GSi GRA User manual

Sampler
Model: GRA
Installation and Operation Manual
PNEG-2174
Version: 1.0
Date: 01-04-18
PNEG-2174

2PNEG-2174 Sampler - Model GRA
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.

Table of Contents
PNEG-2174 Sampler - Model GRA 3
Contents
Chapter 1 Introduction ..........................................................................................................................................4
General Safety Statements ................................................................................................................... 4
Scope .................................................................................................................................................... 4
Ordering Parts ....................................................................................................................................... 5
Replacement Parts ................................................................................................................................ 5
Repair Kits ............................................................................................................................................. 5
Chapter 2 Safety .....................................................................................................................................................6
Safety Guidelines .................................................................................................................................. 6
Cautionary Symbol Definitions .............................................................................................................. 7
Safety Cautions ..................................................................................................................................... 8
Safety Sign-Off Sheet ......................................................................................................................... 11
Chapter 3 Decals ..................................................................................................................................................12
Chapter 4 General Information ...........................................................................................................................15
System Description ............................................................................................................................. 15
Optional Features ................................................................................................................................ 16
Material Sampled ................................................................................................................................ 16
Sampler Construction .......................................................................................................................... 16
Chapter 5 Installation ..........................................................................................................................................17
Receiving Inspection ........................................................................................................................... 17
Pre-Installation Preparation ................................................................................................................. 17
Location ............................................................................................................................................... 17
General Mounting Guidelines .............................................................................................................. 17
Material Sample Transport Lines ........................................................................................................ 18
Controller Location .............................................................................................................................. 18
System Wiring ..................................................................................................................................... 18
System Piping ..................................................................................................................................... 19
Chapter 6 Operations and Adjustments ............................................................................................................21
Control Components and their Functions ............................................................................................ 21
Pneumatic Components ...................................................................................................................... 25
Chapter 7 Maintenance and Repair ....................................................................................................................27
General Maintenance .......................................................................................................................... 27
Periodic Inspection .............................................................................................................................. 27
Lubrication ........................................................................................................................................... 27
Draining and Servicing the Filter ......................................................................................................... 28
Mechanical Repair Procedures ........................................................................................................... 28
Chapter 8 Troubleshooting .................................................................................................................................31
General GRA Sampler Troubleshooting ............................................................................................. 31
Directional Solenoid Valve Troubleshooting ....................................................................................... 32
Air Components Troubleshooting ........................................................................................................ 33
Chapter 9 Parts List .............................................................................................................................................35
Sampler Model GRA Parts List ........................................................................................................... 35
Chapter 10 Warranty ............................................................................................................................................39

4PNEG-2174 Sampler - Model GRA
1. Introduction
This manual covers the installation and operation for the Sampler GRA Model. This manual provides
guidelines for installing the product. You must retain a qualified contractor to provide on-site expertise.
INTERSYSTEMS IS NOT RESPONSIBLE FOR THE INSTALLATION OF THIS PRODUCT.
InterSystems reserves the right to improve its product whenever possible and practical to do so. We
reserve the right to change, improve and modify products at any time without obligation to make changes,
improvements and modifications on equipment sold previously.
General Safety Statements
1. The Sampler system is designed and manufactured with operator safety in mind. However, residual
hazards remain due to the nature of material handling, and specific material hazards. Use extreme
caution at all times.
2. 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.
3.Intersystemsrecommendsthatyoucontact the localpowercompanyto have a representativesurvey
the installation to ensure wiring is compatible with their system and adequate power is supplied to
the unit.
4. Consult InterSystems before making any changes to the sampler or its operating environment.
Careless changes could result in death or serious injury to people and reduce the performance and
service life of the equipment.
5. Never perform any service on this equipment or any powered equipment until all power has been
shut off and locked out so that it cannot be restored without the consent and knowledge of the person
who interrupted power. Power includes electrical, fluid, mechanical or pneumatic energy.
6. Never perform any service on this equipment without utilizing the required PPE (Personal Protective
Equipment). Refer to the MSDS (s) (Material Safety Data Sheet (s)), on all the productsto which this
equipment is in contact to determine what PPE is required.
Scope
The certified drawings list the non-standard components that have been incorporated into the equipment.
InterSystems, Inc. normally stocks non-fabricated parts and non-custom OEM parts. Replacement parts
for any other components, including fabricated parts and custom OEM components can be supplied
upon request.
This equipment is to be operated only on the voltage designated on the certified
electrical drawings. Fire or explosion may result, which can cause death, serious
injury and extensive damage to equipment. Do not connect to voltages other than
designated.
Compressed air can cause severe injury. Shut off and lock out compressed air
source to the sampler and bleed off any and all present compressed air within the
sampler pneumatics before attempting any service on this sampler.

