AIC WAIKATO Expresso 72560 User manual
Expresso Tie Stall
1 © 2012 Agricultural Instruments Corporation
Expresso Tie Stall
2 © 2012 Agricultural Instruments Corporation
Introduction…………………….…………………………………………………………………………………..3
Technical Specifications …………………………………..…………………………………………………4
Power Supply Specifications…………………………………………………………………………………….5
Power Supply Installation……………...…………………………………………………………………………6
Hardware Installation……………………………………………………………………………………………..8
Power Supply and Stall Cock Wiring……………………………………………………………………………9
Expresso Tie Stall Control Layout…….………………………………………………………………………10
Internal and External Wire Connections……………………………………………………………………....11
External Wire Schematic………………………………………………………………………………………..12
Milking Support Cable System………………………………………………………………………………....13
Break away Clip and Spring Clip……………………………………………………………………………....14
Hose Hook up…………………………………………………………………………………………………....15
Detacher Set up and Switch Operation……………………………………………………………………….16
Switch Operation………………………………………………………………………………………………...17
Control Set up…………………………………………………………………………………………………....19
Setup Definitions………………………………………………………………………………………………...26
Milking Display Screen Layout………………………………………………………………………………....34
Expresso Switch Pad Layout…………………………………………………………………………………..35
Switch and Light Operation…………………………………………………………………………………….36
Startup Procedures……………………………………………………………………………………………...37
Milking with the 72560…………………………………………………………………………………………..38
Milking Data……………………………………………………………………………………………………...39
Download Data…………………………………………………………………………………………………..42
Control Enclosure Assembly…………………………………………………………………………………...43
Maintenance……………………………………………………………………………………………………..43
Diaphragm Pulsator Maintenance……………………………………………………………………………..46
Pulsator Specifications and Servicing…………………………………………………………………………48
Trouble Shooting………………………………………………………………………………………………...50
Electronics Control PC Board Removal and Replacement/MLSO Valve Replacement...……………….52
MLSO Valve Assembly Diaphragm Removal and Replacement…………………………………………..53
Motor Housing…………………………………………………………………………………………………...54
Jog Switch Replacement……………………………………………………………………………………….57
User Settings…………………………………………………………………………………………………….58
Warranty……………………………………………………………………………………………………….....66
Spare Parts
Electronics/Misc……………………………………………………………………………………..…..68
Power Supply…………………………………………………………………………………………....70
Flow Cell (F/C) & Milk Line Shut off (MLSO)……………………………………………………...….71
Hangers, Side and Claw Hooks………………………………………………………………………..72
Pulsator…………………………………………………………………………………………………..73
Stall Cooks……………………………………………………………………………………………....74
Fast Connect…………………………………………………………………………………………….75
Table Of Contents
Expresso Tie Stall
3 © 2012 Agricultural Instruments Corporation
AIC Waikato LLC (AIC) would like to thank you for
purchasing your new Tie Stall Detacher™ and
accessories. The instrument you purchased will be
valuable dairy herd management tool for years to
come
The Expresso Tie Stall Detacher™ hands-off dairy
management system networks with AIC’s “Smart
Sensing” milk meters. With the Expresso Detacher
system is not necessary to learn and maintain
computer software and equipment requiring large
amounts of time and expense. The data is collected
and compiled automatically and is available instantly at
the press of a button
This manual lists the technical specifications and is a
guide for installation, operation and service of the
equipment.
It is essential that all instructions in this manual be
followed as prescribe to achieve the full benefits of the
product as they were designed.
We would also like to point out that failure to follow the
instructions could result in unsafe conditions for the
operator, livestock and equipment.
Rev: 4/2017
Expresso Tie Stall
4 © 2012 Agricultural Instruments Corporation
Technical Specifications
Impact-resistant Polysulfone with scratch-resistant Lexan™ front label.
Size 4.5” x 6.5” x 2.0”, Weight less than 16 ounces (454 grams).
Approved P-1700 Polysulfone materials and 304 stainless steel sensing probes.
Shape is a modified elbow, approximately 3” x 2.5” suitable for use with all 5/8” ID milk
hose.
