Chief Agri/Industerial Bucket Elevator Manual

INSTALLATION AND OPERATION MANUAL FOR

BUCKET ELEVATORS This Manual Includes Maintenance and Safety Instructions

WARNING! READ THIS MANUAL THOROUGHLY BEFORE INSTALLING OR OPERATING BUCKET ELEVATOR. KEEP MANUAL LOCATED FOR QUICK ACCESS AND REFERENCE.

CHIEF INDUSTRIES, INC. AGRI/INDUSTRIAL DIVISION POST OFFICE BOX 848 4400 EAST 39th STREET KEARNEY, NE 68848 Phone (800) 359-7600 In Nebraska Call (308) 237-3186 Fax (308) 389-6703 www.chiefind.com

Part Number 473793 Effective 8/27/2012


TABLE OF CONTENTS Table of Contents …………………………………………………………….……………....…. List of Figures & Tables …………………………….…………………………………….......... Manual Revisions ………………………………………………………………………..….…... Introduction ……………………………………………………………………………..………. Serial Number …..………………………………………………………………...…………..…. Registration ………………………………………………………………………………..……... Service Policy ……………………………………..……………………………………..………. Safety Decals ………………………………………………………………...…………..……… Bucket Elevator Component Identification………………………………………………..…… Typical Inspection Section Stacking Illustration …………….………………………..………. Pre-Erection Information ……………………………………………………………..………. 1. Installation Planning…………………………………...………………….…..…….. 2. Structural Capacity…………………………………………………………...….….. 3. Elevator Location…………………………………………………………...……….. 4. Boot Footing and Pit…………………………………………………….…….....….. 5. Guy Cables and Anchors……………………………...…………………...………. Elevator Installation …………………………………………...…………………..………...… 1. General……………………………….………………...………………………...….. 2. Setting the Boot………………….…………………………………………...….….. 3. Inlet Hopper………………………….……………………………...……………….. 4. Leg Section Assembly………….…………………………………………...…..….. 5. Drive Assembly………………………………………....…………..…………….…. 6. Sheave Alignment………………...…………………...……………………...…….. 7. V-Belt Tension……..…………….…………………………………………...….….. 8. Guy Cables……….………………….……………………………..………….…….. 9. Upper Assembly Inspection…….……………..……...…………………….…..….. 10. Hoisting the Elevator………………….…………………......……………….……. 11. Setting and Guying the Elevator…………….…………..……………….………. Belt & Bucket Installation …………….……………………………...……………………..… 1. Belt Installation……………………………….………..………………………....….. 2. Temporary Belt Splice……………..…………………………………………....….. 3. Bucket Installation………….……….……...………………………...………….….. 4. Final Belt Splice………………....…………………………………………...…..….. 5. Belt Tension Adjustment……………………………....…………………...………. 6. Discharge Baffle Adjustment……………….………...…………………...……….. Start Up & Operation ………………………………………………………………….....……. 1. Pre-Start Up Inspection…………….……………….………..…………………….. 2. Start Up Inspection………………………..……………………………………..….. 3. Flow System Completion………....……….……………………………….……….. 4. Elevator Operation……….…………....………………………………………...….. Periodic Maintenance…………………………………………………………………..……… Trouble Shooting ……………………………………………………………………..………... Bearings, Bushings, & Electrical Components Maintenance and Lubrication …………………………………………………………..….… Manufacturer Publications ………………………………………………………………..….. 1. Peer Bearings………….....……………………………………………..…………… 2. Dodge Bearings………………..………………………………………..…………… 3. Dodge Reducers………………...………………………………...………………… 4. Maska QD Bushings ……….…………………………………………..…………… 5. Van Gorp XT Bushings……………………………………………………………... 6. 4B Plug Wire Kit……………………………….........................…………………… 7. 4B Shaft Speed Sensor……………………………………..………………..…….. 8. Rolfes Belt Alignment Sensor……………………………………………………….

01

PAGE 01 02 03 04 05 06 07 08 09 10 11-13 11 11 11 11 12-13 14-23 14 14 15 17 18 19 19 20 21 22 23 24-25 24 24 25 25 25 25 26-27 26 26 26 27 28 29 30 31-57 31-35 36-41 42-43 44-46 47-48 49-50 51-52 53-57


LIST OF FIGURES AND TABLES FIGURES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Serial Number Plate ……………..……………………………………………….……………....…. Registration Sample…………….……………………….…………………………………….......... Rotating Sheave Decal…………………..………………………………………………………..… Moving Bucket and Belt Decal…….…………………….……………………………………..…… Guard Missing Decal…..…………………….………………………………………...…………..… Bearing Inspection Decal……….……………………………………………………………..…….. Bucket Elevator Component Identification.…….…..……………………………………..………. Typical Inspection Section Stacking Illustrations……………………………………….....……… Typical Elevated Anchor………………………………………………………………………..…… Anchor Placement……….…………………………………………………………………..………. Anchor Locations…………………………………………………………………………………….. Boot Anchor Locations………………………………………………………………………………. Anchor Clip……………………………………………………………………………………………. Inlet Hopper Locations………………………………………………………………………………. Upper Elevator Assembly…………………………………………………………………………… Platform Brackets…………………………………………………………………………………….. Lower Elevator Assembly…………………………………………………………………………… Bolted Flange Leg Section (2 bodies)……………………………………………………………… Bolted Flange Leg Section (1 body - 1 lid)………………………………………………………… Spacer Angles………………………………………………………………………………………… Drive & Belt Guard Assembly……………………………………………………………………….. Sheave Alignment……………………………………………………………………………………. Belt Span………………………………………………………………………………………...……. Guy Wire Bracket Bolted Flange Leg (2 bodies - 16x10 & 16x14)……………………………... Guy Wire Bracket Bolted Flange Leg (1 body - 1 lid - 13x10)…………………………………… Guy Wire Bracket Bolted Flange Leg (2 bodies - 20x14)……………………………………...… Cable Clamp………………………………………...………………………………………...……… Transit Locations……………………………………………………...……………………………… Temporary Belt Splice……………………………………………………………………………..… Bucket Installation…………………………………………………………………………..……….. Final Belt Splice………………………………………………………………………………………. Baffle Adjustment……………………………………………………………………………………..

