PREMAS 4.0, Installation And Commissioning Manual

Page 1: ...Installation and Commissioning Manual PREMAS 4 0 Predictive Maintenance Solution Version for Belt Bucket Elevators CE UL Version December 2020 Version 2 00 EN Document number DOC201125 1 ...

Page 2: ...ssessment evaluation and testing of the devices for each specific application Neither PREMAS AG nor any of its partners or subsidiaries may be liable for any misuse of the information contained herein All relevant state regional and local safety regulations must always be observed when installing and using this device For reasons of security and to ensure compliance with the documented system data...

Page 3: ...12 PREMAS 4 0 Belt Version UL UL Edition added Document Modifications Year Type Changes 2020 DOC201125 1 First Release 2020 12 DOC201125 1 UL Edition added Approvals This document requires the following permissions Name Title Michael Bruckhaus Managing Director Carlos Pinzon Digital Solutions ...

Page 4: ...ymbols Explanation of the safety information on the packaging and the product 19 3 3 Possible health consequences 19 3 4 Personal protective equipment 19 3 5 Privacy 19 3 6 Data processing 19 4 Preparation and installation 20 4 1 Transport and storage of the product 20 4 1 1Dimensions and weight 20 4 1 2Storage of the product 20 4 2 Installation of the product 21 4 2 1Removal of transport and pack...

Page 5: ...5 3 Repairs 42 Appendix I glossary 43 Annex II related documentation 43 ...

Page 6: ...e temperature sensors 27 Figure 8 Mounting of temperature sensors 28 Figure 9 Temperature sensor mounted in the mounting bracket 29 Figure 10 Belt elongation measurement arrangement drawing 31 Figure 11 Detail view to tension axis mounting position of magnet for elongation measurement 31 Figure 12 Positioning of H bracket at the tension axis 32 Figure 13 Bracket for elongation sensor 32 Figure 14 ...

Page 7: ...ature sensor at head 30 Table 6 Electrical connections for temperature sensor at boot 30 Table 7 Electrical connections for elongation measurement 34 Table 8 Signal description 35 Table 9 Connection table for existing signals 36 Table 10 Status check of component LEDs 38 Table 11 Detecting problems with the elongation sensor 39 Table 12 Detecting problems with the temperature sensor 40 Table 13 De...

Page 8: ... be carried out by appropriately trained personnel with professional skills and knowledge in conveying equipment electrical and mechanical engineering 1 2 Explanation of the safety instructions Danger indicates an immediately dangerous situation which if not avoided may cause death or serious injuries Warning indicates a potentially dangerous situation which if not avoided may cause serious injuri...

Page 9: ...erence Look it up and pass it on to future users of the product The manufacturer is not liable for any damage to property or injury resulting from incorrect handling or non compliance with the safety instructions In such cases the warranty is void 1 4 Procurement of documents and information A current version of the documentation is available on the following website https premas ch premas product...

Page 10: ...ge with other equipment than belt bucket elevators The PREMAS 4 0 must not be used in the following cases Incompliance with the design of the bucket elevator Missing access points to mounting locations of required sensors Environmental conditions do not fit as specified for the PREMAS 4 0 system Within ATEX zones Any use other than that described in these instructions The PREMAS 4 0 system shall o...

Page 11: ...se supplement a PREMAS 4 0 system is supplied Exclusions of liability PREMAS AG shall not be liable for whatever legal reasons and to the extent permitted by law for damages not occurring to the delivery item itself such as loss of production loss of profit damages to third parties downtime costs loss of use loss of orders increased operating maintenance or personnel costs or indirect costs and or...

Page 12: ...environments The used communication model is certified according the following standards and regulations CE RED EAC CCC Ukraine UCRF RoHS REACH FCC IC PTCRB Anatel RCM Thailand NBTC E mark Sirim IMDA SDPPI POSTEL AT T approval Verizon Deutsche Telekom AG GCF WiFi Certified Giteki The customer as the builder of a system including a mobile radio system is responsible for the correct and conform oper...

