Contents Title Page No PSV Rollers Series 1900 End Supported Troughing Sets 4, 5, 6, & 7 8&9 PSV 20 PSV 25 PSV 30 Impact Rollers 10 & 11 Flat Belt Impact Rollers Impact Troughing Sets Variable Angle Troughing Sets 12 & 13 Channel Mounted Foot Mounted Base plate Mounted Suspended Troughing Sets 14 Fabricated Bracket Troughing Sets 15 Return Rollers 16 Disc Return Rollers 17 Rubber Spiral Return Rollers 18 Support Brackets and Guide Rollers 19 PL Plastic Rollers 20 & 21 Top & Supreme Thermoplastic Rollers 22 & 23 Rulmeca Belt Tracking Roller 24 & 25 Special Applications 26 & 27 Motorized Pulleys Conveyor Covers Replacement Roller Form 28, 29, 30 & 31 32 & 33 34 3
Contents  Title  Page No  PSV Rollers Series 1900 End Supported Troughing Sets  4, 5, 6,   7 8 9  PSV 20 PSV 25 PSV 30 Imp...

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PSV Rollers Material Specification TUBES: To BS 6323 Part 5 ERW1 / DIN2394 Material - St 37 DIN 17100 (63/76/89/102/108/127/133/159/168 Dia) SHAFTS: To BS 970 Material - 230M07 Free Cutting HOUSINGS: Cold pressed and calibrated to ISO M7 tolerances Material – Steel for Deep Drawing DIN 1623/1624 BEARING ASSEMBLY: Rear Lip Seal – Material ISO PA6 (Nylon 6) Bearing – Deep Groove Precision Ball Bearings (6204/6205/6305/6206/6306/6308) Triple Lip Labyrinth – Material ISO PA6 (Nylon 6) Circlip – Heavy Duty Cover Cap– Cold Pressed Deep Drawn Steel to DIN 1623/1624 and Zinc Plated OUTER SEAL RING Rubber Sliding V-Ring – Material Anti-Abrasive, Low Friction, Anti-Ozone, Nitrilic Rubber STONE GUARD Protective Shield – Material Pom Polymer LUBRICATION Permanent for roller life – Lithium grease NLGI Grade 2 or 3 PROTECTION Single coat of quick drying black primer paint or options to Zinc Plate, Tectyl Oil or Powder Coat 4
PSV Rollers Material Specification  TUBES   To BS 6323 Part 5 ERW1   DIN2394 Material - St 37 DIN 17100  63 76 89 102 108 ...
Main Features • Rugged construction for heavy duties in all Bulk handing applications • Precision manufactured with CNC machines to ensure strict tolerances and fits • Hermetically sealed • Maintenance free • Low starting and frictional resistance for efficiencies and power cost savings • Excellent low eccentricity and balancing for smooth running • Low noise, even at high speeds • Sizes to local and international specifications • Normal working temperature range of -20˚C to +100˚C Roller shell Bearing housing Spindle Internal seal Precision bearing Labyrinth seal Circlip Cover External wiper seal Stone guard 5
Main Features      Rugged construction for heavy duties in all Bulk handing applications     Precision manufactured with C...
PSV Rollers Manufacturing Process Tubes are cut true and square by fully automatic Comecel, rotating head, parting off machinery to very close tolerances. These are then MIG welded to the housings by means of purpose-built double-ended automatic self-centralising welding machines to keep radial tolerances to an absolute minimum. The welded shell is what we call a UNIBLOC construction and gives a strong and watertight enclosure. The spindles are cut and machined on fully automatic double-headed sliding headstock CNC’s to achieve true and accurate fits within the bearings and seals and accurate fitment into whatever mounting elements will be present. Each roller is then assembled on our purpose-built presses. First a nylon back seal prevents any foreign particles or moisture affecting the bearing from within the 6 shell. The bearings are pre-lubricated with the correct amount of approved grease and pressed into the housing. Labyrinths are also pre-greased and then also pressed into position, as is the steel cover. The bearing assembly is held in position by means of heavy-duty circlips. Further to the above, a stone guard is fitted which acts as a highly efficient first barrier to aggregates down to a millimetre in size. A very low friction anti-abrasive rubber lip vee-ring seal mounted behind the stone guard stops the ingress of any liquids or moisture and also acts as a flinger. Following assembly, the rollers are painted one coat of black primer applied through our electro-static paint booth and then packed in cases or on pallets for onward delivery.
PSV Rollers Manufacturing Process  Tubes are cut true and square by fully automatic Comecel, rotating head, parting off ma...
