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Bucket Elevator

Installation and Operation Manual

PNEG-2116

Version: 1.0

Date: 12-12-16

PNEG-2116

Summary of Contents for InterSystems PNEG-2116

Page 1: ...Bucket Elevator Installation and Operation Manual PNEG 2116 Version 1 0 Date 12 12 16 PNEG 2116...

Page 2: ...Elevator All information illustrations photos and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any t...

Page 3: ...ing Trunk Sections for Ladder 19 Elevator Belt Selection 19 Elevator Erection Assembly 20 Ladder Assembly with Safety Cages 23 Typical Small Head Service Platform Assembly 25 Typical Large Head Servic...

Page 4: ...t chain shaft etc or gravity where the load or part of the equipment is suspended Never add restraint to an explosion vent If the elevator structure is damaged to the extent the relief panels will not...

Page 5: ...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...

Page 6: ...ymbol 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...

Page 7: ...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 eq...

Page 8: ...t power source before making adjustments cleaning or maintaining equipment ST 0076 1 Install and Operate Electrical Equipment Properly Electrical controls must be installed by a qualified electrician...

Page 9: ...oxic 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 u...

Page 10: ...authorized persons to have access to the equipment Access to the equipment must be restricted by the use of security fencing and lockable gates Lower sections of ladders must be fitted with a lockable...

Page 11: ...f Sheet Below is a sign off sheet that can be used to verify that all personnel have read and understood the safety instructions This sign off sheet is provided for your convenience and personal recor...

Page 12: ...read and understood by all personnel involved in the installation operation service and maintenance of the equipment To replace a damaged or missing decal contact us to receive a free replacement Inte...

Page 13: ...ye Protection vent during operation Explosion release will cause severe injury or death Stay clear of area around explosion DANGER DANGER Reorder No EMC 12 J3 C Clarion clarionsafety com Exposed bucke...

Page 14: ...Clarion Clarionsafety com WARNING Moving parts can crush and cut Do NOT operate with guard removed Lockout power before removing guard or servicing Reorder No EMC 24 J3 C Clarion clarionsafety com WA...

Page 15: ...H IS 504X3 Platform Limits For I S platform only I Intersystems Serial Number Tag J IS 5210X8 Intersystems Logo Ref Decal Decals Description WARNING Platform Maximum Concentrated Load 100 lbs SQ FT No...

Page 16: ...elevator installation review this manual the certified drawing s furnished with the equipment and other applicable documents including but not limited to O S H A Regulations and the National Electric...

Page 17: ...raffic 2 Guy cables near ground level must be guarded and made visible to prevent injuries 3 Figure 4B shows the proper method for unspooling cable from a reel Figure 4A Guy Bracket Detail Figure 4B P...

Page 18: ...e of the inlet effects the capacity and the condition of the elevated material Too small an inlet means the material must be fed into the boot at excessive speed The excess velocity of incoming materi...

Page 19: ...Positioning Trunk Sections for Ladder Study the drawings to determine where each trunk section fits into the overall layout of the elevator leg This is important so that platforms and ladders can be a...

Page 20: ...n Page 21 Because of the weight of the elevator s head section InterSystems recommends that it always be hoisted in a separate lift and then fastened to the rest of the elevator 1 Lift the boot onto t...

Page 21: ...Typical Foundation H Heavier Gauge Casings if Required C Bottom Level or Grade I Typical Rest Platform D Boot First Section J 3a through 3 n Elevator Height E Expansion Bolt and Anchoring Plates by O...

Page 22: ...on standard height elevator section the certified drawings furnished with the elevator will indicate its intended position usually immediately above the inspection section 5 Plumb each elevator sectio...

Page 23: ...xtend upward through the platform opening to the level of the platform s top rail b An elevator may include a short section of trunk In these cases an extra 10 section of ladder and safety cage is fur...

Page 24: ...er Cage NOTE Repeat the same procees to assemble the remaining safety cages Ref Description Ref Description A Hoop Half F Ladder Seam Splice B Cage Rail Package 44 Sections G Standoff Brackets C Hoop...

