Post on 21-Jan-2023
PNEG-1971CE
CE Compliant Metric Series IIBucket Elevator
Assembly Manual - Original Instructions
PNEG-1971CEVersion: 5.1
Date: 12-21-20
2 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Use of the equipment information page will help you identify the equipment in the case that you need to notify the company. For this reason, this information should be filled out and kept on record.
Equipment Information
Model Number: ______________________________________________
Serial Number: ______________________________________________
RPM: _____________________________________________________
Head Pulley Diameter: ________________________________________
Discharge Height: ____________________________________________
Horsepower: ________________________________________________
GSI Group91-93 Budafoki ut, IP-West Building CBudapest, H-1117Hungary
Date Purchased: ___________________________________________
Dealer Name and Phone Number: ________________________________
________________________________
________________________________
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 3
CE Declaration of Incorporation EC MACHINERY DIRECTIVE
2006/42/EC1004 East Illinois Street, Assumption, IL, 62510, USA
+1 217 226 4429
The GSI Group declares that
GSI Bucket Elevators
Models
15P16/15G16; 20P16/20G16; 25P16/25G16; 30P16/30G16; 30P24/30G24; 40P24/40G24; 50P24/50G24; 56P24/56G24; 50P30/50G30; 60P30/60G30; 70P30/70G30; 50P36/50G36; 60P36/60G36; 70P36/70G36; 75P36/75G36; 80P36/80G36; 100P36/100G36; 80P42/80G42; 100P42/100G42; 120P42/120G42; 140P42/140G42; 150P42/150G42; 200P42/200G42; 140P48/140G48; 150P48/150G48; 160P48/160G48; 200P48/200G48; 250P42; 300P42; 400P42; 250P48; 300P48; 400P48; 500P48; 600P48
Meet the Essential Requirements of the Machinery Directive 2006/42/EC.
1. This declaration applies only to the mechanical elements of the above machines and does not imply conformity by any other items of equipment fitted to or connected with the above machines.
2. The equipment must be operated by an electrical control system designed and installed in accordance with EN60204:2006 and EN ISO 13849:2006, including all necessary safety controls. This is the responsibility of the equipment installer.
3. The equipment above must not be put into service until the machinery into which it is to beincorporated has been declared in conformity with the provisions of all relevant Directives, nor until these components have been assembled in the manner recommended in the attached manufacturers instructions, PNEG-1971CE.
4. This declaration is not valid unless attached to the manufacturers’ instructions PNEG-1971CE.
Signed:
Name:
Date:
4 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Declaration of ConformityATEX DIRECTIVE
2014/34/EU
23 April 2015 GSI Kft91-93 Budafoki ut, IP-West Building C
Budapest, H-1117Hungary
The GSI Group declares that the machine, parts or equipment
Bucket Elevators
Models
Meets the Essential Requirements of the ATEX Directive 2014/34/EU
• Equipment Group II
• Equipment Category 3
Model m3/h MTH Pulley RPM m/s Max HPBucket Size (in)
BucketSpacing (in)
TrunkingSize (in)
15G16-***-X22 53 38 16 95 2.1 0 9 x 5 9 10 x 16
20G16-***-X22 71 51 16 95 2.1 0 9 x 5 7 10 x 16
25G16-***-X22 89 63 16 95 2.1 0 9 x 6 8 10 x 16
30G16-***-X22 106 76 16 95 2.1 0 9 x 6 7 10 x 16
30G24-***-X22 106 76 24 73 2.4 0 10 x 6 8 10 x 16
40G24-***-X22 142 101 24 73 2.4 0 11 x 6 7 10 x 16
50G24-***-X22 177 127 24 73 2.4 0 11 x 6 LP 6 10 x 16
56G24-***-X22 198 142 24 73 2.4 0 11 x 6 LP 5 10 x 16
50G30-***-X22 177 127 30 67 2.8 0 13 x 6 8 12 x 18
60G30-***-X22 213 152 30 67 2.8 0 13 x 7 9 12 x 18
70G30-***-X22 248 177 30 67 2.8 0 13 x 7 8 12 x 18
50G36-***-X22 177 127 36 64 3.2 0 12 x 6 8 12 x 18
60G36-***-X22 213 152 36 64 3.2 0 11 x 7 9 12 x 18
70G36-***-X22 248 177 36 64 3.2 0 13 x 7 9 12 x 18
75G36-***-X22 266 191 36 64 3.2 0 13 x 7 9 12 x 18
80G36-***-X22 283 204 36 64 3.2 0 13 x 7 8 12 x 18
100G36-***-X22 354 255 36 64 3.2 0 13 x 7 LP 6 12 x 18
80G42-***-X22 283 204 42 60 3.4 0 14 x 7 9 14 x 22
100G42-***-X22 354 255 42 60 3.4 0 14 x 8 10 14 x 22
120G42-***-X22 425 306 42 60 3.4 0 16 x 8 10 14 x 22
140G42-***-X22 496 355 42 60 3.4 0 16 x 8 9 14 x 22
150G42-***-X22 531 382 42 60 3.4 0 16 x 8 LP 8 14 x 22
200G42-***-X22 708 510 42 60 3.4 0 20 x 8 LP 7 14 x 26
140G48-***-X22 496 355 48 56 3.7 0 16 x 8 10 14 x 26
150G48-***-X22 531 382 48 56 3.7 0 18 x 8 10 14 x 26
160G48-***-X22 567 405 48 56 3.7 0 18 x 8 9 14 x 26
200G48-***-X22 708 510 48 56 3.7 0 20 x 8 LP 8 14 x 26
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 5
• Combustible material Grain Dust
• Minimum ignition temperature 380°C (max design surface temperature T4 = 135°C)
• Ex II2/3 D T4 (135°C); ‘c’; ‘b’
In accordance with the following standards:
• EN13463-1:2009
• EN13463-5:2011
• EN13463-6:2005
The equipment above must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of all relevant Directives or until these components have been assembled in the manner recommended in the manufacturers instructions.
Signed:
Name:
Date:
Declaration of ConformityATEX DIRECTIVE
2014/34/EU
23 April 2015 GSI Kft91-93 Budafoki ut, IP-West Building C
Budapest, H-1117Hungary
6 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
The GSI Group declares that the machine, parts or equipment
Bucket Elevators
Models
Meets the Essential Requirements of the ATEX Directive 2014/34/EU
• Equipment Group II
• Equipment Category 2
Model m3/h MTH Pulley RPM m/s Max HPBucket Size (in)
BucketSpacing (in)
TrunkingSize (in)
15G16-***-X21 53 38 16 95 2.1 0 9 x 5 9 10 x 16
20G16-***-X21 71 51 16 95 2.1 0 9 x 5 7 10 x 16
25G16-***-X21 89 63 16 95 2.1 0 9 x 6 8 10 x 16
30G16-***-X21 106 76 16 95 2.1 0 9 x 6 7 10 x 16
30G24-***-X21 106 76 24 73 2.4 0 10 x 6 8 10 x 16
40G24-***-X21 142 101 24 73 2.4 0 11 x 6 7 10 x 16
50G24-***-X21 177 127 24 73 2.4 0 11 x 6 LP 6 10 x 16
56G24-***-X21 198 142 24 73 2.4 0 11 x 6 LP 5 10 x 16
50G30-***-X21 177 127 30 67 2.8 0 13 x 6 8 12 x 18
60G30-***-X21 213 152 30 67 2.8 0 13 x 7 9 12 x 18
70G30-***-X21 248 177 30 67 2.8 0 13 x 7 8 12 x 18
50G36-***-X21 177 127 36 64 3.2 0 12 x 6 8 12 x 18
60G36-***-X21 213 152 36 64 3.2 0 11 x 7 9 12 x 18
70G36-***-X21 248 177 36 64 3.2 0 13 x 7 9 12 x 18
75G36-***-X21 266 191 36 64 3.2 0 13 x 7 9 12 x 18
80G36-***-X21 283 204 36 64 3.2 0 13 x 7 8 12 x 18
100G36-***-X21 354 255 36 64 3.2 0 13 x 7 LP 6 12 x 18
80G42-***-X21 283 204 42 60 3.4 0 14 x 7 9 14 x 22
100G42-***-X21 354 255 42 60 3.4 0 14 x 8 10 14 x 22
120G42-***-X21 425 306 42 60 3.4 0 16 x 8 10 14 x 22
140G42-***-X21 496 355 42 60 3.4 0 16 x 8 9 14 x 22
150G42-***-X21 531 382 42 60 3.4 0 16 x 8 LP 8 14 x 22
200G42-***-X21 708 510 42 60 3.4 0 20 x 8 LP 7 14 x 26
140G48-***-X21 496 355 48 56 3.7 0 16 x 8 10 14 x 26
150G48-***-X21 531 382 48 56 3.7 0 18 x 8 10 14 x 26
160G48-***-X21 567 405 48 56 3.7 0 18 x 8 9 14 x 26
200G48-***-X21 708 510 48 56 3.7 0 20 x 8 LP 8 14 x 26
Declaration of ConformityATEX DIRECTIVE
2014/34/EU
23 April 2015 GSI Kft91-93 Budafoki ut, IP-West Building C
Budapest, H-1117Hungary
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 7
Declaration of ConformityATEX DIRECTIVE
2014/34/EU
23 April 2015 GSI Kft91-93 Budafoki ut, IP-West Building C
Budapest, H-1117Hungary
• Combustible material Grain Dust
• Minimum ignition temperature 380°C (max design surface temperature T4 = 135°C)
• Ex II 2/2 D T4 (135°C); ‘c’; ‘b’
In accordance with the following standards:
• EN13463-1:2009
• EN13463-5:2011
• EN13463-6:2005
The equipment above must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of all relevant Directives or until these components have been assembled in the manner recommended in the manufacturers instructions.
