Thoroughbred
Installation Manual DC-Colt
Copyright © 2013
THOROUGHBRED & DC-COLT
TABLE OF CONTENTS
SECTION 1: INTRODUCTION Preface.................................................................................................................... 1 Manual Layout......................................................................................................... 1 Safety & Warning Placards...................................................................................... 1 Safety & Warning Placard Location Diagram........................................................... 2
SECTION 2: PLANNING THE INSTALLATION Preparations and Considerations............................................................................. 3
SECTION 3: BOLTED CONNECTIONS Bolt Tightening Requirements.................................................................................. 5 Turn-of-Nut Pre-tensioning Method.......................................................................... 5 Snug-Tightened Joints............................................................................................. 5 Correction of Errors................................................................................................. 6
SECTION 4: INSTALLATION Prepare for Installation............................................................................................. 7 Placing Plant on Extension Legs.............................................................................. 9 Silo or Cement Batcher Installation........................................................................ 10 Cement Silo Setup..................................................................................................11 Cement Batcher Setup............................................................................................11 Silo Installation (If silo is shipped loose)................................................................ 12 Thoroughbred AGG Bins........................................................................................ 13 Connect Aggregate Bins........................................................................................ 15 Set Up Aggregate Batcher..................................................................................... 15 Connect Electrical Panel........................................................................................ 16 Set-Up Air Compressor.......................................................................................... 17 Set-Up Transfer Conveyor..................................................................................... 18 Set-Up Silo Ladders and Cages............................................................................. 19 Set-Up Water Meter............................................................................................... 19 Service Records.................................................................................................... 20
SECTION 5: CONTACT INFORMATION STEPHENS MFG................................................................................................... 21
REV: A 12-19-12
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 3
THOROUGHBRED & DC-COLT
SECTION
THOROUGHBRED & DC-COLT
SECTION 1: INTRODUCTION
Preface This manual provides setup and installation instructions for the Thoroughbred and DC-Colt portable plants for gravity drop cement. Cement is gravity fed from silo to batcher, then, batcher to truck. The Thoroughbred plant is pre-wired in conduit and the pneumatic lines are pre-plumbed. The main disconnect and plant power panel are enclosed in a steel cabinet with hinged, lockable steel doors, positioned to face away from the transfer conveyor for cleaner, safer operation. The plant air compressor is located on the plant’s tongue above the 5th wheel, away from the transfer conveyor for a cleaner and safer operation.
Manual Layout Refer to the manual, images and content to assist with proper setup and installation of the Thoroughbred and DC-Colt plants. Throughout the manual, safety notices provide help for a successful and safe installation of the plant. Typical safety notices are defined below:
NOTICE
Highlights information that is of special importance.
CAUTION
Draws attention to anything that could damage the equipment or adversely affect the installation of the unit.
WARNING
Draws special attention to anything that could cause injury or death.
Safety & Warning Placards The unit and optional attachments are clearly marked with safety and warning signs, placards, as a reminder to observe safe installation and operating procedures. Read the instructions and become familiar with the safety and warning placards. Failure to observe safety and warning placard instructions can result in serious injury to workers or damage to property. Always replace worn or missing safety and warning placards. See the Placard Location Diagram for sign location on page 2, and contact Stephens Manufacturing to order replacement placards.
REV: A 12-19-12 4
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 1
SECTION 1: SAFETY & WARNING PLACARDS
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 2: PLANNING THE INSTALLATION
Preparations and Considerations Safety & Warning Placard Location Diagram
This is a typical set of instructions for a standard Stephens’ Thoroughbred or DC-Colt. Please consult the factory if your plant has any optional equipment not shown in this manual. This manual applies only to standard Stephens Thoroughbred and DC-Colt equipment.
NOTICE 1
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Your plant may have some unique or special options that might require some additional details or instructions. Stephens may provide instructions that supplement or supersede this manual at any time for standard or non-standard equipment. Owner, operator is responsible to ensure the unit installation complies with all applicable local laws, regulations and codes, and to obtain all necessary permits, inspections and approvals. Stephens makes no representation or warranty that installation according to these instructions will comply with any such local requirements. In the event of a conflict between this manual or any other instructions provided by Stephens and local requirements, contact Stephens.
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For supervision during installation and further unit operation training, contact Stephens MFG. It is the owners responsibility to meet local and federal government guidelines and codes, to include acquiring registered engineer design documents for footings, anchor bolts, shims and grout to complete the installation and operation of the plant.
NOTICE
If your equipment has additional options, or the place where it will be installed differs from standard in any way, contact Stephens for additional instructions.
