GSi InterSystems PNEG-2116 User manual

Bucket Elevator
Installation and Operation Manual
PNEG-2116
Version: 1.0
Date: 12-12-16
PNEG-2116

2PNEG-2116 Bucket Elevator
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-2116 Bucket Elevator 3
Contents
Chapter 1 Introduction ..........................................................................................................................................4
General Information .............................................................................................................................. 4
General Safety Statements ................................................................................................................... 4
Replacement Parts ................................................................................................................................ 4
Chapter 2 Safety .....................................................................................................................................................5
Safety Guidelines .................................................................................................................................. 5
Cautionary Symbols Definitions ............................................................................................................ 6
Safety Cautions ..................................................................................................................................... 7
Safety Sign-Off Sheet ......................................................................................................................... 11
Chapter 3 Decals ..................................................................................................................................................12
Chapter 4 Installation ..........................................................................................................................................16
Receiving Inspection ........................................................................................................................... 16
Pre-Installation Preparation ................................................................................................................. 16
Elevator Foundation ............................................................................................................................ 16
Elevator Guying or Bracing ................................................................................................................. 17
Elevator Intake .................................................................................................................................... 18
Elevator Discharge .............................................................................................................................. 19
Positioning Trunk Sections for Ladder ................................................................................................ 19
Elevator Belt Selection ........................................................................................................................ 19
Elevator Erection (Assembly) .............................................................................................................. 20
Ladder Assembly with Safety Cages .................................................................................................. 23
Typical Small Head Service Platform Assembly ................................................................................. 25
Typical Large Head Service Platform Assembly ................................................................................. 25
Typical Head Service Hatch Assembly ............................................................................................... 26
Belt and Bucket Installation ................................................................................................................. 27
Belt Splicing ........................................................................................................................................ 32
Hood Installation ................................................................................................................................. 34
Drive Installation .................................................................................................................................. 34
Chapter 5 Operation ............................................................................................................................................35
Initial Belt Tracking .............................................................................................................................. 35
Rubber Throat Slide Adjustment ......................................................................................................... 37
In-Service Belt Tension ....................................................................................................................... 38
Elevator Bucket Filling ......................................................................................................................... 39
Chapter 6 Maintenance and Repair ....................................................................................................................41
General Maintenance .......................................................................................................................... 41
General Housekeeping and Periodic Inspection ................................................................................. 41
Lubrication ........................................................................................................................................... 42
Adjustment and Repair Procedure ...................................................................................................... 43
Chapter 7 Warranty ..............................................................................................................................................45

4PNEG-2116 Bucket Elevator
1. Introduction
General Information
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.
This manual covers the installation and operation for the Bucket Elevator. 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.
DO NOT exceed the elevator’s rating. A certified drawing or drawings furnished with the elevator gives
its capacity in BPH (Bushels Per Hour) plus the weight per cubic foot and the weight per bushel of the
commodity or material the elevator is designed to elevate. The drawing also specifies the operating
speed of the elevator belt and other pertinent data. Consult InterSystems. before making any changes to
the elevator or its operating environment; in particular, any change in the speed or power of the elevator
drive. Careless changes could result in death or serious injury to people, and/or reduce the performance
and service life of the equipment.
Never perform any service on this elevator or any other powered equipment until all power has been
shut off and locked out so that it cannot be restoredwithout the consent and knowledge of the person who
interrupted power. Power includes electrical, fluid, mechanical (cable, belt, chain, shaft, etc.) or gravity
where the load or part of the equipment is suspended. Never add restraint to an explosion vent. If the
elevator structure is damaged to the extent the relief panels will not stay in position, make proper repairs.
Remember the vents are designed to blow out readily, limiting damage and injury, in case of explosion.
Failure to observe all safety precautions, including those dictated by ordinary common sense, can result
in death or serious injury to personnel, loss of product (elevated material), and damage or destruction of
the equipment.
General Safety Statements
1. The Bucket Elevator 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.InterSystemsrecommendsthatyoucontactthelocalpowercompany tohavearepresentativesurvey
the installation to ensure wiring is compatible with their system and adequate power is supplied to
the unit.
Replacement Parts
The certified drawings furnished with the elevator list the components, which are likely to require
replacement. Replacements for any other components, including structural members can be supplied
upon request.
For direct parts orders or requests for technical assistance should be directed to:
InterSystems
9575 No. 109TH AVE
Omaha, NE. 68142
Phone: [phone]
FAX: [phone]
Please have available the Model Number and Serial Number of the equipment in question, as well as the
location where the equipment is INSTALLED.

