Boumatic HandyFloor 2015 Manual

ACL
F AL C ON
HA ND Y FL OO R
9e1034
Installation and Maintenance Manual
9e1037
HandyFloor
Model 2015
www.boumatic.com
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03-2016

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1. PREFACE
Contents:
1.1 MANUFACTURER’S ADDRESS ...................................................................................................................................................................4
1.2 CUSTOMER SERVICE ......................................................................................................................................................................................4
1.3 GUIDELINES, LAWS, STANDARDS ...........................................................................................................................................................4
1.3.1 DECLARATION OF CONFORMITY ............................................................................................................................................................ 5
1.4 SUCCESSFUL MILKING ..................................................................................................................................................................................6
2. SAFETY
2.1 OWNER’S DUTY OF CARE ...........................................................................................................................................................................7
2.2 BASIC SAFETY INSTRUCTIONS ..................................................................................................................................................................8
2.3 PERSONNEL QUALIFICATION ....................................................................................................................................................................9
2.4 PROTECTIVE EQUIPMENT ..........................................................................................................................................................................10
2.5 SAFETY SIGNS, STICKERS AND LABELS ..........................................................................................................................................10
2.6 PACKAGING MATERIALS ............................................................................................................................................................................10
2.7 CORRECT APPLICATION ............................................................................................................................................................................10
2.8 NOISE ...................................................................................................................................................................................................................11
3. DESCRIPTION
8. DECOMMISSIONING
8.1 SPECIAL PERSONNEL QUALIFICATION REQUIRED FOR DECOMMISSIONING ................................................43
8.2 SAFETY INSTRUCTIONS FOR DECOMMISSIONING ..................................................................................................43
8.3 SPECIAL DANGERS INVOLVED IN DECOMMISSIONING ..........................................................................................43
8.4 FINAL DECOMMISSIONING / DISPOSAL ......................................................................................................................43
3.1 FUNCTIONAL CHARACTERISTICS .................................................................................................................................12
4. CORRECT USE
4.1 OPERATION..............................................................................................................................................................................13
4.1.1 CALIBRATION..........................................................................................................................................................................13
4.2 LOADING THE FLOOR ..........................................................................................................................................................13
5. INSTALLATION INSTRUCTIONS
5. INSTALLATION INSTRUCTIONS .........................................................................................................................................14
5.1 INSTALLATION EQUIPMENT ..............................................................................................................................................15
5.2 IINSTALLATION OF GUIDE FOR LIFTING UNIT..............................................................................................................16
5.3 PLACING OF GUIDES/LIFTING UNITS..............................................................................................................................17
5.4 INSTALLATION OF THE GUIDE...........................................................................................................................................18
5.5 INSTALLATION OF THE LIFTING UNIT..............................................................................................................................19
5.6 INSTALLATION OF THE FLOOR FRAME ..........................................................................................................................21
5.7 INSTALLATION OF CABLES AND CONTROL .................................................................................................................25
5.8 INSTALLATION OF CABLES AND CONTROL..................................................................................................................27
5.9 IINSTALLATION OF STRINGER AND GRATING ..............................................................................................................28
6. ELECTRICAL DIAGRAMS
6.1 WIRING DIAGRAM FOR 4 SPINDLE MOTORS ...............................................................................................................33
6.2 CABLE DIAGRAM FOR 4 SPINDLE MOTORS .................................................................................................................34
6.3 WIRING DIAGRAM FOR 3 SPINDLE MOTORS ...............................................................................................................35
6.4 CABLE DIAGRAM FOR 3 SPINDLE MOTORS .................................................................................................................36
6.5 WIRING DIAGRAM FOR 2 SPINDLE MOTORS ...............................................................................................................37
6.6 CABLE DIAGRAM FOR 2 SPINDLE MOTORS .................................................................................................................38
7. DETAILED FUNCTIONAL DESCRIPTION FOR SERVICE ENGINEERS
7.1 CONTROL .................................................................................................................................................................................39
7.2 STEUERPLATINE .....................................................................................................................................................................40
7.3 TROUBLESHOOTING IN CONTROL ..................................................................................................................................41
7.4 SERVICE AND MAINTENANCE ..........................................................................................................................................42