• Fly Sprays (petroleum or hydrocarbon based)
• “Super” glues (cyanoacrylates)
• Gasoline, turpentine, brake fluids and ethers
• Réfrigérants (R-12, R-22, R134a, etc.)
• Loctite and similar adhesive compounds
• Phenols
• Alcohol, ethanol and isopropanol
24 Volts DC +/- 10% continuous power with (NO AC). A fully running detacher consumes 36 watts
of power (1.5 Amps). To calculate the power requirements take the number of units X the number of
watts or amps required per unit. Then add 3 amps for a safety factor.
Power Conversion: P = power (watts), I = current (amps), V = (volts)
Amps (I) = watts (P) divided by volts (V)
Volts (V) = watts (P) divided by amps (I)
Watts (P) = amps (I) x volts (V)
Disclaimer
NOTICE
Expresso Tie Stall
5 © 2012 Agricultural Instruments Corporation
10%
-
’
When selecting a power supply there may be several alternatives available. A dedicated power
supply is recommended. When connecting to the power supply follow the step by step procedures.
When finding a location to mount the power supply, attention should be given to minimize
the length of the wires connected to the output circuit.
A qualified electrician should install the power supply according to local and national codes.
The power supply should be connected to the incoming power source with a dedicated 240
or 120 VAC circuit.
Locate the output terminals on the power supply.
In tie stall installations, the output power wires will be hooked to the stall cocks.
On 10amp or lower circuits, it is recommended to use no smaller than 14 gauge stranded
wire from the power supply to the stall cocks and the 14 gauge wire looped back to the
power supply. On 10-20amp circuits it is recommended to use no smaller than 12 gauge
stranded wire and the 12 gauge wire looped back to the power supply.
Power Supply Specifications
Expresso Tie Stall
6 © 2012 Agricultural Instruments Corporation
1. When wiring the output circuits in the barn,
be sure to follow the local electric codes.
Many times the codes differ from region to
region.
2. All 24 VDC output circuits must be looped
meaning the positive and negative output
wires must be connected to the power
supply, service the barn and return to the
power supply.
3. Always use stranded wire.
4. The voltage drop at any stall cock most nor
exceed 10% or approximately 2.5 volts when
all units are operating at the most distant
positions.
5. The wire gauge (diameter) is determined by
the total length of the wire and the number of
units it will service.
1. Be sure all wiring connections are in
excellent condition.
2. Use ring terminals to connect the output
wires to the power supply. Crimp and solder
the wire to the ring terminal.
3. Be sure the stall cock connections are in
excellent condition.
4. Do not exceed recommended wire lengths
Wire Gauge
Size Max # of Detacher Max Wire
Length
12 g 11 182 ft.
12 g 8273 ft.
12 g 6364 ft.
NOTICE
POWER SUPPLY MAX TOTAL NUMBER
OF UNITS
Power Supply Installation
--
Expresso Tie Stall
7 © 2012 Agricultural Instruments Corporation
Power Supply Installation
Expresso Tie Stall
8 © 2012 Agricultural Instruments Corporation
’
1. In all cases the power supply should be
located in clean dry environment.
2. Find a clean dry environment in the utility
room where the power supply can plug into
the near by a 120 VDC outlet.
3. Decide where the power supplies will be
located and mount it to a wall where it can
securely fixed.
After the power supply is securely fastened it is
time to wire in the 12 gauge multi-strand 24 VDC
output wire(s).
There are two breakers internally located in the
power supply. Identify the breakers and proceed
wiring in the 24 VDC circuit.
Disclaimer
Hardware Installation
7 Amp 120 VAC
incoming power
breaker.
20 Amp 24 VDC
output power
breaker.
+ 24 VDC- 24 VDC
Expresso Tie Stall
9 © 2012 Agricultural Instruments Corporation
’
-
Expresso Tie Stall
10 © 2012 Agricultural Instruments Corporation
After installation is complete verify there is adequate voltage at the furthest distance from the power
supply by installing and powering the detachers then checking the voltage. The voltage should be
within the specified operating range.
When milking is occurring verify that the current is the same on both output legs of the power
supply. You'll need a clamp meter capable of DC AMPS to do this measurement. This assures there
is no break in the output loop.
