ATI Technologies 39-0038 Use and maintenance manual

© ATL Agricultural Technology Limited: June 2016
Remote Vacuum Sensor and
Variable Speed Vacuum Pump Control Manual
Version - 1.0
Date - June 2016
Part Number - 39-0038
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Index
Manual Version........................................................................................................... 3
About the Remote Vacuum Sensor................................................................................... 4
Installing the Remote Vacuum Sensor.............................................................................. 5
Good Practice During the Installation............................................................................... 6
Remote Vacuum Sensor Control Wiring Connections.......................................................... 7
Wiring up the Yaskawa V1000 Inverter Drive.................................................................... 10
Inverter Drive 3 Phase Box Wiring.................................................................................. 11
Connecting the Remote Vacuum Sensor to Variable Speed Vacuum Pumps............................ 12
Setting up the Yaskawa V1000 Inverter Drive................................................................... 13
Factory Settings for the Yaskawa V1000 Inverter Drive...................................................... 14
Setting Up the Remote Vacuum Sensor............................................................................ 15
The Keypad................................................................................................................. 15
The Display................................................................................................................. 15
Entering Setup............................................................................................................ 16
Navigating Through Menu Items.................................................................................... 16
The Settings Menu Structure......................................................................................... 17
The Vacuum Settings Menu Structure.............................................................................. 18
The M2Bus Settings Menu Structure................................................................................ 19
The M2Bus IDS Menu Structure...................................................................................... 21
The Device Info Menu Structure..................................................................................... 23
Milking Mode.............................................................................................................. 24
Washing Mode............................................................................................................ 24
Info Function.............................................................................................................. 25
Monthly / Six Monthly / Yearly Routine Maintenance........................................................... 27
Parlour Wash Down...................................................................................................... 27
Troubleshooting.......................................................................................................... 27

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Manual Versions
Version 1.0 - June 2016......................................................First Version of Manual (Software v2.00)

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About the Remote Vacuum Sensor
The Remote Vacuum Sensor from ATL is a simple and easy to use variable speed vacuum pump controller
and digital vacuum gauge. It provides more consistent and efficient vacuum levels during milking and
washing. The system is programmable and it’s versatility provides an excellent variable speed vacuum pump
control to any type of milking parlour.
Control Features
Programmable settings to be optimised for every milking parlour;
Large OLED display showing status;
3 easy buttons, Idle, Milk and Wash;
Different vacuum levels for milking and washing;
Controls up-to 3 variable speed vacuum pumps;
Separate motor minimum and maximum speeds for each drive;
Easily connected to external wash controls to turn in and out of wash and milk modes;
Simple warnings when vacuum level is too low or too high.
Front Cover
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Remote Vacuum Sensor
+
Vacuum Sensor
Idle Key
Milk Key
Wash Key

