BouMatic Robotics MR-D1 Service Manual Download Page 203

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Maintenance

Overview

23 June 2015

Version 1.7

Part V

MAINTENANCE

18.

General information ------------------------------------------------------ 18-1

18.1.

Directions for maintenance -------------------------------------- 18-1

18.2.

Laser beam ------------------------------------------------------- 18-3

18.3.

Electronic parts -------------------------------------------------- 18-3

18.4.

Maintenance scheme -------------------------------------------- 18-4

18.5.

Symbols used in this manual ---------------------------------- 18-16

19.

Service: Commissioning, 1, 2, 3, 4, 5, 6, 7 and 8 ---------------------- 19-1

19.1.

Replacing valve flapper milk pump ----------------------------- 19-1

19.2.

Replacing short pulsation hose milking cup -------------------- 19-4

19.3.

Replacing short pulsation and water hose pretreatment cup -- 19-6

19.4.

Replacing shutoff valves in actuators 4 way block ------------- 19-9

19.5.

Replacing drain valve ------------------------------------------ 19-17

20.

Service: Continuation 2, 4, 6 and 8 ------------------------------------- 20-1

20.1.

Replacing wearing parts in pulsator cups ----------------------- 20-1

20.2.

Replacing spray filter -------------------------------------------- 20-6

20.3.

Replacing cleaning pump hoses --------------------------------- 20-8

20.4.

Replacing wearing parts regulator ---------------------------- 20-12

20.5.

Replacing wearing parts reverse amplifier milk meter ------- 20-18

20.6.

Replacing wearing parts servo vacuum valve ---------------- 20-21

20.7.

Replacing wearing parts amplifier pretreatment container -- 20-24

21.

Service: Continuation 3 and 7 ------------------------------------------- 21-1

21.1.

Replacing non-return valve 6 mm ------------------------------ 21-1

21.2.

Replacing blue and red hoses cleaning pump ------------------ 21-4

21.3.

Replacing milk hoses -------------------------------------------- 21-6

21.4.

Replacing gripper pads ------------------------------------------ 21-9

21.5.

Replacing hing pin and bearing hing -------------------------- 21-11

21.6.

Replacing wearing parts milk meter -------------------------- 21-14

21.7.

Replacing hose pretreatment cup ----------------------------- 21-20

22.

Service: Continuation 4 and 8 ------------------------------------------- 22-1

22.1.

Replacing wearing parts pulsator vacuum shut off ------------- 22-1

22.2.

Replacing hydraulic filter ---------------------------------------- 22-4

22.3.

Replacing wearing parts milk pump ----------------------------- 22-8

Summary of Contents for MR-D1

Page 1: ...Service Manual Original Service Manual Version 1 7 23 June 2015...

Page 2: ...the prior written consent of BouMatic Robotics B V This also goes for the matching drawings photo s and diagrams BouMatic Robotics B V reserves the right to make changes to parts on every moment witho...

Page 3: ...GATE OUT settings Version 1 3 Renewed BRI application Added appendices Appendix A Numbers in viewers Appendix B Wear parts Appendix C Consumables Version 1 4 New photos Adjusted specifications Moved t...

Page 4: ...d Camera calibration New maintenance schedule Version 1 7 Other pictures emergency stops New safety symbols Added photos with position new safety symbols Two post treatment sprayers on attachtool New...

Page 5: ...ral information 4 1 5 Operating box 5 1 6 Managing cows 6 1 7 Consulting attentions and reports 7 1 8 Setting system 8 1 9 Operating milking box parts manually 9 1 10 Controlling system 10 1 11 Settin...

Page 6: ...5 6 7 and 8 19 1 20 Service Continuation 2 4 6 and 8 20 1 21 Service Continuation 3 and 7 21 1 22 Service Continuation 4 and 8 22 1 23 Service Continuation 5 23 1 24 Service Continuation 1 24 1 25 Eve...

Page 7: ...TLE DESCRIPTION I General information Gives information about the requirements demanded of the user Technical properties and safety aspects of the milking box are also shown here II Operations from BR...

Page 8: ......

Page 9: ...2 1 2 1 Emergency stop 2 1 2 2 Entrance door 2 3 2 3 Safety regulations while using milking box 2 4 2 4 Safety regulations during maintenance 2 6 2 5 Safety symbols 2 8 2 6 Position of safety symbols...

Page 10: ......

Page 11: ...dth mm 2200 Netto weight kg 2600 ELECTRICITY Net connection V 3LNPE 400 Frequency Hz 50 Max power kW 11 Max current A 22 IP 55 GENERAL Loudness during production dB A 70 Ambient temperature in use or...

Page 12: ...2 Version 1 7 23 June 2015 1 2 Contact details Manufacturer BouMatic Robotics B V Address Transportweg 6 8304 AX Emmeloord The Netherlands Phone 31 0 527 78 85 00 Fax 31 0 527 78 85 99 E mail info bou...

Page 13: ...x has two emergency stop buttons see Figure 2 1 to stop the milking box in case of emergencies Figure 2 1 Emergency stop buttons Emergency stop button on milking box One emergency stop button 1 see Fi...

Page 14: ...omeone is exposed to potential injury due to their proximity to the milking box Technical problems with milking box parts whereby this can potentially lead to damage to these and others parts Effect u...

Page 15: ...is working A safety switch 1 see Figure 2 4 in the entrance door ensures that the milking box is switched off as soon as someone opens the entrance door Figure 2 4 Entrance door Additional information...

Page 16: ...ch the milking box in MANUAL or SERVICE operating mode when you enter one of these areas Never stay longer than necessary in these areas Figure 2 5 Unsafe areas Table 2 2 Unsafe areas NO COMPONENT DES...

Page 17: ...ldren and animals in the neighbourhood of the milking box especially when the entrance door to the technical area is open Cows Your cows can panic or become stressed by noise and movements in the milk...

Page 18: ...e door of the technical area is open when you are in the proximity of these areas Figure 2 6 Risk of getting wedged Description components Table 2 3 shows an overview of the numbered components in Fig...

Page 19: ...ee section 18 4 of the milking box Periodic maintenance Periodic maintenance is essential for the safety for human and animals who come into contact with the milking box Service technician The periodi...

Page 20: ...t to take notice of these symbols and not to remove them from the milking box Description symbols Below you find an overview and a description of the symbols that are present on the milking box 1 BEWA...

Page 21: ...General information Safety 23 June 2015 Version 1 7 Page 2 9 5 Wear protection gloves 6 Wear eye protection 7 BEWARE danger of becoming wedged 8 BEWARE danger of pinching...

Page 22: ...on the milking box Overview The figures below Figure 2 7 through Figure 2 21 show the positions of the safety symbols on the milking box The numbers correspond with the numbers in section 2 5 Figure...

Page 23: ...General information Safety 23 June 2015 Version 1 7 Page 2 11 Figure 2 9 Safety symbol on step transformer Figure 2 10 Safety symbol on main control cabinet 2 2...

Page 24: ...General information Safety Page 2 12 Version 1 7 23 June 2015 Figure 2 11 Safety symbol near quooker Figure 2 12 Safety symbols on detergent pump cabinet 1 5 6...

Page 25: ...tion Safety 23 June 2015 Version 1 7 Page 2 13 Figure 2 13 Safety symbol on electrobox JB1 not visible located behind blue plate Figure 2 14 Safety symbol on electrobox JB2 not visible located behind...

Page 26: ...ety Page 2 14 Version 1 7 23 June 2015 Figure 2 15 Safety symbol on electrobox JB3 not visible located behind plate Figure 2 16 Safety symbol on electrobox emergency stop not visible located behind ma...

Page 27: ...General information Safety 23 June 2015 Version 1 7 Page 2 15 Figure 2 17 Safety symbols left and right of cow tracker Figure 2 18 Safety symbols left and right of feeding trough 8 8 7...

Page 28: ...General information Safety Page 2 16 Version 1 7 23 June 2015 Figure 2 19 Safety symbols on backside of feeding trough Figure 2 20 Safety symbols between gates at left and right side of cow area 8 7 7...

Page 29: ...General information Safety 23 June 2015 Version 1 7 Page 2 17 Figure 2 21 Safety symbol on boiler 1...

Page 30: ......

Page 31: ...RNING Transport should only be performed by trained and qualified personnel Precautions Before transporting the milking box e g to a different location the precautions in Table 3 1 have to be taken in...

Page 32: ...hoisting machine does not damage the milking box WARNING Hoisting the milking box should only be performed by trained and qualified personnel ATTENTION Due to the size and weight see Table 1 1 in sect...

Page 33: ...Table 3 2 Precautions NO PRECAUTION 1 Use a crane to hoist the milking box 2 Ensure there are people supervising the correct hoisting of the package so the milking box cannot fall of the crane 3 Move...

Page 34: ...l Government regulations Dismantling and disposing of the milking box has to be done in accordance with the government regulations that apply at the moment of disposal It is important to perform this...

Page 35: ...al milking parameters 6 6 6 4 Setting individual feed parameters 6 9 7 Consulting attentions and reports 7 1 7 1 Attentions report 7 1 7 2 Conductivity attentions 7 3 7 3 Milkings reports 7 5 7 4 Sele...

Page 36: ...lly 9 5 9 4 Calibrating 9 7 9 5 Starting pulsator test 9 9 9 6 Resetting PLC 9 10 10 Controlling system 10 1 10 1 Controlling milk routing components 10 2 10 2 Controlling hydraulic components 10 4 10...

Page 37: ...Boumatic Robotics Interface BRI application is an application on the milking box touch screen to control the milking box 4 1 Functionality BRI main window The BRI main window see Figure 4 1 contains c...

Page 38: ...u can perform the following actions operating box consulting milkings 2 OPTION DESCRIPTION Cow settings Opens the COW SETTINGS window from which you perform the next actions recording cows setting mil...

Page 39: ...essible for everyone and is appropriate for performing the daily actions with the BRI application In this level you can perform all actions that are described in this User s manual Administrator Is on...

Page 40: ...justs the settings from the SERVICE window Steps To log in as administrator follow the steps in Scheme 4 1 STEP ACTION 1 Press the SERVICE option in the MENU component of the BRI main window see Figur...

Page 41: ...e 4 4 Numeric keyboard 3 Enter the administrator password As soon as you have entered the correct password the OK button 1 see Figure 4 4 appears in the keyboard The SERVICE window see Figure 4 5 will...

Page 42: ...n Steps To close the BRI application follow the steps in Scheme 4 2 STEP ACTION 1 Press the logo 1 see Figure 4 6 Figure 4 6 BRI main window A numeric keyboard appears on your screen 2 Enter the code...

Page 43: ...Boxstatus 2 Refer to Table 5 1 for a description of the components in Figure 5 1 Scheme 5 1 Consulting box status Table 5 1 Box status components NO DESCRIPTION 1 Displays the number of the respective...

Page 44: ...instance A service technician can perform maintenance activities Replace filter The farmer can now replace the filter Table 5 3 Additional information on box mode MODUS DESCRIPTION In error The box ha...

Page 45: ...aning Performs a main cleaning Milktank offline The milktank is off line for one of the following reasons is being emptied is being cleaned has a malfunction Box cleaning Performs a colostrum or penic...

Page 46: ...iltelefon You will receive an sms regarding manual assistance if your mobile phone number has been set in the WEB application Time for action As soon as the alarm for manual assistance appears you hav...

Page 47: ...for a description of the buttons Scheme 5 2 Performing manual assistance Table 5 5 Manual assistance OPTION DESCRIPTION Not now Drives the cow out of the box without milking Hold Keeps the cow maximal...

Page 48: ...in the BRI main window on the milking box from which you want to change the box control mode The BOX ID window of the respective milking box will be displayed This window contains the COMMANDS part se...

Page 49: ...cally to milk the cows Manual 2 Switches the box in MANUAL control mode The farmer attaches the teat cups manually to milk the cows Service 3 Switches the box in MAINTENANCE control mode The farmer ca...

Page 50: ......

Page 51: ...1 Setting ID parameters Steps To set ID parameters follow the steps Scheme 6 1 STEP ACTION 1 Press the COW SETTINGS option in the MENU part in the BRI main window The COW SETTINGS window see Figure 6...