PAGE 05 06 08 08 08 08 09 10 12 12 13 14 14 15 16 16 16 17 17 17 18 19 19 21 21 21 21 23 24 25 25 25

TABLES 1 2 3 4 5 6 7 8 9 10

Bucket Elevator Footing Loads………………………………………………………………..……. Anchor Loads…………………………………………………………………………………………. Anchor Bolt Locations…………………………………………………………...……………...…… Inlet Hopper Dimensions………………………………………………………...………………….. Belt Torques……………………………………………………………………………………….….. Deflection Force………………………………………………………………………..…………….. Guy Cable Lengths………………………………………………………………….……………….. Cable Clamp Specifications……………………………………………………..………………….. Component Hoisting Weights………………………………………………………….……………. Bearing Set Screw Torque Chart………………………………………………..………………….

PAGE 11 13 14 15 17 19 20 21 22 27

02


MANUAL REVISIONS DATE

REVISION MADE

08.27.2012 Added Manual Revisions page Added Manufacturer Publications for Rolfes and 4B Components

03


INTRODUCTION To Our Valued Customer The Chief Agri/Industrial product you have recently purchased has been engineered and manufactured to the highest possible standards. Caring and trustworthy individuals, who have your best interest in mind, have assembled this unit. Each Chief unit has been 100% quality control inspected to assure efficient and safe handling of your commodity along with optimum dependability for you and your operation. With the proper installation, operation and maintenance according to this manual, we can assure you many years of trouble free service. Thank you for your confidence when purchasing a Chief product. CHIEF BUCKET ELEVATOR MANUAL CHECKLIST Your Chief Bucket elevator is designed for safe reliable operation when properly installed.

WARNING!

THE BUCKET ELEVATOR REQUIRES ELECTRICITY AND HAS A DRIVE ASSEMBLY, MOVING CUPS, AND BELT WHICH, WHEN INSTALLED OR OPERATED IMPROPERLY CAN BE POTENTIALLY DANGEROUS.

Any individual who will operate or install this unit should read this manual before proceeding with installation or operation of the unit. The table below is provided for your convenience to record the individuals training on proper installation and operation of the bucket elevator.

WARNING! The Safety and Performance of this Elevator, Installed and Readied for Operation, will be affected by the Installation Personnel. Careful Consideration must be given to the Structural Requirements. We Highly Recommend the Use of a Skilled Erection Company with a Qualified Structural Engineer. Chief cannot be Responsible for the Installation of the Elevator. The Information Contained in this Manual is offered only as a Convenience to the Installer. No Liability is Expressed or Implied toward the Installer.

04


BUCKET ELEVATOR INSTALLATION AND OPERATION MANUAL This manual is for the installation, operation, and maintenance of all Chief Bucket Elevators with the Serial Number (1) and up. Read this manual thoroughly before installing, operating, or servicing the equipment. Record Bucket Elevator information on spaces provided below, upon receipt of your unit. Keep this manual in a location for quick reference. Recorded information should be available before contacting the dealer or factory for service. 1…Bucket Elevator Model Number________________________________________________ 2…Bucket Elevator Serial Number________________________________________________ 3…Head Pulley Diameter______________________ 5…RPM__________________

4…Discharge Height______________

6…Grain Type___________________

7…Grain Volume_____________________________

8…Horsepower_________________

9…Dealer Purchased From_____________________

10…Date Purchased______________

FIGURE 1. Serial Number Plate Located on Leg Inspection Section

SPECIAL SERVICE NOTICE If you are unable to remedy any service problem after consulting manual, your first line of service is the Dealer from whom you purchased the unit from. Contact Dealer and provide recorded information above and explanation of the problem. If the Dealer is unable to correct the problem then contact the manufacturers Customer Service Department for factory service and provide recorded information above along with an explanation of the problem.

05


PRODUCT WARRANTY REGISTRATION Included with your Chief unit is a Warranty Registration Card as shown in Figure 2 sample below. Complete and return attached card to Manufacturer for the process of this Warranty Coverage and Performance. Failure to fully complete and return the WARRANTY REGISTRATION CARD attached to your unit, could jeopardize any warranty claim on this item.

FIGURE 2. Registration Sample

06


PRODUCT SERVICE: Our top priority is to assure customer satisfaction on all Chief products. If a dealer requires assistance from Chief, contact our Service Department. The dealer purchasing a product from Chief Agri/Industrial (A Division of Chief Industries Inc.) will be responsible for the installation, operation, & service in accordance with Chief Agri/Industrial Service Policy. The dealer will also be responsible for all Standard Limited Warranty procedures in accordance with Chief Agri/Industrial.

SERVICE POLICY CHIEF STANDARD LIMITED WARRANTY: Dealers have the responsibility of calling to the attention of their customers the following limited warranty, prior to acceptance of an order from the customer for any Chief Agri/Industrial products. Chief Agri/Industrial warrants to the purchaser for use that if any part of the product is proven to be defective in material or workmanship within 2 years from the date of original invoice from the factory, and Chief Agri/ Industrial is notified within 15 days after such defect is discovered, Chief Agri/Industrial, will (at company option) either replace or repair said part. This standard limited warranty does not apply to damage resulting from misuse, neglect, material wear, accident or improper installation or maintenance. Said part will not be considered defective if it substantially fulfills performance specifications. The foregoing limited warranty is exclusive and in lieu of all other warranties of merchantability, fitness for purpose and of any other type, whether expressed or implied. Chief Agri/Industrial neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part and will not be liable for incidental or consequential damages. The remedies stated herein shall be the exclusive remedies available under this standard limited warranty. Claims under this standard limited warranty shall be handled under the standard service policy. Chief Agri/Industrial will not be responsible for any charges incurred in repairing or servicing any Chief products except as such repairs are made at Chief or by Chief Field Service Personnel or as approved in writing from Chief Customer Service. IN WARRANTY REPLACEMENT: The Chief Agri/Industrial Standard Limited Warranty Policy will cover any defective part of the product covered by the Standard Limited Warranty. Equipment involved in a warranty claim under the above Standard Limited Warranty shall have the ORIGINAL WARRANTY REGISTRATION CARD on file in Kearney, Nebraska, and have been properly installed, maintained and operated according to the instructions provided by Chief Agri/Industrial. WARRANTY CLAIM PROCEDURES: When a part failure occurs, that in your judgment meets the conditions of the above Standard Limited Warranty; contact your dealer to make arrangements for the shipment of a replacement item and the return of the defective equipment. ELECTRIC MOTOR WARRANTY: The Manufacturers of all electric motors used by Chief Agri/Industrial carry a warranty for these items. If the motor fails under the conditions of Chief Agri/Industrial Standard Limited Warranty Policy, and provided it was protected by the proper protective device, the motor manufacturer’s nearest authorized service center will repair it. See catalog for motor manufacturer’s service centers. Any in warranty replacement motors not satisfactorily handled by motor manufacturer service centers and within the Standard Limited Warranty period and policy will be covered by Chief Agri/Industrial, Kearney, Nebraska. Contact Chief if you have any problems or questions. OUT OF WARRANTY SERVICE: Products requiring Chief Agri/Industrial repair work will be repaired at the standard repair charge plus hourly charges after the first hour. Field service work will require a field service charge plus travel expenses. The repaired part will carry a 30 day limited warranty. Your dealer will be responsible for warranty procedures in accordance with Chief Agri/Industrial. (See Dealer Policy.)

