, TUWS, TULD TUTA, TUHD, TUCP
Frame Size
100-1004
Travel Distance
1.5- 60
*Not all configurations are possible, see catalog for available parts 1-800-321-1558 Find local distribution at superior-ind.com/distributor 2012 Superior Industries CL-122
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Superior Belt Scale
Evaluate Inventory, Production Goals and Rail Car or Truck Loading
Quick Specs u Belt Widths: 18 - 72 u Accuracy: +/- 1% or +/- 0.5% u TPH: Up to 3000*
*(dependant on belt speed and idler spacing)
HD Conveyor Belt Scale
Frequently Asked Questions What are the package options?

u

Precision Accuracy
+/- 1% accuracy or +/- 0.5% accuracy 2 independent load cells for greater accuracy u NOTE: You can achieve (+/- %) accuracy when using 2 HD scales in conjunction with one PM2000 monitor. (Dual idler option)
u 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. If possible, its 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 owners manual is packed with more specific details to help get it right. 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.
Where should I install the scale?

u
Ease of Troubleshooting
u u
Avoid replacing entire system if one cell is damaged Independent load cell read-outs allows you to easily see which load cell is malfunctioning Easy clamping method secures scale package to conveyor frame Superior quality idler with 0.015 TIR tolerance and custom frame PM2000 Limitless integration into existing in-plant controls PM2000 Control the speed of the belt PM1500 & PM2000 Save up to 8 totals PM1500 & PM2000 Built-in inclinometer for use on variable incline conveyors
Fast and Easy Installation

u u
What if I already have a speed sensor?

u
Powerful Integration
u u u u
Speed Sensor Digital Literature

43
Belt Scales
Wide Belt Scale

+/- 1% accuracy u Up to 1,000 TPH u 24" - 36" belt width is primary use u 42 up to 750 TPH u Two independent load cells wired in parallel for easy troubleshooting u Independent weigh bridge brackets accommodate multiple belt widths u Powder Coated
u
Heavy Duty Belt Scale

+/- 0.5% accuracy Up to 3,000 TPH and beyond u Two independent load cells wired in parallel for easy troubleshooting u Continuous weigh bridge for increased accuracy and structural integrity u Powder Coated
u u
Integrators
PM1500
Functions with either WB or HD belt scales u Store up to eight resettable totals u Diagnostics screen shows load cell readings independently u Easy to operate touch screen menu u Output for PLC integration u 10-30VDC and 115VAC power
u
PM2000
u u u
All the functionality of the PM1500

Control the speed of the conveyor belt when used with a VFD
Blend/rate controller uses one output for rate control or two outputs for blending product u Customized and limitless in-plant controls u 10-30VDC and 115VAC power u Wireless options available
Speed Sensors
SS-150 Speed Sensor
Easily mounts to a conveyor frame Adjusts to 24 - 36 belt width u Use existing speed sensor if applicable
u u
44
SonicscoutTM Material Sensor

Accurately Monitor Material on a Conveyor Belt
Quick Specs
u
Belt Widths: 24- 72 Sonicscout Material Sensor
Frequently Asked Questions How does it work?

u

Maintain Material Flow
u 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. Yes, the sensor itself has 2 of thread adjustment up or down. 24VDC electric power.
Detects material on conveyor belt Feeds data to machines automation program
Heavy Duty Sensor

Unaffected by winds up to 30 MPH Unaffected by external noise u Tolerates dusty environments u Tolerates temperatures down to -14 F
u u
Can you adjust the distance?

u
What are the power requirements?

u
Easy Installation
u u
Adjust to custom belt widths (Fig 22.1) Attaches to all brands of idler frames
Adjustable Mount
Replacement Parts
Part Number 11-00966 11-01122 32-000071 32-000072 Description Switch Cord Mount 24-48 Mount 54-72
Flow Switch
Part Number 18-10002 Belt Width 24-48 54-72
Fig 22.1 Adjustable Mount per Belt Width Digital Literature

18-10003
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SentinelTM Belt Speed Sensor

Accurately Monitor Conveyor Belt Speed
Quick Specs
u
Belt Speed: Up to 1,000 FPM Sentinel Belt Speed Sensor
Frequently Asked Questions How does it work?

u

Monitor Belt Movement
Indicates if belt has stopped moving Indicates if belt has slipped u Indicates how fast a belt is moving
u u
The sensor is designed to count return roll idler rotations, feeding the data back to a conveyors 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. The distance between the proximity sensor face and the bolt head lugs on the idler should be 5/16.
Safety Shutoff
u u
What is the install point?

u
Prevent damage to drive components Stops the motor in the event of belt problems Mounts to standard return roll brackets 4-1/2 drop bracket Replacement parts sold separately
Easy Installation
u u
* Part Numbers will be CEMA D, but may be used in B & C applications as well
Minimal Replacement Costs

u
Replacement Parts
Part Number D5-RET-36SEN 11-01299 11-01122 32-00402 18-10006 Description Sentinel Switch, Proximity, 24V, 12MM, QD, P&F Power-Cord, Utrasonic 30MM, Pepperal Drop Bracket Sentinel Multi-System Kit without Controller 11-01114 Kit Part Number 18-10000
Sentinel Belt Speed Sensor Kits

