FULLFLOW PLUS MILK METER USER HANDBOOK

Transcription

1 FULLFLOW PLUS MILK METER USER HANDBOOK INTRODUCTION OPERATING PRINCIPLE INSTALLATION AUTOMATIC CLUSTER REMOVAL FULLFLOW PLUS TERMINAL POWERING UP TERMINAL KEYS DATA EXCHANGE WITH FUSION/AFIMILK SYSTEM PARLOUR CODES MESSAGES FROM THE PARLOUR SIGNALS FROM THE TERMINAL DURING MILKING SIGNALS FROM STAND ALONE METERS SIGNALS WITH FUSION/AFIMILK PROGRAM ERROR MESSAGES PROCEDURES FOR MILKING AND CLEANING PROCEDURES DURING SAMPLING USER MAINTENANCE AUGUST 1996 PAGE 1 OF 16

2 1. INTRODUCTION The Fullflow Plus Milk meter consists of: - Milk meter body, double chambered for yield and conductivity measurement. - Milk meter terminal, the user interface with key pad and display. - Sampling device, for collection of a representative milk sample for later analysis. Normally the system also includes equipment for Automatic Cluster Removal (ACR), the sensing system being already built into the electronics. The Fullflow Plus milk meter is a third generation meter developed based on experience with previous versions of the Fullflow Milk Meter. The following list gives an overview of all features of the Fullflow Plus. Items marked * were not available in previous models of milk meter: Fullflow Plus has following features when not connected to Fusion/Afimilk: + Milk yield measurement. + Milk conductivity measurement. + Actual and average milk flow measurement. + Milking duration measurement. + Self test to display milk meter errors. + Output for ACR. + Heating element to prevent moisture problems in the electronics. +* Gate control keys at every terminal to control cow entry and exit. + Adjustable times for: -* Initial time delay (time during which cluster will not be removed automatically) - Final time delay (time between last valve operation and cluster removal) -* Control of the milk meter valve during cleaning, to obtain maximum cleaning effect with minimum water. + Sampling device to take samples for milk analysis. If Fullflow Plus is connected to a PC and the Fusion/Afimilk system the following features are available in addition: -* Automatic display of cow number and parlour codes when a cow is identified before the cluster is attached to the cow. - Check of current yield and conductivity with the expected yield and conductivity. -* Display of agenda data: + Days after last heat + Days in lactation + Days after insemination + Pregnancy status + Calving date + Insemination date -* Display of feed data: + Daily allowance of four out of parlour feed types + In parlour feed allowance of the current milking. + Out of parlour feed uneaten -* Display of parlour codes To have all above mentioned items supported, an Afimilk version 6.00 or higher is necessary! AUGUST 1996 PAGE 2 OF 16

3 2. OPERATING PRINCIPLE The operating principle of the Fullflow Plus Milk Meter is based on the conductivity of milk. The following schematic drawing gives an overview of the milk flow and the operation of the meter. Fig 1 Milk Meter Body The measuring chamber holds exactly 0,2 kilogram of milk. From the cluster the milk flows into the milk chamber of the meter and from there into the measuring chamber. The measuring chamber is equipped with a double faced valve, which has two positions: 1. When down, the inlet from the milk chamber is open and the outlet from the measuring chamber is closed. 2. When up, the inlet is closed and the outlet is open. Three electrodes in the measuring chamber detect the amount of milk in the chamber. If the level reaches the longest electrode, the valve is lifted to position 2 until the milk level in the measuring chamber reaches the short electrode, then the valve reverts to position 1 and the measuring chamber is refilled. During the lifting and lowering of the valve, 0,2 kg of milk passes through the measuring chamber and is added to the total yield on the display of the Fullflow Plus terminal. During every pulse, the conductivity of the milk is also measured. The vacuum bypass ensures a constant vacuum supply to the milk chamber and also the cluster. A small air bleed just above the vacuum by pass is used to get a smooth and quick flow of milk from the Milk meter to the milk line. The sampling device is installed in the milk outlet tube on days when a samples for testing are needed. This device is only installed for milk sampling and is removed for normal milkings. 3. INSTALLATION Correct installation of the milk meter is essential for proper operation. The following items must not only be correct at installation but also during the working life of the meter. - The meter must be mounted exactly horizontal. - The milk tube from the meter must have a continuous fall to the milk line. If the tube runs slightly uphill the milk will exit the measuring chamber too slowly and the meter will malfunction: this is also very important when the sampling device is used. Badly fitted or undersized tube can also cause unstable vacuum in the meter and the cluster. - The air bleed of the meter (just above the vacuum bypass) and the air bleed in the claw must be kept open to ensure correct operation of the meter. This is particularly important when the sampling device is used. AUGUST 1996 PAGE 3 OF 16

