PREMAS 4.0 Guide

Installation and Commissioning Manual
PREMAS® 4.0 –Predictive
Maintenance Solution
Version for Belt Bucket Elevators, CE & UL-Version
December 2020
Version 2.00/EN
Document number: DOC201125-1

Disclaimer
PREMAS Preventive Maintenance Service AG, hereinafter referred to as PREMAS AG, makes no
representations or warranties with regard to this manual and limits its liability for the breach of any
implied warranty to the replacement of this manual by another to the extent permitted by law. In
addition, PREMAS AG reserves the right to revise this publication at any time without having to
notify anybody about this revision.
The information provided in this documentation includes general descriptions and/or technical
characteristics for the performance of the devices. This documentation cannot be considered a
proper evaluation of the suitability of or reliability of the equipment for a specific application by a
user and may not be used as a substitute for such an assessment. It lies in the responsibility of each
such user or installer, to provide an appropriate and complete risk assessment, evaluation and
testing of the devices for each specific application. Neither PREMAS AG nor any of its partners or
subsidiaries may be liable for any misuse of the information contained herein.
All relevant state, regional and local safety regulations must always be observed when installing and
using this device. For reasons of security and to ensure compliance with the documented system
data, the manufacturer alone is entitled to carry out repairs on components. Failure to observe this
information may result in injury or damage to the equipment.
Copyright © 2020 PREMAS Preventive Maintenance Service AG
All rights reserved. No part of this publication may be reproduced in any form, including photocopy,
recording or any other electronic or mechanical reproduced, processed or used in any other way
without the written permission of the publisher be passed on. Requests for permits must be
submitted in writing to the publisher and can be sent to the address below.
PREMAS Preventive Maintenance Service AG •Haldenstrasse 1 •6340 Baar • Switzerland
[phone] •[email protected] • www.premas.ch

Product Modifications
Year
Type
Changes
2020
PREMAS® 4.0
Belt-Version CE
First Release
2020-12
PREMAS® 4.0
Belt-Version UL
UL Edition added
Document Modifications
Year
Type
Changes
2020
DOC201125-1
First Release
2020-12
DOC201125-1
UL Edition added
Approvals
This document requires the following permissions:
Name
Title
Michael Bruckhaus
Managing Director
Carlos Pinzon
Digital Solutions

Table of contents
1Foreword.................................................................................................................................... 8
1.1 User description......................................................................................................................... 8
1.2 Explanation of the safety instructions ....................................................................................... 8
1.3 Storage instructions for this manual.......................................................................................... 9
1.4 Procurement of documents and information............................................................................ 9
2Description of the product....................................................................................................... 10
2.1 Intended use and reasonably foreseeable misuse ..................................................................10
2.2 Geographical restrictions.........................................................................................................12
2.3 System overview...................................................................................................................... 13
2.4 Technical data.......................................................................................................................... 14
2.5 Product components ...............................................................................................................16
2.6 User interface –PREMAS® Portal ............................................................................................17
3Safety Instructions ................................................................................................................... 18
3.1 Safe handling of the product ...................................................................................................18
3.2 Graphical symbols: Explanation of the safety information on the packaging and
the product ..............................................................................................................................19
3.3 Possible health consequences .................................................................................................19
3.4 Personal protective equipment ...............................................................................................19
3.5 Privacy...................................................................................................................................... 19
3.6 Data processing........................................................................................................................ 19
4Preparation and installation ....................................................................................................20
4.1 Transport and storage of the product .....................................................................................20
4.1.1Dimensions and weight ....................................................................................................................... 20
4.1.2Storage of the product ........................................................................................................................ 20
4.2 Installation of the product....................................................................................................... 21
4.2.1Removal of transport and packaging elements................................................................................... 21
4.2.2Unpacking the product........................................................................................................................ 21
4.2.3Sensor situation plan........................................................................................................................... 22
4.2.4Installation of the product................................................................................................................... 23
4.3 Commissioning.........................................................................................................................38
5Troubleshooting and Repairs...................................................................................................39
5.1 Identify and solve problems: Detecting problems during installation and commissioning ....39
5.2 Frequently asked questions.....................................................................................................41

