Transcript
S50 08.100GB
2013
Maintenance Manual Automatic Milking System
DK 6000 Kolding · TEL: +45 75 52 36 66
17000049980-002
www.sacmilking.com ·
[email protected]
16.08.17
Copyright Information in this document is subject to change without notice and does not represent a commitment on the part of Hokofarm Group BV. In no event shall Hokofarm Group BV be liable for incidental or consequential damages arising from use of this document or the software (if applicable) and hardware described herein. The original English text of this document will be legally binding and shall prevail in case of any variance between the English text and a translation. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the express written permission of Hokofarm Group BV. The software described in this document (if applicable) is furnished under the Software License Agreement. The software may be used or copied only in accordance with the terms of the license. Copyright 2012 by Hokofarm Group BV, All Rights Reserved. Hokofarm Group BV Voorsterweg 28 8316 PT Marknesse The Netherlands
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Revision History Date November 2013 January 2014 February 2016 May 2016
Definition Issue 1.0 Issue 2.0 Issue 3.0 Issue 3.1
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Table of contents 1
2
3
General Information ........................................................................ 1 1.1
About this document ............................................................................................................ 1
1.2
Available technical documentation on the AMS ................................................................... 1
1.3
Document storage ................................................................................................................ 3
1.4
Conventions ......................................................................................................................... 3 1.4.1 Safety alerts ............................................................................................................. 3 1.4.2 Other notices ........................................................................................................... 3 1.4.3 Typographical and authoring conventions ............................................................... 3
1.5
Conversion SI-units – Imperial units .................................................................................... 4
1.6
Service and support ............................................................................................................. 4
1.7
Environmental protection ..................................................................................................... 4
1.8
Abbreviations ....................................................................................................................... 4
Safety instructions .......................................................................... 7 2.1
General ................................................................................................................................ 7
2.2
This document...................................................................................................................... 7
2.3
Decals and instructions on the AMS .................................................................................... 7
2.4
Before starting work ............................................................................................................. 8
2.5
During work .......................................................................................................................... 8
2.6
When work is finished .......................................................................................................... 9
2.7
Safe access to the manipulator area ................................................................................... 9 2.7.1 Safety circuit of the manipulator area ...................................................................... 9 2.7.2 Entrance Control Unit (ECU) ................................................................................... 9
Milking box ..................................................................................... 11 3.1
Check general condition milking box ................................................................................. 11
3.2
Check Entrance/exit gate ................................................................................................... 11
3.3
Check Drive out unit ........................................................................................................... 12
3.4
Check Cow tracker system ................................................................................................ 13
3.5
Check Spray system .......................................................................................................... 13
3.6
Check positions milk beakers ............................................................................................ 13
3.7
Check jettercover ............................................................................................................... 14
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5
6
Pre-treatment process................................................................... 15 4.1
Replace preparation cup liner ............................................................................................ 15
4.2
Check hoses preparation ................................................................................................... 15
4.3
Check gravity drain ............................................................................................................ 16
4.4
Check vacuum shutter ....................................................................................................... 16
4.5
Replace vacuum hose pre-treatment ................................................................................. 16
4.6
Replace milk/pulsation hose pre-treatment ....................................................................... 16
4.7
Check/clean pulsator preparation system .......................................................................... 17
4.8
Check preparation functions/process................................................................................. 17
4.9
Clean preparation sensor valve ......................................................................................... 18
4.10
Replace vacuum sensor (flexprep only) ............................................................................ 18
4.11
Repace non return valve pre-treatment (flexprep only) ..................................................... 19
4.12
Replace cleaning jetters pre-treatment .............................................................................. 19
4.13
Overhaul pulsator pre-treatment ........................................................................................ 19
Scanning / vision / attachtool ....................................................... 21 5.1
Check General condition attachtool ................................................................................... 21
5.2
Check gripper block + arms ............................................................................................... 21
5.3
Check Camera glass .......................................................................................................... 22
5.4
Check Laser glass + laser line ........................................................................................... 22
5.5
Check ribbed flexible tube .................................................................................................. 22
5.6
Overpressure attachtool ..................................................................................................... 23
5.7
Check attach results Vision2Milk / Vision pc ..................................................................... 24
5.8
Replace filter overpressure attachtool ............................................................................... 25
Milking process ............................................................................. 27 6.1
Check milk beaker + milk hose .......................................................................................... 27
6.2
Check detach cylinder (speed) .......................................................................................... 27
6.3
Check bypass shutter + Vacuum shutter ........................................................................... 27
6.4
Replace hoses under shutters ........................................................................................... 27
6.5
Replace the non return valve ............................................................................................. 28
6.6
Check air connection milk line (non-return) ....................................................................... 29
6.7
Check air connection milk hoses (non-return) ................................................................... 30
6.8
Check air pressure (2 bar) regulator(s) CU ....................................................................... 30
6.9
Check milk separation valve .............................................................................................. 31
6.10
Overhaul milk pump ........................................................................................................... 31
6.11
Clean the spray ball and Check level sensors ................................................................... 31
6.12
Milk meter........................................................................................................................... 32 6.12.1 Overhaul milkmeter ............................................................................................... 32 6.12.2 Check milkmeter ................................................................................................... 33 6.12.3 Calibrate the Milk meter ........................................................................................ 34
6.13
Check the IMAC system .................................................................................................... 35
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8
9
Vacuum System ............................................................................. 37 7.1
Vacuum pump .................................................................................................................... 37 7.1.1 Check oil level ........................................................................................................ 37 7.1.2 Refresh oil .............................................................................................................. 37 7.1.3 Cleaning the vacuum pump ................................................................................... 38
7.2
Check/adjust vacuum level ................................................................................................ 38
7.3
Check/clean Pulsator ......................................................................................................... 39
7.4
Overhaul Pulsator .............................................................................................................. 39
7.5
Clean vacuum delete and cleaning valve pulsator ............................................................ 39
7.6
Overhaul reverse amplifier ................................................................................................. 39
7.7
Overhaul vacuum regulator ................................................................................................ 40 7.7.1 Clean vacuum regulator (for systems without external filter) ................................ 40 7.7.2 Check external filter vacuum regulator (optional) .................................................. 40
7.8
Clean the sanitary trap (AMS2013) .................................................................................... 41
7.9
Pulsation measurement ..................................................................................................... 41
Water system ................................................................................. 49 8.1
Replace filter water supply intake ...................................................................................... 49
8.2
Check couplings water supply ........................................................................................... 50
8.3
Clean steam generator ...................................................................................................... 50
Cleaning process........................................................................... 51 9.1
Check main cleaning .......................................................................................................... 51
9.2
Replace cleaning jetters milking box .................................................................................. 51
9.3
Check cleaning fluid system .............................................................................................. 52
9.4
Replace feeder hoses cleaning fluid system ..................................................................... 52
9.5
Calibrate cleaning fluid system .......................................................................................... 53
9.6
Check Tankvalve system ................................................................................................... 53
9.7
Replace drain valve............................................................................................................ 54
10 Manipulator / Robot ....................................................................... 57 10.1
Backup ............................................................................................................................... 57 10.1.1 Make a CMOS backup .......................................................................................... 57 10.1.2 Make a standard backup....................................................................................... 57
10.2
Check safety switch(es) entrance gate(s) .......................................................................... 58
10.3
Check ventilation motoman cabinet ................................................................................... 58
10.4
Lubrication .......................................................................................................................... 59 10.4.1 Roadmap............................................................................................................... 59 10.4.2 Position greasing points. ....................................................................................... 61
11 Other maintenance tasks .............................................................. 65 11.1
Clean filter cabinet CU ....................................................................................................... 65
11.2
Replace filter Cabinet CU (AMS2013) ............................................................................... 65
11.3
Check back-up’s................................................................................................................. 65
11.4
Check air silincer valveblocks ............................................................................................ 66
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12 Auxiliary maintenance information .............................................. 67 12.1.1 12.1.2 12.1.3
Battery Motoman manipulator / CPU .................................................................... 67 Battery UPS system CU ........................................................................................ 67 Battery UPS system TIM controller ....................................................................... 67
12.2
Maintenance to external/other equipment ......................................................................... 67 12.2.1 Compressor and Air dryer ..................................................................................... 67 12.2.2 Pre-Cooler ............................................................................................................. 67 12.2.3 Buffer tank ............................................................................................................. 67 12.2.4 Feeding box .......................................................................................................... 67 12.2.5 Selection gate ....................................................................................................... 67
12.3
OEM documentation .......................................................................................................... 68
13 Appendix ........................................................................................ 69 13.1
Milkpump tools ................................................................................................................... 69 13.1.1 Shaft assembly tool (RD0061) .............................................................................. 69 13.1.2 Milk pump seal assembly tool (RD0060) .............................................................. 70
13.2
Vacuum meter .................................................................................................................... 71
13.3
Pulsator .............................................................................................................................. 73
13.4
Vacuum regulator ............................................................................................................... 75
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General Information
1 General Information 1.1 About this document This document applies on AMS versions build from 2011. Some specific service information may only apply on AMS versions build since 2013. In these cases this will be shown in the manual by adding (AMS2013) to the maintenance topic. This document is intended for qualified and trained service engineers to be able to do all occurring service, troubleshooting and repair tasks on the Automatic Milking System (AMS) mentioned on the front cover of this document. Note Before you start with any service, troubleshooting or repair tasks on the AMS, make sure that you read and fully understand the contents of this document. Strictly observe the instructions given in chapter 2 Safety instructions. This document has been prepared with great care, in compliance with the relevant regulations, and based on our experience and latest knowledge. The information in this document is therefore valid and correct at the moment of release (the release date is shown in the footer of the document). However, changes and improvements may be made to this document at any time and without prior notice. The source language of this document is English. As a translation may be imprecise or inaccurate, the original English text will be legally binding and shall prevail in the case of any difference between the source text and the translation. Note As we continuously improve and develop our products, it is not always possible to provide a truthful picture of every single detail of the AMS. The illustrations in this document therefore always show a typical and standard AMS setup with two milking boxes (double box setup). Optional equipment, or significant differences between AMS setups will be clearly marked, both in the text and (if required) in the illustrations. In accordance with CE regulations, the area around the manipulator is a restricted area secured by sensors. As the area can be screened by different types of customer-specific fencing (a fence, a wall, etc.), the fencing shown merely serves as an example.
