Bird Removal Systems - LubingUSA · Catcher Assembly must be located no more than 18 inches from...

LUBING Systems, LP135 Corporate Drive SWCleveland, TN 37311

Bird Removal

Chick-Out Installation GuidePart # IM-771-0209/2007

Systems

CHICK-OUT INSTALLATION GUIDE

1.1

Table of Contents

1 Warnings and Precautions

2 Tools Required

3 Before You Begin

4 Designing the Layout

4.1 Chute Assy (optional)

4.2 Catcher Assy

4.3 Chick-Out Location

4.4 System Overview

5 Primary Components

6 Installation Procedures

6.1 Building the Front End

6.2 Building the Back End

6.3 Suspending Front End Assy

6.4 Installing Connecting Parts Between Ends

6.5 Attaching the Back End Assy

6.6 Finishing the Corners

6.7 Installing the Chain

6.8 Finishing the Installation

7 Initial Break-In of Conveyor

8 Operating the Chick-Out

9 Electrical Information

1.2

2.1

3.1

4.1

4.1

4.1

4.2

4.3

5.1

6.1

6.1

6.4

6.5

6.7

6.9

6.9

6.14

6.20

7.1

8.1

9.1


1 Warnings and Precautions

Please take the time to read andunderstand this manual beforebeginning assembly.

Carefully follow all safety andoperating instructions.

Observe the following precautionswhen working on or near thismachinery:

• Understand the limitations andhazards associated with operatingthis equipment.

• Wear appropriate eye protectionwhen assembling and using thisequipment.

• Do not wear loose clothing,jewelry, ties, etc.

• Keep sleeves rolled above theelbows.

• Confine long hair.

• Always wear approved protectivefoot wear.

Make sure all personnel understandthe potential danger of someonegetting too close or trying to makerepairs or adjustments while themachinery is running. This equipmenthas several areas where injuries couldoccur if covers or guards areremoved.

Important

• Keep all covers and guards in placewhile equipment is in operation.

• Raise the Chick-Out until the bottomof the transporters are at least 6inches above the top of the tallestoperator.

Observe the following precautionswhen servicing the machinery:

• Do not remove guards except whenperforming maintenance.

• Do not operate the machine withguards or covers damaged orremoved.

• When performing maintenance orrepairs, make sure the local controlswitch is off and the main powercontrol panel is off and tagged "do notoperate".

• Make all adjustments with power inthe off position.

• Never reach into the system whilethe machine is running. Keep handsout of chain and sprocket areas.Keep all guards and covers in placewhen the power is on.

• Work carefully and give the workyou are doing your undividedattention. Do not look away, talk, orotherwise become distracted.Careless acts can result in seriousbodily injury.

1.2


2 Tools Required

2.1


3 Before you Begin

3.1

Before you begin assembling your Chick-Out automated bird removal system, youwill need to do some preliminary work. The following tips will aid the installation ofyour equipment:

• Read through the manual completely before you begin installing your equipment.

• Draw an intended layout of your Chick-Out system before you begin installing.

• Purchase several lengths of framing lumber for additional support for yourequipment. You will need these boards to build supports above areas where youwill install the heavier equipment.

• Keep all components off the ground and clean. Build one or two plywood worktables. These may also help to prevent loose components from getting lost duringinstallation.


4 Designing the Layout

4.1

4.1 Chute Assembly (optional)

The Chute Assembly is a drop door locatedon the end wall. It catches the bird whenreleased from the Transporter and directs itout of the building and into your holdingcontainer. The Chute Assembly must belocated directly below the Catcher Assembly.The side of the Chick-Out conveyor with theCatcher Assembly must be located no morethan 18 inches from the wall to allow the birdto drop onto the chute. If a Chute Assemblyis used on a building with non-framed doors,then it will have to be located somewhereother than the door.

4.2 Catcher Assembly

Corner DriveAssembly

The Catcher Assembly is used to release the bird from the Transporter. It must bepositioned on the system so that the birds will be released before traveling throughthe Corner Drive. Birds must not be placed onto a Transporter located between theCatcher Assembly and the Corner Drive Assembly.

Catcher Assy

Transporter


4.2

4.3 Chick-Out Location

The Lubing Chick-Out system forms a rectangle. Each side of the system can beas short as 42 inches or as long as 500 feet. The maximum total length of asystem is 1,000 feet around its perimeter. It can be sized to fit between otherequipment in most buildings, but Lubing does recommend 12 inches of clearanceon both sides of the Chick-Out track. The width and length of the system must alsobe chosen to avoid interference with other equipment when raised or lowered.