5.3 Repairs ..................................................................................................................................... 42
Appendix I –glossary ............................................................................................................................ 43
Annex II –related documentation........................................................................................................ 43

Index of images
Figure 1: How PREMAS® 4.0 works.......................................................................................................13
Figure 2: PREMAS® 4.0 hardware overview..........................................................................................16
Figure 3: Machine overview of PREMAS® Portal ..................................................................................17
Figure 4 Dimensions and weight of PREMAS® 4.0 packaging...............................................................20
Figure 5: Situation of sensors and signals connected to PREMAS® 4.0 IoT Box ...................................22
Figure 6: Positioning the IoT Box and Antenna.....................................................................................25
Figure 7: Mounting positions for the temperature sensors .................................................................27
Figure 8: Mounting of temperature sensors.........................................................................................28
Figure 9: Temperature sensor mounted in the mounting bracket.......................................................29
Figure 10: Belt elongation measurement, arrangement drawing ........................................................31
Figure 11: Detail view to tension axis, mounting position of magnet for elongation measurement...31
Figure 12: Positioning of H-bracket at the tension axis........................................................................32
Figure 13: Bracket for elongation sensor..............................................................................................32
Figure 14: H-bracket with sensor rail mounted....................................................................................33
Figure 15: H-bracket fixed on the feet..................................................................................................33
Figure 16: Top view to tension axis, distance between magnet and sensor rai...................................33

Index of tables
Table 1: Technical data Field Sensor Temperature...............................................................................14
Table 2: Technical data Field Sensor Elongation...................................................................................14
Table 3: Input Signals from Plant System .............................................................................................14
Table 4: Technical data IoT Box ............................................................................................................15
Table 5: Electrical connections for temperature sensor at head..........................................................30
Table 6: Electrical connections for temperature sensor at boot..........................................................30
Table 7: Electrical connections for elongation measurement..............................................................34
Table 8: Signal description....................................................................................................................35
Table 9: Connection table for existing signals ......................................................................................36
Table 10: Status check of component LEDs..........................................................................................38
Table 11: Detecting problems with the elongation sensor...................................................................39
Table 12: Detecting problems with the temperature sensor ...............................................................40
Table 13: Detecting problems with the IoT Box....................................................................................41

PREMAS® 4.0 Installation and Commissioning Manual
Page 8 / 44
WARNING
DANGER
CAUTION
ATTENTION
1Foreword
1.1 User description
This document is intended for mechanical and electrical professionals to install PREMAS® 4.0
hardware properly, based on this manual. Furthermore, it is intended for End-Users such as
Mechanical personnel, Maintenance Managers or similar professionals.
The electrical and mechanical installation and commissioning of PREMAS® 4.0 must be
carried out by appropriately trained personnel with professional skills and knowledge in
conveying equipment, electrical and mechanical engineering.
1.2 Explanation of the safety instructions
"Danger" indicates an immediately dangerous situation,
which, if not avoided, may cause death or serious injuries.
"Warning" indicates a potentially dangerous situation,
which, if not avoided, may cause serious injuries.
"Caution" indicates a danger that can lead to light to medium
can cause injuries if not avoided and or damage of property as well as assets.
"Attention" identifies information that is important, but are not
connected with potentially dangerous situations.

PREMAS® 4.0 Installation and Commissioning Manual
Page 9 / 44
1.3 Storage instructions for this manual
Make sure that you read the complete manual, and all have read and understood the safety
instructions before using this product. Non-observance of these instructions can lead to light
or heavy injuries. Follow all instructions. This will prevent accidents, which may cause
damage to property or light or medium injuries. Save all safety information and instructions
for later reference. Look it up and pass it on to future users of the product. The
manufacturer is not liable for any damage to property or injury resulting from incorrect
handling or non-compliance with the safety instructions. In such cases the warranty is void.
1.4 Procurement of documents and information
A current version of the documentation is available on the
following website: https://premas.ch/premas-products-
services/premas-knowledge-base.
Documentation, user instructions and technical information
can be requested by e-mail to [e-mail].
For information on special tools and materials and for service-related questions, please
contact your distribution partner for PREMAS® 4.0.

