Bucket Elevator - GAME Engineering · the UK. This directive is concerned with the safety of the workplace and places responsibility on the end user to risk assess their workplace

Bucket Elevator Manual

Guttridge Page 1 of 76

Please read this manual before

commencing installation, operation

or maintenance

Installation, Operation and Maintenance

Manual

Bucket Elevator

Machine No



Guttridge

Tel: +44 (0) 1775 765300 Fax: +44 (0) 1775 765301 Web: www.guttridge.co.uk Email: [email protected]

Wardentree Park, Pinchbeck, Spalding, Lincolnshire, PE11 3UU, ENGLAND


Revision 16 – Dated 09/02/15

Copyright © 2011 Guttridge Limited, All Rights Reserved.



Health and safety

Risk assessment requirements

Installation

It is the responsibility of the installation engineer in conjunction with the end user, to carry out a risk assessment. This is to ensure that the installation, and access for the subsequent operation and maintenance of the equipment, can be carried out in a safe manner.

Operation and maintenance

It is the responsibility of the end user to carry out a risk assessment, to ensure the safe operation and maintenance of the equipment.

Operation

DO ensure all guards and access panels are fitted and in good condition. DO ensure all safety devices and operating interfaces are working correctly. DO ensure all electrical equipment is in good condition and electrical covers are fitted.

DO NOT run the machine without the inlet and outlet apertures properly connected to the mating equipment, or suitable guards or covers in place.

Maintenance

DO ensure safe working access to the equipment, especially when working at height. DO ensure the machine is switched off and electrically isolated before carrying out any maintenance work. DO follow in house plant and maintenance procedures. DO ensure any replacement parts that are fitted are of the correct type.

DO NOT modify any safety features fitted to this machine. DO NOT modify guards.

declaration The equipment conforms to all current EU directives and carries

the marking.



Explosive Atmospheres Assessment (ATEX)

The ATEX 137 Workplace Directive 1999/92/EC, (also known as the ‘Use’ Directive) is implemented by the Health and Safety Executive (HSE) as The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) in the UK.

This directive is concerned with the safety of the workplace and places responsibility on the end user to risk assess their workplace and zone and mark hazardous areas according to their level of risk for gases and dusts. The zones correspond to the Group II Categories 1-3 in the ATEX equipment directive and enable end users to correctly specify to the manufacturers the intended use of ATEX products. Manufacturers can then supply the right category of ATEX equipment (certified under 94/9/EC) to be used within these zones. See www.guttridge.co.uk/atex_information for further information.

Where a machine has been specified to be ATEX compliant, it must only be used in the ATEX zone specified at the time of ordering. Alert symbols used in this manual

Where applicable the ATEX rating of the machine referred to in this manual can be determined from the identification label attached to the machine

Group II

Zone Category

Gas Dust

0 20 1

1 21 2

2 22 3

This symbol is to warn of a potential safety hazard

This symbol is to warn of a potential electrical safety hazard

This symbol denotes an item or operation that MUST be complied with in order to ensure that ATEX integrity is maintained

ATEX label on subject machine may differ slightly.

For illustration only.

Figure 1

http://www.guttridge.co.uk/atex_information



How to use this manual

Purpose of this manual

This manual is provided as a guide to:

The equipment installer Machine operatives Maintenance personnel

on the best way to install, operate and maintain the equipment.

Competence

This manual assumes that the people who install, operate and maintain this equipment have been adequately trained in general engineering installation, machine operation and maintenance respectively, and are experienced and competent to carry out the work.

Scope of manual

All information in this manual is believed to be correct and is provided in good faith. If you require further assistance please contact Guttridge Limited.

Layout of manual

Most pages in this manual refer to the machine or to a procedure in general terms. However, where applicable, machine specific operating procedures, drawings or parts lists will be included under particular section headings. In some cases a machine specific appendix will be included with this manual.

Technical information or operating instructions for particular components on the machine may also be included as an appendix to this manual.

Manual retention

This manual is an important document, and is an integral part of the machine, that should remain with the equipment throughout its life.



1. Machine Installation __________________________________________________ 8

1.1. General _____________________________________________________________ 8

1.2. Safety _______________________________________________________________ 8

1.3. Boot section __________________________________________________________ 8

1.4. Inspection door section_________________________________________________ 8

1.5. Intermediate (leg) sections ______________________________________________ 8

1.6. Joint sealing _________________________________________________________ 10

1.7. Erection procedure ___________________________________________________ 11

1.8. Access platform installation (where applicable) ____________________________ 12

1.9. Access platform ladder installation (where applicable) ______________________ 14

1.10. Belt fitting __________________________________________________________ 14

1.11. Joining of belt _______________________________________________________ 15

1.12. Fitting buckets _______________________________________________________ 16

1.13. Belt Tensioning ______________________________________________________ 17

1.14. Belt alignment _______________________________________________________ 19

1.15. Bearings ____________________________________________________________ 20

1.16. Shaft seal (optional) __________________________________________________ 20

1.17. Deflector ___________________________________________________________ 20

1.18. Inlet flow control (optional) ____________________________________________ 20

1.19. Inlet assembly position ________________________________________________ 21

1.20. Drives ______________________________________________________________ 22

1.21. Backstop ___________________________________________________________ 22

1.22. Shaft mounted speed reducer __________________________________________ 22

1.23. Motor/Gearboxes ____________________________________________________ 22

1.24. Explosion Venting ____________________________________________________ 23

2. Electrical Installation ________________________________________________ 24

2.1. General ____________________________________________________________ 24

2.2. Motors _____________________________________________________________ 24

2.3. Rotation sensor (optional) _____________________________________________ 25

2.4. Belt alignment sensors ________________________________________________ 30

2.5. Explosion venting panels ______________________________________________ 30

3. Drawings and Illustrations ____________________________________________ 31

4. Commissioning run __________________________________________________ 34

4.1. Starting ____________________________________________________________ 34

4.2. Post commissioning checks_____________________________________________ 37

5. Operation _________________________________________________________ 38



5.1. Operating principle ___________________________________________________ 38

5.2. Limitations __________________________________________________________ 38

5.3. During operation _____________________________________________________ 38

5.4. Stopping ____________________________________________________________ 38

6. Maintenance _______________________________________________________ 39

6.1. General ____________________________________________________________ 39

6.2. During operation _____________________________________________________ 39

6.3. Routine Maintenance _________________________________________________ 39

6.4. Maintenance intervals ________________________________________________ 42

6.5. Bearings ____________________________________________________________ 42

6.6. Bearing housing – removal and refitting __________________________________ 43

6.7. Lubrication of sealed for life bearings ____________________________________ 45

6.8. Taper lock bush ______________________________________________________ 46

6.9. V belts _____________________________________________________________ 47

6.10. Drive chain __________________________________________________________ 48

6.11. Drive chain lubrication ________________________________________________ 49

6.12. Packing gland seals ___________________________________________________ 50

6.13. Shaft mounted gear motor unit (GMU) removal ____________________________ 53

6.14. Air/Nitrogen purged seal (optional) ______________________________________ 54

7. Trouble shooting ____________________________________________________ 55

8. Reference __________________________________________________________ 56

9. Weights ___________________________________________________________ 57

10. Parts ____________________________________________________________ 58

List of applicable data sheets

EL01 - BAP2 Motion Alignment Sensor (optional)

EL02 - TouchSwitch™ Installation and Set-Up (optional)

ME05 - Shaft Mounted Speed Reducer (optional)

ME06 - Explosion Panels (optional)



1. Machine Installation

Please read these instructions completely before attempting to start installation. A layout sketch marked 'CUSTOMER SITE COPY' is normally supplied with every machine, read it in conjunction with these instructions. Check all items against delivery note.

1.1. General

Where a machine has been specified to meet a specific ATEX standard, it should only be installed in the area it was designed for, as detailed on the machine identification label. Refer to page 4 for example.

Should a customer consider moving an ATEX compliant machine to a non-ATEX area, consideration should be given to removing all references to ATEX compliance, as subsequent maintenance levels could compromise the ATEX rating of the machine.

1.2. Safety

Whilst Guttridge Limited machines are supplied as precision made components, designed for ease of installation and assembly, installation should always be carried out by competent, trained installation engineers to ensure that the finished machine is correctly assembled and that this has been carried out safely with no hazard to either installing engineer on site or subsequent operators.

It is the responsibility of the installing engineers to ensure that safe access to the installation position is provided to eliminate any hazards to installing personnel.

The installer should also ensure that correct and adequate lifting devices are provided to enable heavy components to be correctly positioned. Ensure that these lifting devices are securely and correctly fixed and supported and that all normal precautions for safety are taken whilst lifting is in progress.

Leg sections should be tied to adjacent walls or floors at intervals of not more than 6 metres. This interval should be reduced to 3 metres for outdoor installations in exposed positions. See illustration below.

1.3. Boot section

Bolt the elevator boot to the floor using fixing holes provided.

Ensure the top flange, to which the intermediate sections are to be bolted, is level before proceeding. This is to ensure that the completed assembly is vertical. Failure to do so could cause the belt to run off true and damage the machine.

1.4. Inspection door section

The inspection door section is best installed on the “up” leg of the elevator and must be fitted with a sealing strip.

1.5. Intermediate (leg) sections

The riveted side of the intermediate section is usually fitted on the outside of the elevator.



Where an optional pressure relief panel is fitted, it should always face outwards. It must be fitted so that should it operate any personnel in the vicinity will not at risk.

At every section joint a leg joint plate must be fitted to ensure the elevator remains stable.

3m

3m

3m

3m

6m max

6m max

Conveyor installed OUTSIDE

Conveyor installed INSIDE



1.6. Joint sealing

On outdoor machines and those requiring a dust proof seal, a suitable mastic compound should be applied to the flanges prior to bolting them together.

The machine installer is responsible for ensuring that the machine is suitably earthed using appropriate flange attachment points1 and a proven grounded earthing point.

Care should be taken to ensure that ALL parts of the machine are properly earthed and no potential difference (PD) is introduced by the use of sealants or jointing materials between sections or components.

Should a PD be identified or suspected, this can be eliminated by bonding each section of the machine to an adjoining section or by earthing that part of the machine to a proven grounded earthing point.

Before starting the equipment ensure that no personnel are working on the equipment and that no tools or loose items have been left in the casing or any other part of the machine.

1 Guttridge Limited recommend earthing links comprising 6mm2 stranded cable terminated with 6mm crimped eyelets secured with M6x25 hex head screws complete with nuts and washers

For NON-ATEX applications GSL recommend SIROFLEX® Polyflex HM. An equivalent may be used, providing the specification is identical.

For ATEX rated machines GSL recommend SIROFLEX® SX High Temperature Silicone. An equivalent may be used, providing the specification is identical.



1.7. Erection procedure

Before assembly refer to any assembly drawings provided, to ensure that sections are assembled in the correct order. As a further aid, all leg sections are numbered at each end and match the number on the adjoining section.

1

6 1 2 2 3 3 4 4 5 5 6

We recommend the following erection procedure:

With the boot section (1) securely fixed to the floor, lift the first section of elevator leg (2) on to it and bolt into place. Repeat for the other leg of the pair (3).

Bolt on the leg joint plate (4) at each joint during erection.

Repeat for all legs (5) & (6).

Lift head section (7) of elevator into place and secure.

Alternatively, the head section can be attached to a lifting device and then raised above the ground sufficiently to have the leg sections fitted. Not recommended for more than 2 pairs of leg sections.

