Gilson TS-1, TS-3, TS-2 Operating Manual

OPERATING MANUAL

Gilson Testing Screen

TS-1, TS-2, TS-3

TS-1 shown with Screen Trays and TSA-169R

PHONE: 800-444-1508 P.O. Box 200, Lewis Center, Ohio 43035-0200 740-548-7298 E-mail: customerservice@gilsonco.com Product Web Page: www.globalgilson.com

TS-2 shown with Screen Trays

TS-3 shown with Screen Trays

Rev: 05/2019

FAX: 80 0 -255-5314 740-548-5314

TABLE OF CONTENTS

Safety

Important Safety Instructions ��3

General Safety Warnings ��3

Testing Screen Safety Warnings ��3

During Operation ��3

Electrical Safety ��4

Specications

TS-1/TS-2/TS-3 Specications ��5

Uncrating

Uncrating Procedure ��5

Site Considerations

Anchoring to Concrete Floors ��6

Weight Load ��6

Machine Elevation ��6

Space Allocation ��6

Physical Environment ��6

Electrical Installation ��6

Installation

Level the Vibrating Assembly Unit ��7

Hydraulic System Check ��8

Verify Power Requirements ��8

Parts

TS-2 Clamp Rod Assembly ��20

Main Drive/Connecting Rod Assemblies ��21

TS-1/TS-3 Clamp Rod Assembly ��22

Hydraulic Hoses and Fittings ��22

Hydraulic Pump ��23

Corner Spring Assembly ��25

Driving Parts ��26

Frame, Cover, and Motor ��27

Schematics

TS-1/TS-2/TS-3 Wiring Diagram ��28

Operation

TS-1/TS-2/TS-3 Operation ��8

Sample Capacity

Coarse Aggregates ��9

Fine Aggregates ��10

Maintenance

Lubrication ��10

Removal of Top and Side/Back Covers �� 11

Drive Assembly ��11

Adjust or Replace the V-belt ��11

Connecting Rod Assembly �� 11

TS-2 Clamp Rod Assembly ��12

TS-2 Rod/Assembly Replacement ��13

TS-1/TS-3 Hydraulic Clamping Systems ��13

Hydraulic Pump ��15

Hydraulic Clamp Rod Assembly ��16

Wire Cloth and Screen Trays ��19

Screen Trays ��19

Troubleshooting

Noisy Operation ��19

Testing Screen Shuts O󰀨 ��19

Shifting of Materials ��19

Sluggish Start-Up or Operation ��19

Safety

WARNING:

DANGER:

WARNING:

CAUTION:

WARNING:

DANGER:

Important Safety Instructions

The buyer is responsible for ensuring that users are properly trained, that they are aware of all the information and instructions in this document, and that they are aware of the potential risks of operating the machine� The manufacturer will not be held responsible for any damage to people and/ or property caused by non-compliance with any instructions in this manual�

General Safety Warnings

Do not perform tasks on the machine other than those for which it was designed. Only use the machine in the manner in which it was intended, as described in this instruction manual.

• Keep work area clean and well lit�

• Keep children and bystanders away while operating the machine�

Testing Screen Safety Warnings

Read all safety warning and instruc-

tions. Failure to follow the warnings and instructions may result in electric shock, re, and/or serious injury. Keep these instructions for later use.

The purpose of safety symbols is to attract your attention to possible dangers� The safety symbols, and their explanations, deserve your careful attention and understanding� The safety warnings DO NOT by themselves eliminate any danger� The instructions or warnings they give are not substitutes for proper accident prevention measures�

Signals an EXTREME hazard. Failure

to obey a safety DANGER symbol WILL result in seri-

ous injury or death to yourself or to others.

Signals a SERIOUS hazard. Failure to

obey a safety WARNING symbol CAN result in seri-

ous injury to yourself or to others.

Signals a MODERATE hazard. Failure

to obey a safety CAUTION symbol MAY result in prop-

erty damage or injury to yourself or to others.

NOTE: Advises you of information or instructions vital to

the operation or maintenance of the equipment�

The Testing Screen is NOT explosion-proof or approved for operation in hazardous locations. Only operate the testing screen in a properly ventilated area. DO NOT operate in explosive or hazardous atmospheres, such as in the presence of

ammable liquids, gases or dust.

