073-2_2004-10 dynayield 2 equip manual.pdf

8/10/2019 073-2_2004-10 Dynayield 2 Equip Manual.pdf

1/56

Rader DynaYieldTM

II Chip Condit io ner

Equipment Manual

Manual Numb er 073-2, Oct 2004

Rader Com panies, Inc

Rader Canada

Rader AB


2/56

Rader DynaYieldTMII Equipmen t Manua

Manual Number 073-2 Oct 2004

Table of Contents

Page

A. OVERVIEW AND GENERAL SAFETYA.1. Preface . . . . . . . 1A.2. General Safety . . . . . . 1A.3. Warning Signs . . . . . . 2A.4. Lockout/Tagout Procedures . . . . 3A.5. Confined Spaces Procedures . . . . 3A.6. Material Safety Data Sheets . . . . 3

B. GENERAL INFORMATIONB.1. DynaYield

TMChip Conditioner Background . . 4

B.2. Functional Description . . . . . 4B.3. Standard Model information . . . . 6B.4. Optional Features . . . . . . 6B.5. DynaYield

TMSafety Warning Signs . . . 6

C. INSTALLATION

C.1. Shipping, Handling, and Storage . . . . 7C.2. Mounting and Supports . . . . . 8C.3. Service Access . . . . . . 9C.4. Infeed Requirements . . . . . 10C.5. Outfeed Requirements . . . . . 11C.6. Electrical Requirements

C.6.a. Conditioner Electric Motors . . 12C.6.b. Hydraulic Unit Electrical Requirements 12C.6.c Speed Sensing Probes . . . 12C.6.d. Nip Setting Proximity Probes . . 12C.6.e. Electrical Lock-Out . . . . 12C.6.f. System Interlocking . . . 13

C.7. Hydraulic System Requirements . . . . 15

D. START-UP CHECK OFF SHEET . . . . . . 16


3/56



E. OPERATIONE.1. Material Pre-Conditioning Requirements . . 18

E.2. Basic DynaYieldTM

Chip Conditioner Operation . . 18

F. MAINTENANCE . . . . . . . . 21F.1. Preventive Maintenance . . . . . 21F.2. Lubrication Information . . . . . 22F.3. Hydraulic Unit . . . . . . 22F.4. Speed Sensing Components . . . . 24F.5. Mechanical Components . . . . . 24F.6. Periodic Maintenance . . . . . 25

F.6.a. Roll Nip Adjustment . . . 25

F.6.b. Axial Roll Adjustment . . . 27F.6.c. Roll Scraper Adjustment . . . 28F.6.d. Roll Segment Replacement . . 29F.6.e. Hydraulic Cylinder Replacement . 31F.6.f. Drive Reducer Replacement . . 32F.6.g. Spherical Bearing Replacement . 34

F.7. Bolt Torque Specifications . . . . . 38F.8. Special Tools . . . . . . 38

G. RECOMMENDED SPARE PARTS . . . . . 39

Appendices

Optional Distr ibut ing Screw App endix

Opt ional Fluid Coupl ing App endix

Falk Reducer Append ix

Spher ical Bear ing App endix

Prox imi ty Sens ing Appendix

Hydraul ic Power Uni t App endix

This manual, the design and ideas shown herein, and any copies made from this document are confidential andproprietary information of Rader Companies, Inc., Rader Canada, and Rader AB. It is to be returned on requestThis manual, designs, and ideas shown herein shall not be used, copied, or disclosed to others, in whole or inpart, either in written or electronic form, without the prior written permission of Rader Companies, Inc. Theserestrictions are in addition to and not in lieu of any other confidential / non-disclosure restrictions owed to RaderCompanies, Inc.


4/56


5/56


6/56


7/56



2004 Rader Companies, Inc. Page 4

B. General Info rmat ion

B.1. DynaYieldTMChip Condi t ioner Background

The DynaYieldTM

Chip Conditioner was primarily developed to increase the efficiency of the paper

making process, by conditioning the overthick/oversize wood chips into a usable form for pulping.In the recent past, many mills would simply send all unprocessed overthick/oversize woodreceived to the pulp mill, resulting in heavy usage of pulping chemicals, high digester knotterreject rates. and lower pulp yield. By processing the overthick/oversize wood through theDynaYield

TM, pulping liquor can more easily penetrate the chip, and enhance the pulp yield from

the chip. The DynaYieldTM

has the additional advantage over other types of overthick/oversizeprocessing equipment of extremely low pins and fines production during the conditioning process.

B.2. Funct ional Descr ipt ionThe DynaYield

TM Chip Conditioner is a continuous duty machine, designed to condition wood

chips in a single pass through the unit.

The DynaYieldTM

Chip Conditioner consists of two major parts, the Chip Conditioner Unit, and aHydraulic Power Unit for roll positioning. The Chip Conditioning Unit consists of 2 segmentedrolls, approximately 37" in diameter. The rolls are arranged horizontally, and rotate in an oppositedirection so the wood fed into the top ingoing nip is pulled between the two rolls (see Figure #1)The rolls are positioned with bearings into a rigid frame, with the static roll solidly anchored to theframe, and the dynamic roll allowed to move in a horizontal direction away from the static rollThis movement in the dynamic roll allows for rocks and tramp to go through the machine, andminimize damage to the roll surface. Each roll has it's own motor, V-Belt drive, and shafmounted reducers with motor mounts.

The roll surface is comprised of removable segments, which permit replacement of the outeprofiled surface when worn. The rolls are positioned closely to a minimum nip setting bymechanical stops, and the dynamic roll is held against this stop by hydraulic cylinders at both endsof the dynamic roll. When the separate Hydraulic Pump unit (located near the Chip Conditioneris started, the hydraulic fluid pressurizes the hydraulic cylinders, pushing the dynamic roll againstthe mechanical stops for the desired nip setting. If tramp iron or some other hard object goesthrough the DynaYield

TMChip Conditioner, the hydraulic pressure is overcome in the cylinders

moving the dynamic roll back, and allowing the object to pass through the unit. Once the hardobject has passed through the unit, the dynamic roll moves back to the original minimum nip

Figure 1


8/56




setting automatically. The hydraulic unit may also be used to open the nip clearance fomaintenance on the roll assemblies, or to help clear a plug in the infeed area.

The Hydraulic Unit consists of a separately located skid mounted 20 gallon sealed (non bladder)type reservoir, flooded suction pumping system with an electric motor driving a hydraulic pump

heat exchanger, accumulator, and 5 micron filter for the fluid returning to the reservoir. TheHydraulic Unit is connected to the DynaYield

TMChip Conditioner through runs of high pressure

hydraulic hose and pipe.

Figure 2


9/56




B.3. Standard Model Informat ionThe DynaYield

TMChip Conditioner is manufactured of high quality components, and machined

fabricated and assembled with great care. All units are test run at the manufacturing shop foproper operation before shipment.

All DynaYieldTMChip Conditioners will have attached to the frame at one corner a metal Radenameplate. On this nameplate is permanently stamped the Rader Job Number and Rader ModeNumber for each conditioner. This information should be referred to whenever the chipconditioner requires service or spare parts.

Three models are currently available, as shown the table below.

Model Number 40-150 60-200 80-300

Roll Length 4-0 Long 6-0 Long 8-0 Long

Roll Horsepower (2) 75 Hp (2) 100 Hp (2) 150 Hp

HPU Horsepower (1) 7.5 Hp Pump Motor, w/ (1) 1/4 Hp Heat Exchanger Motor

Approx. Weight 33,000 lbs 41,000 lbs 52,500 lbs

B.4. Optio nal FeaturesBelow is a partial listing of optional features that may be selected at the time of order. In manycases, features may be added to existing units, contact a Rader product representative for moreinformation on in-field modifications.

- Electric Motor(s) by Rader- Fluid Couplings mounted on the electric motors- Infeed/Outfeed Chute work- Distributing Infeed Screws- High Pressure Hydraulic tubing, flex hose, and fittings between the Chip Conditioner and

the Hydraulic Unit.- Water to oil heat exchanger

- Various special materials and/or coatings to meet specific operating conditions.- Special preparation, primer and paint as required

B.5. DynaYieldTMSafety Warning Signs

The following safety warning signs are used on the DynaYieldTM

Chip Conditioner. Should any othe signs on the conditioner be missing, damaged, or illegible, they should be cleaned or replacedto ensure the safe operation and maintenance of the DynaYield

TM. Replacement warning signs

are available for a nominal charge by contacting the Rader product representative at one of theaddresses listed in Section A.1.