Roller Standards Section through sealing Roller Type PSV1 PSV2 PSV3 PSV4 PSV5 PSV7 Roller Diameter Tube Thickness Spindle Dia Bearing Type 63 76 89 102 108 127 133 76 89 102 108 127 133 159 168 89 102 108 127 133 159 168 89 102 108 127 133 159 89 102 108 127 133 159 168 108 127 133 159 168 194 3 3 3 3 3.5 3.6 4 3 3 3 3.5 3.6 4 4.5 5.0 3 3 3.5 3.6 4 4.5 5.0 3 3 3.5 3.6 4 4.5 3 3 3.5 3.6 4 4.5 5.0 3.5 3.6 4 4.5 5.0 6.3 20 6204 25 6205 25 6305 30 6206 30 6306 40 6308 Approximate Weights (kgs) First 200mm Addt'l 10mm 2.1 2.3 2.5 3.1 3.2 3.9 4.1 2.9 3 3.5 3.6 4.5 4.7 5.4 5.7 3.4 3.9 4 4.7 4.8 6 6.3 3.9 4.5 4.7 5.7 5.9 6.5 6.3 7 7.1 8 8.3 8.9 9.5 8.2 8.9 9.3 10.7 11.5 14 0.07 0.09 0.1 0.11 0.12 0.14 0.16 0.09 0.1 0.13 0.14 0.16 0.17 0.19 0.20 0.11 0.13 0.14 0.16 0.17 0.19 0.22 0.12 0.13 0.14 0.17 0.18 0.22 0.12 0.13 0.14 0.17 0.18 0.22 0.25 0.19 0.21 0.22 0.25 0.30 0.39 Other diameters and tube thicknesses available on request 7
Roller Standards  Section through sealing  Roller Type  PSV1  PSV2  PSV3  PSV4  PSV5  PSV7  Roller Diameter  Tube Thicknes...
End-supported Troughing Sets to BS8438: 2004 for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV4 -30mm shafts 102, 127 & 159 Dia Choosing the correct roller and transom combination for each application is important to ensure that the maximum designed capacity is always reliably available. By advising us of the required conveyor parameters and capacities, we can recommend the correct size and duty to suit each specific application. Direction of Travel 2˚ RL D RL H Rulmeca standard transom sets are of a heavy duty jigfabricated construction, manufactured to BS8438 dimensions with inverted angle self-cleaning bases. Roller shafts have machined flats for drop-in fitment into frames. E E + 50 Slots 18 x 25 Two, four and five roll sets are also available upon request. V 8 G G + 50 Angle Variations 20˚ 25˚ 30˚ 35˚ 40˚ & 45˚
End-supported Troughing Sets to BS8438  2004  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV4 -30mm shafts 102, 127  ...
Standard Troughing Set Dimensions Belt Width RL E G H 102 Diameter Weight kgs 400 500 600 650 750 800 900 1000 1050 1200 1350 1400 1600 1800 2000 160 200 240 250 295 315 350 380 410 465 530 530 600 670 750 640 740 840 890 990 1040 1140 1240 1300 1450 1650 1700 1900 2100 2300 75 75 75 75 75 75 75 75 75 100 100 100 100 100 100 200 200 200 200 200 200 200 200 200 215 215 215 23 25 27 28 31 32 33 35 36 41 45 49 Weights are approximate for complete assemblies. H 127 Diameter Weight kgs H 159 Diameter Weight kgs 225 225 225 225 225 225 225 225 225 240 240 240 240 240 240 25 28 31 32 35 36 39 42 44 48 52 54 61 70 79 275 275 275 275 275 275 275 275 275 275 275 275 275 33 34 38 40 43 45 48 52 61 63 73 82 95 Other diameters available on request. 9
Standard Troughing Set Dimensions  Belt Width  RL  E  G  H  102 Diameter Weight kgs  400 500 600 650 750 800 900 1000 1050...
Impact Rollers & Impact Troughing Sets to BS8438: 2004 for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV4 -30mm shafts 89, 108, 133, 152, 159 & 180 o/all Dia Roller Standards PSV1 Impact rollers are normally required in areas around transfer points where shock loads need to be absorbed, and to give the belt and the material carried, added protection from damage or degradation. Rulmeca impact rollers consist of a base steel roller on to which are fitted our own design of shock absorbing rubber impact discs in various sizes held in place by welded retaining rings. 10 PSV2 PSV4 Impact Diameter Inner Roller Diameter Spindle Dia Bearing Type 89 108 133 152 159 133 152 159 133 152 159 180 63 63 89 102 89 89 102 89 89 102 89 108 20 6204 25 6205 30 6206 Other diameters or special vulcanised sizes are available on request
Impact Rollers   Impact Troughing Sets to BS8438  2004  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV4 -30mm shafts ...
