Installation and Commissioning Manual PREMAS® 4.0 ...
Transcript of Installation and Commissioning Manual PREMAS® 4.0 ...
Installation and Commissioning Manual
PREMAS® 4.0 – Predictive Maintenance Solution Version for Belt Bucket Elevators, CE & UL-Version
December 2020
Version 2.00/EN
Document number: DOC201125-1
Disclaimer
PREMAS Preventive Maintenance Service AG, hereinafter referred to as PREMAS AG, makes no
representations or warranties with regard to this manual and limits its liability for the breach of any
implied warranty to the replacement of this manual by another to the extent permitted by law. In
addition, PREMAS AG reserves the right to revise this publication at any time without having to
notify anybody about this revision.
The information provided in this documentation includes general descriptions and/or technical
characteristics for the performance of the devices. This documentation cannot be considered a
proper evaluation of the suitability of or reliability of the equipment for a specific application by a
user and may not be used as a substitute for such an assessment. It lies in the responsibility of each
such user or installer, to provide an appropriate and complete risk assessment, evaluation and
testing of the devices for each specific application. Neither PREMAS AG nor any of its partners or
subsidiaries may be liable for any misuse of the information contained herein.
All relevant state, regional and local safety regulations must always be observed when installing and
using this device. For reasons of security and to ensure compliance with the documented system
data, the manufacturer alone is entitled to carry out repairs on components. Failure to observe this
information may result in injury or damage to the equipment.
Copyright © 2020 PREMAS Preventive Maintenance Service AG
All rights reserved. No part of this publication may be reproduced in any form, including photocopy,
recording or any other electronic or mechanical reproduced, processed or used in any other way
without the written permission of the publisher be passed on. Requests for permits must be
submitted in writing to the publisher and can be sent to the address below.
PREMAS Preventive Maintenance Service AG • Haldenstrasse 1 • 6340 Baar • Switzerland
+41 41 766 82 01 • [email protected] • www.premas.ch
Product Modifications
Year Type Changes
2020 PREMAS® 4.0
Belt-Version CE
First Release
2020-12 PREMAS® 4.0
Belt-Version UL
UL Edition added
Document Modifications
Year Type Changes
2020 DOC201125-1 First Release
2020-12 DOC201125-1 UL Edition added
Approvals
This document requires the following permissions:
Name Title
Michael Bruckhaus Managing Director
Carlos Pinzon Digital Solutions
Table of contents
1 Foreword .................................................................................................................................... 8
1.1 User description ......................................................................................................................... 8
1.2 Explanation of the safety instructions ....................................................................................... 8
1.3 Storage instructions for this manual .......................................................................................... 9
1.4 Procurement of documents and information ............................................................................ 9
2 Description of the product ....................................................................................................... 10
2.1 Intended use and reasonably foreseeable misuse .................................................................. 10
2.2 Geographical restrictions ......................................................................................................... 12
2.3 System overview ...................................................................................................................... 13
2.4 Technical data .......................................................................................................................... 14
2.5 Product components ............................................................................................................... 16
2.6 User interface – PREMAS® Portal ............................................................................................ 17
3 Safety Instructions ................................................................................................................... 18
3.1 Safe handling of the product ................................................................................................... 18
3.2 Graphical symbols: Explanation of the safety information on the packaging and
the product .............................................................................................................................. 19
3.3 Possible health consequences ................................................................................................. 19
3.4 Personal protective equipment ............................................................................................... 19
3.5 Privacy ...................................................................................................................................... 19
3.6 Data processing ........................................................................................................................ 19
4 Preparation and installation .................................................................................................... 20
4.1 Transport and storage of the product ..................................................................................... 20
4.1.1 Dimensions and weight ....................................................................................................................... 20
4.1.2 Storage of the product ........................................................................................................................ 20
4.2 Installation of the product ....................................................................................................... 21
4.2.1 Removal of transport and packaging elements ................................................................................... 21
4.2.2 Unpacking the product ........................................................................................................................ 21
4.2.3 Sensor situation plan ........................................................................................................................... 22
4.2.4 Installation of the product ................................................................................................................... 23
4.3 Commissioning ......................................................................................................................... 38
5 Troubleshooting and Repairs ................................................................................................... 39
5.1 Identify and solve problems: Detecting problems during installation and commissioning .... 39
5.2 Frequently asked questions ..................................................................................................... 41
5.3 Repairs ..................................................................................................................................... 42
Appendix I – glossary ............................................................................................................................ 43
Annex II – related documentation ........................................................................................................ 43
Index of images
Figure 1: How PREMAS® 4.0 works ....................................................................................................... 13
