GSi PNEG-2309 User manual

Horizontal Fertilizer Mixer
Installation and User Manual
PNEG-2309
Version 1.0
Date: 12-03-20
PNEG-2309

All information, illustrations, photos, and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any
time without notice.
2PNEG-2309 Horizontal Fertilizer Mixer

Contents
Chapter 1 Safety Precautions ....................................................................................................................5
Safety Guidelines........................................................................................................................5
Cautionary Symbol Definitions......................................................................................................6
Safety Cautions...........................................................................................................................7
Safety Decals ...........................................................................................................................12
Safety Sign-off Sheet.................................................................................................................15
Chapter 2 Introduction.............................................................................................................................17
Contact Information ...................................................................................................................17
General Safety Statements .......................................................................................................17
Uncrating and Inspection ...........................................................................................................18
Chapter 3 Mixer Parts and Specifications................................................................................................19
Mixer Specifications ..................................................................................................................19
Mixer Dimensions......................................................................................................................21
Service Parts (4-Ton Mixer)........................................................................................................22
Service Parts (8-Ton Mixer)........................................................................................................24
Chapter 4 Mixer Assembly.......................................................................................................................27
Assembling the Mixer Halves .....................................................................................................27
Installing the Center Cover.........................................................................................................28
Nozzle Installation .....................................................................................................................29
Installing the Torque Arm Gear Reducer......................................................................................29
Installing the Torque Arm and Turnbuckles ..................................................................................34
Installing the Motor Mounts and Motors.......................................................................................36
Installing the Sheaves and Belts .................................................................................................38
Belt Tension Adjustment ............................................................................................................41
Installing the Bearing Guards .....................................................................................................42
Installing the Limit Switches .......................................................................................................43
Hazard Monitoring.....................................................................................................................44
Chapter 5 Mixer Installation.....................................................................................................................45
Important Pre-Startup Notifications .............................................................................................45
Lifting the Horizontal Mixer.........................................................................................................45
Wiring Installation......................................................................................................................46
Chapter 6 Operation ................................................................................................................................47
Loading the Mixer......................................................................................................................47
Loading Sequence ....................................................................................................................47
Chapter 7 Troubleshooting......................................................................................................................49
Chapter 8 Maintenance............................................................................................................................55
General ....................................................................................................................................55
Bearings...................................................................................................................................56
Gear Reducer ..........................................................................................................................56
Drive V-Belts.............................................................................................................................56
Shafts Seals .............................................................................................................................56
Limited Warranty - N.A. Fertilizer Products .............................................................................57
PNEG-2309 Horizontal Fertilizer Mixer 3

NOTES
4PNEG-2309 Horizontal Fertilizer Mixer

1Safety Precautions
Topics Covered in this Chapter
▪ Safety Guidelines
▪ Cautionary Symbol Definitions
▪ Safety Cautions
▪ Safety Decals
▪ Safety Sign-off Sheet
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered by the
operator and other personnel when using this equipment. Read and save these instructions.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all
times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable regula-
tions, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be delivered
with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the
equipment.
ST-0001–4
PNEG-2309 Horizontal Fertilizer Mixer 5

Chapter 1: Safety Precautions
Cautionary Symbol Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
Table 1-1 Description of the different cautionary symbols
Symbol Description
This symbol indicates an imminently hazardous situation which, if
not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to personal
injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005–2
6PNEG-2309 Horizontal Fertilizer Mixer

Chapter 1: Safety Precautions
Safety Cautions
Use Personal Protective Equipment
• Use appropriate personal protective equipment:
Eye
Protection
Respiratory
Protection
Foot
Protection
Hearing
Protection
Head
Protection
Fall
Protection
Hand
Protection
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004–1
Follow Safety Instructions
• Carefully read all safety messages in this manual and safety
signs on your machine. Keep signs in good condition.
Replace missing or damaged safety signs. Be sure new
equipment components and repair parts include the current
safety signs. Replacement safety signs are available from
the manufacturer.
• Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
ST-0002–1
PNEG-2309 Horizontal Fertilizer Mixer 7

