D021003e Aqua Star Technical Manual

STAR WATER MANAGEMENT SYSTEM

TECHNICAL MANUAL EDITION 1.8

GASCOIGNE MELOTTE

Prom version > V20000711

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GASCOIGNE MELOTTE

PUBLICATION INFORMATION 1.

2.

3.

4.

COPYRIGHT- Copyright in this publication is vested in:- GASCOIGNE MELOTTE DISCLOSURE- All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording and/or otherwise without the prior written permission of GASCOIGNE MELOTTE. LIMITATIONS OF USE - This book may not be lent, resold, hired out or otherwise disposed of by way of trade in any form of binding or cover other than that in which it is published, without the prior consent of GASCOIGNE MELOTTE. ENQUIRIES AND AMENDMENTS - All enquiries regarding comment, correction or amendment to this publication should be addressed to:GASCOIGNE MELOTTE, Rankine Road, Daneshill, Basingstoke, Hampshire. RG24 8PP Tel.: ++ 44 (0)1256 394300 Fax: ++ 44 (0)1256 460684

The exclamation mark within a triangle is intended to alert the user to important operating and maintenance or service instructions in this literature.

Check the voltage of the control box before connecting to the mains supply.

Before opening any electrical equipment, always disconnect from the mains supply.

To reduce the risk of fire or electric shock, do not expose any of the electrical equipment to water or moisture.

The wires in the mains lead of the power supplies are coloured in accordance with the following code: Blue to N (neutral) Brown to L (live) Yellow/Green to E (earth) Do not allow large surges of electrical current to make contact with this equipment - e.g. welding on stallwork.

Always isolate all electronic equipment totally from the mains supply if large currents are applied to the milking machine.

If a stand-by generator is used to supply mains voltage, first disconnect all electronic equipment totally from the mains. Start the generator and check the stability of the generated current before connecting the electronic equipment.

Gascoigne Melotte use high performance, modern engineering plastics in the construction of milking equipment. The materials chosen are the best available for any given application.

The plastics used in the Aquastar water management system have good resistance to hot water, acid and alkali milking machine detergents and disinfectants even at high temperatures.

However, chemical resistance can be affected by products containing ketones, chlorinated hydrocarbons, aromatic hydrocarbons and higher alcohols, which are always present in petrol, paraffin, methylated spirits, diesel fuel, etc. They are also present in varying concentrations in products such as fly sprays, some teat dip solutions and are sometimes used as propellants in aerosol cans.

Great care must be taken to ensure these products do not come into contact with plastic components on milking machines.

Gascoigne Melotte will not accept responsibility for equipment damaged by chemicals.

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CONTENTS Chapter 1.

2.

3.

Page

INTRODUCTION Introduction Notes on circulation cleaning Circulation cleaning with MR2000 milk meters

1-1 1-3 1-4

DESCRIPTION Aquastar control box Aquastar distribution box Chemical dosing pump Large bore wash valve (normally open) Large bore wash valve (normally closed) Changeover valve Air injector Support bracket Chemical trap

2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9

INSTALLATION Schematic of the standard basic Aquastar water management system Mounting the control box Mounting the distribution box Installation and wiring of the Aquastar Connecting MR 2000 display boxes Wiring the Aquastar system Plumbing the Aquastar system Plumbing the large bore wash valves to the pipework Installing the changeover valve Expansion tool instructions Installing the wash pick up support bracket A note on the position of the upper water level probe Installing the pick up valves Plumbing the air injectors Installing a milk/wash safety switch Installing the chemical containers Plumbing the fill pipes Calibrating the dosing pumps Installing a high vacuum system Installing the temperature probe (optional)

3-2 3-4 3-4 3-5 3-5 3-6 3 - 12 3 - 16 3 - 16 3 - 17 3 - 18 3 - 19 3 - 19 3 - 20 3 - 20 3 - 21 3 - 21 3 - 22 3 - 22 3 - 23

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Chapter 4.

5.

6.

Page

OPERATION Aquastar wash programs The left keypad The right keypad Setting the operators password Using the operators password Setting the clock time Chemical containers low warning Power cut warning Manually running milk pump Preparing the parlour for washing Selecting an adjusted time main wash cycle What to do in an emergency Emergency wash procedure

4-1 4-2 4-4 4-7 4-7 4-8 4-8 4-9 4-9 4 - 10 4 - 10 4 - 11 4 - 11

SETTINGS Setting the correct amount of wash water Starting a wash program automatically

5-1 5-2

SERVICE AND TROUBLESHOOTING Components in the Aquastar control box Leds on the board Fuses Emergency switch Proms Maintenance

6-1 6-2 6-2 6-3 6-3 6-4

APPENDICES Appendix 1 - Settings and adjustments Programming a typical wash program Default preset program table A functions Time/function diagram Water diversion T functions S functions N functions Appendix 2 - Description of phase codes Appendix 3 - Blank table for default settings and time codes Appendix 4 - Error Codes Appendix 5 - Aquastar terminology Appendix 6 - Emergency Kit Instruction Sheet

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Appendix 1 - 2 Appendix 1 - 3 Appendix 1 - 6 Appendix 1 - 7 Appendix 1 - 16 Appendix 1 - 22 Appendix 1 - 24 Appendix 1 - 26

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GASCOIGNE MELOTTE

Chapter

1

INTRODUCTION

The Gascoigne Melotte AQUASTAR is a complete water management system. During its development all current environmental regulations have been taken into consideration.

AQUASTAR is an intelligent cleaning system combining excellent cleaning abilities with ease of operation. It can be completely adapted to your milking installation. It is not only suitable for new installations but also for existing systems; for both milk parlours and round-the-shed systems.

The AQUASTAR water management system consists of a control box which controls a number of valves and pressure switches. Because the valves and the control system are separate, it is possible to install the valves in the water supply line. In so doing the control box can be fitted in a remote (dry) location. The control box has a display window and two keypads that allow you to select the desired wash program with the touch of a button.

STANDARD FEATURES ✔

Five fully adjustable wash programs.

✔

Automatic dosage of cleaning agents or disinfectant. Three possible chemical agents.

✔

Warning for empty chemical container.

✔

Wash duration configured to match your milking machine.

✔

Display of the vacuum pump running time.

✔

Air injector control.

✔

Automatic control of wash trough fill

✔

Daily/weekly program selector to start any wash program automatically.

✔

Manual and automatic milk pump control

✔

Compartmental cleaning for use with MR2000 milk meters.

The Aquastar system can be upgraded with : •

The possibility to make considerable water savings by storing main wash water in order to clean the milking parlour and by using the final rinse water for the following pre-rinse.

•

Milk/wash safety switch to prevent wash water from entering the bulk tank and milk from running into the sewer.

•

High vacuum system to improve wash quality.

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•

Temperature monitoring.

•

In Parlour Diagnostics (IPD) which can include: • • • •

Milk Pump Monitoring.

Milk Meter Monitoring.

Error Warnings.

Chemical Conductivity Monitoring.

The basic standard Aquastar system is delivered complete as follows :❏

1 Aquastar system control box

❏

1 Aquastar distribution box comprising 3 chemical dosing pumps, 8 solenoid valves and 2 pressure switches

❏

1 Changeover valve

❏

1 or 2 Pick up valves (normally closed) + plastic tee piece for vacuum connection depending on plant.

❏

1 Support bracket for mounting pick up tubes, water level probes etc.

❏

2 x 20mm (3/4” B.S.P. gas fitting) hot and cold water fill valves with 24 V solenoids

❏

1 or 2 Aquastar air injectors depending on plant.

❏

2 Water level probes (Tulips)

❏

Clear PVC tubing for vacuum connections

❏

Coloured PVC tubing for chemical transport

❏

Pipe and brackets to connect system

❏

Wire and cabling (where appropriate)

❏

Reinforced PVC hose for hot and cold water fill

❏

1 Chemical trap with vacuum nozzle

NB :

A discharge tube with automatic drain should be ordered for each milk pump.

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NOTES ON CIRCULATION CLEANING Always refer to the chemical suppliers instructions and note safety procedures.

After milking, clean the clusters and wash jetters externally with a hot sanitant solution.

Set the complete milking machine for washing and CHECK THE HOT WATER SUPPLY TEMPERATURE COMPLIES WITH THE CHEMICAL MANUFACTURERS RECOMMENDATIONS. The first rinse water must discharge to drain until the returning water is clear.

Circulate the main wash cleaning solution for approximately 10 minutes ENSURING THAT THE CORRECT TEMPERATURE IS MAINTAINED. Rinse the plant with clean water and ENSURE THE PLANT DRAINS COMPLETELY. In some cases the addition of a hypochlorite solution of 25 ml per 40 litres of water is required.

Examine the plant once a week to check for deposits. Pay particular attention to rubber tubing, the inside of liners and receiver deflector plates (where fitted).

To remove milkstone, use an approved brand of milkstone remover. Follow the instructions carefully.

Clean and disinfect any part of the equipment that is not normally in contact with milk, e.g. supplementary pipeline vacuum interceptor vessels, at least once a month. Rinse through after cleaning with clean, cold water.

NEVER MIX DAIRY CHEMICALS. IT IS EXTREMELY DANGEROUS Cleaning deteriorates the nitrile rubber of the liners therefore it is essential to use a good quality detergent and follow the dilution instructions on the container.

INCREASING THE RECOMMENDED DILUTION RATIO NEVER IMPROVES THE SANITIZATION EFFECT.

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CIRCULATION CLEANING WITH MR2000 MILK METERS It is important to understand that the MR 2000 Milk Meter has been designed to be FLOOD WASHED in the normal milk flow direction and that the software controls the pattern of washing each meter in sequence.

The cycle for washing each MR 2000 Milk Meter is as follows.

Initially, the top chamber is closed for 64, 80, 96 or 112 seconds, depending on the cycle time. This allows THE TOP CHAMBER TO FLOOD AND OVERFLOW DOWN THE BYPASS TUBE into the measuring chamber, through the open outlet valve and out of the meter via the bottom chamber. See diagram A. To ensure good agitation in the top chamber when flooding, THE AIRBLEED HOLE IN THE TOP COVER OF THE MILK METER MUST BE KEPT CLEAN. After the set time, the top chamber outlet opens and water floods down into the measuring chamber and overflows through the bypass tube into the bottom chamber and out of the meter. See diagram B. This flooding lasts for 4 seconds. After a further 4 second delay it floods again for a further 4 seconds to allow the meter to empty prior to repeating the cycle.

The above milk meter wash cycle is SEQUENCED with a 4 second delay between each milk meter to limit the number of milk meters that are flooding at any one time.

At the end of each wash stage, the meter will DRAIN providing the wash sequence continues without a fresh solution entering at the meter and SUFFICIENT VACUUM IS MAINTAINED TO OPERATE THE METER VALVE. It is essential that there is sufficient water available to allow ALL THE MILK METERS TO FLOOD (see diagrams). If compartment cleaning is installed, only 75% of the water is required as both halves of the parlour are washed alternately.

NOTE: To ensure the conductivity probes in the top chamber remain effective, it is recommended to circulate an acid descaling solution once or twice a week depending on the hardness of the water.

Follow the instructions carefully.

B

A

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Chapter 1a

2

DESCRIPTION 5 14 1b

8

2

6

9

7

3 13

4

10

11 12 1(a).

1(b).

2.

3.

4.

5.

6.

7.

8.

Display PCB (rear) D498766 Display PCB (front) Control keypad Data keypad Hinged lid D498767 Transformer Panel covering wiring connectors 5 Amp fuse D263947 Clock D272644

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9.

10.

11.

12.

13.

14.

2-1

Clock holder 1 Amp fuse for vacuum pump control box relays D263925 (2 Amp for 110V D263932) 2 Amp fuse for pulsation controller power supply D263932 (4 Amp for 110V D263951) 1.6 Amp fuse for mains supply to transformer D263977 (3.15 Amp for 110V D263978) Prom V2.1 D398534 {V2 D398513} Eprom V2.1 D398535 {V2 D398514}

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AQUASTAR DISTRIBUTION BOX

3

9

12

10 11

7

2

8

4

6 5

1

1.

2.

3.

4.

5.

6.

7.

Outer cover Inner box lid Vacuum in connecting tee D240742 Rear solenoid bank Dosing pump 3 D498741 Front solenoid bank Dosing pump 2 D498741

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9.

Dosing pump 1 D498741 Low water level pressure switch D263739 10. High water level pressure switch D263739 11. Connecting strip C1 12. Connecting strip C2

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CHEMICAL DOSING PUMP (and chemical pick up tube with non return valve assembly)

14

14

1

2

3

13 13 13

4 5

15 6

7

12

8

9 11

WARNING THERE MAY BE RESIDUAL CHEMICAL INSIDE THESE PUMPS PROTECTIVE CLOTHING, GLOVES AND EYE PROTECTION MUST BE WORN WHEN HANDLING AND DISMANTLING.

10

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Inlet nozzle Outlet nozzle Main body Glass ball valve Valve cover outlet Diaphragm Piston Spring Cap Vacuum connection nozzle Locking ring Pick up tube Non return valve PVC Tube PVC Connector

Connect the non return valve assembly to the inlet side of the dosing pump. The assembly must be installed vertically.

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LARGE BORE WASH VALVE : NORMALLY OPEN 1

2 3 4 6

5 7

8

9 10 11 13

12 14

1.

2.

3.

4.

5.

6, 7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Screw 8AB x12.7 D200785 (x20) Screw M4x40 D200784 Vent Cap Nut M5 (Nylon insert) D204615 Washer M5 D204016 Diaphragm clamp D385755 Diaphragm D381673 Piston D385757 Valve spring D243721 Bearing D385753 Distributer seal D242738 Vacuum connection nozzle Upper body Body seal D382756 Valve D385766 Valve seal D242740 Nut M4 D204525 Main body (flanged) Complete assembly (flanged) D498742

15

16 17 20 18 19

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LARGE BORE WASH VALVE : NORMALLY CLOSED

The normally closed version of this valve has identical parts to the normally open version. However it is built differently inside, items 7, 8, 9 and 10 are reversed (see diagrams). The wash valves are available with flanged or plain nozzles.

Normally closed valve Vacuum connection Vent

- Upper vacuum nozzle - Lower vacuum nozzle

Normally open valve As shown on page 2 - 4 : Vacuum connection - Lower vacuum nozzle Vent - Upper vacuum nozzle

Normally closed valve in pick up position

Normally closed valve in diverter position = Direction of flow

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CHANGEOVER VALVE

The changeover valve has the vacuum connection on the lower vacuum nozzle. The upper vacuum nozzle is left open to atmosphere.

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AIR INJECTOR

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Locking ring D385573 Vacuum connection nozzle Cap D385574 Spring D243712 Diaphragm D381667 Screw M3 x 10 Check valve D498762 Main body D390677 Filter D390678 Filter housing D498753 Gasket D391541 Upper bracket Screw M6 x 25 Lower bracket Washer M6 Nut M6 10

1

2 3

4 5

7

6

9 8

11 12

13

14 15 16

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SUPPORT BRACKET

1 6 2 6

3

8

4 9 10

5

7 11

12

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

4mm I.D. rubber tube 6mm to 4mm reducer D240913 6 mm PVC tube Upper water level tube (tulip) Clip Pick up tubes Rubber end cap D381590 Water fill nozzles Support tube U-bracket Chemical nozzles Lower water level probe (tulip)

This bracket is reversible - see page 3 - 18

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CHEMICAL TRAP

1

2 1.

2.

3.

4.

32mm solvent welded union Vacuum connection nozzle D240741 Transparent PVC tube Tap D240917

3

4

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Chapter

3

INSTALLATION

ALL WORK ON MAINS ELECTRICAL INSTALLATION MUST BE CARRIED OUT BY A FULLY QUALIFIED ELECTRICAL ENGINEER AND CONFORM TO ALL LOCAL AND NATIONAL STANDARDS. THE MAINS PLUMBING WORK SHOULD BE CARRIED OUT BY A FULLY QUALIFIED PLUMBER AND CONFORM TO ALL LOCAL AND NATIONAL STANDARDS. EXTREME CARE MUST BE TAKEN WHEN HANDLING CHEMICALS. PROTECTIVE CLOTHING, EYE GOGGLES AND GLOVES MUST BE WORN WHEN DISMANTLING ANY PART OF THE SYSTEM WHICH IS IN CONTACT WITH CHEMICALS. BEFORE INSTALLATION OF THE AQUASTAR SYSTEM, A SUITABLY SIZED WASH TROUGH MUST BE INSTALLED IN A CONVENIENT PLACE IN THE DAIRY. IT MUST BE LARGE ENOUGH TO HOLD ALL THE WATER REQUIRED TO WASH THE PLANT.

GASCOIGNE MELOTTE WILL NOT ACCEPT RESPONSIBILITY FOR ANY PROBLEMS WHICH MAY OCCUR IF THE INSTRUCTIONS WITHIN THIS MANUAL ARE IGNORED.

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15

14

18

13

17

1

20

16

21 22

2

12

7

9

4

8

3

6

5

19

11

10

SCHEMATIC OF THE STANDARD BASIC AQUASTAR WATER MANAGEMENT SYSTEM

GASCOIGNE MELOTTE

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AQUASTAR CONTROL BOX

DISTRIBUTION BOX

20 mm (3/4” B.S.P. gas fitting) HOT AND COLD WATER FILL 24V SOLENOID VALVES (MOUNT HORIZONTALLY)

PICK UP VALVES

CHANGEOVER VALVE

WASH TROUGH

SUPPORT BRACKET

UPPER WATER LEVEL PROBE (Tulip)

LOW WATER LEVEL PROBE (Tulip)

DISCHARGE TUBE/WASH RETURN LINE

BULK MILK TANK

1.

2.

3.

4.

5.

6.

7.

8.

3 - 3/1.8

9.

10.

11.

22.

21.

20.

19.

18.

17.

TEMPERATURE SENSOR (OPTIONAL)

CHEMICAL TRAP

VACUUM SUPPLY TO DISTRIBUTION BOX

MILK/WASH SAFETY SWITCH (OPTIONAL)

VACUUM PUMP CONTACTOR

PULSATION CONTROLLER

LECTRON TL

MILK PUMP CONTROL BOX

15.

