Big Dutchman Dry Rapid DR 1500 Service manual

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

CE:
EC declaration of conformity
as defined by the following EC directives
machinery
2006/421EC
electromagnetic compatibility 2004/1 08/EC
low voltage 2006/95/EC
Make:Dry feeding system
Type: Dry Rapid DR1500
System no. and year of construction: see customer order no.
has been designed, constructed and manufactured in compliance with the above-
mentioned EC directives; under the sole responsibility of
~8i4 Dutehman
Big Dutchman Pig Equipment GmbH
P.O. Box 1163 D-49360 Vechta Germany
Tel.[phone]
Fax [phone]
E-Mail: [email protected]
The following harmonised standards apply:
DIN EN ISO 12100-1 and 12100-2 (2004-04): safety of machinery -basic concepts,
general principles for design
DIN EN ISO 13850 (2008-09): safety of machinery - emergency stop equipment-
principles for design
DIN EN 60204-1 (2007-06): safety of machinery - electrical equipment of
machines, part 1:general requirements
Authorised person for technical documents: Productmanager "Dry feeding"
Auf der Lage 2; 49377 Vechta

Table of contents Page I
DR 1500
Edition: 08/10 M 4021 GB
1 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Explaining the symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Safety symbols in the manual and on the installation . . . . . . . . . . . . . . . . . . . . . 2
1.3.3 Warnings and safety instructions on your installation . . . . . . . . . . . . . . . . . . . . . 2
1.4 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Disorders due to power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8 First aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Pollution abatement regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.10 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.11 Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.12 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Safety instructions when operating electrical appliances . . . . . . . . . . . . . . . 7
2.3 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.2 Danger signs on the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Specific safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.1 Clothing for personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.2 Assembly and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.3 Employing external personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Safety contrivances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1 In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 Safety contrivances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.3 Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Dangers resulting from the non-compliance with the safety instructions . 13
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Limit values for dry feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.2 Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Assembly and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Outline of the entire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Page II
DR 1500
Edition: 08/10 M 4021 GB
5 Planning and preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2 Planification of the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.3 Planification of the feed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.4 Planification of the feed discharge points . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.5 Planification of the feed supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.6 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
7 Preparatory measures and technical requirements before the 
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.1 Notes for mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.2 Explanation on the lay-out of the assembly instructions . . . . . . . . . . . . . . .29
7.3 Before starting to assemble the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7.4 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7.5 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7.6 Placing the dowels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.6.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.6.2 Assembly order for dowelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.7 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.7.1 Sealing with sealing tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.7.2 Sealing with silicone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7.8 Glueing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
8 Feed supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.1 Silo extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.2 Transfer FlexVey to Dry Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.3 Connecting the feed supply with the feed hopper . . . . . . . . . . . . . . . . . . . . .36
8.3.1 Connection with shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
8.3.2 Adapter with shutter SST cpl. for sack-silo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
8.3.3 Adapter with shutter galvanized cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
8.3.4 Y-tube cpl for feed hopper RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
8.4 Feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.4.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.4.2 Hopper 1line cplt. SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
8.4.3 Hopper 2line cplt. SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
8.5 Feed hopper with forced insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.5.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.5.2 24V single-channel feed hopper with forced insertion . . . . . . . . . . . . . . . . . . . . .44
8.5.3 Single channel feed hopper 0,37 kW with forced insertion . . . . . . . . . . . . . . . . .47
8.5.4 2-channel 24V feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Page III
DR 1500
Edition: 08/10 M 4021 GB
8.6 Feed hopper RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.6.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.6.2 Feed hopper RAS 1line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.6.3 Feed hopper RAS 1line with recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.7.1 Foot fully threaded M12x165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8 Dosimeter for small quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.8.2 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.1 Assembly and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.2 Driving modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.2.1 Drive DR1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.2.2 Drive DR1500 - XXL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4.1 Wall fastening for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4.2 Floor rack galv. cplt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.4.3 Foot fully threaded M12x165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.4.4 Foot adjustable M12x200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.4.5 Covering SST cplt. for motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.4.6 Tensioning device cpl. for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10 Feed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.1 Tube-unit with conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.2 Control segment and flat steel reinforcement . . . . . . . . . . . . . . . . . . . . . . . . 76
10.2.1 Control segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.2.2 Flat steel reinforcement cpl. for control segment . . . . . . . . . . . . . . . . . . . . . . . . 77
10.3 Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.3.1 Corner 90deg PA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.3.2 Corner 90deg SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.4 Tube supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.4.1 Support 1" x1750 cpl. for 1 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.4.2 Extension 1" cpl. for second pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10.4.3 Double pipe clamps complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.4.4 Pipe clamp B 32/60 cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.5 Wall fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.5.1 Wall bracket for 2 tubes with tube clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.5.2 Wall fastening 150 mm for 1 pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10.5.3 Wall bracket 400 mm for 2 pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.5.4 Angle rail cpl. for central aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.6 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.7 Recommended assembly order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.7.1 Laying out the feed line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.7.2 Assembly of the feed discharge points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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DR 1500