1.2 Available technical documentation on the AMS Each AMS comes with a complete set of technical documents. The documents are arranged in five different guides, one guide per target group. Table 1.1 Available technical documentation on the AMS lists these documents, the document ID numbers and the target groups.
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General Information
Table 1.1 Available technical documentation on the AMS Guide number Target group Documents in this guide
/i
Guide 1
(Future) owners and users
Site Preparation Manual (SPM) Commissioning Manual (CM)
Document ID number UK11*** UK12***
User Manual (UM)
UK13*** UK14***
Guide 2
Installation engineers
AMS Management Software Manual (MSM) Installation Manual (IM)
Guide 3
Service engineers
Service Manual (SM)
UK31***
Wiring Manual (WM)
UK32***
Maintenance Manual (MM)
UK41***
Maintenance schedule & parts
UK42***
Spare Parts Catalogue (SPC)
UK51***
Guide 4
Guide 5
Maintenance engineers Maintenance engineers Service engineers and AMS dealers
UK21***
The document ID (e.g. [UK1] [1] [1] [00] consists of four fields. See Table 1.2 Structure of the document ID number Table 1.2 Structure of the document ID number
Field number
Description
Definition
1
Guide number
2 3
Number of the document in the guide Execution of the AMS
[UK1] = Guide 1 [UK2] = Guide 2 [UK3] = Guide 3 [UK4] = Guide 4 [UK5] = Guide 5 E.g. [1], [2], etc.
4
Two-digit language number
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[0] = Hokofarmgroup system (default) [1] = Insentec system [2] = SAC system [3] = Happel system [*] = applies to all above-mentioned systems
[00] = UK English (default) [01] = Dutch (nl) [02] = German (de) [03] = French (fr) [04] = Danish (da) [05] = Swedisch (sv) [06] = Finnish (fi) [07] = Norwegian(no) [*] = Applies to all above-mentioned languages
2
General Information
1.3 Document storage This document must be kept in a safe place, near the AMS. The document must be accessible at all times.
1.4 Conventions The following conventions are used in the technical documentation of the AMS. 1.4.1 Safety alerts The following safety alerts may be used throughout the technical documentation of the AMS. Warning Identifies safety instructions that are intended to warn of possible danger to life and limb or possible serious damage to property. Failure to comply with these safety instructions could result in fatalities, serious personal injuries (disablement) or serious damage to property. The icon in front of the alert identifies the nature of the warning. The exclamation mark denotes a general warning. CAUTION Identifies safety instructions that are intended to warn of minor personal injuries or minor damage to property. Failure to comply with these safety instructions may result in minor personal injuries or minor damage to property. The icon in front of the alert identifies the nature of the caution. The exclamation mark denotes a general caution. Note Identifies an important note or an instruction that you must always observe.
1.4.2
Other notices Tip Identifies an important recommendation.
1.4.3
• • •
Typographical and authoring conventions Listings and enumerations without prescribed order are always preceded by a bullet. Steps in a procedure that must be performed in consecutive order are always numbered. Abbreviations are defined upon first use in the document (except in a title).
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General Information
1.5 Conversion SI-units – Imperial units Table 1.3 Conversion SI-units - imperial units
SI-units => Imperial units
Imperial units => SI units
1 mm = 0.03937 in
1 in – 25.4 mm
1 cm = 0.3937 in
1 in – 2.54 cm
1 m = 3.28 ft
1 ft = 0.3048
1 kg ≈ 2.2046 lb
1 lb ≈ 0.453592
1 mPa (= 1000 kPa, = 10 bar) = 145 psi
1 psi = 0.0068966 mPa (0.0689 bar)
1 l = 0.264172051242 US gallon
1 US gallon = 3.79 l
⁰Celsius x 1.8 +32 = ⁰Fahrenheit
⁰Fahrenheit – 32 / 1.8 = ⁰Celsius
1 dH = 0.056 ppm (CaCo3)
1 ppm (CaCo3) = 17.8 dH
1.6 Service and support For information about service, troubleshooting and repair that is beyond the scope of this document, please always contact Hokofarm Group Services.
1.7 Environmental protection Please observe all local regulations and recommendations for the disposal, recycling or environmentally friendly processing of parts and materials that have been used or replaced during the tasks described in this document.
1.8 Abbreviations The following abbreviations may be used throughout the technical documentation of the AMS. The abbreviations are defined upon first use in a document (except in a title) Table 1.4 Abbreviations Abbreviation Definition AMS
Automatic milking system
CM
Commissioning manual
COG
Centre of Gravity
ECU
Entrance Control Unit
FBWF
File-Based Write Filter
IM
Installation Manual
MCU
Milking box Control Unit
MSM
AMS Management Software Manual
MSU
Multi Separation Unit
PCB
Printed Circuit Board
SCU
Service Control Unit
SM
Service Manual
SPC
Spare Parts Catalogue
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General Information
SPM
Site Preparation Manual
UM
User Manual
FMS
Farm Management Software
TIM
Total Integrated Management
.
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Safety instructions
2 Safety instructions 2.1 General • •
•
•
Service and maintenance work is strictly reserved to qualified and trained service and maintenance engineers. We accept no liability for any damage or physical injury caused by non-compliance with the safety instructions in this document, or by carelessness during service, maintenance or commissioning of the AMS. Depending on the specific working conditions at the work site, additional safety instructions may be applicable. As we have no direct control over these specific working conditions, it is the engineer’s sole responsibility to ensure that the local Health and Safety regulations are adhered to. Please inform us immediately if you have dealt with unsafe situations that have not been described. The AMS also uses third party components (e.g. the boiler). For the specific safety instructions on these third party components please consult the corresponding manuals.
2.2 This document • • •
Read this document thoroughly before performing any service or maintenance task. Make sure that you always have the latest version of the Service Manual (SM) or Maintenance Manual (MM) at your disposal. Carry out the procedures in the order given. Do not change the order of the steps.
2.3 Decals and instructions on the AMS •
•
Decals or instructions fitted on the AMS (see Table 2.1 Possible decals and instructions on the AMS) are part of the safety features provided. They must not be covered or removed, but must be present and legible throughout the entire life of the AMS. Damaged or illegible decals and instructions must be replaced or repaired immediately.
Safety decal
Description WARNING This area contains a device with moving parts that may start automatically. Before you enter this area, proceed as described below. CAUTION The component contains a laser unit. Do not look directly into the laser beam.
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Safety instructions
WARNING This moving part may start to move unexpectedly
WARNING Risk for entrapment. You may get caught between the fencing and the milking box.
WARNING Your fingers may be pinched off. Keep your hands clear
WARNING Hazardous voltage. This area contains live parts. Disconnect the power before you open the component in question. WARNING Mordant acids. Wear adequate eye propection
2.4 Before starting work • • • • • •
Check that the working area is completely safe and clear. Make sure that unauthorized persons have no access to the working area. Make sure that the working area is sufficiently lit and ventilated. Dress properly. Do not wear torn or loose fitting clothes, but wear protective clothing. Remove jewelry, watches, etc. to prevent them from being caught in moving parts. Wear protective shoes and keep long hair out of the way.
