GSI Group 100P36/100G36, Assembly Manual

Page 1: ...PNEG 681CE CE Compliant Series II Bucket Elevator Assembly Manual Original Instructions PNEG 681CE Date 04 29 14 ...

Page 2: ...______________________________________________ RPM _____________________________________________________ Head Pulley Diameter ________________________________________ Discharge Height ____________________________________________ Horsepower ________________________________________________ GSI Group 1004 E Illinois St Assumption IL 62510 Phone 1 217 226 4421 Date Purchased __________________________...

Page 3: ...ines 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...

Page 4: ...4 PNEG 681CE CE Compliant Series II Bucket Elevator NOTES ...

Page 5: ...aching Boot to Foundation 22 Inspection Sections 23 Chapter 7 Trunking 24 Standard Trunking 24 Pressure Relief Trunking 25 Trunking Installation 26 Chapter 8 Lower Head Section 27 Head Bonnet Section 27 Chapter 9 Maintaining Plumbness 29 Chapter 10 Belting Splicing and Buckets 30 Belts 30 Splicing 30 Buckets 31 Belt Slack Removal 32 Chapter 11 Drive Motor and Motor Mount 34 Drive 34 Motor Mount As...

Page 6: ...act 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 discr...

Page 7: ... sections Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death DANGER WARNING CAUTION NOTICE This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING indicates a hazardous situation which if not avoide...

Page 8: ...uipment clearance Clearance of portable equipment that may be taken to the bin site should also be reviewed and considered Any electrical control equipment in contact with the bin should be properly grounded and installed in accordance with National Electric Code provisions and other local or national codes This product is intended for the use of grain storage only Any other use is a misuse of the...

Page 9: ...lowed in all cases Authorities having jurisdiction should be consulted before installations are made 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 safety signs are availabl...

Page 10: ...hile it is in operation Keep hands feet and clothing away from rotating parts Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any built up grease oil and debris Maintain Equipment and Work Area Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by weld...

Page 11: ...to the job Remove all jewelry Tie long hair up and back Wear safety glasses at all times to protect eyes from debris Wear gloves to protect your hands from sharp edges on plastic or steel parts Wear steel toed boots to help protect your feet from falling debris Tuck in any loose or dangling shoestrings A respirator may be needed to prevent breathing potentially toxic fumes and dust Wear a hard hat...

Page 12: ...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 ...

Page 13: ...n 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 Heights The 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 platfor...

Page 14: ... 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 Safety It 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 electrica...

Page 15: ...esigned 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...

Page 16: ... 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 2248 GSI Group 217 226 4421 DC 2249 GSI Group 217 226 4421 DC 2251 GSI Group 217 226 ...

Page 17: ...1004 E Illinois St Assumption IL 62510 USA Model Height to discharge Pulley diameter Pulley speed Belt speed Maximum capacity Bucket size Bucket spacing SN Date 56 RPM 720 fpm 3 66 m s 18750 cfh 531 m3 h 01 May 2012 30 hp 22 5 kW 240 V AC 73 A 50 Hz 3 123456789 18 x 8 9 1 2 241 mm 105 32 01m 150P48 105 48 1219 mm Rating plate G H DC 2213 DC 2253 ...

Page 18: ...cals 18 PNEG 681CE CE Compliant Series II Bucket Elevator Decal Placement Head section Inspection trunking Boot section Decal numbers A DC 2248 B DC 2249 C DC 2251 D DC 2250 E DC 2238 F DC 2252 G DC 2213 H DC 2253 ...

Page 19: ...n Figure 4A 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 Upside Hopper Downside Hopper Optional ...

Page 20: ...e 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 ...

Page 21: ...are 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 6A NOTE The up leg inlet position is approximately six inches 6 higher than the down leg side Figure 6A Boot Section Ref Description A Inlet Hopper On Up Side B In...

Page 22: ...nd 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 eleva...

Page 23: ...pical 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 b...

Page 24: ...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 7A Painted Trunking Figure 7B Galvanized Trunking Ref Description A Cross Tie Only 42 or larger diameter pulleys only B Tie Angle Additional set shown for orientation C Painted Trunking 10 Section shown Ref Description A Tie Angle Addi...

Page 25: ...OR DEFECT 1 These panels will be located on the short sides of the trunking directly opposite of each other and centered on ten foot 10 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 7C Figure 7C Pressure Relief Trunking Ref Description A Cross ...

Page 26: ...n thirty 30 linear feet 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 1 2 diameter bolts This h...

Page 27: ...ts 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...

Page 28: ...ad Section 28 PNEG 681CE CE Compliant Series II Bucket Elevator Head Bonnet Section Continued Figure 8B Head Bonnet Ref Description A U Lug B Inspection Door C Pressure Relief Panel DC 2253 GSI Group 217 226 4421 ...

Page 29: ...ess To ensure proper Bucket Elevator plumbness set up two 2 transits one in each direction Refer to Figure 9A for proper tolerance in elevator erection Figure 9A Plumbing Tolerance Ref Description A Bucket Elevator to be Plumb Top to Bottom within 1 2 B Trunk Section Casing ...

Page 30: ...ay 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 Splicing After 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 sp...

