Beruflich Dokumente
Kultur Dokumente
7053-9001-038
09-2012
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Owner's Obligation of Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Explanatory notes on the safety symbols and pictograms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Product Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Product Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Checking what has been delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Special personnel qualifications required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Preparations before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Environmental Conditions for Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5 Checks before the start of assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6 Assembly of milking parlour frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7 Installing the component support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.8 Installing the support rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.9 Installing the pipe support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.10 Installing the swing over arm and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.11 Installing the cluster removal control valve (Metatron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.12 Installation of cable duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.13 Installing the pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.13.1 Installation of the vacuum line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.13.2 Installing the "pulsator air supply line" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.13.3 Installing the milk line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.13.4 Installing the rinsing line / cluster receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.14 Installing the pipes (3A layout - for USA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.14.1 Installing the "pulsator air supply line" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.14.2 Installation of the vacuum line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.14.3 Installing the milk line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.14.4 Installing the rinsing line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.15 Instaling milk transfer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.15.1 Installation material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.15.2 Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.16 Installing standard components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.17 Installing optional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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5.18 Laying hoses/cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.19 Adjusting the length of the removal cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.20 Information on disposing of installation material after installation is finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.1 Special personnel qualification required for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.2 Safety instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.3 Work stations of the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.4 Operating (Metatron P21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.4.1 Controls and key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.4.2 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.5 Operating (DemaTron 60 / DemaTron 70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8 Operating faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.1 Special personnel qualification required for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2 Safety Instructions for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.3 Troubleshooting possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.1 Special personnel qualification required for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.2 Safety instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3 Inspections and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.4 Cleaning the sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10 Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1 Special personnel qualifications required for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.2 Safety instructions for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.3 Final decommissioning/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11.1 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11.2 Swing over arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.3 Cluster removal control valve (Metatron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.4 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.5 Milk flow monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.6 Milk meter with accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.7 Pulsators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11.8 Milk transfer assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Preface
Information on the instructions
1 Preface
1.1 Information on the instructions
Required documents:
D Instructions on components connected with the product:
(not a complete list)
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Preface
Information on the instructions
Pictograms used
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Preface
Customer services
US Contact Information:
GEA Farm Technologies, Inc.
1880 Country Farm Dr.
Naperville, IL 60563
+1 630 369 - 8100
+1 630 369 - 9875
contact_us@gea.com
www.gea-farmtechnologies.com
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Preface
Declaration of Incorporation
Attention!
We would point out that commissioning is not permitted until it has been established that the
machine/system in which this product is installed meets the conditions of the directives on which they
are based.
Person responsible for compiling the Josef Schrer
relevant technical documents: GEA Farm Technologies GmbH
Siemensstrae 25-27
D-59199 Bnen
' +49 (0) 2383 / 93-70
Reinhard Frenser
(Head of Research and
Bnen, 24.March.2010 Development)
The undersigned is acting by virtue of power of attorney from the management of:
GEA Farm Technologies GmbH, Siemensstrae 25-27, D-59199 Bnen
This declaration certifies compliance with the guidelines indicated, but does not establish any guarantee in the sense of paragraphs
443, 444 BGB.
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Preface
Successful Milking
Attention!
Always avoid milking without milk flow (blind milking) because it will
very quickly have a negative effect on teat condition and udder
health!
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Preface
Successful Milking
Milking routine
1 Visual inspection
Monitor the animals as they enter the milking parlour. Identify any
treatment, injury or udder infection.
3 Preliminary milking
Check the milk to see if it is saleable and monitor udder health.
Start the stimulation process.
Recommended: Use automatic stimulation.
7 Remove cluster
No blind milking. Shut the vacuum off first, then remove the cluster.
8 Dip teats
Directly after removing the cluster dip each teat to at least 3/4 of its length.
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Safety
Owner's Obligation of Care
2 Safety
2.1 Owner's Obligation of Care
The product has been designed and constructed while taking account of a
potential risk analysis and after careful selection of the harmonized standards
and other technical specifications to be complied with. It therefore guarantees
a maximum level of safety.
This safety can only be achieved in practice on the farm however when all of the
necessary measures have been taken. It is part of the farmer's obligation of care
to plan these measures and check that they are carried out.
Note
See also the section on "Personnel qualification"
D The personnel will be regularly instructed in all relevant matters of safety at
work and protection of the environment and be familiar with the manual,
particularly the safety instructions it contains.