4 4. AUTOMATIC CLUSTER REMOVAL The Fullflow Plus Milk meter measures milk flow from the frequency of valve operation. The measured milk flow is used to control the ACR system. The ACR output from the milk meter will drive a 12 volt DC solenoid rated at 0.5 amps. This output is activated if the time between two milk pulses from the measuring chamber exceeds a pre-set limit, this can be set by your service engineer. A typical value is between 25 and 35 seconds, this means that the cluster will be removed if the Milk meter does not detect a 0.2 kg pulse of milk within the set time. The initial time delay can also be set by the engineer. This controls the length of time from pressing the start button to the ACR being able to remove the cluster. We recommend that this is not altered from the normal setting of three minutes. If measured milk flow through the meter suddenly drops to zero, the meter will interpret this as the cluster falling or being kicked off. The meter will then react by flashing the display and beeping for 30 seconds to draw the milkers attention to that cow for examination and potential re-application of the cluster. 5. FULLFLOW PLUS TERMINAL There is one Fullflow Plus terminal for each milk meter body, which has a 4 digit display, a 23 key keypad, 3 signal LED (small lamps) and a beeper. Figure 2 shows the terminal and a description of the keys. 5.1 POWERING UP When power to the milk meter is switched on, the stall number of the terminal is shown on the terminal s display for several seconds. This is presented in the following format: Example: Fullflow Plus No. 5 displays: id05 After that the terminal goes into normal start up mode (which is the cleaning mode of the meter) and milk production (00.0) is shown on the display. AUGUST 1996 PAGE 4 OF 16

5 If the meter is connected to a Fusion/Afimilk system and the program is in milking mode the display will show blinking 0--0 to indicate communication to the computer system. After a cow is identified the cow number will appear on the display. If a cow has parlour codes, the cow number will be shown alternately with the codes on the display. The codes are always shown on the two outside digits of the display. When the cluster is attached to the cow the display will show the current milk production. After cluster removal the display will remain on milk production except for cows with parlour codes 7 and 8. In that case the display will show the production alternating with the codes. 5.2 TERMINAL KEYS The diagram below shows the terminal keys and their functions. The keys are listed in full and a description of their functions given on the following pages. AUGUST 1996 PAGE 5 OF 16

6 Note Keys with an * are only active when the Milk meter is connected to a Fusion/Afimilk system. Used to select the milking or cleaning mode of the meter. When first turned on the meter starts in the cleaning mode, to enter milking mode the key should be pressed once. After completing the milking, this key should be pressed again to set the meter in cleaning mode, In cleaning mode the meter will operate the valve in the measuring chamber from a timer to give the optimum flow of water for cleaning. These times are adjustable by your service engineer and will be set when the meters are installed. The cleaning LED above the key is lit when the meter is in cleaning mode. I 7 I I 7 1 I A 1 Stand alone operation (without link to PC): Starts milking, when pressed the cluster is lowered for attachment the cow, the ACR initial time delay is started and the display is set to If, because of a kick off, the cluster has to be re-applied, start key must be pressed twice; this will retain the yield to kick off and add additional milk to the total after re-application. * Fusion/Afimilk operation (with link to PC): Releases the cluster for attachment to the cow. The display does not react on the Start key in this mode, but is reset by the gate switch. If a cow is not identified or if the cow has a parlour code, the key has to be pressed twice to release the cluster. This is to draw the milkers attention to the fact that the cow is not identified and that the cow number has to be entered to ensure correct records or to cows that have parlour codes and may need special treatment before attaching the cluster. Removes the cluster immediately, over riding the ACR settings. Turns the ACR function off. To milk a small proportion of cows correctly it is necessary for the milker to control take off point, this key is used for this purpose. Freshly calved or very slow milking cows may need this feature. The ACR LED (just above the key) will light up if the ACR is turned off. * Shows or manually enters cow number. If a cow is not identified, the display shows a blinking 0--0 The cow can be manually identified by entering the cow number with the numeric keys following by this key. When the Afimilk system accepts the cow number it appears on the display and the cow can be milked. If an incorrect cow number is entered it can be corrected at any time up to the operation of the exit gate. Entering the correct number deletes the original entry. AUGUST 1996 PAGE 6 OF 15

