GSI Group II Sweep Series Owner'S Manual Download | Manualshive

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PNEG-1366

12" and 16" Series II Sweep Quick Disconnect Control Box Kit

37

9. Maintenance

Maintain the Auger

A. Use caution when repairing or replacing equipment parts.

B. Make sure ALL decals are legible and securely attached to the auger. If necessary, replace them

FREE OF CHARGE

by contacting GSI at:

GSI

P.O. Box 20

1004 E. Illinois St.

Assumption, IL 62510

Phone: 1-217-226-4421

C. Ensure that ALL electric motors, etc. are operating at the proper speed.

D. Make sure ALL electrical wiring is not damaged and that it meets proper wiring codes.

E. Make sure ALL components are in good working condition before use.

ALWAYS shut down and disconnect the power supply before adjusting,
servicing or cleaning the equipment.

ALL SPEED REDUCERS ARE SHIPPED DRY. OIL MUST BE ADDED PRIOR TO
OPERATION. Do not operate the unit without making sure it contains the correct
amount of oil. Do not overfill or underfill with oil or injury to personnel, unit or other
equipment may result.

Do not mix non-synthetic and synthetic oil in the unit.

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Summary of Contents for II Sweep Series

Page 1: ...PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit Owner s Manual PNEG 1366 Date 12 21 20 ...

Page 2: ...ered Date Installed Notes Personnel operating or working around this equipment should read this manual This manual must be delivered with equipment to its owner Failure to read this manual and its safety instructions is a misuse of the equipment Any misuse of the equipment may void the warranty ...

Page 3: ...Panel Into Docking Station 24 Control Panel Setup 25 Calibration 30 Operation 31 Chapter 6 Start Up 32 Perform Pre Start Checks 32 Start the Auger 33 Chapter 7 Operation 34 Operating the Sweep Auger 34 Operating the Sweep Auger Control Panel 35 Chapter 8 Shut Down 36 Normal Shut Down 36 Emergency Shut Down 36 Storage Preparation 36 Chapter 9 Maintenance 37 Maintain the Auger 37 Chapter 10 Control ...

Page 4: ...ick Detach Control Panel Pre June 2010 49 Dock Station Assembly GC10116 for Quick Detach Control Panel Pre June 2010 50 Conduit Assembly GC10113 for Quick Detach Control Panel 51 Drop Cord Assembly GC10079 for Quick Detach Control Panel Pre June 2010 52 Quick Detach Control Panel Receptacles Parts 53 Quick Detach Control Panel Package GK80112 54 Lift Base Panel Assembly GK80108 55 Lift Base Dock A...

Page 5: ...ox is needed to control all of the same size sweeps Each sweep location will require a docking station for the control box base to slide into The control box base is supplied with four 4 handles for manual lifting These handles can be installed in any of the holes located on the outside edges of the base back plate The base back plate also has two 2 chain lift holes for mechanical hoisting Figure ...

Page 6: ...structions is a misuse of the equipment and may lead to serious injury or death This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially...

Page 7: ...uld be consulted before installations are made Follow Safety Instructions Carefully read all safety messages in this manual and safety signs on your equipment Keep signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from the manufacturer Learn how to operate the mac...

Page 8: ...ipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made Electrical controls should be installed by a qualified electrician and must meet standards set by the national electrical code and all local and state codes A main pow...

Page 9: ...ition and properly installed Fix damage immediately Replace worn or broken parts Remove any build up grease oil or debris Understand service procedures before doing work Keep area clean and dry ALWAYS turn off and lock out all power sources before performing any maintenance Prepare for Emergencies Be prepared if fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers fo...

Page 10: ...yes from debris Wear gloves to protect your hands from sharp edges on plastic or steel parts Wear steel toe boots to help protect your feet from falling debris Tuck in any loose or dangling shoe strings A respirator may be needed to prevent breathing potentially toxic fumes and dust Wear hard hat to help protect your head Wear appropriate fall protection equipment when working at elevations greate...

Page 11: ...r area or situation iii Unqualified or incompetent persons are to remain out of the work area iv O S H A Occupational Safety and Health Administration regulations state At the time of initial assignment and at least annually thereafter the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is or will be involved Federal Occupational ...

Page 12: ...ontrol Panel and Quick Disconnect Control Kit NOTE Please remember safety signs provide important safety information for people working near bin unloading equipment that is in operation Any safety signs that are worn missing illegible or painted over should be replaced immediately Obtain FREE replacements by contacting GSI Figure 3A Control Panel Located Outside of Bin ...