When erection is complete, all sections must be checked for alignment and the elevator checked for being vertically true.

Check the surface finish of the machine to ensure that it has not been damaged during the assembly process.

Where the paint surface has been broken or where bare metal has been exposed, the finish should be restored as soon as possible, especially where a machine is being installed outside or in harsh conditions. This is particularly important where the machine has been installed to comply with ATEX standards.

Care should be taken to ensure that ALL parts of the machine are properly earthed and no potential difference (PD) is introduced by the surface finish or by the use of sealants or jointing materials, between sections or components.

Should a PD be identified or suspected, this can be eliminated by bonding each section of the machine to an adjoining section2 or by earthing that part of the machine to a proven grounded earthing point.

2 Guttridge Limited recommend earthing links comprising 6mm2 stranded cable terminated with 6mm

crimped eyelets secured with M6x25 hex head screws complete with nuts and washers

90o

1

3 2

5 6

7

4



Caution: When determining the height the access platform is to be fitted at, a check should be made of the working height that will be achieved i.e. can all parts of the head assembly be reached from the platform floor WITHOUT the use of any form of step stool or step ladder.

The use of a step stool or step ladder will compromise the safe working height of the safety rail around the access platform.

If it is found necessary to fit the access platform at a height that could require maintenance personnel to use a step stool or step ladder on the access platform, a risk assessment should be completed and serious consideration

given to the installation of an increased height safety rail.

1.8. Access platform installation (where applicable)

Clamp bars are provided with the access platform to facilitate positioning of the platform support stays, prior to fitment of the platform.

To facilitate assembly, the platform support stays may be assembled to the elevator legs prior to lifting them in to place.

Keeping in mind the above caution, distance X in the figure below, should be approximately 100cm. This is the distance from the centre line of the head pulley to the top face of the floor panel.

If a precise elevator decking height is required, e.g. to match up with an existing platform, position the platform support stay upper horizontal cross member, 30mm below the required platform height.

Where exact positioning is not required, the platform support stay bracket assembly can be located by resting the upper and lower horizontal stays against a convenient set of leg cover fasteners. Refer to caution note above.

Position each platform stay bracket assembly against the leg trough cover. Position a clamp bar (2 off) on the inside face of the leg trough. Secure together using the threaded bar and nuts supplied.

Once the horizontal stay brackets assemblies (2 off) have been clamped to the elevator legs, they must be fully secured by bolts through the leg flanges.

Using the two inner holes in each horizontal stay bracket as a guide, drill through the leg flange to accommodate a M12 bolt.

Secure each bracket to leg using 2 off, M12 x 30 hex head bolt, M12 plain washer and M12 Nyloc nut.

Repeat for second elevator leg.

The platform can now be lowered on to the stay brackets and secured using supplied bolts, once the leg assemblies are in place.

Fit the angled bracing strut between the lower horizontal stay bracket and the underside of the platform.

Care should be taken to ensure that the assembled platform is properly earthed and no potential difference (PD) is introduced by the surface finish or by the use of



sealants or jointing materials, between the individual sections of the platform, or between the platform and the machine itself.

Should a PD be identified or suspected, this can be eliminated by bonding each section of the platform to an adjoining section3 or by earthing that part of the machine to a proven grounded earthing point.

3 Guttridge Limited recommend earthing links comprising 6mm2 stranded cable terminated with 6mm crimped eyelets secured with M6x25 hex head screws complete with nuts and washers

Drill thorough inner holes on horizontal stay bracket and leg casing flange to secure access platform stay bracket assembly to casing.

Repeat for second stay bracket assembly. Do not attempt to use the access platform without these bolts in place.

Upper clamp bars

2 off

Platform stay bracket

assembly 2 off

Angled bracing strut 1 off

Lower clamp bars

2 off

Access ladder

Safety gate

Note: Platform floor panels have been omitted from the drawing for clarity

X



In order to avoid danger to personnel, the platform floor panels should be attached to the platform using the clips provided, before the ladder is attached and available for use. If the ladder is to be attached before the floor panels are in place and secured, the ladder should be closed off at its base to prevent use until the floor panels are fitted.

1.9. Access platform ladder installation (where applicable)

Bolt access ladder assembly to access platform base and secure lower end of ladder using the anchor bracket supplied.

Finally, fit the safety gate to the platform rails at the top of the access ladder.

1.10. Belt fitting

The belt is heavy and must be handled in such a way to ensure that it is always balanced or clamped to prevent it running around the top pulley. Failure to do so could lead to serious injury.

Fit the eye assembly to the belt and feed it into the elevator either by: a) Lifting the belt to the top of the elevator and threading the belt over the top pulley and down each leg. or b) Pass a stout rope from the top of the elevator down the “up” leg. At the inspection door fasten the rope to the eye assembly on the belt and haul it over the top pulley, then pass it down the “down” leg.

Typical belt weight

Belt thickness Weight per m2 in kgs

5.2mm 6.5

7.0mm 8.0

8.5mm 10.0

Note: To calculate the weight of the belt fitted to a particular size of machine, the following information is required:

1. Length of belt 2. Width of belt 3. Belt weight per m2 for given belt thickness. To determine the overall weight of the belt as fitted to the machine, the weight of the buckets will also need to be included. Bring the belt ends to the inspection door. Ensure the trailing edge of the belt is secured to prevent it running over the top pulley under its own weight.

Belt Material Details

Belt Type Covers Carcase Max operating temperature

Standard Styrene Butadienne

Rubber Polyester fabric warp and polyamide weft

separated by 0.3mm SBR rubber 70oC

Optional Nitrile Butadienne

Rubber Polyester fabric warp and polyamide weft

separated by 0.3mm NBR rubber 80oC

All belts are categorised as anti-static by manufacturer



1.11. Joining of belt

Care must be taken not to over tension the belt, as this could lead to bearing failure. Standard belts are made from synthetic materials with a maximum stretch of 2%.

Note: The elevator capacity may be reduced if the bottom pulley is set above halfway in its adjustment slots.

Initially, the bottom pulley adjustment should be set to its highest point. However, there is a possibility that, where a particularly short belt is being installed, the bottom pulley could remain above the halfway point in the adjustment slots after final tensioning. The installing engineer should therefore take this in to consideration when setting the top pulley position.

The top pulley is factory set to the mid position to allow for belt tracking adjustment and should not be disturbed at this time.

Fit the ratchet tensioner (Tirfor) (not supplied) to the eye assemblies, as illustrated below and tension. As a rule of thumb good initial tension is achieved when it is possible to pull the belt to the front of the casing and some resistance is felt. If unsure seek advice from an experienced person.

NB: Backing bars are supplied for fitment under the nuts securing the eye assemblies to the belt sections. This will avoid the possibility of the bolts being pulled through the belt during tensioning.

When the correct initial tension has been achieved, drill holes in the belt and fit clamp bars as illustrated.

NB: It is vitally important that the clamp bars remain square to the edge of the belt and that the edges of each belt section remain in line once the clamp bar securing bolts have been tightened up.

Trim off excess belting to within 25mm of clamp bar.

Tensioning tool (not supplied)

Bucket

Eye assembly

Clamp bars

IMPORTANT NOTE:

To prevent damage to the belt leading to possible belt failure, ensure all clamp bar corners and edges are well rounded

90◦

Backing bar

Backing bar

Belt joining



Bucket Belt

In some instances a Gripwell7 belt fastener system will be supplied as an alternative to the backing bars illustrated in figure above.

When the joint has been completed, remove the tensioning tool and eye attachments.

Final belt tensioning is achieved by lowering the bottom pulley to ensure the belt drives without slippage. This must be done evenly on each side to ensure that the belt runs centrally on the pulley during operation. See section 1.13 for full details.

1.12. Fitting buckets

Bolt the buckets to the belt. It is advisable to fit a bucket to every 4th pitch initially to avoid having the belt out of balance.

For steel buckets use the special bucket bolts provided and secure with a plain nut and star washer and tighten to a torque of:

M8 = 11Nm (8lb ft) M10 = 22Nm (16lb ft) Alternatively use Nyloc nuts for extra security.

Bucket attachment detail and recommended torque loadings

If nylon or polythene buckets are used it is recommended that a plain washer is fitted under the head of the nut to prevent damage. Nyloc nuts may be used for extra security where bucket flexing could be an issue.

Bucket options

Type Notes

Pressed mild steel

Reinforced steel Has wear strip to leading edge

Plastic

HDP/Nylon/Polyamide Warning

Do not use with materials that will create static electricity when rubbed against bucket material

Gripwell belt fastener

Nylon insert self locking

nut

5/16” Whitworth high tensile plated

bolt

25mm

Square neck



Once the belt and buckets have been fitted and the belt correctly tensioned a final check of the bucket clearances should be carried out to ensure that there will be no contact when the machine is running.

These checks are particularly important where a bucket is being replaced or refitted once the machine is in service and the atmosphere within the elevator is potentially flammable or explosive.

Bucket clearances in mm

Model HL150 HL230 HL300 HL370

Tip to front casing 17 58 69 59

Side to side casing 29 34 43 54.5

Belt to side casing 20 25 32 30

1.13. Belt Tensioning

Initial belt tensioning is achieved by adjustment of the bottom pulley bearing adjusters.

Two types of bottom bearing adjuster may be encountered. The procedure for each is detailed below.

Adjustment of Mk2 type bearing mounts

1. Loosen bolts (1) (6 off) securing bearing slider plates on both sides of boot assembly.

2. Slacken off nuts (2 & 3) on both threaded adjuster rods. Depending on whether the belt is to be tensioned or loosened, back off the appropriate nut along the threaded bar so that it does not bind as the rod moves through the mounting plate.

3. To tension the belt, turn nut (3) anti-clockwise (when viewed from above) so that the bearing assembly is pushed down the bearing sliders. Adjustment should be carried equally and in stages on both sides of the boot assembly. Excessive adjustment on one side only, may lead to adverse belt alignment or excessive side loading on the lower pulley bearings, leading to early bearing failure.

4. Check that any adjustments have been applied equally to both bearing adjusters by measuring distance X on both sides of boot assembly.

5. Tighten down nuts (2 & 3) to lock position of adjuster rod. Both sides.

6. Tighten bolts (1). Both sides.

7. The clearance between the buckets and the bottom plate of the boot assembly should be checked at this stage. Insufficient clearance once all other adjustments have been made, may indicate a need to shorten or replace the belt.

1 1

2

3

X

Note: The elevator capacity may be reduced if the bottom pulley is set above halfway in its adjustment range.



Adjustment of older type bearing mounts

1. Loosen nuts (1) (4 off) securing flange bearing on both sides of boot assembly.

2. Slacken off nuts (2 & 3) on both threaded adjuster rods. Depending on whether the belt is to be tensioned or loosened, back off the appropriate nut along the threaded bar so that it does not bind as the rod moves through the mounting plate.

3. To tension the belt, turn nut (2) clockwise so that the bearing mounting plate is pushed down the guide assembly. This should be done equally in stages on both sides of the boot assembly. Excessive adjustment on one side only, may lead to adverse belt alignment or excessive side loading on the lower pulley bearings, leading to early bearing failure.

4. Check that any adjustments have been applied equally to both bearing adjusters by measuring distance X on both sides of boot assembly.

