Start-up and Operation

Start-up and Operation NEVER FORGET THAT ANY MACHINE CAN BE VERY DANGEROUS WHEN NOT OPERATED CORRECTLY AND SAFELY. ALWAYS VISUALLY CHECK TO MAKE SURE THAT ALL PERSONS ARE CLEAR BEFORE TURNING ON ANY CONTROLS. 1. Make sure blender is securely anchored to footing. 2. Before you run your vertical screw blender, bump the starter motor and make sure the screw is turning in a clockwise rotation looking from the top of the blender. 3. The vertical screw blender should be running before any attempt to load material is made. 4. Depending on the size of your vertical screw blender and the material being blended, blend for 2 to 2½ minutes after all material has been ingested completely from hopper into blender. CAUTION: THE STANDARD INLOAD HOPPER WILL HOLD IN EXCESS OF 2,500 LBS OF MATERIAL. BLENDER SHOULD BE LOADED AT A STEADY, EVEN RATE TO GUARD AGAINST TIP-OVER. 29

Figure #1 Pre-assembly Notes: CAUTION: The vertical screw blender and some of its component parts are heavy. Use a safe lifting device when unloading and during assembly. Fasteners may vibrate loose during shipping. It is recommended you check nuts, bolts, and set screws on pre-assembled parts prior to start-up. STEP #1 Refer to Figure #1 - Detail A-A. Position the blender on a level concrete pad or floor. Level the scale frame and anchor at each corner. A 5/8" diameter Hilti type wedge anchor is recommended for this procedure. It is important to have the blender level and solid to obtain the maximum accuracy of the scale system. STEP #2 Refer to Figure #1 - Detail B-B & C-C. If your ladder weldment has not been preassembled to the blender, assemble it now. Refer to Detail B-B and assemble the upper portion of the ladder to the pre-assembled ladder mount weldment using two (2) each 1/2" x 1 1/2" stainless steel carriage bolts and two (2) each 1/2" stainless steel hex nuts and lock washers. Refer to Detail C-C and assemble the lower part of ladder to the blender using two (2) each ladder bracket straps, four (4) each 5/16" x 1" stainless steel bolts and four (4) each 5/16" stainless steel hex nuts and lock washers. 30

Figure #1 31

Figure #2 STEP #1 Refer to Figure #2 - Detail A-A. Assemble the electric motor to the motor mount using four (4) each 1/2" x 2" bolts, four (4) each 1/2" hex nuts and lock washers. Refer to the blender specifications on pages 4-7 for the motor requirements. Detail B-B is a diagram of the three different hole patterns in the motor mount. STEP #2 Refer to Figure #2 - Detail A-A. Assemble the motor sheave and bushing as shown. Use a straight edge to align it with the gearbox sheave. NOTE: 40 Hp electric motor requires four (4) each 5/8" x 2 1/2" bolts, four (4) each 5/8" lock washers, and 5/8" hex nuts at this step. STOP! Have you correctly filled your gearbox with oil? 32

Figure #2 30 HP 25 HP 40 HP 33

Figure #3 STEP #1 Refer to Figure #3 - Detail A-A. Assemble the V-belts to the motor sheave and gearbox sheave by first loosening the 1/2" carriage bolts "A" located on either side of the motor mount. Slide the motor and motor mount towards the gearbox as close as possible and install the V-belts. Apply tension to the V-belts with the take-up bolt "B" and re-tighten the nuts on the 1/2" carriage bolts "A". STEP #2 Refer to Figure #3 - Detail B-B. Assemble the belt guard as shown using two (2) belt guard brackets "C" and four (4) 1/4" x 3/4" stainless steel bolts and four (4) each 1/4" stainless steel hex nuts and lock washers. NOTE: The end of the belt guard with the long slot will mount to the motor mount. STEP #3 Refer to Figure #3 - Detail C-C. Install the manhole cover over the manhole and run a bead of silicone caulk around the bottom. 34

