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GSI Group II Series Installation & Operation Manual

Sweep hopper with collector ring
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Series II Sweep Hopper
with Collector Ring
34,000 BPH Capacity & 30" Flange
60,000 BPH Capacity & 36" Opening
Installation & Operation Manual
PNEG-970-HC
Date: 05-17-2006
®
PNEG-970-HC

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Summary of Contents for GSI Group II Series

  • Page 1 Series II Sweep Hopper with Collector Ring 34,000 BPH Capacity & 30" Flange 60,000 BPH Capacity & 36" Opening Installation & Operation Manual PNEG-970-HC Date: 05-17-2006 ® PNEG-970-HC...
  • Page 2 Catalog No. Slip Ring Serial No. Date of Purchase The manufacturer 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.

  • Page 3: Table Of Contents

    Table of Contents Personnel operating or working around this equipment should 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. Any misuse of the equipment may void the warranty. 1.

  • Page 4: Safety

    Safety SAFETY GSI equipment is built to provide many years of dependable service to our customers through durable craftsmanship. One of the most important aspects of GSI engineering is SAFETY 1 design throughout all product lines. At GSI safety is NO ACCIDENT! That is why GSI is implementing its SAFETY 1 program.
  • Page 5 Safety SAFETY GUIDELINES This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines.
  • Page 6 Safety Safety Instructions GSI’s principle concern is your safety and the safety of others associated with grain handling equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems which may be encountered by the operator and other personnel. As owner and/or operator, it is your responsibility to know what requirements, hazards and precautions exist, and to inform all personnel associated with the equipment or in the area.
  • Page 7 Safety ROTATING FLIGHT DANGER! Rotating Flight Grain augers can kill or dismember. Keep clear of all augers and never enter the bin unless all power is disconnected and locked out. Failure to do so will result in serious injury or death! OPERATE UNLOAD EQUIPMENT PROPERLY Make sure ALL equipment is locked in position before operating.
  • Page 8 Safety INSTALL & OPERATE ELECTRICAL EQUIPMENT PROPERLY Electrical controls should be installed by a quali- Electric Shock fied electrician and must meet the standards set Hazard by the national electrical code and all local and state codes. Disconnect and lock out all power sources before installing wires/cables or servicing equipment.
  • Page 9 Safety PREPARE FOR EMERGENCIES Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambu- lance service, hospital, and fire department near Keep Emergency Equipment your telephone. Quickly Accessible. WEAR PROTECTIVE CLOTHING Eye Protection Wear close fitting clothing and safety equipment appropriate to the job.
  • Page 10 Safety Decals The images below show the location of the decals and safety signs which should appear on the Series II Sweep hopper with collector ring. Decal “D” (DC-1224) on top of collector ring shield plate Decal “D” (DC-1224) on side of collector ring shield Decal “A”...
  • Page 11 Safety Decals (cont.) DANGER Sign No. DC-1395 was supplied with your bin unloading equipment. This safety sign should be applied to the side of the bin near the bin opening, so it will be viewed by people entering into the bin storage building. Do not cover any safety signs or any other signs that are already there.
  • Page 12 Safety 7. Operator Qualifications. A. The User/Operator must be competent and experienced to operate auger equipment. Any- one who works with or around augers must have good common sense in order to be quali- fied. These persons must also know and meet all other qualifications, such as: 1.

  • Page 13: Introduction

    Introduction 1. Product Information A. The Series II Sweep Hopper with Collector Ring includes the following components: - hopper - collector ring - center brace support - collector ring shield NEVER enter a grain bin unless ALL power driven equipment has been shut- down.
  • Page 14 Introduction 4. Slip Ring Information Slip rings must be enclosed and protected from any contact by personnel. Specifications & Listings A. R-Series Slip Ring products are built to UL specifications but are not generally certified or listed by any independent certifying or regulatory body. Temperature &...

