GSI Group CE Compliant II Series User manual

PNEG-681CE
CE Compliant Series II
Bucket Elevator
Assembly Manual - Original Instructions
PNEG-681CE
Date: 04-29-14

2 PNEG-681CE CE Compliant Series II Bucket Elevator
Use of the equipment information page will help you identify the equipment in the case that you need to notify the
company. For this reason, this information should be filled out and kept on record.
Equipment Information
Model Number: ______________________________________________
Serial Number: ______________________________________________
RPM: _____________________________________________________
Head Pulley Diameter: ________________________________________
Discharge Height: ____________________________________________
Horsepower: ________________________________________________
GSI Group
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
Date Purchased: ___________________________________________
Dealer Name and Phone Number: ________________________________
________________________________
________________________________

PNEG-681CE CE Compliant Series II Bucket Elevator 3
CE Declaration of Incorporation
EC MACHINERY DIRECTIVE
2006/42/EC
1004 East Illinois Street, Assumption, IL, 62510, USA
[phone]
The GSI Group declares that
GSI Bucket Elevators
Models
15P16/15G16; 20P16/20G16; 25P16/25G16; 30P16/30G16; 30P24/30G24; 40P24/40G24;
50P24/50G24; 56P24/56G24; 50P30/50G30; 60P30/60G30; 70P30/70G30; 50P36/50G36;
60P36/60G36; 70P36/70G36; 75P36/75G36; 80P36/80G36; 100P36/100G36; 80P42/80G42;
100P42/100G42; 120P42/120G42; 140P42/140G42; 150P42/150G42; 200P42/200G42;
140P48/140G48; 150P48/150G48; 160P48/160G48; 200P48/200G48; 250P42; 300P42; 400P42;
250P48; 300P48; 400P48; 500P48; 600P48
Meet the Essential Requirements of the Machinery Directive 2006/42/EC.
1. This declarationapplies only to themechanical elements ofthe above machines anddoes not imply
conformity by any other items of equipment fitted to or connected with the above machines.
2. The equipment must be operated by an electrical control system designed and installed in
accordance with EN60204:2006 and EN ISO 13849:2006, including all necessary safety controls.
This is the responsibility of the equipment installer.
3. The equipment above must not be put into service until the machinery into which it is to be
incorporated has been declared in conformity with the provisions of all relevant Directives,
nor until these components have been assembled in the manner recommended in the attached
manufacturers instructions, PNEG-681CE.
4. This declaration is not valid unless attached to the manufacturers’ instructions PNEG-681CE.
Signed:
Name: Frank Ward Director Hennock International Limited On behalf The GSI Group
Date:
Digitally signed by Frank Ward
DN: cn=Frank Ward, o=Hennock
International Limited, ou,
[email protected], c=GB
Date: 2014.05.02 11:21:37 +01'00'

