PREMAS 4.0 Guía

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.

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

1Foreword.................................................................................................................................... 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

2Description 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

3Safety 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

4Preparation and installation ....................................................................................................20

4.1 Transport and storage of the product .....................................................................................20

4.1.1Dimensions and weight ....................................................................................................................... 20

4.1.2Storage of the product ........................................................................................................................ 20

4.2 Installation of the product....................................................................................................... 21

4.2.1Removal of transport and packaging elements................................................................................... 21

4.2.2Unpacking the product........................................................................................................................ 21

4.2.3Sensor situation plan........................................................................................................................... 22

4.2.4Installation of the product................................................................................................................... 23

4.3 Commissioning.........................................................................................................................38

5Troubleshooting 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

Page 8 / 44

WARNING

DANGER

CAUTION

ATTENTION

1Foreword

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.

PREMAS® 4.0 Installation and Commissioning Manual

Page 9 / 44

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 support@premas.ch.

For information on special tools and materials and for service-related questions, please

contact your distribution partner for PREMAS® 4.0.

PREMAS® 4.0 Installation and Commissioning Manual

Page 10 / 44

2Description 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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