Page 52: ...PONENT DESCRIPTION Name Names the cow Transponder Recognizes the cow in the milking box by the unique transponder number You have to enter here the number on the transponder preceded by 9840000 For th...

Page 53: ...ow Steps To set attach parameters follow the steps in Scheme 6 2 STEP ACTION 1 Press the COW SETTINGS option in the MENU part in the BRI main window The COW SETTINGS window will be displayed 2 Open th...

Page 54: ...this setting you overrule the value that has been set by means of the teach pendant see section 15 1 Alarm Displays an alarm when the cow enters the milking box The settings have the following meaning...

Page 55: ...PONENT DESCRIPTION Selection Sets the cow s selection to a selection room None Does NOT send the cow to a selection room Once Sends the cow once to a selection room even at NOT YET Always Sends the co...

Page 56: ...verrule the milk parameters specified in the WEB application Steps To set milk parameters follow the steps in Scheme 6 3 STEP ACTION 1 Press the COW SETTINGS option in the MENU part in the BRI main wi...

Page 57: ...ng failed In this way you avoid a number of failed milkings in a row Pre milk time Reattaches the teat cups if the milk flow is still below the required level after the specified time The teat cup rem...

Page 58: ...Milk sampling Takes a sample according one of the following settings during the current period SETTING DESCRIPTION No samples Takes no samples One sample One sample at one milking turn Optimal More th...

Page 59: ...rrule the default feed parameters set in the WEB application Steps To set individual feed parameters follow the steps in Scheme 6 4 STEP ACTION 1 Press the COW SETTINGS option in the MENU part in the...

Page 60: ...m per milking kg Specifies the minimum amount of feed during a visit to the box Eat speed Controls the dosing speed Use group settings On Feeds the cow according group settings Off Feeds the cow accor...

Page 61: ...ONS list displays milkings with attentions Steps To consult the ATTENTIONS list follow the steps in Scheme 7 1 STEP ACTION 1 Press the ATTENTIONS option in the MENU REPORTS part in the BRI main window...

Page 62: ...box access 8 Displays that the cow satisfies all activity parameters and the best time for insemination 9 Opens after selecting a line of a cow with increased activity a graph with day production and...

Page 63: ...n the BRI main window see section 4 1 The CONDUCTIVITY attentions see Figure 7 2 will be displayed below the MENU REPORTS part Figure 7 2 Conductivity attentions 2 Refer to Table 7 3 for a description...

Page 64: ...2015 Table 7 3 Conductivity attentions NO DESCRIPTION 6 Displays the percentage deviation of the average conductivity value 7 Opens after selecting a line a separate window with the following additio...

Page 65: ...ne single cow Steps To consult the MILKINGS report follow the steps in Scheme 7 3 STEP ACTION 1 Press the MILKINGS option in the MENU REPORTS part in the BRI main window see section 4 1 The MILKINGS r...

Page 66: ...isplays the yield 8 Displays the minimum expected yield 9 Displays the cause of a deviating milking see Table 7 5 10 Opens after selecting a line a separate window with the following additional data o...

Page 67: ...selection room data see Figure 7 4 will be displayed below the MENU REPORTS part Figure 7 4 Selection room report 2 Refer to Table 7 6 f r a description of the selection room report Scheme 7 4 Consul...

Page 68: ...part in the BRI main window see section 4 1 The MILK SEPARATION data see Figure 7 5 will be displayed below the MENU REPORTS part Figure 7 5 Milk separation attentions 2 Refer to Table 7 7 for a descr...

Page 69: ...attention settings and CALENDAR attention settings Steps To consult the CALENDAR attentions list follow the steps in Scheme 7 6 STEP ACTION 1 Press the CALENDAR option in the MENU REPORTS list in the...

Page 70: ...endar attention 2 Displays the cow s calendar status including the time duration of that status in days 3 Displays the attention type 4 Displays the best moment date and time to inseminate the cow 5 O...

Page 71: ...see Figure 7 7 will be displayed below the MENU REPORTS part Figure 7 7 Alarm report 2 Refer to Table 7 9 for a description of the components in the ALARMS report Scheme 7 7 Consulting Alarm report Ta...

Page 72: ...in the BRI main window see section 4 1 The feed attentions see Figure 7 8 will be displayed below the MENU REPORTS part Figure 7 8 Feed attentions report 2 Refer to Table 7 10 for a description of the...

Page 73: ...une 2015 Version 1 7 Page 7 13 Table 7 10 Feed attentions report NO DESCRIPTION 6 Opens after selecting a line a separate window with the following additional data of the respective cow a graph with d...

Page 74: ......

Page 75: ...ations from BRI Setting system 23 June 2015 Version 1 7 Page 8 1 8 SETTING SYSTEM Introduction The SETTINGS tab page see Figure 8 1 displays buttons to set the system settings Figure 8 1 Settings tab...

Page 76: ...the steps in Scheme 8 1 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the MAIN CLEANING button The MAIN CLEANING settings see Figure 8 2 will be displayed Figure 8 2 Main cleaning...

Page 77: ...DESCRIPTION First cleaning Specifies the starting time of first daily cleaning Second cleaning Specifies the starting time of second daily cleaning Third cleaning Specifies the starting time of third...

Page 78: ...s follow the steps in Scheme 8 2 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the SERVICE button The SERVICE settings see Figure 8 3 will be displayed Figure 8 3 Service settings...

Page 79: ...as soon as the water is at the temperature you set here Separation pipe length Is the length of the separation pipe in centimeters Pre cooler delay Specifies the pre cooler delay in milliseconds Tank...

Page 80: ...2015 Table 8 2 Service settings COMPONENT DESCRIPTION Spray robot db Specifies the spraying system to spray the teats 0 Sprays with the sprayers in the milking box floor 1 Sprays with the sprayers in...

Page 81: ...follow the steps in Scheme 8 3 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the CLEANING button The CLEANING settings see Figure 8 4 will be displayed Figure 8 4 Cleaning settings...

Page 82: ...he pumping time in seconds Acid total dose cc Specifies the amount of acid that needs to be applied Acid speed cc s Specifies the pump speed in cc per second Chlorine length s Specifies the duration o...

Page 83: ...re 8 5 will be displayed Figure 8 5 Feed settings 3 Select the desired milk box 1 4 Refer to Table 8 4 for a description of the FEED settings Scheme 8 4 Adjusting feed settings Table 8 4 Feed settings...

Page 84: ...ngs follow the steps in Scheme 8 5 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the SYSTEM button The SYSTEM settings see Figure 8 6 will be displayed Figure 8 6 System settings 3...

Page 85: ...System id Specifies the system ID Box id Specifies the ID of the box Gate in Specifies the entrance gate side 1 Left 2 Right Gate out Specifies the exit gate side 1 Left 2 Right 3 Both Simulate dairy...

Page 86: ...T DESCRIPTION Milk meter Specifies the milk meter 0 Old BouMatic model 1 New model with tipping scale Blood sensor Specifies the presence of a blood sensor 0 No blood sensor 1 Blood sensor present Sep...

Page 87: ...erval cleaning settings 3 Select the desired milk box 1 4 Refer to Table 8 6 for a description of the INTERVAL CLEANING settings Scheme 8 6 Adjusting interval cleaning settings Table 8 6 Interval clea...

Page 88: ...3 June 2015 Table 8 6 Interval cleaning settings COMPONENT DESCRIPTION Clean floor interval Specifies the number of box visits between two consecutive box floor cleanings 0 no cleaning 1 one visit bet...

Page 89: ...2 Press the PULSATOR button The PULSATOR settings see Figure 8 8 will be displayed Figure 8 8 Pulsator settings 3 Select the desired milk box 1 4 Refer to Table 8 7 for a description of the PULSATOR...

Page 90: ...the steps in Scheme 8 8 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the MILK SAMPLING button The MILK SAMPLING settings see Figure 8 9 will be displayed Figure 8 9 Milk sampling...

Page 91: ...conds to fill the clapper Shuttle time seconds Specifies the time in seconds to fill the sampling bottles Suck time ms Obsolete Milk pump speed cm s Specifies the speed of the milk pump Milk volume hi...

Page 92: ...follow the steps in Scheme 8 9 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the MILK SETTINGS button The MILK settings see Figure 8 10 will be displayed Figure 8 10 Milk settings...

Page 93: ...pre milk flow to start the main milking cycle Use as feedbox 0 Uses the system as a milking box 1 Uses the system as a feeding box Attach after teach 0 Does not attach after teach 1 Attaches after tea...

Page 94: ...RIPTION Milkmeter calibration Sets the calibration value for the milk meter in the single box or on the left side of the double box 0 Standard d h 0 025 cc Perc min yield Re attaches the milking cups...

Page 95: ...window you have to specify some settings with regard to this electric current Steps To set the COW DRIVER settings follow the steps in Scheme 8 10 STEP ACTION 1 Open the SETTINGS tab of the SERVICE w...

Page 96: ...driver after the specified time in msec Cow driver voltage delay Applies an electric current of the cow driver after the specified time in msec Cow driver voltage length Applies the electric current o...

Page 97: ...Steps To adjust the hydraulic system follow the steps in Scheme 8 11 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the HYDRAULIC SYSTEM button The HYDRAULIC SYSTEM settings see Fig...

Page 98: ...ess doors Controls the hydraulic pressure in bar that is applied on the gates Antifreeze minutes Starts the hydraulic pump to warm up the hydraulic fluid if the milking box has not been used during th...

Page 99: ...3 will be displayed Figure 8 13 Vacuum settings 3 Select the desired milk box 1 4 Refer to Table 8 12 for a description of the VACUUM settings Scheme 8 12 Adjusting vacuum settings Table 8 12 Vacuum s...

Page 100: ...on follow the steps in Scheme 8 13 STEP ACTION 1 Open the SETTINGS tab of the SERVICE window 2 Press the SELECTION button The SELECTION settings see Figure 8 14 will be displayed Figure 8 14 Selection...

Page 101: ...he entrance of the milking box You set the number of minutes in the ALARM component in the SETTINGS tab page Steps To set the alarm follow the steps in Scheme 8 14 STEP ACTION 1 Open the SETTINGS tab...

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Page 103: ...milking box parts manually 23 June 2015 Version 1 7 Page 9 1 9 OPERATING MILKING BOX PARTS MANUALLY Introduction The COMMANDS tab page see Figure 9 1 displays buttons to operate milkbox parts manually...

Page 104: ...ff follow the steps in Scheme 9 1 STEP ACTION 1 Open the COMMANDS tab of the SERVICE window 2 Press the SPRAY button The SPRAY PRESSURE buttons see Figure 9 2 will be displayed Figure 9 2 Spray comman...

Page 105: ...ns of GATE buttons Steps To open or close the gates manually follow the steps in Scheme 9 2 STEP ACTION 1 Open the COMMANDS tab of the SERVICE window 2 Press the GATES button The GATES buttons see Fig...

Page 106: ...OPEN LR button Opens the left rear gate CLOSE LR button Closes the left rear gate OPEN RR button Opens the right rear gate CLOSE RR button Closes the right rear gate OPEN LF button Opens the left fro...

Page 107: ...g operating buttons Steps To perform cleanings manually follow the steps in Scheme 9 3 STEP ACTION 1 Open the COMMANDS tab of the SERVICE window 2 Press the CLEANINGS button The CLEANING buttons see F...

Page 108: ...erforms a peni cleaning cycle INTERVAL button Rinses the milking system You can perform this cleaning when the milking box has not been used for some time SHORT button Desinfects the teat cups PREPARA...

Page 109: ...or calibration purposes Steps To start the calibration follow the steps in Scheme 9 4 STEP ACTION 1 Open the COMMANDS tab of the SERVICE window 2 Press the CALIBRATION button The CALIBRATION buttons s...

Page 110: ...lly Page 9 8 Version 1 7 23 June 2015 Table 9 4 Calibration commands COMPONENT DESCRIPTION CLEANING AGENT button Starts calibrating the cleaning agent pump ACID button Starts calibrating the acid pump...

Page 111: ...ST button The PULSATOR TEST buttons see Figure 9 6 will be displayed Figure 9 6 Pulsator test commands 3 Select the desired milk box 1 4 Refer to Table 9 5 for a description of the PULSATOR TEST butto...

