INSTRUCTION MANUAL

GRAIN DISCHARGER
MODEL - BE-100, BE-125, BE-150,
BE-200, BE-250, BE-300, BE-350, BE-375
INDEX
A ERECTION & COMMISSIONING

1.0 Receipt of material at site 3

2.0 Unloading of equipment 3

3.0 Checking of foundation 3

4.0 Assembly and erection of components/sub-assiys 4

5.0 Electrical connections 10

6.0 No Load Trials 11

7.0 Load Trials 11

B OPERATION & MAINTENANCE

B.1 Construction 12

B.2 Operating instructions 13

B.3 Periodic Maintenance 14

B.4 Trouble Shooting 15

B.5 Packing Details 16

B.6 Load Trial Format 17

B.7 Pre-Trial Checks & Post-Trial Checks 18

B.8 Annexure 19

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Grain Discharger
 INTRODUCTION

Grain Discharger
In the present era of globalization, Eminence strives to come up with
new, ultramodern machinery to suit grain handling needs of its clients
achieving the world class standards.

To handle a variety of free flowing material like rice and wheat Eminence
has developed a special Grain Discharger. It handle the grains very
gentle having negligible fall back and negligible broken percentage.

Modular design of Eminence's Grain Discharger ensures perfect fitment.

It keeps the system rigid, resulting in absolute alignment and easy
operation.

This technical manual aims to provide all the details necessary for its
operation and maintenance.

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Grain Discharger
A. ERECTION AND COMMISSIONING

1.0 RECEIPT OF MATERIAL AT SITE

Refer to the list of “Packing Details” for Grain Discharger, given in the manual . These parts
are independently despatchable and at times erectable items. These are dispatched in one or
more lots. Verify the goods received at site and Packing List received with the consignment for
the Grain Dischargers. Acknowledge the receipt of materials to Eminence Equipments Pvt.
Ltd. within 3 days from the date of receipt of material at site. Any loss, damage or mismatch
(Quality , Packing List quantity and actual received quantity) should be informed to Eminence
and / or to the Insurance company to make the necessary claims, as the case may be. The
G.A. drawing and layout drawing of Grain Discharger is also attached for reference in the
manual.

2.0 UNLOADING OF EQUIPMENTS AND PARTS

Use proper lifting tools / tackles and devices for unloading of material from truck. In case of
manual unloading, proper care should be taken to avoid any possibility of damage to any of
the packing or sub assembly. Please do not throw the Box on Ground from Truck.

For longer storage, prior to erection, keep all material in covered area while the bases of these
units raised by 100mm from the floor. Ensure that all units rest on their bases and not on any
sides, during or after the unloading.

3.0 CHECKING OF FOUNDATION

Before erection of equipments, sub-assemblies etc., verify overall foundation provided for the
equipment with the help of drawing.

A. Orientation of overall foundation, equipment foundation with respect to the plant

layout.

B. Numbers, sizes and depths of all the foundation pockets.

C. Relative location and level of these foundations with respect to

each other and the other foundation in the plant.

In case of any variations, get the same corrected before starting the erection of the
equipment.

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Grain Discharger
 4.0 ASSEMBLY AND ERECTION OF GRAIN DISCHARGER
4.1 Assembly Of Bottom Casing
4.1.1 After rectification & ensuring correct foundations
for discharger, bottom casing of Grain Discharger
is kept on foundations, leveled and grouted. Refer
procedure for leveling and grouting, given in
Annexure
4.1.2 After 72 hrs of curing once again check the level of
top flange of bottom casing. Correct the same by
adding shims below the equipment base if
necessary.
4.1.3 Check level of Tail-shaft in this position by water
level and correct the same if required, using Take
up screw assembly.
4.1.4 Keep the Tail-shaft in its upper most position
again using the take-up screw.

