GSi VersaLoop User manual
®
VersaLoop™
Models:
Owner’s Manual
PNEG-1966
Version 1.0
Date: 11-05-14
PNEG-1966
2 Pneg-1966 VersaLoop™
Table of Contents
Contents
Chapter 1 Safety Precautions ....................................................................................................................5
Safety Guidelines ........................................................................................................................5
Correct Use ................................................................................................................................6
Cautionary Symbols ....................................................................................................................7
Safety Decals..............................................................................................................................9
Safety Sign-off Sheet.................................................................................................................10
Chapter 2 General Information.................................................................................................................11
VersaLoop™ — Information ....................................................................................................... 11
Motor – Specifications................................................................................................................12
Recommended Motor Overload Protection ..................................................................................12
Gearbox - Specifications ............................................................................................................13
VersaLoop™ – Inspection ..........................................................................................................13
Chapter 3 Operation ................................................................................................................................15
Start-up and Break-in Guidelines ................................................................................................15
VersaLoop™ – Standard Operation.............................................................................................15
VersaLoop™ – Shutdown...........................................................................................................16
Chapter 4 Assembly ................................................................................................................................17
VersaLoop™ – Typical Layout ....................................................................................................17
Tube Section – Assembly...........................................................................................................19
Gearbox and Motor – Installation ................................................................................................21
Non-drive End – Installation........................................................................................................22
Drive End – Installation ..............................................................................................................23
Chain and Paddles – Installation.................................................................................................24
Chapter 5 Accessories ............................................................................................................................27
Hopper – Installation..................................................................................................................27
Discharge Spout – Installation ....................................................................................................28
Discharge with Gate Assembly ...................................................................................................29
Bypass Inlet – Installation...........................................................................................................30
Drop through Gate Assembly – Installation ..................................................................................31
Chapter 6 Maintenance and Troubleshooting...........................................................................................33
Maintenance .............................................................................................................................33
VersaLoop™ – Cleanout Process ...............................................................................................34
VersaLoop™ Chain – Adjustment ...............................................................................................35
VersaLoop™ – Gearbox Mounting Process .................................................................................36
Troubleshooting ........................................................................................................................38
Chapter 7 Parts........................................................................................................................................39
Non-Drive End Assembly ...........................................................................................................40
8 in. Drive End Assembly ...........................................................................................................42
10 in. Drive End Assembly .........................................................................................................44
Chain and Paddle Assembly.......................................................................................................46
By Pass Inlet.............................................................................................................................47
Intermediate Supports – Parts ....................................................................................................48
Drive Kits – Parts.......................................................................................................................49
GSI Group, LLC Limited Warranty............................................................................................51
Pneg-1966 VersaLoop™ 3
NOTES
4 Pneg-1966 VersaLoop™
1Safety Precautions
Topics Covered in this Chapter
▪ Safety Guidelines
▪ Correct Use
▪ Cautionary Symbols
▪ Safety Decals
▪ Safety Sign-off Sheet
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be respected at all times in the grain stor-
age environment.
Safety guidelines shall be followed at all times. This manual is written to help you understand safe operat-
ing procedures and problems that can be encountered by the operator and other personnel when using
this equipment. Save these safety guidelines for future reference.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations shall not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment shall be installed in accordance with the current installation codes and applicable regula-
tions, which should be carefully followed in all cases. Authorities having jurisdiction shall be consulted
before installations are made.
When necessary, you shall consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment shall read this manual. This manual shall be delivered
with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the
equipment.
Pneg-1966 VersaLoop™ 5
Chapter 1: Safety Precautions
Correct Use
WARNING
Incorrect use can be extremely dangerous. Moving chain, paddles, pulleys and shafts
can cause serious injury and kill.
• VersaLoop™ is for conveying whole agricultural seeds and grains only. Any other use is prohibited.
• VersaLoop™is only intended for fixed applications and not to be moved or transported.
• VersaLoop™is not designed for use in potentially explosive atmosphere and such use is prohibited.
• It may be equipped to receive grains from trucks, trailers, other mechanical grain handling
equipment.
• Electrical control systems shall be designed to the requirements.
• The final installation shall be accordance with all the safety requirements outlined in this manual.
• Never use the VersaLoop™ with any guards removed.
• Never attempt to work on the VersaLoop™ unless the power supply to all other equipment associated
with the VersaLoop™ is OFF, TAGGED and LOCKED.
