Staalkat Farmpacker 40 Using this manual This manual provides a guideline for the safe and effective operation and maintenance of the Staalkat Farmpacker 40. We recommend that you

Translation of original user’s manualDocument version: Reprint date: 22-06-10

Machine order no: .......................................

Year of manufacture: .......................................

Article no:

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Copyright © 2010 Staalkat International B.V. Document: SFP40 user eng.fm

User’s Manual

STAALKAT INTERNATIONAL B.V. Telephone: +31 (0) 543 473 868Fax: +31 (0) 543 474 995

Ambachtsstraat 4 · P.O. Box 70 www.staalkat.com - [email protected] AB Aalten · Holland Banker: ABN AMRO · nr. 52.69.70.790Trade register Arnhem, No. 09102326 BTW/VAT nr. NL807264714B01

The Global Supplier forEgg Handling and Processing

*TD0108203010*

StaalkatFarmpacker 40

FP102TB001

http://www.staalkat.com

http://www.staalkat.com

mailto:[email protected]

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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61.1 Using this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Other documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2.1 Tray stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2.2 Parts catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1.2 Presence of children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1.3 Before starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1.4 Cleaning, inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . 82.1.5 Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1.6 Working on the electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . 82.1.7 Adjustments and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.1.8 Dismantling, moving and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1.9 Decommissioning and the environment . . . . . . . . . . . . . . . . . . . . . . 92.2 Guards and warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.1 Names of major parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2.1 Denester (1 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2.2 Carton transport lane (6 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . 143.2.3 Peak absorber (2 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2.4 Packer (5 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2.5 Incline conveyor (7 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2.6 Control box (4 in diag. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2.7 Identification plate/CE-marking (3 in diag. 8) . . . . . . . . . . . . . . . . . . 153.3 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.4 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.6 Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.6.1 Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.7 Sound level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.8 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184.1 Work positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.3 Warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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User’s Manual Staalkat Farmpacker 40

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4.4.1 Normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.4.2 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.5 Setting for type of cartons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.5.1 Denester, changing accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.5.2 Carton transport lane, changing steps cam . . . . . . . . . . . . . . . . . . . 244.5.3 Carton transport lane, setting side guides . . . . . . . . . . . . . . . . . . . . 254.5.4 Packer, insert pitch adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264.6 Very small or very large eggs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274.6.1 Leaf springs in gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274.6.2 Clip-on gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285.1 Maintenance routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.2 Safety during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.2.1 Before starting maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . 285.2.2 At the end of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.1 Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.2 Bearings with grease nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.3 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.4 Guides in denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.5 Egg holder shafts in packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.4.6 Memory pins of packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5.1 Cleaning in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5.2 Removing drip trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5.3 Tipping the packer gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.5.4 Removing the spin roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.6 Greasing of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.6.1 Flange bearings with grease nipple . . . . . . . . . . . . . . . . . . . . . . . . . 335.7 Lubrication and tensioning of chains . . . . . . . . . . . . . . . . . . . . . . . . . . 345.7.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.7.2 Tensioning in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.8 Motor and reduction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.8.1 Checking reduction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.9 Denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.9.1 Tensioning belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.9.2 Greasing the gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.10 Peak absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.10.1 Tensioning of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.10.2 Tensioning of extended belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.11 Packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.11.1 Lubrication of egg holder shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.11.2 Greasing the memory pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.12 Incline conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.12.1 Tensioning the conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426.1 Peak absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.1.1 Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.2 Denester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.2.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.2.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446.2.3 Drive clutch release pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456.2.4 Start moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466.2.5 Drive Staalkat Farmpacker 40 right hand model . . . . . . . . . . . . . . . 486.2.6 Drive Staalkat Farmpacker 40 left hand model . . . . . . . . . . . . . . . . 496.2.7 Wedge holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506.2.8 Gripper cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516.2.9 Gripper levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526.2.10 Grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536.2.11 Hinge pins for auxiliary grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.2.12 Auxiliary gripper rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.2.13 Auxiliary grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.3 Carton transport lane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556.3.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556.3.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556.3.3 Drive clutch release pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566.3.4 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576.4 Packer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.4.1 Mechanical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.4.2 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596.4.3 Clearance of fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606.4.4 Locking star in locked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616.4.5 Lock pawl play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626.4.6 Using gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.4.7 Transfer strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646.4.8 Starwheels in locked position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656.4.9 Position of fingers between starwheels . . . . . . . . . . . . . . . . . . . . . . 666.4.10 Start starwheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676.4.11 Friction clutch starwheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.4.12 Ejector height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.4.13 Tipping plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706.4.14 Distance between egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.4.15 Pitch of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726.4.16 Height of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736.4.17 Opening of egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.4.18 Catch flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756.4.19 Start moment of carton transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 766.4.20 Cam for egg holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.4.21 Cams for ejectors, tipping plates and gate movement . . . . . . . . . . 786.4.22 Cam for insert mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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7 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .807.1 Error messages general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807.2 Fuses and thermal relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .818.1 Using the Parts Catalogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818.1.1 Order form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818.1.2 Finding the right page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818.1.3 Type of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818.1.4 Right hand and left hand machines . . . . . . . . . . . . . . . . . . . . . . . . . 828.1.5 Before/after a certain date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 838.1.6 Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848.1.7 Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848.1.8 Assembled units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.1.9 Non-standard parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.1.10 Machine-order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.2 Other documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.2.1 Other equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.2.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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1 Introduction

1.1 Using this manual

This manual provides a guideline for the safe and effective operation and maintenance of the Staalkat Farmpacker 40. We recommend that you read this manual carefully before operating the machine, and also before carrying out any maintenance works in a later stage. This will ensure that the Farmpacker is used optimally and above all safely.

Warning:It is important that everyone working on the machine is thoroughly acquainted with the contents of this manual, and particularly with the safety regulations in the next chapter.

1.2 Other documentation

1.2.1 Tray stackerA tray stacker is available as an option. When installed the User's Manual for it can be found behind its own divider in this book.

1.2.2 Parts catalogueThe Parts Catalogue can be found behind its own divider in this book.

Note:n Take notice of the chapter ‘Ordering spare parts’ on page 81 before using the

Parts Catalogue and ordering spare parts.

1.2.3 Electrical installationA set of diagrams is included in a separate file.

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2 Safety

2.1 Safety regulations

2.1.1 Warnings

The machine has rotating parts that can be dangerous if maintenance and/or inspection work is carried out during operations.

Always follow the safety instructions in the User’s Manual and on the machine, and take heed of the following warnings:

The machine must always be switched off before any work is carried out on it!

Switch off the power supply before carrying out work on the machine, and make sure that nobody can switch it on again!

Never allow children near the machine, even when it is switched off!

Beware of the risk of electric shock when opening the cabinet!

Safety


Safety regulations

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2.1.2 Presence of childrenMoving parts have been covered to protect persons 14 years and older. However, there are also moving parts in areas that must remain accessible while the machine is in operation. Children must therefore never be allowed to come near the machine.

Large warning stickers, which have been supplied with the machine, must be attached to the access door. Additional stickers can be supplied on request.

2.1.3 Before starting the machineCheck that all protective screens, covers and drip trays are in place, before starting the machine, especially after carrying out maintenance or repair work.

Wherever possible, warning stickers have been attached on or near safety screens, covers, drip trays, or parts that are under dangerous voltage, the removal or opening of which may give access to components that can cause injury. Please check that all the relevant stickers are in place.

2.1.4 Cleaning, inspection and maintenanceAlways switch off the machine for cleaning, inspections or maintenance work. This applies in particular, if covers or safety screens have to be opened or removed, and when drip trays are removed. After switching off the machine, disconnect the power supply. To do this, use the main switch and secure it with the padlock that is provided, to prevent someone inadvertently switching the machine on again.

2.1.5 Periodic inspectionsIt is not necessary to carry out periodic inspections or to replace parts for safety reasons. However, regular maintenance in accordance with the Maintenance Schedule is required to keep the machine in good working order.

2.1.6 Working on the electrical installationWork on the electrical installation must only be carried out by authorised personnel. Alterations or additions may only be carried out by the manufacturer.

2.1.7 Adjustments and repairsAdjustments and repairs, as far as not described in this User’s Manual, must be carried out by Staalkat service engineers, so as to prevent damage to the machine or injury to persons. Our service technicians dispose over the necessary expertise and equipment.

Safety


Safety regulations

9

2.1.8 Dismantling, moving and installingThe machine should only be moved by Staalkat service engineers, to prevent any damage occurring to the machine while it is moved, and to ensure that it is safe for subsequent operation.

2.1.9 Decommissioning and the environmentThe machine can be dismantled, after the power supply has been disconnected by an authorized person. See the chapter ‘Technology’ for the utilised materials, and the chapter ‘Maintenance’ for the utilised lubricants. These must be discarded in accordance with local regulations.

Safety


Guards and warning stickers

10

2.2 Guards and warning stickers

Warning stickers have been applied, wherever possible, at or near the safety screens, covers and drip trays, which, when removed or opened, give access to moving parts that can be dangerous or to parts under dangerous voltage.

See the diagrams below for the location of the various safety screens and warning stickers..

Fig. 1 Guards and warning stickers on Staalkat Farmpacker 40 right hand

Fig. 2 Guards and warning stickers on Staalkat Farmpacker 40 right hand

STAALKAT170132

FP102VS001

STAALKAT170132

FP102VS002

Safety


Guards and warning stickers

11

Fig. 3 Guards and warning stickers on Staalkat Farmpacker 40 left hand

Fig. 4 Guards and warning stickers on Staalkat Farmpacker 40 left hand

STAALKAT170132

FP102VS003

STAALKAT170132

FP102VS004

Safety


Main switch

12

2.3 Main switch

Fig. 5 Guards and warning stickers on egg stamping unit (optional)

FP102VS005

Fig. 6 Position of main switch

FP102HS001

Safety


Emergency stop

13

2.4 Emergency stop

In emergencies the machine can be stopped immediately by pressing the button once. This emergency stop button is located in top of the Farmpacker frame. The button is red with a yellow background.

Danger:Check why the emergency stop has been used. The machine may only be started once it is certain that everything has been made safe.

