CSU-Manual & DWG in Last Pages - Coal Sampling Unit

ADVANCED
SYST EM S
6x150 MW CAPTIVE POWER PLANT,
LAPANGA, ORISSA
Client: Thyssenkrupp Industries Pvt. Ltd
OPERATION CUM
MAINTENANCE MANUAL
ADVANCED SYSTEMS SAMPLING PVT. LTD.

BUSINESS TOWER, BLOCK-6A, 206 A. J. C. BOSE ROAD, CALCUTTA – 700 017
PHONE: (33) 229 02360/61 ; FAX: (33) 229 00943 ; Email: info@sampling.co.in

OPERATING AND MAINTENANCE
MANUAL

Advanced Systems Sampling. Pvt. Ltd. Continuation sheet ……2 of 101
1. ORDER INFORMATION
CLIENT: Thyssenkrupp Industries Pvt. Ltd
END USER: Hindalco Industries Limited
JOB NUMBER: 159
CLIENT ORDER NUMBER: 2500003533 dtd. 18.01.2011

1.1. This Manual is important because:

 It contains all the information needed to make an inquiry about the sampler.
 It shows all the parts of the sampler.
 It provides clear instructions explaining how to:
 store the sampler,
 install the sampler,
 get the sampler up and running,
 operate, maintain and troubleshoot the sampler.
 It shows you how to get the most out of the sampler.

 It contains safety cautions as well as operational tips.
1.1.1 Using this section of the Manual

Each of the instructions is written in a clear action based way. This means that you merely
have to read the actions and follow them. Diagrams have been used to illustrate the more
complex steps and so assist the relevant staff.

2.2. SALIENT FEATURE:

 The sampling swing arm and cutter can be inspected through Inspection
door at the side of the hood.
 The electric drive is modular and mounted on the frame by torque arm.
 The rubber scraper are all easily replaceable.
 The rubber scraper at the rear of cutter ensure that a complete sample,
including fines, is taken. The material is discharged via gravity through the
chute-work.
 The cutter crosses the material flow just above the surface of the belt (
5mm) providing an exact cross-section of material. This lower limit of the
cutter prevents it from touching the conveyor belt.
 The volume of the cutter is designed to correspond to the maximum belt
loading. This ensures that a complete cross-section of material is taken
without sample material piling up in front of the inlet slot.
 The drive shaft of the sampler with the swing arm cutter is connected to a
gear brake motor, which is activated by a timer.
 The unit minimizes spillage when taking cuts. The cutter assembly is made
from SS-304 Grade.
 Adjustable rubber skirts are located on either side of the mounting frame
and are designed to contain any turbulence and consequent spillage, which
may result during the sampling action.
2.3. Description of the Major Components of

the Sampler
2.3.1. The Control Panel:

A PLC based control panel controls the operation of the sampler; it is a very important
component. Details of same are furnished subsequently.
2.3.2. The Housing:

The main components of the housing are:
2.3.2.1. the top cover for the sampling arm and cutter.
2.3.2.2. the dust cover to minimize pollution and spillage during the sampling
action.
2.3.2.3. the mounting position for the sensor proximity switch.
2.3.2.4. the sample discharge chute work.

Inspection covers are located on the housing for inspection and maintenance of the
rubber scraper and nylon brush. This is done when the cutter is in the ‘parked’ position.
2.3.3. The Mounting Frame:

The frame is usually mounted onto the existing conveyor stringers. Please ensure that the
conveyor structure is sound. If required, extra post are to be provided below stringer to
avoid buckling of stringer.
The frame is supplied with a number of packing plates of various thickness. This is for
final adjustment purposes prior to commissioning. This will ensure that the sampling
swing arm (without rubber) passes between 5-10mm from the conveyor when sampling.
2.4.4. The Motor and Gearbox:

The size of the motor and gearbox is designed to the requirements of each specific
application. The motor is of the squirrel cage type. The geared motors are supplied with
a built-in, spring applied, electrical release brake on the rear of the motor. The air gap on
the brake is factory set. The brake will keep the swing arm in the parked position between
8 o’clock and 11 o’clock. This ensures that the swing arm is kept out of the stream on the
conveyor belt.
During the sampling action, the motor is energized via an PLC operated timer. The motor
is switched off only once the sensor plate has passed the proximity switch.
2.4.5. The Sampling Arm:

The major components of the sampling swing arm are the:
2.4.5.1. The arm extension:
The arm is manufactured from stainless steel and its length is dependent
on the belt width; the trough angle; the number of idlers and their length.
2.4.5.2. The swing arm with cutter:
The cutter blades are chamfered on their leading edges to ensure that a
clean cut is taken through the material flow. The blades are manufactured
from abrasion-resistant (304) stainless steel.
2.4.5.3. The rubber scraper and/or nylon brush:
The rubber scraper and/or nylon brush are mounted on a sliding block at
the rear end of the cutter. It is important that they are set at the correct
level to ensure that all fines are removed from the belt.

2.4.5.4. The proximity sensor and proximity sensor shield:
Motor runs from start and is de-energized by proxy. It is important that the
hammer sampler and the conveyor belt are inter-locked to ensure a fail-
safe system. This should be taken into account if operated via a PLC.
The inductive sensor or proximity is mounted on a bracket in line with the

energizing plates at the 9 o’clock position.
The correct position of the hammer sampler head with cutter is dependent
on the inductive sensor shield. The shield is mounted on the shaft. The
park position of the swing arm depends on the setting of the shields and
loading on the belt.

2.5. The functioning of the Sampler:

The diagram below shows:
 the action of the sampling arm and cutter moving across the material on the
conveyor belt;
 the movement of the sample from the cutter into the hammer discharge chute.
Process
stream
Sampling
swing arm
Discharge chute
Sample container
Cross Section through the Hammer Sampler showing process flow

3. Transport and store the Sampler
Introduction This section of the manual deals with:
1. How to lift the sampler off the truck
2. How to store the sampler
Importance of The sampler can be damaged during this stage. By following
this stage the easily understandable instructions in this section, you will
ensure that it is not damaged.

3.1. Steps to follow to store the Sampler

STEP ACTION
3.1.1. Lift sampler off truck using a Lift sampler off truck using a forklift
1 forklift.
Samplers are top-heavy; so ensure that the
unit is firmly attached to the pallet or crate
before attempting to lift it.
It is advisable to use a forklift for smaller units,

but a crane is required for larger units.
Position the truck as close to the storage site
as possible before off-loading.
2 3.1.2. Store in an upright position.

Store in a upright position
The unit must be stored in an upright position
to prevent damage while storing.
Always store in a dry and level area (preferably

indoors) to prevent damage to the unit and the
paintwork.
This diagram shows the correct storage

position of the sampler.
3 3.1.3. Store control panel

Store the control panel in a dry and dust-free place – and indoors.

4. Install the Sampler
Introduction This section of the manual demonstrates how to:
1. Select the point of installation
2. Transport the sampler to the installation site
3. Unpack the sampler
4. Prepare the point of installation
5. Lift the sampler into position
6. Prepare support connections
7. Bolt the sampler into position
8. Set the wipers / brush
9. Mount the control panel
10. Identify the cables required
11. Connect cables to the motors and proxy switches
12. Connect cables to the control panel.
13. Install auxiliary equipment
Importance of If this stage is not correctly completed, problems such as,
this stage damage to the unit, inaccessibility to critical parts of the unit,
poor ergonomics, inefficient operation, etc. will result.

4.1. Steps to follow to install the Sampler

STEP ACTION
1 Important notes on selecting the point of installation of the

hammer sampler:
Confirm the adequacy of the structure to support the hammer-sampler

loads. The static and dynamic loads must be considered. The dynamic
load has a vertical and horizontal component.
Larger samplers for 1200mm and wider conveyors may need to be

supported by civil plinths on either side of the conveyor. Cross bracing
of the conveyor support steelwork is not always adequate to handle the
static and dynamic loading during the sampling action.
Do not install the hammer sampler at a transition point between a

horizontal or inclined section of a conveyor. In most cases the belt lifts
off the idlers under no-load conditions at these points and will cause the
cutter to become fouled.
The hammer sampler must be installed at a point where the conveyor

belt always touches the idlers. This is because the conveyor/idler set
combination is instrumental in creating a circular radius of curvature for
the swing arm to follow across the belt while operating.
Do not install a curved former or belt support plate below the conveyor
under the samplers. This can cause belt damage when sampling.
Steps to follow to install the Sampler cont.

Step 1 The correct idler toughing must be provided. The idler frames must be
continue changed if the existing troughing angle does not conform to the profile
on the GA.
The quantity of idlers must be correct. Conveyors 1200mm and wider

should have 5 idler frames to have better profile and thus sampling.
The idlers must be immediately adjacent to the sampler housing. Idlers

should not be placed under the cutter; this will destroy the idlers and
cause belt damage.
If the idlers are placed too far from the cutter, the belt will deflect during
operation causing loss of sampler. Inaccurate samples will be taken.
Ensure that the sampler can be easily accessed once in position. This is
important for maintenance purposes.
Allow sufficient room during installation to allow easy access to

inspection covers for checking and maintaining the rubber scraper and
nylon brush.
The belt line as given on the GA must be provided. The equipment is

designed to a specific belt line and troughing angle.
Transport the sampler to planned installation site

2
Plan the transportation route so that equipment is not damaged whilst in
transit.
Check that the installation site allows free access to the geared motor
and inspection hatch once installed. This will be needed for
maintenance purposes and for routine operational checks.


3 Prepare the conveyor where the sampler will be installed:
- Remove or re-route all cable racking, pipe work or steel

structures, which may hinder the installation and accessibility of
the sampler.
- Identify correct sampler i.e. right hand or left hand discharge type
as per system GA drawing.
- Confirm that the following aspect of the conveyor at the point of

installation conforms to the dimensions given on the sampler GA
in the appendix.
 Belt line.
 Position of idlers under the sampler.
 Idler toughing angle.
 Idler frame type and quantity of idlers.
4 Lift the sampler into position using

Lift the sampler into position
a crane:
- Remove the bottom chute from both

sides with rubber seals where the
conveyor passes through the
housing.
- Clear any obstructions at the height of
the final sampler position.
- Insert four “D” shackles onto the four
corners of the frame. Attach slings.
- Hoist the sampler to the required
height and lower to the mounting
position.
- Maneuver into position.
Ensure that the slings are securely

attached before hoisting the unit up.

Steps to follow to install the Sampler cont
Prepare sampler support connections – mark and drill
5 Ensure that drive shaft is centralized over conveyor belt.

Ensure that drive shaft is parallel to conveyor belt in both
horizontal and vertical planes.
It is very important that the hammer axis of rotation is central and

parallel to the belt at the point of sampling.
Mark holes of sampler foot plates on stringer and support.