2.5 During work •
•
Stay alert and watch what you are doing. Use common sense. Do not work on the AMS when you are tired or have been taking alcohol, medicine or drugs. Do not smoke. Use a lifting device when lifting 25 kg or more. Only use suitable and technically perfect lifting devices with adequate lifting capacity, built in compliance with all safety measures. Fastening of loads and giving instructions to the operator of the lifting
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Safety instructions
•
• • •
device is restricted to experienced personnel who is within sight or sound of the operator of the lifting device. Only use tools, parts, materials, lubricants and installation techniques that were approved by Hokofarm Group BV. Do not use contaminated or used lubricants. Used lubricants, cleansing agents, etc. must be disposed of in an environmentally safe way. Avoid bodily contact with lubricants. Never use worn tools. Do not leave any tools behind in the AMS. Never weld on any part of the AMS without the prior written permission of Hokofarm Group BV. Never re-use self-locking fixing materials. Always replace them.
2.6 When work is finished • • •
Inspect the entire AMS. Check the system for damage, leakage or defects. Do not clear the AMS for operation unless you have verified that it is absolutely safe, clean and in perfect working order. Before leaving the farm, engineers should always ensure that the safety circuit for the AMS (see 2.7.1 Safety circuit of the manipulator area) is operational.
2.7 Safe access to the manipulator area 2.7.1 Safety circuit of the manipulator area In accordance with CE regulations, the area around the manipulator is a restricted area secured by a safety circuit installed on the door or the fence that gives access to this area. When the door or the fence is opened accidentally, this safety circuit -functioning as an EMERGENCY STOP- automatically and immediately stops the manipulator, allowing you to enter the manipulator area without risk. As the manipulator will stop at once, it will not regain its home position and may stop at an undesirable position. Therefore, if you want to go inside to the manipulator area (e.g. to attach the cows manually) always use the Entrance Control Unit (ECU). Warning Never disable or bridge the safety circuit of the manipulator area. The manufacturer accepts no liability whatsoever from any injury or damage arising from tampering with the safety circuit.
2.7.2 Entrance Control Unit (ECU) To prevent the manipulator from stopping at an undesirable time or position, the AMS also comprises an ECU (see Fig. 2.1 ECU). This ECU is generally mounted on the fence (or the door) that gives access to the manipulator area.
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Fig. 2.1 ECU
A Red lamp B Tumbler switch
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Milking box
3 Milking box 3.1 Check general condition milking box When checking the general condition of the milk box pay attention to the following items.
Check the milk box for damaged parts, loose screws (feed trough/gates/feed dispenser etc.), sharp edges or other imperfections. Check for air leakages at couplings, hoses and cylinders. Check if the milk box is clean, especially around the feed trough. If not, make the user aware of this. Check the rubber protection caps on the buttons of the MCU. The caps should ensure a watertight fit. Check if all cabling and air hoses are tied up. Tie up any loose cable or hose. Info Don’t forget to check for loose screws, bolts and nuts of fencing around the robot.
3.2 Check Entrance/exit gate Check the entrance and exit gate as follows.
Check the opening speed and closing speed of the gates as explained in chapter 8.2.2. of the service manual UK312xx. Grease all moving parts and hinges of the gates using silicon spray. Check if the gates are moving smoothly. Check if the grounding cables of the gates are still installed. Info For more information on adjusting the Entrance and exit gate check chapter 8.2 of the service manual UK312xx
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Milking box
3.3 Check Drive out unit Check the operation of the Drive out unit by pulling the electrode cords down and gently touching the ends of the electrodes together. A good functioning drive out unit should create a small spark. Check if Drive out cords doesn’t create a small spark in upward position. Warning There is voltage at the cords of the Drive out unit. Make sure you don’t touch the cords with your hands/ body but with an isolated tool.
Info For more information on the working principle and adjustments of the drive out unit check chapter 8.4 of the service manual UK312xx
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Milking box
3.4 Check Cow tracker system Check the cow tracker system as follows
Check if the cow tracker bar is moving free and that the construction is not deformed. Grease the hinge points of the cow tracker bar using silicon spray Check the cow position data via Vision2Milk according to chapter 8.5.6 of the service manual UK312xx Info More information on the working principle and adjustments of the cow tracker system can be found in chapter 8.5 of the Service manual UK312xx
3.5 Check Spray system Check the spray system as follows.
Check if the sprayer arm moves up and down freely. On the SCU Select [actuators]-[spray unit] press ‘enter’ Check whether there is enough spray coming from the nozzle Take care of a correct spreading of the spray fluid (in consultation with user) Check the pressure at the vessel.
If the spray pattern is not correct the system might be blocked. In that case it needs to be cleaned. Cleaning of the spray system is done as follows:
Fill the spray vessel with warm water and soap. Activate the valve via valve block 3 valve 6 or via the [valves]-[flush sprayunit] menu in the SCU. Tip Cleaning the spray system is a user task. Cleaning the system works best when the spray-vessel is empty and the user needs to refill.
3.6 Check positions milk beakers Check the positions of the milk beakers by moving the Motoman arm to each specific beaker position.
If the beaker position is ok: do not change If the beaker position is not ok: change the position (more information can be found in the service manual chapter 21) o The position is not OK when: The attachtool ‘moves’ when closing the gripper The gripper closes the arms on one of the ‘rings’ of the beaker When closing the gripper you should hear a short sound of the grippers touching the beaker
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Milking box
o
Check if guiding sleeve is in good condition. When not, the beaker will be pulled too far into the guiding sleeve. Take in to account that when the beakers deviate very much, the beaker unit might be changed from position. Check this and if things are bend away or moved, try to correct the deviation there first.
Note If deviations on the beaker positions are large or when making major changes: always make a Backup and a CMOS backup. (service manual UK312xx, Chapter 23.3.1 and Chapter 23.3.2)
3.7 Check jettercover For a proper cleaning of the milkbeakers it’s important that the jetters are sealing tight. It’s adjustable at three points. (See fig. 3.1 Jettercover adjustment points).
Fig. 3.1 Jettercover adjustment points
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Pre-treatment process
4 Pre-treatment process 4.1 Replace preparation cup liner Check the preparation cup when replacing the teat liner.
Remove the liner. When the preparation beaker is dirty, clean the inside of the beaker. Tip When the preparation beaker is dirty inside, also check the pulsation line for dirt. If the pulsation line is dirty or clogged, flush the pulsation line with water. Before flushing the pulsation line, disconnect the hose end from the pulsator. When connecting the pulsation hose back to the pulsator, blow out any remaining water in the hose.
On older systems the preparation cup is attached rigid to the bracket, It might be deformed. when it is not clamped straight between the grippers, put the handle of a hammer into the pre-treatment beaker. Using the handle as a lever, force the pre-treatment beaker in the correct position. o
Mount a new preparation cup liner Note Preparation beakers without the Flex Prep sytstem use different teatliners. Mount the correct teat liner.
Info Information on replacing the preparation cup liner can be found in chapter 9.2.2 of the Service manual UK312xx
4.2 Check hoses preparation Check the milk hose, pulsation hose, water/air hose and vacuum sensor hose of the preparation as follows
Check the hose for hair cracks or unusual wear. Check if the hoses are tied up correctly. Check for constipation.
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Pre-treatment process
4.3 Check gravity drain Check the drain valve for dirt or pollution and vacuum leakage. Ensure that draining of the preparation milk and cleaning water is ok. Info Information on the drain valve can be found in chapter 9.3.1 of the Service manual UK312xx
4.4 Check vacuum shutter Check the vacuum shutter as follows.
Go to the I/F panel of the programming pendant Check if the I/F PANEL is enabled. The switch position in the upper right corner must be PERMIT Press the TEST button and choose VACUUM. Thoroughly inspect the condition of the vacuum hose. Info Information on the vacuum shutter can be found in chapter 9.3.2 and 9.5.3 of the Service Manual UK312xx
4.5 Replace vacuum hose pre-treatment Replace the vacuum hose as follows
Open the vacuum shutter as explained in 4.4 Check vacuum shutter Cut the hose 30 cm before the vacuum shutter Place a hose joiner on the existing vacuum hose Place a new vacuum hose onto the joiner, and guide it through the vacuum shutter Connect the hose to the preparation unit vacuum system.
4.6 Replace milk/pulsation hose pre-treatment Replace the milk pulsation hose as follows. (See fig. 4.1 Pretreatment hose)
Disconnect the milk/pulsation hose from the coupling at (C) Disconnect the milk/pulsation hose from the coupling of the preparation beaker (E) Install a new hose, mount with cable ties.