Fig. 7 Position of emergency stop button

FP102NS001

14

3 Technology

3.1 Names of major parts

3.2 Description

3.2.1 Denester (1 in diag. 8)The Staalkat denester denests fully automatically stacks of egg trays. The denester has a set of accessories for 17 lbs trays fitted as standard. Sets for different trays are available on request.

3.2.2 Carton transport lane (6 in diag. 8)The carton transport lane is fitted with bars that move the cartons step by step underneath the packer. The lane is driven through a clutch with a cam that determines the size of the steps. The lane has a steps cam for 17 lbs trays fitted as standard. Steps cams for different trays can be fitted on request.

Fig. 8 Major parts

1 Denester2 Peak absorber3 Identification plate/CE-marking4 Control box5 Packer6 Carton transport lane7 Incline conveyor

FP102OZ009

1 2 3 4 5 6 7

Technology


Description

15

3.2.3 Peak absorber (2 in diag. 8)The peak absorber divides the stream of supplied eggs to the packer. Moving gates take care that the packer will receive six eggs at once each time.

With the standard, short model peak absorber egg supply is possible from the end. With the extended peak absorber (optional) supply is also possible from both sides. The Staalkat Farmpacker 40 can be used with supply belts of a height between 900 and 1000 mm.

The control box contains a relay to which the supply belts can be connected. When used the belts will stop when the Staalkat Farmpacker 40 stops. A pressure control, fitted on the peak absorber, will stop the supply belts temporarily when too many eggs are supplied.

3.2.4 Packer (5 in diag. 8)The Staalkat packer inserts the eggs accurately, points down, in the tray. The pitch of the insert mechanism can be easily adjusted to the pitch of the tray.

3.2.5 Incline conveyor (7 in diag. 8)The incline conveyor brings the trays on the correct height for taking them away. A take away table is fitted to the end of the conveyor. The conveyor has sufficient accumulation length for 5 filled trays. A jam indicator stops the Farmpacker automatically when the incline conveyor is getting filled up.

3.2.6 Control box (4 in diag. 8)The control box of the Staalkat Farmpacker 40 is built in at the left hand side of the peak absorber. The box contains the power supply and the Farmpacker control.

The relay for switching off the egg supply belt(s) is also found in this control box.

3.2.7 Identification plate/CE-marking (3 in diag. 8)The identification plate shows the type of machine and the machine/order number. The CE-marking is also found on this plate. The EC Declaration of Conformity is included in this manual.

Technology


Use

16

3.3 Use

The Staalkat Staalkat Farmpacker 40 is intended for the packing of eggs on egg trays.

3.4 Ambient conditions

The machine is suitable for use in ambient temperatures of between 0º and +35ºC and a relative humidity of between 40% and 85%. Sharp fluctuations in temperature and the accumulation of condensation must be avoided.

3.5 Capacity

The gross capacity of the Staalkat Farmpacker 40 is 40 cases (14.400 eggs) per hour.

3.6 Energy

3.6.1 ElectricityThe needed mains supply is 230 V (± 10%), 1 phase, 50 Hz.

On request the Staalkat Farmpacker 40 can be supplied for 230 V, 1 phase, 60 Hz.

The connection rating is 0,3 kVA.

3.7 Sound level

The sound level of a Staalkat Farmpacker 40 is 70 dB(A), measured on the work positions at the denester, the take away table and the peak absorber. Measurements are conform EN-ISO 11201.

Technology


Materials

17

3.8 Materials

The frame sheet metal of the denester, the carton transport lane and the incline conveyor is made of stainless steel.

The frame of the packer is of cast aluminium.

The guards are made of stainless steel sheet metal.

The perforated steel guard is powder-coated.

Stainless steel has been used for the deck plate of the carton transport lane and the take away table.

The shafts are made of stainless steel.

The conveyor belts of the peak absorber and incline conveyor are made of nylon material.

The incline conveyor rollers are of aluminium.

The various mechanical parts, when not made of stainless steel, aluminium or plastic, are zinc plated.

18

4 Operation

4.1 Work positions

The following work positions may be used by the staff:

1 at the denester for filling stacks of trays2 at the take away table for removing the filled trays3 at the peak absorber for inspection of the arriving eggs

Fig. 9 Work positions Staalkat Farmpacker 40 right hand model

Fig. 10 Work positions Staalkat Farmpacker 40 right hand model

1

2

3FP102OZ002

1

2

3FP102OZ003

Operation


Starting

19

4.2 Starting

Danger:Check before starting the Farmpacker if all guards, covers, drip trays and warning stickers are (back) in place.

When trays are present in the denester and on the carton transport lane till underneath the packer the Staalkat Farmpacker 40 can be started as follows:

1 Plug in the mains lead.2 Turn the main switch (4) to on (I).3 Turn the on/off switch (2) to on.4 Press the reset button (3). The warning light in the button will come on and

the Farmpacker starts running.

The machine will not start when:

• the guard with safety switch (6) is not (entirely) closed• the emergency stop button (1) has been pressed• the jam indicator (5) signals a filled up incline conveyor

In these situations the warning light in the reset button (3) will flash. See ‘Warning light’ on page 20 for an explanation of the warning light functions and how to act.

Fig. 11 Controls

1 Emergency stop button2 On/off switch3 Reset button with warning light4 Main switch5 Jam indicator6 Guard with safety switch

Staalkat

OFF ON

1 2 3 4

65

FP102BP001

Operation


Warning light

20

4.3 Warning light

When the Staalkat Farmpacker 40 does not start or has stopped automatically the cause is indicated by the warning light in the reset button.

Light Situation Cause How to start (again)

Off Farmpacker is not running

On/off switch is off Turn switch to on and press reset button

Lead not plugged in Plug in mains lead and press reset button

On Farmpacker is running

Flashing slowly

Farmpacker has stopped Guard with safety switch not (entirely) closed

Close the guard and press reset button

Emergency stop button has been used

Check why the emergency stop has been used. The machine may only be started once it is certain that everything has been made safe.

Release the emergency stop button by turning it, then press the reset button

The main supply has been interrupted

Press the reset button

No trays in denester Fill denester, put a tray in front of photocell and press reset button

Trays jammed in denester

Separate trays, put a tray in front of photocell and press reset button

Flashing rapidly

Farmpacker is running Pressure control activated, too many eggs supplied

Egg supply starts automatically when surplus on peak absorber is away

Farmpacker has stopped Jam indicator signals filled up incline conveyor

Farmpacker starts automatically after taking away trays from incline conveyor

Flashing very rapidly

Farmpacker is in service-mode

On/off switch has been turned to on while reset button was pressed

Press reset button to move Farmpacker in small steps (“inching”)Turn the switch to off and start again for normal use

Operation


Stopping

21

4.4 Stopping

Depending on the situation, the Staalkat Farmpacker 40 can be stopped as follows:

4.4.1 Normal stop1 Turn the on/off switch (2) to off.2 Wait until the packer has stopped in its stop-position and turn the main

switch (4) to off (O).

4.4.2 Emergency stopPress the emergency stop button (1) or turn the main switch (4) to off (O).

The Farmpacker will stop immediately, with no regard to its position.

Warning:The emergency stop must only be used in an emergency. After restarting there is a risk of cracking of eggs.

Danger:Check why the emergency stop has been used. The machine may only be started once it is certain that everything has been made safe.

Fig. 12 Controls

Staalkat

OFF ON

1 2 3 4

65

FP102BP001

!

Operation


Setting for type of cartons

22

4.5 Setting for type of cartons

As standard the Staalkat Farmpacker 40 is supplied for use with 17 lbs trays.

When you want to use a new type of carton please contact Staalkat for information about its suitability for automatic handling. Order, when necessary, the right set of accessories.

The settings for the use of different trays are described in the following chapters.

Operation



23

4.5.1 Denester, changing accessories

1 Start the Farmpacker in the service-mode by turning the on/off switch to on while the reset button is kept pressed. When in the service-mode it is possible to move the Farmpacker, including the denester, in small steps ("inching").

2 Press the reset button until the lift table with the centring sections (5) is in its top position.

3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Remove the cartons from the carton holder.6 Undo the fixing bolts and move the adjustable strip (1) forward and the

carton holder guides (2) apart.7 Change the accessories. Usually these are:

• two grippers (6)• two wedges (4)• two centring sections (5)

The wedges can be taken out after pressing the locking button (3). Be sure that the wedges are locked again after changing them.

8 Place a stack of new cartons in the denester. Put the stack tight against the strip with fixed guides (7). Adjust the centring sections (5) when needed to make sure that the stack is exactly central in the denester and cannot move sideways.

9 Move the strip (1) and the carton holder guides (2) towards the stack and tighten their fixing bolts.

When the denester does not lay certain cartons correctly between the transport bars of the carton transport lane it is possible to adjust the start moment. See ‘Start moment’ on page 46. Release the emergency stop button by turning it, then press the reset button.

1 Adjustable strip2 Carton holder guide3 Locking button4 Wedge5 Centring section6 Gripper7 Strip with fixed guides

Fig. 13 Changing denester accessories

12

34567

FP102DN001

Operation



24

4.5.2 Carton transport lane, changing steps cam

1 Switch off the power supply and ensure that nobody can switch it on again.

2 Remove the guard (1).3 Remove the locking bolt (2).4 Press the release pawl (4) and pull the hub disc with steps cam (3) from the

clutch.5 Remove the three fixing bolts (5) and take the steps cam (6) from the hub

disc.6 Fit the new steps cam and fix it. Do not forget the spacers (7).7 Press the release pawl (4) and slide the hub disc with steps cam back onto

the clutch.8 Fit the locking bolt (2) back in the clutch.9 Fit the guard (1).

1 Guard2 Locking bolt3 Hub disc with steps

cam4 Release pawl5 Fixing bolt6 Steps cam7 Spacer

Fig. 14 Steps cam guard

Fig. 15 Changing steps cam

1FP102SK004

FP102KO005

Operation



25

4.5.3 Carton transport lane, setting side guides


2 Lay trays of the desired type on the carton transport lane.3 Undo the fixing bolts (2) slightly.4 Adjust both side guides (3) close to the carton. Keep a gap, just wide

enough to prevent the trays jamming. Be sure that the trays will arrive exactly midway underneath the packer.