Move sampler and drill holes in stringer/support. Holes to be
the same size as in footplates.
The sampler frame with its four legs usually mounted onto existing
conveyor stringers.
The spacers, as required, must be placed under the legs to ensure a

maximum gap of 5 – 10mm between swing arm extremity and the
conveyor belt while the unit is sampling.
Bolt the sampler into position by

6 doing the following: Placing the packers
Align the sampler feet boltholes with the

conveyor stringer boltholes or the
grouted bolts in civil work for larger
units.
Manually release motor brake to lower

hammer head over belt.
Place the packers under the legs to
ensure a maximum gap of 5 –
10mm between the swing arm and
the conveyor belt on up and down
streamside of the hammer hood.

- Bolt sampler legs securely to conveyor stringers or plinths.

Step 6 Re-install the side bottom chutes on both sides with 4 off rubber
continue seals on the housing. Cut the seal according to the belt height
and depth. The position of the cut must be measured from the
seal locators to the belt.
- Bolt hammer discharge chute flange to discharge chute work (if
required).
- Insert a transition chute between discharge chute and belt feeder.
Note: the discharge chute can be extended to direct the sample to

where it is required.
The rubber scraper and nylon brush will brush across the surface of the
belt, ensuring that all fines are taken as part of the sample. Adding or
removing the packers can result in precise adjustments to the height of
the sampler.
Set the Wiper blades

7
The wiper blades or brush must protrude the hammer head with
approximated 10mm.
The different layers of the rubber wiper are. With 2mm each. This will
provide a multiple cleaning action.
Do not over extend the rubber wiper. This will cause high wiper wear
and loss of sample.


10 Connect cables to the PLC based
control panel Refer to manual
Follow the wiring diagram contained in the

Appendix for Local relay panel and PLC
panel.
- These cables will be terminated in the
panel:
1. The main supply cable;
2. The motor cable;
3. The proximity sensor wiring;
4. The brake switch cable if required
- Remove bottom cover of MCC & PLC
control panel.
- Make a hole in the bottom plate of the
control panel for each wire that is to be
fitted.
- Prepare cables and fit cable glands.
- Fasten the cable gland securely to the
bottom plate.
- Terminate appropriate cable wires into the
correct terminal positions as indicated in the
wiring diagram.
THE INSTALLATION OF THE SAMPLER IS COMPLETE

5. THE CONTROL PHILOSOPHY OF

THE HAMMER SAMPLER
Introduction This section of the manual explains the control philosophy
of the hard wired circuit and PLC operation. It is important
to distinguish between these and their compatibility if and
when required.
Importance of If the sampler is not correctly installed and controlled, it can
this stage result in wind milling, multiple samples being taken, damage
to the conveyor and sampler.

5.1. Power & Control

The hammer sample is to be controlled via a local dedicated PLC panel and local
relay panel. It is important that the below mentioned control philosophy is applied. If
not, it can result in wind milling, multiple cuts, sticking in the stream and damage to
the sampler and conveyor.
In general, the control of the sampler is quite fast, 1-2 seconds per operation. It was
found that PLC cycle times and responses is sometimes too slow to control the
sampler. It is strongly recommended that the PLC suitability to manage the below
mentioned control philosophy is checked.
5.2. Auto and Manual Modes of Operation

When controlled from a remote MCC and PLC, the sampler can be operated in Auto
or Manual mode.
MANUAL: The individual equipment are operated by individual start / stop command.
AUTO: The PLC timer generates a signal to operate the samplers.
The detailed control write up is provided alongwith PLC part of the manual.
5.3. Operation and Function of Components

The sampler consists of a scoop or hammer driven by a geared motor with an
electromechanical brake. The motor is started direct on line and the brake is powered
from the motor contactor via an ancillary contact.
A single normally open proximity switch with adjustable shield indicates the hammer
position. An LED light on the proximity sensor indicates that the shield is detected and
that the proximity switch is operating.

5.4. Control Philosophy

The hammer is parked between the 8-11 o’clock position. The position is a function of
belt loading, hammer speed and proximity shield position.
The brake keeps the hammer from falling back into the stream.
Control philosophy diagram
In the park position, the proximity switch senses the shield and is activated. Upon
receiving a signal to operate, manual or auto, the motor is energized. The brake
connected to the motor is released and the hammer is rotated. The motor remains
energized until the hammer passes through the stream to the 8 o’clock position. At the
8 o’clock position, the shield moves before the proximity switch and the proximity
switch is activated. The activation of the proximity switch de-energizes the motor.
Due to the momentum on the system, the hammer will continue to travel to the “park”
position (before 11 o’clock).
If the hammer moves beyond the 11 o’clock position, the proximity switch will be
deactivated and the motor energized to rotate the hammer to the 8 o’clock position.
The motor will always be energized if the proximity switch is de-activated or damaged.
This phenomenon is called wind milling of the sampler.
Wind milling can also be caused by excessive gap between the proximity and the
shield. Depending on the speed of the sampler and the type of brake installed, the
brake might be too slow to stop the hammer before the 11 o’clock position. In such
cases the sampler will windmill. The link on the brake rectifier must then be connected
to a potential free normally open contact on the contactor.

6. DO COLD COMMISSIONING
Introduction This section of the manual explains how to:
1. Check the oil level
2. Check electrical connections
3. Set overload protection
4. Turn on mains power to sampler panel
5. Turn on isolator switch on control panel
6. Set to manual mode of operation
7. Rotate swing arm
8. Change direction of motor if necessary
9. Rotate sampling arm
10. Set sample frequency
11. Fit belt interlock
12. Check that the control panel works in auto
Importance of Once the sampler has been installed you are ready to begin the start-
up process. The first stage of the start-up process is doing a cold

this stage
commissioning. Once this stage is correctly completed, the second
stage of the start-up can begin - doing a hot commissioning. During
the cold commissioning stage the wiring and mechanical functioning
and settings of the sampler are checked without material on the
conveyor. During the hot commissioning stage samples are taken
from the conveyor.
6.1. Steps to follow to do Cold Commissioning

STEP ACTION

1 Check the oil level according to section of the geared motor manual
appendix
This is a very important step and must always be performed.
As standard practice gear boxes are dispatched without oil. It must be filled in
accordance to Geared Motor manual.
Make sure the vent plug is open.
Check electrical connections

2
- Open control panel with panel key supplied.
- Ensure that all wires are securely fastened to terminal strips, motor connections,
proximity, and control panel.
- Check that all the cable glands are fitted and securely fastened to the bottom of
the control panel.
- Tighten if loose. This will prevent hot connections.
- Check that all connections are connected to the correct numbers as indicated on
the control panel circuit diagram (incoming power cable, motor power cable,
and proximity cable).
Set the overload protection

3
Check that the motor overload is set to the amperage indicated the motor
nameplate.

Steps to follow to do Cold Commissioning cont.
Turn on mains power to sampler panel

4
Do this at the isolator switch at the MCC, which feeds power to the sampler motor.
Turn on isolator switch on control panel in a clockwise direction

5
This step supplies electrical power
Set to manual mode of operation from PLC Panel
6 Switching to manual mode allows the sampler to be run using only the manual
button on the control panel HMI.
Rotate swing arm of the sampler by pressing the manual sample button.
7
This step ensures that the arm is able to move freely inside the housing.
The hammer will now do a full rotation and park again in its original position. It
may windmill once or twice, as there is no feed on the belt. The 'park' position of
the sampling arm is pre-set in the workshop during assembly. Do not make any
adjustments at this stage. If adjustments need to be made they can be done during
the hot commissioning stage.
It is important that the motor direction is correct, as the swing arm must throw
material towards the discharge chute. If the swing arm rotates backwards and/or
remains motionless on the conveyor belt while the motor is running, the direction of
the motor is incorrect. In this case change its direction by swapping two of the
phases on the motor.

Change direction of the motor if incorrect

8 by doing the following: Figure 21 Change direction
- Switch off power coming into the control panel

by means of the main isolator.
- Switch off isolator on front of control panel.
- Unscrew two wires feeding the motor at the
terminal block.
- Swap the U1 and V1 wires.
- Refit the wires.
Rotate sampling arm inside the housing several times

9
Press the manual sample button to rotate the hammer swing arm. The arm
might ‘windmill’ once or twice as there is no material on the conveyor or
because the conveyor is standing.
Note that a conveyor interlock might be in place.
If the sampler receives a signal from a weight meter to sample and not from
a timer, then the sampler might not be able to sample repeatedly. If the
sampler frequency is time-based the hammer will operate repeatedly when
the Manual button is pushed.

Set the sample frequency using the PLC based timer.
10 With remote PLC control the PLC variable must be set to the required time.
Fit the belt interlock

11
A relay contact is included in the PLC panel to provide the client with the
facility to stop the conveyor belt when the sampling arm is stuck in the
stream.
The belt interlock is usually a closed relay connection with a timer. The relay
will switch to open when it operates to stop the belt.
With remote PLC control, the belt interlock timer must be set on the PLC.
Check that the control panel is working in auto:

12
- Turn on the isolator
- Switch to auto on front of control panel
- Check that the arm moves across the housing once a signal is received
from the timer (time-based) or from a belt weight meter (mass-based).
This step checks that the sampler is operating in auto as well as manual.
COLD COMMISSIONING IS COMPLETE

7. DO HOT COMMISSIONING
1. Start the conveyor belt
2. Start the succeeding equipment
3. Switch sampler to manual setting
4. Take a sample
5. Check the parked position of the sampling arm
6. Set the proximity sensor shields
7. Measure sample mass
8. Calculate sample frequency
9. Set PLC timer
10. Check sample requirements
11. Empty container
Importance of This stage can only be started once the cold commissioning
this stage stage has been completed.
In order for the sampler to operate, this stage must be
completed correctly. Ensure that each of the steps listed
above is followed in the correct order.

7.1. Steps to follow to do Hot Commissioning

STEP ACTION
1 Start conveyor belt
DO NOT start this process until the sampler has been cold commissioned.
The client must start the conveyor belt.
Check for spillage indicating that the rubber skirts need to be adjusted.
Moving the rubber skirts closer to the conveyor can prevent spillage.
Place sample container under sample

2 collector
3 Switch sampler to manual setting
Ensure that the conveyor belt is loaded to the

normal operation of the conveyor belt. By
setting the sampler to manual, a sample can be
taken manually from PLC HMI.

Steps to follow to do Hot Commissioning cont.
4 Take a sample by pressing manual sample button
- Check for spillage.

- Switch off conveyor.
- Reset rubber skirts where required.
Check the parked position of the sampling

5 arm Position of arm check
This step is done to check that the arm moves

smoothly and parks in the correct position. The
sampling arm should stop in the parked
position between 8 o’clock and 11 o’clock
depending on belt loading at the time.
The arm needs to be adjusted at site to take

care of any misalignment during transportation /
storage / erection.
If the parked position is correct, do NOT alter the settings as described in step 6.
Instead go to step 7.

