Boumatic HD2 Rapid Exit User manual

9e1082
Operator Manual
HD2”
Rapid Exit Milking System
www.boumatic.com
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09-2018

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CONTENTS
1. PREFACE
1.1 MANUFACTURER’S ADRESS ......................................................................................................................................................... 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
3. DESCRIPTION
3.1 INSTALLATION CONDITIONS......................................................................................................................................................12
3.2 NOISE LEVEL .....................................................................................................................................................................................12
3.3 DELIVERY............................................................................................................................................................................................13
3.4 STORAGE............................................................................................................................................................................................13
3.5 GENERAL ASSEMBLY INSTRUCTIONS.....................................................................................................................................14
3.6 SYMBOLS ..........................................................................................................................................................................................15
3.7 RECOMMENDATIONS....................................................................................................................................................................15
3.8 CHARACTERISTICS......................................................................................................................................................................... 16
3.9 COMPRESSED AIR CONSUMPTION .........................................................................................................................................16
4. SETTINGS, START-UP AND CONTROL
4.1 USER CONTROLS.............................................................................................................................................................................17
5. CLEANING
5. NETTOYAGE ......................................................................................................................................................................................18
6. MAINTENANCE
6.1 GENERAL MAINTENANCE............................................................................................................................................................19
6.2 PERIODIC MAINTENANCE...........................................................................................................................................................19
6.2.1 GREASING POINTS ENTRANCE GATE......................................................................................................................................20
6.2.2 GREASING POINTS FRONT REEL...............................................................................................................................................21
6.3 MONTHLY CHECK ...........................................................................................................................................................................21
6.4 HALFYEARLY CHECK....................................................................................................................................................................22
7. PROBLEMS AND SOLUTIONS
7.1 PROBLEMS AND SOLUTIONS.....................................................................................................................................................23
7.2 PROCEDURE IN CASE OF FAILURE ...........................................................................................................................................23

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8. DECOMMISSIONING
8.1 SPECIAL PERSONNEL QUALIFICATION REQUIRED FOR DECOMMISSIONING .......................................................24
8.2 SAFETY INSTRUCTIONS FOR DECOMMISSIONING...................................................................................................................... 24
8.3 SPECIAL DANGERS INVOLVED IN DECOMMISSIONING .............................................................................................................24
8.4 FINAL DECOMMISSIONING / DISPOSAL........................................................................................................................................... 24

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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
If necessary, please contact your nearest authorised dealer.
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.
1. PREFACE
1.1 MANUFACTURER’S ADRESS
1.2 CUSTOMER SERVICE
1.3 GUIDELINES, LAWS, STANDARDS
BouMatic A/S
Jernvej 2
6900 Skjern
Denmark
Tel: [phone]
Fax: [phone]
BouMatic Gascoigne Melotte Sprl.
Rue Jules Melotte 31
4350 Remicourt
Belgium
Tel: [phone]
Fax: [phone]

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IN PREPARATION
1.3.1 DECLARATION OF CONFORMITY

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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.
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
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

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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!
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!
2.2 BASIC SAFETY INSTRUCTIONS

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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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2.4 PROTECTIVE EQUIPMENT
2.5 SAFETY SIGNS, STICKERS AND LABELS
2.6 PACKAGING MATERIALS
2.7 CORRECT APPLICATION
Attention!
• Existing protective equipment should be checked at regular intervals to ensure their eective-
ness!
• 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.
Safety signs, stickers and labels axed to the product must be replaced immediately when illegible or lost!
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 parlours 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.

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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 230/400 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.

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The noise level does not exceed 70 dB(A).
DUHS18052201
DUHS18052201
MAIN WORK STATION
3. DESCRIPTION
3.1 INSTALLATION CONDITIONS
The HD2 Rapid Exit milking parlour must be installed in a building (under a roof), protected against negative weather
conditions.
The premises should have a minimum temperature of 5° Celsius and not have excessive humidity levels.
The installation conditions of the HD2 Rapid Exit with regard to the external electrical and water connections, the
structural building conditions and other conditions on site do not fall within the sphere of responsibility of BouMatic.
Please follow the instructions in this manual.
Objects or other components that are added to the system or are located/assembled nearby must not interfere in any
way with its correct and safe operation.
To operate the HD2 Rapid Exit milking parlour, two energy carriers must be available:
1- Electrical power supply: 230 V / 400 V, 50 Hz (Europe)
2- Pneumatic energy: compressed air between 4 and 8 bars, oil free
The system is operated by a control unit installed in the milking pit so that its operation can bemonitored.
3.2 NOISE LEVEL