Be sure that all work is performed in accordance with local electrical codes and that all connections
and cable ends are sealed against water intrusion.
-
The stall cock adaptor is used to bring power and vacuum to the Expresso Detacher. Select the stall
cock that best works for you. Be sure there is sufficient power and vacuum to the unit.
From the stall cock adaptor, a dual hose carries the power wire and vacuum to the unit. When
connecting the power and vacuum to the Expresso Detacher follow the step by step procedures.
Locate the stall cock adaptors that will be used.
Hook the vacuum hose to the nipple on the mounting base of the pulsator.
Hook up power using the power cable supplied. Note: The power is polarity specific
therefore, the BLUE wire must be hooked to common—and the BROWN is power +. If
polarity is reversed a red light will come on, in the right hand corner of the Expresso PCB.
- Manual
- Hold for 4 seconds to
enable wash mode
- Attach/Detach
Milking, SCC and
Temperature Warning
(Yellow Light)
Backlit LCD
Graphic Display
End of Milking
Indicator (Red lights)
Control Layout
Expresso Tie Stall
11 © 2012 Agricultural Instruments Corporation
1. To Pulsator Front
2. To Pulsator Rear
3.
4. To Pulsator GRD
5. To ML Shut Off
6. To ML Shut Off
7. To Motor
8. To Motor
9. Not Used
When the Expresso (MS34) PC board is 24VDC output (when used to power a 24
VDC pulsator or 24 VDC shifting valves), the output is the same as the
peak input voltage. The input voltage must be adjusted to supply the
proper voltage for the valve coils used.
NOTICE
Internal and External Wire Connections
1. To Flow Cell
2. To Flow Cell
3. To Flow Cell
4. To Flow Cell
5. To 24VDC -
6. To 24VDC +
1.
2.
3. to Jog Switch
4. Jog Switch
1. Not Used
2. Not Used
3. Not Used
Expresso Tie Stall
12 © 2012 Agricultural Instruments Corporation
External Wire Schematic
BLACK
BROWN BROWN
N/C BLACK
BLUE ORANGE
BLACK YELLOW
BLACK
GREEN
WHITE
N/C WHITE
BLACK
GREEN
SHIELD RED
BLUE BROWN ( + )
WHITE BLUE ( - )
Output to Motor
Harness
To Flow Cell/
Sensor
Output to Milk Line
SO Valve
Output to Pulsator
Remote Switch
Connection
Not Used
Not Used
Power In
Expresso Tie Stall
13 © 2012 Agricultural Instruments Corporation
The 72560™ has a hook on the top to hang the detacher during milking. For proper milking unit
positioning and retraction location, the detacher needs to be positioned beside the cow approxi-
mately six inches behind the cow’s front shoulder (See the following illustration). If the detacher is
hung from the pipeline or structure toward the head of the cow, the detacher rope may not be long
enough and/or the claw may hit the floor during retraction.
• Typically, ¼” galvanized cable is used for handing the detacher units during milking time. The
cable can usually be anchored to a wall at each end of the facility.
• The cable should be high enough to allow the user to view the control over the backs of the
cows.
• The detacher should be positioned properly with respect to the udder in order to
provide good retract motion.
• The cable will need additional supports over the length of type of support is
recommended between each stall cock. Putting the support between stall cocks will reduce
the interference of the supports during milking time.
Try to avoid crossing walkways with the cable if the cable will be low enough to Interfere with safe
passage. If this situation can’t be avoided hand a flag, or other signal to mark the cable location.
The steel cable and related hardware must be supplied locally. Be sure that the cable does not in-
terfere with cow trainers. To avoid damage to the detacher control electronics, Cow
Trainers MUST Be OFF during milking
Installing a Steel Cable to Hang the 72560™ for Milking
Milking Support Cable System
Steel Cable
48in (1219cm)
80in - 85in
(2032cm—21596cm)
Expresso Tie Stall
14 © 2012 Agricultural Instruments Corporation
The break-away clip helps to protect the detacher if a cow gets her foot caught on the milking unit
or rope by releasing and separating the claw from the detacher.
