STAR WATER MANAGEMENT SYSTEM
OPERATING INSTRUCTIONS
GASCOIGNE MELOTTE
EDITION 3.1 01/99.-3.1
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GASCOIGNE MELOTTE
PUBLICATION INFORMATION 1.
COPYRIGHT Copyright in this publication is vested in:GASCOIGNE MELOTTE
2.
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.
3.
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.
4.
ENQUIRIES AND AMENDMENTS All enquiries regarding comment, correction or amendment to this publication should be addressed to:The Technical Publications Manager GASCOIGNE MELOTTE Rankine Road Daneshill Basingstoke Hampshire RG24 8PP Tel.: 01256 394300 Fax: 01256 460684
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WARNING
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. THE EXCLAMATION MARK WITHIN A TRIANGLE IS INTENDED TO ALERT THE USER TO IMPORTANT OPERATING AND MAINTENANCE OR SERVICE INSTRUCTIONS IN THIS LITERATURE.
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WARNING
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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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 flush water must discharge to drain until the returning water is clear. Circulate the sanitant solution for approximately 10 minutes ENSURING THAT THE CORRECT TEMPERATURE IS MAINTAINED. Flush the plant with clean, cold 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 jar 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. Flush 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 52, 68, 84 or 100 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 the wash and between each solution change, the meter will DRAIN UNDER GRAVITY 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 compartmental 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 a week. Follow the instructions carefully.
B
A
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Start milking by pushing :
1
2
E
E
3
STOP Ensure the milk line is in the bulk tank
Start washing by pushing : Preset 1 1
2
E
3
E
Preset 2
E
STOP
E
Preset 3 etc. Ensure the milk line is connected to the changeover valve
Stop milking or washing by pushing : 1
2
3
STOP
E
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STOP
3
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INDICATOR LIGHTS 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 main cleaning wash water. Lights up when water temperature falls below a preset limit (set to your requirements by your dealer) Remains lit until a new instruction is given to the system. (This is an optional feature not available on the standard Aquastar system).
5.
Accelerated quick check for servicing purposes.
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 flash 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. The milking mode is ended after 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 then appear on the display. These are denoted by a flashing P and then a code number. 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 program is started by pressing the E key. Once a 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. 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 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 also clears 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 01/99.-3.1
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. Key : 0
Displays the number of hours on the vacuum pump. Function N=1. 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 a calibration figure in the Aquastar control box by the amount of time that the Aquastar detects the milk pump to be running.
2 b
You can start wash programs with the 3 key instead of the WASH key. Select which 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 a non circulating flush 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. 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.
3 c
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.
4 d
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.
5 e
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
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 flush 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 cleaning 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.
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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). See the “time code table” and “Starting a program automatically” towards the back of this book.
8 h
9
The 9 key can be used to directly access the S programs.
j
The arrow key has two different functions. To access the S and T functions the arrow key and 1 key must be pressed. Once you are in one of the programs the arrow key is used to select successive functions. 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.
C 1
Display or change program settings (A-1 to 99).
a
3
Input operators password.
c
9
Used to skip to another program number in the T or S programs.
j
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 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.
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).
Press
3
the display will toggle between S= 1 and no. Press
c
operators password. e.g.
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. It is possible to set the control box so that there is no need to enter an operators password to gain access to the above functions. Your dealer or service representative can do this simply by adding the value 128 in function A-04. N.B. the operators password can only be overridden in this way AFTER entering a service password.
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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= 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. 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. This value can be displayed by pressing 4 followed by d
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. NOTE : The new volume must be entered in centilitres e.g. For a 25 litre chemical container enter the value 2500. N= 7
The dose of the chemical in container 2 used per cleaning in litres. From standby mode this value can be displayed simply 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
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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. 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 simply 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.
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.
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CALIBRATING THE DOSING PUMPS
PROTECTIVE CLOTHING, GLOVES AND EYE PROTECTION MUST BE WORN WHEN HANDLING DAIRY CHEMICALS. 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 by pressing the 1 key. S= 9 is displayed alternating with Pr-C (Press C). a Press the or
3 c
C
key, select which chemical pump you want to calibrate by entering
on the keypad followed by
1
2
a
b
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 pump was calibrated using the following method :CHANGING THE NUMBER OF TIMES THE CHEMICAL DOSING PUMPS PULSE First enter the operators passcode. Access the correct N function for the chemical pump you want to affect. i.e. for chemical pump 2 access function N-8, either by pressing 5 or by pressing the 4 key, followed by pressing the d
e
arrow key several times until function N-8 is shown on the display. N-8 is displayed , alternating with the current value set in N-8. Press the current value, input the new value followed by the E key.
C
key to cancel the
The number of times that chemical pump 2 will pulse each time a wash program using chemical 2 is selected is now set.