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Installing the Remote Vacuum Sensor Control Unit and Variable Speed Vacuum Pump Control
System
The ATL variable speed vacuum pump system consists of a remote vacuum sensor control unit, the variable
speed vacuum pump inverter drive unit and the vacuum pump and motor unit.
All of the controls should be mounted on the wall.
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Good Practice During the Installation
A separate mains supply and earth running directly from the consumer meter is essential.
Avoid routing the mains cable to the power supply close to other supplies especially those providing
intermittent current motors that are starting and stopping continually or high power heaters with
thermostatic control.
Terminate the Remote Vacuum Sensor Control supply in a sealed, fused, double pole switched outlet
fitted with a 13Amp (Type 1362) fuse or trip. A 3-pin ring main socket is not suitable in parlour
conditions. All mains cabling must be contained in a firmly secured durable conduit.
Variable Speed Inverter Drive: Siting
Fix the unit to a wall in a well ventilated area sufficiently high to avoid physical contact or damage,
leaving a gap of at least 250mm (10") between the top of the box and the ceiling.
Ensure that S-Y Flex is used between the drive output and motor.
Ensure that the S-Y Flex is correctly terminated using the screen clamp within the unit.
Position the power supply so that the output cables are as short as possible even if this means extending
the mains supply.
ATL Remote Vacuum Sensor Power Supply: Output Voltages
ATL remote vacuum sensor power supply outputs are factory set and should not be adjusted.
Remote Vacuum Sensor Power Supply
Input: 100 - 240vAC
Output: Nominal 12vDC
The Remote Vacuum Sensor 12vDC power supply has a thermal cutout and overload protection which
removes power from the output in the event of an overload.
Control Cables and Conduit
Cables must be kept as short as possible running directly from point to point. Cut out any excess cable
rather than leaving it coiled.
Wherever possible cables should be contained in a waterproof conduit using the correct csa cable
specified in the diagrams.
Entries must be made into the bottom of control casings but never into the top. This will
invalidate the warranty.
Strip existing cables back to bright copper before connection.
Keep high voltage and heavy current carrying cables away from low voltage and data cables. Cross
o
only at 90 where necessary and do not enclose in conduit with other cables.
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Remote Vacuum Sensor Control Wiring Connections
The remote vacuum sensor control wiring connections are shown in the diagram and corresponding table
below. The control comes with one 4 port gland and one 6mm vacuum connection. The 4 port gland can take
a maximum cable OD of 6.5mm.
IMPORTANT - DO NOT INSTALL TWO CABLES THROUGH 1 CABLE HOLE IN THE 4 PORT GLAND. THIS WILL
INVALID THE WARRANTY.
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Connects To
Sys Power +Ve
M2Bus Data A
M2Bus Data B
M2Bus EOL Link
M2Bus Screen
Sys Power -Ve
Power In +Ve from PSU
Power in -Ve from PSU
Wash Output 0vDC Switched
Wash Output +12vDC Common
Milk Output 0vDC Switched
Milk Output+12vDC Common
Inverter Data A
Inverter Data B
Inverter EOL Link
Inverter Screen
Cable Specification
Unused - Only Use if instructed by ATL
Twisted Pair - Red
Twisted Pair - Black
Unused - Only Use if instructed by ATL
Twisted Pair - Screen
Unused - Only Use if instructed by ATL
Factory Fitted
Factory Fitted
1mm CSA
1mm CSA
1mm CSA
1mm CSA
Twisted Pair - Red
Twisted Pair - Black
Unused - Only Use if instructed by ATL
Twisted Pair - Screen
13
14
15
16
Remote Vacuum Control
7
8
9 11
10 12
1
2
3
4
5
6
17
18
19
20
21 22
23
24 25 26 27 28
Top

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Remote Vacuum Sensor Control Wiring Connections - Continued
Number
17
18
19
20
21
22
23
24
25
26
27
28
Connects To
Milk Input +Ve
Milk Input -Ve
Wash Input +Ve
Wash Input -Ve
Cat 5e M2Bus Connection
Cat 5e M2Bus Connection
Vacuum Pipe Connection
Live Mains In
Neutral Mains In
Earth Mains In
-12vDC Power to Board
+12vDC Power to Board
Cable Specification
1mm CSA
1mm CSA
1mm CSA
1mm CSA
Cat 5e Cables provided by ATL
Cat 5e Cables provided by ATL
Factory Fitted
Use 1mm CSA Mains 3 Core
Use 1mm CSA Mains 3 Core
Use 1mm CSA Mains 3 Core
Factory Fitted
Factory Fitted