Fig. 4.1
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Pre-treatment hose
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Pre-treatment process
4.7 Check/clean pulsator preparation system Check the pulsator for dirt or pollution and blockage When the pulsator is polluted, clean the pulsator as follows
Remove the pulsator from the vacuum tube Dismantle the pulsator Clean the pulsator in warm water with soap CAUTION Be careful of loose parts. Small parts inside!
4.8 Check preparation functions/process Check the preparation function and the cleaning of the preparation beaker as follows.
Select the Job ‘Service’ in the programming pendant Set the mode switch (Q) to PLAY Close the safety gate(s) Press ‘Servo on Ready’ (E) Press the ‘Play’ button (A) Go via the I/F panel to the tab ‘test’ Check if the I/F PANEL is enabled The switch position in the upper right corner must be PERMIT Test the following functions Prepare The prep cycle starts. Check the prep cycle Short cln The short cleaning procedure starts. Check the amount of steam, the position and that water and air are sprayed onto the laser and camera lenses optimal. Main cln Check that the main cleaning Rubber washer is pushed backwards (≈1cm.) to open the valve.
Fig. 4.2
Programming pendant
Caution When starting the Short cln and Main cln program, the manipulator will move on operating speed! Keep a safe distance.
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Pre-treatment process
4.9 Clean preparation sensor valve Check small hole during every service visit (see figure 4.3 preparation sensor).
Dismount air hose from coupling (1). Dismount coupling (1). Check inside on dirt and scale. If hole is blocked, clean system until visually clean. o It is allowed to use air on outlet 1. o Use toothbrush/water/etc. Mount coupling and hose again.
1
Caution Never put air pressure on outlet 2, the sensor cannot handle high pressure. Be careful, hole size is 0.5 mm, don’t damage the hole size.
2
Figure 4.3 Preparation sensor
4.10 Replace vacuum sensor (flexprep only) Replace the vacuum sensor as follows.
Disconnect the sensor connection in the robot controller, connector CN306 Remove the cable tie from the sensor and valve to dismount it. Remove the protection cap from the sensor and disconnect the cable lugs from the sensor. Exchange the old vacuum sensor with a new sensor on the valve. Mount cable at the new sensor (pin 2 and pin 3). Tune the sensor at 100 mbar and mount the protection cap. Connect the sensor connection in the robot controller, connector CN306 Mount the sensor and valve again by using a cable tie. Test prep cycle. See chapter 4.8 of this manual.
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Pre-treatment process
4.11 Repace non return valve pre-treatment (flexprep only) According the maintenance schedule replace the non return valve. (See figure 4.4 Non return valve pre-treatment “part 4”).
Fig. 4.4 Non return valve pre-treatment
4.12 Replace cleaning jetters pre-treatment Replace the cleaning jetters of the pre-treatment system as described in the service manual UK312xx chapter 9.4.2
4.13 Overhaul pulsator pre-treatment The pulsator should be overhauled once a year. Revision sets are available. For an exploded view of the pulsator see the appendix 13.3 of this manual. CAUTION Be careful of loose parts. Small parts inside!
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Scanning / vision / attachtool
5 Scanning / vision / attachtool This chapter describes all the maintenance checks on the attachtool, and the vision system. Info More information on the attachtool the vision system and the scanning process can be found in chapter 15, 16 and 17 of the Service manual UK312xx
5.1 Check General condition attachtool Perform the following actions to check the general condition of the attachtool
Check for damage to the attachtool housing Check whether all nuts and bolts are secured Check the screws in the side cover of the attachtool. o Secure them with a torque of 2Nm Check for dirt or moisture inside the attachtool on the laser and camera glasses. If so, o Check the amount of overpressure o Check the pneumatic installation on moisture in the air circuit. o Check for water in the air compressor (malfunctioning air dryer or reverse valve in the air/cleaning circuit) o Clean the camera and laser lenses. If there has been water in the attachtool, optimal working cannot be guaranteed. In this cases replace the attachtool. Note The attachtool is a calibrated unit. Do NOT open the attachtool. If the attachtool is opened, Hokofarm Group BV can no longer be held responsible for the correct functioning of the unit. All guarantee will be void.
5.2 Check gripper block + arms Check the gripper block and arms as follows.
Check the opening width of the gripper Check general condition of gripper system. Check for damaged parts. Info The opening width of the gripper should be between 80-90 mm (measured from tip to tip of the gripper arms. It is not possible to adjust the closing width. The gripper must hold the milk beaker firmly, without any clearance. If there is too much play (4mm) in his closed position, replace the gripper block or replace the gripper arms.
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Scanning / vision / attachtool
5.3 Check Camera glass Check the camera glass for scratches or damage. When the protection glass is damaged (e.g. due to scratches or a dull surface), the protection glass must be replaced as this will affect the scanning process.
5.4 Check Laser glass + laser line Check the camera glass for scratches or damage. When the protection glass is damaged (e.g. due to scratches or a dull surface), the protection glass must be replaced as this will affect the scanning process. Visually check the laserline. Follow the next steps:
Turn the laser on via Vision2milk: [Service] – [Framegrabber] –[Capture test] Hold a white piece of paper (A4) on a distance of 20 cm in front of the laser The laser line should be projected on the paper and form a sharp, straight line, around 1 mm thick. It should not be interrupted or fuzzy
5.5 Check ribbed flexible tube Check the ribbed flexible tube for cracks or damages. If the ribbed flexible tube is damaged, but the wiring and the air hoses are OK, replace the ribbed flexible tube only. CAUTION Be careful when installing a new ribbed flexible tube. Take care for the video connector or Ethernet-connector.
If the wiring and the air hoses inside the ribbed flexible tube are damaged, replace the entire attachtool. Info See section 16.5.3 Replace the ribbed flexible tube and section 16.7 Replace the attachtool of the service manual UK312xx
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Scanning / vision / attachtool
5.6 Overpressure attachtool The AMS uses overpressure to prevent the formation of condensation inside the attachtool. Check the overpressure as follows.
Remove the overpressure hose at the speed governors in the front of the CU. Check the overpressure coming out of the speed governor. It should be a gentle breeze of air. Adjust pressure to 2 bar (pressure regulator fully open).
The pressure reducer should regulate the pressure from 6 to 2 bar. Check if the overpressure nipple (F) on the front of the attachtool is leaking air (see fig. 5.1 Attachtool – main components and service items). If so this is caused by to high air pressure on the attachtool (faulty pressure reducer), or because the overpressure nipple is broken.
Figure 5.1
Attachtool - main components and service items
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Scanning / vision / attachtool
5.7 Check attach results Vision2Milk / Vision pc Check the vision pc and Vision2Milk as follows.
Check the free hard disk space on the vision pc. Warning Logging stops under following circumstances: C:\ has less than 100 Mb remaining space The FBWF filter has less than 50 Mb Space remaining space The logging drive (default D:\) has less than 50 Mb remaining space
Check the position of the cow tracker assembly Info More information on checking and calibrating the cow tracker assembly can be found in chapter 8.5.5 of the Service manual UK312xx
To check the attach results: o Ask the farmer if he is satisfied on the attach results. o Check the attach results in the milking box visits overview in management software Check Amount of failed milkings and the combination with low score cows. Check the amount of max scans, manual and combined attachments. o Visually check the attachment process The milk beakers are grabbed firmly from the beaker unit The milk beakers are positioned firmly between the gripper arms The hoses are released with sufficient speed. The beakers are not falling on the box floor if a teat is missed o Check the following in Vision2Milk: PPP results [cowtracker] – box 1 and box 2. The position should be correct: Around 0 (+3 max) when to the back of the milkbox and no errors counting during attachment. [cowtracker] – pattern 3 and pattern 4 no errors counting during attachment. An incidental error might be present. If there are no attach problems this does not need to be a problem. Info IP-vision systems won’t have the Pattern 3 and pattern 4 display at the [cowtracker]
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5.8 Replace filter overpressure attachtool Replace the filter element of the overpressure filter attachtool to ensure a supply of clean air.
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Milking process
6 Milking process 6.1 Check milk beaker + milk hose Check the milk beaker and milk hoses as follows.
Check the liners for twists, the arrow/lines (on head and tail) should be directly opposite to each other. Check the number of milkings of current teat liners Check airbleed in short milkline Tip Alert the user if the maximum number of milkings on the liners have expired.
Check the milk beakers for damages such as dents and distortions. Replace if needed.