16.

AIR INJECTOR

AUTOMATIC DRAIN VALVE

CHEMICAL CONTAINERS

14.

13.

12.

GASCOIGNE MELOTTE

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MOUNTING THE CONTROL BOX The Aquastar control box should be mounted on the wall in a dry location within 3 metres of the distribution box, where it cannot be affected by steam etc. The control box should be mounted at a convenient height for operating and must have adequate access for everyday use.

As all the components are mounted in relation to the wash trough, position this first. Determine where the control box is to be mounted and mark slot hole A on the wall. The control box is supplied with a fixing kit, drill and plug a hole and mount a screw. The distance from the back side of the screw head should only be a few millimetres as the control box has a recessed slot.

Hang the control box on the screw and ensure that it is horizontal. Now mark holes B and C on the wall.

The distance between holes B and C is 282 mm, centre to centre. Drill both holes and mount the control box on the wall.

28 mm

A

282 mm C

B

MOUNTING THE DISTRIBUTION BOX The AQUASTAR distribution box should be mounted on the wall, to one side of and approximately 50 cm above the wash trough, adequate access must be provided for servicing purposes. The back plate has 4 key hole slots. Mark the position of the slots on the wall and use the fixing kit supplied to mount the 420 mm distribution box.

290 mm

30 mm

GASCOIGNE MELOTTE

STAR WATER MANAGEMENT SYSTEM

385 mm

1

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3-4

2

3

X

D ep th

=

15

5

m

m

The vacuum supply for the distribution box is taken from the chemical trap which should be installed as close as possible to the box. The 6mm PVC tube linking the chemical trap vacuum nozzle to the vacuum nozzle on the box must be kept AS SHORT AS POSSIBLE.

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INSTALLATION AND WIRING OF THE AQUASTAR The diagram on the following page shows the connectors necessary for the correct wiring of the AQUASTAR. The connectors are located behind the removable panel at the bottom of the control box.

Grommets have been integrated into the bottom of the control box for the cables to enter the box.

9

8

7

6

5

4

3

2

1

ALL WORK ON MAINS ELECTRICAL INSTALLATION MUST BE CARRIED OUT BY A FULLY QUALIFIED ELECTRICAL ENGINEER It is recommended that the cables enter the glands as described below : 1.

2.

3.

4.

5.

6.

7.

8.

9.

Incoming mains Cable to vacuum pump contactor. Voltage is the same as the mains.

Cable to pulsation controller power supply. Voltage is the same as the mains.

4 wire cable to milk pump control box.

21 wire cable to the distribution box.

3 wire cable to air injectors.

2 wire screened communication cable to the milking parlour.

Outgoing 2 wire cable to the wash mode relay. (12V D.C. contact voltage).

Temperature sensor: 3 wire cable; or, heater: 6 wire cable.

TO PREVENT WATER FROM ENTERING THE CONTROL BOX, ANY GROMMETS WHICH ARE NOT USED SHOULD BE SEALED.

CONNECTING MR 2000 DISPLAY BOXES The communication cable automatically assures the correct wash/milking position on the display boxes.

This is important if the milking installation is fitted with compartmental cleaning. If the communication cable is connected to the AQUASTAR, the switch on the wash/reset box should always be set to the milking position. The display boxes will automatically be switched to the washing mode by the AQUASTAR. The communication cable must be connected either to the first display box in the chain or to the wash reset box. The screen on the cable must be connected to the screen in the display box chain.

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WIRING THE AQUASTAR SYSTEM TIP : When wiring the Aquastar control box connect all the wires in the bottom row first.

CN7

CN8 CN10 28 26

29

27 25

24

22

23

20 18

21

19 17

16 14

12 10

15 13

CN5

CN2

CN3 6

30

CN9

11

8

9

6

7

4

5

2

3

6

1

4

5

4

16 14

2

12

10

8

6

4

2

10

8

6

4

2

6

4

2

2

3

1

5

3

1

15 13

11

9

7

5

3

1

9

7

5

3

1

5

3

3

1

2

Connector 2

Connection no.

Wired to

Cable gland

Wire

CN2/1

Communications + (6 in MR 2000 control box OR 9 in wash reset box)

7

2 x 0.25 screened

CN2/2

Communications - (7 in MR 2000 control box OR 8 in wash reset box)

7

2 x 0.25 screened

CN2/3

Earth (connect screen to screen)

7

2 x 0.25 screened

CN2/4,5,6

Not connected

Connector 3 - 230/120 VOLT (Verify voltage of control box before connecting)

Connection no.

Wired to

Cable gland

CN3/1

Mains + live (Brown Wire)

1

CN3/2

Mains - neutral (Blue Wire)

1

CN3/3

Mains Earth (Green/Yellow)

1

Wire

3 x 0.75

Connector 5 - 230/120 VOLT

Connection no.

Wired to

Cable gland

CN5/1

Vacuum pump contactor (-)

2

CN5/2

Vacuum pump contactor (+)

2

CN5/3

Vacuum pump contactor GND

2

CN5/4

Pulsation controller power supply GND

3

CN5/5

Pulsation controller power supply (-)

3

CN5/6

Pulsation controller power supply ( +)

3

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3-6

Wire

3 x 0.75

3 x 0.75

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00.0

00.0

3 - 7/1.8

AI2SV

23

24

21

22

19 17

20 18

15 13

16 14

11

12 10

9

8

7

6

5

4

3

2

1

6

3

2

1

6

5

4

3

2

1

12

15 13

16 14

11

10

9

8

Connector

14

7

6

5

4

1 2 3 4 5 6

Milk Pump control 13 box

5

4

CN2

CN7

3

2

1

10

9

8

7

6

5

CN9 4

3

1

230 V

6

5

4

3

2

3

2

1

Vacuum Pump Contactor

Mains IN

230 V

CN3

To Vacuum Pump

1

To pulsation controller

GASCOIGNE MELOTTE

POWER SUPPLY TRANSFORMATEUR TRANSFORMATOR 12A

Pulsation Controller Power Supply

2

CN5

BECAUSE THE VACUUM PUMP IS OPERATED REMOTELY BY THE AQUASTAR CONTROL BOX IT MUST BE FITTED WITH A WARNING SIGN INDICATING THAT IT MAY START AT ANY TIME WITHOUT WARNING.

1 2 3 4 5 6 7 8 9 10 11 12

AI1SV = Air Injector 1 Solenoid Valve AI2SV = Air Injector 2 Solenoid Valve {Usually in Lectron TL}

AI1SV

27 25

28 26

Temperature Monitor Probe (optional)

29

30

CN10

CN8

GASCOIGNE MELOTTE

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Connector 7 (neutral is 12 Volt DC).

Connection no.

Wire/Remarks

Connected Via

CN7/1

To

Cable gland

Spare (not connected)

CN7/2

Auxiliary alarm

CN7/3

3 x 0.50

Solenoid for air injector 1

6

CN7/4

3 x 0.50

Solenoid for air injector 2

6

CN7/5

21 core (Violet)

C1 (10)

CN7/6

21 core (Grey)

C1 (5)

Solenoid for pick up valve (SV5)

5

CN7/7

Wash mode (if applicable)

8

CN7/8

Spare

9 Used with water storage for reuse system

CN7/9

21 core (Pink)

C1 (6)

Solenoid for diverter D (drain valve) (SV6)

CN7/10

21 core (Blue)

C1 (7)

Solenoid for diverter 1 valve (SV7)

CN7/11

21 core (Red)

C1 (8)

Solenoid for diverter 2 valve (SV8)

CN7/12

21 core (Black)

C1 (9)

Solenoid for diverter valve 3 (if applicable) {Additional solenoid required}

CN7/13

21 core (Yellow)

C1 (4)

Solenoid for changeover valve (SV1)

5

CN7/14

21 core (White)

C1 (1)

Solenoid for dosing pump 1 (SV2)

5

CN7/15

21 core (Brown)

C1 (2)

Solenoid for dosing pump 2 (SV3)

5

CN7/16

21 core (Green)

C1 (3)

Solenoid for dosing pump 3 (SV4)

5

Connector 8 (+12 volts).

Connection no.

Wire

Connected Via

To

Cable gland

CN8/1

21 core (Grey/Pink)

C1 (11)

Solenoid valves in distribution box return

5

CN8/2

Not connected

CN8/3

Not connected

CN8/4 CN8/5

3 x 0.50

Air injectors return

6

Not connected Wash mode relay return (If applicable)

CN8/6

8

The 21 core cable to connect the control box to the distribution box comes supplied wired to the control box. Length 4m.

D021003/E

3 - 8/1.8

8/01.-1.8

8/01.-1.8

SV1

Return Red

SV2 Red SV3 Blue SV4 Black SV1 Grey SV5 Orange SV6 Mauve SV7 Red SV8 Blue

SV2

3-9 SV5

SV3

1 2 3 4 5 6 7 8 9 10 11 12

C1

SV6

7

6

5

4

3

2

1

6

5

4

3

2

CN2

1

6

5

4

SV4

SV7

3

SV8

White CN7 (14) Brown CN7 (15) Green CN7 (16) Yellow CN7 (13) Grey CN7 (6) Pink CN7 (9) Blue CN7 (10) Red CN7 (11) Black CN7 (12) Violet CN7 (5) Grey/Pink CN8 (1)

29 27 25 23 21 19 17 15 13 11 9

30 28 26 24 22 20 18 16 14 12 10 8

CN10 1 15 13 11 9 7

CN7

2 16 14 12 10 8

CN8 6

5

4

3

C1

1 9

2 10 8

7

6

5

4

CN9

C1

3 1

2

C2

6

5

4

3 1

2

CN5

5 3 1

CN3

GASCOIGNE MELOTTE

D021003/E

GASCOIGNE MELOTTE

Connector 9 (24 Volts AC and contact).

Connection no. Wire / Remark

Connected Via

To

Cable gland

Wash/idle mode signal for use with Isolator 3 systems. When Aquastar is in wash or idle mode, the relay contact between CN9/1 and CN9/2 is closed, in milking mode it is open.

CN9/1

Contact

CN9/2

Contact

CN9/3

4 x 0.5mm

Milk Pump C1 (4 in milk pump control box)

4

CN9/4

4 x 0.5mm

Milk Pump C2 (5 in milk pump control box)

4

CN9/5

21 core (Grey/Brown)

Solenoid for cold water fill (24V)

5

C2 (6)

Relay to switch additional heater or drain AC (if fitted) (24V)

CN9/6 CN9/7

21 core (Pink/Brown)

C2 (8)

Preheated water solenoid valve (24V)

5

CN9/8

21 core (White/Pink)

C2 (7)

Solenoid for hot water fill (24V)

5

21 core (White/Blue)

C2 (9)

Water fill returns

5

CN9/9

Additional heater relay return or drain AC

Connector 10 Connection no.

Wire/Remark

Connected Via

To

Cable gland

CN10/1

21 core (White/Green)

C2 (1)

High level pressure switch

5

CN10/2

21 core (White/Yellow)

C2 (3)

Pressure switches return

5

CN10/3

21 core (White/Grey)

C2 (5)

Milk/wash safety switch

5

CN10/4

21 core (Yellow/Brown)

C2 (4)

Milk/wash safety switch return

5

CN10/5

4 x 0.5mm

Milk pump switch signal

4

CN10/6

4 x 0.5mm

Milk pump switch signal return

4

CN10/7

21 core (Brown/Green)

Low level pressure switch

5

C2 (2)

CN10/8

Not connected

CN10/9

Signal

Heater Control Box

Additional heater thermal overload switch (signal)

CN10/10

Signal

Heater Control Box

Additional heater thermal overload switch (return)

CN10/17

Signal (Yellow)

Temperature sensor

CN10/18

Return (Brown)

Temperature sensor

CN10/22

+5V (Green)

Temperature sensor

CN10/23 CN10/24

D021003/E

CN10/25

Signal

Heater Control Box

Heater pressure switch

CN10/26

Signal

Heater Control Box

Heater pressure switch

3 - 10 / 1.8

8/01.-1.8

8/01.-1.8

3 - 11/1.8

13

11

PS1

12

13

PS2

11 12

PS1 (13) Red PS2 (13) Blue PS (Return) Black M/WSS (Return) M/WSS CWSV HWSV PHSV Water Valves (Return)

M/WSS

1 2 3 4 5 6 7 8 9 10 11 12

C2

CWSV

HWSV

White/Green CN10 (1) Brown/Green CN10 (7) White/Yellow CN10 (2) Yellow/Brown CN10 (4) White/Grey CN10 (3) Grey/Brown CN9 (5) White/Pink CN9 (8) Pink/Brown CN9 (7) White/Blue CN9 (9) Blue/Red CN10 (23)

29 27 25 23 21 19 17 15 13 11 9

30 28 26 24 22 20 18 16 14 12 10 8

CN10

7

6

5

4

3

2

1

6

5

4

3

2

CN2

1

6

5 3

6

5

4

3 1 9

2 10 8

7

6

5

4

CN9

3 1

2 6

5

4

3 1

2

CN5

5

3

1

CN3

C2

C1

C2

PHSV = PreHeater Solenoid Valve

HWSV = Hot Water fill Solenoid Valve

CWSV = Cold Water fill Solenoid Valve

M/WSS = Milk/Wash Safety Switch

PS2 = Pressure Switch 2 (Low level pressure switch)

PS1 = Pressure Switch 1 (High level pressure switch)

1 15 13 11 9 7

CN7

2 16 14 12 10 8

PHSV

4

CN8

GASCOIGNE MELOTTE

D021003/E

GASCOIGNE MELOTTE

PLUMBING THE AQUASTAR SYSTEM C1

C2

19

16 15

10

12

9

13

14

7 6

7 4 8

5

1

2

3

11

17 18

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

D021003/E

3 - 12

Chemical container 1 Chemical container 2 Chemical container 3 High water tulip Low water tulip Changeover valve Pick up valve Diverter D valve (normally open) Diverter valve 1 (normally closed) Diverter valve 2 (normally closed) Wash trough Dosing pump 1 Dosing pump 2 Dosing pump 3 Hot water fill Cold water fill 40 mm wash line Wash jetter Vacuum in

8/01.-1.8

GASCOIGNE MELOTTE

The diagram on page 3-12 gives a schematic view for plumbing the vacuum and chemical connections of the Aquastar system. 8, 9 and 10 on the diagram are additional parts of the system which are needed when the water saving option is being used. The support bracket is mounted over the wash trough, this holds the pick up tubes, the water level probes, the chemical dosing tubes and the hot and cold water fill hoses.

1.

Chemical container 1, (nominally alkali) is plumbed into dosing pump 1 (12). Blue Ă˜6 mm PVC tubing is connected to the non-return valve assembly which is inserted through a hole drilled in the chemical container cap, it is necessary to have an air bleed hole in the cap if the non-return valve assembly has a tight fit. This tubing runs directly to the front plastic nozzle to the left of dosing pump 1. Another tube runs from the rear nozzle to the support bracket above the wash trough.

TIP To fit PVC tubing to the non-return valve assemblies and nozzles, warm the end of the tubing in hot water to soften it.

2.

Chemical container 2, (nominally acid) is plumbed into dosing pump 2 (number 13 on diagram), Red PVC tubing runs directly to the front plastic nozzle to the left of dosing pump 2. Another tube runs from the rear nozzle to the support bracket above the wash trough.

3.

Chemical container 3, is plumbed into dosing pump 3 (number 14 on diagram). Clear PVC tubing runs directly to the front plastic nozzle to the left of dosing pump 3. Another tube runs from the rear nozzle to the support bracket above the wash trough.

4.

Upper water level probe (Tulip). This is connected directly to pressure switch PS1 with 4 mm rubber tube. A reducer is used at the tulip to connect the 6mm PVC tube attached to the top of the tulip to the 4 mm rubber tube. The tulip is fixed to the support bracket above the wash trough, at a height determined by the amount of water required in the system. See “Setting the correct amount of wash water� in Chapter 5.

5.

Lower water level probe (Tulip). This is connected directly to pressure switch PS2 with 4 mm rubber tube. A reducer is used at the tulip to connect the 6mm PVC tube attached to the top of the tulip to the 4 mm rubber tube. The tulip is fixed to the support bracket above the wash trough so that it is positioned at the lowest part of the wash trough. This component MUST be fitted when an additional heater is used for the main wash. Tell the Aquastar than this component is present by adding the value 128 to A-03.

6.

Changeover valve. The upper half is normally closed, the lower half is normally open (to drain).

In the setup shown opposite with the water saving option, the bottom of the changeover valve is connected to another pipe for water diversion. Without water saving, the bottom of the changeover valve goes to drain. The changeover valve has a vacuum connection from the lower vacuum nozzle on the changeover valve to solenoid valve SV1 inside the distribution box. This connection is made with 6 mm PVC tube. The upper vacuum nozzle should be left open to atmosphere as the vent.

7.

Pick up valves. These are normally closed. The two upper vacuum nozzles on the pick up valves are connected with a nylon tee piece. This is then connected with 6 mm PVC tube to solenoid valve SV5 in the distribution box. The lower vacuum nozzles on the pick up valves are left open to atmosphere.

8/01.-1.8

3 - 13

D021003/E

GASCOIGNE MELOTTE

8.

Diverter D Valve. This normally open drain valve is only present in systems with optional water saving options. In the standard system the bottom of the changeover valve is used to direct water down the drain. This valve should be positioned directly above the sewer. The upper nozzle of this valve is connected to solenoid valve SV6 in the distribution box with 6 mm PVC tube.

9.

Diverter Valve 1. This normally closed wash valve is only present in systems with optional water saving options. It can be used (for example) to direct post rinse water into a tank, so it can be used for the following pre-rinse. The lower nozzle of this valve is connected to solenoid valve SV7 in the distribution box with 6 mm PVC tube.

10.

