Crowd Gate Installation And Operation Manual Calf-Star 4324 N. County Road P. New Franken, WI 54229 Phone: 920-866-2485 Email: ...
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
Crowd Gate
Installation And Operation Manual
Calf-Star
4324 N. County Road P.
New Franken, WI 54229
Phone: 920-866-2485
Email: info@calfstar.com
Website: www.calfstar.com
September 2015
Calf-Star Crowd Gate 12 Calf-Star Crowd Gate
Contents
1. Introduction........................................................................................................... 4
1.1 Introduction .........................................................................................................................4
2. Component Identification .................................................................................... 5
3. Safety ..................................................................................................................... 6
3.1 Safety Alert Symbol And Signal Words .............................................................................6
3.2 Installation Hazards .............................................................................................................6
3.3 Operational Hazards ............................................................................................................6
3.3.1 Prepare For Emergencies ...........................................................................................7
3.4 Maintenance Hazards ..........................................................................................................7
3.5 Pressurized Air Hazards ......................................................................................................7
3.6 Hazards From Modifying Equipment..................................................................................7
4. Assembly And Installation ................................................................................... 8
4.1 Assemble Structure .............................................................................................................8
4.2 Install Structure ....................................................................................................................8
4.3 Install Gate ............................................................................................................................9
4.4 Install Air Fittings And Hoses ...........................................................................................10
4.5 Install Air Line Track ..........................................................................................................10
4.6 Chain Drive Units ...............................................................................................................11
4.7 Drive Unit Bumpers............................................................................................................11
4.8 Fill Oilers .............................................................................................................................12
4.9 Level Structure ...................................................................................................................12
4.10 Crowd Gate Air Control Operation .................................................................................12
5. Operation............................................................................................................. 13
5.1 Crowd Gate Operation .......................................................................................................13
6. Maintenance ........................................................................................................ 14
6.1 Lubrication..........................................................................................................................14
6.2 Fill Oilers .............................................................................................................................14
7. Wiring Diagrams ................................................................................................. 15
7.1 Wiring Without PLC ...........................................................................................................15
7.2 Wiring With PLC .................................................................................................................16
Calf-Star Crowd Gate 31. IntroductIon 1.1 IntroductIon Congratulations on your purchase of a Calf-Star Crowd Gate. This equipment has been designed and manufactured to meet the needs of a discriminating buyer. Safe, efficient and trouble free operation requires that you and anyone else who will be operating or maintaining the equipment, read and understand this manual. Use of the equipment outside of the intended use, or without written approval from Calf-Star is not covered by our performance guarantee, nor will damages caused be covered by our warranty. Calf-Star cannot be held liable for consequential damages, including, but not limited to, loss of production, personal injury or property loss. Installation, setup, operation, maintenance and repairs must be performed by qualified personal only. Modification and tampering and/or the use of unapproved spare parts will exempt Calf-Star from any and all responsibility and will void the warranty. 4 Calf-Star Crowd Gate
2. component IdentIfIcatIon
B D B
C G
F
E
H
A A
I
A. 4 Inch Channel (Supplied By Customer)
B. Drive Unit
C. Structure
D. Air Cylinder (4)
E. Drive Shaft
F. Drive Motor
G. Cylinder Oiler (4)
H. Tension Rods (2)
I. Gate
Calf-Star Crowd Gate 53. Safety 3.2 InStallatIon HazardS
3.1 Safety alert Symbol and SIgnal ^ WARNING
WordS Prevent serious injury or death.
You must read, understand and follow the instructions
in this manual. Electrical and mechanical installation
must be performed by qualified
The safety information in this manual is denoted by technicians.
the safety alert symbol:
Installation must conform to all national,
^ local, and provincial codes and standards.
This symbol means ATTENTION! BECOME ALERT! ^ WARNING
YOUR SAFETY IS INVOLVED! Prevent serious injury or death.
The level of risk is indicated by the following signal
Use adequate lifting devices to raise,
words:
move and install equipment.
^ DANGER 3.3 operatIonal HazardS
DANGER - Indicates a hazardous
situation, which, if not avoided, WILL ^ WARNING
result in death or serious injury. Safely operate equipment.
Allow only properly trained and qualified
^ WARNING personnel to operate this equipment.
WARNING - Indicates a hazardous
situation, which, if not avoided, could Carefully read all safety messages in this manual and
result in death or serious injury. on equipment safety signs. Keep safety signs in good
condition and replace missing or damaged safety
signs.
^ CAUTION
CAUTION - Indicates a hazardous New equipment components and repair parts must
situation, which, if not avoided, could include the current safety decal.
result in minor or moderate injury.
