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Fullwood M²erlin

Operating Instructions for Safe Use

User Manual 294130
Revision C

ORIGINAL MANUAL

Fullwood Limited
Grange Road
Ellesmere
Shropshire
SY12 9DF
England

Summary of Contents for M2erlin

Page 1: ...Fullwood M erlin Operating Instructions for Safe Use User Manual 294130 Revision C ORIGINAL MANUAL Fullwood Limited Grange Road Ellesmere Shropshire SY12 9DF England...

Page 2: ...sources of danger 9 2 5 1 Electrical Safety 9 2 5 2 Operating fluids materials 9 2 5 3 Unsuitable spare parts 9 2 5 4 Conversion or modification of the machine 9 2 6 Users Responsibility 10 2 7 Assemb...

Page 3: ...Areas 20 4 Site Positioning Fixing Levelling and Assembly 21 5 Handling and Transporting 21 5 1 The Crate 21 5 2 Process Cabinet 23 6 Cow Compatibility with Robotic Milking 24 6 1 Udder Shape Require...

Page 4: ...se only 39 10 2 Milking the Cows 40 10 3 Introducing new cows 40 10 4 Using the HMI 42 10 5 Milk Separation 48 10 5 1 Withheld and Undesirable Milk 48 10 5 2 Abnormal Milk 48 10 6 Milk Cooling and sto...

Page 5: ...ary without warning Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind ari...

Page 6: ...nce capability performance of design manufacture and reliability Whilst Fullwood equipment will comply with all relevant directives customers are reminded that all equipment into which Fullwood equipm...

Page 7: ...sonnel visitors as well as your business It helps you focus on the risks that really matter in your workplace the ones with the potential to cause real harm In many instances straightforward measures...

Page 8: ...not liable for any damages that may result from incorrect use The user alone is liable for any risks incurred 2 4 General Safety All covers and guards shall be in place before operating M erlin Keep h...

Page 9: ...stem 2 5 2 Operating fluids materials The used operating fluids and material can cause adverse health effects Suitable measures must be taken in order to prevent injuries Only Fullwood recommended che...

Page 10: ...oundings and electrical loads applied Never dismantle compressed air pipes until they are fully vented Only use pressure lines that are suitable and approved for the maximum working pressure and inten...

Page 11: ...islation Dispose of machine in accordance with local environmental regulations or hand over to an authorised disposal expert 2 11 Danger Areas During handling and operation of this machine everyone in...

Page 12: ...e will stop and all energy will disperse electricity compressed air vacuum etc The cups will drop from the teats The exit gate s will become free to be pushed pulled open so that the cow can leave the...

Page 13: ...ted inside the electrical cabinet and provides the model and important technical information The identification plate must not be removed 2 15 Size of Machine Length mm 3693 Width mm 3285 Height mm 24...

Page 14: ...ent compressed air control equipment Milk metering receiving and milk pumping equipment Feed dispensing 2 Crate and Arm Positioning device carrying teat preparation rollers laser teat cups and teat sp...

Page 15: ...are bonded to earth in accordance with local and national legislation M erlin must be earthed according to local legislation Starting up M erlin without proper earthing will render the warranty null a...

Page 16: ...surface of the machine and 1 6M from floor level and does not exceed 70 dB A Note Other surrounding equipment may increase the noise in the working area subject to their location This should be assess...

Page 17: ...cordance with current Dairy Hygiene Regulations Drainage shall be through trapped gullies with water seals and rodent proof grid covers Water from roofs and open yards not subject to fouling shall be...

Page 18: ...trols and automates processes on the dairy farm such as Automatic Identification Feed allocation to optimize milk production at most profitable feed costs Milk yield conductivity to improve udder heal...

Page 19: ...ns and Location 3 1 Understanding safety signs Read user manuals Stop machine before removing guards Finger hand trapping point Electrical Hazard Compressed Air Harmful chemicals No access Do not pres...