7 Note Cow numbers must be entered with a minimum of two digits, example; cow number 2 must be entered as 02 etc. When this key is pressed the highest conductivity measured during milking the current cow is shown on the display. (The units of measurement are mmho) * If both keys are pressed at the same time then the alarm level for conductivity of the current cow will be shown on the display. This conductivity level is based on a number of previous milkings of this cow, so this parameter will not be available in the first five milkings of the system or of cows at the start of a lactation. This alarm level is calculated by the Afimilk software and is the average conductivity minus the pre-set alarm level. If both keys are pressed at the same time the group number of the cow will be displayed on the terminal When pressed at the same time the lowest conductivity measured for this cow will be displayed (in mmho). * Shows the minimum expected yield of the cow. This expected yield is based on an average of five previous milkings, so will not be shown in the first five milkings of the system or of cows at the start of a lactation. This alarm level is calculated from the average yield minus pre-set alarm level in the software. Shows the current milk flow rate in kg per minute measured over the last three valve operations of the meter. Pressing both keys at the same time shows the length of time the cluster has been attached to the cow. The display is MM.SS, where MM is minutes and SS is seconds. Pressing both keys displays the average milk flow rate in kg per minute. This is calculated from the current yield divided by the cluster on time. * Pressing both keys displays any parlour code or message which has been entered or deleted during this milking. (Also see chapter 6.1). AUGUST 1996 PAGE 7 OF 15

8 1 or 2 or 3 or 4 * If connected to a Fusion system with out of parlour feeding, these key combinations display the feed allowances of the cows in the format AKK.k, where: A = type of feed (A,B,C or D) KK = kilogram of feed k = ),1 kilogram of feed (rounded downwards) 1 or 2 or 3 or 4 * If connected to a Fusion system with out of parlour feeding, these key combinations display the feed uneaten since the last reset time in the same format as above * If Fusion system with in parlour feeding, displays the in parlour feed allowance of the cow for this milking in the same format as mentioned above. * Displays the number of days since the cow was in heat last. * Displays the number of days since the cow calved (lactation days). * Displays the number of days since the cow was inseminated last. If the cow has a code 'P' in Afimilk (pregnant) then the first digit of the display will show 'P'. * Displays the calving date in the format DD.MM, where: DD = days and MM = months. AUGUST 1996 PAGE 8 OF 16

9 5 * Displays the last insemination date in the same format as for the previous item. * When held in, all the existing parlour codes of the cow will be displayed sequentially. This key can also be used to enter one parlour code or message from the parlour. Refer to the Chapter 6 'Exchange of data'. If Fullflow Plus is connected to a gate controller, gates can be operated remotely from individual terminal boxes. This key controls the entrance gate to the side of the parlour in a Herringbone or to the stall in case of a tandem parlour. Press once to open and press again to close. Controls the exit gate from the side of the parlour or the stall in case of a tandem parlour. Press once to open and press again to close. If the Fullflow Plus is connected to an auto-tandem parlour, then this key can be used to open the entrance flapper doors for that side of the parlour. If the Fullflow Plus is connected to an auto-tandem parlour, this key can be used to manually block the exit gate of the stall. AUGUST 1996 PAGE 9 OF 16