D Unauthorized people (e.g. children) do not stand in the danger areas.
D Follow all of the instructions given in the manuals for the components used.
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Safety
Basic safety instructions
Warning!
The indication "Warning" signals danger to life or health of personnel.
Death or serious injury may result if the danger is not avoided.
Attention!
The indication "Attention" signals important information on risks for the
product or the environment.
Note!
There are warnings about specific residual dangers in the
corresponding chapters.
D There are risks involved in the operation and maintenance of equipment for
dairy farms. For your own safety, read and follow the operating manual
carefully!
D The chapter on "Technical data" gives the permissible working conditions
(pressure ranges, temperature ranges, airflow quantities etc.) and these
must be observed!
D Do not open or dismantle devices (risk of injury)!
D Protect live and high-voltage components against moisture. Under no
circumstances may water jets or high-pressure cleaners be directed at
these!
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Safety
Personnel qualifications
Anyone who is to carry out work or activities in connection with the product must
read the operating instructions carefully and sign to confirm that they have
understood them and will heed them!
D Generally, all work on electrical equipment and electrical connections
should only be performed by qualified electricians.
D All work on pneumatic equipment should only be performed by technicians
trained for this purpose.
D All welding work must only be performed by trained welders.
In addition, special qualifications are required for the following activities:
D Start-up
D Operating
Note
If the work requires special qualifications, these are described in the
corresponding chapters!
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Description
3 Description
Installing SwingOver components turns a EuroClass 800 or EuroClass 850
herringbone milking parlour into an equivalent SwingOver milking parlour.
The dimensions of the operator pit are adapted according to the new
requirements.
Size of parlour
2x4 2x5 2x6 2x7 2x8 2x9 2x10 2x12 2x13 2x14
EuroClass 800 / 850
2x15 2x16 2x18 2x20 2x22 2x24 2x25 2x28 2x30 2x32
With the pipelines in the middle, two opposite milking places can use one set
of "milking place equipment" (cluster, control unit, removal, pulsator,...) by
means of a swing over arm.
D Type of swing over arm
PosiSwing PosiSwing D
without cluster removal cylinder with cluster removal cylinder
Feature
Vacuum cut-off x x x
Removal control system x x x
Pulsator control x x x
Milk metering
x x
(Option)
Automatic animal identification
x x
(Option)
Gate control, group milking parlour
x
(herringbone milking parlour)
Animal administration for 2 animals x
Feeding system M x
Switching between active / passive side of
x x
the milking parlour
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Description
Product Changes
The product described has been designed for use in agricultural (mainly milk
producing) environments.
SwingOver is intended solely for supplying two opposite milking places with one
set of milking place equipment (cluster, control unit, cluster removal, pulsator,
..).
The area of use is limited to the following milking parlours:
- Herringbone milking parlour EuroClass 800
EuroClass 850
Applications which are not listed here are not part of the intended purpose and
are therefore considered as improper use!
The following in particular are prohibited:
- using SwingOver in other milking parlours!
The manufacturer/supplier is not liable for any resulting damage. The user
alone bears the risk.
Correct use also includes reading the instructions and observing the inspection
and maintenance conditions.
D We would specifically like to point out that parts or accessories not supplied
by ourselves and setting instructions not provided by the
manufacturer/supplier are not checked or released by us either.
D The installation or use of products from other manufacturers may affect the
specified properties of the original parts and lead to injury to people and
animals.
D The manufacturer does not accept any liability for injury to people or
animals, or damage to the product, caused by the use of products from other
manufacturers.
7053-9001-038
14 09-2012
Description
Product Components
9 17 5 16 12 1 11 10 6 7 8 3
7053-9001-038
09-2012 15
Description
Functional description
Once milking standby has been established, the right-hand side of the milking
parlour is active.
With DemaTron it is possible to set the active side of the milking parlour.
Setting in DPSetup
Parameter: 040/000/155
A active side
B A
side with the animal being
milked or about to be milked
B passive side
side where the animals are
being changed over.
C
7053-9001-038
16 09-2012
Description
Technical specifications
7053-9001-038
09-2012 17
Transport
Dimensions and weight
4 Transport
4.1 Safety instructions for transport
7053-9001-038
18 09-2012
Transport
Checking what has been delivered
Note
If there is a lot of installation work, the installation material supplied
should be stored, as far as possible by the installation personnel, in the
order in which it will be installed.
This will mean that the minimum amount of time is spent looking for
individual parts during the installation work.
