KUHL QUAD BOXER 40k / 60k

AUTOMATIC CHICK BOXER / COUNTER

OPERATION MANUAL VER. 2.00


2
TABLE OF CONTENTS



Introduction . . . . 3
Electrical Control Panel . . . . 4
Computer (CPU) Control Box . . . . 5
Quad Boxer Startup Procedures . . . . 6
Software Operation Guide . . . . 8
Changing System Parameters . . . . 11
Error Conditions . . . . 12
Specifications & Maintenance . . . . 14
Sensor Adjustment Instructions . . . . 15
Box Position Sensor Adjustment . . . . 18
System Specifications
Motors / Bearings & Shafts . . . 19
Conveyor Belts / Pneumatics . . . 20

Service Bulletin #001 . . . . . 21

Installation & Use of Ver. 2.9 Software . . . 22
4.02 Software Upgrade . . . 24
Electrical Diagrams . . . 25









3
INTRODUCTION

The Kuhl Quad Boxer is a state of the art microprocessor controlled
machine designed to accurately count and box day old chicks. A four lane,
three conveyor design allows a chick boxing speed of sixty thousand birds
per hour, while gently handling the chicks.

The system was designed with simplicity and dependability in mind.
The onboard computer utilizes an easy to read Vacuum Fluorescent screen
that quickly displays vital information on the status of the counter. A loud
audio alarm feature warns the user of any problems such as no box in
place when there are no empty boxes on the conveyor and or when the
boxes are stuck on the line. The complete boxer and all systems are NEMA
4X rated for daily machine wash-down. A complete spare parts package is
available for quick replacement of any part on the system. All components
have been carefully chosen and designed to handle high volume use in an
industrial environment. When a problem does occur, components can be
quickly replaced.
























4
ELECTRICAL CONTROL PANEL

DO NOT open this panel unless you are qualified to do so.

ALL wiring MUST be done by a qualified / certified electrician in
accordance with local electrical codes in effect at the time of installation.
The machine MUST be grounded according to approved electrical code.

The electrical panel houses the motor starters, overload protectors, low
voltage transformer, start / stop relays and the pneumatic control valves. Six
fuses in this NEMA 4X rated box protect the machine and operator from any
electrical system malfunction.

DO NOT OPEN THIS PANEL UNLESS YOU ARE QUALIFIED TO DO SO !

Disconnect ALL power entering the control panel BEFORE working
within !

DO NOT modify anything in the control panel unless authorized by the
manufacturer.

Use ONLY replacement fuses with the correct ratings.

Except for external power hookup, NO OTHER external connections
should be made in this panel.

Keep panel door secured tightly at ALL times. Make sure gaskets are
ALWAYS in good condition (i.e. CANNOT be torn or loose, ect.).
Periodically check inside the panel for ANY signs of water leakage.

FUSE RATINGS:
If the system does not run, the fuses should be checked. Blown fuse
indicators may have been installed in fuse holders #1, 2, 3 & 4. If these
fuses are blown the LED at the top of the fuse base will light when the
power is turned on.



DO NOT FORGET TO
DISCONNECT POWER BEFORE REPLACING FUSES !







5
The following table summarizes the various fuse ratings:

FUSE # RATING
1 2 -- 3 250 VOLT 10 AMP SLOW BLOW
4 5 -- 6 250 VOLT 4 AMP FAST ACTING

All fuses are type 3AG (1 long). Spare fuses are stored in the control box
and spare parts kit.


COMPUTER (CPU) CONTROL BOX

The system computer is housed in a NEMA rated control box for
protection from daily system wash-down. Both the keypad and the display
panel are also NEMA rated. We recommend however, that this panel not be
washed with a high-pressure washer. The high-pressure may damage the
unit. Clean the unit daily with a soft cloth.

This unit contains the onboard computer, DC power supply and Solid
State Relays that control the motor and pneumatic functions. The computer
utilizes state of the art software (copyright) that allows the user to easily
interact with the machine. The system incorporates an alarm feature that
alerts the operator when any problems occur.

The CPU control box has four switches. The RED emergency stop
push-pull switch located on the side of the panel must be pulled out to the
ON position before power is available to the lighted GREEN push button
switch. The switch with the YELLOW band turns the computer on or off.
Never turn the computer off and on repeatedly. Always wait a few seconds
between turning it off and or on again. While washing the system, the
computer must be turned off.

The switch with the white band serves two functions:
1) MANUAL position runs the conveyors during wash-down and
2) AUTO position is used during production runs.

One fuse is located on the main board inside the control panel. It is a 1/4
OD x 3/8 high round shape rated at 1.0 amp.




