Isolator X
p
Pulsation and A.C.R. System
Operators manual
D 480197 / D 480199 / D 480200 / D480201
08/03-1.0
Edition 1.0 D105022
General information 1. Copyright The copyright of this publication rests with Gascoigne Melotte Technology B.V. 2. Notice All rights reserved. No part of this publication may be reproduced, stored in a database or published in any form or in any way, electronically, mechanically, by print, photoprint or any other means, without prior explicit permission from Gascoigne Melotte Technology B.V. 3. Restrictions on use This document may not be lent out, resold, rented out or handed out in any other way, bound or with a cover, other than the way it was published, without prior permission from Gascoigne Melotte Technology B.V. 4. Information and improvements Any information in terms of comments, correction and improvements with regard to this information should be addressed to: Gascoigne Melotte Technology B.V. Publications Department P.O. Box 34 2140 AA Vijfhuizen Phone: Fax:
0031-023-558 9050 0031-023-558 9051
In the event of a breakdown: ·
Maintenance work to this equipment must be carried out by trained service personnel.
·
Disconnect electric equipment from the mains power supply before work is carried out.
·
Ensure that electric equipment is kept away from water and moisture to prevent fire risks and perilous electric shocks.
·
Disconnect electric equipment from the mains power supply when changing over to a standby generator.
·
Following the generator start-up, first check the stability of the voltage before connecting the electronic equipment.
The exclamation mark in the warning triangle is to draw the user’s attention to the safety, operational, maintenance and service instructions in this manual.
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Warning: Plastic materials as part of the Isolator Xp are resistant to hot water, as well as to acid and alkaline cleaning agents. However: the chemical resistance may be adversely affected by products containing ketone, chlorinated hydrocarbons, aromatic hydrocarbons and higher alcohols. They will always be found in petroleum and paraffin-like substances, as well as in methyl alcohol, diesel fuel, etc. They can also be found in certain insecticides; some teat ointments; and sometimes in spraycan propellants. Please make sure that such products are kept away from the plastic parts. The resistance of metal paint used for the Isolator Xp may be adversely affected by cleaning agents for stainless steel or products like ammonia. Please make sure that such products are kept away from the metal parts. Gascoigne Melotte shall assume no liability of any kind for damages caused by the use of chemicals that are not recommended or sold by Gascoigne Melotte. Furthermore, Gascoigne Melotte shall not be liable and reject any claim for injuries to animals, consequential damages, or any other damages and losses as a result of failing to carefully observe the instructions in this manual.
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Contents 1 Safety ----------------------------------------------------------------------------------------------------- 5 2 Introduction -------------------------------------------------------------------------------------------- 6 2.1 Features Isolator Xp ------------------------------------------------------------------------------------------ 6
3 Components / System features ------------------------------------------------------------------ 7 3.1 Initial vacuum delay ------------------------------------------------------------------------------------------3.2 Start milk time -------------------------------------------------------------------------------------------------3.3 Cluster drop off system -------------------------------------------------------------------------------------3.4 Cluster drop off delay ----------------------------------------------------------------------------------------3.5 Cluster venting delay ----------------------------------------------------------------------------------------3.6 Milk sweep -----------------------------------------------------------------------------------------------------3.7 Pulsation --------------------------------------------------------------------------------------------------------3.8 Stimulation -----------------------------------------------------------------------------------------------------3.9 Milk flow controlled stimulation -----------------------------------------------------------------------------
8 9 9 9 9 9 9 10 10
4. Switching on / off ------------------------------------------------------------------------------------ 11 5. Working ------------------------------------------------------------------------------------------------- 12 5.1 The switch ------------------------------------------------------------------------------------------------------- 12 5.2 Typical operation sequences ------------------------------------------------------------------------------- 12
6. Cleaning / maintenance ---------------------------------------------------------------------------- 16 6.1 Maintenance ---------------------------------------------------------------------------------------------------6.1.1 Before each milking ---------------------------------------------------------------------------------------6.1.2 Every month -------------------------------------------------------------------------------------------------6.1.3 Annually ------------------------------------------------------------------------------------------------------6.1.4 Every three years ------------------------------------------------------------------------------------------6.2 Cleaning procedure for Isolator Xp with a.r.m. --------------------------------------------------------6.3 Wash / idle mode control ------------------------------------------------------------------------------------
16 16 16 16 16 16 16
7 Trouble shooting ------------------------------------------------------------------------------------- 17 8. Product specifications ----------------------------------------------------------------------------- 18 8.1 Isolator Xp milk flow sensor --------------------------------------------------------------------------------- 18 8.2 Isolator Xp ram ------------------------------------------------------------------------------------------------- 18
9 Installation ---------------------------------------------------------------------------------------------- 19 10 Storage and transport ----------------------------------------------------------------------------- 20 11 Dismantling and the environment ------------------------------------------------------------- 21 Appendix 1: Certification ----------------------------------------------------------------------------- 22
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1 Safety All machines with the CE mark comply with the demands contained in EG-machine guideline 89/336EEG, when used for their intended purpose (see EU-declaration of conformity, appendix 1).