  • Page 15: Assembly

    Assembly 1. ASSEMBLE THE CROSSBRACE A. Assemble the 1" x 9 3/8" conduit to the 1" chase nipple using one (1) 1" conduit coupling. B. Feed the nine (9) stranded wires from the collector ring through the conduit assembly and fasten it to the collector ring.
  • Page 16 Assembly 1. ASSEMBLE THE CROSSBRACE (cont.) C. Feed the nine (9) stranded wires from the collector ring through the pivot tube and bolt the collector ring to the crossbrace assembly using four (4) 1/4"-20 x 1" hex bolts, lock washers, and hex nuts.
  • Page 17 Assembly 1. ASSEMBLE THE CROSSBRACE (cont.) D. Bolt the collector ring shield to the crossbrace assembly using four (4) 1/4"-20 x 1" hex bolts, flat washers, lock washers, and hex nuts. Do not use the remaining bolts. crossbrace assembly 1/4"-20 x 1" hex bolt flat washer collector ring shield lock washer...
  • Page 18 Assembly 1. ASSEMBLE THE CROSSBRACE (cont.) E. Slide the lower tube assembly into the shield assembly. Bolt the crossbrace to the hopper using four (4) 1/2"-13 x 1 3/4" hex bolts, flat washers, lock washers, and hex nuts (One on each side.).
  • Page 19 Assembly 2. WIRE THE COLLECTOR RING Electrical controls and wiring should be installed by a qualified electrician. The motor disconnect switches and conductor cables should comply with the National Electrical code and any local codes which apply. Reset and motor starting stations should be located so that the operator can see that all personnel are clear of the equipment.
  • Page 20 Assembly 2. WIRE THE COLLECTOR RING (cont.) The collector ring comes pre-wired from the factory. It is wired per the following: 1. Thermal Protection Leads a. Wire the "P1" lead from the control panel to ring "1". b. Wire the "P2" lead from the control panel to ring "2". 2.
  • Page 21 Assembly 3. ASSEMBLE THE CROSSBRACE TO THE HOPPER A. Feed the multi-conductor cord through the collector ring shield, lower tube assembly, and drilled hole in hopper side. B. Bolt the collector ring shield to the crossbrace assembly using sixteen (16) 1/4"-20 x 1" hex bolts, flat washers, lock washers, and hex nuts.
  • Page 22 Assembly 3. ASSEMBLE THE CROSSBRACE TO THE HOPPER (cont.) D. Making sure the lower tube assembly and drilled hole are aligned, bolt the crossbrace to the hopper using eight (8) 1/2"-13 x 1 3/4" hex bolts, flat washers, lock washers, and hex nuts. crossbrace assembly hopper...
  • Page 23 Assembly 4. ASSEMBLE THE CROSSBRACE TO THE SWEEP A. Feed the nine (9) stranded wires from the collector ring through the pivot tube and hole in the back of the sweep head section. B. Align the hole in the backshield with the pivot tube and push the sweep onto the pivot tube. stranded wires PNEG-970-HC S2 Hopper w/ Collector Ring - High Capacity...
  • Page 24 Assembly 4. ASSEMBLE THE CROSSBRACE TO THE SWEEP (cont.) C. Connect the pivot plate to the backshield using two (2) 1/2"-13 x 1 3/4" hex bolts, flat washers, lockwashers, and hex nuts. D. Fasten the pivot rod to the backshield and pivot plate using two (2) 1/2"-13x1-3/4" hex bolts, lockwashers, and hex nuts.
  • Page 25 Assembly 5. WIRE THE COLLECTOR RING TO THE SWEEP NOTE: The liquid tight flex conduit may need to be trimmed to length. A. Attach one(1) 1" liquid-tight flex conduit coupling to each end of the trimmed 1" x 48" liquid-tight flex conduit. B.
  • Page 26 Assembly 5. WIRE THE COLLECTOR RING TO THE SWEEP (cont.) Wire the nine (9) stranded wires to the junction boxes in the following manner. 1. Thermal Protection Leads Wire the "P1" lead from both motors to "1". Wire the "P2" lead from both motors to "2". 2.
  • Page 27 Assembly 6. Wire the Upper Conduit Assembly to the Sweep and Motor D. Attach the 3/4" x 12" liquid-tight flex conduit to the other end of the rigid conduit using one (1) 3/4" conduit coupling and one (1) 3/4" liquid-tight flex conduit coupling. E.
  • Page 28 Assembly 6. Wire the Upper Conduit Assembly to the Sweep and Motor (cont.) J. Place the 3/4" rigid conduit assembly onto the back frame of the sweep between the con- necting angle and connecting flange. connecting flange 3/4" rigid conduit connecting angle FIG.
  • Page 29 Assembly 6. Wire the Upper Conduit Assembly to the Sweep and Motor (cont.) L. Attach the 3/4" rigid conduit assembly to the sweep using the 5/16"-18 x 3/4" studs welded to the sweep using 1" conduit clamps, lockwashers, and hex nuts. M.