Diverter Valve 2. This normally closed wash valve is only present in systems with optional water saving options. It can be used (for example) to direct main wash water into a tank, so it can be used for floor washing. The lower nozzle of this valve is connected to solenoid valve SV8 in the distribution box with 6 mm PVC tube.

11.

Wash trough. A suitably sized wash trough must be installed in a convenient place in the dairy.

It must be large enough to hold all the water to wash the plant.

12.

Dosing pump 1. This pump doses the preset amount of chemical from container 1 directly into the wash trough reducing the chance of direct contact with chemicals. Container 1 is nominally alkaline.

13.

Dosing pump 2. This pump doses the preset amount of chemical from container 2 directly into the wash trough reducing the chance of direct contact with chemicals. Container 2 is nominally acid.

14.

Dosing pump 3. This pump doses the preset amount of chemical from container 3 directly into the wash trough reducing the chance of direct contact with chemicals. Container 3 is nominally sanitizer.

15.

Hot water fill. The pipe from the hot water boiler/tank to the wash trough must be plumbed to the 20 mm (3/4� B.S.P. gas fitting) water fill valve by a fully qualified plumber. The fill is controlled by commands from the control box to the 24 volt solenoid valve. The plastic nipple supplied should be screwed into the valve and reinforced PVC hose connects the nipple on the water valve to the nozzle on the pick up support bracket. The valves should be mounted horizontally.

16.

Cold water fill. The pipe from the cold water tank to the wash trough must be plumbed to the 20 mm (3/4� B.S.P. gas fitting) water fill valve by a fully qualified plumber. The fill is controlled by commands from the control box to the 24 volt solenoid valve. The plastic nipple supplied should be screwed into the valve and reinforced PVC hose connects the nipple on the water valve to the nozzle on the pick up support bracket. The valves should be mounted horizontally.

17.

40 mm stainless steel wash line.

18.

Wash jetter. The wash jetters must be correctly installed to ensure good transfer of water between the wash line and the milk line. See your wash jetter manual for correct installation instructions.

19.

Vacuum in. The vacuum supply to the distribution box is taken from the nozzle on the chemical trap using a short length of 6mm PVC tubing. Ensure that the vacuum supply is taken as close as possible to the distribution box.

D021003/E

3 - 14

8/01.-1.8

GASCOIGNE MELOTTE

C1

A

M

D

C2

SV1

SV2

SV5

SV3

SV6

SV4

SV7

SV8

SV1

SV2

SV5

SV3

SV6

SV4

SV7

SV8

C

D

E

F

G

H

J

K

B

N

SV2

F

P

SV3

SV4

H

Q L

A. B. C. D. E. F. G. H.

L

L

From high level tulip From low level tulip Solenoid valve SV1 to changeover valve Solenoid valve SV2 to dosing pump 1 Solenoid valve SV5 to pick up valves Solenoid valve SV3 to dosing pump 2 Solenoid valve SV6 to diverter D valve Solenoid valve SV4 to dosing pump 3

8/01.-1.8

J. K. L. M. N. P. Q.

3 - 15

Solenoid valve SV7 to diverter valve 1 Solenoid valve SV8 to diverter valve 2 Chemicals into wash trough From chemical container 1 From chemical container 2 From chemical container 3 Vacuum in

D021003/E

GASCOIGNE MELOTTE

PLUMBING THE LARGE BORE WASH VALVES TO THE PIPEWORK For wash valves with flanged nozzles, a Ø50.8 mm clamp has been designed to join the valve nozzle to a flange fitting which has been expanded onto the end of a Ø50.8 mm (2”) stainless steel pipe.

To make a connection between the 40 mm wash line and the wash valves, a 50 to 40 mm stainless steel reducing flange should be expanded onto the 40 mm stainless steel wash line, this can then be coupled to the wash valves with a Ø50.8 mm plastic clamp.

INSTALLING THE CHANGEOVER VALVE The lower body of the changeover valve has two flanged nozzles, the upper body has a plain nozzle.

Return from milk line

To make a connection between the 40 mm wash line and the lower horizontal nozzle, a 50 to 40 mm stainless steel reducing flange should be expanded onto the 40 mm stainless steel wash line, this can then be coupled to the nozzle with a Ø50.8 mm plastic clamp.

A 50 mm rubber bend should be used to connect the upper nozzle to the wash trough return pipe.

For washing, the 40 mm return line is removed from the bulk milk tank and connected to the pipe attached to the changeover valve. This allows wash water to circulate or diverts it down the drain. The changeover valve is normally open to drain.

The changeover valve has a vacuum connection from the lower vacuum nozzle on the changeover valve to solenoid valve SV1 inside the distribution box. The upper vacuum nozzle is left open as a vent.

Return to wash trough for To drain circulation

D021003/E

3 - 16

8/01.-1.8

GASCOIGNE MELOTTE

EXPANSION TOOL INSTRUCTIONS Gascoigne Melotte can supply a comprehensive set of expansion tools to enable stainless steel flange couplings to be expanded onto the end of stainless steel pipe. The tool set also includes a cutting block to assist in cutting the stainless steel pipe true. ❏

Use the cutting block to hold the pipe securely in a vice, cut the pipe to the correct length using the cutting block to obtain a clean, true cut. File off any burrs.

❏

Place the flanged coupling on the end of the pipe as shown in the diagram. The end of the pipe should be recessed by approximately 1mm from the end of the coupling.

❏

Insert the expansion tool into the pipe.

❏

Fit the handle to the end of the expansion tool and turn clockwise, expanding the pipe within the coupling until the handle becomes more difficult to turn. Do not expand the pipe so much that the pipe beyond the end of the coupling becomes deformed.

DO NOT OVERTIGHTEN THE EXPANSION TOOL. ❏

Loosen the expansion tool by reversing the handle and turning anticlockwise.

❏

Verify that the coupling is firmly attached to the pipe.

❏

The flange which has been expanded onto the end of the pipe can be coupled to another flange to join two lengths of pipe together or to a flanged nozzle on a wash valve.

8/01.-1.8

3 - 17

D021003/E

GASCOIGNE MELOTTE

INSTALLING THE WASH PICK UP SUPPORT BRACKET The wash pick up support bracket is mounted on the wall just above the wash trough using the coach screws provided. It is used to support the Ă˜51 stainless steel pick up tubes and the tulips. It provides entry nozzles for the hot and cold water fill pipes and the chemicals from the dosing pumps.

The pick up tubes must be mounted so they are at the deepest part of the wash trough. They should be positioned 10 - 12 mm from the bottom of the trough, and the lower ends cut at a slight angle (10 - 20 degrees) to prevent them from becoming closed off.

To allow the pick up tubes to be at the deepest part of the wash trough, the bracket has been designed to be fully adjustable. It can be mounted on the support tube in either direction, and can slide along the tube until the pick up tubes and the low level tulip are at the deepest part of the trough. The tulip should not be positioned too close to the end of the pickup tubes. The bracket is securely fixed to the support tube using the 2 plastic U bolt brackets supplied. The support tube can be cut off to an appropriate length and a 40 mm rubber end cap fitted to the end.

The reinforced PVC hose from the plastic nozzles on the hot and cold water fill valves is pushed onto the large nozzles and secured with the plastic hose clips supplied. The 6 mm PVC tubes from the chemical dosing pumps are pushed onto the small nozzles. Warm the end of the tubes in hot water to make it easy to push onto the nozzle.

10 - 12 mm

D021003/E

3 - 18

8/01.-1.8

GASCOIGNE MELOTTE

A NOTE ON THE POSITION OF THE UPPER WATER LEVEL PROBE The upper water level probe tells the Aquastar system when the water in the trough has reached an upper level. If the wash trough is big enough, it should be filled with the correct amount of water to wash the complete milking machine (See chapter 5 for guidelines for the correct amount of water). The high level tulip should be lowered into the water until the pressure switch PS1 in the distribution box switches (clicks). The upper probe should be secured at this height using the bracket on the pick up support.

However in the case where your wash trough is filled to the brim when all the water to wash the plant is added, you do not want to put the tulip right at the very top of the trough, as it in this way it may or may not trigger. It is preferable to ensure that the tulip has positively triggered by having it placed lower down in the wash trough and then adding extra water after the trigger using functions A-87 to A-90.

These A functions allow you to add water for an additional percentage of the time it took to fill the trough to the upper tulip.

NOTE : When adding extra water, the circulation will start 15 seconds after the upper tulip triggers, this 15 seconds is the time required for the vacuum to build up in the plant. The extra water will be added to the trough after the pick-up valve has opened. In this way you are not limited by the size of your wash trough.

INSTALLING THE PICK UP VALVES The pick up valves (normally closed) are installed above the wash trough as shown. The pick up tubes are Ă˜51 stainless steel and are connected to the flanged nozzle on the pick up valves using a stainless steel flanged coupling and a Ă˜50.8 plastic clamp. A support bracket has been designed to hold the pick up tubes in the correct place above the wash trough, this should be mounted on the wall just above the wash trough and the distance adjusted so the pick up tubes will be at the lowest part of the wash trough.

The pick up tubes should be positioned approximately 10 - 12 mm from the bottom of the trough, and the lower ends cut at a slight angle (10 - 20 degrees) to prevent them from becoming closed off.

The two upper vacuum nozzles on the pick up valves are connected with a nylon tee piece. This is then connected with 6mm PVC tube to solenoid valve SV5 in the distribution box. The lower nozzles on the pick up valves are left open to atmosphere.

8/01.-1.8

3 - 19/1.8

D021003/E

GASCOIGNE MELOTTE

PLUMBING THE AIR INJECTORS In order to clean the air injectors, they are plumbed into the milk pump using Ă˜14 rubber or silicon tubing as shown below. The vacuum connection between the nozzle on the air injector and the nozzles on the Lectron TL is made using 6mm P.V.C. tubing. The air injectors are controlled by an electronic signal from the Aquastar control box to the Lectron TL.

TAP

TAP

Note: Where two air injectors are installed, a small tap must be fitted between the Lectron TL and the air injector. These taps are used to control the operation of the appropriate air injector when washing looped lines.

It is recommended that the looped lines are washed in opposite directions on alternate days.

If the slope to the receiver is less than 1%, one air injector is required, for slopes greater than 1%, two air injectors are required. < 1% = 1

> 1% = 2

INSTALLING A MILK/WASH SAFETY SWITCH An optional milk/wash safety switch can be attached to the swing arm of the return line. This switch is connected to the Aquastar control box and is used to tell the system which position the return line is in.

This prevents wash water from entering the bulk milk tank and stops milk going down the drain.

D021003/E

3 - 20

8/01.-1.8

GASCOIGNE MELOTTE

INSTALLING THE CHEMICAL CONTAINERS

PROTECTIVE CLOTHING, GLOVES AND EYE PROTECTION MUST BE WORN WHEN HANDLING DAIRY CHEMICALS. The chemical containers are connected to the dosing pumps with Ø6 mm PVC tubing. This tubing is colour coded, red for acid, blue for alkali, and clear for sanitant. Drill a hole in the cap of the chemical container (remove the cap from the container before drilling) and insert the non-return valve assembly supplied with the Aquastar through the cap so it reaches the bottom of the container, the non return valve MUST be installed VERTICALLY. If there is a tight fit between the hole in the cap and the nonreturn valve assembly (as we recommend in order to prevent spillages) it will be necessary to make a small air bleed hole in the cap.

The chemical containers must be stored upright, as close to the distribution box and wash trough as possible. They must be stored in accordance with the chemical manufacturers instructions and all local and national regulations concerning the storage of hazardous chemicals must be taken into account.

It is recommended to connect the system as follows ❏

alkaline to dosing pump 1

❏

acid to dosing pump 2

❏

sanitant to dosing pump 3

Note arrows on pump body

From chem To w ical ash t cont roug aine h r

PLUMBING THE FILL PIPES The hot and cold water fill pipes to the wash trough must be plumbed to the 20 mm (3/4” B.S.P. gas fitting) water fill valves by a fully qualified plumber. The plastic nipple supplied should be screwed into the valve and the reinforced PVC hose used to connect the nipple on the water valve to the nozzle on the pick up support bracket. The hose clips supplied should be used to secure the hose to the nozzles. The 24 volt solenoid fill valves should be mounted horizontally.

8/01.-1.8

3 - 21

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GASCOIGNE MELOTTE

CALIBRATING THE DOSING PUMPS NOTE : Before calibrating the dosing pumps it is very important to prime them first. If necessary the calibration process can be run as set out below until the pumps are primed. Once primed the proper calibration process can be carried out.

Calculate the amount of chemical you need to add to the wash trough for each type of chemical.

When the system is installed and ready to run, the dosing pumps must be calibrated to pump the correct volume of chemical. Select the dosing pump calibration function (S-09) by pressing the key.

1 S= 9 is displayed alternating with Pr-C (Press C). a Press the 3

C

key, select which chemical pump you want to calibrate by entering

on the keypad followed by

c

1

2

a

b

or

E

The vacuum pump is automatically switched on by starting the calibration function, you must now wait while the vacuum builds up, when the system is ready for calibration the display shows Pr-0 (Press 0).

Place the outlet tube of the dosing pump into a suitable measuring beaker, press and hold 0 The dosing pump will run and the beaker will start to fill with chemical, the number of pulses the dosing pump has made is displayed on the screen. When the required volume (calculated previously) has been pumped, release key 0, the display will show END and the number of pulses the dosing pump made.

Enter this number in N-5, N-8 or N-11 depending on which chemical was calibrated. These N functions can only be changed with a user or service password.

INSTALLING A HIGH VACUUM SYSTEM The Aquastar system washes much more efficiently at high vacuum levels (50-60 kPa). In many cases parlours are run in milking mode at a lower vacuum level (i.e. 40 kPa). If a servo vacuum regulator is fitted to the plant it is very simple to install an additional solenoid valve which on receipt of a signal from the Aquastar control box that the system has gone into wash, will open the solenoid valve, ‘fooling’ the vacuum regulator into thinking that the plant is at a lower vacuum level than it actually is, the regulator will react and thus automatically increase the vacuum level for washing the parlour. The ‘WASH MODE’ signal from the Aquastar is a 12 volt contact voltage emitted between connectors CN7/ 7 and CN8/6.

A “High Vacuum System for Washing” kit of parts is available for this application. The part number of this kit of parts is GM210021.

Please note that a filter/regulator is included which may be adjusted. Allowing more air into the vacuum regulator via the filter/ regulator will increase the plant vacuum level.

Note also that if the solenoid valve becomes faulty, it will remain in the closed position thus allowing the vacuum regulator to function normally.

IMPORTANT It is mandatory to carry out a full plant test after adjusting the vacuum regulator system.

D021003/E

3 - 22

8/01.-1.8

GASCOIGNE MELOTTE

INSTALLING THE TEMPERATURE PROBE (OPTIONAL) 1. Mount the bracket to the wall so that the temperature sensor is positioned between the return pipe and the pickup. Therefore use the screws that mount the Aquastar support pipe to the wall. Determine which screws have to be used: the two at the left or at the right.

2. Mount the temperature sensor with the cleats to the bracket. The distance between the temperature sensor and the bottom of the wash trough must be approximately 1cm.

3. Pull the cable through the cable duct to the Aquastar control box.

4. Pull the cable through gland 6 (4th from the left) and connect the three-core cable to connector CN10: see the connector table below.

8/01.-1.8

CONNECTOR NO.

CORE

CN10/17

Signal (yellow)

CN10/18

Return (Brown)

CN10/22

+5V (green)

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GASCOIGNE MELOTTE

D021003/E

8/01.-1.8

GASCOIGNE MELOTTE

Chapter

4

OPERATION

AQUASTAR WASH PROGRAMS See Appendix 1 for details on configuring Aquastar wash programs to your requirements.

The day to day operation of the Aquastar requires the use of only a few keys.

The control panel has two keypads. The left keypad is used to start the milking and washing procedures.

The right keypad is used to recall data and change settings.

Start milking by pushing :

E

Ensure the milk line is in the bulk tank

Start washing by pushing : Preset 1 Preset 2

Preset 3

8/01.-1.8

E E

Remove the return line from the bulk milk tank

E

4-1

etc.

D021003/E

GASCOIGNE MELOTTE

THE LEFT KEYPAD The left keypad is used to start milking and washing procedures. It has three elements: Display : The display has four numbers. It will, for example, display the current cleaning phase being executed by the system, data recalled using the right keypad, and error messages (with an E-code.)

Indicator lights : Eight indicator lights are positioned directly below the display. Each indicator light is denoted by a symbol identifying its purpose. Definitions of each symbol follow below.

Light no.

Definition

1.

When a preset program using the cleaning agent in container no. 1 (nominally alkali) has been selected, this LED lights up. If the chemical in the container is low this LED will flash when a program using this chemical is selected. This LED also flashes to indicate that the dosing pump is pumping.

1

2.

2

3.

3

When a preset program using the cleaning agent in container no. 2 (nominally acid) has been selected, this LED lights up. If the chemical in the container is low this LED will flash when a program using this chemical is selected. This LED also flashes to indicate that the dosing pump is pumping.

When a preset program using the cleaning agent in container no. 3 (nominally sanitant) has been selected, this LED lights up. If the chemical in the container is low this LED will flash when a program using this chemical is selected. This LED also flashes to indicate that the dosing pump is pumping.

4.

Low temperature warning for cleaning wash water when start and/or end temperature too low. Lights up when water temperature falls below a preset limit (set in functions A-25, A-26, A-91 and A-92). Remains lit until a new instruction is given to the system. The temperature measurement occurs in function A-15 (see time/function diagram). (This is an optional feature not available on the standard Aquastar system).

5.

Accelerated quick check for servicing purposes. Indicates a wash program using a different wash time than the default preset program time. The programmed wash time may be increased or decreased, depending on the settings. Lights up after pressing the arrow key then the 0 key followed by the E key. This selection must be made before starting the preset program. (Set in function A-38)

6.

Lights up after pressing the STOP key. Indicates that the system is in stand-by mode.

STOP

7.

The system is in wash mode. Lights up after pressing the WASH key followed by the E key. The light will blink when the wash water in the wash trough has reached its preset level and continues flashing until the wash program has been completed.

8.

