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- Rexnord® Idlers, Belt Conveyor Components, Whisperol® Rollers and Spray Nozzles
Rexnord® Idlers, Belt Conveyor Components, Whisperol® Rollers and Spray Nozzles
Rexnord® Idlers, Belt Conveyor Components, Whisperol® Rollers and Spray Nozzles
- Introduction: Highlights the global presence of Rexnord salespeople and the technical support available. It introduces the CEMA B+, C & D idlers, known for their superior seals and economical pricing for light duty applications.
- Product Classification: Details the CEMA and Rex Idler classification system, including service classes and roll diameters. It provides an identification guide and ordering information for selecting the appropriate idler.
- Idler Types and Specifications: Describes various idler types, including Series B, B+, C, D, and E, along with their dimensions and weights. It also covers polyethylene and live shaft idlers.
- Ordering and Maintenance: Provides information on ordering complete roll assemblies, replacement parts, and brackets. It includes maintenance guidelines and troubleshooting tips for conveyor systems.
- Technical Data: Contains detailed tables and specifications for idler selection, load ratings, and product specifications. It also includes information on the weight of rotating parts and the properties of conveyed materials.
- Additional Components: Discusses polymeric conveyor rollers (Whisperol®) and spray nozzles, with selection procedures and specifications.
Rex Idlers are designed to meet various service requirements, from light to heavy material conveying. They conform to CEMA dimensional standards and are interchangeable with competitive idlers.
Series Specifications:
- Series B: Light Duty, exceeds CEMA B specifications, available with 4" and 5" diameter rolls, belt widths 18" to 48".
- Series C: Medium Duty, exceeds CEMA C specifications, available with 5" and 6" diameter rolls, belt widths 18" to 60".
- Series D: Medium Duty, exceeds CEMA D specifications, uses Series C construction with heavier shafts, belt widths 24" to 60".
- Series E: Heavy Duty, exceeds CEMA E specifications, available with 6" and 7" diameter rolls, belt widths 36" to 96".
- Series B+: Combines CEMA B frame with Rex patented "G" Seal, available in 4" and 5" diameter rolls, belt widths 18" to 48".
Types of Idlers:
- Carrying Idlers: Support the belt in the material transport section, available in 20°, 35°, and 45° trough angles.
- Impact Idlers: Prevent belt damage at loading points, standard practice at impact forces over 40 foot pounds.
- Return Idlers: Support the empty belt, available in steel, spiral, and disc types.
- Training Idlers: Assist in keeping the belt centered, available in carrying and return types.
Idler Index:
The document provides a comprehensive index of idler numbers, descriptions, roll diameters, materials, and corresponding page numbers for detailed specifications.
- Ribbed Covered Return Idlers: Available in chevron and straight ribbed patterns, these idlers are designed to remove carry-back from conveyor belts and prevent idler build-up. They offer dual-direction bolt operation and are available with a 4½" drop bracket.
- Training Idlers: These idlers sense misalignment and react immediately, featuring a self-aligning roller bearing and a ribbed rubber cover to eliminate material build-up. They are effective on reversing conveyors.
- V-Return Idlers: Designed with a 15° angle, these idlers are factory-sealed and available in 5-inch and 6-inch disc rolls. They are suitable for various belt widths and are designed to fit existing conveyor frames.
- Polyethylene Roll Idlers: Made from high-density polyethylene, these idlers resist corrosion and material build-up, extending belt life and reducing maintenance. They are available in regreasable or factory-sealed options.
- Side Guide Idlers: Used for belt training during installation, these idlers are not recommended for permanent use due to potential belt-edge wear. They feature factory-sealed ball bearings to minimize wear.
- Corrosion Resistance: Polyethylene rolls resist corrosion and material build-up, providing longer belt life and reducing the risk of belt damage.
- Easy Maintenance: Features like slotted mounting holes and jig-welded frames ensure easy adjustment and alignment, reducing maintenance time and costs.
- Durability: The use of rugged materials and designs, such as tapered roller bearings and solid shafts, ensures long-lasting performance even under severe conditions.
