Technical Bulletin
Belt Guard® Product Range

BG5k

Non-Contact Rip Detection — All Belt Types
Overview

Rip Detection via Belt-Width Monitoring

The Belt Guard BG5k detects longitudinal rips by continuously monitoring the width of the conveyor belt using two non-contact sensors. When a rip causes the torn sections to separate, overlap, or fold, the resulting change in belt width triggers an automated conveyor stop via PLC relay or Modbus command.

The system works on all belt types — fabric, PVC, and steel cord — and requires no sensor loops, no antennae, and no belt modification. It is belt manufacturer independent and can be retrofitted to any existing conveyor structure.

+ Belt Tracking: Continuous lateral position data in mm via Modbus TCP/IP or 4–20mA
BG5k Rip Detector
Key Benefits

Why BG5k

All Belt Types
Works on fabric, PVC, and steel cord belting. The only Belt Guard rip detector that covers every belt type.
Non-Contact
Sensors monitor belt edges without touching the belt. No wear, no drag, no belt damage.
Automatic Buildup Detection Sensors
Sensors automatically detect and report excessive buildup. Blocked probe detection alerts automatically if cleaning is required.
Belt Tracking Data
Real-time belt lateral position in mm — standard output. Detects developing mistracking before damage occurs.
1-Day Installation
Simple installation by site personnel from detailed documentation. Typical 1-day commissioning.
Multi-Point Deployment
Install multiple units along a conveyor — one after each load point — to minimise potential rip length.
System Operation

How It Works

Two sensors are permanently mounted on the conveyor structure, one measuring each belt edge position. They continuously calculate belt width in real time. An operator-set tolerance window defines the acceptable range. Normal belt wander does not trigger a response because belt width remains constant during lateral movement.

01
Monitor
Two sensors continuously measure the position of each belt edge, calculating belt width and lateral tracking position in real time.
02
Detect
When a rip causes the belt to widen, narrow, or fold, the measured width deviates beyond the operator-set tolerance window (Belt Width OK Window ±).
03
Halt
If the deviation persists beyond the configurable Fail Delay timer, a HALT signal is sent to the PLC via Modbus TCP or relay dry contacts, stopping the conveyor.
Detection Limitation
The BG5k requires a measurable change in belt width following a rip event. This width-change effect has not been noted on all occasions of ripping, particularly on thicker, laterally stiff steel cord belting. If no (or insufficient) belt width change occurs, the BG5k will not stop the conveyor. Contact Beltscan to discuss suitability for steel cord applications where this limitation is a concern.
Technical Features

Capabilities

Non-contact belt-width monitoring
Works on fabric, PVC, and steel cord belting
Continuous real-time belt tracking in mm
Any belt width — no limitation
Any belt speed — no limitation
Any product type on belt
Automatic buildup detection sensors with blocked probe alert
Adjustable Belt Width OK Window ±
Configurable Fail Delay timer
HALT output via Modbus TCP or relay
Belt tracking via Modbus TCP/IP or 4–20mA
No sensor loops or antennae required
Belt manufacturer independent
Retrofit to existing conveyor structures
System Components

What's Included

Sensing Probes
2× buildup-detecting probes with mounting hardware
Sensor Mounts
2× mounting hardware for conveyor structure attachment
Main Electrical Enclosure
316 SS, IP66/IP67, all control electronics and PLC interface
Specifications

Technical Data

ParameterValue
Belt TypeFabric, PVC, Steel Cord
Belt WidthNo limitation
Belt SpeedNo limitation
ContactNon-contact
Sensors2× non-contact (buildup-detecting)
Power Supply100–240VAC 50/60Hz or 24VDC
Power Consumption120W max
CommunicationModbus TCP/IP or Control Cables
Belt Tracking OutputModbus TCP/IP or 4–20mA
MEE Enclosure316 SS, IP66 (Manual) / IP67 (QSG)
MEE Size (Manual)H400 × W300 × D250mm
MEE Size (QSG)H600 × W400 × D200mm
Operating Temp-25°C to +70°C
Storage Temp-40°C to +80°C
Humidity5–95% RH
Default Width Window±50mm (factory set)
Deployment

Installation

Location: 10–20m after each load point in the carry path. Multiple units recommended on conveyors with several load points. The closer the sensor to the load point, the shorter any resulting rip.

Installation: Performed by site personnel from detailed wiring and mounting specifications. Consists of sensor mounting hardware and PLC connection. Typical 1-day installation and commissioning.

Calibration: Belt Width OK Window must be set after measuring the normal width variation over a full belt revolution. The factory default of ±50mm may require adjustment to prevent false tripping.

Maintenance

Ongoing Requirements

The BG5k requires very little maintenance. Sensors are buildup-detecting when powered. If a sensor becomes blocked, the device reports an unhealthy state and de-energises the HEALTHY relay. An audible buzz from each sensor confirms operational status.

If cleaning is needed: hose down or wipe the sensor face with an alcohol wipe. The MEE should be protected from direct sunlight and aggressive hose down.

Applications

Where It's Used

Coal Handling Grain Terminals Aggregate Processing Cement Plants Port Facilities Fabric Belt Conveyors PVC Belt Systems Multi-Load-Point Conveyors

Particularly suited to fabric and PVC belt operations where sensor loop systems cannot be used, and as a secondary rip detection layer on steel cord systems.