4.2 Assembly of Middle Intermediate Casing

There are three types of middle casing, namely Inspection
casing, Standard Intermediate casing & non-standard
Intermediate casing. Each of these middle casing has two
trunks of equal lengths. Inspection has same length as of
Standard Intermediate casing.
First dissemble the bottom 'c' (Flange) & keep the
Standard Intermediate casing on one side and Inspection
casing on one side & place 'C' clamps & fasten the bolts.
We can place the Inspection Casing as per requirements
on first floor or the required position.
Unscrew the hex bolts at both the ends of Intermediate
casing. Place the casing on each other to increase the
height & place the joining clamp.
Place the distance piece in between the two
Intermediate casing & tighten the four m8 x
25 bolts joining two joining clamps, four
Intermediate casing & one Distance Piece.
Check for the alignment with help of plumb
& proceed further. )
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Grain Discharger
4.3 Assembly Of Top Casing

Top casing consists of head pulley, shaft, bearings, casings, mechanical type hold-back etc.
And is relatively heavy and bulky. Since it is to be assembled on the top of the middle casings
assembled so far, proper lifting arrangement should be made before starting erection and
assembly of top casing. Please note following points before starting the erection and
assembly of top casing.

4.3.1 Bottom flange of the Top-casing is punched for assembly with Top Intermediate casing
and should be perfectly horizontal. (Check it by water level).

4.3.2 Sliding arrangement should not damage the Top casing while lifting.

4.3.3 The orientation of outlet from Top casing and shaft extensions are as per drawing.
Head Shaft has extention at both the ends & we can change the Drive motor position &
Hold back position on both sides.

4.3.4 Unfolded edges of triangular piece of top housing are

arranged inside and outside of the trunks of top casing
respectively on Return and Carrying side of the elevator
belt. Refer Sketch and details 'A' in Annexure for 5623
clarification. Fix Top casing to the top (Intermediate)
casing by bolting both the matching flanges together
firmly.

4.3.5 Level of the top flange of Bottom casing using water level, correct the same if
necessary. Use suitable packing for this purpose.

4.3.6 Complete balance Grouting.

Inspection and Bottom casings are to be assembled respectively at the start. Standard
Middle casing are to be assembled in between. Following precautions should be
taken while assembling the Middle Casings.

l) Bolts used for fixing “Distance pieces” are to be tightened only after checking &
assuring of respective casing by plumb in all planes thoroughly.

ll) While placing trunks of middle casing over the another, inner surfaces of both the
trunks should flush correctly with that of the other. Refer sketch in the annexure for
details. Any damage to horizontal edges of inner surface of trunking would result in
obstruction to the belt movement during operation. This must be rectified immediately
if found.

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Grain Discharger
 lll) Middle casing of Grain Discharger must be laterally
supported at every 4 meters. Support brackets or members
must only be bolted to Grain Discharger casing. Welding is
not to be adopted on any of the Grain Discharger parts.
Lateral supports may be obtained from any adjoining
structure. Ensure that verticality / plumbline of Grain
Discharger casing is not disturbed because of these lateral
supports. Refer sketch in annexure for details.

4.4 CHECKING THE PLUMB OF GRAIN DISCHARGER

The most Important factor which directly affects the performance of the
Grain Discharger is plumb (Alignment of Grain Discharger)

To check the plumb level, remove the plate as shown in photo of top
casing. Insert the plumb from inside the Intermediate casing.

Remove the side plate at bottom casing & check for the plumb level
Three points on both sides as shown in the photo.

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Grain Discharger
4.5 ASSEMBLY FOR GRAIN DISCHARGER BELT

Assembly of Grain Discharger belt is an important as well as critical process. As such it is very
important to adhere the procedure given here under for the assembly.

4.5.1 Ensure that length of the Grain Discharger belt received at site is not less than that
given in the packing list of the Grain Discharger. Inform Eminence otherwise,

4.5.2 For Paddy Grain Discharger normally black belt is provided. For rice / wheat food
grade white belts are provided & for discharges after Polisher Oil Resistant Belts are
provided. Choose the belts accordingly referring the Bill of material & drawing.

4.5.3 Place the belt on ground & insert the bucket bolts from
Higher rubber thickness side ( 3mm) Bolt head should
be at higher thickness side & bucket should be fixed
from lower rubber thickness side as shown in photo.

