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19

V. MAINTENANCE AND REPAIR

DANGER

FAILURE TO OBSERVE ALL SAFETY RULES, WRITTEN AND IMPLIED, AND THOSE

SUGGESTED BY COMMON SENSE, CAN RESULT IN DEATH, SERIOUS INJURY, AND /OR

EQUIPMENT DAMAGE. LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE.

5.1 General Maintenance

A good maintenance program involves thorough general housekeeping, adequate periodic re-lubrication, and

replacement of worn or damaged components.

5.2 Periodic Inspection

At regularly scheduled intervals, while observing all safety precautions, observe the sampler as it operates.

Inspect for:

A. Loose or missing hardware

B. Noisy motor or motor/reducer bearings

C. Overheated motor or reducer

D. Adequate lubricant in gear reducer

E. Structural damage

F. Rust or corrosion

G. Damaged wiring, including exposed conductors and connections

H. Make sure that all guards are in place and that all warning labels are in place and legible. Section

I, GENERAL SAFETY INFORMATION, explains the purpose and intended location of the warning signs.

Warning signs are an important part of any safety program; replace any missing signs IMMEDIATELY!

5.3 Lubrication
5.3.1 Auger & Auger Tube Spur Gears

The auger & auger tube spur gears are designed to run dry. If grease is applied to the gears, extra care must be

taken to ensure that the grease remains free from contaminates.

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Summary of Contents for GSS-U

Page 1: ...P MA M AFETY STALLATIO PERATION AINTENAN M A N U ON NCE U A L O ww S Mod No Re 9575 N Omaha Nebra 402 ww intersyst SAMP del GS o PC 519 evised 200 109th Ave ska 68142 330 1500 tems net PLER SS U 9824C 9 08 07 ...

Page 2: ...S 2 12 4 1 2 SAMPLING MODE Switch S 3 Automatic Manual 12 4 1 3 MANUAL SAMPLING Switch S 4 12 4 1 4 CONTINUOUS SAMPLING Switch S 5 12 4 1 5 POWER Pilot Light 12 4 1 6 SAMPLING Pilot Light 12 4 1 7 Digital Display Timer T 1 Standard 13 4 1 8 Digital Display Counter C 1 Optional 14 4 1 9 Printed Circuit Board 15 4 1 9 1 Main Fuse 15 4 1 9 2 Motor Fuse 15 4 1 9 3 PC Board Fuse F3 15 4 1 9 4 Motor Tim...

Page 3: ...eplacement Parts 25 7 4 Repair Kits 25 VIII WARRANTY 29 List Of Illustrations Drawings FIGURE 1 1 GSS U SAMPLER SAFETY LABEL LOCATIONS 4 FIGURE 2 1 TYPICAL INSTALLATION MODEL GSS U SAMPLING SYSTEM 5 FIGURE 4 1 STANDARD NEMA 4 CONTROL PANEL DETAIL 11 FIGURE 4 2 PRINTED CIRCUIT BOARD 15 FIGURE 4 3 LIMIT SWITCH CONNECTIONS 17 FIGURE 5 1 LIMIT SWITCH CAM ADJUSTMENT 20 DRAWING 525255 GSS U SAMPLER DRIV...

Page 4: ... its operating environment Careless changes could result in death or serious injury to people and reduce the performance and service life of the equipment Never perform any service on this equipment or any other powered equipment until all power has been shut off and locked out so that it cannot be restored without the consent and knowledge of the person who interrupted power Power includes electr...

Page 5: ...4 FIGURE 1 1 GSS U SAMPLER SAFETY LABEL LOCATIONS ...

Page 6: ...motor operating through a right angle gear reducer rotates the drive housing input shaft The clutch solenoid which energizes at the same time the motor starts allows the slotted sampling tube auger tube in the product line to rotate through one revolution to collect a sample of the material As the auger tube rotates the sample auger also is turning and continues to auger material out of the auger ...

Page 7: ...s 1 Groups D Division 1 2 Class 2 Groups E F G Division 1 2 The explosion proof sampler control is available in two enclosure classifications 1 The NEMA 9 control with the rating of Class 2 Groups E F G Division 1 2 2 The NEMA 7 control with the rating of Class 1 Groups C D Division 1 2 Class 2 Groups E F G Division 1 2 C Components of special materials such as 316 stainless steel monel inconel or...

Page 8: ... flow conveying line carrying the product to be sampled as in Figure 2 1 The sampler axis must be installed perpendicular at a 90 degree angle to the axis of the product line for optimum performance 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...

Page 9: ...tube Verify that the auger tube rotates without interference F Install the sampler drive assembly by re installing the hinge pins 3 4 3 Field Mounted Sampler Using Weld On Plates Weld on plates are typically used when mounting the sampler to a large existing surface such as on a storage hopper or a long section of chutework A Locate and mark the desired mounting location on the conveying line B Cu...

Page 10: ...w material to flow via gravity to a convenient collection point At that point the sample line may be connected to a collection jar bracket or a Sample Collection System cabinet Make all connections airtight and make sure all interior surfaces of joints are smooth and flush Any ragged or raised tube ends will collect dust and debris as well as retard material flow Air leaks can interfere with the p...

Page 11: ...t from any vibration originating in the product conveying line and sampler 3 7 1 Electrical Power Requirements System 110 120 VAC 50 60 Hz Single Phase 15 Amp Service Optional 220 240 VAC 50 60 Hz Single Phase 10 Amp Service Refer to the certified electrical drawing s for specific wiring requirements Intersystems strongly recommends that electrical service to the sampling system be an isolated lin...