Page 20: ...Ref Pt No 294130 Operating Instructions for Safe Use Fullwood M erlin Revision C Date 24 Mar 17 294130 Page 20 of 81 3 3 Hazard Areas...

Page 21: ...ing Attempting to perform any of the above will result in endangering persons animals and possible damage to the machine 5 Handling and Transporting 5 1 The Crate Care must be taken when lifting or tr...

Page 22: ...achine The crate must be lifted from the cow gate side using either the fork tubes at the top of the crate or the transport frame at the bottom of the crate The transport frame ensures each leg is hel...

Page 23: ...or Safe Use Fullwood M erlin Revision C Date 24 Mar 17 294130 Page 23 of 81 5 2 Process Cabinet The process cabinet can be lifted from the front or the side using forks It can also be craned using bot...

Page 24: ...ths Tails should be trimmed and the hair kept as short as possible The udder should be free from extra teats bumps and swellings Teat separation distance A The inner dimension between the teats must b...

Page 25: ...achine No personnel on cow side of machine All access doors are closed All removable panels and guards in place and secured Ensure the process cabinet door nearest the robot arm is closed before opera...

Page 26: ...electrical cabinet Switching off Press the EMERGENCY STOP push button Result The EMERGENCY STOP button remains latched after actuation All energy sources are disabled to the machine and the machine i...

Page 27: ...Ensure a Full Plant Test has been carried out and certificate issued Verify the compressed air system has been commissioned Carry out a hot wash ensuring the water temperature in the boiler has reach...

Page 28: ...water with compressed air down the liners and to waste via the foremilk rejection chambers 7 4 3 Cleaning Chemicals Chemical MUST NOT be stored near M erlin as this will cause premature corrosion of t...

Page 29: ...above chemicals in line with manufacturer s instructions Store all chemicals in their original containers ensuring they are not misidentified and used for the wrong application 7 4 5 Chemical All the...

Page 30: ...frequency of the alkali wash If it is set to 0 only acid washes will be done If it is set to 1 every other wash will be an alkali wash If it is set to 2 two acid washes will be done to one alkali etc...

Page 31: ...r 17 294130 Page 31 of 81 7 5 Calibrate Feeders Ensure feed hopper is full prior to calibration and all robots on the system are off line 1 Start the Crystal program on the PC and select Programs menu...

Page 32: ...Page 32 of 81 3 The calibration screen will appear left click on the weigh scales again 4 The calibrate station screen will appear click on the feed dispense button type the weighed amount and click t...

Page 33: ...tags ensure that the tags line up correctly on the applicator and will lock together when correctly fitted Ensure both parts of the plastic tag have the same number If Fullwood tags are used the numb...

Page 34: ...ect arrow down 8 2 1 Removal of the Pedometer Fullwood Ltd recommends that the strap is cut and a new one used Once fitted it is difficult to remove straps by prizing out the plastic wedge while attac...

Page 35: ...r effects on the willingness of cows to visit the milking station 9 1 Preparation Ensure all building work has been completed prior to introducing cow to the M erlin Ensure all contractors and non aut...

Page 36: ...ispensed The remainder of the group should be introduced over the following days Following the initial introductory period it is essential that the farm personnel ensure that cows attend the automatic...

Page 37: ...release cow Change screen refresh Teat not yet attached detach teat when attached Teat attached Do not milk teat 75 of expected milking time reached Milking finished Manually identify cow OK Confirm A...

Page 38: ...n cups Cold wash Luke warm wash Lubricate wash Hot wash First drain pumping Second drain dry Forwards Backwards Down Left Move arm upwards Move arm downwards Move arm fast Move arm slow Start automati...

Page 39: ...Fullwood M erlin Revision C Date 24 Mar 17 294130 Page 39 of 81 I O test menu Save System information details Version Conductivity Wait for assistance Change language country Note Not all the icons ar...

Page 40: ...to display the screen for manually positioning the robotic head under the cow udder when first introducing cows to the machine once this operation has been performed for the first time the coordinates...