  • Page 30: Startup

    Start-Up 1. Preform Pre-Start Checks Warning! To ensure that the drive is not unexpectedly started, turn off and lock out or tag out the power source before proceeding. Failure to observe these precautions could result in bodily injury. Danger! Failure to perform any or all of these pre-start checks may cause damage to the equipment and/or cause SERIOUS INJURY or DEATH to those in the work area.

  • Page 31: Maintenance

    Maintenance 1. Maintain the Hopper ALWAYS shutdown and disconnect the power supply before adjusting, servicing or cleaning the equipment. A. Use caution when repairing or replacing equipment parts. B. Make sure ALL decals are legible and tightly attached to the hopper. If necessary, replace them FREE OF CHARGE by contacting GSI at: P.O.
  • Page 32 Maintenance 2. Collector Ring Maintenance 3. To remove and replace the brush: a) remove the clamp screw from the brush A. Lubrication holder 1. All bearings are lubricated for life at the factory. b) remove the screw from the brush lead Additional lubrication should not be required.
  • Page 33 Maintenance 2. Collector Ring Maintenance (Cont.) G. Rings 3. Periodically perform an inspection by removing the 1. Inspect the ring surface for dirt, oxidation, or enclosure and checking for condensation, water other contaminants. A properly operating ring will and dust collection. If contaminants are found, have a film that appears burnished in color with a wipe the enclosure and the assembly with a lint darker surrounding color where the brushes...

  • Page 34: Troubleshooting

    Troubleshooting Problem Solution Possible Cause Power cords may be A1. Plug in the power cords. . Sweep will not run. unplugged. Foot switch may not be B1. Make sure the foot switch is actuated. depressed and the switch is operating properly. Overloads may be tripped.