1. Introduction
PNEG-2174 Sampler - Model GRA 5
Ordering Parts
Direct parts orders or requests for technical assistance to your sales representative or to:
InterSystems, Inc.
13330 “I” St.
Omaha, NE. 68137
Phone: [phone]
FAX: [phone]
Please have available the MODEL NUMBER, SERIAL NUMBER and CUSTOMER ORDER NUMBER of
the equipment in question as well as the location where the sampler is INSTALLED.
Replacement Parts
The InterSystems, Inc. sampler is a quality built piece of machinery. As with any machine, parts do wear
out and fail. It is InterSystems recommendation that a small supply of spare parts be kept on hand to cover
any minor breakdowns. A separate priced spare parts list will be sent identifying the suggested spare
parts. It is also necessary to check the certified drawings, which will list any special or custom components
utilized on this equipment.
Repair Kits
The following chart lists repair kits and parts that are available from InterSystems. These kits are offered
as a more economical solution by rebuilding the defective part rather than replacing it. However in some
cases the part may be beyond repair and replacement will be necessary.
Product Code Description
512762 Spool Kit for 4-Way Directional Valves (ISI 375 Series)
28166 Standard 120 VAC Valve Coil and Housing (ISI 375 Series)
515835 Optional 240 VAC Valve Coil and Housing (ISI 375 Series)
519287 Optional 120 VAC Explosion-Proof Coil and Housing (ISI 375 Series)
527132 Rod Seal Kit for 5/8'' Rod Air Cylinder (Parker 2MA Series)
527133 Rod Seal Kit for 1'' Rod Air Cylinder (Parker 2MA Series)
523998 Piston Seal Kit for 2-1/2" Bore Air Cylinder (Parker 2MA Series)
523999 Piston Seal Kit for 3-1/4" Bore Air Cylinder (Parker 2MA Series)
524000 Piston Seal Kit for 4" Bore Air Cylinder (Parker 2MA Series)
513963 Gauge for Filter Regulator
524011 Filter Element for Filter Regulator (Norgren B08 Series)

6PNEG-2174 Sampler - Model GRA
2. Safety
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating 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 must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable
regulations,which must becarefullyfollowed in allcases. Authorities having jurisdiction must be consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must 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.
ST-0001-3

2. Safety
PNEG-2174 Sampler - Model GRA 7
Cautionary Symbol Definitions
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.
DANGER
WARNING
CAUTION
NOTICE
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, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which,
if not avoided, can 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.
ST-0005-2

2. Safety
8PNEG-2174 Sampler - Model GRA
Safety Cautions
Use Personal Protective Equipment
Eye
Protection
Hearing
Protection
Hand
Protection
Head
Protection
Respiratory
Protection Foot
Protection
Fall
Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004-1
Follow Safety Instructions
• Carefully read all safety messages in this manual and
safety signs on your machine. Keep signs in good
condition. Replace missing or damaged safety signs.
Be sure new 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.
ST-0002-1

2. Safety
PNEG-2174 Sampler - Model GRA 9
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.
ST-0003-1
Stay Clear of Hoisted Equipment
• Always use proper lifting or hoisting equipment when assembling
or disassembling equipment.
• Do not walk or stand under hoisted equipment.
• Always use sturdy and stable supports when needed for
installation. Not following these safety precautions creates the
risk of falling equipment, which could crush personnel and cause
serious injury or death.
ST-0047-1
Sharp Edge Hazard
• This product has sharp edges, which can cause serious injury.
• To avoid injury, handle sharp edges with caution and always use
proper protective clothing and equipment.
ST-0036-2
Install and Operate Electrical Equipment Properly
• Electrical controls must be installed by a qualified electrician and
must meet the standards set by applicable local codes (National
Electrical Code for the US, Canadian Electric Code, or EN60204
along with applicable European Directives for Europe).
• Lock-out power source before making adjustments, cleaning, or
maintaining equipment.
• Make sure all equipment and bins are properly grounded.
ST-0075-1