Page 112: ...ab page Steps To reset the PLC follow the steps in Scheme 9 6 STEP ACTION 1 Open the COMMANDS tab of the SERVICE window 2 Press the PLC button The RESET PLC button see Figure 9 7 will be displayed Fig...

Page 113: ...ons from BRI Controlling system 23 June 2015 Version 1 7 Page 10 1 10 CONTROLLING SYSTEM Introduction The SERVICE tab page see Figure 10 1 displays buttons to control the system Figure 10 1 Service ta...

Page 114: ...bot and the several components that are involved in this process Figure 10 2 Process viewer Controlling components You can press on the components shown in the Process viewer this allows the user or s...

Page 115: ...r follow the steps in Scheme 10 1 STEP ACTION 1 Open the SERVICE tab of the SERVICE window 2 Press the PROCESS VIEWER button The Process viewer see Figure 10 2 appears on your screen 3 Consult Appendi...

Page 116: ...ic diagram of the milking robot Figure 10 3 Hydraulic viewer Controlling components You can press on the components shown in the Hydraulic viewer this allows the user or service technician to control...

Page 117: ...follow the steps in Scheme 10 2 STEP ACTION 1 Open the SERVICE tab of the SERVICE window 2 Press the HYDRAULIC VIEWER button The Hydraulic viewer see Figure 10 3 appears on your screen 3 Consult Appen...

Page 118: ...um diagram of the milking robot Figure 10 4 Vacuum viewer Controlling components You can press on the components shown in the Vacuum viewer this allows the user or service technician to control that s...

Page 119: ...er follow the steps in Scheme 10 3 STEP ACTION 1 Open the SERVICE tab of the SERVICE window 2 Press the VACUUM VIEWER button The Vacuum viewer see Figure 10 4 appears on your screen 3 Consult Appendix...

Page 120: ...t work any more In this case you can restart one of the control programs Table 10 1 Table 10 1 Control programs PROGRAM DESCRIPTION Guppy Controls the camera Services Control the processes in the milk...

Page 121: ...Operations from BRI Controlling system 23 June 2015 Version 1 7 Page 10 9 STEP ACTION The respective program will be restarted then Scheme 10 4 Resetting system...

Page 122: ...down your complete system ABSOLUTELY do NOT shut down the PC if your system is in operating Steps To close the PC follow the steps in Scheme 10 5 STEP ACTION 1 Open the SERVICE tab of the SERVICE wind...

Page 123: ...of all actions of the farmer regarding milk separation or collection Location The logfile is saved in the C AMS BRI LOG folder and will have the file name AMSLOG TXT Steps To generate a logfile follo...

Page 124: ...window will be displayed Figure 10 6 Configuration Settings The components have the following meaning Box id Is the ID of the box you are setting Always enter the value 1 here Activity Specifies the r...

Page 125: ...Figure 10 7 Figure 10 7 Configuratie Robots 4 Select from the NUMBER OF ROBOTS drop down list the number of milking boxes in your system Below this control the entered number of milking boxes will be...

Page 126: ......

Page 127: ...15 Version 1 7 Page 11 1 11 SETTING STATIONS Introduction The RFID tab see Figure 11 1 displays a screen to set your stations You can set selection criteria for milking boxes and external selection un...

Page 128: ...in the same room Selection after leaving the milking box Cows that have to return to the stable leave the milking box through the exit gate that you have set for this milking box If you have set sele...

Page 129: ...ield has not been reached Selection on activity Selects cows with increased activity Selection on blood Selects cows with blood in milk Selection on grazing Selects cows that are allowed for grazing S...

Page 130: ...set the selection criteria for a milking box follow the steps in Scheme 11 1 STEP ACTION 1 Open the RFID tab of the SERVICE window The RFID window will be displayed see Figure 11 2 Figure 11 2 RFID wi...

Page 131: ...ilking box as a selection unit or Switch on one or more of the remaining selection criteria Refer to section 11 2 for a description of the selection criteria 8 Specify the maximum period of time 5 tha...

Page 132: ...dy selected and a second selection can occur In this case it is possible to send cows to a maximum of 4 different areas Steps To set the selection criteria for a post selection gate follow the steps i...

Page 133: ...Setting post selection 5 Open the tab page for the milking box side that is connected to the post selection gate 6 Specify the selection criteria 2 for the selection gate as follows Switch on option s...

Page 134: ...w the steps in Scheme 11 3 STEP ACTION 1 Open the RFID tab of the SERVICE window The RFID window will be displayed see Figure 11 6 Figure 11 6 RFID window 2 Select the station from the station list 1...

Page 135: ...fy per feed type the portion size 3 a cow can get per station visit 7 Enter a value for the augur speed 4 NOTE You should not enter here the value 0 Advise enter value 8 8 Press per feed type you use...

Page 136: ...FID tab of the SERVICE window The RFID window will be displayed see Figure 11 8 Figure 11 8 RFID window 2 Select the station from the station list 1 that has to be set as an external selection unit 3...

Page 137: ...he selection criteria 2 for the selection gate as follows Switch on option selection off if you don t use the selection unit or Switch on one or more of the remaining selection criteria Refer to secti...

Page 138: ...on unit Table 11 3 Settings external selection unit SETTING DESCRIPTION Sel set time ms Time in milliseconds that is needed to set the selection gate Entr close delay ms Waiting time in milliseconds b...

Page 139: ...on 1 7 Page 11 13 Table 11 3 Settings external selection unit SETTING DESCRIPTION Max entr open time s Time in seconds that the entrance gate closes again after it opened and the cow sensor is still a...

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Page 141: ...2 13 3 Calibrating camera 13 10 13 4 Checking calibration 13 14 13 5 Finetuning camera 13 18 13 6 Setting exposure 13 22 14 Teaching cup positions 14 1 14 1 Zeroing the robotic arm positions 14 2 14 2...

Page 142: ......

Page 143: ...You can use the teach pendant see Figure 12 1 to operate manually the robot arm and several parts in the milking box Using the teach pendant you teach the teat coordinates These coordinates will then...

Page 144: ...ble 12 1 Teach pendant buttons NO BUTTON DESCRIPTION 1 Emergency stop Stops the hydraulic functions in an emergency 2 Teach Operate the several parts of the milking box 3 Jog Provides hydraulic pressu...

Page 145: ...TION 1 Switch the milking box to SERVICE control mode 2 Close the GUPPY program 3 Follow step 4 and 7 to make a backup 4 Add a backup folder in C AMS GUPPY with the name BACKUP DD MM YY day month year...

Page 146: ...clamp 2 at the front side Figure 13 2 Disassembling clamp 2 Hang the calibration board firmly in the milking box at the cow box side 3 Move the robotarm with the teach pendant to the hand grip of the...

Page 147: ...obotarm to calibration board upper side Figure 13 4 Moving robotarm to calibration board left side 4 Start the GUPPY program On the screen a dialog appears with the message CAN NOT READ CALIB CAL beca...

Page 148: ...robotarm to the following position see Figure 13 6 Front side attachtool head hand grip 26 3 cm The distance between the camera and the hand grip is 30 cm by this Figure 13 6 Distance front side attac...

Page 149: ...ue is mostly around 500 Y 118 Z 170 Always use this value for Z 12 Enter these coordinates in the GUPPY INI file as follows Open the GUPPY INI file in the C AMS GUPPY folder see Figure 13 8 Open the o...

Page 150: ...3 8 to close the GUPPY INI file A dialog appears to save the file 14 Press the YES button to save the file 15 Close the GUPPY program wait 10 seconds and then restart the GUPPY program On the screen a...

Page 151: ...Figure 13 9 19 Open the CALIBRATION tab see Figure 13 10 Figure 13 10 Calibration tab 20 Enter in the CAM CAL CORR part 1 see Figure 13 10 the value 0 in the X en Y fields 1 Cam Cal Corr correction on...

Page 152: ...RGET POSITION part 1 see Figure 13 11 Value 0 in the X and Y fields Value 12 in the Z field Enter the value 100 in the SPEED field 2 see Figure 13 11 WARNING Use the arrow keys next to the field for t...

Page 153: ...lues in this tab 125 in the GAIN field 1 4 in the EXPOSURE field 2 25 Open the CONFIGURATION tab see Figure 13 13 Figure 13 13 Configuration tab 26 Press the SAVE CHANGES button 1 to save the settings...

Page 154: ...3 Calibrating camera Steps To calibrate the camera follow the steps in Scheme 13 3 STEP ACTION 1 Clean the camera window 1 see Figure 13 14 in front of the 2D camera thoroughly Figure 13 14 Camera wi...

Page 155: ...tion tab 5 Press the REF POS button 1 see Figure 13 16 The robotarm moves to the setted distance of 26 3 cm between hand grip calibration board and front side attachtool head see step 8 in section 13...

Page 156: ...h on the next options Show image 1 Objects 2 10 Press the DISPLAY button 1 see Figure 13 18 a number of times until you see the 2D images 2 in the window WARNING Notice strange abnormalities in the wi...

Page 157: ...ure 13 19 Figure 13 19 Configuration tab 13 Press the SAVE CHANGES button 1 to save the settings 14 Close the GUPPY program wait 10 seconds and then restart the GUPPY program 15 Put the clamp 1 see Fi...

Page 158: ...Figure 13 15 Figure 13 21 Configuration tab 2 Enter the password 196426ZERO 1 see Figure 13 21 In the next steps you perform the calibration on 30 20 and 10 cm from camera to hand grip You have to ch...

Page 159: ...setted distance of 26 3 cm between hand grip calibration board and front side attachtool head see step 8 in section 13 2 5 Check the distance 26 3 cm 6 Open the CAMERA SETTINGS tab see Figure 13 23 Fi...

Page 160: ...1 see Figure 13 24 a number of times until you see the 2D images 2 in the window 11 Maximize the GUPPY program window 12 Position the mouse cursor on the middle cross 5 and read the X and Y coordinat...

Page 161: ...p 14 Perform the calibration again in case of deviations Move in this case the following files again to the backup folder see also section 13 1 Calib cal Calib lut 15 Follow the steps 16 until 18 if t...

Page 162: ...camera follow the steps in Scheme 13 5 STEP ACTION 1 Ensure the GUPPY program is running 2 Start the BRI program 3 Switch the milking box to AUTOMATIC operation mode 4 Milk a cow manually and watch th...

Page 163: ...GE THE COORDINATES behind teat Y increase Y in front of teat Y decrease Y left from teat X increase X right from teat X decrease X WARNING Use the arrow keys next to the field for the entrance of valu...

Page 164: ...x Calibrating Camera Page 13 20 Version 1 7 23 June 2015 STEP ACTION Figure 13 28 Configuration tab 10 Press the SAVE CHANGES button 1 to save the settings 11 Open the TOOL tab see Figure 13 29 Figure...

Page 165: ...he onscreen keyboard 13 Change the X and Y coordinates 1 see Figure 13 27 as follows if the robot arm does not attach correctly CUP IS CHANGE THE COORDINATES behind teat Y in front of teat Y left from...

Page 166: ...he steps in Scheme 13 6 STEP ACTION 1 Open the VIEW tab see Figure 13 30 Figure 13 30 2D image 2 Switch on the next options Show image 1 see Figure 13 30 Raw 2 3 Press the DISPLAY button 3 see Figure...

Page 167: ...see Figure 13 30 In the status bar below the intensity displays the value 250 6 see Figure 13 30 6 Check this with white and dark teats 7 Adapt if necessary in the CAMERA SETTINGS tab the next values...

Page 168: ...7 23 June 2015 STEP ACTION Figure 13 32 View tab 9 Switch off the SHOW IMAGE 1 option 10 Open the TOOL tab see Figure 13 33 Figure 13 33 Tool tab 11 Change the value in the SPEED field 1 into the orig...

Page 169: ...June 2015 Version 1 7 Page 13 25 STEP ACTION Figure 13 34 Configuration tab 13 Press the SAVE CHANGES button 1 to save the changes 14 Eventually check if the cow tracker has been set correctly see se...

Page 170: ......

Page 171: ...and z see section Abschnitt 14 1 Actually this procedure has been performed in the factory but it may happen that it should be performed again 2 Release the jetters from the cups see section 14 2 3 T...

Page 172: ...lking box into SERVICE operation mode see section 5 3 2 Open the HYDRAULIC viewer see section 10 2 3 Switch on the ENABLE check box 1 see Figure 14 1 4 Set the control voltage for all axes to 0 5 volt...