Learn how to properly operate equipment. NEVER
operate or work around this equipment without proper
NOTICE instruction, while fatigued or under the influence of
alcohol, prescription or non-prescription medication
NOTICE - Indicates a situation that could
or if feeling ill.
result in damage to the equipment or
other property. Keep your equipment in proper working condition.
Know the regulations and laws that apply to you
and your industry. This manual is not to replace any
regulations or laws. If you do not understand any part
of this manual, contact Calf-Star at 920-866-2485.
6 Calf-Star Crowd Gate3.3.1 prepare for emergencIeS 3.5 preSSurIzed aIr HazardS
Be prepared in case of emergencies. Compressed air can cause serious injury or death.
Keep a fire extinguisher and first aid kit close to the
equipment. ^ WARNING
Do not use compressed air for any other
Keep emergency phone numbers close to, or
purpose than that for which it is provided.
programmed in your phone.
Know your address so emergency services can locate Never direct a stream of compressed air
you if an emergency arises. towards your body or the body of another
person.
Before using, check all components for
damage or wear. Verify connections are
tight and all hoses and lines are in good
condition.
3.6 HazardS from modIfyIng equIpment
3.4 maIntenance HazardS
Do not alter or modify equipment in any way. Altering
^ WARNING or modifying may cause your equipment to be unsafe
and may void the manufacturers’ warranty.
Prevent serious injury or death.
Contact Calf-Star before altering or modifying
Equipment maintenance must be equipment.
performed by qualified technicians.
Before performing service, maintenance or
adjustments, lockout power source and close air
pressure supply.
Always wear face and/or eye protection, safety shoes,
and other protective equipment appropriate for the
job. Follow company stated safety procedures and
policies.
Always use Calf-Star replacement parts.
Calf-Star Crowd Gate 74. aSSembly and InStallatIon engage coupler on motor. Tighten coupler set
screws.
^ WARNING
Prevent serious injury or death.
Electrical and mechanical installation
must be performed by qualified
technicians.
Installation must conform to all national,
local, and provincial codes and standards.
4.1 aSSemble Structure
^ WARNING 5. Install two tension rods (F) on bottom of structure.
Prevent serious injury or death. Install nuts and snug against brackets. Do not
tighten nuts at this time.
Use an adequate lifting device to setup
and install equipment.
Use of inadequate equipment may result
in serious injury or death.
^ WARNING
Prevent serious injury or death.
Never go under equipment suspended by
a lifting device.
Unassembled structure pieces weigh approximately 4.2 InStall Structure
35 lbs per foot. Measure the length of one end piece
and multiply by 35 to get the weight of that piece.
^ WARNING
Use an adequate lifting device to setup and install Prevent serious injury or death.
equipment.
Use an adequate lifting device to setup
1. Center section (A) is pre-assembled to one end and install equipment.
section (B). Set assembly on a level surface.
2. Move other end section (C) into position, close to
Use of inadequate equipment may result
center section. in serious injury or death.
3. Slide shaft through hole and install coupler (D)
and shaft key on shaft. Place sections together
^ WARNING
and install ½ x 1½ bolts, lock washers and nuts Prevent serious injury or death.
(E).
Never go under equipment suspended by
4. Install spyder in coupler and slide coupler (D) to a lifting device.
8 Calf-Star Crowd GateAssembled structure weight is approximately 35 lbs 1. Attach an adequate lifting device to gate and raise
per foot. Measure the length of the structure and gate into position.
multiply by 35 to get the total weight.
Gate attaching brackets will be aligned with cylinder
Use an adequate lifting device to raise and install mounts on top rail of structure.
structure.
2. Attach gate (A) to rear structure tube (B) with
1. Attach an adequate lifting device to structure bearing blocks (C) and ½ x 6½ bolts, lock washers
assembly and install on track. and nuts (D). Gate will be position between
structure supports (E) and can be installed in only
2. Position retainer bracket (A) ½ inch from bottom of one position.
channel, on inside corner of drive housing. Mark
hole locations and drill ⅝ inch holes to align with
predrilled holes in drive housing. Install ½ inch
bolts (B) and lock washers. Repeat this step for
remaining three retaining brackets.
3. Attach base end of cylinder to mount with ¾ x 3
inch bolt (F) and lock nut.
4. Attach rod end of cylinder to gate with ¾ x 5 inch
bolt (G) and lock nut.
4.3 InStall gate
^ WARNING
Prevent serious injury or death.
Use an adequate lifting device to setup
and install equipment.
Use of inadequate equipment may result
in serious injury or death.
^ WARNING
Prevent serious injury or death.
Never go under equipment suspended by
a lifting device.
Calf-Star Crowd Gate 96. Install ½ inch hose (G) and ½ inch hose (H). Hose
length to be determine by installer. Repeat this
step for remaining air cylinders.