It also gives the installation personnel an idea of any parts that might
be missing as soon as the individual parts are delivered so that they
can be re-ordered without delay.
Check the goods supplied against the packing list enclosed for completeness
and damage.
Size of parlour 2x4 2x5 2x6 2x7 2x8 2x9 2x10 2x12 2x13 2x14
7053-9001-038
09-2012 19
Transport
Checking what has been delivered
Size of parlour 2x15 2x16 2x18 2x20 2x22 2x24 2x25 2x28 2x30 2x32
7053-9001-038
20 09-2012
Transport
Disposing of packing material
When storing the goods supplied, the location must provide protection against:
D Humidity
D External damage (bumps, knocks, rodents and insects . . . )
D Remove the heat-shrink film and adhesive tape if the product is to be stored
for any length of time.
Attention!
Risk of corrosion!
Do not store stainless steel together with steel!
7053-9001-038
09-2012 21
Installing
Safety instructions for installation
5 Installing
If necessary, please contact your nearest authorized technical dealer.
Warning!
Risk of falling!
During installation work there is a risk of falling, e.g. from a ladder.
Only use equipment which ensures a secure standing position and
adequate safety.
D Injury can be caused by the electrical current from live cable ends and
components.
D Lines which are not laid properly (e.g. bending radius too small) can cause
scorching and electrical fires.
If the bending radius is too small, it should be removed.
D Electrostatic processes can cause damage to electronic components.
Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.
7053-9001-038
22 09-2012
Installing
Safety instructions for installation
D Parts loosely placed on top of each other can slip and fall off.
D Components with exposed sharp edges represent a source of injury.
D The central pipelines may be damaged by misuse (e.g. by standing on them
during installation).
Never place any unusual weight on the pipelines.
D Serious injury to personnel or damage to property can be caused if the
incorrect torque is applied when tightening screws.
Attention!
Before metal-cutting work:
- Protect any sensitive surfaces, e.g. from flying sparks.
After metal-cutting work:
- Deburr the edges that have been cut.
- Thoroughly remove all chips and impurities!
Attention!
Risk of corrosion!
Do not use tools to work on stainless steel which were used to work on
steel before!
To work on stainless steel only use special tools (saw blades, cutting
wheels etc.)!
Attention!
Always avoid flying sparks on special steel
surfaces or other sensitive components!
Metal dust on stainless steel surfaces can lead to
corrosion!
Attention!
All screws and nuts made of stainless steel are to
be greased thoroughly to prevent them from
seizing during tightening!
7053-9001-038
09-2012 23
Installing
Environmental Conditions for Setup
Necessary documents
For more information on this subject, please refer to the section on:
Information on the instructions
Special tools
69860296300 30/28
69860296400 40/38
Rolling tool
69860296500 52/50
69860296700 70/66
The foundation must have been produced in accordance with the foundation
plans produced by the manufacturer.
The product must be installed in a well ventilated frost-free room.
7053-9001-038
24 09-2012
Installing
Assembly of milking parlour frame
Attention!
Check the dimensions of the operator pit!
Required dimension: 1700 mm
Cross member
1% (1,5%)
7053-9001-038
09-2012 25
Installing
Installing the component support
Installation material
7053-3262-010 7053-3262-020
20
Assembly procedure
Centre of pit
16
16
7053-3262-020 7053-3262-010
7053-9001-038
26 09-2012
Installing
Installing the component support
Assembly dimensions
A B C D
D
Height of Dim Operator's Dimension,
cross-member ensi height component
on support
1226 1160
B
: :
3085 699 : Increment: 16 mm
: :
1980 406
C
Example:
A - B - C = D
Metatron Operator's height
3085 mm - - = 556 mm
(699 mm) (1830mm)
1.
2.
3. 4. 6. 8. ...