Signed:
Name:
Date:
Table of Contents
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 9
ContentsChapter 1 Introduction ........................................................................................................................................11
General Safety Statements ................................................................................................................. 11Receiving Inspection ........................................................................................................................... 11Pre-Installation Notifications ................................................................................................................ 11
Chapter 2 Safety ...................................................................................................................................................12Safety Guidelines ............................................................................................................................... 12Cautionary Symbols Definitions .......................................................................................................... 13Safety Cautions ................................................................................................................................... 14Safety Sign-Off Sheet ......................................................................................................................... 17Correct Use of the Bucket Elevator ..................................................................................................... 18Working at Heights .............................................................................................................................. 19Electrical Safety .................................................................................................................................. 20
Chapter 3 Safety Decals ......................................................................................................................................22Decal Placement ................................................................................................................................. 24
Chapter 4 Elevator Parts .....................................................................................................................................25Part Identification ................................................................................................................................ 25
Chapter 5 ATEX Compliance Instructions .........................................................................................................26Installation ........................................................................................................................................... 26Vibration .............................................................................................................................................. 26Explosion Pressure Vents ................................................................................................................... 26Hours Run Meter ................................................................................................................................. 26Safety Interlocks .................................................................................................................................. 26Maintenance ........................................................................................................................................ 28ATEX Compliance of GSI Bucket Elevators ........................................................................................ 29
Chapter 6 Bucket Elevator Foundation ..............................................................................................................34
Chapter 7 Boot Section .......................................................................................................................................35Attaching Boot to Foundation .............................................................................................................. 36Inspection Sections ............................................................................................................................. 37
Chapter 8 Trunking ..............................................................................................................................................38Standard Trunking ............................................................................................................................... 38Pressure Relief Trunking ..................................................................................................................... 39Trunking Installation ............................................................................................................................ 40
Chapter 9 Lower Head Section ...........................................................................................................................41Head Bonnet Section .......................................................................................................................... 41
Chapter 10 Maintaining Plumbness ...................................................................................................................43
Chapter 11 Belting, Splicing and Buckets .........................................................................................................44Belts ................................................................................................................................................... 44Splicing .............................................................................................................................................. 44Belt Installation .................................................................................................................................. 45Installation ......................................................................................................................................... 46Installing the Buckets ......................................................................................................................... 53Installation of Light Narrow Belts ....................................................................................................... 53Buckets .............................................................................................................................................. 53Belt Slack Removal ........................................................................................................................... 54
Table of Contents
10 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Chapter 12 Drive Motor and Motor Mount .........................................................................................................56Drive .................................................................................................................................................. 56Motor Mount Assembly ...................................................................................................................... 56NORD Drive - Table Style Torque Arm Assembly Instructions .......................................................... 62
Chapter 13 Final Checks, Tracking, Start-Up and Maintenance ......................................................................64General Final Checks ........................................................................................................................ 64Belt Tracking ...................................................................................................................................... 65Start-Up ............................................................................................................................................. 65Maintenance ...................................................................................................................................... 65Dealing with Elevator Blockages ....................................................................................................... 66
Chapter 14 Appendix 1 - Reference Information ...............................................................................................68
Chapter 15 Reducer Lubrication ........................................................................................................................69Lubricant Table .................................................................................................................................. 70
Chapter 16 ATEX Ignition Source Instructions .................................................................................................71
Chapter 17 Warranty ............................................................................................................................................77
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 11
1. Introduction
Thank you for choosing a GSI product. It has been designed to provide excellent performance and service for many years.
This manual covers general information about installing the GSI Bucket Elevator.
Due to the large variety of equipment features offered, this manual cannot cover every aspect of installation with this manual. This manual provides suggested and recommended methods for installing the product. GSI recommends you retain a qualified contractor to provide on-site expertise.
GSI is not responsible for the installation of this product.
General Safety Statements1. Our primary concern is your safety and the safety of others associated with the use of this product.
All personnel responsible for installing, operating or maintaining this equipment should read and understand this manual. It is the responsibility of the owner to make this manual available to the person or persons involved with this equipment.
2. Guards and safety labels have been installed prior to leaving the manufacturing plant. These should not to be removed, altered or defaced in any way.
3. Modifications to equipment may cause extremely dangerous situations that could result in damage to the equipment as well as serious injury or death. Never modify the equipment.
4. GSI recommends that you contact the local power company to have a representative survey the installation to ensure wiring is compatible with their system and adequate power is supplied to the unit.
Receiving Inspection
1. Carefully inspect the shipment for damage as soon as it is received and verify that the quantity of parts or packages actually received corresponds to the quantity shown on the packing slip.
2. Report any discrepancies, shortages or damages to the delivering carrier as soon as possible.
3. The manufacturer’s responsibility for damage to the equipment ends when the carrier accepts the equipment for delivery. Refer to the bill of lading for more detailed information.
4. Save all paperwork and documentation furnished with any of the elevator components.
Pre-Installation Notifications
1. GSI is the manufacturer and vendor of the elevator and is responsible only for the optional accessories also manufactured by GSI.
2. The elevator has not been designed to support other equipment such as cleaners, distributors or spouting. Separate structures must be provided for any accessory equipment.
3. This installation manual should be used for reference only.
4. The owner/user/installer of this equipment is responsible for consulting and retaining a civil or structural engineer regarding the design, construction and supervision of the entire installation, including the elevator foundation and the guying cable and/or bracing system.
5. GSI Bucket Elevators are designed to be vertically self-supporting when erected but must be supported or guyed against wind loads.
12 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
2. Safety
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is written to help you understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. Read and save these instructions.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable regulations, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
ST-0001-4
2. Safety
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 13
Cautionary Symbols Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use the symbols that are defined below.
NOTICE
DANGER
WARNING
CAUTION
This symbol indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to personal injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005-2
2. Safety
14 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Safety Cautions
Use Personal Protective Equipment
Eye Protection
Hearing Protection
Hand Protection
Head Protection
Respiratory Protection
Foot Protection
Fall Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.ST-0004-1
Follow Safety Instructions
• Carefully read all safety messages in this manual and safety signs on your machine. Keep signs in good condition. Replace missing or damaged safety signs.Be sure new equipment components and repair parts include the current safety signs. Replacement safetysigns are available from the manufacturer.
• Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
• If you do not understand any part of this manual or need assistance, contact your dealer.
ST-0002-1
2. Safety
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 15
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep area clean and dry.
• Never service equipment while it is operating. Keep hands, feet, and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace worn or broken parts immediately.
ST-0003-1
Operate Motor Properly
• All electrical connections must be made in accordance with applicable local codes (National Electrical Code for the US, Canadian Electric Code, or EN60204 along with applicable European Directives for Europe). Make sure equipment and bins are properly grounded.
• Lock out power before resetting motor overloads.
• Do not repetitively stop and start the drive in order to free a plugged condition. Jogging the drive in this manner can damage the equipment and drive components. ST-0009-3
Toxic Fume and Dust Hazard
• Do all work outside or in a well-ventilated area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:
— Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
— If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
— If you use solvent or paint-stripper, remove stripper with soap and water before welding.
— Remove solvent or stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
ST-0043-2
2. Safety
16 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Fall Hazard
• Keep access door closed while on platform to avoid falls.
• Always use proper personal protective equipment and proper clothing when using equipment. Failure to follow safety precautions can result in severe injury or death.
ST-0042-2
> 500 lbs(2.25 kN)
Platform Load Limit
• The platform load limit is 500 LBS (2.25 kN). Do not exceed this weight.
• Excessive load will damage the platform and cause platform to fall. Severe injury or death will result.
ST-0044-2
2. Safety
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 17
Safety Sign-Off Sheet
Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
ST-0007
2. Safety
18 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Correct Use of the Bucket Elevator
1. These elevators are designed solely for conveying whole agricultural grain and seeds. Use for any other material is a misuse and could result in serious injury and equipment damage.
2. Never operate the Bucket Elevator without completely enclosing the inlet or outlet, making all moving parts in-accessible to any person. (See Figure 2A.)
Figure 2A Example of Enclosed Inlet and Outlet
Ref # Description
A Example Enclosed Inlet Conveyor Feeding Elevator
B Example Enclosed Outlet Feeding Conveyor
2. Safety
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 19
Correct Use of the Bucket Elevator (Continued)3. Never operate with guards removed or inspection covers open.
4. Never open or work on the moving parts of the Bucket Elevator unless:
a. It has been run completely empty of grain. (A loaded elevator might result in unexpected movement of the belt and buckets even when locked out.)
b. It is locked out and tagged out at the main electrical isolator.
c. All equipment working with the elevator are also locked out and tagged out.
5. The elevator must be installed vertical in all directions and must not be used at any other angle.
6. Do not fix a hoist or other lifting equipment to the Bucket Elevator, nor to the ladders or platforms attached to the elevator.
7. Ladders and platforms attached to the elevator are for personnel access only and must not be used to carry or support heavy pieces of equipment.
8. Do not exceed the maximum ladder and platform load, noted on the warning decal (225 kg).
9. Never alter or adjust the elevator from it is original specification.
10. Always lock out and tag the electrical power to the elevator before working on it.
11. Do not use the elevator in an enclosed, potentially explosive area.
Working at HeightsThe equipment has been designed to operate primarily at ground level, at some stages during the life cycle it will be necessary to work at heights. For this reason the equipment has been provided with access ladders and platforms, to minimize the risk to health and safety. In addition attention should be paid to the following safety requirements.
1. The ladders, platforms and walkways are for use by competent and trained personnel only. NEVER allow children or members of the general public to gain access to the equipment, its ladders or access platforms.
2. Where the equipment is sited in an unsecured location, access must be restricted by use of security fencing and lockable gates.
3. Lower sections of ladders on the equipment should be fitted with a lockable safety gate, to prevent unauthorized access.