DO NOT OPEN THIS PANEL U NLESS YOU HAVE BEEN TRAINED !




6
QUAD BOXER STARTUP PROCEDURES

1) Turn on the air supply

2) Turn the MAIN DISCONNECT switch (black handle on the electrical
panel) to the ON position.

3) Pull the RED emergency stop button (on the side of the CPU panel)
outward to the ON position. Be sure that the MAN / AUTO switch is in the
AUTO mode.

4) Press the GREEN start ( power ) push button. When the green light is on
the box conveyor will run.

5) Load the Box feed conveyor with empty chick boxes.

6) Turn on the computer (switch with YELLOW band).
The computer will boot and display the quad Boxer status screen.
If you ever need to reset the computer, simply turn the switch off,
wait 5 seconds and then turn it on again.

7) Clear any previous counts stored in the computers memory.
To clear the count memory, press the CE/E or CLEAR button on
the keypad, followed by the <1> key.
The four deflectors will shift to the up position at this point.

8) If you do not intend to use flock management skip to step #9.
Press the <2> key
Press the <3> key to erase the memory
Press the <1>key to confirm deletion

9) Check the system parameter setting by pressing the <8>key on the CPU.

The following setting should be displayed:

Birds / box =100 Small =8 Medium =9 Large =10

Press ENTER to return to the main menu.

The bird size should be set at Medium, if not, press the <1>key
until Medium is displayed at the top right hand corner of the screen.
If the above settings are incorrect, refer to the instructions on
CHANGING SYSTEM PARAMETERS.



7
10) Start the boxer by pressing the LEFT arrow key or the RUN key.
At this point a box will be moved into place and all four deflectors
will shift to the UP position, all conveyor motors will now run.
The system is ready to count chicks.

11) At the end of each flock, record the bird count, then press the <6>
key and follow the prompts.
At this point, a new box will be pushed into position
The flock counts will be stored in the flock management memory
To access the flock menu, press the <2>key on the keypad.







































8
KUHL 40k 60k QUAD BOXER
SOFTWARE OPERATION GUIDE
VER. 2.00 FLOCK MANAGEMENT


Most day-to-day operations require knowing a limited number of keystrokes
on the computer keypad. The following describes the various functions
available.

KEYPAD LAYOUT:

LANE 1 DIVERTER 1

LANE 2 DIVERTER 2
7
Spray Vacc
ON / OFF
8
Display
Parameters
9
Setup
Menu
RUN

LANE 3 DIVERTER 3

LANE 4 DIVERTER 4
4
Chicks
Per Hour
5
Diagnostics
Menu
6
End of Flock
STOP

FILL BOX

SPARE

Q BOX CONVEYORS
1
Bird Size
2
Flock Menu
3
Calibrate
Bird Size
Clear

INPUT 7 BOX STOP

INPUT 8 SPRAY VACC

Advance
Box
0

Spray Vacc
Enter

STANDARD SCREEN LAYOUT:






If you see asterisks (***) in the box totals across the screen, press the Clear
key followed by the <1> key.

RUN KEY
Starts system: When the system is turned on for the first time a new
box will automatically be moved into filling position. The motors will start,
sensors will be activated and the diverters will open. The screen will display
the RUN command with running cursor at the top left hand corner of the
screen.


STOP * QUAD BOXER * MEDIUM
BOX =0 Flock =0 Total =0
9
STOP KEY
Stops the system

<1>KEY (Change Bird Size)
Pressing this key increments the current bird size from small to
medium, to large. The three size settings correspond to the numeric bird
sizes entered in the setup screen. This feature is useful in situations where
accuracy drops between different size flocks. Usually when running
between 40-60 thousand birds per hour, it is important to set the bird size
numbers (i.e. small medium, large) to correspond to your chick sizes. For
example if a bird size of 9 works best with most of your chicks, you may
need to bring the bird size up to 10 for your older flocks and 8 for your
youngest flocks. Set the small at 8, medium at 9 and large at 10 (these are
the default settings).

<2>KEY (Flock Menu)
One unique feature of the software is ability to store 60 individual
flocks. These counts can be viewed or even printed while counting chicks.
Whenever you end the flock with the <6>key, the total count is transferred
in the computers memory in sequential order. The flock sequence number
is displayed on the main screen. To view the counts, simply access the
flock submenu and press the <1> key. The screen will display: flock
sequence number, time, total birds, adjusted count & total number of boxes.
The adjusted count represents the flock count minus the adjusted
percentage, which is setup in the birds per box setting. Use the right & left
arrow keys to scroll through the stored counts.
To print the counts summary, press the <2> key under the flock
submenu. If you have the optional printer, a report detailing all the flock
counts will be instantly printed. To ERASE the counts stored in the flock
database, press the <3> key while in the flock menu. If the <3> key is
pressed by mistake, restore the counts by pressing the <4> key. Counts
cannot be restored if the <3>key is pressed twice. At the beginning of each
day, erase all flocks stored in the computers memory.