Also, keep in mind that the suspension system will be directly above the Chick-Outand will need to be secured to a strong structure. Lubing recommends using twolines of winching, winches with a minimum rating of 3,000 pounds, 3/16 inch wirerope for the main line, and 1/8 inch wire rope for the drops.

Any questions regarding your suspension should be directed to your installer.


4.4 System Overview

Pictured below is an overview drawing of a suspension system showing generalinformation about its components.

Note: The suspension system is not supplied with the Chick-Out. Concernsabout the operation of the suspension system should be directed to theinstaller of the system.

The Winch is usually installed in the center of the house and directly controls theMain Winching Cables, which run from the Winch to each end of the house. DropPulleys are installed along the length of the Main Winching Cables every 10 feet orless. Drop Cables attach to the Main Winching Cable and are threaded through theDrop Pulleys. The loose end is then attached to the equipment.

Note: Each of the four corners of the Chick-Out system require two DropCables and may require installing some framing lumber for additional support.

4.3


5 Primary Components

5.1

Corner Drive Assy[one unit per system]

Corner Intermediate Drive Assy[one unit per system]

Corner Idle Assy[two units per system]

Connecting Part

Gear Motor[one unit per Drive Assy]

Chain with Transporter Links


5.2

Transporter Master Link Master Link

Transporter Assy[one unit per 10 feet of chain]

Catcher Assy[one per system]

Discharge Chute Assy[shown mounted to wall]


6.1

6 Installation Procedures

6.1 Building the Front End

6.1.1 Determine the Width

a. An overall width of 142.5 inches can be attained by using one Connecting Part.

6.1.1 Determine the Width


6.2

6.1.2 Fasten the Connecting Part to the Corner Unit

a. Modify the end of the PVC Profile that will attach to the Corner Drive Unit.

Set All Three Flush

b. Clamp into position on the Corner Drive Assembly and drill five pilot holes.Secure with A-10 screws.


6.3

UHMW RunnersPVC Profiles

Support Bars

A-10 Screw

c. Two or more Connecting Parts will be needed for wider systems. The joints ofthe Support Bar, the PVC Profile, and the UHMW Runner should be offset fromeach other when coupling Connecting Parts together.

Note: Before attaching the Connecting Part to the Corner Drive Unit, cut 10 inchesoff of the PVC Profile and 22 inches off of the UHMW Runner. The joints shouldresemble the above illustration.

Set All Three Flush

d. Drill pilot hole and install A-10 screw on one side of the PVC Profile joint.

e. Repeat steps "a" and "b" for the Corner Idle Unit Assembly.


6.4

6.1.3 Installing the Support Bar

a. The Support Bar should be at least 2 inches longer than the Connecting Part(s)in order to extend beyond the support brackets on both corners.

b. Insert the end of the Support Bar through the support bracket of the Corner IdleUnit at least 2 inches and snap into the PVC Profile.

c. Tap the end of the Support Bar extending through the support bracket with arubber mallet to drive it through the support bracket of the opposite corner unit.

6.2 Building the Back End

a. Repeat steps 6.1.1 through 6.1.3, substituting the Corner Drive with the CornerIntermediate Drive.


6.5

6.3 Suspending the Front End

6.3.1 Attach the Front End to the Suspension System

a. Each Corner Unit has two suspension points.


6.6

6.3.2 Add suspension to Connecting Parts (if needed)

96" 120"

Acceptable

120" 144"

Unacceptable

a. The maximum distance between two suspension points is 10 feet (120 inches).

b. Directly below the suspension cable, drill a 1/4 inch hole into the rib of the PVCProfile below the Support Bar. Thread the suspension cable through the hole tosupport the Connecting Part.

drill 1/4" hole


6.7

6.4 Installing the Connecting Parts between the Ends

6.4.1 Modify and Fasten the Connecting Parts to the FrontCorner Units

Set All Three Flush

a. Refer to Step 6.1.2 "a" through "d" on beginning of page 6-2 for modifying andfastening the Connecting Part to the Corner Unit.

Note: Before attaching the Connecting Part to the Corner Drive, cut 10 inches offof the PVC Profile and 22 inches off of the UHMW Runner. This will generate theoffset as previously mentioned.

Note: Do not let the loose ends of the Connecting Parts drag on the ground;temporarily support them from the suspension system or rest them on a work table.

116 1/2"

b. Insert the Support Bar through the support bracket of the Corner Drive at least 1inch and snap into the PVC Profile.


6.8

c. Repeat step 6.4.1 for the Corner Idle Unit.

6.4.2 Install Additional Connecting Parts

Drill 1/8" Hole andInstall A-10 Screw

a. Match the PVC Profile to the previously installed Connecting Part and slide theUHMW Runner in until it touches the Runner of the previously installedConnecting Part.

