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GSI Group E Series Installation And Operation Manual

Ce compliant chain conveyors
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CE Compliant E-Series
Chain Conveyors - All Models
Installation and Operation Manual -
Original Instructions
PNEG-1993
Version: 2.0
Date: 04-26-16
PNEG-1993

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  • Page 1 CE Compliant E-Series Chain Conveyors - All Models Installation and Operation Manual - Original Instructions PNEG-1993 Version: 2.0 Date: 04-26-16 PNEG-1993...
  • Page 2 CE Declaration of Incorporation EC MACHINERY DIRECTIVE 2006/42/EC Vendel Park, Erdoalja U1, Biatorbagy, H-2051, Hungary The GSI Group declares that GSI E-Series chain conveyors Models 225 W x 225 T 300 W x 225 T 300 W x 300 T...
  • Page 3 CE Declaration of Incorporation EC MACHINERY DIRECTIVE 2006/42/EC Vendel Park, Erdoalja U1, Biatorbagy, H-2051, Hungary Maintenance 1.6.1 Machinery maintenance 1.6.4 Operator intervention Information 1.7.1 Information and warnings on the machinery 1.7.1.1 Information and information devices 1.7.2 Warning of residual risks 1.7.4 Instructions 1.7.4.1 General principles for the drafting of instructions...
  • Page 4 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-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 5: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..............................6 Safety Guidelines ..........................6 Cautionary Symbols Definitions ......................7 Safety Cautions ............................. 8 Safety Sign-Off Sheet ......................... 12 Correct Use ............................13 Correct Installation ..........................14 Guards ..............................15 Electrical Safety ..........................15 Possible Hazards Inside Grain Bins ....................

  • Page 6: Chapter 1 Safety

    1. 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 7: Cautionary Symbols Definitions

    1. 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 8: Safety Cautions

    1. 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 9 1. 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 10 1. Safety Stay Clear of Slide Gate • Keep hands away from slide gate opening. Slide gates can crush and dismember. Motor can start at any time. • Lock-out power source before making adjustments, cleaning, or maintaining equipment. ST-0049-1 Toxic Fume and Dust Hazard •...
  • Page 11 1. Safety Fall Hazard • Ladders, stairways and platforms are for use by competent and trained personnel only. Do not allow children or other unauthorized persons to have access to the equipment. • Access to the equipment must be restricted by the use of security fencing and lockable gates.

  • Page 12: Safety Sign-Off Sheet

    1. 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-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 13: Correct Use

    1. Safety Correct Use Incorrect use can be extremely dangerous. Moving chain, paddles, sprockets and shafts can cause serious injury and kill. 1. The E-Series Chain Conveyor system is for conveying whole agricultural seeds and grains only. Any other use is prohibited. 2.

  • Page 14: Correct Installation

    1. Safety 7. Power must be OFF, TAGGED and LOCKED before entering grain bin or store or working on the conveyor. (See Figure 1B.) Figure 1B 8. Wherever possible run the En-Masse Conveyor empty before stopping it. 9. Never leave the En-Masse Conveyor running unattended. 10.

  • Page 15: Guards

    1. Safety Guards The following minimum guarding must be fitted at all times. 1. All trough, head and tail covers. 2. Inlet and outlet guarding. (See Page 14.) 3. Belt drive and pulley guard. Electrical Safety Motors must be: 1. Selected to suit the length of conveyor (check with GSI). 2.
  • Page 16 1. Safety Figure 1C 6. The electrical supply must include a properly designed protective earth system (PE), with connection to all exposed conductive parts. 7. All motors shall be connected to protective earth at the terminal provided. 8. The control system shall include, a.

  • Page 17: Possible Hazards Inside Grain Bins

    1. Safety Possible Hazards Inside Grain Bins The inside of a grain bin, no matter what size, is a dangerous location. Grain bins should be kept locked shut at all times. NEVER allow a child or untrained, inexperienced person to enter a grain bin. Hazards present at any time may include: Mass flow of grain when filling or emptying which could draw you in and cause suffocation/burial.

  • Page 18: Chapter 2 Safety Decals

    Below are the safety warning decals that should be fitted and visible/legible at all times. On side (not visible here) On side (not visible here) GSI Group DC-2259M DC-2259M on head and tail section PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 19 2. Safety Decals GSI Group DC-2258M GSI Group DC-2258M DC-2258M on intermediate trough sections. PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 20: Ce Mark And Rating Plate

    2. Safety Decals CE Mark and Rating Plate Once the conveyor has been assembled equipped, in accordance with the instructions given in this manual, the installer or supplier shall make the full Declaration of Conformity and apply the CE mark, in accordance with the EU Machinery Directive 2006/42/EC.