6.2 Check detach cylinder (speed) Check the speed of the cylinders as described in chapter 10.4.2 of the service manual UK312xx
6.3 Check bypass shutter + Vacuum shutter Check the bypass shutter and the vacuum shutter as follows.
Check the vacuum shutter for internal and external air leakage Check the hoses under the vacuum shutters for leakage
6.4 Replace hoses under shutters All hoses under the shutters need to be replaced once a year because of knuckling and deformation. The following hoses need to be exchanged
Vacuum shutter hoses Bypass shutter hoses Main cleaning water hoses (box 1 and 2) Hose to sprinkle ball in milk receiver
To replace the hoses, actuate the corresponding valves via the valve menu in the SCU.
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Milking process
6.5 Replace the non return valve To replace the Non return valve, follow the steps below
Fig. 6.1 Non return valve on AMS version 2013
Fig. 6.2 Replace the non-return valve (version 2011)
Note The non return valve in the 2011 version of the AMS needs to be replaced every service The non return valve in the 2013 version of the AMS needs to be replaced according the maintenance schedule. Set the milking box in the service mode. The milk receiver is automatically emptied.
Blow away the milk in the milk line by pressing one of the beaker release buttons Open the exit gate. The separation valve opens. This prevents milk flowing back out of the milk line, also it prevents milk coming out in case the other milk box suddenly starts pumping milk) Unscrew the union nut Open the coupling clamp Take away the non-return valve Mount the new non-return valve Tip The non-return valve is a critical part. Make sure to mount the non-return valve in the correct position and without tension. AMS2011: flat side towards the milk pump / hinge section on top. (See figure 6.2 Replace non-return valve (version 2011)) AMS2013: According the maintenance schedule replace O-ring and gasket around ‘part b’ and ‘part c’. (See figure 6.1 Non return valve on AMS version 2013).
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Milking process
6.6 Check air connection milk line (non-return) Check air connection milk line (non-return) (AMS 2011) Check the transparent air hose for milk or water. Milk residues and dirt particles inside the air hose can stick together, clog up and be blown in the milk line.
Fig. 6.3 Non-return valve in the air connection (AMS 2011)
A B
Air coupling Non-return valve
If you have any doubt about the correct working of the non return valve, replace it. If the air hose is contaminated, replace it.
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Milking process
Check air connection milk line (non-return) (AMS 2013) Check the transparent air hose for milk or water. Milk residues and dirt particles inside the air hose can stick together, clog up and be blown in the milk line. According the maintenance schedule replace O-rings “part 1”, “part 2” and spring “part 3” (See figure 6.4 Non-return valve air connection).
Fig. 6.4 Non-return valve air connection (AMS 2013)
6.7 Check air connection milk hoses (non-return) Follow the same procedure as described at checking the air connection for the milk line. Check that the valve is not leaking inside the air circuit. The air hose should be clean and dry. Also check that the non return valve is opened when the air supply valve is opened. The ‘blow off milk hose’ can be actuated in the ‘valves’ menu to be found in the SCU.
6.8 Check air pressure (2 bar) regulator(s) CU To avoid damage to the milk when blowing off the milk line, check that the air pressure reducers in the CU are set to 2 Bar.
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Milking process
6.9 Check milk separation valve Check whether any milk is leaking through the outlet when the valve is shut. Info Information on how to replace the O-rings of the non return valve can be found in chapter 10.16 of the service manual UK312xx.
Tip After this check, check for general milkleakages inside the central unit. Milkpump leakages can be checked by checking the drainhole in the bottom of the white housing. This must be clean and dry.
6.10 Overhaul milk pump To overhaul the milk pump follow the steps below
Set the milking box in the service mode. The milk receiver is automatically emptied. Blow away the milk in the milk line by pressing one of the beaker release buttons Open the exit gate. The separation valve opens. This prevents milk flowing back out of the milk line, also it prevents milk coming out in case the other milk box suddenly starts pumping milk) Follow the steps in chapter 10.14.2 of the service manual UK312xx Perform a colostrum cleaning after replacing the seals of the milk pump Important Distance of shaft assembly is a critical adjustment. More information can be found in Appendix 13.1.
6.11 Clean the spray ball and Check level sensors Together with replacing the seals of the milk pump, the spray ball needs to be cleaned as dirt particles, pieces of straw, etc. end up inside the spray ball during the cleaning processes. Info Information on how to clean the spray ball can be found in chapter 10.12 of the service manual UK312xx.
When cleaning the spray ball, also check the level sensors in the milk receiver for mineral build-up or other contamination. If so, remove it using scotch brite. When the electrodes are mounted in the milk receiver cover, be sure to position the cover back in the original position UK41000 Maintenance manual(issue
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Milking process
6.12 Milk meter 6.12.1 Overhaul milkmeter Overhaul the milk meter as follows.
Unscrew the milk inlet’s coupling Remove the diaphragm Release the top part of the milk meter CAUTION The plastic sockets can be fragile, disassemble with care
Remove the seal and the airing plate Unscrew the cleaning valve under the milk meter Remove the silicone ring Remove the diaphragm in the cleaning valve and the small seal at the outside of the cleaning valve Assemble the milk meter in reverse order.
Fig. 6.4 Milkmeter
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6.12.2 Check milkmeter Check milkmeter for dirty and damaged parts. Check if diaphragm and sealing are closing probably. Tip Don’t forget to check both 6mm vacuum hoses that are connected to the milkmeter. Check for water and dirt. Clean them when necessary.
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Milking process
6.12.3 Calibrate the Milk meter To calibrate the milk meter you need to bypass the milk to an extra ‘milk receiver’ so it is possible to measure the amount of milk and compare this with the value which is shown in the SCU. Before you start, you will need to have the following tools
Fig. 6.4
Weighing scale 2 hoses (approx 1.5 meter) Shut off valve to shut of vacuum on one hose (D in figure below) Milk bucket with closing lid and connections for 2 hoses. Calculator
Milk meter calibration setup
A – Milk receiver B – Milk meter C – Drain valve D – Manual Shutoff valve F – Milk bucket (with closing lid and hose connections) To calibrate the milk meter follow the next steps.
Put the MCU on service Take off the hose between the milk receiver A and milk meter B and connect the milk bucket as shown in the figure above. Turn the milk pump off (in the PDC cabinet(AMS2013) or using the switch near the milk pump (AMS2011)) Put the MCU on automatic and let a cow in.
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Milking process
Perform a manual attachment, do not press the ‘IN’ button at the end of the attachment, the cow will have stay in until you have finished measuring the amount of milk. Wait until the cow has been finished milking. When the cow is finished, keep her inside the milk box. Write down the amount of milk which is shown at the SCU in the [milking] menu. Measure the amount of milk which is in de milk bucket Put the hose with the shut-off valve in the milk bucket, slowly opening the valve. The milk will be sucked into the milk receiver. Turn the milk pump on Let the cow out.
Now compare the milk yield from the software with the real yield measured. If there is a difference, a good way to calculate the correct the ‘tilt volume’ is to use the following 2 equations: Calculation 1:
OM RM s Calculation 2 NTV OTV s
Where: OM = Original Milk yield OTV = Original Tilt Volume (to be found in [calibration] menu – [Tilt volume]) s= amount of signals (given by tipping scale) RM = Real measured yield (from milk in milk bucket) NTV = New Tilt Volume
Fill in the new found ‘Tilt Volume’ and verify by milking a second cow repeating the procedure.
6.13 Check the IMAC system Check the calibration of the IMAC system. A good calibrated IMAC will show color values for red, green and blue in the range 190-210. The difference between red and green cannot be more than 6. If a set deviation between red and green (normal ‘sep r-g’ = 25) is exceeded, the system will flag the milk as blood milk. The colors which the system is measuring can be read during milking in the ‘milking’ menu on the SCU display. If the values deviate too much for normal milk, calibrate the IMAC sensor.
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Vacuum System
7 Vacuum System 7.1 Vacuum pump Carry out the following maintenance tasks to keep the vacuum pump in good operating condition.