Page 41: ...tions under the udder to achieve better vision If still unable to achieve a representitive pattern with one or more teats press the buttons of the teats that have not been identified and move the head...

Page 42: ...anger drops into position on pressing button once and feed dispenses on second press Motor runs as long as button is pressed Separate cow default destination Separate milk shows dialog with drain buck...

Page 43: ...5 5 1kg act expected yield 3 24min since start milking Robot in online run mode No alarms Current time Toggle icon in lower right corner is used to toggle between main milk screen and details screen A...

Page 44: ...ate 24 Mar 17 294130 Page 44 of 81 Milking Details Teats not attached Milking Details The circle details the teat attachment and will progress through the next six screens showing milking progress Tea...

Page 45: ...lking Details 3 teat cow do not milk RF teat Milking Details All teats attached flow detected above threshold on right rear and front teats green background No flow detected yet on LR orange backgroun...

Page 46: ...On the milking details screen by pressing one of the teats the user can select if a teat A Should not be milked B Should be detached will be reattached if exp milk time has not been reached C has milk...

Page 47: ...Instructions for Safe Use Fullwood M erlin Revision C Date 24 Mar 17 294130 Page 47 of 81 Milking Details Milking Details 75 of expected milk time reached on front teats Milking Details All teats deta...

Page 48: ...nd or high electrical conductivity The operator via Crystal should define the conditions in which milk likely to be abnormal can be rejected to drain or separate collection If in Crystal the milk is p...

Page 49: ...mn with the exclamation mark icon indicates if a cleaning should be performed according to the embedded system The column with the clock icon shows the time the last cleaning of a certain type has bee...

Page 50: ...Mar 17 294130 Page 50 of 81 Cleaning Progress Milk sampling Shows progress of the cleaning cycle The upper progress bar A shows the progress of the indicated step the lower progress bar B shows the p...

Page 51: ...and milkings Screen details the following milking statistics Date of milking Time of milking Cow ID Actual and Expected yield Time in crate Destination of milk Result of milking ok not ok Overview of...

Page 52: ...ge and country settings When the tap icon is used all buttons are ignored for 20seconds This allows for cleaning the screen without accidentally pushing buttons Overview of Alarms Screen details the f...

Page 53: ...Check arm has correct park position r Check air bleeds on shells r Check the Cartesian belts and rails for damage r Check the Z axis rollers are clean and free form dirt r MILKING EQUIPMENT Check teat...

Page 54: ...ow milkings or every six months whichever comes first Liners should always be replaced in sets of four Select the correct liner to go with the shell vacuum chamber and liner gauge Put the robot into P...

Page 55: ...ssure washer Holding Crate Robotic Arm Using a hose pipe low pressure or a bucket of soapy water and a brush remove all debris from interior and exterior of crate and arm External Milking Equipment Us...

Page 56: ...bers x x x x x Check vacuum sensor calibration x x x x x Check adjust ACR ropes x x x Change ACR Ropes x x Change diaphragm on milk flow sensor x Change O Rings on rope end cover and shell x x x x x C...

Page 57: ...during a main clean x x x x x Check Chemical usage x x x x x Check sanitary trap x x x x x Change acid injection periceltic pump tube if fitted x x x x x Feeding System Check all feed types dispense...

Page 58: ...f machine for correct End Gate Linkage Bushes to be fitted during service one in year 2 3 4 Change end gate linkage bushes Pre Rev 1 5 1 x 291421 Pre Rev 1 5 Tri Link Service Kit one gate Change end g...

Page 59: ...Liner Name FL7S FL7W SL2CTF WT SL1CTS SL1CTW Vacuum level kPa 47 50 46 48 Ratio 65 35 60 40 60 40 65 35 Rate ppm 60 Preferred Setting Matching Liners to Breeds Liner Part No 020146 020167 020138 02022...

Page 60: ...007663 O Ring 10 00mm x 2 00mm 007670 Rope End Cover 092259 Liner Cutting Gauge 091369 As M erlin does not use the short milk tube section of the liner the following liners can be substituted 020169 F...