07


DECALS WARNING & MAINTENANCE The following Decals are installed on Chief Equipment at the appropriate locations. NOTE: For individual safety, please keep decals wiped clean at all times. If decals are destroyed, missing, or no longer readable they MUST BE REPLACED. If additional or replacement decals are needed they are available upon request. Write to: Chief Industries, Inc. Agri/Industrial P.O. Box 848 Kearney, Nebraska 68848

FIGURE 3. Rotating Sheave Decal Locate decal on the outside of the belt guard cover.

FIGURE 4. Moving Bucket & Belt Decal Locate decal on the Fixed End and Take Up Covers

FIGURE 5. Guard Missing Decal Locate decal on the inside of the belt guard back panel.

FIGURE 6. Bearing Inspection Decal Locate decal on conveyor cover at bearing location.

08


BUCKET ELEVATOR COMPONENT IDENTIFICATION

FIGURE 7: Bucket Elevator Component Identification Standard Chief Bucket Elevator Shown – Left Hand Projection

09


FIGURE 8: Typical Inspection Section Stacking Illustrations

10


PRE-ERECTION INFORMATION 1. Installation Planning Elevators of this type should be preplanned to meet the job requirements. If so, engineering installation drawings have been made which will simplify the installation. These drawings should reflect the following considerations. 2. Structural Capacity Safety is the first consideration in all planning for installation and operation of the elevator. This elevator has been designed to safely support its own weight and withstand winds to 100mph to the height specified. It is not designed to support or brace other equipment. ALL DISTRIBUTORS, CLEANERS AND/OR SPOUTING MUST BE APPROVED IN WRITING BY CHIEF AGRI/ INDUSTRIAL WHEN INTENDING TO USE THE ELEVATOR FOR EITHER FULL OR PARTIAL SUPPORT OR BRACING. OTHERWISE, EXTRA ATTACHMENTS MUST BE INDEPENDENTLY SUPPORTED AND BRACED. 3. Elevator Location The elevator must be properly located to receive incoming material and discharge it at the desired location. This requires an exact location for the elevator boot unit. Determine whether the boot is to be fed from the down or the up leg side or both sides of the elevator. The down leg side is recommended for light materials like ground feed. The up leg side is recommended for heavier, free flowing materials like whole grains. • On outside installations, check the planned location for the boot, head, spouting, and guy cables for clearance to other structures. Driveways, overhead power lines and building structures can present special hazards and obstructions. • On inside installations, check the location for the leg as it passes through each floor. Additional clearance for the ladder must be provided. 4. Boot footing and Pit Sufficient footings must be provided to adequately support the weight of the elevator and cable reaction loads in high winds. See Table 1 below for Footing Loads required per model and height elevators. Consult a local structural engineer for a properly designed boot footing. If the boot is installed in a pit or other permanent structure then adequate clearance must be provided to service the elevator. Adequate clearance must also be provided for removal of the boot pulley and the use of cleanout door. On outdoor installations the pit will require a sump pump or drain.

TABLE 1. Bucket Elevator Footing Loads (lbs.) Includes weights and cable reactions for 100mph winds

11


5. Guy Cables and Anchors The leg must be braced every 20 ft. between the head section and the top of the boot unit. Guy cables are generally used for bracing above ground level. For legs extending into pits (below ground level) bracing near ground level is recommended, to obtain maximum overhead guy cable clearance.

CARE SHOULD BE GIVEN TO PROTECT GUY CABLES FROM ACCIDENTAL DAMAGE. TRUCKS OR FARM MACHINERY COULD CAUSE SERIOUS DAMAGE TO A CABLE AND RESULT IN THE ELEVATOR TO COLLAPSE. Some protection is gained by guard fences and elevated anchors. Guard fences will keep equipment a safe distance from the cables. Elevated anchors will help vehicles to pass under the cables near the anchors. See Figure 9 below for a typical elevated anchor.

FIGURE 9. Typical Elevated Anchor

Anchors are to be located 90 degrees apart around the elevator, and must be properly designed to withstand the cable loads. Anchor locations are shown in Figure 10 and loads are charted in Table 2 (see page 13). All anchors must be designed by a Structural Engineer to match soil and ground conditions.

FIGURE 10. Anchor Placement

12


TABLE 2. Anchor Loads

FIGURE 11. Anchor Locations

ALL CABLES OR BRACES ATTACHED TO BUILDINGS OR OTHER STRUCTURES MUST BE APPROVED BY THE MANUFACTURER OF THE STRUCTURE OR BY A STRUCTURAL ENGINEER.

