9e921b rotary drive system inst instr

9e921b 10/22/2012

BouMatic P.O. Box 8050 Madison, WI, 53708-8050 USA • Telephone: (608) 222-3484 Fax: (608) 222-9314 • www.boumatic.comRemicourt 31, Rue Jules Melotte B 4350 Remicourt Belgium • Telephone: +32 (0)19 544 266 Fax: +32 (0)19 545 544

External Rotary Milking System

Xcalibur™ 360EX

Rotary & Drive System Installation Instructions

9e921b 2 Xcalibur™ 360EX Rotary & Drive System Installation

Instructional Content and Purpose

These instructions aim to aid those responsible (outlined under “Re-sponsibilities”) for installing, operating, maintaining, troubleshooting, and servicing this product.

Responsibilities

Procedures in these instructions are to be performed according to ap-plicable codes (state, local, and other) by the person(s) qualified (li-censed, if applicable) to do so—that is:

• Welding must be done by a qualified welder;

• AC power wiring for voltages over 40V (50V in Europe) must be done by a qualified (licensed) electrician in compliance with the latest edition of the ANSI/NFPA Standard 70, National Electri-cal Code, (USA) or either LVD 2006/95/EC or EMC 2004/108/EC (Europe) and in compliance with the local wiring codes as applicable;

• Other installation, major maintenance, and service work must be done by an authorized BouMatic dealer;

• Product/system checkout and troubleshooting steps are to be performed by an authorized BouMatic dealer;

• Deviation from these instructions could affect product perfor-mance or create a hazardous situation. Under no circumstances will BouMatic be responsible for any problems caused in whole or in part by any deviation from the procedures specified in these instructions without prior written approval from BouMatic;

• Operation steps may be performed by the owner/operator once the dealer or technician has successfully finished the product/system checkout. The owner/operator is responsible for properly operating, maintaining, and monitoring the product/system to ensure that it works properly.

Close compliance with the procedures herein is essential for the owner to get maximum benefit from the product/system.

Disclaimers

No warranties are contained in these instructions. The division of re-sponsibilities, stated above, is a general reminder of those provisions in the applicable dealer contract and does not change any agreement between BouMatic and the dealer. Information in these instructions is not all-inclusive and cannot cover all unique situations.

IndexIntroduction ....................................................................................................41. Preparation .................................................................................................5 1.1 Part and Tool Requirements ...............................................................5 1.2 Reviewing Personal Safety Messages ...................................................52. Drive System ..............................................................................................8 2.1 Platform Drive System ......................................................................8 2.1.1 Motor Specifications .............................................................8 2.1.2 Conduit Routings .................................................................8 2.1.3 Electronic Drive Pedestal Installation Instructions .....................8 2.1.4 Rotary Control ....................................................................8 2.1.5 Air Bag Control ....................................................................9 2.1.6 Installation of Warning Labels ...............................................9 2.2 Rotary Parlor Components .................................................................9 2.2.1 Cabinets and Divider Fence ...................................................9 2.2.2 Detacher Assembly ..............................................................9 2.2.3 Entrance/Exit Gates and Bridge Switch ...................................9 2.2.4 Rump Rail .........................................................................10 2.2.4.1 Installation of Pull Rope .........................................10 2.2.5 Proximity Switches ......................................................................10 2.2.6 Skirt ..........................................................................................103. Checkout and Start-Up ...............................................................................11 3.1 Platform Drive Power Unit Start-Up ...................................................11 3.1.1 Outside Pull-Rope ..............................................................12 3.1.2 Inside Pull-Rope (Basement Versions Only) ...........................12 3.1.3 Entrance/Exit Gate ............................................................12 3.1.4 Bridge/Platform Gap Switch ................................................12 3.1.5 Washline Proximity ............................................................12 3.1.6 Emergency Stop Button ......................................................12 3.1.7 Stop Button ......................................................................12 3.1.8 Forward Button .................................................................13 3.1.9 Reverse Button .................................................................13 3.1.10 Home Position Proximity ...................................................13 3.2 Milk Pump Start-Up ........................................................................13 3.2.1 Opti-Flo™ .........................................................................13 3.2.2 Milk Pump Controller (optional) ...........................................13 3.3 Stall Identification Controller Start-up ...............................................134. Final Checklist ...........................................................................................14 4.1 Before First Milking .........................................................................14 4.1.1 Vacuum System ................................................................14 4.1.2 Pulsation System ...............................................................14 4.1.3 Milk Pump ........................................................................14 4.1.4 Platfiorm Drive ..................................................................14 4.1.5 ProVantage Controller/Personal Computer .............................14 4.1.6 Detachers .........................................................................14 4.1.7 Identification System .........................................................14 4.1.8 Cleaning System ...............................................................14 4.1.9 Cooling System .................................................................15 4.2 During First Milking ........................................................................15 4.2.1 Vacuum System ................................................................15 4.2.2 Detachers .........................................................................15 4.2.3 Milk Pump ........................................................................15 4.2.4 Identification System .........................................................15 4.2.5 SmartDairy™ Network Controller .........................................15 4.2.6 Cooling System .................................................................15 4.2.7 Rotary Platform .................................................................155. Tables and Figures .....................................................................................16