4. The equipment should be OFF and all power LOCKED OFF before work on or in the equipment. Ensure the power isolator is OFF and LOCKED and TAGGED to prevent inadvertent re-start. This must include all equipment attached to the elevator on which you are working. (See Figure 2B on Page 20.)
2. Safety
20 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Working at Heights (Continued)
Figure 2B
5. NEVER attach lifting equipment to ladders or platforms.
6. When working on the equipment, NEVER go outside the safety rails provided.
7. Do not work at heights during high winds, heavy rain, snow, ice or storm.
The majority of routine service can be carried out from the service platforms provided. In the rare event that access is required outside these structures additional access and safety equipment may be required, such as powered access lift platforms and safety harness. Such work must only be carried out by specialist technicians trained and qualified in working at heights and only after a complete risk assessment has been carried out and safe working methods established.
Electrical SafetyIt is recommended that the electrical system to the equipment include, at minimum, the following:
1. Main power supply protected by suitable fuses or over current circuit breaker.
2. Main electrical disconnect lock out switch which can be locked.
a. To disconnect all electrical power to the equipment and other associated equipment.
3. Service disconnect which can be locked.
a. Installed immediately adjacent to each motor.
b. Wired to disconnect all electrical power to the equipment motor.
c. May also be wired to stop other equipment if required for safety during maintenance and servicing.
2. Safety
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 21
Electrical Safety (Continued)4. Emergency stops.
a. Wired to stop the equipment motor (and any other associated equipment) immediately when pressed.
b. Must remain engaged until manually disengaged.
c. The equipment should not be able to re-start immediately the emergency stop is re-set.
5. The electrical supply must include a properly designed protective earth system (PE), with connection to all exposed conductive parts.
6. All motors must be connected to protective earth at the terminal provided.
7. The control system to include.
a. Short circuit protection.
b. Start/stop controls (labelled 1 and 0 respectively).
c. Controls designed to default to OFF after a power interruption. (Ex: Self maintained relay.)
d. The equipment should not be able to immediately re-start following re-establishment of power or following the re-set of an emergency stop or other safety interlock.
8. Motor circuits must include motor over current protection, wired to stop the motor when the current exceeds the motor full load current, stated in the motor rating plate.
9. It is also recommended that the electrical supply is protected by earth leakage protection, such as Residual Current Device (RCD) or Residual Current Circuit Breaker (RCCB), to provide additional automatic disconnection from the power in the event of a fault.
All electrical installation and design must be carried out by a qualified electrical engineer, in accordance with EU Directives and standards and in accordance with local laws and codes. Ex: IEC 60204-1:2006.
22 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
3. Safety Decals
Safety decals have been affixed to the equipment to warn of danger to persons and of possible equipment damage. These decals must never be removed, tampered with, painted over or obscured in any way. If labels are damaged or become unreadable, replacement labels are available from the manufacturer.
If a decal is damaged or is missing contact:
GSI Decals 91-93 Budafoki ut, IP-West Building CBudapest, H-1117Hungary
International Decals
International, translated versions of the decals fitted to the equipment are available as part of the Language Pack that was supplied with the product. If you need further copies or a different language, please contact GSI or you dealer.
The international decals have been designed to be placed directly over the USA standard versions. Normally these will be factory fitted, but if you need to change them, please refer to the decal cross reference sheet, provided with the Language Pack and the decal locations given in the user’s manual.
DC-2248GSI Group 217-226-4421
DC-2249GSI Group 217-226-4421
DC-2251GSI Group 217-226-4421
DC-2250GSI Group 217-226-4421
>220 kg
DC-2252GSI Group 217-226-4421
Automatic MachineryAutomatické stroje a zařízeníAutomatikus Machineryавтоматични машиниautomatische machinesАвтоматические машиныавтоматичні машиниAutomātiskā MašīnasAutomatinis Machinerymachines automatiquesMaquinaria automáticamacchine automaticheautomatiska maskinerOtomatik MakinaMáquinas automáticasAparateAutomaattinen Machinery
A
B
CDC-2248
DC-2250DC-2249
DC-2251
DC-2252E
D
3. Safety Decals
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 23
DC-2253GSI Group 217-226-4421
40.9 m
2.3 m/s
200 tph
267 m3/h
-20°C - +40°C
120°C
1234567
22 October 2018
40 hp / 30 kW
3 ~
380 V (AC)
61 A
II 2/- D T4 (135°C); ‘c’; 'b 50 Hz
Date
SN
Ambient temperature
GSI HUNGARY KFT1-93 Budafoki ut, IP-West Building C
Budapest, H-1117HUNGARY
Max capacity
Tcrit
Max bucket speed
Height
BUCKET ELEVATOR200P36-40.9
3x
F DC-2213
Rating plate
Belt drive Elevator belt gravity
DC-2213GSI Group 217-226-4421
G DC-2253
3. Safety Decals
24 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Decal Placement
Head section
Boot section
Inspection trunking
Decal numbers
A. DC-2248
B. DC-2249
C. DC-2251
D. DC-2250
E. DC-2252
F. DC-2213
G. DC-2253
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 25
4. Elevator Parts
Part Identification
Figure 4A Figure 4B
Ref # Description
A Bonnet
B Pressure Relief Panel (One Each Side)
C Head Pulley
D Lower Head Section
E Inspection Door
F Up-Leg Trunking
G Down-Leg Trunking
H Belt
I Buckets
J Tie Angles
K Inspection Section
L Inspection Door
M Boot Section
N/S Upside Hopper (Downside Hopper Optional)
26 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
5. ATEX Compliance Instructions
Installation
General installation shall be in accordance with manual PNEG-1971CE, however for installation in hazardous locations, additional requirements shall be met:
Vibration
Where the elevator may be subject to vibration from other items of equipment, suitable measures shall be taken to isolate the elevator, by use of resilient mounts or other suitable means.
Explosion Pressure Vents
Elevators fitted with explosion pressure vents, providing pressure release in the event of an explosion originating in equipment connected to the elevator, shall not be installed within a hazardous location.
Elevators located in hazardous locations shall be fitted with means to prevent the propagation of explosion pressures originating in other connected equipment. This shall be a one way valve or other method of preventing explosion pressures from entering the elevator.
Hours Run Meter
It is recommended that the control system to each elevator be fitted with an hours run meter to enable regular monitoring and inspection of the equipment at the recommended hourly intervals.
Safety Interlocks
In order to prevent ignition of explosive mixtures of dust and air, both inside and outside the elevator, protective interlocks are provided, in accordance with EN13463-6:2005. These shall include:
• Slack belt/belt slip sensor
• Shaft speed sensor
• Belt alignment sensor
• Bearing temperature sensors
• Motor winding thermal cut out
5. ATEX Compliance Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 27
Figure 5A Shaft Speed Sensor
In order to provide the required level of ignition prevention, these shall be connected into a control system, designed in accordance with ISO 13849.
• Minimum protection level is IPL2.
• Minimum performance level, in accordance with EN13849 is PL(d).
Ref # Description
A 10 mm Screws Four (4) (Supplied)
B 18/30 mm Bracket (Supplied)
C Cylindrical Sensor
D M800 Sensor
E Whirligig
F Cover
G Tap Shaft for 1/2'' (12 mm) UNC Centered
H Machine Shaft
I Flexible Strap
J Flexible Conduit
K 50 mm Screws Four (4) (Supplied)
5. ATEX Compliance Instructions
28 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Maintenance
Routine Inspection
Elevators operating in hazardous environments must be inspected on a regular basis for signs of wear which could give rise to ignition sources. Elevators shall be installed with suitable, safe access ladders/stairs/platforms and catwalks to allow ease of access for inspection.
Daily:
1. Observe the elevator operating when empty and full and listen for sound of possible impact unusual sound of buckets on internal parts.
At least every 150 hours of operation:
1. Visually inspect the bearings for signs of over-heating, loss of grease and wear.
2. Check operation of the safety interlock switches:
a. Belt alignment
b. Shaft speed switch
c. Motor thermal cut out
3. Check operation of bearing temperature sensors if fitted.
4. Check cooling fans on motor and gear reducer are clean.
5. Check cooling fan and air inlets on motor and gear reducer – if fitted – are clear.
6. Check belt tension.
7. Check chain tension and condition of wear plates inside the elevator.
8. Check general condition of the elevator trunking.
9. Check for damage/loose connections of electrical cables into motors/switches.
10. Check condition of belts and buckets
All worn or damaged items must be replaced.
Repairs/Replacements
All repairs must be carried out in accordance with the product manual.
Replacement parts shall be matched like for like and be genuine GSI replacements. Failure to do so will render the elevator rating invalid.
5. ATEX Compliance Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 29
ATEX Compliance of GSI Bucket Elevators
GSI Bucket Elevators are provided with three (3) levels of ATEX compliance:
1. Internal zone 21D, no external zoning (Ex II 2/-)
2. Internal zone 21D, external zone (Ex II 2/3)
3. Internal zone 21D, external zone (Ex II 2/2)
It is vital that you check the designation of your bucket elevator is correct for the zone into which it is to be installed. If in doubt consult an ATEX Expert. You will find the rating for your bucket elevator on the rating plate attached to the elevator boot. (See Figure 5B.)
Figure 5B
Ensuring the elevator continues to operate correctly and safety within the ATEX environment requires operator intervention at to ensure potential ignition sources cannot become active. See Pages 71-75 for a full list of identified ignition sources, with indication off the type and frequency of user intervention required.
5. ATEX Compliance Instructions
30 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
V-Belt Drives
Certain models of elevator are fitted with V-belt drives. To ensure continued safe operation, the V-belts must be installed, tensioned and maintained according to this manual.
Tensioning is vital to ensure minimal slipping and frictional heating. Refer to the belt tensioning plate attached to your elevator.