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3.3 DELIVERY
Please check the scope of delivery of the delivered goods and conrm receipt.
Check the delivered goods against the order conrmation and delivery note for correctness and possible
transport damage.
Damages or apparent inconsistencies must be reported in writing within 48 hours of delivery.
Ensure that the machine used to unload the system from the lorry (forklift, tractor with front loader, etc.) has the
appropriate power.
The weight per pallet varies according to the milking parlour size. The weight does not exceed 3000 kg per
pallet/unit however.
BouMatic cannot be held liable for damage caused by improper unloading!
Do not stay under suspended loads during unloading and later assembly!
Receipt of goods:
3.4 STORAGE
The following rules must be observed when storing the delivered goods:
Do not store the product outdoors or in areas with chemical vapours, moisture, excessive temperature and/or
dirt.
Do not store the product on the bare oor/ground.
Ensure proper storage of electrical components and/or fragile objects.
Strong exposure by e.g. exposure to sunlight at high humidity inuences the appearance of metal parts and
can cause damage to electrical and pneumatic components.
Plastics can change in colour due to excessive UV radiation and, in extreme cases, can become brittle.

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3.5 GENERAL ASSEMBLY INSTRUCTIONS
The milking parlour is delivered in individual parts. It must be assembled by trained personnel, taking into account the
contents of this manual.
Installation personnel must have knowledge of the type of installation and possible risks.
The instructions in this manual must be followed. BouMatic accepts no responsibility or warranty for damages resulting
from improper installation and their consequential damage.
The following instructions must be observed:
During welding operations, in particular of galvanised parts, harmful gases can lead to damage to health. Avoid
breathing these vapours and ensure adequate ventilation.
Adaptations, e.g. cutting certain parts, requires mechanical expertise.
A bitumen coating shall be applied to all parts to be encased in concrete up to 50 mm (2“) above the top edge of the
nished concrete.
If possible, use greases approved for the food industry, such as“Unil Opal Polyfood 2”or a comparable lubricant.
Always grease stainless steel screws before mounting.
If you weld galvanised surfaces or galvanised parts mechanically, immediately apply a new zinccoating.
For screw connections, observe the permissible torques.
4,6 4,8 5,6 5,8 6,6 6,8 8,8 10,9 12,9
M4 1,12 1,50 1,40 1,87 1,68 2,25 3,00 4,21 5,06
M5 2,17 2,89 2,71 3,62 3,26 4,34 5,79 8,15 9,78
M6 3,74 4,90 4,60 6,24 5,62 7,49 9,99 14,00 16,80
M8 8,92 11,90 11,10 14,80 13,30 17,80 23,70 33,40 40,10
M10 17,90 23,80 22,40 29,80 26,80 35,80 47,70 67,20 80,60
M12 30,40 40,50 38,00 50,70 45,60 60,80 81,10 114,10 137,00
M16 73,40 97,90 91,80 122,40 110,20 146,90 195,90 275,60 330,70
M20 143,20 191,00 179,00 238,70 214,80 286,50 382,00 537,10 644,60
Strength class
Torques of the fixing screws (Nm)
ØScrew

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3.6 SYMBOLS
: Grind : Grease : Left side
: Drill: Weld
: Apply protective
coating
: Galvanize
: Right side
3.7 RECOMMENDATIONS
Before commissioning the system, it must be ensured that the installation of the system complies with the
technical guidelines and national laws.
The control elements must be installed in such a way that the functions they set in motion can be monitored by
the operator.
The highest priority is the safety of humans and animals.
Failure to do so could result in serious, permanent injury.
It must be possible to disconnect the HD2 from its pneumatic and power supplies.
Please pay particular attention to the oor covering in areas where people and animals circulate to prevent
skidding and falling and to facilitate cleaning.
All electrically conductive system components must be connected to the building’s potential
equalization.