• The Testing Screen is NOT counterbalanced� It must be adequately mounted to a substantial, rigid foundation to prevent excessive vibration. A poured concrete oor is recommended�

• Level the Testing Screen before operation�

During Operation

Dress properly� DO NOT wear loose clothing or jewelry� Keep your hair, clothing and gloves away from moving parts� Secure hair above shoulder level� Loose clothes, jewelry or long hair can be caught in moving parts�

• DO NOT operate the machine without all guards and covers in place�

• Keep all body parts away from moving parts of the machine while it is in operation�

• Wear approved NIOSH/ MSHA respirator as required by the sample to prevent inhaling any dust which may be considered hazardous�

• Wear safety glasses or goggles that meet current ANSI / ISEA Z87�1 standards and are marked as such�

• Wear ear/hearing protection when operating this machine�

• If the machine starts to vibrate abnormally, stop the machine immediately� Inspect the machine for the cause of the vibration�

Electrical Safety

DANGER:

WARNING:

Electric Shock Hazard. Touching some

of the internal components can cause serious per-

sonal injury or death. Disconnect the power supply

before removing covers or performing maintenance on the machine.

Electric Shock Hazard. Improper use of the grounding can result in electric shock. Do not plug the machine into an outlet until it is properly installed and grounded.

The supply voltage must correspond

to that stated on the identication plate and in the technical specications. NEVER use any other type

of power supply.

Remove plug from the mains immediately if the cable is damaged or cut.

• This machine must be grounded� In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current� This machine is equipped with a cord having a grounding wire with a grounding plug� The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances�

• Do not modify the plug provided with the machine: if it

will not t the outlet, have a proper outlet installed by a qualied electrician.

• Consult a qualied electrician or service technician if the grounding instructions are not completely understood, or if doubt exists as to whether the machine is properly grounded�

• If it is necessary to use an extension cord, use only a 3-wire extension cord that has a 3-blade grounded plug, and 3-slot receptacle that will accept the plug on the machine� The marked rating of the extension cord shall be equal to or greater than the electrical rating of the machine�

• Make sure that the power cord does not come into contact with hot objects, wet or oiled surfaces, and/or sharp edges�

• The power cord should be checked regularly and before each use to check for signs of damage or wear� If the power cord is worn or damaged, replace the cord�

• Do not use the power cord to remove the plug from the socket or move the machine�

SAVE THESE INSTRUCTIONS

DANGER:

Specications

TS-1/TS-2/TS-3 Specications

Electrical �� 115V/60Hz/9�2A

Electrical (F Model)��230V/50Hz/4�7A

Motor type��Universal Motor

No load speed ��1725 RPM

Maximum ambient operating temperature �� 104º F (40ºC)

Hydraulic oil (TS-1 and TS-3) �� Shell Tellus 25 or Mobil AW 32

Estimated Shipping Weight (TS-1) ��405lb (184kg)

Estimated Shipping Weight (TS-2) ��399lb (181kg)

Estimated Shipping Weight (TS-3) ��454lb (206kg)

Uncrating

Uncrating Procedure

IMPORTANT: Save all packing materials until inspection

is complete�

Check the Testing Screen for damage immediately upon receipt� Examine the shipping carton before uncrating, then inspect the machine and trays before removal from the skid�

Pay particular attention to the covers on top of the Testing Screen� If any damage is noted, STOP HERE and notify the freight carrier to request an inspection� This inspection must include a check for internal damage to motor, drive, and clamping mechanisms� Follow the procedures in Maintenance section on page 10 to remove and reinstall the covers�

You must use lifting equipment to lift

and install this machine. Inspect all lifting equipment

to make sure it is in working order and rated for the load before attempting to lift. Ignoring this warning

may lead to serious personal injury or death.

4. Using proper lifting equipment, lift the machine about 6in

o󰀨 the oor. Securely block up the machine so that the

skid can be safely removed�Remove the skid, then set

the machine in place on the oor.