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10. APPENDIX
10.1 SERVICE SCHEDULE FOR HANDYFLOOR MODELL 2015 ........................................................................................55
9. SPARE PARTS DRAWINGS AND PARTS LISTS
9.1 SPARE PARTS DIAGRAM HANDYFLOOR........................................................................................................................45
9.2 LIFTING UNITS........................................................................................................................................................................47
9.3 CONTROL WITH 2 SPINDLE MOTORS ............................................................................................................................49
9.4 CONTROL WITH 3 SPINDLE MOTORS.............................................................................................................................50
9.5 CONTROL WITH 4 SPINDLE MOTORS ...........................................................................................................................51
9.6 ELECTRICAL PARTS ..............................................................................................................................................................53

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1. PREFACE
These instructions are supplied with the product.
They should be kept close at hand and remain with the equipment even if the equipment is sold.
This manual is not covered by an amendment service. The current version can be obtained through your
technical dealer or directly from BouMatic.
We reserve the right to make changes of the data and illustrations in this manual due to technical
developments.
Reproduction, translation or copying in any form, including extracts, requires written authorization from
BouMatic.
1.1 MANUFACTURER’S ADDRESS
1.2 CUSTOMER SERVICE
If necessary, please contact your nearest authorised dealer.
1.3 GUIDELINES, LAWS, STANDARDS
BouMatic Gascoigne Melotte Sprl.
Rue Jules Melotte 31
4350 Remicourt
Belgium
Tel: [phone]
Fax: [phone]
BouMatic B.V.
Transportweg 6
8304 AX Emmeloord
The Nederlands
Tel: [phone]
Fax: [phone]
BouMatic Europe
EMC compliance has been tested and this equipment meets the requirements of the applicable European
and national guidelines.
Conformity has been proved and the manufacturer holds the relevant statements and documents.
To maintain this state and ensure safe operation, you, as a user, must observe this operator manual.

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1.3.1 DECLARATION OF CONFORMITY
www.boumatic.com
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EC Declaration of Conformity
Emmeloord/Remicourt, 15/12/2015
BouMatic Europe
BouMatic B.V.
Transportweg 6
8304 AX Emmeloord
The Netherlands
BouMatic Gascoigne Melotte Sprl.
Rue Jules Melotte 31
4350 Remicourt
Belgium
Declares under its sole responsibility that the
•"HandyFloor" Adjustable floor
has been manufactured in conformity with the
provisions of the following Council Directives (EEC):
•Low Voltage Directive 2006/95/EC
•Machinery Directive 2006/42/EC
•EMC Directive 2004/108/EC
Authorized signatory
15/12/2015
Date
Modell: 2015
Jørgen Frederiksen
Manager, Technical Department/R&D, BouMatic A/S

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1.4 SUCCESSFUL MILKING
Prerequisites for successful milking:
• A milking installation designed in accordance with ISO 5707 or 3 A and set up correctly.
• Stable vacuum conditions due to an appropriately sized vacuum pump, a balance tank and vacuum
reserve as well as properly sized vacuum lines.
• Milking vacuum and automatic cluster removal must be set correctly to suit the animals.
Regular checks and adjustments to meet any herd changes will also ensure successful milking.
• A milking cluster selected to suit the animals.
• Correctly positioned cluster. Keep hoses as short as possible to avoid unnecessary sagging.
• Scheduled maintenance and cleaning of the milking installation. Regular thorough cleaning and
disinfection of the milking installation will help improve animal health, milk quality and therefore milking
results.
• When replacing parts, only use genuine BouMatic spare parts!
• Recommended settings are only valid in conjunction with genuine BouMatic products.
• The conscientious implementation of milking routines will have a positive eect on milking results.
Attention!
Milking without milk ow (overmilking) must be avoided, as it will very quickly have an adverse
eect on teat condition and udder health
Rub to
remove any
residual
bedding.
Dip with
pre-dip.
Strip/wash
teat end
with
gloved hand.
Dry with
one circular
motion - flip
towel and
aggressively
squeeze
teat end.
Attach
unit.
Adjust unit
for proper
placement.
Post-dip -
cover
complete
teat!!
10 to 12 seconds of teat contact
time. (stripping, washing and
drying)
Attach unit
within 75-90
seconds after
steps 3 and 4.
After attachment, adjust unit to
hang squarely on the cow as soon
as the last teat cup is attached.
Gently,
Quickly and
Completely
Always Milk Your Cows...
7 Step Udder Prep
BouMatic.com
1 2 3 4 5 6 7

