MERCURY USER MANUAL Technical Manual 006917 Revision A ORIGINAL MANUAL Fullwood Limited Ellesmere Shropshire SY12 9DF UK www.fullwood.com
Contents Contents... 2 Important information - read this first... 4 1. Health and Safety Statement... 4 1.1 Risk Assessment... 4 2. Icons... 5 3. Revision Control... 5 4. Safety and Responsibility Instructions... 5 4.1 Basic Instructions... 5 4.2 Intended Use... 5 4.3 Improper Use... 6 4.4 General Safety... 6 4.5 Safety dealing with sources of danger... 6 4.5.1 Electrical Safety... 6 4.5.2 Operating fluids/materials... 6 4.5.3 Unsuitable spare parts... 7 4.5.4 Conversion or modification of the machine... 7 4.6 Users Responsibility... 7 4.7 Safe Machine Operation... 7 4.7.1 Personal Protective Equipment... 8 4.7.2 Transporting... 8 4.7.3 Assembly... 8 4.7.4 Positioning... 8 4.7.5 Commissioning, operation and maintenance... 9 4.7.6 De-commissioning, storage and disposal... 9 4.7.7 Danger Areas... 9 4.8 Safety devices... 9 5. Introduction... 10 6. Overview of Manual Content... 10 6.1 Modifications... 10 6.2 Storing and Handling Dairy Chemicals... 10 7. Introducing Animals to a New Milking Parlour... 11 7.1 Start Milking... 12 7.2 Things to Avoid... 12 8. Hygienic Milking... 13 9. Operating Instructions... 13 006917 Page 2 of 28
9.1 Start Up Procedure... 13 9.2 Milking Procedure... 18 9.3 Platform Rotation and Loading... 18 9.4 Platform Stop/Start Procedure by rope... 19 10. Emergency Stop Procedure... 19 10.1 Restarting after Emergency Stop... 19 11. Cleaning Down Procedure... 20 12. Chemicals used on the Plant... 23 12.1 Manual Cleaning... 23 12.1.1 Clusters... 24 12.1.2 Milk meter... 24 12.1.3 Control panels... 24 12.1.4 Platform... 24 12.1.5 Parlour Floor... 24 13. Shut Down Procedure... 24 14. Maintenance... 24 14.1 Plant Daily Checks... 25 14.2 Plant Weekly checks:... 25 14.3 Yearly Maintenance Plan... 26 15. Effective Reserve, As Calculated and Measured... 27 17. Troubleshooting... 27 18. Disposal... 27 19. Disclaimers... 28 Copyright 2014, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release. 006917 Page 3 of 28
Important information - read this first 1. Health and Safety Statement Fullwood Limited specialises in the design, procurement, manufacture, installation and commissioning of dairy and associated equipment comprising of pneumatic, electropneumatic and electrical industrial control equipment. The nature of the company s business activity places emphasis on experience, capability, performance of design, manufacture and reliability. Whilst Fullwood equipment will comply with all relevant directives, customers are reminded that all equipment into which Fullwood equipment is to be incorporated must comply with all applicable European directives. The attention of the purchaser is drawn to the provision of Section 6 of the Health and Safety at Work Act 1974. Section 6 of the Act provides that manufacturers, designers, importers or suppliers of equipment for use at work have a duty to ensure, so far as reasonably practical, that the equipment will be safe and without risk to health when properly used. The equipment is not regarded as being properly used if it is used without regard to any relevant information or advice relating to its use made available by the manufacturer, designer, importer or supplier. It is the responsibility of the purchaser to take such steps as are necessary to ensure that appropriate information relevant to the equipment is made available to their employees and any person to whom the purchaser supplies them. It is important that the equipment be installed, commissioned, maintained and used by competent trained/skilled persons in accordance with good engineering practice. International and national Wiring Regulations, Codes of Practice and all current relevant legislation requirements and accepted rules or art for the industry concerned. All installations and maintenance should be carried out within the provisions of The Electricity at Work Regulations, 1989 and by persons so qualified as defined in that act. Fullwood Limited supplies document packs with all equipment. These documents are supplied for information and should be disseminated to the relevant persons. 1.1 Risk Assessment Risk Assessments are a legal obligation and is an important step in protecting your workers as well as your business. It helps you focus on the risks that really matter in your workplace, the ones with the potential to cause real harm. In many instances, straightforward measures can readily reduce risks. These measures should be reviewed annually or when the process changes, whichever comes first. The law does not expect you to eliminate all risk but measures must be taken to reduce the risk as far as reasonably practicable. For most, that means simple, cheap and effective measures to ensure your most valuable asset your workforce is protected. 006917 Page 4 of 28
