FLAT CHAIN SYSTEM OWNER S MANUAL

Transcription

1 FLAT CHAIN SYSTEM OWNER S MANUAL...Manufacturers of Quality Poultry Equipment Pax Steel Products, Inc. - Manual

2 Table of Contents Safety Warnings General Information Introduction Locating the Drive Unit Drive Unit Assembly Layout and Install Suspension System Install Trough Install Flat Chain Install Grill Install Drop Cables and Finish Suspension System Startup System Lubrication and Maintenance Troubleshooting REPORT ALL SHORTAGES TO YOUR DISTRIBUTOR Contact your distributor for repair parts. When ordering try to have the part number and description for quicker assistance. Refer to your manual for part numbers and descriptions. 2

3 GENERAL INFORMATION HORSEPOWER REQUIREMENTS OVERALL CHAIN LENGTH UP TO 500 MOTOR REQUIRED FOR 60 FPM DRIVE 1.0 hp motor 501 to hp motor FEED DELIVERY RATES 20 Feet per Minute = 425 lbs../hr. 40 Feet per Minute = 1200 lbs../hr. 60 Feet per Minute = 1740 lbs../hr. 3

4 SAFETY WARNINGS Pax Steel Products primary concern is your safety. This section is included in the manual as a guide to help and encourage a safe operation. However, it is your responsibility to evaluate each operation and to determine and implement safe working practices to protect yourself as owner and/or operator. This manual must be delivered with the equipment and failure to read the manual and its safety instructions is a misuse of equipment. Warning decals have been placed on the equipment to warn of potentially dangerous situations. Care should be taken to keep these decals in good condition and readable at all times. Replace any missing or damaged decals. Using Pax equipment for purposes other than those specified in this manual could cause serious personal injury or equipment damage. This safety alert symbol is used to warn you of potential safety hazards: BECOME ALERT! PAY ATTENTION! YOUR SAFETY IS INVOLVED Keep hands and tools away from exposed chain Keep all safety guards and covers in place Disconnect electrical power before inspecting or servicing equipment. All electrical wiring should be done by a qualified electrician in accordance with local and national electrical codes. Be sure equipment is grounded properly. 4

5 INTRODUCTION Installing your new Pax flat chain system must start with a thorough understanding of the system you are installing and a plan to follow in order to complete this installation properly. It is very important that you take the time now to read this manual carefully. It will save you time and costly errors later. Before you start planning your new installation, you should consider the following suggestions: 1) Location of feed bins and overhead fill systems should be planned to match the location of the drive unit. 2) Drive hoppers should be positioned to allow for routine maintenance that will be required during the life of your system. As with any major project, the planning and layout phase is the most critical to the success of the entire project. A complete and systematic plan is essential before starting. After your equipment arrives, be sure to store it in a dry, safe location to avoid dirt, moisture or wind damage. 5

6 ASSEMBLE AND LOCATE DRIVE HOPPER The drive hopper must be located as close as possible to the center of the feed line so there is equal travel to both sides of the hopper. You will also want to be sure that the hopper is located properly for the type of installation you are planning and that the requirements for your building specifications. After hopper is located, it is time to assemble the motor, pulley, belts and guard to the hopper. Align pulleys and V--belts. These parts are pre-assembled to gear reducer and drive hopper housing. Before assembling motor and pulley parts to hopper be sure to check that they are the size and model that you ordered. Begin assembly by attaching pulley to motor with square key and set screw keeping hub side of pulley away from motor. Do not tighten set screw at this time. Mount motor to motor mount on hopper with hex bolts found in motor mount. Leave bolts loose to align motor pulley with gear reducer pulley. Slip V-belt over both pulleys and adjust large bolt on motor mount until belt is pulled taut. Proper belt tension is important for extended belt life. DO NOT OVERTIGHTEN BELT. DAMAGE TO MOTOR OR REDUCER MAY RESULT After proper tension is set and pulleys aligned, tighten set screws securely. Place pulley guard over belt. A good way to check for proper tension on belts is by striking the belt with your fist. A slack belt feels dead while a properly tensioned belt will feel alive and vibrate. 6