4 PNEG-681CE CE Compliant Series II Bucket Elevator
NOTES

Table of Contents
PNEG-681CE CE Compliant Series II Bucket Elevator 5
Contents
Chapter 1 Introduction ..........................................................................................................................................6
General Safety Statements ................................................................................................................... 6
Receiving Inspection ............................................................................................................................. 6
Pre-Installation Notifications .................................................................................................................. 6
Chapter 2 Safety .....................................................................................................................................................7
Safety Guidelines .................................................................................................................................. 7
General Safety Statement ..................................................................................................................... 8
Safety Instructions ................................................................................................................................. 9
Correct Use of the Bucket Elevator ..................................................................................................... 12
Working at Heights .............................................................................................................................. 13
Electrical Safety .................................................................................................................................. 14
Chapter 3 Safety Decals ......................................................................................................................................16
Decal Placement ................................................................................................................................. 18
Chapter 4 Elevator Parts .....................................................................................................................................19
Part Identification ................................................................................................................................ 19
Chapter 5 Bucket Elevator Foundation ..............................................................................................................20
Chapter 6 Boot Section .......................................................................................................................................21
Attaching Boot to Foundation .............................................................................................................. 22
Inspection Sections ............................................................................................................................. 23
Chapter 7 Trunking ..............................................................................................................................................24
Standard Trunking ............................................................................................................................... 24
Pressure Relief Trunking ..................................................................................................................... 25
Trunking Installation ............................................................................................................................ 26
Chapter 8 Lower Head Section ...........................................................................................................................27
Head Bonnet Section .......................................................................................................................... 27
Chapter 9 Maintaining Plumbness .....................................................................................................................29
Chapter 10 Belting, Splicing and Buckets .........................................................................................................30
Belts ................................................................................................................................................... 30
Splicing .............................................................................................................................................. 30
Buckets .............................................................................................................................................. 31
Belt Slack Removal ........................................................................................................................... 32
Chapter 11 Drive Motor and Motor Mount .........................................................................................................34
Drive .................................................................................................................................................. 34
Motor Mount Assembly ...................................................................................................................... 34
Slide Base ......................................................................................................................................... 36
Torque Arm ........................................................................................................................................ 37
Shaft Mount Reducer ......................................................................................................................... 38
Drive Guard ....................................................................................................................................... 39
Drive Belts ......................................................................................................................................... 44
Chapter 12 Final Checks, Tracking, Start-Up and Maintenance ......................................................................45
General Final Checks ........................................................................................................................ 45
Belt Tracking ...................................................................................................................................... 46
Start-Up ............................................................................................................................................. 46
Maintenance ...................................................................................................................................... 46
Dealing with Elevator Blockages ....................................................................................................... 47
Chapter 13 Appendix 1 - Reference Information ...............................................................................................49
Chapter 14 Warranty ............................................................................................................................................51

6 PNEG-681CE CE Compliant Series II Bucket Elevator
1. Introduction
Thank you for choosing a GSI product. It has been designed to provide excellent performance andservice
for many years.
This manual covers general information about installing the GSI Bucket Elevator.
Due to the large variety of equipment features offered, this manual cannot cover every aspect of
installation with this manual. This manual provides suggested and recommended methods for installing
the product. GSI recommends you retain a qualified contractor to provide on-site expertise.
GSI is not responsible for the installation of this product.
General Safety Statements
1. Our primary concern is your safety and the safety of others associated with the use of this product.
All personnel responsible for installing, operating or maintaining this equipment should read and
understand this manual. It is the responsibility of the owner to make this manual available to the
person or persons involved with this equipment.
2. Guards and safety labels have been installed prior to leaving the manufacturing plant. These should
not to be removed, altered or defaced in any way.
3. Modifications to equipment may cause extremely dangerous situations that could result in damage
to the equipment as well as serious injury or death. Never modify the equipment.
4. GSI recommends that you contact the local power company to have a representative survey the
installation to ensure wiring is compatible with their system and adequate power is supplied to
the unit.
Receiving Inspection
1. Carefully inspect the shipment for damage as soon as it is received and verify that the quantity of
parts or packages actually received corresponds to the quantity shown on the packing slip.
2. Report any discrepancies, shortages or damages to the delivering carrier as soon as possible.
3. The manufacturer’s responsibility for damage to the equipment ends when the carrier accepts the
equipment for delivery. Refer to the bill of lading for more detailed information.
4. Save all paperwork and documentation furnished with any of the elevator components.
Pre-Installation Notifications
1. GSI is the manufacturer and vendor of the elevator and is responsible only for the optional
accessories also manufactured by GSI.
2. The elevator has not been designed to support other equipment such as cleaners, distributors or
spouting. Separate structures must be provided for any accessory equipment.
3. This installation manual should be used for reference only.
4. The owner/user/installer of this equipment is responsible for consulting and retaining a civil or
structural engineer regarding the design, construction and supervision of the entire installation,
including the elevator foundation and the guying cable and/or bracing system.
5. GSI Bucket Elevators are designed to be vertically self-supporting when erected but must be
supported or guyed against wind loads.