13


ELEVATOR INSTALLATION 1. General The preferred method of elevator erection is to first set the boot on the footing. Second, with the use of a crane, assemble the head, drive, leg sections & any service accessories from the top down. The elevator can be completely assembled, including drives, platforms, ladders, & cables while working within about 10’ of the ground if this method is used. Crane time can be reduced if about 30’ of legging, ladders, and etc. are attached to the head horizontally on the ground and then up righted with the crane. The head assembly, motor drive, upper leg sections, platforms and ladders can be assembled horizontally on the ground before hoisting the assembly, (see assembly in Figure 15 page 16). Position the head assembly with the discharge hopper up and with enough clearance to attach the leg sections horizontally to it. Attach the 20-30 feet of legging in this position, then upright elevator. Additional leg section, ladders, and etc. are then added as the elevator is raised. CAUTION: Do not allow any portions of the elevator assembly to drag on the ground, or in any other manner to become damaged while erecting assembly. 2. Setting the Boot Locate the boot on its foundation according to pre-planned requirements. Refer to Figures 12-13 & Table 3 for suggested method for anchoring the boot. The boot must be bolted into position prior to erecting the elevator to avoid accidental movement. Use lag bolts for Anchor Clip attachment. NOTE: The boot top flanges where the leg sections attach MUST be exactly level. Use a grouting cement under the boot base angles as needed to level boot. Be sure grouting cement is under the complete leveled surface of the boot base angles for proper boot support. FIGURE 12. Boot Anchor Locations (based on clip as shown in Figure 13)

TABLE 3. Anchor Bolt Locations

14

FIGURE 13. Anchor Clip (based on layout shown in Figure 12)


3. Inlet Hopper The Inlet Hopper location has been predetermined as described on page 11 (3). To locate the inlet hopper on the boot use the dimensions in Table 4 & Figure 14. NOTE: Never locate the inlet hopper lower than the given dimensions in Table 4. To do so will affect the elevator capacity. These dimensions are based on Chief Standard Inlets; consult the factory for other loading conditions.

FIGURE 14. Inlet Hopper Locations

TABLE 4. Inlet Hopper Dimensions

15


FIGURE 16. Platform Brackets 1. Head Assembly 2. Discharge Hopper 3. 10’ Leg Section with welded Platform Brackets, see Figure 16 (A) (not included on models 10, 42, & 48’s, will use standard leg section at this location, see Figure 16 (B) 4. Standard Leg Section 5. Spacer Angle 6. Head Service Platform 7. Distributor 8. Distributor Service Platform 9. Ladder (safety cage not shown) 10. Reststop Platform 11. Boot Assembly 12. Inspection Section 13. Heavier Gauged Material Leg Section (if required) for your unit

FIGURE 15. Upper Elevator Assembly

FIGURE 17. Lower Elevator Assembly

16


4. Leg Section Assembly Bolted Flange Leg Sections will vary in assembled components depending upon models. Leg sections will consist of two body sections (see Figure 18) or of a body section and a lid panel (see Figure 19). When attaching Leg Sections that consist of a body section and lid panel, these must be positioned with the lid panel located away from the center of the elevator (see Figure 19).

FIGURE 18. Bolted Flange Leg Section consisting of two body sections

FIGURE 19. Bolted Flange Leg Section consisting of body section and lid panel

The elevator height will determine if heavier gauged material leg sections are required at specific locations of your unit. Bolted Flange Leg Sections will be factory stamped, identifying the material gauge. This gauge will determine the placement of the leg section. When attaching Leg Sections that are heavier gauged, these must be positioned closest to the boot assembly (see Figure 17 page 16). Caulking compound is provided to apply to the faces of the leg flanges prior to joining the leg sections together to seal the joints from dust and weather leaks. Use only 3/8” diameter, grade 5 bolts provided to join the leg sections. Accurately align the flanges on the leg sections before tightening bolts to the values indicated in Table 5. Place spacer angles between the lower ends of each pair of leg sections (see Figure 20). The spacers hold the sections parallel and help reduce flange stress while making the horizontal assembly.

FIGURE 20. Spacer Angles

TABLE 5. Bolt Torques

17


5. Drive Assembly Install Reducer Drive on elevator. The Reducer Drive is packaged separately and includes manufacturer’s complete instructions for installation. Follow these instructions for Reducer Drive installation. WARNING: REDUCER DRIVES ARE SHIPPED WITHOUT LUBRICANT. DO NOT Operate the elevator until the Reducer Drive has been filled with an approved lubricant as noted in the manufacturer’s instructions. A Reducer Backstop is recommended on tall and large capacity elevators. The backstop prevents a loaded elevator from reversing direction when power is lost to the head pulley. If the Reducer Drive has been equipped with a backstop, then a check for correct direction of rotation is required. To do so rotate the top of the head pulley towards the discharge side of the head, see Figure 15 (page 16), the pulley should rotate freely in this direction but not in the opposite direction. If the backstop is reversed, refer to the reducer manufacturers instructions. Position motor on the head assembly motor mount and attach with bolt package provided. Adjustment to the motor mount may be required so that the end of the motor shaft is in line with the end of the reducer input shaft. Tighten belts to specified tension according to V-Belt tension (page 19). NOTE: All sheaves, sprockets, and drive components assembled at the manufacturer (including the bucket elevator pulley) should be checked for alignment, centered and tightened prior to operation and at regular operating intervals.

WARNING: Explosion Proof Electrical Equipment must be used whenever an elevator is located in an explosive atmosphere. A Safety Switch should be installed on the head to prevent accidental motor operation when servicing the head. WARNING: Do Not operate elevator without Belt Guard Assembly properly installed.

FIGURE 21. Drive & Belt Guard Assembly

Install Belt Guard & Drive components (see Figure 21). Configurations and bracketing of Belt Guards differ per model of elevator and reducer drive. Refer to Supplemental Drive & Belt Guard Assembly Drawings shipped with drive package for installation instructions on your specific model. Install belt guard back panels and bracketing (some field drilling may be required for bracket attachment to back panels). Adjust belt guard bracketing to allow for back panel clearance away from motor & reducer. Install sheaves and belts allowing for clearance away from back panels. Complete installation by placing belt guard shell over the sheaves and belts and then attaching the shell to the back panels. 18


6. Sheave Alignment Check that sheaves on motor and reducer are aligned and level. Use straight edge that lies across the face of each sheave to check alignment as shown in Figure 22.

FIGURE 22. Sheave Alignment

7. V-Belt Tension Install the drive belts and adjust belt tension. Using Belt Tension Checker adjust the belts so that a force in the middle of each belt will deflect the belt 1/64” for each inch of distance between the sheave centers, as shown in Figure 23. The Deflection Force is shown in Table 6. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions. Over tensioning shortens belt and bearing life. Check tension frequently during the first 24-48 hours of operation.

FIGURE 23. Belt Span

NOTE: Compare the force you have applied with the values in Table 6. The force should be between the minimum and maximum shown. The maximum value shown is for “New Belt”, and new belts should be tensioned at this value to allow for expected tension loss. Used belts should be maintained at the minimum value as indicated in Table 6.