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2 Introduction This document contains the operation and maintenance of the: ·
D480197 Isolator Xp Milk flow indicator standard cow
·
D480199 Isolator Xp Milk flow indicator goat ACR retractor
·
D480200 Isolator Xp Milk flow indicator goat hi-line ACR retractor
·
D480201 Isolator Xp Milk flow indicator goat ACR cylinder
The Gascoigne Melotte Isolator Xp Automatic Cluster Removal System is an electronically controlled means of removing the milking cluster from the cow at the end of milking equipped with stimulation and pulsation. This system brings a double advantage to any milking routine by reducing the danger of over or under milking thus easing the workload of the operator. Productivity is further increased since there are no valves or switches to operate, it is only necessary to attach the cluster to the cow. The main features of the Gascoigne Melotte Isolator Xp Automatic Cluster Removal System are:
2.1 Features Isolator Xp ·
End of Milking Sensor design incorporating vacuum shut off valve, conductivity probe sensor control for positive end of milking indication, and internal ACR control PCB.
·
No clawpiece shut-off valve is required, positive milking vacuum shut-off supplied by valve in milk flow sensor.
·
Gentle cluster removal is controlled by an adjustable cluster venting delay time, between closing the milking vacuum and removal of the cluster.
·
Lifting the milk cluster starts milking automatically
·
Automatic or Manual Mode cluster removal selection.
·
Mechanism to detect cluster drop off prior to end of milking, automatically shuts off the vacuum supply and lifts the cluster.
·
Removal cylinder with build-in magnetic valve and autostart switching, or operated with manual button.
·
Time delay between initiation and application of vacuum to the cluster.
·
Accurate control of Time Delays.
·
Simplified modular design to aid installation and service access.
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Self adjusting to the end of milking characteristics of each cow.
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Milk sweep facility to chase milk through the long milk tubes and the milk chamber (Direct to line only).
·
Pre-washing facility to place clusters in jetters.
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Internal Pulsation control with adjustable pulsation parameters
·
Milk flow controlled stimulation
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3 Components / System features The Gascoigne Melotte Isolator Xp A.C.R. system physically consists of 2 main parts : 路
The Isolator Xp Milk Flow Sensor
路
A vacuum operated Automatic Cluster Removal (ACR).
Figure 1: Isolator Xp
Figure 2: Removal arm The system is controlled by the state of the milk flow from the cow, which is measured using conductivity between two probes. The figure below shows the front of the milk flow sensor detailing the position of the two probes inside the milk chamber and the 5 visible LEDs. The Isolator Xp ACR system senses milk flowing between the two probes using the conductive properties of the milk. i.e. when there is milk between the two probes, an electrical current can pass from one to another, thus completing a circuit. When there is no milk between the probes, there is no current and therefore no circuit. The time percentage that milk is detected between both probes is measured over a progressive rolling time of 30 sec.
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Figure 3: Led’s 1. Power on/off LED 2. Drop of adjustment LED (diagnostic use only) 3. Standby / drop off LED 4. ACR on/off LED 5. Milkflow LED (diagnostic use only) 6. Probes The A.C.R. system is initiated when the cluster is lifted, this relieves the weight of the cluster on the diaphragm in the piston assembly. The diaphragm is then sucked up by the vacuum and the metal contact plate touches the bulkhead contact, which completes the electrical circuit. The vacuum supply to the ram is shut off, allowing the cluster assembly to be lowered. This action activates the initial vacuum delay and the ACR sensor delay.