10 6. DATA EXCHANGE WITH FUSION/AFIMILK SYSTEM If the Fullflow Plus is connected to a Fusion/Afimilk system then a large number of data items are sent from the Afimilk program to the terminal when the cow is identified; this may be either manually or automatically. Cow data sent from the Fusion/Afimilk program to the terminal: General data: Agenda data: Feed data: - cow number, - expected yield, - expected conductivity, - group number, - parlour codes. - days since last heat, - days in lactation, - days after last insemination, - pregnancy status, - calving date, - insemination date. - daily allowance of up to four out of parlour feed types A,B,C&D. - in parlour feed allowance per milking, - feed uneaten of out of parlour feed types A,B C&D. TO HAVE ACCESS TO ALL ABOVE MENTIONED ITEMS SUPPORTED, AN AFIMILK VERSION 6.00 OR HIGHER IS NECESSARY! AVERAGES FOR COMPARISON WITH PERFORMANCE AT THE CURRENT MILKING ARE BUILT UP OVER FIVE DAYS AS AVERAGES FOR THE MORNING, NOON AND EVENING MILKINGS. NEW COWS OR COWS THAT HAVE JUST CALVED WILL NOT HAVE THIS FEATURE FOR YIELD AND CONDUCTIVITY UNTIL THE AVERAGES HAVE BEEN COMPILED. When the exit gate of the parlour (or the stall for tandem parlours) is opened the data gathered during the milking is sent from the terminal to the Fusion/Afimilk system. This consists of : - milk production at this milking, - conductivity of the milk at this milking, - parlour code or message from the parlour entered or deleted during milking, - time the cow left the parlour. AUGUST 1996 PAGE 10 OF 16

11 6.1 PARLOUR CODES Parlour codes are one digit codes from 1 to 8 which are stored in the PC database and which are displayed on the Fullflow Plus terminal to draw the milkers attention to individual cows where special treatment is necessary (eg separation of milk, antibiotics, colostrum, three teated cows, etc). These codes can be added to or deleted from the database using the keypad of the terminal during milking: + To add a parlour code to the database press "000X" on the numeric keypad (where "X" is the code to be sent) followed by the "health" key. Example, to enter parlour code 8 press: "0", "0", "0", "8", " health" - To delete a parlour code from the database press "00XX" on the numeric keypad (where "X", the code to be deleted, is repeated) followed by the "health" key. Example, to delete parlour code 8 press: "0", "0", "8", "8", "health" Parlour codes entered during milking will show at the next milking if not deleted on the PC program itself. 6.2 MESSAGES FROM THE PARLOUR Messages from the parlour are two digit codes which can be sent from the terminal to the Fusion/Afimilk program. These messages will only be listed in the Afimilk software and will not be shown at the terminal at the following milking. These messages can be used by a milker to inform the farm manager or himself of agreed messages (eg cow needs a certain treatment, cow is on heat, cow is ill, etc). The two digit code can be any number from 12 up to 98 except 11, 22, 33, 44, 55, 66, 77, and 88. The list of double digits is used by the system to delete parlour codes, see previous chapter. To send a message from the parlour press "00YX" on the numeric keypad followed by the "health" key. Example, to enter message number 12 press: "0", "0", "1", "2", "health" CODES OR MESSAGES FOR A COW CAN ONLY BE ENTERED ON THE TERMINAL AFTER IDENTIFICATION AND BEFORE THE EXIT PROCEDURE FOR STALL IN ACTIVATED. ONLY ONE CODE CAN BE ENTERED OR DELETED PER COW AT A MILKING. SOFTWARE MUST BE SUITABLE FOR CODE TRANSFER. IF THIS TYPE OF MILK METER IS SET TO "3" IN THE AFIMILK SOFTWARE, THEN CODES MUST BE ENTERED WITH THE "CONDUCTIVITY" KEY INSTEAD OF THE "HEALTH" KEY. AUGUST 1996 PAGE 11 OF 16