Edition: 08/10 M 4021 GB
10.7.3 Inserting of the conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
11 Feed discharge points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
11.1 Weepholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
11.2 Draw-Offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
11.2.1 Outlet MI cpl. and drop pipe telescopic for outlet MI . . . . . . . . . . . . . . . . . . . . .101
11.2.2 Outlet with cable actuation DR1500 and drop pipe telescopic . . . . . . . . . . . . .102
11.3 Volume dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
11.3.1 Volume dispenser BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
11.3.2 Volume dispenser TI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
11.4 Drop pipes for volume dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
11.4.1 Drop-pipe cpl. for volume dispenser BR/TI . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
11.4.2 Drop-pipe cpl. s-shaped for volume dispenser TI . . . . . . . . . . . . . . . . . . . . . . .110
11.4.3 Drop-pipe for volume dispenser BR/TI at crate stand . . . . . . . . . . . . . . . . . . . .111
11.4.4 Drop pipe DR-BR cpl. HT Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
11.4.5 Drop pipe DR-BR cpl. HT Garthe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
11.4.6 Drop pipe 75 cpl. straight at crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
11.4.7 Drop pipe 75 cpl. straight for farrowing crate . . . . . . . . . . . . . . . . . . . . . . . . . .116
11.4.8 Drop pipe 75 cpl. elbowed at crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
11.4.9 Drop pipe 75 cpl. elbowed for farrowing crate . . . . . . . . . . . . . . . . . . . . . . . . . .120
11.5 Protection pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
11.5.1 Protection pipe SST cpl for trough built in the wall . . . . . . . . . . . . . . . . . . . . . .123
11.5.2 Protection pipe SST cpl. at wall or partition PVC . . . . . . . . . . . . . . . . . . . . . . .124
11.5.3 Protection pipe SST cpl for trough built in the wall . . . . . . . . . . . . . . . . . . . . . .125
11.5.4 Protection pipe galv cpl. standard tiltable / concrete trough . . . . . . . . . . . . . . .126
11.5.5 Protection pipe galv cpl. Garthe tiltable / standard & standard stand . . . . . . . .126
11.6 Recommended assembly order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
12 Release for volume dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
12.1 General component parts for the release . . . . . . . . . . . . . . . . . . . . . . . . . . .128
12.1.1 Release ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
12.1.2 Guidance for release rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
12.1.3 Guide wheel at corner cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
12.1.4 Tension spring with accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
12.1.5 Idler roller 107mm cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
12.1.6 Idler roller 105mm cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
12.1.7 Alternative idler rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
12.2 Release with cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
12.2.1 Assembly and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
12.2.2 Release with wall-mounted cable winch cpl. . . . . . . . . . . . . . . . . . . . . . . . . . . .134
12.2.3 Safety regulations for the cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
12.3 Automatic release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
12.3.1 Assembly and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
12.3.2 Automatic release with winch motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
12.3.3 Winch motor incl. limit stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
12.3.4 Assembly of the winch motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
12.4 Recommended assembly order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Page V
DR 1500
Edition: 08/10 M 4021 GB
13 Control and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
13.1 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
13.1.1 Sensor with fastening cpl. at conveyor tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
13.1.2 Sensor with fastening cpl. at drop pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13.1.3 Sensor at volume dispenser TI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
13.1.4 Sensor for volume dispenser BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
13.1.5 Description and Operation of the Sensors MS45R . . . . . . . . . . . . . . . . . . . . . 151
13.1.6 Description and installation of sensor DOL-41R . . . . . . . . . . . . . . . . . . . . . . . 154
13.2 Control and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
13.3 DryRapid Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
14 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
14.1 Terminal connection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
14.2 Feed hopper with forced leading-in resp. feedback . . . . . . . . . . . . . . . . . . 158
14.3 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
14.4 Adjustment drive of the automatic release . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.5 Sensor DOL 41 R and DryRapid Controller . . . . . . . . . . . . . . . . . . . . . . . . . 160
15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
15.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
15.1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
15.1.2 Dosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
15.1.3 Single channel feed hopper 0,37 kW with forced insertion . . . . . . . . . . . . . . . 162
15.1.4 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.1.5 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.2.1 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.2.2 Release with cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
15.2.3 Adjustment drive of the automatic release . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
16 Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
16.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
16.1.1 Entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
16.1.2 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
16.1.3 Feed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
16.1.4 Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
16.1.5 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
16.1.6 Feed hopper with forced leading-in resp. feedback . . . . . . . . . . . . . . . . . . . . . 165
16.1.7 Adjustment drive of the automatic release . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
16.2 Malfunction identification and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
16.2.1 In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
16.2.2 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
16.2.3 Feed supply and feed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
16.2.4 Adjustment drive of the automatic release . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Page VI
DR 1500
Edition: 08/10 M 4021 GB
17 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
17.1 Entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
17.2 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
17.3 Feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
17.4 Volume dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
17.5 Adjustment drive of the automatic release . . . . . . . . . . . . . . . . . . . . . . . . . .170
18 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
19 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
19.1 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