<3>KEY (Calibrate Bird Size)
This key is used to verify bird sizes. When you choose this option the
conveyors start and the computer displays the minimum and maximum bird
size screen. As birds are placed on the belt & run through the fill lane, the
computer displays a corresponding bird size. Usually you need to pass 10
to 20 chicks through this lane observing the size at each pass until a
number repeats often. The bird size that is used is the maximum bird size
plus one. If the maximum number is way out (3 points or above) in relation
to the maximum size column, disregard this test and repeat. The average
sizes are also the default sizes: Small =8, Medium =9, Large =10.
When calibration is complete, press ENTER to exit, and CLEAR to
clear the memory. These sizes must be written into the memory through the
setup menu, <9> key.
10
<4>KEY (Chicks Per Hour)
Pressing this key while the system is running, displays the current
processing speed in birds per hour. The screen is updated every two
seconds. To exit this screen press and hold the Enter key until it returns to
the main menu.

<5>KEY (Diagnostics Menu)
With the system stopped, tests can be made to the motor and
pneumatic controls. It is recommended that these tests be done on a daily
basis as part of a preventive maintenance procedure. The following
functions are available.

Sub Menu Keys:

1. Conveyor Test : Turns conveyors on, press the Enter key to stop the
motors.

2. Deflector Test : Activate all four deflectors, all four should activate
simultaneously.

3. Box Loader : Opens box stop, releases one box with each press.

4. Sensor Test : Displays the status of each sensor. Display AB4321 on the
screen, chick boxes should be in position for these tests to prevent
constant beeping of the alarm. When each lane sensor is tested, the
corresponding lane deflector operates.

Press ENTER to return to the main menu.

<6>KEY (End of Flock)
This key will transfer box counts to the total count, eject the current
box and start a new box. You must choose the box fill option in the setup
menu, <9>key.

<7>KEY (Spray Vaccinator)
This key turns the IB Spray Vaccinator off or on.

<8>KEY (Display Parameters)
Use this key to view settings daily before starting a production run.
These settings (system parameters) are critical for proper operation. The
following system settings are displayed:

A) Bird / Box =100 (Default Setting)
B) Bird Size =Small =8, Medium =9, Large =10.

(If for any reason these numbers need to be restored or changed, it must be
done manually using the setup menu, <9> key).
11
<9>KEY (Setup Menu)
Displays the following setup screen: The system must be stopped for
you to change the system parameters.






CHANGING SYSTEM PARAMETERS

To change the system parameter settings, simply choose the corresponding
number.

1. Time Enter the time, HH MM SS, in 24-hour format. Use the left and right
arrow keys to move between the intervals after the numbers are typed
in.

2. Date Enter todays date YY MM DD.

3. Birds / Box Enter the number of birds required per chick box. The
minimum value is 50 and the maximum value is 150. Default =100. After
entering the number of birds per box, the computer prompts for an
adjusted percentage between 0 & 15%. This percentage is used primarily
for the flock management database to calculate the adjusted birds per
box column. For example, if you supply 102 birds per box, but only bill
for 100 (98%), enter a percentage of 2.

4. Bird Size For accurate counting of birds, especially when two or more
birds are bunched together, the proper bird size value has been entered.
This number is determined through Bird Size Calibration, the Quad Boxer
allows you to store three different bird sizes, i.e. small, medium, large.

5. Finish 1: Fill-up last box, 2: Dont fill last box.

6. Unit This option is used to identify a machine when you are printing a
report.

7. Auto For future use

Press ENTER to exit this screen

CLEAR KEY
Clear all counts and resets to 0, clears all counts in memory. Perform
this function at the beginning of each day or the end run of the present day
will be added to previous days flocks. The system prompts you for
verification. Stop system to perform this function.
1 Time 2 Date 3 Birds / Box 4 Bird Size
5 Finish 6 Unit 7 Auto ENTER to exit
12
<0>KEY
Service number, function is not available for end user.

LEFT ARROW KEY
Used primarily for box advance and can only be used when system is
stopped. It is also used as a character edit key under various entry screens.

RIGHT ARROW KEY
Used primarily to bleed and flush the IB Spray Vaccinator. It is also
used as a character edit key under various entry screens.