TABLE 6. Deflection Force

19


8. Guy Cables The elevator must be guyed, or otherwise laterally supported every 20 feet from the top of the boot to the head section. At each 20 foot level, four cables must be attached in equal directions and attached to anchors previously planned & placed according to Pre-erection Information (Guy Cables and Anchors page 12). Cables must be of sufficient strength, uniform elastic nature, & adequately tensioned to prevent the elevator from bending or whipping in wind storms. Cables can be precut to length by following Table 7. This chart corresponds with Pre-erection information (Figure 11 Anchor Locations, page 13). Anchor cables A, B, & C correspond with (Figure 11) A, B, & C anchor location. Lengths of cable listed in Table 7 start with the highest cable at each anchor location and work down and also start at the brackets located just below the head section and continue down the elevator at 20’ intervals. NOTE: Cable lengths shown are straight line lengths. NO allowance in the cable length has been made for cable clamping, turn buckles, cable sag or any deviation in bracket or anchor locations. See Table 8 (page 21) for additional lengths required for clamping. WARNING: All 3/8” diameter guy cables are to be 6,950 (lbs.) minimum TABLE 7: Guy Cable Lengths strength (Siemens martin or equivalent) NOTE: All cables are 3/8” diameter except for & all 1/2” diameter guy cables are to be lengths shown as xx*. This denotes 1/2” 12,100 (lbs.) minimum strength diameter cable must be used at this location. (Siemens martin or equivalent). DO NOT mix types of cables even though they meet the minimum strength requirements. WARNING: Guy Cables must not be attached by other means than those provided. Welding to or cutting into the leg sections is prohibited unless approved by Chief Manufacturing in writing. WARNING: All cables or braces attached to buildings or other structures must be approved by the manufacturer of the structure or by a structural engineer. WARNING: Care should be given to protect guy cables from accidental damage. Trucks or farm machinery could cause serious damage to a cable and result in the elevator collapsing. The top sets of cables are attached to the work platform angle at the thimble locations. All other cable sets are attached to the Bolted Flanged Leg as shown in Figure 24 (legs consisting of two body sections) or as in Figure 25 (legs consisting of body & lid sections). Figure 26 illustrates 20X14 trunking (legs consisting of two body sections.) ( All shown on page 21.) 20


FIGURE 24. Guy wire bracket on Bolted Flange Leg with two body section (Shown below is 16X10 & 16X14 trunking).

FIGURE 25. Guy wire bracket on Bolted Flange Leg with body & lid sections (Shown below is 13X10 trunking).

FIGURE 26. Guy wire bracket on Bolted Flange Leg with two body sections (Shown at left is 20X14 trunking).

The recommended method of connecting a cable is to bend the cable around the thimble for the specified cable turn back, see Table 8. Place the first cable clip 3 inches from the dead end. Place the second clip as close to the loop as possible, see Figure 26. TABLE 8. Cable Clamp Specifications typical each cable connection

FIGURE 27. Cable Clamp typical each cable connection To organize the attachment of cables while the elevator is being erected, pre-mark each guy wire bracket with its future position on the leg (height and direction), then determine the length of the cable for each guy wire bracket being sure to allow for all cable connections. Cut and attach the cables to predetermined guy wire brackets. As the elevator is assembled the guy wire brackets can be installed with the proper cables attached. 9. Upper Assembly Inspection Make a final inspection of all parts on the upper 30ft. of the elevator prior to hoisting. A few points to check include: a. Are all flange joints aligned properly and caulked? b. Are all bolts installed and properly torqued? c. Have any damaged parts been used? 21


10. Hoisting the Elevator In hoisting the elevator certain understanding and safety considerations must be made. These are best understood by an experienced erection crew. Always consider safety first. a. The crane or hoisting equipment must have adequate lifting capacity and height to safely handle the load, see component weights Table 9. b. The crane must be sitting on firm ground. c. Position the crane to allow the leg to be lowered onto the boot with clearance to attach all guy cables. d. Weather conditions for the erection period must be favorable. e. Anchors must be installed and concrete cured prior to usage. f. Boot footings must be cured and boot upper flange leveled. TABLE 9. Component Hoisting Weights (lbs.)

Attach hoisting slings or chains to all eye bolts provided on the head section. Attach the slings so that the load is distributed evenly. Raise the upper elevator section into the vertical position with the crane. CAUTION: Do not allow any portions of the elevator assembly to drag on the ground, or in any other way to become damaged while erecting assembly. Lift the assembly to a height sufficient to assemble the next section of legging, ladder, cables, & etc. Be certain to caulk leg flanges prior to assembly of leg sections. Torque all bolts according to Table 5 (page 17). Continue with assembly completing all leg sections, reststops, ladders, cables, & etc. The inspection section must be properly located on the up leg side, see Figure 8 (page 10) for stacking illustrations. The inspection door must be accessible from work floor area and located to the outside of the elevator. Keep all components intact during assembly. Any removal of component parts during erection reduces elevator strength. Do not under any circumstances cut into or weld onto the legging or the inspection section of the elevator. Cutting or welding can cause structural damage. Use only approved leg sections and leg bracketing. 22


11. Setting and Guying the Elevator After completion of all legging inspection sections, lift the assembly over top of the boot. Before setting assembly on the boot, insure plumb between the head and boot sections. Use one or more transits to check the position. Caulk the flanges and set the assembly into position. Torque all bolts according to Table 5 (page 17). Connect each guy cable to its anchor, starting with the lowest set of cables and progressing towards the top. Locate a turnbuckle on each cable at a convenient distance from the anchor. Extend the turnbuckles as far as possible to allow for later adjustment. Refer to Figure 26 and Table 8 for cable clamping information. Use two transits to keep the leg straight and plumb while tightening the cables. Locate one transit in line with one row of anchors, and 50 feet additional from the farthest anchor. This transit will be used for adjusting cables extending to the right and left of it. Set a second transit 90 degrees from the first transit in line with the row of anchors, to adjust the cables extending in the other two directions (see Figure 27).