Figure 5C
Pulley speed sensing is to be used to detect potential belt slippage where bucket elevators are installed in ATEX zone 21D. The speed sensing should be set to shut down the elevator if the driven pulley speed drops below Scrit, identified on the rating plate. This is the critical speed at which frictional heating caused by belt slip may result in high belt temperatures. Snorm marked on the same plate is the normal speed at which the pulley should run.
When tensioned correctly, the belt should deflect 10 mm when the weight shown on the plate is applied to the centre of the belt, as shown:
Figure 5D
Where the belt is becoming frayed or damaged, it should be replaced immediately, using the same make and model of belt as was originally supplied.
5. ATEX Compliance Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 31
Elevator Flat Belt
Correct installation of the elevator belt and buckets are critical to ensuring and maintaining ATEX compliance. The belt must have the correct pre-tensioning and run in true alignment. True alignment can be checked by use of belt alignment sensors. Refer to the belt decal applied to your elevator boot for correct tensioning arrangements:
Where the belt pre-tension is provided by standard take-up screws, the rating plate will show Tp and a figure in mm. When initially installing the belt, this is the approximate stretch required to provide the correct pre-tension.
If accessible, the deflection at the middle of the belt may be checked by applying a horizontal force across the width of the belt and checking the deflection is approximately 25 mm.
Figure 5E
5. ATEX Compliance Instructions
32 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
On elevators where the belt pre-tension is provided by a gravity take-up, the plate will show Tp and a figure in kg. This is the approximate mass that should be installed in the gravity take-up weight box to provide the correct pre-tension. Note that this figure may present as zero, due to the mass of the take-up mechanism itself be adequate to provide belt pre-tensioning.
Slipping elevator belts may result in frictional heating of the belt. This is avoided by maintaining the correct tension, and by monitoring the boot pulley speed, according to the value Scrit given on the elevator belt rating plate. In the event, the pulley speed drops below this value, the elevator should be stopped.
Figure 5F
5. ATEX Compliance Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 33
Damage to the belt should be checked for, and if necessary the belt replaced. The belt may only be replaced using the same make and model of belt supplied at first installation. Failure to do so could result in an ignition source becoming active.
Figure 5G
Bearing Temperature Monitoring
Where the elevator is installed in ATEX zone 21D, bearing temperatures shall be monitored, in accordance with Tcrit give on the elevator rating plate. This is the critical temperature which if exceeded shall result in elevator shut down. In this event, the bearings should be checked for signs of failure, loss of lubrication and should be replaced or repaired before re-starting the elevator.
34 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
6. Bucket Elevator Foundation
1. The Bucket Elevator foundation must be designed by a qualified civil engineer and installed by a qualified contractor.
2. Always consider the additional weight of live loads, dead loads, wind loads and soil bearing loads.
3. Always provide for proper moisture run-off on the top of the foundation.
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 35
7. Boot Section
Boot sections are pre-assembled at the factory. Boot inlet hoppers are typically shipped separately.
1. Before installing boot on foundation, examine boot for damage or loose hardware. Do not attempt to install if parts are damaged.
2. Proper position of boot is critical for successful installation. Boot inlet section can be installed as an up-leg or a down-leg inlet.
3. Identify the up and down side of boot. (See Figure 7A.)
NOTE: The up-leg inlet position is approximately 152.0 mm higher than the down-leg side.
Figure 7A Boot Section
Ref # Description
A Inlet Hopper (On Up Side)
B Inlet Blank Plate (Standard)
C Up Side
D Down Side
7. Boot Section
36 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Attaching Boot to Foundation
1. Remove the nuts and inlet blank plates to attach boot inlet hopper.
2. Anchor and level boot. Boot must be level and plumb. There are a variety of ways to accomplish this. GSI recommends that you shim to the perimeter, secure with hold-downs and grout the base.
3. Set boot in place.
4. Level in all directions prior to anchoring.
5. Use anchor bolts and mounting brackets (not supplied) to secure boot to foundation.
6. Check boot levelness and plumbness periodically throughout the installation process to ensure proper elevator erection.
7. Boot Section
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 37
Inspection Sections
The inspection section of the GSI Bucket Elevator has been designed for easy installation and maintenance.
1. The removable panels can be installed in any order, to allow for the installation of inspection doors at any preferred locations.
NOTE: Typical installations often place the inspection section directly above the boot on the up-leg side as the first trunking section.
NOTE: Installation will vary and depend on the configuration and application.
NOTE: Along with the inspection section, you will receive installation hardware and two (2) tie angles. Units containing 42" diameter pulleys and larger, will include a cross tie on the legs, which will be included. (See Figure 7B below and Figure 8B on Page 39.)
Figure 7B Inspection Section
Ref # Description
A Tie Angle
B Inspection Section
38 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
8. Trunking
Standard Trunking
Standard trunking sections may be fabricated from painted or galvanized steel.
IMPORTANT: Galvanized steel trunking MUST have the bolted seams located to the inside, facing each other on the up-leg and the down-leg. (See Figure 8A.)
NOTE: Trunking sections come complete with appropriate hardware and two (2) tie angles. Units containing 42" diameter or larger pulleys have a cross tie angle included for additional support.
Figure 8A Galvanized Trunking
Ref # Description
A Tie Angle (Additional set shown for orientation.)
B Cross Tie
C Note Orientation of Bolted Trunking (Galvanized only.)
D Cross Tie (Only 42" or larger diameter pulleys only.)
8. Trunking
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 39
Pressure Relief Trunking
Pressure relief trunking is standard trunking that has been modified to include one panel specifically designed for pressure relief.
NOTE: This unit requires special attention to the relief panel. This area must be inspected for damage to the panel, frame and particularly the hardware. DO NOT INSTALL TRUNKING IF THERE IS ANY APPARENT DAMAGE OR DEFECT.
1. This panel will be located on the long side of the trunking and centered on 3.0 m sections of trunking.
2. Two (2) tie angles are included with the mounting hardware.
3. Systems utilizing 42" diameter and larger pulleys require the installation of a cross tie located on the legs. (See Figure 8B.)
Figure 8B Pressure Relief Trunking
Ref # Description
A Tie Angle (Additional set shown for orientation.)
B Pressure Trunking (3.0 m Section shown.)
N/S Cross Tie (Only 42" or larger diameter pulleys only.)
WARNING
Remove all shipping bolts in the pressure relief panels prior to operating any Bucket Elevator.
8. Trunking
40 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Trunking Installation
Prior to any trunking installation, inspect for damage to equipment. Immediately repair or replace defective item(s).
NOTE: Always assemble trunking sections on a level surface.
1. Section together to make double trunking.
2. Attach tie angle to single trunking as shown in Figure 8C. (If 42" diameter or larger install cross tie angle.)
3. Multiple sections can be ground assembled.
4. Make sure sections are assembled straight, without twist.
5. Caulk all mating companion angle surfaces to ensure water and dust resistance.
NOTE: Do NOT assemble more than nine (9.0) linear meter at any time.
NOTE: It is important to maintain plumb and square trunking in all directions.
• Guy and plumb trunking in all directions after installing each section.
• Check levels through legging installation process.
• Check all connecting hardware is secure after each installation.
NOTE: Attachment bolt holes in the tie angles are intentionally tight for the M12 diameter bolts. This helps ensure more precise plumbing of the trunking. Never drill these holes out for easier installation.
Figure 8C Trunking Joint
NEVER drill out attachment holes for easier installation of the 12.5 mm diameter bolts. If bolts are hindered going through hole, thread bolts through to reduce chances of damaging threads.
Ref # Description
ACross Tie (Only 42" or larger diameter pulleys only.)
B Tie Angle
C Typical Trunking Joint
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 41
9. Lower Head Section
The Bucket Elevator lower head section is primarily assembled at the factory.
1. The installation hardware used to attach the head section to the trunking system is included with the shipment.
2. The drive is shipped separately from the lower head section.
3. Inspect all parts for damage and to ensure that all hardware is secure prior to proceeding with installation. (See Figure 9A.)
Head Bonnet Section
The bonnet has been designed in two-piece construction to allow the front (discharge) side to slide forward and clamp in place for maintenance to the belt, buckets, pulley, etc.
1. The rear (up-leg) side bonnet on 30" Bucket Elevators and larger sizes includes factory installed pressure relief panels. These panels should be carefully inspected for damage including screws and washers.
2. Pressure relief vent door should not be altered in any way, except to remove shipping bolts.
3. Motor mount and torque arm must be adjusted to fit the drive package per supplied detail.
4. Hardware used to attach bonnet section to head section is included. (See Figure 9B on Page 42.)
Figure 9A Lower Head Section
WARNINGUse bonnet section ‘U-lugs’ to lift ONLY the bonnet section.
WARNINGNEVER lift or lower the bonnet section together with the lower head section.
WARNING
Remove all shipping bolts in the pressure relief panels prior to operating any Bucket Elevator.
Ref # Description
A Pulley
B Inspection Door
C Discharge
9. Lower Head Section
42 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Head Bonnet Section (Continued)
Figure 9B Head Bonnet
Ref # Description
A U-Lug
B Inspection Door
C Pressure Relief Panel
DC-2253GSI Group 217-226-4421
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 43
10. Maintaining Plumbness
To ensure proper Bucket Elevator plumbness, set up two (2) transits, one in each direction. Refer to Figure 10A for proper tolerance in elevator erection.
Figure 10A Plumbing Tolerance
Ref # Description
A Bucket Elevator to be Plumb Top to Bottom within ±12 mm.
B Trunk Section Casing
44 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
11. Belting, Splicing and Buckets
BeltsThe belt for the elevator leg has been specifically chosen based on leg height, grain, weight, pulley diameter, etc.
The belt has been pre-punched to accommodate special buckets with specific spacing.