Chapter 1: Safety Precautions
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep
area clean and dry.
• Never service equipment while it is operating. Keep hands,
feet, and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace
worn or broken parts immediately.
ST-0003–1
Install and Operate Electrical Equipment Properly
• Electrical controls must be installed by a qualified electrician
and must meet the standards set by applicable local codes
(National Electrical Code for the US, Canadian Electric
Code, or EN60204 along with applicable European Direc-
tives for Europe).
• Lock-out power source before making adjustments, cleaning,
or maintaining equipment.
• Make sure all equipment is properly grounded.
ST-0027–4
Fall Hazard
• Keep access door closed while on a platform to avoid falls.
• Always use proper personal protective equipment and
proper clothing when using equipment. Failure to follow
safety precautions can result in severe injury or death.
ST-0042–2
Flying Material Hazard
• Flying material can cause severe eye
injury or blindness.
• Wear safety glasses around operating
equipment.
ST-0074–1
8PNEG-2309 Horizontal Fertilizer Mixer

Chapter 1: Safety Precautions
Toxic Fume and Dust Hazard
• Do all work outside or in a well-ventilated area. Dispose of
paint and solvent properly.
• Remove paint before welding or heating:
— Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by weld-
ing, soldering, or using a torch.
— If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
— If you use solvent or paint-stripper, remove stripper with
soap and water before welding.
— Remove solvent or stripper containers and other flam-
mable material from area. Allow fumes to disperse at
least 15 minutes before welding or heating
ST-0043–2
Fall Hazard
• Ladders, stairways and platforms are for use by competent
and trained personnel only. Do not allow children or other
unauthorized persons to have access to the equipment.
• Access to the equipment must be restricted by the use of
security fencing and lockable gates.
• Lower sections of ladders must be fitted with a lockable
safety gate to prevent unauthorized access.
• Make sure that hot surfaces have had adequate time to cool
before working on or in the equipment.
• Lock out and tag out power supplies and fuel supplies to all
equipment.
• Do not attach lifting equipment to ladders or platforms.
• Do not go outside of the safety rails provided on elevated
platforms.
• Do not work at heights during high winds, rain, snow, or ice
storms.
ST-0056–1
PNEG-2309 Horizontal Fertilizer Mixer 9

Chapter 1: Safety Precautions
Confined Space Hazards and Entry Procedures
• Note that the interior of this equipment is considered a con-
fined space. Maintenance of this equipment can require
access to the confined space.
• Access doors must be shut and locked except when access
is required.
• Doors giving access to dangerous equipment must be safety
interlocked.
• The following entry procedures must be followed:
— Be aware of all possible hazards present inside the con-
fined space and wear personal protective equipment
(PPE) as needed.
— Complete a permit to work and follow all permit required
confined space entry procedures defined by the site
manager.
— Make sure that the area has been purged of any hazard-
ous products or gases. Check the atmosphere for harm-
ful gases or vapors with a suitable gas analyzer and
make sure levels are safe before entering.
— Do not smoke or use naked flames.
— Lock out and tag out power supplies and fuel supplies to
all equipment.
— Do not work alone. Work in teams of at least three so
that help is immediately available in the event of an
emergency.
— Confirm that all personnel have safely exited the equip-
ment and tools have been recovered once work is
complete.
ST-0055–1
Stay Clear of Hoisted Equipment
• Always use proper lifting or hoisting equipment when assem-
bling or disassembling equipment
• Do not walk or stand under hoisted equipment.
• Always use sturdy and stable supports when needed for
installation. Not following these safety precautions creates
the risk of falling equipment, which can crush personnel and
cause serious injury or death.
ST-0047–1
10 PNEG-2309 Horizontal Fertilizer Mixer

Chapter 1: Safety Precautions
Stay Clear of Rotating Parts
• Do not service equipment while the
equipment is in operation.
• Entanglement in rotating shafts, mixing
paddles or exposed belts will cause seri-
ous injury or death.
• Keep all guards and covers in place at
all times.
• Lock-out power source before making
adjustments, cleaning, or maintaining
equipment.
ST-0088–1
Stay Clear of Moving Parts
• Entanglement in drop gate operating
mechanism can cause serious injury.
• Keep all guards and covers in place at
all times.
• Lock-out power source before making
adjustments, cleaning, or maintaining
equipment.
ST-0089–1
PNEG-2309 Horizontal Fertilizer Mixer 11