FIGURE 28. Transit Locations

While plumbing the leg, tension all cables in alternate succession to 600-700 pounds. Starting at the lowest guy wire bracket location, tighten two cables in opposite corners of the elevator. Check leg for plumb, and then tighten the two remaining cables. Repeat this procedure for each successive guy wire bracket. A final recheck for plumb is made with a plumb bob. If the leg is not perfectly plumb, one can experience difficulty with the belt not running true. Insert a plumb bob into the up leg section from the head section and lower it past the inspection door. Tie the plumb line to a cross board over the top of the head frame. Locate the line so it clears all sides inside the leg. Note the position of the plumb line with respect to the leg casing at the top and bottom ends of the elevator. If it is not the same within 1/2 inch, readjust the guy cables. After all cables have been tensioned and the leg rechecked for plumb and straightness, permanently secure the turnbuckles from loosening. Note: Either end or the center of a turnbuckle may turn and loosen the cable. One method of securing the cable is to lace a short length of cable through the ends and center of the turnbuckle and secure the cable with cable clamps. This also deters unauthorized persons from loosening the cables.

23


BELT AND BUCKET INSTALLATION The belt and buckets are installed after the leg is erected, guyed and plumbed. The general procedure is to install the belt, make a temporary belt spice, install the buckets and then make the final splice. 1. Belt Installation Adjust the boot pulley into its highest position to allow maximum belt adjustment. Remove the clean out doors at the bottom of the boot. Remove the hoods on the head to expose the head pulley. Open the inspection section by removing the front door, screen and back cover. Care should be taken in removing inspection section parts. Forces from an improperly plumbed leg can cause leg to collapse when inspection panels are removed. Therefore, loosen all bolts first to see if the covers are free of side loading on the bolts. If they are not free, do not remove the bolts until problem is corrected. Note: The screen and cover should never be removed during winds in excess of 20 MPH. Several methods may be used to place the belt inside the elevator legs. Generally the belt is pulled with a rope or cable in through the inspection section opening, up and over the head pulley, down and around the boot pulley and back up to the inspection opening for splicing. The rope or cable used for this purpose must have sufficient strength to lift the belt to the head pulley. With the head hoods removed, drop one end of the rope down the up leg and out the inspection opening. Drop the other end of the rope down the down leg, around the boot pulley and back up to the inspection opening. Removal of the cleanout doors will aid in feeding the rope around the boot pulley. Attach the belt to the end of the rope coming down the up leg. Use a piece of angle to attach the rope to the belt. The angle should be the same width as the belt width with holes along one side to match the bucket holes and an eye bolt in the center of the other side for connecting the rope. Bolt the angle to the belt using the flat headed bolts provided for the buckets. It will be necessary to remove the motor drive belt to allow the upper head pulley to turn freely. Be careful that the belt does not run away when the belt in the down leg becomes longer than the belt in the up leg.

2. Temporary Belt Splice Make a temporary Lap Splice (see Figure 29) by overlapping the belt ends and inserting flat head bucket bolts through 3 or more sets of pre-punched bucket holes. The lap is made so that the trailing end of the belt is in contact with the pulleys and not the leading end. Lift the lower end of the belt to remove the excess slack from the belt. The flat head of the bolt is to run on the pulley side of the belt. Use flat washers under the nuts at this time.

FIGURE 29. Temporary Belt Splice

24


3. Bucket Installation Install the buckets by bolting them to the pre-punched holes in the belt (see Figure 30). Insert bolts from pulley side of belt and tighten nuts until bolt head is flush with belt. Tighten bolts to 10 ft-lbs of torque. Install buckets at intervals of 15 or more hole spacing to reduce unbalance on the belt. Continue adding another bucket to each interval on each round of the belt until all buckets are installed. FIGURE 30. Bucket Illustrations

FIGURE 31. Final Belt Splice

4. Final Belt Splice Allow the belt and buckets to hang for 24 hours or more to remove much of the initial belt stretch. The belt can then be re-spliced, tightened, adjusted and squared. With the boot pulley in its highest position, disconnect the temporary lap splice at the inspection door. Remove the excess slack from the belt and re-splice the belt. A five foot overlap is recommended on the lap splice (see Figure 31). Using the bucket bolts, match the overlapping pre-punched holes then bolt the belts together at the bucket hole locations. On pre-punched belt with holes spaced over 12 inches apart the spice must have 4 sets of bolt holes. Field drill extra sets of holes if required. Note: Recheck all bolts in the belt and buckets for proper tension. All bolt heads are to be snug with the belt surface. Replace clean out doors, inspection section back panel, screen door front panel, & head hoods. 5. Belt Tension Adjustment Belt tension at the boot pulley must be maintained to eliminate belt slippage at the head pulley. Adjust boot pulley until slack is taken out of the belt. Then adjust the boot pulley down one more inch. Steering (centering) is accomplished by adjusting one side of the pulley tighter than the other. The belt will move to the slack side. If belt still slips, adjust the boot pulley down one more inch. 6. Discharge Baffle Adjustment A discharge baffle is located in the head discharge section to deflect material from the buckets, so minimum material returns down the leg (termed ‘back legging’). Adjust the baffle so it will clear the buckets by 1/8” (see Figure 32). Note: Buckets mounted on lapped belt splices will run closer to the baffle, final adjustments need to be made at this location. FIGURE 32. Baffle Adjustment 25


START UP AND OPERATION 1. Pre-Start Up Inspection Prior to operating the elevator, check all areas for safety issues and machine damage which could occur during operation. Follow all manufacturers’ pre-start up instructions for each individual component provided with your elevator. DISCONNECT AND LOCK OUT ALL ELECTRICAL POWER a. Is leg properly plumbed, with guy cables tensioned and secured from loosening? b. Check that head and boot pulley keys are in place. Check all set screws in drive sheaves, head and boot shafts and pulleys, shaft bearings and gear reducers. c. Head pulley is level, centered, and squared in housing. d. Discharge baffle properly positioned and that discharge is cleared of obstructions. e. All hardware is in place and tight, motor, bearing bolts, and etc. f. Elevator belt spice is square and belt properly tensioned. g. Check that sheaves are properly aligned and V-belts properly tensioned. h. Bushing bolts in sheaves and reducer are torqued to manufacturer specifications. i. Drive guard and other safety devices are in place. j. All debris is removed from the elevator boot. Frequently recheck the boot for debris during the first few days of operation. During construction debris can be left in other areas that feed to the bucket elevator, e.g. dump pit, bin unload conveyor, or the grain bin. k. Head hood, boot cleanouts, and inspection section panels in place and properly secured. l. Reducer manufacturer specifications have been met. m. Reducer has Lubricant and is filled to proper level. NOTE: REDUCER HAS BEEN SHIPPED WITHOUT OIL. Additional Safety Checks Is there possibility of damage to leg or guy cables from vehicles? Is access to the electric controls and climbing ladder secure from unauthorized persons? Are pits designed to equipment to prevent personal injury? Is electrical equipment installed to meet national electric code and/ or local safety codes, including explosion proof equipment where required?