Page 13: ...ontrol Box Kit 13 DC 1756 A DC 1756 Location Corners of mounting plate Size 4 3 4 x 2 1 4 DC 1756 DC 889 B DC 889 Location Interior of control panel On electrical boxes Size 2 13 16 x 1 7 16 DC 1224 C DC 1224 Location Corner of control panel Size 2 7 8 x 5 DC 1224 ...

Page 14: ...odifications other equipment in the area or any reason then locate the safety sign in a more suitable location C Be certain the surface is clean dry and free of dirt and oil Peel paper backing from decals and stick into place The adhesive backing will bond on contact NOTE Please remember safety signs provide important safety information for people working near bin unloading equipment that is in op...

Page 15: ...isfaction and service obtained By following the instructions and suggestions recommended the owner should receive quality service for many years If additional information or assistance should be required please contact GSI 3 It is important to check both the quantity of parts and their descriptions with the packing list enclosed within each package All claims for freight damage or shortage must be...

Page 16: ...8 79 8 78 m 2 10 10 15 28 85 8 79 m 62 2 7 5 7 5 10 29 79 9 08 m 2 10 10 15 29 85 9 10 m 63 2 7 5 7 5 10 29 79 9 08 m 2 10 10 15 29 85 9 10 m 66 2 7 5 7 5 10 31 79 9 69 m 2 10 15 15 31 85 9 71 m 68 2 7 5 7 5 10 32 79 10 00 m 2 10 15 15 32 85 10 01 m 69 2 7 5 7 5 10 32 79 10 00 m 2 10 15 15 32 85 10 01 m 72 2 7 5 7 5 10 34 79 10 61 m 2 15 15 15 34 85 10 62 m 75 2 10 10 10 35 79 10 91 m 2 15 15 15 3...

Page 17: ...Some motors have built in thermal overload protection If this is the type of motor being used use only those with a manual reset 3 The motor starting controls must be located outside the bin They must NEVER be installed on the Series II auger inside the bin 4 Disconnect and lock out the power before resetting motor overloads 5 Disconnect and lock out the power before entering the bin 6 Disconnect ...

Page 18: ...ugh to the bin door to plug in the 10 long foot switch cord The operator must be outside of the bin and be able to depress the foot switch while visually monitoring the sweep through the bin door Figure 5A Docking Station The control panel must be mounted outside the bin near the door The foot switch has to be plugged into the control panel and depressed before the sweep is operational It has a 10...

Page 19: ...ill fit either style box Hardware is provided to mount an older style box with ears to the mounting plate The new style box already has hardware installed in the rear of the box 1 Cut a hole into the side panel of the control box in the location shown in Figure 5B Hole to be sized for 1 1 2 rigid conduit approximately 1 900 Make sure all metal chips shavings are removed from the inside of the box ...

Page 20: ...ere are three 3 mounting positions on the lift base panel assembly in which to mount the control panel See Figure 5C Figure 5C Electrical controls should be installed by a qualified electrician and must meet standards set by the National Electrical Code and all local and state codes A main power disconnect switch capable of being locked only in the OFF position should be used The disconnect must b...

Page 21: ...nting positions may not be possible See Figure 5D Figure 5D A sample installation configuration is shown in Figure 5E for the auger drive power outlet tractor drive power outlet overload for motor control outlet and the drop cord outlet Figure 5E shows preliminary dimensions for all the necessary holes that need to be cut into the panel Actual sizes may vary Figure 5E ...

Page 22: ...es Four 4 handles are supplied and can be located in any of the holes on the outside edges of the back base plate USE THE CORRECT SIZE SCREWS Only two 2 handles shown See Figure 5F below and Figure 5G on Page 23 Figure 5F Use 1 4 14 x 1 1 4 screws for handles that attach to the base back plate at the stiffener bar locations Use 1 4 14 x 1 screws for handles that attach at all other locations These...

Page 23: ...5 Assembly PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit 23 Figure 5G ...

Page 24: ...l box to the docking station by sliding the tongue into the pocket on the docking station See Figure 5H Figure 5H Do not lift equipment without personal or mechanical assistance Single person lift could cause injury To avoid muscle strain or back injury use lifting aids and proper lifting techniques when removing or replacing the control box ...

