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Version 2.

RECOMENDATIONS
AND HANDLING

00

INDEX

RECOMMENDATIONS AND HANDLING


01 introduction to poultry farming . . . . . . . . . . . . . . . . . . . . . . . .

04

02 zucami vertical battery materials . . . . . . . . . . . . . . . . . . . . . . . . 05


03 feed distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
04 egg collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
05 dropping removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

06 electric switchboard management . . . . . . . . . . . . . . . . . . . . . . . . 16


07 humidification - panel operation . . . . . . . . . . . . . . . . . . . . . . . . . 22
08 ventilation for poultry farming . . . . . . . . . . . . . . . . . . . . . . . . . 24
09 breeding and rearing cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 temperature controls: orion vs. sirius . . . . . . . . . . . . . . . . . . . . . .

31

11 scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12 egg control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13 WATERwater level alarm . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . 49

14 waste predrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

RECOMMENDATIONS AND HANDLING | 3

01

INTRODUCTION

INTRODUCTION TO POULTRY FARMING WITH VERTICAL BATTERY SYSTEMS


This is the last step to intensive poultry farming, being able to have cages several levels high and achieving
population densities far above those of any other system.
We need to create a definition that agrees with reality. We are in the food industry. To the animal-machine
created by geneticists and the nutritionist s feed composition, we must add all the designer s ingenuity in
order to reach the highest level of animal well- being, with the objective being the maximum results from
its potential productive capacity.
Housing birds in batteries is ideal. Their situation is comparable to that of persons who leave the country
to go live in flats in the city. The birds receive a balanced diet and enough air and water in an environment
that has been designed specifically for them. With isolated buildings, and in cells of 8 to l0 birds, we can
say that the pecking order does not create problems.
Hens transform feed, water and air into eggs, a finished product ready for consumption. The habitat
in their installations must be controlled according to temperature, relative humidity, adequate
ventilation, etc. We need to eliminate spider webs, dust, odors, rats, flies, etc.
Highlights concerning results in vertical batteries:
Large density (fewer sheds, greater control)
More comfortable living quarters or cells
Easy handling
Absence of insects
Absence of gases (ammonium)
Less stress on the birds
Lower mortality: 0.5% monthly, over the total life cycle
5 grams less feed, 95-97 grams (white hens)
1.5% fewer dirty, cracked eggs
75% less manpower than normal batteries

4 | RECOMMENDATIONS AND HANDLIN

02

BATTERY MATERIALS

n this section, we will see all the materials making up the ZUCAMI vertical battery, and their main
characteristics.

LEGS
Due to the special configuration of the battery, the legs are distributed every 610 mm, in other words,
in every space. They may be regulated for height and are totally hidden within the battery. They run the
entire height, from the floor to the feed cart, which they support. They are made of galvanized pipe.

FLOOR
The cage floor is made of mesh that, after welding, is hot-galvanized and guaranteed to last 20 to
25 years. The maximum diameter of the wire is 0 2 m/m. The cage floor is flexible and designed for
optimal egg reception, cradling the egg at a height of approximately 4 cm.
The galvanized plating components are top quality (GALVAMIR Z-275), with their properties being
guaranteed for 25 years.

RECOMMENDATIONS AND HANDLING | 5

02

BATTERY MATERIALS

PARTITION OR DIVIDER
The partitions or dividers are manufactured entirely of co-polymer polypropylene plastic (never recycled
plastic) that are UV treated to preserve all their mildness. Generally speaking, their composition provides
the following characteristics: It is non-toxic, rust inhibiting, anti-static, and prevents migration.
They are resistant to temperature differences and their openings are 25 mm in diameter, contributing to
better side ventilation and lower stress on the birds, as they make side access and visibility more difficult.
These side dividers help keep the birds plumage in better condition, compared to mesh or plate dividers.
They are meadow-green in color, a relaxing color which has a calming effect on bird behavior, leading to
better zootechnical results.

ZUCAMI POULTRY EQUIPMENT, certifies and guarantees that the plastic used in constructing
their batteries for poultry farming is of the highest quality, based on present knowledge of the R.F.A.
regulations and the U.E. Directive.
The most important characteristics of the material used are:
Balance among tenacity, rigidity and strength
High stability of shape under heat
High stability of shape when exposed to temperatures below zero degrees centigrade
Low water absorption and water vapor permeability
Extremely varied transformation without problems
Non-stick agent
Anti-static agent
Stabilization when exposed to UV rays
Anti-electrostatic additives

6 | RECOMMENDATIONS AND HANDLIN

02

BATTERY MATERIALS

It should be pointed out that there are a great number of pieces within the ZUCAMI Vertical Battery line
that are manufactured in the same meadow-green color as the partition or divider.
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For the greater confidence of our clients, they may conduct an analysis of the material used at the Instituto
Juan de la Cierva (Madrid).

DOOR
The cage door is easy to operate, and is completely retractable. Its opening leaves the entire front surface
free, making it easier to place the birds inside without hurting them or damaging them due to its perfectly
finished frame.
It is made of electrically welded horizontal steel bars covered in white P.V.C.

RECOMMENDATIONS AND HANDLING | 7

02

BATTERY MATERIALS

FEEDING TROUGH
The feeding trough is manufactured with a channel that has been plated with a high quality galvanizing
material, GALVAMIR Z-275. Its carefully designed shape prevents feed from being spilled, as the outer
side is large enough to prevent this.
It is not a structural part of the battery, so it does not need to withstand unnecessary force. It only has a
purely feeding-related function.

EGG TRANSPORT BELT


The egg transport belt is manufactured with synthetic fiber threads that have earned the OEKO-TEX
certification, meaning that this material has passed the strictest tests and controls for strength, aqueous
extract pH, etc., as well as ensuring that the material used to manufacture the egg transport belts is free
from any product that might be hazardous to human health.

DEBRIS REMOVAL BELT


The manure removal belt is located below each level, and is manufactured in white polypropylene.
The belt width varies according to the cage model, ranging from 945 mm to 1304 mm, while the thickness
in all cases is 1 mm.

DRINKING TROUGH
The drinking trough consists of a square water supply tube with a valve or multidirectional nipple and a
V-shaped recovery trough that runs the entire length of the battery. The valve or nipple placement is as
follows: one at each divider and another in the center so that three are available in each cage. They are
located in the rear, on the dividing line.

This is a closed system where the water is not contaminated. The valve or nipple is self- cleaning,
improving sanitation. It is controlled by low pressure to make it easier for the birds to activate the vale or
nipple.

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02

BATTERY MATERIALS

Under the drinking tubes we find the recovery trough


(V-shaped) that runs the length of the battery.
The recovery trough is made of P.V.C. and is inclined 120.
The water pressure is controlled by independent tanks on each level.
The capacity of each tank is 7 L, and their operation is optimal up to 5
bar maximum pressure.

NIPPLE WATER FLOW STUDY


The table below shows the quantity of water a nipple may release when installed on the vertical battery,
depending on the height of the water tank compared to the drinking tube line.

LT/H

CC/MIN.

nipple water flow 4006H

water column height CM.

RECOMMENDATIONS AND HANDLING | 9

03

FEED DISTRIBUTION

FEED DISTRIBUTION
This may be carried out by means of:
Flat Chain
Coil spring
Carts
Le systme de chariots plaques de nivellement et de redistribution des aliments sur la mangeoire est le
plus simple et obtient des rsultats optimums.
The cart system with leveling guides, which redistributes the feed in the feeding trough is the simplest
system, with the best results.
The feeding trough must have a vertically-pointed V-shape bottom, permitting the guide to in at the sides
vertically-horizontally, making it very stable.
The guide or shoe rests in the feeding trough, and its function is to redistribute the feed in the feeding
trough, lining it up, at the same time that it cleans the trough, scraping away crusted on bird saliva,
allowing the galvanized plate to air out, thereby preventing rust.
lt has been proven that smaller doses of feed are the best distribution system, always leaving fresh feed all
along the feeding trough.
With this distribution method, we avoid feed piling up in the feeding trough and the birds wasting or
spilling the feed.
When there is a lot of feed in the feeding trough, the hen looks through it, and with the movement of her
head, throws a certain amount of feed onto the floor or the droppings belt. This produces an inaccurate
figure for the feed consumption per bird.
The minerals and feed components are deposited in the bottom of the feeding trough, since the hen eats
the feed on the surface, never on the bottom of the feeding trough. With excess feed, we run the risk of
damaging the trough, since the minerals and feed components (besides the already mentioned bird saliva)
form a layer so abrasive that it will eventually perforate the sheet used to manufacture the feeding trough.
Feed is regulated in the feeding troughs by means of the control timer and the feed dispenser outlet.
The dispenser outlets all have to be equal, with 10 mm openings, for the hopper to travel its round-trip
path with the feed. This ensures adequate food distribution.
lf the amount of feed in the feeding troughs is not correct, we can increase or decrease one or more feed
deliveries at the control timer, never at the dispensers.
To ensure adequate feeding of all the birds, we advise allowing for a cart wait time of 10-12 minutes,
letting the hopper rest at the end opposite of where it is filled.