PREMAS® 4.0 Installation and Commissioning Manual
Page 10 / 44
2Description of the product
2.1 Intended use and reasonably foreseeable misuse
The Predictive Maintenance Solution PREMAS® 4.0, belt edition, is intended to be used as a
monitoring system for belt bucket elevators in the heavy industry.
PREMAS® 4.0 includes the following functionalities:
•Online condition monitoring of belt bucket elevators
•Presentation of measurement and analysis results to the user via an user interface
•Detection of anomalies during operation
•Prediction of service life for major components
The PREMAS® 4.0 belt edition is specifically designed for belt bucket elevators and is not
intended for use with any other conveying equipment.
Please contact PREMAS AG for usage with other equipment than belt bucket elevators.
The PREMAS® 4.0 must not be used in the following cases:
•Incompliance with the design of the bucket elevator
•Missing access points to mounting locations of required sensors
•Environmental conditions do not fit as specified for the PREMAS® 4.0 system
•Within ATEX zones
•Any use other than that described in these instructions
The PREMAS® 4.0 system shall only be used with its original accessories, software and
components consisting of:
•PREMAS® 4.0 IoT Box for belt bucket elevators including data collection interface
and mobile router
•LTE antenna
•Magnetostrictive Sensor system including mounting bracket
•Temperature transmitters including mounting brackets
•Data storage and processing in PREMAS® Cloud
•Access to PREMAS® Portal
The installation and usage of the system must be aligned and validated with the design,
instructions, and manuals of the original equipment manufacturer of the bucket elevator.

PREMAS® 4.0 Installation and Commissioning Manual
Page 11 / 44
Warranty for PREMAS® 4.0 systems
The warranty period is 12 months after commissioning, maximum 18 months after
notification of readiness for dispatch.
The installation must be carried out in accordance with the installation and operating
manual. Excluded from the warranty are defects caused by the purchaser or third parties,
e.g. by improper installation, improper use, improperly performed repairs or modifications
without prior written consent of AUMUND as well as defects caused by external influences.
Normal wear and tear do not constitute a defect.
Warranty is excluded if and to the extent that the buyer has provided incorrect or
incomplete information to AUMUND regarding the condition of the machine or plant to be
monitored with the delivered PREMAS® 4.0 system and/or the operating conditions of the
machine or plant.
Separately agreed warranty conditions apply to the machines or plants for whose
supplement a PREMAS® 4.0 system is supplied.
Exclusions of liability
PREMAS AG shall not be liable, for whatever legal reasons and to the extent permitted by
law: for damages not occurring to the delivery item itself, such as loss of production, loss of
profit, damages to third parties, downtime costs, loss of use, loss of orders, increased
operating, maintenance or personnel costs or indirect costs and/or consequential damages
of any kind.
The messages generated by the PREMAS® 4.0 system regarding the condition of the
machines or plants are based on the measurement data, a machine comparison of these
data with measurement values obtained during the operation of similar machines or plants
and the experience knowledge of OEM.
System indications regarding wear and service life are basically only approximations and are
not legally binding, since in continuous operation special influences, e.g. from the material
to be conveyed, from hidden defects of the machines or plants, from other plant
components and/or environmental conditions can occur at any time, which are not detected
by the sensor technology or only become effective with a time delay after a measurement.

PREMAS® 4.0 Installation and Commissioning Manual
Page 12 / 44
2.2 Geographical restrictions
The system must be used in compliance with any and all applicable national and
international laws and with any special restrictions regulating the utilization of the
communication module in prescribed applications and environments.
The used communication model is certified according the following standards and
regulations: CE/RED, EAC, CCC, Ukraine UCRF, RoHS, REACH, FCC, IC, PTCRB, Anatel, RCM,
Thailand NBTC, E-mark, Sirim, IMDA, SDPPI (POSTEL), AT&T approval, Verizon, Deutsche
Telekom AG, GCF, WiFi Certified, Giteki
The customer, as the builder of a system including a mobile radio system, is responsible
for the correct and conform operation and assumes the responsibility for ensuring that
the system at start-up complies with local regulations.

