OPERATING INSTRUCTIONS
Bucket elevator
with
a 1m. square hopper
Clemco
International GmbH
Revision: 05.2016
Carl-Zeiss-Straße 21
83052 Bruckmühl
Germany
Tel.: +49 (0) 8062 – 90080
Mail: info@clemco.de
Web: www.clemco-international.com
INDEX
1
Abbreviations, definitions, symbols and pictograms .................................... 4
2
Description of the product................................................................................ 4
2.1
Utilization as directed and restrictions .................................................... 4
2.2
Utilization not as directed – warning against misuse ............................. 4
2.3
Functioning of the entire system .............................................................. 4
2.4
Description ................................................................................................. 5
2.4.1 The bucket elevator´s components ........................................................... 5
2.4.2 Operator´s controls ................................................................................... 6
3
2.5
Energy consumption and power supply .................................................. 6
2.6
Emissions ................................................................................................... 6
Preparing for use ............................................................................................... 7
3.1
Transport and trans-shipment .................................................................. 7
3.2
Unpacking and removal of the packaging material ................................. 8
3.3
Prerequisites for installation ..................................................................... 8
3.3.1 Dimensions of the recycling system.......................................................... 8
3.3.2 Parts that are not included in the standard extent of supply ..................... 9
3.3.3 Requirements for the installation´s electrical control unit and earthing ..... 9
3.4
4
Installing, mounting and the functional test ............................................ 9
Operating instructions .................................................................................... 12
Starting up and operation; putting out of operation after finishing work ...... 12
4.1
EMERGENCY OFF .................................................................................... 12
4.2
Putting out of operation for a long interruption of work or conversion
of the installation ................................................................................................ 12
4.3
Special working steps.............................................................................. 13
4.3.1 Mounting the belt .................................................................................... 13
4.3.2 Removing a worn belt ............................................................................. 15
4.3.3 Mounting the head for repair work .......................................................... 15
5
Servicing, maintenance and cleaning............................................................ 17
5.1
Generally ................................................................................................... 17
Blasting devices are subjected to heavy wear. Safety and high efficiency will
only be ensured with regular servicing............................................................. 17
6
5.2
After 8 operating hours max.................................................................... 17
5.3
After 40 operating hours max.................................................................. 17
5.4
After 150 operating hours max................................................................ 17
5.5
After 1,000 operating hours max............................................................. 17
5.6
After 20,000 operating hours max........................................................... 17
Faults and remedying them ............................................................................ 18
2
7
Permissible modifications .............................................................................. 18
8
Spare parts list ................................................................................................ 19
9
Appendices ...................................................................................................... 23
3
1
Abbreviations, definitions, symbols and pictograms
WARNING
Risk of injury
Secure components from tipping over.
Risk of injury
Ensure that nobody is working on the bucket
elevator before switching it on. Switch off the
installation before working on it.
2 Description of the product
2.1
Utilization as directed and restrictions
The bucket elevator is suitable:
• for continuous operation at high output in industrial blasting rooms,
• for steel shot slag and other metallic or mineral blasting materials,
• for blasting materials down to a lower grain size of 0.125mm,
• for use in closed rooms,
• for a conveying capacity of
- 7,000kg/h max. for steel shot,
- 3,150kg/h max. for corundum.
2.2
Utilization not as directed – warning against misuse
Use is prohibited:
- in explosive zones,
- for transporting substances and bulk goods, etc., where substances will be released,
o whenever the risk of explosion exists,
o which lead to damaging the health if there is a defect.
2.3
Functioning of the entire system
The bucket elevator is a component of the blast material recycling system. A complete system
consists of:
- (1) blast material recycling floor or reversing hopper,
- (2) bucket elevator,
- (3) cleaner,
- (4) silo,
- (5) blasting container,
- (6) filter with fan.
4
2
3
4
6
5
1
Figure 1
2.4
2.4.1
Description
The bucket elevator´s components
1
2
1. Bucket elevator head
with drive motor
2. Bucket elevator central part
3. Bucket elevator - foot
4. Cover plates (option)
5. Hopper
6. Sieve
7. Grating
3
Figure 2
5
2.4.2
Operator´s controls
These are components of the complete installation.
where
ON - OFF
EMERGENCY OFF
2.5
Energy consumption and power supply
Energy consumption
output
Height of the bucket
conveyor
(Figures 3 and 4)
2.6
Comments and functions
switch box
switch box
0.75kW
1.5kW
2.2kW
Up to 7,000mm
7,050mm to
8,500mm
8,550mm to
11,000mm
Emissions
- Dust: no emissions in proper condition.
