GSi GSS-U User manual

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1
Table of Contents
I. GENERAL SAFETY INFORMATION .....................................................................................................................3
II. GENERAL INFORMATION ...................................................................................................................................5
2.1 System Description .................................................................................................................................5
2.2 Optional Features ...................................................................................................................................6
2.3 Material Sampled....................................................................................................................................6
2.4 Sampler Construction .............................................................................................................................6
III. GENERAL INSTALLATION REQUIREMENTS ....................................................................................................7
3.1 Receiving Inspection...............................................................................................................................7
3.2 Pre-Installation Preparation ....................................................................................................................7
3.3 Location ..................................................................................................................................................7
3.4 General Mounting Guidelines .................................................................................................................7
3.4.1 Factory Pre-Mounted Sampler.............................................................................................................8
3.4.3 Field-Mounted Sampler Using Weld-On Plates ...................................................................................8
3.5 Material Sample Transport Lines............................................................................................................9
3.6 Controller Location..................................................................................................................................9
3.7 System Wiring.......................................................................................................................................10
3.7.1 Electrical Power Requirements, System............................................................................................10
3.7.1.1 Controller ........................................................................................................................................10
3.7.1.2 Clutch Solenoid Coil........................................................................................................................10
3.7.1.3 Drive Motor .....................................................................................................................................10
IV. OPERATIONS AND ADJUSTMENTS................................................................................................................11
4.1 Control Components And Their Functions............................................................................................11
4.1.1 POWER OFF/ON Switch S-2 ............................................................................................................12
4.1.2 SAMPLING MODE Switch S-3 (Automatic/Manual) ..........................................................................12
4.1.3 MANUAL SAMPLING Switch S-4 ......................................................................................................12
4.1.4 CONTINUOUS SAMPLING Switch S-5.............................................................................................12
4.1.5 POWER Pilot Light.............................................................................................................................12
4.1.6 SAMPLING Pilot Light........................................................................................................................12
4.1.7 Digital Display Timer T-1 (Standard)..................................................................................................13
4.1.8 Digital Display Counter C-1 (Optional)...............................................................................................14
4.1.9 Printed Circuit Board..........................................................................................................................15
4.1.9.1 Main Fuse .......................................................................................................................................15
4.1.9.2 Motor Fuse......................................................................................................................................15
4.1.9.3 PC Board Fuse F3 ..........................................................................................................................15
4.1.9.4 Motor Timer Switches (Tens & Ones).............................................................................................15
4.1.9.5 Solenoid Timer Switches (Tens & Ones)........................................................................................16
4.1.9.6 Motor LED Indicator........................................................................................................................16
4.1.9.7 Solenoid LED Indicator ...................................................................................................................16
4.1.9.8 Mode Select Switch ........................................................................................................................16
4.1.9.9 Terminal Strip..................................................................................................................................16
4.1.9.10 115V/230V Switch.........................................................................................................................17
4.2 Sampler Mounted Electrical Components.............................................................................................17
4.2.1 Limit Switch........................................................................................................................................17
4.2.2 Drive Motor ........................................................................................................................................17
4.2.3 Clutch Solenoid..................................................................................................................................18
V. MAINTENANCE AND REPAIR ...........................................................................................................................19
5.1 General Maintenance............................................................................................................................19
5.2 Periodic Inspection................................................................................................................................19
5.3 Lubrication ............................................................................................................................................19
5.3.1 Auger & Auger Tube Spur Gears.......................................................................................................19
5.3.2 Gear Reducer ....................................................................................................................................20
5.4 Mechanical Repair Procedures.............................................................................................................20

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5.4.1 Limit Switch Cam Adjustment ............................................................................................................20
5.4.2 Clutch Solenoid Replacement And Adjustment .................................................................................21
5.4.3 Clutch Replacement & Timing ...........................................................................................................22
VI. TROUBLESHOOTING .......................................................................................................................................23
6.1 General GSS-U Sampler Troubleshooting ...........................................................................................23
6.2 PC Board Troubleshooting....................................................................................................................24
VII. REPLACEMENT PARTS...................................................................................................................................25
7.1 Scope....................................................................................................................................................25
7.2 Ordering Parts ......................................................................................................................................25
7.3 Replacement Parts ...............................................................................................................................25
7.4 Repair Kits ............................................................................................................................................25
VIII. WARRANTY.....................................................................................................................................................29
List Of Illustrations & Drawings
FIGURE 1-1, GSS-U SAMPLER SAFETY LABEL LOCATIONS ...............................................................................4
FIGURE 2-1, TYPICAL INSTALLATION, MODEL GSS-U SAMPLING SYSTEM......................................................5
FIGURE 4-1, STANDARD NEMA 4 CONTROL PANEL DETAIL.............................................................................11
FIGURE 4-2, PRINTED CIRCUIT BOARD...............................................................................................................15
FIGURE 4-3, LIMIT SWITCH CONNECTIONS ........................................................................................................17
FIGURE 5-1, LIMIT SWITCH CAM ADJUSTMENT .................................................................................................20
DRAWING 525255, GSS-U SAMPLER DRIVE END SECTION VIEW....................................................................28
DRAWING 525256, GSS-U SAMPLER DISCHARGE END SECTION VIEW & PARTS LIST ................................29