3.1 Initial vacuum delay This is the period of time that passes before vacuum is applied to the cluster. This allows a short period of time to lower the cluster and manipulate it into the correct position before the vacuum is applied, so as little air as possible enters the system. This delay is adjustable between 0 and 4.5 seconds; it is factory set at 1.5 seconds.
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3.2 Start milk time This 2 minute period (1 minute for goats) is the time allowed for milking to start and for milk to flow through the milking sensor. It prevents premature cluster removal and is controlled only by the elapse of time and not by milking characteristics. When the ACR sensor delay has expired the cow continues being milked. After a certain time the milk flow rate begins to reduce until the flow rate falls below the level preset on the PCB, at this point the vacuum to the clawpiece is shut off and the cluster is removed automatically.
3.3 Cluster drop off system The Isolator Xp ACR system has a mechanism which shuts off the vacuum and lifts the cluster a short time after the cluster has dropped off. A flashing light warns the operator that the cluster has dropped off, and that milking has not yet finished. It is possible to switch off the cluster drop off facility by pushing the appropriate button on the control panel and simultaneously lifting the cluster in the hand.
3.4 Cluster drop off delay This 20 second period is the time allowed before the cluster drop off operation will take place. e.g. after initiation, 20 seconds is allowed to attach the cluster to the udder before the ACR system recognises that the cluster is not attached and the ram raises the cluster. The drop-off signal is reset when the wash signal is activated. It is also possible to switch off the drop-off sequence when sampling. The user should press the button for about 4 seconds in idle mode. After this time the large LED will switch on. The drop-off signal will be recognised again after the Isolator Xp has been put in wash mode.
3.5 Cluster venting delay This is the period of time between the moment the vacuum to the cluster is shut off and the removal of the cluster by the ram. It allows a clean, comfortable removal of the cluster from the udder. This time interval is adjustable between 1 and 4 seconds.
3.6 Milk sweep This feature of the Isolator Xp ACR system allows a rush of air through the tubes after milking to clear them of any residual milk. After milking the vacuum shut off valve is closed, the cluster is removed after the cluster venting delay, then after 15 seconds the valve opens for a short time allowing a rush of air into the system, thus clearing the tubes. This feature can be set on or off. Milk sweep is not available with jar plants because the jar is vented after ACR, therefore no vacuum is available for the milk sweep. Milk sweep is standard switched off
3.7 Pulsation When pulsation control is activated the pulsation will start when vacuum is present and the Isolator Xp is initiated. Standard pulsation setting with milking (no stimulation): 路
Pulsation system:
Alternate
路
Pulsation ratio:
60:40
路
Pulsation speed/min: 58
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3.8 Stimulation Pre-stimulation When pre-stimulation is activated the stimulation will start when the first milk is detected and will stop after a number of pre set seconds (standard setting 20 sec)
3.9 Milk flow controlled stimulation When the milk flow control stimulation is activated, this will start when the following requirements are met: ·
The stimulation blocking time must be finished (standard setting 30 sec). This time starts when the first milk is detected.
·
The stimulation time window must be started, (standard setting 70 sec) and the milk flow must be lower in this period than the set value (standard setting 400 gram / min)
The stimulation stops after the pre set stimulation time has expired (standard setting 20 sec) Standard pulsation settings with stimulation: ·
Pulsation system:
Alternate
·
Pulsation ratio:
60:40
·
Pulsation speed/min: 200
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4. Switching on / off The Isolator Xp can be switched on or off using the switch on the power supply unit, in normal use the power supply unit is never switched off. If the Isolator Xp is in status Pause (status not milking) then the system will switch off both magnetic coils (one in the Isolator Xp sensor, the other in the ACR cylinder) but the heating element on the Isolator Xp print will remain switched on. When an Aquastar water management system is part of the installation, then the previous settings are controlled automatically. If no Aquastar system is available, then this switching has to be done manually using an additional switch.