PNEG-2116 Bucket Elevator 5
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 be carefully followed in all cases. Authorities havingjurisdiction must beconsulted
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
6PNEG-2116 Bucket Elevator
Cautionary Symbols 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
PNEG-2116 Bucket Elevator 7
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
8PNEG-2116 Bucket Elevator
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 Moving Parts
• Entanglement in rotating sprocket or moving chain
will cause serious injury or death.
• Keep all guards and covers in place at all times.
• Lock-out power source before making adjustments, cleaning,
or maintaining equipment.
ST-0076-1
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
Electric 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 is properly grounded.
ST-0027-4
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

2. Safety
PNEG-2116 Bucket Elevator 9
Fall Hazard
• Keep access door closed while on a platform to avoid falls.
• Always use proper personal protective equipment and proper
clothing when using equipment. Failure to follow safety precautions
can result in severe injury or death.
ST-0042-2
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
> 500 lbs
(2.25 kN)
Platform Load Limit
• The platform load limit is 500 LBS (2.25 kN).
Do not exceed this weight.
• Excessive load will damage the platform and
cause platform to fall. Severe injury or death
will result.
ST-0044-2

2. Safety
10 PNEG-2116 Bucket Elevator
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 can crush personnel and cause serious injury
or death.
ST-0047-1
Fall Hazard
• Ladders, stairways and platforms are for use by competent and trained
personnel only. Do not allow children or other unauthorized persons to
have access to the equipment.
• Access to the equipment must be restricted by the use of security
fencing and lockable gates.
• Lower sections of ladders must be fitted with a lockable safety gate to
prevent unauthorized access.
• Make sure that hot surfaces have had adequate time to cool before
working on or in the equipment.
• Lock out and tag out power supplies and fuel supplies to all equipment.
• Do not attach lifting equipment to ladders or platforms.
• Do not go outside of the safety rails provided on elevated platforms.
• Do not work at heights during high winds, rain, snow, or ice storms.
ST-0056-1
Flying Material Hazard
• Flying material can cause severe
eye injury or blindness.
• Wear safety glasses around operating
equipment.
ST-0074-1

2. Safety
PNEG-2116 Bucket Elevator 11
Safety Sign-Off Sheet
Below is a sign-off sheet that canbe 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
ST-0007

12 PNEG-2116 Bucket Elevator
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 or missing decal, contact us to receive a free replacement.
InterSystems
9575 N. 109th Ave.
Omaha, Nebraska 68142
Toll Free: [phone]
Figure 3A Bucket Elevator Safety Decals Locations

3. Decals
PNEG-2116 Bucket Elevator 13
NOTE: These labels 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 Intersystems.
Ref # Decal # Decals Description
A EMC 12 J3 Explosion (Typical all panels)
B EMC 22 J3 Exposed Buckets
C EMC 28 J3 Eye Protection
vent during
operation.
Explosion release
will cause severe
injury or death.
Stay clear of area
around explosion
DANGER
DANGER
Reorder No. EMC 12 J3
CClarion clarionsafety.com
Exposed buckets and
moving parts will
cause severe injury
or death.
Lockout power before
removing cover or
inspection door.
DANGERDANGER
Reorder No. EMC 22 J3
CClarion clarionsafety.com
WARNING
Flying material can
cause severe eye
injury or blindness.
Wear safety glasses
around operating
equipment.
Reorder No. EMC 28 J3
CClarion clarionsafety.com

3. Decals
14 PNEG-2116 Bucket Elevator
D EMC 25 J3 Rotating Parts
E EMC 24 J3 Exposed Belt
F EMC 402 34 Lock Out Machine
G EMC 31 J3 Platform Collapse
Ref # Decal # Decals Description
WARNING
Rotating parts can
crush, cut and entangle.
Do NOT operate with
guard removed.
Lockout power before
removing guard or
servicing.
Reorder No. EMC 25 J3
CClarion Clarionsafety.com
WARNING
Moving parts can
crush and cut.
Do NOT operate with
guard removed.
Lockout power before
removing guard or servicing.
Reorder No. EMC 24 J3
CClarion clarionsafety.com
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 34
CClarion Clarionsafety.com
WARNING
Platform
collapse can
cause severe
injury.
Do NOT exceed
posted load.
Reorder No. EMC 31 J3
CClarion Clarionsafety.com

3. Decals
PNEG-2116 Bucket Elevator 15
H IS 504X3 Platform Limits
For I.S. platform only
IIntersystems Serial Number Tag
J IS 5210X8 Intersystems Logo
Ref # Decal # Decals Description
WARNING
Platform
Maximum Concentrated
Load 100 lbs / SQ FT
Not to Exceed 500 lbs
OMAHA, NEBRASKA USA