5 Tighten the fixing bolts.

Note:n It is possible to adjust the height of the guides by moving the supports (1). This

should be done only when the tray side tends to stick underneath the guides. Be sure there is still room between the side guides (3) and the transport bars (4).

1 Support2 Fixing bolt3 Side guide4 Transport bar

Fig. 16 Setting side guides

1 2 3 4

FP102DT001

Operation



26

4.5.4 Packer, insert pitch adjustment

1 Start the Farmpacker in the service-mode by turning the on/off switch to on while the reset button is kept pressed. When in the service-mode it is possible to move the Farmpacker in small steps ("inching").

2 Put a tray on the carton transport lane underneath the packer and check if it is exactly midway. Adjust the side guides (3) when needed.

3 Press the button until the egg holders (2) are in their lowest position.4 Check if the egg holders are in the right position above the tray. The insert

pitch van be adjusted by pulling the knobs (1) a little and then move them sideways. Adjust as much on the left as on the right. There are four different positions to use.The recommended insert pitch for 17 lbs trays is the second smallest.

5 Turn the on/off switch to off. The Farmpacker may now be started for normal use again.

1 Knob2 Egg holder3 Side guide

Fig. 17 Insert pitch adjustment

123

FP102PK001

Operation


Very small or very large eggs

27

4.6 Very small or very large eggs

4.6.1 Leaf springs in gates

The leaf springs in the gates are adjusted to a height of 66 mm, measured between the transverse section (2) and the peak absorber (1).

• When very small eggs are being packed it may be necessary to set the leaf springs a little lower to prevent double eggs in the packer rollers.Use the supplied clip on gates as well when packing very small eggs.

• When very large eggs are being packed it may be necessary to set the leaf springs a little higher to prevent jamming.

Adjustment is possible by using the wing nuts (4) and the knurled knobs (3). Adjust as much on the left as on the right.

4.6.2 Clip-on gates

A set of clip-on gates has been supplied to reduce the width between the gates when very small eggs are being packed.

1 Peak absorber2 Transverse section3 Knurled knob4 Wing nut

Fig. 18 Adjustment of leaf springs

66 mm

1 2 3 4

VerplijnPK003

Fig. 19 Clip-on gates

VerrplijnPK053

28

5 Maintenance

5.1 Maintenance routine

In order to keep the Farmpacker in optimum condition and to ensure correct operation, various checks and maintenance activities should be implemented on a regular basis.

For this purpose, establish a daily, weekly, monthly and annual routine, in accordance with the enclosed schedule.

5.2 Safety during maintenance

5.2.1 Before starting maintenance work Always switch off the machine during cleaning inspection or maintenance. This applies in particular if guards or covers are opened or removed and if drip trays are taken out.

After stopping the machine, disconnect the power supply. To do this, use the main switch and secure it by using the provided padlock to prevent anybody reconnecting the power.

5.2.2 At the end of maintenance workCheck that all guards, covers, drip trays and warning stickers are (back) in place.

29

Staalkat Farmpacker 40

Before starting maintenance: Switch off the power supply and ensure that nobody can switch it on againAfter ending maintenance: Check if all guards, covers, drip trays and warning stickers are (back) in place

FP102OZ005

5.3 Maintenance schedule

Denester Peak absorber Carton transport lane Packer Incline conveyor

Daily • Blow dust away• Clean photocell

• Clean drip tray• Clean belt

• Clean drip trays• Clean deck plates

• Clean drip trays• Clean starwheel shaft• Clean rollers• Clean tipping plates• Clean egg holders• Clean gates

• Clean belt• Clean photocell jam

indicator

Weekly • Lubricate egg holder shafts

Monthly • Tension belts when needed• Lubricate chain and

tension when needed• Grease gear wheels• Grease guides

• Grease bearings• Lubricate chains and

tension when needed• Check belt and tension

when needed

• Grease bearings• Lubricate chains and

tension when needed

• Lubricate chains and tension when needed

• Grease memory pins

• Grease bearings• Check belt and tension

when needed

Yearly • Check motor


Lubricants

30

5.4 Lubricants

We advise to use the lubricants mentioned below or to use equivalent products.

5.4.1 ChainsUse KLÜBEROIL 4 UH1 460 N, Staalkat order no. 24.150004, to lubricate both the drive chains and the carrier chains.

5.4.2 Bearings with grease nippleUse MULTIPURPOSE GREASE 2 (Staalkat order no. 51.30027) in the grease gun.

5.4.3 Gear wheelsUse MULTIPURPOSE GREASE 2 (Staalkat order no. 51.30027) on open gear wheels.

5.4.4 Guides in denesterUse KLÜBEROIL 4 UH1 460 N (Staalkat order no. 24.150004) for the guides.

5.4.5 Egg holder shafts in packerUse MOLYKOTE BR 2 PLUS (Staalkat order no. 24.220039) for the shafts.

5.4.6 Memory pins of packerUse MULTIPURPOSE GREASE 2 (Staalkat order no. 51.30027) for the memory pins.


Cleaning

31

5.5 Cleaning

5.5.1 Cleaning in general1 Switch off the power supply and ensure that nobody can switch it on

again.2 Blow the dust from places which are difficult to reach, using an air pistol.3 Wipe sheet metal, the frame, rubber and plastic parts with a damp cloth and

possibly a non-aggressive detergent.4 Take care to keep the peak absorber belt smooth.

Warning:Do not use a detergent or soap for cleaning a transport belt. Use clean water only. Rub it dry immediately after cleaning it.

Warning:Never hose down the machine with water!

5.5.2 Removing drip trays

The Staalkat Farmpacker 40 has easy removable drip trays in the following three locations:

• underneath the peak absorber belt• underneath the packer• underneath the carton transport lane

Danger:Switch off the power supply and ensure that nobody can switch it on again. Relocate the drip trays before starting the machine again.

!

!

Fig. 20 Drip trays

FP102OZ008


Cleaning

32

5.5.3 Tipping the packer gates

For easier cleaning the packer gates (2) can be tipped after pulling out the securing knob (1) in the packer just below the guard.

Take care that the securing knob is completely back into its position after tipping back the gates. It may be needed to move the gates a little forward or backward. The gates have recesses for the pins that move the gates.

5.5.4 Removing the spin roller

For cleaning the spin roller can be removed. Proceed as follows:


2 Remove the guards at both sides of the packer and open the guard on top.3 Unscrew the shaft ends with the knurled knob (1 and 3) from the spin

roller (2).4 Remove the spin roller (2).5 Relocate the spin roller after cleaning by screwing in both shaft ends with

knurled knob (1 and 3).6 Fit the guards again.

1 Securing knob2 Gates

Fig. 21 Tipping the packer gates

1

2

1 Shaft end with knurled knob

2 Spin roller3 Shaft end with

knurled knob

Fig. 22 Removing the spin roller

1 2 3


Greasing of bearings

33

5.6 Greasing of bearings

5.6.1 Flange bearings with grease nipple

Grease the flange bearings with grease nipple every month. Proceed as follows:


2 Remove the guards at both sides of the Farmpacker.3 Use the grease gun to grease all 18 bearings. The flange bearings near the

take away table are accessible from underneath.4 Fit the guards.

Fig. 23 Flange bearings with grease nipple

Fig. 24 Flange bearings with grease nipple

FP102SN001

FP102SN002


Lubrication and tensioning of chains

34

5.7 Lubrication and tensioning of chains

5.7.1 Lubrication

Regular lubrication of the drive chains and the carrier chains is very important. Neglected chains will wear out more quickly, requiring more frequent tensioning, and they will not function as smoothly, thereby affecting a good operation of the machine.

Preferably use of KLÜBEROIL 4 UH1 460 N (Staalkat order no. 24.150004). Proceed as follows:

1 Switch off the power supply and make sure that no-one can switch it on again.

2 Apply KLÜBEROIL using an oil can or a brush.3 Wipe away any surplus oil, after the oil has penetrated the chain.

Note:n Make sure to observe the maintenance schedule.

5.7.2 Tensioning in generalChains that do not have a spring-loaded chain tensioner can generally be tightened with a tensioning wheel or shaft.

Do not tighten chains excessively.

Danger:Switch off the power supply and make sure that no-one can switch it on again.


Motor and reduction box

35

5.8 Motor and reduction box

5.8.1 Checking reduction boxThe denester, peak absorber, packer, carton transport lane and incline conveyor are all driven by a central motor with incorporated reduction box.

These motor is lubricated "for life". Check regularly for leaks and replace or repair the drive in the event of oil loss.

5.9 Denester

5.9.1 Tensioning belts

When the denester belts (3) are stretched they can slip. Tension them as follows:


2 Untighten both bolts (4) of the tensioner shaft (2) a little.3 Pull the tensioner shaft forward.4 Tighten both bolts (4) again. Take care that the shaft remains at a right

angle in the denester.

Check if the belts keep running on the middle of the rollers (1). If a belt tends to run off the roller the cause could be that the belt is tensioned too tightly or that the tensioner shaft (2) is not at a right angle in the denester.

1 Roller2 Tensioning shaft3 Belt4 Bolt

Fig. 25 Tensioning of denester belts

1

2

3

4

VerplijnDN001


Denester

36

5.9.2 Greasing the gear wheels

Grease the bevel gear wheels in the denester monthly as follows:


2 Remove the guard at the end of the denester.3 Clean both gear wheels.4 See ‘Lubricants’ on page 30 for which grease to use.5 Fit the guard.

Fig. 26 Gear wheels in denester

FP102DN002


Peak absorber

37

5.10 Peak absorber

5.10.1 Tensioning of belt

The peak absorber belt is chain driven by the packer. Tensioning is needed when the drive roller starts to slip inside the belt. The bearings of the return roller have tensioners fitted for this purpose. Proceed as follows:


2 Remove the guards at both sides of the peak absorber.3 Undo the bolts (2) of the rake (1) a little, move the rake up and tighten the

bolts temporarily.4 Undo the flange bearing bolts (3), two at each side, a little.5 Turn back both counter nuts (5).6 Tension the belt by turning both tensioner nuts (4). Take care to turn the

tensioner nuts as much at both sides.7 Tighten both counter nuts (5).8 Tighten the four bolts of the flange bearings (3).9 Move the rake (1) down until close to the belt and tighten the two bolts (2).10 Fit the guards back to the peak absorber.11 Check the tracking of the belt. When the belt tends to run sideways off the

rollers it must be checked if the tensioner roller is at a right angle in the frame. Adjust one side a little when needed.

