Big Dutchman Dry Rapid DR 1500 Mounting And Operating Instructions Download Page 5

Page: 5 / 185

Table of contents

Page I

DR 1500

Edition: 08/10 M 4021 GB

Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2

Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3

Explaining the symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.1

Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.2

Safety symbols in the manual and on the installation . . . . . . . . . . . . . . . . . . . . . 2

1.3.3

Warnings and safety instructions on your installation . . . . . . . . . . . . . . . . . . . . . 2

1.4

Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5

Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6

Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.7

Disorders due to power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.8

First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.9

Pollution abatement regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.10

Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.11

Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.12

Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2

Safety instructions when operating electrical appliances . . . . . . . . . . . . . . . 7

2.3

Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3.1

Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3.2

Danger signs on the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4

Specific safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4.1

Clothing for personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4.2

Assembly and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4.3

Employing external personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5

Safety contrivances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5.1

In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5.2

Safety contrivances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5.3

Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6

Dangers resulting from the non-compliance with the safety instructions . 13

System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.1

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2

Limit values for dry feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.3.2

Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Assembly and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2

Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3

Outline of the entire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Summary of Contents for Dry Rapid DR 1500

Page 1: ...Mounting and operating instructions Dry Rapid DR 1500 Code No 99 97 4021 GB Edition 08 2010...

Page 2: ......

Page 3: ...y of 8i4 Dutehman Big Dutchman Pig Equipment GmbH P O Box 1163 D 49360 Vechta Germany Tel 49 0 4447 801 0 Fax 49 0 4447 801 237 E Mail big bigdutchman de The following harmonised standards apply DIN E...

Page 4: ......

Page 5: ...structions 7 2 2 Safety instructions when operating electrical appliances 7 2 3 Special safety instructions 8 2 3 1 Danger zone 8 2 3 2 Danger signs on the system 9 2 4 Specific safety devices 10 2 4...

Page 6: ...dowels 31 7 6 1 Prerequisites 31 7 6 2 Assembly order for dowelling 32 7 7 Sealing 32 7 7 1 Sealing with sealing tape 32 7 7 2 Sealing with silicone 33 7 8 Glueing 33 8 Feed supply 34 8 1 Silo extract...

Page 7: ...ing SST cplt for motor 71 9 4 6 Tensioning device cpl for the drive 72 10 Feed pipe 74 10 1 Tube unit with conveyor chain 74 10 2 Control segment and flat steel reinforcement 76 10 2 1 Control segment...

Page 8: ...23 11 5 1 Protection pipe SST cpl for trough built in the wall 123 11 5 2 Protection pipe SST cpl at wall or partition PVC 124 11 5 3 Protection pipe SST cpl for trough built in the wall 125 11 5 4 Pr...

Page 9: ...0 14 5 Sensor DOL 41 R and DryRapid Controller 160 15 Operation 161 15 1 Initial operation 161 15 1 1 Prerequisites 161 15 1 2 Dosing 161 15 1 3 Single channel feed hopper 0 37 kW with forced insertio...

Page 10: ...0 M 4021 GB 17 Cleaning 170 17 1 Entire system 170 17 2 Drive unit 170 17 3 Feed hopper 170 17 4 Volume dispenser 170 17 5 Adjustment drive of the automatic release 170 18 Spare parts 172 19 Annex 173...

Page 11: ...g system DR1500 is used for transporting and metering out dry feed as meal or pellets It can be used in sow management piglet rearing and finishing The Big Dutchman installation may only be used accor...

Page 12: ...They indicate remaining technical dangers when handling the system and give information on how to avoid these dangers Implicitly observe the instructions attached to the installation such as the arro...

Page 13: ...the safety instructions have to be observed by everyone working with this system Moreover the regulations and instructions for the prevention of accidents valid at the respective place of use have to...

Page 14: ...ifications on the system inappropriate repairs in the event of a disaster caused by foreign matters or force majeure 1 7 Disorders due to power failure We recommend the installation of warning systems...

Page 15: ...s after putting the installation out of service 1 11 Notes for use We reserve the right to modify the construction and technical data for reasons of further development Therefore no claims can be deri...

Page 16: ...arks of their respective owners and are recognised as patented Copyright 2010 by Big Dutchman For further information please contact Big Dutchman Pig Equipment GmbH P O Box 1163 D 49360 Vechta Germany...

Page 17: ...aintained according to the electro technical regulations Immediately switch off the installation in the event of malfunctions of the power supply units Use a bipolar voltage probe to make sure that th...

Page 18: ...e see the enclosed connecting plan of the system parts delivered 2 3 Special safety instructions 2 3 1 Danger zone DANGER OF INJURY due to electric voltage Touching live parts results in electric shoc...

Page 19: ...motor over a driving wheel As certain mounting and maintenance works are only possible with an open cover it is necessary to be extremely careful In the feed containers with forced leading in resp fe...

Page 20: ...for the operation of the installation which are important for your safety and for the safety of the installation The service staff must be informed about the functioning and the arrangement of the sa...

Page 21: ...power supply companies or the regulations valid in the country Only work with appropriate tools in case of possible danger to hands use protective gloves and safety glasses in case of danger to the ey...

Page 22: ...be informed in detail about the dangers in their field of activity The operator should check their working method and intervene in time 2 5 Safety contrivances 2 5 1 In General After any repair or ma...

Page 23: ...inal box of the control unit has to be switched to the OFF position immediately if a dangerous situation occurs That way the power supply is cut and the system immediately stops 2 6 Dangers resulting...