7 LAYOUT CIRCUIT AND INSTALL WINCHES After drive hopper is located and assembled, it is time to layout your flat chain circuit. The first step is to establish a straight line to locate the winch systemsuspension hooks. The best way is to string a straight line from one end of the building to the other along the bottom of the ceiling trusses directly above the planned chain circuit. Screw in hooks along line at 8-10 intervals depending on spacing of ceiling trusses and skip the hooks directly above the drive hopper. Stagger every other hook approximately 1 off center of line. This will provide for a smooth, uniform draw on the drop cables. Hang 1.5 (38mm) pulleys on each hook. Near the drive hoppers you will need extra support to mount the overhead winches. These headers need to be of good sound 2 x 8 lumber or better. Mount them along center line near middle of building using heavy lag screws. Fasten winch to header with lag screws and pilot holes to avoid splitting header. 7

8 SUSPENDING FEED HOPPERS To suspend feed hoppers, use (2) cutoff lengths of bulk bin legs approximately 6 longer than overall width of feed lines Be sure to keep hoppers and bracing square. Bolt both hoppers secure to bracing Fasten an eyebolt in both ends of both braces to attach the drop cables later. Above each hopper attach a mounting angle slightly outside of the planned cable line. Be sure angle is securely attached and capable of handling full hoppers Drill holes in mounting angles directly above the eyebolts in hopper bracing and attach (4) 3.5 (89mm) pulleys to angles. 8

9 SUSPEND MAIN CABLE LINES You are now ready to hang the main 3/16 (5mm) cable lines. Run end of cable through last pulley in line and attach it to the floor slats or end wall temporarily. Run cable back to winch and wrap around winch making sure to wrap cable at least twice around top half and bottom half of winch. Continue running cable to the last pulley other end of line. Slip through last pulley and secure as first end. Remove slack in cable by manually turning winch. Do not overtighten cable. Repeat procedure for each main line. To avoid kinks in cable, always roll cable off spool using a rod or dowel as an axle. Never peel cable off sides of spool. 9

10 TROUGH INSTALLATION Start assembling your trough from one end of line working towards the feed hoppers. It is very important to get a good square corner to start with. Be sure trough is properly seated in corner housings. Tapping end with a mallet and a wood block to protect ends will help assure a tight fit. Continue assembling troughs and couplers until you reach the hoppers. If it necessary to shorten a standard length of trough, be sure to allow 2-5/8 (68mm) for the portion of trough that will be inserted into corner, coupler and or hopper. Cut trough ends to same profile as standard troughs. IMPORTANT: TROUGH ENDS MUST BE CUT SQUARE Repeat same procedure for other half of trough line. When assembling trough to outgoing end of hopper make sure trough is placed under the power shoe and against the trough stops. When installing the last trough to the return side of drive hopper, cutout a rectangular opening approximately 2.75 (72mm) x 4 (104mm) to use for a cleanout hole. CAUTION: CUT CORNERS ON TROUGH ARE SHARP! CHAIN INSTALLATION Before installing chain be sure trough connections are tight and corners square. Get chain and distribute around system. Work the leading end (hooked end) through drive hopper with open part of hooked end down starting from the return side making sure chain is properly seated under repacker wheel, through hopper, over power shoe, under drive sprocket and approximately 10 into outgoing trough. Layout chain in troughs being careful not to kink or twist chain. Connect chains from tail end using chainbreaker and hammer. Manually pull chain tight as you proceed. Thread chain through corners keeping chain flat and under hold down rails inside corners. Continue around entire circuit and through auxiliary hopper until reaching starting end. Attach chain puller (come-along) to both ends of chain and tighten chain carefully while observing tension on chain in opposite side of line. Fasten ends together. After system runs for a few days, chain will need retightened to remove slack. Chain is properly tightened when it is impossible to squeeze links with thumb and forefinger. 10

11 GRILL INSTALLATION After chain has been installed you can install grill into trough. Snap grill sections into trough so bottom wire goes under trough lip and top wire goes above lip. Butt ends together squarely. At corners or feed hoppers extend grill past trough ends approximately 1 to eliminate excess opening on ends. Place grill caps on all open ends of grill. Butt grill ends together tightly to maintain proper spacing for openings Proper hopper to grill fitting Proper grill to corner fitting with grill caps applied 11

