Table of Contents
Troubleshooting
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Summary of Contents for GSi GSS-U
- Page 1 AFETY STALLATIO ON PERATION AINTENAN NCE M A N U U A L SAMP PLER del GS SS‐U o. PC 519 9824C evised 200 9‐08‐07 9575 N. Ave. Omaha, Nebra ska 68142 (402) 330‐1500 ...
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Page 2: Table Of Contents
Table of Contents I. GENERAL SAFETY INFORMATION ........................3 II. GENERAL INFORMATION ...........................5 2.1 System Description ..........................5 2.2 Optional Features ...........................6 2.3 Material Sampled ............................6 2.4 Sampler Construction ..........................6 III. GENERAL INSTALLATION REQUIREMENTS ....................7 3.1 Receiving Inspection..........................7 3.2 Pre-Installation Preparation ........................7 3.3 Location ..............................7 3.4 General Mounting Guidelines .........................7 3.4.1 Factory Pre-Mounted Sampler......................8... - Page 3 FIGURE 4-1, STANDARD NEMA 4 CONTROL PANEL DETAIL................11 FIGURE 4-2, PRINTED CIRCUIT BOARD.......................15 FIGURE 4-3, LIMIT SWITCH CONNECTIONS ......................17 FIGURE 5-1, LIMIT SWITCH CAM ADJUSTMENT ....................20 DRAWING 525255, GSS-U SAMPLER DRIVE END SECTION VIEW..............28 DRAWING 525256, GSS-U SAMPLER DISCHARGE END SECTION VIEW & PARTS LIST ........29...
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Page 4: General Safety Information
I. GENERAL SAFETY INFORMATION SAFETY FIRST! The symbols shown identify examples of the safety labels and signs to be found on Intersystems equipment. They are affixed to the equipment to warn of danger persons possible equipment damage. These signs must never be removed, tampered with, painted over or obscured in any way. - Page 5 FIGURE 1-1, GSS-U SAMPLER SAFETY LABEL LOCATIONS...
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Page 6: General Information
The GSS-U Sampler is designed to collect a representative sample of granular, flake, powder, or other materials in a gravity conveying line or from a hopper tank. Figure 2-1 illustrates a typical GSS-U Sampler application. Sample collection is initiated in response to either an operator's manual command or a signal automatically generated by controller logic, usually time-based but which could also be volume or quantity based. -
Page 7: Optional Features
304 Stainless Steel. The auger is machined from a solid bar (no welds on flights) and hand polished. The sanitary GSS-U sampler design allows for quick removal of the auger and auger tube for easy clean-out and washing. Other materials and/or finishes appropriate to the operating environment and the material or product being sampled may be used. -
Page 8: General Installation Requirements
3.3 Location The GSS-U sampler is typically mounted horizontally onto a vertical gravity flow conveying line carrying the product to be sampled as in Figure 2-1. The sampler axis must be installed perpendicular (at a 90 degree angle) to the axis of the product line for optimum performance. -
Page 9: Factory Pre-Mounted Sampler
NOTE: IF THE SURFACE AREA TO WHICH THE MOUNTING PLATE IS TO BE ATTACHED IS WARPED OR BENT, STRAIGHTEN AND SMOOTH THE METAL SO THE SAMPLER WILL BE PROPERLY ALIGNED WHEN THE INSTALLATION IS COMPLETE. THE SURFACE TO WHICH THE SAMPLER IS MOUNTED MUST NOT FLEX. -
Page 10: Material Sample Transport Lines
I. Tack weld the sides of the mounting plate to the product line surface and double check alignment. Also from the inside of the chute weld a continuous bead around the 4" diameter clearance hole. J. Re-install the auger tube an re-verify that the auger tube rotates without interference. K. -
Page 11: System Wiring
3.7 System Wiring Refer to the certified electrical drawing(s) for specific wiring requirements. As explained in Paragraph 4.1.9.9, the 20-position barrier terminal strip on the circuit board mounted INSIDE the controller enclosure is the connection point for ALL external circuitry. The controller was completely assembled and tested with the sampler before it left the factory. -
Page 12: Operations And Adjustments
IV. OPERATIONS AND ADJUSTMENTS DANGER FAILURE TO OBSERVE ALL SAFETY RULES, WRITTEN AND IMPLIED, AND THOSE SUGGESTED BY COMMON SENSE, CAN RESULT IN DEATH, SERIOUS INJURY, AND /OR EQUIPMENT DAMAGE. LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE. 4.1 Control Components And Their Functions FIGURE 4-1, STANDARD NEMA 4 CONTROL PANEL DETAIL Refer to the certified electrical drawing(s) for dimensions on control panels with optional features. -
Page 13: Power Off/On Switch S-2
4.1.1 POWER OFF/ON Switch S-2 This toggle switch controls all electrical power to the controller and the sampler unit. WARNING THIS MACHINE STARTS WITHOUT WARNING. MOVING PARTS CAN CAUSE SEVERE INJURY. CLEAR AREA PRIOR TO CONTROLLER START-UP. 4.1.2 SAMPLING MODE Switch S-3 (Automatic/Manual) This switch permits the operator to select whether samples will be collected automatically at precisely timed or counted intervals as determined by the Digital Display Timer (T-1) or Counter C-1, OR manually whenever the operator momentarily actuates the MANUAL SAMPLING toggle switch (S-4). -