Installing the belt can be accomplished several different ways. GSI recommends the following:
1. Prior to installing the belt, raise the boot pulley to its upper most point to allow for proper tensioning.
2. On shorter installations, consider assembling the buckets to the belt before installing the belt. While this may be less time consuming, the additional weight of the buckets and connecting hardware may make the belt more difficult to handle.
3. Feed belt up through the inspection section, over the head pulley, through the down-leg, around the boot pulley and back up to the splice.
SplicingAfter connecting the ends of the belt together, a winching device such as a come-a-long may be required.
GSI recommends splicing the belt by overlapping the belts or by using the bar splice method.
1. When overlap splicing, draw a 1.5 m minimum of the belt (B) coming up from the bottom of the boot over belt hanging down from head. (See Figure 11A.)
2. An alternative method, the bar splice (not included) is accomplished by turning the ends of the belt out and affixing the manufactured bar splice components per the manufacturer’s recommendations.
NOTE: Lacing and other specific types of belt splicing are NOT recommended.
Figure 11A Belt Splicing
Ref # Description Ref # Description
A Belting going down from head C Direction of Travel
B 1.5 m Minimum D Belting going up from boot
To prevent the belt from rolling over the top, anchor the upper end securely.
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 45
Belt Installation
Installation of textile elevator belts with BC1 and supergrip numbers 3, 4 and 5 belt fasteners.
These instructions are intended to assist the erector to install correctly the BC1 and supergrip numbers 3, 4 and 5 belt fasteners.
Before commencing any work, advice should be sought from the safety. Advisor and relevant personal protective equipment should be worn.
Only skilled fitters should assemble the belt and belt connectors.
It is recommended that any safety instructions are followed explicitly.
General Information
The elevator belt is in a roll and should be treated with care the roll should not be unloaded by dropping onto rough ground and should not be rolled on rough ground storage should be in a dry environment away from sunlight, UV lighting, ozone, oils, acids and solvents.
Prior to Installation
Tools and equipment required.
• Belting clamps with D shackle location holes positioned 50 mm wider than the belt.
• 2 x 1-1/2 Tonne chain blocks or two (2) adequately strong screw.
• Turnbuckles, electric or pneumatic drill m/c with 14 mm and 16 mm diameter drills.
• D Shackles.
• M14 and M16 threaded rods 300 mm long each with a nut welded to one end.
• M14 and M16 sockets, ring spanners and torque wrench.
11. Belting, Splicing and Buckets
46 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Installation
Remove the head cover and the inspection doors immediately above the boot. The inspection doors (A) should be about 70 mm wider than the belt for ease of access. Lift the elevator boot pulley to its highest position. Isolate the elevator drive and electric power in the elevator. Position the elevator belt in front of the down side inspection doors (A) above the boot.
Prepare one end of the elevator belt about 400 mm from the end to accept either the BC1 sections or the numbers 3, 4 and 5 belt fasteners at 55 mm each shoulder to shoulder starting from the middle, by using a 3 mm thick steel template with pre-drilled holes as required for the belt fastener. The template must be at an exact right angle to the belt side and when correctly positioned, drill the mounting holes through the template in the belt end.
Lift the belt by means of clamps and shackles into the elevator either by means of a winch threading the belt under the boot pulley, up over the head pulley and down the down side to the inspection door (A) or by a crane lowering the belt down from the head pulley. (See Figure 11B.) Ensure that the prepared end is uppermost at the inspection door (A).
Figure 11B
Ref # Description
A Inspection Door
B Winch Rope
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 47
Position both ends of the belt within close proximity to the inspection door (A).
Fasten to the upper and lower belt ends each a clamp (D) about one meter away from the proposed joint and with either a chain block or turnbuckle on each side of the clamps (D), pull the prepared end and the lower end together, taking up the slack and just through the inspection door (A), bend the prepared end and the lower end together. Mark a line across and at right angles to the side of the lower belt opposite the center line of the upper fastener mounting holes. (See Figure 11C.)
Figure 11C
Ref # Description
C Mark Line
D Clamp
E Tensioner
11. Belting, Splicing and Buckets
48 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Slacken off the clamps a small amount and bend out the lower belt end through of the inspection door (A). As Figure 11D with the template at right angles to the belt side, drill the fastener mounting holes. Use an engineers square to accurately set the template. (See Figure 11D.)
Figure 11D
Ref # Description
F Drill holes to template along marked line.
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 49
Secure the two (2) ends of the belt together by tightening up the chain blocks and clamps. Ensure that when pulling the two (2) ends of the belt together an even tension on each side of the belt is applied. (See Figure 11E.)
Figure 11E
Ref # Description
D Clamp
E Tensioner
11. Belting, Splicing and Buckets
50 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Fold out the belt ends and assemble the BC1 belt fastener blocks or the number 5 fastener segments to the belt ends with the tongue part between the belts. Starting with the centre parts use the 300 mm threaded rods to initially pull the parts together. (See Figure 11F.)
Figure 11F
Check that all the fastener blocks are in line and install and tighten all the bolts and nuts into the fasteners. Then, remove the threaded rods and replace with bolts and nuts.
View the side of the fasteners and check that all are square. Re-tighten all the bolts starting from the centre outwards repeat the tightening torque the bolts. For 16 mm bolts to 252 N-M. For 14 mm bolts to 162 N-M.
Cut off the spare loose ends of the belt at about 50 mm from the belt fasteners. (See Figures 11G and 11H on Page 51.)
Ref # Description
GM16 Threaded rod, with nut welded on end. Pull center block assembly together 300 mm.
H Belting
I Clamp Blocks
J Center Clamp Blocks
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 51
Figure 11G Figure 11H
Ref # Description
K Belt Clamp
L Trim Off Excess
M Pitch
11. Belting, Splicing and Buckets
52 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Figure 11I
Remove the tension on the chain blocks or turnbuckles and remove the belt clamps.
Apply tension to the belt by adjusting the belt take up device as fitted to the elevator.
Run the belt round with the inching or pony slow drive and track and tension the belt accordingly.
Once the belt has been tensioned and tracked centrally, run the belt at full speed for 30 minutes. At the end of this period stop the belt and with the inching drive position the belt fastener within the inspection doors. Re-check the bolt tensions with a torque wrench starting from the centre bolts and working alternatively towards the outsides of the belt.
The belt clamps should be checked every month to ensure the correct torque.
Ref # Description
N 210 Minimum Overlap
Clamp material = Mild steel zinc plated
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 53
Installing the Buckets1. Install the buckets to the belt in sections, so as not to unbalance the whole assembly and torque up
the bucket bolts to the required tension.
2. When all the buckets are installed, operate the elevator on full load for about 12 hours and then check that the belt is running centrally on the pulleys and re-tighten all the bucket bolts.
3. Check the bucket bolt torque once a month.
Installation of Light Narrow Belts1. Lift the boot pulley up to its highest point in the boot prepare one belt end with the holes for
the fasteners.
2. Install the belt into the elevator with the two (2) belt ends situated at the lower inspection doors. Overlap the two (2) ends and attach securely two (2) clamps about 1500 mm apart. One on the top belt part and one on the bottom part of the belt. Attach to the clamps on each side of the belt either chain blocks or adjustable turn buckles. Tighten these tensioners up until the belt is tight and the two (2) ends are easy to fold out to work on.
3. Bend out the prepared belt end and bend out the other end immediately under the prepared end. Mark out and drill the lower belt fastener holes at right angles to the to the belt side. It is essential that the fasteners are at right angles to the belt otherwise the belt will not track correctly. Clamp the belt fasteners to the belt with the tongue part in between the belts with the 300 mm screwed rods starting at the middle of the belt. Install all the bolts and nuts and fasten and torque as in the previous instruction.
BucketsBuckets are attached to belting using elevator bolts pushed through the belting back side, through the elevator bucket, a flat (fender) washer, a lock washer and a nut.
1. Secure bucket by tightening nut to slightly indent belt back with bolt head.
2. Remember to leave buckets off near the splice area, if installing buckets prior to belt installation.(See Figure 11J on Page 55.)
Torque requirements are as follows:
• 5 N-M (44" pounds) for M6 bolts
• 15 N-M (133" pounds) for M8 bolts
• 40 N-M (354" pounds) for M10 bolts
3. ALWAYS re-check bolts for correct torque after initial start-up and periodically thereafter.
Belt Width Quantity of Clamps Required Belt Width Quantity of Clamps Required
Inches mm Supergrip 4 (SG4) Inches mm Supergrip 4 (SG4)
10 254 4 21-1/2 546 9
12 305 5 31 787 14
14 356 6 36 914 16
17-1/2 445 8 64 1626 29
DO NOT OVER TIGHTEN BOLTS.
Over tightening can lead to breakage.
11. Belting, Splicing and Buckets
54 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Belt Slack Removal
Remove any slack in belt after splice connection by lowering boot pulley. It is important that the boot pulley and shaft are checked and maintained to be horizontally level.
Manual Screw Take-Ups
1. Turn the take-up screws on each side of the boot to control the boot pulley position.
2. After each adjustment, ALWAYS lock each take-up screw in position with the lock nut provided.
Gravity Take-Ups
Weight provides the tensioning method for gravity take-up.
NOTE: The weight box may not require any additional weight because the weight of the belt, cups, weight box assembly and boot pulley assembly provide adequate tensioning in the belt to eliminate slippage at the head pulley.
If additional weight is needed:
1. Add weights (not included) - Do not use increments of greater than 45 kg (100 pounds).
2. Equally distribute weight from side to side for proper belt tracking.
3. Use the bearing plate adjustment screws to level the boot pulley after any needed weight is added.
4. Loosen the bolts attaching the channels of the weight frame assembly to the bearing plate assembly before adjusting the bearing screws.