Page 173: ...etters Process viewer You can open the jetters from the process viewer see Figure 14 2 Figure 14 2 Process viewer Jetter position Table 14 2 displays the jetter symbol 1 see Figure 14 2 in closed and...

Page 174: ...the jetters from the cups follow the steps in Scheme 14 2 STEP ACTION 1 Switch the milking box into SERVICE operation mode 2 Open the PROCESS viewer 3 Ensure the PREP JETTER symbol and the JETTER 1 s...

Page 175: ...w guppy program Starting window guppy program Table 14 3 shows an overview and a description of the numbered areas in Figure 14 3 Table 14 3 Starting window guppy program NO DESCRIPTION 1 Displays the...

Page 176: ...achtool head Opens or closes the gripper Switches the hydraulic pressure on JOG button see also section 12 Moves the robot arm width directional rightwards Moves the robot arm width directional leftwa...

Page 177: ...gripper position for the right rear teat cup Saves the gripper position for the preparation cup Steps To teach the correct cup positions follow the steps in Scheme 14 3 STEP ACTION 1 Start the GUPPY p...

Page 178: ...ach pendant ST 2 Close the entrance door when service technician 1 is inside the technical area Press the RESET button below the touch screen on the milking box Operate the EMERGENCY STOP button if ne...

Page 179: ...does not move when testing the gripper position 12 Press the button to save the gripper position for the desired cup TWICE 13 Repeat steps 9 until 12 until all cups have been taught 14 Leave the techn...

Page 180: ...cup positions follow the steps in Scheme 14 4 STEP ACTION 1 Open the TOOL tab page see Figure 14 8 of the GUPPY program Figure 14 8 Tool tab page 2 Set the following values 1 CONTROL VALUE Accel 50 Sp...

Page 181: ...ose the entrance door when service technician 1 is inside the technical area Press the RESET button below the touch screen on the milking box 6 Ask service technician 2 to press the TEST CUP FETCH but...

Page 182: ......

Page 183: ...ITIONS Teat positions The robot has to know the exact teat positions Procederes To teach the teat positions perform the procedures in Table 15 1 Table 15 1 Procederes to teach teat positions NO PROCED...

Page 184: ...straight back and is free in the milking box the cow tracker is 3 5 cm free from the frame Correct moment You have to teach the feeding trough position during the first session of manual Buttons Table...

Page 185: ...Teaching Milking box Teaching teat positions 23 June 2015 Version 1 7 Page 15 3 STEP ACTION 5 Start the manual milking Scheme 15 1 Teaching feeding trough position...

Page 186: ...buttons which you use for teaching the teat positions Table 15 3 Buttons BUTTON DESCRIPTION Starts and stops the teaching mode Switches the hydraulic pressure on JOG button see also section 12 Moves t...

Page 187: ...Version 1 7 Page 15 5 Table 15 3 Buttons BUTTON DESCRIPTION Flaps the gripper to the right or to the left Confirms the teat position right front Confirms the teat position left front Confirms the teat...

Page 188: ...n move the robot arm until the gripper is positioned as described below see also Figure 15 1 For all teats align the middle of the gripper at a distance not more that 2 5 cm from the teat Y position F...

Page 189: ...ect position of the teat follow the steps in Scheme 15 2 STEP ACTION 1 Switch the milking box to AUTOMATIC control mode 2 Let a cow enter the milking box wait for the TEACHING status 3 Press the TEACH...

Page 190: ...ox Teaching teat positions Page 15 8 Version 1 7 23 June 2015 STEP ACTION 10 Release the JOG button 11 Press the TEACH button if you have finished teaching all desired teat positions Scheme 15 2 Teach...

Page 191: ...COMMUNICATION OVERVIEW 16 Connection 16 1 16 1 Displaying network connections 16 1 16 2 Searching for network connection details 16 2 16 3 Setting network connection details 16 4 17 Communication 17 1...

Page 192: ......

Page 193: ...network cards Local Area connection 1 Local Area connection 2 Steps To display the two network connections follow the steps in Scheme 16 1 STEP ACTION 1 Select START CONTROL PANEL NETWORK CONNECTIONS...

Page 194: ...he SUBNET MASK DEFAULT GATE WAY and the DSN SERVER details as you have to enter them in the network settings of the robot Panel PC Steps To search for the desired network connection details follow the...

Page 195: ...23 June 2015 Version 1 7 Page 16 3 STEP ACTION Figure 16 3 Network connection details screen 5 Write down the following addresses for the subnet mask IP address 1 Subnet mask 2 Default gateway 3 DNS s...

Page 196: ...ORK CONNECTIONS screen see section 16 1 2 Right click the LOCAL AREA CONNECTION 1 shortcut 3 Select the PROPERTIES option from the pop up menu This will open the LOCAL AREA CONNECTION PROPERTIES scree...

Page 197: ...This address is high enough not to interfere with the automatically distributed addresses NOTE in case of a double box system the IP address of the second box will be set to 10 6 1 101 7 Enter the val...

Page 198: ...ION Figure 16 6 Advanced TCP IP settings screen Here you can see that the second IP address 1 is set to 192 0 1 200 NOTE In case of a double box system the address of the second box will be set to 192...

Page 199: ...ION 17 1 Communication scheme Communication scheme Figure 17 1 shows the communication scheme Figure 17 1 Communication scheme Panel PC Master withDB Switch 3D camera 2D camera ID Milkbox PLC Router I...

Page 200: ...ions between panel PC and ID milking box ID feed station between PLC and the air valve blocks to the measurement circuit board Air valve blocks The air valve blocks have to be set to the correct addre...

Page 201: ...running on the panel PC Table 17 2 Programs PROGRAM DESCRIPTION Bri Performs the farmer s daily work with the milking box Guppy Provides the preparation and attachment of the cow Bri data Communicates...

Page 202: ...1 Enter the master box IP address in a web browser In the example see step 6 Scheme 16 3 section 16 3 you use the IP address 10 6 1 100 After entering the IP address the WEB APPLICATION LOGIN SCREEN a...

Page 203: ...ulsator cups 20 1 20 2 Replacing spray filter 20 6 20 3 Replacing cleaning pump hoses 20 8 20 4 Replacing wearing parts regulator 20 12 20 5 Replacing wearing parts reverse amplifier milk meter 20 18...

Page 204: ...stem 25 1 25 2 Testing SMS 25 3 25 3 Calibrating milk meter 25 5 25 4 Checking cow tracker 25 7 25 5 Checking gate sensors 25 11 25 6 Lubricating feeding trough guides 25 14 25 7 Checking image and la...

Page 205: ...eanliness milk meter 25 59 25 24 Checking boiler cyclus 25 62 25 25 Checking dosing pumps cleaning agent and acid 25 64 25 26 Checking receiver jar 25 66 25 27 Checking jetters 25 68 25 28 Checking mi...

Page 206: ......

Page 207: ...obot Therefore it s important that the service technician strictly follows the instructions of the maintenance schedule See section 18 4 for a maintenance scheme and the frequency of all maintenance a...

Page 208: ...ause of the risk of injury Don t leave cleaning materials like brooms brushes or pit forks standing in the proximity of the milking robot They obstruct the movements of the machine and people or anima...

Page 209: ...in the following actions The automatic connection of the teat cups by the robotic arm Locating the teat positions Testing the robotic arm when locating the teat positions 18 3 Electronic parts Descrip...

Page 210: ...Service 4 12 months Service 5 15 months Service 6 18 months Service 7 21 months Service 8 24 months Service 1 27 months Service 2 30 months Every maintenance Table 18 2 Table 18 3 Table 18 4 Table 18...

Page 211: ...ation Checking rotation Pivot staalkabel Checking pivot steel cable Spray image Checking spray image Table 18 4 Technical area COMPONENT ACTIVITY Pulsation Checking pulsation Vacuum Checking vacuum pr...

Page 212: ...vice 2 4 6 8 Measuring for Quality ensurance Service Milking parts Milk meters Service 4 8 Calibrating milk meter Table 18 7 Commissioning service SEC COMPONENT ARTICLE NUMBER MR S1 MR D1 19 1 Valve f...

Page 213: ...19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose pretreatment cup 040300105A 45 cm 45 cm 19 4 Actuator revision set actuators at 4 wayblock 033559260 4 8 19 5 Drain valve 0...

Page 214: ...040300100B 60 cm 120 cm 19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose pretreatment cup 040300105A 45 cm 45 cm 19 4 Actuator revision set actuators at 4 wayblock 0335592...

Page 215: ...6 1 2 19 2 Short pulsation hose milking cup 040300100B 60 cm 120 cm 19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose pretreatment cup 040300105A 45 cm 45 cm 19 4 Actuator r...

Page 216: ...ter 070401290A 1 1 22 3 Set gasket milk pump FP4600 030300200A 1 2 Gasket milk pump FP4600 030300201A 1 2 22 4 Vacuum pump oil 5L 040400110A 1 1 Table 18 11 Service 5 SEC COMPONENT ARTICLE NUMBER MR S...

Page 217: ...ion hose milking cup 040300100B 60 cm 120 cm 19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose pretreatment cup 040300105A 45 cm 45 cm 19 4 Actuator revision set actuators a...

Page 218: ...38515506 1 2 19 2 Short pulsation hose milking cup 040300100B 60 cm 120 cm 19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose pretreatment cup 040300105A 45 cm 45 cm 19 4 Act...

Page 219: ...MBER MR S1 MR D1 19 1 Valve flapper milk pump 038515506 1 2 19 2 Short pulsation hose milking cup 040300100B 60 cm 120 cm 19 3 Short pulsation hose pretreatment cup 040300100B 15 cm 15 cm Water hose p...

Page 220: ...1 1 22 1 Revision set pulsator vacuum shut off 03858408A 1 2 22 2 Hydraulic filter 070401290A 1 1 22 3 Set gasket milk pump FP4600 030300200A 1 2 Gasket milk pump FP4600 030300201A 1 2 22 4 Vacuum pu...

Page 221: ...ulic oil 040400101A 20L 2 2 24 2 Tooth belt X axis 070900965A 250 cm 164 cm L 264 cm R 24 3 Tooth belt Y axis 070900970A 280 cm 280 cm 24 4 Tooth belt milking cups front 070900955A 244 cm 488 cm Tooth...

Page 222: ...bols used in this manual Table 18 16 Symbols used in this manual SYMBOL DESCRIPTION Visual inspection Feel Hear Measure required measuring tool is mentioned if necessary Gives strict recommendations r...

Page 223: ...Maintenance General information 23 June 2015 Version 1 7 Page 18 17 Table 18 16 Symbols used in this manual SYMBOL DESCRIPTION Important note Wear protection gloves Wear eye protection...

Page 224: ......

Page 225: ...ND 8 19 1 Replacing valve flapper milk pump Valve flapper milk pump The rubber valve flapper see Figure 19 1 in the milk pump prevents the milk from flowing back to the milk pump The valve is located...

Page 226: ...15 Steps To replace the valve flapper in the milk pump follow the steps in Scheme 19 1 STEP ACTION 1 Remove the clamps 1 and 2 see Figure 19 2 Figure 19 2 Remove clamps 2 Remove the pipe 3 between the...

Page 227: ...e 2015 Version 1 7 Page 19 3 STEP ACTION 4 Place the valve on the pump outlet The flat side of the valve flapper should be directed to the milk pump 5 Reassemble the pipe and clamps in reverse order o...

Page 228: ...4 Milking system Components milking system Table 19 1 shows an overview of the numbered component in Figure 19 4 Table 19 1 Components milking system NO COMPONENT 1 Short pulsation hose See Appendix...

Page 229: ...3 Place the new short pulsation hose in hot water 4 Assemble the short pulsation hose with the correct Oetiker clamps see Figure 19 6 to the connection piece and the tulle of the milking cup ATTENTIO...

Page 230: ...pretreatment system Table 19 2 shows an overview of the numbered components in Figure 19 7 Table 19 2 Components pretreatment system NO COMPONENT 1 Short pulsation hose 2 Water hose See Appendix B We...

Page 231: ...e 5 and the tulles 6 of the pretreatment cup 3 Place the new short pulsation hose and water hose in hot water 4 Assemble the short pulsation hose to the tulle with the largest diameter 1 see Figure 19...

