GSI PNEG-1204 User Manual
Enclosed Belt
Conveyor
Installation and Operation Manual
PNEG-1204
DATE: 10-16-06
PNEG-1204
Introduction
READ THIS MANUAL carefully to learn how to
properly use and install equipment. Failure to do
so could result in personal injury or equipment
damage. This manual and safety signs on your
equipment may be available in other languages.
(Consult with your dealer to see what is available)
INSPECT the shipment immediately upon arrival.
The Customer is responsible for ensuring that all
quantities are correct. Report any damage or
shortages by recording a detailed description on
the Bill of Lading to justify the Customer’s claim
from the Transport Firm. Our responsibility for
damage to the equipment ends with acceptance
by the delivering carrier. Save all paperwork and
documentation furnished with any of the enclosed
belt conveyor components.
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your equipment and should be
easily accessible when needed.
WARRANTY is provided as part of the company’s
support program for customers who use and
maintain their equipment as described in the
manual. The warranty is explained on the warranty page located on the inside back cover of
this manual.
This warranty provides you the assurance that the
company will back its products where defects
appear within the warranty period. In some circumstances, the company also provides field
improvements, often without charge to the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the factory specifications, the warranty will become void and field
improvements may be denied.
i
Use of the Equipment Information page will help you identify your equipment in the case that you need to
call your dealer or installer. This information should be filled out and kept on record.
Equipment Information
Model Number:__________________________
Serial Number:___________________________
Material Handling
1004 East Illinois Street
Assumption, Illinois 62510 USA
Phone: (217) 226-4421
FAX: (888) 741-3004
e-mail: gsi@grainsystems.com
Date Purchased:____________________
Dealer/Distributor Name and Phone Number:
ii
Table of Contents
Introduction.....................................................................................i
Equipment Information ...................................................................ii
Safety Guidelines...........................................................................1
Safety ............................................................................................2
Safety Decal Locations. .................................................................5
Overview ........................................................................................9
Intermediate Section Installation .....................................................10
Cover Installation............................................................................12
Loader Installation ..........................................................................13
Motor & T orque Arm II Reducer Installation......................................14
Reducer ....................................................................................15
T orque Arm................................................................................16
T orque Arm Bracket...................................................................1 6
Motor Mount Brackets ...............................................................17
Motor Mount Adjustment Plate ...................................................17
Rear Guard ...............................................................................17
Sheaves and Belts ....................................................................18
V-Belt Adjustment ......................................................................18
Front Guard ...............................................................................19
Reducer Lubrication ..................................................................19
Finding Belt Center Line.................................................................19
Squaring the Belt End ....................................................................20
Check Belt Squareness .................................................................20
Installation of Belt ...........................................................................21
Splicing Belt...................................................................................22
Belt T ension ...................................................................................26
Belt Tracking..................................................................................27
Spouting.........................................................................................30
Spouting Location ..........................................................................31
Belt Conveyor Loading...................................................................32
Motion Sensor Option ....................................................................33
Pressure Plug Switch Option..........................................................34
Starting Conveyor...........................................................................35
Care & Maintenance ......................................................................36
Troubleshooting..............................................................................37
T orque Arm II Appendix...................................................................38
Imperial Bearings Appendix ...........................................................49
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 time without notice.
iii
NOTES
iv
Safety
SAFETY GUIDELINES
This manual contains information that is important for you, the owner/operator , to know and
understand. This information relates to protecting personal safety and preventing equipment
problems. It is the responsibility of the owner/operator to inform anyone operating or working in
the area of this equipment of these safety guidelines. To help you recognize this information, we
use the symbols that are defined below. Please read the manual and p ay attention to these
sections. Failure to read this manual and it’s safety instructions 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.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury .
W ARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury .
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury .
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
NOTE indicates information about the equipment that
you should pay special attention to.
1PNEG-1204 Enclosed Belt Conveyors
Safety
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual
and on your machine safety signs. 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 controls properly . Do not let anyone operate
without instruction.
Keep your machinery in proper working condition. Unauthorized modifications to the machine
may impair the function and/or safety and affect
machine life.
If you do not understand any part of this manual
and need assistance, contact your dealer.
STAY CLEAR OF ROTATING IDLER
Entanglement in rotating idlers can cause serious injury or death.
Keep all shields and covers in place at all times.
Wear close fitting clothing. S top and lock out
power source before making adjustments,
cleaning, or maintaining equipment.
OPERATE MOTOR PROPERLY
Do not operate electric motor equipped units
until motors are properly grounded.
Disconnect power on electrical driven units
before resetting motor overloads.
Do not repetitively stop and start the drive in
order to free a plugged condition. Jogging the
drive in this type of condition can damage the
conveyor and/or drive components.