2. Icons Icons are used in this manual to draw the reader s attention to specific information. These icons have the following meaning: Failure to follow the instructions can result in severe injury to engineers, users, bystanders or livestock. Indicates special precautions that must be taken to avoid damage to equipment. Gives important information to prevent potential problems. Gives advice or suggestions to make procedures easier or clearer. 3. Revision Control Version Date Pages Writer Checked by 0.01 06/07/2011 All J Tomlin J Tomlin A 20/05/2014 All G Williams G Williams NRC 07/02/2017 Updated front Cover G Williams G Williams NRC = NON REVISION CHANGE 4. Safety and Responsibility Instructions 4.1 Basic Instructions Before installing or operating the equipment, this manual and the appropriate operating instructions must be read and understood. The machine is manufactured to the latest engineering standards and acknowledged safety regulations. Nevertheless, dangers can arise through its operation; Danger to life and limb of the operator or third parties, Damages to the machine and other material assets, Use this machine only if it is in a technically perfect condition and only for the purpose it is intended; observe all safety measures and instructions. Immediately rectify (have rectified) any faults that can cause serious injuries. Wear the correct protective clothing and equipment. Circulation cleaning temperature must not exceed 90 C 4.2 Intended Use Your machine is for use in dairy farming to facilitate the milking of cows; any other use is considered incorrect. (e.g. Medical treatment of cows). The manufacturer is not liable for any damages that may result from incorrect use. The user alone is liable for any risks incurred. Operate the machine only within its performance limits and under the permitted ambient conditions. 006917 Page 5 of 28
SWITCH OFF the machine, disconnect and isolate the electrical power supply, release pneumatic pressure and wait for all moving parts to stop before you clean or do maintenance. 4.3 Improper Use Improper use can cause damage to property and/or severe injuries. Only use machine as intended Never use the machine for any other use (e.g. medical treatment of cows) 4.4 General Safety Install all covers and guards before you operate the milking machine Keep hands, feet, hair and clothing away from all moving parts Keep unauthorized persons, especially children away from the milking machine at all times Do not enter the operating area of the machine Do not block/obstruct the moving parts of the machine. It can move with sufficient force to cause injury to you and/or the cow Do not look directly into the laser light (if fitted) of the teat detection system Keep the working area as clean and as dry as possible First aid kits and firefighting equipment shall be made available near to the machine. Never use, or attempt to service the equipment if you are not adequately trained or authorised to do so 4.5 Safety dealing with sources of danger 4.5.1 Electrical Safety Touching voltage carrying components can result in electric shocks, burns or death. Only a qualified and authorized electrician or trained personnel under the supervision of a qualified and authorised electrician shall install the electrical power supply to the machine according to electrical engineering regulations. All power supplies must be fitted with lockable isolating devices. Make sure all electrical switches are in the OFF position before you switch on the electrical power supply. Replace any damaged electrical lines, conduits, switches and components immediately. Only use fuses corresponding to the machine power. Isolate the electrical power supply at the master panel before you open the electrical panel to work on the electrical system. 4.5.2 Operating fluids/materials The used operating fluids and material can cause adverse health effects. Suitable measures must be taken in order to prevent injuries. Only Fullwood recommended chemicals shall be used, any other product may result in damage. Material Safety Data Sheets (MSDS) shall be reviewed prior to use together with a risk assessment performed in accordance with COSHH regulations. Read safety instructions on the containers. Always wear protective gloves and safety goggles when handling chemicals, or when working on parts of the machine where you may come into contact with chemicals. Strictly forbid fire, open flame and smoking. 006917 Page 6 of 28