Standard Impact Set Dimensions Direction of Travel 2˚ RL RL H E E + 50 V Angle Variations 20˚ 25˚ 30˚ 35˚ 40˚ & 45˚ G Slots 18 x 25 Belt Width RL E G H 400 500 600 650 750 800 900 1000 1050 1200 1350 1400 1600 1800 2000 160 200 240 250 295 315 350 380 410 465 530 530 600 670 750 640 740 840 890 990 1040 1140 1240 1300 1450 1650 1700 1900 2100 2300 75 75 75 75 75 75 75 75 75 100 100 100 100 100 100 200 200 200 200 200 200 200 200 200 215 215 215 Weights are approximate for complete assemblies. 108 Diameter Weight kgs 25 27 27 31 33 34 36 38 39 44 48 53 H 225 225 225 225 225 225 225 225 225 240 240 240 240 240 240 133 Diameter Weight kgs 29 32 35 36 39 40 43 46 48 52 56 60 66 76 86 G + 50 152/159 Diameter H Weight kgs 275 275 275 275 275 275 275 275 275 275 275 275 275 38 39 42 44 47 50 51 57 63 68 76 87 98 Other diameters available on request. 11
Standard Impact Set Dimensions  Direction of Travel 2    RL  RL  H  E E   50  V  Angle Variations 20   25   30   35   40  ...
Variable Angle Troughing Sets for Rollers PSV1 -20mm shafts 102 & 127 Dia A RL Direction of Travel 2˚ L BR L 38 90 BR 76 Channel Mounted C 25.5 127 14mm wide x 30mm long slots A RL Direction of Travel 2˚ L BR L 38 90 BR Foot Mounted C 22 76 150 14mm wide x 30mm long slots A RL BR L Direction of Travel 2˚ L 90 BR Baseplate Mounted 25 C 65 130 25 14mm wide x 30mm long slots V 12 Angle Variations 20˚ 30˚ 40˚ 50˚ 60˚ Available on all sets
Variable Angle Troughing Sets  for Rollers PSV1 -20mm shafts 102   127 Dia  A RL  Direction of Travel 2    L BR  L  38  90...
Standard Variable Angle Set Dimensions Belt Width ‘B’ RL 102 Dia Rollers Code for Transome Weight Kgs ‘B’ RL 127 Dia Rollers Code for Transome Weight Kgs ‘A’ RL C 450 500 600 650 750 800 900 1000 1050 1200 220 220 220 220 270 270 270 270 220 220 49VC 49VC 49VC 49VC 49VC 49VC 49VC 49VC 49VC 49VC 15 16 17 18 19 20 21 23 24 26 225 225 225 225 275 275 275 275 225 225 49VF 49VF 49VF 49VF 49VF 49VF 49VF 49VF 49VF 49VF 18 19 20 21 23 24 26 28 30 32 200 220 320 370 370 420 520 620 780 930 686 737 838 889 991 1041 1143 1245 1295 1448 Belt Width ‘B’ RL 102 Dia Rollers Code for Transome Weight Kgs ‘B’ RL 127 Dia Rollers Code for Transome Weight Kgs ‘A’ RL C 450 500 600 650 750 800 900 1000 1050 1200 220 220 220 220 270 270 270 270 220 220 49VE 49VE 49VE 49VE 49VE 49VE 49VE 49VE 49VE 49VE 15 16 17 18 19 20 21 23 24 26 225 225 225 225 275 275 275 275 225 225 49VG 49VG 49VG 49VG 49VG 49VG 49VG 49VG 49VG 49VG 18 19 20 21 23 24 26 28 30 32 200 220 320 370 370 420 520 620 780 930 690 740 840 890 990 1040 1140 1240 1300 1450 Belt Width ‘B’ RL 102 Dia Rollers Code for Transome Weight Kgs ‘B’ RL 127 Dia Rollers Code for Transome Weight Kgs ‘A’ RL C 450 500 600 650 750 800 900 1000 1050 1200 220 220 220 220 270 270 270 270 220 220 49VB 49VB 49VB 49VB 49VB 49VB 49VB 49VB 49VB 49VB 14 15 16 17 18 19 20 21 22 24 225 225 225 225 275 275 275 275 225 225 49VA 49VA 49VA 49VA 49VA 49VA 49VA 49VA 49VA 49VA 17 18 19 20 22 23 24 26 28 30 200 220 320 370 370 420 520 620 780 930 305 330 405 485 485 535 635 840 890 1040 Weights are approximate for complete assemblies. Other diameters available on request. 13
Standard Variable Angle Set Dimensions  Belt Width     B    RL  102 Dia Rollers Code for Transome  Weight Kgs     B    RL ...