A-101270 "Lift Here"

C-103175 "WARNING: Equipment starts and stops automatically..."C-103176 "WARNING: Rotating Shafts and/or moving drive components..."C-103179 "WARNING: Falling through unsupported surface..." (with pictorial)C-103190 "NOTICE : Refer to manual for installation, operation,..."C-103313 "DANGER: Aggressive Ingoing Nip..." (with pictorial)C-103404 WARNING: Control Voltage... (with pictorial)


10/56




C. Instal lat ion

C.1. Shipp ing , Handlin g, & StorageThe DynaYield

TMChip Conditioner is designed with four lifting brackets located at the top of the

four corners of the conditioner frame. The drive housing at the drive end of the conditioner doesnot need to be removed for lifting as long at the lifting lines to not interfere with any part of thedrive housing.

WARNING!

Before lifting the DynaYieldTM

Chip Conditioner, check the

approximate total weight listed on the assembly drawing, and

the location of the center of gravity of the unit. Care should

always be taken to insure adequate capacity in any equipment

used to lift or move the conditioner. Lifting lines must be

arranged as shown in Figure #3.

When shipping by truck, the conditioner should be placed on wooden cribbing and bound to theflatbed trailer using the lifting brackets. Straps may be used only over the lifting bracket area, andnot over any of the lightweight covers or guards. Under no circumstances should the conditionebe lifted or secured by any of the shafts within the unit. Any damage incurred from shippingshould be reported to both Rader and the shipping carrier involved as soon as possible afterreceipt of the DynaYield

TMChip Conditioner.

Equipment will be shipped with all bare metal surfaces primered or coated with a suitable shippingrust protectant, such as Cosmoline. If the equipment is to be stored before installation, unpack o

Figure 3


11/56




uncrate the equipment immediately, clean off existing protectant, clean any rust or dirt that mayhave accumulated during shipment, and recoat with a suitable rust protectant.

If equipment is to be stored before installation, store the equipment under cover out of directsunlight, and keep dry. WATERPROOF TARPING OR COVERINGS ARE NOT ADEQUATE

Temperature should be ideally controlled to 70o

F. (21o

C.) and less than 60% relative humidityMinimize all temperature variations that can cause internal condensation in bearings andgearboxes. Allow air to circulate freely around the equipment. Keep equipment away from anycorrosive or hazardous environments during storage. Keep equipment away from any blowingdusts or dirt, which could damage shaft seals. It is highly recommended that the hydraulic poweunit be stored in a temperature and humidity controlled environment for all storage periods.

If the equipment is to be stored for an extended period of time (over 4 months), it is recommendedthat the shafts of the equipment be turned manually every two weeks to redistribute grease insidethe bearing housings. Gear reducers should be filled to manufacturer recommendations with arust preventative oil to protect internal gears and bearings, and rotated every two weeks toredistribute oil inside the gear reducer housing. Seal any breathers or vents if instructed by thegear reducer manufacturers. Additional instructions for extended storage can be found in the

Rader Long Term Storage Manual 00-2.

If equipment is to be stored longer than 9 months, and the equipment due to size or weight cannotbe stored in the above parameters, it is strongly recommended that the gear reducers, motorsand bearings be removed from the equipment and stored in an controlled environment.

After any extended storage, all protective oils should be drained and flushed from the gearbox, asany internal condensation will contaminate the oil with water.

C.2. Mount ing and Suppo rtsThe DynaYield

TMChip Conditioner may be mounted to either structural steel framework or to stee

imbeds in concrete floors. Installation drawings should also be referred to when calculatingsupport pad loads. The mounting supports must be flat and level to within 1/16" for both the chipconditioner and the hydraulic unit. The hydraulic unit must be located under 40'-0" from the chipconditioner, as measured by the hydraulic line run. Infeed and outfeed chute work must not besupported off the DynaYield

TMChip Conditioner or it's supports.

Because all components in the roll assemblies is balanced, dynamic forces resulting from theoperation of the conditioner are low. Beams directly supporting the DynaYield

TMChip Conditione

should be designed with a natural frequency in the vertical plane 40% above or below 0.6 Hz (themachines operating frequency) with an expected imbalance of 100 lbs. This frequencycorresponds with the rotational speed of the rolls. Assume the beams are pin supported at bothends during the structural design process. During the operation of the conditioner, the crushingforces necessary to condition the chips is fully contained inside the frame of the unit. Experiencewith the conditioner at existing operating locations has shown the normal operation results in

minimal support steel vibration, if all applicable structural codes are followed. No speciastructural requirements have been required at any of the existing installations.

When installing the DynaYieldTM

Chip Conditioner, take care to protect the interior components othe unit from damage, particularly from welding and falling objects. This is especially important athe infeed opening, as infeed chutework is mounted above the conditioner.


12/56


13/56




Compressed air should be provided at the DynaYieldTM

Chip Conditioner floor level to removeaccumulated dust and foreign matter at maintenance cycles.

C.4. Infeed Requirem entsThe infeed material should be free of large rocks and tramp steel that might damage theconditioning rolls. Experience has shown that in installations where tramp materials (rocks, boltsball bearings, etc.) are not removed, roll segment life decreases in direct proportion to the amountof tramp put through the DynaYield

TMConditioner. In addition to roll segment damage, additiona

damage is sometimes seen in the drive system of the DynaYieldTM

, mainly in the gear reducer andtorque arm. Rader highly recommends effective tramp protection in front of a DynaYield

TM, with

our first choice being an ADS (Air Density Separator) system. In addition to removing the heavytramp material, the ADS has the additional benefit of removing a large percentage of the knotsand compression wood.

In installations where it is suspected that tramp material may be encountered on more than aaccidental basis, Rader will recommend and supply fluid couplings on the motor shafts, which can

provide additional protection against motor overloads in the gearbox. The addition of fluidcouplings will not prevent damage to the roll segments from tramp materials.

Distribution of the infeed material across the width of the conditioner is required for maximum

conditioning efficiency. If distribution is a problem, Rader can provide a distribution screwconveyor to evenly distribute the infeed material. In addition, the DynaYield

TM is extremely

sensitive to changes in the infeed rate. All infeed material must be metered at a near constanrate, to provide a thin curtain of material entering the unit. If the rate is not held constantinconsistent conditioning results may be encountered, or the unit may tend to plug. A bypassaround the chip conditioner, for use during maintenance cycles should also be provided.

The material to the Conditioner should also be scalped of all oversize material, as this oversizematerial could cause insufficient conditioning action if it goes through the conditioner at the sametime as the normal oversize wood. Material over 3/4 in thickness, 2 in width, and/or 8 in lengthis considered oversize.

Figure 5


14/56




Material infeed to the conditioner may free fall vertically up to three feet from above the inlet flangeof the conditioner. Beyond this height, it is recommended to slide the material against a slopedsurface, at a greater than 55

Ofrom the horizontal. Infeed chute can be sloped from both sides i

necessary, sloped from one side only is preferred. See Figure #5 for several examples o

acceptable infeed arrangements.

Recommended access to the nip points between the two rolls is an access door that is the fullength of the infeed chute, set as low as possible to the infeed chute flange, as shown in Figure#6. If a distributing screw is required to be located immediately above the top inlet flange of theconditioner, this access should be provided in the distributing screw discharge housing. This wilallow a visual inspection of the nip point from above the machine all the way across the rolls. Nippoint access may be provided from below the unit, in conjunction with Section C.3. if necessaryhowever, access from above is preferred.

As mentioned above, the infeed chute work must not be supported by the DynaYieldTM

, or to anyof its supports. Access doors for sampling and examining infeed material is alwaysrecommended.

C.5. Outfeed RequirementsService access must be provided in the outfeed area of the conditioner as outlined in Section C.3All discharge chute work must not be supported by the DynaYield

TM or to any of its supports

unless chute weight is below the maximum stated on the general arrangement drawings. Accessdoors for sampling and examining all outfeed materials is always recommended. Sufficient surgecapacity should be allowed in the design of all outfeed chutes should the outfeed equipment beshut down without warning, allowing for at least 1 1/2 to 2 minutes of capacity during DynaYield

TM

time-out. Plug detectors in the discharge chutework are also recommended.

Figure 6


15/56




C.6. Electr ical Requirem ents

C.6.a. Conditioner Electric MotorsThe general arrangement drawing calls out the specific horsepower and number ofmotors required for a given DynaYield

TM Chip Conditioner. When wiring the chip

conditioner motors, use a watertight flexible conduit at the motor which allows thedynamic roll motor to move horizontally as shown on the general assembly drawingsRecommended conduit entrance into the drive housing is from below, and alongside thegear reducer to bottom facing conduit opening in the motor.

It is also recommended that operator push button jog controls be provided at the chipconditioner floor. Start and stop controls may be added if required. If the hydraulic poweunit is located on a different floor than the conditioner, operator controls to start and stopthe power unit, and to extend and retract the cylinders should also be provided.