Fig. 7.1
Vacuum Pump
A B C D E F G H I J
Motor Transmission Oil sight glass Oil Drain plug Pumphouse Exhaust Exhaust outlet One way valve Clean hose connection Venting valve
7.1.1 Check oil level Check that the oil level at the oil sight glass(C) is between the minimum and maximum level. Refill oil when oil level is inder minimum level. Normal level is on ¾ of the sight glass. Check the oil level when the vacuum pump is off. 7.1.2 Refresh oil The oil needs to be exchanged as described in the maintenance scheme. To refill oil, follow the next steps:
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Vacuum System
Put the system on pause and/or the milk boxes on service. Make sure that the vacuum pump is shut down and locked against start up by putting the vacuum pump switch on the central unit from ‘AUTO’ to ‘0’ Undo the venting valve (J) Place a drain tray underneath the drain plug (D) Unscrew the oil drain plug (D) Let the oil drain. Make sure that the seal ring on the drain plug is serviceable, replace if necessary. Firmly reinsert the drain plug, together with the seal ring. Fill in new gear oil until the level is slightly above the middle of the sight glass (C) Make sure that the seal ring on the venting valve is undamaged, if necessary replace the venting valve Firmly reinsert the venting valve together with the seal ring Dispose the used oil in compliance with applicable regulations
7.1.3 Cleaning the vacuum pump When cleaning the vacuum pump, pay attention to the following points:
Make sure that the housing is free from dust and dirt, clean if necessary Clean the fan cowling, the fan wheel, the ventilation grille and the cooling fins Clean the pump house of the vacuum pump by connecting a 6 mm air hose to the hose coupling (I) on the vacuum pipe. Put the air hose in a bucket containing 5 liter warm (45C) water with soap. Regulate the flow of water to a minimal amount using a speed governor. Tip Let the pump run on ‘manual’ mode until the bucket is empty. In this way it can better handle the water. Do not put lots of water in the pump at one time! This can bring severe damage to the pump.
7.2 Check/adjust vacuum level Check if the vacuum is on the correct level, when checking this, always pay attention on correct working of the vacuum regulator and frequently controller. Correct working of vacuum regulator and frequency controller results in a stable vacuum with a more or less calm running vacuum pump. When the vacuum pump alters speed excessively, check if the temperature sensor is mounted correctly, and if the filters and diaphragms of the vacuum regulator are clean. If the vacuum level is too low, adjust the vacuum level to the desired vacuum level. The correct vacuum level should be written down twice a year in the vacuum measurement report. UK41000 Maintenance manual(issue
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Vacuum System
Indication for vacuum level Square liners Round liners
48 Kpa 46 Kpa
Info Read more about adjusting the vacuum level, chapter 11.5.2 in the service manual.
7.3 Check/clean Pulsator At every service, the operation of the pulsator should be checked on dirt and debris.
Clean the filter inside the pulsator Clean the internal pulsator mechanics
7.4 Overhaul Pulsator The pulsator should be overhauled twice a year. Revision sets are available. For an exploded view of the pulsator see the appendix 13.3 of this manual. CAUTION Be careful of loose parts. Small parts inside! SAC pulsator: Airbleed hole pulsator cap should be Ø3.5 mm
7.5 Clean vacuum delete and cleaning valve pulsator The pulsator vacuum delete and cleaning valve is a crucial part in the sampling process and cleaning process. Follow the next steps to overhaul the pulsators. If parts are worn or not in optimal condition, replace the parts.
Disassemble the pulsator Clean the parts in warm water with soap Dry with a cloth Assemble the pulsator
7.6 Overhaul reverse amplifier Follow the next steps to overhaul the reverse amplifier
Disassemble the reverse amplifier Clean the parts in warm water with soap Replace the diaphragm Assemble the reverse amplifier
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Vacuum System
7.7 Overhaul vacuum regulator Perform the overhaul of the vacuum regulator as follows. For exploded view see appendix 13.4 of this manual.
Remove the regulator from the vacuum system Disassemble the regulator and clean the parts with warm water and soap Replace the diaphragms and filters Assemble the vacuum regulator
After the overhaul, check the vacuum level and, if necessary adjust the vacuum level. Info In case of a vacuum regulator with external filter (see chapter 7.7.2), the filter element GL4411 lapses in assembly.
7.7.1 Clean vacuum regulator (for systems without external filter) Clean vacuum regulator assembly including filters. Use compressed air to clean the vacuumregulator.
7.7.2 Check external filter vacuum regulator (optional) The external filter for the vacuum regulator is optional, see figure 7.2. This filter needs be clean, check this filter according the maintenance schedule. Clean the filter with compressed air, blow from inside filter to outside.
Fig. 7.2 External filter vacuumregulator
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Vacuum System
7.8 Clean the sanitary trap (AMS2013) Due to milk particles ending up in the sanitary trap,it needs to be cleaned. When cleaning the sanitary trap, also clean the gravity drain on the lower end of the trap.
Fig. 7.3 Sanitary trap
7.9 Pulsation measurement To ensure correct milking, at least once a year the pulsation has to be measured. Testing pulsation exists of 2 procedures, the pulsation measurement and a measurement to verify if the vacuum pump has enough overcapacity to ensure stable vacuum. Tools used: Pulsator tester Airflow tester Digital vacuum tester plugs to shut-off the holes in the teatliner Air flow tester for teatliners.
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Vacuum System
Checklist before starting a pulsation measurement Overhaul the pulsators (L) as described in this manual Overhaul the vacuum regulator (D) as described in this manual Check all hoses leaks or withdrawal of false air Clean and check all gravity drains. Check If the bleed holes in the milk hose couplings are open – use a needle.
.
Pulsation measurement Set the milk boxes to service mode (MCU) Switch the mode selector switch on the SCU to ‘Manual’ The vacuum pump will start running. Check the vacuum level. Check maintenance logbook for farm specific vacuumlevel. Indication for vacuum level Square liners Round liners
48 kPa 46 kPa
Tip Measure the vacuum using a digital vacuum tester. Verify if the system vacuum meter is measuring the correct value, if the deviation is too large, calibrate the meter, or notice the farmer about the deviation. Calibration and functioning of meter is described in appendix 13.2 of this manual.
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Vacuum System
The following routine counts for each milk box which has to be measured Switch the mode selector switch on the MCU to [automatic]. The entrance gate will stay closed Push the [IN] button on the MCU, the entrance gate opens CAUTION keep cows out of the milk box!
Push the [IN] button again. The entrance gate closes and the beaker unit opens. Put the plugs into the teat liners. Release the beakers by pushing [1,-2,-3,-4]. The pulsator starts. On the SCU, go to the menu [system setup] to [duty front] set this value to the setting ‘duty front’ which is set in the FMS software, do the same for [duty back]. Note If pulsation settings have been altered in the TIM controller or FMS, always verify the settings for a normal milking cow there before taking over these settings into the SCU.
Connect the pulsator tester to beaker 1 and 3. Test the pulsation. The value’s for the A-phase has to be about: 150 ms ( 120 – 180) The value’s for the B-phase has to be about: 500 ms ( 440 – 530) The value’s for the C-phase has to be about: 150 ms ( 125 – 170) The value’s for the D-phase has to be about: 220 ms ( 200 – 250) The value’s for the A+B phases has to be about: 650 ms ( 620 – 680) The value’s for the C+D phase has to be about: 350 ms ( 325 – 380)
If the measured values are within the advised ranges, continue with the next milk box. If not, check the milking system and pulsators on leaks and correct working. then perform a measurement again.
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Vacuum System
Fig. 7.2
Pulsation curve
Measuring air capacity vacuum pump Measure the air capacity of the vacuum pump according to the regulations in your country. From factory the AMS has an overcapacity of 600/700 ltr./min at 46kPa Before you start Connect the airflow tester at (F) Remove the rubber cap and connect the airflow tester at the opening.
Set the milk boxes to service mode (MCU)
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Vacuum System
Switch the mode selector switch on the SCU to ‘Manual’ The vacuum pump will start running.
The following routine is based on a vacuumlevel of 48 kPa. In case of a vacuumlevel of 46 kPa, you have to measure items 1 till 5 at 44 kPa (46 kPa – 2 kPa = 44 kPa) Switch the mode selector switch on the MCU to [automatic]. The entrance gate will stay closed Push the [IN] button on the MCU, the entrance gate opens CAUTION keep cows out of the milk box!
Push the [IN] button again. The entrance gate closes and the beaker unit opens. Put plugs into the teat liners to close the holes. Connect a digital vacuum tester at the vacuum measurement point next to (F). The value at the digital vacuum tester has to be 46 or 48 kPA (depending on type of liner used). 1) pump capacity Open the airflow tester until the digital vacuum tester is 48 Kpa – 2 kPa = 46 kPa Vacuum pump starts to go to full speed! This is normal Read and write down the value for the air flow. Info The airflow measured at a vacuum decrease of 2 kPa, at minimum should be 460 l/min. (A higher flow is better).
2) airflow leakages vacuumregulator Disconnect the vacuum sensing air hose from the vacuum regulator. And shut this hose so no air is sucking in. If necessary, open the air flow tester again until the vacuum level is 46 kPa. Read and write down the value for the air flow. Info The difference in flow compared with previous measurement should be less 10%
3) airflow use pulsator Switch off the pulsator of both milk boxes using the tumbler switch on the SCU.