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Wiring up the Yaskawa V1000 Inverter Drive
DANGER:
Electrical Shock Hazard: DO NOT CONNECT OR DISCONNECT WIRING WHILE THE POWER IS ON
Failure to comply will result in death or serious injury.
WARNING:
Electrical Shock Hazard: Do not operate equipment with covers removed. Failure to comply could
result in death or serious injury. The diagrams in this manual may show drives without covers or safety
shields to show details. Be sure to reinstall covers or shields before operating the drives and run the drives
according to the instructions described in this manual.
Always ground the motor-side grounding terminal: Improper equipment grounding could result in
death or serious injury by contacting the motor case.
Do not perform work on the drive while wearing loose clothing, jewelry or without eye
protection: Failure to comply could result in death or serious injury. Remove all metal objects such as
watches and rings, secure loose clothing, and wear eye protection before beginning work on the drive.
Do not remove covers or touch circuit boards while the power is on: Failure to comply could
result in death or serious injury.
Do not allow unqualified personnel to perform work on the drive: Failure to comply could result
in death or serious injury. Installation, maintenance, inspection, and servicing must be performed only by
authorized personnel familiar with installation, adjustment, and maintenance of AC drives.
Do not touch any terminals before the capacitors have fully discharged: Failure to comply could
result in death or serious injury. Before wiring terminals, disconnect all power to the equipment. The
internal capacitor remains charged even after the power supply is turned off. The charge indicator LED
will extinguish when the DC bus voltage is below 50 Vdc. To prevent electric shock, wait at least five
minutes after all indicators are off and measure the DC bus voltage level to confirm safe level.
FIRE HAZARD:
Tighten all terminal screws to the specified tightening torque: Loose electrical connections could
result in death or serious injury by fire due to overheating of electrical connections.
Do not use improper combustible materials: Failure to comply could result in death or serious injury
by fire. Attach the drive to metal or other noncombustible material.
Do not use an improper voltage source: Failure to comply could result in death or serious injury by
fire. Verify that the rated voltage of the drive matches the voltage of the incoming power supply before
applying power.
Always use a thermal overload relay or an over-temperature contact when using a braking
resistor: Failure to comply could result in death or serious injury by fire.Power to the drive should be
interrupted when the relay is triggered.
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Wiring up the Yaskawa V1000 Inverter Drive
NOTICE:
Observe proper electrostatic discharge procedures (ESD) when handling the drive and
circuit boards: Failure to comply may result in ESD damage to the drive circuitry.
Never connect or disconnect the motor from the drive while the drive is outputting voltage:
Improper equipment sequencing could result in damage to the drive.
Do not use unshielded cable for control wiring: Failure to comply may cause electrical interference
resulting in poor system performance. Use shielded, twisted-pair wires and ground the shield to the
ground terminal of the drive.
Check all the wiring to ensure that all connections are correct after installing the drive and
connecting any other devices: Failure to comply could result in damage to the drive.
Do not modify the drive circuitry: Failure to comply could result in damage to the drive and will void
warranty. ATL is not responsible for any modification of the product made by the user. This product must
not be modified.
Inverter Drive Single Phase Box Wiring
Input Filter
Yaskawa V1000 Inverter Drive
Motor Connections
Motor SY Flex Braid
Clamp
Mains Input SY Flex
Braid Clamp
Mains In Connections
Earth Point
ESC LO
RESET ENTER
STOP
RUN
ALM REV
DRV FOUT
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Inverter Drive 3 Phase Box Wiring
Properly terminating the SY Flex Input and Output Cables
Input Filter
Yaskawa V1000 Inverter Drive
Motor Connections
Motor SY Flex Braid
Clamp
Mains Input SY Flex
Braid Clamp
Mains In Connections
Earth Point
1. Fold Braid back over
the cable.
2. Tape the braid down, to
ensure no stray wires.
3. Clamp the braid into
the Braid Clamp
ESC LO
RESET ENTER
STOP
RUN
ALM REV
DRV FOUT
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Connecting the Remote Vacuum Sensor to Variable Speed Vacuum Pump Control Inverter
Screen - Connect into connection number 16
Red (from Red / Black pair)- Connect into connection number 13 (Rx / A)
Black (from Red / Black pair) - Connect into connection number 14 (Tx / B)
Twisted Pair Wire connects to Remote Vacuum Sensor
Wire Red to R+ and S+, Black to R- and S-, Connect Screen to Ground Connection (Metal screw on inverter
base).
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ALM REV
DRV FOUT
ESC LO
RE
RESET ENTER
STOP
RUN
R+|R-|S+|S-|IG