<ENTER>KEY
Accepts entries and functions, exits menus


ERROR CONDITIONS

The system contains four distinct error codes. All these conditions
stop the system until the error condition is corrected. These measures
ensure bird safety. The following is a summary of the error conditions along
with steps to correct them.

ERROR #1: ALARM SIGNAL 3 SHORT BEEPS, NON-FATAL ERROR

MESSAGE: A NEW BOX IS NOT READY TO LOAD
Add new box to the conveyor

This condition occurs when an empty box is not in position to be loaded by
the powered conveyor. To correct this error condition, place empty boxes
onto the powered box conveyor. Once the computer senses the box, it will
move the box into position and restart the system automatically.

ERROR #2: ALARM SIGNAL 2 SHORT, 2 LONG BEEPS, FATAL ERROR

MESSAGE: Q-BOX OVERLOAD SYSTEM STOPPED
Return chicks to the infeed conveyor to be recounted

Press ENTER to exit

This condition occurs when there are no birds passing through the fill lane
causing more then the set maximum birds to enter the queue box (set to a
maximum of 65 chicks). This is a very rare occurrence. Pressing ENTER will
reject that count, release the box and return the chicks to the infeed
conveyor to be recounted to ensure accuracy.



13
ERROR #3: ALARM SIGNAL 1 SHORT, 1 LONG BEEP, NON-FATAL
ERROR

MESSAGE: BOXES DID NOT MOVE ! SYSTEM STOPPED
Check box loader

Press ENTER to exit

This condition occurs when for some reason the boxes did not move into
the fill position fast enough, or boxes may have moved but the sensors may
need re-adjustment. To correct, check for box jams, broken boxes and or
check the box sensors for proper operation. Press the ENTER key to restart
the system.

ERROR #4: ALARM SIGNAL CONTINUOUS LONG BEEPS, FATAL ERROR

MESSAGE: SENSOR # ? IS BLOCKED OR DIRTY
Press ENTER to continue

A sensor-blocked error usually occurs immediately after a box has been fed
incorrectly. Sometimes when the system is stopped, a bird happens to be
sitting directly underneath and blocking the sensor. Rarely, dirt will collect
on the sensors causing blockage. In both of these situations, clear the
appropriate sensors. Looking from the front of the machine towards the
rear, the sensor order is from left 4 3 2 1, pressing the ENTER key will
activate another error:

THE SYSTEM HAS BEEN STOPPED FOR SAFE CLEANING, MANUALLY RE-
COUNT THIS BOX. This count will be rejected, return the chicks to the
infeed conveyor for recount.

Press ENTER to continue, then manually restart the system.















14
SPECIFICATIONS AND MAINTENANCE

LUBRICATION & ADJ USTMENTS

Air Flow Requirements:
Plant Air 50 to 80 PSIG Dry Filtered Air
Diverter Pneumatics Regulated at 14 to 20 psi.
The lowest operating pressure is desirable for gentle handling of chicks
Box Stop 50 to 60 PSIG

Air System Lubrication: Turn off air supply at valve
Remove tubing from outlet port of air filter or remove cap from tee fitting
(mounted to the left of the main electrical panel). Place 8 to 12 drops of
pneumatic tool oil (i.e. #27 hydraulic oil, 3 in 1 oil) into the line or fitting.
Remove tubing at the top inlet port of each diverter air cylinder and insert a
few drops of oil every three (3) months, or as necessary.

* * DO NOT USE PRODUCTS SUCH AS WD40 * *
IT WILL CAUSE PREMATURE FAILURE OF THE
AIR CYLINDER & VALVE SEALS

Flow Control Adjustment:
The MAC valves used on this machine have ports identified as A & B, it also
has air flow controls built into the valve body which are used as cushioning
devices to control cycling speed of the air cylinders. Air flow is restricted
when the opposite flow control needle valve is screwed inward, i.e. If the
piston on a deflector is slamming on the upstroke (port A), adjusting the
needle inward for port B restricts the air flowing back through port A causing
the piston to be cushioned. Screwing in the needle valve at port A cushions
the piston coming down as it restricts the air flowing back through port B.
All adjustments to the screws must be done as gently as possible to
prevent damage to the valve seal if the screw bottom is out.

From the closed position back off the needle half a turn at a time, cycle the
piston and adjust until desired speed is achieved. In the center of the coil
housing there is a small (3 mm) round hole, within that hole is a clear plastic
disk. Using a small pointed object (such as a screwdriver or pen tip)
depressing this disk, cycles the circuit when the pistons are moving freely
up and down without slamming hard at the end of each stroke.

Chick Deflectors:
Valves # 1, 2, 3 and 4 have been adjusted to approximately 1 to 2 turns
from fully closed on both ports A and B. All adjustments should be done
from a fully closed position. Valves #5 and 6 are fully open to line pressure.