Figure 2: PREMAS® 4.0 hardware overview.......................................................................................... 16
Figure 3: Machine overview of PREMAS® Portal .................................................................................. 17
Figure 4 Dimensions and weight of PREMAS® 4.0 packaging ............................................................... 20
Figure 5: Situation of sensors and signals connected to PREMAS® 4.0 IoT Box ................................... 22
Figure 6: Positioning the IoT Box and Antenna ..................................................................................... 25
Figure 7: Mounting positions for the temperature sensors ................................................................. 27
Figure 8: Mounting of temperature sensors ......................................................................................... 28
Figure 9: Temperature sensor mounted in the mounting bracket ....................................................... 29
Figure 10: Belt elongation measurement, arrangement drawing ........................................................ 31
Figure 11: Detail view to tension axis, mounting position of magnet for elongation measurement ... 31
Figure 12: Positioning of H-bracket at the tension axis ........................................................................ 32
Figure 13: Bracket for elongation sensor .............................................................................................. 32
Figure 14: H-bracket with sensor rail mounted .................................................................................... 33
Figure 15: H-bracket fixed on the feet .................................................................................................. 33
Figure 16: Top view to tension axis, distance between magnet and sensor rai ................................... 33
Index of tables
Table 1: Technical data Field Sensor Temperature ............................................................................... 14
Table 2: Technical data Field Sensor Elongation ................................................................................... 14
Table 3: Input Signals from Plant System ............................................................................................. 14
Table 4: Technical data IoT Box ............................................................................................................ 15
Table 5: Electrical connections for temperature sensor at head .......................................................... 30
Table 6: Electrical connections for temperature sensor at boot .......................................................... 30
Table 7: Electrical connections for elongation measurement .............................................................. 34
Table 8: Signal description .................................................................................................................... 35
Table 9: Connection table for existing signals ...................................................................................... 36
Table 10: Status check of component LEDs .......................................................................................... 38
Table 11: Detecting problems with the elongation sensor ................................................................... 39
Table 12: Detecting problems with the temperature sensor ............................................................... 40
Table 13: Detecting problems with the IoT Box .................................................................................... 41
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WARNING
DANGER
CAUTION
ATTENTION
1 Foreword
1.1 User description
This document is intended for mechanical and electrical professionals to install PREMAS® 4.0
hardware properly, based on this manual. Furthermore, it is intended for End-Users such as
Mechanical personnel, Maintenance Managers or similar professionals.
The electrical and mechanical installation and commissioning of PREMAS® 4.0 must be
carried out by appropriately trained personnel with professional skills and knowledge in
conveying equipment, electrical and mechanical engineering.
1.2 Explanation of the safety instructions
"Danger" indicates an immediately dangerous situation,
which, if not avoided, may cause death or serious injuries.
"Warning" indicates a potentially dangerous situation,
which, if not avoided, may cause serious injuries.
"Caution" indicates a danger that can lead to light to medium
can cause injuries if not avoided and or damage of property as well as assets.
"Attention" identifies information that is important, but are not
connected with potentially dangerous situations.
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1.3 Storage instructions for this manual
Make sure that you read the complete manual, and all have read and understood the safety
instructions before using this product. Non-observance of these instructions can lead to light
or heavy injuries. Follow all instructions. This will prevent accidents, which may cause
damage to property or light or medium injuries. Save all safety information and instructions
for later reference. Look it up and pass it on to future users of the product. The
manufacturer is not liable for any damage to property or injury resulting from incorrect
handling or non-compliance with the safety instructions. In such cases the warranty is void.
1.4 Procurement of documents and information
A current version of the documentation is available on the
following website: https://premas.ch/premas-products-
services/premas-knowledge-base.
Documentation, user instructions and technical information
can be requested by e-mail to [email protected].
For information on special tools and materials and for service-related questions, please
contact your distribution partner for PREMAS® 4.0.
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2 Description of the product
2.1 Intended use and reasonably foreseeable misuse
The Predictive Maintenance Solution PREMAS® 4.0, belt edition, is intended to be used as a
monitoring system for belt bucket elevators in the heavy industry.
PREMAS® 4.0 includes the following functionalities:
• Online condition monitoring of belt bucket elevators
• Presentation of measurement and analysis results to the user via an user interface
• Detection of anomalies during operation
• Prediction of service life for major components
The PREMAS® 4.0 belt edition is specifically designed for belt bucket elevators and is not
intended for use with any other conveying equipment.
Please contact PREMAS AG for usage with other equipment than belt bucket elevators.
The PREMAS® 4.0 must not be used in the following cases:
• Incompliance with the design of the bucket elevator
• Missing access points to mounting locations of required sensors
• Environmental conditions do not fit as specified for the PREMAS® 4.0 system
• Within ATEX zones
• Any use other than that described in these instructions
The PREMAS® 4.0 system shall only be used with its original accessories, software and
components consisting of:
• PREMAS® 4.0 IoT Box for belt bucket elevators including data collection interface
and mobile router
• LTE antenna
• Magnetostrictive Sensor system including mounting bracket
• Temperature transmitters including mounting brackets
• Data storage and processing in PREMAS® Cloud
• Access to PREMAS® Portal
The installation and usage of the system must be aligned and validated with the design,
instructions, and manuals of the original equipment manufacturer of the bucket elevator.
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Warranty for PREMAS® 4.0 systems
The warranty period is 12 months after commissioning, maximum 18 months after
notification of readiness for dispatch.