5. After adjustments have been made, re-tighten bolts and snug the bearing plate adjustment screw lock nuts. (See Figure 11J on Page 55.)
NOTE: Lowering the bearing plate which the belt is tracking towards on the boot pulley should cause the belt to track back towards the center of the pulley. Inversely, raising the bearing plate which the belt is tracking away from will also center the belt.
11. Belting, Splicing and Buckets
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 55
Belt Slack Removal (Continued)
Figure 11J Take-Ups
Ref # Description
A Manual Take-Up Screw
B Gravity Take-Up Weight Box
C Gravity Take-Up Assembly
D Bearing Plate Screw
E Bearing Plate Adjusting Bolt
48" (60") Boot section shown
Do not over tighten belt, as this will decrease the life of the belt.
48" (26") Boot section shown
56 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
12. Drive Motor and Motor Mount
Drive
The following assembly instructions are for standard drives as purchased with the elevator. The standard drive is designed using the shaft mounted NORD direct drive. Details for this application are included in the Appendix section on Page 68.
If you purchased a special drive or drive components from another source, refer to manuals supplied with these materials.
1. The drive assembly is designed so that the same components fit a left or right hand drive application.
2. If facing the head side, the reducer is between you and the head and the head discharge is on the right hand side of you, then you have a right hand drive application.
3. If the head discharge is on the left side of you, then you have a left hand drive application.
The figures shown for a right hand application.
Motor Mount Assembly
1. Assemble torque arm bracket (X2) on the lower head with torque arm side wise cross member. (Do not tight yet, further adjustments might be required.)
2. Assemble the drive support cross member. (Do not tight yet, further adjustments might be required.)
3. Slide the NORD drive on pulley shaft by using center lifting lug on the reducer.
4. Set the reducer in horizontal position and mount the drive pivot bracket using the hardware provided with the torque arm kit.
5. Put bolt (Refer to Figure 12G on Page 60) through the bracket and drive torque console to avoid rotation. Lock it with the stover nut provided.
6. Lock the drive on the shaft using provided retaining washer. (Refer to Figure 12H on Page 61.)
7. Mount the cap (Refer to Figure 12H on Page 61) on the drive.
8. Before first run, remove the locking rubber piece from the breather plug on the top of the drive. (Refer to Figure 12H on Page 61.)
12. Drive Motor and Motor Mount
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 57
Motor Mount Assembly (Continued)
Figure 12A
Ref # Description
A Torque Arm
B Drive Assembly
C Pivot Bracket
12. Drive Motor and Motor Mount
58 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Motor Mount Assembly (Continued)
Figure 12B Torque Arm
Figure 12C
Ref # Description
D Torque Arm Mounting Bracket
E Torque Arm Side Wise Cross Member
Ref # Description
F Drive Support Cross Member
12. Drive Motor and Motor Mount
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 59
Motor Mount Assembly (Continued)
Figure 12D Drive Assembly
Figure 12E Pivot Bracket
12. Drive Motor and Motor Mount
60 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Motor Mount Assembly (Continued)
Figure 12F
Figure 12G
Ref # Description
G Bolt
H Stover Nut
12. Drive Motor and Motor Mount
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 61
Motor Mount Assembly (Continued)
Figure 12H Locking Washer and Cap
Ref # Description
I Locking Washer
J Bolt
K Cap
L Bolt
M Breather Plug
12. Drive Motor and Motor Mount
62 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
NORD Drive - Table Style Torque Arm Assembly InstructionsIn the field, slide the table frame weldment (A) over the column weldment (B) to the required height and weld the legs of table weldment (A) to the column weldment (B). (See Figure 12I.)
Figure 12I Anchor Points and Fixing Points for Each Model
12. Drive Motor and Motor Mount
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 63
Figure 12J Isometric View
Torque Arm Table for SK9082 (CETATAB-9082)
Ref # Part # Description Qty
A CE-14188M Table Frame Weldment 1
B CE-13975 Column Weldment 4
C S-LWM36 M36 Lock Washer 4
D S-BM24050 M24 x 50 HHCS Bolt 4
E S-LWM20 M20 Lock Washer 16
F S-BM20070 M20 x 70 HHCS Bolt 16
G S-HNC20 M20 Hex Nut 16
Torque Arm Table for SK9092 (CETATAB-9092)
Ref # Part # Description Qty
A CE-14469M Table Frame Weldment 1
B CE-14471M Column Weldment 4
C S-BM20080 M20 x 80 HHCS Bolt 16
D S-BM36080 M36 x 80 HHCS Bolt 4
E S-LWM20 M20 Lock Washer 16
F S-LWM42 M42 Lock Washer 4
Torque Arm Table for SK9086 (CETATAB-9086)
Ref # Part # Description Qty
A CE-13980 Table Frame Weldment 1
B CE-13975 Column Weldment 4
C S-FWM36 M36 Flat Washer 4
D S-LWM36 M36 Lock Washer 4
E S-BM36070 M36 x 70 HHCS bolt 4
F S-LWM20 M20 Lock Washer 16
G S-BM20070 M20 x 70 HHCS Bolt 16
H S-HNC20 M20 Hex Nut 16
Torque Arm Table for SEW KT127 (CETATAB-KT127)
Ref # Part # Description Qty
A CE-14609M Table Frame Weldment 1
B CE-13975 Column Weldment 4
C S-FWM36 M36 Flat Washer 8
D S-LWM36 M36 Lock Washer 4
E S-BM36080 M36 x 80 HHCS bolt 4
F S-LWM20 M20 Lock Washer 16
G S-BM20070 M20 x 70 HHCS bolt 16
H S-HNC20 M20 Hex Nut 16
I S-HNC36 M36 Hex Nut 4
64 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
13. Final Checks, Tracking, Start-Up and Maintenance
General Final Checks
1. Adjust the throat plate in the head discharge so there is approximately 6.0 mm clearance between it and edge of the buckets on the lap splice. (See Figure 13A.)
Figure 13A Throat Plate
1. Check clearance at the mechanical splice.2. Do a final check of all parts to be sure all hardware is tight and no foreign objects or tools are left inside elevator.3. Check all guards, inspection doors and removable plates to be sure they are in place and secure.4. Tighten the take-up screws on the boot evenly to tighten the belt on the pulley, keeping bottom pulley level and work from side to side in small amounts until belt is tight.5. Rotate by hand or carefully jog drive to check for proper rotation, clearance and operation of entire unit. Make any adjustments necessary.6. Jog the drive a minimum of one complete revolution of belt. If no problems exist, carefully run the Bucket Elevator.
13. Final Checks, Tracking, Start-Up and Maintenance
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 65
Belt Tracking
Tracking of the belt is very important for optimum results.
1. To correct any tracking problems.
• First adjust the boot bearing plates.
• Adjust the take-up screws downward on the side that the belt is tracking toward.
2. If this does not correct the problem or if the belt is tracking properly on the boot pulley but not the head pulley, further adjustments to the head pulley may be required.
3. The bearing side that the belt is tracking toward may need to be shimmed to compensate.
• Loosen the head bearing bolts that go through the head angle.
• Use the jacking screws to raise the bearing.
• Place a full shim the bearing base.
• Back off the screws.
• Re-tighten the bearing mounting bolts.
NOTE: Use thin shims to make small adjustments until the belt tracks properly.
Start-Up
Once you are sure all installations, safety checks, adjustments and lubrications have been completed:
1. Run the elevator for WITHOUT LOAD an initial break-in period of several hours.
2. Look and listen for any irregularities before running any material through the unit.
3. Re-check all moving parts and adjust as needed.
4. Adjust belt for final tension under load as needed.
Maintenance
Regularly scheduled maintenance helps ensure long life and safe operation of the unit.
1. Routine maintenance checks may include general wear, loose nuts and bolts, electrical wiring, contacts, switches, misalignment, guy wire inspection, bearing seals and lubrication and oil content for gearbox.
2. The belt will stretch after installation and may need further adjustment. Expect some stretching during the first few weeks of operation.
3. On manual take-up boots, belt tension should be maintained by turning the boot take-up screws slowly and evenly to maintain proper tracking. When the screw adjustment is completely used, the belt will have to be re-spliced.
NOTE: Good belt tension is critical for proper traction on the pulley and optimum performance.
13. Final Checks, Tracking, Start-Up and Maintenance
66 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Dealing with Elevator BlockagesElevator blockage is an unlikely event, but can occur if the equipment being fed by the elevator becomes blocked. To resolve this, take the following steps:
1. Stop the elevator and run the down stream equipment to eliminate any down stream blockage.
2. Attempt to re-start the system.
3. If the elevator has become so blocked that it will not start freely, it may need to be emptied. Do not continually start and stop the elevator motor, as this will result in motor over heating and equipment damage.
4. Turn off the elevator; lock out all power, lock and tag the electrical power isolator so that the equipment cannot be re-started inadvertently. (See Figure 13B.)
Figure 13B
13. Final Checks, Tracking, Start-Up and Maintenance
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 67
Dealing with Elevator Blockages (Continued)5. At the boot of the elevator, un-bolt and open the clean-out doors. (See Figure 13C.)
Figure 13C
6. Allow grain to drop by gravity and remove by hand.
a. Do not attempt to run the elevator with the clean-out door open.
b. Do not attempt to have the elevator ‘dig’ itself out by running it with the clean-out door open.