12 INSTALLING DROP CABLES Use 1/8 (3mm) cable for all drop cables. The first drop cable (pullback cable) on both sides of the winch will be rigged differently and require an extra pulley. Mount the extra 1.5 (38mm) pulley adjacent to the 2nd pulley on both sides of winch. Clamp pullback cables to main cable approximately 1 on winch side of extra pulley. Run cable back thru extra pulley and up thru the first pulley and let hang to floor. Connect all remaining drop cables along line working from winch to end of line. Each cable should be clamped to main line approximately 1 from each pulley and toward winch side. Clamp cables secure and thread thru pulley and let hang to floor. 12

13 When connecting the cables for suspending the feed hoppers, clamp both cables on each line 1 in front of winch side of pulley. Use (2) clamps for each cable. Run other end of line thru eyebolts on hopper bracing and clamp secure with (2) clamps. WINCH SIDE Place trough hangers around troughs directly below each drop cable and secure end of cable to hanger with cable clamp. To suspend end of lines, release the main cable from its mooring and use as the end drop cable. Run cable thru end pulley and secure to corner unit hanger with clamp. After all cables are attached, raise winch lines approximately 6 and check that troughs are hanging level and straight. Make adjustments by loosening cable clamps on hangers and retighten after adjustments are made. 13

14 CIRCUIT START-UP Before starting the system, walk the line and carefully check that all trough and grill connections are secure and remove all foreign material from troughs. Oil all corners and check if vent plug is installed on gearbox if required. Test run system dry for no more than 5 minutes. Watch chain next to drive sprocket to make sure no slack gathers and chain takes off smoothly. If not, readjust chain tension as described earlier. Note that system will operate noisy while running without feed. Shutoff system as soon as you determine chain is running properly or notice a problem. Running system without feed will damage equipment. After system is shutoff check chain tension again. You should be able to raise chain approximately 1-1/2 by hand. Place covers over corners and fill feed hoppers 1/4 full. Test run system again and make adjustments to feed level feed gate and repacker wheel slide to obtain proper feed levels. System should run smooth and quiet after feed is distributed through entire circuit. NEVER WORK ON SYSTEM WITHOUT DISCONNECTING ELECTRICAL POWER! 14

15 WIRING DIAGRAM FOR MOTORS LESS THAN 1 HP TIMER/CLOCK Ground L2 L1 Ground MOTOR 230V 60Hz L1 L2 L2 L1 WIRING DIAGRAM FOR 1HP & 1-1/2HP MOTORS TIMER/CLOCK MOTOR 230V 60Hz Ground Ground L1 L2 L1 L2 230V Input from Fuse Box To Coil Control L1 RELAY 1PH 230V Ground L2 To Coil Control USE ONLY QUALIFIED ELECTRICIANS FOR ALL WIRING! 15

16 WIRING DIAGRAM FOR TWO MOTORS 1HP TO 1-1/2HP AND ONE TIME CLOCK L1 MOTOR 230V 60Hz TIMER/CLOCK L2 RELAY 1PH 230V Ground Ground L1 L1 To Coil Control L2 To Coil Control L2 MOTOR 230V 60Hz L1 L2 RELAY 1PH 230V To Coil Control Ground L1 L2 230V Input from Fuse Box L2 L1 To Coil Control USE ONLY QUALIFIED ELECTRICIANS FOR ALL WIRING! 16