The installation must be carried out in accordance with the installation and operating
manual. Excluded from the warranty are defects caused by the purchaser or third parties,
e.g. by improper installation, improper use, improperly performed repairs or modifications
without prior written consent of AUMUND as well as defects caused by external influences.
Normal wear and tear do not constitute a defect.
Warranty is excluded if and to the extent that the buyer has provided incorrect or
incomplete information to AUMUND regarding the condition of the machine or plant to be
monitored with the delivered PREMAS® 4.0 system and/or the operating conditions of the
machine or plant.
Separately agreed warranty conditions apply to the machines or plants for whose
supplement a PREMAS® 4.0 system is supplied.
Exclusions of liability
PREMAS AG shall not be liable, for whatever legal reasons and to the extent permitted by
law: for damages not occurring to the delivery item itself, such as loss of production, loss of
profit, damages to third parties, downtime costs, loss of use, loss of orders, increased
operating, maintenance or personnel costs or indirect costs and/or consequential damages
of any kind.
The messages generated by the PREMAS® 4.0 system regarding the condition of the
machines or plants are based on the measurement data, a machine comparison of these
data with measurement values obtained during the operation of similar machines or plants
and the experience knowledge of OEM.
System indications regarding wear and service life are basically only approximations and are
not legally binding, since in continuous operation special influences, e.g. from the material
to be conveyed, from hidden defects of the machines or plants, from other plant
components and/or environmental conditions can occur at any time, which are not detected
by the sensor technology or only become effective with a time delay after a measurement.
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2.2 Geographical restrictions
The system must be used in compliance with any and all applicable national and
international laws and with any special restrictions regulating the utilization of the
communication module in prescribed applications and environments.
The used communication model is certified according the following standards and
regulations: CE/RED, EAC, CCC, Ukraine UCRF, RoHS, REACH, FCC, IC, PTCRB, Anatel, RCM,
Thailand NBTC, E-mark, Sirim, IMDA, SDPPI (POSTEL), AT&T approval, Verizon, Deutsche
Telekom AG, GCF, WiFi Certified, Giteki
The customer, as the builder of a system including a mobile radio system, is responsible
for the correct and conform operation and assumes the responsibility for ensuring that
the system at start-up complies with local regulations.
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2.3 System overview
The Predictive Maintenance Solution, PREMAS® 4.0, belt edition, is specially made for belt
bucket elevators in the heavy industry. Every machine receives a hardware package.
Provided field sensors as well as some existing signals from the plant control system (motor
current, level switch, speed switch, drift warning) will be connected to the IoT Box, which
sends the collected data through mobile connectivity to the PREMAS® Cloud. There, the data
will be analyzed based on the latest technologies for predictive analytics (e.g. algorithms,
machine learning …). The PREMAS® Portal visualizes and provides all relevant data for a
complete online condition monitoring, securely online accessible to authorized users 24/7
through any mobile or desktop device.
Figure 1: How PREMAS® 4.0 works
The system requires a 3G/4G mobile network at the location of the IoT Box installation.
Without a reliable mobile network the PREMAS® Cloud and PREMAS® Analytics will not
function.
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2.4 Technical data
PREMAS® 4.0 enables the early detection of wear and aging of important machine
components at your conveying equipment. Please find below further technical details of the
hardware of this Predictive Maintenance Solution.
Field Sensor: Temperature
Measurement Range -50°C to 150°C
Connection cable 4-wire connection to IoT Box
Signal type 4 to 20 mA
Location 1 at Boot, 1 at Head, mounted at machine
wall
Transmitter required No
External power supply required No (24 VDC supply from IoT Box)
Protection class IP IP67
Table 1: Technical data Field Sensor Temperature
Field Sensor: Elongation
Measurement Range 0 to 400 mm
Connection cable 4-wire connection to IoT Box
Signal type 4 to 20 mA
Location 1 at Boot (mounted at parallel tension device)
Transmitter required No
External power supply required No (24 VDC supply from IoT Box)
Protection class IP IP67
Table 2: Technical data Field Sensor Elongation
Input Signals from Plant System
Motor current Analogue signal: 4 to 20 mA
Level Switch Digital signal (on/off): 0 to 24 VDC
Speed Switch Digital signal (on/off): 0 to 24 VDC
Drift Warning Digital signal (on/off): 0 to 24 VDC
Input Impedance 27.4 ohms
Table 3: Input Signals from Plant System
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IoT Box
Material Metal enclosure
Operation conditions Ambient temperature from -30°C to 70°C
Size 30 x 40 x 21 cm (11,8 x 15,75 x 8,3 in)
Miniature circuit breaker Compact, single phase, rated current 10A
Input types 8x analog, 5x digital
Output types 2x digital (warning/alarm to external)
Power supply 110 to 230 VAC (uninterrupted power
supply – UPS)
Power requirement 25 W
Location Nearby bucket elevator boot
Mobile communication 4G (LTE), UMTS/HSPA+; EDGE; GPRS; GSM
SIM Card Global SIM card with data package included
Protection class IP dust proof (Nema 4/IP65)
Table 4: Technical data IoT Box
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2.5 Product components
Figure 2: PREMAS® 4.0 hardware overview
PREMAS® 4.0 IoT Box (Art. 3001066)
1. 1 PREMAS® 4.0 IoT Box including pre-mounted mounting brackets
PREMAS® 4.0 Antenna Kit (Art 3001068-1)
2. 1 LTE antenna incl. mounting brackets
3. 1 Antenna cable SMA, 5 m
PREMAS® 4.0 Elongation Kit W
(Art. 3001068-2)
4. 1 Magnetostrictive Sensor, Serie MAP
5. 1 Elongation magnet incl. screws
6. 2 Sensor mounting clamps incl. screws & sleeves
7. 1 Sensor cable, 10 m, 5-pole-plug-connector
PREMAS® 4.0 Temperature Kit (Temperature Kit Art. 3001068-4)
8. 2 Temperature Transmitter
9. 2 Sensor cables 10 m
PREMAS® 4.0 Mounting Brackets
10. 2 Temperature sensor mounting brackets (Temperature Bracket Art. 3001068-5)
11. 1 Elongation mounting H-bracket W incl. screws
(Elongation H-Bracket W Art. 3001068-6)
12. 1 Elongation magnet mounting bracket belt W (Elongation Magnet Bracket Art.