12 Check the tracking again after the belt has been running a short time.

Caution:c Do not tension the belt too tightly. If the belt is again carried by the drive roller,

this is sufficient.

1 Rake2 Bolt of rake3 Flange bearing bolt4 Tensioner nut5 Counter nut

Fig. 27 Tensioning of peak absorber belt

1 21 2 3 43 4 5

FP102DB001FP102DB001


Peak absorber

38

5.10.2 Tensioning of extended belt

The peak absorber belt is chain driven by the packer. Tensioning is needed when the drive roller starts to slip inside the belt. The frame with the return roller has tensioners fitted for this purpose. Proceed as follows:


2 Remove the guards at both sides of the peak absorber.3 Undo the bolts of the frame extension (2), two at both sides, a little.4 Undo the bolts of both support strips (1) a little.5 Turn back both counter nuts (4).6 Tension the belt by turning both tensioner nuts (3). Take care to turn the

tensioner nuts as much at both sides.7 Tighten both counter nuts (4).8 Tighten the four bolts of the frame extension (2).9 Tighten the bolts of both support strips (1).10 Fit the guards back to the peak absorber.11 Check the tracking of the belt. When the belt tends to run sideways off the

rollers it must be checked if the frame extension is at a right angle in the frame. Adjust one side a little when needed.



this is sufficient.

1 Bolt of support strip2 Bolt of frame

extension3 Tensioner nut4 Counter nut

Fig. 28 Tensioning of extended peak absorber belt

1 2 3 4

FP102DB002


Packer

39

5.11 Packer

5.11.1 Lubrication of egg holder shafts

Lubricate the egg holder shafts weekly as follows:


2 Press the button until the egg insert mechanism is nearly in its lowest position.


again.5 Remove the cap nut of the front packer guard and remove the guard.6 Lubricate the four shafts at several places using thin oil, see

‘Lubricants’ on page 30.7 Fit the front packer guard and secure it by the cap nut.

Fig. 29 Lubrication of egg holder shafts

VerplijnPK002


Packer

40

5.11.2 Greasing the memory pins

Grease the memory pins monthly as follows:


2 Remove the guard at the right hand side of the packer.3 Grease the four memory pins using grease see ‘Lubricants’ on page 30..4 Fit the guard.

Fig. 30 Greasing the memory pins

FP102PK003


Incline conveyor

41

5.12 Incline conveyor

5.12.1 Tensioning the conveyor belt

The incline conveyor belt is chain driven by the carton transport lane. Tensioning is needed when the drive roller starts to slip inside the belt. The take away table which holds the return roller has tensioners fitted for this purpose. Proceed as follows:


2 Undo the bolts (1), three at each side, a little.3 Turn back both counter nuts (3).4 Tension the belt by turning both tensioner nuts (2). Take care to turn the

tensioner nuts as much at both sides.5 Tighten both counter nuts (3).6 Tighten the six bolts (1).7 Check the tracking of the belt. When the belt tends to run sideways off the

rollers it must be checked if the take away table is at a right angle in the frame. Adjust one side a little when needed.



this is sufficient.

1 Bolts2 Tensioner nut3 Counter nut

Fig. 31 Tensioning conveyor belt

1

2 3

VerplijnOB001

42

6 Adjustments

Danger:To prevent damage to the machine or injury to persons adjustments and repairs, as far as not described in this user's manual, have to be done by Staalkat service technicians only. They posses the needed skills and have the right tools at disposal.

6.1 Peak absorber

6.1.1 Pressure control

The pressure control on the peak absorber stops the supply belts temporarily when too many eggs are supplied. As a standard period the time has been set to 2 seconds. This means that if the photocell sees eggs during 2 seconds the peak absorber will stop. When the photocell is clear (doesn't see eggs anymore) the peak absorber will automatically start again. When desired this period can be changed to a maximum of 6 seconds. Proceed as follows:


2 Remove the guard (1).3 Turn the potmeter (2) on the PCB (1) clockwise to extend the stop period.4 Fit the guard.

Fig. 32 Control box guard Fig. 33 Adjustment of pressure control

1 Guard2 Potmeter3 PCB

1FP102SK003

2

3

FP102BK001

Adjustments


Denester

43

6.2 Denester

6.2.1 Mechanical operation

The Staalkat Farmpacker 40 uses a side denester. It throws the trays from the side on the carton transport lane.

The mechanism of the denester is driven by the motor through a drive clutch. A system of moving grippers (4) and wedges (2) separates the bottom one of a stack of trays that has been inserted in the carton holder (1) by hand. The separated carton is dropped on the lift table (5). The lift table lowers the carton on the transport belts (6). These two belts will throw the carton on the carton transport lane.

To make the denester suitable for different types of carton, the carton holder is adjustable and the grippers and wedges are exchangeable. For cartons that are difficult to separate it is possible to fit a set of auxiliary grippers (3).

1 Carton holder2 Wedge3 Auxiliary gripper4 Gripper5 Lift table6 Transport belt

Fig. 34 Denester, mechanical operation

456

1

23

DenesterAF012

Adjustments


Denester

44

6.2.2 Electrical operation

The denester is electronically controlled by the microprocessor in the lane control box. This control will see to the following functions:

• The denester starts, when the Farmpacker switch is on, after receiving the start signal. This signal comes once each time the carton transport lane moves a full pitch of the bars. The start moment is given by the proximity switch on the steps cam shaft. This proximity switch gives a signal to the microprocessor which commands the electromagnet for releasing the locking disc of the clutch. The denester will make a cycle, during which the moving grippers and wedges separate the bottom one of a stack of trays and puts it under the photocell. At the same time the tray, laying under the photocell, will be moved to the carton transport lane.

• The denester stops when after several efforts no carton has been separated. Resetting is done by pressing the reset button.

• The Farmpacker stops when there are no more trays in the denester, or when there is no tray under the photocell. Resetting is done by pressing the reset button.

Fig. 35 Photocel in the denester

FP102DN008

Adjustments


Denester

45

6.2.3 Drive clutch release pawl


2 Press the reset button until the lift table is in its top position.3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Remove the guard (1) with a right hand Farmpacker, remove the deck plate

(2) in the denester with a left hand Farmpacker.6 Use the adjusting nut (5) to set the release pawl (3) in such a way that it will

be against the stop of the locking disc (4) at a distance of 5 mm.7 Fit the guard (1) or deck plate (2).

Fig. 36 Denester drive clutch guard Fig. 37 Deck plate denester

1 Guard2 Deck plate3 Release pawl4 Locking disc5 Adjusting nut

Fig. 38 Drive clutch release pawl

1

FP102SK001

2

FP102DN003

5 mm

3 4 5

FP102KO001

Adjustments


Denester

46

6.2.4 Start moment

Adjust the start moment of the denester only when the adjustment of the carton transport lane is right. Proceed as follows:


2 Pull out the securing knob of the gates (see Fig. 21 on page 32) turn the knob so it would stay in this position (this action is necessary to let the transport bars move during the inching).

3 Press the reset button until the transport bars (3) are in the position as in the diagram.


again.6 Remove the guards (1 and 2).

Fig. 39 Guards Fig. 40 Position of transport bars

Fig. 41 Position of steps disc Fig. 42 Position of switch cam

1 Guard2 Guard3 Transport bar4 Steps cam5 Fifth stop

6 Release pawl7 Proximity switch8 Switch cam9 Grub screw

1 2

FP102SK002

3

FP102DN004

4 65

FP102KO006

1 à 2 mm

7 8 9

FP102DN005

Adjustments


Denester

47

7 Check if the release pawl (6) is against the fifth stop (5) of the steps cam (4). When not, adjust the carton transport lane first (see ‘Carton transport lane’ on page 55).

8 Undo the grub screw (9) of the switch cam (8), turn the switch cam to the position as in the diagram and secure the grub screw.

9 Adjust the proximity switch (7) at 1 to 2 mm distance of the switch cam (8).10 Fit the guards (1 and 2).

Fig. 43 Guards Fig. 44 Position of transport bars

Fig. 45 Position of steps disc Fig. 46 Position of switch cam

1 Guard2 Guard3 Transport bar4 Steps cam5 Fifth stop

6 Release pawl7 Proximity switch8 Switch cam9 Grub screw

1 2

FP102SK002

3

FP102DN004

4 65

FP102KO006

1 à 2 mm

7 8 9

FP102DN005

Adjustments


Denester

48

6.2.5 Drive Staalkat Farmpacker 40 right hand model

Adjust the drive of the denester only when the adjustment of the carton transport lane is right. Proceed as follows:


2 Remove the guard (1).3 Remove the deck plate (2) in the denester.4 Take the double strand chain off when the denester sprocket (4) has already

been secured on its shaft.5 Turn the denester by hand until the lift cam (5) is in the position as in the

diagram. The rib (see arrow) must be horizontal.6 Turn the locking disc (6) of the drive clutch against the release pawl (7).7 Secure the sprocket (4) on the shaft or fit, when it was taken off, the chain

around the sprockets. It may be necessary to turn the denester a little by hand. *)

8 Fit the guard (1) and the deck plate (2) in the denester.

*) When a tray is not being laid down correctly it may be necessary to move the position of the denester sprocket one tooth with respect to the sprocket on the drive shaft.

Fig. 47 Deck plate denester Fig. 48 Position of lift cam 40right hand model

Fig. 49 Guard Fig. 50 Position of locking disc

1 Guard2 Deck plate3 Drive shaft with sprocket4 Denester sprocket

5 Lift cam6 Locking disc7 Release pawl

2

FP102DN003

34

5

1

FP102SK001

76

FP102KO003

Adjustments


Denester

49

6.2.6 Drive Staalkat Farmpacker 40 left hand model

Adjust the drive of the denester only when the adjustment of the carton transport lane is right. Proceed as follows:


2 Remove the deck plate (2) in the denester.3 Take the double strand chain off when the denester sprocket (4) has already

been secured on its shaft.4 Turn the denester by hand until the lift cam (5) is in the position as in the

diagram. The rib (see arrow) must be horizontal.5 Turn the locking disc (6) of the drive clutch against the release pawl (7).6 Secure the sprocket (4) on the shaft or fit, when it was taken off, the chain

around the sprockets. It may be necessary to turn the denester a little by hand. *)

7 Fit the deck plate (2) in the denester.

*) When a tray is not being laid down correctly it may be necessary to move the position of the denester sprocket one tooth with respect to the sprocket on the drive shaft.