5. Tighten down nuts (2 & 3) to lock position of adjuster rod. Both sides.

6. Tighten nuts (1) (4 off). Both sides.

7. Belt alignment and tracking should now be checked.

8. The clearance between the buckets and the bottom plate of the boot assembly should be checked at this stage. Insufficient clearance once all other adjustments have been made, may indicate a need to shorten or replace the belt.

1 1

2

3

X

With belt correctly tensioned shaft will be approximately 2/3rd of the way down slot




1.14. Belt alignment

When the elevator is run for the first time check that the belt runs centrally on the top pulley.

If adjustment is required, slacken the four securing bolts on the flanged bearing on the non-drive side at the head of the machine. Then move the bearing up or down using the threaded adjuster to suit, retighten securing bolts. Do not adjust too far as this may cause the drive shaft to rub on the casing or place excessive side loading on the drive side flange bearing.

If further adjustment is necessary this can be done by adjusting the drive side in the same way.

In some cases, it maybe necessary to adjust the belt tensioning adjusters in the elevator boot to fine tune alignment. However, this should only be done after satisfactory belt tensioning and initial alignment has been achieved using the head pulley assembly adjusters.


Securing bolts x 4

Adjusting device

Top pulley adjuster



1.15. Bearings

Sealed for life flanged bearings are fitted as standard, these require little if any lubrication, except in conditions of high ambient temperature or extreme load.

Other types of bearing can be fitted and may require more frequent lubrication. Refer to bearing manufacturer’s website (see Section 8) or contact Guttridge Limited for advice.

1.16. Shaft seal (optional)

Where plummer block or stand off bearings are fitted, seals are fitted to the shafts to prevent product leakage. Standard felt or polyethylene seals are fitted during manufacture and cannot be adjusted, but can be replaced.

1.17. Deflector

Ensure the deflector in the head of the elevator is set to a minimum clearance with the front of the buckets of 2 to 3mm. Too much clearance will mean product may return to the bottom of the elevator, therefore reducing capacity.

1.18. Inlet flow control (optional)

Set the flow of material going into the elevator by adjusting the height of the control slide. This is done by undoing the clamp screw, and raising or lowering the control rod until the correct height is achieved, retighten clamp screw.

Control slide

Clamp screw

Control rod

Deflector and bucket clearance set here.

Deflector plate setting

Inlet flow control



1.19. Inlet assembly position

The elevator is designed to operate with the inlet installed in the HIGH position, for normal UPLEG feed operation.

With the inlet in this position and with the belt tensioning adjuster set at 2/3rds of the way down the adjustment slot, the elevator will be operating at its optimum capacity.

Should the end user require a reduction in throughput on an elevator with the inlet installed on the UPLEG section, the inlet can be repositioned to the low position.

To reposition the inlet assembly, first remove the filler plate fitted to the leg below the inlet.

Remove the inlet assembly and relocate it to the low position, picking up on the holes exposed by the removal of the filler plate.

Refit the filler plate to cover the hole left by the repositioning of the inlet assembly.

Ensure that both the inlet and the filler plate are refitted using an appropriate sealing material.

Where the conveyor is configured for a DOWN-LEG (dredging) feed arrangement, the inlet assembly will normally be fitted in the LOW position.

Inlet assembly – fitted to upleg side of elevator in the UPPER position

Repositionable filler plate

With belt correctly tensioned shaft will be approximately 2/3rd of the way down slot

When fitted to down-leg side of elevator the inlet will normally be fitted in the LOWER position

Inlet positioning



1.20. Drives

The standard drive is a shaft mounted speed reducer, which is driven by a motor via V belts.

Alternatively a direct drive motor/speed reducer linked via a flexible coupling or a directly mounted motor/speed reducer can be fitted. The drive end is supplied ready assembled and comprises of a direct geared motor drive. The gearbox will normally come ready filled with manufacturers recommended type and quality of lubricant. However, this should be checked prior to running the machine for the first time. Refer to separate component IOM for detailed maintenance instructions.

1.21. Backstop

A backstop is either fitted in the shaft mounted speed reducer, the motor gearbox or as a separate item, to prevent the belt rotating in the wrong direction.

Note: Backstop units may not have any markings to indicate the direction of rotation. It is therefore extremely important that the orientation of the unit is marked before any disturbance. Direction of rotation and correct orientation must be determined prior to fitment of any replacement unit.

1.22. Shaft mounted speed reducer

Before running the machine, ensure the speed reducer is filled with the correct lubricant to the required level. See the component data sheet at the back of this manual for further information.

1.23. Motor/Gearboxes

Before running the machine ensure gearboxes are filled with the correct lubricant to the correct level.

Depending on the type of drive unit specified, the gearbox may be a sealed for life unit or require regular checking of the lubrication medium. Always check the separately supplied component manual for any commissioning and maintenance requirements.

The oil level is dependent on gearbox type and orientation. For further information refer to the gearbox manufacturer’s website. (See Section 8). Or contact Guttridge Limited for advice.

Motor gearboxes normally come filled with a standard mineral oil with a viscosity ISO VG 220, which is suitable for ambient conditions of 0˚C to 40˚C.

Speed reducer gearboxes are normally supplied empty. Refer to data sheet at back of this manual for full details.

Below is a table of commonly available oils. Others brands can be used.

Synthetic and food grade lubricants can be used but these must NOT be mixed with the standard mineral oils normally used.

Under filling can lead to bearing or gear failure. Over filling may lead to over heating or oil seal failure.



Mineral Synthetic

BP Energol GR-XP 220

BP Enersyn SG-XP 220

Mobilgear 630

Shell Omala 220

Shell Tivela WB

Kluberoil GEM 1-220

Klubersynth GH 6-220

Optimol Optigear BM 220

Fuchs Renolin CLP 220

1.24. Explosion Venting

(optional) see separate data sheet at back of manual for full details

An explosion vent is a pressure relief device designed to give an instantaneous opening at a predetermined pressure in a closed system. Various types of pressure relief devices can be fitted to protect the machine from excessive pressures caused by a dust or gas explosion. See component data sheet at back of this manual for further details.



2. Electrical Installation

2.1. General

All work must be carried out by a qualified electrician, to current local regulations and codes of practice.

2.2. Motors

Make sure the local mains voltage and frequency matches the motor plate. For additional information refer to manufacturer’s website (see Section 8). Or contact Guttridge Limited for advice.

Wire the motors in to suitable starters, (or the control equipment supplied with the machine if ordered specially).

The starters should then be wired into suitably located isolators.

At this stage the thermal overloads in the starter must be checked and reset if necessary.

The motor should only be inverter driven if specified when ordered; otherwise this could lead to poor start up performance or overheating of the motor.

If the motor runs in the wrong direction it will damage the backstop arrangement or overload the motor. When checking motor direction adopt one of the following procedures:

a) For external backstops, remove the backstop to test motor direction.

b) For internal backstops with a belt drive, remove drive belts.

c) For direct drives with an internal backstop, flash the drive motor for a split second, any longer will damage the backstop.

Before running the motor ensure the drive is disconnected. If the drive is not to be disconnected, ensure that no personnel are working on the equipment and that the equipment will not be damaged by foreign objects or by incomplete assembly of other parts.



2.3. Rotation sensor (optional)

General

An under-speed monitoring system is fitted to the non-drive end of the machine. The system comprises of:

A WHIRLIGIG® unit containing a signal generator to transmit shaft rotation data.

An under-speed monitoring unit (Rotamatic or Rotaslip) to capture and monitor the shaft rotation data.

Operation

Once setup, the unit will monitor the speed of the machine and depending on the specific machine requirements, either shut down the machine or cause an alarm signal/light to be activated.

Installation

WHIRLIGIG® unit

The WHIRLIGIG® unit is attached to the end of the shaft being monitored by a threaded stud using a suitable thread locking adhesive. A flexible strap is provided to secure it to the fixed structure of the machine being monitored.

The WHIRLIGIG® unit has a mounting plate on to which the under speed monitoring unit is either bolted directly or attached by the use of a mounting bracket, depending on the type fitted. See Figure 4.

Do not remove the WHIRLIGIG® unit cover. The rotating components under the cover could cause serious injury.



Rotamatic PU1DR unit

When fitting to a WHIRLIGIG® unit, correct fitment is achieved when a gap of approximately 2mm is set between the sensor face of the monitoring unit and the WHIRLIGIG® cover.

Where the PU1DR is fitted without a WHIRLIGIG®, the snout of the unit should not be mounted flush with surrounding metal, as this will cause the sensor to ‘latch on’ permanently. The sensor snout should be mounted proud of the surrounding metal by at least 10mm and have as much air gap around it as possible. See Table 1 for set up dimensions.

Range for setting up (without Whirligig)

A = 12mm max for ferrous target 20mm dia.

A = 6mm max for non-ferrous target 200mm dia.

B = 15mm minimum

Table 1 - Standard set up dimensions

Rotaslip PU1TZ(A) & PU1TR(A)

Figure 4 - Whirligig to sensor unit gap

Sensor

Figure 5 - Setup details

A

B

B

A

Shaft being monitored

Sensor

2mm gap (approx.)

Whirligig

Monitored shaft

Flexible strap

Rotamatic PU1DR

Rotaslip PU1TZA



When fitting to a WHIRLIGIG® unit, correct fitment is achieved when a gap of approximately 2mm is set between the sensor face of the monitoring unit and the WHIRLIGIG® cover, see Figure 4.

Where the unit is fitted without a WHIRLIGIG®, the Rotaslip should be mounted adjacent to the target. Ideally, the target should be of ferrous metal but non-ferrous metal will be detected at short range.

Maximum range for ferrous and non-ferrous materials is 12mm and 5 mm respectively with a 30mm diameter circular target. Smaller targets may be used, but the operating distance will need to be reduced accordingly. See Error! Reference source not found. for standard dimensions.

When mounted against a solid steel shaft, the target bolt head should protrude from the shaft at least 15mm, otherwise the sensor will not be able to distinguish the target from the shaft and the red input light will stay on permanently. Calibration

Rotamatic PU1DR unit

Two LED’s are provided for information purposes. The input LED is red and flashes every time a target passes the face of the sensor. The output LED is tri-coloured. Under normal running, the output LED is a static green. Under fault conditions the colour may be orange or red (see Table 2 for fault codes).

Output LED Fault codes

Orange Programming not accepted, unit has defaulted back to previous program settings and requires reprogramming

Red Follow procedure for ‘Recalibration to a different setting’. If the output LED remains red contact Guttridge Services Ltd

Table 2 - LED fault codes

The unit is factory set to a speed of 10PPM and a start-up time of 5 seconds. If the time delay required is greater than 5 seconds, see Recalibration for a different setting section below, otherwise proceed as follows.

1. Apply power to both the machine and the PU1DR.

2. Once the machine has reached the normal running speed, place the calibration magnet on the ‘Cal’ point.

3. Now count the number of flashes made by the green LED to set the start delay required in seconds, 1 flash = 1 second delay.

4. Remove the ‘Cal’ magnet as soon as the required number of flashes has occurred. The green output LED will echo the setting in seconds.

At the same time automatic calibration to 20% below the normal operating speed will

take place.