IntroductionBouMatic’s Xcalibur™ 360EX Exterior Rotary Milking System is an integrated high performance system built around a rotating platform. Cows enter and exit the slowly rotating platform continuously dur-ing milking. This design moves cows through milking quickly, resulting in a highly productive parlor. All of its components and systems have been designed to work together to increase productivity, harvest high quality milk, and provide reliable performance.

Rugged rollers support a large steel double I-beam that is driven by a powerful electric drive system. A sturdy steel support structure is bolted to the I-beam and in turn supports a thick concrete deck, reinforced with steel rebar.

The main airline, milk delivery line, electric power, compressed airline, and communication pivots are located at the center of the rotary. The receiver group, Opti-Flo milk pump speed control, and me-ters (if installed) are mounted under the platform to

provide an uncluttered, yet easily accessible, milking system. A stainless steel skirt around the rotary’s ex-terior perimeter shields these components and pro-tects the operators while the rotary is in operation.

Critical components and electronics are conveniently located in stainless steel cabinets. The detachers’ electronics, valves, cylinders, and CIP jetters are easily accessible. This integrated design provides optimal protection.

These instructions are designed to help the install-er safely and efficiently install rotary and hydraulic components. Review these instructions (especially “Section 1-Preparation”) and the concrete drawings, available through the BouMatic Equipment Catalog, before planning and installing the parlor. Instructions for the operator are found in the Xcalibur 360EX Ex-terior Rotary Milking System Operating Instructions (9E-910).


N O T I C EAbbreviations:

1. a/r=As required2. Ø=Diameter or Phase, depending on context3. OD=Outside diameter4. ID=inside diameter or identification,

depending on context5. D/M=Detacher/Meter6. D/O= Detacher Only7. P/N=Part Number

1.1 Part and Tool Requirements

To prepare, be sure that you have the following items:

Dealer-Supplied Parts QuantityMasonry cement (grout) a/rAny components normally mounted outside the parlor (in the milk room, utility room or elsewhere)

a/r

Plate cooler circulation pump a/rPolished dairy tubing and fittings for the milk delivery line and washline connection

a/r

Milk delivery line support system from the center pivot to the milk room

a/r

Compressed air supply line and fittings a/rCompressor to main swivel and flexible compressed airline from the air swivel to filter-filter-regulator (milk and jetter line inlets, hose, ferrules clamps and gaskets)

a/r

PVC pipe and fittings a/rZinc spray paint a/rAluminum spray paint a/r

Optional Dealer-Supplied Electrical Parts:

Air Blow Timer: P/N 8516131, optional, 1-30 sec. (included with solenoid in P/N 8516132)

Literature Referenced in these Instructions:Rotary Operation Instructions 9E-910Rotary Automation Instructions 9E-920Rotary Control 9E-942VIP System Analysis “BouMatic Guidelines Manual”

9E-737

Air-blow Operation 9E-696CIP System Analysis “BouMatic Guidelines Manual”

9E-736

620 Air Injector 9E-794Guardian II Pipeline Washer 9ES-680Water Tests (Appendix A and B) Perfection Milk Meter & Control

9ES-764

Liquid Level Controller Instructions 9ES-453

Note: Please review the online dealer portal found at www.BouMatic.com for the most current literature.

1.2 Reviewing Personal Safety Messages

Follow the safety messages found here and throughout this instruction manual to prevent possible bodily inju-ry. The owner is responsible for replacing safety labels should they become illegible.

Provide positive, lockable disconnects to prevent unin-tended application of electrical, hydraulic, or pneumatic power to the equipment. Refer to national regulations for proper lock-out procedures for equipment service or re-pair. See Figure 1 for an illustration of possible methods.

Check all safety devices before each milking. The only exception to this rule is a trained dealer technician en-gaged in servicing this equipment.

The rotary milking system is intended exclusively for the milking of cows and is not intended for any other use.

1. Preparation


W A R N I N G Improper use of the milking parlor could cause seri-ous injury or death.

• Do not allow children in the parlor during use.• Only trained operators should operate this

system, and only if all safety devices are functioning.

• Never allow anyone on the platform or its structure, inside the platform, or underneath the platform while it is in operation.

• Do not obstruct the view from the rotary con-trol panel to the cow entry and exit area.