- Noise: less than 90dB(A) in proper condition.
6
3 Preparing for use
3.1
Transport and trans-shipment
4
Min
5°
G1
Max 2000
Ca.1210
Ca.900
A
A
G3
G2
A
A
A
A
Figure 3
G1= 120kg max., G2 = 100kg max., G3 = 250kg max.
Euro pallet
A = 1,200mm x 800mm x 150mm
7
3.2
Unpacking and removal of the packaging material
- Pallets: wooden pallets
no special measures.
- Plastic sheets
disposal according to local regulations.
3.3
Prerequisites for installation
- Blasting room´s wall thickness: 300mm max. – mounting difficulties otherwise!
3.3.1
Dimensions of the recycling system
Figure 4
Figure no.
H (mm)
H min (mm)
H1min
(mm)
S (mm)
S1 (mm)
B1 (mm)
B2 (mm)
Figure 5
1 cu.m.
1 exit
3
6,330
5,120
4,220
Silo volume / number of outlets
2 cu.m.
2 cu.m.
4 cu.m.
1 exit
2 exits
2 exits
3
3
3
6,760
6,710
7,610
5,550
5,500
6,400
4,650
4,600
5,500
5,770
4,560
3,660
2,920
1,590
1,780
1,510
3,350
1,590
1,780
1,510
2,450
960
800
610
3,300
1,590
1,780
1,510
4,200
1,590
1,780
1,510
200 litres
direct
4
8
3.3.2
Parts that are not included in the standard extent of supply
Building measures
Electrics
Earthing
3.3.3
Parts not included
Angle and angle lugs for stabilizing
the excavation.
Rawlbolts for fixing onto the floor.
Struts for fixing the bucket elevator
head onto the blasting room wall.
Cover plate for the pit.
Cables
Earthing
Earthing cable
Comments
- Pins for fixing the foot.
+ Type and size: adapt to the
floor conditions
+ Typical dimensions:M10 x 80
mm
M8 is recommended.
10 sq.mm. min. is recommended.
Requirements for the installation´s electrical control unit and earthing
The bucket elevator must be connected to the complete system. The following connecting sequence is
recommended.
Switching on
1. Dust filter
2. Blasting material cleaner
3. Bucket elevator
Switching off
1.Bucket elevator
2. Blasting material cleaner
3. Dust filter
- Essential measures for protecting and laying the cables and hoses must be taken on site by the
buyer or operator and adapted to the locally essential safety requirements.
-See to it when connecting the motor that the matter concerns a braking motor. ==> Follow the
wiring diagram ==> separate operating instructions for the motor.
3.4
Installing, mounting and the functional test
Prepare the
foundations
(customer/ general
building contractor)
Figure 6
- Level and right-angled. Divergences of ± 3.0mm maximum.
- Upper edge fitted with a 50mm sq. x 5mm angle profile (by means of anchoring
9
Mounting work on the
foot; casing parts
lugs).
- Profiles are not part of the extent of supply.
- Put the bucket elevator in the pit (outside the blasting room
Figure 7, Area II).
- Put the hopper (1m. sq.) in the blasting room (Figure 7, Area I) in the pit.
- Align the hopper and the bucket elevator foot (height and plumb line). Adjust the
height if necessary (e.g., underlay shims).
- Fasten the bucket elevator foot with 4 rawlbolts.
- Lay the sieve (Figure 2, Item 6) and grating (Figure 2, Item 7) in the hopper.
I
II
Figure 7
Risk of injury
Secure the components against tipping
over.
Mount the central part
- Screw the central part(s) to the foot part (10 units of M10 x 30mm). Do not
forget the seal!
- Note the ‘sight opening’ position.
Risk of injury
Secure the components against tipping
over.
Mount the head part
- Lower the upper tensioning roller - Turn the tensioning screws
downwards completely on both sides.
10
Figure 9
Figure 8
- Fasten the head part onto the central part (M10 x 30mm bolts). Do not forget the
sealing!
- Fasten the bucket elevator to struts (not in the extent of supply) in the blasting
room.
Risk of injury
Ensure that nobody is working on the
bucket elevator before switching it on.
Switch off the installation electrically
before starting work.
- By means of an authorized skilled worker.
- Wiring diagram: refer to the ‘motor’ installation. Caution: three-phase motor with
integrated brake.
- Inspect the direction of rotation.
Feed in the belt and test Sub-section 4.4.1.
the running
Electric motor
connection
Make connections with
the complete
installation´s other
components
- Follow the other operating instructions.