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Setting up the Yaskawa V1000 Inverter Drive
IMPORTANT: Auto Tuning of the motor will need to be carried when the motor is disconnected from the load
(i.e. with the milk pump head removed), as it will run the motor for a period and it needs to be
connected to the correct length of SY cable on the final installed system.
SEE SECTION 4.7 of the Yaskawa Technical Manual for Auto Tuning of the Yaskawa Inverter Drive
Manual for a detailed method for auto tuning the motor.
Brief Summary of auto tuning the drive:
Press the down arrow on the Yaskawa V1000 drive control panel until it displays `rune’.
Press Enter, then change the `r1-01’ to read 03.
Enter the motor nameplate data for setting `r1-02’ to `r1-07’.
Ensure the motor can run unloaded.
The display will say `run13’, Press the green run key to auto tune.
The motor will run and the drive will tune its capabilities.
After tuning is complete; Enter the motor operating speeds;
Change Parameter d1-01 for the override running frequency, this frequency is used when inverter
drive box is put into manual and the green start button is pressed.
Change Parameter d1-02 for the milking maximum output frequency.
Change Parameter d1-03 for the milking minimum output frequency.
Change Parameter d1-04 for the washing maximum output frequency.
Change Parameter d1-05 for the washing minimum output frequency.
The minimum, and maximum output frequencies are read by the remote vacuum sensor control and
used to determine the pump running speed.
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Factory Settings for the Yaskawa V1000 Inverter Drive
Parameters are accessed by pressing the down key until the display reads `par’ then pressing the
enter key.
Frequency Reference and Run Command
See section 5.2 in the Yaskawa V1000 Technical Manual
Parameter b1-01 (Frequency reference selection 1): Set to 2 (MEMOBUS/Modbus)
Parameter b1-02 (Run command selection 1): Set to 2 (MEMOBUS/Modbus)
Parameter b1-15 (Frequency reference selection 2): Set to 0 (Operator Keypad)
Parameter b1-16 (Run command selection 2): Set to 1 (Terminals)
Input Terminal Functions
See section 5.7 in the Yaskawa V1000 Technical Manual
Parameter H1-01 (Digital Input S1 Function): Set to 40 (Forward Run Command)
Parameter H1-02 (Digital Input S2 Function): Set to 41 (Stop Command)
Parameter H1-03 (Digital Input S3 Function): Set to 00 (Three Wire Sequence)
Parameter H1-04 (Digital Input S4 Function): Set to 02 (External Reference 1 / 2 Selection)
Parameter H1-05 (Digital Input S5 Function): Set to 0F (Unused)
Parameter H1-06 (Digital Input S6 Function): Set to 0F (Unused)
MEMOBUS/Modbus Communications Settings
See Appendix C in the Yaskawa V1000 Technical Manual
Parameter H5-01 (Drive Slave Address): Set to 01 for 1st drive, 02 for 2nd drive and 03 for 3rd drive
Parameter H5-02 (Communications Bus Speed): 03 (9600 baud)
Parameter H5-03 (Communications Bus Parity): 00 (No Parity)
Parameter H5-04 (Stopping Method After Communications Error): 01 (Coast to Stop)
Parameter H5-05 (Communications Fault Detection): 00 (Disabled)
Parameter H5-06 (Drive Transmit Wait Time): 05 (5ms Wait Time)
Parameter H5-07 (RTS Selection): 01 (Enabled)
Parameter H5-09 (CE Detection Time): 5.0 (5 Second Maximum Time)
Parameter H5-10 (Unit Selection for Register 0025H): 0 (0.1 Volt Units)
Parameter H5-11 (Communications Enter Function): 01 (Command not necessary)
Parameter H5-12 (Run / Stop Method Selection): 00 (Forward / Stop, Reverse / Stop)
Motor Frequency Reference Settings
See Appendix B, part B.2 in the Yaskawa V1000 Technical Manual
Parameter d1-01 (Frequency Reference 1): 5000 (50.00 Hz - Override Manual Frequency)
Parameter d1-02 (Frequency Reference 2): 5000 (50.00 Hz - Milking Maximum Frequency)
Parameter d1-03 (Frequency Reference 3): 3500 (35.00 Hz - Milking Minimum Frequency)
Parameter d1-04 (Frequency Reference 4): 5000 (50.00 Hz - Washing Maximum Frequency)
Parameter d1-05 (Frequency Reference 5): 5000 (50.00 Hz - Washing Minimum Frequency)

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Setting up the Remote Vacuum Sensor
Before it can be used, the Remote Vacuum Sensor must be setup. This is outlined in the following pages.
The Keypad
There are 3 keys on the keypad, allowing the user to put the system into milk, wash and back to idle.
The keypad is constructed from a tough membrane overlaying individual key switches. This is a proven,
reliable construction which will last for many years provided it is cleaned only with warm soapy water and
not hosed down at high pressure.
The Display
The display is an OLED dot matrix type display, allowing for large and small characters to be displayed.
During milking and washing, the vacuum level is displayed in kPa in a large font.
The Remote Vacuum Sensor Control is very energy efficient; power saving was an important element of the
design criteria, the display will dim after 5 minutes to conserve energy.
+
Vacuum Sensor
Idle Key
Milk Key
Wash Key

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Entering Setup
During the setup process, it is necessary to enter and modify data. Before this can be achieved, the Remote
Vacuum Sensor Control has to be put into setup using this key sequence:
Press all 3 keys together to enter setup.
Once the 3 keys have been pressed, the settings menu will be shown;
Navigating Through Menu Items
To navigate through menu items the Idle and Milk keys are used. To enter a menu item the wash key is used.
To navigate forwards through a list of menu items or increase a
settings value, press the Milk key.
To navigate backwards through a list of menu items or decrease a
settings value, press the Idle key.
To enter into a menu item or accept a settings value, press the Wash
key.
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+
+
+
RVS Settings
Vacuum Setup >
+

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The Settings Menu Structure
The settings menu is structured as shown below;
Entry point into settings menu.
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Vacuum Setup: This settings menu controls the vacuum
levels for the wash and milking modes, the number of
vacuum pumps and the length of the wash time.
RVS Settings
Vacuum Setup >
M2Bus Setup: This settings menu controls the device
information for connecting to the M2Bus.
RVS Settings
< M2Bus Setup >
M2Bus IDS: This menu item allows the user to test
connectivity to different devices on the M2Bus.
RVS Settings
< M2Bus IDS >
Device Info: this menu item lists the software version
and serial number of the device.
RVS Settings
< Device Info >
Exit Setup: This menu item exits the setup menu.
RVS Settings
< Exit Setup