Page 61: ...opened manually A cow enters M erlin and rejected after identification Cow is not in the database Transponder Pedometer has failed Cow isn t ready for milking Enter cow details onto the database Repl...

Page 62: ...fter milking has finished a The exit gate does not open b The exit race is blocked c The cow does not move 2 Sensor stops sensing cow 1 Remove the cow from the box a Check the gate control operation b...

Page 63: ...rror class alarm is generated Error will be generated Cow will be released system will stop all action No communication to Merlin Arm Fatal when arm is turned in otherwise Error class System needs to...

Page 64: ...eout is passed After timeout an error will be generated the cow will be released and the system will continue milking other cows Animals need to be taught for the first time milking or user has marked...

Page 65: ...22 fatal error ARM_NOTEATS No teats are marked for milking in data send to Merlin Fatal when arm is turned in otherwise Error class Milking which is started will be aborted Will happen when main cont...

Page 66: ...ror will be generated Merlin will stop all actions Milk vessel is not emptied within the set time default 5 minutes after the milk pump has been started Check milk pump and level sensors and reset ala...

Page 67: ...onger than set time in configurator and or milk tank has jumped in error after cleaning When the delivery line to the milk tank is not available for a longer time Than set in the Configurator Check mi...

Page 68: ...ed info message will be generated and system will continue milking cows After 3 fails in a row system will generate an error and will stop milking cows No teats can be found After certain number of re...

Page 69: ...l continue milking cows After 3 fails in a row system will generate an error and will stop milking cows A certain level of flow is not detected when expected Check system and reset alarm 48 info ARM_N...

Page 70: ...ox UI Check system and reset alarm 51 info ARM_COMM _ABORT Break off milking on arm control box milking aborted by command from Merlin Cow will be release info message will be generated and system wil...

Page 71: ...pause mode No cows will be milked but cleanings will be executed Error generated if blood sensor sees 3 animals in a row with blood in the milk warning when old type blood sensor doesn t communicate a...

Page 72: ...tning protection input is disabled An error will be generated all activities will be stopped and Merlin will go into off line mode The input activated by the air pressure monitoring unit is deactivate...

Page 73: ...ve and feedback reset alarm 72 error FlowVacuum sensors One More of the flow vacuum sensors aren t working Broken pulsator problem wiring pulsator not programmed and or not configured System cannot co...

Page 74: ...case arm is outside the box No communication between the Festo PLC and the UCC Check system and reset alarm 78 warning NO_SYSTEM_ COMMUNICATIO N No communication timeout between the HMI and the main...

Page 75: ...ge milk time on that teat Check arm milk flow sensor and air bleeds and reset alarm 84 info ARM_MILK SENSOR_RR Milk sensor gives incorrect value on RR Air bleed not open Milking will be terminated sys...

Page 76: ...s incorrect value on LF Air bleed not open Milking will be terminated system will continue milking other cows no increase in milk yield detected by the milk meter for 120 seconds teat milking for a mi...

Page 77: ...ling 16 1 Setting Cows for Sampling in Crystal Open Crystal and then go Animals Milk As long as the cow is able to be milked in the robot the next time she is milked a sample will be taken 1 Click the...

Page 78: ...f 81 In the Samples take column modify the value to 1 to set all cows to have 1 sample Click Apply to accept the changes All the animals will be set to take 1 sample Note The fields within the table t...

Page 79: ...nect the red flexible airline from the Sampler to the quick connect port A on M erlin Remove the plug B from the underside of the milk receiver and replace with connector C Connect the other end of th...

Page 80: ...age 80 of 81 Set M erlin HMI to display menu For further operating instruction refer to the user manual for the sampler used Example of report Animal No Milking date and time of cow Recorded productio...

Page 81: ...t should be familiar with relevant safety regulations i e BS EN 1012 1 1997 Compressors and vacuum pump Standards and recommendations are available from BSI or HMSO Water All owners or occupiers of pr...

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