16 PNEG-2116 Bucket Elevator
4. Installation
IMPORTANT: Thoroughly read safety information from Pages 5-15 before beginning installation
and start-up.
Receiving Inspection
1. Carefully inspect the shipment for damage as soon as it is received. Verify that the quantity of parts
or packages actually received corresponds to the quantity shown on the packing slip. One or more
cartons containing the fasteners required for assembly are included with the shipment. Report any
damage or shortage to the delivering carrier as soon as possible.
2. InterSystems responsibility for damage to the equipment ended with acceptance by the delivering
carrier. Refer to the bill of lading for more detailed information.
3. Save all paperwork and documentation furnished with any of the elevator components.
Pre-Installation Preparation
1. The MOST IMPORTANT preparations are retaining a licensed engineer to plan the installation and
a qualified millwright or contractor to erect the elevator and the accompanying equipment and
structures. Before starting the bucket elevator installation, review this manual, the certified
drawing(s) furnished with the equipment, and other applicable documents, including but not limited
to, O.S.H.A. Regulations and the National Electrical Code. You should also obtain a copy of
“Guidelines for Supporting Outside Elevator Legs”, Bulletin No. F-646-75, available from Mill Mutual
Fire Prevention Bureau, North Riverside Plaza, Chicago, IL 60606, as it is referenced throughout
the manual.
2. InterSystems is the vendor of the bucket elevator and certain of its optional accessories only, and
does not assume responsibility for the installation.
3. InterSystems Bucket Elevators are designed to be vertically self-supporting when erected. The
elevator does require guying and/or bracing from another structure for horizontal support. The
elevator has not been designed to support other equipment such as cleaners, distributors, spouting,
etc. Separate structures must be provided for any accessory equipment.
Elevator Foundation
Refer to Mill Mutual Publication No F-646-75.Additionally, in the process of leveling the boot,
InterSystems recommends that the installer plan on shimming the boot around its perimeter and grouting
the base plate after the hold down fasteners are in place and tightened.

4. Installation
PNEG-2116 Bucket Elevator 17
Elevator Guying or Bracing
Refer to Mill Mutual Publication No F-646-75.
NEVER attach any bracing directly to the sheet metal trunk. Sheet metal lacks the necessary stiffness and
thickness for sound structural joints.
The engineer or contractor supervising elevator installation is ultimately responsible for determining
suitableguying and/orbracingmethods and materials. Recommendedmaximum distance between lateral
bracing is 20' increments vertically at trunk flange seams to adjoining structure. The following
considerations are presented in addition to those set forth in Mill Mutual Publication No F-646-75:
1. Consider placing curbs or guards around anchors to prevent impact and damage from area traffic.
2. Guy cables near ground level must be guarded and made visible to prevent injuries.
3. Figure 4B shows the proper method for unspooling cable from a reel.
Figure 4A Guy Bracket Detail Figure 4B Proper Cable Unspooling
Incorrect attachment of guying cables to elevator or lateral bracing from an
adjoining structure will result in support failure, collapse of the elevator and death
or severe injury to anyone in the area.
Attach guying cables to the elevator only by means of the 4 wire bolt-on brackets
as shown in Figure 4A. If bracing from an adjoining structure is used, attach only at
flange joints between legging sections.
Incorrect Correct
Ref # Description Ref # Description
AMount guy brackets atop legging frame to
prevent brackets from working down-legging. BKinks
C Dog Leg
Excessive guy cable tension will twist, bend and/or collapse the elevator structure,
causing severe injury or death. Maintain proper guy cable tension at all times.

4. Installation
18 PNEG-2116 Bucket Elevator
Elevator Intake
Several factors should be taken into account when planning the intake to feed material into the elevator:
1. The method and location of intake openings in the boot usually will have been determined when the
elevator was ordered. However, if the intake arrangements have or are being changed, several
factors must be considered. (See Figure 4C.)
a. Inlet or Hopper Size: The size of the inlet effects the capacity and the condition of the elevated
material. Too small an inlet means the material must be fed into the boot at excessive speed.
The excess velocity of incoming material cause damage, the buckets do not fill properly, and
material backs up in the boot, clogging the inlet.
Figure 4C Boot Intake Conditions
Gravity Fed Boot
Incorrect Correct
Intake too low, shown
below centerline of pulley Intake above centerline
of boot pulley
Auger Fed Boot
Incorrect Correct
Gravity intake too small
and below centerline of pulley Gravity intake of adequate size with
control gate and above centerline of pulley