• Keep all guards in place when machine is in operation.

W A R N I N G Welding of galvanized steel parts may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. Use adequate ventilation.

W A R N I N G Only a qualified person shall open this electrical en-closure without locking out power. Electrical hazard could cause severe personal injury or death.

W A R N I N G • Lock out power to the platform drive power

unit before servicing the electrical system.• Failure to follow these procedures could

cause injury.

W A R N I N G • Do not operate when anyone is on or un-

der the cow platform. Do not reach under the platform unless power to the platform drive power unit has been disconnected and locked out.

• Only trained operators shall operate this system, and only if all safety devices are functioning.

• Check all safety devices before each milking.• Failure to do so could cause serious injury

or death.

W A R N I N G Disconnect and lock out power to the platform drive power unit before servicing the rotary platform. Fail-ure to do so could cause serious injury or death.

W A R N I N G Electric drive unit startup requires two people — an operator at the rotary control panel to stop and start the rotary as needed, and a person to observe inside the platform.

The operator must stay at the panel during the entire observation procedure so they can safely start and stop the platform as necessary and prevent anyone else from doing so inappropriately. Failure to follow these procedures could cause serious injury or death.

W A R N I N G Use proper lifting equipment rated to handle heavy objects to prevent serious injury. The drive brackets require mechanical assistance to install.


W A R N I N G Adjustment of the milk pump during operation should only be done by the dealer. Be aware of moving parts and pinch points to avoid serious injury.

W A R N I N G Failure to follow these instructions could cause seri-ous injury or death.

• Do not open this control while platform is rotating or when water is being sprayed.

• Follow these procedures detailed in the rotary installation instructions to adjust the Opti-Flo safely.

W A R N I N G Do not obstruct the view from the rotary control pan-el to the cow entry and exit area.

W A R N I N G Keep fingers away from the roller wheels when the platform is rotated, or injury could result. To prevent injury or damage to product or property, follow all safety messages in this instruction manual.


2.1 Platform Drive System

Install components of drive system are detailed in the following sections.

2.1.1 Motor Specifications

Input Voltage 230 - 480 VAC, 3Ø, 50/60 HzAmps 4.8 Amps (240V, 50 Hz)

2.7 Amps (380V, 50 Hz)2.8 Amps (480V, 60 Hz)

Power 1.5 HP [1.1 kW]Max Motor Torque .885 ft-lbs [1.2 N-m] @ 50 HzMin Motor RPM 500 RPM @ 17 HzMax Motor RPM 2053 RPM @ 73 HzGear Box Ratio 177:1 (Input:Output)Inverter Duty Motor YesIP Rating IP 55Agency Approvals CE, CSA, ULGear Box Oil ISO VG 150-220

Note: Refer to 9E-942 for total power requirements.

2.1.2 Conduit Routings

Reference literature 9E-942 for additional con-duit considerations.

Figure 2 indicates how the conduit might be routed for a typical installation. Conduit routing may vary from site to site in order to suit the needs of the par-ticular installation. Refer to the numbered notes on Figure 2 to route the following:

• Route minimum 2 in. (50mm) ID conduit for the shielded electrical cables. Each motor will have its own power cable running out from the Variable Frequency Drive.

W A R N I N G Use proper lifting equipment rated to handle heavy objects to prevent serious injury. The drive brackets require mechanical assistance to install.


W A R N I N G Do not obstruct the view from the rotary control pan-el to the cow entry and exit area.

2.1.3 Electric Drive Pedestal Installation Instructions

Installing the Electric Drive Pedestal and Air Bag Control

1. The electric drives are shipped fully assembled to the drive pedestals. The drill plate will be a separate plate that installs under the drive pedestal assembly. This drill plate is used to properly locate and drill the holes for the drive pedestal anchors. Refer to Technical Manual 9E-909 for the dimensions and proper placement of the drive pedestal drill plate. Figures 3, 4a, and 4b show how the Electric Drive Drill Plate and Drive Pedestal are anchored to the floor and how they are positioned under the rotary.

2. After the electric drive assembly is located properly, the Air Bag Control can be in-stalled. See Figure 5.

N O T I C EDo not place the wheels against the drive ring or pressurize the Air Bag Control until “Platform Drive Power Unit Start-Up.” Rotation of the drive wheel MUST be checked before turning the platform.

2.1.4 Rotary Control

Refer to literature 9E-942 for Rotary Control installa-tion instructions.

2. Drive Systems


2.1.5 Air Bag Control1. Mount the air control panel in the utility

room near the platform drive power unit.2. Run the supply air line from a dry, filtered

source to the air control panel.3. Run a 1/4 in. OD air line from the air control

panel to each of the drive pedestals. Connect each line to an Air Bag Control and one of the switches in the control panel. Ensure that the switches are all turned “OFF” at this time.