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Vacuum System
Open the airflow tester until the vacuum level is 46 kPa. Read and write down the value for the air flow. Info The difference in airflow value should be about 40 – 80 L/min.
4) airflow use airbleed milkhoses Retract the milk beakers by pushing [1,-2,-3,-4] on the MCU. Open the airflow tester until the vacuum level is 46 kPa. Read and write down the value for the air flow. Info The difference in airflow value should be about 40 – 80 L/min
Remove the plugs from the milk beakers Push [out] on the MCU of both boxes The beaker unit close again 5) airflow leakages milkline Switch the mode selector switch of the MCU for both milk boxes to “service”. Open the airflow tester until the vacuum level is 46 kPa. Read and write down the value for the air flow. This is the capacity of the vacuum pump Info The difference in airflow value should not be greater than 12 L/min for a single box and 14 L/min for a 2 box. If this difference is more, there must be some part leaking in the vacuum circuit until the vacuum shutters of the milk boxes.
6) pump capacity 50 kPa Close the air flow tester until the vacuum level is 50 kPa. Read and write down the value for the air flow. Info This is the capacity of the vacuum pump at 50 kPa.
7) airflow teatcup liner Connect the vacuum sensing hose to the regulator.
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Vacuum System
Close the airflow tester complete. The vacuum level has to be 48 kPa. This is to test the vacuum regulator. Change the mode selector switch on the MCU on [automatic] for both milkboxes. The entrance gates stay closedPush [IN], the -entrance gate opens-keep cows out of the milk box- push[in] again – entrance gate closes - beaker unit comes towards the box. Place the caps in the teat liners. Release the beakers by pushing [1,-2,-3,-4] Remove the cap out of the first teat liner. Measure the vacuum level in this teat liner without opening the air flow tester. Open the air flow tester until the vacuum level has decreased 2 kPa. Read the value for the air flow. The difference in air flow must be more than 30 l/min. Than it is OK. Is it less than 30 l/min there must be a constipation. Remove the airflow tester. The beaker have to pull in when free air is sucking in. This is testing the vacuum sensor for this beaker, of the system. Do the same for all teat liners. Push “out” on the MCU. The beaker unit will go out of the milk box. Switch the mcu to “service”. Switch both the SCU’s back to “automatic”. The vacuum pump will stop. Switch the pulsators back on via the tumbler switch on the SCU. Remove the air flow tester from the T-connector on the vacuum pipe line.
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Water system
8 Water system 8.1 Replace filter water supply intake The filters of the water supply intake have to be replaced twice a year. This guarantees the correct water flow.
Single box system - 8 liters per minute. Double box system - 12 liters Per minute.
To replace the filter, close the water supply, take off the protection cap ‘B’, and unscrew the watertight locking screw. replace the filter and put the parts together in reverse order.
Fig. 8.1 Water supply intake components
A B C D
Valve shut off lever Valve cap (color indicates water flow rate) Water tight locking screw Filter
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8.2 Check couplings water supply Check all water couplings in the water supply on leaking or sweating water. If the coupling shows any sign of leaking or sweating, replace the coupling. Tip Water leakage might cause severe damage the electronic parts inside the Central Unit. If doubting about reliability of a coupling, choose to replace!
8.3 Clean steam generator Due to possible lime scale build up inside the steam generator, it has to be cleaned minimal once a year. Warning Before any maintenance work is carried out on the steam system it is essential that the tasks described in section “Release steam from the water system” are carried out first. Release steam from the water system
Make sure the water hot water supply to the steam water heater is open. That is, the hot water valve has not been shut off. Set the milk box to: Service mode as explained in chapter 3.4 in the service manual. Then using the Service Control Unit (SCU), select the menu options: valves / steam valve / activate. Explained in chapter 3.4 and chapter 18.6 in the service manual. Warning This action releases very hot water into the milk beaker cleaning jetters.
Shut off the valve on the main hot water intake to the AMS. Remove the power supply plug from the steam system water heater. Remember to reconnect the power supply and turn the hot water intake valve back on after work is complete.
Clean the steam generator
Take the steam generator out, and take off the red cover on top. Take the insulation out Open the lid by loosening the bolts on top Clean the inside of the generator and carefully undo the heat elements from eventual lime scale build-up Re-assemble the steam generator in reverse order, using a new set of gaskets.
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Cleaning process
9 Cleaning process 9.1 Check main cleaning Check the main cleaning process on correct working, this means:
Check the logging of the main cleaning in the management software o Check if there are attentions on water temperature o Check if there are attentions on dosing of detergent Check that all parts involved in the process are working correct this means o No false air in cleaning hoses to jetterblock o Jetterblock is correctly aligned onto the beakers (Fig. 9.1) o Milk meter is cleaned correctly (fills up with water) o The pre-treatment beaker on the robot arm is retrieving cleaning water. Tip More detailed information about the main cleaning described in chapter 3.4 and chapter 14.5 in the service manual.
9.2 Replace cleaning jetters milking box The cleaning jetters need to be replaced once a year.
Fig. 9.1 Cleaning jetter block (beaker unit) components
Set the box on service via the MCU Open the exit gate the beaker unit opens Gently pull of the old jetters ‘C’ Mount a set of 4 new jetters onto the block
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9.3 Check cleaning fluid system Check the cleaning fluid system on following points:
The hoses attached to the input of the pump should not contain air. Check the pumps on leaking detergent Check that the connection of the cleaning agent hoses to the hot water reservoir ((‘E’) in Fig. 9.2 Hot water tank reservoir) are connected tight and do not leak.
Fig. 9.2 Hot water tank reservoir
9.4 Replace feeder hoses cleaning fluid system Replace the feeder hoses in the cleaning fluid according the maintenance schedule.
Fig 9.3 Cleaning fluid system
Loose the hoses connected to the in and outlet of the pump. Remove the front plastic cover from the pump. Take out the feeder hose, install a new one. Put the plastic cover back in place and mount it with the 3 screws. (do not tighten completely yet) Activate the pump on the dairyroom print via [system setup]-[pumps&valves test] [detergent/acid pump]
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Fasten the screws of the cover while the pump is running. Connect the hoses to the in and outlet of the pump (eventually use a cable tie) Calibrate cleaning fluid system, described in Chapter 9.5 of this manual. Tip Heat up the hoses a bit before mounting them, in this way they will be more flexible and this ensures a airtight fit!
9.5 Calibrate cleaning fluid system According the maintenance schedule, calibrate the dosing of the cleaning agents. o o o o
Use a canister to measure the amount of dosed cleaning agent Loose the hose connected to the outlet of the pump Activate the pump on the dairyroom via [system setup]-[pumps&valves test] [detergent/acid pump] Check the amount dosed, if necessary adjust the pump time in the [system setup]-[pumps & valves ]-[acid pumptime]/[detergent pumptime] menu. Amount can be country specific, depend on chemicals. CAUTION NEVER MIX ACID AND DETERGENT!
Tip More detailed information about the cleaning fluid system described in chapter 14.9.7 in the service manual.
9.6 Check Tankvalve system
Always verify that the tankvalve is not leaking milk internal (to drain) or external via milkline and tank connections. Check that the sensors (tankvalve, temperature sensor) are in good condition. Check functioning of sensor by pulling off airhose. Tip Don’t forget to check the buffertank system.
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Cleaning process
9.7 Replace drain valve Replace drain valve (AMS 2011) The drain valve should be replaced periodically. If the valve is not closing correctly then it is possible that the rubber plunger inside the drain valve is worn and therefore causing the valve to not close properly. Also the cylinder should be replaced periodically. This cylinder can be corroded by the cleaning water and chemical residues.
Fig 9.4 Drain valve components (AMS 2011)
A B C D
Drain valve cylinder Threaded rubber plunger Drain valve housing Screws x 4
Replace the rubber plunger “part B” and the cylinder “part A” according the maintenance schedule. See figure Fig 9.5 Drain valve components (AMS 2011).
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Replace hose drain valve (AMS 2013) Replace hose ‘part A’ according maintenance schedule. See figure 9.5.
Fig 9.5 Drain valve components (AMS 2013)
Tip Check during each maintenance check the condition of hose ‘part A’
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10 Manipulator / Robot 10.1 Backup Read more about backup procedures in Chapter 23.3.1 and Chapter 23.3.2 in the service manual UK312xx Tip When not having a CF-card reader present. Make a second backup on a USB drive to copy the backup on the management pc!