Page 13: ...the IoT Box which sends the collected data through mobile connectivity to the PREMAS Cloud There the data will be analyzed based on the latest technologies for predictive analytics e g algorithms machine learning The PREMAS Portal visualizes and provides all relevant data for a complete online condition monitoring securely online accessible to authorized users 24 7 through any mobile or desktop de...

Page 14: ...quired No 24 VDC supply from IoT Box Protection class IP IP67 Table 1 Technical data Field Sensor Temperature Field Sensor Elongation Measurement Range 0 to 400 mm Connection cable 4 wire connection to IoT Box Signal type 4 to 20 mA Location 1 at Boot mounted at parallel tension device Transmitter required No External power supply required No 24 VDC supply from IoT Box Protection class IP IP67 Tab...

Page 15: ...r Compact single phase rated current 10A Input types 8x analog 5x digital Output types 2x digital warning alarm to external Power supply 110 to 230 VAC uninterrupted power supply UPS Power requirement 25 W Location Nearby bucket elevator boot Mobile communication 4G LTE UMTS HSPA EDGE GPRS GSM SIM Card Global SIM card with data package included Protection class IP dust proof Nema 4 IP65 Table 4 Te...

Page 16: ...ongation magnet incl screws 6 2 Sensor mounting clamps incl screws sleeves 7 1 Sensor cable 10 m 5 pole plug connector PREMAS 4 0 Temperature Kit Temperature Kit Art 3001068 4 8 2 Temperature Transmitter 9 2 Sensor cables 10 m PREMAS 4 0 Mounting Brackets 10 2 Temperature sensor mounting brackets Temperature Bracket Art 3001068 5 11 1 Elongation mounting H bracket W incl screws Elongation H Bracke...

Page 17: ...l be processed in the PREMAS Cloud and made available to the user via the PREMAS Portal AN example of a machine dashboard is shown below To access the Portal please follow the instructions based on the operational manual which is available online https premas ch premas products services premas knowledge base Figure 3 Machine overview of PREMAS Portal ...

Page 18: ...any of your own standards and preventive maintenance requirements and other product installation information supplied with the product You should be prepared to provide the installer with all necessary installation information to assist in the installation Make sure that you have read and understood the manual and all safety instructions before using this product The non observance of these inform...

Page 19: ... are stored and processed in the PREMAS cloud Data are stored anonymous and are accessible only for authorized with user rights managed by PREMAS AG Beside the username and password there are no personal data stored in the system 3 6 Data processing The buyer agrees that PREMAS AG may use the operating data of the buyer s plants or machines obtained with the supplied PREMAS 4 0 systems after anony...

Page 20: ...e found on the corresponding packing list Gros weight 48 kg Net weight 32 5 kg Dimensions 96 x 55 x 50 cm Figure 4 Dimensions and weight of PREMAS 4 0 packaging 4 1 2 Storage of the product The electronic components of the system IoT Box sensors antenna shall be stored in a dry and clean location under the following ambient conditions Storage Temperature 20 C to 70 C 4 F to 158 F Relative Humidity...

Page 21: ...dure will protect the element and ease later identification 4 2 2 Unpacking the product Unpack your PREMAS 4 0 package Check delivered items with the packing list Read this installation guide and the online operational manual carefully see PREMAS Knowledge Base https premas ch premas products services premas knowledge base Review of the scope of delivery Check that the package contains the ordered...

Page 22: ...d signals connected to PREMAS 4 0 IoT Box The PREMAS 4 0 system delivery includes two temperature sensors and one elongation sensor for supervision of the operation Additional signals are required from existing installation see green marked signals in Figure 5 and need to be prepared for connection to the PREMAS IoT Box ...

Page 23: ...d tools Following tools are required for installation The list may be extended depending on the local situation and needs For mechanical work Folding yardstick caliper marker pen Drill bit for metal and drilling machine Angle grinder with cut off wheel for metal Power cord extension Metal file rasp Welding equipment Paint and paintbrush Spanner wrench set Plus additional tools depending on local s...