Note: Remember that the joints of the Support Bar, PVC Profile, and the UHMWRunner are offset approximately 12 inches from each other.

b. Install another Support Bar.

c. Drill a 1/8" hole into the angled corner of the PVC Profile while keeping PVCProfile and UHMW Runner joints tight and install an A-10 screw.

d. Add suspension cable to the Connecting Part. Refer to page 6.5 for details.

e. Repeat steps "a" to "d" until the desired length is achieved. The last ConnectingPart may have to be cut to fit.


6.9

6.5 Attaching the Back End

6.5.1 Suspending the Back End

a. Refer to Section 6.3 on Page 6.5 for detailed instructions.

6.5.2 Modify and Fasten the Connecting Part to the Corner DriveUnit

a. Refer to Section 6.1.2 on Page 6.1 for detailed instructions.

b. Repeat for the Corner Idle Unit.

6.6 Finishing the Corners

6.6.1 Prepare and Install a Piece of a Connecting Part

a. Cut a piece of Connecting Part 7 inches long.

b. Remove the top part of the profile.


6.10

c. Position on the Corner Intermediate Drive and clamp into place.

d. Drill three pilot holes and insert A-10 screws.

e. Repeat this procedure for both Corner Idle Units using four A-10 screws.


6.11

6.6.2 Install Motors and Gearboxes onto Drive Corner Units

a. Position the motor and gearbox onto the Corner Drive and use four 3/8" bolts,nuts, and washers to secure. The bolt head should be on the bottom of thecorner plate.


6.12

b. Repeat for the Corner Intermediate Drive.

c. Install Breather Plug in both Gearboxes (refer to Gearbox manual).

Note: Each Gearbox comes with a manual that contains detailed instructions oninstallation and maintenance. Read and undertand this manual before connectingpower to the system. Store the manual in a safe location for future reference.

d. Connect the power supply leads to the motors.


6.13

6.6.3 Check the Output Shafts' Rotations

a. Position the motor and gearbox onto the Corner Drive and use four 3/8" bolts,nuts, and washers to secure. The bolt head should be on the bottom of thecorner plate.

b. The Corner Intermediate Drive output shaft should be turning counter-clockwisewhen viewed from the end of the shaft.

c. Install drive sprockets onto the output shafts.

d. Disconnect and lock out power supply after checking the rotation.


6.14

6.7 Installing the Chain

6.7.1 Install the Chain from the Corner Drive to the CornerIntermediate Drive

a. At the Corner Drive Assembly, insert a section of chain into the Connecting Partleading down the length of the house and pull to the Corner Intermediate Drive.

Note: Connect another section of chain before theprevious chain end is pulled into the UHMW Runner. Usethe Transporter Master Link that is installed at the end ofthe chain section (these are shipped in a separate boxwith the shipment if not installed in the sections.)

TransporterMaster Link

Note: Pulling more than two sections of chain may be toodifficult. Sections may be joined in the middle of the run ofConnecting Parts by pulling two separate sections of chain intoplace, carefully separating the Connecting Part joint nearest theends of the two chain sections, joining the chain sectionstogether, and then joining the Connecting Parts again.


6.15

12"

b. Continue to pull the chain until approximately 12 inches of the lead section ofchain are showing at the Corner Intermediate Drive Unit.

c. At the Corner Drive Assembly, insert another section of chain into theConnecting Part leading across the width of the house.


6.16

d. Continue to pull and add chain sections until approximately 12 inches of thesecond lead chain are showing at the Corner Intermediate Drive Unit.

Transporter Master Link

e. Thread the chain through the Corner Intermediate Drive and join the two looseends of chain together using a Transporter Master Link.

f. Pull the chain to the Corner Drive to remove as much of the slack as possible.


6.17

6.7.2 Tension the Chain

Clamp Here

a. At the Corner Drive, thread the chains through the sprockets as shown.

b. Clamp the chain, as indicated above, to prevent it from being pulled into theUHMW Runner.

c. Check that the chain is engaged with the sprockets at each corner.

d. Remove the fan cover from the motor and turn the motor fan by hand to removeall slack in the chain.


6.18

10"

Clamp Here after stretching 10-in.Clamped

e. Continue rotating the fan until an additional 10 inches of chain are pulledthrough and clamp this chain where indicated.


6.19

Tension Rod

Tension Springs

Tension Nut

f. Check that the Tension Nut is backed to the end of the Tension Rod.

g. Use a Chain Break Tool to remove any excess chain and join the two looseends of the chain together with a Master Link or a Transporter Master Link.

h. Tighten the Tension Nut until the springs are completely compressed.

i. Remove the clamps.

j. Reconnect to the power supply and test the operation of the system. Tighten thetensioning nut if the springs decompress.