5. Install oiler (H) approximately 6 inches from
cylinder. Attach to structure top tube with hardware
provided.
6. Repeat steps 3-5 for remaining cylinders.
7. Apply pipe sealant to threads and install ½ inch
4.4 InStall aIr fIttIngS and HoSeS elbow fittings (B) into drive housing threaded
ports. Orient top fitting forward and bottom fittings
Each cross pipe is charged with air during operation.
downward. Left drive housing is illustrated below.
Top pipe carries air for lift/lower functions. Lower front
Your application may have the threaded ports on
pipe carries air for forward motion. Lower rear pipe
the right side drive housing.
carries air for reverse motion.
1. Apply pipe sealant to threads and install ½ inch
straight fittings (A) and ½ inch elbow fittings (B)
into structure. Push hose into fitting to lock. To
release hose, push ring toward fitting and pull
hose out.
2. Install hose (C). Hose is labeled number 1.
3. Install hose (D). Hose is labeled number 2.
4. Install hose (E). Hose is labeled number 4.
5. Install hose (F) between super structures sides. 4.5 InStall aIr lIne track
Hose is labeled number 3.
1. Install air line track (A) to support (B) a minimum
of 2 in. (C) from crowd gate track (D).
A E
D
F
C
B
Rear View End View Of Track
10 Calf-Star Crowd Gate2. Install liner (E) in front half of track only. 4.6 cHaIn drIve unItS
3. Route air lines (F) under liner (E) and into flexible Note: This procedure is for chain drive units only.
air line track (G)
1. Disconnect one end of chain and route over
G sprocket on drive shaft (A) inside housing as
F E A Mid Point shown. Chain must be routed under center of
wheels (B). Reconnect end of chain.
2. Repeat step for other drive unit.
Side View Of Track
Note: Depending on clearance, your track (G) may be
installed on top as shown or on bottom of support.
4. Place end of flexible air line track (G) on drive
housing track support (H). Mark location of two
holes and drill through support (H). Attach track to B B
support with two bolts and nuts. A
4.7 drIve unIt bumperS
Stop (A) is 4'' C channel (same as the track) welded
perpendicular to the track. This will assure proper
strength for stopping crowd gate and rubber bumper
mounting.
1. Weld stop (A) at the ends of each track. Mark
bumper (B) location on bracket.
2. Drill ⅜ inch hole through bumper and bracket. Bolt
5. Connect rearward travel air hose to connector (I).
bumpers to brackets.
6. Connect forward travel air hose to connector (J).
7. Connect cylinder air hose to connector (K).
B
A
Calf-Star Crowd Gate 114.8 fIll oIlerS 4.10 croWd gate aIr control operatIon
1. Remove canister (A) and fill with vacuum pump The Crowd Gate is designed to lift gate at 35-50 psi
oil until at top of sight gauge (B). Install canister. If (2.4-3.4 bar) and travel forward/reverse at 70-100 psi
temperature will be below 32° F, use Kill Frost air (4.8-6.9 bar). Air pressure settings for travel may vary
oil in canister oiler. based on size of gate and amount of force required.
For connection within the parlor, electric/air control
switches must be used. Most installation have the
crowd gate switches mounted directly in one of the
rear and/or front detacher panels. If no panel exists,
please use a water tight plastic enclosure for mounting
switches.
The base crowd gate does not come with any controls,
you must order the electric/air switches separately
from Calf Star. A PLC control system is also available
and highly recommended. The PLC Controller allows
much flexibility and control during the operation of the
Crowd Gate. The PLC Control allows the flexibility of
cycling the forward movement of the Crowd gate in
a timed event every time the parlor entrance gate is
2. Remove oiler cap (C) and fill with vacuum pump opened. For example, every time the Parlor entrance
oil. Install cap. Repeat this step for remaining gate is opened, the crowd gate will operate in the
cylinder oilers. Automatic oilers oil during reverse forward motion for a pre-determined time. This will
travel. help keep your parlor employees in the parlor prepping
the cows vs. in the holding area pushing the cows.
To calculate the operation time, calculate the space
needed for the cows on the single side of the parlor.
For example, if it is a 2x20 parlor, calculate the amount
of space occupied by 20 cows, then program the PLC
to energize for enough time to move that span. So, if
the space occupied by the cows is 10’ and the crowd
gate moves at 5’ per second, program the PLC for 2
second.
3 sets of controls will be needed; Lift/Lower; Forward;
and Reverse.
4.9 level Structure a. The Lift/Lower is controlled by a two way switch,
energized for UP, de-energized for DOWN.
