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Rader DynaYieldTM II Chip Conditioner

Equipment Manual

Rader Companies, Inc


Rader Canada
Rader AB
Manual Number 073-2, Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Table of Contents
Page
A.

B.

C.

D.

OVERVIEW AND GENERAL SAFETY


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

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GENERAL INFORMATION
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B.1. DynaYield Chip Conditioner Background
B.2. Functional Description
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B.3. Standard Model information
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B.4. Optional Features .
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B.5. DynaYield Safety Warning Signs
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3
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4
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INSTALLATION
C.1. Shipping, Handling, and Storage .
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C.2. Mounting and Supports
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C.3. Service Access
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C.4. Infeed Requirements
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C.5. Outfeed Requirements
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C.6. Electrical Requirements
C.6.a. Conditioner Electric Motors
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C.6.b. Hydraulic Unit Electrical Requirements
C.6.c Speed Sensing Probes .
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C.6.d. Nip Setting Proximity Probes
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C.6.e. Electrical Lock-Out .
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C.6.f. System Interlocking
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C.7. Hydraulic System Requirements .
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12
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15

START-UP CHECK OFF SHEET .

16

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

E.

OPERATION
E.1. Material Pre-Conditioning Requirements
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E.2. Basic DynaYield Chip Conditioner Operation .

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F.

MAINTENANCE
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F.1. Preventive Maintenance .
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F.2. Lubrication Information
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F.3. Hydraulic Unit
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F.4. Speed Sensing Components
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F.5. Mechanical Components .
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F.6. Periodic Maintenance
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F.6.a. Roll Nip Adjustment
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F.6.b. Axial Roll Adjustment
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F.6.c. Roll Scraper Adjustment .
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F.6.d. Roll Segment Replacement
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F.6.e. Hydraulic Cylinder Replacement
F.6.f. Drive Reducer Replacement
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F.6.g. Spherical Bearing Replacement
F.7. Bolt Torque Specifications .
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F.8. Special Tools
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24
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25
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27
28
29
31
32
34
38
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G.

RECOMMENDED SPARE PARTS

39

Appendices
Optional Distributing Screw Appendix
Optional Fluid Coupling Appendix
Falk Reducer Appendix
Spherical Bearing Appendix
Proximity Sensing Appendix
Hydraulic Power Unit Appendix

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

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

A.

Overview and General Safety


A.1.

Preface
This manual is provided as a guide to personnel involved with the installation, operation, and
maintenance of Rader equipment. Operators, Inspectors, and Maintenance personnel of Rader
equipment should read and become familiar with the general procedures and information
contained within this manual. In addition we recommend that this manual be kept readily available
for reference before beginning any work associated with equipment.
Safety precautions and instructions for awareness and information on potential hazards are found
throughout this manual. Due to the complexities of the systems in which this equipment is used
and the environment in which it operates, situations may arise which are not directly discussed in
detail in this manual. When such a situation arises, past experience, availability of equipment,
and common sense play a large part in what steps are to be taken. In addition, a Rader service
representative is available to answer your questions, perform inspections and safety reviews,
provide operator training, and supervise maintenance crews upon request.
Please feel free to contact a Rader representative at the following Rader office locations.
Additional contact information can be found on the Internet at WWW.RADER.COM.

A.2.

Rader Companies, Inc.


1225 Old Alpharetta Road, Suite 260
Alpharetta, GA 30005
Tel. 770-777-8000
Fax. 770-751-3804

Rader AB
Domnarvsgatan 11, 163 53
Spnga, Sweden
Tel. +46 (0)8-56 47 57 47
Fax. +46 (0)8-56 47 57 48

Rader Canada
2350 Place Trans Canadienne
Dorval, PQ H9P 2X5
Tel. 514-822-2660
Fax. 514-822-2699

Rader Canada
6400 Roberts Street, Suite 101
Vancouver, BC V5G 4E1
Tel. 604-299-0241
Fax. 604-299-1491

General Safety
All parts of the equipment and the system into which it's installed must be used in keeping with
sound safety practices. This manual contains safety information designed to be used in two ways:
first as a primary reference for operators and mill maintenance personnel, providing them with
details and explanations of operational and maintenance safety procedures; and second as a
training tool within your mill's safety program.
Safety begins with properly designed and manufactured equipment. To that end, Rader has
designed this equipment with safety in mind. However, the use of the equipment is subject to
certain hazards that cannot be met by mechanical means alone, but only by the exercise of
intelligence, care, and common sense. Once the equipment enters service, Rader has no direct
control over its inspection, maintenance, or operation. For this reason, safety in the field is the
responsibility of the user.
Any maintenance other than inspection, cleaning, or obvious repair due to damage should be
discussed with your Rader representative. Certain design parameters are utilized in the
construction of this equipment. Wear for example, can render the equipment hazardous to
operate and should be discussed with your Rader representative.

2004 Rader Companies, Inc.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
The following notes provide basic safety guidelines that should be incorporated into a
comprehensive safety program at your mill.
-

Do not remove warning signs from the equipment. If warning signs become damaged,
contact Rader for replacements.
Make certain that all barriers, covers, and guards are in place before starting the
equipment.
Keep aisles around equipment clear of unnecessary or potentially hazardous articles.
Wipe up spilled oil, grease, or water to minimize the risk of slips and falls.
Keep clothing and all parts of the body away from moving machinery parts.
Keep hands away from belt and chain drives.
Wear appropriate safety protection equipment as required by the job and environment.
This includes hard hats, safety goggles, hearing and eye protection, dust masks, safety
shoes, etc.
Read and understand all safety related information in this manual.

A.3. Warning Signs


Signs of various types are posted throughout this manual and on the equipment to warn the end
user of potential hazards associated with the operation of this machinery. These signs aid in the
safe and efficient operation of this equipment, and it is recommended that periodic inspection of
all signs be included in the machines inspection program. If signs are missing, damaged or
illegible, they should be cleaned or replaced to ensure the safe operation of the equipment.
Replacement warning signs are available for a nominal charge by contacting the Rader
representative at one of the addresses listed in Section A.1. Refer to Section B.5. for a complete
listing of warning signs.
Signs used in this manual and on Rader equipment use the following signal words to emphasize
important and critical instructions.

DANGER

Danger is used to indicate an imminently hazardous situation which, if not


avoided, will result in death or serious injury. This signal word is to be limited to
the most extreme situations.

! WARNING
Warning is used to indicate a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

! CAUTION
Caution is used to indicate a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury or property damage.

NOTICE
Notice is used for special important instructions, but not hazard related.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
A.4.

Lockout/Tagout Procedures
When performing inspection or maintenance on Rader equipment, always follow Lockout/Tagout
Procedures as required by OSHA 29 CFR Part 1910.147 and outlined in ANSI Z244.1. Refer to
the maintenance section of your manual prior to performing any maintenance. If the specific topic
is not covered, contact Rader before proceeding.
Lockout/Tagout Procedures are intended to protect personnel working on or around the
equipment by preventing accidental start up and exposure to hazardous energy release such as
electrical shocks and stored energy. The procedure requires that individual locks and tags are
placed on controls, shutoff switches, valves, or other devices to prevent usage until the person
who installed the lock removes it. Never attempt to operate any control device when it is locked
and tagged out.
OSHA required Lockout/Tagout Procedures include:
1.
A documented and established site policy on the steps to follow for lockout and
tagout such as:
a.
Notify all affected people including supervisors before lockout or
tagout is used.
b.
Shut off the affected machine, equipment, system or function.
c.
Disengage, isolate or release energy supply or source.
d.
Apply individual locks and tags on controls, or other devices to
prevent usage.
e.
Try or test the equipment to check that the energy has been
removed before service or maintenance.
2.
Employee training on proper Lockout/Tagout Procedures for the facility.
3.
Identification and location of shutoff switches and controls that isolate hazardous
energy are predetermined at the Site facility.
4.
After maintenance is complete and the appropriate individual removes each
Lockout/Tagout, all affected people are notified, and the energy or power is
restored.