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The Vacuum Setup Menu Structure
The vacuum setup menu is structured as shown below;
Entry point into vacuum setup menu.
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Enable VP1: Yes / No. This setting enables or disables
vacuum pump 1. Press Idle to set to No, Milk to set to
Yes. Press the Wash key to store the setting and move to
the next setting.
Vacuum Settings
Enable VP1: Yes
Enable VP2: Yes / No. This setting enables or disables
vacuum pump 2. Press Idle to set to No, Milk to set to
Yes. Press the Wash key to store the setting and move to
the next setting.
Vacuum Settings
Enable VP2: No
Enable VP3: Yes / No. This setting enables or disables
vacuum pump 3. Press Idle to set to No, Milk to set to
Yes. Press the Wash key to store the setting and move to
the next setting.
Vacuum Settings
Enable VP3: No
Milking Vacuum Level: This setting is the level of
vacuum to be maintained during the milking. This level
can be increased by pressing the Idle key, and
decreased by pressing the Milk key. Press the Wash key
to store the setting and move to the next setting.
Milking Vacuum
Level: -46.0kPa
Milking Vacuum High: This is the level at which after 1
minute of operation the unit will warn the user if the
vacuum increases beyond this level. This level can be
increased by pressing the Idle key, and decreased by
pressing the Milk key. Press the Wash key to store the
setting and move to the next setting.
Milking Vacuum
High: -50.0kPa
ê
Settings continued on next page.

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The Vacuum Setup Menu Structure Continued
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Milking Vacuum Low: This is the level at which after 1
minute of operation the unit will warn the user if the
vacuum drops below this level. This level can be
increased by pressing the Idle key, and decreased by
pressing the Milk key. Press the Wash key to store the
setting and move to the next setting.
Milking Vacuum
Low: 42.0kPa
Wash Settings Mode: Timed or User Stop. This setting
allows the user to select either a timed wash, or a wash
until the user presses the Idle key. Press the Wash key
to store the setting and move to the next setting.
Wash Settings
Mode: Timed
Wash Settings Time: This setting allows the user to
select how long the wash program will run for when the
mode is set to timed. Press the Wash key to store the
setting and move to the next setting.
Wash Settings
Time: 60Min
Wash Vacuum Level: This setting is the level of vacuum
to be maintained during the wash. This level can be
increased by pressing the Idle key, and decreased by
pressing the Milk key. Press the Wash key to store the
setting and move to the next setting.
Wash Vacuum
Level: -46.0kPa
Wash Vacuum High: This is the level at which after 1
minute of operation the unit will warn the user if the
vacuum increases beyond this level. This level can be
increased by pressing the Idle key, and decreased by
pressing the Milk key. Press the Wash key to store the
setting and move to the next setting.
Wash Vacuum
High: -50.0kPa
ê
Settings continued on next page.

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The Vacuum Setup Menu Structure Continued
The M2Bus Settings Menu Structure
The M2Bus setup menu is structured as shown below;
Entry point into M2Bus setup menu.
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Wash Vacuum Low: This is the level at which after 1
minute of operation the unit will warn the user if the
vacuum drops below this level. This level can be
increased by pressing the Idle key, and decreased by
pressing the Milk key. Press the Wash key to store the
setting and return to the main menu.
Wash Vacuum
Low: 42.0kPa
The Vacuum Settings main menu item.
RVS Settings
Vacuum Settings >
M2Bus Settings Address: This setting allows the user to
enter the address of the unit on the M2Bus. This number
can be increased by pressing the Idle key, and
decreased by pressing the Milk key. Press the Wash key
to store the setting and move to the next setting.
M2Bus Settings
Address: 1
M2Bus Settings Milking Point Control: Yes / No. This
setting enables or disables communications with the
Milking Point Controls. Press Idle to set to No, Milk to set
to Yes. Press the Wash key to store the setting and move
to the next setting.
M2Bus Settings
Milking Pt Ctrl: No
M2Bus Settings Milk Pump: Yes / No. This setting
enables or disables communications with the Milk Pump
control. Press Idle to set to No, Milk to set to Yes. Press
the Wash key to store the setting and move to the next
setting.
M2Bus Settings
Milk Pump: No
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Settings continued on next page.