1. Attach the break-away clip to the spring snap.
2. Tie the detacher rope to the break-away clip.
3. The spring snap clips to the loop on top of the claw.
The distance from the very end of the rope to the beginning of the ball is a recommended 15 inch-
es.
Break Away Clip & Spring Clip
90050164 - SS Break-A-Way-Clip
90050165 - SS Milk Unit Spring Clip
Expresso Tie Stall
15 © 2012 Agricultural Instruments Corporation
Pulsator Vac. Supply Hose
from Stall Cock Connector
Milk Hose Inlet from Milking
Unit/Claw to 70026 Flow
Cell Sensor
Milk Hose Exit to Pipe Line
Hose guide: Round Hole for milk
hose to Claw, oval hole for
pulsation hose to Claw
Hose Hook-Up
Expresso Tie Stall
16 © 2012 Agricultural Instruments Corporation
Detacher Set up & Switch Operation
There is a key pad in the decal of the front cover of the EXPRESSO. The key pad has switches
numbered 0-9, two large operating switches pictorially labeled with a hand by the left (manual/wash)
switch and an udder w/milker unit by the right (attach/detach) switch and three actuator switches
labeled with a check mark, X and gear/browser icon.
—The milk and manual switches are used during normal milking. To start milking
press the milk switch. If user detach is desired press the milk switch again. To override automatic
detach press the manual switch. The red lights will flash to remind the operator the detacher is in the
manual milking mode.
—If the detacher detaches prematurely and it is desired to “continue” the milking record for
the same cow, press the manual switch then the milk switch, attach the milking unit and the milking
record will continue from where it left off.
—To enter the wash mode press and hold the manual/wash switch for 3 seconds.
NUMERIC SWITCHES
1-0 = ARE USED TO
ADD COW
NUMBERS,CHANGE
GROUPS, SORT AND
NAVEGATE
ATTACH/DETACH
(Milk Switch)
MANUAL/WASH
ACCEPT
SWITCH = CHECK
MARK
BROWSER SWITCH
DELETE SWITCH =
Expresso Tie Stall
17 © 2012 Agricultural Instruments Corporation
Browser Switch:
AFTER THE BROWSER SWITCH IS PRESSED — DISPLAYED ON THE SCREEN
1. REVIEW DATA
2. CHANGE SETTINGS
3. WRITE TO DATA CARD
4. ERASE MEMORY
5. RESET MAINTENANCE
6. DISPLAY COM STATUS
7. EXERCISE OUTPUTS
8. INITIALIZE WIRELESS
After pressing the Browser/Gear Switch the Numeric Switches are used to navigate through all the
menu offerings listed below. The bottom of the Expresso Screen provides an index for each switch-
es function.
The only time the numeric switches are used, during milking is when ID is selected as YES in the set
up, then when the milk switch is pressed the Expresso will ask for a 4 digit cow ID number. Enter
the number and press the Check Switch to save.
The only time this switch is used is after a cow number has been entered. (Enter the Cow Number
and press the Accept Switch
Delete Switch. Used to delete incorrect entries.
The Remote Start switch is located behind the motor housing.
The remote start switch provided the following functions:
1. Provides remote milk start/stop functions.
2. When pushing and holding the remote switch energizes the retraction motor. This provides the
ability of the detacher to synch up the retractor rope after the milking unit is on the cow.
3. Provides the same function as the (Accept Check Mark Switch) After an ID number is entered,
pressing the check switch or the will
Switch Operation
Expresso Tie Stall
18 © 2012 Agricultural Instruments Corporation
1. REVIEW DATA—After choosing 1 on numeric switch pad, review data, the Expresso will provide
a summary of all the cow milking’s stored then when pressing “next:” will display each individual
cow milking stored.
2. CHANGE SETTINGS (See the Following Setup Tables)– After choosing 2 on the numeric switch
pad brings you to the set-up pages. There are several pages. To navigate though the settings
press change pages by pressing 9 to move forward and 7 to move back. To select an item press
2 to scroll up and 8 to scroll down. After selecting the item to be changed press switches 4 or 6 to
increase or decrease to the desired value. (See the following Set-up Pages)
3. WRITE TO DATA CARD– After choosing 3 the Expresso will ask you if you want to write the
stored data onto a data memory card. A card must be present, if no card is present then the
Expresso will tell you there no card present and a card must be added for this to work.