A.5.

Confined Spaces Procedures


Certain areas of this equipment may be considered a Confined Space, or a Permit Required
Confined Space, per OSHA 29 CFR Part 1910.146 and outlined in ANSI Z117.1. If the
equipment is so designated, a warning sign will be posted, and a documented and established
site policy must detail the steps to follow before any entry is allowed. These procedures, along
with Lockout/Tagout, must be followed before any entry is attempted into a confined space or
permit required confined space

A.6.

Material Safety Data Sheets (MSDS)


In order to transfer MSDS information from our suppliers to our customers, Rader will provide this
service on customer request. All customer requests need to be specific because of the volume
and complexity of the MSDS system. To correctly identify the appropriate MSDS, the Rader part
number must be known. Inquiries concerning the MSDS information can be addressed to the
Rader Engineering Dept.

2004 Rader Companies, Inc.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

B.

General Information
B.1.

TM

DynaYield

Chip Conditioner Background

TM

The DynaYield 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 wood
received to the pulp mill, resulting in heavy usage of pulping chemicals, high digester knotter
reject rates. and lower pulp yield. By processing the overthick/oversize wood through the
TM
DynaYield , pulping liquor can more easily penetrate the chip, and enhance the pulp yield from
TM
the chip. The DynaYield has the additional advantage over other types of overthick/oversize
processing equipment of extremely low pins and fines production during the conditioning process.

Figure 1

B.2.

Functional Description
TM

The DynaYield Chip Conditioner is a continuous duty machine, designed to condition wood
chips in a single pass through the unit.
TM

The DynaYield Chip Conditioner consists of two major parts, the Chip Conditioner Unit, and a
Hydraulic Power Unit for roll positioning. The Chip Conditioning Unit consists of 2 segmented
rolls, approximately 37" in diameter. The rolls are arranged horizontally, and rotate in an opposite
direction 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 the
frame, and the dynamic roll allowed to move in a horizontal direction away from the static roll.
This movement in the dynamic roll allows for rocks and tramp to go through the machine, and
minimize damage to the roll surface. Each roll has it's own motor, V-Belt drive, and shaft
mounted reducers with motor mounts.
The roll surface is comprised of removable segments, which permit replacement of the outer
profiled surface when worn. The rolls are positioned closely to a minimum nip setting by
mechanical stops, and the dynamic roll is held against this stop by hydraulic cylinders at both ends
of the dynamic roll. When the separate Hydraulic Pump unit (located near the Chip Conditioner)
is started, the hydraulic fluid pressurizes the hydraulic cylinders, pushing the dynamic roll against
the mechanical stops for the desired nip setting. If tramp iron or some other hard object goes
TM
through the DynaYield Chip 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 hard
object has passed through the unit, the dynamic roll moves back to the original minimum nip
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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
setting automatically. The hydraulic unit may also be used to open the nip clearance for
maintenance 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. The
TM
Hydraulic Unit is connected to the DynaYield Chip Conditioner through runs of high pressure
hydraulic hose and pipe.

Figure 2

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
B.3.

Standard Model Information


TM

The DynaYield Chip Conditioner is manufactured of high quality components, and machined,
fabricated and assembled with great care. All units are test run at the manufacturing shop for
proper operation before shipment.
TM

All DynaYield Chip Conditioners will have attached to the frame at one corner a metal Rader
nameplate. On this nameplate is permanently stamped the Rader Job Number and Rader Model
Number for each conditioner. This information should be referred to whenever the chip
conditioner 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.

Optional Features
Below is a partial listing of optional features that may be selected at the time of order. In many
cases, features may be added to existing units, contact a Rader product representative for more
information on in-field modifications.
-

B.5.

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

TM

DynaYield

Safety Warning Signs

TM

The following safety warning signs are used on the DynaYield Chip Conditioner. Should any of
the signs on the conditioner be missing, damaged, or illegible, they should be cleaned or replaced
TM
to ensure the safe operation and maintenance of the DynaYield . Replacement warning signs
are available for a nominal charge by contacting the Rader product representative at one of the
addresses listed in Section A.1.
A-101270
C-103175
C-103176
C-103179
C-103190
C-103313
C-103404

2004 Rader Companies, Inc.

"Lift Here"
"WARNING:
"WARNING:
"WARNING:
"NOTICE :
"DANGER:
WARNING:

Equipment starts and stops automatically..."


Rotating Shafts and/or moving drive components..."
Falling through unsupported surface..." (with pictorial)
Refer to manual for installation, operation,..."
Aggressive Ingoing Nip..." (with pictorial)
Control Voltage... (with pictorial)

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

C.

Installation
C.1.

Shipping, Handling, & Storage


TM

The DynaYield Chip 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 does
not need to be removed for lifting as long at the lifting lines to not interfere with any part of the
drive 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.

Figure 3
When shipping by truck, the conditioner should be placed on wooden cribbing and bound to the
flatbed trailer using the lifting brackets. Straps may be used only over the lifting bracket area, and
not over any of the lightweight covers or guards. Under no circumstances should the conditioner
be lifted or secured by any of the shafts within the unit. Any damage incurred from shipping
should be reported to both Rader and the shipping carrier involved as soon as possible after
TM
receipt of the DynaYield Chip Conditioner.
Equipment will be shipped with all bare metal surfaces primered or coated with a suitable shipping
rust protectant, such as Cosmoline. If the equipment is to be stored before installation, unpack or

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
uncrate the equipment immediately, clean off existing protectant, clean any rust or dirt that may
have 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 direct
sunlight, and keep dry. WATERPROOF TARPING OR COVERINGS ARE NOT ADEQUATE.
o
o
Temperature should be ideally controlled to 70 F. (21 C.) and less than 60% relative humidity.
Minimize all temperature variations that can cause internal condensation in bearings and
gearboxes. Allow air to circulate freely around the equipment. Keep equipment away from any
corrosive or hazardous environments during storage. Keep equipment away from any blowing
dusts or dirt, which could damage shaft seals. It is highly recommended that the hydraulic power
unit 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 recommended
that the shafts of the equipment be turned manually every two weeks to redistribute grease inside
the bearing housings. Gear reducers should be filled to manufacturer recommendations with a
rust preventative oil to protect internal gears and bearings, and rotated every two weeks to
redistribute oil inside the gear reducer housing. Seal any breathers or vents if instructed by the
gear 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 cannot
be stored in the above parameters, it is strongly recommended that the gear reducers, motors,
and 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, as
any internal condensation will contaminate the oil with water.

C.2.