- Interchangeability: Polyethylene rolls are interchangeable with steel rolls, and the idlers conform to CEMA standards, allowing for easy integration into existing systems.
The document provides detailed specifications for various types of idlers used in conveyor systems, including dimensions, weight, and material types. It covers different series such as Series E and Series F, with specific focus on steel and rubber rolls of varying diameters (4-inch to 7-inch). Dimensions are provided in inches, and weights in pounds, with notes on potential changes and certified dimensions available upon request.
Instructions are given for ordering complete roll assemblies, specifying the idler model number, and whether they are regreasable or factory sealed. Conversion procedures for different types of idlers, such as converting standard idlers to impact idlers or training idlers, are also detailed.
The document outlines the use of different materials for idlers based on application needs, such as rubber, urethane, and ceramic, each with specific temperature limits (not exceeding 200°F for most materials). Recommendations are provided for handling abrasive and corrosive materials, with specific idler types suggested for different environmental conditions.
Tables provide dimensions and weights for various idler configurations, including belt width, roll diameter, and idler weight. The tables also include information on the weight of rotating parts, which is crucial for calculating additional forces required to overcome roller friction.
Guidelines for the installation of idlers emphasize the importance of alignment and proper spacing to ensure efficient operation. Maintenance tips include ensuring that bearings and seals are properly maintained to extend the life of the idlers.
Key parameters such as belt width, roll diameter, and material characteristics are critical for selecting the appropriate idler. The document stresses the importance of considering peak material volume, material weight, and abrasiveness when determining conveyor capacity and idler selection.
The document provides guidelines for selecting conveyor belt specifications based on material characteristics. Key parameters include the angle of repose, surcharge angle, and material weight per cubic foot. The angle of repose is defined as the angle from the horizontal assumed by the material in a freely formed pile.
Selection Procedure:
1. Determine the minimum belt width using tables based on lump size, surcharge angle, and percentage of lumps and fines. The minimum belt width remains constant regardless of the troughing angle.
2. Select the material symbol from tables based on flowability and abrasiveness. Calculate the design capacity using the formula: 100 x Required Capacity (TPH) / Actual Material Weight (Lbs/Cu.Ft.).
3. Determine the maximum belt speed by referencing the belt width and material symbol. Adjust for optimum belt width and speed by deducting at least 100 fpm and increasing belt width as needed.
Notes:
- Do not select a belt width narrower than the minimum determined.
- Do not exceed the maximum belt speed.
- A minimum belt speed of 300 fpm is recommended for proper discharge from 35° and 45° troughed belts.
Material Characteristics:
The document includes a comprehensive table listing various materials, their weight per cubic foot, angle of repose, and recommended maximum inclination. It also provides a classification system for material characteristics, including size, flowability, abrasiveness, and miscellaneous characteristics such as dustiness and corrosiveness.
Key Data from Tables:
- Materials like alumina, aluminum oxide, and coal have specific angles of repose and recommended inclinations.
- The angle of repose varies significantly across materials, affecting their flowability and handling.
- The document emphasizes the importance of considering fines, moisture content, and particle angularity in determining material handling properties.
- Belt Capacity and Specifications: The document outlines belt capacities for different troughing idlers and belt widths, considering factors like surcharge angle, cross-sectional area, and material flowability. It provides suggested belt speeds for various material conditions.
- Selection Procedure: The selection of Rex idler series is based on factors such as belt speed, weight, width, idler capacity, and environmental conditions. The procedure involves calculating the idler load (CIL) and comparing it with load ratings from provided tables.
- Bearing Life Correction: Steps to adjust the basic L10 life rating of the selected idler class using factors K2, K3A, and K3B are detailed. These factors account for load, roll speed, and roll diameter.
- Potential Idler Life: Factors K4A, K4B, and K4C are used to evaluate potential idler life, considering maintenance, environmental conditions, and operating temperature.
- Tables and Figures: The document includes tables for belt weights, idler load ratings, and recommended idler spacing. Figures illustrate the effects of load, speed, and environmental conditions on idler life.