3001068-7)
Installation Guide Belt-Version (Art. 3001068-8)
13. 1 Installation Guide
1
2
3
4
5
6
7
8
9
10
11
12
13
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2.6 User interface – PREMAS® Portal
The signal data collected via the PREMAS® 4.0 hardware will be processed in the PREMAS®
Cloud and made available to the user via the PREMAS® Portal. AN example of a machine
dashboard is shown below.
To access the Portal please follow the instructions based on the operational manual which is
available online: https://premas.ch/premas-products-services/premas-knowledge-base.
Figure 3: Machine overview of PREMAS® Portal
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3 Safety Instructions
3.1 Safe handling of the product
Correct installation of the product is important for safety and performance. It is critical for
the safety of your operation and those who may perform work on your operation that you
select a qualified and competent electrical installer to undertake the installation. The
product must be installed properly to perform its designed functions. The installer should be
qualified, trained, and competent to perform the installation in accordance with Local and
National Electrical Codes, all relevant OH&S regulations, as well as any of your own
standards and preventive maintenance requirements, and other product installation
information supplied with the product. You should be prepared to provide the installer with
all necessary installation information to assist in the installation.
Make sure that you have read and understood the manual and all safety instructions
before using this product. The non-observance of these information can lead to serious
injury and damage of the equipment.
Risk of injuries and damages of assets during installation and commissioning if not installed
according instructions and by improper workmanship.
Strictly follow instructions given in this document
Risk of injuries due to moving and turning machinery.
Strictly follow local instructions for log-out and tag-out procedure as well as regulations for
isolating electrical supplies.
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3.2 Graphical symbols: Explanation of the safety information on the packaging and the product
3.3 Possible health consequences
Wrong. incorrect or incomplete installation, operation or maintenance may lead to injury or
even death. Specifically, rotating equipment and moving parts of the machine are a high risk
to health and life. Do not open a machine, e.g. bucket elevator, during operation nor an
electrical cabinet if not authorized to do so and the required precautions and measures are
in place.
3.4 Personal protective equipment
PPE shall be used according local regulation and instructions. Always make yourself familiar
with the side specific regulations and adhere to it.
3.5 Privacy
The data captured by the PREMAS® 4.0 systems are stored and processed in the PREMAS®
cloud. Data are stored anonymous and are accessible only for authorized with user rights
managed by PREMAS AG. Beside the username and password there are no personal data
stored in the system.
3.6 Data processing
The buyer agrees that PREMAS AG may use the operating data of the buyer's plants or
machines obtained with the supplied PREMAS® 4.0 systems, after anonymization, for the
further development of similar plants or machines and may forward them to third parties for
the further development of the software and the PREMAS® Portal.
Symbol Meaning
The CE marking on the product is the manufacturer's
declaration that the product meets the essential
requirements of the respective European laws for the
protection of health, safety, and environment.
UL
The UL marking on the product is the manufacturer's
declaration that the product meets the essential
requirements of the respective US American laws for
the protection of health, safety, and environment.
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4 Preparation and installation
4.1 Transport and storage of the product
4.1.1 Dimensions and weight
All system components are delivered in one boxing packed for sea freight, air freight and
road transport (see Figure 4 below). The dimensions and individual weights can be found on
the corresponding packing list.
Gros weight: 48 kg
Net weight: 32.5 kg
Dimensions: 96 x 55 x 50 cm
Figure 4 Dimensions and weight of PREMAS® 4.0 packaging
4.1.2 Storage of the product
The electronic components of the system (IoT Box, sensors, antenna) shall be stored in a dry
and clean location under the following ambient conditions:
Storage Temperature: ‐20°C to +70°C (‐4°F to +158°F).
Relative Humidity: 5 to 95%, non‐condensing.
This section is intended for the Mechanical and Electrical Professionals to install
PREMAS® 4.0 properly
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4.2 Installation of the product
The PREMAS® 4.0 system is designed for easy installation and commissioning.