Page 25: ...he full load amp FLA value for the specific voltage on each motor Auger drive motor full load amps ____ Tractor drive motor full load amps ____ Switch the disconnect switch on the panel to OFF not ON Unlock and open the control panel Adjust the FLA dial screw on the tractor drive motor contactor M1 and the auger drive motor contactor M2 so that the indicator arrowhead is set slightly higher than t...

Page 26: ... OK DEC P should be displayed on the unit Press or on the display unit until 11 11 is shown not 1111 111 1 1 111 or 1111 Press OK DI LO should be displayed on the unit Press or on the display unit until 0 is shown Press OK DI HI should be displayed on the unit The DI HI value is 2x the value that the FLA dial on the auger drive motor M2 that was set earlier 2x FLA Dial ____ Press or on the display...

Page 27: ...g on the auger drive motor The tractor drive motor is meant to shut off idle when the Auger Drive Motor reaches 90 of the nameplate FLA 90 of full load amps ____ The tractor motor is meant to reactivate forward when the auger drive motor reaches 110 of the no load amps amperage observed when the auger flight turns freely in absence of grain 110 of no load amps ____ Final Display Setup NOTE If no k...

Page 28: ...nit Press or on the display unit until 20 is shown Press OK REL2 should be displayed on the unit Press or on the display unit until OFF is shown not SET or SKIP Press OK E PAS should be displayed on the unit Press or on the display unit until NO is shown Press OK This function will allow the values that were entered to be locked NOTE Using a password will stop access to the menu and parameters The...

Page 29: ...oads that are not set at the factory These should be set slightly higher than the Full Load Amp FLA value listed on the motor nameplates A Find the desired High Amp and Low Amp set points 1 High Amp Set Point The Amp load the auger draws when the auger flighting is 90 loaded This will turn OFF the tractor drive motor Initially set the value to 90 of the Full Load Amps FLA listed on the motor namep...

Page 30: ... to i4 20 d Press ENTER to RUN MODE 2 Setting Setup a Press PRGM to SEtuP b Press ENTER to rdEC Use arrow buttons to change the decimal placement Show 0 Amps c Press ENTER to SETLO d Press ENTER Value 0 0 e Press ENTER to SEtHi f Press Enter Value 50 0 Use arrow buttons to change value g Press ENTER to LoCut Press ENTER This value 0 h Press ENTER to RUN MODE ...

Page 31: ... 20 Amps NOTE This is the difference between the High Amp Set Point and the Low Amp Set Point 20 Amps 12 Amps 8 Amps Low amp set point is only used to calculate this value 3 Locking the Amp Meter 1 Locking the Amp meter is not required but prevents the meter from being tampered with once it is programmed 2 In RUN MODE press LOCK three 3 times within five 5 seconds This value A number that is easil...

Page 32: ...before proceeding Failure to observe these precautions could result in bodily injury Failure to perform any or all of these pre start checks may cause damage to the equipment and or cause SERIOUS INJURY or DEATH to those in the work area Failure to perform any or all of these pre start checks may also be a misuse of the equipment Any misuse of the equipment may void the warranty ALWAYS keep ALL gu...

Page 33: ... the first time or for the first time of the season 4 Polish the flighting by running the auger at partial capacity until it is smooth before attempting full capacity DO NOT start or stop the auger while it is under load Failures may occur if the auger is run full before it has been polished during the break in period NEVER operate the auger empty Operating augers empty for any length of time will...

Page 34: ...evel will be far better than subjecting a smaller diameter auger to big loads If an auger is kept from absolute filling it will make start up easier and will convey more efficiently Gear reducer is shipped without oil Add the proper amount of the recommended lubricant before operating Failure to observe these precautions could result in damage to or destruction of the equipment Keep out of the bin...

Page 35: ...eep a Idle Allows the auger motor to run but does not move the sweep forward or reverse b Forward Auger motor will run and moves the sweep towards the grain c Reverse Stops the auger motor and moves the sweep away from the grain Step on the foot switch and press the Start button The auger motor will turn but the sweep will not move Turn the Manual switch to Forward and the sweep will move forward ...

Page 36: ...e Preparation 1 Be sure the sumps and unload conveyor are empty 2 Close the sump control gates 3 Park the sweep behind the intermediate sumps so that the sumps are on the auger side of the sweep 4 Shut down the auger 5 Make sure all fasteners are tight 6 After allowing the motors to cool down cover the motors with the tarps supplied with the sweep 7 Place blocks under the frame of the sweep to hel...