7053-2187-110
7053-9001-038
09-2012 27
Installing
Installing the support rail
Installation material
7053-3262-020
C
A
C
Assembly procedure
7053-9001-038
28 09-2012
Installing
Installing the support rail
7053-9001-038
09-2012 29
Installing
Installing the pipe support
Installation material
A
50,60,80 50,60,80 90,100,110,120
7053-9001-038
30 09-2012
Installing
Installing the pipe support
Assembly procedure
7053-3262-020
680 X X
X
EuroClass 800: 1600
EuroClass 850: 1700 7053-4650-030
30 7053-4650-010
7750-0113-564
7053-9001-038
09-2012 31
Installing
Installing the swing over arm and control unit
Installation material
60
90,100,110,120
130
150,160,170
220
7053-5586-010 7053-5586-020
7053-5586-030
Pos. Part No. Description
7053-5586-000 Swing over arm without cluster removal cylinder
7053-5586-010 Swing over arm with cluster removal cylinder
7053-5586-020 Swing over arm with cluster removal for BioMilker
7053-5586-030 Swing over arm with cluster removal (USA)
0060 7053-9902-070 Set of spare parts Pos. 60a-60c
060a Magnetic switch EasyStart No 3200
060b hose 5x1,5
0090 0019-1144-300 U-bolt M10-2 In
0100 0026-1348-300 Washer DIN 125 10,5
0110 0026-1337-300 Spring washer DIN 127 B10
0120 0013-0279-300 Hexagon Nut ISO 4032 M10
0130 7053-2467-010 Plate 60 5x32,2x62
0150 0013-0294-300 Hexagon Nut DIN 985 M6 with clamping piece
0160 0026-1382-300 Washer DIN 125 6,4
0170 0019-6109-300 Cylindrical head screw ISO 4762 M 6 x 65
0220 0018-3473-750 Reducing coupling
7053-9001-038
32 09-2012
Installing
Installing the swing over arm and control unit
7053-9001-038
09-2012 33
Installing
Installing the swing over arm and control unit
Assembly procedure
D Insert plates in swing-over arm 7053-2467-010
A
B
(C)
X 7053-5586- . . . 7053-2187-200
EuroClass 800: 800
EuroClass 850: 850
- Position component.
- Align with a spirit level.
- Tighten all nuts.
90
7053-9001-038
34 09-2012
Installing
Installing the swing over arm and control unit
- Screw on connectors.
D Fit bracket.
last milking place
20,30,40
Plug
0003-0645-800 7053-2187-190
D Fit plug.
1. 2. 3. 4.
170 150,160
0003-0645-800
7053-9001-038
09-2012 35
Installing
Installing the swing over arm and control unit
A
A
Metatron P21
For further information on the subject, see the
manual
7161-90 . . -062 Metatron P21 / S21
DemaTron / DeMax
Mount the control units as shown.
(installation position as on the right-hand side of the parlour)
7053-9001-038
36 09-2012
Installing
Installing the swing over arm and control unit
60a
270
210
60b
280
Note! Metatron
In SwingOver mode, the external start input (E1) on the
Metatron loses its standard function.
It is then only active in milking standby!
D Closing the housing
7053-9001-038
09-2012 37
Installing
Installing the cluster removal control valve (Metatron)
Installation material
Assembly procedure
D Fasten control valve.
50,60
D Connection
Vacuum
Removal cylinders
Fresh air
7053-9001-038
38 09-2012
Installing
Installation of cable duct
1 Electrical conduit
Installation material
EuroClass 800 / 850 2x4 2x5 2x6 2x7 2x8 2x9 2x10 2x12 2x13 2x14
Sub-assembly 7071 7072 7073 7076 7074 7079 7075 7077 7166 7167
EuroClass 800 / 850 2x15 2x16 2x18 2x20 2x22 2x24 2x25 2x28 2x30 2x32
Sub-assembly 7168 7169 7191 7193 7194 7195 7196 7197 7198 7199
Assembly procedure
50,60,70
7053-9001-038
09-2012 39
Installing
Installing the pipes
Note
If the pipes are installed with a 3A layout, continue with the section
specified:
Installing the pipes (3A layout - for USA only)
2 Vacuum line
4 Milk line
3 2 4 4
2
5.13.1 Installation of the vacuum line
Installation material
Vacuum line
Part No. Description
63 mm, PVC (2x4 - 2x9)
6960-0164-910 Tube 63x3
0018-1170-870 Sleeve 63
0018-2425-700 Rubber coupling
0018-1174-870 T-piece 63
0018-6434-870 Bend 90 (63)
0018-1181-870 Bend 45 (63)
0018-1467-880 Shut-off valve 63
7049-9889-010 test tee
7049-4650-000 Pipe support 63 - 190
90 mm, PVC (2x4 - 2x24)
7057-9901-090 Set of accessories 3in
6960-0164-910 Tube 90x4,3
0018-6542-870 Bend 90 (90x4,3)
0018-4810-700 Rubber coupling 88/100x150
7050-9889-010 test tee
7050-4650-000 Pipe support 90
110 mm, PVC (2x10 - 2x32)
7057-9901-080 Set of accessories 4in
6960-0164-110 Tube 110x5,3
0018-5809-880 Bend 90 (110x5,3)
0018-5808-880 Sleeve 110
0018-5810-880 Bend 45 (110x5,3)
7050-9889-030 test tee
7050-4650-030 Pipe support 110
Accessories for vacuum line
7047-1935-040 Drain valve, compl. 0.5
7059-1935-020 Drain valve, compl. 2"
0015-1016-010 Special adhesive Tangit, 1 kg
0015-1017-010 Cleaner Tangit, 1 l
7053-9001-038
40 09-2012
Installing
Installing the pipes
Material in Connections
Size of parlour 2x4 2x5 ... 2x30 2x32
7053-9001-038
09-2012 41
Installing
Installing the pipes
Assembly procedure
7053-9001-038
42 09-2012
Installing
Installing the pipes
Installation material
Air supply line, pulsators
Size of parlour 2x4 2x5 2x6 2x7 2x8 2x9 2x10 2x12 2x13 2x14
Size of parlour 2x15 2x16 2x18 2x20 2x22 2x24 2x25 2x28 2x30 2x32
7053-9001-038
09-2012 43
Installing
Installing the pipes
Assembly procedure
Attention!