The system is in milking mode. Lights up after pressing the MILK key followed by the E key and flashes until the milking has been completed.

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Function keys MILK key: PROD appears on the display after pressing the MILK key. The wash controller will switch to milking mode after pressing the E key. Codes on the display indicate which milking phase is active. (see Appendix 2). The milking mode is ended by pressing the STOP key.

The milk key is also used to manually run the milk pump, press the key twice and hold it down to start and run the milk pump.

WASH key: By pressing the WASH key once, preset program 1 is selected. rst1 appears in the display.

The program is started by pressing the E key. The phases of the program appear on the display. These are denoted by a flashing P and then a code number (see Appendix 2) By pressing the WASH key repeatedly, the other preset programs can be selected: Press twice Press three times Press four times Press five times

: preset 2 : preset 3 : preset 4 : preset 5

: rst2 on display : rst3 on display : rst4 on display : rst5 on display

The selected preset program is started by pressing the E key.

Once a preset program has been selected (but not started), to skip stages within the program press the arrow key. Every time the arrow key is pressed, the next stage is selected. The first phase number of the stage will appear on the display (see Appendix 2). After pressing the E key, the selected stage of the preset program will be started. The system will complete the entire preset program starting from the selected stage.

If the following systems are available, upon selecting wash, the Aquastar will automatically enter â&#x20AC;&#x153;WASH MODEâ&#x20AC;? - the second milk pump (wash pump) will be activated, a higher vacuum level will be used, the transformer will turn the Isolator 2 ACR off automatically and if preheated water is available this will be used.

If the wash key is pressed while the Aquastar is in MILKING mode, the pickup valve(s) will open for as long as the key is pressed.

STOP Key:

STOP

Pressing the STOP key once stops the program in progress and causes the word STOP to appear on the display. Pressing the STOP key is also used to clear incorrect data, if incorrect data entry has occurred.

When the STOP key is pressed and held down the version and serial numbers appear on the display.

E(nter) Key:

E 8/01.-1.8

Pressing the ENTER key confirms the desired command or selection. The milk and wash programs will only start AFTER pressing the E key.

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THE RIGHT KEYPAD. Data can be recalled and entered or programs started by using the right keypad. AQUASTAR program settings made by the dealer are also entered using the right keypad.

Key 0:

0

Displays the number of hours the vacuum pump has been running. Function N=1.

Key 1 :

1

Selects the dosing pump calibration function (S=9). See page 3 -22.

a

Key 2:

2 b

Aquastar as a rough guide milk volume counter. Press key 2 to display the approximate volume of milk that has been pumped by the milk pump. The total is calculated by multiplying the calibration figure in A-96 by the amount of time that the Aquastar detects the milk pump to be running. Function S 8.

Key 3:

3 c

You can start wash programs with the 3 key instead of the WASH key. Select which preset program you want by pressing the 3 key 1,2,3,4 or 5 times. If you use the 3 key rather than the wash key, a single cleaning stage can be selected and executed (i.e. to only run the non circulating rinse of a particular program.) An F will appear on the display before the first program phase number instead of a P.

Once a program has been selected (but not started) with the 3 key the stage can be selected by pressing the arrow key. Each time the arrow key is pressed the program jumps to the next stage. The first phase number will appear on the display (See Appendix 2). The selected stage of the preset program will be started after pressing the E key. If the program has been started using the 3 key then ONLY the selected stage of the program will be completed and the wash controller will return to the stand-by mode.

Key 4:

4 d

Displays the contents of container no. 1 (nominally alkali) in litres. Press ARROW key to display the amount of chemical agent for each washing. Function N=3.

Key 5:

5 e

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Displays the contents of container no. 2 (nominally acid) in litres. Press ARROW key to display the amount of chemical agent for each washing. Function N=6.

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Key 6: Displays the contents of container no. 3 (nominally sanitant) in litres. Press ARROW key to display the amount of chemical agent for each washing. Function N=9.

6 f Key 7:

Displays clock time. The display switches between [r=25] and the clock time.

By pressing the ARROW key the other 32 clock functions can be selected (r=26 to 57).

Each clock function can be used to set an automatic program start. This allows washing to be started automatically at a preset time. i.e. a sanitizing rinse prior to milking.

7 g

r=26 is the number of the day, which can be set after entering the user password. For example: Sunday is day 1 and Saturday is day 7, (numbering can be set to start from any week day). Functions r 27 to 57 can be used to set an automatic program start. Proceed as follows : ❏ ❏

1st digit : Input the day number on which the wash must start.

2nd and 3rd digits : Input a number between 1 and 24 which corresponds with the number input in function 8. It is possible to program up to 24 different automatic starts. (See Key 8 for more details).

4th digit: Input the preset program number (1,2,3,4 or 5). If the number 6 is input then the system will automatically switch to the milking mode.

❏

EXAMPLE: The setting r= 2.01.3 could mean: Start on Monday (day 2) at 5:30 (time programmed in function r=01) using preset program 3.

Key 8:

8 h

Displays the time at which a wash program can be started automatically.

Up to 24 start times can be programmed (r=01 to r=24).

EXAMPLE: If a preset program must be started at 5:30, the time can be input in r=01. See the time code table in Appendix 3.

Key 9:

9 j

The 9 key is used to quickly access higher functions in preference to using the arrow key.

It is also used to directly access function S= 4.

Arrow key : The arrow key has three different functions. To access the A, T and S functions the arrow key and 1, 2 or 3 keys must be pressed. Once you are in one of the programs the arrow key is used to select successive functions. A double press on the arrow key is used to clear an error and move onto the next stage of a preset program.

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C key:

C

The correction key. This key is used during data entry. By pressing the C key, all data in the display is erased. It is possible to make changes in (program) settings using the C key.

Keys Arrow + 0 :

0

Switch to an adjusted wash time. This feature allows accelerated service checks to be carried out. After selecting an alternative wash time, indicator light 5 will illuminate. This must be done before starting the preset program. By pressing Arrow + 0 again the wash time will return to its default value. The percentage increase or decrease in wash time can be programmed in by the dealer. (Function A-38)

Arrow key + 1 key :

1

Display or change program settings (A-1 to A-99).

a Arrow key + 2 key:

2 b

AQUASTAR hardware test program. Only for servicing purposes. Can only be accessed after input of the service password. (T-1 to T-44).

Arrow key + 3 key:

3

Input of user and service passwords. (S-1 to S-7).

c Arrow key + E key:

E

Only for servicing purposes. This key combination allows the next stage of a preset program to be started. i.e. use the arrow key to skip from the rinse to drain stage of a preset program to start the main wash. The selected program stage will start after pressing the E key. (Only after input of the service password.)

Arrow key + Wash key: Displays todays next automatically starting program phase (only if installed). If display shows 0000, no automatic program start is due for today. To cancel an automatic program start shown on display, press the C key followed by 1.

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SETTING THE OPERATORS PASSWORD The operators password is set in function A-49. The following example shows how to set the password to a nominal figure of 1 2 3 4.

1

Press

a

then

9

followed by

j

4

9

d

j

E

this gives you access to function A-49. The display flashes between A=49 and - - - -.

Press

Press

1

2

3

4

a

b

c

d

C

followed by the operators code.

E

to confirm. The operators password is now set at 1 2 3 4.

NOTE : It is possible to set the control box so that there is no need to enter an operators password to gain access to user adjustable functions. This can be done by adding the number 128 in A-04 (see Appendix A). N.B. the user password can only be overridden in this way after entering the service password.

USING THE OPERATORS PASSWORD As a user of the Aquastar system, to gain access to certain functions and to change the clock time, the operators password must be entered into the control box. Follow the procedure below to enter the code set in function A-49 (above).

3 Press

c

operators password. e.g.

the display will toggle between S= 1 and no. Press

1

2

3

4

a

b

c

d

and

E

C

then the

to confirm.

If entered correctly the control box will display the time, incorrect entry will result in an error code being displayed. The operator will now have access to the N functions and will also be able to change the clock time. Note : when the system is delivered the operators password is set at a default value of 1.

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SETTING THE CLOCK TIME When in standby mode the current system clock time is always displayed on the control box. The clock built into the PCB inside the control box allows washing to start automatically and keeps track of the number of hours the vacuum pump has run. The correct time must be set on the system clock, to do this follow the procedure below :- e.g. to set the time to 3.45 pm.

NOTE : Aquastar works in the 24 hour clock First the service or operators password must be entered on the keyboard. When correctly entered the display will show four dashes ( - - - - ).

Press

7 g

: the current system clock time will be displayed. To change this time press

C

the display will go blank (or display error code E-20 if the operator or service password has not been entered correctly). Press the keys corresponding the time (e.g. 3.45 pm is 15:45 in 24 hour clock) then confirm the input with the E key.

1

5

4

5

a

e

d

e

E

The system clock time will now be set. The time flashes on the display alternating with r=25.

CHEMICAL CONTAINERS LOW WARNING The Aquastar system warns the operator when the chemical containers are nearly empty. The amount of chemical left in the containers is calculated from the initial amount in the container and is reduced by the amount of chemical used for each wash. (This amount is a constant set in the Aquastar control box, Functions N-04, N-07 and N-10).

Each time a wash is done, the amount of chemical which the Aquastar calculates to be in the containers reduces, the amount left can be seen in functions N-03, N-06 and N-09, which can be accessed by the operator, these functions correspond to chemical containers 1, 2 and 3 respectively. When the amount falls to a level preset in function N-12 (e.g. only enough chemical for 5 washes is left in the container), the control box displays a warning. This warning will appear as a flashing LED above the relevant chemical container on the Aquastar control box when a wash program which uses the relevant chemical is selected. The chemical should be changed when the container is empty.

When the chemical container is changed, the Aquastar control box must be told that a new container has been attached, this is done by inputting the amount of chemical in the new container into the function N-03, N-06 or N-09.

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Example : CHEMICAL CONTAINER 1 RUNS OUT AND IS REPLACED BY A NEW CONTAINER OF 25 LITRE CAPACITY. First enter the operators password. (see previous).

Press

4 d

Press

C

to access function N-03. The amount of chemical that the Aquastar calculates to be left in chemical container 1 is displayed alternating with N= 3.

the display will go blank. Enter the new amount of chemical (25 litres) by pressing :

2

5

b

e

0

0

E

The system is now set to 25 litres of chemical in container 1.

POWER CUT WARNING In the event of a power cut to the control box occurring during plant washing the Aquastar system will shut down. When reconnected to the supply the wash will not restart, the display on the control box will alternate between the word VOLT and a program phase number e.g. P205. This tells the operator that the power to the system has been disrupted, in this case during program phase P205 (while the wash trough is filling for the main wash). Using this information, the operator can decide if the plant needs to be washed or just rinsed through depending at which point in the program the power was cut.

MANUALLY RUNNING MILK PUMP The milk pump can be controlled manually with the control box. Press the MILK key twice and hold it down to start and run the milk pump, when the key is released the milk pump will stop.

THE MILK PUMP MUST NEVER BE ALLOWED TO RUN DRY FOR MORE THAN 5 SECONDS AS THIS WILL DESTROY THE SEALS DUE TO HEAT GENERATED FROM THE FRICTION BETWEEN THE SEAL FACES.

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PREPARING THE PARLOUR FOR WASHING 1.

Close one of the butterfly valves next to the milk receiver and leave the other one open. In this way the water will circulate towards the open valve. If desired, you can wash the parlour one way in the morning and in the opposite direction in the evening, OR one direction one day and the opposite the next day.

2.

Open the milk receiver roll box.

3.

Fit all the clusters to the wash jetters.

4.

Remove the return line from the bulk milk tank and connect it to the changeover valve, ensuring the milk/wash safety switch makes contact (if fitted).

Press the wash key on the Aquastar control box until the desired preset program is displayed, then press the Enter key.

SELECTING AN ADJUSTED TIME MAIN WASH CYCLE For servicing purposes it is possible to switch the Aquastar to an adjusted wash time. This feature allows accelerated service checks to be carried out. Press key the control box, {shorter ---longer}. Press

E

then

0

,

S---L

is displayed on

to select an adjusted wash time. The LED underneath

the clock symbol on the control box will illuminate. To cancel the adjusted time wash cycle press the arrow key followed by the 0 key again, S---L appears on the display, press E and the LED underneath the clock symbol extinguishes.

When this function is selected the length of time that the water in the main wash stage circulates is changed by a percentage factor set in function A-38. This function has a default value of 100% so if an adjusted wash time is selected accidentally the time that the main wash water circulates does not change.

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WHAT TO DO IN AN EMERGENCY If for some reason a breakdown occurs which prevents the Aquastar system from working, it is still possible to milk. Normally the pulsation and the vacuum pump is controlled by the wash controller. If the wash programmer fails, then AFTER DISCONNECTING FROM THE MAINS move the emergency switch to the manual position so that pulsation system and the vacuum pump will function.

NOTE: All fuses must be intact.

IMPORTANT : Disconnect the control box from the mains before switching the emergency switch.

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EMERGENCY WASH PROCEDURE After disconnecting from the mains, move the switch inside the control box to the manual position.

The pick up and changeover valves cannot be controlled by the solenoids inside the distribution box so they must be operated by hand. To do this remove the 6mm PVC tube from the vacuum connection nozzles and connect these nozzles to a source of constant vacuum (nozzle on chemical trap) using the 6mm PVC tube with in-line taps and vacuum decay connectors supplied in the emergency kit inside the distribution box cover. These taps will control the opening and closing of the wash valves.

PROCEDURE NON CIRCULATING RINSE Fill the trough manually with cold (or tepid) water either using buckets or taps which bypass the 24V water fill valves.

Turn on the vacuum pump and give it time to build vacuum in the plant. Start the pulsation system.

Open the in-line tap to the pick up valves and suck the water into the plant. This water will be directed down the drain. Close the in-line tap to shut off the pick up valves as soon as all the water has been sucked out of the trough. DO NOT ALLOW AIR TO ENTER THE PLANT THROUGH THE PICK UP VALVES.

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MAIN WASH Fill the trough manually with hot water. Manually dose the correct volume of chemical. Take extreme care and wear protective clothing, gloves and goggles.

Turn on the vacuum pump and give it time to build vacuum in the plant. Start the pulsation system.

Main wash water should be circulated, so the changeover valve must direct the water back to the trough.

Open the in-line tap to the changeover valve, this prepares it for circulation.

Open the in-line tap to the pick up valves, this sucks the main wash water into the plant. Close the tap as soon as all the water is sucked from the trough. This main wash water should return to the trough.

Repeat several times.

Close the in-line tap to the changeover valve to direct the water down the drain.

CIRCULATING RINSE Fill the trough manually with cold or tepid water.

Ensure plant is up to vacuum and the pulsation system is on.

The water should be circulated, so open the in-line tap to the changeover valve.

Open the in-line tap to the pick up valves to suck up the water. Close it as soon as all water is sucked out of the trough. The water should return to the trough. Repeat several times. Close the in-line tap to the changeover valve to direct the water down the drain.

Please refer to the instruction sheet D108802 included in the Aquastar emergency kit.

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Chapter

5

SETTINGS

This chapter deals with the proper cleaning of the milking installation and making the AQUASTAR operational. The correct amount of water must be used by the system to ensure efficient cleaning of the milking installation: the goal is to make sure that milk quality is maintained by keeping the system properly cleaned.

SETTING THE CORRECT AMOUNT OF WASH WATER These settings pertain to a milking installation with milk meters without compartmental washing.

The correct relationship between the following 4 factors ensures proper cleaning: A. Temperature - B. Cleaning agent - C. Turbulence - D. Time A. A hot water supply with enough volume to supply 1.5 times the amount of wash water at the chemical manufacturers minimum recommended temperature for one washing per milking.

B. The correct dose of cleaning agent.

C. A good balance in the circulation: water/air ratio.

D. The temperature at the end of the main wash program should not be lower than 45째C. To balance the wash water circulation properly proceed as follows: 1. If necessary, close the drain on the milk pump discharge tube.

2. Fill the wash trough with water using a scaled bucket. The amount of water should be approximately 7.5 litres x number of milking units in the milking parlour.

3. Start the vacuum pump in the milking mode.

4. Make sure that all the milk meters are filled to the top before they dump. If not, add more water until all milk meters fill up completely until the fluid bypasses through the overflow for at least 3 seconds.

5. Check if sufficient air is sucked in through the wash trough pick-ups. The system must suck air for 4-5 seconds to ensure a proper amount of turbulence in the milk pipeline and milk meters.

6. Knowing the correct amount water now: drain the system completely.

7. Fill the wash trough with the amount of water as established at point 2 (and 4).

8. Adjust by lowering the upper water level tulip until the pressure switch in the distribution box switches (clicks).

9. Check the complete wash program.

NOTE: If compartmental cleaning is applied, the amount of water as established at point 2 should be reduced by 25%

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STARTING A WASH PROGRAM AUTOMATICALLY PROGRAMMING AUTO START TIMES INTO THE AQUASTAR To start a wash program automatically it is first necessary to program the system with a number of times that you want the Aquastar to automatically start at. To do this follow the procedure below :EXAMPLE : To program the times 05:30 and 15:30 into the Aquastar : 1.

2.

3.

4.

5.

6.

Enter the service password Press the 8 key on the Aquastar keypad the text r=01 flashes alternating with a number.

Press the C key Use the keypad to input the time 05:30 Press the E key. The time 05:30 is now input in r=01.

Note the programmed time next to the r=01 space in the table in appendix 3.

7. Press the arrow key, r =02 appears on the display alternating with a number 8. Press the C key 9. Use the keypad to input the time 15:30 10. Press the E key. The time 15:30 is now input in r=02.

11. Note the programmed time next to the r=02 space in the table in appendix 3.

The above method can be used for programming up to 24 start times in r=01 to r=24.

PROGRAMMING THE AQUASTAR TO START A WASH CYCLE AUTOMATICALLY Clock functions r-27 to r-58 can be used to set automatic program starts. These functions are accessed by pressing key 7 followed by the arrow key. g

r-25 r-26 r-27 to r-58

This is the current system clock time.