Page 24: ...owing management types Sow management Individual sow feeding via volume dispensers Supplies the computer controlled CALLMATIC 2 feeding on demand system for feeding pregnant sows in groups SIMULTAN fe...

Page 25: ...Figure 3 1 Possible forms of application for DR1500 SIMULTAN feeding of pregnant sows in group management supplying feeders for piglet rearing and finishing individual feeding via volume dispensers su...

Page 26: ...used for transporting and metering out dry feed standard feed with the following properties Humidity content max 15 particle size K 3 mm pellet length max 15 mm a max of 60 may be milled smaller than...

Page 27: ...ng 4 idler corners 300 m with XXL 500m reduction in length per idler corner 6 m Gradient max 45 Reduction in length with 45 gradient 0 5 m per m Chain size 35 75 x 4 5 mm Washers 42 mm Distance betwee...

Page 28: ...on DR 1500 Edition 08 10 M 4021 GB Figure 3 2 Reduction in system length depending on idler corners installed 3 3 2 Sound level The A rated continuous sound level of DR1500 is below 70 dB A System len...

Page 29: ...is transported through the pipe system to the individual discharge points Due to pipe and chain or rope couplers the system forms an endless unit The system can either run with a conveyor rope or chai...

Page 30: ...del 09 silo from other manufacturer 8 83 05 5501 Y fitting complete for RAS feed hopper 9 83 04 5030 1 channel feed hopper complete stainless steel 10 83 04 5203 2 channel feed hopper complete stainle...

Page 31: ...uantities Basic device on right for 60mm pipe 10 87 3796 MediPut dosing unit for small quantities Basic device on left for 60mm pipe 83 03 9574 Container for MediPut 4 7 L dosing unit for small quanti...

Page 32: ...nch motor 45 10 87 3190 Triggering with cable winch on wall for DR 850 1500 volume dosing unit 46 10 88 3415 Sensor with bracket complete on DR1500 conveying pipe 10 88 3435 10 30V AC DC sensor with b...

Page 33: ...Assembly and operation Page 23 DR 1500 Edition 08 10 M 4021 GB Figure 4 1 Dry Rapid overall view...

Page 34: ...g and preparation 5 1 Preparation Draft a plan for the installation of the feeding system Place the system components within the building according to the local and dimensional conditions that have be...

Page 35: ...u should plan the feed channel with the smallest possible number of idler corners The feed channel gradient affects the conveyor capacity as a result of feed falling backwards That is why the feed cha...

Page 36: ...points and respectively equipped 5 5 Planification of the feed supply The single or dual feed hopper can be located inside the house or outside directly underneath a silo Depending on the installation...

Page 37: ...le human lifting and carrying abilities See that the transport is carried out safely Avoid bumps and impacts and see to a secure standing at every stage of the transport Small parts like screws nuts a...

Page 38: ...Page 28 Transport and storage DR 1500 Edition 08 10 M 4021 GB A rust film that develops during storage does not interfere with the use of the conveyor chain...

Page 39: ...ease with assembly instructions in chapter 13 the building parts for the control unit with assembly instructions There are special assembly instructions for the assembly of the automatic feeders Do no...

Page 40: ...ll building parts necessary for the assembly are available 7 4 Personnel Assembly and mounting of the installation is to be carried out by experienced personnel only 7 5 Tooling You will need the foll...

Page 41: ...of the holding ground walling or concrete floor to ensure solid fixing of the wall bracket to the building or of the floor rack to the concrete floor A safe way of fixing can be achieved by dowelling...

Page 42: ...e dowel length 1 x screw diameter 5 Apply and clean drill holes remove bore dust Figure 7 1 Expanding direction of dowels 6 Insert dowels in expanding direction so that the expanding force of the dowe...

Page 43: ...2 Sealing with silicone 1 Clean the areas that are to be sealed 2 Evenly spread silicone on the surface 3 Compress the sealing surfaces until they are bound by silicone 7 8 Glueing 1 Clean the areas...

Page 44: ...transfer unit to the drive unit of the BD Flex Vey by means of the tension ring pos 6 For the attachment of the sensor a sleeve socket code no 25 60 3100 has to be mounted between the drive and the t...

Page 45: ...6020 transfer cpl FlexVey 75 to DR1500 1 4 99 10 1067 hexagon head screw M 6x16 galv DIN 933 8 8 2 8 99 50 1147 washer B 6 4 DIN 125 galv 3 4 99 10 1045 hexagon nut M 6 galv DIN 934 4 1 83 04 6007 tra...

Page 46: ...e no 83 06 4394 8 3 2 Adapter with shutter SST cpl for sack silo Install the sack silo between the adapter and the clamp Draw up the screw Pos 6 and the nut Pos 7 in order to tighten the clamp around...

Page 47: ...Model 09 2 9 99 20 1453 Hex bolt M 8x 20 stainless steel DIN 933 3 18 99 20 1600 Washer stainless steel A 8 4 DIN 125 4 9 99 20 1193 Locknut M 8 DIN 985 stainless steel with Gleitmo coating 5 1 99 20...

Page 48: ...5 5522 Hopper with galv shutter complete for feed hopper Model 09 silo from other manufacturer 1 1 83 04 7706 Hopper with galv shutter Model 09 for feed hopper silo from other manufacturer 2 9 99 10 1...

Page 49: ...ss steel Y fitting Model 09 DR850 1500 feed hopper 2 18 99 20 1453 Hex bolt M 8x 20 stainless steel DIN 933 3 12 99 20 1402 Hex bolt M 8x 35 stainless steel DIN 933 4 48 99 20 1600 Washer stainless st...