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2. SAFETY
2.1 OWNER’S DUTY OF CARE
Design and construction of this product were preceded by risk assessment and careful identication of applicable
harmonized standards and other technical specications. This product therefore represents the state-of-the-art
of technology and ensures a maximum level of safety. To achieve safety on farms, all necessary measures must be
taken. The owner is responsible for planning such measures and for verifying their implementation.
In particular, the owner has to ensure the following:
• Legal requirements must be met.
• Instructions on basic safety precautions must be followed.
• Safety signs, stickers and labels on the product must be replaced immediately if they are illegible or lost!
• All applied safety signs or warning instructions must stay in place and remain legible.
• Escape routes must be indicated by signs in accordance with national regulations!
• The required personal protection equipment must be available and used by operators, maintenance and
service personnel.
• A full set of legible instructions must always be kept near the product. Anyone having to work on the
product must have the possibility to look into the instructions at any time.
• The owner has to ensure that his sta receive adequate training adapted to suit the specic conditions of
his facility; emphasis should be placed on safety aspects.
• Unauthorised persons (e.g. children) are not permitted into hazardous areas and must not have access to
cleaning agents or disinfectants.
• Anyone involved in the operation, maintenance, inspection or handling of this product in any other way
must know and understand this manual (especially the safety information and warnings).
• This product
-should only be used for its intended purpose.
-should only be used if in perfect operating condition. The safety equipment, in particular, should be
regularly checked to make sure it is in perfect operating condition.
• Operating personnel who require training may only work on the product under the supervision of an
experienced person. The successful completion of training is to be conrmed in writing.
• Persons carrying out work on this product must be suciently qualied!

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• There are dangers involved in the operation and maintenance of dairy farm equipment. For your own safety,
please read and observe these instructions carefully (especially the section on “Safety instructions”).
• Permissible working conditions (pressure ranges, temperature ranges, airow quantities etc.) must be ob-
served!
• Do not open or dismantle any devices (risk of injury)!
Do not remove any protective devices (risk of injury)!
• When working with cleaning and disinfecting agents observe the notes on dangers and protective measures
(risk of caustic burns)!
• When working with products from other manufacturers always observe the warnings on the material safety
data sheets and the operating instructions of the manufacturer!
• Observe noise protection measures!
• Do not stand underneath suspended loads.
• Always keep control cabinets, all power supply units and electrical control units closed.
Access is only permitted to authorized personnel with a key or special tool.
• Protect live and high-voltage components against moisture.
Water jets and high-pressure cleaners must NOT under any dircumstances be directed at them!
2.2 BASIC SAFETY INSTRUCTIONS
Work to be performed by qualied personnel only:
-Transportation
-Handling
-Maintenance
-Cleaning
Work to be performed by authorized personnel only:
-Installation
-Start-up
-Service
-Troubleshooting
-Repairs
-Decommissioning
These personnel will be regularly instructed in all relevant matters of safety at work and protection of the environ-
ment and by familiar with this manual, particularly the safety instructions it contains.
Attention!