10.1.1 Make a CMOS backup For trouble shooting purpose it is important that a recent backup is present. The CMOS backup is a compressed backup of the information stored on the YUI02-E. It contains the complete system configuration and counts as a complete system backup. This information is required to restart a blocked system. Warning Be patient. Do not turn the power of too early. It may take some time to make the backup, wait for the two beeps, or for the text in the left lower corner of the screen to disappear.
10.1.2 Make a standard backup A standard backup contains all information as teached positions and I/F panel settings. This backup can be used for restoring small adjustments like teached positions.
Tip In case of a major mistake during teaching in positions, restore the ‘variable data’- file. This file can be found in the general data. Procedure described in Chapter 23.5 in the service manual UK312xx
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10.2 Check safety switch(es) entrance gate(s) Verify that the safety switches guarding the robot/restricted area are working. if the gates are opened, the robot arm has to stop immediately.
A Working area B Restricted area CAUTION Overruling or dismantling the safety switches will result in an unsafe working situation for any person working with the AMS. Never leave the system with dismantled safety switches as the technician doing maintenance is responsible for ensuring a safe environment at the AMS
10.3 Check ventilation motoman cabinet Ensure that the internal ventilation of the motorman cabinet is working. visually check that the red ‘FAN’ indication light on the CPS is not burning. Confirm that the fans are running. Info FAN indication light not available on Motoman FS100 controller.
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10.4 Lubrication To ensure a proper functioning of the robot arm it is important that the axes of the robot get periodic lubrication. Note When greasing the robot arm, always write down the control time, and the servo on time in the logbook
CAUTION Greasing should only be performed at temperatures above 5 C⁰. At low temperatures the new grease has a to high viscosity. When a to high viscosity grease is used, the arm will move slow. At temperatures close to 5 C⁰, take more time to heat up the grease inside the R-B-T drives. For the lubrication two different types of grease are used. Below is a list of materials needed for lubricating the robot. Material Grease Vigo Re0, HP20D, tube 400ml Grease Harmonic SK-1A, tube 400ml Grease nipple 6mm Grease nipple 1/8” In screw air coupling 6mm 1/8 tread Air pressure hose 6mm, length 50cm Three Bond 1206C 2 Greasing guns Cloths
Article number RZ96151 RZ9616 PELGN61180 RD0054 MF4006 RZ9614
Tip With temperatures between 5 C⁰ and 15 C⁰, heat up the grease before greasing.
10.4.1 Roadmap Position the robot, using the teach pendant, in such a way all greasing inlets and exhaust are easy to access (Coordinates/ axes). For each axis there is a lubricating inlet and an exhaust, remove all inlet and exhaust plugs. before starting the lubrication, so no pressure can build up in the drives. CAUTION Be sure to remove the exhaust plugs before greasing. Not removing the exhaust plugs can cause severe damage to the drives.
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Note Do not used electrical tools for dismounting and mounting the plugs, this might damage the tread of the plugs.
Place grease nipples in the inlets. Place a screw air coupling in outlets S and L. By placing an air pressure hose in this coupling the old grease can be collected. Grease the S-L-U axes using Vigo Re0, HP20D (RZ96151) Grease the R-B-T axes with harmonic drive grease SK-1A. (RZ9616) Grease according to Table 1. CAUTION The R-B-T axes should be lubricated very carefully. The harmonic drives can be damaged if too much grease is pumped in, without intermediate movement. Move the R-B-T axes carefully after inserting a small amount of grease.
Table 1. Grease used per axis.
Axis S L U R1 R2 T1 T2
Grease type Vigo Re0, HP20D Vigo Re0, HP20D Vigo Re0, HP20D Harmonic drive grease SK-1A Harmonic drive grease SK-1A Harmonic drive grease SK-1A Harmonic drive grease SK-1A
Amount 1080 cc 300 cc 180 cc 8 cc 8 cc 5 cc 5 cc
Remark Continue till new grease is seen at the exhaust Continue till new grease is seen at the exhaust Continue till new grease is seen at the exhaust
Tip Measure the amount of grease which is dispensed when applying one stroke with a grease gun. In this way you get a good insight in the amount strokes to pump in the grease inlets. Note The B-axis is greased via the inlets of the T-axis
Start the automatic lubricating program to move the axes for quite a while: o Milk box(es) on service and leave robot area. o Turn teach pendant to TEACH mode. o Choose JOB / SELECT JOB, o Search for the job GREASE L and press select o Then switch the mode selector to PLAY o Press SERVO ON READY, followed by the green START button. The program starts and stops automatically again after approx. 15 minutes o Turn teach pendant to TEACH mode. o Choose JOB / SELECT JOB, followed by RAS
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o Then switch to PLAY on the teach pendant. o Press SERVO ON READY, followed by the green START button. o Run the RAS job for 30 minutes. Then press the HOLD button. Position the robot, using the teach pendant, in such a way all greasing inlets and exhaust are easy to access (Coordinates/ axes). Mount all plugs back in the inlets and exhausts. Seal the plugs by using Three Bond 1206C.
10.4.2 Position greasing points. The picture below shows the positions of the greasing points. Followed by more detailed pictures.
T axis
T axis
R axis
Uaxis
Uaxis
R axis
S axis
S axis L axis L axis
Fig. 10.1 Position greasing points.
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Inlet S
Exhaust S
Inlet L Exhaust L
Inlet U Exhaust U
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Exhaust R1
Exhaust R2
Inlet R1
Inlet R2
Exhaust T1
Inlet T1 Inlet T2
Exhaust T2
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11 Other maintenance tasks 11.1 Clean filter cabinet CU
For AMS2011
Replace the filters in the door of the Power Distribution Cabinet (PDC).
For AMS2013
Clean the filter under the electronics cabinet using compressed air.
11.2 Replace filter Cabinet CU (AMS2013) As the filter gets contaminated over time, replace the filter yearly.
11.3 Check back-up’s Back-up can be very important in case of troubleshooting. Make sure the following backups are present on at least 2 locations! The back-ups which have to be stored and an example how to organize them in windows is shown below:
Backups: Motoman o CMOS o Standard Backup Vision o Settings.xml (Vision2Milk) o Calibration file of the present attachtool. TIM (TIM controller & FMS) o Back-up Helios/TIM controller o Back-up FMS
Motoman and vision backups should be stored both on the management pc and vision pc. Backups from the TIM controller and FMS software should be stored on the management pc and external drive (e.g. USB flash drive)
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11.4 Check air silincer valveblocks The air silencer at the valveblocks can get dirty after a while. This will affect the speed/functioning of the pneumatic parts. Check the air silencer for dirt and dust. See figure 11.1 air silencer (red arrow).
Figure 11.1 Air silincer
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Auxiliary maintenance information
12 Auxiliary maintenance information Note This part currently is under construction.
12.1.1 Battery Motoman manipulator / CPU 12.1.2 Battery UPS system CU 12.1.3 Battery UPS system TIM controller
12.2 Maintenance to external/other equipment 12.2.1 Compressor and Air dryer Check the system for water Check if the oil level is sufficient Refer to maintenance manual Note See compressor and airdryer specific documentation. Fill in compressor maintenance book. 12.2.2 Pre-Cooler o Check the air pressure to the pre-cooler flush valve, correct air pressure is 2 bar. o Check the pre-cooler for water leaks. 12.2.3 Buffer tank o Check the inside of the buffer tank on contamination. o Check that the valves under the buffer tank are clean. 12.2.4 Feeding box Check the feeding system for correct functioning and the provision of the feed concentrate (e.g. by calibration) Check the troughs and the feed concentrate box for visible breakages/problems etc. Verify that the antenna is mounted firmly to the ground and check the antenna cable. Check the feedbox for damaged parts, loose screws (feed trough/gates/feed dispenser), sharp edges or other imperfections 12.2.5 Selection gate Check cabling to sensors, antennas and air valves. Check the cylinders for air leakage. Check selection gate for damaged parts, loose screws (/gates/fencing), sharp edges or other imperfections
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12.3 OEM documentation OEM documentation on the following products can be found on FTP
Keaser SXC-3 compressor Mattei Compressor Motoman Maintenance manual
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Appendix - Milkpump tools
13 Appendix 13.1 Milkpump tools 13.1.1 Shaft assembly tool (RD0061)
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Appendix - Milkpump tools
13.1.2 Milk pump seal assembly tool (RD0060)
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Appendix - Vacuum meter
13.2 Vacuum meter
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Appendix - Vacuum meter
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Appendix - Pulsator
13.3 Pulsator Exploded view pulsators.
Figure 13.3.1 SAC Pulsator
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Appendix - Pulsator
Figure 13.3.2 Interpuls Pulsator
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Appendix - Vacuum regulator
13.4 Vacuum regulator Exploded view vacuum regulator.
Fig. 13.4.1 Interpuls regulator.
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