C.6.b. Hydraulic Unit Electrical RequirementsThe general arrangement drawing calls out the specific horsepower and number ofmotors required for the Hydraulic Unit. Motors on the hydraulic unit include the pump

motor, and a heat exchanger fan on air/oil cooled units. Also included on the unit is atank mounted fluid heater in the reservoir with a temperature controller, a reservoir fluidlow-level switch, high temperature switch for the air/oil cooler, and solenoid control valveall of which must be wired correctly per the recommended interlocking instructions givenin Section C.6.f.

It is also recommended that push button operator controls be provided at the hydraulicunit area, including start and stop control, and extend and retract on the cylinders.

C.6.c. Speed Sensing ProbesTwo proximity type speed sensing probes are included on the conditioner, one positionedon each roll, to provide rotational information to the interlocking controller. The probes

sense off a flag on the shaft, with one pulse equaling one revolution. If either of theconditioner rolls is rotating at less than 30 RPM, the sensor should shut down the infeedto the conditioner. See the Proximity Sensing Appendix and the interlocking instructionsin Section C.6.f. for more information.

C.6.d. Nip Setting Proximity ProbesTwo proximity type sensing probes are included in the conditioner nip setting area, one ateach end. These sensors may be wired and interlocked per the customers requirementsto sound a warning, shut down the system, or any other function. Wire through anadjustable timer so nuisance trips are avoided. See the Proximity Sensing Appendix andthe interlocking instructions in Section C.6.f. for more information.

C.6.e. Electrical Lock-Out

Standard mill procedure for locking out the DynaYieldTM

must follow

the OSHA Lockout/Tagout Procedures outlined in Section A.4. The

DynaYieldTM

must be locked out during any inspection or service

Failure to do so may result in serious or fatal injury. Electrical power

for the conditioner motors and the hydraulic unit must be

disconnected and locked in the "OFF" position before any of the

DynaYieldTM

guards or covers are opened.


16/56


17/56




Start-up:4. Normal start-up sequence will be as follows:

- Start Outfeed- Start hydraulic power unit pump motor. If low fluid level or high

temperature is detected in the hydraulic power unit , an alarm will sound

Timer begins 60 seconds to allow the accumulator to fill. After 60 secondtimer, energize Solenoid A for 10 seconds to retract/open the dynamicroll. After 10 seconds, de-energize Solenoid A, and conditioner motorscan be started.

- After both conditioner motors are running, and low speed probes #1 and#2 are above 30 rpm, Solenoid "B" is energized and held. Theconditioner rolls are now closed, and nip probes #1 and #2 should showthe nip setting closed. Both nip probes should be run through timecircuits so that if either of the nip settings is not made for longer than 5seconds, an alarm will sound, and the customer can decide the results ofthis input.

- Infeed may be started. The conditioner is now in operation.

Operation:5. The hydraulic power unit has a dual setpoint temperature switch. The low startsthe cooling fan when the air/oil heat exchanger is used. High initiates a normashut down and alarm for either heat exchange option.

6. When in operation, if outfeed fails, an alarm will sound. Conditioner infeed isshut-down immediately. Conditioner roll drive motors and hydraulic power unipump motor continue to operate.

7. When in operation, if infeed fails, an alarm will sound. Conditioner roll drivemotors and hydraulic power unit pump motor continues to operate.

8. When in operation, if one or both of the low speed probes on the rolls show 30rpm or less, an alarm will sound. The outfeed continues to operate, the infeed

and both conditioner roll drive motors shut-down. Solenoid "A" is energized andtimer begins for 10 seconds to retract the hydraulic cylinders. After 10 secondtimer, Solenoid A is de-energized. Hydraulic power unit pump motor continuesto operate.

9. When in operation, if the low oil level switch in the hydraulic power unit isenergized, an alarm will sound. The conditioner begins a normal shut-downsequence.

10. When in operation, nip probes #1 and #2 should be run through a timer circuit sothat if either of the nip settings is not made for longer than 5 seconds, an alarmwill sound, and the customer can decide the results of the alarm.

Shut-down:11. Normal shut-down sequence will be as follows:

- Infeed to the conditioner will be stopped. Timer begins for 1 minute toallow the conditioner to clear of material.

- Conditioner roll drive motors and outfeed can be shut-down.- Solenoid "A" is energized for 10 seconds, and the dynamic roll moves to

the fully open position.- Solenoid "A" is de-energized. Hydraulic power unit pump motor may be

left in operation or shut-down as desired.


18/56




12. With the conditioner in a shut-down condition, and the selector switch moved tothe "HAND" position, the conditioner motors can be started and stopped from theoperator control panel.

13. With the conditioner in a shut-down condition, and the selector switch moved to

the "HAND" position, the hydraulic power unit pump motor can be started. Thedynamic conditioner roll can then be opened or closed by activating Solenoids "A"or "B" using the OPEN-OFF-CLOSE selector switch on the operator controstation. Solenoids A and B should never be energized at the same time.

C.7. Hydrau l ic System Requirem entsThe hydraulic system for the DynaYield

TM Chip Conditioner is fully checked out, adjusted, and

tested at the manufacturing shop before shipment. The customer normally supplies all pipingbetween the chip conditioner and the hydraulic unit bulkheads. The hydraulic unit should belocated no farther than 40'-0" from the chip conditioner, as measured by piping run. The hydrauliclines should be routed as not to interfere with maintenance access. It is recommended that the

lines be routed under the conditioner support as they come toward the conditioner frame. Fit thelines tightly against the frame as they come up to the cylinder manifolds, making the finalconnection with a 90 degree elbow.

Cleanliness cannot be overemphasized during the installation, flushing, operation andmaintenance of hydraulic systems. Piping (or equivalent runs of hydraulic tubing) should be 3/4schedule 80 pickled, oiled, and plugged hydraulic piping, that is free from all dirt, rust, and scaleFlexible hose should be supplied to each end of the piping or tubing, and be equivalent to ParkeHannifin 381, SAE 100R2, 5000 PSI or equal. Fittings shall be 3/4" 37 degree JIC Standard tothe piping, and #12 SAE O-Ring fittings where the piping attaches to the power unit and cylindermanifolds.

After completing the piping runs, they should be flushed using the following procedure:

(all equipment to be Locked Out/Tagged Out before starting this procedure)

a. Fill the reservoir with a premium grade of anti-wear, anti-foaming hydraulic oil (AW-32)pumping the oil through a 5 micron filter before going into the reservoir. Disconnect theflexible hoses labeled A and B at the drive end of the conditioner frame. Connecthese two lines together with a fitting.

b. Start-up the HPU using the instructions given in Section D, lines 3 - 6.c. Electrically or manually, move the solenoid valve on the HPU manifold to the A position

This will allow the fluid to move out from the HPU, through the pipework & back to HPU,through the filter, and back to tank continuously. Allow the fluid to flush for at least 2hours, then switch the solenoid to the B position and run for another 2 hours. Draw asample of hydraulic oil and have it tested. Repeat this process until the oil tests cleanethan the specifications on the drawings.

d. Shut down the pump, Lock-Out/Tag-Out the hydraulic pump motor, andremove the fitting connector between Lines A and B at the drive end of the conditionerReconnect both lines to their original locations.

e. Disconnect the flexible hoses labeled A and B at the idler end of the conditioner frameand connect these two lines together with a fitting.

f. Flush these lines as described in Section C.7.c above. Repeat this process until the oitests cleaner than the specifications on the drawings.

g. Shut down the pump, Lock-Out/Tag-Out the hydraulic pump motor, andremove the fitting connector between Lines A and B at the idler end of the conditionerReconnect both lines to their original locations.


19/56




D. Start-up Check Off SheetThe following list is provided to assist with the check-out of the DynaYield

TMChip Conditioner. Both the

conditioner and the hydraulic unit must beLocked Outbefore starting this procedure.

CAUTION!

Do not attempt to start or run the hydraulic unit without

understanding the recommended start-up procedures. Immediate

failure of major system components can occur if correct procedures

are not followed.

_____1. Check the alignment of V-belt drives on the conditioner unit.

_____2. Fill the gear reducers with oil recommended in the Gear Reducer Appendix. Lubricate thelip seals on the motors and reducers with grease. Grease the motors, gear reducersbearings and slide plates from the centralized grease lube station on the conditioner unit.

_____3. Moving to the hydraulic unit, f ill the reservoir with high quality anti-foaming hydraulic fluid(AW-32), using a 5 micron filter. Insure all suction shut off valves in the pump inlet lineare full open prior to start-up. All piston pumps mustbe filled with hydraulic oil in thepump case drain housing port before initial start-up. Remove the piping connection fromthe pump compensator to the oil cooler at the pump. Fill the pump with clean fluid to thetop. Reconnect the piping. Failure to fill the pump case can destroy the pump inseconds. Insure all suction shut off valves in the pump inlet line(s) are fully open prior tostart-up. Disconnect hydraulic lines from the hydraulic unit at the conditioner frame, andinstall temporary connections to allow flushing of the installed piping system.