Avoid contact with skin and eyes. Do not inhale oil mist or vapour. Do not eat or drink when handling chemicals. Suitable fire extinguishing materials must be to hand. 4.5.3 Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine. Use only spare parts approved by the manufacturer for use in this machine. Use only genuine Fullwood replacement parts. 4.5.4 Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredictable dangers. Do not convert or modify the machine Obtain written approval by the manufacturer prior to any technical modification or expansion of the machine, the controller, or the control programs. 4.6 Users Responsibility It is the responsibility of the farmer to check his animals and the performance of the equipment. If, for any reason, the system is not operational or individual animals refuse to use the system, it is the responsibility of the farmer to make alternative arrangements to feed and milk the animals. Calibration of milk meters/monitors and feed dispensers are of utmost importance in obtaining accurate milking and feeding results. If calibration is incorrect, or the wrong values have been programmed, milking results and feed distribution will remain adversely affected until calibration has been corrected. Check that no pipes or similar sharp objects are protruding into the barn or parlour which may cause injury Do not flush the electronic equipment with high pressure water hoses Machinery should never be operated by persons under the influence of alcohol or drugs. There are many work situations which add to the hazards of welding. Each must be assessed carefully, since there may be added hazards such as falls or asphyxiation. Never attempt to service or carry out any maintenance, remove covers/guards or other parts of the equipment unless you are trained and authorised to do so. The manufacturers guarantee does not cover direct or subsequent damage caused by incorrect installation, incorrect usage, improper treatment, inadequate cleaning or servicing, or incorrect software parameter inputs or hardware settings. 4.7 Safe Machine Operation The following is information supporting you in the safe handling of the machine during individual product life phases. 006917 Page 7 of 28
4.7.1 Personal Protective Equipment When working on the machine you may be exposed to dangers that can result in accidents with severe adverse health effects. Wear protective clothing as necessary. Examples of suitable protective clothing Safety overalls Protective gloves Safety boots Eye protection Ear protection 4.7.2 Transporting The weight and size of the machine/machine parts require safety measures during its transport to prevent accidents. Use suitable lifting gear that conforms to local safety regulations. Allow transportation only by personnel trained in the safe movement of loads. Attach lifting gear only to suitable lifting points. Be aware of the centre of gravity to avoid tipping. Make sure the danger zone is clear of personnel. Do not step onto the machine components to climb up the machine. 4.7.3 Assembly Do not climb onto the machine to gain access to upper areas. When working at height assess the risk and use appropriate equipment. Only use electrical cables that are suitable and approved for the surroundings and electrical loads applied. Never dismantle compressed air pipes until they are fully vented. Only use pressure lines that are suitable and approved for the maximum working pressure and intended medium. Do not allow connection pipes to be placed under mechanical stress. Do not induce any forces into the machine via the connections, so that the compressive forces must be balanced by bracing. 4.7.4 Positioning A suitable installation location for the machine prevents malfunction and accidents. Install the machine in accordance with Fullwood plans. Ensure sufficient lighting such that the display can be read and work can be carried out comfortably and safely. Ensure accessibility so that all work can be carried out without danger. Keep suitable fire extinguishing agents ready for use. 006917 Page 8 of 28
4.7.5 Commissioning, operation and maintenance During commission, operation and maintenance you may be exposed to dangers resulting from; electricity, pressure and temperature. Careless actions can cause accidents with severe adverse effects for your health. Allow maintenance work to be carried out only by authorised personnel. Switch off and lock out the power supply isolating device and verify the absence of voltage. Close shut-off valves or otherwise isolate the machine from the compressed air network to ensure that no compressed air can flow back into the machine. Do not open the electrical cabinet while the machine is turned on. Carry out regular inspections; for visible damages. of safety installations. of the EMERGENCY STOP command device. of any components requiring monitoring. Pay attention to cleanliness during all maintenance and repair work. Do not leave any loose components, tools or cleaning rags on or in the machine. Components removed from the machine can still be dangerous. Do not attempt to open or destroy any components taken from the machine. 