The function of the air bag control is to increase the lifespan of the drive wheels and drive system compo-nents. The air perssure to the drive wheels starts at a higher pressure until the platform is up to speed. The pressure is then reduced after an adjustable period of time to minimize the forces on the drive system. The “Start” and “Run” pressures can be adjusted indepen-dently at the air bag controller. The air bag controller has independent air pressure regulators for the “Start” and “Run” pressure settings. To adjust the pressure, turn the air pressure regulator knob until the pressure gauge reads the desired pressure.

2.1.6 Installation of Warning Labels

N O T I C E• The owner of the installation is responsible

for replacing any safety labels that are no longer visible.

• The installation may not be started unless all appropriate safety labels are also in place for the first milking. The installer is responsible for ensuring that all labels are installed in accordance with the instructions in Table 1.

Ensure that safety labels are installed in the milking parlor at their indicated positions.

1. Mount the rotary control warning label and bracket above the rotary control panel, fac-ing the operator (see Figure 6).

2. Mount the two wall warning labels in promi-nent locations so that everyone in the parlor can see them (see Figure 7).

3. If in a European country, please install warning labels shown in Table 1 in addi-tion to the labels mentioned above. This will conform to CE legislation. These lablels are supplied in a pack (P/N 8581965).

2.2 Rotary Parlor Components

2.2.1 Cabinets and Divider Fence1. Install the large guide ring into the cabinet

loop securing it with a 2 in. external snap ring.2. Fasten the loop to the front of the cabinet using

four 1/2-13 X 1.5 in. carriage bolts and nuts.3. Place the cabinet onto the stall divider support

beam and fasten in place with four 1/2-13 X 1.5 in. carriage bolts and nuts. See Figure 8.

4. Place the divider fence onto the stall divider support beam and fasten to the stall divider support beam with two 1/2-13 X 1.5 in. car-riage bolts and nuts.

5. Use two 1/2-13 X 1.5 in. carriage bolts and nuts to attach the fence to the cabinet. Place the detacher support bracket over the top bolt before installing the nut. (See Figure 9.)

6. Install the curved head, breast, and leg rails on the stall divider fence. Each is curved to match the radius of its mounting location. It may be necessary to lay the pieces out to determine the different sizes. Fasten these in place with the provided galvanized U-bolts and nuts. Connect individual sections togeth-er with tube clamps.

2.2.2 Detacher Assembly

Install detacher assembly inside cabinet as shown in Figure 9.

2.2.3 Entrance/Exit Gates and Bridge Switch

See Figures 10 and 11 for details.

N O T I C EThe standard rotary parlor is designed to rotate coun-ter-clockwise and has the entrance lane on the left side of the bridge as viewed from the center. If the dairy has ordered a rotary that rotates clockwise, the entrance will be on the right side of the bridge as you are looking from the center of the parlor towards the bridge.

N O T I C EThe bridge edge is 2 x 6 in. (51 x 152mm) tubing to fa-cilitate the use of it as a conduit for wiring and airlines, or to be filled with water to be used for deck flush.


1. Use multiple 2 in. (51mm) blocks between the bridge edge framework and platform to estab-lish correct spacing between them. Be sure the upper edges of the bridge frame work and are flush with the platform.

2. Weld the short return pieces and post mounting brackets onto the end of the bridge edge mak-ing sure that the top of all joints are flush. See Figure 10 for layout details.

3. Align the tabs on the exit and entrance posts with the post mounting brackets on the edge of the bridge framework to properly position the exit and entrance posts. Use the spacer provided to align the entrance post with the center post.

NOTICEIf using the BouMatic ID, the ID antenna and entrance gate must be located 7 in. (178mm) from the edge of the cow platform to ensure that the gates do not hit the ID antenna. Any other location may cause a reduction in data accuracy or cause safety concerns. Refer to Rotary Automation Instructions, 9E-920, and see Figure 10 (Portal ID) to see how the antenna will be installed in relation to the gate.

4. If using ISO ID, see Figure 10 (ISO ID) for entrance lane detail.

5. Install rebar for the bridge, entrance, and exit lanes. Rebar must be positioned so that the anchor bolts for the antenna will not make con-tact with the rebar. Contact with rebar or other metal may cause interference with antenna performance.

N O T I C ENo piping or conduit can be installed within 6 in. (152mm) of the chamfer on the exit side of the bridge. This is to prevent an interference with the actuation of the bridge/mat switch.

6. Pour the bridge concrete.7. Install the gate linkage. Refer to Figure 11

to ensure that the linkage is correctly placed.8. Install the gate proximity switch.9. Install the bridge/platform gap switch on the

exit side of the bridge.• Position the bridge switch on the exit

side of the bridge framework (see Figure 17) and mark and drill holes through the framework and into the concrete.