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ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13
REV: A 12-19-12 2
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10 11
DESCRIPTION
Caution, LockOut - Decal Caution, Live Circuit - Decal Caution, Batch Plant Disconnect - Decal Caution, Check Lubrication - Decal 480 Volt, Three Phase - Decal 120 Volt, Single Phase - Decal Danger, High Voltage - Decal Warning, Arc Flash & Shock Hazard - Decal Caution, Not Suitable Work Platform - Decal CPMB - Decal Serial Number - Plate Remove Scale Bracket - Decal Conveyor Guard - Decal
The manufacturer warranty does not apply to plants that have not been properly installed, operated or maintained according to Stephens’ drawings, specification, instructions or manuals. During installation, if a contradiction between any said documents and the customer engineered design plans becomes apparent, stop the installation and contact a Stephens representative.
QTY
The owner is responsible to coordinate (hire) certified crane services to unload and erect the plant. It is the owners responsibility to arrange utilities, water and electrical services to the proposed plant site. The customer must enlist a certified scale servicemen, before plant operation, to calibrate and certify scale systems.
7 1 1 3 2 2 2 2 3 1 1 9 2
WARNING
Failure to install equipment according to the instructions of Stephens or any other manufacturer can cause injury or death.
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 3
SECTION 2: PLANNING THE INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 3: BOLTED CONNECTIONS
Bolt Tightening Requirements SECTION 3: BOLTED CONNECTIONS
Unless noted otherwise, all structural connections using 5/8 inch diameter or larger bolts shall be installed as pre-tensioned joints without washers. Smaller bolts or joints, as designated may be installed to a snug-tight condition.
CAUTION
Use the “Turn-of-Nut” method for tightening all structural connections that require 5/8 inch diameter or larger bolts. See detailed explanation of the “Turn-of-Nut” method when tightening structural connections.
NOTICE
Stephens Engineers only recommend minimum size anchor bolts.
Turn-of-Nut Pre-tensioning Method All bolts shall first be installed to a snug-tight condition. Subsequently, the nut or head rotation specified in Table 1 shall be applied to all fastener assemblies in the joint, progressing systematically from the most rigid part of the joint in a manner that will minimize relaxation of previously pre-tensioned bolts. The part not turned by the wrench shall be prevented from rotating during this operation.
CAUTION
Use the “Snug Tight” method for tightening all smaller bolts or joints as designated. Additionally, this method is used for anchoring the plant to the concrete foundation. See detailed explanation of the “Snug Tight” method when tightening these various connections.
Snug-Tightened Joints All bolt holes shall be aligned to permit insertion of the bolts without undue damage to the threads. Bolts shall be placed in all holes with nuts threaded to complete the assembly. Compacting the joint to the snugtight condition shall progress systematically from the most rigid part of the joint. The snug-tightened condition is the tightness that is attained with a few impacts of an impact wrench or the full effort of an ironworker using an ordinary spur wrench to bring the connected piles into firm contact. More than one cycle through the bolt pattern may be required to achieve the snug-tightened joint. Disposition of Outer Face of Bolted Parts Bolt Lengthc
Both faces normal to bolt axis
One face normal to bolt axis, other sloped not more than 1:20d
Both faces sloped not more than 1:20 from normal to bolt axisd
Not more than 4db
1/3 turn
1/2 turn
2/3 turn
Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For required nut rotations of 1/2 turn and less, the tolerance is plus or minus 30 degrees; for required nut rotations of 2/3 turn and more, the tolerance is plus or minus 45 degrees. Applicable only to joints where all material within the grip is steel. When the bolt length exceeds 12db, the required nut rotation shall be determined by actual testing in a suitable tension calibrator that simulates the conditions of solidly fitting steel. Beveled washer not used. Table 1 - Nut Rotation from Snug-Tight Condition and Turn-of-Nut Pretension,b REV: A 12-19-12 4
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 5
SECTION 4: INSTALLATION
SECTION: BOLTED CONNECTIONS
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Correction of Errors
Prepare for Installation
Normal erection operations include the correction of minor misfits by moderate amounts of reaming, chipping, welding or cutting, to align elements through the use of drift pins. Refer to AISC Code of Standard Practices for Steel Buildings and Bridges.
Prepare for installation and setup of your plant. Begin by positioning the plant adjacent to the concrete piers and then proceed with the steps as indicated below.
NOTICE
Place the “Stephens Thoroughbred or DC-Colt” as close to the concrete piers as possible to reduce crane time erecting of the plant on its piers.
Figure 1: DC-Colt
Figure 2: Thoroughbred w/ silo shipped loose
WARNING
Maintain safe clearance from power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment. REV: A 12-19-12 6
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 7
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Placing Plant on Extension Legs Use 7/8” x 2-1/2” Bolts* at column connections. Use 7/8” x 2” Bolts* at bracing.