Page 50: ...late prevents bridging feed in the feed hopper It is connected by a lever to a plastic wheel Item 3 which is moved up and down by the conveyor chain drive plates This movement is transferred to the sw...

Page 51: ...Feed supply Page 41 DR 1500 Edition 08 10 M 4021 GB 8 4 2 Hopper 1line cplt SST Figure 8 9 Code no 83 04 5030...

Page 52: ...Page 42 Feed supply DR 1500 Edition 08 10 M 4021 GB 8 4 3 Hopper 2line cplt SST With this hopper the direction of transportation can be opposed Figure 8 10 Code no 83 04 5203...

Page 53: ...s from entering the feed channel Figure 8 11 Feed hopper with forced insertion shown without cover plate If feed returns from the house the installation stops working You can prevent this with a rever...

Page 54: ...single channel feed hopper with forced insertion 24V DR1500 stainless steel galv feed hopper for recirculation Figure 8 12 Code no 83 04 9374 Table 8 1 Technical data for gear motor Drive power 55W V...

Page 55: ...Description 1 83 07 5596 Feed hopper Model 09 24V DR1500 1 B FKA complete option Recirculation 1 1 83 04 9374 24V DR1500 stainless steel galv feed hopper for recirculation 2 1 83 07 5547 Closing plat...

Page 56: ...1 2 83 00 9214 Half bearing for tap D60 L160 2 2 9 99 20 1422 Hex bolt M 6x 25 stainless steel DIN 933 2 3 9 99 20 1131 Locknut M 6 DIN 985 stainless steel 1 4401 2 4 2 99 10 1223 Self tapper B 4 8x9...

Page 57: ...ainless steel galv feed hopper for recirculation Figure 8 15 Code no 83 04 9361 Table 8 2 Technical data for gear motor Drive power 0 37 kW Voltage 230 400V Speed 56 min 1 Protection class IP 55 To av...

Page 58: ...no Description 1 83 07 5591 Feed hopper Model 09 0 37kW DR1500 1 B FKA complete option Recirculation 1 1 83 04 9361 Model 09 DR1500 feed hopper preassembled recirc 0 37kW 2 1 83 07 5547 Closing plate...

Page 59: ...2 1 2 83 00 9214 Half bearing for tap D60 L160 2 2 9 99 20 1422 Hex bolt M 6x 25 stainless steel DIN 933 2 3 9 99 20 1131 Locknut M 6 DIN 985 stainless steel 1 4401 2 4 2 99 10 1223 Self tapper B 4 8...

Page 60: ...Page 50 Feed supply DR 1500 Edition 08 10 M 4021 GB 8 5 4 2 channel 24V feed hopper With this hopper the direction of transportation can be opposed Figure 8 18 Code no 83 06 8851...

Page 61: ...s the drive is running The conveyor chain starts to move The drive wheel Item 2 which moves the feed screw Item 1 is driven in the inside of the feed hopper by the chain drive plates A contaminant sep...

Page 62: ...Page 52 Feed supply DR 1500 Edition 08 10 M 4021 GB Preassembled RAS DR1500 feed hopper Stainless steel galv for recirculation Figure 8 20 Code no 83 04 9357...

Page 63: ...ansports the feed back in to the circuit Feed rests that remain in the system do not cause blockages any more Thus the system is kept from stalling Pos Qty Code no Description 1 83 07 5590 Feed hopper...

Page 64: ...2 9 99 20 1422 Hex bolt M 6x 25 stainless steel DIN 933 2 3 9 99 20 1131 Locknut M 6 DIN 985 stainless steel 1 4401 2 4 2 99 10 1223 Self tapper B 4 8x9 5 DIN7971 3 0 50 10 87 3701 Tube 60x1 50 5000...

Page 65: ...outlet without shutter 3 drop pipe 4 Y tube 5 feed hopper RAS with recirculation 6 coupler for conveyor chain 7 90 corner Make sure during the assembly that the weep hole is as large as possible and...

Page 66: ...d with the dosimeter for small quantities The max filling is approx 8 kg depending on the desity of the small quantities that are to be dosed When drugs are given the principle of no tolerance is vali...

Page 67: ...arge point Figure 8 25 Code no 83 05 8789 Table 8 3 motor specifications for dosimeter for small quantities For futher specifications see rating plate of motor Pos Qty Code no Description 1 83 05 8789...

Page 68: ...for small quantities 1 1 83 06 1493 DC 24V gear motor 2 1 83 00 1536 Baseplate for DR850 1500 small quantity dosing unit 4 83 03 6237 Hex bolt M 5x 12 stainless steel DIN 933 4 99 20 1505 Locknut M 5...

Page 69: ...l feed content 0 5 Conveying capacity determined in self experimentDR1500 50 kg min The following mineral feed quantity results from this when the formula is used Adjusting the mineral feed dosimeter...

Page 70: ...n a rider pos 4 that is tensioned by springs pos 5 During operation the correct initial tension is controlled by a limit switch pos 6 The limit switch immediately stops the drive unit if the tension o...

Page 71: ...Drive unit Page 61 DR 1500 Edition 08 10 M 4021 GB Figure 9 1 drive DR 1500 Figure 9 2 drive DR 1500 XXL...

Page 72: ...0 230 400V 50Hz 3PH chain 42 1 1 83 01 2657 DR1500 drive preassembled without motor or drive wheel 2 1 83 05 8375 Driving wheel DR1500 plastic 3 1 10 88 4029 Gear motor 1 50 230 400 50 3PH 31U shaft 3...