Carefully remove chips and dirt from all lines!
D Fit angled hose connector.
D Connect hoses.
D Installation of the air filter
7053-9001-038
44 09-2012
Installing
Installing the pipes
4
5.13.3 Installing the milk line
Installation material
70 mm - SSt Size of parlour 2x10 2x12 2x13 2x14 2x15 2x16 2x18 2x20 2x22 2x24
Material in Connections
7053-9001-038
09-2012 45
Installing
Installing the pipes
Assembly procedure
6986-0296-030 52
69860296700 Rolling tool 70/66
4999-1001-203 3
A
C
40
30 70-90 10 60
A Cut pipe to length
Take account of the size of the milk collecting tank!
B Roll on pipe couplings.
C Fit inspection glass.
D Place milk line in the pipe support.
D Mount milk receiver tank.
D Screw down milk line (including tank) and push towards the wall (exit) until
the tank is next to it.
D Mark holes for fixing the milk transfer device.
7053-9001-038
46 09-2012
Installing
Installing the pipes
Y X
VisoFlow / LactoFlow: 100 EuroClass 800: 800
Messbehlter : 120 EuroClass 850: 850
X
32 Y
Schwenkarm
D For further stages of the work, remove and fasten the milk line!
Attention!
Carefully remove chips and dirt from all lines!
- Installation position:
Partno./logo must point to the left side of the milking parlour in the
driving direction.
Slope
7053-9001-038
09-2012 47
Installing
Installing the pipes
Installation material
Wash line
40 mm Size of parlour 2x4 2x5 2x6 2x7 2x8 2x9 2x10 2x12
50 mm Size of parlour 2x13 2x14 2x15 2x16 2x18 2x20 2x22 2x24
7053-9001-038
48 09-2012
Installing
Installing the pipes
Assembly procedure
Install the rinsing line and cluster receptacles as described in the installation
instructions.
Attention!
Note special installation dimensions!
X Example
EuroClass 800: 800
EuroClass 850: 850
200 X
Edge of pit
550
Wash line
Clawpiece
7053-9001-038
09-2012 49
Installing
Installing the pipes (3A layout - for USA only)
2 Vacuum line
4 Milk line
3 2 4 4
7053-9001-038
50 09-2012
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
09-2012 51
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
52 09-2012
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
09-2012 53
Installing
Installing the pipes (3A layout - for USA only)
2
5.14.2 Installation of the vacuum line
7053-9001-038
54 09-2012
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
09-2012 55
Installing
Installing the pipes (3A layout - for USA only)
4
5.14.3 Installing the milk line
7053-9001-038
56 09-2012
Installing
Installing the pipes (3A layout - for USA only)
(70XX-0850-820)
7053-9001-038
09-2012 57
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
58 09-2012
Installing
Installing the pipes (3A layout - for USA only)
7053-9001-038
09-2012 59
Installing
Instaling milk transfer unit
30a
20
30b
10
30
Milk receiver
Pos. Part No. Description
7038-2297-200 70 L (52) CL x
Milk trap, compl.