CONNECT ELECTRICAL POWER KEEP PERSONNEL AWAY FROM MOVING PARTS DURING INSPECTION 2. Start Up Inspection a. Operate the elevator empty under power for a period of time. b. Check that buckets are traveling in the correct direction. c. Check that the belt is running on center over the head and boot pulleys. 3. Flow System Completion To complete an elevator system, material feed and discharge connections must be made to the leg. Complete these connections before placing the leg into service.

26


START UP AND OPERATION (continued) 4. Elevator Operation Since the elevator has been previously operated without material, it may now be tested under load. It is suggested that the flow systems be checked next. Allow only a small amount of material to enter the elevator while it is running. Check that the material can flow through the system connections, valves, distributors, etc. This will check for proper functioning. Once all flow paths have been checked, the elevator may be loaded to capacity. Check elevator, once loaded to capacity for the following: a. Back legging (grain being returned down the down leg). b. Slippage of the head pulley. c. Proper filling of buckets. d. Electrical current (Amperage) draw on the motor. An inspection of the elevator is suggested after the first 8-10 hours of operation. Inspection should include the following: a. Check all bolts holding buckets to the belt for tightness. b. Check that the belt is running in the center of the leg past the inspection section. c. Check motor drive for looseness of pulleys, sprockets, belts, chains and torque arm. d. Check for oil leakage or overheating of gear reducer. e. Check head pulley hub bolts and set screws.

TABLE 10. Bearing Set Screw Torque Chart

27


PERIODIC MAINTENANCE Safe Operation of this Equipment Requires Proper Maintenance. The following are guidelines for maintaining the elevator. Operators will have to determine what inspection and service intervals are necessary for their application. Factors to consider are the frequency of operation and the operating environment of the equipment. DISCONNECT AND LOCK OUT ALL ELECTRICAL POWER PRIOR TO PERFORMING MAINTENANCE OR REPAIRS Daily • Always be aware of the normal operating sounds. If any abnormal sounds occur, stop the elevator, find the source of the noise, then lock out power to the elevator and repair the problem. Weekly • Lubricate bearings according to manufacturer specifications.

DISCONNECT AND LOCK OUT ALL ELECTRICAL POWER PRIOR TO PERFORMING MAINTENANCE OR REPAIRS Monthly • Check V-belt tension and overall condition. Replace if worn, frayed, or cracked. • Check that set screws in pulleys and bearings are tight. If necessary tighten to manufactures’ specifications. • Check for missing or damaged buckets. Replace if necessary. Check bucket bolts for tightness. • Check that the elevator belt is properly tensioned and is running in the center of the leg. • Check oil level in gearbox and inspect seals for signs of leakage. Follow manufacture’s specifications for oil level and oil change periods. • Check that the motor is clean and properly ventilated. • Lubricate motor according to manufacturer’s specifications and intervals. Quarterly Check guy cables, turnbuckles and cable clamps every 3 months for damage or loosening. Any change in cable tension may cause the leg to go out of plumb, resulting in the belt not running on center and/or damage to the leg.

•

Never remove or loosen one or more cables without providing other means of support to the leg.

28


TROUBLESHOOTING The chart shown below is an aide to troubleshooting when a problem is encountered. Some causes can be corrected by reviewing certain areas of the assembly instructions. When checking elevator capacities, note that rated capacities are calculated on a 75% cup fill.

29


BEARINGS, BUSHINGS, & ELECTRICAL COMPONENTS Maintenance & Lubrication Manufacturer Recommendations

The following pages have been provided to assist our customer during maintenance of components that have been factory installed on your Chief Elevator. These pages have been obtained from the manufacturers’ publications and contain recommendations for their specific product.

Locate and read the instructions specific to the bearing or bushing style installed on your components, prior to maintenance or lubrication.

Manufacturer Page Peer Bearings……………………………………………………………………………. 31-35 Dodge Bearings………………………………………..………………………………… 36-41 Dodge Reducers……………………………………………….………………………… 42-43 Maska QD Bushings…………………………………………………………………..… 44-46 Van Gorp XT Pulley Bushings………………………………………………………….. 47-48 4B Plug Wire Kit……………………………..…………………………………………… 49-50 4B Shaft Speed Sensor………………………………….……………………………… 51-52 Rolfes Belt Alignment Sensor………………………………………………………….. 53-57

30


PEER BEARINGS Mounting Locking to the shaft. Cylindrical bore bearings- Set screw locking. For normal operating conditions, ball bearings are fixed to the shaft with socket head set screws as illustrated in figures 4 and 5. It is recommended that the shaft have flats or recesses in the areas where the set screws will contact it. This eliminates the formation of burrs on the shafting

Where vibration, shock and or thrust loads are anticipated, it is recommended that the shaft have a machined shoulder or auxiliary locking collar against which the bearing inner ring can be mounted. See figure6. Set screws on cylindrical bore bearings should be tightened incrementally and firmly to prevent rotation of the shaft in the bearing bore. Tighten one set screw to sufficiently contact the shaft, then tighten the second set screw to the full torque requirement, and then tighten the first set screw to the full torque requirement. It is also recommended the set screws be re-tightened after 24 hours of operation. Tightening torque values are shown in table 16. Caution should be taken to not over tighten the set screws as this can cause inner ring distortion instigating an eccentric rotation and out of balance situation. It is important to mention that PEER high frequency anneals the inner ring in the areas around the set screws. In addition to preventing cracking of the inner ring during set screw tightening, this allows the use of larger diameter set screws increasing the holding power. Set screw sizes and hex sizes are shown in table 16. PEER also uses a special set screw spacing to increase holding power of the set screws during operation. Table 16: Tightening torque of set screws in set screw locking bearings.