Page 232: ...r clamp 6 Assemble the short pulsation hose and the water hose to the connection piece 7 Assemble at the connection of the short pulsation hose to the connection piece the correct Oetiker clamp see Fi...

Page 233: ...nd 4 actuators at the lateral side 2 These actuators contain a shutoff valve that has to be replaced The actuators at the upper side are used more than the actuators at the lateral side That s why the...

Page 234: ...the shutoff valves in the actuator at the upper side of the 4 way block 2 Remove the air tubes 1 see Figure 19 13 from the actuator as follows Label the air tubes from the inside to the outside with t...

Page 235: ...3 June 2015 Version 1 7 Page 19 11 STEP ACTION Figure 19 14 Metal bracket 4 Remove the metal rings 1 see Figure 19 15 that are positioned at the lower side of the actuators Figure 19 15 Metal rings 5...

Page 236: ...9 16 Actuators removed from the block 6 Disassemble the knee 1 see Figure 19 17 from every actuator Figure 19 17 Removing knee 7 Disassemble the bolt 1 see Figure 19 18 at the upper side of every actu...

Page 237: ...ve in every actuator 10 Tighten the shutoff valve again with the bolt at the upper side Screw the bolt hand tight 11 Assemble the knee in de actuator 12 Check the openings 1 see Figure 19 20 in the 4...

Page 238: ...ors in the 4 way block 15 Replace the metal bracket and screw this tight Screw the bolts in order of numbering see Figure 19 22 hand tight Figure 19 22 Order screwing bolts 16 Reconnect the air tubes...

Page 239: ...Air tubes Perform the next action according to step 3 until 16 uit 19 Remove the metal bracket 20 Remove the metal rings 21 Remove the actuators from the block 22 Disassemble the knee or T piece from...

Page 240: ...ctuators 28 Check the openings in the 4 way block in which you should replace the actuators 29 Replace the metal ring at every actuator 30 Replace the actuators in the 4 way block 31 Replace the metal...

Page 241: ...17 19 5 Replacing drain valve Drain valve The drain 1 see Figure 19 24 is positioned at a pipe at the milk pump This drain contains a valve that has to be replaced Figure 19 24 Drain See Appendix B We...

Page 242: ...drain valve follow the steps in Scheme 19 5 STEP ACTION 1 Remove the clamp 1 see Figure 19 25 at the drain 2 Figure 19 25 Clamp at drain 2 Unscrew the sockethead screws see Figure 19 26 at the backsid...

Page 243: ...put them in order of disassembling see Figure 19 28 Figure 19 28 Separate parts 6 Replace the stamper 1 see Figure 19 28 and the valve 2 7 Put loctite 243 4 see Figure 19 28 at the screw threads of t...

Page 244: ...Maintenance Service Commissioning 1 2 3 4 5 6 7 and 8 Page 19 20 Version 1 7 23 June 2015 STEP ACTION Figure 19 29 Leackage hole Scheme 19 5 Replacing drain valve 1...

Page 245: ...Replacing wearing parts in pulsator cups Pulsators milking cups and pretreatment cup Figure 20 1 displays the pulsators pretreatment cup 1 and milking cups 2 Figure 20 1 Pulsators pretreatment cup and...

Page 246: ...eatment cup follow the steps in Scheme 20 1 STEP ACTION 1 Follow step 2 until 13 to replace the parts in the pulsator milking cups 2 Loosen the pull tab 1 see Figure 20 2 at the connector 2 at the bac...

Page 247: ...the tube see Figure 20 4 Figure 20 4 Removing pulsator 5 Replace the ring 1 one Figure 20 4 by the ring with the smallest diameter in the revisionset 6 Unscrew the black nut at the top side of the pu...

Page 248: ...Place the connector back very carefully so that the pins herein do not break 14 Repeat step 2 until 13 for the other pulsator milking cups 15 Follow step 16 until 23 for the pulsator pretreatment cup...

Page 249: ...0 7 Pulsator deleted 20 Replace the ring 1 one Figure 20 7 by the ring with the smallest diameter in the revisionset 21 Follow step 6 until 11 to replace wearing parts in the pulsator 22 Place the pul...

Page 250: ...23 June 2015 20 2 Replacing spray filter Spray filter The spray container contains a spray filter 1 see Figure 20 8 You have to replace this spray filter Figure 20 8 Spray filter See Appendix B Wearin...

Page 251: ...container 3 Remove the blue screw caps 1 see Figure 20 9 Figure 20 9 Removing screw caps 4 Remove the pipes from the filter see Figure 20 10 Figure 20 10 Removing pipes 5 Removes the caps from the pi...

Page 252: ...ning pump The cleaning pump has a number of hoses 1 see Figure 20 11 which has to be replaced Figure 20 11 Cleaning pump hoses See Appendix B Wearing parts Figure 27 9 Cleaning pump hoses 030300401A W...

Page 253: ...cleaning pump hose 2 Remove the colored hose 1 see Figure 20 12 from both sides of the cleaning pump hose 2 3 Remove the pump roller 3 carefully from the motor motor axis 4 Remove the cleaning pump h...

Page 254: ...8 Place the yellow cover back before the cleaning pump hose Note the notch see Figure 20 14 around the yellow cover should be directed forward Figure 20 14 Notch 9 Repeat step 1 until 8 for the cleani...

Page 255: ...ersion 1 7 Page 20 11 STEP ACTION 12 Check the working of the cleaning agent pump Pump is rotating 13 Press 570 to stop the cleaning agent pump 14 Repeat step 11 until 13 to check the working of the a...

Page 256: ...on 1 7 23 June 2015 20 4 Replacing wearing parts regulator Regulator The regulator 1 see Figure 20 16 contains a number of wearing parts which have to be replaced Figure 20 16 Regulator See Appendix B...

Page 257: ...Loosen the regulator from the wet air separator 1 see Figure 20 17 Figure 20 17 Wet air separator 2 Place a cap on the wet air separator so that the milking box can continue to operate 3 Draw a mark s...

Page 258: ...lace the wearing parts 3 and 7 by the corresponding parts in the revision set Figure 20 19 Lower side disassembled 6 Put the point of part 2 see Figure 20 19 in the middle of part 1 7 Put the new part...

Page 259: ...lter in Figure 20 20 Figure 20 21 Paper filter 13 Put the new rings 13 and 14 see Figure 20 20 on the indicated locations in part 12 14 Put the metal plate 10 over the cone 11 15 Put the upper housing...

Page 260: ...20 22 above the ring with the small diameter 13 see Figure 20 20 in part 12 23 Fasten the assembly with the nuts 1 see Figure 20 23 around Figure 20 23 Fastening with nuts 24 Put the new filter 2 see...

Page 261: ...nce Service Continuation 2 4 6 and 8 23 June 2015 Version 1 7 Page 20 17 STEP ACTION Figure 20 24 Fastening nuts 28 Screw the regulator in the wet air separator Scheme 20 4 Replacing wearing parts reg...

Page 262: ...g wearing parts reverse amplifier milk meter Reverse amplifier The reverse amplifier milk meter 1 see Figure 20 25 contains one wearing part that has to be replaced Figure 20 25 Reverse amplifier See...

Page 263: ...teps in Scheme 20 5 STEP ACTION 1 Remove the hoses 1 see Figure 20 26 and 2 from the reverse amplifier Figure 20 26 Disassembling hoses reverse amplifier 2 Unscrew all nuts 1 see Figure 20 27 around t...

Page 264: ...s before disassembling directed to the button of part 7 Part 8 is the cap of the reverse amplifier Figure 20 29 Separated part reverse amplifier 5 Replace part 1 2 4 and 6 Note part 1 is the ring with...

Page 265: ...0 6 Replacing wearing parts servo vacuum valve Servo vacuum valve The servo vacuum valve 1 see Figure 20 30 contains a valve and a ring that has to be replaced Figure 20 30 Servo vacuum valve See Appe...

Page 266: ...e cap 1 see Figure 20 31 Figure 20 31 Servo vacuum valve 2 Unscrew the part in the middle 2 see Figure 20 31 from the lower part 3 3 Unscrew the nut 1 see Figure 20 32 with a screwdriver This is to sc...

Page 267: ...the opening with the smallest diameter of the transparant part 5 7 Put the metal ring 4 over the screw section of the nut 7 8 Put the new valve 3 with the flat side against the transparant part 5 9 As...

Page 268: ...etreatment container Amplifier pretreatment container The amplifier 1 see Figure 20 35 at the pretreatment container contains a number of wearing parts which have to be replaced Figure 20 35 Amplifier...

Page 269: ...STEP ACTION 1 Remove the hose 1 see Figure 20 36 from the amplifier Figure 20 36 Removing hoses 2 Unscrew the upper part of the amplifier from the lower part 2 see Figure 20 36 The lower part is that...

Page 270: ...ide part 7 through the opening in the in the middle from the screw thread side of part 6 7 Put part 5 over the screw thread of part 7 8 Put the new part 4 over the screw thread of part 7 9 Put part 3...

Page 271: ...UATION 3 AND 7 21 1 Replacing non return valve 6 mm Non return valve 6 mm Below the cap 1 see Figure 21 1 of the attachtool are 2 non return valve which have to be replaced Figure 21 1 Location non re...

Page 272: ...chtool the torx bolts 1 see Figure 21 2 from the clamp to disassemble the clamp 2 at the front side Figure 21 2 Disassembling clamp 2 Unscrew at both sides of the attachtool the torx bolts 3 see Figur...

Page 273: ...situated at the side of the gripper pads 5 Press the valve 5 see Figure 21 4 of the valve island on the left side until ALL air has been removed from the hose Figure 21 4 Valve island left side 6 Plac...

Page 274: ...re 21 5 contains three colored hoses You have to change the blue and red hose Figure 21 5 Blue and red hoses cleaning pump See Appendix B Wearing parts Figure 27 15 Supply cleaning hose blue 070900924...

Page 275: ...rom the one side of the cleaning pump hose 2 3 Remove the blue hose see Figure 21 6 from the other side of the cleaning pump hose 3 and the connection to the milking box Figure 21 6 Mounting points bl...

Page 276: ...ave to replace the milk hoses 2 way hoses see Figure 21 7 which pass from the milking cups through the hose guide Figure 21 7 Milk hoses See Appendix B Wearing parts Figure 27 17 Milk hoses 077pfls003...

Page 277: ...hoses follow the steps in Scheme 21 3 STEP ACTION 1 Cut the milk hoses to the correct length LF RF 183 cm LR RR 172 cm Figure 21 8 Milk hoses 2 Remove the Oetiker clamps see Figure 21 9 which are situ...

Page 278: ...ay hose with the correct Oetiker clamps see Figure 21 9 to the connecting piece at the teat cup position 6 Assemble the other side at the other connection piece 7 Check if the cups hang tight in the c...

Page 279: ...e 2015 Version 1 7 Page 21 9 21 4 Replacing gripper pads Gripper pads The gripper pads 1 see Figure 21 11 are located at the front side of the attachtool Figure 21 11 Gripper pads See Appendix B Weari...

Page 280: ...2 at the left side Figure 21 12 Socket head screws 2 Place the new gripper NOTE The small side 1 see Figure 21 13 of the gripper pad is situated at the front side Figure 21 13 Positioning gripper pad...

Page 281: ...hing pin and bearing hings are situated at both sides 1 see Figure 21 14 of the attachtool Figure 21 14 Location hing pin and bearing hing See Appendix B Wearing parts Figure 27 19 Pivot bearing slee...

Page 282: ...d holder from the attachtool At the upper side you find a plastic ring 1 see Figure 21 16 and a bearing hing below At the lower side you find another bearing hing 2 Between both bearing hings you find...

Page 283: ...e Figure 21 17 6 Clean the hing pin and torx bolts 5 see Figure 21 17 with loctite cleaner 7 Dry the hing pin and torx bolts 8 Put loctite 243 at the screw threads of the torx bolts 9 Tighten the hing...

Page 284: ...7 23 June 2015 21 6 Replacing wearing parts milk meter Milk meter The milk meter 1 see Figure 21 18 contains a number of wearing parts which have to be replaced Figure 21 18 Milk meter See Appendix B...