Recalibration for a different setting

If the unit is to be used for a slower speed or with a longer time delay than previously set, the unit may trip out before it can be calibrated. To avoid this occurring use the following procedure:

1. Whilst holding the magnet on the Cal point apply power to the machine.

2. Once the machine has reached normal speed remove the Cal magnet.

3. Wait for the green LED to illuminate permanently and then recalibrate as above.

Specification - PU1DR

Supply 24-240V ac, 12-240 dc

Current consumption 50mA maximum

Operating temp -40oC to +70oC

Operating speed 10 -3,600 pulses per minute

Enclosure Polycarbonate / ABS blend

Protection IP66

Repeat accuracy Better than 2% of working speed over entire range

Output Voltage free relay contact rated 3A 240V ac non-inductive

Output state Relay normally energised with shaft rotating at correct speed (fail safe).

Start-up delay Programmable delay 0 – 30 seconds initiated by application of supply

Termination Supplied with 2 meters PVC cable

LED indication LED indication of input pulses and output relay energised

Weight 350gms

Calibration Automatic. Initiated by magnet

Sensing range 15mm maximum ferrous targets

Target If not used in conjunction with Whirligig. Metal protrusion (ideally min 30mm dia.

Rotaslip PU1TZ(A) and PU1TR(A) unit

Two LED’s are provided for information purposes. The input LED is red and flashes every time a target passes the face of the sensor. The output LED is green. Under normal running, the output LED is a static green and the output LED is on (energised). With an under-speed condition both the input and output LED’s will be off (de-energised).

The unit is factory set to a speed of 10PPM and a start-up time of 5 seconds. If the time delay required is greater than 5 seconds, see Recalibration for a different setting section below, otherwise proceed as follows:

1. Apply power to both the machine and the Rotaslip.

2. Once the machine has reached the normal running speed, place the calibration magnet on the ‘Cal’ point.

Table 3 - Rotamatic specification details



3. Now count the number of flashes made by the green LED to set the start delay required in seconds, 1 flash = 1 second delay.

4. Remove the ‘Cal’ magnet as soon as the required number of flashes has occurred. The green output LED will echo the setting in seconds.

5. At the same time automatic calibration to 20% below the normal operating speed will take place.

Recalibration for a different setting

If the unit is to be used for a slower speed or with a longer time delay than previously set, the unit may trip out before it can be calibrated. This can be avoided by applying power whilst holding the magnet on the Cal point and removing the magnet only when the machine has reached normal speed. Wait for the green LED to illuminate permanently and then recalibrate as above.

Item Specification

Sensor type PU1TZ(A) PU1TR(A) Supply 24-240V ac/dc 12-240V dc or 24-240V ac

Supply rating 2VA 2VA

Output FET S.P.C.O. relay

Switching capacity

200mA max 3A 240V non-inductive maximum

Saturation voltage

6 volts max (output on) N/A

Ambient temp -15oC to +50oC -15oC to +50oC

Output state Normally closed (volt drop 6 volts max) above set speed. Normally open (leakage current

1.6mA max).

Normally open. Closed above set speed.

Calibration Automatic. Initiated by magnet Automatic. Initiated by magnet

Sensing range Nominally 12mm on ferrous metal, 5mm on non-ferrous at 25oC

Nominally 12mm on ferrous metal, 5mm on non-ferrous at 25oC

Input pulse range 10 to 3600 p.p.m. 10 to 3600 p.p.m.

Repeat accuracy 1% 1%

Start up delay Adjustable to 0 – 60 seconds Adjustable to 0 – 30 seconds

Operating settings

Automatic calibration by applying magnet to cal point Relay de-energised at 20% under set

speed

Automatic calibration by applying magnet to cal point Relay de-energised at 20% under set

speed

Enclosure Moulded nylon. DIN threaded 30mm by 1.5mm pitch

Moulded nylon. DIN threaded 30mm by 1.5mm pitch

Protection IP65 IP65

Relative humidity 90% RH 90% RH

LED indication Target Detected and Output Target Detected and Output

Cable Supplied with 5 meters 2 core 600/1000v flame retardant to EN60332-1

Supplied with 5 meters 5 core 600/1000v flame retardant to EN60332-1

Rotaslip specification details

Testing both types of sensor

The system can be tested by placing a thin metal plate between the sensor and the cover of the WHIRLIGIG®. When installing other industry standard sensors, a small gap should be left between the sensor and the WHIRLIGIG® cover for this purpose.

NOTE:

When installing or using either type of sensor in an exterior location, a suitable UV shield should be fitted over the unit. If located in an area with high risk of impact additional guarding/protection MUST be fitted.



2.4. Belt alignment sensors

(optional) see separate data sheet at back of manual for full details

These are fitted to detect when the belt is not running centrally within the elevator leg. Misalignment of the belt will result in machine damage.

For elevators fitted with steel buckets the sensors are fitted to the side of the elevator leg to detect the bucket.

For elevators fitted with plastic buckets the sensors are fitted to the back of the elevator to detect the head of the bucket fixing bolts.

In both cases the sensors are there to detect the presence of a ferrous object. They must be wired so that if they fail to detect the object they are looking for, they will trigger an alarm and stop the drive motor.

Where plastic buckets are fitted using stainless steel bolts, ferrous detecting sensors cannot be used. A pair of contact sensors (see separate data sheet at back of this manual for full details) are fitted, one on each side of the inspection leg casing to detect excessive belt movement to either side of the centre line.

The contact sensors must be wired through the controller so that activation triggers an alarm and causes the drive motor to stop.

2.5. Explosion venting panels

(optional) )see separate data sheet at back of manual for full details

Where the elevator being installed contains a pressure relief device, the micro-switch or bust indicator system should be wired into the control panel, so that the machine is automatically shut down when the pressure relief device is operated by a sudden increase in the pressure within the machine. See component data sheet at the back of this manual for further information.

Plastic Bucket

Belt

Sensor

Steel Bucket

Belt

Sensor

Sensor

Belt sensor positions



3. Drawings and Illustrations

Chain drive

Multi position geared motor with chain drive (cover removed)

Coupled drive

In line geared motor unit connected to drive shaft via flexible coupling (cover removed)

Direct drive

Geared motor fitted directly to shaft

Drive types



Bucket Elevator - principle of operation



General assembly

Drive

motor

Shaft mounted

speed reducer

Hinged door explosion

relief panel

Membrane Explosion

panel

Outlet

Inlet

Belt and

buckets

Top pulley

Lower

pulley

Pulley adjustment

assembly

Head

assembly

Boot

assembly

Motor mounting

plate

Drive belt

cover

Flange

bearing

Pulley mounting

shaft

Flange

bearing

Drive

belt

Leg assembly pair

(comprises of 1 up leg +

1 down leg)

Leg joining

plate

Drive

shaft



4. Commissioning run

4.1. Starting

Before starting the equipment for the first time:

Ensure that no one is working on the equipment.

Ensure that no tools or loose items are left in the casing that could cause damage.

Ensure that no foreign objects can fall in to the inlets thereby causing blockages, overheating or sparking.

The table below contains a list of items to be checked once the machine is in place and in some cases, before it is started. This list is for guidance only. The commissioning engineer should ensure that all aspects of the machine have been

checked to his satisfaction, before it is started for the first time and before it is released to the customer for use.



Customer Machine serial number Customer’s machine number

Site Machine size Product being

handled Throughpu

t

Item Action Comment (if required) Checked

1 Check major component instruction manuals for any commission checks required

2 If machine ATEX rated check installed location is the correct one and is safe to operate machine in

3 Check supply voltage/current is the correct one for the machine being commissioned

4 Check casing alignment along its full length in both front and side vertical planes

5 Check conveyor belt tension and alignment

6 Check drive belt or chain tension

7 Check packing gland seals

8 Check all casing seals are in place

9 Check deflector clearance in head (Page 17 in manual).

10 Check torque arm turnbuckle locknuts and bearing adjuster locknuts for tightness

11 Check gear box oil type and level and that breather has been fitted

12 Check that backstop is operating correctly

13 Check all tools and foreign objects have been removed from internal areas of machine

14 Check that drive motor has been wired correctly to ensure that conveyor rotates in the correct direction

15 BEFORE starting machine check all covers, guards, inlets/outlets in place and no moving parts are accessible

16 BEFORE starting machine check that all personnel in the vicinity are aware. For large machines it may be necessary to post warning signs

17 BEFORE starting machine ensure that any follow on machinery is running

18 Check machine runs quietly without any unusual noises such as rubbing or grinding that may be caused by misalignment

19 Check normal running speed of machine is as per specification sheet

20 During running check that any emergency stop buttons or switches operate correctly

21 If explosion panels fitted check that any micro-switches fitted shut down the machine when operated

22 Check safety interlocks close down the machine when operated and that power cannot be restored until the interlocks are correctly reset

23 Where machine installed to an internal ATEX rating check bearings for signs of overheating, record bearing running temperature recording

24 Use sufficient quantity of sacrificial product, run the machine for several minutes to clear any foreign material

The checks listed above have been completed and the machine is cleared for operation

Name of Commissioning Engineer Signature Date



When the conveyor is started for the first time it should run quietly, any noise above the sound of the drives should be investigated immediately and corrected before proceeding.

Where a machine has been installed specifically to meet the ATEX standard, a 30 minutes ‘safe’ running period MUST be completed. A safe running period is when the machine is run without any ATEX class hazard present i.e. no product in the machine and the surrounding operating area inherently safe.

During the 30 minute ‘safe’ running period, the machine should be visually inspected for any signs of a potential ignition source being generated i.e. loose wiring connections causing arcing, component mis-alignment causing sparking or obvious over-heating.

Where any rectification is carried, a further safe running period should be completed to ensure that the problem has been rectified satisfactorily.

After the 30 minutes initial running period, all areas of the machine should be examined for signs of excessive wear, binding, arcing or over-heating and appropriate rectification action taken.

Where any rectification is carried, a further safe running period should be completed to ensure that the problem has been rectified satisfactorily.

Before operating with production materials we recommend a few minutes running with a sacrificial waste material, to finally ensure the conveyor is purged of foreign matter.

In order to ensure that the machine remains safe for use within the ATEX zone for which it was designed, the end user will need to monitor the running temperature of all bearings on a regular basis.

It is not possible for Guttridge Limited to know what the actual machine operating conditions will be at all times, e.g. ambient temperature, temperature of product, actual loading on machine parts when operating at maximum capacity.

The end user will need to measure the normal running temperatures of all bearings in order to have a start point by which to monitor future bearing performance. The end user is therefore advised to carryout this monitoring at the earliest opportunity. Any bearing showing signs of over heating should be replaced immediately.

Once the operating temperatures for all bearings have been identified and confirmed as acceptable, the end user will need to determine, based on the usage of the machine, how often these temperatures will need to be monitored and ensure maintenance staff of made aware of this requirement.



4.2. Post commissioning checks

Refer to section 6 for post commissioning checks.

The machine referred to in this manual has been designed to operate to the specification detailed by the end user when the machine was ordered. This will have included:

Type of material to be conveyed Electrical supply voltage(s) Systems of control Maximum throughput Machine operating environment Hours of operation Sensing and monitoring systems Safety features (including explosion panel)

Where the machine supplied has been specified to be ATEX compliant the end user will also need to ensure that any replacement item or material is to an identical specification in all respects. This includes the following components and materials:

Conveyor belt material type Conveyor bucket material type Drive belt(s) Sealing strip material Sealing compounds Bearing lubrication medium Electrical components (including explosion panels)

Should an end user consider changing ANY of the above specifications they should contact Guttridge Limited for advice BEFORE doing so.