4.5.4 Do not fix all the buckets on the belt. Leave at least 2
meters from rubber both ends of belt without
buckets.

4.5.5 Check that all the buckets are properly tightened. Cup
washer, washer, square nut & nylock nut are tightened.
Fix the belt joining plate at one end of the belt.

Open both the covers of Inspection casing. Insert the

Rope from top casing. One end of Rope is taken out
from Inspection casing where we can fix the belt joining plate with
Rope to insert the belt. The other end of the Rope is taken out from
bottom casing around the bottom pulley. By pulling the rope around
the bottom pulley we can easily insert the belt.

4.5.6 CHECK The Bucket position before insertion of Belt.

4.5.7 Take out both ends of belt from Inspection casing. Remove the Rope.
Fix belt joining plate on other side of the belt with the provision to tight
the belt with TURN BUCKLE

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Grain Discharger
 4.5.8 The turn buckle should be fully open. Tight the belt with the help;
of TURN BUCKLE. After tightening the belt should freely
rotate in the casings.

4.5.9 Cut the extra length of belt with the help of Hake
Saw.

4.5.10 From the remaining portion of belt the splice is

used to join the belt. Butt joint is a preferred joint.
Tight all the bolts. Put extra bolts at the joint as
shown in photo.

CUT BUCKETS 4 Nos. are provided to fix on the

Belt joint.

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Grain Discharger
4.6 Drive Motor Installation,

Before Installation of Drive motor check the free movement of belt with hand.

4.6.1 Check for Oil in the geared motor before the electrical connection.

Check the no load current of motor on ground floor before installation of motor. No.
load currents should be 60% to 70% of rated current of motor. Rated current 60% to
70% (No load current)

Motor HP Motor KW Full Load No Load

Current Current

0.5HP 0.37 Kw 1.07 Amp 0.7 Amp

0.75HP 0.55 Kw 1.55 Amp 0.93 Amp

1.0HP 0.75 Kw 1.85 Amp 1.15 Amp

1.5HP 1.1 Kw 2.82 Amp 1.7 Amp

2 HP 1.5 Kw 3.7 Amp 2.3 Amp

3 HP 2.2 Kw 5.4 Amp 3.3 Amp

5 HP 3.7 Kw 8.9 Amp 5.4 Amp

7.5 HP 5.5 Kw 11.8 Amp 7.1 Amp

10 HP 7.5 Kw 15.7 Amp 9.5 Amp

4.6.2 On the top casing fix the Motor mounting Bracket if it is

sent loose. Refer Bill of material and Drawing before
fixing the motor mounting bracket.

4.6.3 Mount the drive geared motor after checking in G. A.

drg. / Bill of material. Fix the motor on motor mounting
plate with 4 bolts provided. Check the alignment of
shaft of geared motor & shaft of pulley.

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Grain Discharger
 4.6.4 After correct alignment tight the bolts place the chain.
Lock the chain with lock, apply some grease on chain.
Tight the grub screw on Motor shaft & pulley shaft .
Place the aluminium cover.

5.0 Electrical Connections

5.1 Before making electrical connections, ensure that there is no obstruction for the
movement of Belt - Disengage Preferably the electrical connection to the motor should
be the hold baek paul done with armored cable. Provide the relay of appropriate
rating & set the Tripping current as per following table.

HP 0.5 0.75 1.1 1.5 2.0 3.0 5.0 7.5 10.0

Kw 0.37 0.55 0.75 1.1 1.5 2.2 3.7 5.5 7.5

Amp. 1.07 1.55 1.85 2.82 3.7 5.4 8.9 11.8 15.7

Check the direction of motor running. Run the motor in corrected direction.

5.2 Zero speed Switch (optional)

Zero speed switch is a safety Device. Device is provided as per the

order.

Fix the sensor probe in the bracket keeping distance of 5-7 mm

between 4 way Flag and sensor probe. Fit the Monitoring unit with the
help of Bracket on Inspection casing. For wiring & other details refer
Drawing.