5. Inspect the machine to make sure all fasteners are tightened securely�

1. Lift the carton o󰀨 the Testing Screen. Set it aside in

case you need to return the machine because of shipping damage�

2. Locate the voltage label on the back of the Testing Screen� Make sure that the machine is wired as ordered�

3. TS-1/TS-3: Remove the ve screws that secure the

external pump cover to the top (Figure 3 on page 8)�

Lift the cover o󰀨 and look for oil leaks. Report any leaks

found to Gilson� If none, reinstall the cover and proceed�

Site Considerations

WARNING:

CAUTION:

DANGER:

The Gilson Testing Screen is a ruggedly-constructed machine that will provide years of service if installed correctly and maintained properly� Most cases of poor operation are caused by faulty installation� Problems can be avoided by careful planning before placing the machine into service�

Anchoring to Concrete Floors

Gilson recommends using lag shield anchors with lag

screws to anchor the machine to a poured concrete oor

(Fig� 1)� However, anytime local codes apply, you MUST follow the anchoring methodology specied by the code�

Machine Elevation

An elevated foundation for the machine allows for easier tray handling� However, this also elevates the loading area�

Space Allocation

Provide enough space around the machine for adequate operator material handling, the installation/removal of the screen trays, and maintenance on the machine�

Physical Environment

The physical environment where the machine is operated is important for safe operation and longevity of machine components� For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous or explosive atmospheres, or extreme conditions� Consider the noise and dust created by the machine and ensure that there is adequate ventilation for safe operation�

Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 104°F (40°C) or the relative humidity range exceeds 20%–95% (non-condensing)�

Fig. 1: Concrete Anchoring

Weight Load

NOTE: Install the machine on a level, rigid foundation�

Gilson recommends a poured concrete oor.

Make sure that the surface where the machine is placed will bear the weight of the machine and the weight of the testing materials� Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine�

Electrical Installation

Place this machine near an existing power source� Make

sure all power cords are protected from tra󰀩c, material

handling, moisture, chemicals, or other hazards� Make sure to leave enough space around machine to disconnect the power supply or apply a lockout/tagout device, if required�

Installation

Read all safety warning and instruc-

tions before installation. Failure to follow the warnings and instructions may result in electric shock,

re, and/or serious injury.

DO NOT connect the Testing Screen

to an electrical power source until you have mounted

the machine to its intended foundation, veried that

the machine is wired as ordered and is appropriate for your power source.

You must use lifting equipment to lift

and install this machine. Inspect all lifting equipment

to make sure it is in working order and rated for the load before attempting to lift. Ignoring this warning

may lead to serious personal injury or death.

NOTE: Note: 230V/50Hz models are shipped without a

power plug�

Lag screw mounting

22.25”

Mounting hardware is not provided� These additional items are required for proper lag screw installation on a poured

concrete oor:

Hardware Quantity

0�5in lag screws 4

0�5in lag shield anchor 4

Metal shims Varies

Procedure

1. Place the unit in the desired location. Mark the oor in

the center of the mounting feet�

2. Using lifting equipment, move the unit�

3. Conrm marked mounting location matches the

mounting template (Fig� 2)�

4. Install the lag screw shield anchors in the marked locations�

5. Using lifting equipment, return the unit to the mounting location�

34” 32”

20.50”

Fig. 2: Mounting Template

3. Conrm marked mounting location matches the

mounting template (Fig� 2)�

4. Install the anchor bolts in the marked locations, leaving 1�5in of thread exposed to allow for the mounting feet, shims, and nuts�

6. Place a at washer on the lag bolts and install the lag

screws in the mounting anchors� Do not fully tighten the screws�

7. Initially level the units’ outer case, both front-to-back and side-to-side� Do this by placing and/or removing metal shims under the feet until the top of the unit is level along all four edges�

NOTE: The Testing Screen must be level for proper test

results and best operation of the machine�

8. Tighten the lag bolts equally on all four mounting feet, making sure the unit’s case remains level�

Anchor bolt mounting

Mounting hardware is not provided� These additional items are required for proper anchor bolt installation on a poured

concrete oor:

Hardware Quantity

0�5in anchor bolts 4

0�5in lock nuts 4

Metal shims Varies

Procedure

1. Place the unit in the desired location. Mark the oor in

the center of the mounting feet�

2. Using lifting equipment, move the unit�

5. Using lifting equipment, place the unit on the anchor

bolts, so that the threads extend through the holes in the mounting feet�

6. Place mounting nuts on the anchor bolts to protect the threads while leveling� Use lock nuts or other appropriate locking fastener�

NOTE: Note: The Testing Screen must be level for proper

test results and best operation of the machine�

8. Tighten the mounting nuts equally on all four mounting feet, making sure the unit’s case remains level�

Level the Vibrating Unit Assembly

1. Release the clamping force:

TS-1/TS-3: Pull the handle on the hydraulic pump all the way toward the front of the machine to release hydraulic clamping force� Remove the screen trays if present�

TS-2: Turn the manual screw-type clamp rods counterclockwise to release clamping force� Remove the screen trays if present�

2. Insert a screen tray into the third screen tray position from the top of Vibrating Unit Assembly, leaving 1/3 of its

length extended out of the front of the machine�

3. Apply clamping force to hold the screen tray that extends

Cover

WARNING:

from the front of the Testing Screen�

TS-1/TS-3: Apply short strokes to the hydraulic pump handle�

TS-2: Turn the two clamp rods simultaneously and as equally as possible, using your sense of touch to determine

when the trays are rmly clamped.

4. Place a level on the protruding screen tray then re-level the Testing Screen by adding or removing shims until the Vibrating Unit Assembly and screen tray are level

side-to-side and front-to-back. Give mounting nuts a nal

tightening�

5. Release clamping pressure and put desired screen trays into the machine�

• Locate the voltage label on the back of the Testing Screen, and check to be sure that the machine is wired as ordered�

• Make sure your electrical power source is of a like

conguration.

• Make sure the Testing Screen and your electrical power source are properly grounded�

• Make sure the power switch (located on right, vertical surface of the top cover) is in the OFF position�

Testing Screen Power OFF:

• GREEN button OUT

• RED button IN

Operation

Hydraulic System Check

Screws (5x)

Pump Cover

Fig. 3: TS-1/TS-3 Hydraulic Pump Access

If you have a TS-1 or TS-3 Hydraulic Testing Screen, examine and test the hydraulic system for leaks�

1. Remove the ve screws that secure the external pump cover to the top, then lift the cover o󰀨 (Fig. 3).

2. Observe the position of the internal pump cover before you remove it� Its vent is slightly closer to the front (handle) end of the pump than to the back� Gilson recommends using a marker or other means to mark the operator side of the cover to ensure correct orientation during reassembly�

3. Check the oil level in the pump� It should be 1/4in from the top of the reservoir� If not, refer to instructions for replacing hydraulic oil on page 14� Reinstall the external pump cover�

External Pump Cover

Hydraulic Pump

TS-1/TS-2/TS-3 Operation

safety and operating instructions and sample capacity information in this manual before operating the Testing Screen.

can get caught on the clamp rods while making this

adjustment.

NOTE: These instructions cover operation of the Testing

Screen, not performance of any test�

1. Locate the Testing Screen’s power switch on the right, vertical surface of the top cover�

Make sure that the switch is in the OFF position:

• GREEN button OUT

• RED button IN

Plug the three-pronged plug into a properly-grounded power source; or otherwise properly ground your Testing Screen�

2. Release the clamping force of the Vibrating Unit Assembly:

TS-1/TS-3: Pull the hydraulic pump handle all the way toward the front of the machine�

TS-2: Turn clamp rods counterclockwise�

3. Load the Testing Screen:

Read and understand ALL of the

DO NOT wear loose clothing which

Verify Power Requirements

Verify that the Testing Screen is wired as ordered and appropriate for your power source�

Standard Testing Screens are driven by a 115V/60Hz, 1/2hp electric motor requiring 12-15 amps to operate. A dedicated 20 amp circuit is recommended. Machines with model numbers ending in “F” are congured to operate on 230V/50Hz.