Page 25: ...16 Bucket Elevator 25 Typical Small Head Service Platform Assembly Figure 4J Typical Small Head Service Platform Assembly Typical Large Head Service Platform Assembly Figure 4K Typical Large Head Serv...

Page 26: ...al Head Service Hatch Assembly Figure 4L Typical Head Service Hatch Assembly Ref Description A Hatch Door B Ladder Section C Locking Clip D Ladder Bracket E 5 16 Nut F Perfstrut Deck G Hatch Frame Sid...

Page 27: ...f belt bucket installation and belt splicing are covered in the following paragraphs See Figure 4M below and Figure 4Q on Page 33 Figure 4M Belt and Bucket Installation Ref Description Ref Description...

Page 28: ...shed with the elevator identify the belt to be used either as furnished by InterSystems or as specified by the customer if provided by others The drawings also specify the type size number spacing and...

Page 29: ...Ref Description Ref Description Q Pillow Block Bearing W Lift Here to Raise Pulley S Boot Assembly X Access Door T Removable Cover Y Connection Bolts U Weight Box Z Guide Rollers V Alignment Adjusting...

Page 30: ...f the take up boot bearings etc provides proper belt tension in most applications Additional weight may cause damage to the belt Method 1 Simultaneous Belt and Bucket Installation Less than 100 IMPORT...

Page 31: ...the belt should contact the pulleys and which side should face outward and contact the buckets 2 Connect the haulage line to the end of the belt preferably by means of a spreader bar 3 Begin hauling...

Page 32: ...el to permit tracking of the belt and satisfactory elevator operation 1 Lap Splice View A on Page 33 This is the easiest splicing method Make sure the belt ends overlap as shown so the inner belt end...

Page 33: ...s where belt is spliced H Three 3 bucket overlap on each side of seam between splice ends B Bevel Pulleyside End I Ends of Main Belt C Eye Bolt J Nut D Structural Angle Spreader Bar K Lock Washer E Pr...

Page 34: ...ent must be held to the limits specified to achieve the expected service life In any event the engineer or contractor overseeing elevator installation is responsible for proper installation and operat...

Page 35: ...llow block until both ends of the head shaft are level Shim between the pillow block and its mounting surface Shims should be as nearly equal to the area of the pillow block base as possible so as not...

Page 36: ...keys allowing the pulley to move laterally on the shaft 2 Loose bearing or bearing support 3 Weak or bent head pulley shaft Other Causes of Boot Pulley Misalignment 1 Grain entering the boot at an an...

Page 37: ...justment will minimize one cause of down legging IMPORTANT For lap or butt spliced belt increase the clearance dimension between the rubber throat slide and the buckets by the thickness of the belt to...

Page 38: ...hain drive compare the number of teeth of the drive and driven sprocket Verify that the resultant ratio taken together with the reducer s output speed will produce the specified final pulley RPM If th...

Page 39: ...pty Be certain you know the exact empty and gross weight of the truck train car or whatever you are using for the test 2 Start the elevator and make certain it is running properly and ready to receive...

Page 40: ...ly 3 minutes shut down the feed to the leg 5 After the entire system empties check the throughput on the bulkweigh system and use the formula below to calculate BPH capacity 1 lbs through bulkweigh lb...

Page 41: ...chedule a change of lubricant as soon as possible d Listen carefully for a noisy motor reducer or bearings or a rubbing belt Any of these sounds can be a forewarning of overheating and fire or explosi...

Page 42: ...of the reducer for specific recommendations Motor Many motors have sealed and permanently lubricated bearings with these no re lubrication is possible or desirable If bearings of this type become nois...

Page 43: ...thod of tracking the belt READ THIS FIRST If a tracking problem exists and cannot be corrected by adjusting the boot take up but instead requires that the head and or boot pulley shaft pillow blocks b...

Page 44: ...44 PNEG 2116 Bucket Elevator NOTES...

Page 45: ...ory 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 ot...

Page 46: ...efully followed in all cases Authorities having jurisdiction should be consulted before installations are made InterSystems 9575 N 109th Ave Omaha Nebraska 68142 Toll Free 800 228 1483 www gsiag com C...

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