This is the number of the current day. e.g. Sunday =1, Monday =2 etc.

First figure The day you want the program to start Second figure (Two digits) The number between 1 and 24 which corresponds to the time table above setting the time you want the program to start.

Third figure The preset program number (e.g. Preset program 3). If the number 6 is entered here, the system switches to the milking mode.

Example r-27 =2.01.3 could mean : Automatically start on Monday (day 2) at 05.30 (time programmed into r=01) washing with the program set in preset 3.

Programs which are set to be executed automatically can be cancelled by pressing followed by

E

C

then

9 j

. You can tell that the program has been cancelled because the preceding decimal

point will disappear. A program that is in the cancelled state can be restored by pressing the same keys in the order above (i.e. C, 9, E).

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WORKED EXAMPLE : To set the Aquastar to enter the milking mode automatically at 15:30 on a Wednesday.

1. Enter the service password 2. Ensure that the time 15:30 is set in one of r=01 to r=24 using the above method. For this example we will say that it is set in r=02.

3. Press the 7 key, r=25 will be displayed alternating with the clock time. Press the arrow key twice until r=27 is displayed.

4. Press the C key. the display will go blank. Use the keypad to enter the desired code.

5. The code is made up as follows :- Day.Time.Preset Program In this case the value to input should be 4026. Full stops will automatically be placed on the display giving the result 4.02.6.

How did we arrive at the above code?

4 is the day number on which the wash must start. Since Sunday is nominally day 1, Wednesday is nominally day 4.

02 is the r-number corresponding to the time 15:30 which has been programmed in advance.

6 is the code corresponding to the instruction to automatically set the system to milking mode.

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Chapter

6

SERVICE AND TROUBLESHOOTING

DISCONNECT FROM MAINS BEFORE REMOVING CONTROL BOX COVER COMPONENTS IN THE AQUASTAR CONTROL BOX. A B C

D

E

F

G

H

I

J

The components behind the hinged lid of the AQUASTAR control box generally do not require servicing.

By turning the screws on the side of the lid (a quarter turn) and pushing the clips inwards, it can be opened. The AQUASTAR control box contains two printed circuit boards (PCBs). The display board is located on the left behind the hinged front. The main board is located on the right. These PCBs contain the software (EPROMs), fuses, relays, etc. The letters in the illustration refer to the descriptions below:

A B C D E

= = = = =

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Clock.

LED PROM LED PCB protection fuse

F G H I J

= = = = =

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Transformer EPROM Connectors.

Emergency switch.

Fuses

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B

C

D

E

J1

J2

J3

LED’S ON THE BOARD The main board contains 2 LED’s.

LED B is the ‘watchdog’ for the microprocessor. Normally OFF. It blinks only ONCE when connected to mains supply. When FLASHING: check if the PROM (component C) is properly inserted in its holder. If it keeps on FLASHING: replace the AQUASTAR control box.

LED D: Checks 5 Volt power supply: should be on when mains is switched on.

FUSES Fuse J3.

Fuse for mains supply to the transformer. Fuse type depends on the mains voltage: + 220/230 Volts; 250 V fuse, 1.6 Amp.- 5 x 20, slow blow + 110 Volts; 250 V fuse, 3.15 Amp- 5 x 20, slow blow

Fuse J2.

Fuse for pulsation controller’s power supply. + 220/230 Volts: 250 V fuse, 2 Amp.- 5 x 20 slow blow + 110 Volts: 250 V fuse, 4 Amp.- 5 x 20 slow blow

Fuse J1.

Fuse for vacuum pump control box relays: + 220/230 Volts: 250 V fuse, 1 Amp.- 5 x 20 slow blow + 110 Volts: 250 V fuse, 2 Amp.- 5 x 20 slow blow

Fuse E.

Fuse for print boards components 250 V fuse, 5 Amp.- 5 x 20 fast blow

All 24 volt AC output relays have automatic fuses. In case of an external short circuit outgoing power is automatically cut off until the short circuit has ended. After about 10 seconds power will be switched on again.

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EMERGENCY SWITCH Should the wash controller not function for any reason, milking will be possible by throwing the emergency switch. Normally the pulsation and the vacuum pump is controlled by the wash controller. If the wash programmer fails, then move the emergency switch to the manual position so that pulsation system and the vacuum pump will function. NOTE DISCONNECT FROM THE MAINS FIRST. NOTE: All fuses must be intact.

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PROMS PROM on the Main Board Should the PROM (component C) on the PCB require replacement, ensure that it is done properly: one corner of the PROM has been cut diagonally and this should be located at the right bottom. The PROM can be inserted in its holder only in one position. A PROM remover must be used.

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EPROM on the display board

G

If relevant, replace the EPROM (component G) on the display board with extreme caution so as not to damage the connection points. The small notch in the EPROM must face upwards. Make sure that connectors fit snugly into their holders.

NOTE: Use a PROM remover.

MAINTENANCE REPLACING LARGE BORE WASH VALVE SEALS When replacing the valve seals in the large bore wash valves, disconnect the valve and remove the body.

Remove the old seal and STRETCH the new one over the valve and into the groove. The seal should be placed in the groove as shown below : EVERY TWO MONTHS Clean the air injector air filter. This is made from a washable plastic foam and should be cleaned in a mild detergent solution, then thoroughly rinsed and dried before refitting to the air injector.

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8/01.-1.8

GASCOIGNE MELOTTE

REPLACING THE DOSING PUMP DIAPHRAGMS These diaphragms must be changed every 12 months.

WARNING THERE MAY BE RESIDUAL CHEMICAL INSIDE THESE PUMPS PROTECTIVE CLOTHING, GLOVES AND EYE PROTECTION MUST BE WORN WHEN HANDLING AND DISMANTLING.

1

The diaphragms can be changed without removing the pumps from the distribution box. Carefully unscrew the locking ring (6) and catch the cap (5), spring (4), piston (3) and diaphragm (2). Whilst the pump is open check for cleanliness and clean if necessary.

Insert a new diaphragm and replace the piston and spring. Ensure that the diaphragm is properly seated in the body by gently twisting the diaphragm against the body using the cap. You should be able to feel that the diaphragm is correctly seated before replacing the locking ring.

If the pump fails to prime properly, it is likely that the diaphragm is not seated properly.

2

3 4 5

6

8/01.-1.8

6 - 5/1.8

D021003/E

GASCOIGNE MELOTTE

D021003/E

8/01.-1.8

GASCOIGNE MELOTTE

Appendix 1 SETTINGS AND ADJUSTMENTS

CONFIGURING THE AQUASTAR TO SUIT YOUR MILKING PARLOUR The AQUASTAR washing system allows the user to select the correct wash program through a series of preset programs. The GM dealer can tailor the system to the wishes of the user. The preset programs cannot be changed by the user.

PROGRAMMING The AQUASTAR washing system can be programmed using the keypad. For definition of keys see chapter 4.

Most functions cannot be accessed by the user and can only be changed by the GM dealer after the input of a service password.

User accessible programs can be accessed with a user password.

ACTIVATION OF THE PROGRAMS The AQUASTAR washing system has four different program groups : ❏ ❏ ❏ ❏

A-functions T-functions S-functions N-functions

Setting of system data and presets Test programs Input of passwords Display of vacuum pump running time and chemical usage

These program groups are started using the right keypad on the AQUASTAR control box.

8/01.-1.8

Appendix 1 - 1

D021003/E

GASCOIGNE MELOTTE

AQUASTAR WASH PROGRAMS ✰

The Aquastar can have a maximum of 5 preset programs.

✰

Each preset program can have a maximum of 6 stages.

✰

A stage can be (one of)

✰

Each of these stages can use either cold, tepid or hot water, as required.

✰

Any one of the three chemicals can be added to any of the stages, if desired.

✰ ✰ ✰ ✰ ✰

Rinse (non-circulating) Main Wash (circulating) Rinse (circulating) Sanitizing Rinse (circulating) Waiting period

The table opposite shows the five preset programs AND the default values entered in each stage. These default values are suggestions as to the programs a farmer might require. It is possible to change any (or all) of the stages in any (or all) of the preset programs.

The following text should be read in conjunction with the table opposite, the A-function description tables AND Table F.

PROGRAMMING A TYPICAL WASH PROGRAM EXAMPLE ONE The farmer would like the ability of pressing a key on the Aquastar at any time during the day which will only rinse out the milking machine with cold water, and not circulate this cold water.

The dealer suggests changing preset program 4 to a rinse with cold water.

The first stage of preset program 4 is programmed in function A-68 in the Aquastar control box.

The value in A-68 needs to be changed with reference to table F. This value is

NO CHEMICAL COLD WATER NON CIRCULATING RINSE

= = =

0 0 16

TOTAL

(0+0+16)

=

16

As this is the only function the farmer now wishes to have available in this preset program it is necessary to enter the value 0 in all the other preset 4 A functions (A-69 to A-73)

D021003/E

Appendix 1 - 2 / 1.8

8/01.-1.8

8/01.-1.8

A-53

A-54

A-55

4

5

6

A-51

2

A-52

A-50

1

3

A-FUNCTION

1

STAGE NUMBER

PRESET NUMBER

0

48

COLD WATER

RINSE (CIRCULATING)

Appendix 1 - 3 / 1.8

A-61

A-60

A-59

RINSE (CIRCULATING)

COLD WATER

NO CHEMICAL

0

NO CHEMICAL

HOT WATER

MAIN WASH

A-58

A-57

32

48

41

MAIN WASH

8

ACID

1

ALKALI

HOT WATER

RINSE (NONCIRCULATING)

TEPID WATER

16

A-56

RINSE (NONCIRCULATING)

20

NO CHEMICAL

4

0

A-FUNCTION

2

TEPID WATER

NO CHEMICAL

VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

48

0

0

32

8

2

16

4

0

VALUE

48

42

20

TOTAL VALUE TO ENTER INTO A FUNCTION

A-67

A-66

A-65

A-64

A-63

A-62

A-FUNCTION

3

RINSE (CIRCULATING)

COLD WATER

NO CHEMICAL

MAIN WASH

COLD WATER

ACID

RINSE (NONCIRCULATING)

TEPID WATER

NO CHEMICAL

48

0

0

32

0

2

16

4

0

VALUE

48

34

20

TOTAL VALUE TO ENTER INTO A FUNCTION

DEFAULT WASH PROGRAMS

A-73

A-72

A-71

A-70

A-69

A-68

A-FUNCTION

4

0 64

SANTIZING RINSE (CIRCULATING )

3

COLD WATER

SANITANT

PRE CHEMICAL DOSING

VALUE

67

208

TOTAL VALUE TO ENTER INTO A FUNCTION

A-79

A-78

A-77

A-76

A-75

A-74

A-FUNCTION

5 VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

GASCOIGNE MELOTTE

D021003/E

GASCOIGNE MELOTTE

EXAMPLE TWO The farmer requires a program with the following stages : 1.

2.

3.

4.

5.

Non circulating tepid water rinse Hot water main wash with acid Circulating hot water rinse A wait period of seven hours Non circulating tepid water rinse

It is decided to enter this set of events in preset program 5. ❏

The first stage of preset program 5 is programmed in function A-74 in the Aquastar control box.

The value to enter in A-74 is consulted on table F.

❏

This value is

NO CHEMICAL TEPID WATER NON CIRCULATING RINSE

= = =

0 4 16

TOTAL

(0+4+16)

=

20

The second stage of preset program 5 is programmed in function A-75 in the Aquastar control box.

The value to enter in A-75 is consulted on table F.

❏

This value is

ACID HOT WATER MAIN WASH

= = =

2 8 32

TOTAL

(2+8+32)

=

42

The third stage of preset program 5 is programmed in function A-76 in the Aquastar control box.

The value to enter in A-76 is consulted on table F.

D021003/E

This value is

NO CHEMICAL HOT WATER CIRCULATING RINSE

= = =

0 8 48

TOTAL

(0+8+48)

=

56

Appendix 1 - 4 / 1.8

8/01.-1.8

GASCOIGNE MELOTTE

❏

The fourth stage of preset program 5 is programmed in function A-77 in the Aquastar control box.

The value to enter in A-77 is consulted on table F. This value is

WAITING MODE

=

240

Note: The actual waiting time, 7 hours, is entered in A40 and must be keyed in as 420 (minutes). ❏

The fifth stage of preset program 5 is programmed in function A-78 in the Aquastar control box.

The value to enter in A-78 is consulted on table F.

❏

This value is

NO CHEMICAL TEPID WATER NON CIRCULATING RINSE

= = =

0 4 16

TOTAL

(0+4+16)

=

20

The farmer does not require anything to occur in the sixth stage of preset program 5 so a value of zero should be entered in function A-79 in the Aquastar control box.

Preset programs 1, 2 and 4 are not altered in any way from their default settings. The final result is that the farmer has 5 preset programs as follows :PRESET 1

Remains as the default program, i.e. a three stage wash as follows Stage 1 Non circulating tepid water rinse Stage 2 Hot alkali main wash Stage 3 Circulating cold water rinse

PRESET 2

Remains as the default program i.e. a three stage wash as follows Stage 1 Non circulating tepid water rinse Stage 2 Hot acid main wash Stage 3 Circulating cold water rinse

PRESET 3

The preset program has been changed to the farmers new requirements. Preset program 3 is a one stage non circulating cold water rinse.

PRESET 4

Remains as the default program i.e. one stage circulating cold water rinse with sanitant.

PRESET 5

The farmers requirements have been placed in preset program 5. This is a five stage program as follows :Stage 1 Non circulating cold water rinse Stage 2 Hot water main wash with acid Stage 3 Circulating hot water rinse Stage 4 A wait period of eight hours Stage 5 Non circulating tepid water rinse

8/01.-1.8

Appendix 1 - 5 / 1.8

D021003/E

GASCOIGNE MELOTTE

A FUNCTIONS Program settings can be displayed and changed in program group 1 (programs A-1 to A-99).

This program group is accessed as follows:

1 a The display switches between A= 1 and the value in [A-01] You can scroll to the next programs by repeatedly pressing the arrow key.

Instead of scrolling, programs can be accessed directly. Suppose we want to access program [A-49].

Press:

9 j A= is displayed and the desired program can be keyed in:

4

9

d

j

E

Program A-49 starts and the operators password can be set.

Note: This chapter describes all possible program settings, usually the default settings are used. However depending on the type of the installation these may vary slightly. It is therefore recommended to study the wash program time diagrams in this chapter describing certain A-functions in relation to their influence on the wash phase.

D021003/E

Appendix 1 - 6

8/01.-1.8

8/01.-1.8

Appendix 1 - 7/1.8

wash- idle

diverter 1

drain

changeover

airinjector 2

airinjector 1

pickup 1/2

milkpump

dump mm

wash mm

wash mode

pulsation

vacuum

pre-heated

hot water

Cold water

HBE 20000719

prerinse

Trough filling

A5

A17

A87

0 sec 30

A7

A21

60

optional

A14

A80

120

ISOLATOR 3

A99

A81

90 150 180

A13

A12

210 270

option

240

EXAMPLE TIME FUNCTION DIAGRAMS FOR A THREE STAGE WASH PROGRAM

GASCOIGNE MELOTTE

D021003/E

Main Wash

D021003/E

Appendix 1 - 8/1.8

wash- idle

diverter 1

drain

changeover

airinjector 2

airinjector 1

pickup 1/2

milkpump

dump-mm

wash-mm

wash mode

pulsation

vacuum

chemical dosing

pre-heated

hot water

Cold water

HBE 20000719

A98

A88

A84-A85

A5

Trough filling

A97

A7

120 180 240

A15

300

Isolator 3

Only required with diverter valve

A99

A18

0 sec 60 360 420

A22

A80

480

A12

600

optional

To drain

A14

A81

540

A13

option

660

GASCOIGNE MELOTTE

8/01.-1.8

Postrinse

8/01.-1.8

Appendix 1 - 9/1.8

wash- idle

diverter 1

drain

changeover

airinjector 2

airinjector 1

pickup 1/2

milkpump

dump mm

wash mm

wash mode

pulsation

vacuum

chemical dosing

pre-heated

hot water

Cold water

HBE 20000719

A5

Trough filling 0 sec A89

A7

60

A99

120

A19

180

Isolator 3

240

A23

300

optional

A80 A14

360

A81

A12

420

A13

option

480

GASCOIGNE MELOTTE

D021003/E

GASCOIGNE MELOTTE

Function

A-01

Description

Default Min. Max.

Sets the Aquastar control box unit number

User or Service Password

1

1

5

S

Notes

If there is more than 1 Aquastar control box, input another number

A-02

System configuration

0

0

255

S

See table A

A-03

System configuration

1

0

255

S

See table B

A-04

System configuration

0

0

255

S

See table C

255

S

A-05

BUILD VACUUM: Number of seconds from start of vacuum pump to start of pulsation system and opening of pick up valves OR start of dosing pump

15

0

A-06

Minimum time the temperature should be below set value before stopping main wash circulation

20 sec

0

255

S

Set temperature in A-25, A-26, A-91 and A-92

3 sec

1.0

9.9

S

See diagram D

A-07

Air injectors ON time

A-08 A-09

N/A Maximum off time for milkpump.

A-10

120 sec

0

250

S Must be set to 0

0

A-11

Start number of milk meter served by this Aquastar. This value will be used as first milk meter number if the unit number of the Aquastar is not 1. When the unit number of the Aquastar is 1, the first milk meter number is always 1.

1

0

127

S

When there are more than 63 milk meters to be controlled with one Aquastar (unit number must be 1) A-30 should be set to a value of one, and A-11 to the number of milk meters.

A-12

Number of seconds milk pump runs before pick up valves open. Note at end of A-12 milk pump switches off.

10

0

40

S

Milk pump run time to empty the receiver at the end of each wash stage

A-13

Number of seconds from milk pump switching off.

30

0

255

S

Extra time vacuum pump runs after the milk pump stops with pick up valves open. Sucks air in to rapidly dry the parlour, speeding up drainage time.

110 sec

0

510

S

During this time the pick up valves will be pulse controlled by A-80 and A-81 (i.e. not by the pressure switches.