Page 285: ...6 STEP ACTION 1 Remove the tubes 1 see Figure 21 19 and hose 2 at the indicated locations Figure 21 19 Removing tubes and hose 2 Unscrew the screw cap 3 see Figure 21 19 3 Replace the white silicon r...

Page 286: ...her side 3 see Figure 21 20 the next parts the nut 1 Figure 21 21 the metal ring 2 the little white ring 3 Figure 21 21 Parts to be assembled 6 Remove the membrane 1 see Figure 21 22 with screw 2 at t...

Page 287: ...embrane 1 NOTE the upper side contains the groove 6 9 Slide the bolt through the opening at the other side see Figure 21 21 10 Assemble the new ring 3 11 Place the metal ring 4 12 Tighten the nut 5 at...

Page 288: ...e milk meter 18 Pull the pins of the tabs carefully in the inside of the cover to pull the thickened part through the holes 19 Replace the rectangle gasket 1 Figure 21 26 by the corresponding part 3 s...

Page 289: ...015 Version 1 7 Page 21 19 STEP ACTION Figure 21 27 Membrane upper side 22 Screw the blue screw cap on the milk meter 23 Connect the tubes 1 and the hose 2 see Figure 21 19 at the indicated positions...

Page 290: ...ing hose pretreatment cup Hose pretreatment cup You have to replace the pretreatment cup hose 3 way hose see Figure 21 28 which pass from the pretreatement cup through the hose guide Figure 21 28 Hose...

Page 291: ...hose pretreatment cup follow the steps in Scheme 21 7 STEP ACTION 1 Cut the hose pretreatment cup to the correct length 175 cm Figure 21 29 Hose pretreatment cup 2 Remove the hose at both sides from...

Page 292: ...ght in the cup guide 1 see Figure 21 30 If the cup does not hang tight in the cup guide the length of the hose pretreatment cup is not correct Figure 21 30 Cup in cup guide 5 Adjust the length of the...

Page 293: ...placing wearing parts pulsator vacuum shut off Position pulsator vacuum shut off The pulsator vacuum shut off 1 see Figure 22 1 is located at the back side of the technical area Figure 22 1 Position p...

Page 294: ...w the steps in Scheme 22 1 STEP ACTION 1 Loosen the pull tab 1 see Figure 22 2 at the connector 2 at the back side of the pulsator and pull the connector out see Figure 22 3 Figure 22 2 Pulling out co...

Page 295: ...an the pulsator THOROUGHLY 7 Replace in the white part the wearing parts 2 3 and 4 see Figure 22 4 by the relevant parts in the revisionset 8 Place the blue part back on the white part 9 Place the bla...

Page 296: ...ulic pump The hydraulic pump 1 see Figure 22 5 is located at the back side at the upper side of the milking box You have to replace the filter in it The filter is located in the black pot 2 Figure 22...

Page 297: ...TEP ACTION 1 Press the emergency stop button on the milking box see Figure 2 2 2 Open the main control cabinet MC 1 see Figure 22 6 Figure 22 6 Main control cabinet 3 Switch off F6 1 see Figure 22 7 i...

Page 298: ...d button on hydraulic system 5 Unscrew the black cover 1 see Figure 22 9 from the hydraulic tank Figure 22 9 Unscrewing black cover and black pot 6 Unscrew the black pot 1 see Figure 22 9 7 Remove the...

Page 299: ...EP ACTION Figure 22 10 Inserting filter in black pot 9 Tighten the black pot 10 Tighten the black cover 11 Tighten the red knob 1 see Figure 22 8 12 Switch on the F6 button in the main control cabinet...

Page 300: ...cing wearing parts milk pump Wearing parts milk pump The milk pump 1 see Figure 22 11 has a number of gaskets which have to be replaced Figure 22 11 Milk pump Appendix B Wearing parts Figure 27 25 Set...

Page 301: ...mp follow the steps in Scheme 22 3 STEP ACTION 1 Open the main control cabinet MC 1 see Figure 22 12 Figure 22 12 Main control cabinet 2 Switch off F4 1 see Figure 22 13 in the main control cabinet Fi...

Page 302: ...e 22 14 Disassembling cover 4 Remove the cover from the milk pump 5 Remove the clamp 1 see Figure 22 15 2 wing nuts 2 and the rubber socket 3 to remove the pump housing from the milk pump Figure 22 15...

Page 303: ...placing gasket pump housing 7 Tap the propeller 1 see Figure 22 17 in the direction of the red arrow 2 and unscrew it then The rear plate 3 is disassembled also now Figure 22 17 Disassembling propelle...

Page 304: ...igure displays how to position the gaskets Figure 22 19 Gaskets in propeller and rear plate 10 Lubricate the seals at the place where they get together after assembly well with vaseline 11 Put the rea...

Page 305: ...tention that the gasket 1 see Figure 22 20 is positioned straight between pump housing and milk pump Beware sharp edges Figure 22 20 Gasket 15 Fix the rubber socket again 16 Fix the pump housing with...

Page 306: ...22 4 Replacing vacuum pump oil Vacuum pump The vacuum pump 1 see Figure 22 21 is located at the rear side at the upper side of the milking box You have to replace the vacuum pump oil Figure 22 21 Vac...

Page 307: ...4 STEP ACTION 1 Open the main control cabinet MC 1 see Figure 22 22 Figure 22 22 Main control cabinet 2 Switch off F1 in the main control cabinet 1 see Figure 22 23 Figure 22 23 F1 button in main cont...

Page 308: ...he orange cap 2 see Figure 22 24 from the vacuum pump Figure 22 24 Parts on vacuum pump 6 Wait until the old oil is going out 7 Fill the vacuum pump with new oil The oil level indicator 3 see Figure 2...

Page 309: ...1 23 SERVICE CONTINUATION 5 23 1 Replacing O gaskets in 3 way valve 3 way valve The 3 way valve 1 see Figure 23 1 has a number of gaskets which have to be replaced Figure 23 1 3 way valve See Appendi...

Page 310: ...he steps in Scheme 23 1 STEP ACTION 1 Unscrew the bolts 1 see Figure 23 2 Figure 23 2 Unscrewing bolts 2 Pull off the housing 2 see Figure 23 2 from the 3 way valve 3 Position 2 socket wrenches 1 see...

Page 311: ...re 23 4 of the lower part 2 of the 3 way valve and the large gaskets 3 of the upper part 4 by the corresponding gaskets in the O ring set Figure 23 4 Separate parts 3 way valve 5 Assemble all 3 way va...

Page 312: ......

Page 313: ...il Hydraulic oil You remove the hydraulic oil at the hydraulic system 1 see Figure 24 1 at the right side of the technical area After that your refill fresh oil in the hydraulic pump 2 at the upper si...

Page 314: ...low the steps in Scheme 24 1 STEP ACTION 1 Press the emergency stop button on the milking box see Figure 2 2 2 Open the main control cabinet MC 1 see Figure 24 2 Figure 24 2 Main control cabinet 3 Swi...

Page 315: ...t the rear side of the hydraulic system If the plates of that side is placed against a wall it is not possible to disassemble that plate In this place you can perform step 6 to 8 only from the inside...

Page 316: ...re 24 5 Nut hydraulic system Figure 24 6 Nut hydraulic system from left side hydraulic system 7 Unscrew the nut and let the oil go out 8 Tighten the nut as soon as all oil has gone out 9 Unscrew the b...

Page 317: ...hrough the opening below the black cover in the hydraulic pump 11 Put the black cover back on the hydraulic pump as soon as you have filled 20 L oil in the hydraulic pump 12 Tighten the red knob 1 see...

Page 318: ...is Tooth belt X axis The tooth belt X axis 1 see Figure 24 8 is located above the column of the robot arm The tooth belt length is 2500 mm The tooth belt in the service kit is at the correct length Fi...

Page 319: ...t side of both clamping blocks 3 of the tooth belt Figure 24 10 Disassembling and assembling tooth belt X axis 3 Unscrew the 4 bolts 4 at the upper side of the clamping block 5 4 Remove the belt 5 Put...

Page 320: ...ct length Figure 24 11 Tooth belt Y axis See Appendix B Wearing parts Figure 27 29 Tooth belt Y axis 070900970A Steps To replace the tooth belt Y axis follow the steps in Scheme 24 3 STEP ACTION 1 Fol...

Page 321: ...1 7 Page 24 9 STEP ACTION Figure 24 13 Unscrewing bolts 3 Unscrew the 2 bolsts 1 see Figure 24 14 at the lower side and 1 bolt 2 at the left side of the clamping block which directs to the rear side...

Page 322: ...s where to locate the middle of the tooth belt Figure 24 15 Unscrewing bolt 5 Remove the tooth belt 6 Put the middle of the new tooth belt on the third notch 1 see Figure 24 16 of the clamping block a...

Page 323: ...nt side of the milking box Figure 24 18 Tooth belt clamping block front side milking box 11 Screw the 2 bolts 1 see Figure 24 18 at the low side of the clamping blocks but not completely tight 12 Scre...

Page 324: ...nce Service Continuation 1 Page 24 12 Version 1 7 23 June 2015 STEP ACTION Figure 24 19 Clamping block rear side milking box 15 Check the cup positions see section 14 4 Scheme 24 3 Replacing tooth bel...

Page 325: ...cated at the upperside of the hose guides milk hoses 2 way hoses The tooth belt length of the milking cups front is 1220 mm the tooth belt length of the milking cups rear 950 mm The tooth belts in the...

Page 326: ...tooth belts milking cups front 2 Pull the tooth belt milking cup front voor 1 see Figure 24 21 until the clamping block 2 appears at the lower side of the shaft 2 Figure 24 21 Clamping block milking...

Page 327: ...oth belts protude about see Figure 24 23 Figure 24 23 Tooth belt in clamping block 7 Place it around the pulley 2 see Figure 24 22 8 Tighten the tooth belt at the clamping blocks 1 see Figure 24 21 th...

Page 328: ...igure 24 25 above the milk hoses Figure 24 25 Clamping blocks upper side milking box 12 Tighten the new tooth belts at the clamping blocks 1 see Figure 24 25 13 Place these around the pulley 2 see Fig...

Page 329: ...belt pretreatment cup 1 see Figure 24 26 is located at the upperside of the hose guide hose pretreatment 3 way hoses The tooth belt length pretreatment cup is 1010 mm The tooth belt in the service ki...

Page 330: ...pretreatment cup follow the steps in Scheme 24 5 STEP ACTION 1 Unscrew the bolts 1 see Figure 24 27 of the clamping block at the upper side of the milking box Figure 24 27 Clamping block upper side m...

Page 331: ...4 28 Clamping block above pretreatement hose 3 Tighten the new tooth belt at the clamping block 1 see Figure 24 28 NOTE at all clamping blocks the tooth belts protude about see Figure 24 29 Figure 24...

Page 332: ...uation 1 Page 24 20 Version 1 7 23 June 2015 STEP ACTION 5 Tighten the tooth belt at the clamping block 1 see Figure 24 27 which is located at the upper side of the milking box Scheme 24 5 Replacing t...

Page 333: ...is located at the upperside of the column of the robot arm You find a tooth belt around this encoder which is tightened with two clamping blocks at both sides of the encoder The tooth belt length is 1...

Page 334: ...de of the encoder The tooth belt is loose at the left side then Figure 24 31 Tooth belt in clamping block 2 Also unscrew the bolts of the clamping block at the right side of the encoder to loose the t...

Page 335: ...3 Remove the tooth belt from the encoder and pulleys 4 Place the new tooth belt around the encoder and pulleys as displayed in Figure 24 32 5 Tighten the tooth belt at the clamping blocks at the left...

Page 336: ...re 24 33 is located at the upperside of the cow box You find a tooth belt around this encoder which is tightened with two clamping blocks at both sides of the encoder The tooth belt length is 1580 mm...

Page 337: ...de of the encoder The tooth belt is loose at the right side then Figure 24 34 Tooth belt in clamping block 2 Also unscrew the bolts of the clamping block at the left side of the encoder to loose the t...

Page 338: ...th belt behind the block and then tighten the bolts 7 Place the new tooth belt around the encoder and pulleys as displayed in Figure 24 35 8 Tighten the clamping block at the left side of the encoder...

Page 339: ...ing rubber gasket overflow container Overflow container The overflow container see Figure 24 36 has a rubber gasket in the transparant cover which has to be replaced Figure 24 36 Overflow container Se...