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3.8 CHARACTERISTICS
All electrically conductive system components must be connected to the building’s potential
equalization.
The appearance of the galvanised parts may vary. The galvanisation of metallic part consists of a zinc coating designed to
protect the steel against corrosion. Aesthetic considerations are secondary.
3.9 COMPRESSED AIR CONSUMPTION
HD2 Rapid Exit compressed air volume
HD2 parlour 2×3 2×4 2×5 2×6 2×7 2×8 2×9 2×10 2×11 2×12 2×14 2×15 2×18
Number of cylinders Ø80×150 2 4 6
Number of cylinders Ø40×125 2 4 6
Number of cylinders Ø80×200 2 2 2
Number of cylinders Ø40×250 2 2 2
Theoretical useful compressed air ow rate
(6 bars) (in l/min) 39 50 61
Theoretical useful compressed air volume
per hour (6 bars) (in l/h) (for4cycles/hour) 52 66 81
fz

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4. SETTINGS, START-UP AND CONTROL
4.1 USER CONTROLS
1 -“START”push button:
• It starts the cow exit cycle and restarts a cycle suspended by the“STOP”button.
2 -“STOP”push button:
• It stops a cycle initiated by the“START”push button.
3 - “GATE”push button:
• 1 push: It controls the opening and closing of the entry gate.
• Kept down for 1 second: it controls the indexing and the de-indexing of the exit reel, only when the cycle is not
activated.
• In indexing control (kept down for more than one second), cycle not activated (or stopped by the stop button),
itresets all commands

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5. CLEANING
To secure the longevity of the installation, it is important to regularly clean the exposed elements to protect them
from corrosive attacks. However, some recommendations should be taken into account:
- Do not clean the HD2 Rapid Exit with a jet under too high pressure
- Do not use products that are too aggressive
- Do not spray live components, pneumatic or bearing elements
- When cleaning, pay attention to spraying or inadvertent splashing of electrical equipment
- Make sure the pneumatic components are clean.
During cleaning requiring access out of the milking pit, rst make sure that the HD2 Rapid Exit is stopped,
switched o, with the pneumatic circuit cut so that no third party can endanger intervening sta or aect ongoing
operations.
Waste water and cleaning products must not be abandoned outdoors and must be disposed of in accordance with
the legal provisions in force.

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In all cases of maintenance (unless necessary), the operations must be carried out after ensuring that the HD2
Rapid Exit is stopped, with pneumatic and electric circuits cut in such a way that no third party could endanger the
intervening sta or aect the current operations.
Where appropriate, the means of access to the points of intervention, mainly at height, must be stable and allow
operations to be carried out safely. Before power is restored, make sure that nobody is in the travel range of
moving parts.
6. MAINTENANCE
6.1 GENERAL MAINTENANCE
Periodic monthly and semi-annual maintenance consisting of checks may be carried out by non-specialised
personnel in this eld. However, they must have minimum technical knowledge to understand the purpose of the
operations to be conducted and be able to interpret them accordingly.
If unscheduled maintenance or maintenance requiring more than just a check are required, it must be performed
by qualied personnel who are familiar with the assembly rules for this type of installation and who are aware of
the risks involved.
Parts that are too worn must be replaced with original spare parts.
It is recommended (unless contraindicated) to use the following lubricants:
- Grease : Unil Opal Polyfood
Equipment will perform more eectively over time if it is well maintained. That is why it is important to respect the
maintenance intervals.
6.2 PERIODIC MAINTENANCE
Periodically lubricate the joints. Use the recommended grease or a product with equivalent characteristics.
Warning: A lack of lubrication of the articulated elements can lead to premature wear, even to breakage.
Greasing frequency for the joints concerned:
Joints concerned Greasing frequency (milking hours)
Entrance gate joints 750 or 6 months
Front reel joints 750 or 6 months
fz
When lubricating the joints, it is advisable to operate them in order to ensure proper operation and to properly
dispense the lubricant.

DUHS18052202
DUHS18052202
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Respecting the greasing frequency guarantees good functioning to the extent that the greasing is not aected by
the surrounding operations (e.g. removal of the grease after the cleaning).
If the pneumatic circuit of the installation does not have an automatic purge, it must be purged regularly.
6.2.1 GREASING POINTS ENTRANCE GATE