PNEG-681CE CE Compliant Series II Bucket Elevator 7
2. 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 pay attention to these sections. Failure to read this manual and its
safety instructions is a misuse of the equipment and may lead to serious injury or death.
DANGER
WARNING
CAUTION
NOTICE
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.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

2. Safety
8 PNEG-681CE CE Compliant Series II Bucket Elevator
General Safety Statement
Our foremost concern is your safety and the safety of others associated with grain handling equipment.
This manual is to help you understand safe operating procedures and some problems that may be
encountered by the operator and other personnel.
Asowner and/oroperator,you areresponsible toknow whatrequirements,hazards,andprecautions exist
and inform all personnel associated with the equipment or in the area. Safety precautions may be required
from the personnel. Avoid any alterations to the equipment, which may produce a very dangerous
situation, where SERIOUS INJURY or DEATH may occur.
You should consider the location of the bin site relative to power line locations or electrical transmission
equipment. Contact your local power company to review your installation plan or for information
concerning required equipment clearance. Clearance of portable equipment that may be taken to the bin
site should also be reviewed and considered. Any electrical control equipment in contact with the bin
should be properly grounded and installed in accordance with National Electric Code provisions and other
local or national codes.
This product is intended for the use of grain storage only. Any other use is a misuse of the product.
Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall
bundles is laying horizontally with the arch of the sheet upward, like a dome. Sidewall sheets stored on
edge must be secured so that they cannot fall over and cause injury. Use care when handling and moving
sidewall bundles.
Personnel operating or working around equipment should read this manual. This manual must be
delivered with equipment to its owner. Failure to read this manual and its safety instructions is a
misuse of the equipment.
This product has sharp edges, which may cause serious injury. To avoid injury, handle
sharp edges with caution and always use proper protective clothing and equipment.

2. Safety
PNEG-681CE CE Compliant Series II Bucket Elevator 9
Safety Instructions
Our foremost concern is your safety and the safety of others associated with this equipment. We want to
keep you as a customer. This manual is to help you understand safe operating procedures and some
problems that may be encountered by the operator and other personnel.
As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions
exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be
required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very
dangerous situation where SERIOUS INJURY or DEATH may occur.
This equipment shall be installed in accordance with the current installation codes and applicable
regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
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 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 or need
assistance, contact your dealer.
Read and Understand Manual
Stay Clear of Moving Belt
Entanglement in moving belt can cause serious
injury or death.
Keep all shields and covers in place at all times.
Wear close fitting clothing. Stop and lock out power
source before making adjustments, cleaning, or
maintaining equipment.

2. Safety
10 PNEG-681CE CE Compliant Series II Bucket Elevator
Operate Motor Properly
In an emergency, shut down the power source.
Turn OFF and lock out all power sources before performing
any maintenance.
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 manner can damage
the equipment and/or drive components. Electric Shock Hazard
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 away from rotating parts.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts. Remove any
built-up grease, oil, and debris. Maintain Equipment
and Work Area
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.
Breathing Hazard

2. Safety
PNEG-681CE CE Compliant Series II Bucket Elevator 11
Prepare for Emergencies
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone. Keep Emergency Equipment
Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate
to the job.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel-toed boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection

2. Safety
12 PNEG-681CE CE Compliant Series II Bucket Elevator
Correct Use of the Bucket Elevator
1. These elevators are designed solely for conveying whole agricultural grain and seeds. Use for any
other material is a misuse and could result in serious injury and equipment damage.
2. Never operate the Bucket Elevator without completely enclosing the inlet or outlet, making all moving
parts in-accessible to any person. (See Figure 2A.)
Figure 2A Example of Enclosed Inlet and Outlet
Ref # Description
AExample Enclosed Inlet Conveyor Feeding Elevator
B Example Enclosed Outlet Feeding Conveyor

