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GSi GCE 45, Installation And Operation Manual

The GSi GCE 45 is a top-of-the-line product that offers exceptional performance and versatility. To help you with its seamless installation and operation, we provide a comprehensive Installation And Operation Manual. This manual is available for free download at manualshive.com, ensuring you have easy access to the necessary instructions and guidance.

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CE Compliant GCE Sampler

Model:

 GCE 45 and GCE 90

Installation and Operation Manual -
Original Instructions

PNEG-2175CE

Version: 1.0

Date: 01-13-22

PNEG-2175CE

Summary of Contents for GCE 45

Page 1: ...CE Compliant GCE Sampler Model GCE 45 and GCE 90 Installation and Operation Manual Original Instructions PNEG 2175CE Version 1 0 Date 01 13 22 PNEG 2175CE ...

Page 2: ...0 C Dc without GSI Sentinel Controls In accordance with the following standards 1 All installation shall be in accordance with manual PNEG 2175CE 2 Sentinel controls shall not be installed inside the potentially explosive environment Signed IEC 60079 0 2017 Explosive atmospheres Part 0 Equipment General requirements EN ISO 80079 36 2016 Explosive atmospheres Part 36 Non electrical equipment for ex...

Page 3: ... Guarding of Moving Parts 19 Safety in Maintenance and Servicing 20 Chapter 5 Installation 21 Receiving Inspection 21 Pre Installation Preparation 21 Location 21 General Mounting Guidelines 21 Material Sample Transport Lines 22 Controller Location 22 Field Wiring 22 Chapter 6 Operation 23 Sampler Controls 23 Configuring the Controls 26 Chapter 7 Wiring Diagrams 28 CE Control Electrical Layout 28 C...

Page 4: ...ble with their system and adequate power is supplied to the unit 4 Consult InterSystems before making any changes to the sampler or its operating environment Careless changes could result in death or serious injury to people and reduce the performance and service life of the equipment 5 Never perform any service on this equipment or any powered equipment until all power has been shut off and locke...

Page 5: ...supply of spare parts be kept on hand to cover any minor breakdowns A separate priced spare parts list will be sent identifying the suggested spare parts It is also necessary to check the certified drawings which will list any special or custom components utilized on this equipment Repair Kits The following chart lists repair kits and parts that are available from InterSystems These kits are offer...

Page 6: ...ons must stay out of the work area at all times Alterations must not be made to the equipment Alterations can produce dangerous situations resulting in SERIOUS INJURY or DEATH This equipment must be installed in accordance with the current installation codes and applicable regulations which must be carefully followed in all cases Authorities having jurisdiction must be consulted before installatio...

Page 7: ...ON NOTICE This symbol indicates an imminently hazardous situation which if not avoided will result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided can result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury This symbol is used to address practices no...

Page 8: ... up and back ST 0004 1 Follow Safety Instructions Carefully read all safety messages in this manual and safety signs on your machine 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 machine and how to use contro...

Page 9: ...nstallation Not following these safety precautions creates the risk of falling equipment which could crush personnel and cause serious injury or death ST 0047 1 Sharp Edge Hazard This product has sharp edges which can cause serious injury To avoid injury handle sharp edges with caution and always use proper protective clothing and equipment ST 0036 2 Install and Operate Electrical Equipment Proper...

Page 10: ...g equipment ST 0070 1 Flying Material and High Pressure Air Hazard Flying material and or high pressure air can cause severe eye injury or blindness Wear safety glasses around operating equipment ST 0071 1 Stay Clear of Rotating Parts Do not service equipment while it is in operation Entanglement in rotating parts or exposed belts will cause serious injury or death Keep all shields and covers in p...

Page 11: ...ide or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before...

Page 12: ... and maintenance of the equipment To replace a damaged of missing decal contact us to receive a free replacement InterSystems 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 Figure 3A GCE Sampler Safety Label Locations NOTE These signs must never be removed tampered with painted over or obscured in anyway If labels are damaged or become unreadable replacement la...

Page 13: ...onsafety com WARNING Avoid serious injury or death This machine MUST be locked out in accordance with current OSHA requirements before any maintenance or service is performed Reorder No EMC 402 34 16089 C Clarion Clarionsafety com WARNING Stay clear Machine starts without warning C Clarion clarionsafety com Reorder No EMC 403 34 400 V AC 3 ph 50 hz 7A FLC II2 2D Ex h IIIB T100 C Db 1234567 10 C 40...