Page 73: ...de no Description 1 83 01 2665 Mounting set for motor and driving wheel DR850 1500 4 1 99 10 1274 Hexagon head screw M 12x 30 DIN 558 galv 5 1 20 90 3759 Washer 13x50 2 galv 6 1 99 50 1205 Spring wash...

Page 74: ...50Hz 3Ph chain 42 1 1 83 01 5353 DR1500 XXL drive preassembled without motor or drive wheel 2 1 83 05 8375 Driving wheel DR1500 plastic 3 1 10 88 4029 Gear motor 1 50 230 400 50 3PH 31U shaft 35x58 4...

Page 75: ...850 1500 Pos Qty Code no Description 1 83 01 2665 Mounting set for motor and driving wheel DR850 1500 4 1 99 10 1274 Hexagon head screw M 12x 30 DIN 558 galv 5 1 20 90 3759 Washer 13x50 2 galv 6 1 99...

Page 76: ...it before taking the system into operation to avoid possible damages at the installation Electrical connection see chapter 14 Take care to ensure that the snap ring is right up against the housing wal...

Page 77: ...racket 2 2 99 10 3710 Rod threaded M10x1000 DIN 975 galv 3 8 99 20 1029 Hexagon nut M 10 galv DIN 555 4 4 20 90 3759 Washer 13x50 2 galv 5 4 99 10 1058 Hexagon head screw M 8x 30 DIN 558 galv 6 4 37 8...

Page 78: ...Page 68 Drive unit DR 1500 Edition 08 10 M 4021 GB Figure 9 7 Drive with wall fastening dimensions X Drive DR1500 870mm Drive DR1500 XXL 1070mm...

Page 79: ...DR850 1500 1 2 83 02 1126 Foot galv DR850 1500 2 4 99 20 1409 Hexagon head screw M 8x 50 DIN 933 SST 3 4 99 20 1193 Self locking counter nut M 8 DIN 985 SST 4 8 99 20 1177 Washer A 8 4x25x2 0 DIN 9021...

Page 80: ...38 98 3611 Foot SST M12x165 1 1 83 02 1156 Foot plate M12 galv 2 1 83 02 1153 Threaded rod galv M12x160 3 2 99 20 1053 Hexagon nut M 12 galv DIN 555 Pos Qty Code no Description 1 83 02 4012 foot adjus...

Page 81: ...9 4 5 Covering SST cplt for motor Figure 9 11 Code no 83 07 1629 Pos Qty Code no Description 1 83 07 1629 Blue GFK cover for DR 850 1500 drive Bore the boreholes for the motor cover fastenings with 6...

Page 82: ...tening of twisted conveyor chains during shortening in the scope of maintenance works Clamping device complete for the drive DR1500 and DR 1500 XXL Figure 9 12 Code no 83 04 9760 Depending on the inst...

Page 83: ...Drive unit Page 73 DR 1500 Edition 08 10 M 4021 GB Figure 9 13 Drive with clamping device...

Page 84: ...yor chain 42 1 1 10 87 3701 Tube 60x1 50 5000 wo hole TF D60 DR1500 2 0 1 10 88 4709 Coupler for conveor chain DR1500 3 5m 10 88 4711 Conveyor chain hardened 42mm DR1500 distance between discs 71 5mm...

Page 85: ...a dry feeding system see chapter running direction The individual discs of the chain contain the tool number as well as a date 1 and certain chain links are also stamped with a special marking 2 Alway...

Page 86: ...of the control segment the filling amount is monitored In order to allow for a correct adjustment of the right conveying capacity at the level adjustment of the feed hopper a horizontally aligned conv...

Page 87: ...the conveyor tube pos 1 with integrated control segment pos 2 Figure 10 6 Code no 83 01 1146 Pos Qty Code no Description 1 83 01 1146 Flat steel reinforing cpl for control segment DR1500 3 1 83 01 113...

Page 88: ...Page 78 Feed pipe DR 1500 Edition 08 10 M 4021 GB 10 3 Turns 10 3 1 Corner 90deg PA6 Figure 10 7 Code no 10 87 3730...

Page 89: ...0 87 3731 Body half lower PA6 GK30 DR1500 9 1 10 87 3734 Axle for corner ABS POM TF D60 DR1500 10 2 99 98 4682 Ball bearing 6204 LLU 11 1 10 87 3736 Washer V 14 5x20x3x35 galv 12 1 10 87 3737 Washer R...

Page 90: ...Page 80 Feed pipe DR 1500 Edition 08 10 M 4021 GB 10 3 2 Corner 90deg SST Figure 10 8 Code no 83 00 2198...

Page 91: ...DR1500 7 1 10 87 3745 Corner wheel PA DR1500 TF D60 8 1 83 00 2193 Body half lower SST DR1500 9 1 83 00 2196 Axle for corner SST TF D60 DR1500 10 2 99 98 4682 Ball bearing 6204 LLU 11 2 83 00 3827 Was...

Page 92: ...60 at pipe 1 board 35 1 1 83 04 6016 pipe 1 x1750 mm galv 1 83 04 8498 pipe clamp 60 cpl for pipe 1 2 1 99 50 3003 U bolt galvanized 8x25 W34 H50 3 1 83 04 8422 pipe clamp 60 mm galvanized 4 2 99 20...

Page 93: ...plate galv M 8 30x17x6 10 1 83 04 9623 pipe clamp 1 galv without cotter Pos Qty Code no Description 1 83 04 9678 support 1 x1750 cpl for 1 pipe 60 at board 35 board 35 1 1 83 04 6016 pipe 1 x1750 mm g...