Mounting and Supports


TM

The DynaYield Chip Conditioner may be mounted to either structural steel framework or to steel
imbeds in concrete floors. Installation drawings should also be referred to when calculating
support pad loads. The mounting supports must be flat and level to within 1/16" for both the chip
conditioner and the hydraulic unit. The hydraulic unit must be located under 40'-0" from the chip
conditioner, as measured by the hydraulic line run. Infeed and outfeed chute work must not be
TM
supported off the DynaYield Chip Conditioner or it's supports.
Because all components in the roll assemblies is balanced, dynamic forces resulting from the
TM
operation of the conditioner are low. Beams directly supporting the DynaYield Chip Conditioner
should be designed with a natural frequency in the vertical plane 40% above or below 0.6 Hz (the
machines operating frequency) with an expected imbalance of 100 lbs. This frequency
corresponds with the rotational speed of the rolls. Assume the beams are pin supported at both
ends during the structural design process. During the operation of the conditioner, the crushing
forces necessary to condition the chips is fully contained inside the frame of the unit. Experience
with 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 special
structural requirements have been required at any of the existing installations.
TM

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

2004 Rader Companies, Inc.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
C.3.

Service Access
To provide access for weekly inspections and maintenance, a service platform should be located
TM
at the same level as the DynaYield Chip Conditioner mounting pads, conforming to all OSHA
safety requirements. The service platform should be a minimum of 3'-0" around the outside
perimeter of the plan view shown on the general arrangement drawings. In addition, a crane hoist
rails should be provided as shown on the general arrangement drawings, a minimum of 12'-0"
above the mounting pad level to aid in maintenance. Hoisting capacities will also be shown on the
general arrangement drawings. Should it be necessary to provide hoisting to remove a roll
assembly from the frame, insure capacity of at least 5,000 lbs for a Model 20, 7,000 lbs for a
Model 40, 9,000 lbs for a Model 60, and 11,000 lbs for a Model 80. Rolls must be removed
vertically until the roll clears the top of the conditioner frame.
Access to the underside of the conditioner frame must be provided through the discharge chute
for replacement and adjustment of the roll scrapers located under each roll. Interior supports for
an OSHA removable maintenance platforms inside the chutework should be provided
approximately 7'-6" below the centerline of the rolls. An exterior OSHA approved platform to this
service entrance is strongly recommended.

Figure 4
Should it not be possible to maintain the recommended minimum clearances, pay close attention
to the general arrangement drawings. Some parts of the conditioner may be difficult to remove
with less than the recommended minimum clearances.
Contact Rader for specific
recommendations in tight installations.
The general arrangement drawings will show the flooring extending under the drive housing of the
conditioner to the framework. Allowances have been made for up to 1 1/4" thick bar grating to be
used.

2004 Rader Companies, Inc.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
TM

Compressed air should be provided at the DynaYield Chip Conditioner floor level to remove
accumulated dust and foreign matter at maintenance cycles.

C.4.

Infeed Requirements
The infeed material should be free of large rocks and tramp steel that might damage the
conditioning rolls. Experience has shown that in installations where tramp materials (rocks, bolts,
ball bearings, etc.) are not removed, roll segment life decreases in direct proportion to the amount
TM
of tramp put through the DynaYield Conditioner. In addition to roll segment damage, additional
TM
damage is sometimes seen in the drive system of the DynaYield , mainly in the gear reducer and
TM
torque arm. Rader highly recommends effective tramp protection in front of a DynaYield , with
our first choice being an ADS (Air Density Separator) system. In addition to removing the heavy
tramp material, the ADS has the additional benefit of removing a large percentage of the knots
and compression wood.
In installations where it is suspected that tramp material may be encountered on more than a
accidental 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 fluid
couplings will not prevent damage to the roll segments from tramp materials.

Figure 5
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 screw
TM
conveyor to evenly distribute the infeed material. In addition, the DynaYield is extremely
sensitive to changes in the infeed rate. All infeed material must be metered at a near constant
rate, to provide a thin curtain of material entering the unit. If the rate is not held constant,
inconsistent conditioning results may be encountered, or the unit may tend to plug. A bypass
around 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 oversize
material could cause insufficient conditioning action if it goes through the conditioner at the same
time as the normal oversize wood. Material over 3/4 in thickness, 2 in width, and/or 8 in length
is considered oversize.
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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Material infeed to the conditioner may free fall vertically up to three feet from above the inlet flange
of the conditioner. Beyond this height, it is recommended to slide the material against a sloped
O
surface, at a greater than 55 from the horizontal. Infeed chute can be sloped from both sides if
necessary, sloped from one side only is preferred. See Figure #5 for several examples of
acceptable infeed arrangements.
Recommended access to the nip points between the two rolls is an access door that is the full
length 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 the
conditioner, this access should be provided in the distributing screw discharge housing. This will
allow a visual inspection of the nip point from above the machine all the way across the rolls. Nip
point access may be provided from below the unit, in conjunction with Section C.3. if necessary,
however, access from above is preferred.

Figure 6
TM

As mentioned above, the infeed chute work must not be supported by the DynaYield , or to any
of its supports.
Access doors for sampling and examining infeed material is always
recommended.

C.5.

Outfeed Requirements
Service access must be provided in the outfeed area of the conditioner as outlined in Section C.3.
TM
All discharge chute work must not be supported by the DynaYield or to any of its supports,
unless chute weight is below the maximum stated on the general arrangement drawings. Access
doors for sampling and examining all outfeed materials is always recommended. Sufficient surge
capacity should be allowed in the design of all outfeed chutes should the outfeed equipment be
TM
shut down without warning, allowing for at least 1 1/2 to 2 minutes of capacity during DynaYield
time-out. Plug detectors in the discharge chutework are also recommended.

2004 Rader Companies, Inc.

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
C.6.

Electrical Requirements
C.6.a. Conditioner Electric Motors
The general arrangement drawing calls out the specific horsepower and number of
TM
Chip Conditioner. When wiring the chip
motors required for a given DynaYield
conditioner motors, use a watertight flexible conduit at the motor which allows the
dynamic roll motor to move horizontally as shown on the general assembly drawings.
Recommended conduit entrance into the drive housing is from below, and alongside the
gear reducer to bottom facing conduit opening in the motor.
It is also recommended that operator push button jog controls be provided at the chip
conditioner floor. Start and stop controls may be added if required. If the hydraulic power
unit is located on a different floor than the conditioner, operator controls to start and stop
the power unit, and to extend and retract the cylinders should also be provided.

C.6.b. Hydraulic Unit Electrical Requirements


The general arrangement drawing calls out the specific horsepower and number of
motors 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 a
tank mounted fluid heater in the reservoir with a temperature controller, a reservoir fluid
low-level switch, high temperature switch for the air/oil cooler, and solenoid control valve,
all of which must be wired correctly per the recommended interlocking instructions given
in Section C.6.f.
It is also recommended that push button operator controls be provided at the hydraulic
unit area, including start and stop control, and extend and retract on the cylinders.

C.6.c. Speed Sensing Probes


Two proximity type speed sensing probes are included on the conditioner, one positioned
on 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 the
conditioner rolls is rotating at less than 30 RPM, the sensor should shut down the infeed
to the conditioner. See the Proximity Sensing Appendix and the interlocking instructions
in Section C.6.f. for more information.

C.6.d. Nip Setting Proximity Probes


Two proximity type sensing probes are included in the conditioner nip setting area, one at
each end. These sensors may be wired and interlocked per the customers requirements
to sound a warning, shut down the system, or any other function. Wire through an
adjustable timer so nuisance trips are avoided. See the Proximity Sensing Appendix and
the 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.
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Oct 2004

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.

C.6.f. System Interlocking

TM

Information on the required interlocking for the DynaYield Chip Conditioner is given on
the recommended interlocking drawing, which may be different than the standard
instructions given below. The instructions given below are for reference only.
TM

Whenever possible, the DynaYield should not be shut down with material between the
rolls. This will cause high starting loads, and stress drive components and roll segments
beyond reasonable limits. In most cases, the wedging action of chips in the incoming nip
between rolls will require that the unit be cleared before operation.
Interlocking controls for the standard Rader Chip Conditioner include the following
devices:
-

Low level switch in the hydraulic power unit


Cooling Fan temp. switch in the hydraulic power unit (not used with water/oil
cooling option).
High temperature switch in the hydraulic power unit
Solenoid "A" on the hydraulic power unit (opens the dynamic roll for
maintenance).
Solenoid "B" on the hydraulic power unit (closes the dynamic roll for operation).
Nip probe #1 at the drive end of the conditioner.
Nip probe #2 at the idler end of the conditioner.
Low speed probe #1 for static conditioning roll.
Low speed probe #2 for dynamic conditioning roll.