2. Safety
10 PNEG-2174 Sampler - Model GRA
Stay Clear of Moving Parts
• Stay clear - machine can start without warning.
• Entanglement in gate will cause serious injury.
• Keep all shields and covers in place at all times.
• Lock-out power source before making adjustments, cleaning, or
maintaining equipment.
ST-0070-1
Flying Material and High Pressure Air Hazard
• Flying material and/or high pressure air can cause
severe eye injury or blindness.
• Wear safety glasses around operating equipment.
ST-0071-1
Stay Clear of Rotating Parts
• Do not service equipment while it is in operation.
• Entanglement in rotating parts or exposed belts will cause serious
injury or death.
• Keep all shields and covers in place at all times.
• Lock-out power source before making adjustments, cleaning, or
maintaining equipment.
ST-0072-1

2. Safety
PNEG-2174 Sampler - Model GRA 11
Safety Sign-Off Sheet
Below is a sign-off sheet that canbe used to verify that all personnel have read and understoodthe safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
Toxic Fume and Dust Hazard
• Do all work outside or in a well-ventilated area. Dispose of paint and
solvent properly.
• 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.
— 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.
ST-0043-2
ST-0007

12 PNEG-2174 Sampler - Model GRA
3. 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.
To replace a damaged of missing decal, contact us to receive a free replacement.
InterSystems
13330 “I” Street
Omaha, Nebraska 68137
Phone: [phone]
FAX: [phone]
Figure 3A GRA Sampler Safety Label Locations
NOTE: These signs must never be removed, tampered with, painted over or obscured in anyway. If labels
are damaged or become unreadable, replacement labels are available from InterSystems.

3. Decals
PNEG-2174 Sampler - Model GRA 13
Ref # Decal # Decals Description
1 EMC3034 Moving Part
2 EMC42834 Eye Protection
3 IS526X4 IS Logo
WARNING
Moving parts can
cut and crush.
Lockout energy
source before
inspection or
service.
Reorder No. EMC 3032
CClarion Clarionsafety.com
WARNING
Flying material can
cause severe eye
injury or blindness.
No. EMC 28 34
Wear safety glasses
around operating
equipment.
15225
CClarion
OMAHA, NEBRASKA USA

3. Decals
14 PNEG-2174 Sampler - Model GRA
4ISTag Serial Number Tag
5 EMC40234 Lock Out Machine
6 EMC40334 Starts Without Warning
7 IS 516x1 IS Samplers
Ref # Decal # Decals Description
WARNING
Avoid serious
injury or death.
This machine MUST be
locked out in accordance
with current OSHA
requirements before
any maintenance or
service is performed.
Reorder No. EMC 402 3416089
CClarion Clarionsafety.com
WARNING
Stay clear.
Machine
starts without
warning.
CClarion clarionsafety.com
Reorder No. EMC 403 34
OMAHA, NEBRASKA DALLAS, TX. IS 516X1
InterSystems Samplers

PNEG-2174 Sampler - Model GRA 15
4. General Information
System Description
The GRA Sampler is designed to collect a representative sample of granular, flake, pellet, slurry or other
materials in a vertical gravity conveying line.
Sample collection is initiated in response to either an operator’s manual command or a signal
automatically generated by controller logic, usuallytime-based but which could also be volume or quantity
based. A sample cycle begins when a double-acting pneumatic cylinder pivots the slotted sample cutter
through the product flow to collect a sample of the material. The sample flows through the sample cutter
and out the discharge as it swings through the material flow. The sample cutter, when at rest, is situated
under one of two dust seals that seal the sample cutter. The sample from the sample cutter falls down and
out the 3.00" (76 mm) O.D. discharge tube to the desired sample collection point, at which point an
InterSystems SCS Sample Collection System (optional) may be installed.
Figure 4A Typical Installation, Model GRA Sampling System
Ref # Description
1Electrical Conduits
2 Sampler Control Panel
3Circuit Breaker
4 Directional Control Valve Coils (2)
5Sample Discharge (Extend to desired collection point)
6 1/2'' NPT Compressed Air Line 80-100 PSI Compressed Air Supply. Requied (By others)
7Filters/Regulator
8 Dual Coil Solenoid Control Valve
9Material to be Sampled