• Install the dealer supplied anchor bolts through the bridge switch mount and into the ridge. Tighten the bolts into place.

2.2.4 Rump Rail

Assemble the rump rail as shown in Figure 12. This can be done at a later stage of the installation in order to allow easy access to the platform and the center of the rotary.

W A R N I N G Welding of galvanized steel parts may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. Use adequate ventilation.

1. Clamp the rump rail support to the rump rail posts (set previously) using six M12X50mm bolts and nuts.

2. Align the centerline of the rump rail support 44 in. (1118mm) from the top of the cow plat-form. Visually align the top of the post with the center of the rotary.

3. Mount the kick rail 3 in. (76mm) above the cabinet front loop. The center of the kick rail is 3 in. (76mm) from the outside edge of the platform. Temporarily support it with a 3 in. (76mm) block.

2.2.4.1 Installation of Pull Rope

Refer to Figures 13 and 14 for installation of the inside and outside pull ropes.

2.2.5 Proximity Switches

Reference literature 9E-942.

See Figure 15 for the following steps.

1. Mount the emergency button next to the home position proximity using dealer-supplied self-tapping screws.

2. Mount the cable, spring, and turnbuckle to the E-stop.

3. Wire the emergency stop button.

2.2.6 Skirt.Install skirting as shown in Figures 16a and 16b.


The items below cover the steps that need to be taken to ready the rotary parlor for use. A checklist follows which provides an outline for the dealer to follow when performing a final systems check.

W A R N I N G • Do not operate when anyone is on or under

the cow platform.• Only trained operators shall operate this

system, and only if all safety devices are functioning. Check all safety devices before each milking.

• Failure to do so could cause serious injury or death.

W A R N I N G • Lock out power to the platform drive power

unit before servicing the electric drive system.• Failure to follow these procedures could

cause injury.

3.1 Platform Drive Power Unit Start-up

W A R N I N G Electric drive power unit start-up requires two people, an operator at the rotary control panel to stop and start the rotary as needed and a person inside the platform to observe. The operator must stay at the panel during the entire observation procedure so the operator can safely start and stop the platform as necessary and prevent anyone else from doing so inappropriately. Do not reach under the platform unless power to the platform drive power unit has been disconnected and locked out. Failure to follow these instructions could cause serious injury or death.

1. Grease the following items before starting the unit:• Grease the center pivot while the platform

is rotating. Apply grease until it starts coming out of the bearing around the en-tire circumference of the pivot.

• Grease the drive motor mounting arm pivot by giving two pumps of grease to the grease zerks on the mounting arm.

2. Verify that the platform is free to pivot, the wash lines are disconnected from the platform, and that the milking units will not be crushed between the bridge and the platform.

3. First make sure that all drive wheels are disengaged from the drive ring and then turn on the platform drive power unit and press the FORWARD button on the control panel. Check the rotation of each drive wheel. Each drive wheel should be turning in a direction that would rotate the platform in the milking direction.• Switch the corresponding motor leads at

the motor overload protector to reverse the motor rotation direction if the initial rotation direction is backwards.

4. The function of the Air Bag Control is to in-crease the lifespan of the drive wheels and drive system components. The air pressure to the drive wheels starts at a higher pressure until the platform is up to speed. The pres-sure is then reduced after an adjustable period of time to minimize the forces on the drive system. The Start and Run pressures can be adjusted independently at the Air Bag Control and the run pressure delay can be set at the time delay supplied with the Air Bag Control.

5. With the platform drive power unit turned off and the rotary platform stationary, turn on the Air Bag Controls so they apply pressure to the drive wheels. Inspect each drive to ensure that the wheels are making even contact with the drive ring. If they are not, find and correct the problem.

6. Turn on the platform drive power unit and recheck the system.

3. Checkout and Start-Up


3.1.1 Outside Pull-Rope

The pull-rope around the perimeter stops the plat-form from turning. The platform can only be re-start-ed from the rotary control panel. Pull the pull-rope on both sides of the parlor near the ends of the ropes to verify that both switches stop the platform with a reasonable amount of force (about 20 lbs. or 9kg).

FOR EUROPEAN INSTALLATIONS ONLY: The outer of the two pull-ropes around the perimeter is an emer-gency stop. The platform can only be restarted after releasing the pull-rope and pressing the reset button in the basement. To start moving the rotary forward, press FORWARD once at the control panel.

N O T I C EWhen performing initial start-up procedures for the platform drive power unit, be sure the drive wheels are not in contact with the drive ring. Check the rota-tion of each drive wheel. Each drive wheel should be turning in a direction that would rotate the platform in the milking direction. Failure to check drive wheel rotation before engaging drive wheels to the drive ring could result in equipment damage.