7038-2297-210 70 L (70) CL x
7038-2774-370 70 L (52) CL x
0010 Milk collector tank
7038-2774-380 70 L (70) CL x
0020 7038-9901-850 Set of accessories 70 L x x
0030 7009-4625-050 Pipe connector Ra 52/14 x x
0040 0018-2662-300 Hose clamp, compl. 14/25,5 x x
0050 7021-7103-090 Milk hose 14x5,75x950 x x
x Included in the component
7053-9001-038
60 09-2012
Installing
Instaling milk transfer unit
60
Set of accessories
Pos. Part No. Description
7038-9901-850 Set of accessories 70 L
0020 7038-2777-010 Plug 14
0030 0018-1678-700 Angle 90-B50-40
0040 0019-5311-050 Wood screw DIN 571 8x70
0050 0026-0439-300 Washer DIN 9021 8,4x24x2
0060 0026-2304-890 Rawl plug 10x50
0100 0024-6372-060 Name plate 60x180
0110 0018-3474-700 Reducing coupling 40-28
0120 7720-0023-193 Rubber coupling 40
0130 0018-5319-300 Hose Clamp DIN 3017 Al40-60
0170 0018-0076-300 Tube 40x1x183
0180 0018-6669-820 Angle connector 16
0190 7038-2777-020 Plug 53/15
0200 0018-5328-820 T-Hose connector 20/16
0210 7009-2809-000 Rubber bend 90
0230 7047-1935-010 Drain flapper elbow
0240 0018-0821-300 Tube 16x1x60
0250 7038-2457-010 Lid
0260 7009-2631-010 Profile ring 152/137x10
0270 0019-9350-030 Self-tapping screw DIN 7976 St6,3x19-C
0280 0026-1382-300 Washer DIN 125 6,4
0290 0024-5380-000 Plate DIN 40011 Ground 20
0300 7038-5606-040 Door leaf
0310 7038-9972-000 Drilling jig Papier
7053-9001-038
09-2012 61
Installing
Instaling milk transfer unit
Holder
Pos. Part No. Description
7015-2187-270 Bracket (wall mounting)
0010 7015-2155-020 Stand off bracket 1/2in
0020 0019-6900-300 Hexagon head bolt ISO 4017 M 8x12
0030 0019-5311-050 Wood screw DIN 571 8x70
0040 0026-1345-300 Washer DIN 125 8,4
0050 0026-2304-890 Rawl plug 10x50
7053-9001-038
62 09-2012
Installing
Instaling milk transfer unit
Milk pump
7038-9901- . . .
70 80
7053-9001-038
09-2012 63
Installing
Instaling milk transfer unit
Installation material
Milk transfer assy (2x25 - 2x32)
10
20
30
7053-9001-038
64 09-2012
Installing
Instaling milk transfer unit
7053-9001-038
09-2012 65
Installing
Installing standard components
Examples
Metatron / DemaTron 70 DeMax / DemaTron 60
10 20 40
20 30
Pos. Description
10 Measuring vessel, compl.
AutoPuls Apex M
20 Pulsator complete
StimoPuls Apex M
Milk flow monitor VisoFlow
30
Milk flow indicator LactoFlow
40 Control valve, compl. SwingOver
Pulstor installation
D Screw on pulsator
7053-9001-038
66 09-2012
Installing
Installing standard components
Slope
Part No.
Slope
7053-9001-038
09-2012 67
Installing
Installing optional components
Installation material
Pos. Part No. Description
A 7161-2503-110 Sampling device
0010 7161-2513-010 Sampler Psu
0020 7161-2084-230 Holder 20x73x113
0030 7036-2637-010 Short milk tube 8,5x3,75x320
0040 7021-7102-040 Milk hose 8,5x3,75x225
0140 0021-3134-700 Star knob 32/M6
0220 7161-2084-130 Tube holder
Assembly procedure
One-off installation of the hoses and sampler:
10
30 40
20
A A
D Fit the sampling device between the measuring vessel and the pipe
connection piece.
D Creating the tube connections.
7053-9001-038
68 09-2012
Installing
Installing optional components
C C
B
7053-9001-038
09-2012 69
Installing
Laying hoses/cables
Attention!
Lay the hoses and cables so that they cannot kink or get crushed!
Measure the lengths so that they do not exert any tension on the swing
over arm.
Attention!
Always bore holes in the cable duct for laying cables from underneath!
Attention!
In SwingOver installations only use long milk tubes that are made from
silicon! Otherwise they may exert negative twisting and lifting forces on
the udder.