PREMAS® 4.0 Installation and Commissioning Manual
Page 13 / 44
2.3 System overview
The Predictive Maintenance Solution, PREMAS® 4.0, belt edition, is specially made for belt
bucket elevators in the heavy industry. Every machine receives a hardware package.
Provided field sensors as well as some existing signals from the plant control system (motor
current, level switch, speed switch, drift warning) will be connected to the IoT Box, which
sends the collected data through mobile connectivity to the PREMAS® Cloud. There, the data
will be analyzed based on the latest technologies for predictive analytics (e.g. algorithms,
machine learning …). The PREMAS® Portal visualizes and provides all relevant data for a
complete online condition monitoring, securely online accessible to authorized users 24/7
through any mobile or desktop device.
Figure 1: How PREMAS® 4.0 works
The system requires a 3G/4G mobile network at the location of the IoT Box installation.
Without a reliable mobile network the PREMAS® Cloud and PREMAS® Analytics will not
function.

PREMAS® 4.0 Installation and Commissioning Manual
Page 14 / 44
2.4 Technical data
PREMAS® 4.0 enables the early detection of wear and aging of important machine
components at your conveying equipment. Please find below further technical details of the
hardware of this Predictive Maintenance Solution.
Field Sensor: Temperature
Measurement Range
-50°C to 150°C
Connection cable
4-wire connection to IoT Box
Signal type
4 to 20 mA
Location
1 at Boot, 1 at Head, mounted at machine
wall
Transmitter required
No
External power supply required
No (24 VDC supply from IoT Box)
Protection class IP
IP67
Table 1: Technical data Field Sensor Temperature
Field Sensor: Elongation
Measurement Range
0 to 400 mm
Connection cable
4-wire connection to IoT Box
Signal type
4 to 20 mA
Location
1 at Boot (mounted at parallel tension device)
Transmitter required
No
External power supply required
No (24 VDC supply from IoT Box)
Protection class IP
IP67
Table 2: Technical data Field Sensor Elongation
Input Signals from Plant System
Motor current
Analogue signal: 4 to 20 mA
Level Switch
Digital signal (on/off): 0 to 24 VDC
Speed Switch
Digital signal (on/off): 0 to 24 VDC
Drift Warning
Digital signal (on/off): 0 to 24 VDC
Input Impedance
27.4 ohms
Table 3: Input Signals from Plant System

PREMAS® 4.0 Installation and Commissioning Manual
Page 15 / 44
IoT Box
Material
Metal enclosure
Operation conditions
Ambient temperature from -30°C to 70°C
Size
30 x 40 x 21 cm (11,8 x 15,75 x 8,3 in)
Miniature circuit breaker
Compact, single phase, rated current 10A
Input types
8x analog, 5x digital
Output types
2x digital (warning/alarm to external)
Power supply
110 to 230 VAC (uninterrupted power
supply –UPS)
Power requirement
25 W
Location
Nearby bucket elevator boot
Mobile communication
4G (LTE), UMTS/HSPA+; EDGE; GPRS; GSM
SIM Card
Global SIM card with data package included
Protection class IP
dust proof (Nema 4/IP65)
Table 4: Technical data IoT Box

PREMAS® 4.0 Installation and Commissioning Manual
Page 16 / 44
2.5 Product components
Figure 2: PREMAS® 4.0 hardware overview
PREMAS® 4.0 IoT Box (Art. 3001066)
1. 1 PREMAS® 4.0 IoT Box including pre-mounted mounting brackets
PREMAS® 4.0 Antenna Kit (Art 3001068-1)
2. 1 LTE antenna incl. mounting brackets
3. 1 Antenna cable SMA, 5 m
PREMAS® 4.0 Elongation Kit W
(Art. 3001068-2)
4. 1 Magnetostrictive Sensor, Serie MAP
5. 1 Elongation magnet incl. screws
6. 2 Sensor mounting clamps incl. screws & sleeves
7. 1 Sensor cable, 10 m, 5-pole-plug-connector
PREMAS® 4.0 Temperature Kit (Temperature Kit Art. 3001068-4)
8. 2 Temperature Transmitter
9. 2 Sensor cables 10 m
PREMAS® 4.0 Mounting Brackets
10. 2 Temperature sensor mounting brackets (Temperature Bracket Art. 3001068-5)
11. 1 Elongation mounting H-bracket W incl. screws
(Elongation H-Bracket W Art. 3001068-6)
12. 1 Elongation magnet mounting bracket belt W (Elongation Magnet Bracket Art.
3001068-7)
Installation Guide Belt-Version (Art. 3001068-8)
13. 1 Installation Guide
1
2
3
4
5
6
7
8
9
10
11
12
13