7. Once grain has stopped running by gravity, replace the clean-out door and tighten all bolts.
8. Check that all other people are clear of the elevator and other equipment.
9. Unlock the electrical power and attempt to re-start the elevator.
Ref # Description
A Clean-Out Door
68 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
14. Appendix 1 - Reference Information
Information regarding the NORD drive, SYJ bearings and pillow blocks can be downloaded from the website below:
SYJ Bearing: http://www.skf.com/in/products/bearings-units-housings/bearing-units/ball-bearing-units/ y-bearing-plummer-block-units/index.htmlSNL Bearing: http://www.skf.com/group/products/bearings-units-housings/bearing-housings/ split-plummer-block-housings-snl-2-3-5-and-6-series/index.htmlNord Drive: http://www5.nord.com/cms/us/documentation/dop_documentation.jsp
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 69
15. Reducer Lubrication
Figure 15A
M1 M2 M3 M4 M5 M6
B3 B6 B8 B3I V5 V6
SK9012.1 0,70 1,60 1,90 2,40 1,20 1,70
SK9016.1 0,70 1,60 1,90 2,40 1,20 1,70
SK9022.1 1,30 2,60 3,50 4,20 2,00 2,80
SK9032.1 1,70 4,80 6,40 6,70 4,10 5,10
SK9042.1 4,40 8,70 10,00 9,80 6,80 7,50
SK9052.1 6,50 16,00 19,00 21,50 11,00 15,50
SK9062.1 10,00 27,50 32,00 36,00 18,00 24,00
SK9072.1 10,00 27,50 32,00 36,00 18,00 24,00
SK9082.1 17,00 52,00 63,00 72,00 33,00 47,00
SK9086.1 29,00 73,00 85,00 102,00 48,00 62,00
SK9092.1 41,00 157,00 170,00 172,00 80,00 90,00
SK9096.1 70,00 187,00 194,00 254,00 109,00 152,00
15. Reducer Lubrication
70 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Lubricant Table
“NORD Direct drive is supplied pre-lubricated with mineral oil as standard”.
This table shows comparable lubricants from various manufacturers. The manufacturer can be changed within a particular viscosity or lubricant type. Getriebebau NORD must be contacted in case of change of viscosity or lubricant type, as otherwise no warranty for the functionality of our gearboxes can be accepted.
Lubricant Type
Details onType Plate
Din (ISO)/Ambient
Temperature
Mineral Oil
CLP 680ISO VG 6800...40°C
EnergolGR-XP 680
Alpha EP 680Alpha SP 680Optigear BM 680Tribol 1100/680
RENOLIN CLP680RENOLIN CLP680 Plus
KlüberoilGEM 1-680 N
Mobilgear600 XP 680
Omala S2G 680
CLP 220ISO VG 220-10…40°C
EnergolGR-XP 220
Alpha EP 220Alpha SP 220Optigear BM 220Tribol 1100/220
RENOLIN CLP 220RENOLIN CLP 220 Plus
KlüberoilGEM 1-220 N
Mobilgear600 XP 220
Omala S2G 220
CLP 100ISO VG 100-15…25°C
EnergolGR-XP 100
Alpha EP 100Alpha SP 100Optigear BM 100Tribol 1100/100
RENOLIN CLP 100RENOLIN CLP 100 Plus
KlüberoilGEM 1-100 N
Mobilgear600 XP 100
Omala S2G 100
Synthetic Oil(Polyglycol)
CLP PG 680ISO VG 680-20...40°C
-Alphasyn GS 680Tribol 800/680
RENOLIN PG680
KlübersynthGH 6-680
MobilGlygoyle 680
Omala S4WE 680
CLP PG 220ISO VG 220-25…80°C
EnersynSG-XP 220
Alphasyn GS 220Alphasyn PG 220Tribol 800/220
RENOLIN PG220
KlübersynthGH 6-220
MobilGlygoyle 220
Omala S4WE 220
Synthetic Oil(Hydrocarbon)
CLP HC 460ISO VG 460-30…80°C
-
Alphasyn EP 460Tribol 1510/460OptigearSynthetic X 460
RENOLINUnisynCLP 460
KlübersynthGEM 4-460 N
MobilSHC 634
Omala S4GX 460
CLP HC 220ISO VG 220-40…80°C
-
Alphasyn EP 220Tribol 1510/220OptigearSynthetic X 220
RENOLINUnisynCLP 220
KlübersynthGEM 4-220 N
MobilSHC 630
Omala S4GX 220
Bio-DegradableOil
CLP E 680ISO VG 680-5…40°C
- -PLANTOGEAR680 S
- - -
CLP E 220ISO VG 220-5…40°C
-Tribol BioTop1418/220
PLANTOGEAR220 S
KlübersynthGEM 2-220
-
NaturelleGearFluid EP220
Food Grade Oil
CLP PG H1680
ISO VG 680-5…40°C
-Tribol FoodProof1800/680
-KlübersynthUH1 6-680
MobilGlygoyle 680
CassidaFluid WG680
CLP PG H1220
ISO VG 220-25…40°C
-Tribol FoodProof1800/220
-KlübersynthUH1 6-220
MobilGlygoyle 220
CassidaFluid WG220
CLP HC H1680
ISO VG 680-5…40°C
- Optileb GT 680 GERALYN SF 680Klüberoil4 UH1-680 N
-CassidaFluid GL680
CLP HC H1220
ISO VG 220-25…40°C
- Optileb GT 220 GERALYN SF 220Klüberoil4 UH1-220 N
Mobil SHC Cibus220
CassidaFluid GL220
Gear Unit LiquidGrease
-25 … 60°CEnergreaseLS-EP 00
Longtime PD 00Tribol 3020/1000-00
RENOLITDURAPLEX EP 00RENOLIT LST 00
MICROLUBEGB 00KlübersynthGE 46-1200
Mobil ChassisGrease LBZMobil GlygoyleGrease 00
AlvaniaEP(LF)2
-
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 71
16. ATEX Ignition Source Instructions
Possible Ignition Sources Equipment Related (Yes/No) Reason
Hot Surfaces Yes
1. Friction Vee Belt Drive
2. Friction Elevator Flat Belt
3. Motors
4. Gear Reducers
5. Conductors
Mechanical Sparks Yes
1. Elevator Bucket/Internal Structure Impact
2. Elevator Bucket Foreign Object Impact
3. Elevator Belt Splice Impact
Flames, Hot Gases Yes
1. Conductor Insulation
2. Ignition of Dust/Material Layers
3. Elevator Belt Slippage
Electric Sparks Yes1. Motors
2. Electrical Connections
Stray Electric Current and Cathodic Corrosion Protection
Yes1. Electrical equipment failure plus
inadequate earth path.
Static Electricity Yes
1. Elevator Flat Belt
2. Vee Belt
3. Internal “lagging”
Lightning Yes None Present
Electromagnetic Waves No None Present
Ionising Radiation No None Present
High Frequency Radiation No None Present
Ultrasonics No None Present
Adiabatic Compression No None Present
Chemical Reaction No None Present
16. ATEX Ignition Source Instructions
72 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Ignition Source Ignition Hazard Control MethodOperator Intervention
RequiredFrequency
Hot Surfaces
Elevator Motor
Normal operating surface temperature generated heat due to power losses as heat.
Constructional safety “C” Check motor heat dissipation surfaces are clean.
6 MonthsMotors are designed and certified to run at maximum temperature of 125°C.
Overheat due to dust layers in motor heat sink fins.
Control of ignition source “B”.
Check thermistor connections are sound.Check over current protection is correctly set.
12 Months
Over temperature sensors in motor windings connected into safety control system designed to EN13849.
Safety control system to performance level “C”.
Operator preventative maintenance.
Overheat due to motor overload.
Control of ignition source “B”.
Check thermistor connections are sound.Check over current protection is correctly set.
13 Months
Over temperature sensors in motor windings connected into safety control system designed to EN13849.
Ignition protection level 2 required.
Safety control system to performance level “C”.
Motor over current protection.
Operator preventative maintenance.
Elevator Gear Reducer
Normal operating surface temperature generated heat due to power losses as heat.
Constructional safety “C”
Check and clean the heat sink fins.
6 Months
Gear reducers are pre-certified bought in components.
Maximum operating temperature is 135°C.
Gear reducer overheat due to blocked heat sink fins.
User intervention to maintain clear heat sink fins.
Gear reducer overheat due to insufficient oil.
User intervention to maintain observe oil leakage and maintain correct levels.
Gear reducer overheat due to overloading.
Control of ignition source “B”.
Ignition protection level 2 required.
Gearbox and motor power input/output are matched.
Motor provided with over current protection, such that any overloading at the gear reducer is reflected at the motor and the overload will open and trip the motor OFF.
V-Belt Drive
Surface temperature under full load.
Under correct tensioning, heat gains will not result in temperature rises approaching dust ignition temperature. Max ambient temperature is 40°C. Check and re-tension as
required.6 Months
Normal running for friction based drive should not see rises over 50°C above ambient. Tcrit is established as 120°C.
Surface temperature under overload/slippage.
Control of ignition source “B”
Check speed monitoring system has correct settings in accordancewith the rating plate.
12 Months
Ignition protection level 1 required.
Belt slip detection through speed sensor in accordance with Snorm and Scrit on the
rating plate.
Scrit is calculated based on motor power
being dissipated as frictional heating on slipping belt.
Surface temperature under full load
Under correct tensioning, heat gains will not result in temperature rises approaching dust ignition temperature.
Check and re-tension as required. 6 Months
16. ATEX Ignition Source Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 73
Ignition Source Ignition Hazard Control MethodOperator Intervention
RequiredFrequency
Elevator Flat Belt
Surface temperature under overload/slippage.
Control of ignition source “B”.
Check speed monitoring system has correct settings in accordance with the rating plate.
12 Months
Ignition protection level 1 required.
Belt slip detection through speed sensor in accordance with Snorm and Scrit on the
rating plate.
Scrit is calculated based on motor power
being dissipated as frictional heating on slipping belt.
Frictional heating due to rubbing on elevator sidedue to misalignment.
Control of ignition source “B”.
Ignition protection level 1 required.
Belt alignment sensor system, senses belt misalignment and causes safe shut down.
Bearings
Temperature
Constructional safety “C”
The bearings are designed for the equipment’s intended duty, speed, temperature, loading and variations of speed and loading.