12 7. SIGNALS FROM THE TERMINAL DURING MILKING The terminal is able to give the following signals during milking by using its beeper, display and LEDs. 7.1 SIGNALS FROM STAND ALONE METERS The three LEDs indicate the status of the milk meter: Cleaning LED: Lit if the milk meter is in the cleaning mode. The valve in the measuring chamber is pulsed at pre-set intervals to give the best flow of cleaning solution. ACR LED : Lit if the automatic cluster removal system of the milk meter is inactivated. The cluster will only be removed if the milker uses the manual removal key. Fault LED: Lit if the milk meter self-diagnoses a fault in the electronics system. This Fault LED can be switched off by: - Pressing the "Start" button or - Pressing the numeric keys "1","2" and "3" at the same time or - Removing the fuse at the back of the terminal for more then 12 seconds or - Switching off the power supply to all terminals for a minimum of 15 seconds. Refer also to the section on 'Error messages'. IF THE FAULT LED LIGHTS UP FREQUENTLY, PLEASE CONSULT YOUR DEALER TO HAVE THE PROBLEM INVESTIGATED AND RESOLVED. Kick off: The terminal will give a beep signal if the milk flow suddenly drops to zero, for instance when the cluster is kicked off by the cow. 7.2 SIGNALS WITH FUSION/AFIMILK PROGRAM Conductivity too high: If the milk conductivity is higher then the pre-set value in the Afimilk software, the terminal will give a beep signal. Milk yield too low: If the milk quantity is less than the value in the Afimilk software, the terminal will give a beep signal and the display will show a blinking milk yield. Conductivity too high and milk yield too low: If the milk has both elevated conductivity and reduced milk yield compared with the pre-set values in the Afimilk software, the terminal will give a beep signal and the display will show blinking "9--9". THE ABOVE MENTIONED SIGNALS FOR MILK YIELD OR CONDUCTIVITY ARE NOT GIVEN IF A CLUSTER IS REMOVED MANUALLY FROM THE COW. Cow with code 1, 2, 3or 4: After the cow is identified, these codes will appear alternately AUGUST 1996 PAGE 12 OF 16

13 with cow number on the display. For instance code 3 will appear as "3--3". Cow with code 5 or 6: After identification these codes will appear alternately with cow number on the display and the beeper will sound for 30 seconds. This signal is to draw the attention of the milker to the cow for checking,(eg checking the fore milk, etc). Cow with code 7 or 8: After identification these codes will appear blinking and alternately with cow number on the display and the beeper will sound for 30 seconds. After cluster removal the codes 7 or 8 will appear again on the display to draw the attention of the milker to the cow for treatment after milking. This could be removal of the milk separator or udder treatment, etc. THE BEEPER CAN BE STOPPED BY PRESSING THE "START" BUTTON ONCE. 7.3 ERROR MESSAGES When the Fault LED lights, the self-checker has detected an error. Usually this will be accompanied by one of the following error messages on the display: ERROR MESSAGE E01 The "E01" error message indicates an overload (short circuit) in one of the milk meter outputs. If an error of this type occurs, the "E01" message alternates on the display with an output number message, to show which output is at fault. This message appears in the following format: out x (Where x stands for the output number). IF THIS MESSAGE APPEARS, RECORD THE CODES AND CONTACT YOUR DEALER FOR SERVICE. IT MAY BE POSSIBLE TO CANCEL THE FAULT BY PRESSING KEYS 1, 2 AND 3 AT THE SAME TIME (DO NOT REPEATEDLY OVERRIDE THE PROTECTION OR DAMAGE MAY BE CAUSED). THE FAULT SHOULD BE REPORTED TO YOUR DEALER AND RECTIFIED AS SOON AS POSSIBLE ERROR MESSAGE E02 This error message indicates that valve protection has been activated. This means that the valve in the measuring chamber was powered up for too long. This fault can be caused by a blocked air bleed in the milk meter body or cluster. This message can also appear if the outlet tube is running uphill from the milk meter outlet to the milk line. Try cleaning the air bleeds or checking the tubes connected to the outlet of the meter. If the fault persists call your dealer ERROR MESSAGE E03 This error message indicates a communication fault between the terminal and the computer. Call your dealer to solve the problem. AUGUST 1996 PAGE 13 OF 16