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Grain Discharger
6.0 NO LOAD TRIALS

6.1 Run the Grain Discharger continuously for 8 hours and then observe for belt details,
any abnormal noise, bucket touching, nuts / bolts getting loose etc. and take
corrective action.

6.2 Check current of the monitor when the elevator is in operation which should not be
more than 60% of the full load rated current of the drive motor.

6.3 Recheck that the Discharger is in plumb.

6.4 Belt and buckets are tight.

6.5 Zero speed monitoring is operating.

6.6 There is no abnormal noise / vibration in the equipment.

7.0 LOAD TRIALS

7.1 Ensure that the equipments incoming & outgoing in the line to the Grain Discharger
are in operation and interlocks are functioning.

7.2 Start the Grain Discharger and start feeding the material to the inlet hopper of the
Grain Discharger.

7.3 Gradually increase the feeding till one achieves the capacity of the system.

7.4 Observe the vibrations, shifting of belt etc. If so observed, put off the system and
analyse the problem and take corrective actions.

7.5 Check the current of motor at full load capacity, It should be less than the mentioned
rated full load current.

7.6 Retighten the nuts & bolts of the moving parts.

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Grain Discharger
 B. OPERATION AND MAINTENANCE

B.1 CONSTRUCTION

The equipment consists of mainly 3 parts :

a. Bottom Assembly.

b. Top Assembly.

c. Intermediate Casings.

Standard Grain Discharger Bottom Assembly (Boot) is

fabricated with mild steel with inlet spout, pulley mounted on
shaft with bearings, screw type take-up arrangement which
helps to tighten or loosen the belt. Spout can be mounted on
either side of the boot. Spout is so designed and mounted that
the buckets can be filled to their maximum capacity.

Standard Head Top Assembly is fabricated with mild steel with

Horizontal Discharge Flange. This also consists of pulley
mounted on shaft with bearings. One end of the shaft is fixed with drive and the other end is
fixed with Hold back assembly to prevent / restrict the reverse run of the Grain Discharger
when it is stopped in running condition. UHMWPE Liners are provided from the inside of the
Top Hood to avoid the wear and tear of the hood sheet and these liners are replaceable.

Intermediate Casings are fabricated with mild steel and fixed on each other with the help of
joining clamps and distance pieces. First casing immediately above bottom assembly is
provided with inspection door. This can be used for joining the belt, observing the material in
bucket, to check whether the belt is running at centre etc.

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Grain Discharger
B.2 OPERATING INSTRUCTIONS

Grain Discharger is running equipment which does not need regular supervision. For safe,
trouble free and efficient operation it is necessary to follow the instructions given below,

B.2.1 Do not operate Grain Discharger unless all equipments incoming & outgoing from the
Bucket Elevator are in operation.

B.2.2 Do not run the Grain Discharger when the belt is loose.

B.2.3 Do not run the Grain Discharger when the buckets are loose.

B.2.4 Do not put hands inside the trunking when the Grain Discharger is in operation

B.2.5 Control the feed to the rated capacity of the Grain Discharger.

B.2.6 Run all the electrical cables through proper conduits

B.2.7 Ensure that all connecting parts and chutes are firmly connected to the Grain
Discharger and no abnormal noise is heard during the operation.

B.2.8 After periodic electrical maintenance, before restarting the Grain Discharger, check
and ensure for the correct direction of rotation and hold back assembly in it's locking
position.

B.2.9 Carry out periodic maintenance as per manual

B.2.10 Do not run the Grain Discharger if it's safeties are not functioning

(Zero speed switch, Hold back, O/L relay etc.)

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Grain Discharger
 B.3. PERIODIC MAINTENANCE

For trouble free operations, following schedule of preventive maintenance is recommended:

Sr. No. Activity Frequency

1. Checking of nuts / bolts of Once in six months

moving parts

2. Checking the tightening of belt Once in six months

jointing and buckets

3. Checking the alignment of Once in six months

Grain Discharger (Vertical)

4. Checking the alignment of drive Once in six months

arrangement / coupling

5. Checking the feeding gates position Before starting the

equipment

6. Checking the feeding chute & discharge Once in a year.

chutes wear & tear.