_____4. Hydraulic pumps that are not bolted directly to a bell housing should be checked for shafalignment before start-up. Misalignment should be less than .005".

_____5. Restore electrical power to the hydraulic power unit only, and jog thepump motor for correct rotation. After correct rotation is established, jog the pump motofor up to five seconds to prime the pump. You should hear the sound change when thepump pressurizes. See Section F.3.h if the pump will not prime.

_____6. Start the pump motor and pump. The pressure will build on the main pressure gauge onthe hydraulic power unit slowly as the accumulator fills. Flush the hydraulic system asdescribed in Section C.7.

Set the pressure on the pump to about 900 Psi, and fully extend and retract the cylindersagainst the stops to remove all air from the lines. After all air has been purged from thesystem, increase the pressure to that shown on the drawings. The hydraulic system is

fully tested in the shop, and probably will not require further adjustment on site. Checkthe entire hydraulic system for any leaks at all points in the system.

_____7. Check the nip settings on the conditioning rolls. At this stage, the conditioner

motors should be Locked-Out, and the hydraulic power unit

operational. Fully extend the cylinders, and maintain hydraulic pressure on thecylinders while checking the nip settings. To check the nip setting, Rader uses lead strip1/4 thick x 3/4 wide x 12 long, rolling the strip into the nip from above by turning the V-belt drive by hand. After the lead has be pulled into the nip about 6, the lead is withdrawnby reversing direction on the V-belt drive. The impressed lead profile is then measured


20/56




using special tools. Standard settings are a peak to valley measurement of 2.8mm, andslope to slope at 1.9mm. Adjust if required using the removable shims provided, addingor removing equal amounts of shim to both the upper and lower nip setting at each endRemoving shims decreases clearance, while adding shims increases clearance. Inspecthe rolls for any foreign material on the conditioning rolls, or in the drive area.

_____8. Shut-down the hydraulic power unit and Lock-Out. Access the rolscrapers located below the conditioner rolls, and check the clearance and alignment ofeach scraper to the roll segments. Clearance between the scraper and the roll segmenshould be 1mm while the rolls are turned by hand.

_____9. Insure that all drive covers, drive guards, and belt drive guards are in place and secure onthe conditioner unit.

_____10. Restore electrical power to the DynaYieldTM

Chip Conditioner motors and the hydraulicpower unit, and jog the conditioner motors for correct rotation. Correct rotation is shownin Figure #1, with the ingoing rotational nip at the top of the unit.

_____11. Start the DynaYieldTM

and let run for several minutes, and listen for any abnormal soundsShut the DynaYieldTM

down, retract the hydraulic cylinders fully, and check the hydraulicfluid level in the reservoir, and refill to the center of the sight glass if required. Restart theDynaYield

TM and let run for several hours minimum. Listen for any abnormal sounds

indicating misalignment. Shut down, Lock-Out the electrical power on both theconditioner and the hydraulic unit, and check for any hot bearings or over-temperature(+140 Degrees F.) on the hydraulic system.

_____12. Restore electrical power to the DynaYieldTM

Chip Conditioner and hydraulic unit, and tesall related interlocking systems for proper operation to the rest of the screening system(see Section C.6).

_____13. Start the conditioner and hydraulic unit, and begin feeding material at 1/4 to 1/2 the

normal full rate and observe distribution across the width of the conditioner. Slowlyincrease to full rate, adjusting the distribution of material into the conditioner as required.

The DynaYieldTMChip Condi t ioner is now ready for operat ion.


21/56


22/56




Do not decrease or increase the operating speed of the DynaYieldTM

Chip Conditioner beyond thalisted on the general arrangement drawings, unless by written permission of Rader CompaniesTo do so may cause accelerated wear, increased power consumption, and/or permanent damageto the conditioner and hydraulic unit, and void all warranties. Unauthorized personnel should beprevented from making any changes or adjustments to the conditioner and the hydraulic unit afte

start-up.

Assuming the proper electrical controls, as outlined previously, controlling the DynaYieldTM

ChipConditioner during operation is a simple matter. During the start-up, a Rader producrepresentative will set-up the conditioner for proper operational pressures, and take samples othe conditioned chips to determine the conditioning efficiency of the unit. The only adjustments onthe conditioner are the roll speed, nip setting between rolls and the hydraulic operating pressure &relief valve settings, and these will be set-up during the start-up period.

The DynaYieldTM

Chip Conditioner should always be started and stopped without materiabetween the rolls. The conditioner should be interlocked to the screening system such that theconditioner will automatically be timed-out whenever the infeed device shuts down, except inemergencies. The interlocking system must be maintained and tested on a regular basis.

Should the conditioner stop with material in it, the recommended procedure is to cycle the rolls asfar apart as possible using the control system, and start the conditioner unit. The rolls will beapprox. 1 3/4" to 2 3/4" apart depending on conditioner model, and this should clear the infeed

plug. If this does not clear the plug, the conditioner and hydraulic unit must beLocked-Outinfeed access doors and top covers removed, and the rolls cleared and cleaned by handAttempting to start the conditioner rolls with the dynamic roll extended & material wedged betweenthem can cause high starting loads, and stress drive and roll segments beyond reasonable limits.

In operation, the hydraulic fluid is not moving through the pipework between the hydraulic powerunit and the conditioner, the fluid is static but under pressure. In normal operation, the only fluidmoving through the system is that which is being bypassed from the pump compensator, and onlythis fluid moves through the heat exchanger, filter, and back into the reservoir. The fluid in thelines between the hydraulic power unit and the conditioner only moves due to rocks or tramp

material that may enter the system. When this happens, pressure relief valves located on eachcylinder sense the rapid increase in pressure, and allow fluid to move from the blind end of thecylinder to the rod end, retracting the dynamic roll just enough to allow the obstruction through theunit. Once the hard object has passed, the roll automatically moves back to the fully extendedposition, resuming normal operation. During this process, the solenoid valve does not changefluid direction, nor does the dynamic roll fully retract and re-extend. This feature allows theconditioner to resume correct conditioning operation as quickly as possible.

The conditioner is also equipped with proximity sensors located at the nip point at each end of themachine, these sensors are wired into the control system as desired by the customer to warnwhen the nip points on the dynamic roll are not completely closed. This could result from amechanical failure, such as loss of hydraulic pressure, or from wood dust falling in between thenip area, preventing the dynamic roll from fully returning to proper setting. This proximity switch

will be adjusted at start-up, and can be easily readjusted to provide the required sensitivity for theparticular installation and application.

The hydraulic system has several controls that monitor the system during operation, and warn theoperators of potential problems. The reservoir is equipped with a low level switch, should the fluidlevel drop below a preset value, the switch will sound an alarm and immediately begin to shudown the infeed to the conditioner, and allow the conditioner to time out before shutting down.

The hydraulic unit also includes a tank type oil heater, and a heat exchanger. These two unitswork together to keep the hydraulic fluid above 80 degrees F. and below 180 degrees F. The oiheater is arranged to turn on automatically below 80 degrees F., and turn off at 95 degrees F


23/56




The heat exchanger will turn on at 120 degrees F., and off at 110 degrees F. Both the oil heateand heat exchanger are conservatively sized, and low and high temperatures will not normally bea problem. If the hydraulic system fluid temperatures reach 180 degrees F., the high temperaturesensor in the reservoir should sound an alarm and begin a normal shutdown sequence, and thereason for the high temperatures investigated. If the conditioner is shut-down for a prolonged

period of time, the tank heater should be started, allowing the fluid to heat to at least 80 degreesF. before starting the conditioner.

During the weekly walk-by inspection of the unit, watch and listen for any air in the hydraulicsystem. This can usually be identified as erratic movement of pressure gauges and cylinders, andthe sound of marbles running through the hydraulic pump. Allowing a pump to pump air (cavitatecan result in damage to the pump and to other parts of the hydraulic system.

A visual indicator is provided on the filter for the hydraulic unit. As the filter becomes dirty, theindicator will warn that the filter requires changing. The filter must be changed after the firsseveral days of operation (monitor closely). Thereafter, the normal schedule calls for a yearlychange of the filter, more often in dirty environments.


24/56




F. MaintenanceThe DynaYield

TM Chip Conditioner has been designed to be easily serviced. The conditioner is of a

simple design allowing fast access to all serviceable components to reduce downtime to a minimum. Theuseful life of any piece of equipment can be extended by consistent and sound maintenance practices.

WARNING!

This equipment can cause death or severe personal injury if all

safety precautions are not taken. Lockout/Tagout this equipment

anytime inspection or maintenance is to be performed. All

procedures listed in this section require Lockout before proceeding,

unless otherwise noted.