Filling the system with
blasting material
- The entire system must run, i.e.,
- Angle of the bucket elevator´s outlet: 45° min. inlet cleaner.
- conveyor base if necessary,
- bucket elevator,
- cleaner,
- filtering installation,
- fill blasting material into the conveyor floor or hopper
11
Dosing of the blasting
material
.
closed
open
Figure 10
4 Operating instructions
Starting up and operation; putting out of operation after finishing work
Switching on
Within the framework of the complete system
- Switch on the power supply.
Switching off
Within the framework of the complete system
- Switch off the power supply.
4.1
EMERGENCY OFF
Press the EMERGENCY
OFF push-button switch
4.2
Within the framework of the complete system
- Interrupt the power supply; bucket elevator is inactive.
Putting out of operation for a long interruption of work or conversion of
the installation
Emptying
Switching off
Run the bucket elevator empty; incline the blasting material if it
becomes lumpy
- Close the blasting material dosing completely (Figure 10).
- Run the buckets empty ( allow the buckets to turn for 2 rounds
min.)
Within the framework of the complete system
- Switch off the power supply.
12
4.3
4.3.1
Special working steps
Mounting the belt
(A) Installing a belt
-2 persons.
- Aids: rope with a minimum length of 3m plus twice the bucket
elevator´s height.
Risk of injury
Ensure that nobody is working
on the bucket elevator before
switching it on. Switch off the
installation electrically before
starting work.
Inspection
Are all buckets fixed onto the belt?
Put the rope into position.
- Allow the rope above the upper roller to hang down on both sides
(Figure A).
- Pull through one end of the rope under the lower deflection roller.
- Pull both ends of the rope from the sight window into the central part.
A
B
C.
Figure 11
Fasten the belt onto the rope -Note the direction of rotation! (Figures A and B)
Pull and guide the belt into
the bucket elevator
- Person above: ensure that the rope and then the belt are lying on the
upper drive roller.
- Person above: feed in the belt through the opening and
simultaneously hold the other end of the rope taut, so that the belt
does not slip off.
13
- Allow the belt to move downwards slowly, so that it does not get stuck
or twisted.
- Pull both ends through the sight window.
Connect the belt
Figure 12
1. Belt.
2. Radii of the connecting plates.
3. Upper connecting plate.
4. Lower connecting plate plus 3 M10 x 60 mm screws
Risk of injury
Ensure that nobody is working on
the bucket elevator before
switching it on. Switch off the
installation electrically before
starting work.
Switch on the power supply
Adjust the belt tension
Figure 11C: tighten the screws on the bucket elevator head.
Pre-tensioning
Person above : retighten the screws (Figure 17 / Item 27) on both sides
of the head.
Person below: check the belt tension. It is correct if it can be pressed
together
by hand to between 40mm (1½“) and 50mm (2“).
Check whether the belt runs
well
Check the re-tensioning of
the belt and the belt tension
Figure 13
- One person observes the belt running.
- Another person continuously touches the motor switch only lightly
move the belt in increments of 50cm.
- Constant slight re-tensioning while the bucket elevator is running. The
belt will centre itself during the running.
- Check the belt tension at a standstill.
-Repeat until it does not have to be re-tensioned any more.
Mount all of the cover plates! - Covers on the head.
- Sight window on the central part.
- Covers on the base.
Test run without blasting
material
- 8 hours approx.
- Subsequently check the belt tension and the running again.
14
4.3.2 Removing a worn belt
- The belt is worn if:
+ wear is visible on the material,
+ cracks are visible in the material,
+ on account of the rubber ageing after 6 years max.,
- 2 persons are essential,
- Aid: rope with a minimum length of 3m plus twice the bucket elevator´s height.
Working steps
(1) Create freedom for
mounting
Move the belt until the
connecting point is visible
Slacken the belt
Feed in the rope through the
opening in the central part
and fasten it onto the belt
A second person will be
needed from now on!
Loosen the screwed belt
connection
Pull back the belt
Advice
- Close the blasting material dosing completely (Figure 10).
- Run the buckets empty (allow the buckets to turn for 2 rounds
min.).
- Dismantle the covers on the head part.
- Dismantle the sight window on the central part.
Risk of injury
Ensure that nobody is working
on the bucket elevator before
switching it on. Switch off the
installation electrically before
starting work.
- Loosen the tensioning screws on the head (Figure 17 / Item 27)
- Fasten the rope underneath the connecting point.
- Make the rope taut so that the belt cannot fall in the foot part.
