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Summary of Contents for GSi InterSystems PNEG-2116
- Page 1 Bucket Elevator Installation and Operation Manual PNEG-2116 Version: 1.0 Date: 12-12-16 PNEG-2116...
- Page 2 All information, illustrations, photos, and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. PNEG-2116 Bucket Elevator...
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Page 3: Table Of Contents
Table of Contents Contents Chapter 1 Introduction ............................4 General Information ..........................4 General Safety Statements ........................4 Replacement Parts ..........................4 Chapter 2 Safety ..............................5 Safety Guidelines ..........................5 Cautionary Symbols Definitions ......................6 Safety Cautions ............................. 7 Safety Sign-Off Sheet ......................... 11 Chapter 3 Decals ..............................12 Chapter 4 Installation ............................16 Receiving Inspection ........................... -
Page 4: Chapter 1 Introduction
1. Introduction General Information InterSystems reserves the right to improve its product whenever possible and practical to do so. We reserve the right to change, improve and modify products at any time without obligation to make changes, improvements and modifications on equipment sold previously. This manual covers the installation and operation for the Bucket Elevator. -
Page 5: Chapter 2 Safety
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. Save these safety guidelines for future reference. -
Page 6: Cautionary Symbols Definitions
2. Safety 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. This symbol indicates an imminently hazardous situation DANGER which, if not avoided, will result in serious injury or death. -
Page 7: Safety Cautions
2. Safety Safety Cautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Foot Respiratory Protection Protection Protection Head Fall Hearing Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. • Tie long hair up and back. ST-0004-1 Follow Safety Instructions •... - Page 8 2. Safety 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.
- Page 9 2. Safety Fall Hazard • Keep access door closed while on a 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 Toxic Fume and Dust Hazard •...
- Page 10 2. Safety Stay Clear of Hoisted Equipment • Always use proper lifting or hoisting equipment when assembling or disassembling equipment. • Do not walk or stand under hoisted equipment. • Always use sturdy and stable supports when needed for installation. Not following these safety precautions creates the risk of falling equipment, which can crush personnel and cause serious injury or death.
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Page 11: Safety Sign-Off Sheet
2. Safety 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 PNEG-2116 Bucket Elevator... -
Page 12: Chapter 3 Decals
3. Decals The safety decals on your equipment are safety indicators which must be carefully read and understood by all personnel involved in the installation, operation, service and maintenance of the equipment. To replace a damaged or missing decal, contact us to receive a free replacement. InterSystems 9575 N. - Page 13 3. Decals NOTE: These labels 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 Intersystems. Ref # Decal # Decals Description DANGER DANGER Explosion release will cause severe EMC 12 J3 Explosion (Typical all panels)
- Page 14 3. Decals Ref # Decal # Decals Description WARNING Rotating parts can crush, cut and entangle. EMC 25 J3 Rotating Parts Do NOT operate with guard removed. Lockout power before removing guard or servicing. Clarion Clarionsafety.com Reorder No. EMC 25 J3 WARNING EMC 24 J3 Exposed Belt...
- Page 15 3. Decals Ref # Decal # Decals Description WARNING Platform Platform Limits IS 504X3 For I.S. platform only Maximum Concentrated Load 100 lbs / SQ FT Not to Exceed 500 lbs Intersystems Serial Number Tag IS 5210X8 Intersystems Logo OMAHA, NEBRASKA USA PNEG-2116 Bucket Elevator...
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Page 16: Chapter 4 Installation
4. Installation IMPORTANT: Thoroughly read safety information from Pages 5-15 before beginning installation and start-up. Receiving Inspection 1. Carefully inspect the shipment for damage as soon as it is received. Verify that the quantity of parts or packages actually received corresponds to the quantity shown on the packing slip. One or more cartons containing the fasteners required for assembly are included with the shipment. -
Page 17: Elevator Guying Or Bracing
4. Installation Elevator Guying or Bracing Refer to Mill Mutual Publication No F-646-75. Incorrect attachment of guying cables to elevator or lateral bracing from an adjoining structure will result in support failure, collapse of the elevator and death or severe injury to anyone in the area. Attach guying cables to the elevator only by means of the 4 wire bolt-on brackets as shown in Figure... -
Page 18: Elevator Intake
4. Installation Elevator Intake Several factors should be taken into account when planning the intake to feed material into the elevator: 1. The method and location of intake openings in the boot usually will have been determined when the elevator was ordered. However, if the intake arrangements have or are being changed, several factors must be considered. -
Page 19: Elevator Discharge
4. Installation b. UP Side Infeed Devices: The device which feeds the elevator, (auger, belt conveyor, spout, hopper, etc.), must feed the material into the boot ABOVE the centerline of the pulley. The buckets must complete the turn around the pulley and be moving vertically upward, not at a tangent, before encountering material to be elevated. -
Page 20: Elevator Erection (Assembly)
4. Installation Elevator Erection (Assembly) Erection of the elevator must not be started until the concrete foundation and the guying anchors (if any are needed) have been completed and developed maximum strength. IMPORTANT: No matter who does the installation or what method is employed, the elevator must be plumb. - Page 21 4. Installation Figure 4E Vertical Elevator Assembly Sequence Ref # Description Ref # Description Typical Foundation Heavier Gauge Casings if Required Bottom Level or Grade Typical Rest Platform Boot First Section 3a through 3(n) (Elevator Height) Expansion Bolt and Anchoring Plates by Others Typical Head Service Platform Normal Work Floor Level Head Section...