Fig. 51 Deck plate denester Fig. 52 Position of lift cam 40left hand model

Fig. 53 102S left hand model Fig. 54 Position of locking disc

2 Deck plate3 Drive shaft with sprocket4 Denester sprocket

5 Lift cam6 Locking disc7 Release pawl

2

FP102DN003

34

5

FP102OZ006

76

FP102KO003

Adjustments


Denester

50

6.2.7 Wedge holders


2 Press the reset button until the wedge holders (2) are in their normal position (towards each other). Both arms (5) are resting with the roller on the low part of the wedge holder cam (6).


again.5 Untighten the bolts (4) in the arms (5).6 With gauge 800045 (1):

Put the gauge onto the wedge holders and over the centre block shaft (3). Take care that the gauge does not jam, it has to slide over the shaft easily.Without gauge:Move the wedge holders till their pitch is 353 mm. Take care that the distance A1 is the same as A2.

7 Retighten the bolts (4).8 Remove the gauge.

1 Gauge 8000452 Wedge holder3 Centre block shaft4 Bolt5 Arm6 Wedge holder cam

Fig. 55 Wedge holders

353 mmA1 = A2

1

23

4

5

6

VerplijnDN002

Adjustments


Denester

51

6.2.8 Gripper cam

Adjust the gripper cam to open up the grippers completely before the lift table starts going down. The grippers will then release the carton just before it is on the belts. Proceed as follows:


2 Push the reset button till the lift table (1) is in its top position and the adjustment hole (5) of the lift cam (4) is exactly central.

3 Untighten both grub screws that secure the gripper cam (3) on the shaft.4 Rotate the gripper cam clockwise on its shaft till the grippers have just

completely opened up (the gripper levers (2) as far apart as possible).5 Secure the gripper cam on the shaft by tightening the grub screws.

1 Lift table2 Gripper lever3 Gripper cam4 Lift cam5 Adjustment hole

Fig. 56 Gripper cam

12

3

45

DenesterAF008

Adjustments


Denester

52

6.2.9 Gripper levers


2 Press the reset button till the grippers have just completely opened up (the gripper levers (1) as far apart as possible).

3 Check if both gripper levers make an angle of 92° towards the frame, so a little further than vertical. When needed adjust as follows:

4 Untighten both bolts (3) that hold the flange (4) to the frame a little.5 Move the flange (4) of the command lever (2) at the lower end until the

gripper levers make the right angle. While doing this, keep the top end of the flange pressed against the bearing (6).

6 Tighten both bolts (3).

1 Gripper lever2 Command lever3 Bolt4 Flange5 Gripper cam6 Bearing

Fig. 57 Gripper levers

2

3

1

4 65

92° 92°

DenesterAF009

Adjustments


Denester

53

6.2.10 Grippers

Adjust the distance between the grippers as follows:


2 Press the reset button until the moment that the lift table starts going down again.

3 Untighten the bolts (4) that secure the gripper levers (2) on the gripper shafts (3).

4 Fit two gauges 800043 (1). Take care that the gauges are laying on the springs, and not between the turns.

5 Rotate the gripper shafts till the distance between the grippers is 50 mm. Take care that distance A1 is the same as A2.

6 Tighten the bolts (4).

1 Gauge 8000432 Gripper lever3 Gripper shaft4 Bolt

Fig. 58 Grippers

A1=A2

2

3

4

1

60 mm

DenesterAF010

Adjustments


Denester

54

6.2.11 Hinge pins for auxiliary grippers

1 Check the pitch of the hinge pins (1) for the auxiliary grippers. This distance must be 314 mm. Also take care that distance A1 is the same as A2.

2 Adjust the position of the hinge pins when needed after untightening the bolts that fit the hinge pin holder to the lift table (2).

6.2.12 Auxiliary gripper rods


2 Press the reset button until the grippers are in closed position with the gripper levers (4) vertical.

3 Loosen the counter nuts (2) of the ball joints.4 Turn the auxiliary gripper rods (3) until the distance between the rod ends

and the guide strips (1) is 124 mm.5 Tighten the counter nuts (2).

6.2.13 Auxiliary grippersThe height of the auxiliary grippers can be adjusted. Adjust the height by trial and error according to the carton.

1 Hinge pin2 Lift table

Fig. 59 Hinge pins for auxiliary grippers

314 mmA1 = A2

12

DenesterAF005

1 Guide strip2 Counter nut3 Auxiliary gripper rod4 Gripper lever

Fig. 60 Auxiliary gripper rods

124 mm 124 mm

123

4DenesterAF011

Adjustments


Carton transport lane

55

6.3 Carton transport lane

6.3.1 Mechanical operationThe carton transport lane is driven by the motor through a steps cam. Bars, fitted between two chains, move the cartons that has been thrown on the lane by the denester. The steps cam takes care of the right stopping positions of the bars underneath the packer. Hereafter the bars moved the filled cartons up to the incline conveyor.

6.3.2 Electrical operationThe carton transport lane is electronically controlled by the microprocessor in the lane control box. This control will see for the following functions:

• The carton transport lane starts making a step, when the on/off switch of the Farmpacker is set to on, and a signal (eggs present) is received from the memory disc of the packer. This signal sees to it that the electromagnet pulls the locking pawl, to release the steps cam, so it can rotate until the next stop.

• The carton transport lane does not start in an alarm situation (in which case the start signal from the packer is blocked).

• The carton transport lane stops, when it hits the next stop of the steps cam.

Adjustments



56

6.3.3 Drive clutch release pawl


2 Remove the guard (1).3 Use the adjusting nut (4) to set the release pawl (2) in such a way that it will

be against the entire stop of the steps cam (3). 4 Fit the guard (1).

Fig. 61 Carton transport lane drive clutch guard

1 Guard2 Release pawl3 Steps cam4 Adjusting nut

Fig. 62 Drive clutch release pawl

1FP102SK004

2 43

FP102KO004

Adjustments



57

6.3.4 Drive


2 Press the reset button until the egg holders of the packer are in their lowest position.


again.5 Remove the guards (1 and 2).6 Untighten the grub screws that secure the carton transport lane drive

sprocket (3) on the shaft.7 Turn the steps cam (4) until the third stop (5) is against the release pawl (6).8 Lay a tray underneath the packer and pull by hand the carton transport bars

until the third (centre) row of the tray is laying exactly below the egg holders.9 Check if the release pawl is still against the third stop of the steps cam.

When not, start again from point 7.10 Tighten the grub screws of the drive sprocket (3).11 Fit the guards.

Fig. 63 Guards Fig. 64 Carton transport lane drive sprocket

1 Guard2 Guard3 Drive sprocket4 Steps cam5 Third stop6 Release pawl

Fig. 65 Carton transport lane steps cam

1 2

FP102SK002

3

FP102DT002

4 65

FP102KO002

Adjustments


Packer

58

6.4 Packer

6.4.1 Mechanical operation

The packer mechanism is driven by a motor with reduction box (8) that is fitted underneath. Moving gates (1) split the supplied eggs up in six rows. The first egg of each row rolls into the starwheels (3). The packer checks the starwheels one time at each stroke by means of mechanically operated fingers (2).

When six eggs are present, the starwheel shaft is released, turns a quarter revolution and drops the eggs against the ejectors (4). This starwheel shaft is driven by means of a friction clutch. The ejectors go down and drop the eggs on the spin rollers (5). After being aligned by the spinning of the rollers, the eggs are moved into the tipping plates (6) by the ejectors (4).

The tipping plates are moving away from each other, which will let the eggs go down and at the same time will let them tip with their points down. Six egg holders (7), situated below the tipping plates, take over the eggs, bring them to the right pitch and place them gently into the cartons. To make it possible to use different sizes of packing material, the pitch of the egg holders is adjustable by means of knobs.

Instructions for adjustment of the packer are given in the following chapters.

Instructions for the correct fitting of various cams are given on page 77-79.

Fig. 66 Packer operation

1 Gates2 Fingers3 Starwheel4 Ejector

5 Spin roller6 Tipping plates7 Egg holders8 Motor

1 23456

7

8

VerplijnPK062

Adjustments


Packer

59

6.4.2 Electrical operationThe packer is electronically controlled by the microprocessor in the lane control box. This control will see for the following functions:

• The packer starts when the /off switch for the Farmpacker is on. • The packer stops in a position, fixed by the synchronous stop.• The packer stops immediately after opening the top guard or pressing an

emergency stop button. After closing the guard or releasing the button, the reset button has to be pressed for resetting.

• The packer will move in small steps when the Farmpacker is started in the service mode. By pushing the reset button the packer can inch (move in small steps).

• A proximity switch, fitted to the memory disc, controls the starting moment of the carton transport.

Adjustments


Packer

60

6.4.3 Clearance of fingers

The clearance between fingers and L-section should be between 0,5 and 1 mm. Proceed as follows for adjustment:


2 Remove the side guard from the packer.3 Move the packer until the roller at the bottom of the detection arm (6) rests

on the high part of the cam (7).4 Turn the on/off switch to off.5 Switch off the power supply and ensure that nobody can switch it on

again.6 Loosen the allen bolt (4).7 Move the arm (3) until the clearance between the fingers (1) and the L-

section bar (2) is 1 mm.8 Tighten the allen bolt (4).9 Check the adjusted clearance at both left hand and right hand side.10 Fit the side guard.

If the clearance is different at left and right, the two arms (3) must be set parallel on the shaft. Do this as follows:

1 Loosen the clamp bolt (5) of one of the arms.2 Move the arm until the clearance is the same at both sides.3 Tighten the clamp bolt (5).4 Check again the adjusted clearance, and correct it when needed.

