WY Carousel Stacker Technical and Operations Manual Revision CCarousel Stacker Technical and Operations Manual ‘Table of Contents 1.0 General Information. 4 111 Safety Requirements 4 1.2.Contact Information, 6 13 Equipment Description and Theory of Operation. Ey, 1:4 Shipping Size and Weight 7 8 8 9 9 2.0 Installation 2.1 Configurations 2.2 Typical Set-up Dimensions. 23 Mechanical Connections 24 Electrical Incerconnections... 2.5 Uity Requizements & Connection Points. 10 3.0 Operation & Adjustment, aie a 3.1 Power-Up & Operation At $2 tation - Staring and Stopping 12 33 Timing / Calibration s 14 SSH Gaeee Timing telson ats 4 3.3.2 Elevator Adjustments ice oi) 3.3.3 Adjusting for Different Flats a 3.34 Sensor Adjustment for Timing Star and Infeed Paddle... 15 43.3.5 Adjusting the Broken Shear Pin. ot 16 3.3.6 Carousel Cazziez Chain Adjustment 16 3.4 Operational Options... 16 SE Shutdowa. Z 16 40 Maintenance... 47 42 Lubrication... Peace 17 43 Cleaning. 17 50 Diagnostics / Troubleshooting 18 5.1 Component Locations ah at eet 5.2 Eeror Messages ans RS 19 5.3 Red Vesta Controller Board Iapus/Oupus. : 20 6.0 Pacts : 1 641 Spare Parts. E 21 62.Assembly / Parts Drawings. Esc 6.21 Electical Drawings. i 22 62.2 Mechanical Drawings. 29 7.0 Glossary : 39 “4605700 Rev. C PageCarousel Stacker Technical and Operations Manval 1.0 General Information 1.1 Safety Requirements WARNING! SAFETY AND SERVICING CLEANING, REPAIRING AND/OR ADJUSTING DO NOT OPERATE ANY PART OF THE MACHINE UNLESS ALL GUARDS ARE IN PLACE NEVER service, clean, repair and/or adjust any part of the machine while the machine is still on and/or in operation. STOP the machine and lock it out before servicing, cleaning, repairing, and/or adjusting, If the machine cannot be stopped or turned off, production for the day is completed, If any guards are removed for service, cleaning, repairing, and/or adjusting the machine, replace all guards and secure them before restarting the machine. Keep all floors dry and free of broken egg, water, oil, and debris in traffic area of the processing operation. IF the floor becomes wet take whatever steps are necessary to keep the floor dry Employces should not operate or service the equipment with loose clothing or long hair. Make sure all supervisors and employees understand the importance of keeping all guards in place and keeping the floor clean and dry. February 2012 “4605700 Rev. © Page4Carousel Stacker Technical and Operations Manual IMPORTANT - PLEASE READ! ‘The information provided in this manual has been carefully checked and is believed to be accurate. However, changes are made periodically, which ate then incorporated into newer publications. Diamond Systems may improve and/or change products described in this publication at any time. Due to continuing system improvements, Diamond Systems is NOT RESPONSIBLE for inaccurate information, which may appear in the manual. In no event will Diamond Systems be liable for direct, indirect, special, exemplary, incidental, or consequential damages resulting from any defect or omission in this manual. Even if advised of the possibility of such damages. In the interest of continued product development Diamond Systems reserves the right to make improvements in this manual and the products it describes at anytime, without notice or obligation. For the latest product updates please call Diamond Systems Sales or Service. MAY, 2001 “4603700 Rew. C Pagerouse Stacker Technical and Operations Manwal 1.2 Contact Information Diamond Systems 24300 Haggerty Road Faomington Hills, MI 48335 USA, Phone #: 1.248 476 7100 Facsimile: 1248 476 0849 Diamond Systems Asia 