15
SENSOR ADJ USTMENT INSTRUCTIONS

In order to properly adjust the lane sensors and bird size setting it is
important to understand how the Kuhl Chick Boxer counts chicks.

The goal in any counting application is to achieve some sort of
separation between object and some stability with each object. If we were
counting bricks or beer bottles, this task would be straightforward. With
chicks, the task is more challenging, the guarantee of stability and
separation are more difficult, even more so in high volume situations.

The Kuhl Boxer incorporates four lanes with two or three levels of
conveyors to get the chicks in single file and with some space between
each chick. Separation between each chick at the rated Boxer speed should
occur with 80 90%of the total chicks. The computer and sensors must be
able to count the chicks that are grouped together.

Instead of looking for a change of sensor state, as you would with
well separated objects, we measure the time it takes for a chick or group of
chicks to pass through the sensor beams. This time, which is taken in 10ms
increments, is divided by a present bird size value to achieve the count. The
following integer math is performed by the computer during the counting:

Example A : Bird Size Setting =9
One chick passes the sensor; Computer measures 7 time units (i.e. 70ms).
Result:
The system counts 1 chick.

Example B : Bird Size Setting =9
Two chicks pass through the sensor: Computer measures 12 units (120ms)
(i.e. chicks are close together).
Result:
The system will count 2 chicks.

Example C : Bird Size Setting =9
One large chick passes through the sensor; Computer measures 9 units (i.e.
90ms). If a chick tumbles excessively through the sensor, the computer
could measure a longer time value.
Result:
System will count 2 chicks.

This example shows what happens when the bird size is set too low
or when there is excessive tumbling. A bird size setting of 10 would have
produced a single count.

16
In low volume situations, bird separation could occur 99%of the time.
In this case, by leaving the bird size setting to a high value the computer
would guarantee a single count for each chick.

Another key factor that affects bird size selection is main conveyor
belt speed. The slower the speed, the higher the birds size, conversely, the
faster the belt speed, the smaller the bird size. The factory default belt
speed on a 40k / 60k Boxer is 302 feet per minute. The default bird sizes
that work best with this speed are 8 for small, 9 for medium and 10 for
large. If you are running a belt at a different speed, (i.e. 60 hz motor with 50
hz power) you will have to adjust these bird size settings.

As discussed earlier, bird tumbling and overall poor bird separation
will affect counting accuracy. If the sensors and computer can see gaps
between chicks, 100%accuracy can be achieved. 100%accuracy can also
be achieved with multiple chicks between gaps as long as the bird size is
properly selected and the sensors are properly adjusted.


To reduce bird tumbling i t is important abide by the following guidelines:

A) The peek birds per hour must not exceed the boxers rated speed, i.e.
if for 5 seconds the bird flow hits a peek of 70000 chicks per hour on
a 60k boxer, the accuracy for the current box may be off.

B) The chicks must be partially dry, excessively wet chicks can make the
blue tubes sticky, and restrict bird flow.

C) Chicks must be spread evenly across all four lanes. If two lanes are
getting 80%of the chicks, the machine speed must be de-rated.


Calculating boxer accuracy

With the four-lane defector design, there must be a certain space
between chicks in order for accurate chick placement between movements
of the chick deflector. If two chicks pass through the sensor while the
deflector goes down, both chicks will be placed in the box. This improper
chick placement could potentially occur across four lanes. The chicks will
be counted properly by the computer, but the individual box count will be
off. In a low volume situation, this is not a problem, and most boxes will
have the proper box count.

The chick exchange problem will reduce as box counts that may be
off between 1- 5 chicks. Most of the time it is only off by one chick. If you
count ten consecutive boxes, you will see that they average out. If you
count more than ten stacks, true boxer accuracy can be reached.
17
Lane Sensor Cleaning

The most common problem with poor chick accuracy is improper
lane sensor adjustment and or a dirty, scratched sensor lens. It is very
important to clean sensors with a soft non-abrasive cloth using a glass
cleaner. Dirty or scratched lenses will affect sensor sensitivity.

Sensor sensitivity is extremely important. If the sensor sensitivity is
set too low, you risk missing a chick. If it is set too high, dirt on the belt or
the belt itself may be picked up. The best way to adjust the sensors is to
pass one small chick, at a time, down the lane being adjusted. Verify that
the sensor light activates each time a chick passes through the sensor
beam.

Some customers adjust the sensitivity such that a chick is not missed,
but a small piece of an eggshell is. This is a very fine adjustment and
requires frequent testing as the sensor sensitivity can float up to 20%. We
will be releasing software in the near future that incorporates a more
advanced eggshell rejection system.