Suspended Field Troughing Sets for Rollers PSV1 -20mm shafts PSV2 -25mm shafts 102 & 127 Dia A RL RL RL 14 Belt Width Roller Length Mounting Hole Centres 500 600 650 750 800 900 1000 1050 1200 190 224 240 280 295 330 360 380 432 813 889 940 1041 1092 1194 1280 1346 1499
Suspended Field Troughing Sets  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts 102   127 Dia  A  RL  RL  RL  14  Belt Wid...
Fabricated Bracket Troughing Sets for Rollers PSV1 -20mm shafts 102 & 127 Dia ng RL ng Wi Direction of Travel RL 2  a Di Dia Wi 91 Centre RL Hole Centres 70 Slots 14mm wide x 30mm long Hole Centres + 62 130 Fabricated Bracket Troughing Sets Belt Width 450 500 600 650 750 800 900 1000 1200 Roller Lengths Centre Wing 209 209 310 310 387 424 541 617 762 Weights are approximate for complete assemblies. 213 213 213 213 213 213 213 254 254 Hole Centres 102 Dia Weight Kg 127 Dia Weight Kg 305 305 406 406 483 520 637 713 858 14 14 15 15 16 17 18 20 21 16 16 18 18 19 20 21 23 25 Other diameters available on request. 15
Fabricated Bracket Troughing Sets  for Rollers PSV1 -20mm shafts 102   127 Dia  ng  RL  ng Wi  Direction of Travel  RL  2 ...
Plain Return Rollers for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts -30mm shafts PSV5 PSV7 -40mm shafts 63.5, 76, 89, 102, 127 & 159 Dia Belt Width Roller Length BS8438 Mounting Hole Centres 400 500 600 650 750 800 900 1000 1050 1200 1350 1400 1600 1800 2000 500 600 700 750 900 950 1050 1150 1200 1350 1500 1600 1800 2000 2200 640 740 840 890 990 1040 1140 1240 1300 1450 1650 1700 1900 2100 2300 Other diameters available on request. 16
Plain Return Rollers  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts -30mm shafts PSV...
Disc Type Return Rollers for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts 108, 133, 152, & 159 o/all Dia Belt Width 400 500 600 650 750 800 900 1000 1050 1200 1350 1400 1600 1800 2000 Standard Roller Dia / Disc Diameters Available 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 63.5 / 133 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 76 / 152 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 89 / 159 Roller Length No. of Discs per Roller BS8438 Mounting Hole Centres 500 600 700 750 900 950 1050 1150 1200 1350 1500 1600 1800 2000 2200 7 7 7 8 9 9 9 10 11 12 13 13 15 16 17 640 740 840 890 990 1040 1140 1240 1300 1450 1650 1700 1900 2100 2300 Other diameters available on request. 17
Disc Type Return Rollers  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts 108, 133, 15...
Rubber Spiral Return Rollers for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts 108, 133 & 180 o/all Dia Rubber spiral return rollers enable a greater degree of belt tracking to be achieved than with normal disc return rollers. They also perform a cleaning action on the dirty side of the belt due to the flat top helical spiral form of the rings. Belt Width 400 500 600 650 750 800 900 1000 1050 1200 1350 1400 1600 1800 2000 18 Standard Roller Dia / Disc Diameters Available 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 63.5 / 108 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 133 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 89 / 180 Roller Length BS8438 Mounting Hole Centres 500 600 700 750 900 950 1050 1150 1200 1350 1500 1600 1800 2000 2200 640 740 840 890 990 1040 1140 1240 1300 1450 1650 1700 1900 2100 2300
Rubber Spiral Return Rollers  for Rollers PSV1 -20mm shafts PSV2 -25mm shafts PSV3 -25mm shafts PSV4 -30mm shafts 108, 133...
Return Idler Brackets A to BS8438 25 B 2 Slots 18mm wide x 25mm long 30 115 30 175 6 B 100 100 70 W R Type Spindle Belt Width mm Dim A Dim B Dim W Dim R 44WD 44WE 44WF 44WG 44WH 44WK 20 Dia 25 Dia 20 Dia 25 Dia 25 Dia 30 Dia 400 to 650 400 to 650 750 to 1000 750 to 1000 1050 to 2000 1050 to 2000 65 65 40 40 45 45 90 90 65 65 70 70 16 20 16 20 20 24 10.5 13 10.5 13 13 16 Guide Rollers 127 63 Other diameters, shaft sizes and machining details available on request M20 Thread 19
Return Idler Brackets  A  to BS8438  25  B  2 Slots 18mm wide x 25mm long  30  115  30  175 6  B  100  100  70  W  R  Type...