- Minimum Belt Speed: A minimum speed of 300 FPM is recommended for proper discharge.
- Material Conditions: Suggested belt speeds vary based on material conditions, such as fine, dry, dusty, or wet materials.
- Idler Load Ratings: Load ratings are based on a minimum L10 life of 30,000 to 60,000 hours, depending on the idler series.
For 4" diameter rolls, the maximum belt speed is 500 feet per minute (fpm), and for 5" diameter rolls, it is 600 fpm. These specifications apply to return idlers of series C and D.
The document provides detailed tables for idler roll recommendations based on material characteristics such as abrasiveness and corrosiveness. It includes specifications for different roll diameters and materials like rubber, urethane, and ceramic.
Rex idlers are categorized into different series (B, C, D, E) based on their duty type (light, medium, heavy) and conform to CEMA standards. Each series has specific roll diameters, wall thickness, and bearing specifications. The idlers are designed for durability with features like regreasable fittings and factory-sealed options.
The document emphasizes the importance of proper alignment and installation of idlers to ensure efficient conveyor operation. It includes safety instructions and general recommendations for maintaining the conveyor system, such as ensuring the belt is properly spliced and aligned.
Users are reminded of their responsibility to comply with safety standards, including OSHA regulations. The document suggests conducting a safety study and installing guards where necessary.
Proper alignment of conveyor components is crucial to prevent belt misalignment and undue strain on the system. Misalignment should not be corrected by adjusting the head or tail pulley, as this can damage bearings and the conveyor frame. Instead, idlers should be adjusted by loosening and skewing them slightly to achieve proper belt alignment.
Loading and Belt Protection
Loading should be gradual, starting with a light load and increasing to the designed capacity. Material should be directed onto the center of the belt to prevent off-center loading, which can cause misalignment. Impact idlers should be used to protect the belt from abrasion and impact, and skirts should be adjusted to prevent side spillage.
Training Idlers
Training idlers help maintain belt alignment under varying conditions. Troughing training idlers are used for belts traveling in one direction, while actuating shoe types are used for reversing belts. Tilting idlers can also be used to correct belt movement, but should not exceed a 2-degree tilt to avoid excessive wear.
Lubrication
Rex idlers are prelubricated and require periodic relubrication every 4000 to 6000 hours under normal conditions. The lubrication cycle should be adjusted based on operating conditions. A volume-type grease gun is recommended to avoid damage to bearings and seals.
Inspection and Maintenance
Regular inspection and maintenance are essential to prevent costly downtime. Inspections should include checking for belt damage, ensuring proper loading, and verifying that all idler rolls are rotating. A scheduled maintenance program can help identify and address issues early.
Troubleshooting
The document provides a troubleshooting guide for common belt conveyor problems, listing probable causes and solutions. Issues such as excessive wear, belt misalignment, and material buildup are addressed with specific corrective actions.
Whisperol Idlers
Whisperol idlers are highlighted for their quiet operation and corrosion resistance, made from polymeric materials with a metal hex shaft. They offer easy installation and removal, saving time and money.
Whisperol spherical bearings are unique in the roller industry for their ability to handle significant misalignment without impacting rolling friction. Made from low friction, engineering-grade polymeric materials, these bearings offer exceptional wear life and minimal noise. The patented design makes Whisperol polymeric rollers a cost-effective choice.
Options and Features
- Nickel and stainless steel shafting options provide corrosion resistance, suitable for washdown applications in the food and beverage industry.
- Dual drive grooves are available for line shaft conveying applications, with specific configurations for the 250 Series.
- Steel internal sleeves can be added for increased impact resistance and rigidity, allowing for wider dimensions.
Performance and Maintenance
- Self-aligning bearings can handle up to 5° of misalignment while maintaining efficiency.
- Whisperol rollers are durable, self-lubricating, and require no maintenance, reducing overall maintenance costs.
- FDA-approved materials make them suitable for use in inspected food plants.
- The polymeric roll shell resists build-up of contaminants and is antistatic, reducing dirt attraction.