- Ladder or scaffold.
- Join the person at the cover opening on the head part!
Through the opening in the central or foot part.
- The person above guides the belt over the roller, so that the belt and
the rope cannot slip down.
- The person underneath releases the rope gradually and
simultaneously pulls the belt coming from above out of the opening.
4.3.3 Mounting the head for repair work
Working steps
Mount the height adjustment
Instructions
See Figure 14 A-C
- Screw the angle plates (46) with bolts ( 27) and nuts (49).
- Screw the bearing (51) to the spacer plate (47) and the guide plate
(48).
- Put the shaft (11) through the bearing and adjust it with bolts (27)
and nuts (49) horizontally.
- Pull out the shaft (27) partly again, put the wheel (100) on the shaft
and put it through the bearing again.
-The spring must be in the shaft nut when it is put onto the wheel.
- Fix the wheel centrally with the screw.
- Screw the bearing´s fixing disc to the shaft.
15
49
46
48
1
27
47
100
11
101
51
Figure 14 A
Figure 14 C
Mount the motor
Fix the torque support
101
- Screw the geared motor (1) onto the torque converter bearing (101).
- Push both onto the shaft.
Normally pre-assembled.
- Put the 16 mm dia. bolts through the hole in the torque converter
bearing (101) and weld it to the angle plate (14).
- Do not weld on the torque converter bearing.
W Maintenance and cleaning
16
5 Servicing, maintenance and cleaning
5.1
Generally
Blasting devices are subjected to heavy wear. Safety and high efficiency will only be ensured with
regular servicing.
5.2
After 8 operating hours max.
- Belt tension
- Visual inspection of the belt
- Sieve hopper
-Blasting material
5.3
Correct, if
- the belt can be pressed together by hand to between 40 mm
and
50 mm (1½“ to 2“).
Figure 15
- for wear.
- remove soiling (contamination).
- refill if necessary,
- during the first ½ year of increased consumption of the
blasting
Material.
After 40 operating hours max.
No special measures.
5.4
After 150 operating hours max.
No special measures.
5.5
After 1,000 operating hours max.
Lubricate the bearing (motor
shaft)
5.6
with neutral, non-corrosive mineral grease.
After 20,000 operating hours max.
Change the grease in the geared
motor
see the ‘motor’ operating instructions.
17
6 Faults and remedying them
Description of the
fault
Possible causes
Remedy
Blasting material is not
being conveyed
- Belt slip.
-Tension the belt
- Loose buckets get stuck.
- Fix the buckets or replace them
if necessary
- Replace the belt: 4.4.2 and
4.4.1
- Seek and remove.
- Cracked belt.
The bucket elevator
makes too much noise
when running
Hopper runs over
- Foreign bodies in the bucket elevator
foot.
- Buckets are only fastened onto the
loosely.
- Belt tension.
- Belt does not keep in track.
- Fix the buckets.
- A worn bearing.
Blasting material gets lumpy.
Soiling in the sieve (hopper).
- replace
remove
remove
4.4.1
- Tension the belt 4.4.1
- Worn deflection roller or driving
pulley
replace
7 Permissible modifications
Only with the manufacturer´s approval!
18
Page 19 of 27
8 Spare parts list
Description
Item
no.
Bucket elevator head, complete
Drive shaft for 0.75kW
Drive shaft for 1.5kW motor
11
Drive shaft for 2.2kW motor
Geared motor, 0.75kW
Geared motor, 1.5kW
7
Geared motor, 2.2kW
Profile seal, double
Torque converter bearing for Cyclo Drive Standard RNYM1-1320B20/F80M/4B
Bolt, M10 x 140mm (fastening the motor to the torque converter bearing)
Bearing (30mm dia.)
Top lagged pulley, 6” x 4”
Suction tube, rubber, 4”
Clip, 4” (connecting the bucket elevator to the blasting material cleaner)
Bucket elevator foot, complete
Shaft, 12 1/2“ (l = 320mm, 30mm dia.)
Bearing (30mm)
Wing pulley foot, 8” x 6”
Flange seal (between head, central part and foot)
Rubber plate, 3mm (for all seals)
Standstill detector, A300 (option)
Quantity
1 unit
1 unit
1 unit
1 unit
Article no.
for bucket elevator length mm
Up to 7,000
7,050 to
8,550 to
8,500
11,000
100850
*1)
*1)
20232I
*1)
*1)
*1)
JH080015-3-22
*1)
100831
*1)
JH080015-3-5
*1)
100832
100832
100832
without
-
-
1 unit
2m
1 unit
8
4 unit
2 unit
100854
06057D
06057D
06057D
9
12
13
1 unit
per m.