• Be aware that when stopped, the drive, chain and paddles may move unexpectedly due to the weight
of grain held in angled tubes. Wherever possible run the VersaLoop™ to empty before stopping it.
• Never leave the VersaLoop™ running un-attended.
• Always TURN OFF and LOCK the power supply to the VersaLoop™ before leaving it un-attended.
• Never allow an untrained person or one less than 18 years old to operate the VersaLoop™.
• Never allow someone under the influence of alcohol or drugs to operate the equipment.
• Never modify the VersaLoop™ from it’s original specification.
• Always interlock the bin doors to prevent any equipment operating when the door is open.
• Never work alone.
• Never start equipment until all personnel are clear of the grain bin.
• Keep hands and feet away from all moving parts.
• Always think before acting. Never act impulsively around the equipment.
• Never allow anyone inside a bin, truck or wagon which is being loaded or unloaded. Flowing grain
can trap and suffocate in seconds.
• Manual feeding should be prohibited.
6 Pneg-1966 VersaLoop™
Chapter 1: Safety Precautions
Cautionary Symbols
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use
the symbols that are defined below.
Table 1-1 Description of the different cautionary symbols
Symbol Description
This symbol 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, may result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
This symbol is used to address practices not related to personal
injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
Use Personal Protective Equipment
• Use appropriate personal protective equipment:
Eye
Protection
Respiratory
Protection
Foot
Protection
Hearing
Protection
Head
Protection
Fall
Protection
Pneg-1966 VersaLoop™ 7
Chapter 1: Safety Precautions
Hand
Protection
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
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.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
Operate Motor Properly
• All electrical connections should be made in accordance with
the National Electric Code (US) or Canadian Electrical Code
(CEC). Be sure equipment and bins are properly grounded.
• Thermal overload protection is required for all motors.
• Lock-out power 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.
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep
area clean and dry.
• Never service equipment while it is operating. Keep hands,
feet, and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace
worn or broken parts immediately.
8 Pneg-1966 VersaLoop™
Chapter 1: Safety Precautions
Stay Clear of Moving Parts
• Entanglement in rotat-
ing sprocket or moving
chain will cause serious
injury or death.
• Keep all shields and
covers in place at all
times.
• Lock-out power source
before making adjust-
ments, cleaning, or
maintaining equipment.
Safety Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood
by all personnel involved in the installation, operation, service and maintenance of the equipment.
Location Decal No. Decal Description
All
access
panels
8017001 Shear point danger decal
To replace a damaged or missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois St.
Assumption, IL 62510
Tel: 1-217-226-4421
Pneg-1966 VersaLoop™ 9
Chapter 1: Safety Precautions
Safety Sign-off 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 record keeping.
Date Employee Name Supervisor Name
10 Pneg-1966 VersaLoop™
2General Information
Topics Covered in this Chapter
▪ VersaLoop™ — Information
▪ Motor – Specifications
▪ Recommended Motor Overload Protection
▪ Gearbox - Specifications
▪ VersaLoop™ – Inspection
VersaLoop™ — Information
The VersaLoop™ is a chain and paddle conveyor moving through two tube sections. It is used for loading
and unloading a wide range of free flowing materials with a single drive. It can be used at angles, from hori-
zontal position to an inclination of 60 degrees. The VersaLoop™is primarily intended for grain and grain
products. They will move material into and out of grain storage structures, vehicles, dryers and other facili-
ties with ease and gentleness.
The main components of a VersaLoop™ are motor, gear box, upper and lower tube sections, and chain
and paddles. The horsepower of the motor is determined by the angle of operation required. The Versa-
Loop™ is usually categorized as 8 in. and 10 in. systems based on the tube section diameter.
Operating Capacity
All capacities, length, angle, and horse power is based on dry, free flowing grain.
Refer to the following table for the maximum operating capacity.
NOTE: Maximum capacity will likely reduce as operating angle increases.
VersaLoop™ Maximum Capacity (bushels/hr)
8 in. 4000
10 in. 6000
A VersaLoop™ operating above 50 degrees will have a reduced capacity.
Over-feeding the VersaLoop™ will result in an increased power requirement, additional load on the drive
line, and a possible plugging condition.
Maximum Span Length
Refer to the following table for the maximum span length based on the pipe diameter and pipe material.
Max Span (ft)
Pipe Diameter Wall Thickness
12 ga (Standard) 10 ga 7 ga
8 in. 48 51 53
10 in. 56 59 60
Pneg-1966 VersaLoop™ 11
Chapter 2: General Information
Motor – Specifications
Always use the motor with required horse power as suggested in the following charts.