Page 14: Digital Display Timer T-1 (Standard)
4.1.7 Digital Display Timer T-1 (Standard) As arranged for use in this system, the timer operates in the DOWN & STOP mode. When the AUTO mode is selected, the illuminated display resets to the value dialed in to the Three Digit Preset. Immediately, the timer begins timing down. -
Page 15: Digital Display Counter C-1 (Optional)
4.1.8 Digital Display Counter C-1 (Optional) As arranged for use in this system, the counter operates in the DOWN & STOP mode. When the AUTO mode is selected, the illuminated display resets to the value dialed in to the Three Digit Preset. Immediately, the counter begins counting down. -
Page 16: Printed Circuit Board
4.1.9 Printed Circuit Board The circuit board mounted inside the controller enclosure controls the clutch solenoid and auger motor and serves as the connection point for all sampling system circuitry. Figure 4-2 illustrates a typical board. Depending upon the options selected there may be minor differences. -
Page 17: Solenoid Timer Switches (Tens & Ones)
NOTE: GSS-U SAMPLERS REQUIRE THE MODE SWITCH TO BE POSITIONED ON SETTING "2" (TWO). IF THE MODE SETTING IS NOT CORRECTLY SET, TURN POWER OFF TO THE CONTROL PRIOR TO RE- SELECTING. -
Page 18: 115V/230V Switch
Correct wiring termination is essential to proper sampler operation. Refer to figure 4-3, it shows the limit switch utilized on the GSS-U sampler and the physical orientation of the proper wiring connections. FIGURE 4-3, LIMIT SWITCH CONNECTIONS 4.2.2 Drive Motor... -
Page 19: Clutch Solenoid
4.2.3 Clutch Solenoid This solenoid, when energized, pulls the clutch actuator from the catch on the clutch and allows the clutch to engage. The output shaft on the gear reducer rotates the clutch and clutch gear which in turn rotates the auger tube. -
Page 20: Maintenance And Repair
V. MAINTENANCE AND REPAIR DANGER FAILURE TO OBSERVE ALL SAFETY RULES, WRITTEN AND IMPLIED, AND THOSE SUGGESTED BY COMMON SENSE, CAN RESULT IN DEATH, SERIOUS INJURY, AND /OR EQUIPMENT DAMAGE. LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE. 5.1 General Maintenance A good maintenance program involves thorough general housekeeping, adequate periodic re-lubrication, and replacement of worn or damaged components. -
Page 21: Gear Reducer
5.3.2 Gear Reducer The gear reducer is shipped filled with oil. Check the oil level every six months and add oil if required. Under normal sampler operating conditions the oil should be changed once every two years. Use "Hub City #GL-460" gear lubricant, AGMA number 7 Comp., or equal. Lubricant must be compatible with bronze gear materials and nitrile rubber seals. -
Page 22: Clutch Solenoid Replacement And Adjustment
E. Make sure the thrust washers are in place on the auger shaft. Re-install the cover and gasket to the sampler drive housing. F. Re-install the cover fasteners and tighten. 5.4.2 Clutch Solenoid Replacement And Adjustment When following the instructions below, refer to the applicable drawing of the sampler. Reference the drawings in Section VII and the certified drawing(s). -
Page 23: Clutch Replacement & Timing
5.4.3 Clutch Replacement & Timing When following the instructions below, refer to the applicable drawing of the sampler. Reference the section drawings of the sampler on pages 28 & 29, and the certified drawing(s). A. Shutoff and lockout all power. B. -
Page 24: Troubleshooting
VI. TROUBLESHOOTING 6.1 General GSS-U Sampler Troubleshooting DANGER CARELESS OR ACCIDENTAL RESTORATION OF POWER CAN RESULT IN DEATH OR SERIOUS INJURY. MAKE CERTAIN AREA IS CLEAR BEFORE REMOVING LOCKOUTS. SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Sampler does not cycle in either Power switch OFF. -
Page 25: Pc Board Troubleshooting
Correct. See note below. NOTE: GSS-U SAMPLERS REQUIRE THE MODE SWITCH TO BE POSITIONED ON SETTING "2" (TWO). IF THE MODE SETTING IS NOT CORRECTLY SET, TURN POWER OFF TO THE CONTROL PRIOR TO RE- SELECTING. THE PC BOARD WILL ONLY CHANGE MODES WHEN POWER IS INITIALLY APPLIED. -
Page 26: Replacement Parts
VII. REPLACEMENT PARTS 7.1 Scope The certified drawings list the non-standard components that have been incorporated into the equipment. Intersystems normally stocks non-fabricated parts and non-custom OEM parts. Replacement parts for any other components, including fabricated parts and custom OEM components can be supplied upon request. 7.2 Ordering Parts Direct parts orders or requests for technical assistance to your sales representative or to: Intersystems... - Page 27 This page intentionally left blank...
- Page 28 REPLACE THIS PAGE WITH DRAWING 525255...
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Page 29: Drawing 525255, Gss-U Sampler Drive End Section View
REPLACE THIS PAGE WITH DRAWING 525256... -
Page 30: Warranty
VIII. WARRANTY Intersystems 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 manufactured equipment and components are guaranteed against defects in workmanship or materials for one year from date of shipment.
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