21B, Jalan TS 6/104, Taman Industei Subang 47510 Selangor Malaysia Phone #: +60 3 5631 4991 Facsimile: +60 3 5631 4991 Diamond Systems Europe Fika, 64-Bajo 48006 Bilbso Facsimile: +34 94 433 6734 Service Phone #: 1248 476 7274 Facsimile: 1 248 476 361 4605700 Rev. © PagesCarousel Stacker Technical and Operations Manual 1.3 Equipment Description and Theory of Operation ‘The stainless steel Carousel Stacker is used to stack 30-egg plastic or paper trays into 6 tiers stacks after a farmpacker or after an automatic packer on an egg grading system. Each tray is gently stacked to help save labor and reduce breakage. 14 Shipping Size and Weight rut Size: 3-9" (1.14) wide by 8-1" 2.462) long by 5° (163m) tall Weight: 1,000 Ibs. (453.59 kg). 4003700 Rex. C PageTCarousel Stacker Technical and Operations Manual 2.0 Installation 2.4 Configurations Figure 2.1.1 ‘Note: Shown configurations are standard, custom configurations can be made based on ‘Diamond consulting. 4@DSTOO Rev. C Page 8Carousel Stacker Technical and Operations Manual 2.2 Typical Set-up Dimensions 23" 1 MAX MAX. 2'-94 z 4605700 Rev. © Page 9icker Technical and Operations Manual 2.3 Mechanical Connections ‘© Position stacker i the proper place making sure itis level and atthe proper height. Tafeed conveyor can be slightly sloped up or down 7° if needed. Takeaway conveyor should not be sloped more than 2°. ‘© When instlling the takeaway conveyor, loosen nuts that mount eleetical box and route the conveyor cable behind the box plugging it into the bottom. 2.4 Electrical Interconnections (On 70 Farmpacker: ‘* Inside the Stacker Control Box Step 1. Install relay oa dia eal next to Tezminal TB3-17. Step 2 Install wire from TB3-11 to relay +. Step 3. Install wire from TB3-10 to Relay ~ Step 4. Move the black wire from TB3-8 to Relay C. Step 5. Move the red wire from TB3-9 to Relay NC. ‘© Taside the Signal Junction Box Step 1. Route 2 conductor eables into the Conteol Box Step 2 Connect the black wire TB2-15, 16, 17, or 18 (signal ground), Step 3. Connect the red wise to TB2-2 (6 eges presen). (On 100 Fasmpacker: © Route the conduit to the fasmpacker, making sure it is out of the way and hidden as much as possible. Connect the black wires to 220 VAC and the green wire to the fame for the ground. Route the 2 conductor eable to the farmpacker control box and install the red wire to J3-2 and the black wire to J2-3, after totally removing the ‘original black wire terminated at 3-2 to ground. See Service Bulletin 042007 for more details 2.5 Utility Requirements & Connection Points 208/240 Volt, 3 Phase, 50/60 Hertz 4 Amps (832/960 Watts) Page 10wousel Stacker Technical and Operations Manual 3.0 Operation & Adjustment 3.1 Power-Up & Operation Step 1. Turn the main power switch ON and then press the RESET button that is located just above the main power switch on the side ofthe control box, Step 2. The machine will eycle to a knowa position. After the las cycle the takeaway conveyor will turn on. At this time nothiag will happen until you wipe your hand past the Exit Sensor that is located at the takeaway end of the stacker, (See Figure 3.24) The intial start up i the only time this will have ro be done. Figure 3.1.1 Main Power Swch "Tums the power on for the taker Tatch E-Stop/Reset Button | Resets the stacker and ideatifes stop codes (See Section 5. Figure 3.1.2 On/OW Switch “Turns stacker/ packer on or of (Overde Reset Button | Turns on takeaway conveyor. ‘Emergency Stop ‘Stops siacker/ packer. 