A-14

Number of seconds from pick up valves closing to milk pump switching on at A-12

TOTAL MAIN WASH CIRCULATION TIME = A18 + A15 A-15

A-16

Main wash temperature measurement time

360 sec

N/A

0

0

S

360

S

Non circulating flush time

0

0

252

S

A-18

Main wash circulation time

120 sec

0

996

S

A-19

Circulating flush circulation time

240 sec

0

999

S

Sanitizing rinse circulation time

115 sec

0

255

S

A-17

A-20

Time available to enable a temperature measurement during the main cycle.

When set to zero no temperature measurement will occur and the system wil not stop even if the temperature falls below the level set in A-25 To dump to drain (i.e. no circulation), set at zero

IT IS EXTREMELY IMPORTANT TO NOTE DOWN ANY CHANGES TO THE DEFAULT SETTINGS IN THE TABLE AT THE BACK OF THIS MANUAL D021003/E

Appendix 1 - 10 / 1.8

8/01.-1.8

GASCOIGNE MELOTTE

TABLE A

TABLE B

Definiton of bits in function A-02

Definition of values to add to function A-03

Description

Value

N/A

1

Additional heater used in main wash with chemical 1

2

Additional heater used in main wash with chemical 2

4

Additional heater used in main wash with chemical 3

8

24 V drain valve present

16

In parlour diagnostic (IPD) on

32

Description Milk/wash safety switch Save final circulating rinse water in trough Audio alarm for IPD error

4

Heater present Milk pump on after vacuum shut off at each stage

8

Lower pressure switch present

Milk meters present

64

Milk meters only and/or GM3000

128

Value 1 2

64 128

*

DIAGRAM D

TABLE C A - 07

Definition of bits in function A-04 Value

Description Milkpump error - stop - flag IPD Display temperature if measured during program.

64

No user access code

128

All functions are reset to default also resets N functions to zero

A - 99

32

256

The values which should be entered in functions A-02 to A-04, A-44 to A-47 and A-50 to A-79 have to be calculated using the relevant tables. For each requirement, its corresponding value should be added to the total and entered in the relevant function.

EXAMPLE : An Aquastar system is being installed on a parlour with the following components : a lower water level probe, MR2000 milk meters and a milk wash safety switch. In addition, the operator has specified that they do not want to enter a code to be able to change user adjustable functions.

For the above example the values entered in A-02 to A-04 are shown below followed by the sum used to calculate the value :A-02 = 192 A-03 = 129 A-04 = 128

: : :

From table A, milk meters present means add a value of 64 + 128 From table B, (1 {milk/wash safety switch} + 128 {lower pressure switch present} From table C, no user access code required means add a value of 128

The same principle is applied to calculating the values to input in functions A-50 to A-79, if the default wash programmes need changing :EXAMPLE : In preset program 5, the farmer requires a non circulating tepid water rinse, then a hot main wash with acid, followed by a hot circulating rinse, he then wants a gap of 7 hours when nothing happens and then a non circulating tepid water rinse. The following values should be consulted on Table F and entered in functions A-74 to A-79 : A-74 A-75 A-76 A-77 A-78 A-79 8/01.-1.8

: : : : : :

20 42 56 240 20 0

(No chemical {0} + tepid water {4} + non circulating rinse {16}) (Acid {2} + hot water {8} + main wash {32}) (No chemical {0} + hot water {8} + circulating rinse {48}) Waiting time (Actual time is entered in A40, as 420 (mins) = 7 hrs) (No chemical {0} + tepid water {4} + non circulating rinse {16}) (No action required in this stage of the program)

Appendix 1 - 11/1.8

D021003/E

GASCOIGNE MELOTTE

User or Service Password

Notes

255

S

Time allowed to empty trough before pick up valve air injecton.

0

255

S

Time allowed to empty trough before pick up valve air injection.

60 sec.

0

255

S

Time allowed to empty trough before pick up valve air injection.

Sanitizing rinse, dump time with pick up valves controlled by pressure switches.

10 sec.

0

255

S

Time allowed to empty trough before pick up valve air injection.

A-25

Temperature setting in oC ( i.e. the start temperature of the free heated water).

00.0

40

90.8

S

When set at 0, no temperature measurement is available.

A-26

Temperature setting in oC ( i.e. the start temperature of the tepid water).

00.0

40

90.8

S

When set at 0, no temperature measurement is available.

A-27

N/A

0

N/A

A-28

N/A

0

N/A

Function

Description

Default Min. Max.

A-21

Non circulating flush, dump time with pick up valves controlled by pressure switches.

60 sec.

0

A-22

Main wash, dump time with pick up valves controlled by pressure switches.

10 sec.

A-23

Circulating flush, dump time with pick up valves controlled by pressure switches.

A-24

A-29 A-30

A-31 A-32

The number of milkmeters served by this Aquastar.

1

Set to 1.

0

This number must be precise. The display units will switch to the wash mode automatically.

The ON time of the chemical dosage pumps 500 ms .

The OFF time of the chemical dosage pumps.

A-33

500 ms

0

63

S

0

9950

S

0

9950

S

0

A-34

N/A

0

Set at 0.

A-35

Minimum conductivity for chem1

120

0

255

S

Option in IPD

A-36

Minimum conductivity for chem2

120

0

255

S

Option in IPD

A-37

Minimum conductivity for chem3

120

0

255

S

Option in IPD

A-38

Percentage increase or decrease in circulation time.

100

0

150

S

Accelerated quick check time for reducing main wash circulation time.

A-39

Maximum wash trough fill time.

600

0

2040

S

Safety feature to prevent trough overflowing.

A-40

Waiting mode. Time that elapses between two cleaning stages when the desired program has been selected.

480 mins.

0

996

U or S

A-41

N/A

0

Set at 0.

A-42

N/A

A-43

Hysteresis for temperature 2 in degrees C.

A-44

Nominates diverter valve for use with prerinse water (if required).

1

0

255

S

See Table E.

A-45

Nominates main wash diverter valve.

17

0

255

S

See Table E.

A-46

Nominates diverter valve for use with post rinse water.

17

0

255

S

See Table E.

A-47

Nominates diverter valve for use with rinse between two stages.

17

0

255

S

See Table E.

A-48

Nominates sanitizing water diverter valve.

17

0

255

S

0 indicates no diverter valve, drain is in use.

See Table E.

A-49

Sets the user password.

1

0

9999

NA

Max. 4 digits.

A-50

Preset program 1. Stage 1.

20

0

255

S

Default is tepid water non circulating flush. {4 + 16} See Table F.

D021003/E

0

Set at 0.

5.0Ë&#x161;

Set at 5.

Appendix 1 - 12/1.8

8/01.-1.8

GASCOIGNE MELOTTE

TABLE E (see example, Water Diversion) DEFINITION OF BITS IN FUNCTIONS A-44 TO A-48 Description

Value

Changeover Valve

0

Notes

FOR ALL NON ACIDIC WASHES Diverter Valve D (Drain) Diverter Valve 1 Diverter Valve 2 Diverter Valve 3

1 2 4 8

Affects all stages

FOR ACIDIC MAIN WASHES ONLY 16 32 64 128

Diverter Valve D Diverter Valve 1 Diverter Valve 2 Diverter Valve 3

Only affect acidic main wash

TABLE F Definition of bits in functions A-50 to A-79

8/01.-1.8

Description

Value

No chemical used

0

Use chemical from container 1 (nominally alkaline)

1

Use chemical from container 2 (nominally acid)

2

Use chemical from container 3 (nominally sanitizer)

3

Cold water

0

Tepid water

4

Hot water

8

Preheated water

12

Non circulating rinse

16

Main wash (circulating)

32

Circulating rinse

48

Sanitizing rinse (circulating)

64

Non circulating rinse (dump line)

144

Main wash (dump line)

160

Circulating rinse (dump line)

176

Sanitizing rinse (dump line)

192

(Pre-chemical dosing - not used)

208

Waiting mode (See A-40)

240

Appendix 1 - 13/1.8

D021003/E

GASCOIGNE MELOTTE

User or Service Password

Notes

255

S

Default is hot main wash with chemical from container 1. {1+8+32} See table F

0

255

S

Default is circulating cold water rinse. {0+0+48} See table F

0

0

255

S

When value = 0. No program in this phase is executed. See table F

Preset program 1. Stage 5

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-55

Preset program 1. Stage 6

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-56

Preset program 2. Stage 1

20

0

255

S

Default is tepid non circulating rinse. {0+4+16} See table F

A-57

Preset program 2. Stage 2

42

0

255

S

Hot acid main wash. {2+8+32} See table F

A-58

Preset program 2. Stage 3

48

0

255

S

Circulating cold water rinse. {0+0+48} See table F

A-59

Preset program 2. Stage 4

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-60

Preset program 2. Stage 5

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-61

Preset program 2. Stage 6

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-62

Preset program 3. Stage 1

20

0

255

S

Default is tepid non circulating rinse. {0+4+16} See table F

A-63

Preset program 3. Stage 2

34

0

255

S

Cold acid main wash. {2+0+32} See table F

A-64

Preset program 3. Stage 3

48

0

255

S

Circulating cold water rinse. {0+0+48} See table F

A-65

Preset program 3. Stage 4

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-66

Preset program 3. Stage 5

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-67

Preset program 3. Stage 6

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-68

Preset program 4. Stage 1

208

0

255

S

Pre-chemical dosing.

A-69

Preset program 4. Stage 2

67

0

255

S

Cold water sanitizing rinse (3+0+64).

See table F

A-70

Preset program 4. Stage 3

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-71

Preset program 4. Stage 4

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-72

Preset program 4. Stage 5

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-73

Preset program 4. Stage 6

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-74

Preset program 5. Stage 1

0

0

255

S

When value = 0. No program in this phase is executed. See table F

A-75

Preset program 5. Stage 2

0

0

255

S

When value = 0. No program in this phase is executed. See table F

Function

Description

A-51

Preset program 1. Stage 2

41

0

A-52

Preset program 1. Stage 3

48

A-53

Preset program 1. Stage 4

A-54

D021003/E

Default Min. Max.

Appendix 1 - 14/1.8

8/01.-1.8

GASCOIGNE MELOTTE

Description

A-76

Preset program 5. Stage 3

0

0

A-77

Preset program 5. Stage 4

0

0

A-78

Preset program 5. Stage 5

0

0

A-79

Preset program 5. Stage 6

0

0

A-80

"Pickup" air injection OFF time

10 sec

0

A-81

"Pickup" air injection ON time

2 sec

0

A-82

Vacuum pump overrun time after pressing the stop (milking) key

0 sec

0

Spare

0

A-83 A-84 A-85

Number of pulses for dosage of the alkaline cleaning agent (Pump 1) Number of pulses for dosage of the acid (Pump 2)

A-86

Number of pulses for dosage of the sanitiser (Pump 3)

A-87

Water level 2 for non circulating rinse

Notes

When value = 0, no program in this phase is executed. See table F When value = 0, no program in this phase is executed. See table F

255

S

255

S

255

S

When value = 0, no program in this phase is executed. See table F

255

S

When value = 0, no program in this phase is executed. See table F

S S 200

S

After milking, milkmeters and ACR set to washing.

The vacuum pump can be set to run for X seconds (an input of 0 means it will not run on after milking). The pickup valves will remain open for 5 sec, depending on the position of the low level tulip, to admit air into the plant.

Set to 0

0

0

999

U or S

If value 0 is entered, automatic chemical dosage will not take place. See function N-5.

0

0

999

U or S

If value 0 is entered, automatic chemical dosage will not take place. See function N-8.

0

0

999

U or S

If value 0 is entered, automatic chemical dosage will not take place. See function N-11

0%

0% 255%

S

A certain percentage of extra time can be added to allow more water to be added to the wash trough after the upper pressure switch has been triggered.

A-88

Water level 2 for main wash

0%

0% 255%

S

See diagram G

A-89

Water level 2 for circulating rinse

0%

0% 255%

S

See diagram G

A-90

Water level 2 for sanitising rinse

0%

0%

S

See diagram G

A-91

Temperature setting in 째C (i.e. the start temperature of the main wash) Temperature setting in 째C ( i.e. the end temperature of the main wash) Time in miliseconds between low level pressure switch switching on to pick up valves switching on

0

S

When set at 0, no temperature measurement is available

0

S

When set at 0, no temperature measurement is available

A-92

A-93

A-94

Time in miliseconds between low level pressure switch switching off to pick up valves switching off

A-95 A-96

*

Default Min. Max. User or Service Password

Function

Enter measured milk pump flow rate in litres/min

0 ms

0

5000

S

100 ms

0

25.5 sec

S

0

0

1020

S

0

255

S

Aquastar as an approximate milk meter

S

To dump initial main wash water. Starts when water is detectedby milk pump. 0 = no dumping.

S

The vacuum pump will run for some seconds to build up a vacuum reserve before the chemical dosing pumps start to pump.

0

A-97

Time in seconds that water will be dumped BEFORE circulating main wash water

0

A-98

Time in seconds between the start of the trough fill and the start of the vacuum pump

60

A-99

Air injectors OFF time

255%

30.0 sec

0

160

255

60.0

To empty trough after low pressure switch triggers

1=vacuum sensor present

S

See diagram D

* Enter as 300 Level 2 Level 1

DIAGRAM G High water level probe

8/01.-1.8

Appendix 1 - 15 / 1.8

D021003/E

GASCOIGNE MELOTTE

WATER DIVERSION EXAMPLE A parlour is to be installed with water diversion. The farmer wants three storage tanks. The schematic diagram below sets out a simple solution for the requirements. NOTE : Diverter valve 3 does not have a dedicated solenoid valve in the distribution box, therefore it must have a separate solenoid valve to operate it, this valve connects between connector C1/9 and C1/11 in the distribution box.

FROM MILKING PARLOUR

Diverter D

Diverter 1

Diverter 2

Diverter 3

TANK A

TANK B

TANK C

The farmer has the following requirements : ❏

All pre-rinse water to go to drain

❏

All main wash water with alkali to go to holding tank A

❏

All main wash water with acid to go to holding tank B

❏

All sanitizing rinse water to go to tank A

❏

All post rinse water to go to tank C

Consulting Table E the installer calculates the values to enter into functions A-44 to A-48.

NOTE : Diverter Valves 1 to 3 are normally closed, Diverter D is normally open.

D021003/E

Appendix 1 - 16/1.8

8/01.-1.8

GASCOIGNE MELOTTE

A-44

This function tells the system which diverter valve to open when pre-rinse water is present. The farmer wants all pre-rinse water to go directly to the drain, therefore we want Diverter D to open.

Consulting table E, to open diverter D in a pre-rinse, you must enter the value 1 in A-44.

A-45

This function tells the system which diverter valve to open when main wash water is present. The farmer wants alkali main wash water to go to holding tank A; acid main wash water to go to holding tank B. As you can see in the diagram Tank A is filled by diverter 1 and tank B is filled by diverter 2.

Consulting table E, to open diverter 1 for an alkali main wash, you must enter the value 2 in A-45, and to open diverter 2 for the acid main wash you must ADD the value 64. The total value to enter is 66.

A-46

This function tells the system which diverter valve to open when post rinse water is present. The farmer wants the post rinse water to go to holding tank C. As you can see in the diagram, tank C is filled by diverter 3.

Consulting table E, to open diverter 3 for post rinse water, you must enter the value 8 in A-46.

A-47

This function tells the system which diverter valve to open for rinse water between stages.

Consulting Table E - value 1 through 128.

A-48

This function tells the system which diverter valve to open when water with sanitant is present. The farmer wants the sanitizing rinse water to go to holding tank A. As you can see in the diagram, tank A is filled by diverter 1.

Consulting table E, to open diverter 1 for sanitizing rinse water, you must enter the value 2 in A-48.

8/01.-1.8

Appendix 1 - 17/1.8

D021003/E

GASCOIGNE MELOTTE

NON CIRCULATING RINSE EXAMPLE

WATER FILL VALVES OPEN

FILL

START

FILL TROUGH XX SECONDS

A5 (15 SECONDS) PULSATION ON PICK UP VALVES OPEN A17 (0 SECONDS) CHANGEOVER VALVE TO DRAIN

CIRCULATE

CHANGEOVER VALVE TO TROUGH

BUILD VACUUM

VACUUM ON

DUMP

TROUGH FULL HIGH PRESSURE SWITCH

A21 (60 SECONDS) PICK UP CLOSED

MILK PUMP ON

A12 (10 SECONDS)

FINAL DRAIN

A14 (110 SECONDS)

PICK UP OPEN MILK PUMP OFF / PULSATION OFF A13 (30 SECONDS) VACUUM PUMP OFF PICK UP CLOSED END

D021003/E

Appendix 1 - 18/1.8

8/01.-1.8

GASCOIGNE MELOTTE

MAIN ALKALI WASH EXAMPLE HOT WATER VALVES OPEN

A98 (60 SECONDS)

CHANGEOVER VALVE TO TROUGH A5 (15 SECONDS)

FILL

VACUUM ON

DOSING PUMP ON

TROUGH FULL HIGH PRESSURE SWITCH

PULSATION ON PICK UP OPEN A18+A15 (120+360 = 480 SECONDS)

CIRCULATE

REST WATER FILL XX SECONDS

A22 (10 SECONDS)

DUMP

CHANGEOVER VALVE TO DRAIN

PICK UP CLOSED

MILK PUMP ON A12 (10 SECONDS) PICK UP OPEN

FINAL DRAIN

A14 (110 SECONDS)

MILK PUMP OFF / PULSATION OFF A13 (30 SECONDS) VACUUM PUMP OFF PICK UP CLOSED END

8/01.-1.8

Appendix 1 - 19/1.8

D021003/E

GASCOIGNE MELOTTE

COLD WATER FILL VALVES OPEN

FILL

CIRCULATING RINSE EXAMPLE

FILL TROUGH XX SECONDS

A5 (15 SECONDS) PULSATION ON PICK UP VALVES OPEN A19 (240 SECONDS) CHANGEOVER VALVE CLOSED

CIRCULATE

CHANGEOVER VALVE TO TROUGH

BUILD VACUUM

VACUUM ON

DUMP

TROUGH FULL HIGH PRESSURE SWITCH

A23 (60 SECONDS) PICK UP CLOSED

MILK PUMP ON

A12 (10 SECONDS)

FINAL DRAIN

A14 (110 SECONDS)

PICK UP OPEN MILK PUMP OFF / PULSATION OFF A13 (30 SECONDS) VACUUM PUMP OFF PICK UP CLOSED END

D021003/E

Appendix 1 - 20/1.8

8/01.-1.8

GASCOIGNE MELOTTE

CIRCULATING RINSE WITH SANITANT EXAMPLE

A98 (60 SECONDS)

FILL

WATER VALVES OPEN

VACUUM ON

A5 (15 SECONDS) DOSING PUMP ON

BUILD VACUUM

CHANGEOVER VALVE TO TROUGH

PULSATION ON PICK UP OPEN A20 (115 SECONDS)

CIRCULATE

REST WATER FILL XX SECONDS TROUGH FULL HIGH PRESSURE SWITCH

A24 (10 SECONDS)

DUMP

CHANGEOVER VALVE TO DRAIN

PICK UP CLOSED

MILK PUMP ON A12 (10 SECONDS) PICK UP OPEN

FINAL DRAIN

A14 (110 SECONDS)

MILK PUMP OFF / PULSATION OFF A13 (30 SECONDS) VACUUM PUMP OFF PICK UP CLOSED END

8/01.-1.8

Appendix 1 - 21/1.8

D021003/E

GASCOIGNE MELOTTE

T FUNCTIONS The AQUASTAR wash controller hardware can be tested with programs (T-1 to T-46). The test programs can only be accessed after input of the user or service password.