Load Calculation and Application
- To determine load per roller, ensure three rollers are in contact with the package at all times, divide the package length by four for proper spacing, and divide the package weight by three for load per roller.
- Whisperol rollers can handle various product configurations and loading ranges, including heavy wooden pallets.
Technical Specifications
- Whisperol rollers are available in different series (190, 225, 250) with varying size ranges and load capacities.
- Dynamic friction percentages are provided for different operating conditions and temperatures.
Rex Flat Spray Nozzles
Rex Flat Spray Nozzles are designed for precision applications such as cooling, washing, cleaning, and descaling. They offer a range of liquid patterns and are constructed for durability and long operating life. Installation is simple, and each nozzle is performance inspected.
Selection and Ordering
- Selection involves determining the available water pressure, distance from the nozzle to the line of impingement, and choosing the appropriate orifice size and material code based on the application.
- Ordering requires specifying quantity, pattern number, material code, and orifice size.
- Idler Specifications and Types: The document lists various types of idlers such as Side Guide Idler, Spiral Return Idler, and Troughing Idler, along with their specifications and page references.
- Procedures and Maintenance: Includes sections on shafting replacement, belt training, and troubleshooting for conveyors.
- Technical Parameters: Discusses parameters like belt speed, idler spacing, and surcharge angle, providing page references for detailed information.
- Contact Information: Provides addresses and contact details for Rexnord's service locations across the globe, including Australia, Brazil, Canada, China, Europe, Latin America, Mexico, Singapore, and the United States.
- Idler Styles: Various styles are mentioned, including Troughing Impact, Ribbed Covered Return, and Spiral Return.
- Service Locations: Detailed contact information is provided for each location, which is crucial for customer support and service inquiries.
Catalog excerpts
RGX Idlers, Belt Conveyor Components, Whisperor Rollers and Spray Nozzles Performance, Value and Reliability The Cost Effective Choice For Light To Heavy Duty Applications
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Rexnord Belt Conveyor Components Operation This catalog represents over five decades of Rex® Belt conveyor idler experience. Our organization is here to put that knowledge to work for you. Make use of our belt conveyor engineering, component selection and maintenance training, as many have, to improve your bottom line. We have salespeople located in all key areas worldwide. Their mission is to provide you with the best technical and product support possible… whenever you need it. Our CEMA B+, C & D idler has one of the best seals in the world. We make it ourselves, which promotes excellent idler...
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Belt Conveyor Components, Whisperol® Conveyor Rollers and Spray Nozzles TABLE OF CONTENTS Page Number Page Number BELT CONVEYOR IDLERS Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CEMA and Rex Idler Classification . . . . . . . . . . . . . . . . . . . . . . 3 Identification Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Idler Interchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 The Rex Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Types of Idlers...
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INDEX A N Alignment, Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 – 88 Angle of Repose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 – 73 Angle of Surcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 – 73 Nozzle, Flat Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 – 97 Numbering System, Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 B Ordering Information . . . . . . . . . . . . . . . . . . . . 46, 63 – 67, 92, 98 Bearing, Replacement . . . . . . . . . . . . . . . . . . ....
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REX IDLERS CEMA AND REX IDLER CLASSIFICATION Rex Series Roll Diam. Inches Rex Bearing Type Belt Widths Inches B 4 5 Ball 18-48 B+ 4 5 Roller 18-48 C C 5 6 Roller 18-60 D D 5 6 Roller 18-72 E 6 7 Roller 36-72 Service Class CEMA Class Light Duty B Medium Duty Heavy Duty E For idler selection procedure and idler load ratings, see pages 71 – 81. For product specifications see pages 82 – 83. IDENTIFICATION GUIDE AND ORDERING INFORMATION The following is an example of the Rex Idler Numbering System. Rex Idler Model: 36-C5300FS This number describes the idler as follows: Idler Style Angle Of Trough...