4005700 Rev. © Page ttrouse! Stackee Technical and Operations Mam 3.2 Initiation ~ Starting and Stopping ‘© The stacker will eyele after the Stax Trigger at the end of the infeed is tripped. (See Figure 3.2.1) © Ifthe Double Tray Sensor is blocked it will shut down the stacker. The tay in front Of the trigger will not start the stacker. The white RESET button oa the control box must be pressed. (See Figure 3.2.2) ‘+ Ifthe Start Sensor and the Double Tray Sensor ate both blocked at the same time, the packer will hesitate ual the Start Seasor is cleared. Then it will continue to un except on the 200 farmpacker where the START button will need to be pressed. ‘Ifthe Extra Egg Sensor is blocked the Stacker will shut dawn, Remove the extra eg from the way and press the white RESET button on the control box. (See Figure 322) Once the Tray Detection Sensor is block the stacker will advance to its next position and stop unless there i another fat causing the Start Sensor ta be blocked. Then it will pick up the Mat and continue the same way tntl there ie a fall stack, (See Figure 324) ‘© When the stack is complete, the takeaway conveyor will tim to move it until the Exit Sensor i blocked. (See Figute 3.2.4) The nest incoming fat will not eycle in the stacker until the Exit Sensor is cleat. Ifthe Conveyor Full Sensor which i at the end of the takeaway conveyor is blocked, the stacker will continue (o run until another stack is ready to be shuttled out ofthe stacker. If che sensor remains blocked, the stacker and packer will be turned off See Figure 32.6) '¢ As soon as the stack atthe end of the conveyor is removed the stacker and packer will resume operation, ‘© For the On/Off and the Coaveyor Full condition, correct the condition oa the stacker and packer for it to zestat, or press the Stact button on the 200 farmpacker. “¥605700 Rew. © Page 12Carousel icker Technical andl Operations Manual Extra Ege Sensor Double Tay Sensor Figure ‘Star Trigger Tray Detection Sensor Exit Sensor Figure 3.24 Figure 3.23, ExitEnd Full Conveyor Sensor Figure325 Faken Conveyor 605700 Rev. C Page 13Carousel Stacker Technical and Operations Manual 3.3 Timing / Calibration 33:1 Stacker Timing Note: Remove all trays/eggs from the stacker. Step 1. Check to make sure the stacker comes to its home position which is when the levator platform is all the way down. Check ifthe center of the cam follower of the lift arm isin line with the zero timing mark on the lft cam. (See Figuse 3.3.1.1) If ‘not, loosen timing star and advance or retard the star the proper amount. (See Figure 3.31.2) This procedure may have to be down more than once to achieve the home postion, Figure 33.1.1 Figure 33.1 Note Inside view from the ‘Note: Ouse view from the left hand side ofthe stacker Jett hand side of the stacker Step 2. Check to make sure carter assemblies on the carousel are stopping atthe proper position. The proper position on the pick up is approsimarely %4” (12.7mmm) from the tip of the fingers to the top of the infeed belt, or 1” (254mm) from the top of the carrier plate to the top of the infeed belt. (See Figure 3.3.1.3) Step 3. If carrer assembly is not stopping at the proper position, bring the stacker back to the home position. Loosen the 40A16 pinch collared sprocket (Part #4101000) on. the right hand side of the main shaft, and then cycle the stacker. The stacker will run continuously until stopped by the pressing of the Emergency Stop button. Stop the ‘carousel eartier at the recommended position. (See Figure 33.1.3) Move the cam shafe until eis atthe zero mark, then tighten the 40AL6 sprocket (Pat #4101000) [Now the stacker is ready “4605700 Rex. C Page 1433.2 Elevator Adjustments, Step 1. Bring stacker to home postion where the elevators all the way down, Step 2. Loosen