Basic instructions Page 1
DR 1500
Edition: 08/10 M 4021 GB
1 Basic instructions
1.1 Basics
The DR1500 has been constructed according to the current state of the art and all
acknowledged regulations regarding technical safety. The system is reliable. Upon
operation, however, dangers to life and limb of the user or third persons or impairments
of the system or other material property are still possible.
The system may only be mounted, attended, repaired and used
•for due use
•in an excellent state from the safety and technical point of view
•by persons who are familiar with the safety regulations and who have been
authorized by the owner.
In the event of special problems which are not described in detail in this manual, we
recommend to contact us for your own safety.
1.2 Designated use
The dry feeding system DR1500 is used for transporting and metering out dry feed as
meal or pellets. It can be used in sow management, piglet rearing and finishing.
The Big Dutchman installation may only be used according to its designated use.
Every other use is considered as non-designated use. The manufacturer does not
accept liability for damages resulting from other uses, the user alone has to bear the
risk.
The designated use also includes the exact observance of the operation, maintenance
and repair instructions as prescribed by the manufacturer.
The limit values indicated in the technical data must never be exceeded.
!
Please take care of this manual and always keep it in the same place for
quick reference.
All persons working with the system, assembling, cleaning and servicing
it have to be familiar with the contents of these instructions.
Please take into consideration the comprised safety instructions !
If this manual should get damaged or lost, Big Dutchman will be glad to
provide you with a new copy.

Page 2 Basic instructions
DR 1500
Edition: 08/10 M 4021 GB
1.3 Explaining the symbols
1.3.1 Safety symbols
Upon reading this manual you will come across the following symbols:
1.3.2 Safety symbols in the manual and on the installation
Thesesafetysymbolsillustrateremaining dangers when handling the system. They are
supplements to the above-mentioned symbols:
1.3.3 Warnings and safety instructions on your installation
On the installation you will find the following safety signs (see chapter 2.3.2). They
indicate remaining technical dangers when handling the system and give information
on how to avoid these dangers.
Implicitly observe the instructions attached to the installation, such as the arrow on the
motor indicating the direction of rotation.
Warning This symbol indicates risks possibly leading to personal injury
resulting in death or to severe injuries.
Caution This symbol indicates risks or insecure procedures possibly
leading to injuries or material damage.
Note This symbol indicates notes leading to an effective, economic
and environmentally-conscious handling of the installation.
Warning against the cold
Warning against dangerous electric tension
Warning against slippery surface

Basic instructions Page 3
DR 1500
Edition: 08/10 M 4021 GB
1.4 Ordering spare parts
Indicate the following for ordering spare parts:
•Code No. and description of the spare part or
•Invoice No. of original invoice
•Current supply, e.g. 220/380V 50-60Hz
1.5 Obligations
Closely adhere to the instructions in this manual.
A basic condition for safe operation and trouble-free handling of this system is the
knowledge of the basic safety instructions and regulations.
These mounting instructions, particularly the safety instructions, have to be observed
by everyone working with this system. Moreover, the regulations and instructions for
the prevention of accidents valid at the respective place of use have to be observed.
The manufacturer is not responsible for any damages to the machine resulting from
changes done by the user.
Operational safety is the prime necessity !
For you own safety only use original Big Dutchman spare parts. For
foreign products that have not been released or recommended we cannot
judge whether there is a safety risk in connection with Big Dutchman
systems.
You can find the exact description of the parts for ordering spare parts by
means of the pos. no. in the spare parts list.