1 Finger2 L-section bar3 Arm4 Allen bolt5 Clamp bolt6 Detection arm7 Cam

Fig. 67 Clearance of fingers

1 2 3 4 5

6

7

0,5 à1 mm

VerplijnPK026

Adjustments


Packer

61

6.4.4 Locking star in locked position

The roller of the detection arm (6) will not drop into the recess of the cam (7) at the moment of egg detection when not in all starwheels an egg is laying. The L-section bar (3) above the fingers (4) cannot come down more as the adjusted clearance allows. The locking star (5) will be kept locked. Check the locking as follows:


2 Remove the side guard from the packer.3 Move the packer until the roller at the bottom of the detection arm (6) is

facing the recess of the cam (7). Do this without eggs in the starwheels.4 Turn the on/off switch to off.5 Switch off the power supply and ensure that nobody can switch it on

again.6 Measure the distance of the tip of the locking star (1) that actually rests on

the lock pawl (2). This distance should be 3 to 3,5 mm.7 Correct this distance when needed by correcting the clearance of the fingers

(see page 60).8 Check the distance again when five out of six fingers are lifted. The distance

should still be no less than 2 mm.9 Fit the side guard.

1 Locking star tip2 Lock pawl3 L-section bar4 Finger5 Locking star6 Detection arm7 Cam

Fig. 68 Locking star in locked position

6

7

3 à 3,5mm

12

3

45

VerplijnPK027

Adjustments


Packer

62

6.4.5 Lock pawl play

When the roller (2) on the arm (4) drops into the recess of the cam (3), the lock pawl (6) must let pass the tip of the locking star (5). Adjust the play between them as follows:


2 Remove the side guard from the packer.3 Move the packer until the roller (2) of the arm (4) has dropped in the recess

of the cam (3) and the starwheel shaft just starts rotating.4 Turn the on/off switch to off.5 Switch off the power supply and ensure that nobody can switch it on

again.6 Untighten the nut (1) of the roller (2) a little and move the roller in the

arm (4) until the play between the tip of the locking star (5) and the lock pawl (6) is 0,5 mm.

7 Tighten the nut (1).8 Check the play at all four tips of the locking star.9 Fit the side guard.

1 Nut2 Roller3 Cam4 Arm5 Locking star tip6 Lock pawl

Fig. 69 Lock pawl play

1 2 3 4

5

6

0,5 mm

VerplijnPK022

Adjustments


Packer

63

6.4.6 Using gauges

We recommend to use the gauges 320678 and 320679 for quick and accurate adjustment of the transfer strip, of the starwheels when locked and of the position of the fingers between the starwheels.

Place the gauges between the third and fourth starwheel at the left hand and right side, after tipping the gates. The semi-circular recesses in the gauges should fit around the starwheel shaft (1) and tipping shaft (2).

Caution:c Take care that the gauges are set well against the shafts.

Checking is possible at the following points::

The various adjustments, with as well as without using these gauges, are described in the following chapters.

Fig. 70 Using gauges

1 Starwheel shaft2 Tipping shaft

320679

320678

12

AB

C

D

E

VerplijnPK029

A Height of peak absorberB Height and angle of the transfer stripC Angle of roll-off stripsD Position of starwheels when lockedE Position of fingers between starwheels (after tipping back the gates)

Adjustments


Packer

64

6.4.7 Transfer strip

The transfer strip between the peak absorber and the packer has to be set as close as possible to the peak absorber. Proceed as follows:


2 Remove the guards at both sides of the packer.3 Untighten the allen bolts (1) at both sides.4 With gauges (see page 63):

Move the transfer strip (2) against the bottom of the gauges.Without gauges:Set the transfer strip (2) as low as possible without it touching the peak absorber(3).

5 Tighten both allen bolts (1).6 Check if the peak absorber (3) nowhere touches the strip.7 Fit the side guards.

1 Allen bolt2 Transfer strip3 Peak absorber

Fig. 71 Transfer strip

12

3

Verplijn PK019

Adjustments


Packer

65

6.4.8 Starwheels in locked position

When locked, the tips of the starwheel (2) must be 1 to 2 mm higher as the transfer strip (1). Adjust this after adjustment of the transfer strip (see page 64):


2 Remove the side guard from the packer.3 Move the packer until the starwheel shaft is in the locked position. The roller

of arm (6) will be on the high part of the cam (7) and the locking star (3) against the lock pawl (5).


again.6 Open the top guard and tip the gates.7 Undo the grub screws that secure the collar (4) on the shaft.8 With gauges (see page 63):

Rotate the shaft with starwheels (2) against the stop strips on the gauges. Pay attention that the locking star (3) is kept pressed against the lock pawl (5).Without gauges:Rotate the shaft with starwheels (2) till the point of the starwheels is 2 mm higher as the transfer strip (1). Pay attention that the locking star (3) is kept pressed against the lock pawl (5).

9 Secure the collar (4) on the shaft.10 Fit the side guard.

1 Transfer strip2 Starwheel3 Locking star4 Collar5 Lock pawl6 Arm7 Cam

Fig. 72 Starwheels in locked position

2 mm

123

4

5

76

VerplijnPK020

Adjustments


Packer

66

6.4.9 Position of fingers between starwheels

Adjust the position of the fingers (3) between the starwheels (4) as below:


2 Move the packer until the starwheel shaft is in the locked position.3 Turn the on/off switch to off.4 Open the top guard.5 Undo the allen bolts that secure the L-section bar (2) on the arms (1).6 With gauges (see page 63):

Move the bar (2) till the fingers (3) touch the stop strips on the gauges.Without gauges:Move the bar (2) till the distance between the finger (3) and the point of the starwheels is (4) is 35 mm. Pay attention that the locking star is kept pressed against the lock pawl.

7 Secure the allen bolts of the L-section bar.

1 Arm2 L-section bar3 Finger4 Starwheel

Fig. 73 Distance between fingers and stars

1

3

2

VerplijnPK021

4

35 mm

Adjustments


Packer

67

6.4.10 Start starwheel shaft

One time during each stroke of the packer the starwheel shaft (3) will turn a quarter revolution and drop the eggs on the rollers. The starwheel shaft starts when the lock pawl (5) releases the locking star (4). Adjust the start moment as follows:


2 Remove the side guards from the packer.3 Move the packer until the black marked reinforcement rib (1) on the cam for

insert mechanism (2) has an exactly vertical position.4 Turn the on/off switch to off.5 Switch off the power supply and ensure that nobody can switch it on

again.6 Undo the grub screws that secure the cam (7) on the shaft.7 Rotate the cam anti clockwise until the roller of the detection arm (6) drops

into the recess of the cam and the locking star (4) is just released by the lock pawl (5).

8 Secure the cam (7) on the shaft.9 Check the adjustment.10 Fit the side guards.

Fig. 74 Start moment starwheel shaft

1 Reinforcement rib2 Cam for insert mechanism3 Starwheel shaft4 Locking star

5 Lock pawl6 Detection arm7 Cam

12

3

456

VerplijnPK028

7

Adjustments


Packer

68

6.4.11 Friction clutch starwheel shaft

The starwheel shaft is driven through a friction clutch on the left-hand shaft end. The sprocket (1) rotates continuously between two clutch discs (2) and drives the starwheel shaft when it is unlocked (this is when all sensor fingers are lifted). The starwheel shaft must start rotating immediately and without hesitation after unlocking. Proceed as follows when the starwheel shaft hesitates or does not rotate at all:


2 Remove the side guard from the packer.3 Check if oil has penetrated between the sprocket (1) and both clutch

discs (2). In some packers a black plastic cap covers the clutch. Remove this cap.

Oil has penetrated:

4 Measure the length of the compression spring (3).5 Remove the set bolt (4) from the clutch and take the clutch apart. The

sprocket can be taken off after removing the grub screw from the shaft.6 Clean off the sprocket and both clutch discs.7 Reassemble the clutch. Turn the set bolt so far that the spring length is the

same as before.8 If installed, push the black plastic cap back on the clutch.9 Reinstall the guard.

No oil in clutch:

4 Increase the initial tension of the compression spring (3) by giving the adjuster bolt (4) a few turns.

5 If installed, push the black plastic cap back on the clutch.6 Reinstall the side guard.

1 Sprocket2 Clutch disc3 Spring4 Set bolt

Fig. 75 Friction clutch starwheel shaft

1 2 3 4

VerplijnPK009

Adjustments


Packer

69

6.4.12 Ejector height

A gauge is supplied with the packer to set the ejectors to the correct height. Adjust the ejectors as follows:


2 Move the packer until the ejectors (3) are in their lowest position.3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Open the packer top guard.6 Remove the side guards from the packer.7 Lay the gauge 22752 (1) in the spin rollers (2).8 Loosen the allen bolt (8) that secures the cam follower (7) to the command

arm (6).9 Move the command arm until the ejectors (3) touch the gauge, keep the

cam follower (7) pressed against the cam and secure the allen bolt (8) again.

10 Check the adjustment at the outside left and right ejectors Small height corrections are possible after loosening the bolts (5) in the ejector lever (4).

11 Fit the side guards.

1 Gauge 227522 Spin roller3 Ejector4 Ejector lever5 Bolts6 Command arm7 Cam follower8 Allen bolt

Fig. 76 Ejector height

22752 1

2

3

4

5

6

7

8

VerplijnPK015

Adjustments


Packer

70

6.4.13 Tipping plates

The tipping plates make the eggs tip with the point down. The angle as well as the distance between both tipping plates is important for well functioning. Check and adjust them as follows.


2 Press the reset button until the tipping plates are as close together as possible.


again.5 Remove the cap nut of the front packer guard and remove the guard.6 Open the packer top guard.7 Check the position of the tipping plates with regard to each other by using

the supplied gauge 320432 (3). The hook (2) of the gauge must lay on top of the fixed tipping plate (4), in front of the roller. The fixed tipping plate (4) as well as the moving tipping plate (5) must be tight against the gauge. Check this in front of both outmost rollers.

8 Correct, when needed, the position of the moving tipping plate (5) after untightening the allen bolts (1), pressing the tipping plate against the gauge and tightening the allen bolts again. Do so at both ends of the tipping plates.