  • Page 35: Parts List

    Parts PARTS SECTION PNEG-970-HC S2 Hopper w/ Collector Ring - High Capacity...
  • Page 36 Parts HIGH CAPACITY 12" HOPPER COMPONENTS PNEG-970-HC S2 Hopper w/ Collector Ring - High Capacity...
  • Page 37 Parts 12" & 16" HOPPER COMPONENTS Ref. # Part # Description S2 Sweep Collector Ring Hopper GC04615 Standard Capacity 16" Square Discharge GC11410 High Capacity 30" Square Discharge GC11328 High Capacity 36" Square Discharge Lower Tube Assembly GC04624 16" Square Discharge GC11416 30"...
  • Page 38 Parts HIGH CAPACITY 12" & 16" SUMP COMPONENTS - 34,000BPH FRONT VIEW Ref # Part # Description SWEEP SUMP ASSEMBLY GC09986 MOTOR MOUNT BASE GEAR REDUCER ELECTRIC MOTOR S-8411 CONDUIT CLAMP 1" LMI ZN 1 HOLE GC11523 CONDUIT 3/4" FLEX - UPPER MOTOR MOUNT JACK ASSEMBLY S-2121 WASHER FLAT 1/2"...
  • Page 39 Parts HIGH CAPACITY 12" & 16" SUMP COMPONENTS - 34,000BPH REAR VIEW (OBSOLETE AFTER MAY 2006) Ref # Part # Description SWEEP SUMP ASSEMBLY S2 SWEEP HEAD SECTION GC11511 CONDUIT ASSEMBLY GC07521 BOX JUNCTION - EXPLOSION PROOF GC07744 CONDUIT NIPPLE 1" X 4 3/4" S-8568 U-BOLT 3/8-16 X 1 3/8 IW 054_1024_6...
  • Page 40 Parts HIGH CAPACITY 12" & 16" SUMP COMPONENTS HIGH CAPACITY AFTER MAY 2006 REAR VIEW Ref # Part # Description SWEEP SUMP ASSEMBLY S2 SWEEP HEAD SECTION GC11727 CONDUIT ASSEMBLY GC07521 BOX JUNCTION - EXPLOSION PROOF GC07744 CONDUIT NIPPLE 1" X 4 3/4" S-8568 U-BOLT 3/8-16 X 1 3/8 IW 054_1024_6 CONDUIT HANGER 1 1/4"...
  • Page 41 Parts HIGH CAPACITY 12" & 16" HOPPER SUMP COMPONENTS - 34,000BPH Ref # Part # Description GC11410 HOPPER SUMP WELDMENT GC07877 HOPPER SUMP CROSS BRACE ASSY. - 16 IN. S-2071 BOLT HHCS 3/8-16x1-1/4" S-1054 WASHER LOCK SPLIT 3/8" S-456 NUT HEX 3/8-16 S-6998 BOLT HHCS 1/4-20x1"...
  • Page 42 Parts UPPER CONDUIT ASSEMBLY FOR HIGH CAPACITY 12" & 16" SUMP - HIGH CAPACITY Ref # Part # Description GC07521 BOX JUNCTION EXPLOSION PROOF RED DOT #GASS-3 GC07744 CONDUIT NIPPLE 1" X 4 3/4" S-8568 U-BOLT 3/8-16 X 1 3/8 IW S-8518 CONDUIT FITTING 1"...
  • Page 43 Parts LOWER CONDUIT ASSEMBLY FOR HIGH CAPACITY 12" & 16" SUMP - 34,000BPH (OBSOLETE AFTER MAY 2006) Ref # Part # Description GC11506 CONDUIT ELBOW 1 1/4" GC11509 CONDUIT UNION 1 1/4" GC11510 FORMED 1 1/4 PIPE GC11505 CONDUIT BELL REDUCER 1 1/4" X 1" S-8518 CONDUIT FITTING 1"...
  • Page 44 Parts LOWER CONDUIT ASSEMBLY FOR HIGH CAPACITY 12" & 16" SUMP HIGH CAPACITY AFTER MAY 2006 Ref # Part # Description GC11506 CONDUIT ELBOW 1 1/4" GC11724 CONDUIT STREET ELBOW 1 1/4" GC11509 CONDUIT UNION 1 1/4" GC11726 CONDUIT - 1 1/4 X 32" GC11505 CONDUIT BELL REDUCER 1 1/4"...
  • Page 45 Parts Collector Ring Replacement Parts 7.1 Parts Descriptions (Blank) = No Enclosure Required R = Revolving Unit (RU) Optional S = Swivel Unit (SU) (Blank) = No Special Configuration U = Wrap Around Cover X = Explosion-Proof Enclosure W = Explosion Proof Enclosure w/ 1"...
  • Page 46 NOTES PNEG-970-HC S2 Hopper w/ Collector Ring - High Capacity...

  • Page 47: Warranty

    WARRANTY THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL US- AGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS. GSI'S ONLY OBLIGATION IS, AND...
  • Page 48 Authorities having jurisdiction should be consulted before installation occurs. The GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 217-226-4421 Fax: 217-226-4420 e-mail: gsisales@grainsystems.com internet: http://www.grainsystems.com Copyright © 2006 by The GSI Group Printed in the USA...