17 EQUIPMENT MAINTENANCE DISCONNECT ALL ELECTRICITY BEFORE SERVICING EQUIPMENT CHAIN TENSION Proper tension on chain must be maintained at all times. To check chain tension, lift chain approximately 2 with one hand and press down with other hand approx.. 12 from first hand. Chain should not flex enough to touch the trough. Tighten chain if necessary by removing links and reconnecting chain. CORNER LUBRICATION Center post in corner units should be well lubricated at all times. Remove thumbscrew from corner cover and put S.A.E. 10W oil in center post every 60 days. V-BELT TENSION Inspect drive hopper unit v-belts for excess wear and improper tension regularly. Belts with cracks or frayed edges should be replaced. To check for proper tension, press belts together with fingers. If belt flexes more than 1 it should be retighten. GEARBOX LUBRICATION Check and maintain proper oil level in gearbox every 6 months. Change oil in gearbox every 12 months. Use approximately 3/4 quart of gear oil 80W-90. FEED LINES Feed lines must be kept level and square at all times to reduce excessive wear on equipment. Adjust clamps on drop lines to maintain level line. Check trough connections for proper fit. SHEAR PINS Be sure to remove all broken drive sprocket shear pins from system. Broken shear pins may get lodged in chain and cause damage to equipment or birds. Align sprocket with hub by turning belt manually until holes align and hammer new shear pin into place. Remember; An ounce of prevention is worth a pound of cure! 17

18 TROUBLESHOOTING IF THE CORNER WHEELS ARE NOT TURNING: The chain may be too loose. Remove slack in chain and retighten. Remove any foreign objects from trough or corner. Check inside corner under wheel also. Lubricate wheel with #10 oil. IF THE GEAR REDUCER IS EXCESSIVELY HOT: IF MOTOR STOPS FREQUENTLY: The gear reducer oil may need changed or refilled depending on condition of oil The chain may be too tight. Chain should lift approximately 1-1/2 from trough. Add links if needed. Check that motor is wired as per diagram on motor. A motor wired for 230 volts running on 115 volts will run very sluggishly. Motor may not be getting full voltage causing motor to overheat. Check that proper size wiring was used and always use a licensed electrician for wiring problems. IF FEEDER SQUEAKS NEAR DRIVE UNIT: Lubricate drive sprocket and shaft. Check oil in gearbox. Reducer gears are out of line. Consult your distributor. IF FEED IS NOT BEING TAKEN BACK INTO HOPPER: There may be too much feed coming out of hopper. Lower feed level plate on side of hopper. Repacker wheel may be clogged or not turning freely. Clean wheel and adjust repacker plate to just clear wheel. 18

19 IF FEED BUILDS UP IN CORNERS: Adjust feed level plate to reduce feed flow. Corner wheel may not be turning. IF YOU ARE SHEARING PINS: Too much litter in trough. Keep trough level with back of birds. There may be too much slack in the chain jamming the drive sprocket or corner wheels. Adjust the chain tension as needed. Chain may be binding under power shoe. Be sure trough is slid under shoe and against stops. File any rough spots from sprocket that could bind chain. If worn too much replace sprocket. Chain may be caught on foreign object in line. Check line and remove debris. Chain may be catching on trough. Check that trough is level and all connections are snug and cut square. Gear reducer may not be properly aligned. Feed may be getting wet and can harden in chain links causing them to break. 19

20 90 DEGREE CORNERS DEGREE CORNER W/HANGER DEGREE CORNER L/HANGER DEGREE FLOOR CORNER KEY PART # DESCRIPTION Wire Hanger /4" x 1/2" Thumbscrew /4 Flat Washer Plastic Cover Retainer Snap Ring Post Washer Fiber Washer Corner Wheel w/bushing Corner Post Hold Down Rail Bracket Hold Down Rail /4" x 1" Carriage Bolt /4" Flange Nut Suspended Corner Housing Floor Corner Housing /2" Lockwasher /2" Flat Washer /2-13" Hex Nut Clip for Floor Corner 8 CORNER HOUSINGS INCLUDE HOLD DOWN RAIL AND BRACKET PRE-ASSEMBLED TO HOUSING

21 ONE LINE SUSPENDED DRIVE HOPPER KEY PART # DESCRIPTION KEY PART # DESCRIPTION Welded Housing 11 * Motor Anti-Backfeed Plate Gear Reducer Assy /16" Thumbscrew Moto Mount Repacker Wheel Motor Hinge Rod Repacker Wheel Shaft 15 * Pulley Guard #11 Hitch Pin Sprocket Guard Chain Guide Power Shoe Feed Level Gate Chain Stripper 8 * Motor Pulley Shear Pin Hub Reducer Pulley Drive Sprocket 10 * V-Belts Sprocket Locking Collar * Denotes items ordered seperately 21