N O T I C EDo not rotate the platform for two weeks after pour-ing the concrete. This ensures that it has had ade-quate curing time. Allow the concrete to set slowly to furnish the best result. Periodically wet the surface to help the curing process.

N O T I C EBe sure the milking units will not be crushed between the bridge and the platform.

3.1.2 Inside Pull-Rope (Basement Versions Only)

The pull-rope inside the rotary stops the platform from turning. The platform can only be restarted after releasing the pull-rope and pressing the reset button in the basement. To start moving the rotary forward, press FORWARD once at the control panel.

3.1.3 Entrance/Exit Gate

The entrance/exit gate is spring-loaded and stops the platform if a cow becomes pinched between the bridge and platform. If the gate is adjusted correctly, the platform will stop before the cow is in danger. The operator may have to reverse the platform to al-low the cow to move. Before each milking, while standing in the operator’s area, check that the switch on the cow entry gate stops the plat-form when the gate travels half the distance to the rump rail.

3.1.4 Bridge/Platform Gap Switch

The bridge/platform gap switch, located on the exit side of the bridge, is spring-loaded and stops the platform if a cluster goes between the platform and the bridge, instead of underneath them, while the platform is rotating. Check that the bridge/platform gap switch stops the platform when pushed. The platform can only be restarted from the rotary control panel.

3.1.5 Washline Proximity

These switches prevent the platform from rotating if the washlines are still connected to the platform.

3.1.6 Emergency Stop Button

The EMERGENCY STOP on the rotary control panel is a push/pull button. Pushing in this button shuts off pow-er to the platform drive power unit if a hazard should arise. After the hazard has been removed, restart the system by resetting the EMERGENCY STOP button and pressing the FORWARD or REVERSE button.

3.1.7 Stop Button

If STOP button is pressed, it will stop the rotary. It will not kill power to the platform drive power unit. To start moving the rotary forward, press FORWARD once. To start moving the rotary in reverse, hold the REVERSE button. The rotary will stop once the RE-VERSE button is released.


3.1.8 Forward Button

To start moving the rotary forward, press the FORWARD button once.

3.1.9 Reverse Button

To start moving the rotary in reverse, press STOP or pull the outside rope and hold the REVERSE button. The rotary will stop once the REVERSE button is released.

3.1.10 Home Position Proximity

If the rotary is turning forward and the milk wash switch is moved to the wash position, the rotary will stop. When this occurs, press FORWARD on the control panel. When the home position proximity is activated, the rotary will stop again.

3.2 Milk Pump Start-Up

W A R N I N G • Improper use of the milking parlor can cause

serious injury or death.• Do not allow children in the parlor during use.• Only trained operators shall operate this

system, and only if all safety devices are functioning. Check all safety devices before each milking.

• Never allow anyone on the platform or its structure, inside the platform, or underneath the platform while it is in operation. The only exception to this rule is a trained dealer tech-nician engaged in servicing this equipment.

• The rotary milking system is intended ex-clusively for the milking of cows and is not intended for any other use.

• Do not obstruct the view from the rotary control panel to the cow entry and exit area.

• Keep all guards in place when machine is in operation.


W A R N I N G Failure to follow instructions could cause serious in-jury or death.

• Do not open this control while platform is rotating or when water is being sprayed.

• Follow the procedures detailed in the rotary installation instructions to adjust the Opti-Flo safely.

3.2.1 Opti-Flo

Make any necessary adjustment (refer to Opti-Flo CF Milk Speed Pump Control, 9E-939) and close the enclo-sure before allowing the platform to be restarted.

3.2.2 Milk Pump Controller (optional)

To adjust the liquid level controller refer to the Liquid Level Controller Instructions, 9ES-453.

3.3 Stall Identification Controller Start-up

1. After the stall ID controller has been in-stalled, slowly rotate the platform to make sure the tags do not hit the side of the stall ID controller or scrape its front cover. (The platform does not need to be operational at this time). The mounting bracket can be bent to move the tag if it needs to be adjust-ed. Move the stall ID controller if all the tags are either too close or too far away. The tag should be 1/2 in. (13mm) from the plastic cover of the stall controller.

2. Refer to SmartDairy help files for assigning stall tag numbers to the appropriate stall. Follow the check list to check out.


N O T I C EEntrance and exit gate switches are not used on ro-tary parlors.

Follow the checklist to check out the system before and during start-up. Refer to “Section 3-Checkout and Start-up” for more detailed information, if needed.

4.1 Before First Milking

The following steps are to be performed by the dealer before the cows are milked the first time.