! CAUTION
Solenoids "A" and "B" should never be arranged to
both be energized at the same time. Damage to the
solenoid valve can result.
General:
1.
All wiring to be done to all current local, state, provincial, federal, and NEC
regulations and codes.
2.

Conditioner installation will include an operator control panel near the conditioner
and hydraulic power unit. When the hydraulic power unit is remotely located, it is
recommended that a control station at the power unit be added. The panel
controls should include an H-A selector, an OPEN-OFF-CLOSE selector, and
a hydraulic pump start and stop push button.

3.

The E-Stop switch on the conditioner unit should be hardwired into the customers
electrical system. All motors associated with the conditioner should be stopped
when the E-Stop is depressed. Two sets of contacts have been provided, one for
hardwiring, and one for indication.

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Oct 2004
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 second
timer, energize Solenoid A for 10 seconds to retract/open the dynamic
roll. After 10 seconds, de-energize Solenoid A, and conditioner motors
can 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. The
conditioner rolls are now closed, and nip probes #1 and #2 should show
the nip setting closed. Both nip probes should be run through timer
circuits so that if either of the nip settings is not made for longer than 5
seconds, an alarm will sound, and the customer can decide the results of
this 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 starts
the cooling fan when the air/oil heat exchanger is used. High initiates a normal
shut down and alarm for either heat exchange option.
6.

When in operation, if outfeed fails, an alarm will sound. Conditioner infeed is


shut-down immediately. Conditioner roll drive motors and hydraulic power unit
pump motor continue to operate.

7.

When in operation, if infeed fails, an alarm will sound. Conditioner roll drive
motors 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 30
rpm 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 and
timer begins for 10 seconds to retract the hydraulic cylinders. After 10 second
timer, Solenoid A is de-energized. Hydraulic power unit pump motor continues
to operate.

9.

When in operation, if the low oil level switch in the hydraulic power unit is
energized, an alarm will sound. The conditioner begins a normal shut-down
sequence.

10.

When in operation, nip probes #1 and #2 should be run through a timer circuit so
that if either of the nip settings is not made for longer than 5 seconds, an alarm
will 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 to
allow 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.

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C.7.

12.

With the conditioner in a shut-down condition, and the selector switch moved to
the "HAND" position, the conditioner motors can be started and stopped from the
operator 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. The
dynamic conditioner roll can then be opened or closed by activating Solenoids "A"
or "B" using the OPEN-OFF-CLOSE selector switch on the operator control
station. Solenoids A and B should never be energized at the same time.

Hydraulic System Requirements

TM

The hydraulic system for the DynaYield Chip Conditioner is fully checked out, adjusted, and
tested at the manufacturing shop before shipment. The customer normally supplies all piping
between the chip conditioner and the hydraulic unit bulkheads. The hydraulic unit should be
located no farther than 40'-0" from the chip conditioner, as measured by piping run. The hydraulic
lines 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 the
lines tightly against the frame as they come up to the cylinder manifolds, making the final
connection with a 90 degree elbow.
Cleanliness cannot be overemphasized during the installation, flushing, operation and
maintenance of hydraulic systems. Piping (or equivalent runs of hydraulic tubing) should be 3/4"
schedule 80 pickled, oiled, and plugged hydraulic piping, that is free from all dirt, rust, and scale.
Flexible hose should be supplied to each end of the piping or tubing, and be equivalent to Parker
Hannifin 381, SAE 100R2, 5000 PSI or equal. Fittings shall be 3/4" 37 degree JIC Standard to
the piping, and #12 SAE O-Ring fittings where the piping attaches to the power unit and cylinder
manifolds.
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.

b.
c.

d.

e.
f.
g.

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 the
flexible hoses labeled A and B at the drive end of the conditioner frame. Connect
these two lines together with a fitting.
Start-up the HPU using the instructions given in Section D, lines 3 - 6.
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 2
hours, then switch the solenoid to the B position and run for another 2 hours. Draw a
sample of hydraulic oil and have it tested. Repeat this process until the oil tests cleaner
than the specifications on the drawings.
Shut down the pump, Lock-Out/Tag-Out the hydraulic pump motor, and
remove the fitting connector between Lines A and B at the drive end of the conditioner.
Reconnect both lines to their original locations.
Disconnect the flexible hoses labeled A and B at the idler end of the conditioner frame,
and connect these two lines together with a fitting.
Flush these lines as described in Section C.7.c above. Repeat this process until the oil
tests cleaner than the specifications on the drawings.
Shut down the pump, Lock-Out/Tag-Out the hydraulic pump motor, and
remove the fitting connector between Lines A and B at the idler end of the conditioner.
Reconnect both lines to their original locations.

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D.

Start-up Check Off Sheet

TM

The following list is provided to assist with the check-out of the DynaYield Chip Conditioner. Both the
conditioner and the hydraulic unit must be Locked Out before 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 the
lip seals on the motors and reducers with grease. Grease the motors, gear reducers,
bearings and slide plates from the centralized grease lube station on the conditioner unit.

_____3.

Moving to the hydraulic unit, fill 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 line
are full open prior to start-up. All piston pumps must be filled with hydraulic oil in the
pump case drain housing port before initial start-up. Remove the piping connection from
the pump compensator to the oil cooler at the pump. Fill the pump with clean fluid to the
top. Reconnect the piping. Failure to fill the pump case can destroy the pump in
seconds. Insure all suction shut off valves in the pump inlet line(s) are fully open prior to
start-up. Disconnect hydraulic lines from the hydraulic unit at the conditioner frame, and
install 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 shaft
alignment before start-up. Misalignment should be less than .005".

_____5.

Restore electrical power to the hydraulic power unit only, and jog the
pump motor for correct rotation. After correct rotation is established, jog the pump motor
for up to five seconds to prime the pump. You should hear the sound change when the
pump 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 on
the hydraulic power unit slowly as the accumulator fills. Flush the hydraulic system as
described in Section C.7.
Set the pressure on the pump to about 900 Psi, and fully extend and retract the cylinders
against the stops to remove all air from the lines. After all air has been purged from the
system, 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. Check
the entire hydraulic system for any leaks at all points in the system.

_____7.

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 the

Check the nip settings on the conditioning rolls.

cylinders while checking the nip settings. To check the nip setting, Rader uses lead strip,
1/4 thick x 3/4 wide x 12 long, rolling the strip into the nip from above by turning the Vbelt drive by hand. After the lead has be pulled into the nip about 6, the lead is withdrawn
by reversing direction on the V-belt drive. The impressed lead profile is then measured
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using special tools. Standard settings are a peak to valley measurement of 2.8mm, and
slope to slope at 1.9mm. Adjust if required using the removable shims provided, adding
or removing equal amounts of shim to both the upper and lower nip setting at each end.
Removing shims decreases clearance, while adding shims increases clearance. Inspect
the rolls for any foreign material on the conditioning rolls, or in the drive area.
_____8.

Shut-down the hydraulic power unit and Lock-Out.

_____9.

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

_____10.

Restore electrical power to the DynaYield Chip Conditioner motors and the hydraulic
power unit, and jog the conditioner motors for correct rotation. Correct rotation is shown
in Figure #1, with the ingoing rotational nip at the top of the unit.