This chapter describes the necessary steps and actions for a successful start-up.
4.2.1 Removal of transport and packaging elements
The PREMAS® 4.0 system consists of several elements which are packaged individually.
Each package is labeled for ease of identification.
Do not remove the element from the packaging except you are going to install its content.
This procedure will protect the element and ease later identification.
4.2.2 Unpacking the product
Unpack your PREMAS® 4.0 package Check delivered items with the packing list Read this installation guide and the online operational manual carefully (see
PREMAS Knowledge Base: https://premas.ch/premas-products-services/premas-knowledge-base)
Review of the scope of delivery
Check that the package contains the ordered parts and check the packing list, which is part
of the delivery documents of each system.
Installation and commissioning must be carried out by a suitably qualified and trained
electrician in compliance with the applicable regulations and laws.
The installer is responsible for employing experienced and qualified technical personnel.
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4.2.3 Sensor situation plan
Figure 5: Situation of sensors and signals connected to PREMAS® 4.0 IoT Box
The PREMAS® 4.0 system delivery includes two temperature sensors and one elongation sensor for supervision of the operation. Additional signals are required from existing installation (see green marked signals in Figure 5) and need to be prepared for connection to the PREMAS IoT Box.
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4.2.4 Installation of the product
4.2.4.1 Overview of the most important installation steps
Installation of temperature sensor at the head and boot Installation of elongation measurement at the tension station Laying signal cables from the sensors to the IoT Box Laying signal cables from the I/O terminals of the plant control system to the IoT Box Preparing the signals in the plant control system to interface with IoT Box Installation of the IoT Box and antenna
4.2.4.2 Required tools
Following tools are required for installation.
The list may be extended depending on the local situation and needs.
• For mechanical work - Folding yardstick, caliper, marker pen
- Drill bit for metal and drilling machine
- Angle grinder with cut-off wheel for metal
- Power cord extension
- Metal file/rasp
- Welding equipment
- Paint and paintbrush
- Spanner/wrench set
- Plus additional tools depending on local situation
• For electrical work - Insulated screwdriver for electrical work
- Wire cutter
- Wire stripper
- Multimeter
- Plus additional tools depending on local situation
• General - Scaffolding for access to mounting locations
Note: it is strongly recommended to have a fix installation to access the
measurement points and tension axle of the bucket elevator.
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4.2.4.3 Required materials in addition to PREMAS® 4.0 scope of delivery
• For electrical work - Cable according local standard for sensor signals, shielded, twisted pair ,
length depending on local situation (from sensors to IoT box)
- Small junction box (to connect sensor’s system cable with extension cable)
- Material for laying of sensor and antenna cable
- Material for wall-mounting of the IoT box
4.2.4.4 Installation Preparation
Before you install PREMAS® 4.0, please go through the following steps to make sure you get
most of your Predictive Maintenance Solution.
Minimal technical requirements for successful installation
Mobile 3G/4G coverage available at IoT box location? Power supply 110V or 230V available? Are the required signals available at the plant which need to be connected to the IoT
Box from the plant control system: Motor Current, Level Switch, Speed Switch, Straight run warning?
Is free and safe access to the chosen location given and work areas prepared for safe installation work?
Did you receive the login data to access PREMAS® Portal? If not, please check first internally who should have got the access (predefined Users). In case you cannot find it, contact your AUMUND Support.
Do you have your mobile device with internet access ready to access PREMAS® Portal?
Exposed buckets and moving parts will cause severe injury or death.
Lock-out, tag-out, check-out the machine prior to installation of the sensors.
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4.2.4.5 Installation of PREMAS® 4.0 IoT Box and antenna
In case you have done the preparation work mentioned in chapter “Installation
Preparation”, you are now ready for the hardware installation of PREMAS® 4.0.
Simply follow the instructions below for a successful installation.
Positioning the IoT Box:
Choose a position for the IoT Box next to the machine which should be monitored,
considering:
• ease of reach (like a junction box, local IO-cabinet)
• no exposure to the sun (to avoid additional heat up)
• no risk of mechanical damage
Positioning the antenna:
Choose a position for the antenna with the best 3G/4G connection considering:
• 5 m (16.4 ft) cable to connect the antenna with the IoT Box
• no risk of mechanical damage
• a strong mobile network signal is important for a reliable operation
Figure 6: Positioning the IoT Box and Antenna
IoT Box
Antenna
5m (16.4ft) cable
3G/4G network
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IoT Box and antenna mechanical and electrical work
1. Fix the IoT Box on the defined position
2. Fix the antenna on the defined position
3. Lay the antenna cable (in scope of delivery) from antenna to IoT box.
It is recommended to lay it in a cable tube or on a cable ladder.
Check out that the female connector is on the site of the IoT Box and the male connector
at the site of the antenna.
4. Connect the antenna cable with the antenna and plug the cable into the black router -
A800, port “Mobile” inside the IoT Box. (upper port)
5. Connect the power cable to the circuit breaker -F301 of the IoT Box.
Electrical hazard
Disconnect all sources of supply prior to installation and servicing
Connect antenna cable to this port
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4.2.4.6 Installation of temperature sensor at boot and head
There are two temperature sensors belonging to the PREMAS® 4.0 system, measuring the
ambient temperature inside the elevator´s housing.