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SETTING THE CLOCK TIME The correct time must be set on the system clock; Aquastar works with a 24 hour clock. To set the time follow the procedure below :- eg. to set the time to 3.45 pm. First enter the operators password on the keyboard. When correctly entered the display will show four dashes, incorrect entry results in an error code. 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). 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. Example : CHEMICAL CONTAINER 1 RUNS OUT AND IS REPLACED BY A NEW CONTAINER OF 25 LITRE CAPACITY. First enter the operators password. 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
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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 and 5.
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A FUNCTION
DEFAULT SETTING
1
81
2
0
3
0
4
0
5
15 seconds
6
20 seconds
7
3 seconds
8
30 seconds
9
0
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
N/A set at 0
28
N/A set at 0
29
N/A set at 1
30
0
31
500 ms
32
500 ms
33
0
CURRENT SETTING
13
SETTING CHANGE
SETTING CHANGE
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A FUNCTION
DEFAULT SETTING
34
N/A set at 0
35
N/A set at 0
36
N/A set at 0
37
N/A set at 0
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
1
45
17
46
1
47
0
48
17
49
1
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
CURRENT SETTING
14
SETTING CHANGE
SETTING CHANGE
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A FUNCTION
DEFAULT SETTING
67
0
68
67
69
0
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 seconds
88
0 seconds
89
0 seconds
90
0 seconds
91
0
92
0
93
0 ms
94
2500 ms
95
120 seconds
96
N/A set at 0
97
0 seconds
98
60 seconds
99
0
CURRENT SETTING
15
SETTING CHANGE
SETTING CHANGE
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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.
✰ ✰ ✰ ✰ ✰
a circulating flush a non circulating flush a main wash cycle (long circulation) a sanitizing flush (short circulation) a waiting period
The following tables can be used to fill in the stages programmed into each preset program of your Aquastar water management system. When initially delivered the Aquastar control box has four programs set up as default, your dealer can change any (or all) of the stages in any (or all) of the preset programs.
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AQUASTAR PRESET PROGRAMS PRESET 1 The default is a three stage program made up of the following stages :STAGE
DEFAULT
1
Non circulating tepid water flush Hot alkali main wash Cold water circulating flush
2 3
CHANGED TO
4 5 6
PRESET 2 The default is a three stage program made up of the following stages :STAGE
DEFAULT
1
Non circulating tepid water flush Hot acid main wash Cold water circulating flush
2 3
CHANGED TO
4 5 6
PRESET 3 The default is a three stage program made up of the following stages :STAGE
DEFAULT
1
Non circulating tepid water flush Cold acid main wash Cold water circulating flush
2 3
CHANGED TO
4 5 6
PRESET 4 The default is a one stage program as follows :STAGE
DEFAULT
1
Cold water circulating flush with sanitant
CHANGED TO
2 3 4 5 6
PRESET 5 STAGE
DEFAULT
CHANGED TO
1 2 3 4 5 6
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1
A-FUNCTION
A-50
A-51
A-52
A-53
A-54
A-55
PRESET NUMBER
STAGE NUMBER
1
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2
3
4
5
6
STAGE TYPE
WATER TEMPERATURE
CHEMICAL TYPE
VALUE
TOTAL VALUE TO ENTER INTO A FUNCTION
18
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-74
A-FUNCTION
5
BLANK TABLE TO ASSIST IN PROGRAMMING PRESET WASH PROGRAMS
VALUE
TOTAL VALUE TO ENTER INTO A FUNCTION
GASCOIGNE MELOTTE
01/99.-3.1
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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
TIME
STARTING A WASH PROGRAM AUTOMATICALLY PROGRAMMING AUTO START TIMES INTO THE AQUASTAR To start awash 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.
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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). 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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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.
FIGURE 1
AUT
MAN
230 V
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 FLUSH 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. 01/99.-3.1
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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 FLUSH 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.
FIGURE 2 Please refer to the instruction sheet D108802 included in the Aquastar emergency kit.
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APPENDIX 6 - EMERGENCY KIT INSTRUCTION SHEET
MANUAL WASH HANDBETRIEB WASCHEN
1
1
2
E
3
2
LAVAGE MANUEL HANDBEDIENING WASSEN
3
1
b
c
a
b
c
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
STOP
3
2
a
4
GASCOIGNE MELOTTE
2
E
3
STOP
GASCOIGNE MELOTTE
STAR
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 01/99.-3.1
2
E
3
STOP
GASCOIGNE MELOTTE
STAR WATER MANAGEMENT SYSTEM
=
3
b
5
1
STOP
2
a
4
STAR WATER MANAGEMENT SYSTEM
MANUAL HANDBETRIEB HANDBEDIENING MANUEL
4 23
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24
4 3
1
2
GASCOIGNE MELOTTE
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ERROR MESSAGES Definitions of the AQUASTAR control box error codes
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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 Etschied.
E - 10
Temperature too low.
E - 11
Temperature 2 not set.
E - 12
Level switch has triggered
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 milk meter communication. (When one of the milk meters does not respond to an Aquastar command, the wash will not stop and this error message will be displayed)
E - 255
General communication error
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D021004/E
01/99.-3.1
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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.
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