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ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE OPERATING
DIVISION ENGINEERING MANAGER 2
3 DEFINITIONS 2
4 REQUIREMENTS 3
4.1 GENERAL 3
4.2 ROLLS 3
4.3 DESIGN 3
4.4 ROLL MATERIAL 3
4.5 BEARING ASSEMBLY 4
4.6 IDLERS 6
4.7 CORROSION PROTECTION - MOUNTING BRACKETS 9
5 QUALITY ASSURANCE PROVISIONS 9
5.1 QUALITY MANAGEMENT REQUIREMENTS 9
5.2 DRAWINGS 9
5.3 DESIGN CALCULATIONS 9
5.4 SAMPLING FOR INSPECTION AND TEST 9
5.5 GUARANTEE 9
6 TEST AND INSPECTION METHODS 9
7 MARKING AND PACKING 9
7.1 MARKING 9
7.2 PACKING 10
APPENDIX A : RELATED DOCUMENTS 11
APPENDIX B : ISSUE RECORD 12
APPENDIX C : RELATED CALCULATIONS 13
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
1 SCOPE
This specification details the additions and exceptions to requirements for idlers and rolls
complying with SANS for general purpose belt conveyor systems. This specification shall be
read in conjunction with SANS 1313.
New and upgraded installations shall be specified by the operating division in consultation with
the ATD Design Engineer.
3 DEFINITIONS
For the purpose of this specification the definitions contained in SANS and the following shall
apply:
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
4 REQUIREMENTS
4.1 GENERAL
Unless otherwise specified the dimensions and construction of idlers and rolls shall be in
accordance with the requirements of SANS 1313.
4.2 ROLLS
Rolls supplied in accordance with this specification shall have shafts with closed ends and
without end caps.
4.2.1 Idlers shall be supplied offset and with closed end shafts.
4.2.2 Where inline idlers are required open-end shafts are considered acceptable to comply with
spacing requirements.
4.3 DESIGN
Component parts of rolls including fabrication, seals, lubrication and assembly shall be
designed for a basic life rating of not less than 40 000 hours.
The nominal roll diameter shall be selected from the range permitted in SANS 1313, to limit
the roll rotational speed to 750 min-1, or as specified by the Engineer. However, preference
should be given to the following range of roll diameters.
Minimum shell Thick wall idlers
Type Nominal roll diameter
thickness
127 mm 3,8 mm 4,5 mm
Troughing/Return 152 mm 4,0 mm 6 mm
178 mm 6,0 mm
Impact 159 mm See note
Note: Rubber disks in accordance with SANS 1313, DIN 15209 or DIN 15210 form B only
shall be specified.
Shafts shall be manufactured from steel complying with the requirements of BS 970 part 1
Grade 070M20. (EN3A).
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
Shaft ends shall be machined to the tolerances recommended by the bearing manufacturer
and to a surface finish not rougher than 3,2µm in accordance with the requirements of the Ra
series of BS 1134.
End cap bearing housing shall be manufactured from materials capable of deep drawing.
Commercial quality steel is not permitted.
Bearing housings shall be accurately aligned in relation to each other and the bearing
assembly. Tolerances for fitting the bearing in the housing and on the shaft shall be as
recommended by the bearing manufacturer.
End cap bearing housing shall be manufactured with turned back edges.
The inner race of each bearing shall be positively located on the shaft on at least one side
using either a circlip or a spring clip.
Bearings fitted to rolls shall be one of the following types. Note that deep groove ball bearings
of the 62 and 63 series are to be specified with C4 clearance and with non-metallic cages.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
The following table indicates the maximum loading on a roll, based on a rotational speed of
750 min-1 and a basic bearing life of 40 000 hours.
Dia Series Max Load per roll (kg)
420205 62.. or 63.. 213..
127 25 213 234 -
25 212 234 -
30 - 470 1442
152
35 - 555 1747
40 - 686 2263
30 - 471 1444
178 35 - 556 1749
40 - 687 2266
Note that the idler rolls shall be checked to ensure compliance with the deflection limits. See
4.5.4.
The basic rating life (L10h) as defined in BS 5512 for each bearing shall not be less than
40 000 hours for a bearing load as specified in Clause 4.5.2.
4.5.4 Misalignment
Misalignment caused by roller shaft deflection shall not exceed the following when calculated
as detailed in Appendix C, C1.1.
Bearing type Clearance Misalignment
Standard 0°-6'
Rigid deep groove ball
C4 0°-10’(*)
Seize resistant cage Standard 0°-14'
Spherical roller Standard 1°-30'
(*) DIN 22112 p2 suggests a total misalignment of 0°-15’ for C4 clearance bearings
The deflection limits shown above do not make allowance for manufacturing tolerances.
Spherical roller bearing deflections shall not exceed the maximum functional requirement of the
idler bearing sealing arrangement.
AAC_SPEC_37300112.DOC APPROVED 6 July 2006 Page 5 of 13
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
The manufacturing tolerance for bearing misalignment shall be limited to a maximum of 0°-6'.
