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

mailto:[email protected]

http://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

PREMAS® 4.0 Installation and Commissioning Manual

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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.

https://premas.ch/premas-products-services/premas-knowledge-base


mailto:[email protected]


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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


-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


-X1001 Terminal

Signal 2 Brown AI3: Signal

GND 3 Black AI3: 0V

+V 1 Yelllow/green AI3: +24v

Screen 4 Screen Earth


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


GND AI5: 0V

AI5: +24Vsupply

Spare AI


GND AI6: 0V

AI6: +24Vsupply

Spare AI


GND AI7: 0V

AI7: +24Vsupply

Spare AI


GND AI8: 0V

AI8: +24Vsupply

Level Switch

Signal out DI1: Signal in

GND DI1: 0V

DI1: +24V

Speed Switch


GND DI2: 0V

DI2: +24V

Straight Run/ Drift Warning


GND DI3: 0V

DI3: +24V

Spare DI


GND DI4: 0V

DI4: +24V

Spare DI


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


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.



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.


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.



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



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

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