4.1.1 Vacuum System

□ Lubricate vacuum pump per instructions received with pump.

□ Verify that pump rotates in correct direction. □ Turn on the vacuum system and adjust the

vacuum level. □ Verify check valve prevents reverse rotation

on shut-down. □ Set relief valve. □ Verify amp draw on motor is below name-

plate rating. □ Verify that drain valves are closed when

vacuum pump is on. □ Verify that pulsators operate only when

vacuum pump is on. □ Do manual and effective reserve test per

system analysis. See VIP System Analysis “BouMatic Guidelines Manual,” 9E-737.

□ Find and repair any leaks □ Do vacuum level tests. See VIP System Anal-

ysis BouMatic Guidelines Manual (9E-737). □ Calibrate all vacuum gauges.

4.1.2 Pulsation System

□ Do pulsator tests for all pulsators per system analysis. See VIP System Analysis BouMatic Guidelines Manual (9E-737).

4.1.3 Milk Pump

□ Verify that pump rotates in correct direction. □ Verify that pump control starts when float is

raised. □ Verify that pump starts when manual button

is depressed. □ Set pump control per instructions. □ Set probe float height.

4.1.4 Platform Drive

□ Verify proximity sensors work as they should. □ Verify that platform rotates without interference. □ Inspect the drive/idler wheels for proper rota-

tion direction and alignment with the drive ring.

4.1.5 SmartDairy Network Controller/ Personal Computer

□ Enter the data for the type of parlor, number of stalls, etc.

□ Verify that the SmartDairy Network Con-troller can communicate with the following items: PC (if used) terminal, D/M controls, ID controls and stall reader.

□ Enter cows and ID tag numbers for those cows.

4.1.6 Detachers

□ Verify that air pressure is 60 to 65 psi.

(D/M) □ Test the keypad to ensure all keys func-

tion. Water test per Appendix A and B of literatures 9E-926 (TouchPoint™) or 9E-941 (ViewPoint™).

□ Test the ATTACH/DETACH and AUTO/MANU-AL buttons.

□ Verify that claw drop and claw lift functions operate correctly.

(D/O) □ Test the ATTACH/DETACH and AUTO/MANU-

AL buttons. □ Verify that claw drop and claw lift functions

operate correctly.

4.1.7 Identification System

□ Verify ID tag can be read depending on the ID system.

□ Make sure the ID stall tags do not hit the front of the stall reader control.

4.1.8 Cleaning System

□ Verify pipeline washer operation per Guardian II Pipeline Washer, 9ES 680.

□ Check hot water temperature. □ Set washer variables, including sink fill depth,

per washer instructions. □ Verify the plate cooler solenoid is ON in the milk

condition, and OFF in the wash condition. □ Verify that the air injector wash hoses are

closed in the milk condition, and open in the wash condition.

4. Final Checklist


□ Set the air injectors per 9E-794, 620 Air Injector.

□ Do a CIP Analysis per CIP System Analysis “BouMatic Guidelines,” 9E-736. Make adjust-ments as needed.

□ Verify that all drains operate as intended. □ Check for milk swivel leak, and correct if

needed. □ If equipped, verify air-blow operation. Adjust

per Air-blow Operation, 9E-696.

4.1.9 Cooling System

□ Verify proper operation

4.2 During First Milking4.2.1 Vacuum System

□ Do milking time tests per system analysis. See VIP Systems Analysis “BouMatic Guide-lines,” 9E-737.

4.2.2 Detachers

(D/M) □ Verify that the milking unit is automatically

removed. □ Verify the claw drop and claw lift functions

operate correctly.(D/O) □ Verify that the milking unit is automatically

removed. □ Verify the claw drop and claw lift functions

operate correctly. 4.2.3 Milk Pump

W A R N I N G Adjustment of the milk pump during operation should only be done by the dealer. Be aware of moving parts and pinch points to avoid serious injury.

□ Verify that pump doesn’t cavitate or allow milk to rise high enough to cover milk inlets.

□ Set Opti-Flo per Opti-Flo CF Milk Speed Pump Control, 9E-939, for uniform milk flow.

4.2.4 Identification System

□ Verify that all ID tags are being read.

4.2.5 SmartDairy Network Controller

□ Use the diagnostic report in SmartDairy to determine:• All D/M controls send milk weights to the

SmartDairy Network Controller.• All ID tags read, are assigned to cows.• All stall ID tag numbers are entered cor-

rectly and are being read.

4.2.6 Cooling System

□ Verify proper operation per relevant literature. □ Verify that milk is cooled to the required

temperature.

4.2.7 Rotary Platform

□ Verify that the rotary stops when the safety mat is stepped on.

□ Verify that the safety mat reset button resets the circuit.

□ Verify that the rotary stops when the basement parlor pull rope is pulled.

