How to Operate and Maintain an Air Supported Belt Conveyor
Air supported belt conveyors rely on a uniform air film between the belt and trough to reduce friction, wear, and power consumption. Proper daily operation, standardized startup/shutdown procedures, structured periodic maintenance (minor and major overhauls), and rigorous inspections are crucial to maximize service life and operational efficiency.
1. Standard Operating Procedures
1.1 Mandatory Operational Requirements
Never Reverse the Startup & Shutdown Sequence
Always start the air fan first, then the main drive motor. During shutdown, stop the main drive motor first, then the air blower.
Startup with No-load & Maintain Uniform Feeding
Run empty for a brief period after startup. Begin loading only after ensuring stable operation. Maintain uniform material feeding; avoid sudden surges or overload.
Do Not Stop Under Load
Apart from emergencies, do not stop a loaded conveyor. The normal procedure is to stop feeding and wait until the trough is essentially empty. If an emergency stop does happen under full load, jog the belt a few times or use the auxiliary drive to clear material before restarting — forcing a restart with a full trough is the most damaging thing you can do to belt and trough.
On a Multi-Unit Line, Start From the Last Unit
For multi-conveyor systems, start from the last (downstream) conveyor and work forward (upstream). Reverse the order during shutdown, or implement electrical interlocking.
No Overload Operation
Overload operation is strictly prohibited. Prevent iron parts, large hard objects, and debris from entering to avoid equipment damage.
Proper Lubrication & Safety Alarms
Keep all bearings and drive units properly lubricated. Ensure safety alarms and emergency stop switches are functional, with unblocked access.
1.2 Operational Precautions
Adjustments to drive units, air supply systems, and safety monitoring devices must be performed by designated qualified personnel.
No Cleaning, Part Changes or Lubrication During Operation
Do not clean, replace parts, or perform manual lubrication on belts, pulleys, or idlers while the conveyor is in operation. These are personal safety lines, not efficiency questions. Safety detection devices must not be tampered with either.
Tamper Prohibition
Never tamper with safety monitoring sensors or emergency switches.
Real-Time Patrol & Monitoring
Operators must conduct regular rounds and focus on:
- Motor temperature rise and noise (Drive & Blower)
- Reducer oil level and noise
- Belt tracking (misalignment) and surface damage
- Bearing temperature rise and vibration
- Pulley, idler, cleaner, and take-up unit status
- Electrical control panel conditions
Log any abnormal operating conditions immediately. Stop the machine immediately in case of emergency.
2. Equipment Maintenance & Overhaul
2.1 Setting Overhaul Intervals
Periodic maintenance extends service life, with belt tension control being critical for safe operation. Establish a rigorous inspection log.
Beyond routine checks, minor overhaul is monthly and major overhaul every six or twelve months, and either can be shortened or extended for site conditions, material abrasiveness and running hours. Where dust is heavy and the material is abrasive, shorten them.
2.2 What a Minor Overhaul Covers
| Item | Inspection & Action |
| Belt Maintenance | Inspect belt wear and patch surface damages. |
| Reducer Lubrication | Top up or replace reducer gear oil per manufacturer specs. |
| Pulley Lagging | Check rubber lagging wear and repair damaged sections. |
| Pulley Structure | Inspect pulley weld seams for cracks and repair as needed. |
| Bearings | Replace lubricant in pulley bearing housings. |
| Cleaners & Rings | Replace worn cleaner blades and idler rubber rings. |
| Take-up & Safety | Check take-up travel distance and replace faulty safety sensors. |
| Liners | Replace severely worn chute and impact liners. |
2.3 What a Major Overhaul Covers
Reducer Maintenance: Dismantle, clean, inspect components per manual, and replace severely worn gears/bearings.
Drive Pulley Lagging Replacement: Check driving surface wear; replace rubber lagging strips if severely worn.
Pulley Shell Replacement: Replace the pulley assembly if major unrepairable cracks are found on the shell.
Bearing & Housing Overhaul：Thoroughly clean and inspect all bearing housings and bearings; repair or replace damaged parts.
Structural Frame Inspection：Inspect steel frames for deformation and weld cracks; re-align and re-weld as required.
Belt & Liner Replacement：Re-splice or replace the main conveyor belt. Replace severe wear-resistant liners at loading impact zones and cleaner blades.
Electrical & Safety Overhaul：Test electrical control systems and functional safety devices completely. Replace obsolete or malfunctioning switches/sensors.
3. A Three-Stage Daily Inspection Routine
3.1 Pre-Startup Checklist
Communication： Confirm with site operators that the area is clear and safe.
Mechanical Check： Check wear on head/tail pulleys and idlers; check for loose mounting bolts on brackets.
Lubrication & Protection： Verify oil levels in drive components and test safety switches.
Chute Clearances： Inspect belt surface for debris and remove blockages or tramp iron from loading chutes.
3.2 Running Inspection Checklist
Air Film Stability： Verify that the air cushion under the belt is uniform and stable.
Belt Tracking： Ensure material hits the center of the belt; verify zero belt misalignment.
Thermal & Vibration Patrol： Monitor motor, reducer, and head/tail pulleys for abnormal noise, heat, or vibration.
Idlers & Skirting： Check idler rotation and ensure side skirting rubbers are not leaking material.
Belt Cleaners： Ensure belt scrapers are working cleanly to prevent carryback material from entering the tail pulley.
Oil Leakage： Check for gear oil leakage around reducers and lubricated points.
3.3 Post-Shutdown Checklist
Idler Replacement： Replace sluggish or seized idlers.
Belt Edge Check： Inspect conveyor belt for cracks, edge fraying, or splice separation.
Scraper Adjustment： Re-align or adjust scraper tension for optimal blade contact.
Hardware Tightening： Tighten any loose structural bolts and bracket fasteners.
An air-supported conveyor is low-maintenance, but it demands more discipline than an idler machine. Every correct start, every inspection stage that was not skipped, adds life to the belt.