Page 37: ...rs etc are operating at the proper speed D Make sure ALL electrical wiring is not damaged and that it meets proper wiring codes E Make sure ALL components are in good working condition before use ALWAYS shut down and disconnect the power supply before adjusting servicing or cleaning the equipment ALL SPEED REDUCERS ARE SHIPPED DRY OIL MUST BE ADDED PRIOR TO OPERATION Do not operate the unit withou...

Page 38: ...ries II Sweep Control Package 08 32A 3 12A Non 575V S2PFA Series II Sweep Control Package 08 32A 3 12A Non 575V S2PFA Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 8 32 3 12 208 2 7 1 2 3 4 3 230 3 10 2 3 380 5 15 2 5 415 5 20 3 7 1 2 460 7 1 2 20 1 1 2 7 1 2 ...

Page 39: ...39 Series II Sweep Control Package 30 40A 3 12A Non 575V S2PFB Series II Sweep Control Package 30 40A 3 12A Non 575V S2PFB Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 30 40 3 12 208 10 3 4 3 230 15 2 3 380 20 2 5 415 20 25 3 7 1 2 460 25 30 1 1 2 7 1 2 ...

Page 40: ...ick Disconnect Control Box Kit Series II Sweep Control Package 08 32A 3 12A 575V Only S2PFC Series II Sweep Control Package 08 32A 3 12A 575V Only S2PFC Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 8 32 3 12 575 7 1 2 30 2 10 ...

Page 41: ...10 Control Panel Diagrams PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit 41 Control Panel Schematic 460 3 60 Pre June 2010 ...

Page 42: ...10 Control Panel Diagrams 42 PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit Control Panel Schematic 230 3 60 Pre June 2010 ...

Page 43: ...10 Control Panel Diagrams PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit 43 Control Panel Schematic 380 3 50 Pre June 2010 ...

Page 44: ...aking it fully loaded 2 The auger is moving too slowly 2 Check the auger speed Low capacity will result from speeds slower than recommended 3 Sweep does not move around the bin 1 The control panel may not be in Automatic Mode 1 Turn the switch to Automatic Mode 2 The amp meter is not properly adjusted 2 Set the amp meter so the running amps of the auger motor will turn ON the drive motor 3 The dri...

Page 45: ...Quick Detach Control Panel Pre June 2010 4 Dock Station Assembly GC10116 for Quick Detach Control Panel Pre June 2010 5 Conduit Assembly GC10113 for Quick Detach Control Panel 6 Drop Cord Assembly GC10079 for Quick Detach Control Panel Pre June 2010 7 Quick Detach Control Panel Receptacles Parts 8 Quick Detach Control Panel Package GK80112 9 Lift Base Panel Assembly GK80108 10 Lift Base Dock Assem...

Page 46: ...12 Parts List 46 PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit Control Panel Components Pre June 2010 Style Panel ...

Page 47: ...3P4W 50A 3 PH 480V CS8165C 7 GC03669 Receptacle 3P4W 20A 3 PH 480V L16 20R HBL2430SW N S GC03670 Plug 3P4W 20A 3 PH 480V L16 20P HBL2431SW 8 GC06954 Receptacle 2P3W 20A 277V L7 20R HBL2330SW 9 GC06956 Blank 2 Position Maint Plastic GE P9XSMD0N 10 GC06957 Switch 3 Position Lever SL Momentary GE P9XSVU3N 11 GC06958 Switch Standard Round Push Button Plastic Flush Green GE P9XPNVG 12 GC06959 Contact B...

Page 48: ...isconnect Control Box Kit Quick Detach Control Panel Assembly GC10115 Pre June 2010 Quick Detach Control Panel Assembly GC10115 Pre June 2010 Parts List Ref Part Description Qty 1 GC10109 Control Box Base 1 2 GC10116 Dock Station Assembly 1 3 GC10079 Drop Cord 1 ...

Page 49: ...l Back BB602W 60A with 1 1 2 Hub Hubell 1 3 GC10073 Inlet 1 4 S 6998 Bolt HHCS 1 4 20 x 1 ZN Grade 5 3 5 S 2041 Split Lock Washer 1 4 ZN 3 6 S 1120 Hex Nut 1 4 20 ZN Grade 5 3 7 GC10113 Conduit Assembly 1 8 F 7050 Plastic Handle 2 9 S 9315 Screw SMSAB 1 4 x 1 1 4 HWHS ZN 4 10 S 8166 Screw SMSAB 1 4 x 1 HWH ZN 4 11 DC 1756 Decal Warning Lifting Hazard 2 N S GC10224 Wire 6 Gauge x 3 Stranded Black 3...