Page 14: ...4 Exposed Belt Ref Decal Decals Description WARNING Flying material can cause severe eye injury or blindness No EMC 28 34 Wear safety glasses around operating equipment 15225 C Clarion DC 2553 WARNING Moving parts can crush and cut No EMC 24 34 Lockout power before removing guard or servicing Do NOT operate with guard removed C Clarion ...

Page 15: ...of the more frequently specified optional features are briefly described in the following list 1 Controller arranged to initiate a sampling cycle based on quantity or volume of material passing through conveying line rather than upon elapsed time periods 2 ATEX compliant sampler for use in dusty atmospheres and with internal zone designated up to ATEX zone 21D NOTE ATEX compliant sampler does not ...

Page 16: ...ons 16 Operators should be aware of health risks from dusts mould and other biological agents from the materials being sampled Overall design of the facility in which the sampler operates shall minimize this exposure and personal protective equipment PPE shall be used to further reduce risks if required NOTE The sampler may be installed or used in a potentially explosive environment ONLY when spec...

Page 17: ...49 6 The electrical supply shall include a properly designed protective earth system PE with connection to all exposed conductive parts 7 All motors shall be connected to protective earth at the terminal provided 8 The control system shall include a Short circuit protection b Start stop controls labelled 1 and 0 respectively 9 Equipment shall not immediately restart following re establishment of p...

Page 18: ...ernal thermal switches These must be installed into the control system in the locations provided or for non GSI controls in the location identified by the control manufacturer 2 Where user designed controls are used the controls shall be designed to provide a minimum level of ignition protection b1 or be designed to meet the requirements of control of ignition sources to explosion protection level...

Page 19: ...solated and locked out from the power supply 6 Never operate the sampler with the guards removed Possible Ignition Sources Equipment related Yes No Reason Controls Hot Surfaces Yes Sliding friction of moving parts on static parts Surface temperature of gearbox and motor Slipping torque tamer clutch Bearing temperatures Constructional safety Control of ignition sources Surface temperature control O...

Page 20: ...lely in the possession of the service technician The sampler operates under automatic control and will start without warning Working in or on a sampler that has not been disconnected and locked out can result in very serious injury It may also be necessary to isolate other equipment associated with or attached to the sampler 3 Safe Troubleshooting In extreme circumstances when troubleshooting a ma...

Page 21: ...the axis of the product line for optimum performance Additionally the sampler should be located where the product has a non turbulent flow pattern The sampler and associated equipment should be located for ease of access and maintenance The sampler is to be installed only as shown on the certified drawing s If an alternate mounting arrangement is desired contact InterSystems prior to installation ...

Page 22: ...nclosure or mount the controller in a vibration free location 2 Locate controller so it is protected from water and dust 3 DO NOT locate the controller in explosion risk area 4 Most applications require that the sampler be in easy view of the controller 5 Ideally controllers should be installed at ground level inside or on a suitable work platform making controls readily accessible to the operator...

Page 23: ...r loss or shut down via the isolator or service disconnect the sampler control must be reset before sampling can proceed Reset Button Pressing the reset button 3 following normal power up will reset the sampler to home position fully to the right and leave the control in stand by The status indicator 4 will remain steady ON Stand By Sample Switch The stand by sample switch 5 when turned to sample ...

Page 24: ...pler Status Fault Indicator This status fault indicator 4 has several modes depending on the status of the sampler Mode Description Steady ON Control is reset and in manual mode Continuous flash 1 Hz Safeties satisfied awaiting reset Continuous flash 4 Hz Control in automatic mode Sequence of 2 flashes Limit switch fault Incorrectly wired or stuck Sequence of 3 flashes Panel E stop is open Sequenc...

Page 25: ...rol Ref Description Ref Description 1 Main Isolator 8 Sample Timer 2 Power Light 9 Emergency Stop 3 Reset Button 10 Position Indicator 4 Status Fault Indicator 11 Position Indicator 5 Stand By Sample Switch 12 Right Indicator 6 Sample Button 13 Left Indicator 7 Mode Button 1 4 2 8 7 13 12 10 11 9 6 5 3 ...