Page 340: ...the 3 screw nuts 1 see Figure 24 37 Figure 24 37 Unscrewing screw nuts 2 Remove the metal ring 2 see Figure 24 37 with the transparant cover from the overflow container 3 Remove the metal ring 1 see...

Page 341: ...EP ACTION 5 Put the new rubber gasket in the transparant cover 6 Put the metal ring with the transparant cover on the overflow container 7 Tighten the metal ring with the screw nuts hand tight at the...

Page 342: ......

Page 343: ...estart the system follow the steps in Scheme 25 1 STEP ACTION 1 Shut down the PC see section 10 5 2 Wait until the PC is shut down 3 Swith off the main switch 4 Open the main control cabinet MC1 see F...

Page 344: ...P ACTION Figure 25 2 Accu in main control cabinet 6 Wait 2 minutes 7 Reconnect the accu in the main control cabinet 8 Close the main control cabinet 9 Switch on the main switch The system will restart...

Page 345: ...ON 1 Close the BRI application see section 4 4 2 Press the MY COMPUTER shortcut 1 see Figure 25 3 on the desktop of the control panel to open Window Explorer Figure 25 3 Desktop control panel 3 Open t...

Page 346: ...l program The SEND SMS dialog 1 see Figure 25 5 will be displayed Figure 25 5 Send SMS dialog 6 Enter your telephone number 1 see Figure 25 5 and a text 2 and then press the SEND SMS button 3 An SMS m...

Page 347: ...BRI main screen 5 kg 6 Weigh the milk of each cow in the milk bucket The value may not deviate more than 2 yield in kg from the value that is displayed in the MILK BOX STATE part in the BRI main scree...

Page 348: ...Milk settings 11 Enter the calibration value in the next field s MILKMETER CALIBRATION 1 see Figure 25 6 for a single box MILKMETER CALIBRATION 1 and MILKMETER CAL RIGHT 2 for a double box 12 Switch...

Page 349: ...7 checks the movements of the cow when registrating the udder and teat positions by the 2D and 3D camera The cow tracker also captures the manure of the cow when she is in the milking box Figure 25 7...

Page 350: ...There may not be a cow present in the box and the cow tracker must be in rest position 2 Check the white blocks 1 see Figure 25 8 at both sides of the cow tracker Blocks are fully against the rear pl...

Page 351: ...5 Version 1 7 Page 25 9 STEP ACTION Figure 25 9 Control panel desktop 5 Maximize the GUPPY program window 6 Press the ROBOT STATUS knop 1 see Figure 25 10 to request the actual position of the cow tra...

Page 352: ...eck the DCOW value 2 see Figure 25 10 Value is between 0 and 3 8 Switch the milking box to AUTOMATIC operating mode 9 Wait until a cow enters the milking box 10 Check if the DCOW value in the GUPPY wi...

Page 353: ...11 25 5 Checking gate sensors Position gate sensors You can find the gate sensors 1 see Figure 25 11 at both sides of the cow box at the end gate cylinder bar side The light of the sensor is on if th...

Page 354: ...the steps in Scheme 25 5 STEP ACTION 1 Check the light 1 see Figure 25 12 of a gate sensor of the corresponding gate Light is on Figure 25 12 Light on gate sensor is on 2 Pull the gate 1 see Figure 2...

Page 355: ...Maintenance Every service 23 June 2015 Version 1 7 Page 25 13 STEP ACTION Figure 25 13 Firmly closed gate 3 Repeat step 1 until 2 for the remaining gates Scheme 25 5 Checking gate sensors 1...

Page 356: ...ng trough nipples Above the feeding trough at the side of the cow box you find four nipples 1 see Figure 25 14 You pump a little grease through these nipples to lubricate the feeding trough guides Fig...

Page 357: ...s follow the steps in Scheme 25 6 STEP ACTION 1 Pump grease in each nipple 1 see Figure 25 14 for the feeding trough guides Give each nipple 4 strokes of grease To do this press the handle 1 see Figur...

Page 358: ...der and teats Steps To check the laser and image of the 2D camera follow the steps in Scheme 25 7 STEP ACTION 1 Close the BRI application see section 4 4 2 Press the GUPPY shortcut 1 see Figure 25 16...

Page 359: ...rogram 4 Press the START knop 3 see Figure 25 17 5 Hang the calibration board see Figure 25 18 The distance 1 between front of the cover and calibration board has to be 40 cm Figure 25 18 Laser on cal...

Page 360: ...he SHOW IMAGE check button 2 see Figure 25 19 9 Switch on the RAW radio button 3 see Figure 25 19 10 View the line 4 see Figure 25 18 Straight line 11 Switch off the SHOW IMAGE check button 2 see Figu...

Page 361: ...and the paper should be 4 5 cm Figure 25 20 Paper on calibration board 17 Press the UEYEDEMO shortcut on the control panel desktop 2 see Figure 25 16 to open the UEYEDEMO program 18 Press the OPTIMAL...

Page 362: ...View the text 1 see Figure 25 23 on the paper that is displayed in the UEYEDEMO programma The text should be very clear and legible very well Figure 25 23 Text on paper on calibration board 20 Close...

Page 363: ...behind the window 1 see Figure 25 24 This area may not contain any humidity Figure 25 24 2D camera Steps To check the 2D camera on humidity follow the steps in Scheme 25 8 STEP ACTION 1 View the windo...

Page 364: ...ox 3 Close the BRI application see section 4 4 as soon as the robot arm starts attaching the milking cups 4 Press the GUPPY knop 1 see Figure 25 25 in the control panel task bar to open the GUPPY prog...

Page 365: ...1 7 Page 25 23 STEP ACTION Figure 25 26 3D image 6 Press the MINIMIZE WINDOW button 6 see Figure 25 26 to minimize the GUPPY window 7 Press the BRI shortcut 1 see Figure 25 25 to start the BRI applica...

Page 366: ...23 June 2015 25 10 Checking Gripper Gripper The gripper 1 see Figure 25 27 clamps the pretreatment cup and milking cups to attach them on the cow s teats You have to check if the clamping of the gripp...

Page 367: ...ses or hangs the left front teat cup Releases or hangs the right front teat cup Releases or hangs the left rear teat cup Releases or hangs the right rear teat cup 2 Put a milking cup in the gripper 3...

Page 368: ...ntenance Every service Page 25 26 Version 1 7 23 June 2015 STEP ACTION Figure 25 28 Turning clamped gripper 5 Open the gripper using the teach pendant 6 Hang the milking cup Scheme 25 10 Checking Grip...

Page 369: ...h pendant Rotates the attach tool head 2 Check the connection see Figure 25 29 of the protection hose at the attachtool head The block 1 is firmly attached The protection hose 2 is not worn and does n...

Page 370: ...1 7 23 June 2015 STEP ACTION Figure 25 30 Cable runner rear side robot arm 4 Check the cable runner 1 see Figure 25 31 that is located at the upper side of the robot arm No visual signs of cracks No...

Page 371: ...Maintenance Every service 23 June 2015 Version 1 7 Page 25 29 STEP ACTION Figure 25 31 Cable runner upper side robot arm Scheme 25 11 Checking protection hose and cable runner 1...

Page 372: ...the movements of the X Y and Z axis follow the steps in Scheme 25 12 STEP ACTION 1 Check the movements of the robot arm when attaching the milking cups to left right X axis forwards backwards Y axis u...

Page 373: ...31 25 13 Checking rotation Steps To check the rotation of the attachtool head follow the steps in Scheme 25 13 STEP ACTION 1 Check the reducing valve 4 pieces see Figure 25 32 and Figure 25 33 The red...

Page 374: ...is is a once only action So you don t have to repeat this every service However you always have to check if the reduce valves are opened 3 Loosen the lock nut 1 see Figure 25 33 leftwards 4 Loosen the...

Page 375: ...3 STEP ACTION 7 Rotate the attachtool head leftwards and rightwards using the teach pendant Rotates the attachtool head 8 Check the rotation leftwards and rightwards The attachtool head turns leftward...

Page 376: ...ool head with the robot arm Head is fully aligned 1 see Figure 25 34 with the robot arm Figure 25 34 Head aligned with robot arm 2 Flap the head fully leftwards using teach pendant Flaps the head left...

Page 377: ...d is flapped to that side The rear side of the head 1 see Figure 25 36 is straight against the frontside of the robotarm Figure 25 36 Connection head and robot arm 7 Repeat step 2 until 6 for the righ...

Page 378: ...image of it Figure 25 38 Sprayer Steps To check the spray image follow the steps in Scheme 25 15 STEP ACTION 1 Switch the milking box to SERVICE operation mode 2 Rotate the attachtool head using the...

Page 379: ...ance Every service 23 June 2015 Version 1 7 Page 25 37 STEP ACTION 4 Rotate the attachtool head to its original position 5 Switch the milking box to AUTOMATIC operation mode Scheme 25 15 Checking spra...

Page 380: ...rection Z axis The involved guides have a number of grease nipples which have to be lubricated see Scheme 25 16 Grease nipples X axis The guide for the X axis has grease nipples at the next locations...

Page 381: ...Maintenance Every service 23 June 2015 Version 1 7 Page 25 39 Figure 25 41 Grease nipple X axis front side robot column Figure 25 42 Grease nipple X axis right side robot column 1 1...

Page 382: ...ee Figure 25 43 2 at the right side of the milking box 1 see Figure 25 44 Figure 25 43 Grease nipples Y axis left side milking box Figure 25 44 Grease nipples Y axis right side milking box Grease nipp...

Page 383: ...ce 23 June 2015 Version 1 7 Page 25 41 Figure 25 45 Grease nipple Z axis left side robot arm Figure 25 46 Grease nipple Z axis right side robot arm See Appendix C Consumables Figure 28 18 Multi purpos...

Page 384: ...gure 25 42 of the robot arm guide for the X axis Give each nipple 5 strokes of grease To do this press the handle 1 see Figure 25 47 of the gun very carefully Figure 25 47 Grease gun 2 Repeat step 1 f...

Page 385: ...cup short pulsation hoses Steps To check the short pulsation hoses and the working of pulsation follow the steps in Scheme 25 17 STEP ACTION 1 Check the short pulsation hoses of each milking cup and...

Page 386: ...ed on Valve 19 colors green to indicate that vacuum to the milking system is switched on Figure 25 49 Process viewer Then you wil start testing pulsation one by one at the milking cups 5 Press the 11...

Page 387: ...see Figure 25 50 and buttons 2 valve 12 and button PULS RR for milking cup RIGHT REAR valve 13 and button PULS LF for milking cup LEFT FRONT valve 14 and button PULS RF for milking cup RIGHT FRONT 11...

Page 388: ...ce Page 25 46 Version 1 7 23 June 2015 25 18 Checking vacuum pressure Vacuum gauge You can read the vacuum pressure on the vacuum gauge 1 see Figure 25 51 at the right side of the technical area Figur...

Page 389: ...e 25 18 STEP ACTION 1 Connect the test gauge at the calibration connection 1 see Figure 25 52 of the main vacuum pipe Figure 25 52 Calibration connection at main vacuum pipe 2 Switch the milking box t...

Page 390: ...itch on the vacuum pump 5 Compare the value on the test gauge with the value on the vacuum gauge Both values are equal Default value 45 KPa 6 Adjust if required the value as follows on the vacuum gaug...

Page 391: ...ION Figure 25 54 White cap vacuum gauge Figure 25 55 Adjusting screw vacuum gauge 7 Press the 559 symbol in process viewer op 1 see Figure 25 53 to switch off the vacuum pump 8 Switch the milking box...

Page 392: ...side at the upper side of the milking box Figure 25 56 Vacuum pump Replacing oil Actually you replace vacuum pump oil during service 4 and 8 You check the level to examine if it has to be replaced ear...

Page 393: ...llow the steps in Scheme 25 19 STEP ACTION 1 Check the vacuum pump oil level Oil level in indicator 1 see Figure 25 57 is 2 3 Figure 25 57 Oil level indicator at vacuum pump 2 Fill if required the vac...

Page 394: ...hydraulic pressure You can check the hydraulic pressure on the hydraulic system see Figure 25 58 which is located at the left side of the technical area The hydraulic system has 2 measure points to me...