Maximum 8 in. Lengths (Feet)
Required HP Degree of Incline
Horizontal 15 30 45 60
562 39 27 21 19
10 121 80 55 42 38
15 184 119 82 62 57
20 250 158 109 83 76
25 313 198 136 103 95
Maximum 10 in. Lengths (Feet)
Required HP Degree of Incline
Horizontal 15 30 45 60
10 82 54 36 28 25
15 125 83 55 42 39
20 168 108 74 56 52
25 210 136 92 70 65
30 255 162 112 85 78
Recommended Motor Overload Protection
To protect the gearbox and motor from extreme overload situations, follow the below chart when sizing the
electrical circuit for the VersaLoop™. The circuit breakers should be sized based on the below charts and
appropriate electrical codes.
Required HP
Max Motor Amperage Rating
Three phase 60Hz Single phase 60Hz Three phase 50Hz
208V 230V 460V 575V 230V 240V/380V – 415V
514A 14A 7A 6A 28A 8.7A
10 26A 26A 12A 11A 50A 14.4A
15 40A 37A 19A 17A 68A 21A
20 –50A 25A 22A –28.5A
25 –60A 30A 27A –34A
30 –74A 37A 32A –41A
12 Pneg-1966 VersaLoop™
Chapter 2: General Information
Gearbox - Specifications
Recommended oil for gear box
Mineral oil (ISO/SAE) equivalent to the list in the chart, should be used.
Temperature (°C)
ISO/SAE ENI SHELL ESSO MOBIL CASTROL BP
23°F (-5°C) - 104°F (+40°C)
ISO VG220
BLASIA
220
OMALA
OIL220
SPAR-
TRAN
EP220
MOBIL-
GEAR 600
XP220
ALPHA
MAX 220
ENERGOL
GR-XP
220
5°F (-15°C) - 77°F (+25°C)
ISO VG150
BLASIA
150
OMALA
OIL150
SPAR-
TRAN
EP150
MOBIL-
GEAR 600
XP150
ALPHA
MAX 150
ENERGOL
GR-XP
150
Required oil level for gear box
The gearbox will come filled with the horizontal fill level directly from the manufacturer. The oil level for the
inclined operation is to be increased in addition to the horizontal level in the gear box.
Application DBR–000022 (5
HP) DBR–000023 (10 HP) DBR–000024 (15-
20 HP)
DBR–000025 (25-
30 HP)
Filled to Horizontal 1.3 qrt (1.2 L) 2.7 qrt (2.5 L) 3.9 qrt (3.7 L) 6.0 qrt (5.7 L)
0-14° +0.1 qrt (0.1 L) +0.1 qrt (0.1 L) +0.5 qrt (0.4 L) +0.53 qrt (0.5 L)
15-34° +0.6 qrt (0.5 L) +0.7 qrt (0.6 L) +1.2 qrt (1.1 L) 2.2 qrt (2.1 L)
35-54° +0.9 qrt (0.8 L) +1.0 qrt (0.9 L) +2.1 qrt (2.0 L) +3.5 qrt (3.3 L)
55-60° +1.1 qrt (1.0 L) +1.3 qrt (1.2 L) +3.5 qrt (3.3 L) +4.4 qrt (4.2 L)
VersaLoop™ – Inspection
After the completion of the assembly and before each use, inspection of the VersaLoop™ is mandatory.
Use the assembly instructions in this manual as a reference to determine that the VersaLoop™ is
assembled properly.
This inspection should include, but not limited to:
1. Make sure all the covers listed in the assembly instructions are installed.
2. Check for all safety decals on the VersaLoop™ and replace if worn out, missing or illegible. The
safety decals are listed in this manual.
3. Check all the fasteners are tightened.
4. Check for proper adjustment of the VersaLoop™ chains and paddles. (Refer to VersaLoop™ Chain –
Adjustment, page 35.)
5. Check the oil level in the gear box is to the specified limit for the specific inclination. (Refer the section
above for required oil level).
Pneg-1966 VersaLoop™ 13
NOTES
14 Pneg-1966 VersaLoop™
3Operation
Topics Covered in this Chapter
▪ Start-up and Break-in Guidelines
▪ VersaLoop™ – Standard Operation
▪ VersaLoop™ – Shutdown
Start-up and Break-in Guidelines
It is essential to inspect the VersaLoop™ and drive components before adding power and to know how to
shut down in an emergency. During the operation of the VersaLoop™, one person should be in a position
to monitor the operation.