Set the proximity sensor shields Sampling arm rotation

6
- Move the shield in the opposite
direction of rotation for earlier
stopping of the motor.
- Increase the “width” of the shield
to increase park area.
ENSURE THAT THE HAMMER IS SWITCHED

OFF AND CLOCKED OUT BEFORE SETTING
ARE MADE
The main purpose of the sensor

shields is to stop the motor and adjust
the park position.
Ensure that the proximity switch is set to detect the proximity

shield only and nothing else - for example, the swing arm.
As the proximity switch or sensor only detects distances that are
less than 10mm, ensure that the distance from the proximity
switch to the shield is less than 10mm. Adjust if necessary.
Check that the motor is always on when the proximity sensor
senses the shield. A red light will come on when the proximity
detects the shield.
Check that the motor switches off when the shield passes the
proximity.
If the swing arm has a wind milling effect, the proximity shield
must be adjusted in the same direction as the hammer rotation.
This action will ensure that the motor switches off earlier and that
the swing arm stops quicker. The swing arm should stop
anywhere between 8 and 11 o’clock.

Measure mass of sample taken by doing the following:
7 Empty sample into a measuring bag and weigh it using a scale.
This step will confirm how often samples need to be taken, as well as the final
sample size.
Calculate sample frequency by doing the Final sample mass (kg)

8 following calculation:
Required per 8 hrs =
The client will know how large a sample they
need for analytical purposes. In order to obtain
the correct amount of material the sampler will
Sample increment
be set to take a sample at specified intervals at size (kg) obtained x
frequencies recommended by relevant sample frequency /
standards. shift
EXAMPLE: If a sample increment of 5 kg
was obtained in step 8, and the client
requires a sample of 80 kg per shift or eight
hours, then the sampler can readily be set to
take a sample cut every 30 minutes.

Set Sample timer through PLC control

9 panel software to the sampling frequency
calculated
- Isolate the panel.
- Set timer in PLC if remote controlled.
The timer must be accurately set, otherwise the

sample size will be incorrect, e.g. frequencies
of 15 - 20 minutes for sampling is
recommended as a minimum.

Check that sample requirements are met over an extended period

10 (preferably 24 hours)
- Check that the size of the sample is correct at the end of each day.
- Empty final sample into bags to check mass of material. Use laboratory
scales to do this.
If time-based sampling is used, expect variations in sample increment size

over the course of a day. This is caused by fluctuations in the plant
throughput and can affect the daily final sample size.
Remove sample after each shift or at the end of each day, and replace
11 with an empty container.
Collect final samples in bags. This prevents contamination and moisture loss
while transporting the material to the laboratory for further preparation and
analysis.
HOT COMMISSIONING IS COMPLETE

8. OPERATE THE SAMPLER

Introduction This section of the manual shows how to:
1. Place container in position
2. Set sample frequency timer
3. Set switch to auto setting
4. Check sampling occurs at correct frequency
5. Check that the sample discharges consistently
6. Remove final sample at end of sampling period
7. Replace with an empty sample container
8. Take sample to laboratory.
DO NOT SKIP THIS SECTION OF THE MANUAL.

Importance of
this stage This section deals with the standard operating procedure for the
Hammer Sampler. The correct method of doing each step is
explained. By following these instructions carefully, the sampler
will experience little or no downtime and ultimately require less
maintenance.

8.1. Steps to follow to operate the Sampler

STEP ACTION
1 Place container in position
Placing the sample container correctly in position ensures that the entire
sample increment that is representative is collected.
Ensure that no foreign material enters the sample container, as this will bias
the results of the sample. To do this, use a sealed system.
Set sample frequency timer to required

2 sample frequency
Refer to Do Hot Commissioning for information

on how to calculate the sample frequency.
Ensure that the frequency is set correctly.

Steps to follow to Operate the Sampler cont.
Set switch to “auto” setting
3
Check that sampling occurs at the correct frequency
4 Sampling must occur at the correct intervals for the sample to be

representative. IS / ASTM provides guidelines to follow to set the correct
sampling frequency.
Use your watch to check the frequency between rotational cuts of the cutter
arm across the material stream.
Check that the sampler discharges sample in a consistent manner
5 The sample should move through the sampler at a consistent rate. If it does
not, it may indicate that a blockage has developed or that cutters are clogged
with foreign material.
Remove final sample at end of sampling period
6 The container can be removed or emptied at the end of the sampling period.
The final sample should then be sealed to prevent contamination or loss of
moisture.
The sampling period must allow for the correct total sample mass as required
by the client.
Note: Ensure sampling increment gives the correct mass specified on the Data sheet.

Steps to follow to Operate the Sampler cont.
Replace with an empty sample container

7
Place an empty and clean container under the discharge pipe. Line the
container with a plastic bag if practical.
Take sample to laboratory for testing
8 The final sample should be taken to the laboratory as soon as possible to

prevent contamination of the sample, loss of moisture, or physical and
chemical changes within its constituents prior to ultimate sample analysis.
THE OPERATION CYCLE IS COMPLETE

9. CONDUCT PLANNED
MAINTENANCE
Introduction This section of the manual deals with what maintenance must
be done to the sampler:
 DAILY
 WEEKLY
 MONTHLY
 6 MONTHLY
 3 YEARLY
NOTE: Samplers require regular attention, as does all
mechanical equipment in a process plant.
Prevention is better than cure! By maintaining the sampler on

Importance of
an ongoing basis, costly breakdowns can be avoided and
this stage efficient and effective operation ensured.

9.1. Steps to follow to conduct daily planned

maintenance
WHEN ACTION
D DAILY
A Check the sampler for:
I
L  Spillage
 Final sample size
Y  Visual Assessment
This step will prevent the blade from material buildup or blockages. If this
step is not done, the sampler will not be able to take representative
samples.
Check that the discharge:
 Is flowing unobstructed into the container or down stream equipment.

 Is achieving the required final sample size.
Check the conveyor belt tracking

This prevents damage to the steelwork of the hammer housing, the conveyor
belt and unnecessary spillage.

9.2. Steps to follow to conduct weekly

planned maintenance
ACTION
WHEN
W WEEKLY
E Check the cutter for:
E  obstructions
K  wear
L Check the nylon brush and / or rubber
Y wiper for:
 wear
 tightness - they must be securely bolted
to the rear of the cutter
 adjustments
If they are loose:

- Loosen the bolts at the rear of the swing arm
- Slide the brush (15mm) and wiper (10mm) away from the blades toward
the belt so that the scrap wiper just makes positive contact with the
surface of the conveyor.
- Re-tighten bolts
- Check sampling action on an empty conveyor belt. Listen for the sound of
the brush and wiper making contact with the conveyor belt. Check that
the brush and wiper have left a clean stripe on the conveyor belt.
This is an important step as a well-maintained unit is able to take an entire
crosscut through the stream to provide representative samples.

9.3. Steps to follow to conduct monthly

planned maintenance
WHEN SYMBOL ACTION
M
MONTHLY
O
N Check the brake operation:
T Check that the cutter stops immediately after on revolution operation. If
H slippage occurs (forward or backwards) the brake unit needs replacement.
L Check geared motor: (See section of Geared Motor Manual)

Y
 Observe / check gear unit noise for changes
 Observe / check oil temperature
 Check gear unit for leakage
Check the electrical control panel:
- Isolate the control panel

- Blow out or vacuum any dust in the panel and on the components
DO NOT ALTER THE SETTINGS
Check the rubber skirting
- Check that all the rubber skirting attached to the frame are in place and
touching the conveyor belt. This will minimize the spillage from the
conveyor belt.
- Adjust or replace the skirting if spillage is occurring or if the skirting is not
touching the conveyor belt.
Check the housing side seal:

Replace if worn.

9.4. Steps to follow to conduct 6 – monthly

planned maintenance
WHEN ACTION
6 6 MONTHLY
Geared motor
Check geared motors:
- Check oil level – see section of geared motor

M manual appendix
- Clean vent plug – see section of geared motor
O manual appendix
- Clean drive according to the degree of
contamination – see section of geared motor
N manual appendix
- Check all fixing screws for tightness – see
T section of geared motor manual appendix
- Carry out complete inspection of geared unit –
H see section of geared motor manual appendix
If the gearbox runs without oil, it will be severely

L damaged.
Y Check the bearings in Double Bearing Hammer units:
- Open the bearing housing (located on either side of the hammer sampler
housing
- Re-grease, if required, with standard bearing grease
- Check that the dust seals are in place and are sealing properly. Adjust or
replace if necessary.

Steps to follow to conduct 6 monthly planned maintenance cont.
Check the motor brake:

6
Remove fan cover and clean brake unit with compressed air.
DO NOT ATTEMPT TO MAKE ADJUSTMENTS TO THE

BRAKE. This can cause damage to the motor. Brakes are factory set
and closed.
M NOTE: If any part of the hammer drive chain is removed, ensure that
the swing arm is secured in its ‘parked’ position. This will
prevent the swing arm from falling if the brake on the motor is
O released or the sprag is taken off or unbolted.
If the swing arm has not been secured in the parked position and it
N falls while someone is under the unit, the person can be seriously
injured.

9.5. Steps to follow to conduct 3 yearly

planned maintenance
Y
E YEARLY
A Check the geared motor:
R
Change oil of geared unit – see section of geared motor manual appendix
L
Y

10. TROUBLESHOOTING
Introduction Although there are very few things that can go wrong with
the Hammer Sampler, use this table to determine what
should be done in the case of a breakdown.
How to use this Read through the scenarios in the PROBLEM column until
section of the you find one that describes your situation.
manual
Read across to the CAUSE column. Follow the steps
described in the SOLUTION column to rectify the problem.
Only once you have completed these steps and the problem
has not been solved, should you call a Advanced System’s
engineer for assistance.
ENSURE THAT ALL POWER IS SWITCHED OFF BEFORE

ADJUSTMENTS ARE MADE

Troubleshooting decision table
PROBLEM... CAUSE... SOLUTION...
Sampling arm is Oversize material or Use brake lever on the back of

jammed and motor unwanted objects like steel or the motor to release the cutter.
cannot turn wood. Sampling arm can be moved
manually.
The hammer sampling The air gap on motor brake is Reset air gap on brake and/or
arm moves backwards incorrectly set, and/or the replace brake.
from its parked brake is worn.
position,
The direction of the motor is Change direction by switching
incorrect. two phases.
On start-up, the The phases have been Reverse phases.

sampler arm hangs in incorrectly wired within the
the 6 o’clock position electrical control panel.
while the motor is
running,
During the hammer The proximity shield settings See page of Hot Commissioning.
sampling action, the are incorrect.
arm rotates (windmills)
more than once,
The proximity sensor is Replace with a new proximity

faulty. switch with 10mm detection
range (usually open type).
The proximity sensor doesn’t Move proximity sensor closer to
detect the proximity shield. the proximity shield. The
distance between the shield and
sensor must be between 5 -
10mm.
There is no load on the belt. Check and adjust scraper and

brush.
The proximity is faulty (LED
Swing arm is parked in light is not switching on). Replace the proximity.
the stream - at 6
o’clock
The sampler has been Check wiring diagrams and

incorrectly wired through the correct the fault.
PLC system.

