UNITIZED batching INSTaLLaTION guide

Transcription

1 UNITIZED batching INSTALLATION GUIDE

2 2 General information This manual contains technical information regarding Bayer SeedGrowth Equipment. Please read and understand these instructions completely before proceeding to install and operate the equipment. Bayer reserves the right to change specifications, models, components, or materials at any time without notice. For additional equipment information contact us at Please have this manual available when contacting Bayer. This manual uses signal words and symbols to help avoid personal injury. Danger, Warning, and Caution are signal words used to identify the level of hazard. Danger alerts that an extreme hazard will cause serious injury or death if operators or installers do not follow the recommended precautions. Warning alerts that a hazard may cause serious injury or death if operators or installers do not follow the recommended precautions. Caution alerts that a hazard may cause minor or moderate injury if operators or installers do not follow the recommended precautions. Always use caution and common sense when working with any chemical. Read the product label and SDS carefully and follow their instructions exactly as described. Optimal operating conditions for this piece of equipment requires an ambient temperature 32 F to +104 F (0 C to +40 C), relative humidity less than 90% (minimum condensation). Make necessary provisions to protect this piece of equipment against excessive dust, particles containing iron, moisture and against corrosive and explosive gases. Our technical information is based on Tip: calls attention to special information. extensive testing and is, to the best of our current knowledge, true and accurate but Note: emphasizes general information worthy of attention. given without warranty as the conditions of use and storage are beyond our control. Variables, such as humidity, temperature, Example: gives a problem or exercise that illustrates a method or principle. change in seed size or variety and viscosity of chemical products can all affect the accuracy of the chemical application and seed coverage. To ensure the desired application rate and optimum seed coverage, check the calibration periodically throughout the day, and make adjustments as needed. Bayer Crop Science Division 1451 Dean Lakes Trail Shakopee, Minnesota USA Phone: Toll Free: equipment@bayer.com Web: Bayer SeedGrowth TM and the Bayer Cross are registered trademarks of Bayer. SGRUNITIZEDBATCHINGINSTALLATIONGUIDE

3 CONTENTS 3 CONTENT #1 SYSTEM DIagram 04 #2 EQUIPMENT INSTALLATION 05 Bowl & frame assembly 05 Placement surface 05 Shipping support bracket 05 Weigh scale & frame assembly 06 Inlet hopper HI/LO signal cable 09 Weigh scale solenoid 09 Weigh scale load cells 10 Compressed air 10 Weigh scale load cell shipping brackets 10 Hopper cylinder shipping stop kit 10 Hopper discharge door bungee 10 Weigh scale air lines 11 Calibration shipping bracket 11 Weigh scale guards 11 Optional dust evac manifold assembly 12 Optional powder feeder (200) 14 Optional powder feeder (25,50,100) 15 LP300 tank 16 LP300 tank pump 17 #3 REFERENCE SYmbOLS 19

4 4 CBT UNITIZED System Diagram SYSTEM DIagram CBT200 UNITIZED VOLUMETRIC SYSTEM, REF. HI/LO Sensors Viewing Windows Seed Inlet Dust Evac Port Inlet Hopper Scale & Frame Sub-Assembly Dust Evac Port Chemical Inlet Dust Evac Manifold Assembly Control Panel Bowl & Frame Sub-Assembly Seed Discharge Closed Calibration I/P HR Pump Kit LP 300 Liter Tank OPTIONS DUST EVACUATION An optional Dust Evacuation System can be added POWDER FEEDER Up to two optional Powder Feeder Assemblies can be added LP300 Liter Tank An additional LP300 Liter Tank Assembly can be added

5 cbt unitized Equipment installation 5 InstaLLaTION Note: for all Globally Harmonized System (GHS) symbols (shown left) used in this manual, see page 19 for details. Bowl & Frame Assembly Remove crating. Remove shipping bolts holding the bowl & frame on the pallet. Use proper rigging and lifting techniques to ensure safety during installation (CBT200 dry weight: 1668 Kg). Remove the bowl & frame and spare parts from the pallet. Report damaged or missing parts that may have occurred during shipping! Shipping Support Bracket Step 1: Use the quarter turn key (attached to mixing bowl cover, shown below left) to remove the back guard panel, as shown below, right. Placement Surface Quarter turn key Remove guard panel The recommended location for all components of the treating system should be on one single floor. Locate the bowl & frame on a solid, flat vibration-free surface. Fasten the bowl & frame to the floor with anchors. Plan accordingly! Allow access to the machine from all sides for the purpose of adjustments, maintenance and clean-up. Maintain a minimum three foot perimeter, as shown below. Step 2: Use 17mm & 15mm wrenches to remove bolts holding the red shipping support bracket under the bowl motor. Replace the guard panel. Use the quarter turn key to lock the guard panel in place. CBT200 Top View, ref. Remove Red Bowl Motor Shipping Support Bracket Required installation tools Forklift / material handling device Hose Cutter Standard Screwdriver Phillips Screwdriver 7/16 Wrenches (2) 3/4 Crescent Wrench 17mm & 15mm Wrenches 6mm Allen Wrench Tin Snips Flat Bar Tool