5. Operation

5.1. Operating principle

The belt and bucket elevator consists of a series of buckets equally spaced on a rotating endless belt. The belt is driven by a motor and gearbox mounted on the head of the machine. At the boot each bucket fills with product from the inlet, this is then transported to the top of the elevator. As the bucket rounds the top pulley of the elevator the product is discharged through the outlet.

5.2. Limitations

The flow of product into the bucket elevator must be regulated to match the throughput of the elevator or less. If necessary use the optional inlet feed control.

Before starting the machine check that no one is working on the machine and that all guards and covers are in place.

Ensure the follow on machinery is running BEFORE feeding product. Failure to do so could lead to machine overload and subsequent damage.

5.3. During operation

Maintaining an even flow of product ensures the elevator performs efficiently, which leads to less stops and lessens the likelihood of a breakdown.

If during the operation of the machine there are any unusual noises, vibrations or smells, clear the machine of product, and then stop the machine to investigate the cause.

5.4. Stopping

Before stopping the machine under normal operation it should be empty of product. Unless it is specifically designed to do so. Starting the machine under load could result in overloading of the motor or damage to the machine.

If the machine is stopped due to an emergency or breakdown it may be necessary to remove product from the casing. The machine must be isolated before any attempt is made to remove product from the casing.



6. Maintenance

6.1. General

Regular maintenance ensures that this equipment will continue to perform to its optimum level.

It is good practice to keep the machine and the area around the machine clean and tidy. This helps in the identification of machine faults and makes for a safer working environment.

6.2. During operation

Any defects in machine operation such as those indicated below must be reported to machine maintenance personnel.

Listen for any unusual noises; this could indicate a problem with the machine in particular loose buckets, a misaligned elevator belt, worn bearings or slipping drive belts.

Feel outside casings for vibration. Do not place hands near moving parts. Take care not to touch parts of the machine that may be hot with the bare hand.

Look to ensure all electrical switches and cut outs function properly and are in good condition. Look to make sure all outlets are clear and product is flowing freely. Look to make sure all guards are securely fitted and are in good condition.

Do not run the machine with guards or covers removed for diagnostic purposes, unless other safety precautions have been taken.

Do not attempt to diagnose electrical faults unless qualified to do so. The machine must be electrically isolated before any work is carried out on electrical systems.

6.3. Routine Maintenance

Ensure the machine is switched off and electrically isolated before carrying out any maintenance work



Items marked are vital to ensuring ATEX integrity

Post commissioning checks after 2/3 hours

Item Action Ref

Running parts Check visually for any signs of leaks, binding or overheating

Drive belt(s) or chain(s) Check tension 6.8 6.9

Packing gland seals (where fitted)

Check for leaks and tighten if required 6.10

Seals and gaskets Check for any leaks or damage especially around covers, access panels or removable parts

Earthing and bonding points Check security

Major components Check component instruction manual for any commissioning checks required

Post commissioning checks after one week or 50 hours if sooner

Machine Check all parts secure and in sound condition


Check for leaks and tighten if required 6.10

Seals and gaskets Check for any leaks or damage especially around covers, access panels or removable parts

Bearing and running parts

Check for signs of overheating or binding that could lead to component failure and subsequent risk of explosion. Any bearing showing signs of over heating should be replaced immediately

Daily

Area around machine Clean to ensure safe working for personnel

Guards and covers Check in place and secure

Warning signs Check in place and visible

Weekly or every 100 hours

Gearbox Check for leaks

Monthly or every 200 hours

Complete weekly checks

Conveyor belt Check condition. Check tracking correctly 1.13

Conveyor buckets Check security 1.12

Explosion panels (where fitted)

Check operation of flap or condition of membrane (depending on type fitted)

2.5


Check for leakage and tighten or repack as required 6.10

Motor fan cover Clean

Guards and covers Check condition

Inlet and outlet assemblies Clean to ensure free flow of product



Sensor systems (where fitted)

Check condition and operation

Safety interlocks (where fitted)

Check condition and operation

All electrical cabling, covers and junction boxes

Check undamaged and in a safe condition

All earthing and bonding points Check for security and condition to ensure that earth continuity is maintained

Eathing continuity (where machine is installed in exposed or harsh conditions)

Check using appropriate test equipment

Bearings and running parts

Check for signs of overheating or binding, that could lead to the generation of high temperatures or sparks. Any bearing showing signs of overheating should be replaced immediately

1.4 1.8 6.7 6.8 6.9

Bearings Check running temperatures against those recorded during the commissioning phase. (dependant on frequency requirements determined by end user)

Drive belt(s) and pulleys (where fitted)

Check condition and tension. 6.7

Every 6 months or 2500 running hours

Complete weekly/monthly checks

Gearbox (where fitted) Check oil level and top up if required 1.8

Shaft Mounted Speed Reducer (SMSR) (where fitted)

Drain, flush, refill Data sheet

SMSR/Gearbox breather Clean 1.8

All earthing and bonding points Check for security and condition to ensure that earth continuity is maintained

Drive chain(s) and sprockets (where fitted)

Check condition and tension. Lubricate using suitable lubricant

6.8

Electrical installations Check in good condition and functioning correctly

Flange bearings

Check condition. If required by local procedures, lubricate with an appropriate grease or replace bearing. See table for recommended bearing replacement timescales.

6.5

24 months or every 10000 running hours

Complete all above checks

Gearbox oil Change – See separate component IOM



6.4. Maintenance intervals

The above intervals are based on a 10 hour day operation 5 days a week. If the equipment is run more often than this, maintenance intervals should be adjusted to suit.

Where ambient temperatures are outside the normal operating range of

5ºC to 30ºC, it may be necessary to vary the maintenance intervals.

6.5. Bearings

In order to maintain the ATEX integrity of the machine, it is vital that the condition of all bearings is monitored on a regular basis. It is also critical that all maintenance requirements detailed above are carried out in order to ensure that the machine remains safe to operate.

Table below should be referred to as a guide to when bearing assemblies should be replaced.

Size of Machine Recommended maximum bearing life

All 5 years or 12,500 hours

Notes:

(i) These recommended bearing lives have been calculated based on a standard machine running for 10 hours a day 5 days a week, 50 weeks of the year and within relatively standard conditions.

(ii) Where a machine is being used in excess of the figures given at (a) above or at maximum capacity for extended periods of time, end users should consider shortening the bearings replacement period accordingly. If in any doubt about how to assess bearing life under such conditions end users should contact Guttridge Limited.

(iii) Notwithstanding the above guidelines, it is crucial that end users establish the bearing operating temperatures during the commissioning phase and continue to monitor these at regular intervals throughout the life of the machine.

Bearing type Machine use Description Grease type

Sealed for life Any Mineral oil and

lithium based grease

K 3 N-20 DIN 51 825

For information: INA bearings use FUCHS Renolit

GA3 SKF bearings use Shell Alvnia

grease RL3



6.6. Bearing housing – removal and refitting

Flange mounted bearing housings are fitted as standard. Plummer block (stand-off) bearing housings may also be used where packing gland seals are fitted. The removal/replacement procedure for both is similar.

The information below is for a bearing secured to the shaft using an eccentric lock collar. An alternative fixing of no eccentric locking ring and two grub screws in the bearing inner ring may also be found.

Locking collar with outer face uppermost

Locking collar - grub-screw on right, punch hole on left

Locking collar in place - aligned with inner bearing ring

Locking collar turned to show its movement on eccentric cam in relation to bearing inner ring.

Note: when positioned on to shaft the collar will not rotate around

shaft to this extent

Locking collar showing inner eccentric cam

Flange bearing showing non-symmetrical face on inner bearing ring



mm Thread Tightening torque – Nm 1

2.5 M5 3.6

3 M6 x 0.75 6

4 M8 x 1 14

5 M10 x 1.25 26

6 M12, M12 x 1.25 42 1 Tightening torques are valid for original INA grub screws only

1. Ensure end of drive shaft is clean and free of any debris that prohibit fitment of bearing and housing.

2. Check mounting surfaces of both bearing housing and structure are clean and dry. Also, that no debris or damage is present to prevent faces coming together fully.

3. Push bearing housing on to shaft and align mounting holes

with those on the machine structure. Where a flange bearing is being fitted, fixed mounting studs may be fitted.

4. Secure bearing housing using appropriate fixing screws. Ensure housing remains square to shaft as fixing are being fully tightened.

5. Where more than one bearing housing is being replaced, initially tighten screws by hand, check shaft alignment, then fully tighten all screws. Recheck shaft alignment.

6. Check that locking collar grub screw is not protruding into collar.

7. Slide eccentric locking collar on to shaft and on to locking flange on the bearing inner ring. Ensure that it fully seats on to the face of bearing inner ring.

8. Rotate collar by hand, preferably in same direction as shaft rotation.

9. Using a drift and hammer, fully tighten locking collar on to the drive shaft using one or two strong hammer blows. Ensure drift is kept vertical to the collar as any side loading, towards the drive shaft end, could cause collar to be forced away from the bearing housing.

10. Take care to avoid the drift jumping away from the collar and causing damage to bearing, bearing housing, or machine structure.

11. Tighten grub screw to the appropriate torque. The table below is for initial guidance only.

12. Removal is the reverse of the above.

Ensure grub screw is loosened off BEFORE attempting to loosen the locking collar.

Ensure that the collar is being driven in the opposite direction from that used when fitting it i.e. opposite direction to drive shaft rotation.



6.7. Lubrication of sealed for life bearings

Flange bearings are normally fitted with sealed for life bearings that contain their own lubrication medium and therefore do not require any further lubrication during the life of the bearing (see information on the recommended life cycle of bearings).

The lip seal or seals (on double sealed bearings) are designed to prevent the ingress of external contamination in the first instance and not as a specific means of sealing in the lubrication medium.

However, some flange bearing housings also have a threaded drilling that allows for the installation of a grease nipple.

Where a grease nipple has been installed and a re-greasing schedule introduced, the end user should ensure that maintenance personnel are aware of the correct re-greasing method to be employed. The following points should also be noted:

1. When first installed the spaces within the bearing is not completely filled. SKF bearings have only 30% of the internal space occupied by grease. INA bearing will probably have a similar arrangement.

2. Excessive greasing (over-packing) of the bearing can lead to over-heating of the bearing during operation.

3. If excessive pressure or rate of flow is applied to the grease as it is injected into the bearing housing the lip seals, that are designed to prevent any ingress of contaminants, may become distorted or damaged. In extreme cases the internal bearing components may also become displaced resulting in bearing failure.

4. Mixing of grease type and makes should be avoided as this could lead to an adverse chemical reaction that leads to a breakdown of the lubricant and subsequent bearing failure.

5. Excessive greasing could lead to product contamination or damage to non-metallic parts of the machine e.g. drive belts, conveyor belt.

Where an end user is considering the introduction of grease nipples and a re-greasing schedule, they are strongly advised to contact Guttridge Limited for advice.



Always isolate the machine to prevent accidental start up

6.8. Taper lock bush

Taper lock bushes are used to secure sprockets and pulleys to shafts. Basic removal and fitting details are detailed below.

To remove taper lock bush

1. Slacken screws in hub. Remove one screw and place it in the half threaded hole and tighten until taper lock parts. It may be necessary to tap the outer hub to free it from the inner.

2. Remove assembly from the shaft.

Fitting taper lock bush

1. Ensure all mating surfaces are clean and oil free, particularly the protective film on new components.

2. Insert inner bush into the hub so that the holes line up.

3. Lightly oil the screws and place loosely in threaded holes on both sides.

4. If a key is to be fitted, place it in the shaft keyway before fitting bush. It must be a parallel key and side fitting only, it must have TOP CLEARANCE.