Page 395: ...point 1 1 see Figure 25 59 of the hydraulic system Figure 25 59 Measure point 1 pressure hydraulic system 2 Put a gauge on it 3 Read the pressure at catching on and off the hydraulic pump Catching on...

Page 396: ...ion 1 7 23 June 2015 STEP ACTION Figure 25 60 Measure point 2 pressure hydraulic system 6 Put a gauge on it 7 Read the pressure 30 bar 8 Remove the gauge from measure point 1 and turn the cap on it Sc...

Page 397: ...r side of the milking box Figure 25 61 Hydraulic pump Replacing oil Actually you replace hydraulic pump oil during service 1 You check the level to examine if it has to be replaced earlier or that the...

Page 398: ...tor 1 see Figure 25 61 Oil level is against the MAX indication 4 Effectuez l une des op rations suivantes Oil level to low Fill the hydraulic pump with oil till the required level see section 24 1 OR...

Page 399: ...e reduce valves see Figure 25 63 Pression reduce circuit 1 1 bar Crush security 2 5 bar Blowing off milk 3 2 bar System pressure 4 6 bar Figure 25 63 Reduce valves 2 Adjust if required the pressure un...

Page 400: ...usting pressure 3 Read the temperature on the compressor Kaeser compressor in green area BMR compressor 10 C 4 Read the pressure on the compressor Kaeser compressor Catching on 7 bar Catching off 9 ba...

Page 401: ...you check the tabs 1 see Figure 25 65 the air holes below this and the gasket 2 on cleanliness Figure 25 65 Milk meter Steps To check the milk meter on cleanliness follow the steps in Scheme 25 23 STE...

Page 402: ...7 23 June 2015 STEP ACTION Figure 25 66 Holes below tabs 3 Loosen the clamps 1 see Figure 25 67 at both sides of the milk meter Figure 25 67 Clamps 4 Remove the cover from the milk meter 5 Check the...

Page 403: ...e Every service 23 June 2015 Version 1 7 Page 25 61 STEP ACTION Figure 25 68 Gasket milk meter 6 Put the cover back on the milk meter and fix this with the clamps Scheme 25 23 Checking cleanliness mil...

Page 404: ...rting main cleaning Steps To check the boiler cyclus follow the steps in Scheme 25 24 STEP ACTION 1 Open PROCESS VIEWER see section 10 1 The PROCESS VIEWER see Figure 25 69 will be displayed Figure 25...

Page 405: ...e 23 June 2015 Version 1 7 Page 25 63 STEP ACTION Figure 25 70 Main cleaning settings 5 Check the boiler heating 1 see Figure 25 70 01 00 6 Close the SERVICE part of the BRI application Scheme 25 24 C...

Page 406: ...ng agent and acid Cleaning pump You check the functioning of the dosing pumps cleaning agent 1 see Figure 25 71 and acid 2 Figure 25 71 Dosing pumps cleaning agent and acid Wear protection gloves Wear...

Page 407: ...IEWER see section 10 1 2 Press 570 in PROCESS VIEWER 1 see Figure 25 72 to start the cleaning agent pump Figure 25 72 Process viewer 3 Check if the cleaning agent pump is functioning Pump is running 4...

Page 408: ...e 25 73 and overflow container 2 on cleanliness Figure 25 73 Receiver jar Checking times Before during and after cleaning Steps To check the receiver jar follow the steps in Scheme 25 26 STEP ACTION 1...

Page 409: ...67 STEP ACTION 2 Check during main cleaning the spray ball 1 see Figure 25 74 in the receiver jar Holes in spray ball are open Figure 25 74 Spray ball 3 Check after main cleaning the interior of the...

Page 410: ...e jetters milking cup 2 clean the respective cups after pretreatment respectively a milking during main cleaning Figure 25 75 Jetters Checking jetters You check the jetters on the following cleanlines...

Page 411: ...Maintenance Every service 23 June 2015 Version 1 7 Page 25 69 STEP ACTION 2 Check the jetters during main cleaning Jetters attach properly on cups Scheme 25 27 Checking jetters...

Page 412: ...aintenance Every service Page 25 70 Version 1 7 23 June 2015 25 28 Checking milk pump Checking milk pump You check if the milk pump 1 see Figure 25 76 leaks during pumping milk Figure 25 76 Milk pump...

Page 413: ...ge 25 71 Steps To check the milk pump follow the steps in Scheme 25 28 STEP ACTION 1 Check the milk pump during pumping There is no milk along the gasket 1 see Figure 25 77 of the milk pump Figure 25...

Page 414: ...n in main control cabinet Figure 25 78 Fan in main control cabinet Steps To check ventilation in the main control cabinet follow the steps in Scheme 25 29 STEP ACTION 1 Open the main control cabinet M...

Page 415: ...27 Appendix B Wearing parts 27 1 27 1 Wearing parts Commissioning 1 2 3 4 5 6 7 and 8 27 1 27 2 Wearing parts 2 4 6 and 8 27 3 27 3 Wearing parts 3 and 7 27 5 27 4 Wearing parts 4 and 8 27 8 27 5 Wear...

Page 416: ......

Page 417: ...IN VIEWERS Viewers in BRI The BRI application contains three viewers from which you can operate box parts manually These are the following viewers Process viewer see Figure 26 1 Hydraulic viewer see...

Page 418: ...Appendices Appendix A Numbers in viewers Page 26 2 Version 1 7 23 June 2015 Figure 26 3 Vacuum Viewer...

Page 419: ...ilk hose R R 13 Shutter Boumatic PN3557771 Opens closes vacuum shut off valve milk hose L F 14 Shutter Boumatic PN3557771 Opens closes vacuum shut off valve milk hose R F 15 Cylinder Opens closes drai...

Page 420: ...jetters 46 Cylinder Activates the cow driver 62 Signal Starts stops milking pump 65 Signal 24v Starts stops pulsator L R 66 Signal 24v Starts stops pulsator R R 67 Signal 24v Starts stops pulsator L...

Page 421: ...closes shut off valve water pretreatment 444 Valve Opens closes shut off valve drain pretreatment 451 Valve Opens closes shut off valve cold water pretreatment 452 Valve Opens closes shut off valve ho...

Page 422: ...er valve filling boiler 579 Signal 24 v Opens closes the water valve to pre cooler 629 Sensor Display level water boiler high low Puls LF Switch Switches vacuum on teat cup L F on off Puls RF Switch S...

Page 423: ...overview of all wearing parts which are needed for maintaining a milking box The article numbers are ordering numbers of BouMatic Robotics 27 1 Wearing parts Commissioning 1 2 3 4 5 6 7 and 8 Figure...

Page 424: ...Appendices Appendix B Wearing parts Page 27 2 Version 1 7 23 June 2015 Figure 27 4 Actuator revision set 033559260 Figure 27 5 Drain valve 0738511975 Figure 27 6 For drain valve 0738511971...

Page 425: ...Page 27 3 27 2 Wearing parts 2 4 6 and 8 Figure 27 7 Revision set pulsator milk cups and pretreatment cup 38584808 Figure 27 8 Spray filter below spray container 070500180A Figure 27 9 Cleaning pump...

Page 426: ...ts Page 27 4 Version 1 7 23 June 2015 Figure 27 11 Repair set reverse amplifier for milk meter 030300510A Figure 27 12 Repair set servo vacuum valve 16 mm 030300515A Figure 27 13 Repair set amplifier...

Page 427: ...Wearing parts 23 June 2015 Version 1 7 Page 27 5 27 3 Wearing parts 3 and 7 Figure 27 14 Non return valve 6 mm 070400780A Figure 27 15 Supply cleaning hose blue 070900924A Figure 27 16 Supply cleanin...

Page 428: ...B Wearing parts Page 27 6 Version 1 7 23 June 2015 Figure 27 17 Milk hoses 077pfls0037 Figure 27 18 Gripper pads 070100120C Figure 27 19 Pivot bearing sleeve gripper 070600570A Figure 27 20 Hinge pin...

Page 429: ...Appendices Appendix B Wearing parts 23 June 2015 Version 1 7 Page 27 7 Figure 27 21 Repair kit milk meter 030300206A Figure 27 22 Pretreatment hose 070700260A...

Page 430: ...ing parts Page 27 8 Version 1 7 23 June 2015 27 4 Wearing parts 4 and 8 Figure 27 23 Revision set pulsator vacuum shut off 03858408A Figure 27 24 Hydraulic filter 070401290A Figure 27 25 Set gasket mi...

Page 431: ...Appendices Appendix B Wearing parts 23 June 2015 Version 1 7 Page 27 9 Figure 27 26 Gasket milk pump FP4600 030300201A...

Page 432: ...Wearing parts Page 27 10 Version 1 7 23 June 2015 27 5 Wearing parts 5 Figure 27 27 O ring set 3 way valve 030300102A 27 6 Wearing parts 1 Figure 27 28 Tooth belt X axis 070900965A Figure 27 29 Tooth...

Page 433: ...une 2015 Version 1 7 Page 27 11 Figure 27 30 Tooth belt milking cups front 070900955A Figure 27 31 Tooth belt milking cups rear 070900960A Figure 27 32 Tooth belt pretreatment cup 070900950A Figure 27...

Page 434: ...Appendices Appendix B Wearing parts Page 27 12 Version 1 7 23 June 2015 Figure 27 34 Tooth belt encoder Y axis 070900980A Figure 27 35 Rubber ring overflow container 030300207A...

Page 435: ...dix B Wearing parts 23 June 2015 Version 1 7 Page 27 13 27 7 Every Maintenance Figure 27 36 Cable runner 0709006670A Figure 27 37 Triflex to attachtool 070900740A Figure 27 38 Nozzle MPL 0 21 M SB WL...

Page 436: ......

Page 437: ...rdering consumables This appendix contains an overview of all consumables which are needed for maintaining a milking box The article numbers are ordering numbers of BouMatic Robotics Figure 28 1 Hydra...

Page 438: ...nsumables Page 28 2 Version 1 7 23 June 2015 Figure 28 4 Pretreatment cup liner 738513454 Figure 28 5 Oetiker clamps 13 5 mm 040300200A Figure 28 6 Oetiker clamps 15 mm 040300201A Figure 28 7 Oetiker...

Page 439: ...dices Appendix C Consumables 23 June 2015 Version 1 7 Page 28 3 Figure 28 8 Oetiker clamps 18 mm 040300209A Figure 28 9 Oetiker clamps 22 mm 040300210A Figure 28 10 Connection piece milking cup 070100...

Page 440: ...Appendices Appendix C Consumables Page 28 4 Version 1 7 23 June 2015 Figure 28 11 Connection piece pretreatment cup 070100383A Figure 28 12 Loctite 243 A348009 Figure 28 13 Loctite 542 A077284...

Page 441: ...Appendices Appendix C Consumables 23 June 2015 Version 1 7 Page 28 5 Figure 28 14 Loctite Cleaner Figure 28 15 Udderspray 0218538043 Figure 28 16 Lacta Clean 020200100A...

Page 442: ...Appendices Appendix C Consumables Page 28 6 Version 1 7 23 June 2015 Figure 28 17 San Acide 0218538091 Figure 28 18 Multi purpose grease 020300100A Figure 28 19 Milk filters 0438582755...

Page 443: ...Bucket milk settings 6 8 Button jog 12 2 teach 12 2 C Cleanings performing manually 9 5 Clearing taught teat positions 6 8 Close LF gate commands 9 4 Close LR gate commands 9 4 Close RF gate commands...

Page 444: ...sting mechanism 3 2 precautions 3 3 safety 3 2 Hold 5 5 Hydraulic system adusting settings 8 23 I Interval cleaning commands 9 6 milk settings 6 8 J Jog button 12 2 K Knowledge manual v L Left front p...

Page 445: ...Operating levels 4 3 Optimal milk settings 6 8 P Para milk settings 6 8 Password administrator level 4 3 PC shutting down 10 10 Penicillin cleaning commands 9 6 Perc min yield milk settings 8 20 Perfo...

Page 446: ...mands 9 2 Status box 5 1 Storage area milking box 3 4 Switching box control mode 5 6 Switching off spray pressure 9 2 Switching on spray pressure 9 2 T Target Manual v Teach button 12 2 Teach pendant...

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BouMatic Robotics MR-D1, Service Manual

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