GSi GCE 45 User manual

CE Compliant GCE Sampler
Model: GCE 45 and GCE 90
Installation and Operation Manual -
Original Instructions
PNEG-2175CE
Version: 1.0
Date: 01-13-22
PNEG-2175CE

2 PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90
CE Declaration of Compliance
EC MACHINERY DIRECTIVE
2006/42/EC
1004 East Illinois Street, Assumption, IL, 62510, USA
[phone]
The GSI Group declares that the machine, parts or equipment
GCE Cross Cut Samplers
Models: 45CE, 90CE
Sizes: All
With Sentinel Controls
Model: STL-400-3-***-GCE
Meet the Essential Requirements of the ATEX Directive 2014/34/EU and Machinery Directive
2006/42/EC
• Combustible material Grain Dust
• Minimum ignition temperature 180°C (maximum design surface temperature 100°C)
• Ex II2/2D Ex h IIIB/- T100°C Db with GSI Sentinel Controls
• Ex II3/3D Ex h IIIB/- T100°C Dc without GSI Sentinel Controls
In accordance with the following standards:
1. All installation shall be in accordance with manual PNEG-2175CE.
2. Sentinel controls shall not be installed inside the potentially explosive environment.
Signed:
IEC 60079-0:2017 Explosive atmospheres - Part 0: Equipment - General requirements
EN ISO 80079-36:2016 Explosive atmospheres. Part 36: Non-electrical equipment for explosive atmospheres -
Basic method and requirements
EN ISO 80079-37:2016
Explosive atmospheres. Part 37: Non-electrical equipment for explosive atmospheres -
non-electrical type of protection constructional safety ‘c’, control of ignition sources ‘b’,
liquid immersion ‘k’
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction
EN60204-1:2018 Safety of machinery - Electrical equipment of machines

Table of Contents
PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90 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 ................................................................................................................................ 15
Correct Use of the GCE Sampler ........................................................................................................ 15
Electrical Safety .................................................................................................................................. 16
Safe Access ........................................................................................................................................ 18
ATEX Compliance ............................................................................................................................... 18
ATEX Control Requirements (Zones 22 and 21) ................................................................................ 18
Ignition Hazard Assessment - GCE Samplers .................................................................................... 19
Guarding of Moving Parts ................................................................................................................... 19
Safety in Maintenance and Servicing .................................................................................................. 20
Chapter 5 Installation ..........................................................................................................................................21
Receiving Inspection ........................................................................................................................... 21
Pre-Installation Preparation ................................................................................................................. 21
Location ............................................................................................................................................... 21
General Mounting Guidelines .............................................................................................................. 21
Material Sample Transport Lines ........................................................................................................ 22
Controller Location .............................................................................................................................. 22
Field Wiring ......................................................................................................................................... 22
Chapter 6 Operation ............................................................................................................................................23
Sampler Controls ................................................................................................................................ 23
Configuring the Controls ..................................................................................................................... 26
Chapter 7 Wiring Diagrams .................................................................................................................................28
CE Control Electrical Layout ............................................................................................................... 28
CE Control Motor Connections ........................................................................................................... 30
CE Control Connections ...................................................................................................................... 31
Chapter 8 Maintenance and Repair ....................................................................................................................32
General Maintenance .......................................................................................................................... 32
Testing ATEX Controls ........................................................................................................................ 32
Periodic Inspection .............................................................................................................................. 33
Lubrication ........................................................................................................................................... 33
Mechanical Repair Procedures ........................................................................................................... 34
Chapter 9 Troubleshooting .................................................................................................................................37
General GCE Sampler Troubleshooting ............................................................................................. 37
Chapter 10 Parts List ...........................................................................................................................................38
Sampler Model GCE 45 Parts ........................................................................................................... 38
Sampler Model GCE 90 Parts ........................................................................................................... 41
Chapter 11 Warranty ............................................................................................................................................45

4 PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90
1. Introduction
This manual covers the installation and operation for the Sampler Model GCE 45 and 90. 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. InterSystems 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.
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 products to 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.

1. Introduction
PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90 5
Ordering Parts
Direct parts orders or requests for technical assistance to your sales representative or to:
InterSystems
1004 E. Illinois St.
Assumption, IL 62510-0020
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
34769 Standard SAE 80W-90 EP Gear Lubricant Oil Quart (Pennzoil 4096)
529601 Optional Synthetic Gear Lubricant Oil Quart (Mobil SHC634)
35342 #50 Friction Facing (Ref #16 on Page 36.)
35527 Limit Switch Contact Block 1 N.O. 1 N.C.

6 PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90
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. Read and save these instructions.
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 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-0001-4

2. Safety
PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90 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
8 PNEG-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90
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-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90 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-2175CE CE Compliant Sampler - Model GCE 45 and GCE 90
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