PREMAS® 4.0 Installation and Commissioning Manual
Page 17 / 44
2.6 User interface –PREMAS® Portal
The signal data collected via the PREMAS® 4.0 hardware will be processed in the PREMAS®
Cloud and made available to the user via the PREMAS® Portal. AN example of a machine
dashboard is shown below.
To access the Portal please follow the instructions based on the operational manual which is
available online: https://premas.ch/premas-products-services/premas-knowledge-base.
Figure 3: Machine overview of PREMAS® Portal

PREMAS® 4.0 Installation and Commissioning Manual
Page 18 / 44
3Safety Instructions
3.1 Safe handling of the product
Correct installation of the product is important for safety and performance. It is critical for
the safety of your operation and those who may perform work on your operation that you
select a qualified and competent electrical installer to undertake the installation. The
product must be installed properly to perform its designed functions. The installer should be
qualified, trained, and competent to perform the installation in accordance with Local and
National Electrical Codes, all relevant OH&S regulations, as well as any of your own
standards and preventive maintenance requirements, and other product installation
information supplied with the product. You should be prepared to provide the installer with
all necessary installation information to assist in the installation.
Make sure that you have read and understood the manual and all safety instructions
before using this product. The non-observance of these information can lead to serious
injury and damage of the equipment.
Risk of injuries and damages of assets during installation and commissioning if not installed
according instructions and by improper workmanship.
Strictly follow instructions given in this document
Risk of injuries due to moving and turning machinery.
Strictly follow local instructions for log-out and tag-out procedure as well as regulations for
isolating electrical supplies.

PREMAS® 4.0 Installation and Commissioning Manual
Page 19 / 44
3.2 Graphical symbols: Explanation of the safety information
on the packaging and the product
3.3 Possible health consequences
Wrong. incorrect or incomplete installation, operation or maintenance may lead to injury or
even death. Specifically, rotating equipment and moving parts of the machine are a high risk
to health and life. Do not open a machine, e.g. bucket elevator, during operation nor an
electrical cabinet if not authorized to do so and the required precautions and measures are
in place.
3.4 Personal protective equipment
PPE shall be used according local regulation and instructions. Always make yourself familiar
with the side specific regulations and adhere to it.
3.5 Privacy
The data captured by the PREMAS® 4.0 systems are stored and processed in the PREMAS®
cloud. Data are stored anonymous and are accessible only for authorized with user rights
managed by PREMAS AG. Beside the username and password there are no personal data
stored in the system.
3.6 Data processing
The buyer agrees that PREMAS AG may use the operating data of the buyer's plants or
machines obtained with the supplied PREMAS® 4.0 systems, after anonymization, for the
further development of similar plants or machines and may forward them to third parties for
the further development of the software and the PREMAS® Portal.
Symbol
Meaning
The CE marking on the product is the manufacturer's
declaration that the product meets the essential
requirements of the respective European laws for the
protection of health, safety, and environment.
UL
The UL marking on the product is the manufacturer's
declaration that the product meets the essential
requirements of the respective US American laws for
the protection of health, safety, and environment.

PREMAS® 4.0 Installation and Commissioning Manual
Page 20 / 44
4Preparation and installation
4.1 Transport and storage of the product
4.1.1 Dimensions and weight
All system components are delivered in one boxing packed for sea freight, air freight and
road transport (see Figure 4 below). The dimensions and individual weights can be found on
the corresponding packing list.
Gros weight: 48 kg
Net weight: 32.5 kg
Dimensions: 96 x 55 x 50 cm
Figure 4 Dimensions and weight of PREMAS® 4.0 packaging
4.1.2 Storage of the product
The electronic components of the system (IoT Box, sensors, antenna) shall be stored in a dry
and clean location under the following ambient conditions:
Storage Temperature: ‐20°C to +70°C (‐4°F to +158°F).
Relative Humidity: 5 to 95%, non‐condensing.
This section is intended for the Mechanical and Electrical Professionals to install
PREMAS® 4.0 properly