5. Ensure shaft is clean and fit bush to shaft as one unit. Position it on the shaft to get correct alignment, allow for the fact that the hub will draw slightly up the bush when fully tightened.

6. Tighten the screws gradually and alternately to ensure the hub remains square on the bush when fully tightened.

7. Give the bush a firm tap with a soft hammer or drift, retighten screws. Repeat until all screws are fully tightened.

8. Fill empty holes with grease to prevent ingress of dirt. This will also make removal at a later date easier.




Take care not to trap fingers between belts and pulleys

6.9. V belts

To replace and adjust V belts

1. Remove guard.

2. Slacken the locking nuts on the torque arm and turn adjuster to loosen belts.

3. Remove old belts.

4. Replace all belts with the correct type.

5. Do not mix belt types or old with new.

6. Put new belts onto pulleys ensuring that you do not force them on, as this could damage them and cause them to twist when running.

7. Turn the adjuster on the torque arm until there is approximately 15mm deflection on the belt, at the midpoint between the pulleys, when applying a reasonable force by hand.

8. 15mm deflection is for a belt with a one metre span. Any difference in span length, should be reflected by a corresponding difference in deflection.

9. Over tensioned belts could damage the belts or bearings, Under tensioned belts could cause slippage, which can cause the elevator to stall or the belts to overheat and become damaged.

10. Tighten all locking nuts and replace guard. Guards must be in place BEFORE machine is restarted.

1m span (typical)

15mm deflection (typical)

Drive belt adjustment



6.10. Drive chain

Always isolate machine drive to prevent accidental start up Take care not to trap fingers between chains and sprockets

Drive chain and sprocket condition should be checked as follows:

1. No excessive play between links.

2. Not kinked.

3. Free from rust.

4. Sprockets not dog toothed.

5. Sprockets secure.

6. Replace as required.

Setting chain tension

1. Slacken locking bolts in the motor mounting slide and adjust chain tension by moving the tension plate, using the adjuster nut.

2. Do not slacken locking bolts excessively as this could cause the gearbox alignment to change excessively.

3. Do not remove bolts completely as this will cause the gearbox to be come detached from the mounting plate.

4. Ensure locking bolts are retightened evenly to avoid distorting the casing or misaligning the gearbox.

5. Correct tension is achieved when movement at the midway point between sprockets is between 15 and 20mm.

6. Check tension at other positions in the drive to ensure it is not over tight.

7. DO NOT OVERTENSION CHAIN, as this can lead to premature wear of chains, sprockets or bearings.

8. Lubricate with good quality chain oil.

Drive chain adjustment

15-20mm

Adjuster nut

Locking bolts 4 off




6.11. Drive chain lubrication

All drive chains are fitted with the manufacturer’s anti-corrosion treatment applied only. Therefore, an appropriate lubricant must be applied before the machine is first operated.

Chain lubricants

Recommended lubricant is a penetrating non-mineral oil which lubricates the chain pins and frees seized chain. It forms a dry film which will not attract dust and dirt, and is also non-drip.

Chain drives should be protected against dirt and moisture and be lubricated with good quality non-detergent mineral based oil. A periodic cleaning and re-oiling is desirable. Heavy oils and greases are generally too stiff to enter the chain working surfaces and should not be used.

Care must be taken to ensure that the lubricant reaches the bearing areas of the chain. This can be done by directing the oil into the clearances between the inner and outer link plates, preferably at the point where the chain enters the sprocket on the bottom strand. The table below indicates the correct lubricant viscosity for various ambient temperatures.

Ambient Temperature Lubricant Rating

Celsius SAE BS4231

-5 to +5 20 46 to 68

5 to 40 30 100

40 to 50 40 150 to 220

50 to 60 50 320

For the majority of applications in the above temperature range, a multi-grade SAE 20/50 oil would be suitable

Use of grease

As mentioned above, the use of grease is not recommended. However, if grease lubrication is essential, the following points should be noted:

Limit chain speed to 4 m/s.

Applying normal greases to the outside surfaces of a chain only seals the bearing surfaces and will not work into them. This causes premature failure. Grease has to be heated until fluid and the chain is immersed and allowed to soak until all air bubbles cease to rise. If this system is used, the chains need regular cleaning and re-greasing at intervals depending on the drive's power and speed. It should also be noted that temperatures above 80°C will cause damage to many greases and reduce their effectiveness.

Abnormal ambient temperatures



For elevated temperatures up to 250°C, dry lubricants such as colloidal graphite or M0S2 in white spirit or poly-alkaline glycol carriers are most suitable.

Conversely, at low temperatures between -5°C and -40°C, special low temperature initial greases and subsequent oil lubricants are necessary. Lubricant suppliers will give recommendations.

6.12. Packing gland seals

The packing glands sealing the paddle and the screw shaft should be checked for leakage after the first 2-3 hours of use, then at regular monthly intervals (more frequently if the machine is subjected to heavy use or for some materials) and tightened if necessary by turning the compression screw with a 6mm dia. rod.

Note: Both the compression screw and the paddle in the hopper bottom have LEFT HAND THREADS to prevent loosening during running.

To replace the packing gland seal material

Remove the paddle (or lower screw module - as appropriate).

Remove the three nuts securing the packing gland assembly and withdraw the complete assembly from above the machine.

The packing material can now be easily replaced.

The correct type of replacement packing material is available from the machine supplier. Use of the wrong type will cause leakage and possibly damage the shaft.

Check the condition of the insert bush within the housing and replace if necessary - this prevents the shaft rubbing on the housing.

Replace the assembly, refit the retaining nuts and tighten the compression screw.

Pilot packing joint alignment

Threaded compression

screw

Note: This is a LEFT hand thread

Bush

Housing

Pilot packing

Figure 6 - Packing gland arrangement



To adjust packing gland seals

1. If the seals have hardened or the product has been leaking for a long time tightening the gland could damage the shaft.

2. Slacken inner lock nuts on the packing gland bush assembly equally (2 to 3 flats) then tighten outer lock nuts.

3. Adjustment is best done in small steps as over tightening can cause the pilot packing to pinch the shaft and stall the machine.

Repacking gland - quick method

1. Release locknuts and move packing gland bush assembly out as far as possible.

2. Remove the pilot packaging material and fit new material of the correct type and size. See parts list.

3. Adjust inner and outer locknuts EVENLY to ensure pilot packing contacts the shaft squarely.

4. Adjust until pilot packing lightly compresses against the shaft.

5. Tighten locknuts.

6. After 2/3 hours check for leakage. Tighten if required.

Repacking gland

1. If it is not possible to remove the pilot packing as above or the product has been leaking for some time and caused a build up on the shaft, proceed as follows:

2. Remove flanged bearing assembly.

3. Release locknuts and remove packing gland bush assembly.

4. Remove the pilot packing.

5. Clean the shaft and packing gland assembly.

6. Replace bronze bush if worn.

7. Fit new pilot packing of the correct type and size. Ensure joints are staggered to prevent leakage (See figure below).

8. Refit packing gland sealing bush assembly.

9. Adjust inner and outer locknuts EVENLY to ensure pilot packing contacts the shaft squarely.

10. Adjust until pilot packing lightly compresses against the shaft.

11. Tighten locknuts.

12. Refit flanged bearing assembly.



13. After 2/3 hours check for leakage. Tighten if required.

Packing gland seals

Pilot packing

Inner lock nut

Packing gland bush assembly

Outer lock nut

Packing.gland bronze bush

Pilot packing joint alignment



6.13. Shaft mounted gear motor unit (GMU) removal


Warning – The GMU may be extremely heavy and must be properly supported before any attempt is made to remove the torque arm securing bolt.

Where it is not possible to use the GMU lifting eye to take the weight of the unit, support should be placed underneath. Care must be taken to ensure that any support is stable and strong enough to take the full weight of the unit once it is disconnected from the drive shaft.

Warning – With the torque arm securing bolt removed the GMU will rotate downwards. Depending on the drive arrangement this could occur rapidly and could cause the machine conveying system to rotate. Do not allow personnel to work on any other part of the machine unless full safeguards are in place.

Lifting eye

Drive shaft end

cover

Plastic cap

Torque arm securing bolt

1. Stepped bush 2. Spring washer 3. Socket headed

cap screw

1. Refer to local manual handling guidance to determine need for mechanical assistance due to weight of GMU.

2. Remove the drive shaft cover plate by removing the two retaining bolts.

3. Carefully remove the plastic cap covering the cap screw. Avoiding using any sharp tools as this may damage the cap.

4. Remove the socket headed cap screw, spring washer and stepped bush.

5. Recheck that the weight of the GMU is fully supported and that it cannot rotate unexpectedly once the torque arm securing bolt is removed.

6. Check that other personnel are not working on the machine and could be injured by any movement of the conveying system.

7. Remove torque securing bolt.

8. Carefully rotated the GMU until the torque arm is clear of the bracket.

9. Slide GMU off of the drive shaft.

10. Caution – Even where the GMU has not rotated with the torque arm bolt removed, once it is disengaged from the keyway on the drive shaft, it will be free to rotate under its own weight. Care must be taken to avoid injury due to the uncontrolled rotation of the unit.

11. Refitting is the reverse of the above. Ensure that the key is fully located in the keyway. Apply a suitable lubricant to the shaft. Ensure circlip (where used) is correctly located inside gearbox. Where the GMU is installed on a bucket elevator, care must be taken not to damage any installed backstop.



6.14. Air/Nitrogen purged seal (optional)

Seal housing to be supplied Where an optional air/nitrogen purged seal is fitted it should be supplied with a pressure no greater than 0.5 bar.

The air/nitrogen purged seals sealing the screw shafts should be checked for leakage after the first 2-3 hours of use.

The seal should then be checked at regular monthly intervals.

Regular checks may need to be more frequent if the machine is subject to heavy usage or where certain materials are being conveyed.

Replace lip seals if necessary.



7. Trouble shooting

Fault Possible cause Solution

Motor fails to start

No power Check power supply

Isolator button operative Release isolator button

Faulty start switch Repair/replace switch

Explosion micro switch operative

Reset explosion micro switch, replace membrane if required

Rotation sensor operative Rectify cause and reset

Belt alignment sensor triggered Rectify cause and reset

Motor running, reduced or

no material flow from outlet

No or inadequate material feed Restart or increase material feed

Elevator belt slipping Check for cause of slippage,

re-tension if required.

Buckets not close enough to bottom of boot

Lower bottom pulley

Inlet flow control incorrectly adjusted Reset control slide

Air movement interfering with material flow (Windage)

Provide exhaust for displaced air

Drive belts broken or slipping Replace or re-tension

Intermittent noise at elevator head

Loose or damaged buckets contacting the casing at the outlet

Retighten or repair

Bumping noise in elevator boot

Belt sagging Re-tension belt

Accumulation of sticky material on the bottom pulley

Clean pulley

Bearing failure Lack of lubrication

Apply lubrication and increase lubrication frequency

Incorrect lubricant Change lubricant type

Belt running to one side

Elevator not vertical Straighten elevator

Accumulation of wet or sticky materials on the pulleys

Clean pulleys

Bearings incorrectly adjusted or worn Reset or replace

Motor tripping out

Boot filled with material Clear boot of accumulated material

Deflector clearance excessive Adjust deflector to minimum clearance,

section 1.17



8. Reference

Motors and Gearbox

Manufacturer Web site

ABB www.ABB.com

SEW www.sew-eurodrive.com

NORD www.nord.com

CEG www.ceg.it

Fenner www.fptgroup.com

Rossi www.rossimotorid.it

Bonfiglioli www.bonfoglioli.com

Pujol www.pujol.com

Flender www.flender.com

David Brown Radicon www.Textron.com

Motovario www.motovario.com

Renold www.renold.com

Bearings

Manufacturer Web site

SKF www.skf.com

INA www.ina.de

RHP www.eu.nsk



9. Weights

All weights given are only approximate and are based on a ‘typical’ standard machine installation. End users must check the specification of the particular machine installed to determine its actual weight, before selecting and using any form of lifting equipment to assemble or dismantle their machine.