Page 4 Basic instructions
DR 1500
Edition: 08/10 M 4021 GB
1.6 Warranty and liability
Warranty and liability claims regarding personal or material damage are excluded if
they result from one or several of the following causes:
•non-designated use of the installation,
•inappropriate mounting and operating of the system,
•operating the system with defective safety equipment or not duly fixed or not
functioning safety and protective devices,
•non-observance of the instructions in this manual regarding transport, stock
keeping, mounting, maintenance and upgrading of the system,
•unauthorized modifications on the system
•inappropriate repairs,
•in the event of a disaster caused by foreign matters or force majeure.
1.7 Disorders due to power failure
We recommend the installation of warning systems for a better control of your
production units or the use of an emergency power-generating set for supplying the
system with power in case of power failure. By this, you protect the animals and thus
your own economical health.
1.8 First aid
For the case of an accident, unless specified otherwise, a first-aid kit must always be
available at the place of work. Material taken out and used is to be replaced
immediately.
If you need help, describe the accident as follows:
•where it happened
•what happened
•the number of persons injured
•what type of injury
•who is reporting the accident! (your data)

Basic instructions Page 5
DR 1500
Edition: 08/10 M 4021 GB
1.9 Pollution abatement regulations
All works on and with the installation have to be carried out in compliance with the legal
requirements concerning waste prevention and proper recycling / disposal of waste.
Special care has to be taken when carrying out installation, repair and maintenance
works, as water pollutants like lubricating grease and oils, as well as solvent-containing
cleaningsolutionsarenot to pollute the soil or get into the canalisation! These materials
have to be kept, transported, collected and disposed of in appropriate containers!
1.10 Waste disposal
After finishing the assembly or repair of this installation, dispose of the packing material
and remains which do not need to be further used according to the legal provisions for
recycling.
The same applies to the component parts after putting the installation out of service.
1.11 Notes for use
We reserve the right to modify the construction and technical data for reasons of further
development.
Therefore, no claims can be derived from the information, pictures, drawings and
descriptions. Subject to correction !
Get the information on mounting, adjusting, operating and maintaining before taking
the system into operation.
Apart from the safety-relevant instructions in this manual and the safety precautions
valid in the country of use, also consider the generally acknowledged technical
regulations (safe and appropriate working according to UVV, VBG, VDE etc.).
1.12 Copyright
This manual is subject to copyright. The information and drawings included in this
manual shall not be copied without the manufacturer's consent, nor shall they be used
for anything other than the designated use. Neither shall they be given to third parties.
The contents of this manual can be altered without prior notice.
If you find mistakes or unclear information in this manual, please do not hesitate to let
us know.

Page 6 Basic instructions
DR 1500
Edition: 08/10 M 4021 GB
All trade marks mentioned or shown in the text are trade marks of their respective
owners and are recognised as patented.
Copyright 2010 by Big Dutchman
For further information please contact:
Big Dutchman Pig Equipment GmbH, P.O. Box 1163, D - 49360 Vechta, Germany
Phone [phone], Telex: 25510 big d, Fax: [phone]
E-Mail: [email protected], Internet: www.bigdutchman.de