Page 94: ...clamp cpl 1 x 1 5 2 65 00 3676 T pipe clamp halve 1 x 1 6 1 99 20 1065 self locking counter nut M 10 DIN 980 8 galv 7 1 99 10 1236 hexagon head screw M 10x60 galv DIN 558 Pos Qty Code no Description 1...

Page 95: ...e clamp 60 32 mm cpl 1 1 99 40 3930 pipe clamp 32 mm PP 2 1 99 10 1156 mushroom head square neck bolt M 6x20 DIN 603 galv 3 1 83 00 0705 pipe clip 60 65 mm PP Pos Qty Code no Description 1 99 40 4055...

Page 96: ...B 32 60 cpl 1 2 10 87 3733 clamp ABS for corner TF D60 DR1500 2 1 99 40 3731 pipe clamp B 32 without strap 3 2 99 10 1039 hexagon head screw M 8x25 galv DIN 933 4 2 99 10 1040 hexagon nut M 8 galv DIN...

Page 97: ...Qty Code no Description 1 20 50 3059 Wall bracket for 2 tubes 63mm 1 1 20 50 3717 Angle bracket galv for 2 3 tubes 2 2 99 10 3733 Hexagon wood screw 8x 60 DIN 571 ST galv 3 2 99 40 3766 Tube clip A 6...

Page 98: ...1 pipe 2 2 99 98 3794 Multipurpose plug TRI 10 61 3 2 99 10 3780 Hexagonal wood screw 8x 80 DIN 571 ST galv 4 2 37 80 2011 washer A 8 4x25x2 0 DIN 9021 galvanised 1 83 06 9280 Pipe clamp 60 complete...

Page 99: ...83 04 5382 wall bracket 400mm galv 3 2 99 10 3780 hexagon wood screw 8x 80 DIN 571 ST galv 4 2 99 98 3794 dowel multi purpose TRI 10 61 2 83 04 9409 pipe clamp 60 cpl for wall bracket 1 83 04 9409 pi...

Page 100: ...ngle bracket for 1 pipe 5 8 37 80 2011 washer A 8 4x25x2 0 DIN 9021 galv 6 4 99 10 3780 hexagon wood screw 8x 80 DIN 571 ST galv 7 4 99 98 3794 dowel multi purpose TRI 10 61 Pos Qty Code no Descriptio...

Page 101: ...od jack galv 140x22x7 8 10 93 1642 Tripod jack galv 120x22x7 8 10 93 1629 Tripod jack galv 80x22x7 8 2 99 98 3822 Dowel S 10 MEA 3 99 50 0012 Suspension chain no 30 63 00 0080 Suspension chain SST 28x...

Page 102: ...the following solutions For this you need additional suspension material Figure 10 19 Suspension options When cutting up the suspension chains keep in mind that a certain length is required in order...

Page 103: ...te all tubes couplers corner housings erection material and accessories according to the blue prints in the house 4 If required drill cuttings through the wall for the feed pipes Figure 10 20 cuttings...

Page 104: ...the conveying direction Figure 10 22 Installation direction of the corner wheel 9 Push the tubes up to the limit stop into the corners and fasten them DANGER OF INJURY Always wear safety gloves and g...

Page 105: ...orizontally Make sure that there are no tube distortions 11 Tighten all screws of the supports 10 7 2 Assembly of the feed discharge points Support the corners at site and seal them with silicone in c...

Page 106: ...s in it 3 Always pull in the chain with the help of a second person One person pulls in the chain and the other person ensures that there are not twists in the chain To ensure that the dry feeding sys...

Page 107: ...ll the chain from one corner to the next and assemble every corner At the same time a second person inserts every segment of the conveyor chain into the opening of the corner Figure 10 26 Insertion of...

Page 108: ...dance of chain through the drive 8 Release the tensioning wheel of the drive with the tensioning device code no 83 01 5136 9 Shorten the conveyor chain by the required length and connect both ends at...

Page 109: ...feed drops down without any problems the length of the opening X should be as long as possible as determined by the slider Figure 11 1 shows an ideal form of a weephole Figure 11 1 Weephole 1 Drill 2...

Page 110: ...shows another possibility Figure 11 2 Weephole rectangular The carrier plates of the conveyor chain rope might get caught at messy cutting edges when the system is in operation which might lead to dam...

Page 111: ...0 89 3765 Outlet MI DR1500 cpl 1 1 83 01 1423 Outlet MI DR1500 with shutter 2 1 99 10 3868 Drilling screw 3 9x16 DIN 7504 P H 3 2 99 50 3775 Strap 280mmx4 5 Pos Qty Code no Description 1 83 01 1096 Dr...

Page 112: ...o 83 04 4081 or 83 05 0438 Carefully read the assembly instructions by Big Dutchman code no 99 97 2744 containing safety instructions explosion drawings and parts lists Use the instructions for the as...

Page 113: ...ipe 15 1 83 04 6804 Translucent outer tube 65 for telescopic drop pipe 16 1 83 04 6805 Clamping device 60 65 for telescopic drop pipe Pos Qty Code no Description 1 83 05 0438 Blue tap with DR1500 rope...

Page 114: ...let by Big Dutchman code no 99 97 2656 6L 99 97 2691 8L with explosion drawing and parts list Use the instructions for the assembly and spare parts orders Fasten the drop pipes with the pipe clamps Po...

Page 115: ...11 6 Code no 83 03 9070 unassembled or 83 05 5843 mounted Pos Qty Code no Description 1 83 03 9070 8L volume dosing unit complete DR1500 unassembled 1 1 83 04 3766 8L volume dosing unit without access...