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Anyone carrying out work or activities in connection with the product must carefully read the manual and sign to
conrm that they have understood it and will act accordingly!
Responsibilities:
• AC power wiring for voltage over 40 V (in Europe 50 V) must be done by a qualied (licensed) electricain in
compliance with the latest edition of the ANSI/ NFPA-Standard 70, National Electrical Code (USA) or either LVD
2006/95/EC oder EMC 2014/30/EU (in Europe) and in complianced with the local wiring codes as applicable.
• Any work on the hydraulic and pneumatic equipment should only be performed by specialist personnel trained
for this purpose.
• Any welding should only be performed by specialist personnel with knowledge in welding.
• Other installation, major maintenance, and service work must be done by an authorized BouMatic dealer.
• Product / system checkout and troubleshooting must be done by an authorized BouMatic dealer.
In addition, special qualications are required for the following activities:
• Transportation
• Handling
• Maintenance
• Cleaning
• Installation
• Start-up
• Service
• Troubleshooting
• Repairs
Deviation from these instructions could aect product performance or create a hazardous situation. Under no
circumstances will BouMatic be responsible for any problems caused in whole or in part by a deviation from the
procedures specied in these instructions without prior written approval from BouMatic.
Operation steps may be performed by the owner/operator once the dealer or technician has successfully nished
the product/system checkout. The owner/operator is responsible for properly operating, maintaining, and moni-
toring the product/system to ensure that it works properly.
Disclaimer
No warranties are contained in these instructions. The division of responsibilities, stated above, is a general reminder
of those provisions in the applicable dealer contract and does not change any agreement between BouMatic and
the dealer. Information in these instructions is not all-inclusive and cannot cover all unique situations.
2.3 PERSONNEL QUALIFICATION

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Attention!
2.4 PROTECTIVE EQUIPMENT
• Risk of death from electric shock!
Covers of electrical connection boxes must always be closed, otherwise there is danger of contact with
live parts.
• Risk of burns from acidic or alkaline detergents!
Risk of eye injuries or skin irritation.
• Risk of injury by putting your hand into the vacuum system!
Never reach into openings of the system when the machine is running. Extremities could be sucked in
by the vacuum prevailing in the system.
2.5 SAFETY SIGNS, STICKERS AND LABELS
Safety signs, stickers and labels axed to the product must be replaced immediately when illegible or lost!
2.6 PACKAGING MATERIALS
Packaging materials must be disposed of in accordance with applicable local regulations!
BouMatic equipment and components are designed exclusively for agricultural facilities (mostly dairy farms).
This product/component is designed exclusively for use during the milking process in parlors for cows or goats.
Any application not listed here is not part of the intended purpose and therefore considered as improper use!
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.
Genuine BouMatic parts and accessories are specially designed for Boumatic components; use only genuine spare
parts.
2.7 CORRECT APPLICATION

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Attention!
• Please note that parts or accessories not supplied by us and instructions not provided by BouMatic
are not checked or released by us either.
• If such products are installed or used, this can have a negative eect on the specied properties of
BouMatic products and put people and animals at risk.
• The manufacturer cannot be held liable for injury to people and animals or for damage to Bou-
Matic products caused as a result of using non-original parts or accessories or by incorrect settings.
• During repair and service operations, always cut the power to the control unit by turning o the
switch.
• The control unit contains 230 V AC circuits and may only be opened by a BouMatic installer or a
qualied electrician.
• Installation, together with any repairs during the warranty period, may only be undertaken by an
authorised BouMatic dealer/installer, or in accordance with instructions from BouMatic, otherwise
the warranty will be invalid.
• When the Handy Floor is in motion and the milker operating the oor is adjusting the height, he
must constantly ensure that people on the oor do not get their hands, arms or legs trapped
between the oor and the walls of the milking pit. To minimise the risk of getting trapped in the
milking pit, the distance from wall to oor is approx. 5 cm.
• The Handy Floor control is designed in such a way that the manual controller’s up or down button
must be held pressed to operate the oor. If the button is released, the oor stops immediately for
safety reasons.
• Never crawl beneath the HandyFloor without the oor being securely supported.
2.8 NOISE
The noise level does not exceed 70 dB (A).