2. Safety
PNEG-681CE CE Compliant Series II Bucket Elevator 13
Correct Use of the Bucket Elevator (Continued)
3. Never operate with guards removed or inspection covers open.
4. Never open or work on the moving parts of the Bucket Elevator unless:
a. It has been run completely empty of grain. (A loaded elevator might result in unexpected
movement of the belt and buckets even when locked out.)
b. It is locked out and tagged out at the main electrical isolator.
c. All equipment working with the elevator are also locked out and tagged out.
5. The elevator must be installed vertical in all directions and must not be used at any other angle.
6. Do not fix a hoist or other lifting equipment to the Bucket Elevator, nor to the ladders or platforms
attached to the elevator.
7. Ladders and platforms attached to the elevator are for personnel access only and must not be used
to carry or support heavy pieces of equipment.
8. Do not exceed the maximum ladder and platform load, noted on the warning decal (225 kg).
9. Never alter or adjust the elevator from it is original specification.
10. Always lock out and tag the electrical power to the elevator before working on it.
11. Do not use the elevator in an enclosed, potentially explosive area.
Working at Heights
Theequipmenthas beendesignedtooperateprimarily atgroundlevel,atsome stagesduringthelife cycle
it will be necessary to work at heights. For this reason the equipment has been provided with access
ladders and platforms, to minimize the risk to health and safety. In addition attention should be paid to the
following safety requirements.
1. The ladders, platforms and walkways are for use by competent and trained personnel only. NEVER
allow children or members of the general public to gain access to the equipment, its ladders or
access platforms.
2. Where the equipment is sited in an unsecured location, access must be restricted by use of security
fencing and lockable gates.
3. Lower sections of ladders on the equipment should be fitted with a lockable safety gate, to prevent
unauthorized access.
4. The equipment should be OFF and all power LOCKED OFF before work on or in the equipment.
Ensure the power isolator is OFF and LOCKED and TAGGED to prevent inadvertent re-start.
This must include all equipment attached to the elevator on which you are working. (See Figure 2B
on Page 14.)

2. Safety
14 PNEG-681CE CE Compliant Series II Bucket Elevator
Working at Heights (Continued)
Figure 2B
5. NEVER attach lifting equipment to ladders or platforms.
6. When working on the equipment, NEVER go outside the safety rails provided.
7. Do not work at heights during high winds, heavy rain, snow, ice or storm.
The majority of routine service can be carried out from the service platforms provided. In the rare event
that access is required outside these structures additional access and safety equipment may be required,
suchas poweredaccess liftplatformsandsafetyharness. Suchworkmustonlybecarriedoutby specialist
technicianstrained andqualifiedin workingatheightsand only after a complete risk assessment has been
carried out and safe working methods established.
Electrical Safety
It is recommended that the electrical system to the equipment include, at minimum, the following:
1. Main power supply protected by suitable fuses or over current circuit breaker.
2. Main electrical disconnect lock out switch which can be locked.
a. To disconnect all electrical power to the equipment and other associated equipment.
3. Service disconnect which can be locked.
a. Installed immediately adjacent to each motor.
b. Wired to disconnect all electrical power to the equipment motor.
c. May also be wired to stop other equipment if required for safety during maintenance
and servicing.

2. Safety
PNEG-681CE CE Compliant Series II Bucket Elevator 15
Electrical Safety (Continued)
4. Emergency stops.
a. Wired to stop the equipment motor (and any other associated equipment) immediately
when pressed.
b. Must remain engaged until manually disengaged.
c. The equipment should not be able to re-start immediately the emergency stop is re-set.
5. The electrical supply must include a properly designed protective earth system (PE), with connection
to all exposed conductive parts.
6. All motors must be connected to protective earth at the terminal provided.
7. The control system to include.
a. Short circuit protection.
b. Start/stop controls (labelled 1 and 0 respectively).
c. Controls designed to default to OFF after a power interruption. (Ex: Self maintained relay.)
d. The equipment should not be able to immediately re-start following re-establishment of power or
following the re-set of an emergency stop or other safety interlock.
8. Motor circuits must include motor over current protection, wired to stop the motor when the current
exceeds the motor full load current, stated in the motor rating plate.
9. It is also recommended that the electrical supply is protected by earth leakage protection, such as
Residual Current Device (RCD) or Residual Current Circuit Breaker (RCCB), to provide additional
automatic disconnection from the power in the event of a fault.
All electrical installation and design must be carried out by a qualified electrical engineer, in accordance
with EU Directives and standards and in accordance with local laws and codes. Ex: IEC 60204-1:2006.