Figure #3 35

Figure #4 STEP #1 Refer to Figure #4 - Detail A-A. Assemble the hopper to the blender by first applying rope caulking on the surface of the flange of the tank opening. Assemble the hopper using 3/8" x 1" stainless steel bolts, flat washers, and hex nuts. NOTE:The 6, 8, & 10 ton hoppers require twenty-one (21) fasteners, the 5 ton requires twenty-three (23). If you have purchased the weather cover option for your hopper, refer to the weather cover assembly instructions on page 48 and assemble it now. If not, continue with STEP #2. STEP #2 Refer to Figure #4 - Detail B-B. Remove the shipping brackets "A" from the scale base frame and the blender legs. This will free the torque arms for scale installation. NOTE: If you have purchased a conditioner hopper with your blender, continue with assembly instructions for Figures #5, #6, & #7. If not, continue with Figure #8 on page 46. 36

Figure #4 37

Figure #5 STEP 1. Refer to Figure #5. Assemble limit switches "A" to brackets "B" and "C" using #10-24 x 3/4" bolts and hex nuts. Attach bracket "B" to bottom of hopper on straps and bracket "C" to front of hopper using 5/16" x 3/4" carriage bolts, flat washers, and hex nuts. Adjust these bolts to allow limit switches to function properly. See figures 5a & 5b. Figure #5 Figure #5A Figure #5B Adjust limit switch to allow bolt on grate to apply pressure on plunger of limit switch. Adjust bracket to allow strap on door to apply pressure on plunger of limit switch. IMPORTANT: When grate or door are removed, the plunger on the limit switch should release and stop the motor. Check both switches to make sure they are adjusted to function properly. 38

DANGER THIS UNIT MUST BE WIRED ACCORDING TO THE ENCLOSED INSTRUCTIONS TO ALLOW THE CONDITIONER HOPPER MOTOR TO AUTOMATICALLY SHUT DOWN WHEN THE GRATE OR THE CLEAN OUT DOOR IS REMOVED. THE DECAL IN THE PARTS CARTON IS TO BE PLACED ON THE FRONT OF THE BLENDER ABOVE THE HOPPER. APPLY DECAL BEFORE OPERATING THIS UNIT. Wiring Instructions Wire the two(2) plunger style limit switches (Part #01049600) in series ahead of the motor starter coil for the conditioner motor. The switches should be wired in the normally open (NO) position. This allows the motor to run when the plunger has pressure against it; when the pressure is removed, the conditioner motor will stop. Limit Switch Limit Switch Line MS (motor starter) Black Blue Black Blue Coil 39

Figure #6 Figure #6 5T Conditioner Hopper IMPORTANT: Shaft must rotate toward the load side as shown. STEP #1 Refer to Figure #6. Attach strap "A" to clips "B" around blender leg as shown using 3/8" x 1 1/4" SS HHCS, flat washers, and hex nuts. Bolt the end of strap "A" to the flange on the bottom of the gear box "C" using 1/2" x 2" SS HHCS and hex nylock nut. 40

Figure #7 Figure #7 8T Conditioner Hopper IMPORTANT: Shaft must rotate toward the load side as shown. STEP #1 Refer to Figure #7. Attach strap "A" to bracket "B" around blender leg as shown using 3/8" x 1 1/4" SS HHCS and hex nuts. Bolt the end of strap "A" to the flange on the bottom of the gear box "C" using 1/2" x 2" SS HHCS and hex nylock nut. 41