Chapter 1: Safety Precautions
Safety Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood
by all personnel involved in the installation, operation, service and maintenance of the equipment.
Figure 1-1 Safety decal locations
12 PNEG-2309 Horizontal Fertilizer Mixer

Chapter 1: Safety Precautions
Ref# Location Decal No. Decal Description
AOutside of belt guard
covers DC-2468 Decal, Warning, Rotating
Parts
BInside of belt guard
covers DC-2469 Decal, Danger, Missing
Guard, Rotating Parts
CTop of bearing guard
covers DC-2525 Decal, Warning, Rotating
Shafts
DOn the tub to the left
and right of bearings DC-2526 Decal, Danger, Missing
Guard, Rotating Shafts
PNEG-2309 Horizontal Fertilizer Mixer 13

Chapter 1: Safety Precautions
Ref# Location Decal No. Decal Description
EOn actuator guard
front panel DC-2527 Decal, Warning, Moving Parts
FOn top of inspection
panels DC-2528 Decal, Warning, Confined
Space Hazard
GOn top of inspection
panels DC-2529 Decal, Danger, Mixing
Paddles
To replace a damaged or missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois St.
Assumption, IL 62510
Tel: [phone]
14 PNEG-2309 Horizontal Fertilizer Mixer

Chapter 1: Safety Precautions
Safety Sign-off Sheet
Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
ST-0007
PNEG-2309 Horizontal Fertilizer Mixer 15

NOTES
16 PNEG-2309 Horizontal Fertilizer Mixer

2Introduction
Topics Covered in this Chapter
▪ Contact Information
▪ General Safety Statements
▪ Uncrating and Inspection
Contact Information
Please contact your GSI dealer if you have any questions or contact GSI. Visit our website at www.grain-
systems.com. If calling with questions about your product, please have the following information ready:
• Serial Number
• Model Number
• Part Description
• Quantity Required
General Safety Statements
1. Precautions have been taken to ensure that machinery is supplied with all necessary safety guards,
covers, and warning labels. However, since this equipment is often part of a larger plant process, it
is the responsibility of the customer to ensure that the machinery is safely installed in the process.
2. Always disconnect and lock out the power before any physical inspection or work is performed.
3. If one of the safety decals is damaged or illegible, contact GSI immediately for a replacement.
4. Under no circumstances should any attempt be made to override the safety equipment that is
supplied on this mixer. Micro switches should never be tampered with so that the machine will
operate when the covers and grates are open. If the mixer must be loaded with the cover open,
safety grating with a lock out switch must be provided.
5. Under no circumstances should any person attempt to put their hand through the inlets or the
discharge of the machine. If the agitator is in operation, amputation of a limb will occur.
6. This machine should only be operated by trained personnel. Proper training includes reading and
understanding this manual.
PNEG-2309 Horizontal Fertilizer Mixer 17

Chapter 2: Introduction
Uncrating and Inspection
What You Should Know
CAUTION
Use proper lifting equipment when lifting or moving the mixer. Failure to do so can
lead to personal injury and equipment damage.
• Transportation and moving should only be performed by trained personnel.
• Improper handling can result in misalignment of the machine main shaft with the cylinder and end
plates.
• Observe local safety practices and procedures.
NOTE:
1. After uncrating your mixer, check for shipping damage and report any damage
immediately to the carrier and to GSI. Please make sure that all parts are accounted
for.
2. If the mixer is not to be installed immediately, make sure to store it in a clean, dry
location that is protected from extreme temperature conditions.
3. Improper motor storage will result in reduced reliability and even motor failure.
18 PNEG-2309 Horizontal Fertilizer Mixer