Page 26: ...sult in potential damage IMPORTANT Do not set the ON time any less than 0 5 seconds This can result in the start signal not being recognized by the controller Setting the Auto Reverse Time Auto reverse is a safety feature built into the control to detect potential blockage or damage to the sampler resulting in it not being able to complete the traverse from left to right or vice versa In this situ...

Page 27: ...or closing knife jumpers A B C and D located inside the control enclosure according to the table below Reverse Time s Switch Status 1 CLOSED 0 OPEN A B C D 1 2 0 0 0 0 1 4 1 0 0 0 1 6 0 1 0 0 1 8 1 1 0 0 2 0 0 0 1 0 2 2 1 0 1 0 2 4 0 1 1 0 2 6 1 1 1 0 2 8 0 0 0 1 3 0 1 0 0 1 3 2 0 1 0 1 3 4 1 1 0 1 3 6 0 0 1 1 3 8 1 0 1 1 4 0 0 1 1 1 4 2 1 1 1 1 ...

Page 28: ...PLY SAMPLER MOTOR 2 2 KW 400 VAC 50 Hz THERMALLY PROTECTED DIVIDER MOTOR 60 W 400 VAC 50 Hz THERMALLY PROTECTED RIGHT HAND LIMIT SWITCH LEFT HAND LIMIT SWITCH LOCKABLE SERVICE DISCONNECT SWITCH S10 EXTERNAL EMERGENCY STOP SWITCH CONTROL ENCLOSURE 400 VAC 3 CORE PE MINIMUM 2 5 mm 2 24 VDC 2 CORE MINIMUM 1 5 mm2 400 VAC 3 CORE PE MINIMUM 1 5 mm 2 24 VDC 2 CORE MINIMUM 1 5 mm 2 400 VAC 6 CORE PE MINI...

Page 29: ...making connections to the sampler and divider components refer to the certified drawing provided with your controls See Figure 7B on Page 30 Figure 7C on Page 31 and Table below Electrical Connections Item Voltage Maximum Current Terminal Block Numbers Power Supply TPN 400 VAC 10 Amp X1 1 2 3 N PE Service Disconnect Switch 400 VAC 10 Amp X1 4 5 6 7 8 9 PE Sampler Motor 400 VAC 7 Amp X2 1 2 3 PE Di...

Page 30: ...7 Wiring Diagrams 30 PNEG 2175CE CE Compliant Sampler Model GCE 45 and GCE 90 CE Control Motor Connections Figure 7B Motor Connections ...

Page 31: ...7 Wiring Diagrams PNEG 2175CE CE Compliant Sampler Model GCE 45 and GCE 90 31 CE Control Connections Figure 7C Control Connections ...

Page 32: ...en the knife switch on that terminal c The control should go into a non volatile lock out d Close terminal X3 2 e Reset the control f Locate terminal X3 4 and open the knife switch on that terminal g The control should go into a non volatile lock out h Close terminal X3 4 2 Sampler over speed testing shall be carried out by simulating a higher sample pelican speed 1 m s resulting in a non volatile...

Page 33: ... up of dust and debris which might result in over heating Clean and repair as required 2 Loose or missing hardware 3 Noisy motor or motor reducer bearings 4 Overheated motor or reducer 5 Adequate lubricant in gear reducer 6 Loose drive chain 7 Structural damage 8 Rust or corrosion 9 Damaged wiring including exposed conductors and connections 10 Make sure that all guards are in place and that all w...

Page 34: ...ctrical pneumatic and hydraulic 2 Shut down conveying line 3 Open the large inspection door on the sampler housing and the seal door over the sample cutter 4 Remove the 1 4 20 UNC hex head bolts fastening the sample cutter to the sample pelican 5 Using a utility knife cut the caulking seal around the bottom of the cutter blade and remove 6 Install the new cutter blade on the sample pelican 7 Re in...

Page 35: ...rough several collection cycles Drive Clutch Facings Bushing and Sprocket Replacement The drive clutch may need to be replaced if adjustment fails to prevent slippage When following the instructions below refer to the clutch detail on Page 36 Also reference the drawings of the samplers on Pages 38 and 41 and the certified drawing s 1 Shut off and lock out all power electrical pneumatic and hydraul...