Page 116: ...Page 106 Feed discharge points DR 1500 Edition 08 10 M 4021 GB 11 3 2 Volume dispenser TI Figure 11 7 Code no 10 88 3200 3210 and 3220...

Page 117: ...3 9x16 DIN 7504 P H 3 1 99 50 3922 Hose band clip 50 70 4 1 99 50 0120 Cable clamp 5mm 3 16 galv 5 2 10 88 3412 Strap 360mmx7 5 6 1 10 87 3116 Adapter for volume dispenser TI DR1500 TF D60 7 1 10 87...

Page 118: ...pes for volume dispensers To avoid obstructions in the drop pipe make sure to deburr the pipes thoroughly from the inside To make sure that possible vibrations during operation of the installation hav...

Page 119: ...volume dispenser BR TI 1 1 83 01 3794 Connecting sleeve 60 63 75 2 0 33 99 40 3767 Pipe 63x4 70 5000 PVC DIN 8061 62 3 2 99 50 3866 U bolt galv 8x50 W67 110 4 2 99 50 3867 Counter plate galv for U bo...

Page 120: ...olume dispenser TI 1 1 99 40 3850 Bend 63x68 30 deg small PVC 2 0 28 99 40 3767 Pipe 63x4 70 5000 PVC DIN 8061 62 3 1 99 40 3851 Bend 63x63 30 deg small PVC 4 2 99 50 3866 U bolt galv 8x50 W67 110 5 2...

Page 121: ...r U bolt 8mm W75 4 1 99 50 3029 U bolt galv 8x50 W75 125 5 2 99 20 1064 Self locking counter nut M 8 DIN 985 6 galv 6 2 99 20 1026 Washer A 8 4 DIN 125 galv 7 1 83 01 3794 Connecting sleeve 60 63 75 2...

Page 122: ...astic 75x 250 2 2 99 50 3763 Bend plastic 75mm 30deg 3 1 83 01 5342 Pipe plastic 75x1000 4 2 99 10 3879 Tapping screw B 4 2x19 DIN7981 1 65 02 3355 Protect pipe galv cpl stand tiltable concrete 6 4 83...

Page 123: ...d stand 1 1 83 01 5172 Pipe plastic 75x 250 2 2 99 50 3763 Bend plastic 75mm 30deg 3 1 83 01 5342 Pipe plastic 75x1000 4 2 99 10 3879 Tapping screw B 4 2x19 DIN7981 1 65 02 6371 Protect pipe galv cpl...

Page 124: ...Page 114 Feed discharge points DR 1500 Edition 08 10 M 4021 GB 11 4 6 Drop pipe 75 cpl straight at crate Figure 11 13 Code no 83 03 9896 83 04 1019...

Page 125: ...inless steel A 8 4 DIN 125 16 1 99 50 3084 counter plate galv for U bolt 8mm W90 17 4 99 20 1193 self locking counter nut stainless steel M 8 DIN 985 18 2 99 20 1064 self locking counter nut M 8 DIN 9...

Page 126: ...Page 116 Feed discharge points DR 1500 Edition 08 10 M 4021 GB 11 4 7 Drop pipe 75 cpl straight for farrowing crate Figure 11 14 Code no 83 04 1040 83 04 1241...

Page 127: ...stainless steel 17 2 83 03 9862 spacer 130x30 10 B 107 protection pipe at crate 18 4 99 20 1600 washer stainless steel A 8 4 DIN 125 19 4 99 20 1464 hexagon head screw stainless steel M 8x 65 DIN 931...

Page 128: ...Page 118 Feed discharge points DR 1500 Edition 08 10 M 4021 GB 11 4 8 Drop pipe 75 cpl elbowed at crate Figure 11 15 Code no 83 04 1034 83 04 1254...

Page 129: ...125 14 4 99 20 1427 Hex wood screw 8x 120 DIN 571 A2 stainless steel 15 4 99 98 3822 Dowel S 10 HD 16 2 83 04 1041 Spacer 130x30 45 B 107 for drop pipe on wall Pos Qty Code no Description 1 83 04 125...

Page 130: ...Page 120 Feed discharge points DR 1500 Edition 08 10 M 4021 GB 11 4 9 Drop pipe 75 cpl elbowed for farrowing crate Figure 11 16 Code no 83 04 1039 83 04 1021 83 04 2078...

Page 131: ...ng crate type 05 1 2 99 50 3763 bend plastic 75 mm 30 deg 2 1 10 88 3443 pipe plastic 75x150 3 1 99 40 4087 pipe plastic 75x500 4 1 10 88 3444 socket plastic 75 mm 5 6 99 10 3868 drilling screw 3 9x 1...

Page 132: ...tiltable trough farrowing crate 4 leg 11 1 10 88 3441 pipe 75x2 00 750 galv 30 deg 18 4 37 80 2011 washer A 8 4x25x2 0 DIN 9021 galv 19 4 99 20 1064 self locking counter nut M 8 DIN 985 6 galv 20 2 9...

Page 133: ...or the animals also install a protecting tube against gnawing Pos Qty Code no Description 1 10 87 3270 Protection pipe 600mm SST cpl for trough built in wall 1 1 10 87 3271 Protection pipe 70x2 600 SS...

Page 134: ...Description 1 10 87 3275 Protection pipe 600mm SST cpl at aisle or partition 1 1 10 87 3271 Protection pipe 70x2 600 SST 2 2 99 50 3042 U bolt SST 8x30 W90 120 3 2 99 50 3043 Counter plate SST for U b...