From the milk meter / milk flow monitor to the swing over arm
Y-piece
Extended length: maximum 100 mm
7053-9001-038
70 09-2012
Installing
Laying hoses/cables
From the pulsator to the swing over arm / cluster removal cylinder
D The milk tube must not touch the edge of the pit when the cluster is applied!
Length: approx. 1300 mm (depending on the width of the pit).
7053-9001-038
09-2012 71
Installing
Information on disposing of installation material after installation is finished.
7053-9001-038
72 09-2012
Starting for the first time
Safety instructions for initial commissioning
Warning!
There is a risk of the head and hands being knocked or trapped when
the arm swings over.
D Incorrectly wired connections can destroy electrical/electronic components.
D Electrostatic processes/interference may endanger electronic components
and also lead to software faults and data loss. Back up data regularly
therefore.
Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.
7053-9001-038
09-2012 73
Starting for the first time
Settings in DPSetup
Metatron P21
(for equipment with Metatron P21 and electronic identification with DPNet gate
control)
1. 2.
3. 4.
5.
7053-9001-038
74 09-2012
Starting for the first time
Settings in DPSetup
DeMatron/DeMax
1. 2.
3. 4.
5.
7053-9001-038
09-2012 75
Starting for the first time
Handing over to the farmer
Attention!
The vacuum height depends upon the height at which the milking line
is installed!
(measured from the animals' standing surface).
D Determine the height of the milking line.
D Set the vacuum height.
7053-9001-038
76 09-2012
Operating
Safety instructions for operation
7 Operating
Operation is performed, for example, with the following milking control units:
D Metatron P21
D DeMax 55/DeMax 60/DemaTron60/DemaTron 70
Warning!
There is a risk of the head and hands being knocked or trapped when
the arm swings over.
D Danger from animals.
Before operating, make sure that you are adequately familiar with:
D The operating and control elements
D The equipment
D The method of operation
D The immediate surroundings
7053-9001-038
09-2012 77
Operating
Operating (Metatron P21)
Note
If Metatron is used as the control unit:
D SwingOver mode is only possible with
Metatron P21 (program version WMP
1.61 and above)!
D Operation is not possible with Metatron
S21, or Metatron S21 combined with
Metatron P21.
7053-9001-038
78 09-2012
Operating
Operating (Metatron P21)
The assignment of signal lamps, key and display functions on the control unit
to the left or right-hand side of the milking parlour is determined by the position
in which the control unit is installed.
Note
The assignment cannot be changed!
Key functions
Menu
"Animal information" 1 0
2 9
Call up information menu 2 9
3 8
Open "Information display" menu 3 8
4 7
Open "Animal-related
information
4 7 F1 F2
(hot keys active in the
information pages)
7053-9001-038
09-2012 79
Operating
Operating (Metatron P21)
"SwingOver" menu
The graphics menu shows the animal data for both sides of the milking parlour.
Setting in DPSetup under:
Device Management-> Parlor and Stall Setup-> Milking Control at Stalls-> Display
020/000/120 Graphics display = 3 (standard)
right-hand side
"SwingOver" graphics menu left-hand side active
active
Gate open
Gate closed
7053-9001-038
80 09-2012
Operating
Operating (Metatron P21)
7053-9001-038
09-2012 81
Operating
Operating (Metatron P21)
7.4.2 Operating
Drive in animals
Note
When driving in the animals, start with the milking parlour side that is
opposite the cluster receptacles. The first milking operation will then
be started automatically via the remote start.
Start milking
D "Start/Stop" key or
D Remote start
(swinging the arm over to the opposite milking place)
D When milking starts, the indicator light (yellow) flashes briefly on the active
side.
Side switch
D At the end of the end of milking time switch back to the side manually.
7053-9001-038
82 09-2012
Operating
Operating (Metatron P21)
Switch to rinse
D Press F1 (according to allocation).
7053-9001-038
09-2012 83
Operating
Operating (DemaTron 60 / DemaTron 70)
Drive in animals
Note
When driving in the animals, start with the milking parlour side that is
opposite the cluster receptacles.
The first milking operation will then be started automatically via the
remote start.
Start milking
D "Start/Stop" key or
D Remote start
(swinging the arm over to the opposite milking place)
D A flashing decimal point next to the animal ID or milk quantity shows which
side is active.
- left-hand side .105
- right-hand side 105.
Side switch
Restart
Restarting the milking process after an automatic change has been completed
D At the end of the end of milking time switch back to the side manually.
See "Change of side by place".