_____11.

Start the DynaYield and let run for several minutes, and listen for any abnormal sounds.
TM
Shut the DynaYield down, retract the hydraulic cylinders fully, and check the hydraulic
fluid level in the reservoir, and refill to the center of the sight glass if required. Restart the
TM
DynaYield and let run for several hours minimum. Listen for any abnormal sounds,
indicating misalignment. Shut down, Lock-Out the electrical power on both the
conditioner 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 DynaYield Chip Conditioner and hydraulic unit, and test
all 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. Slowly
increase to full rate, adjusting the distribution of material into the conditioner as required.

Access the roll


scrapers located below the conditioner rolls, and check the clearance and alignment of
each scraper to the roll segments. Clearance between the scraper and the roll segment
should be 1mm while the rolls are turned by hand.

TM

TM

TM

TM

The DynaYield

2004 Rader Companies, Inc.

Chip Conditioner is now ready for operation.

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E.

Operation
E.1.

Material Pre-conditioning Requirements


TM

Generally, the DynaYield infeed material should be free of large rocks and tramp steel that
might damage the conditioning rolls. Experience has shown that in installations where tramp
materials (rocks, bolts, ball bearings, etc.) are not removed, roll segment life decreases in direct
TM
proportion to the amount of tramp put through the DynaYield Conditioner. In addition to roll
TM
segment damage, additional damage is sometimes seen in the drive system of the DynaYield ,
mainly in the gear reducer and torque arm. Rader highly recommends effective tramp protection
TM
in front of a DynaYield , with our first choice being an ADS (Air Density Separator) system. In
addition to removing the heavy tramp material, the ADS has the additional benefit of removing a
large percentage of the knots and compression wood.
In installations where it is suspected that tramp material may be encountered on more than a
accidental 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 fluid
couplings 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
TM
conditioning efficiency. In addition, the DynaYield is extremely sensitive to changes in the
infeed rate. All infeed material must be metered at a near constant rate, to provide a thin curtain
of material entering the unit. If the rate is not held constant, inconsistent conditioning results may
be encountered, or the unit may tend to plug.
The material to the Conditioner should also be scalped of all oversize material, as this oversize
material could cause insufficient conditioning action if it goes through the conditioner at the same
time as the normal oversize wood. Material over 3/4 in thickness, 2 in width, and/or 8 in length
is considered oversize.
TM

is not normally designed or manufactured to operate handling hazardous


The DynaYield
materials or in a hazardous environment. Hazardous materials are those classified as explosive,
flammable, toxic, or otherwise dangerous to personnel if not completely contained inside the
equipment during operation. If the conditioner is to be operated in any of the above environments,
or handle any form of hazardous material, contact Rader for a complete review of the application.

E.2.

TM

Basic DynaYield

Chip Conditioner Operation

! WARNING
All covers and guards must be in place while operating a
DynaYieldTM Chip Conditioner. Serious injury or death can
result from the improper use of this machine.
Always
Lockout/Tagout the conditioner, hydraulic unit, and any
adjacent equipment before inspection or maintenance of this
equipment.
Do not use the top surface of the DynaYieldTM as a walk or
working surface during the operation of the machine.

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Oct 2004
TM

Do not decrease or increase the operating speed of the DynaYield Chip Conditioner beyond that
listed on the general arrangement drawings, unless by written permission of Rader Companies.
To do so may cause accelerated wear, increased power consumption, and/or permanent damage
to the conditioner and hydraulic unit, and void all warranties. Unauthorized personnel should be
prevented from making any changes or adjustments to the conditioner and the hydraulic unit after
start-up.
TM

Assuming the proper electrical controls, as outlined previously, controlling the DynaYield Chip
Conditioner during operation is a simple matter. During the start-up, a Rader product
representative will set-up the conditioner for proper operational pressures, and take samples of
the conditioned chips to determine the conditioning efficiency of the unit. The only adjustments on
the 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.
TM

Chip Conditioner should always be started and stopped without material


The DynaYield
between the rolls. The conditioner should be interlocked to the screening system such that the
conditioner will automatically be timed-out whenever the infeed device shuts down, except in
emergencies. 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 as
far apart as possible using the control system, and start the conditioner unit. The rolls will be
approx. 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 be Locked-Out,
infeed access doors and top covers removed, and the rolls cleared and cleaned by hand.
Attempting to start the conditioner rolls with the dynamic roll extended & material wedged between
them 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 power
unit and the conditioner, the fluid is static but under pressure. In normal operation, the only fluid
moving through the system is that which is being bypassed from the pump compensator, and only
this fluid moves through the heat exchanger, filter, and back into the reservoir. The fluid in the
lines 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 each
cylinder sense the rapid increase in pressure, and allow fluid to move from the blind end of the
cylinder to the rod end, retracting the dynamic roll just enough to allow the obstruction through the
unit. Once the hard object has passed, the roll automatically moves back to the fully extended
position, resuming normal operation. During this process, the solenoid valve does not change
fluid direction, nor does the dynamic roll fully retract and re-extend. This feature allows the
conditioner 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 the
machine, these sensors are wired into the control system as desired by the customer to warn
when the nip points on the dynamic roll are not completely closed. This could result from a
mechanical failure, such as loss of hydraulic pressure, or from wood dust falling in between the
nip 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 the
particular installation and application.
The hydraulic system has several controls that monitor the system during operation, and warn the
operators of potential problems. The reservoir is equipped with a low level switch, should the fluid
level drop below a preset value, the switch will sound an alarm and immediately begin to shut
down 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 units
work together to keep the hydraulic fluid above 80 degrees F. and below 180 degrees F. The oil
heater is arranged to turn on automatically below 80 degrees F., and turn off at 95 degrees F.
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Oct 2004
The heat exchanger will turn on at 120 degrees F., and off at 110 degrees F. Both the oil heater
and heat exchanger are conservatively sized, and low and high temperatures will not normally be
a problem. If the hydraulic system fluid temperatures reach 180 degrees F., the high temperature
sensor in the reservoir should sound an alarm and begin a normal shutdown sequence, and the
reason 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 degrees
F. before starting the conditioner.
During the weekly walk-by inspection of the unit, watch and listen for any air in the hydraulic
system. This can usually be identified as erratic movement of pressure gauges and cylinders, and
the sound of marbles running through the hydraulic pump. Allowing a pump to pump air (cavitate)
can 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, the
indicator will warn that the filter requires changing. The filter must be changed after the first
several days of operation (monitor closely). Thereafter, the normal schedule calls for a yearly
change of the filter, more often in dirty environments.

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F.

Maintenance
TM

The DynaYield 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. The
useful 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 Maintenance
TM

The DynaYield should be checked over on a regular schedule shown below to maximize
TM
operator safety and the conditioners usable life. Always look the DynaYield Chip Conditioner
over for damage, signs of improper operation or malfunction, and listen for odd noises that may
signal the need for a more thorough investigation.
After the first several days of operation, the conditioner should be shut-down, Locked out, and
inspected for any roll segment damage, loose bolts, and hydraulic system leaks. The hydraulic
unit fluid filter should be changed at this time as well.

Lockout before any inspection or adjustment


WeeklyCheck all guards and covers are in place, and function properly.
Check for hydraulic system leaks, check hydraulic unit fluid level.
3-MonthGrease spherical bearings & dynamic roll slides.
Grease motor and gearbox seals.
Check gear reducer oil levels.
6-MonthVisually 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.
YearlyFull 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 ManufacturerChange gear reducer lubricant.

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Oct 2004
F.2.