Page 135: ...7 3280 Protection pipe 600mm SST cpl for trough built in front of wall 1 1 10 87 3271 Protection pipe 70x2 600 SST 2 2 99 50 3914 Pipe clip 70x30 SST 3 2 10 87 3671 Spacer 130x45 30 for drop pipe at w...

Page 136: ...e trough 1 4 83 00 8102 Spacer 130x45 30 for protect pipe at farrowing crate stand 2 2 83 00 8650 U bolt galv 8x45 W75 150 3 4 99 20 1064 Self locking counter nut M 8 DIN 985 6 galv 4 4 37 80 2011 Was...

Page 137: ...make sure that all holes for the feed discharge points lie directly on the center line of the underside of the tube draw a cord 3 Drill out the weepholes see chapter 11 1 4 Assemble the feed outlets...

Page 138: ...60 40 3105 Wire rope 3 mm SST 1 4301 99 50 3708 Wire rope 6mm PP coated core 5 mm DIN 123855 4 Set 2 rope guides per tube 5m Pos Qty Code no Description 1 10 88 3461 Guide for releasing rope at volum...

Page 139: ...4 1 99 10 1317 hexagon head screw M 8x80 galv DIN 558 5 1 99 20 1064 self locking counter nut M 8 DIN 985 6 galv 2 99 10 1276 hexagon head screw M 6x 60 galv DIN 558 for DR850 4 99 10 1045 hexagon nut...

Page 140: ...3814 tension spring 2 5x25x280 B DIN 17223 2 1 10 93 1642 cup hook galv 120x22x7 8 3 1 99 98 3822 dowel S 10 HD 1 99 98 3794 dowel multi purpose TRI 10 61 4 1 99 50 0120 cable clamp 5mm 3 16 galv Pos...

Page 141: ...0 87 3149 Idler roller 105mm cpl w threaded rod for DR 1 1 99 20 3708 Lifting eye nut M 10 DIN 582 galv 2 1 00 00 3006 Pulley 4 1 8 105mm plastic with split strap 3 2 20 90 3759 Washer 13x50 2 galv 4...

Page 142: ...pipe cpl 63x4 7 1650 for volume dispenser 11 4 1 7 83 04 1019 drop pipe 75 cpl straight at crate with clay trough 11 4 6 83 04 1241 drop pipe 75 cpl straight at wall for farrowing crate 11 4 7 8 83 04...

Page 143: ...Release for volume dispenser Page 133 DR 1500 Edition 08 10 M 4021 GB Figure 12 7 example for a release with wall mounted cable winch...

Page 144: ...ST galv 4 2 10 93 1642 cup hook galv 120x22x7 8 5 1 37 76 3814 tension spring 2 5x25x280 B DIN 17223 6 1 99 50 0120 cable clamp 5mm 3 16 galv similar DIN 741 7 4 99 50 1483 washer A 10 5x30x2 5 DIN 90...

Page 145: ...hen the ratchet lever is in unlocked position with a load on the winch Otherwise the handle will spin violently thus causing severe injuries Check for proper ratchet operation before each use of the w...

Page 146: ...galv 5 10 87 3235 drop pipe cpl 63x4 7 1450 elbowed for volume dispenser 11 4 2 6 10 87 3135 drop pipe cpl 63x4 7 1650 for volume dispenser 11 4 1 7 83 04 1019 drop pipe 75 cpl straight at crate with...

Page 147: ...Release for volume dispenser Page 137 DR 1500 Edition 08 10 M 4021 GB Figure 12 10 Example of wall mounted automatic release...

Page 148: ...e detachable rubber band at the adjusting spindle For opening closing of the volume dispenser a max of 290mm lifting height are provided Provided that the opening rope with the closing ball of the vol...

Page 149: ...9 Pipe 2 3 1 83 00 1680 Bracket for winch motor LA28 1 450 24 01 4 1 83 00 1141 Tension screw for automatic releasing device 5 6 99 10 1040 Hexagon nut M 8 galv DIN 934 8 6 6 99 10 3780 Hexagon wood s...

Page 150: ...ing operation Pay attention to abnormal sounds and irregular operation Immediately turn off the winch motor as soon as you notice anything strange If the installation is not running Disconnect power s...

Page 151: ...ng the assembly always make sure that the winch motor sits tightly but that there is enough freedom of movement at its holding straps it is supported in the bushes of the seat that twist is prevented...

Page 152: ...limit switch forward until the required travel is reached This is measured from the centre of the pan head screw of the first switch up to the centre of the pan head screw of the second 2 Fix the brac...

Page 153: ...r with safety nut M 10 Figure 12 17 Assembly of the winch motor 4 Insert the tension screw trough the opening at the top of the bracket and through the drill hole in the spindle rod Figure 12 18 Inser...

Page 154: ...r the release rope at the feed pipe 3 Position the wire rope in the area of the volume dispensers 4 Assemble the idler rollers at the same height and alignment as the course of the release wire at the...

Page 155: ...is activated and the drive is turned off When feed is ingested and the sensor is released the drive is switched on again after an appropriate time delay and refills the automatic feeders Figure 13 1...

Page 156: ...ption 1 10 88 3415 Sensor with fastening cpl at conveyor tube DR1500 1 1 60 40 0654 Sensor MS 45R 220V 2 1 60 41 0112 T piece for sensor MS 45R 3 2 10 88 3413 Strap 360mm x 7 5mm black UV resistant 4...

Page 157: ...or is activated and the drive is turned off When feed is ingested the sensor is released and the drive is switched on again after an appropriate time delay and refills the automatic feeders Figure 13...