6 6 cbt unitized Equipment installation Step 4: Ensure the weigh scale and scale support frames are aligned correctly: SIDE A to SIDE A, SIDE B to SIDE B. Weigh scale frame sticker matches the scale support frame sticker, as shown below. Weigh Scale & Frame Assembly Step 1: Remove crating. Remove shipping bolts holding the weigh scale on the pallet. Report damaged or missing parts that may have occurred during shipping! Use the quarter turn key to remove the guard panels. Remove Guard Panels Step 5: Align the frame holes. Fasten the weigh scale frame to the scale support frame with the M10 hardware (previously removed bolts, nuts, washers from the transition support frame) in the following order: bolt+flat washer+[weigh scale frame+support frame]+flat washer+lockwasher+nut. Securely tighten hardware in place. Step 2: Remove the M10 hardware (bolts, nuts, washers) from the transition and scale support frame, shown below. Scale Orientation Calibration Weights Step 3: Use proper rigging and lifting techniques to ensure safety when installing the weigh scale onto the scale support frame (CBT200 dry weight: lbs). CBT25: weigh scale orientation for CBT25/50/100, ref. CBT25 & 50 ship with weigh scale & control mounted CBT200: weigh scale orientation, ref. CBT 100 & 200 ship with control mounted, weigh scale field installed

7 cbt unitized Equipment installation 7 Step 6: Use a 3/4 wrench to remove the factory installed 1/2 bolt and washers from on top of the weigh scale sides, eight (8) total, as shown. B Inlet Hopper Assembly Step 1: Remove crating. Remove shipping bolts holding the inlet hopper on the pallet. Report damaged or missing parts that may have occurred during shipping! conduit > A dust evac A CBT200 weigh scale top view, ref. Tip: recommend cutting a seed inlet hole on top (see page 8) prior to installing the inlet hopper on top of the weigh scale. The A in the image above indicates the FRONT side (discharge) of the weigh scale. This side of the weigh scale and the inlet hopper windows side must be oriented together, as shown on page 8. A A CBT200 weigh scale - remove hardware, ref.

8 8 cbt unitized Equipment installation Step 2: Use proper rigging and lifting techniques to ensure safety when installing the inlet hopper on top of the weigh scale (CBT200 dry weight: lbs). Orient the inlet hopper windows towards the FRONT (discharge) of the machine (side A of the weigh scale). Align bolt holes of the inlet hopper side rails with bolt holes on top of the weigh scale. Inlet Hopper Field Cut Seed Inlet Hole Orientation Weigh Scale A Inlet Hopper Step 3: Use the previously removed hardware (see page 7) eight 1/2 bolt and washers to connect the inlet hopper to the weigh scale. Use the hardware shipped with the inlet hopper to connect the center flange to the weigh scale. Securely tighten all hardware in place with a 3/4 wrench. A Weigh Scale Mixing Bowl Discharge CBT200; Inlet hopper installed - verify windows and dust evac orientation, overall height (with inlet hopper): inches, ref.

9 cbt unitized Equipment installation 9 Optional Inlet Hopper HI/LO Signal Cables Step 1: HI-LO sensor cables ship connected to the sensor kit on top of the inlet hopper, as shown below. Cables are labeled as HIGH SENSOR and LO SENSOR (see inset photo below). Weigh Scale Solenoid Step 1: Connect the scale solenoid cable (insert yellow cord through top of the scale hole) to the control panel backside marked: SOLENOID BOX, as shown below. HI/LO Sensor Cables HI/LO Sensor Kit Factory Installed Note: inlet hopper HI/LO sensors will only work/engage if the feed elevator is powered by the CBT control panel. Step 2: Connect the high level and low level sensor cables to the control panel (backside) marked HIGH LEVEL PROX and LOW LEVEL PROX, as shown below.