All weights in Kg Wt of motor +

SMSR only Boot Head

Pair of 3m legs

Machine 150HL bare 145 150 85

With 3Kw motor fitted (incl speed reducer C) 27 + 14

With 5.5Kw motor fitted (incl E) 33 + 29

With 11Kw motor fitted (incl F) 100 + 41


With 3Kw motor fitted (incl speed reducer C) 27 + 14

With 5.5Kw motor fitted (incl F) 33 + 41

With 15Kw motor fitted (incl G) 106 + 64


With 4Kw motor fitted (incl speed reducer F) 33 + 41

With 5.5Kw to 11 Kw motor fitted (incl G) 100 + 64

With 7.5Kw to 22 Kw motor fitted (incl H) 141 + 84

Machine 370HL bare With 4Kw motor fitted (incl speed reducer) With 5.5Kw motor fitted (incl) With 7.5Kw motor fitted (incl) With 11Kw motor fitted (incl) Machine 450HL bare With 4Kw motor fitted (incl speed reducer) With 5.5Kw motor fitted (incl) With 7.5Kw motor fitted (incl) With 11Kw motor fitted (incl)

Not yet

issued

Not yet

issued



10. Parts

Head assembly parts



Item Description Qty

1 Bearing backing plate 2

2 Head side panel – lh 1

3 Head side panel – rh 1

4 Head end panel 1

5 Head outlet panel assembly 1

6 Head access door assembly 1

7 Head outlet deflector bracket assy 1

8 Head shedder bracket 1

9 Motor mount assembly 1

10 Head side frame – flanged bearings 2

11 Rear head assembly 1

12 Front head assembly 1

13 Drive cover 1

14 Belt guard back plate 1

15 Bearing backing plate 2

16 Head shaft 1

17 Head pulley assembly 1

18 Bearing adjuster 2

19 Head support foot 1

20 Torque arm bracket 1

21 Belt drive housing support 1

23 Flanged bearing 2

24 Bush taper lock 2

27 Deflector clamp plate 1

28 Head outlet deflector plate 1



Boot assembly parts



Item Description QTY

1 boot inlet assembly 1

2 boot inlet make-up panel 1

3 boot bearing slide assembly 2

4 boot access panel assembly 2

5 boot lower end panel 1

6 bearing adjuster bracket assy 2

7 boot bearing slide assy 2

8 boot bearing slider retainer 4

9 guide bar 4

10 boot top cover plate 1

11 boot top access cover 1

12 studding 2

13 boot back-up assembly 2

14 boot side plate 2

15 boot sweep plate assembly 1

16 boot end panel 1

17 pulley assembly 1

18 square flange housing 2

19 boot shaft 1

20 BUSH TAPER LOCK 2



Accuracy of information provided

This data sheet gives technical information for a component fitted to materials handling equipment manufactured by Guttridge Limited. Every effort has been made to ensure that the technical information is accurate. However, it is in general a duplication of the information supplied to us by the original equipment manufacturer and is therefore only offered in good faith and cannot be guaranteed. Users should ensure that the information provided in a particular section applies to their specific installation before disturbing or adjusting their equipment. If there is any doubt, please contact Guttridge Limited for advice and assistance.

BAP2 Motion Alignment Sensor

Description

The BAP2 sensor detects moving ferrous material and is designed for use with bucket elevators

and conveyors to detect the buckets, for measurement of speed and alignment. It can also detect

ferrous bolts, which are used to attach non-ferrous buckets. The sensor is used

in conjunction with a PLC or with a Watchdog or A400 Elite control unit. Two output signals

are provided: one signal is a pulse output, representing each bucket detected: the second signal is a

continuous output when moving buckets are detected.

Specification

Model No BAP21V34 BAP22V34FC

Voltage 12-24vdc 12-24vdc

Supply current 40-90ma 40-90ma

Outputs, current sinking max 100ma (NPN with pull up) 100ma (NPN with pull up)

Detection range (1” bolt head) 25mm-75mm 25mm-75mm

Detection rate 20-2000/min 20-2000/min

Protection IP66 IP66

Hazardous area classification See protection below See protection below

Cable 6 core 2m long 6 core 2m long

Conduit entry - ½” NPT

Weight (shipping weight) 405g (530g) 428g (553g)

Cable connections

RED +ve supply 12-24v dc

BLACK -ve supply 0v

GREEN Earth (Ground) Connected to case

YELLOW/ORANGE Control 0-24v dc

BLUE Pulsed output, normally low, high when detecting

WHITE Continuous output, normally high, low when detecting

Protection

Ex II 1 D T140°C IP66 ¦ Ex II 2 D T80°C IP66

CE0600 BAS01ATEX1192X ¦ CE0600 BAS01ATEX2193X

When installed as category 2D equipment adequate cleaning must ensure dust layers are kept

below 5mm. Installation is only allowed where the exposed face of the Encapsulant is

unlikely to be subject to impact damage. GuttridgeLimited Component Data Sheet EL01



BAP2 Motion Alignment Sensor

Control

Sensitivity adjustment is achieved with the internal potentiometer and the voltage on the

YELLOW/ORANGE wire.

To use the internal potentiometer, connect the YELLOW/ORANGE wire to the RED wire

(+ve, 12-24v). Turn the potentiometer clockwise to increase sensitivity.

To use the external control voltage (A400 etc) connect the YELLOW/ORANGE wire to the

control voltage from the A400 and turn the potentiometer on the BAP2 fully anti-clockwise.

Reduce the control voltage to increase sensitivity.

In both arrangements, reduce the sensitivity if the pulsed output (LED) becomes unstable.

Led indicator

The green LED shows the state of the pulsed output and flashes once for each bucket (bolt)

detected. The LED should be off when no buckets (bolts) are detected, if not, reduce the

sensitivity.

Mounting

When mounting on a steel elevator leg, cut a hole of 50-60mm dia and fix with four M6

screws. Alternatively, cut a larger square hole, fit a polycarbonate window and fix the sensor

with four M6 screws in the centre of the window.

When fixing to aluminium, plastic or nonmagnetic stainless steel panels, it is not necessary to cut a

hole as the sensor can ‘see’ through

these materials.

Installation is only allowed where the exposed face of the Encapsulant is unlikely to be subject to

impact damage.

1K

1K5

BLUE

RED

1K

WHITE

BLACK





General

A motion alignment sensing system is installed on bucket and belt elevators to monitor the running

position of the belt during operation. Dependent on the machine specification, either a single

sensor is fitted to monitor the centre alignment of the belt or a pair of sensors is fitted to monitor

side to side movement of the belt.

Figure 7 - TouchSwitch™

Description

The TouchSwitch™ is an electronic limit switch with no moving parts. When a belt misaligns or a

pulley moves over and contacts the sensor, the built in solid-state electronic circuitry detects the

lateral force of the belt or pulley and activates a voltage free relay contact. This relay contact can

be used to alarm or shutdown the machine.

The face of the sensor is made from hardened and annealed stainless steel, so that there is no wear

when a belt contacts it. The sensor is not affected by dust or material build up and will still work

when completely covered by material.

Sensors are normally installed in pairs on opposite sides of the casing. Usually a pair of sensors at

each pulley is used, but additional pairs can be installed as required. An external test knob allows

for quick and simple sensor/system testing.



Installation

Always isolate the machine from the electrical supply before carrying out any work.

When installing/reinstalling the sensor, ensure that it is centred in the casing hole with the conduit

entry pointing downwards.

Ensure that the rubber gasket is in place.

Also, ensure that any additional rubber gaskets, provided to reduce the distance that the sensor face

protrudes into the casing, are refitted.

Specification

Supply Voltage 12 vdc (TS2V3CA) 24 vdc (TS2V4CA)

Power Consumption

60mA

Indication Red LED indicates when powered up and relay is energized.

Adjustment Force Sensitivity “Screw-Pot” (0 to 12 lbs approx.)

Output Voltage free changeover relay contact rated at 5A 250vac Non-inductive

Body Construction

Pressed seamless steel with epoxy paint.

Face Construction Hardened and annealed stainless steel.

Conduit Entry ½” NPT

Cable Length 6ft

Conductors 6 at 22awg

Weight 3 lbs

Approvals Class 2 Div. 1 groups e, f, g approved (US and Canada)

Protection ATEX and CE approved (Europe) NEMA 4X, IP 65

Dimensions 3.5” Diameter x 1.75” Deep

Table 4 - TouchSwitch™ specification details

Indication

The relay contact is energized when power is supplied to the sensor and de-energizes

when the sensor detects the belt or pulley.

Red LED on: indicates power and relay energized.

Red LED off: indicates relay de-energized and/or no power.

Set-up and Test:

1. Observe that the red LED on the sensor housing is on and the belt or pulley is not

touching the sensor.

2. Slowly turn the test knob clockwise by hand, until the LED goes out.

3. Check that alarms and shutdowns work as expected.

4. Turn the test knob back to its original position.

5. Observe that the LED is now on.



Maintenance

Periodically test the sensor and system by moving the belt over to contact the sensor.

Check that alarms and shutdowns work as expected.

If required, use a flat head screwdriver to adjust the sensitivity screw on the back of the sensor for

fine trip force adjustment.

Clockwise for increased sensitivity.

Counter-clockwise for reduced sensitivity.

Output LED

Sensitivity adjustment

Test

Figure 8 – TouchSwitch™ setup and testing





To identify the type of speed reducer, refer to speed reducer plate as illustrated below.

SMSR Lubrication

IMPORTANT The reducer is despatched without oil. It must be filled as instructed before running. Use high grade oil as stated below. Fill to level plug when reducer is not running. The approximate quantities are shown in table below. Drain, flush and refill every six months of operation, check oil level regularly. Positions of filler, breather and drain plug for different mounting positions are shown in fig. 1.

CAUTION Too much oil will cause over-heating. Too little oil will cause gear failure.

Figure 1

Health and Safety at Work Act 1974 Attention is drawn

to the "Codes of Practice” issued by oil companies in

respect of the handling of their products.

Filler plug Level plug Drain plug

Units are fitted with filler, level and drain plugs generally in positions

shown.

Product code 116E2002

E refers to the size of

speed reducer

20 refers to the ratio

2 1

3 4



Normal operating positions are shown in fig. 1.

Note that the reducer is supplied with four plugs. After the reducer has been mounted in its running position, the plugs must be located as shown in fig.1 for the appropriate mounting position. If the reducer is not within 20° of one of the positions shown, the oil level plug cannot be safely used to check the oil level.