In addition, equipment adjacent to the DynaYieldTM

may require

Lockout during DynaYieldTM

inspection and maintenance. Determine

all necessary Lockout requirements before any work is performed.

F.1. Preventative Maintenanc eThe DynaYield

TM should be checked over on a regular schedule shown below to maximize

operator safety and the conditioners usable life. Always look the DynaYieldTM

Chip Conditioneover for damage, signs of improper operation or malfunction, and listen for odd noises that maysignal the need for a more thorough investigation.

After the first several days of operation, the conditioner should be shut-down,Locked out, andinspected for any roll segment damage, loose bolts, and hydraulic system leaks. The hydraulicunit fluid filter should be changed at this time as well.

Lockout before any inspection or adjustmentWeekly-

Check all guards and covers are in place, and function properly.Check for hydraulic system leaks, check hydraulic unit fluid level.

3-Month-Grease spherical bearings & dynamic roll slides.Grease motor and gearbox seals.Check gear reducer oil levels.

6-Month-Visually check roll segments for damage.Check roll scrapers for proper location and alignment.Check speed sensors for proper operation and interlocking.

Check V-Belt adjustment on motor/reducer drive.Check nip between the conditioning rolls and shim packs.

Yearly-Full inspection of conditioner for wear and damage, hydraulic leaks.Change Hydraulic Unit fluid and filter.Check all roll segment bolts for damage, replace if necessary.

As specified by Manufacturer-Change gear reducer lubricant.


25/56




F.2. Lub r icat ion Informat ionThe following items will require lubrication service at intervals listed in Section F.1. as specified.

- Motor & Gear Reducer Grease Seals:

(Lock-Out Not Required) Grease motor and gearbox grease seals fromthe lubrication station located on the drive end of the conditioner, the quantity offittings varies with model. Use only one or two shots of high quality greaseconforming to NGLI #2 every 2000 hours (3 months) per seal to prevent seablow-out and early bearing failure. Grease more often in dusty environments.

The standard arrangement of the lubrication stations on the conditioner asshipped from the factory allow the motors to be lubricated from the main greasingstations near the drive end. If it is not desired to have the normal lubrication crewlubricate the motors, remove the grease lines to the motors and install pipe plugsin place of the grease zerk fittings for the motors.

- Gear Reducer Oil Reservoirs:

(Lock-Out Required) See Reducer Appendix

- Hydraulic Unit:

(Lock-Out Required) The hydraulic unit should be filled with a premiumgrade anti-foaming hydraulic fluid (AW-32), passing through a 5 micron filteduring entry to the reservoir. The fluid levels should be checked on a weeklybasis, and the fluid changed yearly (more often in very dusty environments).

- Conditioner Roll Bearings and Dynamic Roll Slide Base:

(Lock-Out Not Required) Bearings and slide base should be relubricatedwith a high quality grease conforming to NGLI #2 every 2000 hours (3 months) ormore often in dusty environments. Grease fittings are located on the dynamic rolside of the machine , 3 fittings at each end, 6 fittings total.

F.3. Hydrau l ic UnitThe Hydraulic Unit for the DynaYield

TMChip Conditioner is very simple and straightforward, and

by following the guidelines below, and the information contained in the appendixes, majoproblems with the hydraulic system can be avoided. The hydraulic unit as shipped has been fullytested and run, and major adjustments made.

a. AlwaysLock-Outthe hydraulic system before inspection and maintenance.

b. Cleanliness is essential when working with precision hydraulic components, to ensurelong life. All pipes, hoses, and tubing must be cleaned thoroughly during installation, andkept clean during all maintenance procedures. If any new hoses or pipes are replacedthe entire system should be flushed to minimize dirt in the system, and the filter changedseveral days after.

c. Alignment between the motor and pump is critical, and should always be checked if thepumps do not bolt together to a bell-type housing that maintains alignment duringshipping and handling. Although recommendations between manufacturers will vary, themaximum allowable alignment should be less than .005". Pump shafts are designed tobe installed in the couplings with a slip fit or very light locational fit. Forcing the couplingend on a pump shaft can damage bearings. Care should be used when replacingcouplings.


26/56




d. Check and double check all pump rotations by jogging the motors before running thepump. Pumps will have rotational arrows showing the correct rotation. Hydraulic pumprotational direction is always determined by viewing the pump from the shaft end. Pumpmodels numbers will identify the correct rotation, if the direction of rotation is not clear,contact the nearest Rader office.

e. Always use the correct hydraulic oil, and filter all oil as it is poured into the reservoir with a5 micron filter. The hydraulic fluid should be a premium quality, anti-wear, anti-foamingAW-32 hydraulic oil. Maintain the fluid level to at least the mid point on the sight glasswhen the hydraulic unit is off.

f. All piston pumps must be filled with hydraulic oil in the pump case drain housing porbefore initial start-up. Failure to do so can destroy a unit in seconds. Insure all suctionshut off valves in the pump inlet line(s) are fully open prior to start-up. Open all pumpdischarge valves to allow fluid to flow and fill the system.

g. Set pressure controls (relief valves and pump settings) to minimum or approx. 500 PSIJog the motor several times. You should notice a distinctly quieter sound as fluid reaches

the pump and begins to flow into the system. Once the system is operating properlyincrease the settings to operating pressure.

h. All pumps can be severely damaged if they are run without fluid. If the pump fails toprime, verify the following.

- Verify the motor and pump are turning the correct direction.- Make sure the pump shaft is not sheared, or the coupling disengaged.- Verify the inlet to the pump is open and unblocked. If a suction valve is installed in

the inlet, check that it is fully open. Check any inlet filters for pluggage.- Check the viscosity of the hydraulic fluid. Verify that the proper, clean hydraulic

fluid is in the reservoir.- Check the pump case drain port and ensure that the housing is completely filled

with hydraulic fluid. Fill if necessary.

- Check the pump suction line for air leaks. Air leaks will cause the pump to ingesair (cavitate), and will make a sound like marbles are running through the pumpCavitation can cause excessive damage to the pump, so correct immediately.

j. Check the system regularly for leaks, and unusual sounds that could be warnings opotential problems.

k. Erratic movement of pressure gauges and cylinders can be caused by air trapped in thesystem. Bleed air from the component by slightly loosening the highest connection on thecomponent until a steady stream of oil exits.

m. Allow only trained individuals to adjust, operate, and maintain the hydraulic system.

The hydraulic system contains three pressure relief valves that operate to control system pressureand operation. The main pressure relief valve is located on the hydraulic power unit itself, and theindividual cylinder relief valves are located on each cylinder, accessible through the small doorabove each cylinder. The procedure for adjusting these valves is as follows:

- Drawings provided with the conditioner will show the pressure values for both the mainand cylinder relief valves.

- With the hydraulic power unit pump motor operating, and the solenoid valve centered(solenoids A and B off), loosen the locknut on the adjustment screw for the mainpressure relief valve located on the HPU. Have a helper slowly increase the pressure a


27/56




the hydraulic pump, and note the pressure the valve cracks open and fluid can be heardpassing through. Readjust the valve if necessary by turning the allen socket screwclockwise to increase or counterclockwise to decrease the pressure setting. Reduce thepressure in the pump, reset the system, and recheck in the same manner after setting thepressure. Make sure that after the adjustment is complete, and the pressure at the pump

is reduced back to the original setting, that no fluid can be heard passing through thevalve. A stethoscope or equivalent is helpful here. Retighten the locknut.

- To adjust the cylinder pressure relief valves located directly above the hydraulic cylindershave the hydraulic power unit operating and the solenoid valve B energized (supplyingpressurized fluid to the blind end of the cylinder, to extend it). Using the supplied gaugeon each cylinder, adjust in a similar manner to above, using the cylinder relief pressuresettings shown on the drawings. Fully adjust one cylinder, then adjust the secondcylinder. Make sure to reset the pump operating pressure to that shown on the drawingsbefore returning the system to operation.

F.4. Speed Sensing Compo nentsTwo speed sensors are provided as part of the DynaYieldTMChip Conditioner to sense low shaftspeed, warn the operators, and shutdown the conditioner and related equipment. The sensorsare located on the ends of each roll shaft to directly pick up any loss of speed. These sensorsmust be interlocked into the screening system, and must be operating properly to preventunnecessary downtime. Every 4500 hours (6 months) the sensors should be individually checkedto insure proper operation, and proper interlocking into the screening system. See ProximitySensing Appendix for more information on these units.

F.5. Mechanical ComponentsThe following mechanical components should also be checked on a routine basis, as follows.

Always Lockout/Tagoutbefore performing any of the following functions.

- On a weekly basis, check the hydraulic system for leaks. Change the hydraulic filter andfluid as required. Follow all start-up procedures given in Section D and recommendationsgiven in Section F.3.