9 Fit the front packer guard and secure it by the cap nut.10 Close the packer top guard.

Fig. 77 Tipping plates adjustment

1 Allen bolt2 Hook3 Gauge 3204324 Fixed tipping plate5 Moving tipping plate

28,5 mm

4°

VerplijnPK005

1

2

4

3

5

Adjustments


Packer

71

6.4.14 Distance between egg holders


2 Move the packer until the insert mechanism is in its highest position.3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Remove the side guards from the packer.6 Measure the distance between the egg holders (4 and 8). It must be 19 mm

for Farmpackers.7 Loosen the allen bolts (3 and 5) and rotate the egg holder shafts (2 and 6) in

the arms (1 and 7) to adjust the aperture. Pay attention to keep the angle of the front and rear egg holders identical.

8 Fit the side guards.

1 Arm2 Egg holder shaft3 Allen bolt4 Egg holder5 Allen bolt6 Egg holder shaft7 Arm8 Egg holder

Fig. 78 Egg holders

19 mm

1

= =VerplijnPK016

23

4

5

6

7

8

Adjustments


Packer

72

6.4.15 Pitch of egg holders

The pitch of the egg holders must be 72 mm when the insert mechanism is in its highest position. The pitch over all six egg holders should not be over 360 mm. When needed correct this distance as follows:


2 Press the reset button until the insert mechanism is in its highest position.3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Remove the cap nut of the front packer guard and remove the guard.6 Remove the side guard from the packer.7 When needed alter the length of the tie rod (2) to adjust the pitch of the egg

holders. One of the ball joints (1 and 3) has left handed thread. The total pitch, measured over all six egg holders, must be between 358 and 360 mm.

8 Fit the front packer guard and secure it by the cap nut.9 Fit the side guard.

Fig. 79 Egg holder pitch adjustment

1 Ball joint2 Tie rod3 Ball joint

VerplijnPK017

72 mm

123

358-360 mm

Adjustments


Packer

73

6.4.16 Height of egg holders

The height of the egg holders should be the same at the left hand and right hand side. When needed correct the height as follows:


2 Set the insert mechanism to the largest pitch by setting the knobs (1 and 3) in the outmost position.

3 Press the reset button until the insert mechanism is in its lowest position.4 Turn the on/off switch to off.5 Switch off the power supply and ensure that nobody can switch it on

again.6 Remove the cap nut of the front packer guard and remove the guard.7 Adjust the ball joint (4) in the connecting rod (2) to get the height the same

at both sides. A difference of maximum 1,5 mm is allowed.8 Fit the front packer guard and secure it by the cap nut.

1 Knob2 Connection rod3 Knob4 Ball joint

Fig. 80 Height of egg holders

1 2 3 4

A A ± 1,5 mmVerplijnPK030

Adjustments


Packer

74

6.4.17 Opening of egg holders

The opening of the egg holders has to be adjusted as follows:

1 Put an egg with a diameter of 35,5 mm on the rollers of the packer.2 Close the top guard.3 Start the Farmpacker in the service-mode by turning the on/off switch to on

while the reset button is kept pressed. When in the service-mode it is possible to move the Farmpacker in small steps ("inching").

4 Move the packer until the egg has just been dropped by the tipping plates and is hanging in the insert mechanism.


again.7 Remove the cap nut of the front packer guard and remove the guard.8 Remove the side guards from the packer.9 Check if the distance between the outmost egg holders is 350 mm. If the

difference is over 2 mm, despite careful use of the inching button, correction of this size is possible by turning the insert mechanism cam somewhat on its shaft. Loosen the three bolts (2) as well as the central allen bolt (3) to do so.

10 Undo the two grub screws that secure the egg holder cam (1) on the shaft.11 Turn the egg holder cam until the distance between the egg holders is 26

mm.12 Secure both grub screws.13 Fit the front and side guards.

Fig. 81 Opening of egg holders

1 Egg holder cam2 Bolt3 Central allen bolt

1

VerplijnPK018

350 ± 2 mm

26 mm

2

3

Adjustments


Packer

75

6.4.18 Catch flap

We recommend to use the gauge 320926 for quick and accurate adjustment of the catch flap.


2 Move the packer until the ejectors are in their lowest position.3 Turn the on/off switch to off.4 Switch off the power supply and ensure that nobody can switch it on

again.5 Remove the side guards from the packer.6 Loosen the clamp bolt of the command arm (2).7 With gauge:

Put the gauge (4) on the follower arm shaft, keep it pressed against the command arm shaft and move the command arm (2) against the stop strip (3) on the gauge.Without gauge:Move the command arm (2) to an angle of 55º.

8 Tighten the clamp bolt of the command arm (2).9 Loosen the clamp bolt of the follower arm (1).10 Keep a ruler (7) in the thin part of a spin roller (6) and rotate the catch flap

(5) until it is aligned against the ruler.11 Tighten the clamp bolt.12 Remove the gauge.13 Fit the side guards.

Fig. 82 Stop flap

1 Follower arm2 Command arm3 Stop strip4 Gauge 320926

5 Catch flap6 Spin roller7 Ruler

55º

1 2 3 4 5 6 7

VerplijnPK032

Adjustments


Packer

76

6.4.19 Start moment of carton transport

The moment when the carton transport starts after a row of eggs has been inserted in the carton, is fixed by the proximity switch (2) on the memory disc (3) of the packer. Adjust the start moment as follows:


2 Press the reset button until the insert mechanism has been in its lowest position and went up that far that the distance between egg holders and deck plate is at least 90 and at most 110 mm.


again.5 Remove the side guard from the packer.6 Loosen the bolts that secure the base plate with proximity switch (2) on the

memory disc (3).7 Rotate the base plate clockwise until the switch is actuated. 8 Tighten the base plate bolts.9 Check the gap between the proximity switch and memory pin (1). This

should be 1 to 2 mm.10 Fit the side guard.

Fig. 83 Adjustment of carton transport start moment

1 Memory pin2 Proximity switch3 Memory disc

VerplijnPK033

90-110 mm

1 - 2 mm

1 2 3

Adjustments


Packer

77

6.4.20 Cam for egg holders

The packer is fitted with a cam for opening of the egg holders, that has two different shapes.

Shape B has to be used for Farmpackers and packers in graders that handle all grades.

Shape A has only been used for packers in graders, that handle a limited range of grades.

Change the position of the cam follower bearing (2) on the lever by choosing between fitting one or two spacing collars (1) between the bearing and lever.

1 Spacing collar2 Cam follower bearing

Fig. 84 Cam for egg holders

Adjustments


Packer

78

6.4.21 Cams for ejectors, tipping plates and gate movement

When fitting the cams for the ejectors and tipping plates on the shaft, the correct position of the hub and the cams is important. Pay attention to the following notes:

• The key slot that is closed at one end has to be used to fit the hub (7) on the key (1). The indication ridge (6) must point towards the cams for the tipping plates (8 and 9).

• The cams for the tipping plates (8 and 9) must be fitted to the hub in the position as on the diagram. The cam with the text “Farmpacker” will be at the outside.

• The cam for the ejectors (5) must be fitted to the other side of the hub. Pay attention to have the indication ridge (4) at the hub side, facing the indication ridge on the hub (7).

• The cam for tipping plates “Farmpacker” (9) has to be used for Farmpackers and for packers in graders that handle all grades. Fit the cam roller in such a position that it follows the “Farmpacker” cam (9).

• The cams for gate movement (3 and 10) have a fixed position on the shaft. For this reason the shaft is provided with pre-drilled holes for the grub screws of the cams. Pay also attention to fitting the cam hub at the right side (see diagram).

Fig. 85 Cams for ejectors and tipping plates

1 Key2 Key slot closed at one end3 Cam for gate movement4 Indication ridge5 Cam for ejectors

6 Indication ridge7 Hub8 Cam for tipping plates9 Cam for tipping plates “Farmpacker”10 Cam for cate movement

1 2

3 4 5 6 7 8VerplijnPK025

9 10

Adjustments


Packer

79

6.4.22 Cam for insert mechanism

When fitting the cam for the up and down movement of the insert mechanism to the shaft, the correct position of the hub and cam is important. Pay attention to the following notes:

• The indication ridge (1) on the hub (2) must be laying against the cam (3).• The cam for insert mechanism (3) must be fitted to the hub in the position as

on the diagram.

Key slot A has to be used to fit the cam to the shaft.

1 Indication ridge2 Hub3 Cam for insert

mechanism

Fig. 86 Cam for insert mechanism

1

3

2

A

VerplijnPK024

80

7 Trouble shooting

7.1 Error messages general

The Staalkat Farmpacker 40 has a warning light in the reset button that may come on or flash during normal service. See ‘Warning light’ on page 20 for a survey of its meaning. In this survey you will also find details about solving these errors.

7.2 Fuses and thermal relay

• The complete installation is protected by an automatic fuse (2). The thermal protection of the motor is included in this fuse.

• The PCB is protected by a glass fuse F 6,3A (4).

Always use the indicated type and value when replacing a glass fuse. A higher value or different type (slow instead of fast) may cause serious damage. Contact Staalkat Service Department when fuses fail repeatedly.

The automatic fuse is to be found in the control box at the side of the peak absorber. When the switch (3) of the automatic fuse is pointing down this fuse has been actuated. The automatic fuse can be reset by turning up the switch. Check the drive. The overload may be caused by a jamming or by too tight or not sufficiently lubricated chains. After cooling down the fuse can be reset. Contact Staalkat Service Department when fuses fail repeatedly.

Fig. 87 Control box guard Fig. 88 Position of fuses

1 Control box guard2 Automatic fuse for complete installation3 Switch4 Glass fuse F 6,3A

1FP102SK003

1-ON 1-ON

2 3 4FP102BK002

81

8 Ordering spare parts

8.1 Using the Parts Catalogue

The Parts Catalogue contains a set of exploded views to enable the right parts numbers to be found easily.

We recommend that you take note of the following remarks before using this book and ordering spare parts.

8.1.1 Order formUse the Staalkat order form. You will find a number of these forms at the back of the book with exploded views.

8.1.2 Finding the right pageA survey of the machine with page numbers for the main sections can be found at the front of the Parts Catalogue.