4.7.6 De-commissioning, storage and disposal Improper handling of old operating fluids and components represent a danger for the environment. Drain off fluids/materials and dispose of them according to environmental regulations. These include oils and chemicals. Dispose of machine in accordance with local environmental regulations. 4.7.7 Danger Areas The danger areas of the machine are given in the table below Activity Danger area Authorised personnel Transport Within 3 m radius of the machine/machine parts Installation personnel for transport preparation. No personnel during transport. Beneath the lifted machine/machine parts No personnel Installation With the machine. Within 1 m radius of the Installation personnel machine and its supply cables Operation Within 1 m of machine Operating personnel Maintenance Within the machine Within 1 m of the machine Maintenance personnel 4.8 Safety devices Various safety devices ensure safe working with the machine. Do not change, bypass or disable safety devices. Regularly check safety devices for their correct function. Do not remove or obliterate labels and notices. Ensure labels and notices are clearly legible. 006917 Page 9 of 28
5. Introduction Thank you for choosing a Fullwood Ltd Rotary Herringbone Parlour (Mercury). This manual is a guide to the operating, functioning, maintenance and general running of your parlour. It should not be construed as making any claim or guarantee of performance. The Mercury has been ergonomically designed to deliver fast, efficient milking for the modern dairy farmer, and to create a safe working atmosphere for the farm staff and the cows alike. Please read this manual carefully and store in a safe place for future reference. 6. Overview of Manual Content This manual will cover a typical specification; information on deviations from this will also be detailed by reference to other manuals. A complete guide to all maintenance required on your plant, daily, weekly, monthly and all testing procedures for compliance with BS ISO 5707:2707 and ISO 6690:2007 is also detailed within. All operational information is detailed in full with every aspect of the routine covered. The don ts relating to operator and animal welfare are also included in this manual and should be adhered to at all times without exception. 6.1 Modifications Making structural modifications or converting the machine is not permitted without written permission of Fullwood Ltd. 6.2 Storing and Handling Dairy Chemicals Chemicals should be stored in a cool, dark place. They should be kept dry and away from children and animals. They should be stored in the original container and must not be used after the expiry date as indicated on the label. In case of accidental spillage, especially if in contact with the skin, they should be washed off immediately with plenty of cold water. Most dairy chemicals contain caustic alkali or acids and are, therefore, corrosive and cause burns. They should not be allowed to come into contact with aluminium. They must not be used for hand washing equipment. Chlorine releasing solutions must be kept apart from acids, and any containers used for both must be VERY THROUGHLY rinsed with warm water between using. Poisonous chlorine gas is given off when the two chemicals react. Storage drum openings should be kept tight to prevent dissipation of ingredients into the air, including teat dips and sprays. Safety data sheets should be kept on site. 006917 Page 10 of 28
The labels along with the manufacturer s directions on the containers should be read properly by all staff. Have an eye wash station located by the chemicals; any chemicals in the eyes should be flushed immediately for at least 15 minutes, followed by a doctor s examination. Any chemical detergent contacting the skin should be flushed immediately with water for 15 minutes. Remove any clothing that has been contaminated by chemical detergent and flush affected area. Obtain medical assistance at once. Empty containers must be thoroughly rinsed and disposed of according to local environmental regulations. 