4. Installation
PNEG-2116 Bucket Elevator 19
b. UP Side Infeed Devices: The device which feeds the elevator, (auger, belt conveyor, spout,
hopper, etc.), must feed the material into the boot ABOVE the centerline of the pulley. The
buckets must complete the turn around the pulley and be moving vertically upward, not at a
tangent, before encountering material to be elevated. If the buckets ARE NOT moving vertically
upward when they encounter the incoming material, material will be forced back into the infeed
device or chute. Grinding and churning in the boot area will damage the product and excessive
power will be required to operate the system.
c. DOWN Side Infeed Devices: Several factors, most importantly the nature of the material being
elevated, are important in determining the location of down side or down-leg infeed devices. If a
changein infeed arrangementfrom that shown on thecertified drawingsis contemplated,consult
InterSystems before proceeding with modifications.
d. FLOW of material to the infeed Devices: Every effort should be made when designing the
feedingequipmentor spouting suchthatthe directionof theflowing material willbe perpendicular
to the buckets. Reduce or eliminate any side loading of the buckets. Achieving the bucket
elevators rated capacity is determined by even and consistant bucket fill.
Elevator Discharge
1. Spouting to carry off the material must be sized so that its capacity equals or exceeds the maximum
capacity of the elevator to prevent material plugging in the head or down-legging.
2. The elevator IS NOT designed to support the weight of any accessory equipment. Spouting,
cleaners, distributors, etc. must have their own supporting structures.
Positioning Trunk Sections for Ladder
Study the drawings to determine where each trunk section fits into the overall layout of the elevator leg.
This is important so that platforms and ladders can be attached to the elevator without having to
re-assemble ladder brackets. The final ladder at the head section (at the top of the elevator) must be
near the trunk closest to the discharge (the down-leg trunk). Figure 4I on Page 24 for ladder and cage
assembly details.
Elevator Belt Selection
If InterSystems has supplied the belt, no further action is required at this time. However, if the belt is being
obtained independent of the elevator, those ordering the belt must be aware of a number of requirements.
1. Belt length must take into considerationthe method of belt splicing to be employed in this installation.
Refer to belt splicing on Page 32 and Figure 4Q on Page 33 for an overview of the three (3) splicing
methods commonly employed in elevator installations. A mechanical splice requires the least extra
belt while a butt splice requires the greatest length of extra belt.
2. The pattern, spacing, and size of prepunched holes must be correct for the number, type, and size
of the buckets to be attached to the belt. If the belt is purchased with the wrong hole pattern, it will
be extremely difficult and expensive to correct the problem in the field. If the hole sizes aretoo small,
they may have to be re-drilled in the field. If the holes are too large, the buckets may have to be
re-drilled to accept larger bolts or be replaced. Elevator bolts must fit snugly in the belt.
3. The installer should fabricate spreader bars in advance to avoid delay once belt installation begins.
See View D of Figure 4Q on Page 33.
4. A belt manufacturer or a local belt supplier sales representative can assist in the correct selection
and specification of belting and advise in proper installation procedures.

4. Installation
20 PNEG-2116 Bucket Elevator
Elevator Erection (Assembly)
Erection of the elevator must not be started until the concrete foundation and the guying anchors (if any
are needed) have been completed and developed maximum strength.
IMPORTANT: No matter who does the installation or what method is employed, the elevator must be
plumb. If it is not, it almost certainly cannot be made to operate satisfactorily.
There are two (2) basic methods of elevator erection. In this manual only the vertical assembly or
section-by-sectionmethodisconsidered.InterSystemsdoesnotrecommendhorizontalassembly wherein
entire elevators or multiple sections thereof are assembled horizontally at ground level and then raised to
the vertical and hoisted into position. The potential for damage to the elevator structure is too great.
Vertical Assembly
This method could also be termed section-by-section assembly. (See Figure 4E on Page 21.) Because of
the weight of the elevator's head section, InterSystems recommends that it always be hoisted in a
separate lift and then fastened to the rest of the elevator.
1. Lift the boot onto the foundation. (See Elevator Foundation on Page 16.) BE SURE THE BOOT IS
POSITIONED CORRECTLY ON THE FOUNDATION AS SHOWN ON THE DRAWINGS.
2. While the hoisting gear is still attached to the boot to prevent its tipping, accurately plumb and level
the boot base. Use appropriatefasteners to connect the base securely in position and grout the boot
base. Allow the grout to cure before further assembly is attempted.
3. InterSystems recommends that all joints between elevator sections be weather-proofed by applying
mastic compound, especially if the elevator is to remain an outdoor structure. Mastic or caulking
compound is to be provided by the user or installer. Do not use weather stripping. Use grade 5 or
higher bolts to connect sections.
Figure 4D Support Placement
Ref # Description
ASupports at each end of each section
Correct
Maximum Strength of Leg Section
Incorrect
Maximum Strength of Leg Section,
May Buckle or Warp