14 8. PROCEDURES FOR MILKING AND CLEANING Before milking: 1. Remove cluster from jetters. 2. Switch on the power supply of the complete system including Milk meters. 3. Attach the cluster to ACR ropes. 4. Press the "Cleaning" key to set the terminal in the milking mode and press the "Manual Cluster Removal" key to pull up the cluster. After milking but before circulation cleaning: 1. Clean the outside of clusters. 2. Disconnect clusters from the ACR ropes and put on the jetters. 3. Press the "Start" button to open the ACR diaphragm valve. 4. Press the "Cleaning" button. MAKE SURE THAT THE SYSTEM IS KEPT UNDER VACUUM UNTIL THE FIRST PHASE OF CLEANING HAS TAKEN PLACE. IF THIS IS NOT DONE THEN MILK MAY CREEP UNDER GASKETS WHEN THE VACUUM IS SWITCHED OFF. THIS MILK WILL NOT BE REMOVED DURING CLEANING BECAUSE WHEN VACUUM IS RE-APPLIED GASKETS ARE CLAMPED IN POSITION BY ATMOSPHERIC PRESSURE. THESE MILK RESIDUES CAN CAUSE PROBLEMS WITH MILK QUALITY IF LEFT IN THE METER. During cleaning:! As well as washing the measuring chamber, cleaning solution must also completely fill the milk chamber and overflow down the bypass to wash the meter correctly. In order to fill up the milk chamber of the meter quickly and ensure the overflow, the operation of the valve can be adjusted by your dealer.! The milk meter relies on accurate measurement of conductivity for all it s functions and any deposits on the electrodes will affect them. To prevent the build up of milk stone, the system must be regularly rinsed out with milk stone remover. The frequency of this rinse will depend on the hardness of the water but must be at least once a week. Dirty electrodes will cause deviations in milk yield and conductivity measurement, usually resulting in reduced yields and conductivity levels being recorded. The build up of dirt can be caused by: - insufficient cleaning water or detergent, - reduced water temperature during the main wash, - poor quality or out of date detergent, - build up of milk stone, particularly in areas with hard water, - build up of protein film where the washing system uses heat disinfection. If necessary the electrodes can be cleaned with a plastic Scotchbright scourer. The use of steel wool to clean any part of the meter will cause permanent damage AUGUST 1996 PAGE 14 OF 16

15 9. PROCEDURES DURING SAMPLING The Fullflow Plus Milk meter comes complete with an approved sampling device. This is only fitted to the meter when samples are to be taken. In order to get accurate samples the following procedure must be followed. Before milking:! Clean the air bleeds in the claw and the milk meter body (the air bleed is just above the bypass and is a 1mm. hole, take care not to enlarge it).! Fully drain the meters before starting milking, failure to do this may cause the first samples to be diluted.! Replace the small connecting pipe from the milk meter outlet with the sampling device ensuring that: - the arrows on the sampling device body and lid are both pointing in the milk flow direction. - the sampling device is horizontal and the bottle vertical. During milking: 1. Wait for 30 seconds after the cluster is removed for any final pulse of milk from condensed froth. Remove the sampling bottle. 2. Replace with a clean bottle. 3. Before sub-sampling the milk in the bottle must be thoroughly mixed. After milking:! Remove the sampling devices and bottles and install the small connecting pipes again.! Clean the milking machine as usual.! The sampling devices and bottles should be cleaned by hand in warm water and detergent. After washing rinse the sampling equipment with clean water to remove all detergent residues, then drain.! Store sampling equipment in a clean, dry place. AUGUST 1996 PAGE 15 OF 16

16 10. USER MAINTENANCE To prevent problems and ensure the best operation the following routine should be carried out by the user : " Check on a regular basis whether all meters are cleaning properly. If not have this corrected by your dealer. " Wash the machine with milk stone remover at least once a week to prevent deposits. This may need to be done more frequently in hard water areas. " To manually clean the electrodes, the electrode housing is removed by undoing the two plastic clips and the electrodes are then cleaned carefully, to prevent damage to the stainless steel, using a plastic scourer. This procedure should only be necessary if there has been a failure in the wash cycle. When reassembling care must be taken to avoid trapping the valve. Either reassemble with the meter body inverted so the valve is against the fixed seat in the meter body when the electrode housing is clipped into position or switch the meter into wash mode and only clip the electrode housing in place when the valve is lifted. " The terminal of the milk meter must only be cleaned with a damp cloth. " Clean the air bleed in the meter and in the claw regularly. If these are blocked they can cause failures of the meter. NEVER USE A HOSE TO CLEAN THE MILK METER OR TERMINAL! " The material of the terminal and the milk meter body can be affected by some types of insecticides and defatting fluids. Take care that these chemicals are not used on milk meter equipment. AUGUST 1996 PAGE 16 OF 16