Sensor shields have shifted Replace or reset the alignment of

or are missing. the shields and tighten bolts.
See page in Hot Commissioning.
The distance between the Move proximity sensor closer to

proximity sensor and the proximity shield for a gap of
energizing plates is too great. approximately 5 - 10mm
The motor direction is Change direction by switching

incorrect. the two phases.
Hammer sampler The power supply to the Switch power to control panel on.
does not operate control panel is off.
The auxiliary equipment Check the functioning of all
interlocks are faulty. auxiliary equipment interlocks.

Fines are not being Brush and/or rubber scraper Adjust and/or replace.
completely removed is worn.
from the conveyor belt,
Brush and/or rubber scraper Replace with new rubber scraper

is missing. and brush.
Hammer sampler clearance Remove packers and adjust

from the belt is too great. clearance from the conveyor belt
to the swing arm to between 5 -
10mm.
Belt is tracking to one side. Adjust the tracking of the belt.
Excessive spillage is Rubber skirts are badly worn Adjust and/or replace
occurring during the or are missing.
sampling action,
Continuous spillage Belt is overloaded. Control the feed rate to the belt.
is occurring around
the hammer sampler
structure,
Hammer sampler is parked in

the stream - at 6 o’clock See previous problem.

The overload trip lights Overloads have been set too The responsible electrician
indicate on the front of low for the relevant motor should reset or adjust as
the control panel, amps. required.
See hot commissioning
There are blockages, There is excess moisture in Reduce if possible. If not,

the material causing high consider installing special, low-
material viscosity and friction linings for the cutter and
‘stickiness’. discharge chute work.
Tramp material - steel wires, Inspect and remove tramp

logs, etc present in main material downstream of the
process stream, especially hammer sampler. Connect metal
ROM applications. detector and photoelectric cell in
conjunction with the hammer
sampler.

11. SAFETY PROCEDURES FOR

REPAIRS TO DRIVE LINE
(Brake, motor, gearbox, sampling arm)
Note that all the moving parts operate as a unit, and if repairs are made to one of the
driveline units the following steps have to be followed:
1. Lock out the main/works MCC.
2. Lock out the conveyor belt at the main/works MCC
3. Ensure that all power supplied to the control panel is off by trying to
operate the unit, and by testing the cables.
4. Rotate the sampling arm slowly to the 6 o'clock position on the

conveyor belt by releasing the manual brake.
5. The sampling swing arm must be secured in the 6 o 'clock position to

ensure that all mechanical tension in the driveline is released.
6. The brake motor can now be removed after draining the gearbox oil.
The hammer swing arm can now be removed from the 6 o’ clock
position as in (5).
7. All other mechanical fitting can be done to the standard safety

procedures.
8. If hammer swing arm is in the stream, it should only be pulled out

manually in the normal direction of the swing arm rotation.

LUBRICATION SCHEDULE
PRIMARY SAMPLER
DESCRIPTION LUBRICATION SPECIFICATION QUANTITY LUBRICATION

TYPE (LITRE) PERIOD
GEARED OIL VG – 220 8.2 20,000 Hrs.

MOTOR


MANUAL

INDEX
Sl. No. Description Page
A. GENERAL 2
1. INTRODUCTION 2
2. EQUIPMENT DESCRIPTION 2
B. INSTALLATION 3
1. RECEIVING INSTRUCTIONS 3
2. STORAGE PROCEDURE 3
3. PRE INSTALLATION PROCEDURE 4
4. INSTALLATION 4
5. PRE-INSTALLATION CHECK (COLD COMMISSIONING) 4
6. OPERATION (HOT COMMISSIONING) 4
7. SAFETY 5
8. LUBRICATION SCHEDULE 6

A. GENERAL:
1. INTRODUCTION:
Proper installation, operating and maintenance procedures are essential for reliable
operation of industrial equipment. Belt feeders are no exception. This manual will help
you to become familiar with the Belt Feeder and its required maintenance. Any
questions should be resolved by contacting “Advanced Systems Sampling Pvt. Ltd.”
before and after installing the Belt Feeder.
2. EQUIPMENT DESCRIPTION:
a) General:
This is a material handling equipment. The material collected from the main Conveyor
by Primary Sampler (Hammer Type) directly goes to the Belt Feeder and this Belt
Feeder conveys the material to the crusher. Since the speed of the Belt Feeder used
here is relatively very slow this is acting as a material control feeding devices also. In
auto mode it will start only after a pre-fix time of starting the Crusher and stops after a
pre-fix time of stopping the Primary Sampler. Since the Belt Feeder is flat type, so to
taking the consideration to nullify any fines lose, the side wall type Belt is used. Here
the Belt Feeder is being used to carry the sample material there fore to avoid any
contamination taken place with the Sample material the Stainless Steel skirt board
has been used. One of the special features of this Belt Feeder is totally enclosed.
b) Major Components:
Idler:
In the Belt Feeder two types of Idlers used, one is carrying and other is return. Both
are made of ERW steel tube mounted on EN-8 materials spindles by means of heavy
duty seize resistant type ball bearing. The length of the idlers are different but the dia
are same. In this Belt Feeder single idlers are used as a carrying idler. The carrying
and return idlers are fitted with individual bracket from the Belt Feeder frame.
Pulley:
Two type of Pulley also used in this Belt Feeder. One is head pulley (which is directly
mounted with geared motor) and the other is tail pulley. Both the pulleys are made
from MS and keyed to forged steel shafts of EN-8 material. The pulleys are
vulcanized and natural rubber lagged. For drive / head pulley it is crowned & diamond
lagging and for non-drive one crowned & plain lagging is required. The lengths of the
pulleys are same but the dia is different. The pulleys are fitted with respective base
frame of the Belt feeder and which are fitted with the Belt feeder frame.

Belt:
In this Belt Feeder considering the handling material the FR grade belt has been
0
used. Since the Belt Feeder’s speed is very slow and the troughing angle is 0 means
flat type, so to restrict the lose of fines material, side wall type Belt is also used.
Technological Structure:
The technological structures of the Belt Feeder is totally bolted fitting means all the
parts can be dismantled and assembled very easily. All the structures are made by
MS except the skirts, which are made by SS. The Belt Feeder is totally enclosed with
side and top cover and which can be easily removable.
Drive Unit:
The Belt Feeder is driven by a very low rpm geared motor. The drive unit is connected
with the drive pulley shaft by a coupling. The drive unit is placed on a separate base
frame for the geared motor.
Screw Take-up:
One Screw take-up is used for belt adjustment of the Belt Feeder. The screw take-up
has been fitted with the tail frame.

B. INSTALLATION:
1. Receiving Instructions:
Where possible, Belt Feeder has been despatched as a complete assembly.
However, due to size and weight limitations, large Belt Feeder will be despatched in
sub-assemblies. When handling the Belt Feeder parts during unloading and erection,
care should be taken to avoid damage by dropping or improper use of slings.
Relatively small completely assembled parts should be rigged with the slings around,
under or laced the heavy support members of the lower portion. Never sling on the
shaft or bearing housing.
Special care is required when handling the Pulley assembly and drive unit assembly.
In case of pulley assembly some clothes should be used between the sling and
rubber lagging to avoid any pilled of the rubber from the pulley head. In case of drive
unit the sling should be used in proper and careful manner without disturbing the
shaft.
2. Storage Procedures:
Before erection, after unloading, the Belt Feeder should be stored on cribbing or
suitable shoring to keep them free of dirt, mud and water and placed under cover. In
addition, cover the Geared Motor and Plummer block with canvas or plastic sheet to
prevent dirt, dust, rain and the elements from entering the above.

3. Pre-installation Procedure:
Remove all protective covering if stored outside and should take all the care at the
time of installation to prevent the equipment from any damage.
4. Installation:
The Belt Feeder installation site should allow adequate clearance for access the
covers for maintenance from every side since this Belt Feeder is completely covered.
If the equipment comes in disassembled condition as per match mark the equipment
will be assembled. All the sub-assembled portion and loose part will be erected /
installed as per GA drawing. At the time of installation the level of the equipment
should be checked, specially the horizontal centre line of the pulleys. To compensate
for any inaccuracy of the leveling of the equipment, the use of grout and shims is
recommended to assure proper contact between the contact points to facilitate
leveling. The power transmission device connecting the driving motor to the driven
equipment is a key link in all systems. Improper installation and poor maintenance of
drive equipment will inevitably cause needless shutdown due to equipment failure.
Any problem / questions should be resolved by contacting “Advanced Systems
Sampling Pvt. Ltd.” before and after installing the Belt Feeder.

5. Pre-Operation Check (Cold Commissioning):

Once the Belt Feeder has been installed you are ready to begin start up the process.
The first stage of the start-up process is doing pre-operation check. In this process the
following operation should be done sequentially.
1) Oil level check of the Gear Box.

2) Belt alignment.
3) Check Electrical connections.
4) Turn on mains power to sampler panel.
5) Set to manual mode of operation.
6) Set material control gate.
7) If possible, check that the panel works in auto or not.

6. Operation (Hot commissioning):

This stage only be started once the cold commissioning stage has been completed
and all other related equipment of the Sampling System are ready to perform. Keep
the material feed shut of during pre-operation check. Allow the belt to move in no load
condition and listen for any unusual noises. When satisfied the Belt Feeder is running
properly in empty condition, allow feed to enter the Belt Feeder. After a few times, the
alignment of belt must be checked. If there is any movement of belt found towards
any direction of the Belt Feeder that should be rectified by adjusting the Screw Take-
up placed in the tail side. After running of some time the scrapper should be checked
whether it is working properly or not. At the time of load condition running the material
can be controlled by using the vertical hand operated slide gate placed in the top of
the Belt Feeder. Ensure that the proximity sensor of zero speed switches is properly
working.

7. Safety:
It is important to follow rigorous safety procedures when operating any machinery /
equipment. We have necessarily designed this equipment of a rugged nature to
withstand the abuse mechanical parts undergo during operation. In any equipment
can, if proper safety precautions are not observed, cause serious injury or death. The
following are a few of the safety rules suggested to form the basis of a safety
programme. This list may not be complete. Thus, applicable local or general safety
codes and individual plant safety rules and regulations may alter or add to the
following list.
a. Any maintenance work on Belt Feeder should start after completely

disconnected the drive unit. Never operate the equipment without checking to
be absolutely sure that the equipment is totally enclosed and all personnel are
clear of machine and its drive.
b. All related equipment must be interlocked with the Belt Feeder so that it cannot
be operated when the Belt Feeder is not operating or visa versa.
c. If the feed equipment to the Belt Feeder is not interlocked, any operating or
maintenance personnel must lock out this feed equipment, before performing
any work on the Belt Feeder.
d. Do not attempt to operate the Belt Feeder at any speed other than that for
which it was originally designed, without consulting “Advanced Systems Sampling
Pvt. Ltd.” Speeds in excess of design speed can cause component failure and other
damages of the equipment.
e. Do not feed materials into the Belt Feeder other than those for which the Belt
Feeder was originally applied or designed. Alternate materials could cause
premature component failure and other damages.

