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The KUHL QUAD BOXER is a state of the art microprocessor controlled machine designed to accurately count and box day old chicks. A four lane, three conveyor design allows a chick boxing speed of sixty thousand birds per hour, while gently handling the chicks. A loud audio alarm feature warns the user of any problems such as " no box in place " when there are no empty boxes on the conveyor and or when the boxes are stuck on the line.
The KUHL QUAD BOXER is a state of the art microprocessor controlled machine designed to accurately count and box day old chicks. A four lane, three conveyor design allows a chick boxing speed of sixty thousand birds per hour, while gently handling the chicks. A loud audio alarm feature warns the user of any problems such as " no box in place " when there are no empty boxes on the conveyor and or when the boxes are stuck on the line.
The KUHL QUAD BOXER is a state of the art microprocessor controlled machine designed to accurately count and box day old chicks. A four lane, three conveyor design allows a chick boxing speed of sixty thousand birds per hour, while gently handling the chicks. A loud audio alarm feature warns the user of any problems such as " no box in place " when there are no empty boxes on the conveyor and or when the boxes are stuck on the line.
The Kuhl Quad Boxer is a state of the art microprocessor controlled machine designed to accurately count and box day old chicks. A four lane, three conveyor design allows a chick boxing speed of sixty thousand birds per hour, while gently handling the chicks.
The system was designed with simplicity and dependability in mind. The onboard computer utilizes an easy to read Vacuum Fluorescent screen that quickly displays vital information on the status of the counter. A loud audio alarm feature warns the user of any problems such as no box in place when there are no empty boxes on the conveyor and or when the boxes are stuck on the line. The complete boxer and all systems are NEMA 4X rated for daily machine wash-down. A complete spare parts package is available for quick replacement of any part on the system. All components have been carefully chosen and designed to handle high volume use in an industrial environment. When a problem does occur, components can be quickly replaced.
4 ELECTRICAL CONTROL PANEL
DO NOT open this panel unless you are qualified to do so.
ALL wiring MUST be done by a qualified / certified electrician in accordance with local electrical codes in effect at the time of installation. The machine MUST be grounded according to approved electrical code.
The electrical panel houses the motor starters, overload protectors, low voltage transformer, start / stop relays and the pneumatic control valves. Six fuses in this NEMA 4X rated box protect the machine and operator from any electrical system malfunction.
DO NOT OPEN THIS PANEL UNLESS YOU ARE QUALIFIED TO DO SO !
Disconnect ALL power entering the control panel BEFORE working within !
DO NOT modify anything in the control panel unless authorized by the manufacturer.
Use ONLY replacement fuses with the correct ratings.
Except for external power hookup, NO OTHER external connections should be made in this panel.
Keep panel door secured tightly at ALL times. Make sure gaskets are ALWAYS in good condition (i.e. CANNOT be torn or loose, ect.). Periodically check inside the panel for ANY signs of water leakage.
FUSE RATINGS: If the system does not run, the fuses should be checked. Blown fuse indicators may have been installed in fuse holders #1, 2, 3 & 4. If these fuses are blown the LED at the top of the fuse base will light when the power is turned on.
DO NOT FORGET TO DISCONNECT POWER BEFORE REPLACING FUSES !
5 The following table summarizes the various fuse ratings:
FUSE # RATING 1 2 -- 3 250 VOLT 10 AMP SLOW BLOW 4 5 -- 6 250 VOLT 4 AMP FAST ACTING
All fuses are type 3AG (1 long). Spare fuses are stored in the control box and spare parts kit.
COMPUTER (CPU) CONTROL BOX
The system computer is housed in a NEMA rated control box for protection from daily system wash-down. Both the keypad and the display panel are also NEMA rated. We recommend however, that this panel not be washed with a high-pressure washer. The high-pressure may damage the unit. Clean the unit daily with a soft cloth.
This unit contains the onboard computer, DC power supply and Solid State Relays that control the motor and pneumatic functions. The computer utilizes state of the art software (copyright) that allows the user to easily interact with the machine. The system incorporates an alarm feature that alerts the operator when any problems occur.
The CPU control box has four switches. The RED emergency stop push-pull switch located on the side of the panel must be pulled out to the ON position before power is available to the lighted GREEN push button switch. The switch with the YELLOW band turns the computer on or off. Never turn the computer off and on repeatedly. Always wait a few seconds between turning it off and or on again. While washing the system, the computer must be turned off.
The switch with the white band serves two functions: 1) MANUAL position runs the conveyors during wash-down and 2) AUTO position is used during production runs.
One fuse is located on the main board inside the control panel. It is a 1/4 OD x 3/8 high round shape rated at 1.0 amp.
DO NOT OPEN THIS PANEL U NLESS YOU HAVE BEEN TRAINED !
6 QUAD BOXER STARTUP PROCEDURES
1) Turn on the air supply
2) Turn the MAIN DISCONNECT switch (black handle on the electrical panel) to the ON position.
3) Pull the RED emergency stop button (on the side of the CPU panel) outward to the ON position. Be sure that the MAN / AUTO switch is in the AUTO mode.
4) Press the GREEN start ( power ) push button. When the green light is on the box conveyor will run.
5) Load the Box feed conveyor with empty chick boxes.
6) Turn on the computer (switch with YELLOW band). The computer will boot and display the quad Boxer status screen. If you ever need to reset the computer, simply turn the switch off, wait 5 seconds and then turn it on again.
7) Clear any previous counts stored in the computers memory. To clear the count memory, press the CE/E or CLEAR button on the keypad, followed by the <1> key. The four deflectors will shift to the up position at this point.
8) If you do not intend to use flock management skip to step #9. Press the <2> key Press the <3> key to erase the memory Press the <1>key to confirm deletion
9) Check the system parameter setting by pressing the <8>key on the CPU.
The following setting should be displayed:
Birds / box =100 Small =8 Medium =9 Large =10
Press ENTER to return to the main menu.
The bird size should be set at Medium, if not, press the <1>key until Medium is displayed at the top right hand corner of the screen. If the above settings are incorrect, refer to the instructions on CHANGING SYSTEM PARAMETERS.
7 10) Start the boxer by pressing the LEFT arrow key or the RUN key. At this point a box will be moved into place and all four deflectors will shift to the UP position, all conveyor motors will now run. The system is ready to count chicks.
11) At the end of each flock, record the bird count, then press the <6> key and follow the prompts. At this point, a new box will be pushed into position The flock counts will be stored in the flock management memory To access the flock menu, press the <2>key on the keypad.
Most day-to-day operations require knowing a limited number of keystrokes on the computer keypad. The following describes the various functions available.
KEYPAD LAYOUT:
LANE 1 DIVERTER 1
LANE 2 DIVERTER 2 7 Spray Vacc ON / OFF 8 Display Parameters 9 Setup Menu RUN
LANE 3 DIVERTER 3
LANE 4 DIVERTER 4 4 Chicks Per Hour 5 Diagnostics Menu 6 End of Flock STOP
If you see asterisks (***) in the box totals across the screen, press the Clear key followed by the <1> key.
RUN KEY Starts system: When the system is turned on for the first time a new box will automatically be moved into filling position. The motors will start, sensors will be activated and the diverters will open. The screen will display the RUN command with running cursor at the top left hand corner of the screen.
STOP * QUAD BOXER * MEDIUM BOX =0 Flock =0 Total =0 9 STOP KEY Stops the system
<1>KEY (Change Bird Size) Pressing this key increments the current bird size from small to medium, to large. The three size settings correspond to the numeric bird sizes entered in the setup screen. This feature is useful in situations where accuracy drops between different size flocks. Usually when running between 40-60 thousand birds per hour, it is important to set the bird size numbers (i.e. small medium, large) to correspond to your chick sizes. For example if a bird size of 9 works best with most of your chicks, you may need to bring the bird size up to 10 for your older flocks and 8 for your youngest flocks. Set the small at 8, medium at 9 and large at 10 (these are the default settings).
<2>KEY (Flock Menu) One unique feature of the software is ability to store 60 individual flocks. These counts can be viewed or even printed while counting chicks. Whenever you end the flock with the <6>key, the total count is transferred in the computers memory in sequential order. The flock sequence number is displayed on the main screen. To view the counts, simply access the flock submenu and press the <1> key. The screen will display: flock sequence number, time, total birds, adjusted count & total number of boxes. The adjusted count represents the flock count minus the adjusted percentage, which is setup in the birds per box setting. Use the right & left arrow keys to scroll through the stored counts. To print the counts summary, press the <2> key under the flock submenu. If you have the optional printer, a report detailing all the flock counts will be instantly printed. To ERASE the counts stored in the flock database, press the <3> key while in the flock menu. If the <3> key is pressed by mistake, restore the counts by pressing the <4> key. Counts cannot be restored if the <3>key is pressed twice. At the beginning of each day, erase all flocks stored in the computers memory.
<3>KEY (Calibrate Bird Size) This key is used to verify bird sizes. When you choose this option the conveyors start and the computer displays the minimum and maximum bird size screen. As birds are placed on the belt & run through the fill lane, the computer displays a corresponding bird size. Usually you need to pass 10 to 20 chicks through this lane observing the size at each pass until a number repeats often. The bird size that is used is the maximum bird size plus one. If the maximum number is way out (3 points or above) in relation to the maximum size column, disregard this test and repeat. The average sizes are also the default sizes: Small =8, Medium =9, Large =10. When calibration is complete, press ENTER to exit, and CLEAR to clear the memory. These sizes must be written into the memory through the setup menu, <9> key. 10 <4>KEY (Chicks Per Hour) Pressing this key while the system is running, displays the current processing speed in birds per hour. The screen is updated every two seconds. To exit this screen press and hold the Enter key until it returns to the main menu.
<5>KEY (Diagnostics Menu) With the system stopped, tests can be made to the motor and pneumatic controls. It is recommended that these tests be done on a daily basis as part of a preventive maintenance procedure. The following functions are available.
Sub Menu Keys:
1. Conveyor Test : Turns conveyors on, press the Enter key to stop the motors.
2. Deflector Test : Activate all four deflectors, all four should activate simultaneously.
3. Box Loader : Opens box stop, releases one box with each press.
4. Sensor Test : Displays the status of each sensor. Display AB4321 on the screen, chick boxes should be in position for these tests to prevent constant beeping of the alarm. When each lane sensor is tested, the corresponding lane deflector operates.
Press ENTER to return to the main menu.
<6>KEY (End of Flock) This key will transfer box counts to the total count, eject the current box and start a new box. You must choose the box fill option in the setup menu, <9>key.
<7>KEY (Spray Vaccinator) This key turns the IB Spray Vaccinator off or on.
<8>KEY (Display Parameters) Use this key to view settings daily before starting a production run. These settings (system parameters) are critical for proper operation. The following system settings are displayed:
A) Bird / Box =100 (Default Setting) B) Bird Size =Small =8, Medium =9, Large =10.
(If for any reason these numbers need to be restored or changed, it must be done manually using the setup menu, <9> key). 11 <9>KEY (Setup Menu) Displays the following setup screen: The system must be stopped for you to change the system parameters.
CHANGING SYSTEM PARAMETERS
To change the system parameter settings, simply choose the corresponding number.
1. Time Enter the time, HH MM SS, in 24-hour format. Use the left and right arrow keys to move between the intervals after the numbers are typed in.
2. Date Enter todays date YY MM DD.
3. Birds / Box Enter the number of birds required per chick box. The minimum value is 50 and the maximum value is 150. Default =100. After entering the number of birds per box, the computer prompts for an adjusted percentage between 0 & 15%. This percentage is used primarily for the flock management database to calculate the adjusted birds per box column. For example, if you supply 102 birds per box, but only bill for 100 (98%), enter a percentage of 2.
4. Bird Size For accurate counting of birds, especially when two or more birds are bunched together, the proper bird size value has been entered. This number is determined through Bird Size Calibration, the Quad Boxer allows you to store three different bird sizes, i.e. small, medium, large.
5. Finish 1: Fill-up last box, 2: Dont fill last box.
6. Unit This option is used to identify a machine when you are printing a report.
7. Auto For future use
Press ENTER to exit this screen
CLEAR KEY Clear all counts and resets to 0, clears all counts in memory. Perform this function at the beginning of each day or the end run of the present day will be added to previous days flocks. The system prompts you for verification. Stop system to perform this function. 1 Time 2 Date 3 Birds / Box 4 Bird Size 5 Finish 6 Unit 7 Auto ENTER to exit 12 <0>KEY Service number, function is not available for end user.
LEFT ARROW KEY Used primarily for box advance and can only be used when system is stopped. It is also used as a character edit key under various entry screens.
RIGHT ARROW KEY Used primarily to bleed and flush the IB Spray Vaccinator. It is also used as a character edit key under various entry screens.
<ENTER>KEY Accepts entries and functions, exits menus
ERROR CONDITIONS
The system contains four distinct error codes. All these conditions stop the system until the error condition is corrected. These measures ensure bird safety. The following is a summary of the error conditions along with steps to correct them.
ERROR #1: ALARM SIGNAL 3 SHORT BEEPS, NON-FATAL ERROR
MESSAGE: A NEW BOX IS NOT READY TO LOAD Add new box to the conveyor
This condition occurs when an empty box is not in position to be loaded by the powered conveyor. To correct this error condition, place empty boxes onto the powered box conveyor. Once the computer senses the box, it will move the box into position and restart the system automatically.
ERROR #2: ALARM SIGNAL 2 SHORT, 2 LONG BEEPS, FATAL ERROR
MESSAGE: Q-BOX OVERLOAD SYSTEM STOPPED Return chicks to the infeed conveyor to be recounted
Press ENTER to exit
This condition occurs when there are no birds passing through the fill lane causing more then the set maximum birds to enter the queue box (set to a maximum of 65 chicks). This is a very rare occurrence. Pressing ENTER will reject that count, release the box and return the chicks to the infeed conveyor to be recounted to ensure accuracy.
13 ERROR #3: ALARM SIGNAL 1 SHORT, 1 LONG BEEP, NON-FATAL ERROR
MESSAGE: BOXES DID NOT MOVE ! SYSTEM STOPPED Check box loader
Press ENTER to exit
This condition occurs when for some reason the boxes did not move into the fill position fast enough, or boxes may have moved but the sensors may need re-adjustment. To correct, check for box jams, broken boxes and or check the box sensors for proper operation. Press the ENTER key to restart the system.
ERROR #4: ALARM SIGNAL CONTINUOUS LONG BEEPS, FATAL ERROR
MESSAGE: SENSOR # ? IS BLOCKED OR DIRTY Press ENTER to continue
A sensor-blocked error usually occurs immediately after a box has been fed incorrectly. Sometimes when the system is stopped, a bird happens to be sitting directly underneath and blocking the sensor. Rarely, dirt will collect on the sensors causing blockage. In both of these situations, clear the appropriate sensors. Looking from the front of the machine towards the rear, the sensor order is from left 4 3 2 1, pressing the ENTER key will activate another error:
THE SYSTEM HAS BEEN STOPPED FOR SAFE CLEANING, MANUALLY RE- COUNT THIS BOX. This count will be rejected, return the chicks to the infeed conveyor for recount.
Press ENTER to continue, then manually restart the system.
14 SPECIFICATIONS AND MAINTENANCE
LUBRICATION & ADJ USTMENTS
Air Flow Requirements: Plant Air 50 to 80 PSIG Dry Filtered Air Diverter Pneumatics Regulated at 14 to 20 psi. The lowest operating pressure is desirable for gentle handling of chicks Box Stop 50 to 60 PSIG
Air System Lubrication: Turn off air supply at valve Remove tubing from outlet port of air filter or remove cap from tee fitting (mounted to the left of the main electrical panel). Place 8 to 12 drops of pneumatic tool oil (i.e. #27 hydraulic oil, 3 in 1 oil) into the line or fitting. Remove tubing at the top inlet port of each diverter air cylinder and insert a few drops of oil every three (3) months, or as necessary.
* * DO NOT USE PRODUCTS SUCH AS WD40 * * IT WILL CAUSE PREMATURE FAILURE OF THE AIR CYLINDER & VALVE SEALS
Flow Control Adjustment: The MAC valves used on this machine have ports identified as A & B, it also has air flow controls built into the valve body which are used as cushioning devices to control cycling speed of the air cylinders. Air flow is restricted when the opposite flow control needle valve is screwed inward, i.e. If the piston on a deflector is slamming on the upstroke (port A), adjusting the needle inward for port B restricts the air flowing back through port A causing the piston to be cushioned. Screwing in the needle valve at port A cushions the piston coming down as it restricts the air flowing back through port B. All adjustments to the screws must be done as gently as possible to prevent damage to the valve seal if the screw bottom is out.
From the closed position back off the needle half a turn at a time, cycle the piston and adjust until desired speed is achieved. In the center of the coil housing there is a small (3 mm) round hole, within that hole is a clear plastic disk. Using a small pointed object (such as a screwdriver or pen tip) depressing this disk, cycles the circuit when the pistons are moving freely up and down without slamming hard at the end of each stroke.
Chick Deflectors: Valves # 1, 2, 3 and 4 have been adjusted to approximately 1 to 2 turns from fully closed on both ports A and B. All adjustments should be done from a fully closed position. Valves #5 and 6 are fully open to line pressure.
15 SENSOR ADJ USTMENT INSTRUCTIONS
In order to properly adjust the lane sensors and bird size setting it is important to understand how the Kuhl Chick Boxer counts chicks.
The goal in any counting application is to achieve some sort of separation between object and some stability with each object. If we were counting bricks or beer bottles, this task would be straightforward. With chicks, the task is more challenging, the guarantee of stability and separation are more difficult, even more so in high volume situations.
The Kuhl Boxer incorporates four lanes with two or three levels of conveyors to get the chicks in single file and with some space between each chick. Separation between each chick at the rated Boxer speed should occur with 80 90%of the total chicks. The computer and sensors must be able to count the chicks that are grouped together.
Instead of looking for a change of sensor state, as you would with well separated objects, we measure the time it takes for a chick or group of chicks to pass through the sensor beams. This time, which is taken in 10ms increments, is divided by a present bird size value to achieve the count. The following integer math is performed by the computer during the counting:
Example A : Bird Size Setting =9 One chick passes the sensor; Computer measures 7 time units (i.e. 70ms). Result: The system counts 1 chick.
Example B : Bird Size Setting =9 Two chicks pass through the sensor: Computer measures 12 units (120ms) (i.e. chicks are close together). Result: The system will count 2 chicks.
Example C : Bird Size Setting =9 One large chick passes through the sensor; Computer measures 9 units (i.e. 90ms). If a chick tumbles excessively through the sensor, the computer could measure a longer time value. Result: System will count 2 chicks.
This example shows what happens when the bird size is set too low or when there is excessive tumbling. A bird size setting of 10 would have produced a single count.
16 In low volume situations, bird separation could occur 99%of the time. In this case, by leaving the bird size setting to a high value the computer would guarantee a single count for each chick.
Another key factor that affects bird size selection is main conveyor belt speed. The slower the speed, the higher the birds size, conversely, the faster the belt speed, the smaller the bird size. The factory default belt speed on a 40k / 60k Boxer is 302 feet per minute. The default bird sizes that work best with this speed are 8 for small, 9 for medium and 10 for large. If you are running a belt at a different speed, (i.e. 60 hz motor with 50 hz power) you will have to adjust these bird size settings.
As discussed earlier, bird tumbling and overall poor bird separation will affect counting accuracy. If the sensors and computer can see gaps between chicks, 100%accuracy can be achieved. 100%accuracy can also be achieved with multiple chicks between gaps as long as the bird size is properly selected and the sensors are properly adjusted.
To reduce bird tumbling i t is important abide by the following guidelines:
A) The peek birds per hour must not exceed the boxers rated speed, i.e. if for 5 seconds the bird flow hits a peek of 70000 chicks per hour on a 60k boxer, the accuracy for the current box may be off.
B) The chicks must be partially dry, excessively wet chicks can make the blue tubes sticky, and restrict bird flow.
C) Chicks must be spread evenly across all four lanes. If two lanes are getting 80%of the chicks, the machine speed must be de-rated.
Calculating boxer accuracy
With the four-lane defector design, there must be a certain space between chicks in order for accurate chick placement between movements of the chick deflector. If two chicks pass through the sensor while the deflector goes down, both chicks will be placed in the box. This improper chick placement could potentially occur across four lanes. The chicks will be counted properly by the computer, but the individual box count will be off. In a low volume situation, this is not a problem, and most boxes will have the proper box count.
The chick exchange problem will reduce as box counts that may be off between 1- 5 chicks. Most of the time it is only off by one chick. If you count ten consecutive boxes, you will see that they average out. If you count more than ten stacks, true boxer accuracy can be reached. 17 Lane Sensor Cleaning
The most common problem with poor chick accuracy is improper lane sensor adjustment and or a dirty, scratched sensor lens. It is very important to clean sensors with a soft non-abrasive cloth using a glass cleaner. Dirty or scratched lenses will affect sensor sensitivity.
Sensor sensitivity is extremely important. If the sensor sensitivity is set too low, you risk missing a chick. If it is set too high, dirt on the belt or the belt itself may be picked up. The best way to adjust the sensors is to pass one small chick, at a time, down the lane being adjusted. Verify that the sensor light activates each time a chick passes through the sensor beam.
Some customers adjust the sensitivity such that a chick is not missed, but a small piece of an eggshell is. This is a very fine adjustment and requires frequent testing as the sensor sensitivity can float up to 20%. We will be releasing software in the near future that incorporates a more advanced eggshell rejection system.
The sensors have been adjusted at the factory, however, if your counting accuracy drops, you should follow this procedure to re-adjust the sensors.
Turn the quad boxer computer on:
1) Remove the top cover from the sensor assembly bracket, use a 5/16 wrench to remove bolts.
2) Ensure that all four sensors are: Securely fastened to the assembly At the same level with all indicator lights pointed in the same direction, for example, facing the rear of the machine.
3) Place the main blue lane assembly in the UP position. Attach an 18 long piece of I wide standard masking tape along the width of the main belt. Do this at the back idler pulley, so that you can ensure that the tape is evenly adhering to the belt. The belt must be dry and clean.
4) Place the blue lane assembly in the normal working position. With the computer turned on and the system energized, turn the motors on using the AUTO / MANUAL over-ride switch.
5) Adjust the sensitivity using the supplied jewelers screwdriver: Slowly turn the adjusting screw on each lane sensor counter- clockwise until it stops. The indicator light should be off at this 18 point. (The adjusting screw is located directly under the indicator light on each sensor) Slowly turn the adjusting screw clockwise until the indicator light comes on, the result of sensors sensing the masking tape each time it passes. Now slowly back off the screw until the sensor cannot sense the masking tape causing the indicator light to turn off, this is a very fine adjustment.
6) Repeat Step 5 for the remaining lane sensors.
7) Once all the sensors have been adjusted turn off the main belt and remove the masking tape. Turn on the boxer and count chicks one at a time on each lane to verify that the system has not missed any counts. If you are missing counts, try increasing the sensitivity.
8) Replace sensor cover and bolts.
BOX POSITION SENSOR ADJ USTMENT
Turn the quad boxer computer on:
1) Ensure that, the box sensors are securely fastened tot the box positioned conveyor and that you can see the sensor indicator light.
2) Adjust the sensitivity using the supplied jewelers screwdriver: Slowly turn the adjusting screw on each sensor (located directly under the indicator light) counter-clockwise until it stops. With a chick box positioned in front of the sensor, the indicator light should be off. Slowly turn the screw clockwise until the indicator light comes on, the result of the sensor sensing the positioned box. Then turn the screw again clockwise to ensure that the sensor will properly sense boxes that are deformed or damaged.
3) Slide the chick box out of position and verify that the indicator light has turned off. If not, the sensor may be picking up a reflection from some object. Slowly turn the sensor adjustment counter clockwise until the indicator light turns off again and repeat the procedure. Verify that the sensor still senses a chick box as it passes over the sensor
4) Repeat Steps 2 and 3 for the other box sensors.
Note: Perform this test on all box styles and colors. A darker colored box Will require more sensor sensitivity compared to the lighter colored boxes. 19 SYSTEM SPECIFICATIONS
MOTORS
Box Feed Conveyor hp 67 rpm Flange Mounted Sealed Gear Main Drive hp 189 rpm Foot Mounted Sealed Gear Middle Conveyor hp 142 rpm Flange Mounted Sealed Gear Top Conveyor hp 67 rpm Flange Mounted Sealed Gear Voltage Rating 208v 3 60 hz 5 wire
All motors are independently protected by overload protectors in the control box. You must manually reactivate the overload device if the motor trips the overload limit. Please refer to the motor manual supplied with the quad boxer for any maintenance information. The flange mount motors are mounted on adjustable torque arms. These toque arms allow the motor to move freely with the shaft, thus preventing the motor bearings from absorbing any abnormalities in the shaft. The lock nut used in shipping MUST BE LOOSENED OFF to allow clearance at the torque arm adjusting bolt and facilitate free motor movement and backlash.
If the motors are removed, always make sure that there is a coating of ANTI SEIZE type compound on the keyed drive axle at re-assembly.
THE CHAIN AND FRONT BEARINGS SHOULD BE GREASED AT LEAST ONCE A MONTH. PRIOR TO DOING THIS, THE CHAIN GUARD HAS TO BE REMOVED.
ALL SIDE COVERS MUST BE IN PLACE ON THE QUAD BOXER WHILE THE MACHINE IS ON.
THE CHAIN GUARD ON THE MAIN HIGH SPEED BELT MUST NOT BE REMOVED UNLESS IT IS BY A QUALIFIED MAINTENANCE PERSONNEL AT TIME OF SERVICE ONLY.
BEARINGS AND SHAFTS
Wash-down rated pillow block bearings are used on all shafts. 1 pillow blocks are used on drive and idler rollers and 1 3/16 on the box feed conveyor shafts. All bearings must be greased at least once a week and more frequently when high-pressure (over 150 psi) washers are used. We recommend a USFDA approved waterproof synthetic base grease with Teflon. This item is available from Kuhl Corporation. After lubricating the bearings, remove excess grease from outside the bearing housing to prevent grease from coming into contact with the belts.
20 CONVEYOR BELTS
Box conveyor belt Intralox Series 900 Acetel, ApproxiIimately 25 Top conveyor belt 20 x 50 with dual V-Guides Middle conveyor belt 20 x 70 with dual V-Guides Main conveyor belt 20 x 106 with dual V-Guides
Conveyor belts only need enough tension to prevent slippage. Over- tightening will reduce the life of the belts and bearings. The v-guides ensure that the belts will track properly. The belt expands or contracts slightly over the first few weeks of operation and it will require re-tensioning when this occurs. Replacement belts are split seam. To install a new belt, simply cut the old belt off and loosen the bolts at the idler bearings, and slide the roller. After installing a new belt, re-tension by adjusting both sides of the shaft as evenly as possible.
PNEUMATICS
The pneumatic control system incorporates a manual safety lock out valve with a .5 micron filtration with automatic drain. Five Bimba air cylinders controlled by a (6 bank) MAC Valve Assembly mounted within the main electrical panel (5/32 OD tubing is used for the 4 deflector cylinders) & (1/4 OD tubing is used for the box stop cylinder). The sixth valve supplies the control air for the IB spray vaccinator. A filtered dry regulated air supply of 50 to 60 PSI is required for proper operation. This pressure is split at the MAC Valve Assembly where the pressure is regulated to approximately 14 to 18 psi for the four diverter air cylinders. Air system lubrication is required every three months. Remove the tubing or cap at the outlet port of the filter, inject about 8 to 12 drops of air tool or light hydraulic oil into the tube and reinsert the tube or recap the fitting. The flow controls have been pre-set at the factory and may require periodic adjustment. This should be done by a trained technician. Each valve has a test button that allows cycling of each individual cylinder. The solenoid is driven by a 24 VAC signal from the computer. The computer incorporates diagnostic functions that allow testing of the pneumatics. For technical help or information please call, (908) 782 5696.
21 KUHL 40K / 60K CHICK BOXER SERVICE BULLETIN #001
TESTING SENSORS AND COMPUTER COUNTING ACCURACY:
Parts & Tools Required
18 foil tape (2 wide) Available in spare parts kit or at local hardware store
Sensor input chip #MC14490 For ver.1, 2 & 3 motherboards ONLY (IE, stainless steel computer box)
1) Ensure that the sensors are properly adjusted. Refer to the sensor adjustment instruction sheet in this manual or, if necessary, contact the support line at (519) 652-0808.
2) Lift the blue lane guide assembly on the main belt and carefully adhere foil tape horizontally on the belt (the belt must be clean and dry). Only remove the paper backing as you attach the tape to the belt. Use skid plate as a hard surface for adhering the tape.
3) Load empty boxes in to the counter and start the system as normal. Each revolution of the belt should generate 4 counts on the display panel. Run the boxer for a total of 60 revolutions. The boxer should display 240 counts after this test.
4) If the system does not count properly, clear the counts and repeat the test.
Try the following if the system does not count properly:
Test each sensor with the sensor test function under diagnostics, <5> key on keypad.
Clean the sensors with rubbing alcohol and a soft cloth.
Replace the sensor input chip on the main green computer motherboard (#MC14490 For ver.1, 2 & 3 motherboards ONLY ).
Try replacing CPU board (4 square blue board in spare parts kit)
Contact the Kuhl Boxer Support Line @ (908) 782-5696.
22 INSTALLATION & USE of VER. 2.9 CHICK BOXER SOFTWARE
This software upgrade allows the Kuhl 40, 60 and dual boxer to support various non North American standard chick boxes (i.e. four corner, paper, ect.). The following steps will have to be done in order to use this software version.
1) Install the supplied sensor bracket on the current box stop and move fill box sensor from current position to this new box sensor bracket (i.e. sensor at the front of the machine).
2) Install new EPROMs onto CPU board, configure software settings (see installation notes below).
3) Possible upgrade of box stop to allow for four corner chick boxes.
EPROM Installation Instructions:
1) Turn Boxers power off.
2) Open cover on computer.
3) Carefully remove 4 square CPU card from motherboard.
4) Using chip puller supplied in the spare parts kit, remove two EPROMs on 4 square CPU card. Pay attention to chips A and B placement along with chip orientation (i.e. notch on EPROM).
5) Install new EPROMs into sockets. Do not install backwards and be careful not to bend any pins. Ensure that the chips are well seated in the board.
6) Re-install CPU card onto motherboard. Pay close attention to board orientation and pin to socket connection.
7) Double-check your work, then close cover
8) Turn on boxer and ensure that the computer turns on properly.
9) Go to setup menu, <9> key on keypad.
10) Check all system settings:
Verify the bird per box setting. For a four corner box, this setting must be set to the qty. of chicks placed in the first half of the box (i.e. 50 chicks for a 100 chick box). 23 Verify the small, medium and large bird size setting (settings depend on belt speed, defaults are 8, 9, 10).
This software has a new setting, i.e. #7 SCOOP DELAY. You have a choice of a delay setting of 1 to 30. Each increment represents a 33ms delay from the time the box stop closes and the four deflectors to open. This time delay is critical for short distance travel (i.e. four corner boxes). Use a low value (i.e. between 1 and 5) for four corner boxes.
Under system setting #5 choose the fill box method, either 1 of 2, then after pressing the enter key, choose the end of flock method, i.e. 1- use next flock (your current method) or 2- Select flock.
Notes on Box sensor algorithm and Box sensor adjustment:
In order to accommodate different box styles we have changed the box movement detection algorithm in the software. It is important to understand the following logic in order to properly adjust the box sensors.
Start System:
Check the Que. box sensor for box: (sensor behind/next to control panel) Box present: Proceed No Box: Box Not Ready to Load Error
(This error occurs just prior to the deflectors activating)
Check Fill Box Sensor for Box: (Sensor on new bracket) Box Present: Proceed No Box: Box Not Ready to Load Error
When count reaches Birds per box limit Open Box Stop Close Box Stop When Fill Box Sensor is off. Delay (i.e. between 130 on setup menu or 33ms 990ms) Open all four deflectors.
If box did not move Stop the system Display Box did not move error
The fill box sensor must be adjusted, both physically and electronically (i.e. with the sensitivity adjustment) so that it only picks up the side of the box. You can also adjust the speed by which the box stop goes up and down by adjusting the sensitivity and location of this sensor.
24 4.02 SOFTWARE UPGRADE (FOR USE WITH INFARED SENSORS)
THE 4.02 SOFTWARE WITH THE ADJ USTABLE MARGIN IS MORE ACCURATE AT HIGHER SPEEDS AND ALLOWS CUSTOM SETTINGS FOR DIFFERENT BREEDS OF CHICKS.
4.02 SOFTWARE ALLOWS THE ADJ USTMENT OF THE MARGIN, WHICH IS THE SIZE DIFFERENCE BETWEEN SET BIRD SIZE AND WHAT THE COMPUTOR SEES.
EXAMPLE: BIRD SIZE SETTING SM =8, MED =9, LG =10
MARGINS SETTING SM =5, MED =6, LG =6
THE MARGIN IS AUTOMATICALLY SET AT +1, DEPENDING UPON THE NUMBER BEING ODD OR EVEN.
WE HAVE FOUND THAT SIZE 9 SETTING WITH MARGIN 6 IS BEST. THIS SETTING MEANS: ANYTHING EQUALTO BIRD SIZE 15 AND LOWER IS COUNTED AS 1 & ANYTHING EQUALTO BIRD SIZE 16 AND HIGHER IS COUNTED AS 2. THIS REFERS TO SIZE AND MARGIN.
THE 4.02 SOFTWARE IS ALSO QUICKER THAN THE OLDER VERSIONS, ALLOWING THE COUNTERS TO COUNT AT A HIGHER CAPACITY.
EXAMPLE:
ONE CUSTOMER HAS AN 80K COUNTER, WITH INFARED SENSORS, THAT COUNTS OVER 100K AND IS STILL WITHIN THE GUIDELINES, WITH LESS THAN PERCENT ACCURACY.
A SECOND CUSTOMER HAS A 60K COUNTER, WITH INFARED SENSORS, THAT PEAKS OVER 90K AND IS STILL WITHIN THE GUIDELINES WITH 1 PERCENT ACCURACY. 25