Safety instructions Page 7
DR 1500
Edition: 08/10 M 4021 GB
2 Safety instructions
2.1 General safety instructions
All established safety precautions and other generally accepted safety regulations and
medical references have to be observed. Please check safety and function control
devices to ensure safe and accurate operation:
•before putting into operation
•at adequate time intervals
•after modifications or repairs.
Check the proper functioning of the system after any kind of repair works. You may only
take the device into operation, when all protective systems have been put into place
again.
Also observe the regulations of local water distribution and power supply companies.
2.2 Safety instructions when operating electrical appliances
You have to make sure that the system with the electrical appliances is operated and
maintained according to the electro-technical regulations.
Immediately switch off the installation in the event of malfunctions of the power supply
units. Use a bipolar voltage probe to make sure that the electrical equipment is not
alive.
Check the electrical wiring and cables for recognisable damage before putting the
device into operation. Replace damaged wiring and cables before taking the device
into operation.
Only use the fuses indicated in the circuit diagram. Immediately replace damaged
fuses. Never repair or bypass the fuses!
Installations and work on the electric components/structural groups may
only be carried out by qualified personnel according to electro-technical
regulations (e.g. EN 60204, DIN VDE 0100/0113/0160).
Dangerous electric tensions are bare in case of open control equipment.
Please be aware of the danger and keep workers of other professions
away from the danger zone !
Do not install control units directly in the house but in the service room in
order to prevent damages due to ammonia vapours (NH3).

Page 8 Safety instructions
DR 1500
Edition: 08/10 M 4021 GB
Never cover the electrical motor. This can cause high temperatures resulting in fire and
a break-down of the equipment.
The control box as well as the terminal and connector boxes of the installation must
always be kept shut.
Let damaged or broken plugs be replaced by an electrician.
Do not pull the plug from the socket at the flexible cable.
For the respective connections please see the enclosed connecting plan of the system
parts delivered.
2.3 Special safety instructions
2.3.1 Danger zone
DANGER OF INJURY due to electric voltage!
Touching live parts results in electric shock!
During repair or maintenance work, live parts may be bare.
Never touch bare electrical components. Equipment with bare electrical
components must not be used.
Never reach into the running installation. Before reaching into the
installation, turn the system off and secure it against unintentional
actuation.
Assure yourself beforehand that the main switch is in the OFF position and
can not be put in the ON position without your knowledge.

Safety instructions Page 9
DR 1500
Edition: 08/10 M 4021 GB
2.3.2 Danger signs on the system
DR1500 has been equipped with all mechanisms that guarantee a safe operation. In
places where the danger zone could not be safeguarded totally, with consideration to
the operational reliability, safety signs have been placed. They indicate remaining
technical dangers when handling the system and give information on how to avoid
these dangers.
For your safety, the following safety symbols have been fixed to the installation. Please
make yourself familiar with the signification of these symbols. The following
explanatory notes will provide you with detailed information.
At the drive, the chain or the rope is actuated by a gear motor over a
driving wheel. As certain mounting and maintenance works are only
possible with an open cover, it is necessary to be extremely careful.
In the feed containers with forced leading-in resp. feedback or RAS
the feed is further transported with a feed auger. Never try to push your
fingers into the feed opening to remove possibly stuck material.
If the release switches, do not try to help with your fingers if it jams.
GENERAL DANGER!
Installation automatically starts working. Before starting
any repair, maintenance or cleaning works, put main
switch to "OFF".
DANGER OF BRUISING due to rotating machine
parts!
Close protective devices every time before taking the
system into operation. Protective devices may only be
opened by authorized persons, when the system is idle.
DANGER OF INJURY due to operating auger, chain
and/or rope sheave!
Never reach into the drive unit and/or feed container while
the motor is running.

Page 10 Safety instructions
DR 1500
Edition: 08/10 M 4021 GB
These signs and safety instructions always have to be visible and must not be
damaged. If they are soiled by dust, manure, feed remains, oil or grease, clean them
by means of a water-detergent mixture.
Damaged, lost, or unreadable safety signs have to be replaced immediately. The code-
no. in the bottom left corner of every safety sign can be used as order number.
If a safety symbol or instruction is fixed to a part to be replaced, ensure that it will be
fixed to the new part as well.
2.4 Specific safety devices
These safety instructions shall inform you about significant details for the operation of
the installation which are important for your safety and for the safety of the installation.
The service staff must be informed about the functioning and the arrangement of the
safety devices, above all the emergency stop.
The service staff must participate at safety instructions at regular intervals (as
prescribed for example by professional associations).
All maintenance work must only be carried out by especially educated and instructed
service staff.
PULL-IN DANGER due to operating auger!
Never reach into the feed auger while the motor is
running.
Missing knowledge on the structural design of the installation can lead to
injuries.
Make yourself familiar with the design and construction of the installation
Inform yourself and your colleagues about the remaining dangers in
connection with this installation!