8.
BELT FEEDER
COAL SAMPLING SYSTEM

TYPE (LITRE) PERIOD
GEARED OIL VG – 220 7.6 20,000 Hrs.

MOTOR
OPERATING AND
MAINTENANCE MANUAL

Advanced Systems Sampling.Pvt. Ltd. Continuation sheet ……61 of 101
1.1. This Manual is important because:

 It contains all the information needed to make an inquiry about the sampler.
 It shows all the parts of the sampler.
 store the sampler,

 install the sampler,
 get the sampler up and running,
 operate, maintain and troubleshoot the sampler.
 It shows you how to get the most out of the sampler.
1.1.1 Using this section of the Manual

Each of the instructions is written in a clear action based way. This means that you
merely have to read the actions and follow them. Diagrams have been used to illustrate
the more complex steps and so assist the relevant staff.

2. INTRODUCTION
2.1.1. What this Divider can do for you:

This divider is a highly sophisticated piece of equipment that has the following features:
It allows ease of access :
 The cutter can be inspected and accessed via an inspection cover on the side of the
housing.
 The electric drive is self-contained and is rated at 0.37 kW.
 The cutters are easily replaceable .
It provides efficient and effective sampling :
 The slot width of the cutter is 3 times the nominal particle top size of the solids with a
minimum of 30mm..
 Cutter peripheral speed is  0.6m/sec and is consistent throughout its travel.
 Cutter cuts the stream at right angles after each revolution.
 Cutter can rotate continuously or be controlled by a proximity sensor and geared
brake motor.
The unit limits dust generation and material turbulence.
 The cutter is made of Stainless Steel.

 The drive units are splash and corrosion protected.

2.2. Description of the Components of the

Divider
The Rotating Plate Divider has been designed as a secondary sampling and
division unit. The division ratio of the unit varies depending on the top size of
the material, the number of cutters and their related sizes, as well as on the size
(i.e. rotating plate diameter) of the divider.
2.2.1. The Housing:

The mild steel housing totally encloses the dividing plate, protecting it from unnecessary
corrosion contains dust generation and enclosing all moving parts. (the housing is also
available in 304 stainless steel.) The housing is supplied complete with feed chute, rejects
and sample outlets as well as a base plate for mounting the geared motor.
2.2.2. The Divider Plate:

The vertical divider plate is manufactured from mild steel (or other materials) with a low
coefficient of friction. This feature, together with a 60 o slope of the cutters ensures that no
“hang-up” of material is experienced. One or more cutters can be fitted to the circumference
of the dividing plate, allowing the client to take multiple cuts (minimum of 6) of a primary
sample increment.
o
The divider plate operates continuously rotating vertically through a 360 arc. The plate can
be activated and de-activated by means of a sequence stop/start operation.
2.2.3. Geared Motor:

The speed of the geared motor depends on the diameter of the dividing plate. It is designed
to provide a cutter tip speed 0,6 m/sec. The motor shaft is coupled directly onto the hub of
the rotating plate.
A motor brake is fitted on some units to ensure that the cutter does not stop in the path of the
incoming feed and is ‘parked’ in the 12 o’clock position. This modus operandi is generally
used during purge cycles of sample stations sampling various materials or from various
sources.
The lubrication schedule is contained in the Appendix.
2.2.4. The Control Panel:

The divider is controlled through Sampling System PLC.

3. TRANSPORT AND STORE THE

DIVIDER
1. How to lift the divider off the truck
2. How to store the divider
Importance of The divider can be damaged during this stage. By following the
this stage easily understandable instructions in this section, you will
3.1. Steps to follow to Store the Divider
The Unit is self contained and fully assembled. The unit should be stored in door.
THE STORAGE OF THE DIVIDER IS COMPLETE

4. INSTALL THE DIVIDER
1. Transport the divider to the installation site
2. Unpack the divider
3. Construct chute work
4. Lift the divider into position
5. Move the divider into the correct position
6. Bolt the chute work to the divider
7. Connect cables to the motor
8. Connect cables to the central control panel.
Importance of If this stage is not correctly completed, problems such as,
poor ergonomics, inefficient operation, etc will result.

4.1. Steps to follow to Install the Divider
- Plan the transportation route so that the equipment is not damaged whilst in
transit.
- Check that the site allows free access to the unit inspection hatch and motor
once installed. This will be needed for maintenance purposes and for routine
operational checks.
- The pedestal of the divider was designed to be mounted onto the floor or onto a
dedicated structural steel frame.
- Mark the position the Sampler in correct orientation and location as per system
GA drawing.
- Lift the divider and place the Sampler in position.
- DO NOT FORCE THE DIVIDER INTO POSITION. If flange-to-flange distance is

incorrect, one of the sections of chute work will need to be modified.
- Connect the inlet and outlet chute works.
- Isolate the MCC feeder.
- Drill gland plate to suit.
- Fit cable gland and connect cables.
- Connect the Motor cable.
- Connect the Proxy cable, if proxy is provided.
THE INSTALLATION OF THE DIVIDER IS COMPLETE

5. CONTROL PHILOSOPHY OF THE

DIVIDER
5.1. Functional Description

The rotating plate divider is installed in the middle of Sampling System. It has to be
started only when succeeding equipment are started as per control scheme elaborated
in PLC section.
Some models will be fitted with a proximity sensor (positioned on the side of the
housing) to stop and start the unit. This will occur in certain applications where a
purge cycle is needed when sampling various types of material. The same is not
applicable here. The motor brake, if provided, has to be isolated in such case.
Each time a new product or consignment is to be sampled by the primary sampler, 2-3
primary increments are fed through the sample station without final secondary
subdivision. Thus no sample is collected. This will clear out the system of foreign
matter which may contaminate the following batch / consignment to be sampled.

1. Check the drive oil level
2. Isolate the wiring
4. Check top and bottom flanges
5. Turn on mains power to divider panel
6. Turn on isolator switch on central control panel
7. Set to manual mode of operation
8. Check that the divider is operating efficiently
9. Set the control panel to auto.
Importance of Once the divider has been installed you are ready to begin the start-
this stage up process. The first stage of the start up process is doing a cold
commissioning. Once this stage is correctly completed, the second
stage of the start up can begin - doing a hot commissioning. During
the cold commissioning stage the wiring and mechanical functioning
of the divider is checked without material being passed through it.
During the hot commissioning stage material is passed through the
divider.

6.1 Steps to do Cold Commissioning

- Check the oil according to geared motor manual appendix. Typically the gear unit
will not have oil filled in.
- Make sure, vent is open prior to filling the oil.
- Isolate the wiring.
- Check electrical connection.
- Ensure that all wires are securely fastened to terminal strips and motor
connections.
- Tighten if loose.
- Check top and bottom flanges are sealed and secure
- Doing this step correctly will prevent leakage or dust emission once the material
is passed through the divider.
- A rubber seal or packing can be inserted between the two flanges to prevent
unnecessary spillage. Silicone can also be used for this.
- Turn on mains power to divider
- Do this at the isolator switch, which feeds power to the divider. (In the MCC.)
- Set to manual mode of operation.
- Check that the divider is working efficiently.
- Check that the divider plate is running in the correct direction as indicated with
the rotation arrow on the housing (this is only applicable in brake motor units
operating with a proximity).
- Check for scraping noises or any other sounds that indicate that the divider plate
is touching the housing.
- Set the control panel to auto.
- Turn on isolator

- Switch to auto on front of control panel.
- Check that the divider plate rotates and operates in sequence with other
mechanical units before and after it.
The Cold Commissioning is Complete.
1. Start material flow through the divider
2. Place sample container under sample outlet chute
3. Switch divider to manual setting
4. Take sample increments
5. Measure sample volume
6. Check sample frequency
In order for the divider to operate, this stage must be completed
correctly. Ensure that each of the steps listed above is
followed in the correct order.
- Start Material flow through divider.

- DO NOT start this process until the divider has been cold commissioned.
- Start-up procedure could be as follows (where applicable): first divider, then

crusher, feeder then Primary Sampler.
- Check for dust generation indicating that the flange bolts are not tightened
properly or that the rubber seal/packing has not been installed.
- Place empty container in bottle Collector.
- See that sample increments report to the sample container and that there is no
build up or obstruction anywhere.
- See there is no undue vibration in machine.
- Measure mass of sample collected.
The Hot Commissioning is Complete.

7. OPERATE THE DIVIDER

This section of the manual shows how to:
Introduction 1. Position the bucket under the outlet chute
2. Set switch on central control panel to auto setting (if
Importance of supplied)
this stage 3. Check sampling is occurring at correct intervals
4. Remove final sample at end of sampling period specified by
Multotec
5. Replace with an empty sample bucket
6. Take sample to laboratory.
DO NOT SKIP THIS SECTION OF THE MANUAL.
This section deals with the standard operating procedure for
the Rotating Plate Divider. The correct method of doing each
step is explained. By following these instructions carefully, the
divider will experience little or no downtime and ultimately
require less maintenance.

8.1 Steps to follow to Operate the Divider

- Ste the control panel in Auto.
- Check the sampling is done uniformly at equal interval.
- Check the motor is running at constant speed without any jerk.
- After approx. 30 mins. Of operation, stop the system and see no built up of
material is there inside the divider.
- Check no undue heating of motor and gearbox is there.
- The divider will continue to run as per control programming done through PLC
and will stop only after completion of cycle.
THE OPERATION CYCLE IS COMPLETE

9. CONDUCT PLANNED
MAINTENANCE
Introduction This section of the manual deals with what must be done to the
divider:
 DAILY
 WEEKLY
 MONTHLY
 YEARLY
Importance of Prevention is better than cure! By maintaining the divider on an
this stage ongoing basis, costly breakdowns can be avoided.

9. 1. Steps to follow to Conduct Planned

Maintenance
DAILY
- Check daily that the cutter is free from contamination . The Operator by means of
a visual inspection through the inspection cover must do this.
- If this step is not done, the sampler may not be able to take representative
samples.
WEEKLY
- Check weekly that the

 cutter is free of obstructions / contamination
 cutter edges are sharp
 cutter is securely bolted onto the divider plate
This is an important step as only a well-maintained cutter is able to take representative

samples free from bias.
MONTHLY
- Check the geared motor.

- Observe / check gear unit noise for changes
- Observe / check oil temperature
- Check gear unit for leakage
- Check oil level
- Clean vent plug
ANNUALLY
- Change oil according to section of geared motor manual appendix.

- Clean the drive according to the degree of contamination according to section of
geared motor manual appendix.
- Check fixing screws for tightness
- Carry out complete inspection of the Divider.

10. TROUBLESHOOTING
the Rotating Plate Divider, use this table to determine what
should be done in the case of a breakdown.
How to use this Read through the scenarios in the IF column until you find
table one that describes your situation.
Read across to the THEN column. Follow the steps
described in this column to rectify the problem.