PL Rollers PL2 PL4 There are some environments where extremely corrosive elements are a major hindrance to the smooth running of belt conveyors. Those such as in the production of salt, various chemicals, fertilisers and some marine conditions require a reliable and corrosive resistant roller. It must demonstrate a particular resistance to high humidity and water and to the aggressive material that is to be conveyed. The use of plastic/PVC materials in our range of PL rollers is an excellent and economic alternative for traditional roller materials in poor environments such as stainless steel, bronze and aluminium. -20mm shafts -20mm shafts 90, 110 & 140 Dia Testing and actual plant trials have demonstrated the efficiency and versatility of these rollers with their excellent low running resistance in severe conditions, especially when one considers their low purchase and maintenance costs. PL Rollers can be supplied with shafts that are completely covered with polypropylene caps (PL2) or with exposed shafts (PL4) where they can then be machined to be utilised as replacements for existing machinery. Stainless steel shafts are commonly supplied in these instances. PL rollers can also be manufactured with steel shells and be supplied complete with end supported, variable angle or fabricated bracket type transom sets. Recommended functioning temperatures are -10 Deg to +50 Deg C. Roller Type PL2 PL4 20 Roller Diameter Tube Thickness Spindle Dia Bearing Type 90 110 140 90 110 140 4.3 5.3 8.5 4.3 5.3 8.5 20 6204 20 6204 Approximate Weights (kgs) First 200mm Addt'l 10mm 1.3 1.8 3.1 1.3 1.8 3.1 0.04 0.06 0.08 0.04 0.06 0.08 Note Fitted with Polyamide Mounting Bush over Shaft Ends (30 a/f x 10 lg) Shafts Exposed and Machined (14 a/f x 9 lg)
PL Rollers  PL2 PL4  There are some environments where extremely corrosive elements are a major hindrance to the smooth ru...
PL2 PL4 21
PL2  PL4  21
Top Roller New thermoplastic roller Rulmeca is proud to introduce the new TOP roller, a totally thermoplastic roller with the exception of the steel in the ball bearing and the shaft. High Density Polyethylene (HDPE) tube, black, colour, long fitting between the tube and the bearing housing Bearing housing: Homopolymer Acetal Resin (POM), colour: yellow RAL 1018 FEATURES AND BENEFITS: • lower weight with respect to a steel roller (about 50%). That means: - lower power consumption during start/stop operation of the belt conveyor and therefore reduction of power requirements on the plant; - easier mounting/maintenance ope-rations, preventing back injuries of the operator and guaranteeing a safer intervention, especially in application where roller mounting or replacement might be critical (suspended belt conveyor, difficult access, long conveyors…) - easier/cheaper transportation • low level of abrasion and corrosion of the roller (wear resistant). That means: - longer life of the roller; Available types Load capacity (**) Sealing Sealing system: standard contact-less execution Material: Tube Bearing Housing Working temperatures Applications 89 mm diameter, 20 mm shaft, 6204 bearings 108 mm diameter, 20 mm shaft, 6204 bearings 102 mm diameter, 25 mm shaft, 6205 bearings 127 mm diameter, 25 mm shaft, 6205 bearings 133 mm diameter, 25 mm shaft, 6205 bearings Designed for light/medium duty applications Available in both hermetic and contactless execution, therefore guaranteeing excellent performance in presence of any kind of contaminant High Density Polyethylene (HDPE) Homopolymer Acetal Resin (POM) -25˚C,+50˚C Suitable for use in a wide variety of applications and products such as cement, coal, gravel, fertilisers, ports, chemicals and many others (**) contact your local Rulmeca Company for information and updates Sealing system: optional hermetic execution 22 - lower maintenance of the whole plant. • belt friendly, since HDPE tube will not wear the belt • high resistance to chemical agents. That means: - the roller will not rust - the roller is suitable for a wide variety of applications • low noise emission (due to thermoplastic noise absorption) • self-cleaning roller surface. That means: - prevention of build up of material, maincause of belt mis-tracking - less spillage from the belt • low running resistance sealing system. That means: - lower motor torque need in conveyor starts - lower motor power size - reduction of energy consumption of the belt conveyor (added effect to that of the lower weight) - lower belt consumption
Top Roller New thermoplastic roller  Rulmeca is proud to introduce the new TOP roller, a totally thermoplastic roller with...