Lubrication Information
The 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 from
the lubrication station located on the drive end of the conditioner, the quantity of
fittings varies with model. Use only one or two shots of high quality grease
conforming to NGLI #2 every 2000 hours (3 months) per seal to prevent seal
blow-out and early bearing failure. Grease more often in dusty environments.
The standard arrangement of the lubrication stations on the conditioner as
shipped from the factory allow the motors to be lubricated from the main greasing
stations near the drive end. If it is not desired to have the normal lubrication crew
lubricate the motors, remove the grease lines to the motors and install pipe plugs
in 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 premium


grade anti-foaming hydraulic fluid (AW-32), passing through a 5 micron filter
during entry to the reservoir. The fluid levels should be checked on a weekly
basis, and the fluid changed yearly (more often in very dusty environments).
-

F.3.

Conditioner Roll Bearings and Dynamic Roll Slide Base:


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

Hydraulic Unit

TM

The Hydraulic Unit for the DynaYield Chip Conditioner is very simple and straightforward, and
by following the guidelines below, and the information contained in the appendixes, major
problems with the hydraulic system can be avoided. The hydraulic unit as shipped has been fully
tested and run, and major adjustments made.

Lock-Out the hydraulic system before inspection and maintenance.

a.

Always

b.

Cleanliness is essential when working with precision hydraulic components, to ensure


long life. All pipes, hoses, and tubing must be cleaned thoroughly during installation, and
kept clean during all maintenance procedures. If any new hoses or pipes are replaced,
the entire system should be flushed to minimize dirt in the system, and the filter changed
several days after.

c.

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

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Oct 2004
d.

Check and double check all pump rotations by jogging the motors before running the
pump. Pumps will have rotational arrows showing the correct rotation. Hydraulic pump
rotational direction is always determined by viewing the pump from the shaft end. Pump
models 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 a
5 micron filter. The hydraulic fluid should be a premium quality, anti-wear, anti-foaming,
AW-32 hydraulic oil. Maintain the fluid level to at least the mid point on the sight glass
when the hydraulic unit is off.

f.

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

g.

Set pressure controls (relief valves and pump settings) to minimum or approx. 500 PSI.
Jog 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 properly,
increase the settings to operating pressure.

h.

All pumps can be severely damaged if they are run without fluid. If the pump fails to
prime, 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 ingest
air (cavitate), and will make a sound like marbles are running through the pump.
Cavitation can cause excessive damage to the pump, so correct immediately.

j.

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

k.

Erratic movement of pressure gauges and cylinders can be caused by air trapped in the
system. Bleed air from the component by slightly loosening the highest connection on the
component 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 pressure
and operation. The main pressure relief valve is located on the hydraulic power unit itself, and the
individual cylinder relief valves are located on each cylinder, accessible through the small door
above each cylinder. The procedure for adjusting these valves is as follows:
-

Drawings provided with the conditioner will show the pressure values for both the main
and 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 main
pressure relief valve located on the HPU. Have a helper slowly increase the pressure at

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Oct 2004
the hydraulic pump, and note the pressure the valve cracks open and fluid can be heard
passing through. Readjust the valve if necessary by turning the allen socket screw
clockwise to increase or counterclockwise to decrease the pressure setting. Reduce the
pressure in the pump, reset the system, and recheck in the same manner after setting the
pressure. 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 the
valve. A stethoscope or equivalent is helpful here. Retighten the locknut.
-

F.4.

To adjust the cylinder pressure relief valves located directly above the hydraulic cylinders,
have the hydraulic power unit operating and the solenoid valve B energized (supplying
pressurized fluid to the blind end of the cylinder, to extend it). Using the supplied gauge
on each cylinder, adjust in a similar manner to above, using the cylinder relief pressure
settings shown on the drawings. Fully adjust one cylinder, then adjust the second
cylinder. Make sure to reset the pump operating pressure to that shown on the drawings
before returning the system to operation.

Speed Sensing Components

TM

Two speed sensors are provided as part of the DynaYield Chip Conditioner to sense low shaft
speed, warn the operators, and shutdown the conditioner and related equipment. The sensors
are located on the ends of each roll shaft to directly pick up any loss of speed. These sensors
must be interlocked into the screening system, and must be operating properly to prevent
unnecessary downtime. Every 4500 hours (6 months) the sensors should be individually checked
to insure proper operation, and proper interlocking into the screening system. See Proximity
Sensing Appendix for more information on these units.

F.5.

Mechanical Components
The following mechanical components should also be checked on a routine basis, as follows.
Always Lockout/Tagout before performing any of the following functions.
-

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

On a yearly basis, fully check the condition of the rolls in the conditioner unit. Remove
and 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 and
injuring themselves.
Always work from an approved
platform.
-

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

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

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F.6.

Periodic Maintenance

TM

Because of it's inherently simple design, the DynaYield Chip Conditioner has few wear parts
that require replacement at specified intervals. These parts include the roll nip adjustment, axial
roll alignment, roll scraper, roll segments, cylinders, drive reducer, and conditioner roll bearings.
This 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 Adjustment


See Figures #7, #8, and #9 for reference. The roll nip in the conditioner is preset at the
manufacturing facility, and will not normally require readjustment in the field. Even when
replacing the roll segments, alignment is maintained, but should always be checked after
roll segment replacement. The standard values for the nip are given below in Figure #7.

Figure 7
Adjust the nip setting as follows.
- Retract the dynamic roll cylinder fully, then shut down the conditioner and hydraulic
power 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 that
may have accumulated on all nip surfaces, use Rader Blower Cleaner if necessary
to 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 while
checking the nip settings.

! CAUTION
Follow all safety procedures when handling lead
strips.
Wear rubber gloves and wash hands
thoroughly after handling the lead strips.

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- Rader uses lead strips 1/4 x 3/4 x 12 long to check the nip point. With one
person working through the access door above the conditioner infeed as shown in
Figure 8, the lead strip is inserted into the nip between rolls, and a second individual
manually pulls on the V-belt drive to draw the lead in between the rolls. After the
lead 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 measured
using a micrometer with a special tip to get into the depression formed on one side
of the strip, as shown in Figure 9.
- Check in a similar manner on
every segment, rotating both
drums by hand to check all four
quadrants of each roll.
The
amount of shims to be removed
or added can then be determined
by the average total readings at
each end of the drums.
- A quick check of the nip
setting can also be done
with a 1/8 (3mm) dia.
welding rod or similar.
Although not as accurate,
this method can quickly
check if the rolls are
approximately
at
the
correct nip point. Rader
adjusts the rolls to where
the rod snugly contacts
both rolls, to the point
where you can just
forcibly pull the roll out from the rolls without turning them.

Figure 8
Figure 9

- Adjust if required using the removable stainless steel shims provided between the
bearing housing at both ends of the conditioner. Once the amount of shims to be
removed or added is determined from both ends, the hydraulic power unit should be
used 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.
Extra
shims are located on the frame of the unit, below the nip setting area. Removing
shims decreases clearance, while adding shims increases clearance. Inspect the
rolls 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 both
faces 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 nip
adjustment.
After the nip settings have been adjusted, make sure all bolts are properly Loctited and
torqued, re-install all covers and guards that were removed, and remove Lock-Out. The
equipment is now ready to be put back into operation.

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F.6.b. Axial Roll Alignment
The bearings located at the idler end of the conditioner are the fixed or held bearings in
this design. A special adjustment rod is included on the static bearing housing at the idler
end to facilitate the adjustment of the static roll assembly to the dynamic roll assembly.
Do not try to adjust the dynamic roll to the static roll.
-

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

Lockout the DynaYieldTM


Hydraulic Unit.

Remove the idler end


guard, and remove the
idler end upper frame link
above
the
bearing
housings. Loosen, but do
not remove the four bolts
holding the static bearing
housing at the idler end.
To loosen the bolts on the
conditioner roll side of the
housing, an extension of
at least 20 is required.