Note: Disconnect and lock out the power supply before continuing to the next step.


6.20

6.8 Finishing the Installation

6.8.1 Install Transporters

Direction of travel

a. Bolt Transporters to the Transport Links on the chain.


6.21

6.8.2 Install Catcher Assembly

Direction of travel

a. Slide the Catcher Assembly over the top of the PVC Profile, drill a 1/4" hole inthe rib, and install the bolt.

b. Reinstall any guards that may have been removed during installation.


7 Initial Break-In of Conveyor

7.1

7.2 Adjust Chain Tension

Turn the system on and watch for smooth operation. Pay close attention to theTension Assembly on the Corner Drive Unit.

Note: The conveyor should be fairly quiet and very smooth while in operation.Other than the gear motors running and the chain engaging the sprockets,there should be very little noise or erratic movement. During the initial startup,be prepared to stop the conveyor if you see or hear any suspicious activity.Investigate the problem before re-starting the conveyor.

7.1 Start and Operate the Chick-Out

Turn the Tension Nut clockwise to keep Tension Springs collapsed as needed.

Note: During the initial break-in of the system, the chain will begin to seat withthe components. This may allow too much excess slack in the system for theTension Assembly to work correctly. If this occurs, chain will have to beremoved from the system. Refer to section 6.7.2 for instructions on tensioningthe chain.

7.3 Operate System

After all adjustments have been made, allow the chain to make at least onecomplete revolution before shutting down the conveyor.

Note: The Chick-Out system may be used during this break-in period afterperforming the steps in sections 7.1 & 7.2. Be sure to observe the ChainTension closely; the Tension Springs should be almost completely collapsedduring normal operation.


8 Operating the Chick-Out

8.1

8.2 Starting the Conveyor

Run the conveyor system at least one complete revolution each day to keep thesystem loose and ready to use.

8.1 Operate the Chick-Out Every Day

The conveyor should be running before adding birds to the Transporters.

Note: For safety, make sure the conveyor height is set per the instructions insection 1 of this manual before starting the conveyor.

8.3 Attaching Birds to Transporters

If a Chute Assembly is installed, ensure that it is open before attaching birds toTransporters. Make sure the Catcher Assembly is securely fastened and located sothat the birds fall onto the Chute.

Note: Never chase the Chick-Out system. Transporters are located every 10feet so be patient and wait for the next one to come. Looking upward andrunning could cause tripping or loss of balance and could result in seriousinjury or death.

8.4 Stopping the Chick-Out

When you are finished using the system, shut it off.

Note: Do not leave the Chick-Out system running unattended.


9 Electrical Information

9.1

F1

20A System Disconnect

OL2

M2

To additional PB stationStart buttons

Note 1Minumum wire size varies depending upon thedistance between the motor and its power sourceas follows:Less than 100-ft = #10 AWG copper100-ft to 200-ft = #8 AWG copper200-ft to 300-ft = #6 AWG copper300-ft to 500-ft = #4 AWG copper

Note 2All power wiring to be minimum #12 AWG copper

Note 3All control circuit wiring to be minimum #16 AWG copper

Note 4Control circuit wire length not to exceed 800-ft.

Note 1

OL2

S1

PB1 Start

2P 20A Breaker

M1

Neutral

ToadditionalPB stationStop buttons

Single Phase

OL1

PBX Start

Note 1

S2

Motor Starter 2

Motor Starter 1

PB1 StopS2

PBX Stop

230VAC

S1

5A

115/230 Breaker Panel

S1 OL1

Control Circuit Fuse

1HP

S2

1HP

Important Notes:• Installation should be performed by a licensed electrical contractor.• All components should be installed, protected, and fused according to local, state,and national guidelines and codes.• Refer to the manufacturer's specifications and local, state, and national guidelinesfor proper mounting and placement of all electrical components.• Observe all original equipment manufacturer warnings regarding safety,operation, maintenance, and repair work.• Never work on any portion of the equipment without following proper Lock-Out /Tag-Out safety procedures.• All maintenance and repair work should be performed by trained and qualifiedpersonnel.• In multi-motor applications, the control circuit should be wired in such a way thatall motors start and stop together. Failure to do so can result in equipment damageand cause serious injury or death.• In multi-motor applications, the system should be installed with externalinterlocking overloads and powered from a single source to ensure all motors stopon any motor overload or electrical feed fault. Failure to do so can result inequipment damage and cause serious injury or death.

Bird Removal Systems - LubingUSA · Catcher Assembly must be located no more than 18 inches from...

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