4.5.5 Seals
Inner lip seal: shall prevent contamination from inside the roll and loss of grease from the
bearing.
Bearing outer seal: shall be of the multiple labyrinth type. Minimum length of the effective
sealing passage shall be 18 mm.
Outer cover: shall assist grease retention and prevent ingress of dirt or water.
4.5.6 Lubrication
The bearings shall be greased for life at assembly, using grease type GPG-2LXEP complying
with the requirements of AAC specification 166014 and in the quantities as recommended by
the bearing manufacturer. Other grades or consistencies of grease may be specified in
consultation with the engineer.
4.6 IDLERS
Idlers supplied in accordance with this specification shall be as follows:
For belt widths less than 500 mm, consideration should be given to 2-roll vee-form carrying
idlers.
Impact and troughing idlers shall be 3 rolls for belts up to and including 1200 mm wide, and 5
rolls for belts over 1200 wide unless otherwise specified by the Engineer.
4.6.2 Type
Notes
1
Consideration may be given to the use of in-line idlers where appropriate, as specified by
the Engineer.
AAC_SPEC_37300112.DOC APPROVED 6 July 2006 Page 6 of 13
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
2
Single roll flat return idlers of series 25 shall not be specified for belt widths greater than
1200 mm.
3
Vee return idlers are preferred for belt widths greater than 1200 mm.
4.6.3 Series
Idlers shall be of the following series as specified in SANS 1313 and shall be specified by the
Engineer (see Clause 2.7.1).
Dia Series
127 25
25
30
152
35
40
30
178 35
40
The use of series 25 impact idlers is not preferred. See also 4.5.3.
The drop height of flat return idlers shall be 40 mm or 90 mm as specified by the Engineer.
The drop height for vee return idlers shall be 150 mm.
Mounting brackets shall be manufactured from steel to SANS 1431 Grade 300WA.
Construction and the design shall be such that belt damage shall be minimal in the event of
rolls becoming detached.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
Note that, in the case of tubular construction or 'belt-friendly' impact idler brackets, the design
shall be such that the torsional deflection of the roll supports shall be minimised.
All idler brackets for impacting rolls shall be so designed as to facilitate ease of removal.
The Engineer shall consider the chute design when considering the options for the above.
The troughing angle shall be one of the standard angles as permitted in SANS 1313, as
appropriate, namely
20°
35°
45°
The troughing angle of transition idlers shall be selected as appropriate for the transition
distances determined by design.
Generally, the forward tilting of idlers is not preferred. When this is specified by the Engineer,
the outer inclined rolls shall be tilted forward in the direction of the belt travel to assist training
where specified. The angle of tilt of outer inclined wing rolls shall be the minimum
commensurate with the application and shall not exceed 2° for belt widths up to and including
1 050 mm or 1,5° for belt widths above 1 050 mm. The tilting of wing idlers is not applicable to
reversible conveyors.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
The colour of the final coat shall be in accordance with the supplier’s standard colour, unless
otherwise specified by the Engineer (see Clause 2.8).
5.2 DRAWINGS
When requested by the Engineer, Contractors shall submit certified general arrangement
drawings with sufficient detail to prove compliance with the requirements of this specification.
Drawings shall be approved in principle by the Engineer prior to contract award.
5.5 GUARANTEE
The Contractor shall guarantee idlers against all defects attributable to faulty manufacture,
workmanship and quality of materials for a period of 18 months after installation. Idlers that
fail before 18 months normal service shall be replaced free of charge by the Contractor.
In addition to the test methods as specified in SANS 1313, rolls shall be inspected for bearing
misalignment as per the requirements of 4.5.4.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
7.2 PACKING
Idlers and rolls shall be packed in such a manner as to prevent damage during transit and
storage.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
The latest issues of the following documents shall be deemed to form part of this specification:
BS 970 PART I : Wrought steels for mechanical and allied engineering purposes.
BS 5512 : Specification for roller bearings. Dynamic load ratings and rating life.
SANS 657 PART III : Steel tubes for rolls for conveyor belt idlers.
SANS 1313 : Dimensions and construction of conveyor belt idlers and rolls.
SIS 05 5900 : Pictorial surface preparation standards for painting steel surfaces.
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.
AAC SPECIFICATION 373001
ISSUE 12
BELT CONVEYOR IDLERS AND ROLLS
COPYRIGHT
Misalignment
W ⋅ A ⋅ (G − 2 ⋅ A ) × 180
Q= .........................(1)
4 ⋅ π ⋅E ⋅ Ι
Where
Q = Misalignment in degrees
π ⋅ d4
I = Moment of Inertia =
64
0,0014 ⋅ W ⋅ A ⋅ (G − 2 ⋅ A )
From (1) Q= .....................(2)
d4
Design Life
Select bearings using bearing calculations as published by bearing manufacturers to allow for the
following :
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the
information contained therein, irrespective of the cause and quantum thereof.