7. Introducing Animals to a New Milking Parlour Introducing cows to a new parlour or a new way of working is a stressful time for cows and operators, this section will aim to make the transition smoother. THE MERCURY MUST NOT BE USED UNTIL THE WHOLE PLANT HAS BEEN FULLY TESTED AND CLEARED TO BE USED. Before you introduce the cows to the new parlour you might want to spread some sawdust and manure over the floor in the collecting yard, as the fresh concrete and the absence of familiar smells might make the cows more stressed Move small groups of cows (one group at any one time) into the new collecting yard by the Revolution. The cows should be walked quietly and the collecting yard should be well lit. If the cows are accustomed to music or radio in the parlour, it may be helpful to continue this practice. Let the cows stand for a while with no operators in the area; this will enable the cows to get familiar with the new surroundings. Start up the plant so that all equipment is ready for milking, give the plant a good wash down so that manure will not stick to the fresh surfaces (set the platform to rotate at the slowest possible speed). You may need to set up some additional stall work or you can improvise with bales or gates, etc, but ultimately you want to usher the cows towards the platform in a single file formation. See below. 006917 Page 11 of 28
Extra stalling is set up here to give the cows a more defined route on to the Revolution On the first attempt, it may be necessary to stop the platform for each cow. Subsequently, the platform speed should be set at a level which can sustain continuous rotation with minimal stopping, starting or reversing. Don t worry about the gaps between cows in the stalling as the cows have already been milked so no need to worry about throughput. Don t worry about throughput on the first few occasions. It is much more important to accustom the cows to the parlour. Some farmers find it useful to allow the cows to ride the parlour, without being milked. 7.1 Start Milking When confident about the cows in the new parlour, bring all cows into the collecting yard, using the backing gate (if installed) and one operator in the collecting yard, usher the cows towards the platform. Do not handle the cows until they are at least one quarter of the way around the rotation, then prepare the teats thoroughly. Clusters should not be attached until at least a minute has elapsed from start of stimulation. Extra time spent on teat preparation during the first few milkings will be well worthwhile. Note: Milking in a new plant can be stressful to cows and operators, so take regular breaks to let everybody cool down, lift the backing gate and let the cows have a break too. 7.2 Things to Avoid Excessive noise and shouting Too many people in the milking and collecting areas Use of sticks, cattle prods; this will only stress you and the cows. Do not rush these early stages; throughput time will decrease as the cows become accustomed to the Revolution. 006917 Page 12 of 28
8. Hygienic Milking Milk from a healthy udder is virtually bacteria free. Contamination stems from three main sources: 1. The interior of the udder due to tissue infection (mastitis) Foremilk from every teat should be inspected for signs of abnormality. Where abnormality is found, milk from that cow should be discarded. 2. The exterior of the teats Cows should be kept in clean conditions. Udders should be regularly shaved or flamed. Teats should be cleaned prior to teatcup attachment. 3. Surfaces of milking equipment Prior to each milking session, the milking equipment must be cleaned and disinfected. 9. Operating Instructions 9.1 Start Up Procedure Based on the washing cycle finished and milking routine about to be started. 1. Remove delivery line from wash position 2. Connect delivery line to milk tank 006917 Page 13 of 28
3. Unscrew and remove milk filter 4. Remove used sock by taking off O ring and sliding sock off cage 5. Slide new sock onto cage, re-fit the O ring and reassemble into outer casing 6. If applicable, disconnect compressed air line from platform 006917 Page 14 of 28
7. Close butterfly valves then disconnect wash hoses from platform Butterfly valves in closed position 8. Secure both caps in place 006917 Page 15 of 28
9. Ensure that the flexible wash hoses are located on the stand and the switches depressed. 10. Start up the hydraulic power pack by pressing the green button on the starter Note: If the hydraulic system is linked to the FullClean then there is no need to manually start the power pack 11. Remove clusters from the jet sets and fold jet sets up into the bail 006917 Page 16 of 28
Butterfly valve in open position 12. Ensure that the butterfly valve is open to allow milk into each receiver 13. Note: When FullClean is put into milking mode the plant will automatically start For troubleshooting and more technical information on the FullClean plus, please refer to the user handbook, Part number - 006608 006917 Page 17 of 28