Figure #8 STEP #1 Refer to the 5, 6, 8 & 10 ton vertical screw blender dimensional drawing on page 8. Locate the dial head stand weldment in the general area you have selected. DO NOT anchor at this time. STEP #2 Refer to Figure #8 - Detail A-A. Assemble the fulcrum stand plate "A" to the scale base frame as shown using four (4) 1/2" x 1 1/2" bolts and four (4) 1/2" hex nuts. Assemble the fulcrum stand "B" to the stand plate using one (1) 5/8" x 2" bolt and one (1) 5/8" hex nut. DO NOT tighten the fulcrum stand bolt at this time. IMPORTANT: WHICHEVER SIDE OF THE BLENDER YOU MOUNT THE DIAL HEAD, THE FULCRUM STAND AND PLATE WILL MOUNT ON THE OPPOSITE SIDE. STEP #3 Refer to Figure #8 - Detail B-B. Level and block the scale torque arms "C". Assemble the transverse lever "D" onto the fulcrum stand and secure with hold down clips "E". Level and block the transverse lever. STEP #4 Refer to Figure #8 - Detail C-C. With the torque arms and transverse lever now level and blocked, assemble the shackle "F". NOTE: If the shackle assembly cannot be easily fitted around torque arms, disassemble the two lower plates and reassemble in place. STEP #5 Refer to Figure #8 - Detail D-D. Assemble the shelf lever "G" to the dial head stand as shown using bolt furnished with shelf lever. NOTE: The shelf lever may be mounted to one of two slots in the top of the dial head stand. STEP #6 Refer to Figure #8 - Detail D-D. Assemble the dial head to the dial head stand and attach the hook of dial head into the loop of the shelf lever. Position the dial head and stand assembly so the shelf lever and the transverse lever can be attached with the turnbuckle assembly. Attach all parts and level, starting with the dial head stand. The shelf lever can be leveled by adjusting the hook on the dial head. IMPORTANT: Refer to FIgure #8 - Detail E-E. MAKE SURE SCALE U-BOLTS "H" ARE CUT OFF FLUSH WITH TOP OF LOCK NUT, OR NO MORE THAN TWO (2) THREADS ABOVE LOCK NUT TO ACHIEVE 1/4" CLEARANCE BETWEEN CORNER STAND AND U-BOLT ENDS. IMPORTANT: HAVE A QUALIFIED SCALE REPRESENTATIVE CALIBRATE THE DIAL HEAD. 42

Figure #8 43

Figure #9 STEP #1 Refer to Figure #9 - Detail A-A. Assemble the load cell stand "A" to the scale base frame as shown using four (4) 1/2" x 1 1/2" bolts, four (4) 1/2" hex nuts and flat washers. STEP #2 Refer to Figure #9 - Detail B-B. Assemble the load cell hardware "B" to the load cell as shown. The load cell hardware eye-bolts should be screwed into the load cell approximately 3/8" or until flush. Secure with jam nuts "C". STEP #3 Refer to Figure #9 - Detail C-C. Level and block the torque arms. STEP #4 Refer to Figure #9 - Detail D-D. Assemble the shackle assembly "D" to the torque arms as shown. If the shackle assembly cannot be easily fitted around the torque arms, disassemble the two lower plates and reassemble in place. STEP #5 Refer to Figure #9 - Detail E-E. Assemble the load cell and hardware assembly "E" to the shackle assembly "D" and to the load cell stand as shown. Make all necessary adjustments so when the leveling blocks are removed from under the torque arms they will remain level. IMPORTANT: Refer to Figure #9 - Detail F-F. MAKE SURE SCALE U-BOLTS "H" ARE CUT OUT FLUSH WITH TOP OF LOCK NUT, OR NO MORE THAN TWO (2) THREADS ABOVE LOCK NUT TO ACHIEVE 1/4" CLEARANCE BETWEEN CORNER STAND AND U- BOLT ENDS. IMPORTANT: HAVE A QUALIFIED SCALE REPRESENTATIVE CALIBRATE THE LOAD CELL AND DIGITAL READ OUT. 44