the short pinch collar arm on the bottom of light shaft. Step 3. Straighten the clevator platform to he parallel with the takeaway conveyor. Wait oa setting and tightening the pinch collar Step 4, Ifthe elevator platform appears to be sticking, pull ot the lft shaft and apply some ‘white lithium grease 10 the shaft 3.33 Adjusting for Different Flats ‘Step 1. Place the flat on the cartier assembly checking to make sure the fingers go into the ‘outside cells, and does not slide back and forth. ‘Step 2. Make suze any adjustment made is made equally to both sides so that the flat is ‘centered in the stacker. Step 3. IFextreme adjustments are needed to be made daily, then use the wing nuts in the Spare Parts Kit Note: For plastic barwood flats, which have sell, short cells on the bottom, then use the adaptor goide in the Spare Parts Kit for the elevator platform. 3.3.4 Sensor Adjustment for Timing Star and Infeed Paddle “The sensor face must be as close to the metal for sensing as possible. Diamond recommends the distance of 0.03" (0,762mm) while nat exceeding 09" (2.286me), “FO0STO0 Rev. C Page 153.35 Adjusting the Broken Shear Pin Step 1. Bring the motor driven sprocket with the hole until it line ups with the hole i the pinned hub. Step 2. Insect the 1/8" pin deiver or sheat pin into the inner hole so that it ine ups with the ‘outer hoes. Step 3. Drive out the broken shear pin into the auter hole while making sure the beating Dbehind the sprocket isnot ialine with the pin hole. Step 4. Place the shear pin in the outer hole and remove everything from the inner hole Step 5. Cycle the stacker few times to bring the stacker to the home position, then check the timing. (See Section 3.3.1) 3.3.6 Carousel Carrier Chai Adjustment Step 1. When the stacker is at any stop position, press inthe Emergency Stop button, Step 2. Check the chain for tightness atthe poiat where the cartier chain (#40) transfers from the hig 96 tooth sprocket on the bottom to the side chain guides. The chain should not move back and forth more than 1/8” (3.18mm) each way Seep 3, If the chain is loose, then the Cain Take Up plate needs to be lifted, Step 4, Loosen the 4 bolts holding the plate to the side plate and the 2 nuts on the top of the plate fange. Step 5. Slowly turn the nut on the bottom of the plate flange until the chain is tight DO NOT over tighten the chain which will increase the load on the shear pia, 1p 6. Tighten back up the 4 bolts holding the Take Up plate and then the 2 on the top of the plate ange. 3.4 Operational Options Avany time the stacker is needed to be cleared ofits stacks, switch the On/Off switch to Off and then press the white Override button to eyce the stacker one eycle at atime, 3.5 Emergency Operation / Shutdown ‘To immediately sop the stacker/packer for any reason, press the Emergency Stop button con the control panel ‘To restat the stacker and packer, pl the button out and then press the Reset burton on the contol box. 4605700 Rev. C Page 16Carousel Stacker Technical and Operations Manual 4.0 Maintenance 4.2 Lubrication '* Use 30 weight motor il on all chains ‘© Allbeatings with grease nipples should use multi-purpose grease. © Grease all bearings once a moath. # Check chain tension every two weeks. © Lubzicae all rod ends and pivot points once a week, A recommended method of cling chains is using @ paint brush co paint the ol on. ‘This directs the oil where it s needed as opposed to using a squirt can and getting oil cveaywhere 4.3 Cleaning All of the items listed below should be performed everyday ‘© Remove and clean all drip trays ‘© Wipe down any parts of the stacker with a