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I. GENERAL SAFETY INFORMATION
SAFETY FIRST! The symbols shown identify
examples of the safety labels and signs to
be found on Intersystems equipment. They
are affixed to the equipment to warn of
danger to persons and of possible
equipment damage. These signs must
never be removed, tampered with, painted
over or obscured in any way. (See Page 4
for label locations.) If labels are damaged or
become unreadable, replacement labels are
available from Intersystems. The user must
institute a continuing program to instruct all personnel in safe operating and maintenance procedures, and to
insure that all safety devices, guards, and covers are intact and operable, and that all safety signs are legible.
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.
Never perform any service on this equipment or any other 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.
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 products to which this equipment is in contact with
to determine what PPE is required.
DANGER
THIS EQUIPMENT IS TO BE OPERATED ONLY ON THE VOLTAGE DESIGNATED ON THE
CERTIFIED ELECTRICAL DRAWING(S)! FIRE OR EXPLOSION MAY RESULT, WHICH CAN
CAUSE DEATH, SERIOUS INJURY, AND EXTENSIVE DAMAGE TO EQUIPMENT. DO NOT
CONNECT TO VOLTAGES OTHER THAN DESIGNATED.

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FIGURE 1-1, GSS-U SAMPLER SAFETY LABEL LOCATIONS

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II. GENERAL INFORMATION
2.1 System Description
The GSS-U Sampler is designed to collect a representative sample of granular, flake, powder, or other materials
in a gravity conveying line or from a hopper tank. Figure 2-1 illustrates a typical GSS-U Sampler application.
Sample collection is initiated in response to either an operator's manual command or a signal automatically
generated by controller logic, usually time-based but which could also be volume or quantity based. A sample
cycle begins when an electric motor operating through a right angle gear reducer rotates the drive housing input
shaft. The clutch solenoid, which energizes at the same time the motor starts, allows the slotted sampling tube
(auger tube) in the product line to rotate through one revolution to collect a sample of the material. As the auger
tube rotates the sample auger also is turning and continues to auger material out of the auger tube for a period of
time after the auger tube stops rotating. The sample then falls down and out the 2.00" (51mm) OD discharge tube
to the desired sample collection point, at which point an Intersystems SCS Sample Collection System (optional)
may be installed.
FIGURE 2-1, TYPICAL INSTALLATION, MODEL GSS-U SAMPLING SYSTEM

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2.2 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.
A. Controller arranged to initiate a sampling cycle based on quantity or volume of material passing through
conveying line rather than upon elapsed time periods.
B. 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 typically have the following
features.
1. An explosion-proof clutch solenoid with the rating of:(Std, furnished on all GSS-U samplers)
Class 1, Groups C & D, Division 1 & 2
Class 2, Groups E, F & G, Division 1 & 2
2. An explosion-proof limit switch with the rating of: (Std, furnished on all GSS-U samplers)
Class 1, Groups C & D, Division 1 & 2
Class 2, Groups E, F & G, Division 1 & 2
3. An explosion-proof motor with the rating of: (Optional)
Class 1, Groups D, Division 1 & 2
Class 2, Groups E, F & G, Division 1 & 2
The explosion proof sampler control is available in two enclosure classifications.
1. The NEMA 9 control with the rating of:
Class 2, Groups E, F & G, Division 1 & 2
2. The NEMA 7 control with the rating of:
Class 1, Groups C & D, Division 1 & 2
Class 2, Groups E, F & G, Division 1 & 2
C. Components of special materials, such as 316 stainless steel, monel, inconel or nedox coatings.
D. Programmable Controls to sequence the sampler and the sample collection equipment.
2.3 Material Sampled
Most materials from light to heavy density powders, granules, flakes and pellets.
2.4 Sampler Construction
Standard sampler housing construction is of painted cast aluminum. The sample auger & auger tube are of type
304 Stainless Steel. The auger is machined from a solid bar (no welds on flights) and hand polished. The
sanitary GSS-U sampler design allows for quick removal of the auger and auger tube for easy clean-out and
washing. 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.