4. General Information
16 PNEG-2174 Sampler - Model GRA
Optional Features
The certified drawings indicate which, if any, optional features are included with a sampling system. Some
of the more frequently specified optional features are briefly described in the following list.
1. Controller arranged to initiate a sampling cycle based on quantity or volume of material passing
through conveying line rather than upon elapsed time periods.
2. Explosion-Proof Sampling System. There are several major differences in an explosion-proof
sampler as compared to a standard sampling system. An explosion-proof sampler will typicallyhave
the following features.
a. An explosion-proof solenoid on the directional control valve with the rating of:
Class 1, Groups C and D, Division 1 and 2
Class 2, Groups E, F and G, Division 1 and 2
The explosion proof sampler control is available in two enclosure classifications.
a. The NEMA 9 control with the rating of:
Class 2, Groups E, F and G, Division 1 and 2
b. The NEMA 7 control with the rating of:
Class 1, Groups C and D, Division 1 and 2
Class 2, Groups E, F and G, Division 1 and 2
3. Positive mechanical seals for sealing the sample cutter when slight conveying line pressures
are present.
4. Components of special materials, such as 316 stainless steel, monel, inconel or nedox coatings.
5. Programmable controls to sequence the sampler and the sample collection equipment.
6. Abrasion resistant linings of urethane, AR carbon steel plate, 304 stainless steel or ceramic tile.
Material Sampled
Most materials from light to heavy density granules, flakes, pellets, powders and slurrys.
Sampler Construction
Standard sampler construction is of painted carbon steel or Type 304 Stainless Steel. Other materials
and/or finishes appropriate to the operating environment and the material or product being sampled may
be used. Refer to the certified drawing(s) for any optional or special components installed on the sampler.

PNEG-2174 Sampler - Model GRA 17
5. Installation
Receiving Inspection
Carefully inspect the sampling system for damage as soon as it is received. Also, verify that the quantity
of parts or packages actually received corresponds to the quantity shown on the packing slip. Report any
damage or shortage to the delivering carrier as soon as possible. InterSystems responsibility for the
equipment ended with acceptance by the delivering carrier. Refer to the bill of lading.
Pre-Installation Preparation
NOTE: Before starting sampling system installation, study this manual, the certified drawing(s) furnished
with the system and other applicable documents (including, but not limited to OSHA Regulations,
the National Electrical Code and all other applicable federal, state and local codes and
regulations).
Location
The GRA sampler is typically mounted vertically into a gravity flowing conveying line carrying the product
to be sampled as shown in Figure 4A on Page 15. The sampler axis must be installed parallel to the axis
of the product line for optimum performance. Additionally, the sampler should be located where the
product has a non-turbulent flow pattern. The sampler and associated equipment should be located for
ease of access and maintenance.
The sampler is to be installed only as shown on the certified drawing(s). If an alternate mounting
arrangement is desired contact InterSystems prior to installation for proper guidance. The sampler is
of a general design with modifications specifically for your application. It may be necessary to rework the
sampler in order for it to function properly if you alter the application.
General Mounting Guidelines
1. Locate and mark the desired mounting location of the sampler on the product conveying line.
2. Cut out the section of conveying line 1/16" to 1/8" longer than the length of the sampler.
3. Slip a companion flange over each end of the conveying line.
4. Locate the sampler in the desired position and adequately brace. Braces are to be permanent.
5. Bolt the companion flanges to the sampler and weld companion flanges to the chute.
Sampler cannot support any other equipment or conveying line. Collapse of the
whole system can cause death, serious injury and extensive damage to equipment.
Properly support all spouts, containers and conveying lines.