Page 50: ...nel Pre June 2010 Dock Station Assembly GC10116 Parts List Ref Part Description Qty 1 GC10103 S2S2 Fixed Base Weldment Kid Control Box 1 2 GC10071 Box S2S2 Electrical Back BB602W 60A with 1 1 2 Hub Hubell 1 3 GC10072 Receptacle 1 4 S 6998 Bolt HHCS 1 4 20 x 1 ZN Grade 5 3 5 S 2041 Split Lock Washer 1 4 ZN 3 6 S 1120 Hex Nut 1 4 20 ZN Grade 5 3 ...

Page 51: ...p Quick Disconnect Control Box Kit 51 Conduit Assembly GC10113 for Quick Detach Control Panel Conduit Assembly GC10113 Parts List Ref Part Description Qty 1 GC10111 Elbow 1 1 2 Conduit 1 2 GC10110 Hub 1 1 2 Conduit 1 3 GC10112 Nipple 1 1 2 Conduit 2 ...

Page 52: ...ck Disconnect Control Box Kit Drop Cord Assembly GC10079 for Quick Detach Control Panel Pre June 2010 Drop Cord Assembly GC10079 Parts List Ref Part Description Qty 1 GC10078 S2S2 Electrical Cable for Drop Cord 1 2 GC10074 Plug Male 1 3 GC10075 Plug Female 1 ...

Page 53: ...P4W 60A 3 PH 600V HBL460R5W 2 S2PFA Series II Sweep Control Package 08 32A 3 12A Non 575V 2 S2PFB Series II Sweep Control Package 30 40A 3 12A Non 575V 2 S2PFC Series II Sweep Control Package 08 32A 3 12A 575V Only 3 GC03666 Receptacle 3P4W 50A 3 PH 480V CS8169 4 GC03667 Cover 50A Receptacles FS FD Mount 1 Gang HBL7774WO 5 GC03669 Receptacle 3P4W 20A 3 PH 480V L16 20R HBL2430SW 6 GC06954 Receptacl...

Page 54: ...ep Quick Disconnect Control Box Kit Quick Detach Control Panel Package GK80112 Quick Detach Control Panel Package GK80112 Parts List Ref Part Description 1 GK80110 Lift Base Dock Assembly 2 GK80108 Lift Base Panel Assembly 3 GK80111 Drop Cord Assembly ...

Page 55: ...d Assembly 2 F 7050 Plastic Handle 3 S 9315 Screw SMSAB 1 4 x 1 1 4 HWHS ZN 4 DC 1756 Decal Warning Lifting Hazard 5 GC11769 Receptacle Female 3P4W 60A 3 PH 600V HBL460R5W 6 S 8166 Screw SMSAB 1 4 x 1 HWH ZN 7 S 7447 5 16 18 x 1 Serrated Flange Bolt Stainless Steel 8 S 8452 5 16 18 Serrated Flange Nut Waxed Stainless Steel N S GC10224 Wire 6 Gauge x 3 Stranded Black N S GC10225 Wire 6 Gauge x 3 St...

Page 56: ...Parts List Ref Part Description 1 GC10103 S2S2 Fixed Base Weldment Kid Control Box 2 GC10071 Box S2S2 Electrical Back BB602W 60A with 1 1 2 Hub Hubell 3 GC11769 Receptacle Female 3P4W 60A 3 PH 600V HBL460R5W 4 DC 889 Decal Danger High Voltage 5 S 6998 Bolt HHCS 1 4 20 x 1 ZN Grade 5 6 S 2041 Split Lock Washer 1 4 ZN 7 S 1120 Hex Nut 1 4 20 ZN Grade 5 ...

Page 57: ...6 Series II Sweep Quick Disconnect Control Box Kit 57 Drop Cord Assembly GK80111 Drop Cord Assembly GK80111 Parts List Ref Part Description 1 GC10078 S2S2 Electrical Cable for Drop Cord 2 GC11770 Plug Male 3PW4 60A 3 PH 600V HBL460P5W ...

Page 58: ...58 PNEG 1366 12 and 16 Series II Sweep Quick Disconnect Control Box Kit NOTES ...

Page 59: ... DESIGN OF SUCH PRODUCTS The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paid for the product purchased This Warranty only covers the value of the warranted parts and equipment and does not cover labor charges for removing or installing defective parts shipping charges with respect to such parts any applicable sales or other taxe...

Page 60: ...e regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made GSI Group 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2010 by GSI Group Printed in the USA ...

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