10 | RECOMMENDATIONS AND HANDLIN

03

FEED DISTRIBUTION

SUGGESTED FEEDING PROGRAM


IN THE SUMMER

First delivery: 1 hour after first light.


The following 7 deliveries every hour.
For deliveries 8-12, every two hours. 12th through 14th, once an hour. Total number of deliveries: 14.
These 14 deliveries correspond to the hoppers at the loading point, departing for delivery.
Wait time: 10-12 minutes.
Total: 28 deliveries.

DURING THE REST OF THE YEAR

First delivery: 1 hour after first light.


Following deliveries: every 2 hours, until completing a total of 8 deliveries.
These 8 deliveries correspond to the hoppers at the loading point, departing for delivery.
Wait time: 10-12 minutes.
Total: 16 deliveries.

RECOMMENDATIONS AND HANDLING | 11

03

FEED DISTRIBUTION

RECOMMENDATIONS FOR DISPENSER INSTALLATION


1st. Position the dispenser tube intake as low as possible over the building s coil loading distributor, so that
the feed falls under its own weight;
Place it in an area that is as vertical as possible. If coils are joined, the junction box might be a good place.
We recommend that you try it out manually in order to see if the spot you have chosen allows the feed to
be dispensed before preparing the table.
2nd. Make the connections according to the accompanying schematic diagram, making sure that the
electrical intake current to the three wires (brown, blue and black) is 220 V.
3rd Program the Timer: switch it to the middle (automatic) position.
Example: if we fill the intake at 7 in the evening (according to our veterinarian s advice) and we have 20
minutes of lift operation time, we should program it with a little bit of margin, say, between 6:50 and 6:30.
To adjust the dispensed amount: On the first day, we should supply the exact amount. In other words:
If, for example, we have to add 2 grams per hen and we have 20,000 hens in the building, we will do the
following:
We place 40 Kg in the dispenser.
We try the middle regulator position (point 5), checking to see if we run out of feed or if some remains in
the hopper at the end. In the first case, we need to lower the regulator. If the opposite is true and there is
still feed in the hopper, we must raise it until it comes out even. Once we do this, we need only fill it in the
future.

12 | RECOMMENDATIONS AND HANDLIN

03

FEED DISTRIBUTION

OUTPUT HOSE

PHASE

LIFT
NEUTRAL

MAKE SURE THAT THERE ARE 220 VOLTS BETWEEN


THE BROWN AND THE BLUE.
MAKE SURE THAT THERE ARE ALSO 220 VOLTS
BETWEEN THE BLUE AND THE BLACK.

RECOMMENDATIONS AND HANDLING | 13

04

EGG COLLECTION

EGG COLLECTION
The first trip the egg makes after it first sees light is a 4 centimeter drop; therefore, we must think about how we
are going to catch it. The floor is made of galvanized mesh to allow the droppings to pass through, support the
birds and delicately catch the falling egg, the factory end product and our ultimate objective.
The floor is made of mesh, and is inclined to move the egg out. The hen lays the egg about 4 cm above this
mesh.
The mesh must be flexible, having wires with a maximum diameter of 2mm, but sturdy enough to support the
weight of the birds and to last 25 years.
The egg may break: on the cage floor, during the automated collection, during transporter unloading o during
packaging or sorting.
lt has been proven that the more flexible the floor, the fewer the possibilities of breakage.
We can conduct the following test to see how much breakage is occurring in our installations.

EXAMPLE
We pick up 1,000 eggs by hand from the cage belts on their way to the cones. We then pick up another 1,000
on their path aboard the transporters before they reach the packing equipment, and another 1,000 after passing
through the packing equipment.
We pass them through the sorter and we will have data to analyze the points that cause cracked eggs.
lf the belts that pick up the eggs from the cages are going too fast, the eggs will bump together when unloading
into the transporter, causing increased numbers of cracked eggs.
These belts may be regulated between 1 and 8 meters per minute. This system allows us to control the number
of eggs the packing equipment needs for its optimal operation, while eliminating the risk of cracked eggs.
The transporter has to work almost continuously, with very few interruptions, in order to achieve the best egg
treatment and prolong the life of the equipment.
With continual starts and stops, we cause sudden contact between the eggs, the motors use more energy than
during continual operation, and mechanically speaking, the motors, chains and pinions run a greater risk of
breaking.

14 | RECOMMENDATIONS AND HANDLIN

05

DROPPING REMOVAL

DROPPING REMOVAL
The droppings are deposited on the polypropylene belts located under the mesh floor supporting the bird
s feet.
This system permits the droppings to dry out in their initial phase, losing weight and volume, beginning
the process of evaporation so that their initial moisture content of 75- 80% is reduced to 65-70% at the
moment the system is cleaned.
In this manner, the ammonium emissions are eliminated that would otherwise circulate in the atmosphere,
coming into contact with the personnel during operation.
2 systems exist for dropping removal:
CLEANING THE DROPPINGS ALL AT ONCE
It is recommended to leave the droppings on the belts from 3 to 5 days, always depending on the length
of the outbuilding, but never more than 7 days, as fermentation will begin. We remove all of the rows at
once. We should bear in mind that the more days we wait, the dryer the droppings will be.
CLEANING THE DROPPINGS BY SECTIONS
We will measure the length of the row of cages and divide it by the 6 days that make up the work week.
We will call this result a module.
Every day, we will remove 7 days accumulation, thereby achieving drier droppings. The percentage of
moisture content in the droppings depends in a large part on the quality of the feed and good ventilation.
The moisture content in the droppings is estimated to be between 60-65%.
The pre-drying system in the battery is able to reduce this moisture content by approximately 10%.

RECOMMENDATIONS AND HANDLING | 15

06

ELECTRIC SWITCHBOARD MANAGEMENT

In this chapter, we will demosntrate the main controls of the different electric switchboards supplied by
Zucami.
In the following pages, we will see the operation of the:
Feeding switchboard
Transporter control switchboard
Cleaning switchboard

FEEDING SWITCHBOARD
Each feeding switchboard is equipped with a start-stop switch and two buttons, one for each direction of
operation.
Manual operation (0)
To begin operating a specific feed cart in manual mode,
we must activate the power switch corresponding to that
cart and press the button for the direction in which we
wish the hopper to operate. The cart will continue until
it reaches the end of its path, activating the limit switch
for that direction, and then it will stop. We repeat the
same procedure with the button assigned to the opposite
direction, and the corresponding limit switch.
This process should be repeated with all of the feed hoppers, checking to see that all the feed limit
switches work properly.
Automatic operation (l)
To program the feeding switchboard in Automatic mode (I), we should activate the switches for all the
feed hoppers and proceed to program the K5 timer with the times that we want the hoppers to begin
operation (only time of departure).
When the timer reaches the selected time, the feed hoppers leave the front area or the pick up point
towards the cleaning area or the rear and the K5 timer activates and programs the timer signal to the K1
relay for every two seconds. Upon arriving at the limit switch, they stop. When all the hoppers are at the
back, the series corresponding to the rear limit switches and the K6 timer is activated.
We must operate this timer if we want to increase or decrease the time the hoppers stop at the end
opposite the coil loading distributor. Once the stop time is up, the K6 timer activates the K1relay and
it sends the feed hoppers towards the front or collection area. When the hoppers arrive at the front
or the collection area, the limit switch series is closed so that the coil distributor may begin to operate
automatically and fill the hoppers with feed. The system is now ready for the next feed delivery.

16 | RECOMMENDATIONS AND HANDLIN

06

ELECTRIC SWITCHBOARD MANAGEMENT

COIL LOADING DISTRIBUTOR OPERATION


The coil distributor consists of a three-position switch
(automatic-stop-manual) and a blue button.
In automatic mode, it begins operation when the
hoppers arrive and continues working until the coil
distributor limit switch turns off.
In manual mode, the blue button must be pushed for it
to operate. If it is not pushed, it will not operate and the
coil distributor limit switch will not turn off.
The K2 timer is on the switchboard. This is the timer
that controls the filling of the hoppers. Its job is to
disconnect the coil distributor if the hoppers have not been filled during the prescribed time. This time
must be a bit longer than the time needed to fill the empty hoppers. If this timer remains in operation, it
will be necessary for us to cut off the operational circuit breakers on the switchboard and then restart them
so that the coil distributor can operate automatically.

INSTRUCTIONS FOR MODIFYING THE CART STOP TIME


The time pre-programmed at the factory is 12 minutes.
If you wish to modify this time, we must operate the K6 timer on the feeding switchboard. To do this,
select the full scale or scale that includes the desired time and use the adjustment knob to select it within
that scale.

RECOMMENDATIONS AND HANDLING | 17

06

CAPTULO
6.- MANEJO
CUADROS ELCTRICOS
ELECTRIC SWITCHBOARD
MANAGEMENT

CONTROL SWITCHBOARD OPERATION


The control cabinet contains various signals (lights).
Yellow lights One per level, plus another for parking (lit on the corresponding level).
Green lights Egg transversal (lit when in operation), Egg collection (lit when in operation).
Blue light Signals the status of the speed variator (lit when operating correctly).
Switches
In addition, we have two switches: One to activate the operation of the egg transversal and the other for
the egg collection.
Lift control


A= AUTOMATIC
I= MANUAL

It has 2 green lit buttons (one for each operating direction), and 1 red two-position switch to stop the lift. It
is also equipped with a 2-position switch to select the mode of operation for the lift.
Lift in automatic operation mode
From the stopped position, we can only give the first order to go down. The lift then positions itself at the
next level. If we activate the egg collection mechanism, the meter counter will begin counting down the
meters until it reaches zero. At that time, the upper blinking light will come on, and it will move to the next
level, and so forth, successively, until it finishes collecting the eggs on the first level.
When it finishes collecting the eggs and the meter counter shows zero, it will be commanded to raise itself
up to the parking position.
Lift in manual operation mode
We give the first order for it to go down, and it positions itself at the next level. When it finishes collecting
the eggs on that level, the upper blinking light will come on and we must push the down button for it to
move to the next level , and so on, successively, until it reaches the end.
Egg belt speed control
Using the potentiometer located underneath the blue light, we can control the speed of the egg collection
belts. This speed may be increased or decreased by 10 turn units for greater precision.

18 | RECOMMENDATIONS AND HANDLIN

06

CAPTULO 6.- MANEJOELECTRIC


CUADROS
ELCTRICOS
SWITCHBOARD MANAGEMENT

MODIFICATION OF THE EGG COLLECTION BELTS IN REVERSE


If we wish to modify the time the belts operate in reverse, we must modify the following times. The times
pre-configured in the factory are listed in parenthesis.
K3 Timer controlling the raising of the lift (15 SECONDS)
K4 Timer controlling the lowering of the lift (15 SECONDS)
K15 Timer controlling the rearmament of the lift (1 SECOND)
K16 Timer controlling the reverse collection time (10 SECONDS)
K17 Timer activating the normal collection rotation in order to release the clutch (2 SECONDS)
K18 Timer controlling the reverse collection delay time for the stop at the sorter (3 SECONDS)
MODIFY THE TIME ON K50 (18 SECONDS), FOUND ON THE CONTROL CABINET, AS WELL AS ON
K51 (0.4 SECONDS)

PROGRAMMING THE EGG COLLECTION BELT METER COUNTER


In order to program the rotation counter (in other words, the meter counter) for the egg collection belts,
we need to know the length of the belt. This is the length of the cage + 2 meters for the separation that
exists between the cage and the collection mechanism.
Practical Example
Calculation: 85 meters (space occupied by the cage)
2 meters (space between the cage and the machinery)
Total: 87 meters (total length of the egg belt)
Once the counter has power, press the keys e and 1 at the same time for about 20 seconds. The
following will appear on the screen: O O O X X X.
This indicates that the counter left the factory pre-programmed or that at this moment it is programmed
for a egg belt length of OOOXXX meters.
Pressing the keys 1, 2, 3, 4, 5 or 6 allows us to modify the corresponding digit, with each keystroke
increasing the value of the digit in increments of one.
By pressing:
6 we modify the hundred thousands
5 the ten thousands
4 the thousands
3 the hundreds
2 the tens
1 the ones
Pressing the E key memorizes the digit and the counter is now programmed and ready for operation.
The counter will count down the total meters on the belt.

RECOMMENDATIONS AND HANDLING | 19

06

ELECTRIC SWITCHBOARD MANAGEMENT

If our model is an enhanced cage, designated with the initials M.E.C., we can program the collection
switchboard with the automatic command to advance the egg collection belt. The objective of this
command is to prevent eggs from accumulating in the nest. Below, we will see the procedure for
programming this system.
Egg collection will be carried out between 7:00 and 11:00. The length of the belt being advanced is 3.6
meters. We advance the eggs on the belt in 8 different segments, with each segment lasting 53 seconds,
which will give us a belt advance distance of approximately 45 centimeters, within the time frame of 7:00
to 11:00. On weekends, it might be the case that eggs are not collected. We therefore assign two days
during which we only use 4 of the 8 assigned segments.
Example: from Tuesday to Saturday, 8 assigned segments, Sunday and Monday, 4 assigned segments.
In this manner, we make it so that the advance of eggs on Sunday and Monday is equal to the other days of
the week. The schedule for the factory assigned segments is the following:
Connection time
7:00:00
7:30:00
8:00:00
8:30:00
These 4 segments are assigned everyday.

Disconnection time
7:00:53
7:30:53
8:00:53
8:30:53

9:00:00
9:00:53
9:30:00
9:30:53
10:00:00 10:00:53
10:30:00 10:30:53
These 4 segments are assigned Tuesday, Wednesday, Thursday, Friday and Saturday.
If we need to modify the time frame on the timer, we can do so, but we must abide by the number of
segments (8) and the 53 second duration. Sample segment programming.
Press OK and see:














menu programa (program menu)


programa prog 01 (prog. program 01)
prog 01 modificar (prog 01 modify)
prog 01 c1: pulso (prog 01 cl: pulse)
prog 01 lu: si (prog 01 Mon: yes)
prog 01 ma: si (prog 01 Tue: yes)
prog 01 mi: si (prog 01 Wed: yes)
prog 01 ju: si (prog 01 Thur: yes)
prog 01 vi: si (prog 01 Fri: yes)
prog 01 sa: si (prog 01 Sat: yes)
prog 01 do: si (prog 01 Sun: yes)
prog 01 hora 07 (prog 01 hour 07)
prog 01 minuto 00 (prog 01 minute 00)
prog 01 pulso on 00 (prog 01 pulse on 00)
prog 01 pulso off 53 (prog 01 pulse off 53)
programa prog 02 (prog. program 02)

20 | RECOMMENDATIONS AND HANDLIN

Repeat this process as many times as


necessary and assign the desired time
up to prog 08, corresponding to
segment 8.

06

ELECTRIC SWITCHBOARD MANAGEMENT

CLEANING SWITCHBOARD OPERATION


This consists of the following elements: Debris belts (example with two belts) Cleaning rows (example
with 5 rows) up to 4 levels high, 1 motor per row 5-8 levels high, 2 motors per row
Each debris belt and each cleaning row has an Start-Stop switch.
This switchboard is designed in such a way that if Belt 1 (the one outside the building) is not operating, Belt
2 (inside the building) cannot operate. If the two belts are not operating, no cleaning motor on any row can
operate. As long as the two belts are operating, we can select whether we want row 1, row 2, row 3, row 4,
row 5, and so on, to be cleaned.
Each motor has a circuit breaker for protection.
If the circuit breaker is overloaded and tripped on Belt 1, everything stops.
If the circuit breaker is overloaded and tripped on Belt 2, everything stops except Belt 1.
If the circuit breaker is overloaded and tripped on the cleaning motor, only this motor will be affected. The
rest will operate normally.

TIMES FOR THE VARIOUS TIMERS


K-02 timer for the lift stop time (3 seconds, as a guide).
K-2 timer for the upper coil distributor operation time, when loading carts.
K-3 timer for the lift raising, egg collection motor stop time greater than the k-16 timer (4 seconds, as a guide).
K-4timer for lift lowering, egg collection motor stop time greater than the k-16 timer, the same time
as the k-3 timer (4 seconds, as a guide).
K-5 clock pulse timer (2 seconds).
K-6 timer for cart reverse time (depending on feeding program).
K-15 lift timer, lift rearmament timer (1 second, as a guide).
K-16 timer, collection reverse time (2 seconds, as a guide).
K-18 timer that times the signal from the sorter, time greater than k-16 (3 seconds, as a guide).

RECOMMENDATIONS AND HANDLING | 21

07

HUMIDIFICATION

Refrigeration using an evaporation system consists of passing an air flow with certain humidity and
temperature conditions, and that has not reached the saturation point, through a previously dampened
cellulose panel. As this air passes, it becomes more humid, getting as close as possible to the saturation
point.
The principle of physics that governs this process is the so called adiabatic cooling (at constant enthalpy)
of air in which no heat transfer with the outside is produced. What really has happened to the air is that
the appreciable heat in the air (represented by its temperature) has been transformed into latent heat
(represented by its humidity). The temperature goes down, but not the humidity.
As we can see, the final temperature depends a great deal on the air conditions upon intake, especially its
relative humidity. That is to say, the greater the airs relative humidity is upon intake, the lesser the cooling
capacity, since the water absorption capacity of the air is reduced.
Comparing the performance graphs for the different types of evaporation panels that exist on the market,
we can see that the cooling capacity increases when:

22 | RECOMMENDATIONS AND HANDLIN

Te panel thickness is increased, increasing the contact


time between the air and the panel water.
The speed the air passes through the panel is
decreased, and the contact time between the air an
water is increased.
The number of cells on the panel are increased,
increasing the contact surface between the air and
the water.

07

HUMIDIFICATION

Efficiency (%)

For PHC XX module humidifiers, the 7090 15


panel with a thickness of 100 mm is used, whose
performance with respect to air speed is shown in
the following graph.

Air speed (m/sec)

Air speed
(m/sec)

0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 2.0

Efficiency

82.8 81.5 80.8 79.5 78.9 78.0 77.2 76.5 75.7 74.8 73.9 70.8

As a practical example of the variation in the temperature of air leaving the module, we have made
calculations for an entry air temperature of 30 C and different air speeds and relative humidities.
entry conditions
entry
temp. (C)

relative
humidity (RH)


30C
30C
30C
30C
30C
30C
30C
30C
30C

exit conditions
f1 wb
(C)

temperature
v=1m/seg

temperature temperature
v=1.5 m/seg
v=2m/seg

10% 13.2 16.9


20%
15.7
18.8
30%
18.0
20.6
40%
20.0
22.2
50%
22.0
23.8
60%
23.8
25.2
70%
25.4
26.4
80%
27.1
27.7
90%
28.7
29.0

17.6
19.4
21.1
22.6
24.1
25.4
26.6
27.9
29.0

18.1
19.9
21.5
22.9
24.3
25.6
26.7
27.9
29.0

To obtain high panel performance, while the panel surface being installed should be as small as possible for the
100 mm thick 7090 15 panel, we will consider an air speed going past at 1.5 m/sec.

WATER EVAPORATION
We can also calculate the water consumption needed to cool the air using the following formula:
E=flow (m3/h)*(x2-x1)(kg/kg)*1.2 kg air/m3
In our case, we know that:
x1= 0.0143 kg of water/kg of dry air
x2 = 0.0177 kg of water/kg of dry air
E=12.000 m3 / h *(0.0177 0.0143)(kg/kg)*1,2 kg air/m3= 48.96 kg/h

RECOMMENDATIONS AND HANDLING | 23

08

VENTILATION IN POULTRY FARMING

VENTILATION

In a naturally ventilated building, it is important for the air to be able to enter and exit the building as easily
as possible. One way of ensuring good air renewal is to keep the area around the farm free of any object
that might obstruct air flow towards the inside of the building. Vegetation, buildings and farm equipment
may affect the air flow by a factor between 5 and 9. The ventilation openings in the roof do very little to
bring in fresh air. As a matter of fact, if the windows on both side walls are open, the roof ventilation is
responsible for less than 10% of the air flow. The main factor that determines the air renewal value is the
number of openings in the each side wall of the building. For warm climates, it is traditionally suggested
that the side wall openings be between 2.5 and 3 meters high. This helps ensure good air circulation in the
building.
When buildings are constructed in warm climates, they should include a roof with a slope of approximately
42%. A steeply sloped roof collects less heat from the sun than a flat roof. In addition, a slope of 42%
increases the volume of the building, which minimizes the heat increase.
To make sure that air can easily move through the building, it is best to keep the building as narrow as
possible. Most experts recommend that naturally-ventilated farm buildings have a width between 10 and
12 meters. A building wider than 12 meters tends to restrict air flow, therefore producing problems with
heat during the summer months.
Dirty side wires can also restrict air flow, and for this reason it is important to keep them clean. If only 1/8
of an inch of dust forms on the cage wires, the effective opening is reduced by 25%

24 | RECOMMENDATIONS AND HANDLIN

08

VENTILATION IN POULTRY FARMING

THE IMPORTANCE OF AIR MOVEMENT


Birds always try to remove excess heat from their bodies. Heat is a by-product of the birds metabolism,
digestion and activity. When summer temperatures are low, the difference between the bird s body
temperature and its surroundings is large enough to eliminate the excess heat, presenting no significant
problems for the bird. As the temperature rises, it becomes more and more difficult for the bird to
eliminate the excess heat by itself.
For example, a cup of hot soup cools much more quickly in the refrigerator than in a 30 room.
In order to survive, the birds try to increase their heat loss as well as decrease production. The birds will
start to pant in order to increase their heat loss due to the evaporation of the humidity in their respiratory
systems. They will flap their wings away from their bodies in an effort to increase cooling by air
movement. Their feed consumption will decrease in order to minimize the heat produced by digestion. If
the birds cannot reduce the excess heat by themselves, they will die.
One way of helping the birds eliminate heat is through air movement. As the air moves around the birds
bodies, it picks up their heat. The harder the air moves, the more heat it will pick up from the birds. If
there is enough air speed on their bodies, the birds will react to this increased air in the same way as if
the air temperature had gone down. In fact, research has shown that a bird in a 30 environment is just as
comfortable as one in a 20 environment, as long as the air moving around its body circulates at a speed of
90 meters/minute.
The increased heat loss with higher air speeds is reflected in better production from the birds. Studies
have discovered that during hot weather conditions, if the birds are exposed to an air speed of 150 meters/
minute, they lay more and better quality eggs than those birds exposed to 15 meters/minute.
However, to maintain production throughout the entire building, it is essential for each bird to have
adequate air movement around its body. In those places where birds do not receive adequate air
movement, they will die. This is the reason why birds exposed to dead spots of air are the first ones to die.

FANS
When considering the use of fans, it is important to realize
that, above all, a fan will only move air effectively in an area
with specific dimensions. The shape and measurements of the
coverage area is determined by the type of fan. The air from a
standard 55 fan with a 1.5 c.v. motor moves in an egg-shaped
area. The dimensions of this area are approximately 20-25 meters
x 4.5 meters.

RECOMMENDATIONS AND HANDLING | 25

08

VENTILATION IN POULTRY FARMING

It really does not matter how many birds are in the building, or even how many square meters is the
building. What really matters is the shape of the building and how that relates to the fan s coverage
area. For example, a 110 x 10 building would require eight fans 36 in diameter to provide uniform air
movement. A 110 x 12 building would require the same number. The narrower building would have more
air currents, but there is no practical way to reduce the number of fans and still provide good air movement
throughout the entire building. As you can see, a large number of fans are necessary. If the number of fans
is reduced, spots of dead air will occur in the building.
Total coverage of ground space with fans may not be necessary in every case. In some places, like costal or
mountainous areas, the breeze will be enough so that air movement is only necessary in the center of the
building. Fans may be installed in pairs in those areas of the building where heat builds up and tends to be a
greater problem, such as in the center.
It does not matter how many fans are installed in a building with side curtain walls. There is no way around
the fact that it is a building with side curtain walls. Air renewal and movement is largely random. As a
result, the environment and production cannot be compared to warm farm during a hot period that is
ventilated by a tunnel.
Below are some general rules that are important to remember when installing fans:
Install fans with slats that allow you to direct the air.
Fans that are inclined slightly downward increase air movement over the birds.
The fans must work with the main air supply in order to increase the area covered by each fan.
Avoid placing fans in areas where there are extremely strong air currents, such as in front of another fan.
The birds will note the high air speed and may become sickly because of it.
Always place the fans so that there is air movement at the ends of the building.

26 | RECOMMENDATIONS AND HANDLIN

08

VENTILATION IN POULTRY FARMING

IDEAS TO ALLEVIATE THE HEAT


1. The roof of the shed must have an inclination of 35% and the scaffolding must be 1.2 meters wide (air vent).
2. Install insulation on the roof Insulating the roof is probable the method most recommended for fighting
heat entering through the roof.
3. The sides of the building must be a meter taller than the cage. In other words, if the building measures
4.2 m, the building sides must measure 5.2 m.

Aire movement
4. Buildings housing egg production that have side curtains must have a fan that is at least 55 (1.5 HP,
43,000 cubic meters) for every 20 or 25 meters of building length.
5. Position the air circulation fans so that they blow towards the central aisles, inclined slightly
downward. This will increase the air movement over the birds.
6. The air circulation fans should be placed in stagnant areas, for example, in aisles and in the center of
the building.
7. Air moving through the birds at 120 m/minute will reduce the effective building temperature by 3 to 5.
8. Set the fan thermostat at 23 during the day to ensure that the fans operate long enough at night, giving
the birds the chance to cool off.
9. Operating the fans at night will improve the birds production and food consumption during periods of
greatest heat stress.
10. Clean the droppings deposited on the cage belts (at least once every 7 days). As the waste
decomposes, it produces heat, raising the temperature above 37.
11. Cut any grass or weeds that grow around the building. (They may restrict the air flow entering the
building.)
12. The bare ground around the building will reflect heat inside the farm. It is preferable to have a short
lawn around the building to absorb the heat.

RECOMMENDATIONS AND HANDLING | 27

09

BREEDING AND REARING CAGE

BREEDING AND REARING CAGE


MESH
Hot-galvanized after soldering, with 2mm diameter wire. the grid is 19 x 19 mm in all its compartments.
The battery placement is supported on longitudinal bars and held in place in the center and front.
PARTITION OR DIVIDER
Completely manufactured in Copolymer Polypropylene, with holes 20 mm in diameter.
DRINKING TROUGH WATERERS
Adjustable in height by means of a manual winch located at the start of the battery. Two teats are placed in
the openings at a constant level.
DOOR
The cage door is easy to operate, and is completely retractable. Its opening leaves the entire front surface
free, making it easier to place the birds inside without hurting them or damaging them due to its perfectly
finished frame.
ADJUSTABLE FRONT
Its height is adjustable from one end of the battery, as the birds grow. The feeding troughs, legs, and
dropping belts have the same configuration and quality as the hen battery.

28 | RECOMMENDATIONS AND HANDLIN

09

BREEDING AND REARING CAGE

BREEDING AND REARING CAGE FOR AGES 1 DAY TO 16 WEEKS INSTRUCTIONS FOR USE
First days, temperature at approximately 35.
Light: 60 W Light bulbs. (distance: 2 m, height: 3rd level)

CHICK PLACEMENT IN THE CAGE


The chicks are placed in the spaces available on the 3rd level, whether the cage has 3 or 4 levels. In other
words, if it is a 3-level battery, the chicks are placed on the top level, and if it is a 4-level battery, all the
chicks are placed on the 2nd and 3rd levels. Maximum time: 18 days. After this date, we would double the
space, leaving a proportional part open in each cage.
During the first 4 days, it is advisable to put paper on the level of the cage. By doing so, we prevent the
animals from suffering due to the contact between their feet and the mesh. The paper should never be
placed under the drinking tubes. (If the paper gets wet, the chicks will get wet, too.)

FEEDING
On the first day, deposit a small quantity of feed on the paper on the level of the cage, so that even the
weakest chick can start to eat from the beginning.

On the front of the cage, place a metal plate with holes that provide easier access to the feed in the feeding
trough. In this manner, the chicks eat easier and do not leave the cage. The plate with holes is removed
from the front after 18 days, coinciding with the doubling of the chicks space.
The front of the cage is adjustable using a mechanized system located at the beginning of the cages. Using
this system, we can regulate the front all along the cage, making it easier for the chicks to stick out their
heads.
Feed distribution with the cart is carried out automatically from the first day, since we can place a device
facing the plate with holes on the opening to the feeding trough. We then close the other openings with a
plastic cover. Three days before we double the space, we stop delivering feed so that the chicks finish the
feed that has accumulated in the feeding trough. Once this procedure is finished, the dispensers are placed
on all the cart openings.
RECOMMENDATIONS AND HANDLING | 29

09

BREEDING AND REARING CAGE

DRINKING TROUGHS
Two 360 waterers with troughs are installed in the space. The waterers are situated in the optimal spot
for the chicks to easily activate the nipple. In this manner, we make it easier for the chicks to drink from the
first day. The waterer is adjustable in height as the birds grow, using a mechanized system at the beginning
of the cages.
We regulate the height of the waterer, placing it just above the chicks heads.

DROPPING REMOVAL
During the first 10 days, it is advisable to remove the droppings every three days, and, as the waterer will
be at its lowest level, the chicks will spill some water. With this water, the droppings and the heat of the
first few days, fermentation will occur quickly.

OTHER DATA
Feed consumption: 5.6 kg

VACCINATIONS
According to breed and area.

BEAK CUTTING
Regulated buildings: one beak cutting at 8 weeks.
Open buildings: 2 beak cuttings, one at 8 days and another at 14 weeks.

RECOMMENDATIONS FOR CARE IN BREEDING AND REARING


Keep the cages in good condition.
Begin weight and growth controls early on.
Maintain adequate control of the atmospheric temperature and relative humidity.
Contribute to water and feed consumption.
Use an appropriate light program.
Pay special attention to beak cutting, a determining factor for obtaining a homogeneous lot.
The amount of feed to be distributed depends on the observed weight of the birds.
It is absolutely necessary to pay increasingly more attention to the rearing phase, due to the need for
having an adequate body weight when the hens begin to lay eggs.
The productivity of an egg-layer is largely determined by the quality of work and management performed
during the rearing period.

30 | RECOMMENDATIONS AND HANDLIN

10

SIRIUS VS. ORION

TEMPERATURE CONTROL SYSTEMS


ZUCAMI has 2 temperature control systems presently on the market. These 2 control systems are called
SIRIUS and ORION.
As we will see in the next 2 pages, these two control systems differ mainly in the options each offers.
This control system may be integrated into various places, depending on the type of ventilation that will
be used in the building. We will describe the placement of the temperature control system in a building
designed for transversal ventilation and then for one with a tunnel-type ventilation.

TRANSVERSAL VENTILATION

ORION or SIRIUS
+ 50% FANS

VENTILATION SWITCHBOARD
+ 50% FANS

tTUNNEL-TYPE VENTILATION

ORION or SIRIUS
only Display - CPU

VENTILATION SWITCHBOARD
and electrical part of the control system

RECOMMENDATIONS AND HANDLING | 31

10

SIRIUS VS. ORION

SIRIUS

TEMPERATURE

Max. 2 Interior Temp. sensors, 1 Exterior Temp. sensor

VENTILATION
(BASIC + NATURAL)

Proportional (0-10V), Maximum 8 steps

VENTILATION (NATURAL)

1 flap (0-10V)

SLAT SCREEN

1 screen (0-10V)

WINDOWS
(BASIC + NATURAL)

With timer, negative pressure or in ventilation


Maximum 2 entry flaps (0-10V or exit hole)

WINDOWS (TUNNEL)

1 entry flap (0-10V)

HEATING

Maximum 2 control systems (Proportional or ON/OFF)

COOLING

1 ON/OFF contact

AIR HUMIDITY

1 RH sensor
1 contact (humidification)

TIMERS

Maximum 3 contacts (for example, for feed or water)

FEED RECORDING

With pulse counter (counter total)

FEEDING

Only on timers (with hours ON/OFF)

WATER RECORDING

With pulse controller (with hours ON/OFF)

WATER CONTROL

Only on timers (with hours ON/OFF)

LIGHT CONTROL

Only on timers (with hours ON/OFF)

32 | RECOMMENDATIONS AND HANDLIN

10

SIRIUS VS. ORION

ORION

TEMPERATURE

Max 12 Interior building temp. sensors, 1 exterior temp.


Wind speed and direction

VENTILATION
(BASIC + NATURAL)

Proportional (0-10V + 2 exit holes)


Maximum 16 steps

VENTILATION (NATURAL)

Maximum 3 flaps (chain) (3x 0-10V)

SLAT SCREEN

Maximum 2 screens (0-10V)

WINDOWS
(BASIC + NATURAL)

With timer, negative pressure or in ventilation position;


Maximum 6 entry flaps (0-10V) maximum 2 flaps summer/winter

WINDOWS (TUNNEL)

1entry flap(0-10V)

MIXED VENTILATION

Proportional (0-10V) or ON/OFF

HEATING

Maximum 4 controls (Proportional or ON/OFF)

COOLING

Maximum 2 ON/OFF contacts

AIR HUMIDITY

1 RH sensor and 1 contact (humidification)

TIMERS

Maximum 4 contacts (connected to the main light control or separate)

FEED RECORDING

With pulse counter


Feed weight (maximum 3 silos) or silo weight

FEEDING

With hours ON/OFF or with grams per animal per day (curve) / Row by row

WATER RECORDING

With pulse controller (with hours ON/OFF)

WATER CONTROL

With hours ON/OFF or with ml per animal per day (curve)

LIGHT CONTROL

With ON/OFF times or hours of light per day and level of light (0-10V) for main
illumination + Maximum 4 light controls (connected to the main light control or
separate)

EXIT DOORS

Open/close the exit doors (1 exit hole)

LAYING HENS NESTS

Open/close the egg-laying nests (2 exit holes)

MANURE DRYING

Maximum 2 complete controls for frequency control systems


(for air machine or heat exchanger)

BIRDS WEIGHING

Maximum 2 bird-weighing scales

EGG COUNTER

Totals / By rows and levels / Egg belt speed optimization

RECOMMENDATIONS AND HANDLING | 33

11

CAPTULO
11.- BSCULAS
SCALES

Zucami presently has two types of weighing scales.


Roxells batch weighing scales and Hotracos loading cells.

HOTRACO SCALE (Loading cells - P3000GH)

The loading cells use a program called P300GH that allows you to control the parameters and program all
types of configurations.

34 | RECOMMENDATIONS AND HANDLIN

11

CAPTULO 11.- BSCULAS

SCALES

The following is a list of configuration codes for the previously mentioned program.

CODES
Code 1 Weight section
Code 5 Initial presentation
Code 10 Precise calibration with weight sample
Code 27 Calibration number
Code 37 System adjustment and 0.8mV/V calibration
Code 45 Display speed
Code 55 Pulse activation range, per kilogram
Code 81 Driver on/off
Code 85 Maximum weight definition
Code 90 Language selection
Code 99 Software version and date
To access a particular function in the Code menu, enter into the total weight menu (this is normally the
menu that appears on screen when the unit is turned on) and press the keys F1 F2 for approximately 10
seconds. The Code menu will appear on screen. You may now select the code number. Press the key
F1 to confirm your selection.
Remember that if you wish to change the code number or the parameters within the code, you must
use the keys
. You may increase or decrease the selected number or move from one parameter to
another by pressing these keys.
If the value you wish to change has a cursor (for example 0500 , the selected number is the one in the
black box. Use the arrow key
to select other digits (these graphic keys are normally associated with
the keys F2 F3 ).
Code 1, Weight section
You can select the option of increasing or decreasing the weight
among the digit values 1, 2, 5 and 10. This value is not related to the
transformers unit of measurement. If, for example, you are using
a calibration with kilograms as the unit of measurement (you will
not see decimals) and you select value 5 as the weight section,
the variations in weight will appear on the screen in 5 kilogram
intervals. If, on the other hand, the base measurement is, for
example, 3 grams (you will see three decimal places), the weight
variations will be displayed in 5 gram intervals.

Cdigo 1
Seccin: 2
Exit

Cdigo 5
Presentacin:
Exit

Clear

Code 5, Section presentation


You can insert a personalized introduction (2 lines, with
40 characters) that will be displayed every time the transformer
is turned on. This introduction is printed as a heading on paper
if you are using a printer.

RECOMMENDATIONS AND HANDLING | 35

11

CAPTULO
11.- BSCULAS
SCALES

For this code, the keys F2 and F4 are associated with


.
Press these keys to move the cursor to the insert position: Use the keys
to move between elements
in the character list. To erase all the characters, press Clear .
Press Exit to exit the present code window, saving any modifications. Now turn off the system and turn
it back on again. The personalized introduction will apear on the screen.

Cdigo 10
Valore
Peso campione: 000123
Exit

Code 1, Precise calibration with weight fine-tuning


lf the system does not detect the weight with precision or the
mechanical character stics of the system have been changed, it
may be necessary to calibrate the entire system.
Carefully follow the instructions below:

1. Restart the system, pressing the Clear key on the total weight menu.
2. Place a simple weight on the scale. lt should weigh at least 200 kgs. Please bear in mind that the screen
must read more than 100 kgs or the system will not be able to enter into code 10. (lt may be that it reads
less than 100 kgs before calibrat on, even if your simple is over 200 kgs.)
3. Open the code 10 window. A number will appear on screen. Change this figure by pressing the arrow
keys until it is the same as the weight placed on the scale.
4. Exit the code window by pressing Exit .

Cdigo 27
Nmero
calibrado: 23
Exit

Code 27, Calibration number


The calibration number depends on the sensor you are using
and the number of sensors connected to your system. Consult
the Calibration table to establish your systems calibration
number.
When you enter the window for this code, the calibration
number presently in use will appear on the screen.
You may change the value by pressing
confirm the value and to exit the window.

36 | RECOMMENDATIONS AND HANDLIN

. Press Exit to

11

CAPTULO 11.- BSCULAS

Cdigo 37
Azzeramento eeprom
Vel=2 Div=2 NumCal=14
Azzeramento tara
Calibration 0,8mV/V

SCALES

Code 37, System adjustment and O.SmV/V calibration


This code allows you to set various standard parameters
defined by the manufacturer. To use this code, you should
connect a weight calibrator with an output of 0.8mV to your
transformer.

Exit

1. Connect the calibrator to the loading cell connector. Switch it OFF.


2. Open the code window: wait for the message: calibrated to 0.8
3. Switch it ON.
4. Wait until the system automatically enters the Total weight menu; if the system does not accept the
calibrat on, press the F1 key to exit.
The following table shows the modification relating to code 37.
Code 37 Programming
Erased data . . . . . . . . . . . . . . . . . . . . . . .
Component names . . . . . . . . . . . . . . . . .
User contrast . . . . . . . . . . . . . . . . . . . . .
Weight d splay speed . . . . . . . . . . . . . . . .
Weight section . . . . . . . . . . . . . . . . . . . .
Calibration number . . . . . . . . . . . . . . . . .
Value calibrated to 0,8mV . . . . . . . . . . . . .
Alarm activation . . . . . . . . . . . . . . . . . . .
Continuous alarm upon endf dispensing . . . .
Language . . . . . . . . . . . . . . . . . . . . . . . .

Cdigo 45
Velocidad: 2
Exit

The whole memory (formulas, storage, etc.)


Predefined, standard
Median value
2
2
14
13288
at the last 15% of dispensing
4 seconds
English

Code 45, Weight display speed


By linking several values to this code, you may change the
weight display speed. This means the time that passes between
the moment the weight in the loading cell begins to take effect,
and the moment that this weight is displayed on the screen.
The available speed varies between 1 (slow) and 7 (fast).

RECOMMENDATIONS AND HANDLING | 37

11

CAPTULO
11.- BSCULAS
SCALES

Code 55, Pulse activation range, per kilogram


You may use this code to both acivate and deactivate range 10 of pulses per kilogram. lf this option is
turned off during the discharge, the 7 pole connector screen will have an output of one pulse per kilogram
of weight discharged. lf this option is turned on during the discharge, the 7 pole connector screen will have
an output of one pulse per 10 kilograms of weight discharged. While you are in this code, you may use the
arrow keys to activate and deactivate this option.

Cdigo 81
Printer: On

Code 81, Turning on and off the printer


This code allows you to activate or deactivate the printer
options by pressing the keys
in order to select the
adjustments.
Press Exit

Exit

Cdigo 85
Soglia
Maximum weight: 5000 Kg

to confirm your selections and exit the code.

Code 85, Maximum weight definition


This code allows you to define the maximum weight in order
to check the clients cart use.
Select the maximum possible weight in kilograms using the
keys
.

Exit

Cdigo 90
E - English
Exit

38 | RECOMMENDATIONS AND HANDLIN

Code 90, Language selection


You may choose the language of the Display messages
(and the printing language, in those cases where a printer is
connected). 10 languages are available. To select the language,
press the keys. Press
to confirm your select on and exit
the window.

11

CAPTULO 11.- BSCULAS

SCALES

ROXELL SCALE
Unlike the previous scale, the Roxell batch scale is very
simple and comes equipped with a control panel with a
counter that tells us the number of batches that the scale
has weighed.

Place a container
underneath to
collect the debris

This scale comes with a batch indicator and must be


connected to the weight control panel.
lt may also be connected to a Sirius or Orion system.

HOW TO ADJUST THE SCALE


1. We must first remove the lid with two screws on top of the extractor
box and place the feed drop plate on an outside container.

2. Next, you must start the coil loading distributor at the scale entrance
until it processes the first batch, and then stop.
3. Weigh the container and balance the scale so that it processes 10 kg
per batch. We then know how much each surge weighs.

1 - 10

4. The scale is completely regulated in this manner.

RECOMMENDATIONS AND HANDLING | 39

11

SCALES

As we have previously stated, the scale is equipped with a surge indicator. Once the desired weight
measurement is adjusted, this indicator will measure the number of times this quantity has passed from the
silo to the scale.
Example
lf we adjust the scale with 10 kg of feed and the surge indicator shows us 5, this means that the scale has
received 5 times the quantity of 10 kg, and therefore a total of 50 kg has been consumed.

MAXIMUM AND MINIMUM SENSORS


Are located on the black cone under the scale.
The upper sensor detects the coil loading distributor coming up from the ground, and the sieve, if it has one.
The lower sensor will stop everything if it detects that we have a problem with the coil loading distributor
coming from the silo or that we have run out of feed.

40 | RECOMMENDATIONS AND HANDLIN

12

EGG CONTROL

EGG CONTROL
The EMEC-12 s an egg counter that works together with the
egg counters computer, making it possible to count eggs on
a conveyor belt. The eggs do not need to be positioned in any
certain way. The sensor will count the exact number of eggs
side by side.
The EMEC-12 uses an infrared beam to detect the eggs on the
belt. An electrontc pulse is generated for each egg detected.
The EMEc-12 is also equipped with a CAN-bus, through which
it sends information to a central computer (Or on- EGG), as
shown in the installation diagram.
The EMEC-12 has a minimum precision of 99.5%. The EMEC12s precision depends totally on its assembly.

Illustration of the placement of the EMEC-12 on the egg conveyor velt


RECOMMENDATIONS AND HANDLING | 41

12

EGG CONTROL

To achieve greater precision, the egg counter should be mounted in a place where the eggs do not roll or
move on the conveyor belt. Some conveyor belts move backwards once the transmission motor turns off.
The egg counter counts in both directions, resulting in a count that is too high, if the conveyor belt moves
a considerable distance backwards. This problem may be corrected by installing a brake on the motor, or
installing the egg counter on another part of the conveyor belt.
The egg counter should be mounted on an appropriate base (which can be provided by your supplier)
directly on the conveyor belt. Important: When mounting the base, it is necessary to maintain a height
of approximately 62 mm between the highest side of the conveyor belt and the lowest part of the egg
counter.
The precision of the egg counter may be affected by very bright light, for example, sunlight. With too
much sun, an exact count is not guaranteed and an error message will appear on the counter (the red LED
will come on). For this reason, do not place the egg counter near a door or window.
The egg counter will compensate for normal amounts of background light. Only in special cases

Egg belt

will the egg counter need to be shielded from bright light. The egg must lie still at the point

The eggs must lie still


at this point
40 - 50 cm

Under normal conditions, the egg counter will


need little maintenance. In most cases, if properly
installed, the infrared sensors will remain relatively
clean on the inside. If dust or dirt do tend to
accumulate on the sensors, they should be cleaned
with a soft, damp cloth every now and then.
The egg counter may be easily removed from its
base by loosening the wing nut and moving the
counter horizontally.

Attach the Egg


guide strip solidly
to the bracket

Cross conveyor

62 cm

42 | RECOMMENDATIONS AND HANDLIN

When cleaning the building, be careful not to


damage the sensors by spraying them directly
with high pressure water streams or steam. Before
cleaning, make sure that the compression glands fit
tightly around the sensor wires.
For best results, the egg counter should be left
on during the cleaning process. This way, the
box will be heated from the inside, preventing
condensation.

12

EGG CONTROL

After the EMEC-12 has counted the eggs, we may see it in one of 2 possible manners:
Either in the sorter, using an ORION-EGG unit, or connecting it to a PC and using the RAINBOW
software.
The ORION-EGG may control the sensors in 1 building, 4 buildings or even up to 8 buildings.
The ORION-EGG provides sorter informat on and may also control the desired flow of eggs.
It therefore provides a total accumulated egg count from the moment it is turned on.

OTHER BUILDINGS

500 mts. max

BUILDING-1
Reciving box
2 EMEC-12 (Sensors per row)

SORTER
ORION-EGG
For 1 building
For 4 buildings
For 5 buildings

+ RAINBOW

CAN RS-232 (without modem)


CAN RS-232/M (with modem)

External comunication

EMEC-12 and ORION-EGG installation diagram


RECOMMENDATIONS AND HANDLING | 43

12

EGG CONTROL

ORION EGG
OVERVIEW
The Orion Egg has two functions. The first s to count the eggs by rows and levels. The second allows us
to control the collect on depending on the counted eggs and the number of eggs/hour that we want. The
most important parameters are in bold type. The parameters in itallics may be left as factory programmed.
MENUS AND NAVI GATION
The Orion has been designed for a graphic navigation of its menus, simillar to that of a mobile telephone.
There are 6 maln screens ln the Orlon Egg. They are accessed using the F1 F6 keys . A screens may have
a cursor on the right that indicates if any more options are available. Navigate through the options using
the
and
keys. To enter into an option, use the
key.
Once inside an option, press
to make any changes. We can increase or decrease the parameters using
the
and
keys, or using the numeric keypad. Confirm the change using the OK key. The User code s
470. To leave the current screen and return to the previous one, press the
keys.

Key Summary
On-screen navigation. Increase or decrease number
Go forward or backward. Enter to change a value. User code: 470

OK Confirm value change


F1 F6 Direct access to the main screens

44 | RECOMMENDATIONS AND HANDLIN

12

EGG CONTROL

F1
Date and time

F2
Eggs. Change building:

OK

OK Eggs today/previous days

Egg overview

RECOMMENDATIONS AND HANDLING | 45

12

CAPTULO
EGG CONTROL12.- CONTROL DE HUEVOS

EGG OPTIMITATION

F6

Eggs per hour


Belt speed
Propor range corr
Max mum corr
Hysteresis
Cyclustijd

Buffersize
Startsnelheid

Desired eggs/hour.
Collection speed. Only works for temporary changes.
Correction that will be made with a 50% change.
Maximum correction allowed. This is a limit for the previous parameter.
Within a determined range, it will not correct the belt speed.
Cycle time. This is the time in which calculations for speed correction are made.
This must be a multiple of 12.
Size of the buffer for speed calculation.
Beginning collection speed.

46 | RECOMMENDATIONS AND HANDLIN

CAPTULO 12.- CONTROL DE HUEVOS

F4

12

EGG CONTROL

Present alarms

These are the alarms


that are currently
active. Orion is
equipped with a relay
that may be used to
provide warnings.

Alarm registry
Alarms remain in the
registry until they are
erased.

Delete alarm registry


Erase alarm registry.

RECOMMENDATIONS AND HANDLING | 47

12

EGG CONTROL

F5

Type of computer

These screens only


contain information
about the type of
computer, software
version and serial
number.

See configuration

F6
These screens allow
you to check the
configurations.

Modify options
To change the
options, you need the
Installer code.

Screen to turn on
and off Orion. Only
works if the building
is emptied.

48 | RECOMMENDATIONS AND HANDLIN

Serial number

13

WATER LEVEL ALARM

WATER LEVEL ALARM

RECOMMENDATIONS AND HANDLING | 49

13

WATER LEVEL ALARM

DESCRIPTION
The equipment analyzing water levels in ZUCAMI buildings has been designed to control up to eight rows
with eight water levels in each one.
The system consists of a central station that indicates the malfunctioning row and level, and one satellite
module per row that is connected to the central station.
Its start-up is simple, as only three cables are used to connect the central station and the satellite modules.