- Page 22 4. Installation Incorrect placement of trunk sections of varying gauge sheet metal could result in support failure, collapse of the elevator and death or severe injury to anyone in the area. Trunk sections of varying gauge must be installed in the locations shown on the certified drawings with the heavier gauges toward the bottom.
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Page 23: Ladder Assembly With Safety Cages
4. Installation 6. The last elevator section to be lifted into position onto the elevator is ALWAYS the head section. (The hood is not assembled until belt and cup installation is complete.) Lift the head onto the top elevator section. (See Figure 4G on Page 22.) DO NOT install the hood at this time. - Page 24 4. Installation Figure 4I Standard and Starter Cage Ref # Description Ref # Description Hoop Half Ladder Seam Splice Cage Rail Package (44" Sections) Standoff Brackets Hoop Expander 3/8" Hardware 5/16" Hardware Locking Clip Ladder Section NOTE: Repeat the same procees to assemble the remaining safety cages. PNEG-2116 Bucket Elevator...
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Page 25: Typical Small Head Service Platform Assembly
4. Installation Typical Small Head Service Platform Assembly Figure 4J Typical Small Head Service Platform Assembly Typical Large Head Service Platform Assembly Figure 4K Typical Large Head Service Platform Assembly PNEG-2116 Bucket Elevator... -
Page 26: Typical Head Service Hatch Assembly
4. Installation Typical Head Service Hatch Assembly Figure 4L Typical Head Service Hatch Assembly Ref # Description Hatch Door Ladder Section Locking Clip Ladder Bracket 5/16" Nut Perfstrut Deck Hatch Frame Side Hatch Frame End Hatch Hinge 3/8" Hardware PNEG-2116 Bucket Elevator... -
Page 27: Belt And Bucket Installation
4. Installation Belt and Bucket Installation There are two (2) basic methods of installing the belt and buckets in an elevator. Any of three (3) styles of belt splice can be selected. Customers usually have a definite preference as to the style of splice used. Various methods of belt/bucket installation and belt splicing are covered in the following paragraphs. - Page 28 4. Installation The choice of methods used to install the belt and buckets is determined by: 1. Length and weight of belt 2. Number, size, and weight of buckets 3. Open area available around the base of the elevator 4. Available equipment REMINDER: The hood is not yet assembled to the head section.
- Page 29 4. Installation NOTE: These rollers (Z) are factory adjusted and should never need field adjustment. Figure 4O Posi-Guide Gravity Take-Up Ref # Description Ref # Description Pillow Block Bearing Lift Here to Raise Pulley Boot Assembly Access Door Removable Cover Connection Bolts Weight Box Guide Rollers...
- Page 30 4. Installation 3. Rig a heavy haulage line (rope or cable) through the removable panel in the UP-LEG through which the belt with buckets attached will be pulled into the elevator. The line is then hauled up the UP-LEG, over the head pulley, and down the DOWN elevator leg. Usually, the line can be passed around the boot take-up pulley and out of a cleanout panel to a winch so the belt can be pulled into the elevator.
- Page 31 4. Installation 4. Connect the haulage line to the end of the belt, preferably by means of a spreader bar. 5. As buckets are fastened to each length of belt, pull the length of belt into the elevator leg. Be sure to keep a strain on the haulage line between hauls so the belt does not drop back down the elevator.