2
PNEG-1204 Enclosed Belt Conveyors
PRACTICE SAFE MAINTENANCE
Understand service procedures before doing
work. Keep area clean and dry .
Never lubricate, service, or adjust machine while
it is in operation. Keep hands, feet, and clothing
from rotating belt and idlers.
Keep all parts in good condition and properly
installed. Fix damage immediately . Replace
worn or broken parts. Remove any build up
grease, oil, or debris.
Safety
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.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
• 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 welding.
Remove solvent or stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
3PNEG-1204 Enclosed Belt Conveyors
Safety
PREPARE FOR EMERGENCIES
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy .
Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department near
your telephone.
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Safety glasses should be worn at all times to
protect eyes from debris.
Wear gloves to protect your hands from sharp
edges on plastic or steel parts.
A respirator may be needed to help prevent
breathing potentially toxic fumes and dust.
Wear hard hat and steel toe boots to help
protect your head and toes from falling debris.
Eye Protection
Gloves
Steel Toe
Boots
Respirator
Hard Hat
4
PNEG-1204 Enclosed Belt Conveyors
HEAD SECTION DECAL LOCATIONS
Decals
1
1
1
STANDARD HEAD SECTION
1
1
1
1
DC-1672
SNUB HEAD SECTION
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
Failure to heed will result in
personal injury or death.
5PNEG-1204 Enclosed Belt Conveyors
Decals
TAIL SECTION DECAL LOCATIONS
1
1
DC-1672
1
BELT CONVEYOR TAIL SECTION
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
Failure to heed will result in
personal injury or death.
2
DC-1690
2
1
CAUTION
FALLING HAZARD
Open shroud may fall if unrestrained
and cause bodily injury.
Secure open shroud with chain.
DC-1690
6
PNEG-1204 Enclosed Belt Conveyors
LOADER SECTION DECAL LOCATIONS
Decal On Right Side In
2
Same Location as
Decal on Left Side.
Decals
2
FIXED SKIRT LOADER
2
Decal On Right Side In
2
Same Location as
Decal on Left Side.
2
2
2
DC-1671
SWING-UP SKIRT LOADER
MOVING BELT CAN CUT OR ENTANGLE.
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
Failure to heed can result in
perso n a l injury or death .
7PNEG-1204 Enclosed Belt Conveyors
Decals
INTERMEDIATE SECTION DECAL LOCATIONS
Decals On Right Side
In Same Location as
Decals on Left Side.
1
2
1
DC-1672
INTERMEDIATE INSPECTION SECTION
2
STANDARD INTERMEDIATE SECTION
2
DC-1671
Decal On Right Side In
Same Location as
Decal on Left Side.
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
Failure to heed will result in
personal injury or death.
8
PNEG-1204 Enclosed Belt Conveyors
MOVING BELT CAN CUT OR ENTANGLE.
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
Failure to heed can result in
personal injury or death.
Conveyor Assembly
CONVEYOR ASSEMBLY
OVERVIEW
1. Remove any banding and crating material.
Arrange all the conveyor components in such
a fashion that all are easily accessible.
2. Locate sturdy items to serve as blocking (i.e.
wood blocks, saw horses, etc.). Blocking is
used to support the conveyor sections above
the ground to help in assembly . Locate and
place the conveyor sections on the blocking
in order , starting with the head section and
concluding with the tail section.
3. A clearance of at least the width of the
conveyor is recommended on all sides of the
unit. Less clearance may be acceptable
however, serious consideration must be
given to methods of maintenance, removal
and replacement of the conveyor and/or its
parts.
4. The standard conveyor is constructed with
one discharge located at the drive end. If
tripper discharge sections are to be used,
the location(s) must be determined before
continuing with the conveyor assembly . It
may be necessary to position a shorter
intermediate section to serve as a spacer in
order to accommodate the placement of the
tripper discharge(s) where required.
5. Always consult with the approval prints for
exact conveyor layout. Maintain adequate
clearance for tail extension.
6. During installation of the conveyor , string a
chalk line along the conveyor sides to assure
that the conveyor is being assembled in a
straight line. All hardware should be included
with your conveyor. It is recommended that all
flanges be caulked to seal the conveyor to
keep the dust in and the weather out.
7. After all sections are caulked and bolted, the
loader(s) is/are ready to be installed.
Loaders must be installed with the grain
stream moving in the same direction and
same speed as the conveyor belt. (See page
30 for recommended spout loading).
8. After location of the loader(s) (as to spouts,
gates, and valves) has been established, the
loader(s) are bolted to the conveyor . Do not
weld loader(s) to the conveyor . (See page 13
for loader installation).
9. Belt may now be hand fed through the
conveyor. Make sure when splicing belt that
each cut is clean, square and straight.