Supreme Heavy Duty Corrosion and Abrasion Resistant Roller Ultra thick abrasion and corrosion resistant 12mm HDPE sleeve. Reduced “C” dimension decreases load induced shaft defl ection. The Melco SUPREME boasts a wide range of superior advantages, features & benefits: • Steel tube ensures adequate mechanical strength for heavy duty loads • Ultra thick abrasion and corrosion resistant 12mm thick HDPE sleeve • HDPE contains carbon black increasing ultra violet resistance • Steel and HDPE tube combination provides significantly reduced weight • The bearing housing effectively locks the HDPE tube in position preventing movement along the steel tube • Minimum “C dimension” decreases load induced shaft deflection • Unique large diameter stoneguard with integral labyrinth design minimises possibility of being jammed by spilt material, and provides additional protection from water and dust • Multi part labyrinth seal protects the bearing from ingress of contaminants • Ultra low running resistance and break away mass reduces power consumption for start up and continuous operation • Machined finish ensures LOW run-out, minimizing vibration and noise emission • Castellated HDPE tube is a tight interference fit on the steel tube Typical applications • Mining – Platinum, Copper, Uranium, Iron Ore, Gold, Diamonds, Sand • Coal Process Plants • Coal Fired Power Stations • Import/Export Terminals • Belt scales • Aluminium Smelters • Steel Plants • Fertilizer Plants Programme of production Web reinforced, sturdy polymer bearing housing, smaller diameter results in higher strength ratio. shaft ø mm bearings Diameter ø mm SPRM / 2 25 6205 127, 133, 152, 159 SPRM / 3 25 6305 127, 133 SPRM / 5 30 6306 152, 159 Unique large diameter stoneguard with integral labyrinth design minimises possibility of being jammed by spilt material. Melco’s well-proven multi part Labyrinth seal. 23
Supreme Heavy Duty Corrosion and Abrasion Resistant Roller  Ultra thick abrasion and corrosion resistant 12mm HDPE sleeve....
Belt Tracking Roller Features and Benefits Widely used in the mining industry and other conveyor related industries, the Rulmeca belt tracking roller responds instantly to the misalignment of the belt and does so without special modifications to the structure. The Rulmeca belt tracking roller accommodates belts ranging from 450 - 2300 mm. Frame and guide rollers are often the cause of belt damage, which reduces the lifetime of the belt. The Rulmeca belt tracking roller requires no maintenance and fits into a standard drop bracket. The Rulmeca Centralising Return Pulley can be manufactured to suit all belt sizes in operation, in any country. Special design requirements, such as specific shaft dimensions and lengths, are possible at little or no additional charge. Design and manufacture The Rulmeca belt tracking roller is a quality product that is made of precision-turned C.N.C. components. Special hardened steels and other alloys ensure that the Rulmeca belt tracking roller performs optimally over an extended period of time, in the toughest conditions. The bearings in the Rulmeca belt tracking roller continuously run in oil thus prolonging its life span. The Rulmeca belt tracking roller is a fully serviceable product and carries a 2-year warranty! It does not need to be discarded but can be reconditioned. (Please apply for terms and conditions). Rulmeca belt tracking roller preventing belt damage Rulmeca belt tracking roller in action Rulmeca return belt tracking roller 24
Belt Tracking Roller Features and Benefits  Widely used in the mining industry and other conveyor related industries, the ...
Belt Tracking Roller • • • • • • • Prevent Belt Damage Prevent Structural Damage Prevent Spillage Decrease downtime Decrease maintenance Extend Belt Life Save Money!!! Maximum Load Ratings Item 30 SERIES 40 SERIES 50 SERIES Code SG120/30 SG105/30 SG90/30 SG75/30 SG60/30 SG120/40 SG135/40 SG150/40 SG165/40 SG180/40 SG135/50 SG150/50 SG165/50 SG180/50 Belt Width in mm 1200 1050 900 750 600 1200 1350 1500 1650 1800 1350 1500 1650 1800 in inches Maximum Load in kg 48 42 36 30 24 48 54 60 64 72 54 60 64 72 200 250 350 420 500 700 382 250 230 200 750 620 600 500 Please use this guide to select the best series for the individual applications 25
Belt Tracking Roller                               Prevent Belt Damage Prevent Structural Damage Prevent Spillage Decrease...
Special Applications With belt widths and speeds increasing to cope with the higher tonnages that are now being demanded, the call for the design of high-duty and special purpose sets has also increased. Our experience within Rulmeca enables us to put forward bespoke designs to work with unusual and demanding applications where standard equipment would not normally fit. These can come in the guise of 2, 3, 4, and 5 roll trough sets, garlands, and 2 or 3 roll return sets. We utilise CAD in the design of special transoms, and when coupled with the correct specification of roller needed from the vast range of sizes available, we can offer, specify and guarantee for each individual application. 26
Special Applications  With belt widths and speeds increasing to cope with the higher tonnages that are now being demanded,...
Where there are poor loading conditions or indeed where the belt itself is in a poor condition, the tracking of trough belts can sometimes prove troublesome. An answer in many cases is the fitment of self-aligning or self-centralising sets which can be used on both long and short conveyor stretches. These units work over a central slewing ring mechanism along with guide rollers or brake rollers to keep the belt in line and therefore reduce spillage and undue wear. Heavier loads and higher speeds can be catered for by providing wider sets with multiples of rollers to spread the load over more bearings. The use of 5 rollers can also enhance the control of spillage by allowing higher wing roller angles. 27
Where there are poor loading conditions or indeed where the belt itself is in a poor condition, the tracking of trough bel...