Any conveying equipment, when it is new or after it sits idle for a season, should go through a “break-in”
period. It should be run at partial capacity at full speed until the inside of the housing becomes polished,
before attempting full capacity. Failure will most likely occur when it is run at full capacity before it has a
chance to get shined up.
During the initial start-up and break-in period, the operator should be aware of any unusual vibrations or
noises.
VersaLoop™ – Standard Operation
During the regular operation of the VersaLoop™, one person shall be in position to monitor the operation.
It is a good practice to inspect the unit periodically during the operation and be alert for unusual vibration,
noise and loosening of any fasteners.
Check to make sure the gates are either open or closed to have grain delivered to desired location.
Start the VersaLoop™ motor before adding the grain to the VersaLoop™.
Begin adding grain to the unit slowly, and gradually increase the flow until the VersaLoop™ reaches the
full capacity.
Monitor the grain entering and exiting the VersaLoop™ during operation until shutting down the unit.
Before shutting down, make sure to shut off the grain flow, and then allow the VersaLoop™ to empty.
Make sure to lock out the power source before leaving the work area.
Pneg-1966 VersaLoop™ 15
Chapter 3: Operation
VersaLoop™ – Shutdown
Normal shutdown
Make sure that the hopper is empty before stopping the unit. Before the operator leaves the work area, the
power source should be locked out.
CAUTION
If the operator must leave the work area, or whenever servicing or adjusting, the
VersaLoop™ must be stopped and the power source turned off. Precaution should be
made to prevent anyone from operating the machine when the operator is away from
the work area.
A main power disconnect switch capable of being locked only in the OFF position shall be
provided. This shall be locked whenever work is being done on the VersaLoop™.
Emergency shutdown
If the VersaLoop™ should be immediately shut down under load, disconnect and lockout the power
source.
Clear as much grain as possible and never attempt to restart the VersaLoop™ when full.
16 Pneg-1966 VersaLoop™
4Assembly
Topics Covered in this Chapter
▪ VersaLoop™ – Typical Layout
▪ Tube Section – Assembly
▪ Gearbox and Motor – Installation
▪ Non-drive End – Installation
▪ Drive End – Installation
▪ Chain and Paddles – Installation
VersaLoop™ – Typical Layout
The following steps should be followed when assembling a horizontal or inclined unit.
1. Layout tube sections (C) and determine the inlet and outlets. Refer to Tube Section – Assembly,
page 19.
2. Install the gear box (E) and motor (D) to the center shaft of the drive end section (A). Refer to Gear-
box and Motor – Installation, page 21.The right hand/left hand orientation is determined by the layout.
3. Install the tube sections (C) and drive end (A) section into location. Refer to Drive End – Installation,
page 23.
4. Install the other end of the tube sections (C) to the non-drive end (B). Refer to Non-drive End – Instal-
lation, page 22.
5. Install chains and paddles into the tube section (C) from the drive end section.
6. Tighten the VersaLoop™ chain.
7. Attach the inlet hopper (if equipped). Refer to Hopper – Installation, page 27.
8. Attach the discharge spout (if equipped). Refer to Discharge Spout – Installation, page 28.
Pneg-1966 VersaLoop™ 17
Chapter 4: Assembly
Tube Section – Assembly
1. Center the connecting band (B) over the tube section (A) connections.
2. Position the connecting band (B) with the joint to the side of the tube (A).
3. Position the joint of the connecting band (B) so that the overhanging lip will shed water and not direct
it to the tube (A).
4. Install the bolts (C) and nuts (D) on each connecting band.
Figure 4-2 Tube section assembly
ATube section C 3/8 x 1-1/2 in. hex bolt
BConnecting band D3/8 nut
5. Repeat steps 1 to 4 for the other tube sections.
6. Locate an area on open level ground accessible to chain hoist or other lifting devices where the Ver-
saLoop™ assembly can be laid out full length.
7. Position the tube supports (E) at regular intervals (every 10 ft. on center) on the open level ground.
8. Position the bottom tube section (A) onto the tube supports (E).
9. Position the clamps (F) to the bottom of the tube (A) and tube supports (E).
10.Install bolts (G) and nuts (H) per each tube support (E) and clamp (F).
11.Repeat this procedure for securing the upper tube (I) section.
Pneg-1966 VersaLoop™ 19
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