- On a yearly basis, fully check the condition of the rolls in the conditioner unit. Removeand replace any bolts that are loose, or with heads that are crushed or broken.

CAUTION!

Do not stand or walk on the conditioner rolls during

inspection. Personnel may lose their balance, falling andinjuring themselves. Always work from an approved

platform.

- All drive guards and covers must be in place and functional at all times, and checkedevery week.

- Every 6 months, check the nip settings between the conditioning rolls per Section F.6.aCheck that all shim packs at both ends of the unit are tight, and that the shims are all inplace.


28/56




F.6. Periodic Maintenanc eBecause of it's inherently simple design, the DynaYield

TMChip Conditioner has few wear parts

that require replacement at specified intervals. These parts include the roll nip adjustment, axiaroll alignment, roll scraper, roll segments, cylinders, drive reducer, and conditioner roll bearingsThis section is provided to give detailed instruction on these items. Contact Rader for information

on any other maintenance procedures required on the machine.

F.6.a. Roll Nip AdjustmentSee Figures #7, #8, and #9 for reference. The roll nip in the conditioner is preset at themanufacturing facility, and will not normally require readjustment in the field. Even whenreplacing the roll segments, alignment is maintained, but should always be checked afterroll segment replacement. The standard values for the nip are given below in Figure #7.

Adjust the nip setting as follows.

- Retract the dynamic roll cylinder fully, then shut down the conditioner and hydraulicpower unit.

- Make sure at this point that the conditioner motors and the

hydraulic power unit are Locked-Out.

- Inspect the nip setting surfaces carefully. Remove any wood dust or debris thamay have accumulated on all nip surfaces, use Rader Blower Cleaner if necessaryto remove pitch build-up.

- Remove the lockout from the hydraulic power unit only, leaving

both conditioner motors locked out.

- Fully extend the cylinders, and maintain hydraulic pressure on the cylinders whilechecking the nip settings.

CAUTION!

Follow all safety procedures when handling lead

strips. Wear rubber gloves and wash hands

thoroughly after handling the lead strips.

Figure 7


29/56




- Rader uses lead strips 1/4 x 3/4 x 12 long to check the nip point. With oneperson working through the access door above the conditioner infeed as shown inFigure 8, the lead strip is inserted into the nip between rolls, and a second individuamanually pulls on the V-belt drive to draw the lead in between the rolls. After thelead has been drawn into the rolls at least halfway, reverse the direction of the rolls

and back the lead strip out from between the rolls. The lead strip is then measuredusing a micrometer with a special tip to get into the depression formed on one sideof the strip, as shown in Figure 9.

- Check in a similar manner onevery segment, rotating bothdrums by hand to check all fourquadrants of each roll. Theamount of shims to be removedor added can then be determinedby the average total readings ateach end of the drums.

- A quick check of the nipsetting can also be donewith a 1/8 (3mm) dia.welding rod or similar.Although not as accurate,this method can quicklycheck if the rolls areapproximately at thecorrect nip point. Raderadjusts the rolls to wherethe rod snugly contactsboth rolls, to the pointwhere you can justforcibly pull the roll out from the rolls without turning them.

- Adjust if required using the removable stainless steel shims provided between thebearing housing at both ends of the conditioner. Once the amount of shims to beremoved or added is determined from both ends, the hydraulic power unit should beused to move the dynamic roll away from the static roll, allowing access to remove

the bolts holding the shims in place. At this point, Lock-Out the

hydraulic power unit while removing or adding shims. Extrashims are located on the frame of the unit, below the nip setting area. Removingshims decreases clearance, while adding shims increases clearance. Inspect therolls for any foreign material on the conditioning rolls.

If one of the conditioner rolls has moved axially, the nip setting may not be equal on bothfaces of the conditioning roll surface. To readjust the shaft, first follow the procedures in

Section F.6.b. to re-align the shafts to each other, then proceed with the roll nipadjustment.

After the nip settings have been adjusted, make sure all bolts are properly Loctited andtorqued, re-install all covers and guards that were removed, and remove Lock-Out. Theequipment is now ready to be put back into operation.

Figure 8

Figure


30/56




F.6.b. Axial Roll AlignmentThe bearings located at the idler end of the conditioner are the fixed or held bearings inthis design. A special adjustment rod is included on the static bearing housing at the idleend to facilitate the adjustment of the static roll assembly to the dynamic roll assemblyDo not try to adjust the dynamic roll to the static roll.

- See Figure #10 for reference. Shut-down the conditioner, and make sure that thedynamic roll is fully extended against the nip setting stops.

- Lockout the DynaYieldTM

Conditioner drive motors and

Hydraulic Unit.

- Remove the idler endguard, and remove theidler end upper frame linkabove the bearinghousings. Loosen, but donot remove the four bolts

holding the static bearinghousing at the idler end.To loosen the bolts on theconditioner roll side of thehousing, an extension ofat least 20 is required.

- Arrange for a liftingdevice above the staticroll bearing that iscapable of lifting half theroll assembly weight listedon the customer

drawings. Lift the bearinghousing only enough totake the weight off theframe.

- Using the adjustmentthreaded rod and the hex nuts, adjust the static roll for the best possible interfacewith the dynamic roll. Make sure to turn both rolls over by hand to check alinterfaces. When adjustment is complete, lock the adjusting device using the twonuts, and remove the lifting device. Remove the Lockout from the hydraulic poweunit only, and apply hydraulic pressure to the static roll bearing housing, then applyLoctite and tighten and re-torque the bearing housing to frame bolts. Recheck thealignment between rolls.

- Reinstall the infeed support and the idler end guard. Turn both rolls over by hand toinsure that the infeed chute has not shifted within the machine.

Figure 10


31/56




F.6.c. Roll Scraper AdjustmentRoll Scrapers are used in the conditioner to remove wood that may stick to the rolsegments in operation. When the roll segments are new, very little scraping takes placebut as the segments begin to wear, the scraping action will increase.

- See Figure #11 for reference. Before shutting down the conditioner, make sure thathe dynamic roll is fully against the roll stop.


Conditioner and Hydraulic Unit.

- Gain access in the discharge area of the unit, and arrange internal scaffolding oplatforms as required.

WARNING!

This equipment can cause severe personal injury if hand

or limb is wedged into the nip between the heavy

conditioner rolls if rotated, even rotated by hand. Takeall safety precautions to prevent entry into the nip area.

- Loosen the bolts holding the roll scraper to the roll scrapper support frameWorking with one 12" section at a time, adjust the scraper to be within 1mm of theconditioner roll segment. Spin the roll by hand (the easiest way to do this is to turnthe V-belt drive by hand. Insure that clearance is about 1mm, with no touching ohitting of the conditioner roll to the scraper.

- Adjust the remaining scrapers as per the previous instructions.

- Replace all guards and covers, remove the conditioner Lockout, and start theconditioner without material. Insure that no touching or hitting is occurring betweenthe roll scrapers and the roll segments. Material may now be restarted through theunit.

Figure 11


32/56


33/56




WARNING!

This equipment can cause severe personal injury due to

the imbalance created by removing one or more

segments. Secure the roll with wood wedges or by fixingthe V-Belt drive to prevent injury due to unexpected roll

movement.. Take all safety precautions to prevent entry

into nip area.

- Remove one of the center bolts, and insert a 1"-8UNC lifting eye in its place. Attacha lifting hoist or chain fall of sufficient capacity to lift the segment.

- As shown in Figure #13, remove the remaining bolts, and lift the segment free othe machine. Do not remove more than one segment at a time. This allows eachnew segment to be positioned properly relative to the segments already on the rollIf it is necessary to remove all segments from a roll, follow all instructions on the rol

assembly drawings during the installation of the new segments.

- VERY IMPORTANT: It is absolutely critical that the roll surface and adjacent

ring segments be scraped and thoroughly cleaned completely of all pitch and

wood residue. Failure to clean all surfaces before re-installation of the

segment can cause bolt breakage and bolt loosening, possibly leading to the

roll segment falling out of the machine during operation.

Check the condition of the "Helicoil" threads in the roll, and replace if damaged. Ithe Helicoil requires replacement, remove the old insert, clean the threads in the rolas much as possible, then install the new Helicoil with Loctite Red 271.

- VERY IMPORTANT: Check and remove any burrs on the ring segment on theinside surface and edges before installing. This should also be checked on

new segments shipped from Rader, as a burr may have been formed during

shipment. Failure to remove burrs before ring segment installation can cause

Figure 13


34/56




bolt breakage and bolt loosening, possibly leading to the roll segment falling

out of the machine during operation.

Using a chain fall or hoist, lower a new roll segment into place, and partially instal

new boltsseveral threads into the helicoiled holes in the drum.