Page 158: ...60 40 0754 Sensor MS 45R 220V threaded 7 1 60 41 0112 T piece for sensor MS 45R 8 2 10 88 3413 Strap 360mm x 7 5mm black UV resistant Pos Qty Code no Description 1 10 88 3815 sensor 10 30 V AC DC with...

Page 159: ...ly for Dry Rapid controller Shorten the T piece Pos 7 before the assembly Pos Qty Code no Description 1 10 87 3195 Sensor with fixing device at volume dispenser TI 1 1 10 87 3196 Tube with fixing devi...

Page 160: ...975 Only for Dry Rapid controller Pos Qty Code no Description 1 91 00 3985 Sensor MS 45R with screw union 1 1 99 30 3001 Screw union PG 36 2 1 60 40 0654 Sensor MS 45R 220 V Pos Qty Code no Descriptio...

Page 161: ...Sensor MS 45R has an integrated relay switch as well as adjustable time delay and sensitivity An electrical terminal connecting plan is appended to every sensor During connection and adjustment of th...

Page 162: ...Page 152 Control and operation DR 1500 Edition 08 10 M 4021 GB Description of sensor MS45R...

Page 163: ...R The sensitivity can be activated by pushing and releasing buttons A and B simultaneously The mode indicator has to be green When pushing button A the sensitivity is decreased when pushing button B i...

Page 164: ...a capacitive sensor for solid matters in the range of grain and feed The sensitivity is adjusted by means of two push buttons LED indicate which push buttons are active The sensor is equipped with an...

Page 165: ...witch off When the activation stops the time delay begins red flash and when this delay has run out the relay switches back Besides the two options above the DOL 45R can also be set for delayed switch...

Page 166: ...s clock relay pos 1 to pre set feeding times potentiometer pos 2 for speed control of the dosimeter for small quantities terminal box pos 3 with main switch pos 4 and Start switch pos 5 Figure 13 8 Ex...

Page 167: ...to control the following devices motor of mineral proportioner servo motor for opening of the volume dispensers supply augers soaking system vibrator at the silo illumination Figure 13 9 Example of a...

Page 168: ...er with forced leading in resp feedback All work involved may only be carried out by authorized personnel and under consideration of the established regulations e g VDE Observe the instructions suppli...

Page 169: ...opening in the control box has to be closed by a blind plug The motor casing has to be earthed at the marked safety screw The phase sequence in the network has to be determined before connecting the...

Page 170: ...Figure 14 2 DOL 41R connection to Dry Rapid controller The adjustment drive may only be operated with 24 V DC yellow black green red blue black yellow gr n red blue 1 1 1 1 1 1 1 1 I 1 I 1 N N safety...

Page 171: ...limit switch of the adjustment drive the emergency stop function Test the different operating procedures 15 1 2 Dosing Adjust the flow of material immediately after turning on the level adjustment of...

Page 172: ...eyor chain are not twisted You might have to carry out improvements during the running in period until corrections are no longer necessary 15 2 Operation 15 2 1 Drive unit During operation the correct...

Page 173: ...Check for faultless functioning after the assembly The adjustment drive must not be operated with higher values than the ones stated in the specification The operating cycle must not be exceeded by m...

Page 174: ...to excessive heat generation You can gather the amount and type of lubricant from the lubricant sign that is attached to the gearing Different lubricants must not be mixed If the lubricant is changed...

Page 175: ...u have to make sure to check the feed pipe at regular intervals for dents or other damages and replace damaged pipes 16 1 4 Turns The ball bearings in the turns are lubricated for life and therefore m...

Page 176: ...iston rods housing pluggs and the entire system for faultless operation The adjustment drive is a closed unit and therefore does not need maintenance of the inner parts Intervention at the adjustment...

Page 177: ...on chain is stretched too far shorten chain 2 3 plates draw spring in the drive is overstreched and no longer operative replace the spring trouble cause procedure Excessive heat build up in the gear m...

Page 178: ...d line for foreign matter and remove it the drive unit is built in backwards mount drive unit correctly corner wheels are assembled backwards turn corner wheels see chapter 10 7 too much feed accumula...

Page 179: ...ir excessive power consumption adjustment drive in need of repair motor is running but no movement of spindle or piston rod gearwheel or spindle are damaged adjustment drive in need of repair adjustme...

Page 180: ...ing the cleaning works close the inspection opening 17 4 Volume dispenser If feed with a high fat content is used fat might deposit in the volume dispenser This might cause problems when adjusting the...

Page 181: ...Cleaning Page 171 DR 1500 Edition 08 10 M 4021 GB Never clean the adjustment drive with a high pressure cleaner...

Page 182: ...ppear together with the code number and the description in the respective spare parts lists For ordering spare parts indicate the code no description of the spare part and the number of the original i...

Page 183: ...ts of different suppliers Within the same viscosity class and type of lubricant the supplier can be chosen freely In case you change the viscosity class resp the type of lubricant you should contact B...

Page 184: ...triebe 5 60 C ISO VG 680 Degol GS 680 Energol SG XP 680 Renolin PG 680 Kl bersynth GH 6 680 Glygoyle HE 680 Shell Tivela S 680 Synthetisches l Synthetic oil Huile synth tique ISO VG 220 25 80 C Degol...

Page 185: ...Grease Graisse biod gradables 25 40 C Aralub BAB EP 2 BP Bio grease EP 2 Biotec Plantogel 2 S Kl berbio M 72 82 Schmierfett UE 100 B Shell Alvania RLB 2 Lebensmittelver tr gliches Fett 1 Food grade gr...

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Big Dutchman Dry Rapid DR 1500, Mounting And Operating Instructions

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