For installing the temperature sensor, the mounting bracket has to be welded to the
elevator casing. The threat of the mounting support is prepared to take up the temperature
sensor.
Positioning the temperature sensor at the bucket elevator boot and head:
The positioning of the temperature sensors is shown in Figure 7. Choose a position within
the indicated area and mark a 70 x 70mm cut out for the brackets.
Figure 7: Mounting positions for the temperature sensors
Risk of mechanical damage.
The sensor tip and the sensor bracket protrude into the interior of the machine. They must
be arranged in such a way that there is no risk of collision with the bucket strand!
The temperatur sensor shall be installed always with its mounting bracket.
Failing to to do will result in a damage of the sensor during operation.
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Temperature sensor mechanical work
1. Cut out the marked area and grind the edges
2. Prepare the bracket for welding (grind of color at welding area)
3. Spot weld the sensor bracket to the chosen position.
4. Weld the sensor bracket with a continuous welding seam to the elevator housing.
5. Repeat steps 1-4 for the second position.
Create opening for bracket
Weld bracket to casing
Figure 8: Mounting of temperature sensors
Risk of mechanical and thermal damage.
Before handling the sensor bracket make sure that the sensor is not mounted.
Temperatur sensor to be installed after welding!
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Temperature sensor electrical work
1. Screw in the temperature sensor into the threat of the sensor bracket.
Figure 9: Temperature sensor mounted in the mounting bracket
1. Connect the supplied cable with its 4-pole connector to the sensor and tighten the
coupling nut slightly by hand. Be careful not to damage the pins during connection.
2. Extend the provided sensor cable up to the IoT Box with your own supply and connect it
with the IoT Box (see connecting diagrams below).
The unit must be connected by a qualified electrician.
The national and international regulations for the installation of electrical equipment must
be adhered to.
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Temperature sensor head
Function Connector Pin
Wire code of system cable
Wire code of extension cable*
-X1001 Terminal
Signal 2 White AI1: Signal
GND 3 Blue AI1: 0V
+V 1 brown AI1: +24v
IO-Link 4 Black Not used
* enter the code of your wire
Table 5: Electrical connections for temperature sensor at head
Temperature sensor boot
Function Connector Pin
Wire code of system cable
Wire code of extension cable*
-X1001 Terminal
Signal 2 White AI2: Signal
GND 3 Blue AI2: 0V
+V 1 Brown AI2: +24v
IO-Link 4 Black Not used
* enter the code of your wire Table 6: Electrical connections for temperature sensor at boot
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4.2.4.7 Installation of belt elongation sensor
The belt elongation measurement will be installed at the tension axes of the bucket elevator.
The elongation sensor will be installed to an H-Bracket which serves as mechanical
protection of the sensor and mounting support.
Figure 10: Belt elongation measurement, arrangement drawing
Mechanical Work
1. Installation of magnet to the tension axis:
Position the mounting bracket to the tension axis and fix it (drill, cut threat, screw it)
For the correct position see Figure 11 below. The magnet shall be positioned in the
center of the tension axis.
11. hex screw M6x12 12. Spring ring 6. bracket for magnet
Figure 11: Detail view to tension axis, mounting position of magnet for elongation measurement
Bracket with magnet
Rail sensor
H-Bracket
BracketB
H-Bracket foot
BracketB
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2. Installation of the elongation sensor and the corresponding H-bracket.
The measurement range of the sensor rail shall reflect the traveling distance of the axis
within the tension unit. This for position the center line of the H-bracket´s upper base to
the top position of the tension axis. (see Figure 12)
Hold the H-Bracket in front of the desired position and spot weld the arms to the tension
station´s site plates.
Figure 12: Positioning of H-bracket at the tension axis
3. Take the main frame of the H-Bracket and mount the two brackets for the sensor rail
facing direction elevator. Make sure to use the insulating sleeves on top and bottom of
the bracket!
Figure 13: Bracket for elongation sensor
Risk of mal function and electrical damage.
Make sure to use the insulating sleeves on top and bottom of the bracket.
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4. Press the Magnetostrictive sensor rail into the mounting brackets
Figure 14: H-bracket with sensor rail mounted
5. Fix the H-Bracket (including sensor rail) on the welded H-Bracket feet with the provided
screws.
Figure 15: H-bracket fixed on the feet
6. Align the H-bracket and ensure that a distance of 2-7mm between magnet and the
sensor rail is kept over the entire length of the tension system (see Figure 16)
Figure 16: Top view to tension axis, distance between magnet and sensor rai
Risk of sensor damage.
Distance between magnet and sensor rail (2-7 mm) must be ensured over the entire length
of the tension system!.