Troubleshooting Decision Table
IF... THEN...
Too much sample is being collected Cutter needs to be replaced
OR
Plant process is supplying too much
material. The sample requirements must
be adjusted according to plant supply.
Too little sample is being collected Cutter or discharge chute are choked with
foreign material
OR
Sampling frequency is set too low and must
be adjusted.
No sample is collected Motor is defective

OR
Controls are defective e.g. no power
OR
System choked upstream.
Cutter does not move and the electrical 1. Check power is coming into the panel
connections are secure 2. Check that the isolator switch is on
3. Check that overload has not tripped.
4. Check motor and gearbox are
functioning.
Motor tripped on overload Discharge and sample chutes are blocked

OR
Foreign material stuck in the cutter
OR
Brake at the rear-end of the motor has
seized. This might happen if the divider
has been standing for a long period of time.
The brake needs to be cleaned from rear of
motor with an electrical cleaner.
Motor burnt out No electrical overloads protection in circuit.


MANUAL

1.1. This manual is important because:

 It contains all the information needed to make an inquiry about the Collector.
 It shows all the parts of the Collector.

- store the Collector,
- install the Collector,
- get the Collector up and running,
- operate, maintain and troubleshoot the Collector.
 It shows you how to get the most out of the Collector.


2. INTRODUCTION TO THE COLLECTOR

2.1. The Collector
2.2. What the Collector can do for you:

This Collector is a highly versatile piece of equipment that has the following features:
 It provides accurate separation of samples:

 A brake at the rear end of the motor provides accurate positioning of sample
containers.
 A proximity switch ensures container can be correctly positioned.
 It can take up to different containers of up to 30 litres capacity each for materials
from different sources.
 The unit has a container detector to ensure that no sample material will enter the
Collector unless there is a container under the inlet chute or pipe.
 It allows ease of access:

 The sampling container(s) can be inspected from all sides.
 The drive is self-contained and electric.
2.3. Description of the Components of the

Collector
2.3.1 The Housing

All parts of the mild steel frame are welded together except for the top cover and the sampler
inlet port, which are bolted to the frame and can be removed.
2.3.2. The Sampling Container:

This is manufactured from SS-304 material with a low coefficient of friction, thereby ensuring
no “hang-up” of material.
The lid seals are air tight to prevent moisture loss.
2.3.3. The Drive:

A geared brake motor ranging from 0,25kW to 0,75kW to suit each client requirement.

3. TRANSPORT AND STORE THE

COLLECTOR
1. How to lift the Collector off the truck
2. How to store the Collector
Importance of The Collector can be damaged during this stage. By following
this stage the easily understandable instructions in this section, you will
3.1. Steps to follow to store the Collector
- Lift the Collector off truck using a crane.
- Use the crane to position the Collector in its final position.
- Store in an upright position.
- The Collector must always be in an upright position with the motor on top to
prevent damage while storing.
- Always store in a dry and level area to prevent or minimize damage to the unit and
the paintwork.

4. INSTALL THE COLLECTOR
1. Transport the Collector to the installation site
2. Lift the Collector into position
3. Move the Collector into the correct position
4. Bolt the Collector into position
5. Connect cables to the motor
6. Connect cables to the instruments.
Importance of If this stage is not correctly completed problems such as
poor ergonomics, inefficient operation, etc will result.

4.1. Steps to follow to Install the Collector

- Transport the Collector to planned installation site
- Use the crane to position the Collector in its final position.
- Move the Collector into correct position
- Ensure that the Collector can be easily accessed once in position. This is
important for maintenance purposes.
- Use a spirit level to check the level of the Collector. If it is not perfectly level,
make the necessary adjustment to the feet. Adjust feet height with jacking nuts or
packer plates.
- Once the Collector is in position, chemical or mechanical anchors can be used to

secure the base, however this is not essential.
- Connect cable to the motor:
- Ensure that the Collector supply cable is isolated.
- Remove cover of terminal box on motor.
- Prepare cable and fit cable gland.
- Fit cable into terminal box and connect terminal strip
- Connect instrumentation multi core cable to the Proxymity switch.
THE INSTALLATION OF THE COLLECTOR IS COMPLETE

5. CONTROL PHILOSOPHY OF THE

COLLECTOR
5.1. Description of Collector Components
The Collector has 1 x direct on line motor to drive the Collector table in a
clockwise direction.
The Collector has the specified amount of containers, spaced equally around the Collector. The
inlet chute is in a fixed position (position 1).
The Collector is equipped with a proximity switch, housed in a box on top of the
Collector shaft. The proximity switch senses a target.
The Collector is open and at the sample containers are inserted and removed.
5.2. Control Philosophy

At start up, the Collector motor is energized and the Collector runs
clockwise until the proximity switch is activated to indicate that the
Collector is in position. The control system checks the sensor to see if a
sample container is in position before the Collector feed plant is allowed to
take a sample. If a container is not in position, an alarm will be activated,
indicating that no sample container is in position 1 and the material feed will
be put on hold.
If a sample container is in position, the plant will continue to deposit samples

into the first sample container for the preset time. When the preset time has
expired, the system will wait until the last sample taken has been processed
and deposited in the container. The material feed will be put on hold; the
Collector motor will then be started and will turn the Collector until the indexing
proximity switch is made to indicate that the next sample container is in
position.
The system will check if a container is present and will continue to take
samples.
When a power failure, reset or fault occurred, the control system shall put the
material feed on hold and activate an alarm. When the Collector is reset from
the control system, it will start the Collector motor and drive the Collector until
position 1 is reached.
The Collector is not able to run in the anti clock direction.

1. Check the drive oil level.

2. Remove containers
4. Check instrumentation connectors
5. Check functioning of instruments
6. Check direction of sampling turntable
7. Check bin detector
8. Check stopping position of sampling turntable
9. Check instrumentation interlock
Importance of If all the checks given in this section are not done, serious damage
this stage to the Collector can be caused.
Once the Collector has been installed you are ready to begin the
start-up process. The first stage of the start up process is doing a
cold commissioning. Once this stage is correctly completed, the
second stage of the start up can begin - doing a hot commissioning.
During the cold commissioning stage the wiring and mechanical

functioning of the Collector is checked without a sample being
discharged into it. During the hot commissioning stage samples are
discharged into the Collector.

6.1. Steps to follow to do Cold Commissioning

- Check the drive oil level
- Make sure the drive vent is open.
- Remove containers
- Check electrical connections
- Ensure that all wires are securely fastened to terminal strips and motor
connections.
- Retighten if loose.
- Check the sensor is connected with control panel.
- Check direction of sampling turntable
- The turntable must be able to turn clockwise.
- If the motor direction is wrong, turn around 2 of the phases connected to the motor.
- This is an important step - if not done correctly the Collector will not be able to function
and the sealing plates and canisters will be damaged.
- Check the sampling container positions. The sensor must be activated when a
container is in place.
- Check that the buckets stop directly under the inlet pipe for every container positioned.
- Change the stopping position by loosening and rotating the sensory disc in the box on
top of the Collector. By moving it in the opposite direction of travel will cause earlier
stopping.
COLD COMMISSIONING IS COMPLETE

1. Run the Collector as part of the plant
2. Run material through the plant
3. Check operation of the Collector
In order for the Collector to operate, this stage must be
completed correctly. Ensure that each of the steps listed
above is followed in the correct order.

7.1. Steps to follow to do Hot Commissioning

- Run the Collector as part of the plant
- Allow the plant to run under automatic mode and check that the Collector
responds correctly and in sequence. If a container number is selected, check that
the correct container is positioned and presented under the inlet of table indexer.
- Run material through the plant
- Run material through the plant and allow it to discharge into the correctly
demarcated container.
- Look for any spillage and adjust positioning of the containers if necessary. Should
any other problems arise consult the troubleshooting chart in next section.
HOT COMMISSIONING IS COMPLETE

8. OPERATE THE COLLECTOR
Introduction This section of the manual shows how to:
1. Position empty containers
2. Run Collector as part of the plant and collect samples
3. Remove containers
Importance of DO NOT SKIP THIS SECTION OF THE MANUAL.
this stage
This section deals with the standard operating procedure for the
Collector. The correct method of doing each step is explained.
By following these instructions carefully, the Collector will
experience little or no downtime and ultimately require less
maintenance.

9. CONDUCT PLANNED
MAINTENANCE
Introduction This section of the manual deals with what must be done to the
Collector:
1. DAILY
2. WEEKLY
3. MONTHLY
4. 6 MONTHLY
5. YEARLY
Importance of Prevention is better than cure! By maintaining the Collector on
this stage an ongoing basis, costly or inconvenient breakdowns can be
avoided.

9.1. Steps to follow to conduct planned

maintenance
DAILY
- Check for spillage around the containers. The spillage can be cleaned out by
scraping it through the grid in the floor of the Collector.
WEEKLY
- Check weekly for excess spillage
MONTHLY
- Check gear motor
 Observe / check gear unit noise for changes
 Observe / check oil temperature
 Check gear unit for leakage.
SIX MONTHLY
Check gear motor:
 Check oil level – see section 7.2 of geared motor manual appendix H.
 Clean vent plug – see section 10.2.3 of geared motor manual appendix H
 Clean drive according to degree of contamination – see section 10.2.4. Of geared
motor manual appendix H
 Check fixing screws for tightness – see section 10.2.5. of geared motor manual
appendix H
 Carry out complete inspection of geared unit – see section 10.2.6. of geared motor
manual appendix H.
 Remove top covers and check free movement of sealing plates.

 Check gaps between sealing plates and containers and adjust the sealing plate –
suspension frame. Plate to be at 50% of the travel when containers are installed.
 Clean out inside of unit.
- Clean inside of control box on top of the unit.
YEARLY
Change oil of geared unit – see section of geared motor manual appendix.
The bearings have been greased during assembly and due to the low duty no further
greasing is required.

10. TROUBLESHOOTING
the Collector, use this table to determine what should be
done in the case of a breakdown.
How to use this Read through the scenarios in the IF column until you find
table one that describes your situation.
Read across to the THEN column. Follow the steps
described in this column to rectify the problem. Only once
you have completed these steps, should you call a Multotec
engineer for assistance.


IF... THEN...
Excessive spillage takes place Feeder chute is misaligned with each

sample increment.
Proximity switches are faulty - replace.
Turntable brake is faulty. Investigate and

replace / repair.
Excessive play on turntable Brake unit faulty - check / repair.
Brake coupling loose - tighten.
Indexing does not turn No power to motor - check.
Turntable is jammed - check path and

rollers.
Brake is not disengaging - clean with

electrical cleaner / repair
There is a physical interference between

the turntable and the housing.
The containers do not position correctly Check proximity switches.
Check the proximity switch detector plates.

IF... THEN...
Proxy "detects" container when there Photoelectric proximity eye is dirty - clean.
is none there.
Photoelectric proximity is faulty - check.
The incorrect container is selected. Check the PLC / SCADA programming.