Page 31: ...back with bolt head 2 Remember to leave buckets off near the splice area if installing buckets prior to belt installation See Figure 10A Torque requirements are as follows 5 7 N M 50 pounds for 1 4 bolts 11 0 N M 96 pounds for 5 16 bolts 20 5 N M 180 pounds for 3 8 bolts 3 ALWAYS re check bolts for correct torque after initial start up and periodically thereafter Ref Description A Belting Going Do...

Page 32: ...bly 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 th...

Page 33: ...oval Continued Figure 10B 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 ...

Page 34: ...t side of you then you have a left hand drive application The Figure 11A and Figure 11B on Page 35 shown for a right hand application Motor Mount Assembly 1 Locate the side of the motor mount which has two 2 decals affixed See Figure 11A on Page 35 One decal will have L H for left hand and one will have R H for right hand 2 Place the motor mount with decals facing away from the pulley towards the ...

Page 35: ... Bucket Elevator 35 Motor Mount Assembly Continued Figure 11A Motor Mount Plate Figure 11B Right Hand Motor Placement Decals Ref Description A Motor Mount B Left Hand Decal C Right Hand Decal D Head Bearing Angles Ref Description A Toe of Head Bearing Angle B Decal ...

Page 36: ... onto the motor slide base and position the motor as close as possible toward the pulley NOTE The slide base will fit in only one set of holes See Figure 11C 3 Position the tensioning bolt so that tightening pulls the motor AWAY from the pulley 4 Using the proper hardware bolt the slide base to the motor mount Figure 11C Motor Slide Base Ref Description A Motor Mount B Motor C Tensioning Bolt D Mo...

Page 37: ...n Page 38 NOTE On 16 and 24 elevators the torque arm tube will slide in and out freely with the motor s torque causing a positive lock situation NOTE In 30 and large elevators loosen the three 3 locking bolts and place the torque arm foot mounting tube in the torque arm assembly such that the foot mounting bracket is to the side in which the reducer will be mounted Wait until the reducer is set on...

Page 38: ...lation Appendix which has detailed instructions for the reducer bushing mounting cooling fans and backstops Once the reducer is assembled 1 Attach the torque arm turnbuckle assembly to the reducer with proper hardware 2 Attach the torque arm foot to the foot mounting bracket of the torque arm tube using the proper hardware Ref Description A Motor B Gusset C Foot D Turnbuckle E Nut F Torque Arm Tub...

Page 39: ... the output shaft of the motor and the input shaft of the reducer 6 Place belts upon the sheaves and tension as needed NOTE Reducer may need to be rotated clockwise or counterclockwise in conjunction with slide base adjustments to achieve correct center distance for the drive belts Move the location of the reducer torque arm turnbuckle to achieve this rotation as needed NOTE Belts are designed spe...

Page 40: ...EG 681CE CE Compliant Series II Bucket Elevator Drive Guard Continued Figure 11F Belt Guard Right hand drive shown Ref Description A Side Bracket B Large Sheave C Small Sheave D Belt Guard Cover E Belt Guard Rear Panel F Mounting Brackets ...

Page 41: ...t PNEG 681CE CE Compliant Series II Bucket Elevator 41 Drive Guard Continued Figure 11G Belt Guard Mounted to Brackets Ref Description A Slide Bracket B Bushing C Sheave D Rear Belt Guard Panel E Safety Screen Hole must be cut out ...

Page 42: ...e Guard Continued Figure 11H Slide Bracket Figure 11I Brackets Use for Higher HP Motors Ref Description A Slide Bracket Ref Part Description A DG 48T08200 Bracket 48 Drive Guard 200 HP B DG 48T034 Plate Middle Bracket 48 42 Drive Guard NOTE Brackets shown will be used for higher HP motors ...

Page 43: ...es II Bucket Elevator 43 Drive Guard Continued Figure 11J Brackets Use for Higher HP Motors Ref Part Description A DG 48T08200 Bracket 48 Drive Guard 200 HP B DG 48T034 Plate Middle Bracket 48 42 Drive Guard NOTE Brackets shown will be used for higher HP motors ...

Page 44: ...unt adjustable slide base to properly tension belts to acceptable levels Proper tension is 0 4 mm 1 64 of deflection per 25 mm 1 of sheave centers on one side of belt centered between sheaves See Figure 11K NOTE Too much tension shortens belt life Check belt tension frequently during the first 24 48 hours of operation Figure 11K Drive Belt Ref Description A Span B Force ...

Page 45: ...rdware 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 pro...

Page 46: ...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 ensur...

Page 47: ...he 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 ...

Page 48: ... 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 atte...

Page 49: ... bearings and pillow blocks can be downloaded from the Baldor website Go to www baldor com support product_manuals asp Enter the required manual number into the search field See list below MN1601 Dodge Torque Arm II Speed Reducer Installation MN3033 Dodge S 2000 Spherical Roller Bearings MN3040 Dodge TAF Pillow Blocks and S 1 Units ...

Page 50: ...50 PNEG 681CE CE Compliant Series II Bucket Elevator NOTES ...

Page 51: ... PRODUCTS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth in the Limited Warranty which shall not exceed the amount paid for the product purchased This warranty is not transferable and applies only to the original end user GSI shall have no obligation ...

Page 52: ...be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made GSI Group 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2014 by GSI Group Printed in the USA CN 312365 GSI is a worldwide brand of AGCO Corporation ...