10 10 cbt unitized Equipment installation Weigh Scale Load Cells Step 1: Connect the scale load cell cable (insert gray cable through top of scale) to the control panel backside marked: BOWL SUPPLY HOPPER LOAD CELL, as shown below. Weigh Scale Load Cell Shipping Brackets Use 10mm wrench to remove the red load cell shipping brackets on both sides of the weigh scale. The weigh scale will lower on top of the rubber stops. Use a 3/4 socket & ratchet to tighten down the nut in the middle of both rubber stops to hold the weigh scale in place. TIGHTEN NUT CBT25/50/100 Hopper Cylinder Shipping Stop Kit Remove the hopper cylinder shipping stop kit. Cut the wire tag and the vinyl tubing around the hopper air cylinder, shown below. Compressed Air Optimum compressed air supply must be guaranteed. Only filtered, dry compressed air may be connected. CBT200 Hopper Discharge Door Bungee Remove the red hopper discharge door bungee cord, shown below. The working pressure range requirement is 80psi. Connect shop air to the filter regulator 1/2 air coupler on the scale support frame, as shown right.

11 cbt unitized Equipment installation 11 Weigh Scale Air Lines Step 1: WHITE, BLACK and BLUE air line tubes will be hanging inside the weigh scale frame, as shown below. Weigh Scale Calibration Shipping Brackets Use a 10mm wrench to remove both RED calibration shipping brackets shown below. Step 2: Insert each tube into the press lock fittings inside the transition (top side), in the order as shown below. Each tube needs to correspond with the color that is already connected to the underside (outside) of the transition from the factory as follows: WHITE to WHITE BLACK to BLACK BLUE to BLUE Weigh Scale Guards Replace all four (4) weigh scale guard panels. Use the quarter turn key to lock the guard panels in place. CBT200 only: orient the guard panel with the dust evacuation port out towards the FRONT (discharge) side of the bowl & frame, as shown below. Orientation Replace Guard Panels < dust evac Air line connections inside the transition, top view Weigh Scale Discharge Transition Factory Installed Tubing connected, top and bottom (inside & underside) Weigh scale dust evacuation port orientation, CBT200 only, ref.

12 12 cbt unitized Equipment installation Optional Dust Evac Manifold Assembly Step 4: Connect the dust evac manifold assembly to the scale support frame with the hardware supplied from the factory. Fasten them together in this order: bolt+flat washer+[scale support frame+bracket]+lockwasher+nut. Securely tighten in place. Step 1: Remove the plastic plug from the scale support frame. Step 2: Remove the dust evac manifold assembly from packaging (dry weight: 70.3 lbs). Remove hardware bag from the dust evac manifold assembly, shown below. Step 3: Requires two people. Lift the dust evac manifold assembly onto the scale support frame. Align the support bracket holes on the top and side to the scale support frame, as shown below. Step 5: Connect the dust evac power cord to the control panel (underneath, marked: DUST EVac). Turn ON the dust evac switch. CBT200 with dust evac system, ref.

13 cbt unitized Equipment installation 13 Step 6: Connect factory-supplied tubing to dust ports on the machine according to the diagram shown below. Lid dust port connection Step 7: Slide the tube and hose clamp over each manifold port and securely tighten in place with a slotted screwdriver. Note 5.0 tube from dust evac system to manifold; 3.0 tube from manifold to each machine port (see diagram above). Scale dust port connection (CBT25, 50 & 100) Scale dust port connection (CBT200) Inlet hopper dust evac connection

14 14 cbt unitized Equipment installation Step 4: Connect the powder tubing to the end of the auger tube and to the top of the bowl cover, as shown below. Optional Powder Feeders Step 1: Remove the shipping bolts holding the powder feeder assembly onto the shipping pallet. Step 2: Use proper rigging and lifting techniques to ensure safety when installing the powder feeder assembly. Open the powder feeder lid and connect rigging to each side. Approximate dry weight: 70Kg. Step 5: Connect the signal cable from the powder feeder to the control panel backside marked: POWDER #1 & #2 SENSOR LOW PRODUCT, as shown below. Step 3: Lift and set the powder feeder assembly on the scale support frame (auger tube faces OUT toward the bowl). Align the four drilled holes on the support frame. Fasten in place with supplied hardware: four (4) 5/16-18 x 2.50 hex bolt, washer and serrated nut and 1/2 socket in this order: bolt+flat washer+[frame]+serrated nut (see the inset photo). Tighten securely in place. CBT200 with RH powder feeder assembly installed, ref.