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5. Working 5.1 The switch The Isolator Xp is simple to operate. It has one switch which serves the following purposes :-
·
From stand-by mode (milking cluster lifted, all 3 LEDs lit up) press the switch for 1.5 seconds. This action places the Isolator Xp milk flow sensor in stand-by wash mode: The milking cluster is lowered, but the milk tube shut-off valve remains closed. When the power has been switched off, the valve will open for washing.
·
If the switch is briefly pressed during the stand by wash mode, the Isolator Xp milk flow sensor will return to stand-by milking mode.
·
If the switched is pressed for 1.5 seconds during the milking mode, vacuum to the milking cluster will be shut off. During milking the cluster will be lifted off if the Isolator Xp milk flow sensor is accidentally activated.
·
If the Drop-off/Removal Stand-by LED (35) flashes, press the switch for 1.5 seconds to return the Isolator Xp milk flow sensor to stand-by mode. If the ACR system is then started (after the cluster has been lifted) all wait /delays times are again available.
·
Manual start stimulation (if set). Stimulation will start within the stimulation time window (standard 70 seconds) if the button is pressed.
·
Starting stimulation when the cluster is connected. Press the button to deactivate stimulation for the individual animal.
·
Placing the Isolator Xp milk flow sensor in program mode (service purposes only). Set the sensor to stand-by wash mode. Press the button for 4 seconds until all 5 LEDs light up. Release the button. The Isolator Xp milk flow sensor can now be programmed using a PC and a programming adaptor.
·
Deactivate Drop-off by pressing the button for 4 seconds during milking position. The large LED will switch off.
5.2 Typical operation sequences The majority of milkings will follow the typical sequence detailed below. The numbers relate to the boxes in the diagrammatic operation sequence.
1. ACR in standby mode :- clusters in raised position. All three LEDs on. 2. The cows enter the parlour 3. Ram is initiated by relieving the weight of the cluster from the ram. The standby / drop off LED (35) turns off. The ACR LED (37) flashes. 4.
The cluster lowers.
5. Vacuum is applied to the cluster after the initial vacuum delay. (0 to 4.5 seconds). The cluster is attached to the cow. The cow starts to milk. 6. 2 minutes after initiation, the initial ACR sensor delay ends. The ACR LED (37) stops flashing and illuminates. The end of milking flow rate assessment starts.
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7. Whatever the milking characteristics, the cluster will not be removed for at least 2 minutes 30 seconds. (The initial 2 minute ACR sensor delay + the first 30 second end of milking flow rate assessment period.) A.
IF at some time the cluster drops (or is kicked) off the udder, Isolator 3 will detect the inrush of air through the cluster. The vacuum supply to the cluster will be shut off and the ram will operate. LEDS 35 and 37 will flash 2.5 times per second to indicate that the cluster has dropped off and the milking may not be completed.
B. The ram is reinitiated, the cluster lowers and the drop off LED (35) turns off. The cluster is reattached to the udder, a 20 second delay is applied to allow the milk flow characteristics time to settle down. The ACR LED (37) flashes once per second during this period. 8. At time T, the milk flow has reduced to the end of milking flow rate. The vacuum to the cluster is stopped. {JAR PLANTS ONLY; the DV4 valve opens} 9. After the cluster venting delay (1 - 4 seconds) the ram operates, removing the cluster from the udder. The standby / drop off LED (35) illuminates. {JAR PLANTS ONLY, the DV1 valve closes,venting the jar. The jar starts to empty. When the tee contacts at the bottom of the jar detect that the jar has emptied (no milk flow) the DV4 valve closes}. 10. If set, the milk sweep operates 15 seconds after milking has finished (not available with jar plants). = LED off = LED on = LED flashing
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6. Cleaning / maintenance 6.1 Maintenance 6.1.1 Before each milking Ensure that all the clawpiece air bleeds are clear and that all the rubber tubing and joints are free from leaks. NOTE: Blockages or leaks could prevent milk entering the end of milking sensor at the correct rate and therefore cause an incorrect judgement to be made, resulting in either the cluster staying on too long or coming off too soon.