Motorized Pulleys for Belt Conveyors General Description The Rulmeca Motorized Pulley was first produced in 1953 specifically for belt conveyor systems. The aim was to produce an extremely compact, totally enclosed and highly efficient belt conveyor drive, resistant to dust, water, oil, grease or harmful substances. A Motorized Pulley which would be quick and simple to install and would require virtually no maintenance. These aims were achieved and today the Rulmeca Motorized Pulley is considered to be one of the most reliable and effective belt conveyor drives available throughout the world. The Motorized Pulley is a highly efficient geared motor drive, which is hermetically sealed within a steel cylindrical shell. The shell, which is usually crowned to ensure central belt tracking, is fitted with bearing housings incorporating precision bearings, double lipped seals and rotates about a static pair of shafts. The motor stator is fixed to the shafts and the motor winding cables pass through one of the shafts, eliminating the need for slip rings and brushes. The squirrel cage induction motor, manufactured in steel laminate, is machined concentric to high tolerances and designed to give 200% starting torque for 3 phase versions. The rotor pinion is coupled directly to the gearbox. The gearbox transmits torque to the shell through a geared rim and provides a highly efficiency motor with very little frictional losses. The Motorized Pulley is oil filled, which acts as both a lubricant and coolant. Heat is dissipated through the shell and the conveyor belt. All vital parts are CNC machined! 28 The Rulmeca Motorized Pulley is supplied as standard with: Rulmeca Motorized Pulleys are manufactured according to the Council Directives of the European Communities. • Machined mild steel crowned shell. The CE-marking is according to Directive 73/23/EEC relating to electrical equipment and according to Directive 89/336EEC relating to electrical magnetic compatibility and amendments. • Electric motor manufactured in accordance with IEC 34-1 (EN60034-1), (VDE 0530). • Class F insulation according to IEC 34-1 (EN60034-1), (VDE 0530). • Most international voltages. • Standard voltages supplied with ±10% tolerance in accordance with IEC 38. • Factory oil filled and tested. • Degree of protection IP66/67 (EN60034-1).
Motorized Pulleys for Belt Conveyors General Description  The Rulmeca Motorized Pulley was first produced in 1953 specific...
Standard Range of Pulley sizes Standard Range of Pulley sizes Shell Diameter Reference Power Range (kW) 138 165 216 320 400 500 630 800 1000 138i 165i 220M/220H 320L/320M/320H 400L/400M/400H 500L/500M/500H 630M/630H 800M/800H/800HD 1000HD 0.1 to 1.0 0.11 to 2.2 0.37 to 5.5 0.75 to 11.0 2.2 to 15.0 2.2 to 30.0 5.5 to 55.0 22.0 to 132.0 160.0 to 250.0 Speed Range (Mtr/sec) 0.05 0.06 0.13 0.13 0.16 0.20 0.63 1.25 2.50 to to to to to to to to to 1.25 2.00 2.50 2.50 3.15 3.15 4.00 4.50 5.50 Please contact Rulmeca for options and advice on the following; • Rubber or Ceramic lagging • Rust free and stainless steel options • Brakes and backstops • Special electrical and temperature requirements or synthetic oil • Any other special environments or applications you would like us to consider. • Re-greasable seals for particularly difficult environments • Atex 21 approval • Underground flame proof approval options Alternatively, please request our separate Motorized Pulley catalogue for more information. 29
Standard Range of Pulley sizes  Standard Range of Pulley sizes Shell Diameter  Reference  Power Range  kW   138 165 216 32...