3Mixer Parts and Specifications
Topics Covered in this Chapter
▪ Mixer Specifications
▪ Mixer Dimensions
▪ Service Parts (4-Ton Mixer)
▪ Service Parts (8-Ton Mixer)
Mixer Specifications
Gear Reducer
Table 3-1 Reducer technical data
Mixer Reducer Mechanical Rating
(HP)
Adjusted Thermal
Rating (HP)
Drive Shaft Size
(in.)
Actual Service
Factor
4-Ton TA8407H40 77.35 51 4-7/16 1.93
8-Ton TA10507H40 114.13 89 5-15/16 1.52
NOTE:
1. For 4-Ton Reducer: Thermal rating is 51 HP based on 95°F and below ambient
temperature and up to 5,000' altitude.
2. For 8-Ton Reducer: Thermal rating is 89 HP based on 95°F and below ambient
temperature and up to 5,000' altitude.
Belt Drive
Table 3-2 Belt drive technical data
Mixer Speed Ratio Belt Speed
(ft./min)
Belt Pull
(lbs.)
Static Shaft Load
(lbs.) Service Factor Final Shaft Output (RPM)
4-Ton 1.27 3,207 1,234 1,211 2.06 35
8-Ton 1.67 4,078 1,072 1,078 1.57 26
Table 3-3 Belt drive technical data (Contd.)
Mixer Center Distance
(in.)
Facewidth
(in.)
Driver Pitch
Diameter (in.)
Driven Pitch
Diameter (in.)
Install/Take-up Center
Distance Range (in.)
4-Ton 40.4 3.06 7.00 8.90 39.35 - 41.85
8-Ton 51.1 3.06 8.90 14.90 50.07 - 53.27
PNEG-2309 Horizontal Fertilizer Mixer 19

Chapter 3: Mixer Parts and Specifications
Tensioning
Table 3-4 Sonic tension meter data
Mixer Tension Frequency (Hz) Belt Mass Constant (g/m) Span Length (in.) # of Belts
4-Ton 34 - 41 140.0 40.34 4
8-Ton 25 - 31 140.0 50.98 4
Table 3-5 Force deflection method
Mixer Span Length (in.) Belt Deflection Distance (in.) Belt Deflection Force (lbs.)
4-Ton 40.34 0.63 10.3 - 15.0
8-Ton 50.98 0.80 12.6 - 13.5
NOTE: Values shown are for new belts.
General Specifications
4-Ton Mixer 8-Ton Mixer
• Scott 96" x 96" twin shaft mixer with 151 cu. ft.
mixing capacity at 75% total capacity.
• End plates and tub are 304 stainless steel
construction.
• Bearing shelves and gussets are carbon steel.
• Agitator is carbon steel.
• 1/4" end plates and 3/8" tub.
• Interior finish: Standard mill
• Exterior finish: Painted STEEL-IT
• Seals: Double stuffing box re-packable both ends
• Two 4-7/16" Dodge ISAF drive bearings.
• Two 3-15/16" Sealmaster idle bearings.
• Discharge: Two 16" x 91" air-operated drop gates
• Two 6" x 42" intervents.
Motor and Drive:
• Final mixer speed: 35 RPM
• Two 40 HP motors.
• Two Dodge TA8407H40 shaft mount reducers.
• Two belt drives with covers.
• Scott 120" x 120" twin shaft mixer with 294 cu. ft.
mixing capacity at 75% total capacity.
• End plates and tub are 304 stainless steel
construction.
• Bearing shelves and gussets are carbon steel.
• Agitator is carbon steel.
• 1/4" end plates and 3/8" tub.
• Interior finish: Standard mill
• Exterior finish: Painted STEEL-IT
• Seals: Double stuffing box re-packable both ends
• Two 5-15/16" Dodge ISAF drive bearings.
• Two 5-7/16" Dodge ISAF idle bearings.
• Discharge: Two 20" x 115" air-operated drop gates
• Two 8" x 54" intervents.
Motor and Drive:
• Final mixer speed: 26 RPM
• Two 75 HP motors.
• Two Dodge TA10507H40 shaft mount reducers.
• Two belt drives with covers.
20 PNEG-2309 Horizontal Fertilizer Mixer