15 cbt unitized Equipment installation 15 Step 4: Connect the powder tubing to the end of the auger tube and to the top of the bowl cover, as shown below. Optional Powder Feeders - 25/50 & 100 Step 1: Remove the shipping bolts holding the powder feeder assembly onto the shipping pallet. Step 5: Connect the signal cable from the powder feeder to the control panel backside marked: POWDER #1 & #2 SENSOR LOW PRODUCT, as shown below. Step 2: Use proper rigging and lifting techniques to ensure safety when installing the powder feeder assembly. Open the powder feeder lid and connect rigging to each side. Approximate dry weight: 70Kg. Step 3: Lift and set the powder feeder assembly on the powder frame (auger tube faces IN toward the scale). Align the four drilled holes on the support frame. Fasten in place with supplied hardware: four (4) 5/16-18 x 2.50 hex bolt, washer and serrated nut and 1/2 socket in this order: bolt+flat washer+[frame]+serrated nut (see the inset photo). Tighten securely in place. CBT 25/50& 100 with LH powder feeder assembly installed, ref.

16 16 cbt unitized Equipment installation LP 300 Tank Step 1: Remove the LP300 Tank from shipping crate. Using proper material handling equipment, lift and place in close proximity to the Treater. Lifting lugs welded to the tank are provided for proper lifting. The tank slopes towards the drain plug, located in the rear of the Tank. Remember to leave adequate room around the Tank for clean out and maintenance. LP300 tank assembly (shown with optional deck scale). Tank slopes down towards the drain plug. Step 2: Connect the twist-lock connector plugs to the corresponding receptacle on the bottom of the control panel marked: Liquid Pump, (tank) Agitator and the optional customer-supplied Elevator (control) if used (refer to pictures below). LIQUID PUMP AGITATOR ELEVATOR Twist lock connector plug. Control panel receptacles.

17 cbt unitized Equipment installation 17 LP300 Tank Pump Step 1: Use the pump handle to open the pump head. Step 4: Connect the other press lock fitting into the pump discharge plumbing assembly on the left hand side of the pump head. Step 2: Lay the pump element (either #26 or #73) on the pump rollers. Step 5: Align the pump element on the pump head grooves to ensure proper fit (may require two people). Step 3: Insert element press lock fitting into the tank elbow on the right hand side of the pump head. Step 6: Use the pump handle to close the pump head.

18 18 cbt unitized Equipment installation Treatment Line Connection Step 1: Remove the 3/8 reducer plug from the pump assembly. Optional Washout Valve Step 1: Remove the 1/2 brass hex head plug (use crescent wrench). REMOVE Step 2: Thread in the washout valve assembly and tighten securely. Step 2: Insert one end of 1/2 tubing into the pump outlet press lock fitting. Step 3: Slide a hose clamp on 3/4 tubing and then over the brass hose barb fitting. Tighten hose clamp with a slot screwdriver. Step 3: Cut to fit and insert the other end of 1/2 tubing into the treater inlet assembly press lock fitting. Do not leave the washout valve connected when finished draining. Remove it and replace with the brass plug.

19 REFERENCE SYMBOLS 19 REFERENCE SYmbOLS Symbols and signal words are used to identify the level of hazard and help avoid personal injury. Caution Alerts that a hazard may cause minor or moderate injury. Warning Alerts that a hazard may cause serious injury or death. Electric shock hazard Alerts electric shock is possible. Pinch points Keep hands away from pinch points. Danger Alerts that an extreme hazard will cause serious injury or death. Pinch points entanglement Do not wear loose clothing around turning parts. Tools Required tools for installation and maintenance. Disconnect Disconnect to de-energize before opening. Parts Required parts for installation and maintenance. Use guards Keep guards in place. Do not remove during operation. Lifting Requires two people to safely lift an item. Tip Calls attention to special information. Lift points Requires the use of proper rigging and lifting techniques based on the lift plan. Note Emphasizes general information worthy of attention. Checks Check marks are used to identify areas that need attention before moving on to the next phase, such as check the orientation. Pause Example of a problem or exercise that illustrates a method or principle.

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