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Electrical Work
1. Connect the plug of the sensor cable with the Magnetostrictive sensor and pull it to the
IoT Box diagram (if required extend it with a small junction box and cable, not part of the
scope of delivery)
2. Connect the wires to the terminal -X1001 according the connection diagram.
Function Connector
Pin Wire code of system cable
Wire code of extension cable*
-X1001 Terminal
Signal 2 Brown AI3: Signal
GND 3 Black AI3: 0V
+V 1 Yelllow/green AI3: +24v
Screen 4 Screen Earth
* enter the code of your wire
Table 7: Electrical connections for elongation measurement
The unit must be connected by a qualified electrician.
The national and international regulations for the installation of electrical equipment must
be adhered to.
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4.2.4.8 Connection of signals from the process control system
The following signals must be prepared in the process control system and connected to the
IoT Box:
Signal Description Details
Motor current Analogue signal: 4 to 20 mA
PCS output signal
Current measurement of the bucket elevator’s
main drive.
Level Switch Digital signal (on/off): 0 / 24 VDC
PCS output signal
Signal of the level switch in the elevator’s boot
which acts as overfill indication.
A “0” means overfill, a “1” means no overfill.
Speed Switch Digital signal (on/off): 0 / 24 VDC
PCS output signal
Signal monitoring the turning of the elevator’s
belt.
Straight run
warning
Digital signal (on/off): 0 / 24 VDC
PCS output signal
A belt bucket elevator typically has 4 drift
switches to monitor the straight running of the
belt on the drive and tension drum.
If one of the signals is indicating a drift a “0”
shall be send to the IoT box. If there is no drift,
the signal shall be “1”.
IoT Box warning Digital signal 0 / 24 VDC
PCS input signal
Signal indicating a failure of the IoT Box
1 = all good
0 = IoT more than 12 hours offline
Machine warning Digital signal 0 / 24 VDC
PCS input signal
Signal indicating a machine warning from
prediction or anomaly.
1 = all good, 0 = warning
Shall not trigger an interlocking but an
inspection of the elevator.
Table 8: Signal description
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The signals from sensors and process control system shall be connected as shown in the
table Table 9 below.
Signal Function Terminal of control system
Wire code of cable* -X1001 Terminal
Motor current
Signal out AI4: Signal in
GND AI4: 0V
AI4: +24Vsupply
Spare AI
Signal out AI5: Signal in
GND AI5: 0V
AI5: +24Vsupply
Spare AI
Signal out AI6: Signal in
GND AI6: 0V
AI6: +24Vsupply
Spare AI
Signal out AI7: Signal in
GND AI7: 0V
AI7: +24Vsupply
Spare AI
Signal out AI8: Signal in
GND AI8: 0V
AI8: +24Vsupply
Level Switch
Signal out DI1: Signal in
GND DI1: 0V
DI1: +24V
Speed Switch
Signal out DI2: Signal in
GND DI2: 0V
DI2: +24V
Straight Run/ Drift Warning
Signal out DI3: Signal in
GND DI3: 0V
DI3: +24V
Spare DI
Signal out DI4: Signal in
GND DI4: 0V
DI4: +24V
Spare DI
Signal out DI5: Signal in
GND DI5: 0V
DI5: +24V
Box Warning
Signal in DQ1: Signal out
GND DQ1: 0V
Machine Warning
Signal in DQ2: Signal out
GND DQ2: 0V
* enter the code of your wire
Table 9: Connection table for existing signals
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Final Hardware Installation Check
If you have gone through all steps, please check whether your installation had been
successful. You will recognize it through the following points:
Temperature Sensor at bucket elevator’s head is mechanically installed. The cable connector is plugged into the sensor and tightened. Cable is pulled and connected to the IoT box.
Temperature Sensor at bucket elevator’s boot is mechanically installed. The cable connector is plugged into the sensor and tightened. Cable is pulled and connected to the IoT box.
Elongation sensor is installed at tension station. Magnet and rail are adjusted. The cable connector is plugged into the sensor and tightened. Cable is pulled and connected to the IoT box.
All required signals are connected from process control system to the IoT box. All signals are connected according the wiring diagram. Power supply (230 or 110 VAC) are connected to IoT box Antenna is mounted, cable pulled and connected to the router -A800
Are you able to tick every box? Congratulations! You successfully installed PREMAS® 4.0.
You can now commission it as described in the next chapter.
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4.3 Commissioning
IoT Box commissioning
1. Check the voltage at the terminals of the breaker -F301 for 230VAC respectively 110VAC
2. Switch on the breaker -F301; the system components are starting up.
3. Check the status LEDs of the components and record the result:
Component Label LED Expected
color
Actual LED
color
Power supply -G301 PWR Green
AI module,
Busworks XT 4. -A811
STATUS Yellow
RUN Green
SIMATIC IOT2000 -A801
PWR Green
STAT Green
flashing
USER 1 Green*
USER 2 Green*
* it may take up to 4 minutes for theLED to change from RED to GREEN
Table 10: Status check of component LEDs
If the expected LED status has been confirmed, the system is ready for usage. To use the system online, please connect to the PREMAS® Portal and select your machine for
access to the machine dashboard.