Page 24: ...requirements for successful installation Mobile 3G 4G coverage available at IoT box location Power supply 110V or 230V available Are the required signals available at the plant which need to be connected to the IoT Box from the plant control system Motor Current Level Switch Speed Switch Straight run warning Is free and safe access to the chosen location given and work areas prepared for safe inst...

Page 25: ... a position for the IoT Box next to the machine which should be monitored considering ease of reach like a junction box local IO cabinet no exposure to the sun to avoid additional heat up no risk of mechanical damage Positioning the antenna Choose a position for the antenna with the best 3G 4G connection considering 5 m 16 4 ft cable to connect the antenna with the IoT Box no risk of mechanical da...

Page 26: ...o lay it in a cable tube or on a cable ladder Check out that the female connector is on the site of the IoT Box and the male connector at the site of the antenna 4 Connect the antenna cable with the antenna and plug the cable into the black router A800 port Mobile inside the IoT Box upper port 5 Connect the power cable to the circuit breaker F301 of the IoT Box Electrical hazard Disconnect all sou...

Page 27: ...sor Positioning the temperature sensor at the bucket elevator boot and head The positioning of the temperature sensors is shown in Figure 7 Choose a position within the indicated area and mark a 70 x 70mm cut out for the brackets Figure 7 Mounting positions for the temperature sensors Risk of mechanical damage The sensor tip and the sensor bracket protrude into the interior of the machine They mus...

Page 28: ... the sensor bracket to the chosen position 4 Weld the sensor bracket with a continuous welding seam to the elevator housing 5 Repeat steps 1 4 for the second position Create opening for bracket Weld bracket to casing Figure 8 Mounting of temperature sensors Risk of mechanical and thermal damage Before handling the sensor bracket make sure that the sensor is not mounted Temperatur sensor to be inst...

Page 29: ...plied cable with its 4 pole connector to the sensor and tighten the coupling nut slightly by hand Be careful not to damage the pins during connection 2 Extend the provided sensor cable up to the IoT Box with your own supply and connect it with the IoT Box see connecting diagrams below The unit must be connected by a qualified electrician The national and international regulations for the installat...

Page 30: ...1 brown AI1 24v IO Link 4 Black Not used enter the code of your wire Table 5 Electrical connections for temperature sensor at head Temperature sensor boot Function Connector Pin Wire code of system cable Wire code of extension cable X1001 Terminal Signal 2 White AI2 Signal GND 3 Blue AI2 0V V 1 Brown AI2 24v IO Link 4 Black Not used enter the code of your wire Table 6 Electrical connections for te...

Page 31: ...re 10 Belt elongation measurement arrangement drawing Mechanical Work 1 Installation of magnet to the tension axis Position the mounting bracket to the tension axis and fix it drill cut threat screw it For the correct position see Figure 11 below The magnet shall be positioned in the center of the tension axis 11 hex screw M6x12 12 Spring ring 6 bracket for magnet Figure 11 Detail view to tension ...

Page 32: ...e tension axis see Figure 12 Hold the H Bracket in front of the desired position and spot weld the arms to the tension station s site plates Figure 12 Positioning of H bracket at the tension axis 3 Take the main frame of the H Bracket and mount the two brackets for the sensor rail facing direction elevator Make sure to use the insulating sleeves on top and bottom of the bracket Figure 13 Bracket f...

Page 33: ...cket feet with the provided screws Figure 15 H bracket fixed on the feet 6 Align the H bracket and ensure that a distance of 2 7mm between magnet and the sensor rail is kept over the entire length of the tension system see Figure 16 Figure 16 Top view to tension axis distance between magnet and sensor rai Risk of sensor damage Distance between magnet and sensor rail 2 7 mm must be ensured over the...