2

The test program can be accessed as follows:

b The display switches repeatedly between [t= 1] to [Pr-0] By repeatedly pressing the arrow key you can scroll to other test functions. Instead of scrolling, test functions can be accessed directly.

9

Suppose program â&#x20AC;&#x153;T-10â&#x20AC;? (test air injector 1) is needed. Press:

The display is erased and the desired program number can be keyed in followed by the E key e.g. :-

j

1

0

a

E

Program T-10 starts and air injector 1 now can be tested.

Press

0

to switch on the solenoid valve which operates the air injector. Press

0

again to turn the solenoid off again. YOU MUST PRESS THE ZERO KEY TO FINISH THE TEST. The functions T-01 to T-25 test system outputs and T-26 to T-46 test system inputs.

D021003/E

Appendix 1 - 22/1.8

8/01.-1.8

GASCOIGNE MELOTTE

THE FOLLOWING TESTS CAN BE MADE USING THE TEST PROGRAM. CONTROL BOX OUTPUT TESTS T-01

Vacuum pump test.

T-13

Pick up/valve test

T-02

Pulsator test

T-14

Wash mode test

T-03

Wash/idle mode

T-15

Spare output test (Not Applicable)

T-04

Milk pump test.

T-16

Diverter valve D test

T-05

Cold water fill valve 1 test

T-17

Diverter valve 1 test

T-06

Cold water fill valve 2 test drain AC heater

T-18

Diverter valve 2 test

T-19

Audio test

T-20

Spare

T-21

Diverter valve 3 test (If available)

T-22

Changeover valve test

T-23

Container 1 dosing pump test

T-24

Container 2 dosing pump test

T-25

Container 3 dosing pump test

T-07

Preheater tested/hot 2

T-08

Hot water fill valve test

T-09

Alarm test

T-10

Air injector 1 test

T-11

Air injector 2 test

T-12

Pick up 2 valve test

INPUT TESTS Again press

0

to start the test and the same key to end the test.

If the control box receives an input signal from the attached device it will display number 1, if no signal is received the control box will display 0.

T-26

High water level tulip test

T36

T-27

Milk/wash safety switch test

T-37 to T-39 Spare functions

T-28

Milk pump pulse test

T-40

Milk meter communication test (wash/milk mode)

T-29

Low water level tulip test T-41

Spare

T-30

Temperature sensor test digital input T-42

Measure temperature

T-31

Vacuum sensor test (Not applicable)

T-32

N/A

T-33

ADC test (Not applicable - heater tulip)

Heater thermal overload switch.

T-43 to T-44 Not applicable

T-34 to T-35 Not applicable

8/01.-1.8

T-45

Countdown. Displays the remaining time in seconds in the active phase.

T-46

Display test

Appendix 1 - 23/1.8

D021003/E

GASCOIGNE MELOTTE

S FUNCTIONS Program group 3 is used for programming passwords and data display.

3

This program group is accessed as follows:

c

The display switches between [S= 1] and [no.]

By repeatedly pressing the arrow key the programs can be scrolled through.

[S-01] Note

Allows the input of the operators password allowing the operator to change the N-functions. :

The operators password must first be set in function A-49 before this is possible.

Procedure for input of the user password: (in this example the password is the number 1234)

3

Press

c

operators password e.g.

the display will toggle between S= 1 and no. Press

1

2

3

4

a

b

c

d

C E

and

then the

to confirm.

Successful input will result in the time being displayed, incorrect input will result in an error code. After input of the user password the user can change the A-function settings listed above.

[S-02]

Allows input of the service password allowing service personnel access to all the A, T and S functions.

3 Procedure for input of the service password

c

The display switches between [S= 2.] and a random number, for example, the number [3805]. The service password must now be calculated using the following formula: Service password = The INTEGER value of (the random number on display รท 2) In this example: Service password = (INT (3805 รท 2) On a calculator this calculation works as follows: Input of the number 3805: Divide: Input divisor: Execute calculation:

[3] [8] [0] [5] [รท] [2] [=]

The intermediate answer is:

1902.5

D021003/E

Appendix 1 - 24/1.8

8/01.-1.8

GASCOIGNE MELOTTE

Remove all digits after the decimal (INT in the formula). In this case 1902.5 becomes 1902. Input this number on the control box keyboard.

Key in as follows:

C

1

9

a

j

Confirm with:

0

2 b

E

All settings can now be made or changed by the dealer. If a wash program is started in the mean time, the service password must be input again. If a service password is not input, an error message denoted by the letter E will appear on the display.

NOTE

:

Procedure :

If you use the MR2000 display security box in an installation with milk yield recording then the input of the service password is not necessary.

Connect MR2000 display security box (on socket in wash/reset box) and press AQUASTAR keys:

C

E

[S-03]

*

If program is active, the current temperature from temperature sensor 1 will be displayed, if no program is active, the highest temperature from the last wash cycle will be displayed.

[S-04]

If program is active (compact version only), the current temperature from temperature sensor 2 will be displayed, if IPD program is active, the highest temperature from the last wash cycle will be displayed.

[S-05]

*

If program is active, the current conductivity value from conductivity sensor 1 will be displayed, if no program is active, the maximum value from the last wash cycle will be displayed.

[S-06]

*

If program is active, the current conductivity value from conductivity sensor 2 will be displayed, if no program is active, the maximum value from the last wash cycle will be displayed.

[S-07]

Displays which wash program will be started next automatically.

[S-08]

Total milk volume. Pressing the 2 key on the Aquastar control box displays the value stored in this function, which is the total volume of milk (in litres) pumped by the milk pump based on the calibration figure set in function A-96 in litres pumped per minute.

[S-09]

Dosing pump calibration function (See chapter 3)

NOTE:- * Compact version only

8/01.-1.8

Appendix 1 - 25/1.8

D021003/E

GASCOIGNE MELOTTE

N FUNCTIONS This program group is accessed by pressing the through the N functions.

REMARK :

N= 1

4

key. The arrow key can be used be scroll

d

THE OPERATORS PASSWORD MUST BE ENTERED BEFORE ANY CHANGES CAN BE MADE TO THE FOLLOWING FUNCTIONS.

The total number of hours that the vacuum pump has been running. From standby mode, 0 this time can be displayed by pressing key on the right hand keypad. It can be reset to zero after entry of the service password. It is automatically reset to zero when 9999 running hours are reached.

N= 2

Sets the number of hours the vacuum pump should run before servicing. After this time, the Aquastar display will show a flashing SERV warning. This value requires a service password to alter it.

N= 3

Contents of container 1 (nominally alkali) in litres, accurate to two decimal places. The system decreases this number as the chemical is used. From standby mode the current contents in the container can be displayed simply by pressing key 4 d

When a new chemical container is added to the system this function must be set to the amount of chemical in the container. See “Chemical containers low warning” in chapter 4.

NOTE : The new volume must be entered in centilitres e.g. For a 25 litre chemical container enter the value 2500.

N= 4

The dose of the chemical in container 1 used per cleaning in litres. Accurate to two decimal places. From standby mode this value can be displayed by pressing 4 followed d by

N= 5

The number of times that chemical pump 1 pulses each time a wash program using chemical 1 is selected. This value is accessed by pressing the arrow key again. i.e. 4 d

N= 6

Contents of container 2 (nominally acid) in litres, accurate to two decimal places. The system decreases this number as the chemical is used. From standby mode the current contents of the container can be displayed simply by pressing key 5 e

When a new chemical container is added to the system this function must be set to the amount of chemical in the container. See “Chemical containers low warning” in chapter 4.

NOTE : The new volume must be entered in centilitres e.g. For a 25 litre chemical container enter the value 2500.

D021003/E

Appendix 1 - 26/1.8

8/01.-1.8

GASCOIGNE MELOTTE

N= 7

The dose of the chemical in container 2 used per cleaning in litres. From standby mode this value can be displayed by pressing 5 followed by e

N= 8

The number of times that chemical pump 2 pulses each time a wash program using chemical 2 is selected. This value is accessed by pressing the arrow key again. i.e. 5 e

N= 9

Contents of container 3 (nominally sanitant) in litres, accurate to two decimal places. The system decreases this number as the chemical is used. From standby mode the current contents of the container can simply be displayed by pressing key 6 f

When a new chemical container is added to the system this function must be set to the amount of chemical in the container. See â&#x20AC;&#x153;Chemical containers low warningâ&#x20AC;? in chapter 4.

NOTE : The new volume must be entered in centilitres e.g. For a 25 litre chemical container enter the value 2500.

N= 10

The dose of the chemical in container 3 used per cleaning in litres. From standby mode this value can be displayed by pressing 6 followed by f

N= 11

The number of times that chemical pump 3 pulses each time a wash program using chemical 3 is selected. This value is accessed by pressing the arrow key again. i.e. 6 f

N= 12

Chemical container low warning. This number indicates the number of cleanings left in the chemical containers when the low chemical warning is displayed and can be adjusted to give more (or less) warning time that the chemicals containers are low.

N= 13

Number of times a particular preset program X (programmed in N-15) should run before another preset program Y (programmed in N-16) automatically starts, after pressing the wash key.

N= 14

Displays the number of times that the program in N-15 has been executed. This value can also be changed manually, to promote the execution of program Y.

N= 15

Number of the preset program X. 0 = function disabled, 1 to 5 = preset programs.

N= 16

Number of the preset program Y. 0 = function disabled, 1 to 5 = preset programs.

N= 17

Absolute percentage of number of filled top chamber against the number of milkmeter valve openings range 0-100% (only IPD).

N= 18

Relative percentage of high float readings against the total openings and closing of milkmeter valve. Example: a filled in value of 20 means that no error will show if high/low deviation is in between 80% and 120% (only IPD).

8/01.-1.8

Appendix 1 - 27/1.8

D021003/E

D021003/E

Appendix 1 - 28/1.8

wash- idle

diverter 1

drain

changeover

airinjector 2

airinjector 1

pickup 1/2

milkpump

dump mm

wash mm

wash mode

pulsation

vacuum

chemical dosing

pre-heated

hot water

Cold water

HBE 20000731

Sanatizing rinse

A98

A5

0 A90

60

Only required with diverter valve

A86

Sec.

A7

A20

Isolator 3

A99

A24

120

240

A81

A12

optional

To drain

A80 A14

180

A13

option

300

GASCOIGNE MELOTTE

EXAMPLE TIME FUNCTION DIAGRAM FOR SANITIZING RINSE

8/01.-1.8

GASCOIGNE MELOTTE

APPENDIX 2 - DESCRIPTION OF PHASE CODES. This appendix describes all the phase codes that appear on the display while the program is active. The codes are denoted by a flashing P followed by a number and can be recognised by the first number : -

Non circulating rinse, codes beginning with 1.

Main wash, codes beginning with 2.

Circulating rinse, codes beginning with 3.

Sanitizing rinse, codes beginning with 4.

Milking, codes beginning with 5.

Idle program, codes beginning with 6.

NON CIRCULATING RINSE

CODE

TEST MILK/WASH SAFETY SWITCH

101

MILK METERS OUT OF WASH MODE

102

WATER FILL VALVES OPEN

103

WASH MODE ON

104

TEST UPPER WATER LEVEL

105

MILK METERS IN WASH MODE

106

CHANGEOVER VALVE TO CIRCULATE

107

BUILD UP VACUUM

108

PULSATION ON

109

AIR INJECTOR ON

110

PICK UP VALVE OPEN

111

RINSE PHASE 1

112

DIVERTER SELECT ON

113

CHANGEOVER VALVE TO DRAIN

114

RINSE PHASE 2

115

PICK UP VALVE OFF + DELAY

116

MILK PUMP ON + DELAY

117

PICK UP VALVE OPEN

118

END RINSE + DELAY

119

PICK UP VALVE CLOSED

120

PICK UP VALVE OPEN

121

VACUUM PUMP OFF

122

PULSATION OFF

123

DELAY AFTER VACUUM OFF

124

WASH MODE OFF

125

PICK UP VALVE CLOSED

126

DIVERTER SELECT OFF

127

END OF PROGRAM

8/01.-1.8

Appendix 2 - 1 / 1.8

D021003/E

GASCOIGNE MELOTTE

MAIN WASH

CODE

CIRCULATING RINSE

CODE

TEST MILK/WASH SENSOR

201

TEST MILK/WASH SENSOR

301

TEMPERATURE 2 TEST

202

302

MILK METERS OUT OF WASH MODE

MILK METERS OUT OF WASH MODE

203

MAIN WASH WATER VALVES OPEN

303

204

CIRCULATING RINSE WATER VALVES OPEN WASH MODE ON

304

WASH MODE ON

205

TEST WATER LEVEL 1

305

TEST WATER LEVEL 2 + DOSE

206

MILK METERS IN WASH MODE

207

MILK METERS IN WASH MODE

306

CHANGEOVER VALVE TO CIRCULATE

208

CHANGEOVER VALVE TO CIRCULATE

307

BUILD UP VACUUM

209

VACUUM BUILDUP

308

PULSATION ON

210

PULSATION ON

309

AIR INJECTOR ON

211

AIR INJECTOR ON

310

PICK UP VALVE OPEN

212

PICK UP VALVE OPEN

311

DRAIN TEPID WATER FIRST

213

RINSE PHASE 1

312

MAIN WASH PHASE 1

214

DIVERTER SELECT ON

313

MAIN WASH PHASE 2

215

DIVERTER SELECT ON

216

CHANGEOVER VALVE TO DRAIN

314

CHANGEOVER VALVE TO DRAIN

217

RINSE PHASE 2

315

MAIN WASH PHASE 3

218

316

PICK UP VALVE OFF + DELAY

219

PICK UP VALVE CLOSED + DELAY

MILK PUMP ON + DELAY

220

MILK PUMP ON + DELAY

317

PICK UP VALVE OPEN

221

PICK UP VALVE OPEN

318

END RINSE AND DELAY

222

END RINSE + DELAY

319

PICK UP VALVE CLOSED

223

PICK UP VALVE CLOSED

320

PICK UP VALVE OPEN

224

PICK UP VALVE OPEN

321

VACUUM PUMP OFF

225

VACUUM PUMP OFF

322

PULSATION OFF

226

PULSATION OFF

323

WASH MODE OFF

227

DELAY AFTER VACUUM OFF

324

DELAY AFTER VACUUM OFF

228

WAS MODE OFF

325

PICK UP VALVE CLOSED

229

PICK UP VALVE CLOSED

326

DIVERTER SELECT OFF

230

DIVERTER SELECT OFF

327

CHANGEOVER VALVE TO DRAIN

328

END PROGRAM

END PROGRAM

D021003/E

Appendix 2 - 2 / 1.8

8/01.-1.8

GASCOIGNE MELOTTE

SANITIZING RINSE

CODE

MILKING

CODE

TEST MILK/WASH SENSOR

401

MILK MODE

501

MILK METERS OUT OF WASH MODE

402

MILK METERS OUT OF WASH MODE

502

OPEN WATER FILL VALVES

403

VACUUM BUILDUP

503

WASH MODE ON

404

PULSATION ON

504

TEST WATER LEVEL 1

405

WAIT FOR STOP SIGNAL

505

MILK METERS IN WASH MODE

406

CHANGEOVER VALVE TO CIRCULATE

407

BUILD UP VACUUM

408

PULSATION ON

409

AIR INJECTOR ON

410

PICK UP VALVE OPEN

411

RINSE PHASE 1

412

DIVERTER SELECT ON

413

CHANGEOVER VALVE TO DRAIN

414

RINSE PHASE 2

415

PICK UP VALVE CLOSED + DELAY

416

MILK PUMP ON + DELAY

417

PICK UP VALVE OPEN

418

END RINSE + DELAY

419

PICK UP VALVE CLOSED

420

PICK UP VALVE OPEN

421

VACUUM PUMP OFF

422

PULSATION OFF

423

DELAY AFTER VACUUM OFF

424

WASH MODE OFF

425

PICK UP VALVE CLOSED

426

DIVERTER SELECT OFF

427

END PROGRAM

IDLE PROGRAM

CODE

WAIT FOR NEXT PROGRAM

601

END PROGRAM

END PROGRAM

8/01.-1.8

Appendix 2 - 3 / 1.8

D021003/E

GASCOIGNE MELOTTE

APPENDIX 3 - BLANK TABLE FOR DEFAULT SETTINGS AND TIME CODES The default setting for each A-function is included in the table below. Use column 3 “current setting” to note the settings as made by your GM dealer. Make sure to do this as this table can be used to reset your system to your specifications should a fault occur. Later setting changes can be noted in columns 4 & 5.