Figure #9 45

Figure #10 STEP #1 Refer to Figure #10 - Detail A-A. Assemble the hopper brackets "A" to the back of the hopper as shown using four (4) 3/8" x 1" bolts, four (4) 3/8" lock washers, eight (8) 3/8" flat washers and four (4) 3/8" hex nuts. DO NOT TIGHTEN THESE BOLTS AT THIS TIME. STEP #2 Refer to Figure #10 - Detail A-A. Assemble the weather cover attachment weldment "B" to the hopper brackets "A" using four (4) 3/8" x 1" bolts, four (4) 3/8" flat washers, four (4) 3/8" lock washers, and four (4) 3/8" hex nuts. DO NOT TIGHTEN THESE BOLTS AT THIS TIME. STEP #3 Refer to Figure #10 - Detail B-B. Set the weather cover on top of the hopper and assemble the hinge plates "C" onto the hinge pin as shown, and the bolt to the weather cover attachment weldment "B" using four (4) 3/8" x 1" bolts, eight (8) 3/8" flat washers, four (40 3/8" lock nuts, and four (4) 3/8" hex nuts. DO NOT TIGHTEN THESE BOLTS AT THIS TIME. STEP #4 Refer to Figure #10 - Detail B-B. Assemble the hinge plate support "D" to the hinge plate "C" and to the hopper using six (6) 3/8" x 1" bolts, twelve (12) 3/8" flat washers, six (6) 3/8" lock washers, and six (6) 3/8" hex nuts. STEP #5 Refer to Figure #10 - Detail B-B. Center the weather cover on the hopper. Make sure it will open and close with ease. Tighten all fasteners assembled in STEP #1 thru STEP #4. STEP #6 Refer to Figure #10 - Detail B-B. After all fasteners are secure, drill through the weather cover attachment weldment "B" and tank side using the pre-punched holes in the attachment weldment as guides. Secure with six (6) 3/8" x 1" bolts, six (6) 3/8" lock washers, and six (6) 3/8" hex nuts. STEP #7 Refer to Figure #10 - Detail C-C. Remove the lifting brackets and re-assemble the pulley hanger weldments "E" using the existing bolts. Assemble the pulley assembly "F" to the pulley hanger as shown. STEP #8 Refer to Figure #10 - Detail D-D. Remove the lifting brackets and re-assemble the cable guide assembly "G" using the existing bolts. STEP #9 Refer to Figure #10 - Detail E-E. Assemble one (1) each 3/8" x 1 3/4" bolt "H" through the tabs located on front of weather cover. Double nut this bolt as shown. Assemble the cable thimble "I", cable and cable clamp "J" as shown leaving approximately six (6) inches of cable behind the clamp. Note the cable wrap diagram. STEP #10 Refer to Figure #10 - Detail F-F. Assemble the cable tie to the tank by placing it at the top edge of cone portion and approximately in the center of the pulley hangers. Drill through tank and attach using two (2) 3/8" x 1" bolts, two (2) 3/8" lock washers, and two (2) 3/8" hex nuts. BLENDER INSTALLATION NOTES: After installing outload conveyor, the two corners of the discharge sock facing up the conveyor will need to be cut. Starting at the bottom, cut up 1/4" in from the seams to within 1/2" from the top of the outload hopper. This will allow product to flow up the conveyor. 46

Figure #10 47

Electrical Door Opener Wiring Diagram Minimum Voltage 103.5 Low Voltage Reduce Load Rating of the Actuator CW - Retract CCW - Extend 115 VAC Motor is enclosed, permanent split capacitor induction type. Load/no-load speeds are approximately equal. Equipped with thermal overload which opens and resets automatically. Standard motor requires 28-33 mfd capacitor or a 64-77 mfd capacitor for high speed motor (supplied by customer, or by Duff-Norton at additional cost) for loads up to 500 pounds. A capacitor box is available to provide an enclosure for electrical connections and to give a convenient conduit installation. 48

Hydraulic Gate Opener Wiring Diagram 49

P.O.Box 1438 Dodge City, Kansas 67801 (620) 227-7106