1. Prepare for lifting the plant onto the extension legs. Hook the crane cables to the lifting eyes/lugs and/or at stable braced areas as shown above. 2. Align plant with the top of the lower extension legs (already fastened to concrete piers). While plant is suspended, bolt connection plates together with applicable bolts.
WARNING
Use only certified lifting chain for crane lifting assignments as broken attachments can cause serious injury or death.
Figure 3: Thoroughbred with silo attached
1. Bolt the six (6) bottom extension legs to the concrete piers, refer to Figure 4. (hand tighten only) 2. Bolt the cross bracing (hand tighten only). The minimum size anchor bolts are listed in the base plate layout prints, per Stephens Engineer Recommendations. Stephens supplies bolts for connection plates and leg support braces with the unit. 3. Refer to prints for approximate weight specifications of equipment. It is recommended that you use an oversized crane to eliminate any unnecessary lifts and moves with the smaller cranes. Contact factory for exact weights. 4. Axles can be returned for credit. Remove axles assemblies before the plant is raised. With proper support for the axles, loosen all the bolts that hold the axles to the transportation frame. If the axles, tires, wheels and brake air tank are in good working order they can be returned to the factory for credit. Customer is responsible for delivery freight to factory in Tompkinsville, KY.
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Figure 5: Sketch Shows Thoroughbred
WARNING 2
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Maintain safe clearance of power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment.
2
Figure 4: Lifting Diagram
*Bolt size/length increases for some seismic plants, consult factory. REV: A 12-19-12 8
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 9
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Silo or Cement Batcher Installation
Cement Silo Setup
1. Set crane position to hinge the silo or cement batcher section into the up position.
Customer will need to use the job specific electrical prints to properly connect wires, bindicators, and vents. Always use proper lock-out/tag-out procedures before working on electrical system, customer may also have to connect some pneumatic components. See specific customer prints for more details.
2. Remove the bolts from the bottom section of silo legs from the travel position. 3. Position the crane for lifting the silo in place. Use of a spreader bar/beam may be desirable to connect cables to outside lifting lugs of silo.
WARNING Danger, 120 volt, single phase.
4. With the crane, slowly raise the silo frame and/or silo up into position. 5. While silo frame is suspended by crane, bolt legs to foundation and connection plates (hand tighten only). 6. Install all applicable braces between silo legs (hand tighten only).
CAUTION
Disconnect power and “Lock-Out” before servicing.
WARNING
Use only certified lifting chain for crane lifting assignments as broken attachments can cause serious injury or death.
CAUTION
More than one live circuit.
Column Connections use 7/8” x 2-1/2” Bolts*
Cement Batcher Setup
Bracing uses 7/8” x 2” Bolts*
Normally all electrical and pneumatic items will be wired and connected to the cement batcher. The customer will be responsible to remove all shipping brackets before operation the plant. The work platform around the cement batcher is an optional item; caution will need to be taken while removing brackets.
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CAUTION
Disconnect power and “Lock-Out” before servicing.
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6 Figure 6: Thoroughbred with silo loose.
WARNING
Maintain safe clearance of power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment.
Figure 7: Thoroughbred and/or DC-Colt with silo attached
*Bolt size/length increases for some seismic plants, consult factory REV: A 12-19-12 10
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 11
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Silo Installation (If silo is shipped loose)
Thoroughbred AGG Bins
1. While silo is lying on the ground, install ladders, cages, platforms, etc., included in the order of this plant. Use a 12’-0” spreader bar to pick silo up (spread bar to clear handrails and any vents).
1. Install the middle aggregate partitions. (If bins are welded up type skip no. 1 thru no. 3 of this section.)
2. Lift the silo onto the connection plates as shown in Figure 8.
3. Install the two side partitions.
3. Install cement batcher scale bolts and safety chains prior to un-securing cement weight batcher. (Weight batcher is secured during shipping.)
2. Install the two outside partitions.
Column Connections use 7/8” x 2-1/2” Bolts* Bolt up heap plates 7/8” x 2” Bolts Bolt up Bins 7/8” x 2” Bolts
4. Now go back and tighten all bolts on the cement section by using the “Turn of Nut” method. Refer to Section 3, page 5 for bolt torque table and guidelines. 1
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3
Figure 9: Lifting Diagram
2
CAUTION
Disconnect power and “Lock-Out” before servicing.
3
WARNING
Maintain safe clearance from power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment.
Figure 8: Thoroughbred with silo shipped loose
WARNING
Use only certified lifting chain for crane lifting assignments as broken attachments can cause serious injury or death.