□ Verify that the reset button for the basement emergency pull rope resets the pull rope circuit.

□ Verify that the rotary stops when the outer emergency stop rope is pulled (European in-stallations only).

□ Verify that the reset button for the outer emer-gency pull rope resets the pull rope circuit.

□ Verify that the rotary stops when the entrance/exit gate is pushed to the side.

□ Verify that the rotary restarts when the en-trance/exit gate returns to the normal position.

□ Verify that the rotary stops in the correct posi-tion for washing.

□ Verify that the rotary stops when the outside pull rope is pulled.

□ Verify that the rotary stops when the bridge gap switch is pushed.

□ Verify that the rotary cannot turn when the wash lines are connected to the rotary.

5. Tables and Figures

9e921b 16 Xcalibur™ 360EX Instructions10/22/2012

1. (Section 1.2) Lock-out techniques for power, hydraulic and air L1909_1

2. (Section 2.1.2) Drive Motor Locations l909_6a

PLATFORM DRIVE MOTOR LOCATION: 72/80 - 6 MOTORS (3 DOUBLE)


3. (Section 2.1.8) Installing Electric Drive Pedestal - Basement Shown l909_104

4a. (Section 2.1.8) Assembled Electric drive shown under a basement rotary l909_105


4b. (Section 2.8.1) Assembled Electric drive shown under a non-basement Rotary l909_106

5. (Section 2.8.1) l909_107


6. (Section 2.1.10) Rotary control warning label l909_80


7. (Section 2.1.10) Wall warning label l909_81


8. (Section 2.2.1) Installation of cabinets and stall dividers l909_20a

9. (Sections 2.2.1, 2.2.2) Installation of detacher cylinder assembly inside cabinet l909_22


10. (Section 2.2.3) Bridge, entrance, and exit gate locations L909_46

PORTAL ID

ISO ID


12. (Section 2.2.4) Rump Rail Installation l909_48

11. (Section 2.2.3) Entrance and exit gate details l909_45b


13. (Section 2.2.4) Installation of Pull Rope l909_49

14. (Section 2.2.4) Installation of Pull Rope l909_69

BASEMENT ONLY


15.

(Sec

tion

2.2.

5) In

stal

latio

n of

Lim

it S

witc

h fo

r Hom

ing

l9

09_6

8


16a. (Section 2.2.6) Installation of Skirt for rotary with basement l909_79

16b. (Section 2.2.6) Installation of Skirt for non-basement rotary l908_79a


17. (Sections 2.1.2, 2.2.3) Installation of Bridge Switch l909_52a

0.2

HCTIWS EGDIRBYLBMESSA

HTIW LEVELPOT EGDIRB

NOITATOR WC

NOITATOR

5.61FER

0.5FER

0.2

HCTIWS EGDIRBYLBMESSA

HTIW LEVELPOT EGDIRB

NOITATOR WCC

NOITATOR

5.61FER 0.1

FER

25_909L

WOCMROFETALP YB ERUCES

ECALP NI GNIDLEW

COW PLAT-FORM

2.0 in. (51mm)

16.5 in. (419mm)

5.0 in. (127mm)

COW PLATFORMBRIDGE

COW PLATFORM

BRIDGE

2.0 in. (51mm)

16.5 in. (419mm) 1.0 in. (25mm)

DIRECTION OF ROTATION

DIRECTION OF ROTATION


Table 1: Warning Labels Required for CE Compliance

Label to be installed Reference Quantity Location in the building8581806 2 Near an obstacle from the building

8581807 2 At each entrance gate of the milking parlor

8581808 2 At the cow return lane

8581809 2 On the wash trough of the pipeline washer

8581810 6 On the entry/exit gate; in the operator pas-sages

8581812 2 On the pipeline washer; at the location where the chemical products are stored


Label to be installed Reference Quantity Location in the building8581814 4 On each entrance gate (2), near the pipe-

line washer, and at the location where the chemical products are stored.

8581815 2 Near the pipeline washer and at the location where the chemical products are stored.

8581816 2 Near the pipeline washer and at the location where the chemical products are stored.

8581817 1 To identify the exit of the milking pit (also one with a right pointing arrow to be in-stalled so that it can viewed from any posi-tion in the pit). The other signs must be supplied by the building contractor.

8581818 2 In the milking pit; outside the technical room (extinguisher not provided by BouMatic)

8581833 1 To identify the exit of the milking pit (also one with a left pointing arrow to be installed so that it can viewed from any position in the pit). The other signs must be supplied by the building contractor

9e921b rotary drive system inst instr

Documents

purposethese instructions

platform drive system

boumatic operation steps

applicable dealer contract

electronic drive p

local wiring codes

usa telephone

close compliance