VERY IMPORTANT : After the bolts are partially installed, ensure that theshank of each bolt clears the hole in the ring segment before tightening the

head of the bolt against the segment. Failure to check this can cause bolt

failure and/or bolt loosening, possibly leading to the roll segment falling out

of the machine during operation. The bolt must spin freely into the Helicoi

about halfway, then the locking feature of the Helicoil will engage the bolt

After that, a wrench will be required to fully seat the bolt head against the

segment, however, the bolt must not take an excessive amount of effort to

turn, or at any time be bearing against the side of the hole.

If the bolt does not clear the sides of the hole, the segment must be removed, andeither the hole elongated slightly with a die grinder, or the side the segment ground

with a hand grinder. Do not remove more material than required.

- After all bolts have been checked for clearance, each bolt must be coated withLoctite Red 271. The bolts can be run into the Helicoil using an air wrench with theair turned set low, until the head engages the counterbore in the segment. Do nouse an air wrench to apply any more than 75 ft-lbs to the head of the bolt, as thiscan case damage to the internal socket recess. After all bolts are in place, torquefirst to 100 ft-lbs, then to 350 ft-lbs. Bolts are of a special fatigue resistant designproduced exclusively for Rader conditioners. Use only the approved Rader bolt tofasten the segment to the roll.

.- Replace any other roll segments in the same manner as described above. After al

segments have been replaced, spin the conditioning rolls over by hand, checking

for any interference between the rolls, or between the rolls and scrapers, and adjustas required..

- Check axial roll alignment and re-adjust if necessary per instructions in SectionF.6.b. Check roll nip settings and re-adjust if necessary per instructions in SectionF.6.a. Adjust scrapers per Section F.6.c. as required.

- Replace all guards and covers, remove the conditioner Lockout, and start theconditioner without material. Insure everything is operating correctly before runningthe conditioner with wood.

F.6.e. Hydraulic Cylinder Replacement

- See Figure #14 for reference.

- Operate the hydraulic system to move the dynamic roll to the fully extended

position. Lockout the DynaYieldTM


- Remove the covers and guards from the conditioner, in the area around the cylindeto be removed. If the cylinder on the drive end of the machine is to be replacedconsideration should be given to removing the motor and motor base to give betteaccess.


35/56




- Carefully remove the infeed support plate from the frame to expose the hydrauliccylinder and manifold.

- Remove the bolts from the safety coupler to the dynamic bearing housing, andremove both halves. Also remove the spherical load washer and polyurethane

strip.

- Using a pry bar, retract the cylinder rod into the cylinder. Place a container belowthe hose entry ports on the manifold on the exterior of the conditioner, to catch anyremaining fluid from the cylinders before removal.

- Using a hoist or chain fall, support the cylinder and manifold assembly, the weightsfor which can be found on the parts list drawing. Remove the hex nuts andwashers holding the cylinder in place to the frame. Carefully pull the cylindeextended threaded rods out of the frame, and pull the cylinder and manifoldassembly up and out of the conditioner frame.

- If the cylinder only is to be replaced, remove the four bolts holding the aluminummanifold block to the top of the cylinder. Remove the two o-rings between the twoparts, the o-ring should be replaced.

- Reassembly is the reverse order of disassembly. Make sure to purge any air out o

the hydraulic system during start-up by cycling the dynamic roll several times to itsextremes. Replace all guards and covers, remove the conditioner Lockout, andoperate the hydraulic system to ensure that no binding is occurring in the sphericaload washer area, and no hydraulic leaks are observed. Conditioner is now readyto be put back into operation.

Figure 14


36/56




F.6.f. Drive Reducer ReplacementThe Rader Conditioner uses standard off-the-shelf Falk gearboxes for the drive speedreduction from the motors. These gearboxes have two modifications that are performedin the manufacturing shop before assembly on the Conditioner. Make sure to modify anyspare gearboxes or replacements before trying to replace the gearboxes as supplied by

Rader.

- Pressed in Grease zerk(s) are removed, and drilled out to 1/8-27NPT focentralized grease system.

- Torque arm hole is reamed to 1.752-1.755 diameter, to fit the torque armand pins on the torque arm bracket.

To replace the drive reducers, use the following instructions:

- See Figure #15 for reference.



- Remove the covers and guards from the conditioner, in the area around the drive tobe removed.

- If adequate lifting capacity is available, the motor, drive, and reducer can beremoved from the conditioner as a unit, this is especially useful when themotor/reducer is removed to gain access for another maintenance operationOtherwise, remove the V-Belt drive from the reducer and motor, and remove thedrive motor and motor mount from the reducer as a unit.

- Using a hoist or chain fall, rig the reducer for removal. Approx. weight of reducer isgiven on the Parts List drawing.

- Disconnect the torque arm from the reducer.

- Following the instructions in the Falk Reducer Appendix, dismount the reducer fromthe tapered bushing. Remove the reducer from the shaft.

Figure 15


37/56




- Reassembly is the reverse order of disassembly. Follow all instructions in theFalk Reducer Appendix when installing the reducer back onto the shaft. Thefollowing points from the Falk Appendix are important:

- Make sure there are no burrs on the gearbox hollow shaft, bushing, or shaft.

- Always thread the bushing onto the gearbox before putting the assembly onto theshaft, to make sure the threads of the gearbox are not damaged. Remove thebushing, then install the bushing on the shaft without any oil or anti-seizecompounds between the shaft and the bushing. A light coating of oil may beapplied to the hollow shaft in the gearbox, and onto the threads of the taperbushing.

- On 4507 gearboxes (4 and 6 Conditioners), the key supplied by Falk is notsquare. It is 1.250 wide x about 1.225 tall. Make sure that the key fits properlyinto the 1.25 wide keyway in the conditioner shaft.

- Make sure to line up the gearbox axially on the conditioner shaft with the torquearm brackets located below the reducer.

- The gearbox/bushing must be properly torqued to 4000 lb-in (333 lb-ft) onto theshaft per Falks recommendation. There are two methods given in the FalkAppendix, Rader sometimes uses a third method where the bushing is heldstationary, and the input shaft of the gearbox is torqued to 13.3 lb-ft, using the25:1 ratio of the gearbox as a torque multiplier.

F.6.g. Spherical Bearing Replacement

- See Figures #16 and #17 for reference.

- Operate the hydraulic system to move the dynamic roll to the fully retracted

position. Lockout the DynaYieldTMConditioner and Hydraulic Unit.

- Remove the covers and guards from the conditioner, in the area around the bearingto be removed. The infeed chute may be left in place, but the infeed support plateabove the bearing must be removed. Remove the grease lubrication line to thebearing housing to be removed.

- If the bearing to be removed is on the drive reducer side of the roll, remove thedrive reducer as outlined in Section F.6.f.

- If the bearing to be removed is on the dynamic roll, remove the bolts holding thesafety coupler to the dynamic bearing housing, and remove both halves. Removethe spherical load washer and polyurethane strip. Remove the bolts holding the

bearing retainers to the frame on both sides of the dynamic bearing housing, thenremove the bearing retainers.

- If the bearing to be removed is on the static roll, remove the bolts holding the staticbearing housing to the frame. Loosen the axial adjustment rod from the frame if thebearing to be removed is at the idler end.


38/56




- Using a hoist or chain fall, rig the conditioning roll bearing housing for removal fromthe frame. The lifting device must be capable of lifting at least half the estimatedweight of the roll assembly w/ bearings, listed on the roll assembly drawings. Lifonly the one loose end of the conditioning roll upward approx. 1/8" to gain clearanceto the frame. Block and support the conditioner roll from falling or shifting location

leaving the end of the shaft available to remove the bearing. Leave the hoist on thebearing housing for removal in the next step. See Figure #16.

- If working on the drive end of the unit, slip off the rubber Forsheda V-Ring sealthen remove the bolts holding the outer bearing retainer, then remove the retainerIf working on the idler end of the unit, there is no seal, remove the retainer.

- On the drum side of the bearing housing, slide the rubber Forsheda V-Ring seaback as far onto the radius as possible, then remove the bolts holding the innerbearing retainer and pry loose from the bearing housing.

- Carefully slide the bearing housing over the bearing assembly, taking care that thehousing has some imbalance to it, and may require an additional support line to

maintain control. Set the bearing housing aside.

- Clean the majority of grease from the bearing, and inspect for damage or signs oexcessive wear. Carefully measure the distance from the bearing inner race to theend of the shaft, or some other reference point, and record. During the installationof the new bearing, the location of the new bearing must be as close as possible tothat of the bearing removed, otherwise the two conditioning rolls may not alignproperly when reinstalled. See Figure #17.

Figure 16


39/56




- Following the instructions in the Spherical Bearing Appendix, remove the lock nuand lock washer from the bearing assembly, and dismount the bearing. Clean theshaft, bearing retainers, and the bearing housing for reassembly. Carefully inspecall parts to be reused, especially the locking tab on the lock washer. If the lockingtab is damaged in any way, use a new lock washer. Also check the threads in thetapered adapter for damage.