7. Greasing of bearings. Once in six months

8. Refilling of gearing oil As per the manual of

drive unit.

Above schedule is given on the basis of 8 hours operation of the equipments. In any other
case, change the frequency of maintenance suitably.

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Grain Discharger
 TROUBLE SHOOTING

S. OBSERVATION PROBLEMS / CA USES CORRECTIVE

No. ACTION

1. Machine fails to start 1. Electrical problem. Check starter, motor, cable,

interlock etc.
2. Zero speed switch Check and adjust the speed
not operating. regulator.
3. Boot is jammed Clean the boot.
with material.
4. Belt is loose. Tighten the belt with
take up screw.

2. Abnormal Noise 1. Hissing Noise (Loose Belt) Adjust the Take-up screw such
that the belt remains at centre.

2. Ratting Noise Tighten the bolts.

(Loose bolts of bucket)
3. Hitting Noise Tighten the bucket bolts.
(Loose buckets hitting to
the casing)

3. Increase in vibration 1. Drive arrangement Align and tighten all the

disturbed. hardware.
2. Drive chain loose Tighten the Chain.

4. M/c operates at 1. Input material feed Increase feed rate

lower capacity. rate is low.
2. More fall back. Adjust the upper flap or adjust the
feed rate.
3. Outlet is not of Check flow at outlet & if needed
proper size increase the outlet pipe. Or
smooth the Bend for easy flow of
material.

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Grain Discharger
 PACKING DETAILS

SR. NO. DESCRIPTION FORM

1. Top casing assembly Crate

2. Bottom Casing with foundation bolts. Crate

3. Inspection Casing Crate

4. Standard intermediate casing Crate

5. Non Standard casing Crate

6. Drive Assembly Box

7. Motor Mounting Bracket / Drive base Frame Crate (with Top casing)

8. Coupling With Top Casing

9. Belt loose / Box

10. Bucket Plastic bags in box

11. Hardware Plastic bags in box

12. Joining Clamp Attached with

inter med & casing

13. Distance Piece Box

14. Hardware Box

15. Electricals / Fragile components Box

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Grain Discharger
 LOAD TRIAL FORMAT
SR. BE Height No Load Full Load Capacity
Model HP Remark
NO. NO. Meters Current Current TPH / Hr

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Grain Discharger
 A. PRE-TRIAL CHECKS

S. CHECK POINTS OBSERVATIONS REMARKS

No.

1. B.E. Plumb (Vertically) Perfectly vertical , +/-3mm Yes / No

2. Belt Tensions Just sufficient Yes / No
3. Bucket Bolts Properly tightened with washers Yes / No
Belt Joint as per Drg.
4. Upper sliding plate Properly adjusted to avoid fall Yes / No
at discharge point back and the hitting of the bucket.
5. Drive Aligned as per Sketch & Yes / No
properly tightened.
6. All nuts / bolts Properly tightened Yes / No
7. Obstruction No obstruction Yes / No
8. Electrical connection Properly done as per electrical Yes / No
diagram & properly tightened
check the Relay

B POST-TRIAL CHECKS

S. CHECK POINTS OBSERVATIONS REMARKS

No.

1. Current in each phase of Less than 60% of the full Yes / No

the motor load current.
2. Noise No abnormal noise. Yes / No
3. Vibration No Vibration Yes / No
4. Test duration Max. 8 - 10 Hours Continuously Yes / No

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Grain Discharger
 PULLEY

PULLEY

GRAIN DISCHARGER

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Grain Discharger
 20
(BUTT JOINT)

Bucket Bolt

3 THK. RUBBER COVER

1.5 THK. (PULLEY SIDE)
RUBBER COVER

Grain Discharger
 EMINENCE
EMINENCE EQUIPMENTS PVT . LTD.
Gat No. 343, Plot No. 27 to 32, Near Hindustan Petroleum, Village-Mahalunge, Tal. Khed, Dist. PUNE - 410 501
Phone : 020 - 3230 6023 / 3230 6025 / 3230 5689 Fax : 020 - 2711 9410 • E-mail : eminence@eth.net