Set the control panels to milking. Sensomatic Afiflo Afilite The commands below are required: SENSOMATIC - - - - on the control panel will set all panels to milking AFIFLO - - every control panel AFILITE - - every control panel 9.2 Milking Procedure Fullwood Ltd recommends that optimum performance of a Mercury parlour should be based on two operators; The first prepares the teats The second applies the clusters, ideally 45 to 90 seconds after teat preparation 9.3 Platform Rotation and Loading The platform speed should be adjusted so that the platform rotates: Continuously So that most or all cows are milked out before the end of their rotation Without the need for stopping or reversing So that the cows can enter/exit the platform safely To permit sufficient time for a hygienic milking routine If a cow fails to enter the platform completely and activates the stop gate; clear the area and reset the gate before bringing more cows on. Once the cow clears the stop gate and moves into her stall. See User Manual (006689) for the PLC controller. 006917 Page 18 of 28
9.4 Platform Stop/Start Procedure by rope To start and stop the platform, the rope around the inner perimeter of the platform may be used. 10. Emergency Stop Procedure Or PUSH the red emergency stop button on Control Unit LIFT flexible wash hose off safety switch in parking bracket The Emergency Stop procedure shall be checked monthly 10.1 Restarting after Emergency Stop To restart after the emergency stop the following procedure must be adhered to: 1. Establish the reason for stopping the platform, by communication with other operator(s). 2. Remedy the error. 3. If the platform has been stopped by pushing the red emergency stop button, the button should be reset. 4. If the platform has been stopped by lifting the flexible wash hose off the safety bracket, replace. 5. Restart the hydraulic power pack at the unit. SEE MANUAL 006689 FOR DETAILS ON USING THE ROTARY PLC CONTROLLER WITH REGARD TO SAFETY CONTROL 006917 Page 19 of 28
11. Cleaning Down Procedure WASHING SHOULD BE CARRIED OUT AS SOON AS POSSIBLE AFTER EVERY MILKING. ENSURE THAT THE VACUUM PUMP IS NOT SWITCHED OFF AND IS KEPT RUNNING UNTIL THE END OF THE WASHING PROCESS. ENSURE PULSATION SYSTEM IS RUNNING. Normally this is done by putting the milk meters into Wash Mode 1. Thoroughly clean external surfaces of clusters and shells 2. Unclip jet set, pull down and attach teatcups to jetters 006917 Page 20 of 28
3. Push the air purge button to clear the lines of all residues 4. Connect compressed air line to platform 5. Remove caps and connect the two flexible wash hoses to the platform Butterfly valves in open position 6. Open both butterfly valves Note: Circulation cleaning takes place at high temperatures, periodically check connections where hot water passes, if in doubt call a Fullwood approved engineer. 006917 Page 21 of 28
7. Remove delivery line from milk tank Secure in place using spanner 8. Connect delivery line to wash position 9. Push the wash button on the FullClean to start the circulation cleaning process For troubleshooting and more technical information on the FullClean plus, please refer to the user handbook, Part number 006608 006917 Page 22 of 28
12. Chemicals used on the Plant The FullClean uses three chemicals to perform the circulation wash along with the water; these three chemicals are colour coded as depicted below: Coloured coded tubes Dairy Hypochlorite - is a general farm disinfectant Liquid Circulation Cleaner is a circulation cleaner for all types of milking machine Milkstone Remover is a phosphoric acid based liquid After cluster removal, teat dip should be applied to cow teats, in either a dip cup applicator or using a teat sprayer. Fullwood Ltd recommends: RTU Teat Dip a ready to use iodine based teat dip. Note: When using a teat cup applicator, empty and wash receptacle daily. 12.1 Manual Cleaning In addition to the plant circulation wash, manual cleaning of the plant is also required. All milking equipment, lines, and surfaces that come into contact with milk or dirt or manure must be thoroughly cleaned and/or disinfected before the next milking. No electrical equipment should be volume/pressure washed. For most applications a bucket of soapy warm water will remove all surface dirt. 006917 Page 23 of 28