6.1.2 Every month Lubricate the piston seal and ram tube, check for wear or damage. Silicone lubricant must always be used to lubricate the piston seal. No other lubricant is suitable for this material.
6.1.3 Annually Check the diaphragms in the milk flow sensor and change if necessary. Check the seals, chimneys and shuttles for wear, replace if necessary.
6.1.4 Every three years Change the seals, chimneys and shuttles in the end of milking sensor. Change the diaphragms and cup seals in the rams. Warning - When washing down the parlour after milking take care not to point power washers at the Isolator Xp milk flow sensors. Prolonged direct jets of water could get past the lid seal.
6.2 Cleaning procedure for Isolator Xp with a.r.m. 1. From standby mode, switch the slide valve to 0 to prevent the vacuum sucking on the wash line, immediately after the cluster is lowered. 2. Press the Isolator 3 button for 1.5 seconds or until the large LED extinguishes, the ram will lower. 3. Place the cluster in the wash jetter. 4. When all the clusters have been placed in their jetters turn the servo taps to the wash position. 5. Before starting the next milking the following procedure must be performed to reset the Isolator Xp’s to their standby condition, give a quick press of each Isolator 3 button. NOTE ! When back in standby the large LED will be illuminated.
6.3 Wash / idle mode control When the Isolator Xp is in idle mode (i.e. not milking) the system will turn off the two solenoids (one in the Isolator Xp sensor, the other in the ram) and turn on the power to the heating resistor on the PCB. If you have an Aquastar Water Management System this is done automatically after milking. If you do not have an Aquastar system a simple manual switch can control this function.
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7 Trouble shooting Problem
Possible cause
Action
Problems with attaching the milking cluster
- no vacuum - no pulsation - no power
Check mounting hoses,/ cabling and then contact your service organisation
Other
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Contact your service organisation
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8. Product specifications 8.1 Isolator Xp milk flow sensor Operating voltage :
12 Volts DC ± 2 Volts DC.
Current consumption :
0.25 Amps
Printed circuit board input protection :
1.6 Amp time delay fuse
Acr sensor delay :
2 minutes
Cluster venting delay :
1 - 4 seconds (Default 2 seconds)
Initial vacuum delay :
0 - 4.5 seconds (Default 1,5 seconds)
End of milking flow rate :
Adjustable: minimum 100g/min, maximum > 300g/ min (Default 200 g/min)
Inlet nozzle bore :
ø16
Outlet nozzle bore :
ø16
Cable glands :
4 x pg7 with 2 pg7 blanking plugs. Maximum cable diameter = 6.25 mm2
Vacuum connection nipples :
3 x 7 mm o.d.
Operating vacuum :
36 kPa to 50 kPa
Approximate dimensions (lxhxd) :
190 mm x 160 mm x 100 mm
Weight :
0.75 kg
Pulsation ratio
60:40 (default)
Pulsation speed/min
58 (default)
Pulsation speed/min with stimulation
200 (default)
8.2 Isolator Xp ram Operating voltage :
12 Volts DC ± 2 Volts DC.
Current consumption :
0.25 Amps
Operating vacuum :
36 kPa to 50 kPa
Cord travel :
1 metre
Overall length :
800 mm, diameter : 80 mm
Weight :
1.2 kg
Flying lead :
3.5 m 3 x 0.5 mm2
Vacuum connection nipple :
1 x 7mm o.d.
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9 Installation Contact your supplier for installation.
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10 Storage and transport Transport preferably in the original packaging. Storage recommended in a dry, dust-free and vibration-free environment.
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11 Dismantling and the environment The Isolator Xp contains non-biodegradable parts such as metals and electronics. It is highly recommended that these parts are disposed of according to the prevailing legislation.