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REX IDLERS IDLER INTERCHANGE Interchangeability is one of the most important features of the Rex Idler line, specifically in the dimensional areas of: b. Bolt Hole Spacing — across the width of the conveyor frame for troughing and return idlers. (Belt width plus 9") a. Backing Distance — from the bottom of the base pad to the top of the center roll of troughing idlers. Rex Idlers conform to the CEMA dimensional standards and are interchangeable with competitive idlers listed below. Manufacturer CEMA C CEMA D CEMA E Rexnord Series B Series C Series D Series E Continental Conveyor B Plus H H Plus...
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REX IDLERS THE REX LINE There is a Rex Idler to meet your service requirements ranging from intermittent conveying of light materials to continuous conveying of very heavy materials. Series B The Light Duty line exceeds CEMA B specifications using heavy duty ball bearings, available with 4" and 5" diameter rolls. Furnished in a wide selection of styles in 18" to 48" belt widths. Available factory sealed only. Refer Pages: 12 – 21. Series B+ Series B+ combines a CEMA B frame with the Rex patented “G” Seal to give longer life. Available in 4" and 5" diameter rolls. Furnished in 18"-48" belt widths....
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REX IDLERS THE BELT CONVEYOR The following is a simplified conveyor, used to illustrate basic belt conveyor components. Unlimited variations of elevation, loading, discharge, idlers and idler spacing, pulleys, and accessories are possible. Carrying Idlers Carrying Belt Training Carrying Idler Idlers Transition Idlers Impact Idlers Transition Steel Idler Head Pulley Receiving Hopper Loading Hopper Spiral or Rubber Disc Return Idlers Take-up Tail Pulley Standard Return Idlers Return Belt Training Idler Bend Pulleys Gravity Take-up (optional) TYPES OF IDLERS Carrying Idlers (Troughing or Flat) Support...
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REX IDLERS TYPES OF IDLERS Return Idlers Support the empty belt between the discharge point and the tail pulley. Normal spacing is 10 feet. a. Steel — Used where materials are not sticky, corrosive, or abrasive. Available with urethane covering. Six inch diameter also available in ¹⁄₄" wall thickness. Refer Pages: 18, 36, 41, 56, 61 b. Spiral — Used where sticky materials adhere to the belt, where a corrosive environment is present or abrasive wear is a problem. Unique construction minimizes belt fleet and damage to the return belt due to material build-up on the idler rolls. Spiral roll idlers...
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IDLER INDEX Idler Number Description Roll Diam. In. O3144 O3204 O4044 B4020 B+4020 F4021 B+4030 B+4031 B4040 B+4040 F4041 B+4050 B+4051 B+4052 B4200 B+4200 B+4210 B+4212 B4300 B+4300 B+4310 B+4312 B5020 B+5020 C5020 D5020 C5021 F5022 C5025 D5025 C5027 B+5030 C5030 D5030 B+5031 C5031 D5031 C5035 C5036 B5040 B+5040 C5040 F5041 B5043 B+5043 C5043 D5043 C5045 D5045 C5046 D5046 C5047 B+5050 C5050 D5050 B+5051 C5051 D5051 B+5052 C5052 D5052 C5054 D5054 C5056 D5056 C5059 C5070 B5200 B+5200 C5200 D5200 C5201 D5201 Return, Catenary Trough, Catenary Return, Catenary - Solid Shaft Flat Flat Flat, Live Shaft...
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IDLER INDEX Idler Number D6020 E6020 F6021 F6022 C6025 D6025 E6025 C6027 C6030 D6030 C6031 D6031 C6035 D6035 D6036 C6036 C6040 D6040 E6040 F6041 C6042 D6042 C6043 D6043 E6043 C6045 D6045 C6046 D6046 C6047 C6050 D6050 C6051 D6051 E6051 C6052 D6052 E6052 C6053 D6053 C6054 D6054 C6056 D6056 E6056 C6057 D6057 D6058 C6059 C6070 C6200 D6200 E6200 C6201 D6201 C6202 D6202 C6203 D6203 C6206 C6210 D6210 E6210 C6211 D6211 C6212 D6212 E6212 C6213 Description Flat Flat Flat, Live Shaft Flat, Impact Live Shaft Flat, Impact Flat, Impact Flat, Impact Flat Flat Training, Actuating Shoe Flat Training, Actuating...
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