12.1.1 Clusters As described in Section 10 12.1.2 Milk meter Never use a volume/pressure washer. Use a damp soft cloth to gently clean the external surfaces of the milk meter body. Under no circumstances should any detergents be used. 12.1.3 Control panels Never use a volume/pressure washer. Use a damp soft cloth to gently clean the external surfaces of the control panel. Under no circumstances should any detergents be used. 12.1.4 Platform After milking there will be a substantial amount of milk, dirt and manure on the rotating platform. Use a volume or pressure washer to flush into drainage channels. Never use corrosive chemicals when flushing the parlour. 12.1.5 Parlour Floor The floor of the parlour needs to be cleaned after every milking, a volume/pressure wash clean is sufficient. It may be necessary to periodically take extra action to remove greasy deposits and/or algal growth. 13. Shut Down Procedure When the circulation cleaning has finished the cycle, the plant will be shut down automatically by the FullClean controller. When starting the next milking, set up as 8.1 Automatic drain valves are normally fitted in the delivery line adjacent to the milk pump and should be inspected periodically, for correct operation. 14. Maintenance Maintenance is important for the safe and efficient running of the parlour. A Fullcare Maintenance Plan, based on typical annual usage, should be set up in conjunction with the authorised Fullwood dealer or service provider. A Fulltest by a Fullwood approved engineer, in accordance with ISO 6690:2007, must be carried out at least annually; this will consist of a comprehensive check on all aspects of your parlour. Once the Fulltest is completed, your dealer will issue a certificate saying that the plant is in a safe working condition and that it is running in accordance with the standards set down in ISO 5707:2007. An interim Fullcheck is recommended, at appropriate intervals. The following checks should be carried out by farm staff on a daily/weekly basis. 006917 Page 24 of 28
14.1 Plant Daily Checks VACUUM SYSTEM Check vacuum level Check oil level in vacuum pump (if Applicable) PULSATION SYSTEM Check pulsators are operating and that each liner is flexing CLUSTERS Check shell ends for contamination. Check that the air admission holes on the clusters are clear PLANT ROOM Check oil level on compressor Check oil level in hydraulic power pack Check operation of safety gates 14.2 Plant Weekly checks: PARLOUR VACUUM SYSTEM Check vacuum level Check oil level in vacuum pump (if Applicable) PULSATION SYSTEM (liners should be replaced after 2500 cow milkings, see leaflet Part Number 006631, all other rubber components should be replaced at least annually) CLUSTERS Check shell ends for contamination. Check that the air admission holes on the clusters are clear PLANT ROOM Check oil level on compressor Check oil level in hydraulic power pack PARLOUR Check all rubber parts, including liners, check for wear and tear and replace if necessary. Check general cleanliness of the plant Check for any build-up of milkstone, treat if necessary. Refer to chemical container for instructions on usage Check bulk chemical containers, change if required care should be taken to ensure correct chemical is used. Check the FullClean to confirm correct temperature of the washing water during circulation Check the oil bath, which oils the track, for contamination. If oil is fouled / contaminated with water, drain via the draining plug and refill with multipurpose engine oil. Check the oil in the gearbox, located underneath the platform 006917 Page 25 of 28
14.3 Yearly Maintenance Plan Year One: Change the return oil filter in power pack and check oil level Check drive tension bolt for correct tension Grease the centre bearing Check platform controls for correct operation Year Two: Change the return oil filter in power pack and check oil level Check drive tension bolt for correct tension Grease the centre bearing Check platform controls for correct operation Jack up platform, remove two wheel guards and check wheels for free operation Year Three: Change the return oil filter in power pack and check oil level Check drive tension bolt for correct tension Grease the centre bearing Check platform controls for correct operation Check beam oil bath level Disassemble all wheels, wash out and check bearings and seals. Re grease and reassemble 006917 Page 26 of 28
15. Effective Reserve, As Calculated and Measured Removing a long milk tube under vacuum should not result in any vacuum fluctuation. If two long milk tubes are removed from their respective clusters, a slight fall of no more than 1 kpa should be noted. When the long milk tubes are re-attached, the vacuum should rapidly recover. This test should be done periodically to ensure satisfactory effective vacuum reserve. 16. Nominal Working Pressure and Capacity of the Compressed Air System Refer to separate compressor manual. The correct nominal working pressure should be notified during commissioning. Contact Fullwood Ltd or an approved dealer for service 17. Troubleshooting The following components are covered by separate manuals which should be consulted in the event of problems: FullClean Legato Pulsator Air Purge Pulsation Control - refer to appropriate milk meter or pulsation controller manual Compressor Milk Pump Controller Servac Vacuum Regulator Problems which cannot be solved from information in this manual can be rectified by a Fullwood approved engineer. 