The sensors have been adjusted at the factory, however, if your
counting accuracy drops, you should follow this procedure to re-adjust the
sensors.

Turn the quad boxer computer on:

1) Remove the top cover from the sensor assembly bracket, use a 5/16
wrench to remove bolts.

2) Ensure that all four sensors are:
Securely fastened to the assembly
At the same level with all indicator lights pointed in the same
direction, for example, facing the rear of the machine.

3) Place the main blue lane assembly in the UP position. Attach an 18
long piece of I wide standard masking tape along the width of the
main belt. Do this at the back idler pulley, so that you can ensure that
the tape is evenly adhering to the belt. The belt must be dry and
clean.

4) Place the blue lane assembly in the normal working position. With the
computer turned on and the system energized, turn the motors on
using the AUTO / MANUAL over-ride switch.

5) Adjust the sensitivity using the supplied jewelers screwdriver:
Slowly turn the adjusting screw on each lane sensor counter-
clockwise until it stops. The indicator light should be off at this
18
point. (The adjusting screw is located directly under the indicator
light on each sensor)
Slowly turn the adjusting screw clockwise until the indicator light
comes on, the result of sensors sensing the masking tape each
time it passes.
Now slowly back off the screw until the sensor cannot sense the
masking tape causing the indicator light to turn off, this is a very
fine adjustment.

6) Repeat Step 5 for the remaining lane sensors.

7) Once all the sensors have been adjusted turn off the main belt and
remove the masking tape. Turn on the boxer and count chicks one at
a time on each lane to verify that the system has not missed any
counts. If you are missing counts, try increasing the sensitivity.

8) Replace sensor cover and bolts.


BOX POSITION SENSOR ADJ USTMENT

Turn the quad boxer computer on:

1) Ensure that, the box sensors are securely fastened tot the box
positioned conveyor and that you can see the sensor indicator light.

2) Adjust the sensitivity using the supplied jewelers screwdriver:
Slowly turn the adjusting screw on each sensor (located directly
under the indicator light) counter-clockwise until it stops. With a chick
box positioned in front of the sensor, the indicator light should be off.
Slowly turn the screw clockwise until the indicator light comes on, the
result of the sensor sensing the positioned box. Then turn the screw
again clockwise to ensure that the sensor will properly sense boxes
that are deformed or damaged.

3) Slide the chick box out of position and verify that the indicator light
has turned off. If not, the sensor may be picking up a reflection from
some object. Slowly turn the sensor adjustment counter clockwise
until the indicator light turns off again and repeat the procedure. Verify
that the sensor still senses a chick box as it passes over the sensor

4) Repeat Steps 2 and 3 for the other box sensors.

Note:
Perform this test on all box styles and colors. A darker colored box
Will require more sensor sensitivity compared to the lighter colored
boxes.
19
SYSTEM SPECIFICATIONS

MOTORS

Box Feed Conveyor hp 67 rpm Flange Mounted Sealed Gear
Main Drive hp 189 rpm Foot Mounted Sealed Gear
Middle Conveyor hp 142 rpm Flange Mounted Sealed Gear
Top Conveyor hp 67 rpm Flange Mounted Sealed Gear
Voltage Rating 208v
3
60 hz 5 wire

All motors are independently protected by overload protectors in the
control box. You must manually reactivate the overload device if the motor
trips the overload limit. Please refer to the motor manual supplied with the
quad boxer for any maintenance information.
The flange mount motors are mounted on adjustable torque arms.
These toque arms allow the motor to move freely with the shaft, thus
preventing the motor bearings from absorbing any abnormalities in the
shaft. The lock nut used in shipping MUST BE LOOSENED OFF to allow
clearance at the torque arm adjusting bolt and facilitate free motor
movement and backlash.

If the motors are removed, always make sure that there is a coating of ANTI
SEIZE type compound on the keyed drive axle at re-assembly.

THE CHAIN AND FRONT BEARINGS SHOULD BE GREASED AT LEAST
ONCE A MONTH. PRIOR TO DOING THIS, THE CHAIN GUARD HAS TO BE
REMOVED.

ALL SIDE COVERS MUST BE IN PLACE ON THE QUAD BOXER WHILE THE
MACHINE IS ON.

THE CHAIN GUARD ON THE MAIN HIGH SPEED BELT MUST NOT BE
REMOVED UNLESS IT IS BY A QUALIFIED MAINTENANCE PERSONNEL AT
TIME OF SERVICE ONLY.