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5 Troubleshooting and Repairs
5.1 Identify and solve problems: Detecting problems during installation and commissioning
Elongation sensor
Symptom Problem / Error Solution
Signal disturbances Other static or dynamic magneto restrictive fields in close distance to the sensor
Remove other magneto
restrictive sources
No signal indication Signal cable is connected to the wrong terminal
Make sure that the
elongation signal is
connected to terminal -
X1001: AI3
Check as well the +24V, 0V
and signal are not mixed up.
No signal indication Sensor rail is grounded Check installation of the
sensor brackets: the
insulating sleeves shall be
used together with the
screws. The rail shall not be
grounded.
No signal indication Distance between magnet
and sensor rail
Adjust the H-bracket to
ensure that the distance
between magnet and rail is
always between 2 and 7
mm
No signal indication Magnet out of
measurement area of the
sensor rail.
On the connector site there
is an inactive area of
100.5mm.
On the non-connector site
the inactive area is 53.5
mm.
Adjust the H-bracket to
ensure that the magnet
never moves into the
inactive areas.
Table 11: Detecting problems with the elongation sensor
Do not open nor replace any component of the PREMAS® 4.0 system without prior
approval and advise of PERMAS AG.
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Temperature sensor
Symptom Problem / Error Solution
Temperature sensor cannot
be screwed into the thread
of the sensor bracket
Contaminated threat
Clean the threat
Use a G1/4A threat cutter
No signal indication Signal cable is connected to
the wrong terminal
Make sure that the
elongation signal is
connected to terminal -
X1001: AI4 (for head)
X1001:AI1 (for boot)
Check as well the +24V, 0V
and “signal” are not mixed
up. Table 12: Detecting problems with the temperature sensor
IoT Box
Symptom Possible problem / error Solution
SIMATIC IOT2000, -A801:
The LED USER 1 does not
turn green
Communication with the AI module -A811 could not be established
Disconnect and reconnect the
blue network cable on top of
the-A811 module.
After 15s the LED should turn
green.
SIMATIC IOT2000, -A801:
The LED USER 1 does not
turn green
Network cable not attached to AI module -A811
Check the connection of blue
network cable passing from
SIMATIC IOT2000 Port P1 to AI
module -A811 Port 1.
SIMATIC IOT2000, -A801:
The LED USER 2 is red.
3G/4G communication interrupted.
The router changes networks
automatically if signal level is
too low. During network
change over the LED turns red.
After 4 minutes it will turn
green again.
SIMATIC IOT2000, -A801:
The LED USER 2 does not
turn green
There is no active 3G/4G
mobile network in the
area
Check with your
mobile/cellular phone the
availability of a 3G/4G
network.
If there is a network, restart
the IoT box.
After 4 minutes the LED should
turn green.
Without a network the system
will not run properly.
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Symptom Possible problem / error Solution
SIMATIC IOT2000, -A801:
The LED USER 2 does not
turn green
Network cable not
attached
Check the connection of blue
network cable passing from
SIMATIC IOT2000 Port P2 to
router -A800 Port LAN. Table 13: Detecting problems with the IoT Box
5.2 Frequently asked questions
I am missing a part to install the hardware
In this case, please contact your AUMUND Support. We will provide the missing part as soon
as possible.
Not all required signals from the plant control system are available for the IoT Box
In case you do not have all required signals (Motor Current, Level Switch, Speed Switch,
Straight run warning), please contact your local PREMAS® 4.0 supplier.
Certain functionalities of the analytics and dashboard will not function properly or not at all.
I would like to connect the IoT Box to more than one machine – is this possible?
No. The system is designed for one machine per box. This is due to the "do-it-yourself"
approach and easy to mount components, which makes it possible to function quick without
additional services.
Our cellular network is currently not working – can we still use PREMAS® 4.0?
The current solution requires mobile communication for data transfer. The IoT box is still
collecting data but not transferring it to PREMAS® Cloud. Therefore, your data is collected
but cannot be analyzed and accessed via PREMAS® Portal until the cellular network is
working and the IoT Box connecting again.
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5.3 Repairs
If a component of the PREMAS® 4.0 IoT Box, a sensor or a part of a sensor got damaged,
please notify your local supplier of the PREMAS® 4.0 system or, if not available, directly
PREMAS AG.
Prior to a repair of the system or an exchange of parts of it, PREMAS AG or a local distributor
shall be contacted. During the exchange of a system component (IoT Box, sensor, antenna
...) all local regulations have to be respected in addition to those mentioned under 3.1.
Do not open nor replace any component of the PREMAS® 4.0 system without prior
approval and advise of PREMAS AG.
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Appendix I – glossary
Terminology Meaning
IoT Internet of Things
PCS Process or Plant Control System
LTE Long Term Evolution, 3rd generation of
wireless broadband communication for
mobile devices
Annex II – related documentation
# Document title Version Location Author
Operational Manual V1.0 Online PREMAS AG
PREMAS Preventive Maintenance Service AG • Haldenstrasse 1 • 6340 Baar • Switzerland
Phone +41 41 766 8201 • [email protected] • www.premas.ch • VAT No. CHE-101.920.381
PREMAS Knowledge Base
Questions?