  • Page 21: Chapter 3 Installation

    3. Installation Pre-Installation Preparation Read this and other required manuals. Use personal protection equipment. Arrange the conveyor components. Provide suitable support for the conveyor items for assembly at ground level. Layout the conveyor sections on supports assembly order, starting with the head section. PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 22: Head And Tail Identification

    3. Installation Head and Tail Identification Figure 3A Head Section Figure 3B Tail Section PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 23: Assembling An Un-Assembled Intermediate Section

    3. Installation Assembling an Un-Assembled Intermediate Section Figure 3C Intermediate Trough Assembly Ref # Description Hardware M08 - Flat Head Socket Cap Screw Bottom Plate M08 - Flange Nut M06 - Flange Bolts Cover M06 - Flange Nuts Rail Return M06 - Button Head Screw 1.

  • Page 24: Assemble Conveyor Sections

    3. Installation Assemble Conveyor Sections 1. Side and bottom of sections are punched to emboss at both ends for connecting purpose. (See Figure 3E.) Figure 3E 2. Connecting bracket is punched in the same pattern as head/tail/BPI and intermediate for perfect fit and ensure assembling.
  • Page 25 3. Installation Assemble Conveyor Sections (Continued) 3. Before connecting intermediate together, bend down both the ends of rails slightly (1-4 mm) to ensure smooth chain travel. (See Figure 3H.) Figure 3G Connecting Bracket Assembly Figure 3H PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 26 3. Installation Assemble Conveyor Sections (Continued) Figure 3I Connecting Sections Ref # Description M08 - Flat Head Socket Cap Screw M08 - Flange Nut Connecting Bracket NOTE: Head, tail, bypass inlet and intermediate all fit in a similar fashion. PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 27 3. Installation Assemble Conveyor Sections (Continued) Figure 3J Assembly with By-Pass Inlet Ref # Description Hardware Ref # Description M12 Hex Bolts Head Apply Adhesive Back Foam Strip M12 Hex Nuts M12 Hex Bolts Tail End Cover 10 mm Overhang Lip M12 Hex Nuts M12 Hex Bolts Bypass Inlet (Optional)

  • Page 28: Chain Installation

    3. Installation Chain Installation Figure 3K Chain Travel Direction (Bottom Run) Ref # Description Direction of Chain Travel Bottom Run 1. Assemble and install in 5 m sections. 2. 1.5 m section used to adjust final length. PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 29 3. Installation Chain Installation (Continued) Figure 3L Adjust Chain Tension Ref # Description Take-Up Screws Horizontal “C” Channel 90° 90° 90° 90° Figure 3M Check Correct Alignment Ref # Description Shaft Box Sides PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 30: Gear Motor Installation

    3. Installation Gear Motor Installation NOTE: Gearbox is supplied WITH OIL. See lubrication table on Page 43 and manufacturer’s instructions for OIL spec if necessary. Figure 3P Lock the Motor into the Drive Figure 3N Clean the Conveyor Input Shaft Figure 3Q Assembled View Figure 3O Fit Gear Motor into Drive Ref #...

  • Page 31: Chapter 4 Electric Operated Gate Installation

    4. Electric Operated Gate Installation Overall Head Gate and Intermediate Gate Dimensions Head gate section Intermediate gate section Figure 4A Overall Dimensions of Head Gate and Intermediate Gate Overall Dimentions of Head Gate and Intermediate Gate Gate Size Part # “A”...

  • Page 32: Cut Trough Bottom For Intermediate Gate

    4. Electric Operated Gate Installation Cut Trough Bottom for Intermediate Gate 1. Locate the template (B) at middle of intermediate sections as shown in Figure 2. The bottom of intermediate needs to be cut using appropriate template (ECCGxxx-TEMPLATE). 3. Also drill the side holes (C) using given template (ECCGxxx-TEMPLATE). 4.

  • Page 33: Motor Bracket Installation For Head Gate And Intermediate Gate

    4. Electric Operated Gate Installation Motor Bracket Installation for Head Gate and Intermediate Gate 1. Install the motor bracket (C) to the gate. Then attach the motor (A) to the bracket (C) as shown in Figure 4C, using the provided hardware (F and G). Head gate section Assembled motor bracket view for intermediate gate...

  • Page 34: Limit Switch Installation Of Head Gate And Intermediate Gate

    4. Electric Operated Gate Installation Limit Switch Installation of Head Gate and Intermediate Gate 1. Limit switches (B) are installed on inside the gate frame (C). 2. Install limit switch (B) on the bracket (D) as shown and then fit the bracket (D) to inside of gate frame (C) using the provided hardware (E, F, G and H).
  • Page 35 4. Electric Operated Gate Installation 7. Install switch levers vertically. When the switch target on the gate push in the limit switch arm vertically, the motor will stop. (See Figure 4E and Figure 4F.) Figure 4E Closed Position Ref # Description Switch Target Located on Gate Closed Lever Position...