22 LINE SUSPENDED DRIVE HOPPER

23 LINE SUSPENDED DRIVE HOPPER KEY PART # DESCRIPTION Line Suspended Welded Housing Anti-Backfeed Plate (2) /16" x 3/4" Thumbscrew (2) Repacker Wheel Assy. (2) Line Repacker Wheel Shaft #11-P Hitch Pin Chain Guide - Plated (2) Feed Level Adjuster Plate 8 * Motor Pulley Reducer Pulley 10 * V-Belts 11 * Motor :1 Right-Hand Gear Reducer Motor Mount & Nut Assy Hinge Rod for Motor Mount 15 * Pulley Guard Heavy Duty Coupler Power Shoe Assy. (2) Chain Stripper (2) Double Shear Pin Hub Drive Sprocket Assy. (2) " Flange Bearing (2) Line Double Drive Shaft Sprocket Guard Assy. * Denotes items ordered seperately 23

24 LINE SUSPENDED DRIVE UNIT LINE FLOOR DRIVE UNIT

25 LINE SUSPENDED DRIVE UNIT LINE FLOOR DRIVE UNIT KEY PART # DES CRIPTION Suspended Drive Welded Housing 1F Floor Drive Welded Housing Leg & Adjuster Screw Assy. (4) /2 SAE Flat Washer (4) /16" x 1" Expansion Pin (4) Adjuster Crank Feed Level Adjuster Plate (2) Power Shoe Assy. (8) Motor Mount (2) Chain Stripper (4) 6 * Motor Pulley (2) " Reducer Pulley (2) 8 * V-Belts (2) Heavy-duty Coupler Assy. (2) Right Hand Drive Shaft Left Hand Drive Shaft " Flange Bearing (4) " SAE Flat Washer (vary) " Spring Washer (4) l Double Shear Pin Hub (2) Drive Sprocket Assy (4) Sprocket Spacer (2) Shear Pin (14) :1 RH Gear Reducer Right Hand Sprocket Guard :1 LH Gear Reducer Left Hand Sprocket Guard 19 * Pulley Guard (2) 20 * Motor (2) * Denotes parts are ordered seperately 25

26 PRODUCT WARRANTY Pax Steel Products, Inc. (Pax) warrants to the original purchaser that Pax manufactured products will be free of defects in material and workmanship for one year from date of purchase when used in usual and customary service. Pax will, at its option, (a) repair or replace products found to have a defect in material or workmanship when the defective product is returned prepaid for inspection within one year of date of retail sale, or (b) refund to the original purchaser the original purchase price in lieu of such repair or replacement. All returned merchandise must be authorized and prepaid. Pax will not be liable for any unauthorized expenses incurred in regard to any item presented for warranty adjustment. Pax will not, under any circumstances, be liable for any kind of special, incidental, consequential, or contingent damages (including, but not limited to, lost or damaged product goods, cost of transportation, lost sales, lost orders, lost income, increased overhead, labor and incidental costs and operational inefficiencies) and the warranty liability will be limited to the invoiced price of the product from Pax to the purchaser. Products which are abused, misused, altered, neglected, damaged by accident, or installed different than instructions are not covered under this warranty. Products not manufactured by Pax and supplied by outside manufacturers are warranted separately by the respective manufacturer. This warranty applies only to products used for the care of livestock and poultry - other applications in industry or commerce are not covered by this warranty. Pax reserves the right to make design or specification changes at any time without any contingent obligation to purchasers of products already sold. Pax feed bins are designed for storage of material having a density of no more than 40 pounds per cubic foot. The feed bins are designed for the storage of free-flowing materials only; soybean meal, meat scraps and certain other materials are not considered free-flowing and should not be stored in Pax feed bins. Pax is not responsible for any undertaking, representation, or warranty made by any dealer, distributor, or other persons, beyond those expressly set forth in this warranty. Any exceptions to this warranty must be authorized in writing by an officer of the company. 26

27 Pax Steel Products, Inc. Manufacturers of Quality Live stock & Poultry Equipm ent MAIN OFFICE 210 E. Main St. P.O. Box 117 Coldwater, OHIO USA PHONE: FAX: TOLL FREE: (USA only) Pax Steel Products, Inc. - Manual

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