8.1.3 Type of machine

The type of machine referred to on each page is indicated at the bottom of each page. The designation of your machine can be found on the front page of the User's Manual.

Fig. 89 Type of machine (example)

type

Ardenta 12

algemeenOB001

Ordering spare parts


Using the Parts Catalogue

82

8.1.4 Right hand and left hand machines

When the type designation is followed by an R, it is a right hand version. When the type designation is followed by an L, it is an left hand version of the machine.

When the page number is followed by an R, this page is only for right hand versions. When the page number is followed by an L, this page is only for left hand versions.

When the page number is not followed by a letter, the parts numbers on this page are right for both left hand and right hand versions of the machine.

Fig. 90 Right hand version

Fig. 91 Left hand version

type

Ardenta 12 R

algemeenOB002

type

Ardenta 12 L

algemeenOB003




83

8.1.5 Before/after a certain date

When parts are not interchangeable after certain modifications, different pages may be included for the same detail.

At the bottom of the page, underneath the machine type designation, a date with an arrow in front shows that the page is to be used only for machines built up to that date. A date with an arrow behind shows that the page is to be used only for machines built after that date.

Fig. 92 Before a certain date

Fig. 93 After a certain date

type

Ardenta 12 L> 01-2007

algemeenOB004

type

Ardenta 12 L01-2007 >

algemeenOB005




84

8.1.6 Quantities

The parts numbers in the exploded views are followed by a number between brackets. This number indicates the quantity of that particular part, as used in the section shown on that page. So the required quantity for a complete machine may be quite different.

8.1.7 Length

When a parts number is followed by (?m) please state the required length on your order.

Fig. 94 Quantities

type

Ardenta 12 R/L

0921365 (4x)

0921002 (2x)

algemeenOB006

Fig. 95 Length

type

Ardenta 12 R/L

1.092136 (?m)

algemeenOB007



Other documentation

85

8.1.8 Assembled units

In some cases a parts number is given for assembled units. A brace has been used to indicate the parts that are included in the assembly.

8.1.9 Non-standard partsIt is possible that parts of your machine differ from the Parts catalogue, caused by adaptations which differ from the standard version. Particularly in case of optionally lengthened conveyance sections, the parts numbers for conveyor belts and chains may be incorrect. Therefore always mention these adaptations when ordering spare parts.

8.1.10 Machine-order no.We recommend to give us the machine order no. when ordering spare parts. This number can be found on the identification plate of your machine and on the front page of the User's Manual.

8.2 Other documentation

8.2.1 Other equipmentThe Parts Catalogue for other Staalkat equipment can be found under a separate tab in this manual.

8.2.2 Electrical installationA set of diagrams is included in a separate file. Part numbers of the electric components can also be found in these diagrams.

Fig. 96 Assembled units

type

Ardenta 12 R/L

79155 (1x)

28015 (4x)

79152 (4x)

250233 (2x)

algemeenOB008

86

9 List of figures

Fig. 1 Guards and warning stickers on Staalkat Farmpacker 40 right hand 10

Fig. 2 Guards and warning stickers on Staalkat Farmpacker 40 right hand 10

Fig. 3 Guards and warning stickers on Staalkat Farmpacker 40 left hand 11

Fig. 4 Guards and warning stickers on Staalkat Farmpacker 40 left hand 11

Fig. 5 Guards and warning stickers on egg stamping unit (optional) 12Fig. 6 Position of main switch 12Fig. 7 Position of emergency stop button 13Fig. 8 Major parts 14Fig. 9 Work positions Staalkat Farmpacker 40 right hand model 18Fig. 10 Work positions Staalkat Farmpacker 40 right hand model 18Fig. 11 Controls 19Fig. 12 Controls 21Fig. 13 Changing denester accessories 23Fig. 14 Steps cam guard 24Fig. 15 Changing steps cam 24Fig. 16 Setting side guides 25Fig. 17 Insert pitch adjustment 26Fig. 18 Adjustment of leaf springs 27Fig. 19 Clip-on gates 27Fig. 20 Drip trays 31Fig. 21 Tipping the packer gates 32Fig. 22 Removing the spin roller 32Fig. 23 Flange bearings with grease nipple 33Fig. 24 Flange bearings with grease nipple 33Fig. 25 Tensioning of denester belts 35Fig. 26 Gear wheels in denester 36Fig. 27 Tensioning of peak absorber belt 37Fig. 28 Tensioning of extended peak absorber belt 38Fig. 29 Lubrication of egg holder shafts 39Fig. 30 Greasing the memory pins 40Fig. 31 Tensioning conveyor belt 41Fig. 32 Control box guard 42Fig. 33 Adjustment of pressure control 42Fig. 34 Denester, mechanical operation 43Fig. 35 Photocel in the denester 44

List of figures


87

Fig. 36 Denester drive clutch guard 45Fig. 37 Deck plate denester 45Fig. 38 Drive clutch release pawl 45Fig. 39 Guards 46Fig. 40 Position of transport bars 46Fig. 41 Position of steps disc 46Fig. 42 Position of switch cam 46Fig. 43 Guards 47Fig. 44 Position of transport bars 47Fig. 45 Position of steps disc 47Fig. 46 Position of switch cam 47Fig. 47 Deck plate denester 48Fig. 48 Position of lift cam 40 right hand model 48Fig. 49 Guard 48Fig. 50 Position of locking disc 48Fig. 51 Deck plate denester 49Fig. 52 Position of lift cam 40 left hand model 49Fig. 53 102S left hand model 49Fig. 54 Position of locking disc 49Fig. 55 Wedge holders 50Fig. 56 Gripper cam 51Fig. 57 Gripper levers 52Fig. 58 Grippers 53Fig. 59 Hinge pins for auxiliary grippers 54Fig. 60 Auxiliary gripper rods 54Fig. 61 Carton transport lane drive clutch guard 56Fig. 62 Drive clutch release pawl 56Fig. 63 Guards 57Fig. 64 Carton transport lane drive sprocket 57Fig. 65 Carton transport lane steps cam 57Fig. 66 Packer operation 58Fig. 67 Clearance of fingers 60Fig. 68 Locking star in locked position 61Fig. 69 Lock pawl play 62Fig. 70 Using gauges 63Fig. 71 Transfer strip 64Fig. 72 Starwheels in locked position 65Fig. 73 Distance between fingers and stars 66Fig. 74 Start moment starwheel shaft 67

List of figures


88

Fig. 75 Friction clutch starwheel shaft 68Fig. 76 Ejector height 69Fig. 77 Tipping plates adjustment 70Fig. 78 Egg holders 71Fig. 79 Egg holder pitch adjustment 72Fig. 80 Height of egg holders 73Fig. 81 Opening of egg holders 74Fig. 82 Stop flap 75Fig. 83 Adjustment of carton transport start moment 76Fig. 84 Cam for egg holders 77Fig. 85 Cams for ejectors and tipping plates 78Fig. 86 Cam for insert mechanism 79Fig. 87 Control box guard 80Fig. 88 Position of fuses 80Fig. 89 Type of machine (example) 81Fig. 90 Right hand version 82Fig. 91 Left hand version 82Fig. 92 Before a certain date 83Fig. 93 After a certain date 83Fig. 94 Quantities 84Fig. 95 Length 84Fig. 96 Assembled units 85

89

10 Index

AAccessories 22Air humidity 16Air pistol 31Ambient temperatures 16Assembled units 85Automatic fuse 80Auxiliary gripper rods 54Auxiliary grippers 54

BBearings 33Belts 35

CCam for egg holders 77Cam for ejectors 78Cam for insert mechanism 79Cam for tipping plates 78Capacity 16Carrier chains 34Carton holder 43Carton transport lane 14Carton type 22Cartons 22Catch flap 75CE-marking 15Centre block shaft 50Centring sections 23Children 8Clutch discs 68Control box 15Covers 10

DDecommissioning 9Denester 14, 23, 43Detergent 31Diagrams 6Dismantling 9Drip trays 10, 31Drive 48, 49, 57Drive chains 34Drive clutch 56

EEgg holder shafts 39Egg holders 71, 73, 74

Egg stars 66Ejector height 69Electric components 85Electrical installation 6, 8Electricity 16Emergencies 13Emergency stop button 13Energy 16Environment 9Error messages 80Extended belt 38

FFingers 66Flange bearings 33Frame 31Friction clutch 68

GGates 32Gauge 50, 70Gauges 63Gear wheels 36Grease gun 30Grease nipple 33Gripper cam 51Grippers 23, 43, 53Guard 19Guides 30

HHinge pins 54

IIdentification plate 15Inching 20Incline conveyor 15, 41Incline conveyor belt 41Inspections 8Installing 9

JJam indicator 20

LLeaf springs 27Left hand version 82Lift cam 51

Index


90

Lift table 23, 43, 51Lock pawl 62Locking star 61Lubricants 30Lubrication of chains 34

MMain switch 12, 19Main switch of the machine 8Maintenance schedule 29Materials 17Memory pins 40Motor with reduction box 35Moving 9

NNon-standard parts 85Normal stop 21

OOrder form 81

PPacker 15, 26, 58Padlock 8Parts Catalogue 81Parts catalogue 6Peak absorber 15Peak absorber belt 37Periodic inspections 8Pitch of egg holders 72Plastic 31Potmeter 42Power supply 15Pressure control 20, 42

RReduction box 35Relay 15Release pawl 45, 56Right hand version 82Rubber 31

SSafety instructions 7Safety screens 10Safety switch 19Securing knob 32

Service-mode 20Set of accessories 14Sheet metal 17, 31Side guides 25Sound level 16Spare parts 6Spare parts catalogue 81Spin roller 32Start moment carton transport 76Starting 19Starwheel shaft 67, 68Starwheels 65, 66Steps cam 14, 24Stop flap 75Stopping 21

TTensioning the chains 34Thermal protection 80Tipping plates 70Tracking 37, 38, 41Transport bars 46Tray Stacker 6Type of cartons 22

UUse 16

WWarning light 20Warning stickers 10Wedge holder cam 50Wedge holders 50Wedges 23, 43Work positions 16, 18

Documents

Staalkat Farmpacker 40 Using this manual This manual provides a guideline for the safe and effective operation and maintenance of the Staalkat Farmpacker 40. We recommend that you