This can be overcome by disconnecting the torque-arm and swinging the reducer around to one of the positions shown. Because of the many positions of the reducer it may be necessary, or desirable, to make special adaptations using the plug holes in the reducer with standard pipe fitting, standpipes or oil level gauges.

Recommended Mineral Oil Lubricant Viscosities

Ambient

Temp °C

5:1 Ratio Gearbox 13:1, 20:1 & 25:1 Ratio Gearbox 0-100

rev/min

101-200

rev/min

201-400

rev/min

0-20

rev/min

21-50

rev/min

51-120

rev/min

0-50

rev/min

51-80

rev/min

I.S.O.

Viscosity

Grade

-10 to +5

6 to 25

26 to 40

B -T B-T B-D E-T B-T B-E F-T B - E F -T K, L, M

100

460

800

100

320

680

100

320

680

68

220

460

150

680

800

150

680

800

150

460

800

100

460

680

100

320

460

100

320

460

100

220

320 Mobil SHC XMP 320 Synthetic oil is suitable for all ambient temperatures and all speeds.

Approximate oil quantities required for different mounting positions (see figure 1)

Unit

Size

Approximate Capacity - Litres

Ratio 5:1 13:1, 20:1 & 25:1

Mounting

Position 1 2 3 4 1 2 3 4

B 0.3 0.3 0.3 0.4 0.25 0.4 0.3 0.4

C 0.5 0.5 0.5 0.6 0.4 0.6 0.5 0.6

D 0.8 0.9 0.8 1 0.7 0.9 0.8 0.9

E 1.2 1.7 1.4 1.8 1 1.8 1.4 1.6

F 2.5 2.6 2.4 2.5 2.3 2 .6 2.4 2.2

G 3.3 3.2 3.2 3.3 3 3.2 3.2 3.2

H 4.1 5.3 4.1 5.8 3.8 5.5 4.2 5.1

J 5.7 8.6 8.6 8.6 5.4 8.5 5.9 8.3

S 10.9 18.4 13.6 18.4 9.1 16.4 12.6 15.4

T 15.2 21.7 25.2 20.7 12.7 21.7 15.7 19.2

K 12.5 13.5 24.0 11.5

L 22.5 34.5 52.0 27.0

M 36.0 50.0 79.0 45.0




This data sheet gives technical information for a component fitted to materials handling

equipment manufactured by Guttridge Limited.

Every effort has been made to ensure that the technical information is accurate. However,

it is in general a duplication of the information supplied to us by the original equipment

manufacturer and is therefore only offered in good faith and cannot be guaranteed.

Users should ensure that the information provided in a particular section applies to their

specific installation before disturbing or adjusting their equipment. If there is any doubt,

please contact Guttridge Limited for advice and assistance.

Guttridge designed explosion panels

The location, quantity and type of explosion panels fitted is entirely dependent on site

restrictions. Therefore, the installing engineers, together with the local factories inspectorate,

should specify the requirement. However, as a general guide it is recommended that panels

should be positioned adjacent to the head assembly and as close to the boot assembly as is

practicable and at 6.0m maximum centres.

In all cases, care must be taken to ensure that personnel within the vicinity of the machine are not

able to enter the potential discharge area. In most cases this will mean that the lowest pressure

relief panel will be at least 2m above floor level.

As standard, Guttridge Services Ltd fit one hinged door type pressure

relief panel that includes a micro-switch, with every set of membrane

type explosion relief panels.

The hinged door type pressure relief panel is normally fitted on or

adjacent to the head assembly. When fitted to a leg, it is normally

fitted on the up going side.

In the event of an explosion within the elevator, the hinged door will be

operated thereby activating the micro-switch and shutting down the

elevator. It should not be assumed that because the micro-switch

has been operated the machine is safe to be worked on.

No attempt should be made to access the elevator or the panels

until the belt has stopped rotating completely AND the machine

has been isolated from the electrical supply.

A maintenance platform when fitted, will influence the position of any

pressure relief panel fitted on or adjacent to the head.

Where the pressure relief panel is likely to discharge into an area

containing a potentially flammable atmosphere or in to an area that

personnel may need to access for any reason, it is strongly

recommended that an appropriate ducting is installed to channel any

discharge in to a safe area.

Warning: Do not locate the vent assembly where people are exposed to the vent

itself or to the area above or in front of the vent as they may be injured

by the escaping pressure, fire, noise, chemicals, and/or fragmenting

particles. The location of the explosion vent must be such that the

discharge cannot be the ignition source of secondary explosions.

Interfacing equipment and/or machinery protection must also be

considered.

6m maximum



Figure 9 - Hinged door pressure relief panel assembly

Parts List


1 Cam, micro-switch 1

2 Side plate - latch 1

3 Side plate – plain 1

4 Upper plate 1

5 Lower plate 1

6 Panel grille 1

7 Explosion flap assembly 1

8 Seal, neoprene 1

9 Ball catch plate 1

10 Switch, Honeywell 1

11 Washer, flat 10mm 5

12 ¼ collar 12

13 ¼ Maxlock 12

14 Roller catch - adjustable 1

Extra washers are used

here to pack up flap to clear micro-switch

fixings

Stick to leg cover

around aperture

Detail A – Upper door hinge



Parts List


1 Panel, side plate 2

2 Panel, upper 1

3 Panel, lower 1

4 Membrane, retainer 1

5 Panel, mesh 1

6 Membrane, Novus 20 1

7 Setscrew – M8 2

8 Nut, Nyloc M8 2

9 Washer, flat 8mm 4

10 ¼ collar 8

11 ¼ Maxlock 8

12 Seal, Neoprene (to length) 1

Figure 10 – Membrane type pressure

relief panel assembly

12



Fike® ELEV- EX Explosion Vents

General An explosion vent is a pressure relief device, designed to give an instantaneous opening at a predetermined pressure to a closed system. Its purpose is to protect this system from excessive pressures caused by dust or gas explosions.

Warning: Do not locate the vent assembly where people are exposed to the vent itself or to the area above or in front of the vent as they may be injured by the escaping pressure, fire, noise, chemicals, and/or fragmenting particles. The location of the explosion vent must be such that the discharge cannot be the ignition source of secondary explosions. Interfacing equipment and/or machinery protection must also be considered.

The Elev-Ex series explosion vents are single element flat explosion venting devices, specifically designed for use on vertical bucket elevators. They can be installed directly onto the elevator legs, using minimal bolting arrangements and without the use of additional installation frames. Due to the integral gasket on the process side, the Elev-Ex vent is factory supplied ready for installation. Refer to specific Elev-Ex drawing for details.

Installation

Use explosion vent as template to indicate

placement on elevator to be protected. Best

practise is to provide one explosion relief vent

at each 6 meters length of elevator leg. If in

doubt, consult with system designer.

After cutting relief area and drilling mounting holes attach studs using an appropriate method, for example spot weld to the elevator casing. Be sure the threads are clean and are not damaged. Place the vent carefully on the elevator, making certain that the nameplate of the vent is facing the atmospheric side and fit nuts to bolts/studs. Torque bolts to be 20 Nm (max). Caution: Handle explosion vent with extreme care. Do not bend, poke or in any way distort the vent membrane.

Insulation

Fike Elev-Ex explosion vents can be supplied

with optional insulation. Consult specific Fike

installation instructions when applicable.

Replacement of explosion vents

Remove broken Elev-Ex taking care of sharp

edges. Clean sealing surface. Inspect the

explosion vent carefully. Check that the tag

number and data on the nameplate correspond

with location and system specifications. Place

the new vent carefully on the elevator leg studs.

Lubricate studs with light oil. Fit nuts to studs

and torque to 20 Nm (max).

Burst indicator

The Fike Elev-Ex explosion vents can have as

an option a rupture indicator designed for use

in intrinsically safe electrical circuits.

Caution: The electrical supply MUST NOT EXCEED 48V DC or 50mA. Higher voltage or currents will permanently damage the electrical system and the use of a non-approved intrinsically safe power supply may even be the eventual ignition source of a dust or gas explosion. All burst indicators must be installed in an intrinsically safe circuit which conforms to the applicable (inter)national standard.

Warning: Do not bend the electrical cable at any angle at a distance of less than 20cm from the mechanical bracing part and do not lift the explosion vent by the electrical cable, as this may damage the electrical circuit.

Maintenance

The explosion vent assembly is maintenance-

free due to its basic design and concept.

Maintenance could consist of periodic visual

inspections, consistent with the operating

parameters and severity of service.

Note: Severe service is defined as rapid changes in pressure, high pressure, high temperature, or corrosive process. Explosion vents should be replaced if they appear damaged, corroded, or leaking.



Specifications

Sizes (nominal)

(1)

170 x 470 mm 270 x 458 mm 300 x 500 mm 350 x 650 mm Relief Area (m2) 0.079 0.123 0.149 0.227 Materials of Construction

(2)

Stainless Steel with Silicone FDA seal and Neoprene FDA

gasket Burst Pressure (Standard)

(3)

100 mbarg (lower on request) Burst Pressure Tolerance ±15 mbarg Maximum Operating/Vacuum

Pressure

atmospheric (25% operating ratio) Operating Temperature

Range (4)

-20°C up to 60°C

Notes:

1. Other sizes are available on request.

2. Other materials are available on request.

3. For other burst pressures consult Fike

4. For operating temperatures less than -20°C or exceeding 60°C,

consult Fike.

ELEV-EX EXPLOSION VENT relief

area nominal size In

mm outside

dimensions min. BP max. BP bolts

m2 a x b in mm mbarg mbarg Qty Hole dia. size

0.079 170 x 470 258x558 50 200 6 12 M10

0.123 270x458 358x546 50 200 6 12 M10

0.149 300x500 388x588 50 200 6 12 M10

0.227 350x650 438x738 50 100 6 12 M10

Options

Fike ELEV-EX explosion vents can be made to suit practically any customer

requirements. Some of the standard options available are:

Burst indicators Legislation and process safety will require that upon bursting of explosion vents, the necessary measures shall be taken to initiate actions required for safe operation or shutdown.

Burst indicators are available to provide an electrical contact change upon rupture of the explosion vent. Proximity switch types are standard, other types are available upon request. By using approved power supplies and/or barriers, most burst indicators will meet the intrinsically safe requirements and can be used in hazardous areas.



Atmospheric insulation Some installations may require an insulated vent to reduce heat losses or condensation.

Fike offers a standard insulation pack, mounted on the atmospheric side, to prevent heat

loss or condensation. The added insulation is taken into consideration when establishing

the required burst pressure.

Panel location See illustration to the right for example of typical panel positions. Note: This is not the Guttridge Services standard.

Warning: Do not locate the vent assembly where people are

exposed to the vent itself or to the area above or in

front of the vent as they may be injured by the

escaping pressure, fire, noise, chemicals, and/or

fragmenting particles. The location of the

explosion vent must be such that the discharge

cannot be the ignition source of secondary

explosions. Interfacing equipment and/or

machinery protection must also be considered.

Fike Europe B.v.b.a. • Toekomstlaan 52B2200 Herentals -Belgium Tel. +32 14 210031 • Fax +32 14 210743 • email fike [email protected] • website: http://www.fike.be

Fike United Kingdom • Maidstone • England Tel. (01622)677081- Fax (01622)685737 • email [email protected] • Website http://www.fike.co.uk

http://www.fike.be/





Documents

Bucket Elevator - GAME Engineering · the UK. This directive is concerned with the safety of the workplace and places responsibility on the end user to risk assess their workplace