  • Page 36: Install Gate To Trough Bottom Of Intermediate Gate And Head Gate

    4. Electric Operated Gate Installation Install Gate to Trough Bottom of Intermediate Gate and Head Gate 1. Attach the gate (A) to the connection flanges and trough bottom using supplied hardware (B and C). (See Figure 4G.) 2. Seal all connections with a silicon based caulk to make weather-resistant. Head gate section Intermediate gate section Figure 4G...

  • Page 37: Flipping The Shaft To Change Gate Drive Side

    4. Electric Operated Gate Installation Flipping the Shaft to Change Gate Drive Side 1. Loosen set screws (A) for shaft on both bearings. (See Figure 4H.) 2. Remove bearing on the long side of the shaft (B). 3. Flip shaft (B) and re-install bearing (C). 4.

  • Page 38: Slack Chain Detector And Plug Switch

    4. Electric Operated Gate Installation Slack Chain Detector and Plug Switch 1. Attach the two (2) plates (C and D) with the guide (A) and install it on the cover (B) by using bolt (F) and nut (G). (See Figure 4I.) 2.

  • Page 39: Chapter 5 Electrical Installation

    5. Electrical Installation Example electrical control with safety circuit. (See section electrical safety on Page 15.) Figure 5A NOTE: The parts pointed out on this page are listed on Page PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 40 5. Electrical Installation Ref # Description Power Supply with RCD Protection Control Isolator Short Circuit Protection Safety Contactor 3 Pole Motor Over Current Relay Motor Starter Contactor Motor Service Disconnect H and I Control Transformer Primary Protection Fuses Control Isolating Transformer Control Transformer Secondary Protection Fuse Safety Circuit Re-Set M and N...

  • Page 41: Chapter 6 Reducer Lubrication

    6. Reducer Lubrication Figure 6A PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...
  • Page 42 6. Reducer Lubrication SK0182NB A 0,40 0,55 0,60 0,55 0,35 0,35 SK0282NB A 0,70 1,00 0,80 1,10 1,10 0,90 SK1282 A 0,90 1,30 0,90 1,20 0,95 0,95 SK2282 A 1,65 2,40 1,90 2,00 1,80 1,80 SK3282 A 3,15 4,10 3,25 4,10 3,15 3,15...

  • Page 43: Lubricant Table

    6. Reducer Lubrication Lubricant Table 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. Din (ISO)/ Lubricant Details on...

  • Page 44: Start-Up And Break-In

    6. Reducer Lubrication Start-Up and Break-In NOTE: Gearbox is supplied WITH OIL. See lubrication table on Page 43 and manufacturer’s instructions for OIL spec. 1. Check proper motor shaft rotation before installing drive. 2. Rotate the chain, now on the sprockets, at least one complete revolution. Check to see that the chain and its wear pads are not catching on flanges or rubbing on the trough sides due to the sprockets not being centered within the box.

  • Page 45: Chapter 7 Maintenance

    7. Maintenance 1. Check all bearings and moving parts daily during use. 2. Lubricate bearings at regular intervals to bearing manufacturer’s recommendations. If one bearing is re-lubricated, all other bearings should also be lubricated. Do not over lubricate as this will destroy bearing seals.

  • Page 46: Chapter 8 Optional Components

    8. Optional Components ‘Whirlygig’ Motion Sensor Figure 8A ‘Whirlygig’ Motion Sensor Ref # Description 10 mm Screws Four (4) (Supplied) 18/30 mm Bracket (Supplied) Cylindrical Sensor M800 Sensor Whirligig Cover Tap Shaft for 1/2'' (12 mm) UNC Centered Machine Shaft Flexible Strap Flexible Conduit 50 mm Screws Four (4) (Supplied)

  • Page 47: Chapter 9 Troubleshooting

    9. Troubleshooting Problem Cause Solution 1. Improper chain speed. 1. Check the shaft RPM. 2. Loose chain. 2. Check the sag between idlers. Low capacity 3. Improper feed. 3. Check the grain level at inlet. 4. Plugging. 4. Check the discharges. 1.
  • Page 48 NOTES PNEG-1993 CE Compliant E-Series Chain Conveyors - All Models...

  • Page 49: Chapter 10 Warranty

    GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
  • Page 50 Authorities having jurisdiction should be consulted before installations are made. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com GSI is a worldwide brand of AGCO Corporation. Copyright © 2016 by The GSI Group, LLC Printed in the USA CN-323442...

This manual is also suitable for:

225 w x 225 t300 w x 225 t300 w x 300 t375 w x 300 t

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