clean, damp cloth where necessary ‘© Compressed air may be used on all areas of the stacker. © NEVER spray water on any area of the stacker, 4605700 Rew. © Page 17sntions Manual ‘ i ; j 5.0 Diagnostics / Troubleshooting 5.1 Component Locations eoosvo8. MOSNS AVEL 318N0G zLosvog y- NOSNGS dOLS Z109%08 NOSNIS JOH a TANVd TONLNOQ 440/'NO 4O4 SNOILWSO7 (F) Bamod avon, aw NOLLNA L3S3 IZ ziogvos | MOSNAS (oa34N!) Lavis~ enogv08. wOSNaS 993 S18NOG siogvos / 6009v08 YOSNES TIN MOSN3S LIK ‘HOA IANOD Page 18 HG0STOO Ree. CCarousel Stacker Techical and Operations Manual 5.2 Error Messages ‘Thote is alight located inside of the RESET burton on the side of the control bos. ‘Depending on the season it will blink different stop codes! 1 Blink The On/Off switch is tured off 2 Blinks The Conveyor Full Sensor is blocked: 3 Blinks The EM Stop relay is not ser. Pull our the EM Stop switch and press the reset switch, 005700 Rev. C Page 19Carousel Stacker Technical and Operations Man 5.3 Red Vesta Controller Board Inputs/Outputs ioe] “4605700 Rex. € Page 20Carousel Stacker Technical and Operations Manual 6.0 Parts 6.1 Spare Parts Carousel Stacker Spare Parts Kie #4077400 Part Number ‘Description 073400 “Fad Master Pia Link Stacker T 4076200 Adaptor Stacker Platform 1 4078400 Rod Guide 1 4078600 ‘Shear Pin Stacker 1/832 3/8 S57 a “4181802 12” Mounting Foot 1 4241800 Platform Stacker 1 8021280 Fuse 2 Slo-Blo 5320mm 4 8046032 Retro Reflee Sensor 18mm 1 8250862 %4 Washer T ‘9010004 Camrol” 1 ‘9090004 ‘Nylon Washer 4 9093015 Washer 253 x 4135 002 + ‘124117 3/8x2-5/4 Thunderstud + ‘1800 ‘Wing Nut 10-32 3 ‘9170025 Grip Ring SeSi. 5555-25. + ‘170031 Grip Ring SS 5/16 Dia. #55 6 9224013 Top Plate 5 4282000 Sprocket Assembly Stacker Carrier i 4O0STOO Rex. © Page 21sv aieg 2994 0OLSOoF Tananyy soontIedS pur PSPAL SPAS PAIDwos aGrisaNowwra, r =62 Kd 2 (sed Sus.opoy 228) sfuywwag oumeypay 779 eSne INSIDE VIEW OF RH, SIDE PLATECarousel Stacker Technical and Operations Manual oe Bho] BBR) \Ghecw / Bites “+ eae (4) REGO arse Waser || oe / Seeet come let Saal Real N/ dG ee l aie ie SHAPTMAN ' c 1 p4o7e100 ‘4 SHAFT-CAMS = \_ p1a75100 ‘ 407750 ANGLE Be PAN-FARMPACKER GyReo ——Aao7730" RP PAN-GRADER 4570 Rev. C Page 31aes \ESen Te men EGG FLOW OF LH. SIDE PLATE, INSIDECarousel Stacker Technical and Operstions Manual SALVId JIS YBNOVIS 40 30ISLNO S20" (F) eIBPESSY SAMMI dN ML EDOVIS ATMOS ALY | "vie Ms 20 GuSINO rows 2. 3A Page 33 4G05700 Rew. CCarousel Stacker Technical and Operations Manval 4605700 Rev. © Page 34Carousel Stacker Technical and Operations Manual [eaOTTaOS. FO05T00 Rew. C Page 35Carousel Stacker Technical and Operations Manval dQ) DIV. NIVHO ATEHISSW BLVd avg ooercore [sain Niwa Oot¥c0%8 sino onore0re 034 us us Nie piel vit er a0osz0y aaina wy 200940¥E 7 aay ce LON wNS3 MIMI G2-0/1 2 aeHsvas nos dvoay 0s 1 at oe yt e008, ‘9, patna nivHo 06/08 v wns onactove Page 36 “4605700 Ree. CCarousel Stacker Technical and Operations Manual 4280000. AS SHONN: ‘“2eoo0r AS Som We 4605700 Rew. C Page 37Carousel Stacker Technical and Operations Maswal 63 Ordering Pars Parts may be otdered by the use of the Diamond On-Line Store which is accessible from our website a sexwlamondautomation.com , by e-mailing us at patts@diamondsys ‘ot by fax using the Parts Order Form on the next page at (513) 476-3617, Cerne ‘Wcome to Damcnd System's OnLine Store “Ths sore roids our snes Pater he by to prchave Disnced Systems Products For seca pepo lease enter your ema kes ul paso 1 exer er Yur Emit dies Pewee =) youre Cute oad Sem’ Pra Cer Fant Ws Maso 49 ST6-706E Se ——— 1605700 Rev. C Page 384&DIAMOND AV SYSTEMS 7.0 Glossary ‘Terms: 605700 Rev. ©