D Re-start the milking process START
STOP
7053-9001-038
84 09-2012
Operating
Operating (DemaTron 60 / DemaTron 70)
Display setting
D Press key (short) F i.
<0,5s
Switch to rinse
D
START
Press key STOP
The pre-set side is always active after readiness for milking has been
established.
Setting in DPSetup under:
Device Management-> Parlor and Stall Setup-> Milking Control at Stalls-> Milking 3->
040/000/155"
7053-9001-038
09-2012 85
Operating
Operating (DemaTron 60 / DemaTron 70)
Milk inspection
After the end of milking there is an automatic changeover to the other milking
parlour side and the milk quantity displayed disappears.
The "Milk inspection" function changes the sequence in the following way:
D Changing to the other milking parlour side is blocked.
D The milk quantity continues to be displayed.
D The control unit remains in end of milking mode
(end of milking time runs continuously)
Note
The setting is not lost after a RESET (power failure).
D Switch control unit to rinse.
START
STOP
LED
Call up menu
D Press keys at the same time (long). F F 1. (f
D Displayed: 1st parameter > 1s > 1s
Call up menu
D Press key (short) F I.(o
D Displayed: Milk quality checking (SwingOver) < 1s
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Operating
Operating (DemaTron 60 / DemaTron 70)
Other functions
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Operating faults
Troubleshooting possible faults
8 Operating faults
If necessary, please contact your nearest authorized technical dealer.
Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.
D There are special risks from direct contact with the animal (crushing, risk of
kicking or knocking).
D There is a risk of the head and hands being knocked or trapped when the
arm swings over.
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Maintenance
Safety instructions for maintenance
9 Maintenance
If necessary, please contact your nearest authorized technical dealer.
Before carrying out any maintenance work, make sure of the following:
D The area for the maintenance work and access to the working area should
be secured over a wide area and there should not be any unauthorized
people in the working area.
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Maintenance
Inspections and preventive maintenance
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Maintenance
Cleaning the sampler
190
70 20
70a
90
140
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Spare parts
System components
10 Shut-down
D Components which have not been set down correctly may fall off or twist.
D There is a risk of injury from open components / tools / .... with sharp edges.
D Suspended loads may Case, in which case there is a danger of death - do
not stand under suspended loads.
11 Spare parts
Note
See installation material indicated in the section on "Installation".
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Spare parts
Swing over arm
60
90,100,110,120
130
20
30,40
50,140
150,160,170
220
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Spare parts
Swing over arm
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Spare parts
Swing over arm
Piston, compl.
Pos. Part No. Description
7720-1100-470 Piston, compl. 69.9x91
0010 0019-6901-300 Hexagon head bolt ISO 4017 M 8 x 16
0020 0026-0439-300 Washer DIN 9021 8,4x24x2
0030 7720-1031-670 Disk 58x1.5x8.5
0040 7053-2213-010 X Cup sleeve 69.9x10x35
0050 7720-1478-250 Angle bracket 64x59x30x1
0060 7720-1290-240 Roller 60x66x8,2
DIN 985 M8 with clamping
0070 0013-0291-300 Hexagon Nut
part
X Wear part, see section on "Maintenance" for maintenance interval
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Spare parts
Cluster removal control valve (Metatron)
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Spare parts
Cluster removal control valve (Metatron)
Set of gaskets
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Spare parts
Milk flow monitor
11.4 Sampling
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Spare parts
Milk meter with accessories
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Spare parts
Milk transfer assy
11.7 Pulsators
Note
See installation material indicated in the section on "Installation".
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Appendix
Abbreviations
12 Appendix
12.1 Abbreviations
Term Explanation
Diameter
DM55 / DM60 DeMax 55 / DeMax 60
DT60 / DT70 DemaTron 60 / DemaTron 70
SSt Stainless steel
Pla plastic
Units
degrees (angles)
C Degrees Celsius
s Second
min Minute
(in) Inch (= 25.4 mm)
mm millimetres
cm centimeters
m metres
mm2 Square millimeter
mm3 Cubic millimetre
g Gram
kg Kilograms
kPa Kilopascal
kW Kilowatts
upm Revolutions per minute
A amp (current)
V volt (voltage)
ohm (resistance)
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Appendix
Abbreviations
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company with is one of the largest providers of innovative equipment
and process technologiy. GEA Group is listed in the STOXX Europe 600 Index.
7053-9001-038 09-2012 We reserve the right to modify the construction and design in all cases!