MANUAL

INDEX
Sl. No. Description Page
A. GENERAL 2
1. INTRODUCTION 2
2. EQUIPMENT DESCRIPTION 2
B. INSTALLATION 3
1. RECEIVING INSTRUCTIONS 3
2. STORAGE PROCEDURE 3
3. PRE INSTALLATION PROCEDURE 3
4. INSTALLATION 3
5. PRE-INSTALLATION CHECK (COLD COMMISSIONING) 3
6. OPERATION (HOT COMMISSIONING) 4
7. SAFETY 4
8. LUBRICATION SCHEDULE 5

A. GENERAL:
1. INTRODUCTION:
Proper installation, operating and maintenance procedures are essential for reliable
operation of industrial equipment. Screw Conveyors are no exception. This manual will
help you to become familiar with the Screw Conveyor and its required maintenance. Any
questions should be resolved by contacting “Advanced Systems Sampling Pvt. Ltd.”
before and after installing the Screw Conveyor.
2. EQUIPMENT DESCRIPTION:
a) General:
This is acting here as a reject material handling equipment. The material coming directly
from Secondary Sampler to the Screw Conveyor and this Screw Conveyor discharges
the material to the other plant conveyor. In auto mode it will start first and stops after a
pre-fix time of stopping the Bottle Collector means last.
b) Major Components:
Conveyor Screws:
To remove a section or sections of conventional conveyor screw, proceed from end
opposite the drive.
Remove trough end conveyor screw sections, coupling shafts and hangers until all screw
sections have been removed, or until damaged or worn out section is removed.
To reassemble, follow above steps in reverse order.
Sections of conventional conveyor screws equipped with split flight couplings may be
removed individually with a minimum of disturbance of adjacent sections.
Hanger Bearings:
In Screw Conveyor hanger bearing serves a very important roll. These bearings hold the
screw and as well as help to rotate the same. The hanger bearing hangs from a bracket
of trough.
Technological Structure:
The technological structures of the Screw Conveyor is totally bolted fitting means all the
parts can be dismantled and assembled very easily. All the structures are made by MS.
The Screw Conveyor is totally enclosed with top cover and which can be easily
removable.
Drive Unit:
The Screw Conveyor is driven by a low rpm geared motor. The drive unit is connected
with the screw shaft by a coupling. The drive unit is placed on a separate base frame for
the geared motor.

B. INSTALLATION:
1. Receiving Instructions:
Where possible, Screw Conveyor dispatches as a complete assembly. However, due to
size and weight limitations, large Screw Conveyor will be despatched in sub-assemblies.
When handling the Screw Conveyor parts during unloading and erection, care should be
taken to avoid damage by dropping or improper use of slings. Relatively small completely
assembled parts should be rigged with the slings around, under or laced the heavy
support members of the lower portion. Never sling on the shaft or bearing housing.
Special care is required when handling the drive unit, the sling should be used in proper
and careful manner without disturbing the shaft.
2. Storage Procedures:
Before erection, after unloading, the Screw Conveyor should be stored on suitable place
to keep them free of dirt, mud and water and placed under cover. In addition, cover the
Geared Motor and Plummer block with canvas or plastic sheet to prevent dirt, dust, rain
and the elements from entering the above.
3. Pre-installation Procedure:
Remove all protective covering if stored outside and should take all the care at the time
of installation to prevent the equipment from any damage.
4. Installation:
The Screw Conveyor installation site should allow adequate clearance for access the
covers for maintenance from every side since the Screw Conveyor is completely
covered. If the equipment comes in disassembled condition as per match mark the
equipment will be assembled. All the sub-assembled portion and loose part will be
erected / installed as per GA drawing. At the time of installation the level of the
equipment should be checked, specially the horizontal centre line of the screws. To
compensate for any inaccuracy of the leveling of the equipment, the use of grout and
shims is recommended to assure proper contact between the contact points to facilitate
leveling. The power transmission device connecting the driving motor to the driven
equipment is a key link in all systems. Improper installation and poor maintenance of
drive equipment will inevitably cause needless shutdown due to equipment failure. Any
problem / questions should be resolved by contacting “Advanced Systems Sampling Pvt.
Ltd.” before and after installing the Screw Conveyor.
5. Pre-Operation Check (Cold Commissioning):

Once the Screw Conveyor has been installed you are ready to begin start up the
process. The first stage of the start-up process is doing pre-operation check. In this
process the following operation should be done sequentially.
1) Oil level check of the Gear Box.

2) Screw alignment.
3) Check Electrical connections.
4) Turn on mains power.
5) Set to manual mode of operation.

6) Set slide gate.

7) If possible, check that the panel works in auto or not.
6. Operation (Hot commissioning):

This stage only be started once the cold commissioning stage has been completed and
all other related equipment of the Sampling System are ready to perform. Keep the
material feed shut of during pre-operation check. Allow the Screw to move in no load
condition and listen for any unusual noises. When satisfied the Screw Conveyor is
running properly in empty condition, allow feed to enter the Screw Conveyor. After a few
times, the alignment of Screw must be checked. If there is any movement of screw found
that should be rectified by adjusting the hanger bearing. At the time of load condition
running the discharge of the material should be checked by adjusting the slide gate
placed in the bottom of the Screw Conveyor. Ensure that the proximity sensor of zero
speed switches is properly working.
7. Safety:
It is important to follow rigorous safety procedures when operating any machinery /
equipment. We have necessarily designed this equipment of a rugged nature to
withstand the abuse mechanical parts undergo during operation. In any equipment can, if
proper safety precautions are not observed, cause serious injury or death. The following
are a few of the safety rules suggested to form the basis of a safety programme. This list
may not be complete. Thus, applicable local or general safety codes and individual plant
safety rules and regulations may alter or add to the following list.
a. Any maintenance work on Screw Conveyor should start after completely

disconnected the drive unit. Never operate the equipment without checking
to be absolutely sure that the equipment is totally enclosed and all personnel
are clear of machine and its drive.
b. All related equipment must be interlocked with the Screw Conveyor so that it
cannot be operated when the Screw Conveyor is not operating or visa versa.
c. If the feed equipment to the Screw Conveyor is not interlocked, any operating or
maintenance personnel must lock out this feed equipment, before performing any
work on the Screw Conveyor.
d. Do not attempt to operate the Screw Conveyor at any speed other than that for
which it was originally designed, without consulting “Advanced Systems
Sampling Pvt. Ltd.” Speeds in excess of design speed can cause component
failure and other damages of the equipment.
e. Do not feed materials into the Screw Conveyor other than those for which the
Screw Conveyor was originally applied or designed. Alternate materials could
cause premature component failure and other damages.

8.
SCREW CONVEYOR
COAL SAMPLING SYSTEM

TYPE (LITRE) PERIOD
GEARED OIL VG – 220 2.72.7 20,000 Hrs.
MOTOR

CODE : ADVANCED SYSTEMS
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 1 of 11
OPERATING INSTRUCTIONS & MAINTENANCE
MANUAL FOR HAMMER MILL 400MM X 400MM
EQPT. M/C. NO.414 TO 418
HAMMER MILL 400MM Ø X 400MM WIDE

THIS MANUAL IS FOR INSTALLATION OF MACHINE AS PER FEEDING
ARRANGEMENTS SHOWN IN THE GENERAL ARRANGEMENT DRAWING,
ERECTION, COMMISSIONING AND RUNNING OF HAMMER MILL 400MM Ø X 400
MM WIDE. PLEASE READ CAREFULLY BEFORE YOU PROCEED. FOR ANY
CLARIFICATION, PLEASE SEND US A WRITTEN COMMUNICATION.
DAMAGE DUE TO NEGLIGENCE, IMPROPER HANDLING, ERECTION OR ANY

ALTERATION(S) CARRIED OUT WITHOUT OUR KNOWLEDGE OR OUR WRITTEN
APPROVAL OR IGNORANCE OF THESE INSTRUCTIONS WILL NOT BE BORNE BY
‘McNally SAYAJI’
CLIENT : ADVANCED SYSTEMS SAMPLING PRIVATE LIMITED

BLOCK 6A
206, A J C BOSE ROAD
KOLKATA – 700 017
 033-22902360/61/62
 033-22900943
 sunilkchy@yahoo.com
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 2 of 11
INDEX
1 TECHNICAL DATA 3 of 11
2 DESCRIPTION 4 of 11
3 INSTALLATION 5 of 11
4 LUBRICATION & MAINTENANCE OF 6,7 of 11
BEARINGS
5 ESSENTIAL SPARE PARTS 8 of 11
6 IMPORTANT POINTS FOR 9 of 11
MAINTENANCE & OPERATIONAL
PERSONNEL
7 LIST OF TOOLS 10 of 11
8 LIST OF DRAWINGS 11 of 11
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 3 of 11
TECHNICAL DATA
1 Size : Hammer Mill 400mm dia x 400mm wide

2 Type : Non reversible with grate bar
3 Rotor Dia : 400 mm
4 Rotor Width : 400 mm
5 Drive Motor : 9.2 KW, 1440 RPM, Frame : 12-D160 M
6 Rotor R.P.M. : 1440 RPM
7 Rotor Tip Speed : 30 M/Sec.
8 Material to be Crushed : Coal
9 Bulk Density : 0.8 T/Cu.M
10 Feed Size : 25 to 50mm
11 Product Size : -3.15mm; Min 95%
12 Capacity : 2 TPH
13 V-Belts : B-97 (3 Nos.)
(Matched Set of 3 Nos.)
14 Machine Pulley P.C.D. : V3B-200 PCD
15 Motor Pulley P.C.D. : V3B-200 PCD
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 4 of 11
DESCRIPTION
With uniform speed across the width of the rotor material gets crushed between
the high speed swinging arms and tips and the grinding walls. Desired product is
available through the grate bars, mounted below the hammer path. The
direction of rotation is reversible to take care of uniform wear on tips and
grinding wall. Reversing is done through reversing motor starter.
The hammer mill consists of lower housing bolted to detachable upper housing
with grinding walls on either side or rotor with swinging hammer arms and tips.
The housing consists of welded fabricated structure with replaceable liners on

both upper and lower housing. On the side of lower housing threaded spindle and
hand wheel are housed for adjustment of grate bars wall carrier. The clearance
between grate bars and hammers are adjustable by two hand wheels and lock
nuts arrangement. Lower half of grinding wall carrier can be swung out through
inspection doors. The upper housing is in three pieces; one centrally connected
to feed chute and two side pieces. On the side of upper housing, sliding block
with threaded spindle and nut are housed for adjustment of grinding wall. The
rotor shaft is sealed on the housing.
The grinding wall is split on the horizontal center line of the crusher. Fabricated
grinding wall bracket carries high wear resistant alloy steel liners, bolted through
liner bolts. Grinding wall can be adjusted at top through threaded spindle.
The rotor consists of a single forged piece machined and jig drilled for rotor pins,
arms and tips. The arms are suspended freely on the rotor discs integrally with
the shaft by means of rotor pins. For quite running, the arms and tips, which are,
placed two or three or four in a row between the discs should be of same weight.
The tips of same weight per row are marked. The rotor shaft runs in large
spherical roller bearings in sturdy housing sealed by labyrinth alloys filled with
grease. Hammer mill drive is from electric motor through V-Belts. In order to
insert the V-Belts, push the motor towards the hammer mill on slide rail and
after inspection of all V-Belts stretch them to the required limit.
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 5 of 11
INSTALLATION
The Hammer Mill installation shall be done with respect to erection plan.
For assembly the Hammer Mill can be split into three pieces:-
 Upper Housing with half of grinding wall and liners.
 Rotor with hammer arms and tips along with bearing blocks.
 Lower Housing with half grinding wall and liners.
First place, the lower house on foundation on base frame and anchored.
Secondly, rotor with bearing blocks to be assembled. Bearing blocks are to be
dowelled and bolted. Check the level by spirit level.
In case of RCC foundation, place hammer mill on prepared foundation bolts.