Arrange for a lifting


device above the static
roll
bearing
that
is
capable of lifting half the
roll assembly weight listed
on
the
customer
drawings. Lift the bearing
housing only enough to
take the weight off the
frame.

Conditioner

drive

motors

and

Figure 10
Using the adjustment
threaded rod and the hex nuts, adjust the static roll for the best possible interface
with the dynamic roll. Make sure to turn both rolls over by hand to check all
interfaces. When adjustment is complete, lock the adjusting device using the two
nuts, and remove the lifting device. Remove the Lockout from the hydraulic power
unit only, and apply hydraulic pressure to the static roll bearing housing, then apply
Loctite and tighten and re-torque the bearing housing to frame bolts. Recheck the
alignment between rolls.
Reinstall the infeed support and the idler end guard. Turn both rolls over by hand to
insure that the infeed chute has not shifted within the machine.

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

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

Lockout the DynaYieldTM Conditioner and Hydraulic Unit.

Gain access in the discharge area of the unit, and arrange internal scaffolding or
platforms 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. Take
all safety precautions to prevent entry into the nip area.
-

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

Adjust the remaining scrapers as per the previous instructions.

Figure 11
-

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

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F.6.d. Roll Segment Replacement
-

See Figures #12 and #13 for reference.

Lockout the DynaYieldTM Conditioner and Hydraulic Unit.

The roll segments for the DynaYield Chip Conditioner are made of 12" wide x 90
degree segments, which are attached with 12 bolts per segment. Two of the holes
in the segments also have threaded holes below where the head of the bolt is
located, and allows for lifting eye to be threaded into the segment. The weight of
each segment is approx. 100#.

TM

! WARNING
This equipment can cause severe personal injury if a limb
is wedged into the nip between the heavy conditioner
rolls when rotated, even by hand.
Take all safety
precautions to prevent entry into nip area.

Figure 12
-

Remove the top covers on both sides of the conditioner, and fully inspect the roll
segments.

Using a pick, clean out the wood debris from the internal hex socket of the bolts to
be removed. Alternately, a heating torch can be used to burn off the pitch and
wood debris from the hex socket and from around the head of each bolt.

If the head of bolt is not worn too badly, the bolt may be removed with a 1/2" Allen
head socket wrench. However, in most cases the easiest method of removal will
be to weld a 3/4" hex nut to the head of the bolt in the segment. The heat used to
weld the nut in place will have the added benefit of melting the Loctite used to
secure the bolt in place. Loosen, but do not remove all the bolts for the segment to
be removed.

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! 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 fixing
the 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. Attach
a 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 of
the machine. Do not remove more than one segment at a time. This allows each
new segment to be positioned properly relative to the segments already on the roll.
If it is necessary to remove all segments from a roll, follow all instructions on the roll
assembly drawings during the installation of the new segments.

Figure 13
-

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. If
the Helicoil requires replacement, remove the old insert, clean the threads in the roll
as much as possible, then install the new Helicoil with Loctite Red 271.

VERY IMPORTANT : Check and remove any burrs on the ring segment on the
inside 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

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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 install
new bolts several threads into the helicoiled holes in the drum.
VERY IMPORTANT : After the bolts are partially installed, ensure that the
shank 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 Helicoil
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, and
either 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 with
Loctite Red 271. The bolts can be run into the Helicoil using an air wrench with the
air turned set low, until the head engages the counterbore in the segment. Do not
use an air wrench to apply any more than 75 ft-lbs to the head of the bolt, as this
can case damage to the internal socket recess. After all bolts are in place, torque
first to 100 ft-lbs, then to 350 ft-lbs. Bolts are of a special fatigue resistant design,
produced exclusively for Rader conditioners. Use only the approved Rader bolt to
fasten the segment to the roll.

Replace any other roll segments in the same manner as described above. After all
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 adjust
as required..

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

Replace all guards and covers, remove the conditioner Lockout, and start the
conditioner without material. Insure everything is operating correctly before running
the 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
TM
position. Lockout the DynaYield Conditioner and Hydraulic Unit.

Remove the covers and guards from the conditioner, in the area around the cylinder
to be removed. If the cylinder on the drive end of the machine is to be replaced,
consideration should be given to removing the motor and motor base to give better
access.

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-

Carefully remove the infeed support plate from the frame to expose the hydraulic
cylinder and manifold.

Remove the bolts from the safety coupler to the dynamic bearing housing, and
remove 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 below
the hose entry ports on the manifold on the exterior of the conditioner, to catch any
remaining fluid from the cylinders before removal.

Figure 14
-

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

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

Reassembly is the reverse order of disassembly. Make sure to purge any air out of
the hydraulic system during start-up by cycling the dynamic roll several times to its
extremes. Replace all guards and covers, remove the conditioner Lockout, and
operate the hydraulic system to ensure that no binding is occurring in the spherical
load washer area, and no hydraulic leaks are observed. Conditioner is now ready
to be put back into operation.

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F.6.f. Drive Reducer Replacement
The Rader Conditioner uses standard off-the-shelf Falk gearboxes for the drive speed
reduction from the motors. These gearboxes have two modifications that are performed
in the manufacturing shop before assembly on the Conditioner. Make sure to modify any
spare 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 for
centralized grease system.
Torque arm hole is reamed to 1.752-1.755 diameter, to fit the torque arm
and pins on the torque arm bracket.

To replace the drive reducers, use the following instructions:


-

See Figure #15 for reference.

Lockout the DynaYield

Remove the covers and guards from the conditioner, in the area around the drive to
be removed.

If adequate lifting capacity is available, the motor, drive, and reducer can be
removed from the conditioner as a unit, this is especially useful when the
motor/reducer is removed to gain access for another maintenance operation.
Otherwise, remove the V-Belt drive from the reducer and motor, and remove the
drive 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 is
given on the Parts List drawing.

TM

Conditioner and Hydraulic Unit.

Figure 15
-

Disconnect the torque arm from the reducer.

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

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- Reassembly is the reverse order of disassembly. Follow all instructions in the
Falk Reducer Appendix when installing the reducer back onto the shaft. The
following 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 the
shaft, to make sure the threads of the gearbox are not damaged. Remove the
bushing, then install the bushing on the shaft without any oil or anti-seize
compounds between the shaft and the bushing. A light coating of oil may be
applied to the hollow shaft in the gearbox, and onto the threads of the taper
bushing.
- On 4507 gearboxes (4 and 6 Conditioners), the key supplied by Falk is not
square. It is 1.250 wide x about 1.225 tall. Make sure that the key fits properly
into the 1.25 wide keyway in the conditioner shaft.
- Make sure to line up the gearbox axially on the conditioner shaft with the torque
arm brackets located below the reducer.
- The gearbox/bushing must be properly torqued to 4000 lb-in (333 lb-ft) onto the
shaft per Falks recommendation. There are two methods given in the Falk
Appendix, Rader sometimes uses a third method where the bushing is held
stationary, and the input shaft of the gearbox is torqued to 13.3 lb-ft, using the
25:1 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
TM
position. Lockout the DynaYield Conditioner and Hydraulic Unit.

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

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

If the bearing to be removed is on the dynamic roll, remove the bolts holding the
safety coupler to the dynamic bearing housing, and remove both halves. Remove
the spherical load washer and polyurethane strip. Remove the bolts holding the
bearing retainers to the frame on both sides of the dynamic bearing housing, then
remove the bearing retainers.