Part Numbers Description 32-00401 11-01122 11-01299 11-01114 13-00850 13-10016 13-10086 11-00702 11-00343 11-00965 11-01161 18-10001 Drop Bracket for Sentinel Sensor Cord Switch, Proximity, 24V, 12MM, QD, P&F PLC, Monitor, Sentinel Speed Sensor BLT Carriage 20-1/4 x 3/4 Flanged Nut 20-1/4 Self-Drilling Hex Screw 12 x 3/4 Logo Smart Relay 24 Volt Relay 120 Volt Relay Power Supply 24 VDC
Digital Literature
Includes Everything in 18-10000 except 11-01114 Monitor

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Superior Auto Greaser
Temperature Compensating Electrochemical Lubrication System
Quick Specs Operating Temp: -4F to 140F Discharge Period: 1, 2, 3... to 12 months u Dimensions: Approx. 2.5 x 5.5
u u
Superior Auto Greaser
Frequently Asked Questions What is the typical application?

u

Accurate Lubrication Solution
Provides accurate lubricant delivery across a broad range of settings in extreme temperature environments u Simple to set, install and maintain with a highly intuitive operating menu
u
Superiors 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. It sure is! All of the components are available for order separately, including the lubricator cartridge, battery cap and dust cover. A temperature sensor regularly measures the ambient temperature and the control unit calculates the required gas generation based on this data.
Is the unit reusable?

u
Extends Equipment Service Life

Lubricates equipment while it is running to provide optimal lubricant exchange u Delivers gradual purge of fresh grease to labyrinth and taconite seals to prevent the ingress of contaminants
u
Does the lubricator adjust to temperature?

u
Safer Compared to Manual Greasing

u u
Reduces work load by automating an otherwise manual process Continues to lubricate without the need for shutdown and isolation
Auto Greaser Control Unit Re-usable control unit Display (discharge period + function) Push button programming Gas generating cell LC unit with integrated battery
Lubricant
Push Button Control Digital Literature

Built-in robust support flange with 1/4 NPT outside thread
Oil-filled units come with an integrated oil retaining valve and can be recognized by a red plug.
Dust and Water Proof
47
Auto Greasers in Application
Part Number Guide

Replacement Parts
Part Number 03-03003 03-03002 03-03001 08-02768 08-02569 08-03314 Description Lube Cart. Kit, Cap, Dust Cover Lubricator Cartridge, Dust Cover Cap, Auto Lubricator Black Pipe Nipple A Black Tee-Pipe
B
Brass Pipe, BSH Hex-Reducer C
Optional fittings can be used to install multiple cartridges.

u
45 Elbow and 90 Tee available.
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C 106 Components Handbook Low

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CEMA Rated Idlers

The Broadest Range of Conveyor Idlers on the Market

CEMA Rated Idlers

Frequently Asked Questions Which CEMA class do I need?

Features and Benefits

Which roll diameter do I need?

High Quality Construction

Economical Retrofit Rolls

Where can I buy Superior Idlers?

No Maintenance Base Frame

CEMA D CEMA E CEMA F

SpinGuard Seal Technology

Stationary External Seal

Centrifugal Force Chamber

Triple Labyrinth Seal

Factory sealed metric ball bearing on all CEMA rated idlers

Narrow Roll Gap Center Stands

No pinch point that leads to belt damage

Sheds material, preventing build-up

Plant Superintendent at Eastern Colorado Aggregates, La Junta, CO

Part Number Guide

CEMA Rating or Series

Channel Mount Low Profile

Offset Center Roll

Live Shaft Rollers

Beater Bar Return

Flat Carrier Idler

Rubber Cushion Flat Carrier

Rubber Disc Return

Urathon Return Roll

Spiral Urathon Return Roll

Products Available in CEMA Rated Idlers

Spiral Urathon Return Roll Garland Return

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

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Frequently Asked Questions What are Moxie rolls made from?

Features and Benefits

How thick is the idler shell?

How is the roller easier on my crews?

40 Weight (lbs) 30 20 10 C5-36 C6-36 D5-36

Fig 2.1 No More Corroded Idler Rolls Digital Literature

Fig 2.2 Weight Comparison

SpinGuard Seal Technology

Material will not build up across the flat surface 1 3 4 2

Recessed/Stationary External Seal:

Centrifugal Force Chamber:

Triple Labyrinth Seal:

Factory sealed metric ball bearing on all CEMA rated idlers

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

Part Number Guide

81/91 Series Regreasable Idlers

Fig 3.1 Idler Seal Cutaway

Frequently Asked Questions What are common applications?

Features and Benefits

How often do you regrease?

How do tapered compare to ball bearings?

Figures 3.1 and 3.2

Part Number Guide

Fig 3.2 Idler Frame Digital Literature

Idler Type and Diameter

1-800-321-1558 Find local distribution at superior-ind.com/distributor 2012 Superior Industries CL-103

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Replacement Rollers for Track Mounted or Mobile Equipment