Screw jacks may be used to lift and lower the hammer mill. Check by spirit level
and finally grout the foundation bolts and any pockets left by screw jacks.
Hammer Mill bed plate should rest on the foundation except the discharge
pocket.
While assembling the rotor with hammer arms and upper housing, ensure that
rotor or hammers do not touch the side walls. While installing the drive motor
pulleys, ensure that alignment of V-Belts is maintained and V-Belts are properly
tensioned.
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 6 of 11
LUBRICATION & MAINTENANCE OF BEARINGS
Refer drawing for bearing assembly and follow the instructions as per
lubrications as per lubrication schedule. This is to be strictly followed. Bearing
blocks are filled with grease at our works to last for nearly four weeks.
However, check grease before commissioning the hammer mill. In case the
machine was idle for a long time, check the bearing for any rust formation and
take necessary action to remove it. Labyrinth alleys are to be full of grease all
the time. While greasing it is necessary to rotate the shaft so that grease gets
filled up all over the periphery.
Every six months labyrinth alleys are to be washed from old grease and filled
with fresh grease. To do this, open the covers and clean with petrol or kerosene.
Every two years of operation the bearing blocks are to be dismantled all parts
and bearings thoroughly cleaned and checked. Re-assemble with fresh grease.
Too much grease heats up the bearing while running. During initial period check
the quantity by opening the covers. Do not wipe-off grease from nipple after
greasing cycle is over. Wipe grease nipple clean before greasing. Depending upon
local condition the greasing schedules have to be revised in consultation with
service engineers from bearing manufacturer.
The upper hinge point of grinding wall bracket is to be cleaned and greased
every 12 months.
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 7 of 11
LUBRICATION CHART OF HAMMER MILL
Lubric Type of Frequ- Lubric- Lubric- First During HP Indian

-ation Lubric- ency ant ant Fill- Runn- Oil
Points ation of Proper- Marking ing ing
Lubric- ties Qty. Qty.
ation
2 Manual 100 Lithiu K 250 20 Lithon- Mobi-lux

Bear- Grease Hours m Grms. Grms. 3
ing Gun based Each
Blocks bearing 3 K beari-
on grease ing
Rotor VIOLET
Shaft
4 Manual Every 100 20

Labyr- Grease Three ** ** Grms. Grms.
inth Gun Days
Rings
(2
Outer
+2
Inner)
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 8 of 11
LIST OF ESSENTIAL SPARE PARTS
Sr. Drawing No. / Spare Description Quantity

No. No.
1 424033.01.01 R4 Hammer 1 Set of 16 Nos.

2 424033.01.02 Rotor Shaft 1 No.
3 424033.01.00 SK-1 Rotor Pin 1 Set
4 0702035.01.02.00 Grinding Wall Assembly 1 Set
5 0702035.01.02.01 Great Bars 54 Nos.
6 22215.01.00 Housing assembly 1 Set for Fixed and
without bearing Free Bearing
7 22215 CK+H315 Spherical Roller Bearing 1 Set of 2 Nos.
with Adaptor
8 B-97 Vee Belts 1 Set of 3 Nos.
9 424033.02.00 Sr.No.25 Breaker Plate 1 No.
10 - Set of Liner Plates 1 Set
11 0222023.01.02.11 Machine Pulley 1 No.
12 0702035.01.04.01 Motor Pulley 1 No.
It is advisable to stock these essential spare parts for uninterrupted of Hammer

Mill.
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 9 of 11
IMPORTANT POINTS FOR MAINTENANCE & OPERATIONAL PERSONNEL
 During dis-assembly marks the parts with a piece of chalk for ease of
recognition while assembling again to avoid costly mistakes.
 Grease according to this schedule.
 Check all bolts and nuts from time to time.
 V-Belts guards are in position all the time except during V-Belt changing.
 Before switching ‘on’ ensure the movement of rotor.
 Hammer Mill should run quietly without any unusual noise.
 Our guarantee is adjusted to all the instructions given above.
IMPORTANT:
 Feed material should be strictly fed uniformly across width of the rotor.
 Every three weeks reverse the rotor direction of rotation to ensure uniform
wear of tips, grinding jib and liners. Please follow this carefully for optimum
production from the machines.
 After some service, if vibration is noticed, it indicates usual wear of tips.

Examine the tips carefully and bring its weight equal to the other tips in the
same row.
 Never run the hammer mill without a arm or tip.
 Ensure that all the V-Belts are in position. Never run the mill with any one of
them missing.
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 10 of 11
LIST OF TOOLS
Sr. Spanner’s Name Size Used to Operate

No.
1 Open end super wrench DE 13-14 M8
Spanner
2 Open end super wrench DE 17-19 M 10
Spanner
Spanner
Spanner
Spanner
Spanner
7 Allen key hex key wrench 8 mm. M 12 Hex Socket CSK
head cap screw
8 Screw Driver 12” General Use
9 Hammer 2 Lbs. (Approx.) General Use
10 Grease Gun with Adapter 6” General Use
11 Hook Spanner HN 22 KM 22 Lock Nut
Sheet
SAMPLING PVT. LTD.
S.O. NO.0702127 11 of 11
LIST OF DRAWING
Sl. Drawing Number Description

No.
1 0702127.00.00 Hammer Mill 400mm dia x 400mm wide
2 3502033.02.01.00 M Rotor Assembly with Part List
3 22215.01.00 M Bearing Assembly with Part List
RECORD OF DRAWING
ADITYA ALUMINIUM
(A DIVISION OF HINDALCO INDUSTRIES LIMITED)
DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS ,KOLKATA.
COAL HANDLING SYSTEM
6 X 150 MW CAPTIVE POWER PLANT
AT LAPANGA, ORISSA.
TECHNICAL DETAILS 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
TECHNICAL DETAILS 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
SYMBOL DETAILS 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
SYMBOL DETAILS 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
GENERAL ARRANGEMENT 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
BILL OF MATERIAL 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
MIMIC 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
A
ASS A ASS A
ADITYA ALUMINIUM


AT LAPANGA, ORISSA.
POWER CIRCUIT DIAGRAM 3M0024 G01 000 01

OF CRUSHER HOUSE.
0A
A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.

OF CRUSHER HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
GENERAL ARRANGEMENT 3M0024 G01 000 01

PLC PANEL OF CR. HOUSE.
0A
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.

OF CRUSHER HOUSE.
0A
16 CH. 24V DC DIGITAL INPUT MODULE 1
TYPE : 6ES7321-1BH02-0AA0
RACK : 1
16 CH. 24V DC DIGITAL INPUT MODULE 5
RACK : 1
ADITYA ALUMINIUM

AT LAPANGA, ORISSA.
I/F BETWEEN CSU & CHP 3M0024 G01 000 01

PLC OF CRUSHER HOUSE.
0A
1. SYSTEM PARAMETERS
2. CONSTRUCTION
:

3. NAME PLATE FOR FUNCTIONAL DESIGNATION :
4. EQUIPMENT MARKING FOR TAG DESIGNATION :
5. WIRES & FERRULES

WIRING
:
:
FERRULES
6. TERMINALS

2.2KW RDOL FEEDER FOR BELT FEEDER & SPARE FEEDER 2, FDR. NO. : 2F2 & 2F3, QTY : 2NOS.
E: 11 KW DOL FEEDER FOR CRUSHER & SPARE FEEDER3, FDR. NO. : 2F1, 3F1 QTY : 2NOS.

16 CH. 24V DC DIGITAL OUTPUT MODULE 2
RACK : 1

RACK : 1

RACK : 1


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ADVANCED

Client: Thyssenkrupp Industries Pvt. Ltd

ADVANCED SYSTEMS SAMPLING PVT. LTD.

ADVANCED SYSTEMS SAMPLING PVT. LTD.

ADVANCED SYSTEMS SAMPLING PVT. LTD.

END USER: Hindalco Industries Limited

JOB NUMBER: 159

CLIENT ORDER NUMBER: 2500003533 dtd. 18.01.2011

ADVANCED SYSTEMS SAMPLING PVT. LTD.

1.1. This Manual is important because:

 It shows you how to get the most out of the sampler.

1.1.1 Using this section of the Manual

ADVANCED SYSTEMS SAMPLING PVT. LTD.

2.2. SALIENT FEATURE:

2.3. Description of the Major Components of

2.3.1. The Control Panel:

2.3.2. The Housing:

ADVANCED SYSTEMS SAMPLING PVT. LTD.

2.3.3. The Mounting Frame:

2.4.4. The Motor and Gearbox:

2.4.5. The Sampling Arm:

2.4.5.1. The arm extension:

2.4.5.2. The swing arm with cutter:

2.4.5.3. The rubber scraper and/or nylon brush:

ADVANCED SYSTEMS SAMPLING PVT. LTD.

2.4.5.4. The proximity sensor and proximity sensor shield:

The inductive sensor or proximity is mounted on a bracket in line with the

ADVANCED SYSTEMS SAMPLING PVT. LTD.

2.5. The functioning of the Sampler:

Cross Section through the Hammer Sampler showing process flow

ADVANCED SYSTEMS SAMPLING PVT. LTD.

3. Transport and store the Sampler

Introduction This section of the manual deals with:

1. How to lift the sampler off the truck

2. How to store the sampler

Importance of The sampler can be damaged during this stage. By following

ensure that it is not damaged.

ADVANCED SYSTEMS SAMPLING PVT. LTD.

3.1. Steps to follow to store the Sampler

It is advisable to use a forklift for smaller units,

2 3.1.2. Store in an upright position.

Always store in a dry and level area (preferably

This diagram shows the correct storage

3 3.1.3. Store control panel

ADVANCED SYSTEMS SAMPLING PVT. LTD.

4. Install the Sampler

Introduction This section of the manual demonstrates how to:

1. Select the point of installation

2. Transport the sampler to the installation site

3. Unpack the sampler

4. Prepare the point of installation

5. Lift the sampler into position

6. Prepare support connections

7. Bolt the sampler into position

8. Set the wipers / brush

9. Mount the control panel

10. Identify the cables required

11. Connect cables to the motors and proxy switches

12. Connect cables to the control panel.

13. Install auxiliary equipment

Importance of If this stage is not correctly completed, problems such as,

poor ergonomics, inefficient operation, etc. will result.