Load your desired sequence of screen trays into your

Testing Screen, being careful not to pinch your ngers with

already inserted screen trays� Apply clamping force on the trays�

TS-1/TS-3: Apply short strokes to the hydraulic pump handle� The hydraulic system will apply tension on both sides of the Vibrating Unit Assembly�

TS-2: Turn the two clamp rods clockwise simultaneously and as equally as possible using your sense of touch to

determine when the trays are rmly clamped.

IMPORTANT: The machine is turned ON by pushing the

GREEN button and turned OFF by pushing the RED button�

4. Load the Testing Screen� Choose your loading method by considering the nature and characteristics of your sample and the type of dust it will release into the atmosphere�

5. There are two types of tests:

• Agitation of the sample until separation is complete�

• Agitation of the sample for a predetermined period of time�

Sample Capacity

Coarse Aggregates

The quantity of sample to be loaded is established by test

specications and depends greatly on the type of material

and its particle size range�

The ASTM C 136 specication for “Sieve or Screen Analysis of Fine and Coarse Aggregates” calls for maximum screen loadings for 14-3/4 x 22-3/4in (375x578mm) clear screen areas as follows:

ASTM C136 SAMPLE SIZES

Nominal Max. Size of Max. Screen Particle, in (mm) Loadings, lb (kg)

The choice will depend on the nature and characteristics of the sample and on the requirements of the test�

If the test requires complete separation, watch the test progress through the top of the Testing Screen�

To determine whether material is still passing through a ne

mesh screen, insert the clean dust pan tray directly below the screen tray in question� Separation is complete when no particles fall into the tray�

NOTE: If the Testing Screen or the motor is overloaded, a

circuit breaker in the switch could disconnect the power� If the machine stops in the middle of a test, check the switch� If the RED button is halfway out, the circuit breaker has tripped� Determine the cause of the overload and correct it� To restart, push the RED button all the way in, and then push the GREEN button�

6. Turn OFF the machine by pushing the RED button� Unload the various screen trays and dust pan�

NOTE: Loaded screen trays are not as light as they may

appear� Use common sense and proper equipment�

7. Unless you plan to continue operating the Testing Screen, unplug or disconnect it to eliminate a tripping hazard and reduce electrical hazards�

No.4 (4.75mm) 5.7 (2.6) 3/8in (9.5 mm) 11.2 (5.1) 1/2in (12.5 mm) 14.8 (6.7) 3/4in (19.0 mm) 22.5 (10.2)

1.0in (25.0 mm) 29.8 (13.5)

1.5in (37.5 mm) 44.5 (20.2)

2.0in (50.0 mm) 59.5 (27.0)

2.5in (63.0 mm) 75.0 (34.0)

3.0in (75.0 mm) 89.3 (40.5)

3.5in (90.0 mm) 106.9 (48.5)

4.0in (100.0 mm) 118.8 (53.9)

5.0in (125.0 mm) 148.6 (67.4)

Maximum screen loading for materials denser than limestone aggregates should be adjusted accordingly� Samples can be run in two or more batches if necessary� The capacity of the screen for a given sample is determined by the sample in the tray with the maximum load� A coarse series size tray at completion of sieving should carry a load limit equal to the amount of material needed for one layer of particles over the wire cloth area�

If all tray slots are not required for a test, an intermediate tray may be used to relieve loading on a critical tray and allow the use of a larger test sample� Capacity is a function of volume� Materials such as lightweight aggregate or coal must be tested in somewhat larger amounts by weight�

Many light materials are also soft� Their test times should be limited to avoid degradation of the sample� If you get poor separation or loss of material from the trays should

rst check the amount of sample on the individual screen

tray and adjust the sample size accordingly� Diagnosis should then proceed to checking for proper leveling and looking for worn, broken or out-of-adjustment components as described in the Maintenance section on page 10�

Remember that the ASTM minimum sample weights are for representative samples� Initial sampling should always be done by taking a much larger amount from several areas in a storage bin or stockpile, then combining and reducing the amount to a manageable size by splitting� Gilson Sample Splitters are ideal for this purpose�

+ 19 hidden pages

Gilson TS-1, TS-3, TS-2 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual