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Diamond Automation 200 case per hour egg packer
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200 Farmpacker
IMPORTANT – PLEASE READ! The information provided in this manual has been carefully checked and is believed to be accurate. However, changes are made periodically, THESE CHANGES ARE INCORPORATED IN NEWER PUBLICATIONS. Diamond Systems may improve and/or change products described in this publication at any time. Due to continuing system improvements, Diamond Systems is NOT RESPONSIBLE for inaccurate information, which may appear in the manual. In no event will Diamond Systems be liable for direct, indirect, special, exemplary, incidental, or consequential damages resulting from any defect or omission in this manual. Even if advised of the possibility of such damages. In the interest of continued product development Diamond Systems reserves the right to make improvements in this manual and the products it describes at anytime, without notice or obligation. For the latest product updates please call Diamond Systems Sales or Service. MAY, 2001
23400 Haggerty Road, Farmington Hills, Michigan 48335-2635 USA Office: 248-476-7100 FAX: 248-476-0849
Email: [email protected]
WARNING!
SAFETY AND SERVICING CLEANING, REPAIRING AND/OR ADJUSTING
DO NOT OPERATE ANY PART OF THE
MACHINE UNLESS ALL GUARDS ARE IN PLACE.
NEVER service, clean, repair and/or adjust any part of the machine while the machine is still on and/or in operation.
STOP the machine and lock it out before servicing, cleaning, repairing, and/or adjusting. If the machine cannot be stopped or turned off, wait until production for the day is completed. If any guards are removed for service, cleaning, repairing, and/or adjusting the machine, replace all guards and secure them before restarting the machine.
Keep all floors dry and free of broken egg, water, oil, and debris in traffic area of the processing operation. IF the floor becomes wet it take whatever steps are necessary to keep the floor dry.
Employees should not operate or service the equipment with loose clothing or long hair.
Make sure all supervisors and employees understand the importance of keeping all guards in place and keeping the floor clean and dry.
January, 2001
2OO CPHFARMPACKER
For Parts & Service:
United States:Tel: 248-476-7274Fax: 248-476-3617
Spain:Tel: 34-94-432-9252Fax: 34-94-433-6734
Malaysia:Tel: 60-3-5631-4991Fax: 60-3-5631-5991
Oftice 248'476-7100DirectDial 248-476'7106
+ Ext. -Fax 248'476-0849Service 248-476-7274www.diamondsystem.com
Diamond Automation23400 Haggerty RoadFarmington Hills,Michigan 48335-2635USAE Mail - [email protected]
CONTENTS
Page I of3
INTRODUCTION I
N{ACHINE SPECIFICATIONS AC Power 3
I/IAINTENAIICE Lubrication and Cleaning 516
INSTALLATION AC Hoolary 7House Belt Hookup 8Setting House Belt Delay 9Setting Egg Courter Units l 0
OPERATION Initial StartUp 1 t
RI,'N MODE MESSAGESClamshells Not Home t2Denester EmpB t2Den€ster Flat Jam t2DenesterNotHome t2Denesting Tbrough 13Eggs Out of Position Remove Eggs t3Eggs Out of Position Sensor Blocked 13Emergency Stop 13Me,mory SeH-TestError l 4Missine Both Flats l4Missing First Flat i t4Missing kft Flat t4Missing Right Flat l 5Missing SecondFlat l5Pie Se,osorTimeod t 5Ptsher ChainNot Home 15Running l6Safety Guard Out of Place 1624V Power t6Waiting for Cycle Stop 16Waiting for Eggs 16Waitine for Start Bufron l 6WarningNo Start Sensor t 7
TIMING AhID ADruSTMENTS Head Timing 19Clamshell Timing 20Clcle Stop Block Timing 2lDenester Adiushents 22-24,18Divider Arrangeme,nts 25Long& ShortAdvanceAd 26,27
Paee 2 of3
MECHAMCAL DRIVES Sprockets and Chain Drives 28-31
TROI.]BLESHOOTING Packer Malfunctions 33,34
Farmpacker Service Routines 35Farmpacker Maintenance Mode 35Electical Timing 36Elecnical Timing Diagrams 37,38
ELECTRICAL DEVICE LOCATION 39
ELECTRICAL DRAWINGS VO Board Light Definitions 4 lContol Box Schematic 4244System Schematic 45-51Subplate Assembly Drawing 52Subplate PartNumbers 53,54Electical Box Assembly Drawing 55Electrical Box Assembly Part Nurnbers 56
MECHAMCAL DRAWINGS SI.JB ASSEMBLIESPin Bar Assembly 57Divider Assembly - Thick 58Divider Assembly - Standard 59VPaddle ShaftAssembly 60New V Paddle Shaft Assembly 6 lDenester - Lift Plate AssemblYr 62Denester Side Plate 63Upper Clamshell Assembly &Lower Clamshell Assembly 65End Alignment Shaft Assembly 66Paddle Wheel Assembly 67Slider Bar Assembly 68White Guide Block Assembly 69Stainless Steel Egg Guide Assembly 70
MECTIAMCAL DRAWINGS M^AIOR ASSEMBLIESPKS Assembly 7 lStacker Infeed PKS 72Pre-Reservoir Assembly 73Overhead Shuttle Assembly 73Overhead Shuttle Assembly 74Reservoir Assembly 75Reservoir - Top 76Reservoir Transfer 77Head - FrontView 79-80Head - Inside 81
Page 3 of3
MECHANICAL DRAWINGS MAJOR ASSEMBLIESHead - L.H. Side 82-83Head - R.H. Side 84Head - Part Numbers 85-86Base Drawings 87-89Cross Shuttle 90-92Cross Shuttle - Bottom View Den. End 93Cross Shuttle - Bottom View 94-96Cross Shuttle - Bottom View Drive End 97Cross Shuttle - Back Side 98All Guards 99
GLOSSARY 101-102
INTRODUCTION
Our family here at Diamond Automation is very pleased that after much research andconsideration you have confidently chosen this superior built, American made, 72,000eggs per hour Farmpacker.
This efficient packer is the first successful high capacrty farmpacker available in theworld. Its compact design, single denester, easy maintenance and maximum throughputare qualities that make this packer an intelligent decision.
Diamond's excellent customer service and support includes a worldwide network of salesand service offices that welcome your inquiries and questions.
We are confident you will be satisfied and will enjoy your high quality Farmpacker.Thank you for the trust you have placed in us.
Diamond Automation
MACHINE SPECIFICATIONS
NOTE: Attempting to run this Farmapcker above the Diamond recommendedspecification may void all waranties.
AC POWER INPUT: 230-240 VAC, 60rfz,1 PHASE220-230 VAC, 50 TfZ, 1 PHASE
POWER CONSIIMED: .746 KW. I HP
CASES PER HOUR: VARI,ABLE SPEED WITH 2OO CPH MAXIMUM
J . v
MAINTENAI\CE
There are two key ingredients that go into operating a long term, trouble free farmpacker.They are proper maintenance and keeping the packer clean.
LIIBRICATION:
1. Lubricate all chains with a 30 weight motor oil once a week. Also check chaintensions. Clean before oiling if necessary. Don't forget the #25 chain on the endalignment rollers.
2. Grease all bearings and greasable rod ends with a multi-purpose grease bi-monthly,making sure grease is getting inside bearing.
3. Oil all of the oil lite bearings with a #10 or #20 weight motor oil.
4. Check the oil levels in the reducers every 6 months or sooner if you notice the sealsleaking. They use synthetic 90 weight oil.
5. Oil the lower clamshelts and all internal moving parts with a USDA approved, foodgrade lubricant.
CLEAI\ING:
It is very important to keep specific areas of this farmpacker clean for ma><imumproductivity. For this re{Non, the farmpacker has been designed for our customers "ease
of removal" of certain items. They are listed below:
l. Removable dividers that pivot up. Simply remove rod end assembly for motion from
the divider angle and dividers pivot up so reservoir bed can be cleaned hassle free.
Dividers were designed to be removed for cleaning or exchanged with thicker type
with the Ease of spring loaded finger latches.
2. White divider blocks: A quick drop in/pull out bar assembly for easy access to
paddle wheel cleaning.
3. Pin bar assembly: A quick drop in/pull out angle assembly for easy access to end
alignment roller cleaning.
4. Stainless steel divider assembly: A quick drop in/pull out bar assembly for easy
access to end alignment rollers and paddle wheel cleaning.
5. Spring loaded "v" paddle wheel assembly: Simply pull shaff/paddle assemblytowards spring and remove for cleaning of paddles or access to upper clamshells.
6. Stainless steel chute assembly: A quick drop in/pull out bar assembly pulls out for
easy cleaning or access to upper clamshells.
BASIC CLEANING:
l. Remove and empty all drip trays and pans and rinse out or wipe down with a damp
cloth.
2. Use a darnp cloth to wipe down the farmpacker for general cleaning. Compressed air
_ to clean packer is approved by Diamond Automation. Never use direct water spray
(high pressure or not) to clean any part of this packer.
3. End alignment rollers should be cleaned daily for optimum points down of egg
performance. Clean with damp cloth or very soft brush.
4. Paddle wheel assembly at (12) eggs present sensors should be cleaned daily. If not,
feed dust or debris may give false indications to sensor and a missing egg problem
may occur.
5. Stainless steel chute assembly should be cleaned daily for assuring clear passage of
eggs into clamshells without hesitation or deflection which may cause out an "egg out
of position" message or may result in egg breakage'
6. All sensors, reflectors and optical devices should be wiped with a dry cloth bi-weekly
to assure no false indications from feed dust, oil or other foreign materials.
6
AC HOOKTJP
Using the following chart, connect the input lines to TB-1. TB-l is located in theelectrical confrol box near the bottom.
voLTS (AC)208
FREQ W)606060
PHASEIII
# OF WIRESaJ
33
230240
TB-1
voLTS (AC)200200208230
FREQ W)60506060
PHASE3aJ
J
3
# OF WIRES4444
TB.I
I 2 3 4 5 6 7 8 9 10 1 1 12
L I L2 L3 GND
voLTS (AC)220/380230/400240/4t5
FREQ W)505050
PHASEJ
33
# OF WIRES5)
5
TB.I
L3L1 L2 NEU GRD
HOUSE BELT HOOK I,JP
The farmpacker contols the house belts through relays CR-l and CR-2. Use one of the
following diagrams for your application.
FOR MOTORS UNDER'/I H.P. CONNECT ACCORDINGLY
TB.ICR-I CR.2
FOR MOTORS OVER % H.P. CONNECT ACCORDINGLY
TB-1
cR-1 CR-2
I 2 3 1 4 s 1 6 7 8 9 t0 l l l t z
ACMotor
hAC
8
1 .
2.
SETTING HOUSE BELT DELAY
Remove I/O-1 PCB from the card gate.
Set switches accordingly.
Off On
sw-1
sw-2
sw-3
sw-4
SECONDS SWITCHESI 2 3 4
0.5 OFF OFF OFF OFF1.0 ON OFF OFF OFF1.5 OFF ON OFF OFF2.0 ON ON OFF OFF2.5 OFF OFF ON OFF3.0 ON OFF ON OFF3.5 OFF ON ON OFF4.0 ON ON ON OFF4.5 OFF OFF OFF ON5.0 ON OFF OFF ON5.5 OFF ON OFF ON6.0 ON ON OFF ON6.5 OFF OFF ON ON7.0 ON OFF ON ON7.5 OFF ON ON ON8.0 ON ON ON ON
SETTING EGG COITNTER T]NITS
Remove VO-z PCB from the card gate. See electronic device chart for its location.
Set switches accordingly.
NOTE 1. The message center will display the count of eggs packed. It counts eggs bycounting the base indexes.
NOTE 2. Inaddition, the counter will not count hand cranked cycles. It checks to see if
the motor is on before incrementing the count. If the motor is not on the counter ignores
counting.
NOTE 3. You can clear the current count by stopping the farmpacker and holding down
both the STOP and OVERRIDE buttons simultaneously.
NOTE 4. The counter will not display if the farmpacker is in an error condition. This
way the counter display will not interfere with any of the farmpacker safety messages
which might have stopped the machine. The count will not display if the motor is off. If
you want to see the count while the farmpacker is stopped, press the override button.
OPTION SWITCHESI 2 3 4
NO COUNTER x OFF OFF X
COUNT IS DISPLAY€D IN EGGS X OFF ON XCOUNT IS DISPLAYED IN DOZENS x ON OFF xCOI.INT IS DISPLAYED IN WHOLE CASES X ON ON x
l 0
INITIAL START UP
ACTION: Turn on the main power switch.
NOTE: This main power switch is not to be used as a means of turningthe packer on and offthroughout the day. Main power should beturned on before operating and at the end of the day's operating.Also furn main power offto service, clean, repair and/or adjustany part ofthe packer.
RESULT: The Message Center displays:Diamond )OLXHi Speed Farmpacker
ACTION: Load the denester with flats.
ACTION: Put (2) trays under clamshells, and (2) trays behind clamshell drop.
ACTION: Press the green "Start" button switch.
RESULT: The packer motor turns on and 3 flats are denested and advanced onthe cross shuttle before the head and reservoir move.
\-. RESULT: Then the head starts to cycle continuously and the base pusheradvances for (6) cycles only. To clear the head of any eggs left in it.
ACTION: Place the "House Belts" button switch in the down position.
RESULT: The house belts turn on.
RESULT: When (12) eggs are present at the (12) eggs present sensors, thepaddle wheel clutch will index (1) row of eggs into the end alignmentrollers when the leading edge of the pie sensor is seen.If the packer stops packing eggs it will stop and then display amessage across the "Message Center". Refer to the next section forwhat these messages mean.
NOTE: The emergency stop is not to be used to casually stop the packer.lt is only to be used in an emergency.
l 1
RUN MODE MESSAGES
CLAMSHELLS NOT HOME
Definition: This message comes up if the pie-shaped cam sensor is not on when the
green start button is Pushed.
Cause: Use of emergency stop button or clamshell coast problem, or head handwheel
was turned when Packer was stoPPed.
To restart: Bring the clamshells home, turn the head handwheel until the pie-shaped
cam sensor turns on.
DENESTER EMPTY
Definition: Occurs if there are six consecutive missing flats.
Cause: Empty denester, denester jam.
To restart: Refilt denester and press start buffon.
DENESTER FLAT JAM
Definition: Occurs when the Denester Jam Sensor detects an object'
Cause: A flat out of Position.
To restart: Reposition the carton and press the start buffon. NOTE: A flat does not
have to be present to proceed; simply press the start button.
DENESTER NOT HOME
Definition: Occurs if an affempt is made at starting the packer when the cross shuttle is
not in its home Position.
Cause: Cross shuttle's handwheel has been turned when the packer was stopped.
To restart: Turn cross shuttle's handwheel until red light on the cross shuttle stop sensor
tuns on. Press start button.
t2
DENESTING THROUGH
Definition: Occurs when either the first or second flat out of the denester is missing onthe cross shuttle.
Cause: Empty denester or flats h,rng up in denester.
To restart: Packer does not stop.
EGGS OUT OF POSITION REMOVE EGGS FROM CARTON
Definition: This message comes up when a stray egg has found its way into the head andhas been deposited into the carton. The machine stops and waits for the operator toremove the sfiay egg from the carton to avoid egg breakage.
Cause: Stray egg.
To restart: Remove egg and press the green start button.
EGG OUT OF POSITION SENSOR BLOCKED
Definition: This message appears if the egg in clamshell sensor becomes permanentlyblocked.
Cause: Feed dust, oil mist or foreign material blocking sensor face or because sensor isbad.
To restart: Clean sensor and reflector or change sensor, then press green start button.
EMERGENCY STOP
Definition: Occurs when the emergency stop bottom is pressed.
Cause: Pressing of the emergency stop button.
To restart: Pull up on emergency stop button. Press start button.
NOTE: When restarting after an emergency stop, you might get a 6'clamshells nothome", "denester not home" or both. Follow the restart procedure for each stopcondition.
13
MEMORY SELF'' TEST ERROR
Definition: When packer is initially powered up it does a selftest of its program. If
there is a problem it will display this message.
Cause: Elecffonic hardware malfunction.
To restart: Contact Diamond for assistance.
MISSING BOTH FLATS
Definition: Occurs when both left and right flats are missing or out of position.
Cause: l. Both flats could be out of position.2. This situation will occur first thing in the morning'
To restart: l. If both flats are out of position, reposition them and press start button.
2. Inthe morning if there are no eggs at the paddlewheel, press the override
button until there are flats under the clamshells. If there are eggs at the
paddlewheel manually place flats under clamshells'
MISSING FIRST FLAT
Definition: Occurs when denester misses a flat.
Cause: Denester misses a flat.
To restart: Packer does not stoP.
MISSING LEFT FLAT
Definition: Occurs when a flat is out of position or missing on the left packer base
shuttle.
Cause: A flat is out of position or missing.
Cause: A flat is out of position or missing.
To restart: Reposition flat or manually place one in front of the sensor and press the
start button.
T4
MISSING RIGHT FLAT
Definition: Occurs when aflat is out of position or missing on the right packer base\--, shuttle.
Cause: A flat is out of position or missing.
To restart: Reposition flat or manually place one at the sensor and press the start button.
MISSING SECOND FLAT
Definition: Occurs when denester misses aflat.
Cause: Denester misses a flat.
To restart: Packer does not stop
PIF' SENSOR TIMEOUT
Definition: Message comes up when the softrvare thinks the head clutch is on and therehave been no leading or trailing edge transitions of the pie-shaped cam sensor.
Cause: Maybe the head clutch VO is bad, the clutch is bad, the head clutch wire is\- broken, set screws or pinch collars are loose, pie-shaped cam sensor is bad.
To restart: Press start button.
PUSHER CHAIN NOT HOME
Definition: Occurs if an attempt is made at starting the packer and the base cycle stopsensor is not on. To get past this message, hand crank the base until the cycle stop sensorcomes on and try starting again.
Cause: Pushers have been manually moved with the handwheel when the packer pusherswere stopped.
Cause: Base brake is not functioning properly.
Cause: Cycle stop sensor block not set properly.
To restart: Turn the base handwheel until the red light on the cycle stop sensor turns on.Press start button. See the Device Location Chart for the sensors location.
l 5
RUI\NING
Definition: Occurs when packer is packing eggs.
To restart: Packer does not stoP.
SAFETY GUARD OUT OF PLACE
Definition: Occurs when one of the six cover safety switches is open.
Cause: A cover is open. See device location chart.
To restart: Close open cover and then press start button.
24V POWER
Definition: Occurs when 24 volts is not present.
Cause: Blown Fl or F2 fuse.
To restart: Turn offpacker, replace fuse and then cycle packer on.
WAITING FOR CYCLE STOP
Definition: Occurs if there is a packer malfunction.
Cause: Mechanical or electrical malfunction.
To restart: Turn offpacker, correct malfunction and then cycle packer on.
WAITING FOR EGGS
Definition: Occurs when packer is ready to pack eggs but they are not present in the
paddlewheel at the (12) eggs present sensors.
Cause: No eggs.
T6
WAITING FOR START BUTTON
Definition: Occurs when packer is packing eggs and the stop button is pressed.
Cause: Depression of stop button.
To restart: Press start button.
WARNING NO START SENSOR (USED TO BE MASTERTOOTIT)
Definition: Occurs if there is a packer malfunction.
Cause: Mechanical or electrical malfunction.
To restart: Turn offpacker, correct rnalfunction and then cycle packeron. -
NOTE: Handcranking packerbase handwheel more than one cycle will also causethis message to be displayed. To restart, press the start button.
t7
orNisTER sET uP. 12/1o/sa
ALL tr TNE OINUOTIO TNNTUPACKERS MAT'IUFACTURED AT DIAMOND
AuroMATroNs ARi'bEi Ji-Nt _iEiTib-ici nqN n'rE otnuoND DEEP PocKETTRAv. THEREFoRE, THE DEhIE!1ER-i5'Lsii str. Vt nno resrEo FoR THEsETRA\€. THERE nnb
'ii[o-nelr-qqBG DRoP -Ut BARS THAr ARE PoslTloNED
tN BETVGEN sorFt-oi' ilH]jFlEstr i ivs r9_ nsssT THE DENESTER lNsil rccESSFUr-r-v iuniiNd' r{rt_TRAf
' riirS'-oioe;n BAR ltrLl ALso Asslsr
wtTH oTHER rRAft"Siutr-en 1o_T{E Di;\Mor.io__lqv vult IHE SMAII cEllso.t IHE BorToM, uKE THE Hms'ii5fiRAi. rg-o-mesT oTHER TY?Es oF.rRA\s 'yrTH THE BIIIER cErr !ffiuii"inrs gq_oF-rN BAR sFrouLD BEREMO\ED AND SEE THE FARMNCiiN-IJIT'Ti.JN- FOC THE OTHER CORRECT
DIAMOND DEEP POCKET TRAY
DENESTER ADJI TSTI'IENTS'
DIAMOND IRAYOR OTHER SMALL
CELL BOTTOM TRAY
DENESTER JAWS
TY?ICAL TRAYOR BIG CEIL
BOTTOM TRAY
DENESTER JA\flS
#+552000bm-eonProR(2) READ
DENESTER JAWASSEMBLYONE SIDE SFIOVIN.
NOTEBAR-ADAPTORREMO\ED
DENESTER JAWASSEMBLYoNE SIDE SFloYt/t'|.
t 8
LOWER CLAMSHELLCRANK ARM ATB.D.C.PUSHER INDEXTRAILING EDGE
PADDLE WHEELLEADING EDGE
2OO FARMPACKERH E A D T I M I N G
5 /3 /s8
WITH LOWER CLAMSHTLL CRANKARM AT TOP DEAD CENTER (T.D.C.) .
L I N E U P H OLESPLATES
THRU& GAGE.(2) s tDE
84000700HEAD GAGE
NOTE: WHEN PADDLE WHEELSENSOR (L.E.D. JUSTROLLERS SHOULD BE
CAM IS JUST IN FRONT OFGOES ON) END ALIGNMENTAT 24".
PUSHER ]NDEX -CLUTCH_TRAILING EDGE
PADDLE WHEELCLUTCHLEADING EDGE
NOTE: GAP BETWEENFACE OF SENSOR &CLUTCH CAM:.015".
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21
DENESTTR ADJUSTMINTSFIGURE JAW CTNTERS
LOOSENN U T
JAWASSEMBLY
DENESTERSIDEPLATE
DENESlERSIDEPLATE
JAWASSEMBLY
ADJUST THE JAW CENTERS TO FLAT.
1 .2.
3.
+.
REMOVE THE REAR DENESTER GUARD FROM DENESTER.
TAKE THE FLAT THAT WILL BE USED ON THIS PACKER AND MEASURTrHi brSrnNCE BETWEEN THE OUTER TWO CELLS oF THE FLAT. THATDISTANCE IS WHAT THE TWO JAW ASSEMBLY CENTERS SHOULD BE.
BRING THE JAW ASSEMLIES TO TOP DEAD CENTER. TURN THE HANDWHTTI ON THE CROSS SHUTTLE TO BRING THE JAW ASSEMBLIES TOTHE HIGHEST POINT POSSIBLE.ADJUST BOTH OF THE JAW ASSEMBLIES IN OR OUT WTH A SCREW_onrGn, iHnoucu THE HoLE lN THE SIDE PLATE. loqsE\ NUT oNSIUO flnSf. SEE FTGURE
"JAW CENTERS". BE SURE THATEnCH JAW ASSEMBLY MO\ES THE SAME AMOUNT. DO THIS BYCOUNTINC THE ruRNS OF THE SCREWDRIVER. ADJUST UNTIL THECTT�TENS OF THE JAW ASSEMBLIES MATCH UP WTH THE DIMENSION OFiHE CrNTERS OF THE OUTER Two CELLS oF THE FLAT.
BRING THE JAW ASSEMBLIES TO BOTTOM DEAD CENTER. MAKE SUREiHi. .Inw ASSEMBLiES ARE CENTERED IN THE DENESTER. THE DISTANCErnOru THE CENTin br JAw ASSEMBLY To THE INSIDE oF SIDE PLATEMusi BE THE sAuE oN BoTH SIDES. TAKE MEASUREMENT FRoMCErlrEn oF JAwS, wHERE THE THREADED RoD GoES THRoUGH JAWASSEMBLIES.
6. FOR A FINAL CHECK, PLACE A FLAT IN THE DENESTER JAWS AND
CHECK THE FIT.
7. IF EITHER JAW ASSEMBLY HAS BEEN ADJUSTED, CHECK -B-OTH OF THE
JAWS FOR CORRECT OPENING. SEE ,,ADJUST THE JAW OPENING".
5.
22
DENISTER ADJUSTMTNTSFIGURE JAW OPENIN G 1 3 / 8
(35 mm)TO
1 1 / 2 |(sa mm)l--
NO FLATS IN DENESTER
HARWOODFLATS
ADJUST THE JAW OPENING.
1 . BRING THE JAW ASSEMBLIES TO TOP DEAD CENTER BY TURNING THECROSS SHUTTLE HANDWHEEL. TURN SLOWLY AS APPROACHING THETOP UNTIL JAWS ARE CLOSED AS FAR AS THEY WLL GO.
WITH THE JAW ASSEMBLIES AT THIS POSITION, TAKE A MEASUREMENTACROSS THE TOP OF BOTH SETS OF JAWS. SEE FIG.
' 'JAW OPENING,'.
IF JAWS ARE ADJUSTED FOR HARDWOOD FLATS, THE TENSION ON THESMALL SPRINGS #9076077 AT THE END AND UNDER THE JAW SHAFTMUST BE RELEIVED SLIGHTLY. WHEN THE JAWS ARE IN THE OPENPOS|TION THE SPRING #9076077 SHOULD HAVE ALMOST NO TENSION.
TO ACHIEVE THE DESIRED POSITION, LOOSEN THE CAM ROLLER BOLTFROM THE ARM AND SLIDE IT IN THE SLOT TO GET THE CORRECTJAW OPENING IN BOTH ASSEMBLIES. SEE FIGURE,,ARM ASSEMBLY' ' .
IF BOTH JAW OPENINGS ARE NOT THE SAME, THEN LOOSEN THE ARMWITHOUT THf SLOT FROM THE ROD AND ADJUST THE JAWS TO MATCHTHE OTHER JAW ASSEM BLY. SEE FIGURE
' 'ARM ASSEMBLY' ' .
2.
3.
+.
FI GU RE ARM ASSEMBLY
ARMWTHOUT
SLOT
CAM ROLLER
PLATE CAM3642700
WITH JAW ASSEMBLIES AT TOP DEAD CENTER.
23
_'1
DENESTER ADJUSTMENTS
FIGURE CLAMP PLATE
APPROXTMATELY 3/16"(+ .2 mm)
CLAMP PLATE
BLACKKNOB
L.o3o ( .8 mm) To060 (1 .5 mm) GAP
WHEN CLAMP PLATEIS LIFTED.
ADJUST THE CLAMP PLATES TO THE STACK OF FLATS.
1. BRING THE JAW ASSEMBLIES TO TOP DEAD CENTER WTH THEDENESIER FULL OF FLATS BY TURNING THE CROSS SHUTTLEHANDWHEEL.
2. TURN THE BLACK KNOBS ON THE OUTSIDE OF THE DENESTER SIDEPLATE UNTIL THERE lS APPROXIMATELY 3/16" (J.2 mm) CLEARANCEBETWEEN THE CLAMP PLATE AND THE STACK OF FLATS ON BOTHSIDES. SEE FIGURE ''CLAMP PLATE".
3. WITH THE JAW ASSEMBLIES AT TOP DEAD CENTER. LIFT THE CLAMPPLATE UPWARD BY HAND. THERE MUST BE A .030,, TO .060''(.a mm TO 1.5 mm) GAP..BETWEEN CLAMP PLATE AND BLOCK ONAOTH SIDES. SEE FIGURE
''CLAMP PLATE'"
4. TO ACHIEVE THE GAP DESIRED, LOOSEN THE ROD END ASSEMBLY(rHE oNE THAr LIFrS rHE JAW lSSq1{B_!I). FRoM rHE LlFr ARM,iruO ADJUST THE ROD TO LENGTH NECESSARY. DO THE SAMEADJUSTMENT TO THE OTHER SIDE.
24
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25
LONG AND SHORT ADVANCE ADJUSTMENTS
If it becomes necessary to disassemble the long and short advance assemblies, turn thepower off and follow the steps below:
I. TUrN thE hANdWhECI UNtil thc PUSHER CHAIN COMES TO THE BEGINNINGOF TIIE FIRST STROKE. The clamshell frame assembly should be halfivay upand the clamshell crank arms should be horizontal. See FIGIIRE - RATCHETASSEMBLIES. NOTE: Position of ratchet and pawl.
Z. Make an alignment mark on the chain and sprocket on both sides so they can bereturned to their original positions when being reassembled. Also connt the number
of pitches on the chain from rod end to first engaged sprocket tooth. Follow the sameprocedure on both the L.H. and the R.H. sides.
3. Disassemble the 5/16-18 x 1'A bolt and fiber nut that anchors the rod end (with chain)
to arm. Slip the chain over the sprocket to remove. Both sides if necessary.
4. Do the required repairs. If the ratchet cams must be removed then note the timing
holes are opposite.
5. Reassemble with pusher chain at the FIRST STROKE. Make sure the pusher chain
DOES NOT move when doing the next step.
6. L.H. and R.H. SIDE - Stip the chain over sprocket teeth and sfretch spring until rod
end reaches long and/or short advance arm with ratchet and pawl in original position.
Attach with 5/16 nut and bott. See FIGIJRE - RATHCET ASSEMBLIES.
7. Make sure that the over travel (gap:approx. .060") on the ratchet and pawl
assemblies are the same on both sides between the lst and 2nd stroke only. If not,
then disassemble 5/16-18 nut and bolt that holds the rod end. Then loosen the jam
nut on rod end and adjust a % turn at a time until gap is equal on both sides. Turn
handwheel to cycle packer and check gap each time an adjustment is made. If gap
gets worse, turn rod end in opposite direction. Adjustments can be made on either or
both sides.
26
FI GU RE RATCHET ASSEMBLIES
POSITION OF RATCHETB T G I N N I N G O F 1
ASSEMBLIES ATS T S T R O K I
DoG (enwr-)
APPROX..060"GAP
L . H . S IDE OFLONG ADVANCE
PACKERRATCHET
BASEASSEM B LY
@@@o@o@@
R . H . S I D E O FSHORT ADVANCE
PACKER BASIRATCHET ASSIMBLY
RATCH ET
* EGG TRAY FLOW *
Doc (PAWL)
RATCH ET
27
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31
J L
PACKER MALFUNCTIONS
1. SYMPTOM: Pusher index moving too soon or too late, or coasting pastcausing missing index.
FIX: Check head timing; see pusher index clutch - trailing edge.FIX: Check cycle stop timing.FIX: Check to make sure pusher index brake is engaging. Send (1)
row of eggs through paddle wheel at a time and check indexbrake. Check gap between clutch and clutch pate. Should be.030".
FIX: Check to make sure pusher index clutch is engaging to advancepusher on time.
2. SYMPTOM: Index pushers not moving.FD(: Check to make sure index clutch is getting a signal. Then check
to make sure clutch is engaging.FD(: Check cycle stop timing.FIX: Check long and short advance ratchet assemblies to make sure
they are engaging properly. Also check spring holding camroller against cam is not broken or malfunctioning.
3. SYMPTOM: Missing Eggs in fay.FD(: Check to make sure all (12) sensors are working. Check to make
sure sensor adjustment has not moved. Sensor should not seeegg until egg is all the way in the paddle wheel.
FIX: Check head timing with gage to make sure transfer from paddlewheel to end alignment rollers is correct. Check to see if anyeggs have fallen into drip pan below roller assembly.
4. SYMPTOM: Overhead shuttle firing too soon or too late.FD(: See electrical timing of overhead shuttle start sensor.
5. SYMPTOM: Too many "eggs out of position - remove eggs from carton"messages.
FIX: Check head timing to make sure eggs are transfening whenthey're supposed to.
FD(: Check pressure or drive of eggs going into dividers. Are theextra eggs being forced over other eggs in paddle wheel? Arethere too many eggs on the reservoir? The ideal egg amountshould be eggs full to approximately 2' past the center deadplate. Check egg hold down slats. They should be positionedjust over the biggest egg without touching it.
33
6. SYMPTOM: Paddle does not fire.FD(: Check paddle wheel proximity sensor L.E.D. Does it come on
when it is supposed to. Check gap between sensor and disc -Check (12) eggs present sensors. Check IIO - 3 board. Is signaltelling clutch to fire? Is power signal reaching coil in clutch?
7. SYMPTOM: Extra row of eggs causing "eggs out of position remove eggsfrom carton" message.
FD(: Check head timing.FIX: Check to make sure paddle wheel clutch is not double indexing.
Dog stuck in solenoid while (2) ratchets go by. Check IlO - 3board.
8. SYMPTOM: Overhead shuttle double fires or coasts past stop.
FIX: Check overhead shuttle stop sensor and brake'
g. SYMPTOM: Eggs falling through clamshells,FD(: Arm for clamshell open has slipped and gap when closed is too
big. Gap should be .69 from tip to tip when closed.
FD(: Eggs may be dropping at the wrong time. Check head timingwith gauge.
34
FARMPACKER SERVICE ROUTINES
You may enter the service mode by depressing and holding either the Stop button or theStart button while turning power on. The service mode prompt message on the display is:
FARMPACKER SERVICE OT ROUTINES
At this point, any change of state of any input device on the machine will display amessage on the message display. For example, when you release the Start or Stop buttonafter turning power on, you will see the message START BUTTON UP or STOPBUTTON UP on the display.
The service mode can be used at any time to test the push buttons and sensor devices.
You will get a different message for each change of state of any push button by simplypressing the button and releasing it.
You wilt get a message for the 5 metal proximity sensors by putting a screwdriver in frontof them and then removing it. The 5 proximity sensors are the cycle stop, cross-overheadshuttle start, cross shuttle stop, and overhead shuttle stop sensors, pie sensor.
You will get a message for the 7 optical sensors by simply breaking the beam with yourhand. l"Ite 7 optical sensors are the piggyback, flow control (house belts), denester jam,
denester missing flat, egg in clamshells, and the right and left missing flat sensors.
FARMPACKER MAINTENANCE MODE
This farmpacker is capable of running without eggs or ftays. The sensor inputs areblocked internally which makes the farmpacker think it has eggs and trays, therefore, itwill run. Do not run eggs for production in this mode. The switch is on IlA 2 boardswitch #4.
The farmpacker cannot run without eggs going through the clamshells without being inthe maintenance mode. In other words, you can't fake the farmpacker into thinking it has
eggs by blocking all (12) eggs present sensor and expecting it to run. It will stop with an"egg in clamshell sensor blocked" message.
If there is a problem and you need to evaluate it, but don't want to run (12) eggs widebecause of breakage, you can run one egg at a time by blocking (11) of the (12) eggspresent sensors, leaving one on the end unblocked, but first turn the house belts off, run
the packer and clear the reservoir of eggs. This will stop eggs from going into the (11)
sensor blocked lanes. Then you can send (1) egg at a time through the packer to evaluatethe problem area.
35
2.
3 .
ELECTRICAL TIMING
NOTE: Refer to "Electrical Timing Diagrams" for item locations.
1 . SENSOR GAP ADJUSTMENTa. At the Cycle Stop, Cross Overhead Shuttle start, Overhead Stop and Cross
Shuttle Stop sensors, adjust the gap between the sensor and metal for .050"
(1MM).
CYCLE STOP SENSOR COLLAR(see cycle stoP timing)
CROSS SHUTTLE STOP SENSOR COLLARa. While observing Cross Shuttle Home Viewing Window, turn the Cross Shuttle
Handwheel until the nut is centered in the window.b. Wittr a3/16" Allen wrench, loosen the Cross Shuttle Stop Sensor set collar.
Rotate collar clockwise untit light on sensor just turns on. Retighten set collar-
c.d.
CROSS/OVERIIEAD START SENSOR COLLARWith the packer turned on in the Service Mode, turn the packer base
handwheel until the clamshells are bottom dead center of the third row of eggs.
At this time take a straight edge and place it across the back of a pusher out to
the packer base bed. Make a mark on the bed. Measure %" (6MM) ahead of
this mark and make another mark. Turn the handwheel until the pusher has
advanced to the 7r" (6MM) mark. At this time, using a %" wrench, loosen the
sensor collar, rotate it counter cloclcwise until the sensor lightjust comes on
and then retighten collar.
OVERIIEAD SHUTTLE SENSOR SLIDE BRACKET
Put packer in the run mode with house belts off.gtock l l of the L2 eggpresent sensors. The one remaining sensor will be used
to run packer.Install flats into the denester.Rgn the packer until the Overhead Shuttle cycles. Measure the gap between
the overhead Shuttle Bar Assy. and the front of the shuttle. Refer to the
Electronic Timing Diagrams for item locations. The gap should be 2'88"
(72MM). If it is not, with a7116" wrench, adjust the slide that the Overhead
Shuttte Stop sensor is mounted to, recycle the shuttle and measure again.
Repeat until this gaP is reached.
4.
5 .a.b.
36
ELECTRICAL TIMING DIAGRAMS
1.) SENSOR GAP ADJUSTilENT
3.) CROSS SHUTTLESTOP SENSOR COLI,AR
SETCOLLAR
cRoss slruTTLEHo}J|E VEWINGwtNDow
gtoss SF|UTTLE.HANDIITIEELCROSS SHUTILESTOP SENSOR
3 7
-l
ELECTRICAL TIMING DIAGRAMS
4.) CRoSs-o\ERHEAD START sENSoR coLtAR
MARK AT BOTTOII DEAD CENTEROF srd CEI.J- 0F FLAT
5.) O\ERHEAD SF|UTTI-E SENSOR SUDE BRAKCET
MEASURE AI'ID MARK1/4'(6 mm) AHEAD.
STRAIGHT EDGE
ADJI.'ST FORLAE' (73 tYtM)
3 8
39
2OO L.H. FARMPACKER_ELECTRICAL DEVICE LOCATION
RIGHT SIDE VIEW
8046032FLOW CONTROL(HouSEBELr)SENSOR
8031032PRE_RES CLUTCH
8046032MISSING RIGHTFLAT SENSOR
8046035ALL SENSOR CABLES
80460328046047(12) EGGS PRESENTSENSORPIGGYBACK SENSOR
\
80081 1 7COVER SAFETY
4356000OPERATORSTATION
8046052PADDLE CLUTCH/PUSHER SENSOR
8031 032BASE CLUTCH
8031032HEAD CLUTCH
"[no
o o
LEFT SIDE VIEW
8046032 EGGS tNCLAMSHELL SENSOR
8046032
9195046PADDLE WHEELCLUTCH
4356300DISPLAYASSEMBLY
804601 2OVERHEADSHUTTLESTOP SENS.
9195022OVERHD.SHUTTLEBRAKE
3752900MOTORCONTROLASSY.
r PKS JAM
\r*'o* ,
80081 1 7COVER SAFETY
8031027BASE BRAKE
804601 2CYCLE STOP
SENSOR
8031 032O\ERHEAD
SHUTTLECLUTCH
8046032MISSINGLEFT TRAYSENSOR
8046012cRoss/o\ERHEADSHUTTLE START SENSOR
[-l[ '
DENESTER o=.-_ 8046032r DENESTER
8031032CROSS SHUTTLEJAM SENSOR
4357500ELECTRICAL BOXASSEMBLY
TRAY FLOW+ o
18046032 v 8046012MISSING TRAY SENSOR CROSS SHUTTLE
8008117 STOP SENSOR
COVFR SAFEry
BACK SIDE VIEW OF CROSS SHUTTLE
CLUTCH
4 0
2OO F'ARMPACKER VO BOARD LIGHT DEFINITIONS
M
il e t &r0 r&u r &1 2 @r c @11 (&ls (&ro (&rz t&rs (D
LEDS YO.l BOARD IIO.2 BOARD VO.3 BOARI)
Red #9 M. Flat @enester) Stafi Switch Pre-Orientor SensorRed #10 +24V Supply Emergency Stop Gurd IntRed #11 Rieht Side M. Flat O. Head Shut. Start Sen Left Stacker Int.Red #12 t2 Eggs Present Cross Shuttle Stop Sen. Egg Out of PositioitRed #.13 Anti Jam @enester) Stop SwitchRed #14 Flow Control Ove,rride Switch Anti-Jam PKSRed #15 Left Side M. Flat Cycle Stop Sensor Rieht Stacker Int.Red #16 House belt Sw. On/Off O. Head Shuttle Stop Sen. Pie Timing SensorRed #17Red #18
Green #l O. Head Shuttle Break Pre-Orientor ClutchGreen#2 Sonalert Not UsedGreen #3 Main Clutch Cross Shuttle Clutch Paddle Enable Clutch
Green #4 Not Used NotUsedGreen #5 Not Used Not UsedGreen #6 Main Break House belt Contactor Base BrakeGreen #7 Not Used Not UsedGreen #8 O. Head Shut. Clutch Motor Contactor Head Clutch
Yellow Fl O. Head Shuttle Break Pre-Orientor ClutchYellow F2 Main Clutch Cross Shuttle Clutch Paddle Enable Clutch
Yellow F3 Main Break House belt Contactor Base BrakeYellow F4 O. Head Shut Clutch Motor Contactor Head Clutch
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DESCRIPTIONPCB ASSY I/O.1PCB ASSY I/O-2PCB ASSY t/O-3TATCH BLOCK CARD CAGEPI-ATE. POWER SUPPLYSUBPI.ATECPU-g ASSYSNUBBERCABLE, 2 CONDUCTOR SHIELDEDWIRE, 22 AWG, BLUEWIRE,22 AWG, BI-ACKWRE,22 AWG, WHITEW|RE, 14 AWG, BLACKWRE, 14 AWG, GREENWIRE, 16 AWG, BIACKWIRE, 16 AWG, BROWNWIRE, 16 AWG, BLUEWRE, 16 AWG, GREENWRE, 16 AWG, ORANGEWIRE, 16 AWG, REDWIRE, 22 AWG, BROWNGROMMET, 3/8'OD x1l4'lD x 1/16"LABEL, GROUND SYIL,IBOL
MAIN POWER SWITCHCONTACTOR 24VDC 4 POLETERMINAL, CRIMP, RINGTERMINAL, CRIMP, SPADETERMINAL, CRIMP, RINGTERMINAL, CRIMP, PINTERMIML, CRIMP, DUMMY PINWIRE NUTTERMIT.IAL, CRIMP,TERMINAL, CRIMP,FEMALE PINTERMll.lAL, CRIMP, CONTACT PINEND CIAMPTERMIIIAL BLOCK - GRAYEND PLATE. GRAYMARKING STRIP # 1-10MARKING STRIP # 11.20i'ARKING STRIP#21.30TERMINAL BLOCK- GREENTERMII{AL BLOCK. GRAY, MlO/10DIN RAIL, SLOTTED 15X35MM DEEPDIN RAIL, SLOTTED 15X35MM DEEPMARKING STRIP# 1-50itARKtNG STRIP # 51-100
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ITEM QTY PART NO. DESCRIPTION48 2 8015308 JUMPER,4 POLE49 42 8015310 TERMINAL BLOCK. BRANCH - BEIGE50 4 8015312 TERMINAL BLOCK - BRANCH - BLUE51 1 8015313 ENDPLATE-BLUE52 4 8015314 TERMIML BLOCK. BRANCH. BRO\AN53 3 8017236 EDGECONNECTOR 44POS54 3 8017239 KE\TING PLUG55 1 8021184 FUSE GDGSA56 1 8021191 FUSE BLOCK END PI-ATE57 3 8021192 FUSEBLOCK58 2 8021205 FUSEHOLDER59 1 8021230 FUSE GDG2A60 1 8021273 CIRCUIT BREAKER 2 POLE 8 A61 1 8021274 CIRCUIT BREAKER 2 POLE 16 A62 1 8021275 FUSE GDG500MA63 2 8021276 FUSEKTK.R€FASTBLOW64 1 80?2019 CARD CAGE65 40' 8023035 WIRE DUCT 1'X2'+ COVER6667 1 8026009 DIoDE - 1N400368 2 8026099 ARCSUPPRESSORDC69 1 8026100 ARC SUPPRESSOR DC END PISTE70 1 8037006 SOMLERT71 1 8038041 LINE FILTER72 1 8042038 POVVERSUPPLY24VDC79 1 BO42O39 POWER SUppLy 5V, +12, -12 VDC74 2 8240210 FIAT WASHER 1/47s 2 82s0168 1l+20 JAM NUT76 2 8250355 1l+20 X 2.5" H.H. BOLT77 23 8250623 1G32 X 3/8' P.H. SCREW78 2 8250639 1l+20 x 1'H.H. BOLT79 2 9038003 1l+20 ESNA NUT80- 2 903S017 1l+20 THIN ESNA NUT81 2 9076151 SPRING82 1 8017379 RECEPTACLE2XlTPOS83 8 8015191 RECEPTACLE CONTACT2&'22AWG
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200 FarmpackerOverhead Shuttle Assembly
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74
200 FarmpackerReservoir Assembly
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(2) REQ'D.
9073001SPR}NG
(2) REQ'D.84282900SENSORASSY
A4000100SPACER(13) REO'D.
A3999800SPACER
(13) REO'D.
3620200ANG. GUARD-MOUNT
84267900BAR
A3995400SLAT(12) REQ'D.
?1,3jo1o^o^^.. Sfltoo -
ANGLEASSY. A3847900
4058200DlVIDER(13) REQ'D
3641600GUIDE(2) REQ'D
A3610000BRKT-SENSOR
(2) REQ'D.DISC-RUBBER(2) REO'D.
76
200 FarmpackerReservoir Transfer
To Paddle Wheel AssemblY
A32841 00ROLLOFF PAD
(12) REQ'D.
84340700PADDLE REWORK
THIS END ONLY
84281 900BAR
77
7B
200 FarmpackerHead - Front View
pg . 1a f 2
srw f
I.i.li:"
84282900SENSOR BRKT.
3659000CLIP
35901 00ARM
(4) REQ'�D.
D3692000LOWER
CLAMSHELLASSEMBLY
3643900GUIDE
(4) REQ'D.
4267140GUIDE
(5) REQ'D.
91 1 0003BUMPER(2) REQ'D.(4) REQ'�D.
79
4084500PADDLE
(11) REQ'D.84340700
PADDLE.REWORK(1) REQ'�D.
A4267500SPACER
(2) REA'�D.
80
200 FarmpackerHead - Front View
pg.2 ot 2
A4240900COUPLING
90050611X2" BEARING
A3932400BLOCK(6) REQ'D.
A39963MSPACER
(2) REQ'D.
3960101 SHOWN3960102 oPPOSITEBRACKET
3942300DISC ASSEMBLY3451500 DISCOTHER SIDE3942500SPROCKET(6) REO'�D.
396@00BRACKET{2) REO'D.
3942402CHAIN
90050611i2" BEARING
9076097SPRING(4) REQ'D.
200 FarmpackerHead - Inside
84282300DRIP SHELF SUPPORT
(2) REO'�D.
84340300BRI..'SH
(2) REQ'D.
A4282500BRKT.
{2) REQ'D.
i " \ l i
90050443/4'' BEARING
w282700
A4267444SPACER(2) REQ'�D.
M349300CRANK ROD(2) REQ'D.
A4340800PIE CAM
84282444SENSOR BRKT.
A3999500coLl-AR90050443/4" BEARING
SUPPORT BRKT.
81
200 FarmpackerL.H. Side Head
pg . 1a f 2
BEHINDSPRKT.
BEHINDSPRKT.
200 FarmpackerL.H. Side Head
pg .2 a f 2
83
-.1
200 FarmpackerR.H. Side Head
BEHINDSPRKT.
84
PART NO.
1 01 1121 31 41 51 61 71 81 9202122232425
3738
46
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DIAMOND AUTOMATION
2OO FARMPACKER HEAD
DESCRIPTION
ING3/16 DIA NYLON WASHER
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SHIELD.FRONTSHIELD.TOPSPRING.DIVIDER
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92
200 FarmpackerCross Shuttle
Bottom View Denester Endp g . 1 o f 5
37s6400SHAFTASSY.L.H. SHOWN37s6403R.H. OPPOSITE
90050443/4" BRG.(2) REQ'D.
91869161'' PINCH COLIAR(2) REQ'D.
0460400LEATHER BRAKE2949400HUB
9007004ROD END
0561200HOOKASSY.
93
200 FarmpackerCross ShuttleBottom View
pg,zo f5
3591600BRACKET3604500
CHAIN TRACK
3756600SHAFT
90050481" BRG.
91869123/4'' PINCH COLLAR
3756300PIVOTARM
L.H. SHOV'IN3756303
R.H. OPPOSITE
3591300ARMASSY.
L.H. SHO\^/NI3s91303
R.H. OPPOSITE
91869163604600RAIL
3604100ARM ASSY.L.H. SHOWN3604103R.H. OPPOSITE
1" PINCH COLI.AR
9005048BEARING
9054018CAM FOLLOWER
3756200CAMASSY,L.H. SHOWN3756203R.H. OPPOSITE
3588200CAMASSY.I..H. SHO\AN3588202R.H. OPPOSITE
94
9007007ROD END
3607900ROD
3607000ARM
3606900STUB SHAFT
90480625/8'' SET COLI-AR
200 FarmpackerCross ShuttleBottom View
p g . 3 o f 5
3586400STRAP
90050443/4" BRG.
91960034OAlT IDLER SPRKT.
9076070SPRING
8031032CLUTCH
9076097SPRING(2) REQ'D.
91869123/4" PINCH COLLAR
3607800SHAFT
95
200 FarmpackerCross ShuttleBottom View
p g . 4 o f s
91869105/8" PTNCH COLISR
3589903IDLER BRKI
3641400GEAR BOXRIGHTANGLE1:'1 MTIO
96
200 FarmpackerCross Shuttle
Bottom View Drive Endp g . 5 o f 5
3451400RACHETASSY.
2630900RACHET2681 500
PAWL0254500SPRING
3591100SHAFT
3607100SPACER(4) REQ'�D.
97
200 FarmpackerCross Shuttte
Back Side
3604300GUIDEL.H. SHOWN3604301R.H. OPPOSITE
4267104GUIDE
3604700PLATE
(2) REQ'D"
3605800REFLECTER PLATE
3604400PLATEL.H. SHOWN3604401R.H. OPPOSITE
3621000HAND\A/IIEEL
toouvuuANTI-BK"UP BRG2779940INNERACE3607500SPACER(2) EA. REQ'D.
3659200SENSOR BLOCK
3591500LEG
3606000FRAMEASSY.L.H. SHOWN3606001R.H. OPPOSITE
$4CI404ROUGH TREAD
(2) REQ'�D.3605901SENSOR BRKT.L.H. SHOWN3605902R.H. OPPOSITE
3619200SENSOR BRKT.
3609600PUSHER CHAINASSY.
3702400BRACKET
3619400BRACKET
3640700OTHER END
98
2 O O F A R M P A C K E R G U A R D SRIGHT SIDE VIEW 3620400
SHIELD_TOP
3620300SHIELD_FRONT
9124122LATCH(4) REOD
4340201GUARD-HEAD
3620700GUARD_RH BASELH PACKER3620802GUARD_RH BASERH PACKER
3641800GUARD_RES.
LEFT SIDE VIEW
4340202GUARD-HEAD
5641700GUARD-PKS
3926600GUARD-OVI-IDSHTTL BRAKE
3620800GUARD-LH BASE
LH PACKER3620702
GUARD-LH BASERH PACKER
5609500GUARD-O\ERHEAD
SHUTTLE DRI\E
BACK SIDE VIEW ,OF CROSS Sffi5826800
BAR-GRD
3641900GUARD
4117900GUARD-DEN.(2) REQD 3651600
BAR-GRD3590400
DOOR902601EHINGE(2) REQD
36s1000 3862500GUARD-EXIT GUARD
GLOSSARY
covER SAFETY SWITCII: They are magnetically activated reed relay switches that
are used to insure that all covers are installed and closed. There are 6 switches' See
Device Location Chart.
cRoss oVERIIEAD SHUTTLE START SENSOR: Metat sensing device that is
used as a timing sensor to ten the computer to start trre cross and overhead Shuttles.
cRoss SI{UTTLE: The shuttle assembly that denests and positions flats to be
transferred to the packer base shuttles (left and right).
cRoss SITUTTLE CLUTCH: An elecfiomechanical device that when activated
engages the cross shuttle.
cRoss SHUTTLE STOP SnNsoR: A metal sensing device that is used as a timing
sensor to telt the computer to shut offthe cross shuttle.
cycl,E STOP SENSOR: Metal sensing device that tells the pusher chains brake on the
base when to engage. Not every time, only when there is a missing row of eggs'
DENESTER: Separates and places flats onto the cross shuttle'
EGG IN CLAMSIIELL SENSOR: An optical device that checks with the computer to
see if an egg is supposed to be in the clamshells at a specific time
FLOW CONTROL SENSOR (HOUSEBELT): An optical dwice that tells the
computer that there are too many eggs in the reservoir and it should turn offthe house
belts.
rrf,,AD CLUTCE: An electromechanical device that when activated engages the head to
nrn.
JAIVI SENSOR, DEI\TESTER: An optical device that senses if a flat is out of position'
IVIAIN BRAKE @ASE): An elecfiomechanical device that when activated because
ttrere are no "ggr,'rtops the pusher chains on the base, therefore preventing coast'
MAIN CLIJTCH @ASE): An electomechanicat device that when activated engages
the pusher chains on the base'
MAIN MOTOR: A DC electric motor that drives the farmpacker'
101
MISSING FLAT SENSOR: They are optical devices that tell the computer that there isa flat present or not. There are three missing flat sensors, "Rightside", "Leftsideoo and"Denestgr".
OVERIIEAD SIfUTTLE: Transfers flats from the Cross Shuttle to the Packer BaseShuttles (left and righ|.
OVERIIEAD SI{UTTLE BRAKE: An electromechanical device that when activatedstops the Overhead Shuttle therefore preventing coast.
OVERIIEAD SHUTTLE CLUTCH: An elecfiomechanical device that when activatedengages the Overhead Shuttle.
OVERHEAD SHUTTLE STOP SENSOR: A metal sensing device that is used as atiming sensor to tell the computer to turn off the Overhead Shuttle clutch and engage theoverhead shuttle brake.
PACKER BASE SIIUTTLES: Main shuttles that carry the flats through the packingstation. There is a left and a right shuttle. Left and right is in relation to egg flow.
PADDLEWHEEL CLIITCH: A (a) stop wrap spring clutch that's mounted at the endof the paddlewheel assembly and is activated by the pie sensor when (12) eggs arepresent.
PIE SENSOR: A metal sensing device that is used as a timing sensor to tell thepaddlewheel clutch to fire at leading edge and the main (base) clutch at trailing edge.
PIGGYBACK SENSOR: An optical device that tells the computer when blocked todisengage the pre-reservoir clutch until the sensor is unblocked.
PRE RESERVOIR CLUTCH: An electromechanical device that is controlled by thePiggyback sensor before the dividen on the reservoir that controls the pressure of theeggs. When there are too many eggs in front of the dividen they start to climb slightly,therefore, blocking the pigryback sensor causing the clutch to disengage, and stoppingthe second belt until the sensor is unblocked, then instantly coming back on.
TWELVE EGGS PRESENT SENSORS: An optical device that tells the computer tofire the paddlewheel clutch at the time when the leading edge of the pie sensor is seen.
r02