5. Installation
18 PNEG-2174 Sampler - Model GRA
Material Sample Transport Lines
The tubing used to transport material samples must be compatible with the operating environment and the
material sampled. Typically a 3.00" I.D. flexible hose is slipped over the discharge tube and held in place
by a worm clamp. The hose is then routed to allow material to flow via gravity to a convenient collection
point. At that point, the hose may be connected to a collection jar bracket or a Sample Collection System
cabinet.
Rigid tubing may also be used if desired for the sample transport line.
Makeallconnectionsairtightand make sure all interiorsurfacesofjointsaresmoothandflush.Anyragged
or raised tube ends will collect dust and debris as well as retard material flow. Air leaks can interfere with
the pressure or vacuum conveying and sampling system. Escaping sample material can contaminate
surrounding atmosphere and equipment.
Controller Location
1. Use vibration isolation pads when mounting the control enclosure or mount the controller in a
vibration free location.
2. Unless ordered for severe duty, locate controller so it is protected from water and dust.
3. Unless an explosion-proof rated controller was specifically ordered, DO NOT locate the controller in
a hazardous area.
4. Most applications require that the sampler be in easy view of the controller.
System Wiring
Refer to the certified electrical drawing(s) for specific wiring requirements.
The controller was completely assembled and tested with the sampler before it left the factory. The
electrical installation must comply with OSHA Regulations, the National Electrical Code and all other
applicable federal, state and local codes and regulations.
If wiring between the controller and the sampler unit is run through rigid conduit, use a short length of
flexible conduit to connect wiring to the sampler. This will isolate the rigid conduit from any vibration
originating in the product conveying line and sampler.
Electrical Power Requirements, System
110/120 VAC 50/60 Hz, Single Phase, 10 Amp Service.
Optional - 220/240 VAC 50/60 Hz, Single Phase, 5 Amp Service.
Refer to the certified electrical drawing(s) for specific wiring requirements. InterSystems strongly
recommends that electrical service to the sampling system be an isolated line. Voltage fluctuations and
line noise can affect the controller's circuit board, thus causing the sampler to malfunction.
Controller
110/120 VAC, 50/60 Hz, Single Phase, 4 Amp Max. (Includes motor power requirements).
Optional - 220/240 VAC, 50/60 Hz, Single Phase, 2 Amp Max. (Includes motor power requirements).
Solenoid Valve Coil
110/120 VAC, 50/60 Hz, Single Phase, 7 Watts.
Optional - 220/240 VAC, 50/60 Hz, Single Phase, 7 Watts.

5. Installation
PNEG-2174 Sampler - Model GRA 19
System Piping
The pneumatic system was pre-plumbed and tested with the sampler before it left the factory. The final
installation must comply with OSHA Regulations and all other applicable federal, state and local codes
and regulations.
As shown on the certified drawing(s), the solenoid valves and filter/regulator (F/R) were mounted on the
sampler at the factory. The user or installer must pipe the compressed air supply to the F/R. Minimum pipe
size for the air supply to the filter/regulator is 1/2" NPT, reduced to 3/8" NPT at sampler. Larger piping to
the sampler and/or a surge tank located at the sampler, will be required on installations where the
compressed air source is further than 200' from the sampler to prevent excessive drop in air pressure.
InterSystems recommends installing a shut off valve upstream of the filter/regulator. A shut off valve
facilitatesmaintenanceas it allows thesampler’spneumaticsystem to bemaintainedandrepaired without
shutting down other equipment supplied from the same air source.
Figure 5A Pneumatic Schematic
Ref # Description
1Extend/Retract Cylinder
2 4-Way Directional Solenoid Valve
3Needle Valves (Speed Control)
4 Filter Regulator
5Compressed Air “In”
Use only cleaned, pickled, descaled and oiled pipe for air supply lines. Dirt, scale
and debris usually found in standard pipe quickly clogs filter/regulators, valves, etc.
Use only Teflon tape to seal pipe joints. Carefully apply the tape to pipe and fittings
so no fragments enter the system.

5. Installation
20 PNEG-2174 Sampler - Model GRA
Compressed Air Consumption
A complete sampling cycle requires that the sample cutter drive cylinder either extend or retract. To
determine the compressed air requirements to operate the sampler, multiply the consumption per cycle
(refer to chart) by the number of cycles per minute. The number calculated is the SCFM (Standard Cubic
Feet per Minute) of air required. A typical cycle takes between 1-2 seconds, depending on the sampler
size and speed control valve settings.
The pneumatic system on the sampler, consisting of the filter/regulator, directional control valve and air
cylinder was pre-plumbed and tested at the factory. The regulator is factory set at 80 PSI.
The regulator cannot increase downstream outlet pressure above the upstream inlet pressure. If the
pressurefromtheregulatoris not sufficient to operatethecylinder,somemeansmustbe foundto increase
the inlet pressure to the regulator. Recommended air supply pressure is 80-100 PSI.
Model/Size Air Consumption per Sample Cycle @ 80 PSI
GRA-6 and 10 0.36 SCF
GRA-14 and 18 0.59 SCF
GRA-22, 26 and 30 0.91 SCF