2 unit
1 unit
1 unit
2 unit
1 unit
2 unit
per lin. m.
1 unit
06386I
04010D
11576Z
100852
06409D
06057D
06385I
*1)
90143D
99540D
06386I
04010D
11576Z
100852
06409D
06057D
06385I
*1)
90143D
99540D
06386I
04010D
11576Z
100852
06409D
06057D
06385I
*1)
90143D
99540D
19
8
20
30
19
Page 20 of 27
Hopper, 3 x 3 (1m. sq.) complete
Sieve for hopper, 3 x 3
Grating for hopper, 3 x 3
Anchoring strut (RH), right
Anchoring strut (LH), left
Cover plate, 15 x 21.12“
Cover plate 13.75 x 39.5
Belt, complete with standard bucket, length: 12m
Splice-bucket elevator belt
Bucket (plastic)
Crown gear
Nuts and bolts
Bucket belt lock
Bucket belt without buckets
Shim, 6mm
Miscellaneous /options
Earthing bolt, M8
Earthing cable, 10 sq. mm.
22
1 unit
1 unit
1 unit
1 unit
1 unit
2 unit
2 unit
1 unit
1 unit /belt
6 unit per m
72 unit*2)
12 unit per m
144 unit*2)
12 unit per m
144 unit*2)
1 unit/belt
Per m
12 unit per m
144 unit*2)
per unit
Per m
05850I
05856I
06452I
05853I
05855I
06476I
06451I
06436D
21804I
06486I
05850I
05856I
06452I
05853I
05855I
06476I
06451I
05850I
05856I
06452I
05853I
05855I
06476I
06451I
21804I
06486I
21804I
06486I
03118I
03118I
03118I
03119I
03119I
03119I
06418I
06414D
90674D
06418I
06414D
90674D
06418I
06414D
90674D
100732
100769
100732
100769
100732
100769
*1) Special order, non-standard parts
*2) for a belt with a standard length of 12m
20
Page 21 of 27
Figure 16 : drawing for the spare parts list
21
Page 22 of 27
Figure 17
Drawing for the spare parts list
Figure 18 – Standstill detector– Bucket elevator foot
22
Page 23 of 27
9 Appendices
Installing and operating instructions for 0.75 kW, 1.5 kW and 2.2 kW motors
23
Page 24 of 27
24
Page 25 of 27
25
Page 26 of 27
26
Page 27 of 27
Cycle series
Information about motors
Mechanical features
Mechanical features
Protective system
The motors are completely sealed and air-cooled. The standard protective system is IP55 with IP44 brake.
Further details are given in the table below.
Please contact SUMITOMO CYCLO EUROPE for further queries.
st
st
1
number
Protection against contact and foreign bodies
1
number
Protection against water.
0
No special protection
0
No special protection.
1
Protection against penetration of hard foreign
bodies of more than 50 mm dia.
1
Protection against vertically dripping water.
2
Protection against penetration of hard foreign
bodies of more than 12 mm dia.
2
Protection against vertically dripping water;
operating material tipped up to 15°.
3
Protection against penetration of hard foreign
bodies of more than 2.5 mm dia.
3
Protection against sprayed water up to an
angle of 60° from vertical.
4
Protection against penetration of hard foreign
bodies of more than 1 mm dia.
4
Protection against sprayed water from all
directions.
5
Protection against harmful dust deposits
(dust-protected).
Complete
touching
protection.
5
Protection against sprayed water from all
directions.
6
Protection against harmful dust deposits
(dust-protected).
Complete
touching
protection.
6
Protection against strong water spray or
heavy sea.
7
Protection against water with immersion of
the blasting material under conditions of
pressure and time.
8
Protection against water with continuous
immersion of the blasting material in water.
Motors for vertically installed position
Geared motors that will be installed with the drive* shaft downwards should have a protective cowl for the motor.
Standstill heating system
Motors with coils that are exposed to the risk of dew (i.e., condensation) on account of humid surroundings or
strong temperature fluctuations, can be equipped with a standstill heating system. The standstill heating system is
not allowed to be switched on during the operation.
Vibration severity
The rotors of the motors are designed and constructed according to the vibration severity and by complying with
IEC 34. The dynamic kinetic energy takes place according to DIN ISO 1940 T1, quality stage G 2.5.
SUMITOMO CYCLO EUROPE
Cyclo series
357
* “Abtriebswelle” statt “Antriebswelle” im Ausgangstext
27