BEARINGS AND SHAFTS

Wash-down rated pillow block bearings are used on all shafts. 1
pillow blocks are used on drive and idler rollers and 1 3/16 on the box feed
conveyor shafts. All bearings must be greased at least once a week and
more frequently when high-pressure (over 150 psi) washers are used. We
recommend a USFDA approved waterproof synthetic base grease with
Teflon. This item is available from Kuhl Corporation. After lubricating the
bearings, remove excess grease from outside the bearing housing to
prevent grease from coming into contact with the belts.

20
CONVEYOR BELTS

Box conveyor belt Intralox Series 900 Acetel, ApproxiIimately 25
Top conveyor belt 20 x 50 with dual V-Guides
Middle conveyor belt 20 x 70 with dual V-Guides
Main conveyor belt 20 x 106 with dual V-Guides

Conveyor belts only need enough tension to prevent slippage. Over-
tightening will reduce the life of the belts and bearings. The v-guides ensure
that the belts will track properly. The belt expands or contracts slightly over
the first few weeks of operation and it will require re-tensioning when this
occurs.
Replacement belts are split seam. To install a new belt, simply cut the
old belt off and loosen the bolts at the idler bearings, and slide the roller.
After installing a new belt, re-tension by adjusting both sides of the shaft as
evenly as possible.


PNEUMATICS

The pneumatic control system incorporates a manual safety lock out
valve with a .5 micron filtration with automatic drain. Five Bimba air
cylinders controlled by a (6 bank) MAC Valve Assembly mounted within the
main electrical panel (5/32 OD tubing is used for the 4 deflector cylinders) &
(1/4 OD tubing is used for the box stop cylinder). The sixth valve supplies
the control air for the IB spray vaccinator.
A filtered dry regulated air supply of 50 to 60 PSI is required for proper
operation. This pressure is split at the MAC Valve Assembly where the
pressure is regulated to approximately 14 to 18 psi for the four diverter air
cylinders.
Air system lubrication is required every three months. Remove the
tubing or cap at the outlet port of the filter, inject about 8 to 12 drops of air
tool or light hydraulic oil into the tube and reinsert the tube or recap the
fitting. The flow controls have been pre-set at the factory and may require
periodic adjustment. This should be done by a trained technician.
Each valve has a test button that allows cycling of each individual
cylinder. The solenoid is driven by a 24 VAC signal from the computer. The
computer incorporates diagnostic functions that allow testing of the
pneumatics. For technical help or information please call, (908) 782 5696.








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KUHL 40K / 60K CHICK BOXER
SERVICE BULLETIN #001


TESTING SENSORS AND COMPUTER COUNTING ACCURACY:

Parts & Tools Required

18 foil tape (2 wide)
Available in spare parts kit or at local hardware store

Sensor input chip #MC14490
For ver.1, 2 & 3 motherboards ONLY (IE, stainless steel computer box)

1) Ensure that the sensors are properly adjusted. Refer to the sensor
adjustment instruction sheet in this manual or, if necessary, contact
the support line at (519) 652-0808.

2) Lift the blue lane guide assembly on the main belt and carefully
adhere foil tape horizontally on the belt (the belt must be clean and
dry). Only remove the paper backing as you attach the tape to the
belt. Use skid plate as a hard surface for adhering the tape.

3) Load empty boxes in to the counter and start the system as normal.
Each revolution of the belt should generate 4 counts on the display
panel. Run the boxer for a total of 60 revolutions. The boxer should
display 240 counts after this test.

4) If the system does not count properly, clear the counts and repeat the
test.


Try the following if the system does not count properly:

Test each sensor with the sensor test function under diagnostics, <5>
key on keypad.

Clean the sensors with rubbing alcohol and a soft cloth.

Replace the sensor input chip on the main green computer
motherboard (#MC14490 For ver.1, 2 & 3 motherboards ONLY ).

Try replacing CPU board (4 square blue board in spare parts kit)

Contact the Kuhl Boxer Support Line @ (908) 782-5696.


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INSTALLATION & USE of VER. 2.9 CHICK BOXER SOFTWARE

This software upgrade allows the Kuhl 40, 60 and dual boxer to
support various non North American standard chick boxes (i.e. four corner,
paper, ect.). The following steps will have to be done in order to use this
software version.

1) Install the supplied sensor bracket on the current box stop and move
fill box sensor from current position to this new box sensor bracket
(i.e. sensor at the front of the machine).

2) Install new EPROMs onto CPU board, configure software settings (see
installation notes below).

3) Possible upgrade of box stop to allow for four corner chick boxes.

EPROM Installation Instructions:

1) Turn Boxers power off.

2) Open cover on computer.

3) Carefully remove 4 square CPU card from motherboard.