Page 36: ...5CE CE Compliant Sampler Model GCE 45 and GCE 90 Figure 8A Drive Clutch Detail Ref Description 14 Clutch Hub 15 Splined Plate 16 Friction Facing 17 Adjusting Nut 18 Set Screw 19 Tension Screws 20 Bushing 21 Sprocket 22 Extra Clutch Spring ...

Page 37: ...low motor to cool and reset Defective timer T 1 Replace timer if line voltage is present across 1 and 2 on timer T 1 Sampler leaks air or material continuously out the sample discharge Sample cutter not stopping under the seals Adjust limit switch See Limit Switch Adjustment on Page 34 Sampler installed in a pressurized conveying line Eliminate pressure or relocate sampler Sample cutter worn Inspe...

Page 38: ...38 PNEG 2175CE CE Compliant Sampler Model GCE 45 and GCE 90 10 Parts List Sampler Model GCE 45 Parts NOTE The parts pointed out on this page are listed on Pages 39 and 40 ...

Page 39: ... BL14 14x14 16 x 16 512850 BL18 16x16 18 x 18 512036 BL18 18x18 20 x 20 512851 BL22 20x20 22 x 22 512037 BL22 22x22 24 x 24 512221 BL26 24x24 26 x 26 512038 BL26 26x26 28 x 28 512852 BL30 28x28 30 x 30 512039 BL30 30x30 Ref Part Description Qty 10 14 18 30 14 SPS 8 SPS 12 Slide Plate Seal 2 15 SPSBB 8 SPSBB 12 Slide Plate Seal Backup Bracket 2 16 SPSRB 8 SPSRB 12 Slide Plate Seal Retainer Bracket ...

Page 40: ...ive Guard 1 38 SG 10 P SG 14 P SG 18 45P GCE 45 Solid Guard Plain 1 39 SG 10 D SG 14 D SG 18 45D GCE 45 Solid Guard with Door 1 40 None None 512048 Expand Metal Guard Motor 1 41 None None 512042 Expand Metal Guard Idler 1 Ref Part Description Qty 22 26 30 30 512025 512026 512027 GCE 45 Housing 1 31 523812 523812 523812 Bumper Bracket 2 32 HOP 22 45 HOP 26 45 HOP 30 45 GCE 45 Discharge Hopper 1 33 ...

Page 41: ...10 Parts List PNEG 2175CE CE Compliant Sampler Model GCE 45 and GCE 90 41 Sampler Model GCE 90 Parts NOTE The parts pointed out on this page are listed on Pages 42 and 43 ...

Page 42: ...BS14 14x14 16 x 16 512850 BS18 16x16 18 x 18 512036 BS18 18x18 20 x 20 512851 BS22 20x20 22 x 22 512037 BS22 22x22 24 x 24 512221 BS26 24x24 26 x 26 512038 BS26 26x26 28 x 28 512852 BS30 28x28 30 x 30 512039 BS30 30x30 Ref Part Description Qty 10 14 18 30 14 SPS 8 SPS 16 Slide Plate Seal 2 15 SPSBB 8 SPSBB 16 Slide Plate Seal Backup Bracket 2 16 SPSRB 8 SPSRB 16 Slide Plate Seal Retainer Bracket 2...

Page 43: ...ive Guard 1 38 SG 10 P SG 14 P SG 18 90P GCE 90 Solid Guard Plain 1 39 SG 10 D SG 14 D SG 18 90D GCE 90 Solid Guard with Door 1 40 None None 512804 Expand Metal Guard Motor 1 41 None None 512799 Expand Metal Guard Idler 1 Ref Part Description Qty 22 26 30 30 512031 512032 512033 GCE 90 Housing 1 31 523812 523812 523812 Bumper Bracket 2 32 HOP 22 90 HOP 26 90 HOP 30 90 GCE 90 Discharge Hopper 1 33 ...

Page 44: ...44 PNEG 2175CE CE Compliant Sampler Model GCE 45 and GCE 90 NOTES ...

Page 45: ...tside of our factory or other than by an Authorized Service Representative This warranty does not cover the replacement of parts inoperative because of wear occasioned by use the cost of replacing parts by a person other than an InterSystems employee or an Authorized Service Representative or the adjustment of a product where the product was improperly adjusted by the purchaser In addition this wa...

Page 46: ...gulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2022 by The GSI Group LLC Printed in the USA CN 404870 ...

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