4. ERASE MEMORY—After choosing 4 the Expresso will ask you erase data (Yes/No) Selecting
Yes will erase the data in memory.
5. RESET MAINTENANCE-After choosing 5 the Expresso will ask you if you want to reset the
maintenance schedule. Internally there is a time clock that tracks the operating hours. This clock
will be reset to zero if yes is selected.
6. DISPLAY COM STATUS-After choosing 6 the Expresso will show the status of the
communication network associated with the system.
7. EXERCISE OUTPUTS– After choosing 7 the Expresso allows you to operate the valves by
pressing Cylinder or Milk Line Shut-off. This feature allows you to check to be sure the valves
and operating properly.
8. INITIALIZE WIRELESS— This setting us used when a wireless module is connected and is used
as a means of identifying the wireless connection included in the unit.
Needs to change.
0: Exit
Switch Operation
-
Set-up table: To enter set-up press the browser (gear) switch. Press 2 to change settings. To navigate
through the set-up options press the 2 or 8 switch, when changing a value press the 4 or 6 switch. These
switches have arrows. To page through the setup pages press the 7 or 9 switch. The Expresso will
automatically save the new settings.
Detacher Control Set-up
Expresso Tie Stall
19 © 2012 Agricultural Instruments Corporation
Setting Range Increments Factory
Settings Effects of Adjustment
Language N/A Multiple English Choose Language Displayed
ID Enable Yes/No N/A No EXPRESSO Units will ask for an ID
number when starting milking
Units of Measure LB/F or Kg/C LB/F Change from Imperial to Metric
Take Off Flow Rate
.2 to 6 LB/Min
.09 to 1.82 Kg/
Min
Varies 1.2 LB/Min.
Increase to milk cows wetter decrease to
milk cows drier
Take Off Delay 0 to 60
seconds 1 second 8 seconds Increase to milk cows drier, decrease to
milk cows wetter.
Max Milking Time 0 to 20 minutes 30 seconds 0 seconds
Unit will detach after the maximum time
has expired, except when a continue as
occurred.
Conductivity Delay 0 to 3.9 LB
0 to 1.76 Kg
.1 LB
.4 Kg
3.5 LB
1.6 Kg
Increase to make less sensitive,
decrease to make more sensitive
Milk Letdown Delay 60 to 210
seconds 30 seconds 90 seconds
Increase for longer delay. Allows to
ignore low flow rates at the beginning of
milking.
Vacuum On Delay 0 to 10
seconds .2 seconds 2 second
This setting is the delay from when the
attach switch is pressed and vacuum is
applied to the milking unit. It allows time
to get the milking unit into the milking
position before vacuum is applied.
Detacher Control Set Up
Expresso Tie Stall
20 © 2012 Agricultural Instruments Corporation
Settings Range Increments Factory
Settings Effects of Adjustment
Retract Delay 0 to 10
seconds .2 seconds 1.6 second
This delay allows for soft take-off. The
EXPRESSO control shuts the vacuum off
the claw and then activates the retraction
cylinder in the time this delay is set.
Pull Time 0 to 20
seconds .5 seconds 10 seconds If driving an electric motor, how long
power is to the motor.
Re-Pull Time 0 to 20
seconds .5 seconds 2.8 Seconds
After the Pull Time expires, power is
again applied to the motor for the desired
amount of time.
Sweep Delay 0 to 20
seconds .5 seconds 0 Seconds Time from detach to milk sweep start.
Sweep On-Time 0 to 5
seconds .2 seconds 1 seconds How long sweep occurs for
Pulsation Rate 45-80 ppm 1 60ppm Set-up for the number of pulsation cycles
per minute
Front Ratio 50/50 to
70/30 1 65/35 Set-up front pulsation milk/rest ratio
Rear Ratio 50/50 to
70/30 1 65/35 Set-up rear pulsation milk/rest ratio.
Detacher Control Set Up
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