Detailed belt assembly instructions are listed
on pages 20 - 29. These instructions should
be followed closely and read thoroughly
before starting this step.
10.Check drive belts for tension. Also check the
oil level in the speed reducer. Reducers are
shipped without oil. Refer to page 41 for
the type and quantity of oil. (DO NOT overfill
reducer.)
9PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
INTERMEDIATE SECTION
INSTALLATION
MAKE SURE TO READ ASSEMBLY
OVERVIEW ON PAGE 9 FIRST.
1. Intermediate sections are supplied in standard ten foot (10') lengths. Depending on
your application and individual specifications
however, shorter sections may be required to
accommodate a desired overall length.
2. After making sure the flanges are aligned,
tighten all hardware on the trough section.
(It is recommended that the flanges are
caulked to insure sealing from dust and
outside moisture.)
It is critical for straitness of the conveyor
that the sides and bottom flanges are
aligned flush. Also, it is important that the
inside dimensions of the box measure
equidistant from side-to-side both top and
bottom of the intermediate section
(Dimension A = Dimension B). See diagram
below.
A
3. During assembly of the intermediate sections, carefully inspect each flange joint to
ensure that the inside bottom and side surfaces of the intermediates are flush. A chalk
line is helpful during this phase of the assembly to ensure the proper alignment of the
intermediate section surfaces. The maximum run-out in any direction should be
+/- 1/4". Make sure the conveyor is level in
horizontal applications.
4. Proceed by attaching the head and tail
assemblies using the same alignment procedures and precautions noted in the preceding
paragraph.
B
End View of Intermediate Section
(Liners not shown for clarity)
10
PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
INTERMEDIATE SECTION
INSTALLATION (CONT.)
1. Intermediate Sections bolt together along the
side and bottom flanges. The covers are
fastened to the cover channels by flat clips
and easy grip handles.
2. St andard intermediate sections do not have
a direction in which they bolt to other
intermediate sections. The cover channels
connect intermediate sections on both ends.
3. T wo inspection intermediate sections are
included on each installation. They should be
assembled at the head and tail. The
inspection holes should be oriented closest
to the head or tail.
4. The inspection door end of each
intermediate section has adapter angles
with slotted holes for bolting to head or
tail sections.
Tail Section
Cover
Flat
Clips
Inspection
Door
Cover Channel
Easy Grip
Handles
Intermediate
Inspection
Section
5. A special cover channel is provided with the
tail as shown at right.
Adapter
Angle
with
Slotted
Holes
Tail Cover Channel
11PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
COVER INSTALLATION
1. Fasten covers to the belt conveyor with the
3/8" easy grip handles provided. Adequately
tighten the 3/8" handles so that the covers
are in tight contact with conveyor cross
channels.
2. When a loader is on the conveyor, the cover
section may have to be cut accordingly to
accommodate the loader . For installation of
a loader, see Loader Inst allation on page 13.
3. Conveyor covers are made to fit over the
entire width and half the length of a conveyor
intermediate section. Standard covers measure approximately 4' 7" in length. When a
loader is ordered, the cover may be measured and cut to take up the displacement of
the loader housing. This depends on the
position of the loader.
3/8" Wing
Nut on Tail
Section to
Secure
Cover.
Easy Grip
Handles
DO NOT Walk on Conveyor Covers!
4' 7"
12
Standard Cover Length
PNEG-1204 Enclosed Belt Conveyors
LOADER INSTALLATION
Fixed Skirt Loader
1. The fixed skirt loader always attaches at the
tail end so no cover modifications should be
necessary . The soft rubber skirts are adjustable and can be set to lightly touch the conveyor belt.
Swing-Up Skirt Loader
1. If the loader doesn’t line up exactly with an
intermediate cover, the intermediate covers
will need to be cut to fit. If this is necessary ,
properly position loader and cut a section
from the covers so they will fit between the
cover channel bolted to next section and the
loader flange. Weld cover back together to
achieve required length. Repaint welded
area to prevent rusting.
2. The UHMW swing-up skirts should not touch
the conveyor belt as they can cause wear to
the belt. Use the adjustable set screws to
locate the position of the skirts.
Conveyor Assembly
Fixed Loader
Swing Up Skirt Loader
6"
REMOVE PAINT BEFORE
WELDING OR CUTTING
Avoid hazardous fumes that can be generated
when paint is heated by welding or torching.
Do all work outside or in a well ventilated
area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
• 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 welding. Remove solvent or strip
per containers and other flammable
material from area. Allow fumes to
disperse at least 15 minutes before
welding or heating.
GSI’s recommendation for loader installation includes
a minimum distance of no less than 6" between the
center of loader inlet and the tail assembly .
13PNEG-1204 Enclosed Belt Conveyors
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