START-UP
When the equipment starts up and the lever connected to the switch on the right of the central station is
lowered, a self-check process begins.
The first thing it does is turn on all elements of the two displays and the two lights to allow us to visually
check if the bulbs are burned out and if they are working correctly. This sequence lasts approximately 4
seconds.
Next, it will begin to look for however many satellite modules are connected to the central station.
Beginning with the highest numbered module, it will consecutively show us on the display the satellites it
finds. If all is well, the number for each satellite will appear on the row display.
The level Display remains off. The length of this sequence depends on the number of satellites connected
to the central station.
After this, it will begin the normal use sequence, and if all the water levels are correct, the green light will
come on.

50 | RECOMMENDATIONS AND HANDLIN

13

WATER LEVEL ALARM

USE AND WARNINGS


The following shows how the controller is used and the different water level warnings and communication
malfunctions that may occur.
Correct water levels. Every two minutes, the central station communicated with the
satellites to check the water levels. At that time, the row display shows us the number
of the satellite with which communication is being established. The level display
remains off if all is well.
The green lamp remains lit.

Low water level. If any water level is low, the central station indicated the row and
water levels that are amiss. Besides turning off the green light, it turns on the red light
and activates the secondary output relay. It remains in this state for at least 30 seconds
and until the defective water levels are corrected.
If water levels on different rows malfunction at the same time, the central station
shows only those levels on the first row that it finds, starting with the highest number.
Once the water levels on the first row are corrected, the central station checks and
displays the following rows.
Minor malfunction in satellite communication. Minor
malfunctions in communications may occur, normally due to strong
noise on the electrical grid.
This type of problem does not permanently affect the system. The
corresponding satellite number will appear on the row display, along
with an e (error) on the level display. The green light remains on
and the red light off. The secondary output relay remains inactive.

Serious malfunction in satellite communication. This is a serious


problem, indicating a malfunction or the disconnection of a satellite
module. The system activates the secondary output relay and turns
on the green and red lights alternately for 30 seconds.
If the malfunction occurs in only one of the satellites, the rest of the
system remains operational and, therefore, once 30 seconds have
passed, will continue to check the rest of the satellite modules and
water levels as normal.

RECOMMENDATIONS AND HANDLING | 51

13

CAPTULO
ALARMA DEL NIVEL DE AGUA
WATER LEVEL13.ALARM
INSTALLATION
CENTRAL STATION

Decide upon the spot you wish to install the central unit. It must never be installed outside, as it is not
designed for an outdoor installation. Inside, it is perfectly able to tolerate the humidity and dust that are
produced in a bird housing facility. Install it in such a way that the displays may be easily seen.
Make sure that the central station is turned off and that its two fuses are intact. Connect the green lights to
terminals 5 and 6. Connect the red lamps to terminals 7 and 8 (see the connection diagram).
If it is necessary to connect the secondary output relay, bear in mind that it cannot stand more than 7
amperes of resistance. For greater diversity, this relay does not have electric potential. If you need to
operate with inductive charges or those above 7 amperes, you must install a separate contactor at a
distance of three meters from the central station and with an RC element on the coil terminals.
Check all the elements and turn on the central station (lower the switch lever). The central station should
turn on all sections of the two displays and the red and green lights for four seconds. After a few seconds, a
0 in the row display and an e in the level display will appear, since no satellite is connected. It indicates
that 0 modules have been found and the e (error) is serious. Turn off the central unit and prepare to
install the satellite modules.
SATELLITE MODULES
Place the satellites in rows and near the levels. Select a different consecutive number (starting with 1)
for every satellite you are going to install. The maximum number of satellites per central station is 8. The
number is selected using 3 miniature sliding switches located inside the satellites. The switches are labelled
with numbers 1 to 4 and with the words on and off. See the table accompanying the connection diagram
for the satellite modules.
Connect level 1 to the two terminals labelled with the number 1. Do the same with the rest of the levels.
The level terminals that are not used should be bridged. For example,
if level 8 is not used, the two terminals labelled 8 should be bridged.
INSTALLATION
Glue the half-tube at the water level using PVC glue, and let dry.
Fasten the wires to the corresponding electric terminals.
Thread the half-tube perforations.
The water level must always be above the height of the half-tube.

52 | RECOMMENDATIONS AND HANDLIN

13

CAPTULO 13.- ALARMA DEL NIVEL DEWATER


AGUA
LEVEL ALARM

CENTRAL CONNECTION OF THE SATELLITE MODULES


Connect terminals a, b and c (see the connection diagram) on the central unit to terminals a, b and c on the
satellite modules. Terminals a, b and c are repeated on the satellites to permit the easy connection of the
next module, without the need for a connection box. Refer to the connection illustrations of the central
unit and the satellite modules to identify the terminals. The maximum distance between the central unit
and the modules is 200 meters.
The cable used must be 1.5 millimeters in diameter. Increasing the section does not mean you can increase
the maximum distance of 200 meters, due to its capacity.
If the installation is correctly carried out, when the central unit is turned on the satellite with the highest
number should appear first on the display, followed by the rest of the modules consecutively.

WATER LEVEL CONTROL SYSYTEM


Cleaning the central unit
Use a damp cloth so that the displays may be seen clearly.
Fuses
Always turn off the equipment before replacing the fuses. The central unit is equipped with two fuses
on its inside; one with a voltage of 220 volts and a protective cover, and another with a voltage of 5 volts,
without a cover. Both are 0.5 ampere fuses and measure 5 x 20 millimeters.

RECOMMENDATIONS AND HANDLING | 53

14

WASTE PREDRYING

CONTROLLER FOR THE DROPPING DRYING SYSTEM

54 | RECOMMENDATIONS AND HANDLIN

CAPTULO 14.- PRESECAJE DE BASURA

14

WASTE PREDRYING

TEMPERATURES
INTAKE C

Bettery temperature

Set temperature at 18o oC


To change the value:
Press the INTAKE oC button
Press the - or + button.
Press the INTAKE oC button

Program the alarm temperature


(3 oC below the INTAKE oC temperature).
Below this temperature (8 - 3 = 15oC) the fan will
stop and the MIN C light turns on.

Set the temperature at -3 oC


To change de value:
Press the MIN oC button
Press the - ou + button
Press the MIN oC button

Program the heating temperature (2oC


below the INTAKE C temperature). Below
this temperature (18-2=16C), the heating
unit will start up and heat the air until the
programmed temperature is reached.

Set the temperature to -2oC


To change de value:
Press the HEATING button
Press the - or + button
Press the HEATING button

Minimum amount of outside air

Set the temperature at 18 oC


Set the temperature at 0% with the air mixer.
It is invariable!
Set the temperature at 25% with the heater
To change de value:
Press the MIN% button
Press the - or + button
Press the MIN% button

Maximum amount of outside air

Set the temperature at 100% .


It is invariable!

Bandwhit is the temperature range within


wich the regulator must be regulated, from
minimum to maximum.

Set the temperature to 2.0oC


To change de value:
Press the BANDWHIT button
Press the - or + button
Press the BANDWHIT button

INTAKE C

MIN C

MIN C

HEATING

HEATING

MIN %

MIN %

MAX %

MAX %

BANDWHIT

BANDWHIT

RECOMMENDATIONS AND HANDLING | 55

14

WASTE PREDRYING

CURVES
The curves may be used to pre-program the process in case you wish to control the temperature in the hen
houses. To set a curve, you must press several buttons.
A curve is activated when the number of days is greater than O. To program a curve:
First, press the INTAKE oc button ( the starting temperature. You may change the value using the - or
+ buttons). Second, press the DAYS key. The number of days will appear in the left-hand box. You may
change this value using the - or + buttons.
Next, press the ENDVALUE key and insert the temperature that you have chosen. This is the temperature
to be reached once the number of days has passed. Press the INTAKE oc button two times to register your
changes.

ERROR OUTPUT
When the ERROR light (between the 2 boxes) is blinking, you may press the ERROR OUTPUT button to
read the error code.
The error code appears in the box on the left.
FOO
FOl
FlO
Fll

No error
The temperature sensor is malfunctioning
The fan is stopped
The fan is stopped and the temperature sensor is malfunctioning.

LIGHTS
The ERROR light: Press the ERROR OUTPUT key to read the error code.
The MIN oc light: This light comes on when the INTAKE oc temperature is below the minimum
temperature. In this case, the fan will stop.

56 | RECOMMENDATIONS AND HANDLIN

RECOMMENDATIONS AND HANDLING | 57

58 | RECOMMENDATIONS AND HANDLIN

RECOMMENDATIONS AND HANDLING | 59

Polgono Morea Norte, calle C - N2


31191 Beriain, Navarra, ESPAA
T +34 948 368 301
F +34 948 368 363
www.zucami.com