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

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Figure 16
-

Using a hoist or chain fall, rig the conditioning roll bearing housing for removal from
the frame. The lifting device must be capable of lifting at least half the estimated
weight of the roll assembly w/ bearings, listed on the roll assembly drawings. Lift
only the one loose end of the conditioning roll upward approx. 1/8" to gain clearance
to 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 the
bearing 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 seal,
then remove the bolts holding the outer bearing retainer, then remove the retainer.
If 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 seal
back as far onto the radius as possible, then remove the bolts holding the inner
bearing retainer and pry loose from the bearing housing.

Carefully slide the bearing housing over the bearing assembly, taking care that the
housing 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 of
excessive wear. Carefully measure the distance from the bearing inner race to the
end of the shaft, or some other reference point, and record. During the installation
of the new bearing, the location of the new bearing must be as close as possible to
that of the bearing removed, otherwise the two conditioning rolls may not align
properly when reinstalled. See Figure #17.

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Figure 17
-

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

Reassembly is the opposite of removal. Follow all instructions in the SKF Pillow
Block Bearing Appendix. During the installation of the new bearing, the following
points are important:

Every bearing comes with assembly instructions. Please read and follow this
information before beginning. Work in as clean an area as possible.
Measure the unmounted clearance in the bearing.

Unmounted Clearance:
For Models 20 & 40For Models 60 & 80-

Normal Clearance
.0055 to .0079
.0071 to .0098

C3 Clearance
.0079 to .0102
.0098 to .0126

When installing the tapered adapter onto the conditioner shaft, make sure there is
no 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 axial
movement in the shaft, and possible damage to the interlacing roll segments
on the conditioner rolls.

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

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-

Install the bearing onto the tapered adapter, and install the locknut (no lockwasher).
Tighten the bearing locknut, keeping the weight off the bearing during tightening.
Check for total reduction in clearance of the bearing as follows:
Reduction in Unmounted Clearance:
For Models 20 & 40.0032 to .0043 clearance reduction
For Models 60 & 80.0039 to .0055 clearance reduction
SKF recommends the middle to high range of clearance reduction. Minimum
permissible clearance in the bearing after installation is .0024 on the Model 20 and
40, and .0032 on the Model 60 and 80.

Remove the locknut, and install the lockwasher. Reinstall the nut, fully tighten
against the lockwasher and bearing. Install the lockwasher tab into the slots on the
locknut.

Using a nozzle, inject grease into all internal cavities of the bearing rolling elements.
The machined housing cavity should be filled 1/3 to 1/2 full, and all internal metal
surfaces of the housing coated with grease to help prevent internal rusting.

During reassembly, note that bearing retainers are different for each general
location in the machine. Reinstall each bearing retainer only from its original
location. The fixed bearings are those located at the idler end of the unit. Pack
bearings with clean grease before installation of the bearing housing.
If the dynamic roll has been worked on, reinstall the dynamic roll slide retainers on
either side of the bearing housing with between .005" to .010 clearance between the
bearing housing and the retainers.

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

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

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TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004
F.7.

Bolt Torque Specifications

TM

During the course of maintenance on the DynaYield Chip Conditioner, it is very important to
torque all bolted fasteners to the proper levels to avoid loosening in service. All replacement bolts
must 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
5/16-18 UNC
3/8-16 UNC
7/16-14 UNC
1/2-13 UNC
5/8-11 UNC
3/4-10 UNC
7/8- 9 UNC
1- 8 UNC
1 1/4- 7 UNC
1 1/2- 6 UNC

4 ft-lb
8 ft-lb
15 ft-lb
24 ft-lb
35 ft-lb
75 ft-lb
130 ft-lb
125 ft-lb
190 ft-lb
-

6 ft-lb
13 ft-lb
23 ft-lb
35 ft-lb
55 ft-lb
110 ft-lb
200 ft-lb
320 ft-lb
480 ft-lb
-

9 ft-lb
18 ft-lb
35 ft-lb
55 ft-lb
80 ft-lb
170 ft-lb
280 ft-lb
460 ft-lb
680 ft-lb
800 ft-lb
1000 ft-lb

1- 12 UNF
1- 14 UNF
1 1/8- 12 UNF
1 1/4- 12 UNF

740 ft-lbs
760 ft-lbs
1080 ft-lbs
1500 ft-lb

All fasteners (with the exception of roll segment bolts) should be coated with Loctite Blue 242
before assembly, per the manufacturer instructions.
The bolts used to attach the roll segments to the rolls are of a special design, produced for Rader.
These fasteners should be coated with Loctite Red 271, and torqued to 350 ft-lbs per the
instructions 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.

Special Tools

TM

In working on the Rader DynaYield Chip 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 roll
segments. 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 socket
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.

2004 Rader Companies, Inc.

Page 38

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

G.

Recommended Spare Parts


The following items are recommended spare parts that should be kept on hand at all times. The complete
callout for the following items can be found in the General Arrangement and Parts List drawings for this
job, and are included as part of this manual. This includes necessary ordering information, including
Rader drawing numbers (part numbers) that are required to fill orders. When ordering spares, it is helpful
TM
to have the original Rader Job Number and DynaYield Chip Conditioner Model Number from the metal
TM
Rader nameplate located on the DynaYield Conditioner frame.
TM

Many of the parts of the DynaYield Chip Conditioner are made special for Rader, using special
tolerances and materials. Contact your Rader product representative for all replacement parts.

Quantity

Description

Electric Motor (Conditioner Drive Motors)

Fluid Coupling (only if optional fluid couplings are installed)

Falk Shaft Mount Reducer w/ grease zerk and torque arm


modifications per Section F.6.f.

1 Set

V-Belts

Spherical Bearings w/ Tapered Adapters, Lockwashers, and


Locknuts

Forsheda V-Ring Seals

Proximity Sensors

1 Set

Roll Segments

1 Set

Roll Segment Bolts

20

Helicoils for Roll Assembly

1 Set

Roll Scrapers

Electric Motor (Hydraulic Power Unit)

Piston Pump (Hydraulic System)

Control Valve (Hydraulic System)

Hydraulic Fluid Filter (Hydraulic System)

Breather (Hydraulic System)

Cylinder Pressure Relief Valve (Vickers CG Model)

Hydraulic Cylinder

2004 Rader Companies, Inc.

Page 39

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

2004 Rader Companies, Inc.

Page 40

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Optional Distributing Screw Appendix

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Optional Fluid Coupling Appendix

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Falk Reducer Appendix

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Spherical Bearing Appendix

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Proximity Sensing Appendix

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Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Speed Sensing Appendix:


On standard pieces of Rader equipment, an inductive, 18mm tubular proximity sensor is used for a speed
switch. The "Efector" proximity sensor is mounted adjacent to the last rotating shaft on a driven machine.
The sensor is located in such a way that as the shaft turns, the keyway or a flag attached to the shaft will
pass 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 proprietary
equipment.
Fail-safe dependability, because the sensor is relaying a pulse (on/off transition) for each
revolution 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 be
necessary to use two timers in the control system. This can be best explained with the generic ladder
logic shown below.

If the equipment is to be installed into a hardwired control system, or the control system is slow
(sometimes the case in large distributive controls), it will be necessary to convert the pulsing (on/off) signal
from the inductive proximity sensor into a steady state N.O. or N.C. type of input. When this is necessary,
Rader can supply a relay to perform this task. This relay is mounted in a weatherproof enclosure and is
typically located somewhere on the equipment. The relay used by Rader is manufactured by "Industrial
Solid State Controls, Inc" or ISSC, and is part number ISSC 1260-1-G-C. A product specification sheet
and wiring schematic to indicate the proper method of wiring this relay and the inductive sensor is shown
on the attached pages.

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

TM

Rader DynaYield II Equipment Manual


Manual Number 073-2
Oct 2004

Hydraulic Power Unit Appendix

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