4) Using chip puller supplied in the spare parts kit, remove two EPROMs
on 4 square CPU card. Pay attention to chips A and B placement
along with chip orientation (i.e. notch on EPROM).

5) Install new EPROMs into sockets. Do not install backwards and be
careful not to bend any pins. Ensure that the chips are well seated in
the board.

6) Re-install CPU card onto motherboard. Pay close attention to board
orientation and pin to socket connection.

7) Double-check your work, then close cover

8) Turn on boxer and ensure that the computer turns on properly.

9) Go to setup menu, <9> key on keypad.

10) Check all system settings:

Verify the bird per box setting. For a four corner box, this setting must
be set to the qty. of chicks placed in the first half of the box (i.e. 50
chicks for a 100 chick box).
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Verify the small, medium and large bird size setting (settings depend
on belt speed, defaults are 8, 9, 10).

This software has a new setting, i.e. #7 SCOOP DELAY. You have a
choice of a delay setting of 1 to 30. Each increment represents a
33ms delay from the time the box stop closes and the four deflectors
to open. This time delay is critical for short distance travel (i.e. four
corner boxes). Use a low value (i.e. between 1 and 5) for four corner
boxes.

Under system setting #5 choose the fill box method, either 1 of 2, then
after pressing the enter key, choose the end of flock method,
i.e. 1- use next flock (your current method) or 2- Select flock.

Notes on Box sensor algorithm and Box sensor adjustment:

In order to accommodate different box styles we have changed the box
movement detection algorithm in the software. It is important to understand
the following logic in order to properly adjust the box sensors.

Start System:

Check the Que. box sensor for box: (sensor behind/next to control
panel) Box present: Proceed No Box: Box Not Ready to Load Error

(This error occurs just prior to the deflectors activating)

Check Fill Box Sensor for Box: (Sensor on new bracket) Box
Present: Proceed No Box: Box Not Ready to Load Error

When count reaches Birds per box limit Open Box Stop Close Box
Stop When Fill Box Sensor is off. Delay (i.e. between 130 on setup
menu or 33ms 990ms) Open all four deflectors.

If box did not move
Stop the system
Display Box did not move error


The fill box sensor must be adjusted, both physically and
electronically (i.e. with the sensitivity adjustment) so that it only picks up the
side of the box. You can also adjust the speed by which the box stop goes
up and down by adjusting the sensitivity and location of this sensor.



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4.02 SOFTWARE UPGRADE
(FOR USE WITH INFARED SENSORS)

THE 4.02 SOFTWARE WITH THE ADJ USTABLE MARGIN IS MORE
ACCURATE AT HIGHER SPEEDS AND ALLOWS CUSTOM SETTINGS FOR
DIFFERENT BREEDS OF CHICKS.

4.02 SOFTWARE ALLOWS THE ADJ USTMENT OF THE MARGIN, WHICH IS
THE SIZE DIFFERENCE BETWEEN SET BIRD SIZE AND WHAT THE
COMPUTOR SEES.

EXAMPLE:
BIRD SIZE SETTING
SM =8, MED =9, LG =10

MARGINS SETTING
SM =5, MED =6, LG =6

THE MARGIN IS AUTOMATICALLY SET AT +1, DEPENDING UPON THE
NUMBER BEING ODD OR EVEN.

EXAMPLE OF AUTOMATIC SETTINGS:

SIZE 8; MARGIN 5
SIZE 9; MARGIN 5
SIZE 6; MARGIN 4
SIZE 7; MARGIN 4

WE HAVE FOUND THAT SIZE 9 SETTING WITH MARGIN 6 IS BEST. THIS
SETTING MEANS: ANYTHING EQUALTO BIRD SIZE 15 AND LOWER IS
COUNTED AS 1 & ANYTHING EQUALTO BIRD SIZE 16 AND HIGHER IS
COUNTED AS 2. THIS REFERS TO SIZE AND MARGIN.

THE 4.02 SOFTWARE IS ALSO QUICKER THAN THE OLDER VERSIONS,
ALLOWING THE COUNTERS TO COUNT AT A HIGHER CAPACITY.

EXAMPLE:

ONE CUSTOMER HAS AN 80K COUNTER, WITH INFARED SENSORS, THAT
COUNTS OVER 100K AND IS STILL WITHIN THE GUIDELINES, WITH LESS
THAN PERCENT ACCURACY.

A SECOND CUSTOMER HAS A 60K COUNTER, WITH INFARED SENSORS,
THAT PEAKS OVER 90K AND IS STILL WITHIN THE GUIDELINES WITH 1
PERCENT ACCURACY.
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