Once installation is completed, the structure must b. The Forward of the Crown Gate is controlled
be leveled for proper operation. Tighten nuts (A) on by two separate switches, Forward Start and
tension rods to level structure. Visually verify that Forward Stop.
structure is level. c. The Reverse of the Crowd Gate is controlled
by two separate switches, Reverse Start and
Reverse Stop.
A remote control-box is supplied for mounting in the
back of the holding area for operation of the crowd
gate by an employee in charge of loading the holding
area. Please mount this control box in a safe location
behind the crowd gate. This remote box will be
A A redundant of the controls mounted within the parlor.
12 Calf-Star Crowd GatePlease refer the wiring diagram for connection of the Start and Forward Stop to cycle the crowd gate
controls for the crowd gate. forward to the proper position.
5. operatIon Normal Operation Without PLC Control:
1. Open parlor entrance gate.
2. Press the Forward Start switch. Once the gate
^ WARNING moves forward the correct distance, press the
Safely operate equipment. Forward Stop switch. The Crowd gate comes with
a safety over-ride that will disengage the crowd
Allow only properly trained and qualified gate if it is lifted by a cow.
personnel to operate this equipment.
As the holding area is emptied, normally the next
group of cows is loaded behind the gate. Once the
^ WARNING holding area is completely emptied, press the Crowd
Gate Up switch to lift the crowd gate above the cows
Do not operate without guards, covers heads.
and shields in place.
Once crowd gate is fully up, press the Reverse Start
switch to move the gate to the rear of the holding
^ Do not operate, work on or around this equipment area. When gate reaches desired position, press the
while under the influence of alcohol, drugs or if Reverse Stop switch.
feeling ill.
^ It is your responsibility to operate this equipment There is a safety stop switch to disengage the crowd
gate at the end of the track.
safely. You must be familiar with the equipment
and all safety practices before use. Once all the cows are ahead of the crowd gate, press
^ Do not allow untrained or unqualified people to
the Crowd Gate Down Switch to lower the gate behind
the cows. Repeat this step until all groups are milked.
operate this equipment.
5.1 croWd gate operatIon
The normal rest mode of the crowd gate will be
fully forward in the down position. This removes all
pressure on the lift cylinders and prevents undo stress
on the crowd gate. This will also minimize the risk of
hitting the crowd gate in the open/up position while
cleaning the holding area.
To Load Holding Area:
1. Lift the crowd gate to its fully up position by
pressing the Crowd Gate Up switch.
2. Press the Reverse Start to move the crowd gate
to the rear of the holding area.
3. Bring the cows into the holding area.
4. After holding area is full, lower the crowd gate to
prevent the cows from leaving the holding area.
5. Press the Forward Start switch until the cows are
contained, but not overcrowded.
Normal Operation With PLC Control
1. When parlor entrance gate is opened, the crowd
gate will automatically cycle to keep the cows
contained. If there is a large void in the holding
area at this time, manually press the Forward
Calf-Star Crowd Gate 136. maIntenance
6.1 lubrIcatIon
Lubricate 14 shaft bearings every month.
6.2 fIll oIlerS
1. Remove canister (A) and fill with vacuum pump
oil until at top of sight gauge (B). Install canister. If
temperature will be below 32° F, use Kill Frost air
oil in canister oiler.
2. Remove oiler cap (C) and fill with vacuum pump
oil. Install cap. Repeat this step for remaining
cylinder oilers.
14 Calf-Star Crowd Gate7. WIrIng dIagramS
7.1 WIrIng WItHout plc
PARLOR
V V SWITCHES
24 VDC
POWER
FORWORD
SUPPLY
120/220 VAC
N L
REVERSE
FIELD
CONNECTION
DOWN
UP
DOWN
UP
REVERSE
FORWORD
UP HOLDING PEN
FORWORD REVERSE DOWN
SWITCHES
AIR SOLENOID VALVE
Calf-Star Crowd Gate 157.2 WIrIng WItH plc
+2 4V COM 11 12 13 14 15 16 17 18 + 24V
DC
24 INPUT 8 X 24 D.C.
VOLT
D.C.
POWER
SUPPLY
YELLOW
PURPLE
YELLOW
BROWN
GRAY
GRAY
1 2 1 2 1 2 1 2 120/240 VAC
N L
Q1 Q2 Q3 Q4
BLUE
GREEN
BLACK
YELLOW
RED
ORANGE
GREEN
UP
PURPLE - IN 2 REV FWD COM + 24 IN IN L1 L2
DOWN
BROWN - IN 1 1 2
GRAY - COM
ORANGE - REVERSE
BLUE - FORWARD
YELLOW - 24 VOLT D.C.
16 Calf-Star Crowd GateYou can also read