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Appendix 1: Certification English / Deutsch / Français / Español / Italiano / Svenska / Nederlands
EC-Declaration of Conformity EG- Konformitätserklärung / Déclaration de conformitë CE / Declaración de conformidad CE / Dichiarazione di conformità alle direttive CE / EG – declaration om överensstämmelse / EG conformiteits verklaring Manufacturer / Hersteller / Constructeur / Fabricante / Costruttore / Tillverkare / Fabrikant Gascoigne Melotte Technology B.V. Kromme Spieringweg 289 B, 2141 BS Vijfhuizen, The Netherlands Product name / Produktbezeichnung / Désignation du produit / Designación del producto / Denominazione del prodotto / Produktbeteckning / Productnaam Isolator Xp Typ / Type / Tipo
D480197 / D480199 / D480200 / D480201
The named product is in conformity with the requirements of the following European Directive: Das bezeichnete Produkt stimmt mit den Vorschriften folgender Europäischer Richtlinie überein: Le produit sus-mentionné est conforme aux prescriptions de la Directive Européenne suivante : El producto designado cumple con las prescripciones de las siguientes directivas europeas: Il prodotto denominato corrisponde alle normative delle seguenti direttive CE: Produkten i fråga överensstämmer med följande EU-direktiv: Het genoemde product is in overeenstemming met de voorschriften van de volgende Europese richtlijnen: 89/392/EWG 89/392/EEC 89/392/CEE 89/392/CEE 89/392/CEE 89/392/EEC 89/392/EEG
Richtlinie des Rates zur Rechtsangleichung der Rechtsvorschriften der Mitgliedsstaaten für Maschinen geändert durch 91/368/EWG, 93/44/EWG und 93/68/EWG Council Directive on the approximation of the laws of the Member States relating to machinery amended by 91/368/EEC, 93/44/EEC and 93/68/EEC Directive du Conseil visant l’harmonisation des législations des pays membres relatives aux machines modifiée par 91/368/CEE, 93/44/CEE et 93/68/CEE Directivas del Consejo para la armonización de la legislación de los estados-miembro, relativa a maquinaria modificada por 91/368/CEE, 93/44/CEE y 93/68/CEE Direttiva del Consiglio per l’armonizzazione delle normative dei paesi CE relative alle macchine modif. da 91/368/CEE, 93/44/CEE e 93/68/CEE Rådets direktiv för anpassning av medlemsstaternas rättsföreskrifter, ändrad genom 91/368/EEC, 93/44/EEC och 93/68/EEC Richtlijn van de raad voor harmonisatie van de wetten van de lidstaten voor machines gewijzigd door 91/368/ EEG, 93/44/EEG en 93/68/EEG
Conformity with the requirements of this Directive is testified by complete adherence to the following standards: Die Übereinstimmung mit den Vorschriften dieser Richtlinie wird nachgewiesen durch die vollständige Einhaltung folgender Normen: La conformité aux prescriptions de cette Directive est démontrée par la conformité intégrale avec les normes suivantes : La conformidad con las prescripciones de estas directivas queda justificada por haber cumplido totalmente las siguientes normas: La conformità alle norme di questa direttiva è garantita dal pieno adempimento delle norme seguenti : Överensstämmelse med dessa direktiv dokumenteras genom att följande standarder gäller utan inskränkning: Conformiteit met de voorschriften van deze richtlijnen wordt verklaard door volledige naleving van de volgende normen: Nationale Normen / National Standards / Normes nationales / Normas nacionales / Norme nazionali / Nationella standarder / Nationale normen ISO 5707 This Declaration certifies conformity with the above-mentioned Directive, but gives no assurance of properties within the meaning of the Law Concerning Product Liability.Diese Erklärung bescheinigt die Übereinstimmung mit der genannten Richtlinie, ist jedoch keine Zusicherung von Eigenschaften im Sinne des Produkthaftungsgesetz. Cette déclaration certifie la conformité avec la Directive sus-mentionnée mais n’est pas une garantie de propriétés au sens de la loi sur la responsabilité du fait du produit. Esta declaración certifica la conformidad con las directivas nombradas, pero no garantiza características según la ley de responsabilidad sobre productos. La presente dichiarazione certifica soltanto la conformità alla direttiva sopracitata e non rappresenta una garanzia ai sensi della legge sulla responsibilità del produttore. Denna deklaration bekräftar överensstämmelse med ovannämnda direktiv men får inte uppfattas som försäkran om egenskaper enligt krav i Lagen om produktansvar. Deze verklaring bekrachtigd overeenstemming met de bovenstaande richtlijn, maar is geen verzekering van eigendommen binnen de wet betreffende productaansprakelijkheid.
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