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Page 32: Belt Splicing
4. Installation 10. This procedure uses buckets as counterweights. If buckets are fastened to the belt in consecutive continuous rows, the strand of belt in the UP-LEG will carry appreciably more weight than the strand in the DOWN-LEG. Considerable backward pull on the head pulley would result and it would be much more difficult to advance the belt. - Page 33 4. Installation View A: Lap Splice View B: Butt Splice View C: Mechanical Splice View D: Spreader Bar Detail Figure 4Q Belt Splicing Methods Ref # Description Ref # Description Longer bolts are used to attach buckets Three (3) bucket overlap on each side of where belt is spliced.
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Page 34: Hood Installation
4. Installation Hood Installation After belt splicing is complete, hoist the hood into position on the elevator head and install the fasteners. Drive Installation Refer to the order information and the certified drawings furnished with the elevator for drive installation. The amount of detail will depend upon whether or not InterSystems furnished all or part of the elevator drive. -
Page 35: Chapter 5 Operation
5. Operation Initial Belt Tracking IMPORTANT: This procedure is to be performed with the elevator empty. Should any problem be discovered, it will be much more difficult to correct if the elevator is full of material. 1. When the belt has been spliced, shift the belt laterally on the head pulley so it is centered on the pulley. - Page 36 5. Operation Other Causes of Other Causes of Head Pulley Misalignment Boot Pulley Misalignment 1. Loose set screws or keys, allowing the 1. Grain entering the boot at an angle pulley to move laterally on the shaft. crowding the belt to one side. 2.
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Page 37: Rubber Throat Slide Adjustment
5. Operation Figure 5B Head Section Details Ref # Description Ref # Description Head Pulley Shaft Jack Screw Slide Lag Inspection and Replacement Panel - Hinged Rubber Throat Slide Access Panel - Hinged Explosion Vent Mounting Hardware Shim Pillow Block Mounting Surface Rubber Throat Slide Adjustment The rubber throat slide, as shown in Figure... -
Page 38: In-Service Belt Tension
5. Operation In-Service Belt Tension If the belt tracks properly and does not slip when the elevator is operating at maximum capacity, then the belt is sufficiently tensioned. Tension adjustment, however, must wait until the entire installation is complete and material (the product; grain, etc.) can be conveyed to and from the elevator. 1. -
Page 39: Elevator Bucket Filling
5. Operation Elevator Bucket Filling Proper filing of the buckets is vital to achieving the design capacity of the elevator. Buckets should be filled to slightly above the water level line shown in Figure 5C. In section elevator intake on Page 18, discusses some of the factors influencing elevator capacity in general and bucket filling in particular. - Page 40 5. Operation EXAMPLE: Gross truck weight with corn (56# PER BU) 35,000 Empty truck weight 10,000 Time from opening pit gate to pit empty 5 min 35,000 - 10,000 = 25,000 net pounds of corn 60 / 5 min = 12 (tf) 25,000 lbs.
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Page 41: Chapter 6 Maintenance And Repair
6. Maintenance and Repair IMPORTANT: Thoroughly read safety information from Pages 5-15 before beginning installation and start-up. General Maintenance A good maintenance program involves thorough general housekeeping, periodic inspection, adequate lubrication, and timely adjustment. NOTE: Never service any equipment while operating unless it is necessary; for example, bearing lubrication. -
Page 42: Lubrication
6. Maintenance and Repair 6. Examine guying. Tighten any clamp fasteners, which are loose. If a cable is excessively slack, adjust turnbuckles to restore tension. Excessive guy cable tension will twist, bend and/or collapse the elevator structure, causing severe injury or death. Maintain proper guy cable tension at all times. 7. -
Page 43: Adjustment And Repair Procedure
6. Maintenance and Repair Adjustment and Repair Procedure Boot Take-Up (Belt Tension) Adjustment In-service belt tension on Page 38 states the InterSystems position regarding proper belt tension. Step A of in-service belt tension on Page 38 explains how to adjust a screw take-up boot or how to add weight to a gravity take-up boot. - Page 44 NOTES PNEG-2116 Bucket Elevator...
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Page 45: Chapter 7 Warranty
7. Warranty InterSystems, Inc. reserves the right to make changes in design or in construction of equipment and components without obligation to incorporate such changes in equipment and components previously ordered. WARRANTY, LIMITATION OF LIABILITY, DISCLAIMER OF IMPLIED WARRANTIES: InterSystems, Inc. manufactured equipment and components are guaranteed against defects in workmanship or materials for one year from date of shipment. - Page 46 InterSystems 9575 N. 109 Ave. Omaha, Nebraska 68142 Toll Free: (800) 228-1483 www.gsiag.com InterSystems is a part of GSI, a worldwide brand of AGCO Corporation. Copyright © 2016 by Intersystems, Inc. Printed in the USA CN-326607...
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