Installation, fit, tolerances and alignment are all in accordance with manufacturer specifications.
Lubrication is pre-installed and may be topped up via grease zerk.
Bearings are sealed from dust ingress.
Increase temperature due to ingress of dust/loss of lubrication.
Constructional safety “C”
Visual check of bearingsRe-grease.
Monthly
User intervention to visually check bearings.
Grease bearings as part of routine maintenance.
Control of ignition source “B”.
Ignition protection level 1 required.
Bearing temperature monitoring system to be connected to safety control circuit in accordance with EN13849. Check functionality of
safety control circuit.Each 12Months
Tcrit established as 120°C.
Buckets/Belt/Boot Pulley
Build-up of debris inside elevator boot, resulting in frictional heating between moving parts and compacted debris.
Normal operation of elevator will move dirt and debris from boot area.
Open elevator boot and check for debris build up. Clean out.
Each 3 MonthsConstructional safety “C”
User intervention to carry out regular maintenance to clean-out elevator boot.
16. ATEX Ignition Source Instructions
74 PNEG-1971CE CE Compliant Metric Series II Bucket Elevator
Ignition Source Ignition Hazard Control MethodOperator Intervention
RequiredFrequency
Mechanical Sparks
General
Materials used in construction.
Constructional safety “C”
All construction materials are “non-sparking”.
Impact with inside of trunking.
Constructional safety “C”
Clearance of buckets from internal parts of elevator.
Buckets are non-metallic, non-sparking material.
Impacted bucket fixing hardware and head/tailpulley, with risk of sparking.
Constructional safety “C”
Installer to ensure the buckets are correctly tightened onto the belt and to the correct torque.
Initialinstallation andeach bucketreplacement.
4B Braime DIN 15237 Euro Head bolts are used.
Bolts have flat heads on the pulley side of the belt.
When correctly tightened the head is flush with the surface of the belt. Impact spark is unlikely under normal operation.
Elevator Buckets
Loosened bucket/bolt resulting in bolt head impact with pulley drums, with risk of sparking.
Constructional safety “C”
Check bolts for correct torque after run-in period and periodically afterwards.
Post run-inperiod.Each Quarter
Risk of spark remains low. As belt approaches the surface of the pulley, approach velocity tends towards 0. Impact energy therefore will also tend towards 0.
User to check bucket bolt torque in accordance with belt manufacturer and installation instructions.
Loosened bucket resulting in impact with inside of trunking with risk of sparking.
Constructional safety “C”
Check bolts for correct torque after run-in period and periodically afterwards.
Post run-inperiod.Each Quarter
Buckets are plastic, non-sparking materials.
User to check bucket bolt torque in accordance with belt manufacturer and installation instructions.
Foreign object eg stone or tramp metal friction/impact and sparking.
Constructional safety “C”
Use stone/metal separator. ContinuousGrain to be clean and free from foreign objects (use stone/metal separator).
Mis-aligned belt, risk of impact inside elevatortrunking with risk of spark.
Constructional safety “C”
Belt alignment to be correct in accordance with installation instructions. Pulleys to be installed and adjusted paralell to each other and at 90° to tail/head housing.
Belt alignment goes out of true during operation or due to incorrect adjustment/drift of adjuster bolts. Risk of impact inside elevator trunking with risk of spark.
Constructional safety “B”
Check operation of safety control system.
12 Months
Ignition protection level 1 required.
Belt alignment sensor system, senses belt misalignment and causes safe shut down.
Belt SpliceSparking between belt splice and head/tail pulley.
Risk of spark is low due to near zero impact energy. Belt splice bolts to be
checked.12 Months
Non-sparking splice used, installed according to 4B installation instructions.
Flames/Hot Gases
Electrical System - Conductors
The hazard covered by high surface temperatures above. EN60204 Calculations
16. ATEX Ignition Source Instructions
PNEG-1971CE CE Compliant Metric Series II Bucket Elevator 75
Ignition Source Ignition Hazard Control MethodOperator Intervention
RequiredFrequency
Electrical Sparks
Conductor Connections to Motor or Switch Terminal Box
Loose connection causing arcing.
All electrical installation is responsibility of installer.
Electrical installation to be in accordance with ATEX requirements and EN60204. Carried out by certified electrical installer.
InitialInstallation
Loose connection causing arcing.
All electrical installation is responsibility of installer.
Terminal connections and conductors to be checked for tightness.
12 Months
Stray Electric Current
Electrical System
Normal Use
Elevator is to be provided with equi-potential bonding of all conductive parts to a single earth connection (or multiple earth connections which are interconnect themselves).
Failure of PE connection
Conductive parts to have redundancy in connections to PE terminal, i.e. via dedicated PE connection at the electrical components plus structure bonding to PE.
Check Earth Continuity 12 Months
Static Electricity
Internal Lagging
Normal use - charging due to grain abrasion on non-conductive filaments.
Constructional safety “C”
Lagging material is Tivar,“anti-static”, dissipative material with connection to earth for safe discharge of generated static electricity.
Dust has minimum ignition energy of >20 mJ. In general this eliminates corona, brush and bulking brush discharge as possible ignition sources.
Zone 22, 21 and 20 are generally low risk of ignition from non-conductive material sources of ignition.
Failure of PE connection, charge not dissipated.
Redundancy in the PE will provide alternative route to earth for generated electrostatic charge.
Check Earth Continuity 12 Months
Continuous separation of belt from head/tail pulley. Risk of electrostatic charging and incendive discharge.
Constructional safety “C”
Frasor/steel V-belt is “anti-static”, beingdissipative and having surface
resistance of 3 x 108 ohm.
Belt is connected, via steel pulley, to earth to provide safe discharge of static charge.
Elevator Belt
Replacement of belt with incorrect materials.
Correct replacement belt only to be used. Surface
resistivity <= 3 x 108 ohm.
EachReplacement
Failure of PE connection, charge not dissipated.
Redundacy in the PE will provide alternative route to earth for generated electrostatic charge.
Check Earth Continuity 12 Months
Continuous separation of belt from drive/drivenpulley. Risk of electrostatic charging and incendive discharge.
Constructional safety “C”
Frasor/steel V-belt is “anti-static”, being dissipative and having surface
resistance of 3 x 108 ohm.
Belt is connected, via steel pulley, to earth to provide safe discharge of static charge.
Drive Belt
Replacement of belt with incorrect materials.
Correct replacement belt only to be used. Surface
resistivity <= 3 x 108 ohm.
EachReplacement
Failure of PE connection, charge not dissipated.
Redundacy in the PE will provide alternative route to earth for generated electrostatic charge.
Check Earth Continuity 12 Months
Limited Warranty — N.A. Grain ProductsThe GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanshipunder normal usage and conditions for a period of 12 months from the date of shipment (or, if shipped by vessel, 14months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect inmaterials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund thepurchase price. This Limited Warranty is subject to extension and other terms as set forth below.
Warranty Enhancements: The warranty period for the following products is enhanced as shown below and is inlieu of (and not in addition to) the above stated warranty period. (Warranty Period is from date of shipment.)
Product Warranty Period
Storage
Grain Bin Structural Design▪ Sidewall, roof, doors, platforms and walkarounds▪ Flooring (when installed using GSI specified floor support system for that floor)▪ Hopper tanks (BFT, GHT, NCHT, and FCHT)
5 Years
Conditioning
Dryer Structural Design – (Tower, Portable and TopDry)▪ Includes (frame, portable dryer screens, ladders, access doors and platforms) 5 Years
All other Dryer parts including:▪ Electrical (controls, sensors, switches and internal wiring) 2 Years
All Non-PTO Driven Centrifugal and Axial Fans 3 Years
Bullseye Controllers 2 Years
MaterialHandling
Bucket Elevators Structural Design 5 Years
Towers Structural Design 5 Years
Catwalks Structural Design 5 Years
Accessories (stairs, ladders and platforms) Structural Design 5 Years
Conditions and Limitations:THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTHHEREIN; SPECIFICALLY, GSI DISCLAIMS ANY AND ALL OTHER WARRANTIES OF ANY KIND, EXPRESS ORIMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) ANY PRODUCT MANUFACTURED OR SOLD BY GSI,OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT,REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION,LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.
The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paidfor the product purchased. This Warranty only covers the value of the warranted parts and equipment, and does not coverlabor charges for removing or installing defective parts, shipping charges with respect to such parts, any applicable salesor other taxes, or any other charges or expenses not specified in this Warranty. GSI shall not be liable for any other direct,indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. Expensesincurred by or on behalf of a claimant without prior written authorization from the GSI warranty department shall not bereimbursed. This warranty is not transferable and applies only to the original end-user. GSI shall have no obligation orresponsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor. Prior toinstallation, the end-user bears all responsibility to comply with federal, state and local codes which apply to the locationand installation of the products.
This Limited Warranty extends solely to products sold by GSI and does not cover any parts, components or materials used in conjunction with theproduct, that are not sold by GSI. GSI assumes no responsibility for claims resulting from construction defects, unauthorized modifications,corrosion or other cosmetic issues caused by storage, application or environmental conditions. Modifications to products not specificallydelineated in the manual accompanying the product at initial sale will void all warranties. This Limited Warranty shall not extend to products orparts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained.
Notice Procedure:In order to make a valid warranty claim a written notice of the claim must be submitted, using the RMA form, within 60 days of discovery of awarrantable nonconformance. The RMA form is found on the OneGSI portal.Service Parts:GSI warrants, subject to all other conditions described in this Warranty, Service Parts which it manufactures for a period of 12 months from thedate of purchase unless specified in Enhancements above.(Limited Warranty - N.A. Grain Products_ revised 01 October 2020)
This equipment shall be installed in accordance with the current installation codes and applicable
regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
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