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3. DESCRIPTION
3.1 FUNCTIONAL CHARACTERISTICS
The BouMatic HandyFloor consists of a control panel, a control unit and a oor.
The control panel has 2 pushbuttons for raising and lowering the oor.
For safety reasons, the control unit has a built-in 230V/24V transformer and a printed circuit board so that the
power to the spindle motors is low voltage. Irrespective of the load on the oor, the control unit ensures that the
spindle motors run uniformly so that the oor is always lifted horizontally.
The oor consists of a stainless steel frame with a number of stringers, onto which plastic gratings are mounted.
The frame is supported by 2-4 lifting brackets, depending on the length of the oor.
Each lifting bracket consists of a powerful spindle motor with an aluminium housing and steel lifting lugs. The
spindle motor pulls 2 chains attached to wall brackets that allow the spindle motor to raise and lower the oor.
ACL
F AL CO N
HA ND Y FLOO R
Control panel
Control unit
Wall bracket
Plastic
gratings
Stainless steel
frame
Lifting bracket
Spindle motor

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4. CORRECT USE
4.1 OPERATION
The BouMatic HandyFloor is constructed for use in milking parlours to ensure a good, ergonomically correct
working position for the milker and relieve the stress on the milker’s legs thanks to its non-slip, exible ooring.
The oor is raised and lowered by pressing the up and down buttons on the control panel. It takes approx. 1 sec.
from the button being activated to the oor moving.
Attention!
When operating the oor, care must always be taken while adjusting the height, to ensure that no objects become
trapped between the oor and the milking pit’s other installations, e.g. pipes and stairs, as this could also damage
the oor.
4.1.1. CALIBRATION
The oor is calibrated by running the oor to the furthest position, either top position or bottom position.
Attention!
It is important to ensure that all lifting units run so that the oor is not twisted askew. It is not necessary to
calibrate the oor during normal use.
4.2 LOADING THE FLOOR
The following load table must be observed in order to comply with the applicable safety rules for oors in milking
parlours.
Length of floor (m) Max. load Max. number of per-
sons Max. point load*
0 – 6.5 500 kg 5
150 kg/grating
3 persons/m²
6.5 – 11.0 750 kg 7
11.0 – 16.0 1000 kg 10
Rotary, single 500 kg 5
Rotary, double 750 kg 7
*The point load is the max. load each plastic grating can support

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3.2 DRAWING OF COW BRUSH
5. INSTALLATION INSTRUCTIONS
When building a milking parlour, the HandyFloor should only be installed after the construction of the stall
system and milking system is completed. This minimises the risk of the oor being overloaded or damaged during
construction, and objects (screws etc.) that may be lost in the milking pit during installation of the stall system and
milking equipment can easily be picked up again.
Subsequent installation instructions are for HandyFloor in milking parlours. Should you have any questions in
relation to these installation instructions, do not hesitate to contact your BouMatic dealer or BouMatic.
The HandyFloor is installed in the following 8 steps.
1. Check installation dimensions 2. Install guide for lifting unit
3. Fit lifting brackets onto guide 4. Install frame for floor
5. Install cables and control
6. Install ramp
HA
AC
NDY
L
FA
FLO LC O O
R N
7. Install stringers and plastic gratings8. Final test

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5.1 INSTALLATION EQUIPMENT
Welder for welding 2 mm stainless steel Metal saw for 100x100 mm square tubes
3 x 120 mm plate (stringer).
Hand drill for drilling max Ø12 Saw for adjusting gratings
Gen. hand tools: spanners, screwdrivers,
unbrako spanners, tool for wire ferrules.
Check the following before beginning the installation.
• Measure the dimensions of the milking pit.
• Check that there is consistency between the delivery note/order form/drawing.
• Review the delivery note and the HandyFloor parts.
• Plan the installation.
Attention!