- Reassembly is the opposite of removal. Follow all instructions in the SKF PillowBlock Bearing Appendix. During the installation of the new bearing, the following

points are important:

- Every bearing comes with assembly instructions. Please read and follow thisinformation before beginning. Work in as clean an area as possible.

- Measure the unmounted clearance in the bearing.

Unmounted Clearance: Normal Clearance C3 ClearanceFor Models 20 & 40- .0055 to .0079 .0079 to .0102For Models 60 & 80- .0071 to .0098 .0098 to .0126

- When installing the tapered adapter onto the conditioner shaft, make sure there isno lubricant or anti-seize on the shaft or the inner surface of the tapered adapter

Adding lubricant to this area significantly increases the risk of axia

movement in the shaft, and possible damage to the interlacing roll segmentson the conditioner rolls.

- A light oil coating may be added to the tapered adapter outer surface that comesinto contact with the bearing inner race. Oil the threads on the tapered adapterPosition the adapter and bearing on the shaft, using the x dimension measuredbefore disassembly. The estimated amount of axial movement due to tighteningthe bearing will be .051-.067 on the Model 20 and 40, and .063-.087 on theModel 60 and 80.

Figure 17


40/56




- Install the bearing onto the tapered adapter, and install the locknut (no lockwasher)Tighten the bearing locknut, keeping the weight off the bearing during tighteningCheck for total reduction in clearance of the bearing as follows:

Reduction in Unmounted Clearance:

For Models 20 & 40- .0032 to .0043 clearance reductionFor Models 60 & 80- .0039 to .0055 clearance reduction

SKF recommends the middle to high range of clearance reduction. Minimumpermissible clearance in the bearing after installation is .0024 on the Model 20 and40, and .0032 on the Model 60 and 80.

- Remove the locknut, and install the lockwasher. Reinstall the nut, fully tightenagainst the lockwasher and bearing. Install the lockwasher tab into the slots on thelocknut.

- Using a nozzle, inject grease into all internal cavities of the bearing rolling elementsThe machined housing cavity should be filled 1/3 to 1/2 full, and all internal meta

surfaces of the housing coated with grease to help prevent internal rusting.

- During reassembly, note that bearing retainers are different for each generalocation in the machine. Reinstall each bearing retainer only from its originalocation. The fixed bearings are those located at the idler end of the unit. Packbearings with clean grease before installation of the bearing housing.

If the dynamic roll has been worked on, reinstall the dynamic roll slide retainers oneither side of the bearing housing with between .005" to .010 clearance between thebearing housing and the retainers.

- After the bearing housing has be set back down onto the frame, check the nipinterface per Section F.6.a., axial roll alignment per Section F.6.b., and the scrapersetting per Section F.6.c. by turning the rolls by hand.

- After all work is complete, replace all guards and covers, remove the conditioneand hydraulic power unit Lockout, and re-start the conditioner.


41/56




F.7. Bo lt Torqu e Specif icatio nsDuring the course of maintenance on the DynaYield

TM Chip Conditioner, it is very important to

torque all bolted fasteners to the proper levels to avoid loosening in service. All replacement boltsmust be of the same grade as the original bolt. All specifications below are for lubricated threads.

Bolt Size SAE Grade 2 SAE Grade 5 SAE Grade 8

1/4-20 UNC 4 ft-lb 6 ft-lb 9 ft-lb5/16-18 UNC 8 ft-lb 13 ft-lb 18 ft-lb3/8-16 UNC 15 ft-lb 23 ft-lb 35 ft-lb7/16-14 UNC 24 ft-lb 35 ft-lb 55 ft-lb1/2-13 UNC 35 ft-lb 55 ft-lb 80 ft-lb5/8-11 UNC 75 ft-lb 110 ft-lb 170 ft-lb3/4-10 UNC 130 ft-lb 200 ft-lb 280 ft-lb7/8- 9 UNC 125 ft-lb 320 ft-lb 460 ft-lb1- 8 UNC 190 ft-lb 480 ft-lb 680 ft-lb1 1/4- 7 UNC - - 800 ft-lb1 1/2- 6 UNC - - 1000 ft-lb

1- 12 UNF - - 740 ft-lbs1- 14 UNF - - 760 ft-lbs1 1/8- 12 UNF - - 1080 ft-lbs1 1/4- 12 UNF - - 1500 ft-lb

All fasteners (with the exception of roll segment bolts) should be coated with Loctite Blue 242before assembly, per the manufacturer instructions.

The bolts used to attach the roll segments to the rolls are of a special design, produced for RaderThese fasteners should be coated with Loctite Red 271, and torqued to 350 ft-lbs per theinstructions given in Section F.6.d. Always use new bolts when replacing roll segments.

The Helicoils used to provide threads into the rolls are held in place by Loctite Red 271.

F.8. Spec ial Too lsIn working on the Rader DynaYield

TMChip Conditioner, the following special tools are required, in

addition to the normal set of tools that would be available to the typical millwright.

- Torque wrench capable of measuring up to 1500 ft-lbs.A hand torque wrench capable of measuring up to 400 ft-lbs, for use in tightening the rolsegments. This wrench can be the same as the one above, if necessary.

- Large spanner wrenches for the adapter sleeves of the bearings and gear reducers.- Large size (1 sq. drive) heavy duty socket wrenches and 20 min length socke

extensions to loosen and tighten bolts on the bearings and hydraulic cylinders.

- Helicoil taps #8187-12 (Plug) or #10187-12 (Bottoming)

The following tools are recommended by Rader, but not required.- Falk TA Removal Tool for the gearbox size called out on the assembly drawings.- 1/4 x 3/4 x 12 pure lead strips for the setting of conditioner roll nip point.- Special measurement micrometer for measuring impressed lead strips.


42/56




G. Recommended Spare PartsThe following items are recommended spare parts that should be kept on hand at all times. The completecallout for the following items can be found in the General Arrangement and Parts List drawings for thisjob, and are included as part of this manual. This includes necessary ordering information, includingRader drawing numbers (part numbers) that are required to fill orders. When ordering spares, it is helpfuto have the original Rader Job Number and DynaYieldTMChip Conditioner Model Number from the metaRader nameplate located on the DynaYield

TM Conditioner frame.

Many of the parts of the DynaYieldTM

Chip Conditioner are made special for Rader, using speciatolerances and materials. Contact your Rader product representative for all replacement parts.

Quantity Description -

1 Electric Motor (Conditioner Drive Motors)

1 Fluid Coupling (only if optional fluid couplings are installed)

1 Falk Shaft Mount Reducer w/ grease zerk and torque armmodifications per Section F.6.f.

1 Set V-Belts

2 Spherical Bearings w/ Tapered Adapters, Lockwashers, andLocknuts

2 Forsheda V-Ring Seals

4 Proximity Sensors

1 Set Roll Segments

1 Set Roll Segment Bolts

20 Helicoils for Roll Assembly

1 Set Roll Scrapers

1 Electric Motor (Hydraulic Power Unit)

1 Piston Pump (Hydraulic System)

1 Control Valve (Hydraulic System)

2 Hydraulic Fluid Filter (Hydraulic System)

1 Breather (Hydraulic System)

2 Cylinder Pressure Relief Valve (Vickers CG Model)

1 Hydraulic Cylinder


43/56





44/56


45/56




46/56



Opt ional Dis t r ibut ing Screw Appendix


47/56



Opt ional Flu id Coupl ing Appendix


48/56



Falk Reducer Appendix


49/56



Spher ical Bear ing Appendix


50/56



Prox im i ty Sens ing App endix


51/56



Speed Sensing Ap pendix:

On standard pieces of Rader equipment, an inductive, 18mm tubular proximity sensor is used for a speedswitch. The "Efector" proximity sensor is mounted adjacent to the last rotating shaft on a driven machineThe sensor is located in such a way that as the shaft turns, the keyway or a flag attached to the shaft willpass in front of the sensor's front surface. The sensor will turn on and off each time the shaft rotates.

Rader has standardized on this proximity sensor for the following reasons:

- The sensor is small and easily mounted under guards and out of the way on our proprietaryequipment.

- Fail-safe dependability, because the sensor is relaying a pulse (on/off transition) for eachrevolution the sensor detects.

- Inexpensive, when compared with other low speed detection devices.- Rader's standard sensor uses a stainless steel housing, and the interior components are simple

and very reliable, making the sensor ideal for harsh industrial environments.

Rader's standard sensor is "Efector" part number #IGA-2005-ABOA-V4A. On the following pages are

general specifications and installation instructions supplied by Efector.

If the equipment is to be installed into a system controlled by a PLC or DCS control system, it will benecessary to use two timers in the control

073-2_2004-10 dynayield 2 equip manual.pdf

Documents