16 PNEG-681CE CE Compliant Series II Bucket Elevator
3. Safety Decals
Safety decals have beenaffixed to the equipment to warnof danger to persons and of possible equipment
damage. These decals must never be removed, tampered with, painted over or obscured in any way.
If labels are damaged or become unreadable, replacement labels are available from the manufacturer.
If a decal is damaged or is missing contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
International Decals
International, translated versions of the decals fitted to the equipment are available as part of the
Language Pack that was supplied with the product. If you need further copies or a different language,
please contact GSI or you dealer.
The international decals have been designed to be placed directly over the USA standard versions.
Normally these will be factory fitted, but if you need to change them, please refer to the decal cross
reference sheet, provided with the Language Pack and the decal locations given in the user’s manual.
DC-2248
GSI Group 217-226-4421
DC-2249
GSI Group 217-226-4421
DC-2251
GSI Group 217-226-4421
DC-2250
GSI Group 217-226-4421
>220 kg
DC-2238
GSI Group Inc. 217-226-4421
DC-2252
GSI Group 217-226-4421
Automatic Machinery
Automatické stroje a zařízení
Automatikus Machinery
автоматични машини
automatische machines
Автоматические машины
автоматичні машини
Automātiskā Mašīnas
Automatinis Machinery
machines automatiques
Maquinaria automática
macchine automatiche
automatiska maskiner
Otomatik Makina
Máquinas automáticas
Aparate
Automaattinen Machinery
A
BE
CF
D
DC-2248 DC-2250
DC-2249 DC-2238
DC-2251 DC-2252

3. Safety Decals
PNEG-681CE CE Compliant Series II Bucket Elevator 17
DC-2253
GSI Group 217-226-4421
DC-2213
GSI Group 217-226-4421
The GSI Group
1004 E. Illinois St.
Assumption, IL. 62510
USA
Model
Height to discharge
Pulley diameter
Pulley speed
Belt speed
Maximum capacity
Bucket size
Bucket spacing
SN
Date
56 RPM
720 fpm/3.66 m/s
18750 cfh/531 m3/h
01 May 2012
30 hp/22.5 kW
240 V (AC)
73 A
50 Hz
3 ~
123456789
18 x 8"
9-1/2"/241 mm
105'/32.01m
150P48 - 105
48"/1219 mm
Rating plate
GH
DC-2213 DC-2253

3. Safety Decals
18 PNEG-681CE CE Compliant Series II Bucket Elevator
Decal Placement
Head section
Inspection trunking
Boot section
Decal numbers
A. DC-2248
B. DC-2249
C. DC-2251
D. DC-2250
E. DC-2238
F. DC-2252
G. DC-2213
H. DC-2253

PNEG-681CE CE Compliant Series II Bucket Elevator 19
4. Elevator Parts
Part Identification
Figure 4A
Ref # Description
ABonnet
B Pressure Relief Panel (One Each Side)
CHead Pulley
D Lower Head Section
EInspection Door
F Up-Leg Trunking
GDown-Leg Trunking
HBelt
IBuckets
J Tie Angles
KInspection Section
L Inspection Door
MBoot Section
N Upside Hopper (Downside Hopper Optional)

20 PNEG-681CE CE Compliant Series II Bucket Elevator
5. Bucket Elevator Foundation
1. The Bucket Elevator foundation must be designed by a qualified civil engineer and installed by a
qualified contractor.
2. Always consider the additional weight of live loads, dead loads, wind loads and soil bearing loads.
3. Always provide for proper moisture run-off on the top of the foundation.