Page 34: ...ires to the terminal X1001 according the connection diagram Function Connector Pin Wire code of system cable Wire code of extension cable X1001 Terminal Signal 2 Brown AI3 Signal GND 3 Black AI3 0V V 1 Yelllow green AI3 24v Screen 4 Screen Earth enter the code of your wire Table 7 Electrical connections for elongation measurement The unit must be connected by a qualified electrician The national a...

Page 35: ...off 0 24 VDC PCS output signal Signal monitoring the turning of the elevator s belt Straight run warning Digital signal on off 0 24 VDC PCS output signal A belt bucket elevator typically has 4 drift switches to monitor the straight running of the belt on the drive and tension drum If one of the signals is indicating a drift a 0 shall be send to the IoT box If there is no drift the signal shall be ...

Page 36: ...D AI6 0V AI6 24Vsupply Spare AI Signal out AI7 Signal in GND AI7 0V AI7 24Vsupply Spare AI Signal out AI8 Signal in GND AI8 0V AI8 24Vsupply Level Switch Signal out DI1 Signal in GND DI1 0V DI1 24V Speed Switch Signal out DI2 Signal in GND DI2 0V DI2 24V Straight Run Drift Warning Signal out DI3 Signal in GND DI3 0V DI3 24V Spare DI Signal out DI4 Signal in GND DI4 0V DI4 24V Spare DI Signal out D...

Page 37: ...d The cable connector is plugged into the sensor and tightened Cable is pulled and connected to the IoT box Elongation sensor is installed at tension station Magnet and rail are adjusted The cable connector is plugged into the sensor and tightened Cable is pulled and connected to the IoT box All required signals are connected from process control system to the IoT box All signals are connected acc...

Page 38: ...ult Component Label LED Expected color Actual LED color Power supply G301 PWR Green AI module Busworks XT 4 A811 STATUS Yellow RUN Green SIMATIC IOT2000 A801 PWR Green STAT Green flashing USER 1 Green USER 2 Green it may take up to 4 minutes for theLED to change from RED to GREEN Table 10 Status check of component LEDs If the expected LED status has been confirmed the system is ready for usage To ...

Page 39: ...ignal indication Sensor rail is grounded Check installation of the sensor brackets the insulating sleeves shall be used together with the screws The rail shall not be grounded No signal indication Distance between magnet and sensor rail Adjust the H bracket to ensure that the distance between magnet and rail is always between 2 and 7 mm No signal indication Magnet out of measurement area of the se...

Page 40: ... be established Disconnect and reconnect the blue network cable on top of the A811 module After 15s the LED should turn green SIMATIC IOT2000 A801 The LED USER 1 does not turn green Network cable not attached to AI module A811 Check the connection of blue network cable passing from SIMATIC IOT2000 Port P1 to AI module A811 Port 1 SIMATIC IOT2000 A801 The LED USER 2 is red 3G 4G communication inter...

Page 41: ... Current Level Switch Speed Switch Straight run warning please contact your local PREMAS 4 0 supplier Certain functionalities of the analytics and dashboard will not function properly or not at all I would like to connect the IoT Box to more than one machine is this possible No The system is designed for one machine per box This is due to the do it yourself approach and easy to mount components wh...

Page 42: ...em or if not available directly PREMAS AG Prior to a repair of the system or an exchange of parts of it PREMAS AG or a local distributor shall be contacted During the exchange of a system component IoT Box sensor antenna all local regulations have to be respected in addition to those mentioned under 3 1 Do not open nor replace any component of the PREMAS 4 0 system without prior approval and advis...

Page 43: ...erminology Meaning IoT Internet of Things PCS Process or Plant Control System LTE Long Term Evolution 3rd generation of wireless broadband communication for mobile devices Annex II related documentation Document title Version Location Author Operational Manual V1 0 Online PREMAS AG ...

Page 44: ...PREMAS Preventive Maintenance Service AG Haldenstrasse 1 6340 Baar Switzerland Phone 41 41 766 8201 info premas ch www premas ch VAT No CHE 101 920 381 PREMAS Knowledge Base Questions ...