18. Disposal It is prohibited to dispose electrical and electronic goods into the house and residual waste removal (WEEE Directive). It must be disposed of according to collection point. For the protection of our environment please inform yourself at the communal administrative agency about your nearest disposal point. Some of the equipment supplied by Fullwood Ltd equates to the RoHS-directive 2002/95/EG, for the restriction of the use of certain hazardous substances in electrical and electronic equipment. 006917 Page 27 of 28
19. Disclaimers Foreseen Use of Machine: Your machine has been designed and manufactured for its intended use only as detailed in this manual and should not be used for any other purpose. If you have any doubts and/or questions regarding the specification, servicing, or features of your machine, contact your local Fullwood dealer. Fullwood Limited reserves the right to change the specification and/or operating features regarding this machine without notice or documentation. Warranty: The warranty on your Fullwood Machine will be invalidated if any additional ancillary equipment is fitted, or any modification or adjustments made to the controlling devices without prior notification and/or agreement from Fullwood Limited. Fullwood Limited will not accept responsibility for loss or damage caused by a force majeure e.g. lightning strikes and purchasers are advised to take out suitable insurance to cover their equipment. Fullwood Limited will not accept responsibility for milk contaminated by antibiotics and/or water. Maintenance: All work must be carried out by personnel suitably qualified for each maintenance task to avoid damage to both the machine systems and the maintenance personnel. Fullwood Limited cannot accept responsibility for any damage and/or loss that may occur through incorrect maintenance of your machine. Routine maintenance schedules can be found within this manual and should be adhered to. Electrics: Electrics can be extremely dangerous. All mains electrical work should be performed by a suitably qualified electrician in accordance with the applicable national and/or local regulations along with other relevant regulations and/or local bylaws. Compressed Air: Compressed air can be extremely dangerous. Installers and Users of compressed air equipment should be familiar with relevant safety regulations. (i.e.; BS EN 1012-1:1997 - Compressors and vacuum pump.) Standards and recommendations are available from BSI or HMSO. Water: All owners or occupiers of premises are responsible for the water systems within the premises. Owners and/or occupiers of premises where this machinery is used are responsible for provision of an adequate water supply, where required, and for compliance with relevant national and local legislation relating thereto. An appropriate guide for agricultural premises (Water Supply Systems: Prevention of Contamination and Waste of Drinking Water Supplies. Agricultural Premises) is available from the Water Regulation Advisory Scheme www.wras.co.uk (Tel. 01495 207 9030 UK only) Cleaning Chemicals: Only recommended cleaning chemicals are to be used, details of which can be found within this manual or contact Fullwood Limited Customer Services. Contents of Manual: Fullwood Limited takes pride in the accuracy of information given in this manual, but due to nature of hardware and software developments, be aware that specifications and features of this product can change without notice. The information contained in this manual is correct at the date of publication only. No liability can be accepted by Fullwood Limited, including liability to any person by reason of negligence, for loss, damage or injury caused by errors in, or omissions from, the information supplied in this manual. Any screenshots are used for explanation purposes only. Any numbers, wording, window or button positions may be different for the configuration of the machine control software being used to control your machine. Language: The original of this manual is written using British English. Translations to other languages have been done in good faith and no liability can be accepted by Fullwood Limited for loss, damage or injury caused by errors, or omissions. Contact: If you have any suggestions for improvements or amendments or have found errors in this publication, please notify Fullwood Limited Customer Services, E-mail address: customerservices@fullwood.com 006917 Page 28 of 28