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5.2 INSTALLATION OF GUIDE FOR LIFTING UNIT
Min. Max Remark
A 4.0 m 16.0 m 4.0 – 6.0 = 2 lifting units
6.0 – 11.0 = 3 lifting units
11.0 – 16.0 = 4 lifting units
C1 0.7 m 1.1 m Fixed measurement 0.7 m or 1.1 m (see section/table
7.2.2).
C2 0.7m 1.1 m Measurement adapted to E, F, G (see section/table
7.2.2).
D
E, F, G 4.0 m w/o reinforcement*
4.8 m w/reinforcement* The measurements must not differ from each other by
more than 0.4. E, F, G must be divisible by 0.4 (see
section/table 7.2.2).
H 0.65 m 0.75 m H=0.65 m => height of floor adjusted by 0.7 – 1.0 m
H=0.75 m => height of floor adjusted by 0.8 – 1.1 m
*The reinforcement is welded to the longitudinal stringer between the lifting units (see section below).
Ramp
When installing the plastic gratings, always start from the end of the ramp and work towards the end
of the staircase. Measurements E, F, G must always be divisible by 0.4 m to prevent alifting unit
from being installed below a stringer for the grating.

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H
HEIGHT ADJUSTMENT
5.3 PLACING OF GUIDES / LIFTING UNITS
AC1 C2 D E F G
4.0 0.7 0.9 2.4 2.4
4.5 0.7 1.0 2.8 2.8
5.0 0.7 1.1 3.2 3.2
5.5 0.7 0.8 4.0 4.0
6.0 1.1 0.9 4.0 4.0
6.5 1.1 1.0 4.4 4.4 1 reinforcement
7.0 0.7 0.7 5.6 2.8 2.8
7.5 0.7 0.8 6.0 3.2 2.8
8.0 0.7 0.9 6.4 3.2 3.2
8.5 0.7 1.0 6.8 3.6 3.2
9.0 0.7 1.1 7.2 3.6 3.6
9.5 0.7 0, 8, 8.0 4.0 4.0
10.0 1.1 0.9 8.0 4.0 4.0
10.5 0.7 1.0 8.8 4.4 4.4 2 reinforcements
11.0 1.1 1.1 8.8 4.4 4.4 2 reinforcements
11.5 0.7 0.8 10.0 3.2 3.6 3.2
12.0 0.7 0.9 10.4 3.6 3.2 3.6
12.5 0.7 1.0 10.8 3.6 3.6 3.6
13.0 0.7 1.1 11.2 3.6 4.0 3.6
13.5 1.1 0.8 11.6 4.0 3.6 4.0
14.0 1.1 0.9 12.0 4.0 4.0 4.0
14.5 1.1 1.0 12.4 4.0 4.4 4.0 1 reinforcement
15.0 1.1 1.1 12.8 4.4 4.0 4.4 2 reinforcements
15.5 1.1 1.0 13.6 4.4 4.8 4.4 3 reinforcements
16.0 1.1 0.9 14.0 4.8 4.4 4.8 3 reinforcements
All measurements are in metres.

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5.4 INSTALLATION OF THE GUIDE
� Position the guide on the wall (see sec-
tion 5.2). The guide must be plumb
(max. deviation is 5 mm from top to
bottom).
� Mark mounting holes.
� Drill Ø10 mm for S10 plugs
� Fit plugs
� Fit washer and screw (do not tighten).
� Check that the guide is plumb, and if neces-
sary adjust with washers behind the guide
before tightening the screws. (max. devia-
tion 3 mm from top to bottom).

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Measure the distance between the internal
surfaces (Distance = B measurement)
Saw off lifting unit according to sketch.
NB! Conical Handy Floors have lifting
units of different lengths.
Drill Ø12 hole for sprocket according to
sketch
Attach chain to sprocket
2
Internal surfac-
es.
Distance = B
A= B-66mm
5.5 INSTALLATION OF THE LIFTING UNIT
The lifting units are supplied in standard sizes that can be adapted to the individual milking pit.

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Check distance C Install lifting unit between guides
Attach lifting unit to guide Fine-tune lifting unit
Important: The bolt must be screwed
down at least 15 mm into the adjusting
nut. If the bolt cannot be adjusted far
enough, choose a longer bolt.
Lifting units are installed
C
500
+5
- 0
H+150 mm
C= 120 mm
Attention!
Spindel in spindle
motor must be fully
retracted (see drawing).
+22
-0
Bolt