Motorized Pulleys for Belt Conveyors Features and Benefits of Rulmeca Motorized Pulleys Purpose-built design The Rulmeca Motorized Pulley has been specifically designed for belt conveyors. Totally enclosed The motor, gearbox and bearings are totally enclosed and sealed inside a steel shell; therefore they are unlikely to fail due to harmful environmental conditions such as water, dust, grit, chemicals, grease, oil, etc. Space saving design Because the drive unit and the bearings are mounted inside the Motorized Pulley shell, it takes up much less room than a conventional drive. No need for costly extras like chains, v-belts, couplings, bearings, support structure and special guarding. Crushing & Screening Safety The Rulmeca Motorized Pulley is probably one of the safest drives available because the motor is completely enclosed and the external shafts are always stationary. The only moving external part is the Pulley shell. Low purchasing and installation cost The Rulmeca Motorized Pulley is quite often less expensive than a conventional drive because it has fewer parts, which reduces conveyor design and purchasing costs. It is also much quicker and easier to install – certainly less than a quarter of the time needed to fit an exposed system. Potash & Fertilizer Low maintenance cost The end user also benefits from the Rulmeca Motorized Pulley, because it requires no maintenance other than the recommended oil change every 20.000 hours. Oil changes can now be increased up to 50,000 hours with the use of synthetic oils. Efficiency The Rulmeca Motorized Pulley usually has a much higher efficiency from electrical motor to shell (pulley face) than conventional drives, because it has fewer frictional losses, and therefore efficiencies of up to 97% can be achieved. Cleanliness Because the Rulmeca Motorized Pulley is totally enclosed, it cannot contaminate any special conveyed materials or items such as electrical components; plastics and any other materials that must be kept perfectly clean during handling. Recycling 30 Aesthetic appearance If installed correctly the Rulmeca Motorized Pulley always looks good. Due to its compact size and smooth lines, quite often the Motorized Pulley is out of sight, because it is hidden within the conveyor frame. Thermal Protection All three phase Rulmeca Motorized Pulleys are protected by our thermal protection switch. This heat sensitive bimetal strip is built into the motor windings to protect the motor from overheating. The thermal protector must be connected to a normally closed circuit. Weight saving and distribution Often the Rulmeca Motorized Pulley is lighter than conventional drives and often it is possible to therefore reduce the cost of the conveyor structure. Weight distribution is even within the conveyor frame. Variable frequency converters All Rulmeca Motorized Pulleys with 3 phase motors are easily controlled by variable frequency invertors working in the 15 Hz to 65 Hz frequency range. Fewer parts A Rulmeca Motorized Pulley consists of the drive and two fixing brackets! Conventional drives can require up to 8 or more separate components, most of which have to be purchased from different suppliers or manufactured specially. Low noise Thanks to the totally sealed enclosure and high quality gears, the Rulmeca Motorized Pulley runs almost at a whisper – a very important fact in today’s modern site and plant environments. The Rulmeca Motorized Pulley – the ideal drive unit for all conveyors… "Fit it and forget it"
Motorized Pulleys for Belt Conveyors Features and Benefits of Rulmeca Motorized Pulleys  Purpose-built design The Rulmeca ...
Motorized Pulley examples Sea Dredged Aggregates Cement & Batching Plants Chemical Fertilizers 31
Motorized Pulley examples  Sea Dredged Aggregates  Cement   Batching Plants  Chemical Fertilizers  31
Conveyor Covers As regulations to control environmental conditions become more stringent, the need to enclose conveyors and minimise noise and dust release to the atmosphere has increased. The use of conveyor covers has the added benefit of; • Protecting the material carried from contamination • Protects the belt from the sun and bad weather • Provides better health and safety conditions for operators Fitting Rulmeca conveyor covers has the further advantages of; • Being light, yet rigid and easy to fit to most existing structures • Less cost than other systems or materials • Less maintenance • Has many options/different arrangements such as inspection covers, hinged sections and various quick release fittings • Provides a better integration into the landscape Conveyor Covers in Steel These covers are made from galvanised sheet steel corrugated sections in usable pitches of 1064mm and 1292mm.. They are self supporting, safe, easy to install and adjustable to almost any structure. They are available for all belt widths and supporting structure and can be supplied with opening windows for inspection, as well as removable sections and ventilated covers for hot environmental conditions. They are maintenance free. On request they can be supplied in other materials or finished with special paint. Conveyor Covers in PVC Plastic covers are made of pre-formed anti-shock, neutral colour, transparent PVC in usable pitches of 1050mm. Thanks to the characteristics of the material, they are light, transparent, anti-corrosive and with a smooth surface. Above all they are easy to adapt to any conveyor. 32 Apart from their resistance to corrosion they are classified "NON FLAMMABLE" to DIN 4102. Notwithstanding this property of self-extinguishing, the limit to the use of PVC covers in hot areas should not exceed 65° C.
Conveyor Covers  As regulations to control environmental conditions become more stringent, the need to enclose conveyors a...
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33  200  ern al rad ius  Straight side  Int  r
Replacement Roller Form Order No. Customer Delivery address (if different) Tel: Quantity Date Description Ordered By Complete Dimensions Indicated mm SPINDLE DIA ROLLER DIA mm SPINDLE LENGTH AGL mm mm ROLLER LENGTH R.L. SPINDLE END TYPE............. SPINDLE END TYPE............. Spindle End Types Type ‘D’ Type ‘A’ L mm J mm M mm G mm H mm Type ‘E’ Type ‘B’ G mm M mm L mm H mm Type ‘F’ (Sketch your own requirements) G mm Type ‘C’ Plain 34 Female Threads available M6’ M8, M10, M12, M16 Male Threads available M12, M14, M16, M20, M24
Replacement Roller Form  Order No.  Customer  Delivery address  if different   Tel  Quantity  Date  Description  Ordered B...