CAUTION
Disconnect power and “Lock-Out” before servicing. REV: A 12-19-12 12
*Bolt size/length increases for some seismic plants, consult factory
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 13
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Connect Aggregate Bins Use the specific electrical customer prints to determine if your plant has any special bin level indicators or vibrators for the aggregate bins. Stephens will normally ship the necessary air cylinders for the aggregate bin gates, strapped to the horizontal beam above the aggregate batcher. Customer should remove the cylinders from the beam and install them on the overhead bin gates. 6 4
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Figure 11: AGG Bin
NOTICE
DC-Colt will not have overhead bins.
CAUTION
Figure 10: Lifting Diagram
Disconnect power and “Lock-Out” before servicing.
4. Lift the bin and cone up and install four stub legs. 5. Set the bin and cone back on top of aggregate frame and install angle leg braces.
WARNING
6. If bins are welded up type, set them on top of cone section.
Maintain safe clearance from power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment.
7. Now go back and tighten all bolts on the aggregate section by using the “Turn of Nut” method.
WARNING
Set Up Aggregate Batcher
Use only certified lifting chain for crane lifting assignments as broken attachments can cause serious injury or death.
All electrical and pneumatic items should be connected to the batcher. Customers will have to remove shipping brackets to allow Aggregate Batcher to swing freely.
WARNING
Maintain safe clearance from power and overhead lines when orientating the unit for transfer and erection. Contact with overhead lines could cause serious injury, death, and/or damage to equipment.
Figure 12: AGG Bin Shipping Bracket REV: A 12-19-12 14
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 15
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Connect Electrical Panel
Set-Up Air Compressor
Stephens will normally supply a main disconnect with each new plant. Unless specified otherwise the size disconnect and all starters will only cover items supplied by Stephens Mfg. The customer will need a certified electrician to use the job specific electrical plans to connect main voltage and test/ operate the new plant. Consult the factory if additional prints are required. Follow all safety labels and always use the proper lock-out/tag-out procedures for service and maintenance.
Compressor is normally shipped on the tongue of the plant, away from moving parts. Unless optional work platform is selected at purchase, the tongue area is not to be a work platform area and caution should be taken. To start up compressor use the manufacturers start up instructions located in the maintenance manual, and double check fluid levels and rotation.
WARNING
Danger, 480 volt circuit.
WARNING
Danger, high voltage!
CAUTION
Check lubricant levels in all gear reducers prior to start up.
Figure 13: Electrical Panel
Figure 14: Electrical Panel
WARNING
Danger, 120 and 480 volt circuits.
WARNING
Danger, high voltage!
WARNING
Arc flash, electrical shock hazard. Appropriate PPE and tools required when working on this equipment. Figure 15: Unit Tongue Platform Caution Placard
CAUTION
Batch Plant Disconnect
CAUTION
More than one live circuit.
CAUTION
Disconnect power and “Lock-Out” before servicing.
CAUTION
Check lubricant levels in all gear reducers prior to start up.
REV: A 12-19-12 16
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 17
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 4: INSTALLATION
Set-Up Silo Ladders and Cages Customer will need to look at specific customer prints to determine the number of cage sections, their locations and the locations of rest stops.
Ladders, cages, and platforms are unit specific. Verify unit plans to determine quantities and location of included equipment.
Figure 16: Conveyor Guard
WARNING
Danger, 480 volt circuit.
CAUTION
Disconnect power and “Lock-Out” before servicing.
CAUTION
Check lubricant levels in all gear reducers prior to start up.
CAUTION
More than one live circuit.
Set-Up Transfer Conveyor The transfer conveyor is normally already pre-wired at the factory and run for conveyor tracking purposes. The customer should bolt the collection hopper to the frame of the conveyor. The customer should check fluid level in reducer. The customer should double check the rotation and accuracy of the belt tracking. The conveyor belt should be tightened after initial use. (3-4 weeks after start up) Always use proper lock-out/ tag-out procedures before performing service or maintenance on conveyor.
REV: A 12-19-12 18
Figure 17: Conveyor Guard
Set-Up Water Meter The water meter normally travels with the Thoroughbred and Colt plants. The customer will need to connect the water line/hose to the truck collection hopper.
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 19
SECTION 4: INSTALLATION
THOROUGHBRED & DC-COLT
THOROUGHBRED & DC-COLT
SECTION 5: CONTACT INFORMATION
Service Records SERVICE PERFORMED
DATE
INITIALS
STEPHENS MFG. PO. BOX 488 TOMPKINSVILLE , KY 42167 PHONE: 800-626-0200
OUTSIDE the USA: 270-487-6774 FAX: 270-487-8368
Proud Member of:
REV: A 12-19-12 20
STEPHENS MFG. PO. BOX 488
STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
Copyright © 2013
Copyright © 2013
PHONE 800-626-0200
REV: A 12-19-12 21