Note: Based on class 3A, alloy steel, knurled cup point set screws, cold forged with black oxide finish. Hardness value of 45-53 used in annealed inner rings with class 3B set screw holes. Other set screw styles and types are available upon request. Table 16:a Stainless Steel Set Screw Tightening Torque Requirements

Peer Bearing Instructions Literature obtained online from www.peerbearing.com 31


PEER BEARINGS (continued) Cylindrical bore bearings-Eccentric locking collars. Eccentric locking collar bearings are locked to the shaft by aligning the eccentric area of the collar against the corresponding eccentric area of the inner ring and rotating the collar in the direction of shaft rotation. Using a punch in the blind hole on the collar, tap the punch in the direction of shaft rotation. The eccentric locking collar will continually tighten during shaft rotation. Tightening the set screw in the locking collar to the shaft using the torque values shown in table 17 will provide limited holding power and is not to be relied upon solely for securing the shaft. Eccentric Locking collar bearings are to be used in single direction rotating applications only. If a reversing rotation is desired or expected, set screw locking or “Grip-It” style bearings are required. If thrust or axial loads are expected on locking collar bearings, the use of a machined shoulder or auxiliary locking device is required. Table 17: Tightening torque of set screw in eccentric locking collar.

Note: Metric bore bearings use metric size set screws in the locking collars. See table 16 for tightening torque of metric size set screws.

ECCENTRIC LOCKING COLLAR ASSEMBLY PROCEDURES

Slide shaft into bearing bore. Shaft must be straight, true and free of nicks and burrs and properly aligned in the housing.

Locate bearing/shaft on mounting surface. Mounting surface should be flat and stable. If needed, align bearing to insure that it is.


Secure housing to mounting surface.


PEER BEARINGS (continued) ECCENTRIC LOCKING COLLAR ASSEMBLY PROCEDURES (continued)

If possible, rotate shaft by hand in direction of final rotation to insure the bearing turns freely and smoothly. Slide locking collar over shaft.

Engage locking collar by rotating collar IN DIRECTION OF THE SHAFT ROTATION so the Eccentricity of the collar mates with the eccentricity of the inner ring.

Using a lightweight hammer, strike drift punch smartly to engage the collar IN THE DIRECTION OF THE SHAFT ROTATION. (Illustration shown for counter-INNER RING. Clockwise shaft rotation.)

Insert a drift punch in blind hole of locking collar. Punch must be positioned so striking it rotates the collar IN THE DIRECTION OF THE SHAFT ROTATION.

DO NOT STRIKE PUNCH IN SUCH A MANNER AS TO EXERT FORCE STRAIGHT DOWN ONTO THE BEARING INNER RING.

Tighten the set screw to the prescribed torque.



PEER BEARINGS (continued) Cylindrical bore bearings-Concentric “Grip-It” bearings. “GR” series or Grip-It bearings are locked to the shaft by tightening the concentric collar over the inner ring extension via the cap screw. As the cap screw is tightened, the collar compresses the inner ring extensions capturing the shaft in a concentric manner. Recommended cap screw torque values can be found in Table 18. This mounting style maintains superb shaft to bore concentricity eliminating vibration and fretting corrosion normally associated with insert bearings. In addition, since there is no screw intrusion into the shaft, there is no need to refinish or dress the shaft after removal or replacement of the Bearing. Table 18: Grip-It series cap screw torque recommendations.

Greasing: Greasing Intervals. PEER mounted unit insert bearings are pre-lubricated at the factory and are ready for operation. Under normal operating conditions it is normal for a small amount of grease to purge from the seals during initial start up. This condition will stop once optimum grease fill has been obtained. Re-lubrication of PEER insert bearings is determined by operating conditions and environment. Greases used in re-lubricating PEER bearings should be NLGI # 2 compatible with a lithium thickener, mineral base oil and a temperature range of -10 to +260 degrees F. General greasing intervals based on RPM and operating conditions are shown in table 19. However, experience is the preferred method of determining greasing intervals and fill amounts. Table 19: Greasing intervals.

d=inner diameter of bearing (mm) n=speed in RPM



PEER BEARINGS (continued) Grease fill amounts Care should be taken when re-greasing bearings to avoid overfilling. Overfilling can lead to excessive heat and or unseating of the seals. Grease should be introduced in small increments and under light pressure. The use of pneumatic greasing equipment is not recommended unless low pressure is assured. Whenever possible, the shaft should be rotated during re-lubrication to insure proper grease distribution throughout the raceways. The grease fill shown in table 20 provides a general rule for re-greasing amounts. However, it is preferred that experience dictates fill amounts due to wide variances in applications and operating environments. Table 20: Grease fill amounts.

Grease fittings. PEER offers many styles and types of grease fittings. Figure7 illustrates some of the many styles and sizes PEER units can be equipped with. Optional fitting materials, thread designs and additional styles are available by special order. Table 21 shows the standard fitting sizes used on PEER units. Table 21: Grease fitting equipped in PEER ball bearing mounted units.

Note: Optional 90˚ and 45˚ fittings available.

Location of zerk hole on pillow block units.

PEER has the ability to locate the zerk hole in a wide variety of locations on the pillow block housings. Table 22 shows our standard location. See figure 8 and figure 9. Special locations are available by request.

FIGURE 7

Table 22: Location of zerk fitting on pillow block units.



DODGE BEARINGS

36


DODGE BEARINGS (continued)

37



38



39



40



41


DODGE SHAFT MOUNT SPEED REDUCERS

42


DODGE SHAFT MOUNT SPEED REDUCERS (continued)

43


MASKA QD BUSHINGS

Maska QD Bushing Mounting Instructions Literature obtained from Maska Product Catalog – 2003-a 44


MASKA QD BUSHINGS (continued)



MASKA QD BUSHINGS (continued)



VAN GORP XT PULLEY BUSHINGS

Van Gorp XT Bushing Instructions Literature obtained online from www.vangorp.biz 47


VAN GORP XT PULLEY BUSHINGS (continued)

Van Gorp XT Bushing Instructions Literature obtained online from www.vangorp.biz 48


4B PLUG WIRE KIT

49


4B PLUG WIRE KIT (continued)

50


4B SHAFT SPEED SENSOR

51


4B SHAFT SPEED SENSOR (continued)

52


ROLFES BELT ALIGNMENT SENSOR

53


ROLFES BELT ALIGNMENT SENSOR (continued)

54



55



56



57

Chief Agri/Industerial Bucket Elevator Manual

Recommend Documents