A FUNCTION

DEFAULT SETTING

1

1

2

0

3

1

4

0

5

15 seconds

6

20 seconds

7

3.0 seconds

8

0

9

120

10

0

11

1

12

10 seconds

13

30 seconds

14

110 seconds

15

360 seconds

16

N/A set at 0

17

0 seconds

18

120 seconds

19

240 seconds

20

115 seconds

21

60 seconds

22

10 seconds

23

60 seconds

24

10 seconds

25

0

26

0

27

0

28

0

29

Set at 1

30

0

31

500 ms

32

500 ms

33

0

D021003/E

CURRENT SETTING

Appendix 3 - 1/1.8

SETTING CHANGE

SETTING CHANGE

8/01.-1.8

GASCOIGNE MELOTTE

A FUNCTION

DEFAULT SETTING

34

N/A set at 0

35

120

36

120

37

120

38

100%

39

600 seconds

40

480 minutes

41

N/A set at 0

42

N/A set at 0

43

N/A set at 5

44

17

45

17

46

17

47

17

48

17

CURRENT SETTING

SETTING CHANGE

SETTING CHANGE

49

8/01.-1.8

50

20

51

41

52

48

53

0

54

0

55

0

56

20

57

42

58

48

59

0

60

0

61

0

62

20

63

34

64

48

65

0

66

0

Appendix 3 - 2/1.8

D021003/E

GASCOIGNE MELOTTE

*

**

A FUNCTION

DEFAULT SETTING

67

0

68

208

69

67

70

0

71

0

72

0

73

0

74

0

75

0

76

0

77

0

78

0

79

0

80

10

81

2

82

0

83

0

84

0 pulses

85

0 pulses

86

0 pulses

87

0 pulses

88

0 pulses

89

5 pulses

90

5 pulses

91

0

92

0

93

0 ms

94

2.50 sec

95

0

96

N/A set at 0

97

0 seconds

98

60 seconds

99

30.0 sec

CURRENT SETTING

SETTING CHANGE

SETTING CHANGE

* Enter as 2500 ** Enter as 300 D021003/E

Appendix 3 - 3/1.8

8/01.-1.8

8/01.-1.8

A-53

A-54

A-55

5

6

A-51

2

4

A-50

1

A-52

A-FUNCTION

STAGE NUMBER

3

1

PRESET NUMBER

VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

Appendix 3 - 4

A-61

A-60

A-59

A-58

A-57

A-56

A-FUNCTION

2 VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

A-67

A-66

A-65

A-64

A-63

A-62

A-FUNCTION

3 VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

A-73

A-72

A-71

A-70

A-69

A-68

A-FUNCTION

4 VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

A-79

A-78

A-77

A-76

A-75

A -7 4

A-FUNCTION

5

BLANK TABLE TO ASSIST IN PROGRAMMING PRESET WASH PROGRAMS

VALUE

TOTAL VALUE TO ENTER INTO A FUNCTION

GASCOIGNE MELOTTE

D021003/E

GASCOIGNE MELOTTE

TIME CODE TABLE R-CODE

TIME

R-CODE

01

5:30

13

02

14

03

15

04

16

05

17

06

18

07

19

08

20

09

21

10

22

11

23

12

24

D021003/E

Appendix 3 - 5

TIME

8/01.-1.8

GASCOIGNE MELOTTE

APPENDIX 4 - ERROR CODES The AQUASTAR control box is able to display error codes which are described below.

ERROR CODE

DESCRIPTION

E-1

Milk/wash sensor in milk position. The discharge tube is still in the tank: put into washing position.

E-2

Milk/wash sensor in wash position. The discharge tube is still in the wash trough: put into milking position.

E-3

No or not sufficient water detected by the pressurestat: the system is without water.

E-4

No vacuum detected by the vacuum sensor. System without vacuum or vacuum level is not correct.

E-5

Conductivity is too low.

E-6

Temperature sensor not connected or faulty.

E-7

No chemicals detected or cleaning agent does not match the program.

E-8

Insufficient or no heating.

E-9

Faulty heating. Overheat protection.

E-10

Temperature too low.

E-11

Temperature 2 not set.

E-12

Level switch has triggered: trough not empty by start filling.

E-13

General communication error.

E-14

Relevant part is not connected. Information cannot be displayed without the part concerned being connected.

E-15

Internal system error.

E-16

Incorrect data input. Repeat input again.

E-17

Subject unknown.

E-18

Data cannot be changed.

E-19

Error reading EE-prom. Contact GM.

E-20

No access. Enter password.

E-21

Communication error display keypad.

E-22

Data synchronisation error 1 between the display and main PCB.

E-23

Data synchronisation error 2 between the main PCB and display.

E-24

No answer from main PCB on data request display.

E-25

Power failure.

E-30

General communication error.

E-84 - E-138

EEPROM check error, starts with E-84 for register 0 and ends with E138 on for register 53.

E-254

No answer on milkmeter communicaton. (When one of the milkmeters does not respond to an Aquastar command, the wash will not stop and this error message will be displayed).

E-255

General communication error.

If you get an error within a program, press on to the next part of the program.

8/01.-1.8

twice within 30 seconds, the program will move

Appendix 4 - 1 / 1.8

D021003/E

GASCOIGNE MELOTTE

APPENDIX 5 - AQUASTAR TERMINOLOGY Arrow key - The button on the Aquastar control box which has a picture of an arrow pointing downwards on it.

Changeover valve - changes the destination of the return water. Three way large bore (50mm) valve mounted next to the wash trough. This valve changes the direction of the returning water. In its normal position, returning water will be directed down the drain. When vacuum is applied to the changeover valve, returning water is directed to the wash trough. The vacuum connection is made between the lower vacuum nozzle and solenoid valve SV1 inside the distribution box. However, with water saving for reuse, the bottom of the changeover valve is connected to another pipe and does not go directly to drain.

Chemical probe - This is used to determine the correct amount of chemical when the chemical predosing option is installed.

Chemical trap - This 1â&#x20AC;? bore transparent plastic tube is where the vacuum supply for the distribution box is taken from. The purpose of the tube is to prevent chemicals from entering the vacuum line in the case of a diaphragm in a dosing pump splitting. Any chemical which enters the tube will fall to the bottom under gravity and can be tapped off. Upon seeing chemical in the tube the cause must be investigated immediately.

Circulating rinse - The stage of a preset program where the water is sucked from the trough by the pick up valves and circulates for a time preset in function A-19. i.e. the water travels through the machine a number of times returning to the wash trough to be sucked up again until the preset time is over when it is automatically directed to the drain OR to a storage tank in systems with water storage for reuse.

Compartmental cleaning - Concept to reduce the amount of water used for washing of a parlour equipped with MR 2000 milk meters. One half of the parlour is washed first, then the water is used to wash the other half of the parlour. This method reduces the amount of water required to wash the parlour by approximately 25%.

Distribution box - Wall mounted box containing 8 solenoid valves to distribute vacuum to the wash valves, 2 pressure switches and three chemical dosing pumps.

Diverter D valve - only used in systems with water storage for reuse. This normally open large bore wash valve in its normal position diverts water down the drain, when vacuum is applied, it closes diverting the water towards the storage tanks.

Diverter valves 1, 2 and 3 - Only used in systems with water storage for reuse. These normally closed large bore wash valves are used to direct water into specified storage tanks so that it can be reused at a later stage, for example saving the final rinse water for the following prerinse, or saving the main wash water to wash the floors in the parlour. Diverter valves 1 and 2 are controlled by solenoid valves SV7 and SV8 respectively in the distribution box. If a third diverter valve is required an additional solenoid valve must be used.

D021003/E

Appendix 5 - 1/1.8

8/01.-1.8

GASCOIGNE MELOTTE

Dosing pumps - Safely and accurately add the chemicals to the wash trough. There are 3 dosing pumps mounted in the distribution box. They are controlled by distribution box solenoid valves SV2, SV3 and SV4. The diaphragms in the pumps suck the chemicals from their containers and pump them to the nozzles on the support bracket above the wash trough. This greatly reduces the risk of contact with chemicals. Nominally dosing pump 1 should be used with alkali, dosing pump 2 with acid and dosing pump 3 with sanitant.

Drain valve (automatic)- Mounted on the milk pump discharge tube. Not supplied as standard with the Aquastar system, one must be ordered in addition for each milk pump.

Emergency switch - The switch inside the control box which allows the vacuum pump and pulsation to run if a system breakdown occurs. Warning disconnect the control box from the mains before removing the cover to throw the switch.

Enter key - The button on the Aquastar control box which has E written on it.

High vacuum system - The Aquastar performs best at high vacuum levels (approx. 50 kPa). It is possible to install an additional regulator which ensures the wash is done at a higher vacuum level than may be required for the milking. The Aquastar controls the wash or milking vacuum levels.

IPD - In parlour diagnostic.

Large bore wash valves - Gascoigne Melotte designed and manufactured 50.8 mm wash valves.

Available with flanged or plain nozzles for use with pipeline clamps or rubber connectors respectively.

These valves are available in normally open, normally closed or changeover versions.

Main wash - The stage of a preset program where the water is sucked from the trough by the pick up valves and circulates (usually) with the addition of a chemical for a time set in function A-18 + A-15. i.e. the water travels through the machine a number of times returning to the wash trough to be sucked up again until the preset time is over when it is automatically directed to the drain OR to a storage tank in systems with water storage for floor cleaning.

Milk key - The button on the Aquastar control box which has a picture of a cluster.

Milk/wash safety switch - Prevents wash water entering the bulk milk tank. This switch is activated by putting the return line into the wash position. Connected directly to the Aquastar control box, it prevents the system washing if the return line is in the bulk milk tank and prevents the system milking if the return line is in the wash position.

Milk stone remover - It is recommended to circulate a phosphoric acid solution or proprietary descaler at least once a week to remover milk stone deposits.

Non circulating rinse - The stage of a preset program where water is sucked from the trough by the pick up valves, travels through the entire milking machine once and is directed down the drain. The water does not circulate.

8/01.-1.8

Appendix 5 - 2/1.8

D021003/E

GASCOIGNE MELOTTE

Non return valve assembly - helps maintain dosing pump prime. The non return valve assembly is connected to the inlet side of each dosing pump using 6mm PVC tube. The assembly is inserted through a hole in the cap of each chemical container. It purpose is to prevent chemical from running back into the container thus maintaining the dosing pump prime.

Operators password - This can be entered by the operator enabling him to change various A and N functions. It is set at a default of 1 when the system is delivered.

Pick up valves - pick up the water from the wash trough. Two normally closed large bore (50mm) wash valves mounted above the wash trough. When vacuum is applied to these valves they open; sucking the water out of the wash trough. The vacuum connections on these two valves are coupled together and connected to solenoid valve SV5 inside the distribution box in normal circumstances; however, if compartmental cleaning is used one valve should be used to pick up water for the right hand side of the parlour, the other used for the left hand side of the parlour, in this case it is necessary to control the valves separately, hence another solenoid valve is required.

Phase - Each syage of a program is made up of numerous phases. These phases are displayed on the control box by a flashing P followed by a code number. They relate to an instruction given (or received) by the Aquastar. (See appendix 2 for descriptions of each program phase).

Preset program - The Aquastar system can have a maximum of 5 preset programs each consisting of a maximum of 6 stages.

Pressure switch - Senses the pressure changes in the water level probes. There are two pressure switches mounted in the distribution box. They are connected to the water level probes mounted in the wash trough with 4mm bore rubber tube. They sense the pressure changes in the probes so the system knows when the trough is empty or full.

Return line - See Swingover Arm. Sanitizing rinse - A circulating wash with the addition of a sanitizing chemical. This rinse circulates for a time set in function A-20. This wash contains exactly the same processes as occur for a main wash cycle, the only differences are that the sanitant chemical is used and the wash solution circulates for a shorter time.

Service password -

This password should be entered by the dealer or service personnel to enable access to change the adjustable functions.

Stage

There are a maximum of 6 stages in a preset program. A stage is usually made up of a type of chemical, a water temperature and a type of circulation.

Stop key - The button on the Aquastar control box which has STOP written on it.

D021003/E

Appendix 5 - 3

8/01.-1.8

GASCOIGNE MELOTTE

Support bracket - Mounted above the wash trough, this bracket supports the pick up tubes. It also provides the nozzles to connect the hot and cold water fill hose and the chemical dosing tubes.

Swingover arm - This carries the return line from the parlour and allows it to be placed in the bulk milk tank OR in the wash position. This arm is used to activate the milk/wash safety switch if applicable.

Tepid water - Tepid (warm) water is achieved by opening the hot and cold water fill pipes together for exactly the same time.

Tulip - Nickname for the high and low water level probes.

Wash key - The button on the Aquastar control box which has a picture of a shower head on it.

Wash mode - Concept based on washing at a high vacuum level (50 kPa) to improve the quality of the wash and the performance of the complete Aquastar system. If the following systems are available the Aquastar automatically enters wash mode upon selecting wash : The second milk pump (wash pump) will be activated, a higher vacuum level will be used (see page 3-22), the transformer will turn the Isolator 2 ACR off automatically and preheated water will be used. Connector CN7/7 in the control box is connected to the wash mode relay.

Wash pump - The second milk pump on a milk receiver with two milk pumps is usually only used during the wash. This is known as the wash pump and is connected to a second changeover valve at the wash trough.

Wash valves - See Large Bore Wash Valves.

Water fill valves - Control the water inlet to the wash trough. The system is supplied with 2 20mm (3/4â&#x20AC;? gas fitting) valves which are controlled by 24 V solenoids connected directly to connector CN9 in the control box. These valves are mounted horizontally in the hot and cold water supply lines.

Water level probe -measures the level of water in the wash trough. The lower water level probe is held by the support bracket at the very lowest point of the wash trough. It indicates when the wash trough is empty. The water level probes are connected to pressure sensing switches inside the distribution box by 4mm bore rubber tube. The upper water level probe indicates to the system when there is sufficient water in the trough.

Water storage for reuse - Concept designed to reduce water usage based upon diverting wash water into storage tanks for use at a later stage. For example, main wash water with a dilute chemical content can be used to wash parlour floors and final rinse water can be saved and used for the next prerinse.

8/01.-1.8

Appendix 5 - 4 / 1.8

D021003/E

GASCOIGNE MELOTTE

D021003/E

8/01.-1.8

GASCOIGNE MELOTTE

APPENDIX 6 - EMERGENCY KIT INSTRUCTION SHEET MANUAL WASH LAVAGE MANUEL HANDBETRIEB WASCHEN HANDBEDIENING WASSEN

1

2

E

3

1

2

a

b

3 c

a

b

c

4

5

6

4

5

6

d

e

f

d

e

f

7

8

9

7

8

9

g

h

j

g

h

j

0

C

0

C

1

1

STOP

GASCOIGNE MELOTTE

2

E

3

STOP

GASCOIGNE MELOTTE

STAR

3

2

STAR

WATER MANAGEMENT SYSTEM

WATER MANAGEMENT SYSTEM

230 V

1

2 1

1

2

E

3

2

3

1

GASCOIGNE MELOTTE

c

a

b

c

6

4

5

6

d

e

f

d

e

f

7

8

9

7

8

9

g

h

j

g

h

j

0

C

0

C

3 8/01.-1.8

3

STOP

GASCOIGNE MELOTTE

STAR

MANUAL HANDBETRIEB HANDBEDIENING MANUEL

2

E

WATER MANAGEMENT SYSTEM

=

3

b

5

1

STOP

2

a

4

STAR WATER MANAGEMENT SYSTEM

4 Appendix 6 - 1

D021003/E

D021003/E

Appendix 6 - 2

4 3

1

2

GASCOIGNE MELOTTE

8/01.-1.8

GASCOIGNE MELOTTE

EC - DECLARATION OF INCORPORATION FOR MACHINES (Machine Directive 89/392/EEC as amended by Directive 91/368/EEC, 93/44/EEC and 93/68/EEC) (EMC directive 89/336/EEC, Annex II, Sub A) (Low voltage directive 73/23/EEC) GASCOIGNE MELOTTE HOLDING B.V. Mariastraat 40, NL-4506, AE Cadzand, The Netherlands

declares that

Gascoigne Melotte Aquastar Wash Programmer

complies with the regulations of the above Machine Directives and to the national legislation for the execution of these Directives.

The above assembly has been manufactured to meet the ISO 5707 Standard for Milking Machine Installation - Construction and Performance.

It complies with the regulations of the above machine directive (and as amended by 91/368/EEC, 93/ 44/EEC and 93/68/EEC); the low voltage directive (directive 73/23/EEC); The following harmonised standards have been applied: EN 550022 (1988) Class A EN 50082-1 IEC 801-2 Level 4 IEC 801-3 Level 2 IEC 801-4 Level 2 This assembly must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directives.

8/01.-1.8

D021003/E

GASCOIGNE MELOTTE

SERVICE PASSWORD CALCULATION FROM THE STANDBY POSITION PRESS THE FOLLOWING KEYS ON THE CONTROL BOX KEYPAD TO ACCESS THE RANDOM NUMBER :

3 c

รท2 TAKE THE RANDOM NUMBER DISPLAYED ON THE CONTROL BOX AND DIVIDE BY 2.

TAKE THE RESULT OF THIS CALCULATION AND IGNORE NUMBERS AFTER THE DECIMAL POINT. THIS NUMBER IS THE CODE TO ENTER INTO THE CONTROL BOX. ON THE KEYPAD, PRESS THE C BUTTON FOLLOWED BY THE CODE :

CONFIRM WITH

C

#

#

#

#

X

X

X

X

SUCCESSFUL INPUT WILL RESULT IN THE TIME BEING DISPLAYED ON THE AQUASTAR CONTROL BOX, UNSUCCESSFUL INPUT RESULTS IN A WARNING SOUND AND AN ERROR CODE ON THE DISPLAY.

E

D021003/E

8/01.-1.8