Page 12: ...D BY COMMON SENSE CAN RESULT IN DEATH SERIOUS INJURY AND OR EQUIPMENT DAMAGE LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE 4 1 Control Components And Their Functions FIGURE 4 1 STANDARD NEMA 4 CONTROL PANEL DETAIL Refer to the certified electrical drawing s for dimensions on control panels with optional features ...

Page 13: ... the OFF or Normally Open position Correct operating procedure is to momentarily actuate S 4 to the Start position When the SAMPLING light is illuminated release the switch The sampler will complete its cycle without further operator intervention 4 1 4 CONTINUOUS SAMPLING Switch S 5 This switch functions ONLY when the AUTO MANUAL switch has been set to the Manual Mode position Setting the Continuo...

Page 14: ...gular Time Out symbol appears to the left of the digits The Timing Bar blinks noticeably faster at time out 2 SETTING SWITCHES The three digits are set with the rotary switch knobs located beneath each digit These knobs can be rotated in either direction CW or CCW and they are pull removable if digit set security is desired Changing one or more digits during timing will instantly be reflected by a...

Page 15: ...ppears to the right of the digits and blinks once every count regardless of range When the delay relay is energized at count out a triangular Count Out symbol appears to the left of the digits 2 SETTING SWITCHES The three digits are set with the rotary switch knobs located beneath each digit These knobs can be rotated in either direction CW or CCW and they are pull removable if digit set security ...

Page 16: ... ONLY a Buss Type FNM 10 Amp 250 Volt Slo Blo fuse or equal For 220 240 VAC 1PH operation use ONLY a Buss Type FNM 5 Amp 250 Volt Slo Blo fuse or equal 4 1 9 3 PC Board Fuse F3 This fuse located to the right on the middle of the board protects the printed circuit board against overloads and short circuits Use ONLY a Buss Type AGC 1 1 2 Amp 250 Volt fast acting fuse or equal 4 1 9 4 Motor Timer Swi...

Page 17: ...to 99 seconds The timer is factory set at 4 seconds Refer to Section 4 1 9 4 for further explanation on time settings 4 1 9 6 Motor LED Indicator This LED D1 is illuminated when power is present to K 1 relay coil on the PC board It is a visual signal showing when the motor should be running 4 1 9 7 Solenoid LED Indicator This LED D2 is illuminated when power is present to K 2 relay coil on the PC ...

Page 18: ...ch This switch is actuated when the auger tube is in its home position Upon initiation of a sample cycle the auger tube rotates the cam tripping the limit switch The normally closed contacts on the limit switch close and power is supplied directly to the clutch solenoid When the limit switch is actuated the opening of the normally closed contacts removes power to the clutch solenoid thus stopping ...

Page 19: ... This solenoid when energized pulls the clutch actuator from the catch on the clutch and allows the clutch to engage The output shaft on the gear reducer rotates the clutch and clutch gear which in turn rotates the auger tube ...

Page 20: ... Loose or missing hardware B Noisy motor or motor reducer bearings C Overheated motor or reducer D Adequate lubricant in gear reducer E Structural damage F Rust or corrosion G Damaged wiring including exposed conductors and connections H Make sure that all guards are in place and that all warning labels are in place and legible Section I GENERAL SAFETY INFORMATION explains the purpose and intended...

Page 21: ... 4 1 Limit Switch Cam Adjustment The limit switch cam actuates the limit switch by pushing the switch plunger inward The correct cam position is shown in Figure 5 1 Follow the instructions below A Shutoff and lockout all power B Remove the six 1 4 20UNC hex head screws attaching the cover to the sampler drive housing C Loosen the two 1 4 20UNC hex head screws attaching the limit switch cam to the ...

Page 22: ...d screws attaching the cover to the sampler drive housing C Disconnect the solenoid electrical connection and conduit D Remove the old solenoid from the solenoid bushing E Install the new solenoid use care to avoid cross threading F Solenoid adjustment may be required When solenoid is powered it should just clear the stop cog on the clutch The solenoid will chatter and not release the clutch if po...

Page 23: ... new clutch F Make sure key is in place on reducer shaft and re install the clutch so that the clutch and limit switch cam are positioned as shown in figure 5 1 G Turn the motor fan shaft by hand in the direction labeled on the motor and in figure 1 1 The clutch will rotate until the stop cog engages on the clutch actuator and stops further rotation of the auger tube The limit switch cam should be...

Page 24: ...hematic Power light On PC board fuse is blown Replace Refer to Section 4 1 9 3 Motor fuse is blown Replace Refer to Section 4 1 9 2 Defective clutch solenoid Replace Refer to Section 5 4 2 Sampler timer T 1 digital display does not illuminate but sampler Defective auto manual switch S 2 Replace switch if line voltage is absent across 1 2 on timer T 1 works in manual mode Defective timer T 1 Replac...

Page 25: ...ay timer T 1 does not illuminate when in auto Motor fuse blown Replace Refer to Section 4 1 9 2 mode Defective PC board Replace Motor and or solenoid times cannot be adjusted Defective PC board Replace Solenoid LED illuminates but no Defective PC board Replace full line voltage signal at terminal 13 Improper ground wiring Correct See note below Motor LED illuminates but no full Motor fuse blown Re...

Page 26: ...NSTALLED 7 3 Replacement Parts The Intersystems sampler is a quality built piece of machinery As with any machine parts do wear out and fail It is Intersystems recommendation that a small 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...

Page 27: ...26 This page intentionally left blank ...

Page 28: ...27 REPLACE THIS PAGE WITH DRAWING 525255 ...

Page 29: ...28 REPLACE THIS PAGE WITH DRAWING 525256 ...

Page 30: ... 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 warranty does not cover compone...

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