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III. GENERAL INSTALLATION REQUIREMENTS
3.1 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.
3.2 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).
3.3 Location
The GSS-U sampler is typically mounted horizontally onto a vertical gravity flow conveying line carrying the product
to be sampled as in Figure 2-1. The sampler axis must be installed perpendicular (at a 90 degree angle) 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.
3.4 General Mounting Guidelines
The sampler assembly is designed to support ONLY its own weight.
DANGER
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.

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NOTE: IF THE SURFACE AREA TO WHICH THE MOUNTING PLATE IS TO BE ATTACHED IS WARPED
OR BENT, STRAIGHTEN AND SMOOTH THE METAL SO THE SAMPLER WILL BE PROPERLY ALIGNED
WHEN THE INSTALLATION IS COMPLETE. THE SURFACE TO WHICH THE SAMPLER IS MOUNTED MUST
NOT FLEX.
NOTE: OVER TIGHTENING THE MOUNTING FASTENERS WILL WARP OR CRACK THE SEAL HOUSING
FLANGE. IMPROPER SAMPLING WILL RESULT.
3.4.1 Factory Pre-Mounted Sampler
As furnished, the premounted sampler is already firmly attached to a length of tube, pipe, etc.
A. Remove a section of pipe or chute work where the sampler is to be installed.
B. Remove the sampler from the sampler premount by removing the hinge pins and remove the auger &
auger tube.
C. Locate the sampler premount in the desired position.
D. Attach the sampler premount using one of the following methods.
1-Weld the sampler premount ends directly to the existing pipe or chute work.
2-Clamp the sampler premount ends to the existing pipe utilizing compression couplings.
3-Weld matching flanges to the existing pipe or chute work and sampler premount.
E. Re-install the auger & auger tube. Verify that the auger tube rotates without interference.
F. Install the sampler drive assembly by re-installing the hinge pins.
3.4.3 Field-Mounted Sampler Using Weld-On Plates
Weld-on plates are typically used when mounting the sampler to a large existing surface, such as on a storage
hopper or a long section of chutework.
A. Locate and mark the desired mounting location on the conveying line.
B. Cut and de-burr two 4" diameter holes (opposite each other) in the product line through which the
sample tube will pass to collect material samples.
C. Position the sampler drive mounting plate by centering the auger hole over the 4" diameter clearance
holes.
D. Tack weld the sides of the mounting plate to the product line surface and double check alignment.
E. Weld a continuous bead around all sides of the mounting plate. Also from the inside of the chute weld
a continuous bead around the 4" diameter clearance hole.
NOTE: WHEN WELDING THE MOUNTING PLATE TO THIN GAUGE SHEET OR THIN PLATE, SKIP WELD
ALTERNATING SIDES OF THE MOUNTING PLATE TO LIMIT HEAT INPUT TO MINIMIZE WARPING.
F. Insert the auger tube through the drive mount plate and verify that the auger tube rotates without
interference.
G. Locate the discharge mounting plate assembly by slipping it over the end of the auger tube.

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I. Tack weld the sides of the mounting plate to the product line surface and double check alignment. Also
from the inside of the chute weld a continuous bead around the 4" diameter clearance hole.
J. Re-install the auger tube an re-verify that the auger tube rotates without interference.
K. Remove the auger tube. Grind and polish the interior welds to sanitary requirements.
L. Re-assemble the sampler auger, auger tube, bearings, o-rings, drive coupling, drive unit, discharge
tee, etc.
3.5 Material Sample Transport Lines
The tubing used to transport material samples must be compatible with the operating environment and the
material sampled. The sampler has a 2" OD "Tri-Clover" type sanitary connection. Using the appropriate
compatible adapters, route the sample to allow material to flow via gravity to a convenient collection point. At that
point the sample line may be connected to a collection jar bracket or a Sample Collection System cabinet.
Make all connections airtight and make sure all interior surfaces of joints are smooth and flush. Any ragged 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.
3.6 Controller Location
A. Use vibration isolation pads when mounting the control enclosure or mount the controller in a vibration-
free location.
B. Unless ordered for severe duty, locate controller so it is protected from water and dust.
C. Unless an explosion-proof rated controller was specifically ordered, DO NOT locate the controller in a
hazardous area.
D. Most applications require that the sampler be in easy view of the controller.